Achieving synergy of strength and ductility in powder metallurgy commercially pure titanium by a unique oxygen scavenger

Excessive interstitial oxygen (O) contamination, usually causing a dramatic loss of ductility, remains a longstanding challenge for titanium (Ti) and its alloys. Here, we propose to solve this critical problem by adding a minor CaC ₂ oxygen-scavenger via a simple powder metallurgy (PM) pressureless sintering approach. It is found that the surface oxide layer of hydride-dehydride (HDH) Ti powder begins to dissolve into the Ti matrix between 700 °C and 800 °C during the PM sintering process. The incorporation of CaC ₂ can react with the surface oxide layer (617-676 °C) prior to its active dissolution and form micrometer-sized TiC and nano-sized CaTiO ₃ particles, significantly refining the α-Ti grains and creating clean and well-bonded interface with Ti matrix. Therefore, the unique oxygen-scavenging effect by CaC ₂ produces high strength and superior ductility for Ti alloy. Even with an initially high oxygen content (∼4000 ppm), the Ti-0.4 wt.%CaC ₂ sample still exhibits a high ultimate tensile strength of 621±25 MPa and superior elongation of 29.3±2.6%, respectively. These values correspond to an increase of 17.6% and 301.4% compared to the as-sintered commercially pure titanium (CP-Ti) properties and far exceed the ASTM standard B381 for Grade 4 wrought Ti alloy (550 MPa and 15%) with the same O content. This work offers a novel method to develop high-strength and superior-ductility Ti materials from much more affordable Ti powder.