Advanced gas atomization processing for Ti and Ti alloy powder manufacturing

A multi-layer ceramic composite melt pour tube for superheating and pouring of molten Ti-6Al-4V (wt.%) was tested using an existing Ti atomization system. Free fall gas atomization was conducted with the pour tube while liquid metal temperatures were measured in situ using a two-color optical pyrometer. Post-process pour tube erosion was compared with pre-process matching surfaces, and minimal change in interior liner thickness was found. Microstructural analysis, phase identification, and composition determination of the resulting gas-atomized powder indicated minimal contamination from the composite pour tube despite very high liquid superheat, approaching 300° C. Hot isostatic pressing of the powder resulted in mechanical properties exceeding the MIL-T-9047 standard for Ti-6Al-4V.