A low-cost titanium production process, the CSIR-Ti powder process, which aims to produce titanium powder directly by metallothermic reduction of titanium tetrachloride with lithium, has been under development at the Council for Industrial and Scientific Research (CSIR). Crude titanium powder produced using the CSIR-Ti process is inevitably contaminated with by-products such as lithium chloride, lithium and titanium dichloride. These by-products tend to become sources of impurities in titanium powder, specifically oxygen and chloride impurities. The presence of oxygen and chloride impurities has marked effects on the mechanical properties of titanium finished products. Consequently, for the crude titanium powder to be rendered useful downstream, it must be purified and the by-products reduced to concentrations specified in the commercial standards. The present study was undertaken to examine whether acid leaching could be used to selectively dissolve and prevent hydrolysis of the by-products—specifically excess lithium and unreacted titanium dichloride in the crude titanium powder produced by the CSIR-Ti process. A further objective was to determine whether a purified product that meets both oxygen and total residual chloride content as specified by the standards can be achieved. The effects of key leaching variables and their interaction were also investigated to gain fundamental understanding of these effects on the by-products leaching behaviour. A literature study to select a suitable lixiviant and to establish the aqueous chemistry of the byproducts and their effect on the leaching conditions was undertaken. It showed that of the various acids suggested in the literature, hydrochloric acid was the cheapest and that it was more suited for the CSIR-Ti leaching process than nitric acid, due to the common ion chloride. This simplifies the leachate purification process downstream. The literature study established that Ti(II) has no aqueous chemistry but instead is oxidised to Ti(III) in solution. It was found that Ti(III) is easily oxidised to TiO2+ by dissolved oxygen and water. However, the oxidation rate was slow in hydrochloric acid solutions with the advantage that hydrolysis of the ions could be minimised and the precipitation of the oxides or oxychlorides prevented. It was further revealed that the lithium neutralisation reaction is highly exothermic, with the possibility of raising the leachate temperature to 60°C, resulting in the contamination of the titanium powder particles by the oxide layer and precipitated hydrolysis products. Batch leaching tests were carried out using factorial design of experiments to investigate the effect of initial hydrochloric acid concentration, which was estimated by varying the concentration between 0.032 M and 1 M; particle size, which was varied between −10 mm and +10 mm; and the initial temperature, varied between 14°C and 30°C. The resulting data were modelled and analysed using the analysis of variance statistical method. The solid residues were analysed for oxygen and total residual chloride content. The solid residue was also characterised by scanning electron microscopy (SEM) to examine the morphology of the leached particles. Leaching kinetics model fitting was also conducted. The statistical analysis showed that of the three factors investigated, temperature was the factor with the most statistical significance on both the oxygen and chloride concentration in the purified product, followed by particle size. The effect of acid concentration proved to be minimal, a phenomenon attributed to low concentrations of acid-consuming impurities, specifically excess lithium in the crude product. Thus, the two concentrations of hydrochloric acid investigated were found to be efficient to prevent hydrolysis product formation. Scanning electron micrographs revealed that crushing the crude product with a jaw crusher occluded crude titanium pores, thus locking in some by-products in addition to the pores locked by sintering during the metallothermic reduction. The observation showed that residual chloride impurities in the purified product are not just a consequence of hydrolysis products but also byproducts locked deeper in the pores of the product. Based on the parameter ranges evaluated in the study, a product that satisfied both oxygen and chloride standard specifications was achieved when the crude product was leached in both 1 M and 0.032 M initial HCl concentrations, temperature of 30°C and particle size of +10 mm. The combination of (−10 mm and 14°C) at all concentrations also yielded acceptable oxygen and chloride content levels. Overall, it was concluded from the present work that purification of crude CSIR-Ti product by leaching in dilute HCl is technically feasible. / Dissertation (MSc Applied Sciences (Metallurgy))--University of Pretoria, 2014. / Materials Science and Metallurgical Engineering / MSc (Applied Sciences (Metallurgy)) / Unrestricted

Thesis (MScEng) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: In this study, commercially pure titanium foam was produced using space holder powder metallurgy techniques. Titanium foam is attractive as a scaffolding material for bone replacement and implants in the body. The porous morphology of the foam promotes osteogenesis, while the mechanical behaviour of the foam is closer to that of bone, which has an elastic moduli range of 5 - 40 GPa. Titanium foam was manufactured from powder mixtures of commercially pure titanium (CPTi) powder mixed with 41.4 wt% ammonium bicarbonate (ABC) powder and 1.45 wt% polyethyl glycol (PEG) powder. In this study, two CPTi powders with different particle size distributions, < 75 μm (-200 mesh, designated TiAA) and < 200 μm (-100 mesh, designated TiG), were mixed with the space holder ABC powder, that had been sieved into specified particle size ranges. The size ranges of space holder material studied were: 0 - 710, 250 - 425, 425 - 560, and 560 - 710 μm. This allowed foams with different large or macropore distributions to be produced from the different mixtures. The mixtures were uniaxially compacted at 100 MPa into transverse rupture bars. The ABC and PEG was then removed by thermal debinding in air for 5 hours at 100 °C and 1 hour at 330 °C each, consecutively. The debound samples are then sintered under high (10-6 mbar) vacuum on yttria-stabilised zirconia substrates, heating at 5 °C/min to 1200 °C, with a 2 hour hold at temperature. The microstructures of the different foams were evaluated by examining the polished samples using light optical microscopy. Three point bend tests were conducted on the sintered bars in order to determine the flexural strength and flexural modulus of the different foams. The produced foams had a relative density range between 37.5 - 62.5 % and average macro pore size range between 300 - 500 μm. The foams were found to have an elastic modulus similar to that of bone, 2 - 7 GPa. Finally, the mechanical properties of the foams were compared to known open foam mechanical models and other research projects. It was found that: (i) changes in either metal or space holder powder influences the sintering behaviour of metal foams, (ii) sintered titanium foams with similar densities but different macro/micropore size distributions have different mechanical responses to stress and (iii) the Ashby-Gibson model, based on foam density alone, gives a rough estimate of mechanical properties for the titanium foams studied, but does not capture variations due to pore size distribution. / AFRIKAANSE OPSOMMING: In hierdie studie is kommersiële suiwer titaanskuim geproduseer met behulp van ruimtehouer poeier metallurgie tegnieke. Titaanskuim is aantreklik as 'n raamwerkmateriaal vir beenvervanging en -inplantings in die liggaam. Die poreuse morfologie van die skuim bevorder osteogenese, terwyl die meganiese gedrag van die skuim naby aan dié van been is, met ‘n elasticiteitsmodulus tussen 5 - 40 GPa. Titaanskuim is vervaardig van ‘n poeier mengsel van kommersiële suiwer titaan (CPTi) poeier gemeng met 41,4 gew% ammonium bikarbonaat (ABC) poeier en 1.45 gew% poli-etileenglikol (PEG) poeier. In hierdie studie is twee tipes CPTi poeiers met verskillende deeltjiegrootteverspreiding, < 75 μm (-200 stofdigtheid, TiAA genoem) en <200 μm (-100 stofdigtheid, TiG genoem), met die ruimtehouer ABC-poeier, wat in bepaalde deeltjiegroottereekse gesif is, gemeng. Die wisselende groottes van ruimtehouer wat bestudeer is, was: 0 - 710, 250 - 425, 425 - 560, 560 - 710 μm. Dit het die vervaardiging van skuim met verskillende groot of macroporeuse vanaf die verskillende mengsels toegelaat. Die mengsel is teen 100 MPa in een rigting gekompakteer. Die ABC en PEG is dan verwyder word deur termiese ontbinding in lug vir 5 uur by 100 °C en 1 uur by 330 °C elk, onderskeidelik. Die ontbinde monsters is dan onder hoë (10-6 mbar) leemte op yttrium-gestabiliseer zirconia-substraat, met verwarming teen 5 °C/min tot 1200 °C met 'n verdere 2 uur by 1200 °C, gesinterd. Die mikrostrukture van die verskillende skuim is geëvalueer deur gepoleerde monsters met behulp van ‘n ligmikroskopie te ondersoek . Driepunt draaitoetse is op die gesinterd stawe uitgevoer om die buigsterkte en buigmodulus van die verskillende skuime te bepaal. Die vervaardigde skuime se relatiewe digtheid het tussen 37,5 - 62,5 % gewissel en die gemiddelde makroporiegrootte tussen 300 - 500 μm gewissel. Die skuim het 'n elastisiteitsmodulus soortgelyk aan dié van been getoon, 2 – 7 GPa. Ten slotte is die meganiese eienskappe van die skuim met bekende oop skuim meganiese modelle en ander navorsingsprojekte vergelyk. Daar is bevind dat: (i) veranderinge in óf metaal of ruimtehouer poeier beïnvloed die sinteringgedrag van metaalskuime, (ii) gesinterd titaniumskuim met soortgelyke digthede, maar verskillende makro / mikroporeuse verdelings, toon verskillende meganiese reaksies op stres en die Ashby-Gibson model, gebaseer op die skuimdigtheid alleen, (iii) wat 'n rowwe skatting van die meganiese eienskappe vir die bestudeerde titaniumskuime gee, maar nie die variasies ingrootteverspreiding van porieë ondervang nie.

The purpose of this work is to study the saturation of the sodium NaCl melt, dissolve the titanium rod, and restore TiCl2 in the electrolyte volume with a Na-NaCl melt to develop an electrochemical technology for producing titanium powders. To substantiate the electrode processes, an attempt was made to create reference electrodes for the systems under study. According to the published data, the equations of temperature dependences of the standard, conventional-standard and redox potentials and the concentration dependence of the equilibrium potentials of titanium in molten sodium chloride, which were used in the analysis of polarization curves, were calculated. The kinetics of electrode processes in a sodium chloride melt is studied when metallic titanium is dissolved in it and when sodium is deposited on the iron cathode. An explanation of the processes occurring at the electrodes is given. Powders of metallic titanium are obtained. / Целью данной работы является исследование насыщения расплава NaCl натрием, растворение титанового стержня и восстановление TiCl2 в объеме электролита расплавом Na-NaCl для разработки электрохимической технологии получения порошков титана. Для обоснования электродных процессов, предпринята попытка созданы электроды сравнения для изучаемых систем. По литературным данным рассчитаны уравнения температурных зависимостей стандартного, условно-стандартного и окислительно-восстановительных потенциалов и концентрационной зависимости равновесных потенциалов титана в расплавленном хлориде натрия, которые использовались при анализе поляризационных кривых. Изучена кинетика электродных процессов в расплаве хлорида натрия при растворении в нем металлического титана и при осаждении натрия на железном катоде. Дано объяснение происходящих на электродах процессов. Получены порошки металлического титана.