Circular solid-state processing of Ti swarf—a low-cost, sustainable, and European source of Ti

Purpose and goal:

Titanium—a critical EU raw material—is required for many products in the energy sector but its use is often cost-prohibitive. New low-cost and European sources of Ti are needed for broad adaption. The goal of the project is to establish a new route towards low-cost, high-performance Ti powders for various powder metallurgy routes, primarily cold spray coating and repair, based on waste feedstock.

Expected results and effects:

We will evaluate an industrially viable process that converts Ti waste into low-cost powders by solid-state processing and their consolidation by cold-spray coating and additive manufacturing into Ti parts. Based on this pre-study, we will identify opportunities and challenges as well as necessary methods and expertise for a full-scale project that will realize and proof the technical and economical feasibility of this significant secondary source of Ti.

Approach and implementation:

In this pre-study, we will confirm the feasibility of powder production from Ti waste, test coating simulation and rapid powder optimization by single- and many-particle impact deposition, and theoretically plan and outline industry-scale cold-spray deposition and performance testing of the coatings.