In Situ Ti6Al4V/TiB Composites Prepared by Hydrogen-Assisted Sintering of Blends Containing TiH(2) and Ball-Milled Ti+TiB(2) Powders

In the present study, 98.6–99.5% dense in situ reinforced Ti6Al4V/TiB composites were manufactured with a newly developed approach based on hydrogen-assisted blended elemental powder metallurgy (BEPM). The approach includes the activation milling of titanium powder produced with hydrogenation-dehydrogenation (HDH-Ti powder) with finer TiB(2) additives, following blending with TiH(2) and master alloy (MA) powders, and final press-and-sinter operations. Scanning electron microscope (SEM) observations prove the formation of microstructures with improved density and homogeneous distribution of TiB reinforcements in a sintered Ti6Al4V matrix. Hardness and compressive tests validated the high mechanical characteristics of produced composites. The effect of preliminary milling time over 2–6 h and the ratio of hydrogenated and non-hydrogenated titanium powders used (TiH(2) vs. HDH Ti) on microstructure and mechanical properties were studied to further optimize the processing parameters. Test results indicate the above approach can be regarded as a promising route for the cost-effective manufacturing of Ti6Al4V/TiB composite with reduced porosity, tailored microstructure uniformity, acceptable impurity level and, hence, mechanical characteristics sufficient for practice applications.