Titanium Sheet Fabricated from Powder for Industrial Applications W. H. Peter, T. Muth, W. Chen, Y. Yamamoto, Brian Jolly, N. A. Stone, G.M.D. Cantin, J. Barnes, M. Paliwal, R. Smith, J. Capone, A. Liby, J. Williams and C. Blue In collaboration with Ametek and Commonwealth Scientific and Industrial Research Organization (CSIRO), Oak Ridge National Laboratory has evaluated three different methods for converting titanium hydride-dehydride (HDH) powder into thin gauge titanium sheet from a roll-compacted preform. Methodologies include: sintering, followed by cold rolling and annealing; direct hot rolling of the roll- compacted sheet; and hot rolling of multiple layers of roll compacted sheet that are encapsulated in a steel can. Fabrication of fully consolidated sheet has been demonstrated using all three methods and each processing route has the ability to produce sheet that meets ASTM B265 specifications. However, not every method currently provides sheet that can be highly formed without tearing. The degree of sintering between powder particles, post processing density, and the particle-to-particle boundary layer where compositional variations may exist, have a significant effect on the ability to form the sheet into components. Uniaxial tensile test results, compositional analysis, bend testing, and biaxial testing of the titanium sheet produced from hydride-dehydride powder will be discussed. Multiple methods of fabrication and the resulting properties can then be assessed to determine the most effective and economical means of making components for industrial applications. Aerospace Dependence of Titanium and Alternate Processing Examined Titanium (Ti) and its alloys have many superior properties compared to other metals used in industrial applications, including: high corrosion resistance, ductility, and very good strength-to-weight ratios [1,2,3,4]. The latter attribute makes it compelling for use in aerospace applications. The erratic supply and wide price swings associated with aerospace uses of titanium have the effect of relegating titanium to the status of an exotic material [2,3]. Industrially, titanium is often considered as a last resort; when nothing else will work. If the production of titanium for use in industrial applications such as petroleum refining, chemical processing, pulp and paper processing, condenser tubes, vehicle components, and heat exchangers could be decoupled from the aerospace sector, economic compromises could be made based on a balance between performance and cost. The ongoing expansion of industrial uses for titanium is driven by reduced maintenance intervals, longer service life, and component mass reduction, all of which increase energy efficiency and improve the competiveness of U.S. industry. In 2007, the Department of Energy funded an independent study to evaluate “Industrial Markets for Titanium Manufacturing”. The study included overall energy consumption and the impact of lower cost processing methods for making titanium [5]. The report was not made public, since proprietary information was included. The two product areas that were identified as having the largest potential benefit (i.e., price and energy) by starting with Ti powder and using powder metallurgy consolidation methods were thin gauge Ti sheet and net shape components with complex geometries. In these areas, conventional Ti manufacturing processes result in low yields and require high labor input. An Oak Ridge National Laboratory study performed in 2011 confirmed the independent study’s findings [6]. The overall outcome from these two reports has been a sustained and concentrated research effort on developing 1) affordable thin gauge commercially pure (CP) Ti sheet, and 2) development of powder metallurgy and additive manufacturing methodologies for manufacturing complex net shapes. Most aerospace applications of Ti require the unequivocal surety of properties defined in the Metallic Materials Properties Development and Standardization (MMPDS) handbook. Often, for industrial applications, the most significant mechanical property requirement for Ti sheet is in formability to produce the finished component, not in the mechanical performance in-service. With limited mechanical requirements, and therefore less qualification rigor, production of industrial sheet metal titanium can