| Summary: | A simple, low temperature, method, hydrogen-enhanced atomic transport (HEAT), for creating metallic-bonded brown bodies of order 40% bulk density in molds of designed shape from Ti metal particles is introduced. In this initial study 40 micron titanium particles were poured into graphite molds, then heated to temperatures equal to or greater than 650 °C for four hours in a flowing ambient pressure gas mixture containing some hydrogen led to brown body formation that closely mimicked the mold shape. The brown bodies were shown to be dense, metallic bonded, and consisted of primarily Ti metal, but also some TiH. It is postulated that hydrogen is key to the sintering mechanism: it enables the formation of short-lived TiHx species, volatile at the temperatures employed, that lead to sintering via an Ostwald Ripening mechanism. Data consistent with this postulate include findings that brown bodies are formed with hydrogen present (HEAT process) had mechanical robustness and only suffered plastic deformation at high pressure (ca. 5000 Atm). In contrast, brown bodies made in identical conditions, except the flowing gas did not contain hydrogen, were brittle, and broke into micron scale particles under much lower pressure. HEAT appears to have advantages relative to existing titanium metal part manufacturing methods such as powder injection molding that require many more steps, particularly debinding, and other methods, such as laser sintering, that are slower, require very expensive hardware and expert operation.
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