Titanium tungsten alloys produced by additions of tungsten nanopowder

Abstract

Disclosed herein are titanium-tungsten alloys and composites wherein the tungsten comprises 0.5% to 40% by weight of the alloy. Also disclosed is a method of making such alloys and composites using powders of tungsten less then 3 μm in size, such as 1 μm or less. Also disclosed is a method of making the titanium alloy by powder metallurgy, and products made from such alloys or billets that may be cast, forged, or extruded. These methods of production can be used to make titanium alloys comprising other slow-diffusing beta stabilizers, such as but not limited to V, Nb, Mo, and Ta.

1 . A composition comprising a titanium alloy, said alloy comprising tungsten in an amount ranging from 0.5% to 40% by weight of said alloy, wherein the tungsten has an average diameter less then 3 μm in size.  
   
   
       2 . The composition of  claim 1 , wherein the tungsten powder has an average diameter ranging from 8 angstroms to 1 μm or less.  
   
   
       3 . The composition of  claim 2 , wherein the tungsten powder has an average diameter ranging from 10 nm to 500 nm.  
   
   
       4 . The composition of  claim 1 , comprising at least one beta stabilizer chosen from V, Nb, Mo, and Ta.  
   
   
       5 . The composition of  claim 1 , wherein said alloy comprises dispersions of beta phase islands.  
   
   
       6 . The composition of  claim 5 , wherein said beta phase islands comprise undiffused particulate beta stabilizer at the core of said islands.  
   
   
       7 . The composition of  claim 1 , wherein said titanium material comprises a material chosen from Ti powder and Ti alloy.  
   
   
       8 . The composition of  claim 1 , wherein said alloy has a microstructure that comprises alpha/beta phases, all beta phases, or alpha/beta phases comprising a dispersion of beta phase islands.  
   
   
       9 . The composition of  claim 8 , wherein said beta phase islands include partially diffused beta stabilizer within the beta phase islands.  
   
   
       10 . The composition of  claim 1 , further comprising at least one particulate material chosen from titanium carbide (TiC), titanium boride (TiB), titanium diboride (TiB 2 ) or combinations thereof.  
   
   
       11 . A powder metallurgy method of producing a tungsten comprising titanium alloy, said method comprising: 
 blending a titanium containing powder with a tungsten containing powder to form a blended powder, said blended powder comprising tungsten powder in an amount ranging from 0.5% to 40% by weight of said alloy, wherein said tungsten powder has an average diameter less then 3 μm in size;    compacting the blended powder;    sintering the compacted and blended powder to form a tungsten containing titanium alloy; and    optionally subjecting the sintered tungsten containing titanium alloy to hot isostatic pressing.    
   
   
       12 . The method of  claim 11 , further comprising subjecting the sintered tungsten containing titanium alloy to a process chosen from casting, forging, and extrusion.  
   
   
       13 . The method of  claim 11 , wherein the tungsten containing powder has an average diameter ranging from 8 angstroms to 1 μm or less.  
   
   
       14 . The method of  claim 13 , wherein the tungsten containing powder has an average diameter ranging from 10 to 500 nm.  
   
   
       15 . The method of  claim 11 , wherein the blended powder further comprises at least one beta stabilizer chosen from V, Nb, Mo, and Ta.  
   
   
       16 . The method of  claim 11 , wherein the blended powder further comprises at least one particulate material chosen from titanium carbide (TiC), titanium boride (TiB), titanium diboride (TiB 2 ) or combinations thereof.  
   
   
       17 . The method of  claim 11 , wherein said tungsten containing titanium alloy contains dispersions of beta phase islands.  
   
   
       18 . The method of  claim 17 , wherein said beta phase islands contain residual beta stabilizer at the core.  
   
   
       19 . The method of  claim 11 , wherein said titanium containing powder comprises a Ti powder or a Ti alloy.  
   
   
       20 . The method of  claim 19 , wherein said Ti alloy comprises Ti-6Al-4V.  
   
   
       21 . The method of  claim 11 , wherein the tungsten containing titanium alloy has a microstructure that comprises all-alpha phase, alpha/beta phases, or all-beta phase, or all-alpha phase or alpha/beta phases comprising a dispersion of beta phase islands.  
   
   
       22 . The method of  claim 21 , wherein said beta phase islands include partially diffused beta stabilizer within the beta phase islands.  
   
   
       23 . A product comprising the composition of  claim 1 .  
   
   
       24 . The product of  claim 23 , wherein said product is an orthopedic device chosen from knee, hip, spinal, and dental implants.  
   
   
       25 . The product of  claim 23 , wherein said product is an automotive component chosen from valves, connecting rods, piston pins and spring retainers.  
   
   
       26 . The product of  claim 23 , wherein said product is an military vehicle component chosen from tank track, suspension, and undercarriage parts.  
   
   
       27 . The product of  claim 23 , wherein said product is a tool or die material for metal forming chosen from shot sleeves, plungers and dies.  
   
   
       28 . The product of  claim 23 , wherein said product is an aircraft component chosen from a turbine rotor, and a leading edge of a helicopter rotor blade, tubing, valves and fittings.  
   
   
       29 . The product of  claim 23 , wherein said product is a billet for subsequent casting, forging or extrusion.  
   
   
       30 . A powder metallurgy method of producing a titanium containing product, said method comprising: 
 blending a titanium containing powder with a tungsten containing powder to form a blended powder, said blended powder comprising tungsten powder in an amount ranging from 0.5% to 40% by weight of said alloy, wherein said tungsten powder has an average diameter less then 3 μm in size;    compacting the blended powder; and    sintering the compacted and blended powder,    said method optionally comprising a post-sintering process chosen from hot isostatically pressing, casting, forging and extrusion.    
   
   
       31 . The method of  claim 30 , wherein said product is an orthopedic or dental implant.  
   
   
       32 . The method of  claim 30 , wherein said product is a billet that is subjected to at least one post-sintering process chosen from casting, forging, and extrusion.