Near-Net-Shape Production of Hollow Titanium Alloy Components via Electrochemical Reduction of Metal Oxide Precursors in Molten Salts

This study explores the near-net-shape production of hollow titanium alloy components using a one-step solid slip-casting process to prepare metal oxide precursors consisting of approximately 90 wt pct Ti, 6 wt pct Al, and 4 wt pct V. The precursors were electro-deoxidized in molten calcium chloride at a voltage of 3.2 V and a temperature of 1173 K against a graphite anode. After a 24-hour electrolysis period, the resulting Ti-6Al-4V components maintained their near-net shape with controlled shrinkage and exhibited oxygen content typically below 2000 ppm. The maximum compressive stress and modulus observed in the electrolytic products were approximately 243 MPa and 14 GPa, which meet the requirements for medical implants. Moreover, the study discusses further research directions aimed at enhancing the mechanical properties of these products through densification processes during or after electrolysis. The proposed method is noted for its simplicity, speed, and energy efficiency, offering a promising approach for the low-cost manufacturing of titanium alloy components with desired geometries.