As one of the most sought-after materials in industries ranging from aerospace to medical, titanium alloy production is a complex and highly controlled process. At UkonTech, we understand that the quality of the end product is directly tied to the precision and care taken at every step of manufacturing. In this blog, we will take you through the detailed stages of titanium alloy production—from ore extraction to the creation of high-performance materials like plates, bars, and tubes that meet the rigorous demands of our customers.

1. Titanium Ore Extraction

Titanium is primarily sourced from minerals like rutile (TiO₂) and ilmenite (FeTiO₃). Around 90% of the titanium mined globally is in the form of ilmenite. These ores are mined from locations in Australia, South Africa, and Canada, which together produce more than 80% of the world’s supply. After extraction, titanium ores must go through several processes to separate the titanium from other elements like iron.

One of the key processes used is the Kroll Process, named after William Kroll, who developed it in the 1940s. This process begins by converting titanium ore into titanium tetrachloride (TiCl₄) via chlorination. This is then reduced to metallic titanium using magnesium in a closed system. This initial reduction produces a porous material known as titanium sponge, which is a crucial intermediate in producing titanium alloys.

2. Melting and Alloying

The next step in the production process is the melting and alloying of the titanium sponge. This stage defines the properties of the final titanium alloy by introducing additional elements like aluminum, vanadium, tin, or zirconium, depending on the desired mechanical and chemical properties. For example, Ti-6Al-4V, the most commonly used titanium alloy, consists of 6% aluminum and 4% vanadium.

The melting process is typically done in a vacuum arc remelting (VAR) furnace, where the titanium sponge is melted at extremely high temperatures (around 1,650°C) in a vacuum to avoid contamination. This process not only melts the titanium but also allows for the formation of a homogenous alloy. Often, the titanium is remelted two or three times to ensure purity and uniformity.

At UkonTech’s Supply Chain, we employ advanced remelting techniques to produce high-purity titanium alloys with consistent properties. Their furnaces can melt up to 10 tons of titanium per batch, ensuring scalability while maintaining the highest standards of quality.

3. Casting

Once the titanium alloy is melted, it is ready for casting. The molten titanium alloy is poured into molds to form ingots. These ingots can vary in size, depending on the intended final product, but typically range from 500 kg to 5,000 kg.

Casting titanium requires precision due to its reactivity at high temperatures. UkonTech’s suppliers use investment casting for intricate shapes and continuous casting for larger-scale products like bars and plates. The casting process must take place in a controlled environment to prevent contamination and oxidation, which can severely affect the alloy’s properties.

After casting, the ingots are allowed to cool slowly to minimize stress and cracking. These ingots are then ready for further processing, such as forging and rolling.

4. Forging

Forging is the process where the titanium ingots are heated and shaped into various forms such as billets, bars, and plates. The key advantage of forging is that it refines the grain structure of the titanium alloy, leading to improved mechanical properties such as strength, toughness, and fatigue resistance.

At UkonTech, our closed-die forging process ensures precise control over the shape and properties of the titanium products. We can forge titanium alloys into billets ranging from 100 mm to 400 mm in diameter, which are then processed into smaller shapes or rolled into plates.

The forging process is typically done at high temperatures, between 700°C and 1,000°C, depending on the alloy. This high-temperature process helps in deforming the material while retaining the desirable properties of the titanium alloy.

5. Rolling and Extrusion

For products like titanium plates, sheets, and tubes, the next step is rolling or extrusion. Rolling involves passing the heated titanium alloy through a series of rollers to achieve the desired thickness. Plates can be rolled as thin as 0.5 mm for applications like medical implants or as thick as 100 mm for aerospace components.

Extrusion, on the other hand, is used to produce long, uniform shapes like bars and tubes. The titanium billet is heated and forced through a die to create a continuous length of material. At UkonTech, we offer extruded titanium tubes in a variety of diameters, from as small as 10 mm up to 200 mm, depending on the customer’s specific requirements.

6. Heat Treatment and Annealing

After rolling or extrusion, many titanium alloys undergo heat treatment or annealing. This process involves heating the alloy to a specific temperature (usually between 600°C and 900°C) and then slowly cooling it. Heat treatment alters the internal structure of the titanium alloy, enhancing properties like toughness, corrosion resistance, and machinability.

For example, Ti-6Al-4V is often annealed at 705°C to increase its ductility and make it easier to machine without losing its strength. This heat treatment step is critical for ensuring the material performs well in high-stress applications like aircraft engines or medical implants.

7. Machining and Surface Finishing

Titanium alloys are known for being challenging to machine due to their hardness and low thermal conductivity. However, advanced CNC machining technology makes it possible to produce complex components with tight tolerances.

At UkonTech, we use 5-axis CNC machines to fabricate high-precision parts like aerospace fasteners, medical implants, and automotive components. Our machining capabilities allow us to produce parts with tolerances as tight as ±0.005 mm, ensuring the highest level of accuracy for demanding applications.

In addition to machining, titanium alloys often undergo surface finishing processes like polishing, sandblasting, or anodizing. These treatments enhance the appearance of the titanium and improve its resistance to wear and corrosion. For instance, anodizing can create a thin oxide layer that not only protects the titanium but also gives it a decorative finish.

8. Quality Control and Testing

Quality control is a vital part of the titanium production process at UkonTech. We employ stringent testing procedures to ensure that every batch of titanium meets the highest standards for purity, strength, and performance. Our in-house testing includes:

• Ultrasonic testing to detect internal defects like voids or cracks.
• Tensile testing to measure the material’s strength and ductility.
• Chemical analysis to verify the composition of the alloy and ensure it meets industry standards like ASTM and AMS specifications.

We also perform microstructure analysis using advanced imaging techniques to confirm that the alloy’s grain structure is uniform and free of impurities. This level of quality assurance ensures that our titanium products meet the exacting requirements of industries like aerospace, medical, and defense.

Why Choose UkonTech for Your Titanium Needs?

At UkonTech, we are dedicated to providing our customers with high-performance titanium alloys that meet the demands of modern industries. Our advanced production processes, combined with rigorous quality control, ensure that our products consistently deliver in terms of strength, corrosion resistance, and precision.

Whether you need titanium plates, bars, tubes, or custom machined components, UkonTech offers competitive pricing, fast delivery, and unmatched expertise. With our state-of-the-art facilities and commitment to innovation, we are the ideal partner for all your titanium alloy needs.

Conclusion

The production of titanium alloys is a complex, multi-stage process that requires precision and expertise at every step. From the extraction of titanium ore to the final finishing and quality control, each stage plays a crucial role in delivering high-quality titanium products. At UkonTech, we take pride in our ability to provide top-tier titanium alloys that meet the most demanding industrial applications.

By understanding the intricacies of titanium production, you can make more informed decisions when sourcing materials for your projects. Contact us today to learn more about how UkonTech can support your business with world-class titanium products.