Titanium Carbide Powder

titanium carbide powder is an extremely hard ceramic material used in a variety of industrial applications that require high hardness, wear resistance, thermal conductivity, and chemical stability at extreme temperatures. This article provides a comprehensive technical reference on TiC powder covering properties, manufacturing methods, applications, suppliers, specifications, grades, and more.

Overview of Titanium Carbide Powder

Titanium carbide (TiC) powder is composed of carbon and titanium, typically with small amounts of other metallic elements. It has an extremely high melting point at 3140°C and high hardness close to titanium nitride. Some key properties and characteristics include:

Table 1: Properties and Characteristics of Titanium Carbide Powder

Properties	Characteristics
Chemical formula	TiC
Composition	Titanium (88.1%), Carbon (11.9%)
Color	Gray to black powder
Melting point	3140°C
Density	4.93 g/cm3
Mohs hardness	2800-3200 HV
Strength	High compressive and flexural strength
Thermal properties	High thermal conductivity and resistance to thermal shock
Electrical conductivity	Metallic electrical conductor
Oxidation resistance	Resists oxidation up to 800°C in air
Acid resistance	Insoluble in room temperature acids

Some key advantages of titanium carbide powder are extreme hardness and wear resistance, maintenance of mechanical strength over 3100°C, and chemical inertness. Disadvantages include brittleness and lower resistance to oxidation over 800°C compared to other carbides.

Manufacturing Methods

Titanium carbide powder can be produced via several manufacturing processes:

Table 2: Overview of Titanium Carbide Powder Manufacturing Methods

Method	Description	Characteristics
Direct carbide reaction	Titanium powder is carburized by heating with carbon above 1600°C	Lower purity, larger grains
Self-propagating high-temperature synthesis (SHS)	Highly exothermic thermite reactions used to produce TiC	Finer grain sizes
Sol-gel	Wet chemical method using titanium and carbon precursors	Ultrafine uniform powder particles
Plasma synthesis	TiC formed from gaseous reactants in plasma discharge	Spherical nanopowders with high purity
Other methods	Electrolysis, laser pyrolysis, combustion synthesis	Specialty powders with unique sizes and shapes

Key factors in selecting a production method include required powder characteristics like particle size, shape, purity levels, and cost.

Applications of Titanium Carbide Powder

Some major applications for titanium carbide powder include:

Table 3: Overview of Industrial Applications of Titanium Carbide Powder

Industry	Applications
Aerospace	Thermal protection systems, blast nozzles
Automotive	Ceramic vehicle armor, brake discs
Manufacturing	Cutting tools, forming dies, bearing surfaces
Construction	Nozzle liners, rock drilling buttons
Energy	Nuclear fuel coatings, fusion reactor materials
Chemicals	Fluid catalyst supports, corrosion resistant linings

Titanium carbide creates lightweight composites like TiC-Ni and TiC-Co with extreme hardness and wear resistance suitable for the most demanding mechanical and high-temperature applications.

It is most valued for the following capabilities:

• Maintains strength over 3100°C – retains properties where steels and carbides fail
• Extreme hardness resists abrasion wear even at high temps
• Low thermal expansion aids thermal shock resistance
• Resists erosion, corrosion, and chemical attack

Specifications and Grades

Titanium carbide powder is available in standard and customized specifications:

Table 4: Specifications and Grades of Titanium Carbide Powder

Parameter	Specification Range
Purity	89-99.5% TiC
Carbon content	5-15%
Particle size	0.5 μm – 45 μm
Particle shape	Spherical, angular, crushed
Density	4.90 – 5.10 g/cm3
Hardness	2800-3200 HV Vickers
Oxygen content	< 2% wt
Specific surface area	0.5 – 15 m2/g
Tap density	2.0 – 3.5 g/cm3

Grades:

• Nuclear grade >99% TiC
• Structural grade 89-92% TiC
• Metallurgical grade 70-75% TiC

Higher purity nuclear grades have lower free carbon, iron, nickel contaminants. Structural TiC has higher hardness and uniform coarse grains.

Standards and Testing Methods

Titanium carbide powder products must meet various application standards for composition, impurities, particle size distribution, and other parameters specific to the end use. Some common standards include:

Table 5: Standards and Testing Methods for TiC Powder

Standard	Description
ISO 11358	Carbide powders – Determination of particle size distribution by laser diffraction
ASTM C1046	Standard Practice for Inspection of Titanium and Titanium Alloy Castings
AMS-H-8656	Tungsten base, cobalt base, iron base, nickel base; ceramic and carbide powder, aircraft quality
MIL-PRF-32159	Performance requirements for titanium alloy powder and hot isostatic pressed (HIP) ring forgings for rotating turbomachinery components
GB/T 5481	Metallurgical analysis methods for carbide powders
JIS R 1611	Powder metallurgy – Carbide powders Sampling and testing methods

These standards help ensure product reliability across different production lots and multiple suppliers. Both suppliers and end users frequently utilize additional analytical techniques like SEM, EDX, XRD, and laser particle size analysis to characterize materials in detail.

Suppliers and Pricing

Titanium carbide powder is commercially available from many major suppliers globally. Some leading manufacturers include:

Table 6: Select Suppliers of Titanium Carbide Powder

Supplier	Location	Product Grades
Atlantic Equipment Engineers	US	Nuclear, structural, metallurgical
H.C. Starck	Germany	Nuclear, sputtering grades
Kennametal	US	Custom alloys and composites
Materion	US	High purity nuclear grades
Micron Metals	US	Standard and custom particle sizes
Reade Advanced Materials	US	Powders and HIP products
UK Abrasives	UK	Multiple purities

Pricing can range widely:

• Nuclear grade TiC powder – $1800+ per kg
• Structural grade TiC powder – $20-100 per kg
• TiC ingots for HIP products – $50-200 per kg

Exact pricing depends on purity levels, particle size specs, purchase quantities, and more.

Comparing Titanium Carbide Powder to Alternatives

Table 7: Comparison of Titanium Carbide Powder with Alternative Hard Ceramics

Parameter	Titanium Carbide	Tungsten Carbide	Silicon Carbide
Density	4.93 g/cm3	15.63 g/cm3	3.21 g/cm3
Hardness	2800-3200 HV	1300-2400 HV	2400-2800 HV
Max use temp	3100°C	700°C	1650°C
Fracture toughness	3-6 MPa√m	10-15 MPa√m	3-5 MPa√m
Oxidation resistance	Good to 800°C	Poor above 500°C	Excellent to 1600°C
Cost	Moderate	Low	Low
Toxicity	Low	High	Low

Key Differences:

• Tungsten carbide has higher toughness
• Silicon carbide has better oxidation resistance
• Titanium carbide can withstand extremely high temps
• Titanium carbide offers the best all-round performance

Advantages and Limitations

Table 8: Advantages vs Limitations of Titanium Carbide Powder

Advantages	Limitations
Extreme hardness at high temperatures	Brittle with lower fracture toughness
High corrosion and wear resistance	More expensive than tungsten carbide
Maintains strength above 3100°C	Oxidizes readily over 800°C
High thermal conductivity	Sensitive to oxygen contamination

Key Applications In Depth

Titanium carbide enables exceptional performance improvements across industries from aerospace and automotive to manufacturing and energy. This section explores some key applications highlighting titanium carbide’s superior properties.

Aerospace Applications

Aerospace applications demand materials that withstand extreme environments. Titanium carbide maintains strength over 3000°C, resists thermal shock, and does not degrade after repeated heating cycles – ideal properties for hypersonic aircraft components.

Leading Edge Materials and Coatings

Titanium carbide composites TiC-Ni and TiC-Co allow sharp leading wing edges on hypersonic vehicles to resist intense frictional heating during atmospheric reentry up to 3200°C. Performance is far superior to traditional graphite or ceramic matrix composites.

Additionally, titanium carbide coatings applied via chemical vapor deposition (CVD) or physical vapor deposition (PVD) protect wing surfaces, engine intakes, and other components from oxidation and abrasive wear at speeds over Mach 5.

Thermal Protection Systems

Reusable thermal protection systems (TPS) on spacecraft endure extreme temperature swings from -150°C in space to 1650°C during re-entry. Titanium carbide maintains strength across this range and resists thermal fatigue cracking after repeated exposures better than other ceramics.

For example, the X-37B spaceplane uses a TiC layer in its TPS to protect underlying vehicle structure. TiC ablators also insulate rocket nozzles and hypersonic scramjet engines from exhaust gases reaching 3300+°C.

Aircraft Brakes

Carbon brakes on jet aircraft must withstand over 700°C during landings at 160 knots speeds. However, carbon oxidizes readily resulting in dusting and early wear.

Replacing carbon components with titanium carbide rotors and stators dramatically extends part life and increases allowable braking temps to 1150°C resulting in lighter braking systems overall.

Armaments

Molten metal rapidly destroys traditional gun barrel linings causing uneven wear or barrel explosions. However, plasma-sprayed titanium carbide coatings resist metal erosion exceptionally well and allow sustained firing of high-caliber armaments beyond normal operating temps with minimal wear.

Automotive Uses

Automakers constantly research materials to build faster, safer, lighter cars and trucks. The auto industry heavily utilizes titanium carbide for armor, brakes, and engine components.

Vehicle Armor

Military vehicles use titanium carbide ceramic composites like TiC-Kevlar rather than traditional steel for ballistic armor. This reduces weight by 30% while actually increasing protection levels against armor-piercing threats.

Ceramic laminates with a TiC strike face better disperse and deform incoming projectiles versus metallic plates. Lighter armor improves vehicle mobility and fuel efficiency critical for combat missions.

Brake Discs

Formula 1 and other high-performance vehicles run titanium carbide ceramic matrix composite (CMC) brake discs to handle extreme temperatures from repeated braking G-forces at top speeds up to 350 kph.

TiC discs also improve stopping power and eliminate brake fade issues plaguing high-end sports cars during racing use. Regenerative braking systems on electric vehicles similarly rely on titanium carbide rotors for extreme heat tolerance.

Wear Components

Titanium carbide extends the life of highly-loaded engine components prone to abrasion at high temperatures above 1000°C. For example, replacing traditional steel valves and piston sleeve inserts with TiC versions achieves 50-100% longer operating times before wear reaches failure limits.

In coated engine bores, TiC outperforms the nickel-carbide thermal spray coatings used currently. This allows higher peak pressures and combustion temps for increased fuel efficiency.

Cutting Tools

All major cutting tool suppliers offer an extensive range of inserts, drills, endmills, and specialty tooling with a titanium carbide substrate bonded with other carbides, ceramics, or diamond coatings.

Wear Resistance

TiC maintains hardness past conventional tool steels softening point around 600°C allowing faster material removal rates, higher cutting speeds, and lower wear in dry high-speed machining applications.

Thermal Properties

The high thermal conductivity prevents localized hot spots during interrupted cuts which cause tool breakage. TiC also exhibits minimal thermal expansion equaling diamond – critical for micro-manufacturing precision tooling.

Performance Upgrades

Replacing traditional tungsten carbide components like indexable inserts with TiC upgrades extends tool life 2-4x for the same operating parameters. Alternatively, cutting speeds or feed rates can be increased significantly while achieving the same insert wear levels.

For next-generation aerospace alloys difficult to machine like Inconel 718, titanium aluminide TiAl, and metal matrix composites MMCs, titanium carbide tooling enables viable manufacturing options not otherwise possible.

Nozzle Inserts

Titanium carbide nozzles stand up to highly erosive particle flows handling abrasives from agricultural materials and minerals processing to shot peening and powder metal sintering:

Abrasion Resistance

TiC nozzle inserts used in food, pharmaceutical, and specialty chemicals processing routinely outlast traditional tungsten carbide, silicon carbide, and chromium carbide versions by 300 – 500% in extremely abrasive fine powder streams.

High Velocity Protection

Titanium carbide shrouds containing cooling air vortexes shield composite aircraft engine blades from incoming grit exceeding 650 m/s speeds. During blade containment tests, TiC components survive blade punctures from fan disintegration events intact where alternative materials fracture.

Extreme Temperature Usage

Plasma spray nozzles for molten zirconium, steel, and glass fiber production consist of free standing TiC pipes without additional cooling. TiC reliably withstands slag corrosion and metal droplet ejection heat fluxes over 3000°C which easily destroy cobalt and nickel alloys.

Nuclear Applications

Titanium carbide is widely deployed across the nuclear power industry from cladding nuclear fuels to first wall protection in experimental fusion reactors.

Fuel Cladding

Conventional zirconium fuel cladding alloys can oxidize, melt, and release radioactive isotopes during a reactor core overheating accident. However, titanium carbide coatings allow cooler, slower reactions forming a passivating TiO2 layer to contain escaping particles – greatly increasing safety limits.

Plasma Facing Components

Inside experimental tokamak fusion reactors, intense 40 MW/m2 plasma heat fluxes rapidly erode solid armor tiles as fusion particles and x-rays continually bombard surfaces. Thermal sprayed layers or free-standing TiC components withstand these harsh conditions better with 2-3x longer operational lifetimes versus tungsten alternatives before requiring replacement.

Radioactive Waste Containers

After fuel reprocessing, high-level radioactive liquids are vitrified into borosilicate glass logs stored in corrosion resistant canisters. Titanium carbide’s complete impermeability to gases and liquids over geological time periods enables safe long duration storage without leakage into the environment.

Oil and Gas Drilling

Titanium carbide deserves special distinction as the hardest, hottest, most wear resistant rock drilling insert material ever developed. TC buttons have become the gold standard across the oil, gas, and geothermal drilling industry outperforming previous polycrystalline diamond compact (PDC) solutions.

Frictional Rock Abrasion

Rotary cone drill bits utilized for deep land drilling to 6000 m depths encounter extreme rock face pressures and 100 kW frictional heat fluxes during cutting. Solid TC inserts maintain hardness exceeding 3200 HV under these conditions while drilling 5-10x faster than steel teeth before requiring replacement.

High Speed Rock Penetration

Geothermal and oil/gas drilling firms specializing in hard sedimentary or basalt layers exclusively run TC button bits clocking penetration rates up to 4x higher than alternative drill types with equivalent wear life.

Bottom line – nothing cuts through rock better than titanium carbide while standing up to the punishing downhole environment.

Conclusion

With extreme hardness, temperature resistance beyond 3000°C, and high wear performance, titanium carbide empowers exceptional material properties not found in competing ceramics or traditional alloys. TiC reliably withstands the most violent thermal, chemical, and mechanical extremes across every industry.

Yet despite the significant performance benefits, titanium carbide costs less than comparable refractory metals like molybdenum or tungsten. This unique combination of capabilities and affordability drives titanium carbide’s growing utilization in aerospace, automotive, manufacturing, energy, and the most demanding applications globally.

As technology progresses enabling more reliable production and availability, expect titanium carbide penetration to accelerate further. The material defines the cutting edge.

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