Titanium Sponge Powder

Titanium sponge powder is a key material used as the feedstock for manufacturing titanium metal components and products. This powder metallurgy route offers several benefits over extraction from mineral ores. This article provides an overview of titanium sponge including its composition, key characteristics, processing methods, applications, suppliers, and more.

Overview of Titanium Sponge Powder

Titanium sponge is the porous form of unalloyed titanium that is the raw material used in powder metallurgy to produce titanium metal components. It is prepared by reducing titanium tetrachloride (TiCl4) derived from mineral ores using magnesium or sodium.

The sponge particles have high surface area and reactivity, allowing them to be easily converted into powders, ingots, mill products, and parts using processes like vacuum arc remelting (VAR), hot isostatic pressing (HIP), additive manufacturing, metal injection molding, and powder forging.

Below is a summary of titanium sponge powder’s properties, applications, global production, pricing, and more.

Titanium Sponge Powder – Key Details

Parameter	Details
Composition	Unalloyed titanium (>99% titanium)
Particle shape	Porous, irregular shaped sponge particles
Particle size	Typically <15 mm size
Purity	>=98%, can be up to 99.9%
Density	2.2 – 2.7 g/cc
Melting point	1668°C
Key properties	Low density, high strength, excellent corrosion resistance even at high temperatures
Main applications	Feedstock for titanium metal powders, mill products, additive manufacturing
Annual global production	~300,000 tonnes with 75,000 tonnes in USA and 100,000 tonnes in China
Cost	~$8-15 per kg for CP-Ti grade sponge

Titanium sponge enables the economical production of titanium components using near-net shape and powder metallurgy techniques compared to traditional ingot metallurgy involving multiple melt-mill-weld steps with high material waste.

Next, we examine the composition and characteristics of titanium sponge powder in more detail.

Composition of Titanium Sponge Powder

Titanium sponge powder consists of porous aggregates of titanium metal containing small amounts of impurities like chlorides, magnesium, iron, silicon, nitrogen, carbon, and oxygen. High purity sponge with low O and N content is required for critical aerospace applications.

Titanium Sponge Composition

Element	Weight %
Titanium (Ti)	98 – 99.9%
Oxygen (O)	0.08 – 0.45%
Nitrogen (N)	0.02 – 0.15%
Carbon (C)	0.04 – 0.16%
Iron (Fe)	0.15 – 0.5%
Chloride (Cl)	0.10 – 0.30%

The ASTM International standard ASTM B837 specifies the requirements for commercial purity unalloyed titanium sponge based on the sponge grade as follows:

ASTM Specification for Titanium Sponge Grades

Grade	Titanium Content	Oxygen Content	Iron Content	Nitrogen Content
CP Ti Grade 1	99.2% min	0.40% max	0.20% max	0.03% max
CP Ti Grade 2	98.9-99.5%	0.25% max	0.30% max	0.05% max
CP Ti Grade 3	98.3-99.2%	0.35% max	0.30% max	0.05% max
CP Ti Grade 4	97.75-99.2%	0.40% max	0.50% max	0.05% max

Higher purity sponge powder with controlled low levels of O and N is required for critical applications like aircraft engine components. This is when grades with 99.5%+ titanium like Ti-6Al-4V Grade 5 or Grade 23 are specified.

Next, we look at the key properties of titanium sponge that make it an excellent engineering material across industries.

Properties of Titanium Sponge Powder

Titanium is valued for its unique combination of low density coupled with high strength retention even at elevated temperatures beyond 500°C. It also offers excellent corrosion resistance in harsh environments.

Key properties of titanium sponge powder are:

Properties of Titanium Metal Sponge

Property	Details
Density	4.5 g/cm3, almost half that of steel and nickel alloys
Tensile strength	340-450 MPa for CP grades, higher for Ti alloys
Yield strength (proof strength)	170-380 MPa for CP grade sponges
Melting point	1668 ± 10°C
Young’s modulus	100-115 GPa, lower than steel
Poisson’s ratio	0.32-0.34
Coefficient of thermal expansion	8.5 x 10<sup>-6</sup> /K (20-100°C)
Thermal conductivity	6.7-21 W/m.K at 20°C
Electrical resistivity	420-470 nΩ.m at 20°C
Magnetism	Non-magnetic
Corrosion resistance	Excellent due to protective oxide layer
Biocompatibility	Highly bioinert material

The combination of low weight, high strength at low and high temperatures, corrosion and heat resistance makes titanium indispensable across aerospace, chemical, power generation, automotive, marine, and biomedical industries among others.

Next, we examine some of the major applications and uses of titanium sponge powder across industries.

Applications of Titanium Sponge Powder

The main industrial applications of titanium sponge include the following sectors:

Applications of Titanium Sponge Powder

Sector	Applications
Aerospace	Jet engine and airframe components, blades, fasteners, landing gear
Power generation	Components for steam and gas turbines, heat exchangers
Chemical processing	Tanks, vessels, heat exchangers, pipes, pumps
Marine	Components for ships, submarines, offshore platforms
Automotive	Connecting rods, valves, springs, fasteners, exhausts
Biomedical	Implants, prostheses, surgical instruments, devices
Petroleum	Drill strings, wellhead system components
Sporting goods	Golf clubs, tennis rackets, bicycles
Military	Aircraft, vessels, armour products
Desalination	Heat exchangers, pressure vessels, tubes

Titanium usage continues to grow at 8-10% CAGR in industries like aerospace, chemical processing, power generation, and seawater desalination. Market demand is forecast to increase from 300,000 tonnes currently to around 575,000 tonnes by 2030.

Let’s look at the various product forms derived from titanium sponge powder.

Titanium Powder Types and Forms

Titanium metal powder and mill products are manufactured from sponge feedstock using processes like vacuum arc remelting (VAR), hot isostatic pressing (HIP), additive manufacturing (AM), metal injection molding (MIM), and others.

Titanium Powder Products Derived from Sponge

Form	Details
Hydride-dehydride (HDH) powder	Irregular shaped <150 μm size powder
Gas atomized spherical powder	Spherical 15-150 μm size used in AM
Alloyed prealloyed powders	Ti-6Al-4V, Ti-6Al-2Sn-4Zr-6Mo etc.
VAR ingots, billets	Remelted ingots and wrought products
HIP powder metallurgy products	Custom near-net shape parts
Metal injection molding feedstock	Powders for MIM process
Powder forged connecting rods	Automotive, marine applications
Additive manufacturing feedstock	Laser powder bed, direct laser deposition

These mill products are further fabricated into finished components and end products across industries.

Next, we examine the manufacturing process and supply chain aspects of titanium metal sponge powder.

Manufacturing Process of Titanium Sponge

Titanium sponge powder is commercially produced by reducing titanium tetrachloride (TiCl4) using sodium or magnesium under strict process controls. TiCl4 itself is produced

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The basic steps for titanium sponge production are:

Titanium Sponge Manufacturing Process

1. Extract titanium dioxide (TiO2) from mineral ores
2. Convert TiO2 to titanium tetrachloride (TiCl4) using the chloride process
3. Reduce TiCl4 with magnesium/sodium under vacuum at 800-850°C
4. Diffuse out the salts and condense pure titanium
5. Process the porous titanium sponge by crushing, cleaning and sieving

The titanium sponge powder is highly reactive and pyrophoric. So it is handled and stored under inert atmospheres like argon to prevent ignition and explosion hazards.

The porous irregular shaped sponge particles have very high surface area to volume ratio, allowing efficient degassing, compaction and alloying during subsequent melt and powder consolidation steps.

About 75% of titanium sponge output is used to manufacture titanium mill products. The remaining 25% is utilized to produce titanium powders for additive manufacturing and powder metallurgy applications.

Global Production and Leading Suppliers

Currently, global titanium sponge production is around 300,000 metric tons annually. The geography is concentrated with USA and China accounting for almost 60% of world output.

Some of the major titanium sponge manufacturers globally include:

Key Titanium Sponge Manufacturers

Company	Location	Capacity
VSMPO-Avisma	Russia	52,000 mt
Western Titanium	USA	30,000 mt
Toho Titanium	Japan	20,000 mt
UKTMP JV	Kazakhstan	30,000 mt
Northwest Institute of NTM	China	20,000 mt
ZTMC	China	15,000 mt

USA has proposed restrictions on titanium exports to Russia and China due to strategic concerns in the aerospace sector. This may restructure supply chains and boost production expansions in other regions.

Overall, there is increased installed capacity expected globally with growth opportunities for titanium sponge manufacturers and traders serving various user industries.

Cost Analysis and Pricing Trends

Titanium sponge powder prices vary in the range of $8-16 per kg based on supplied quantity, grade/quality, geography, delivery schedules, long term contracts, and other commercial factors.

Titanium Sponge Price Range

Grade	Price per kg
CP Grade 1	$8 – 12
CP Grade 2	$10 – 14
CP Grade 3	$12 – 15
CP Grade 4	$10 – 16
Ti 6Al-4V Grade 5, Grade 23	$14 – 20

Prices rose sharply in 2022 due to strong demand recovery across aerospace and other sectors post-pandemic, as well rising energy, feedstock, and logistics costs.

However, some easing is expected from mid-2023 with global sponge capacity rising. Overall industry outlook remains positive with titanium sponge demand forecast to grow steadily at 6-8% CAGR over the next decade.

FAQs

Q. What is titanium sponge?

Titanium sponge is a porous form of high purity titanium metal in powder form that is used as feedstock to manufacture titanium mill products, powders, and parts across industries.

Q. How is titanium sponge powder produced?

It is produced commercially by reducing titanium tetrachloride (TiCl4) derived from mineral ores using magnesium or sodium metal under strictly controlled conditions.

Q. What are the applications of titanium sponge?

Key applications are in aerospace engines and airframes, power generation plants, chemical plants, marine hardware, biomedical implants and devices. It serves industries needing high strength, low weight and corrosion resistant metal components.

Q. What are the advantages of titanium vs. steel?

Compared to steel, titanium offers higher strength-to-weight ratio, superior high temperature properties, non-magnetic response, and much better corrosion resistance benefiting demanding applications.

Q. Who are leading manufacturers of titanium sponge?

Major global producers include VSMPO-Avisma, Western Titanium, Toho Titanium, UKTMP JV, Northwest Institute of NTM, ZTMC with capacities spanning from 15,000 to 50,000 metric tons per annum currently.

Q. What is the price range for titanium sponge per kg?

Prices vary from $8-16 per kg based on grade, order size, geographies, delivery schedule and other commercial factors. Multi-year contracts also impact effective realized pricing for buyers and sellers.

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Frequently Asked Questions (FAQ)

1) How does Titanium Sponge Powder differ from spherical titanium powder for AM?

• Sponge powder is porous/irregular and typically used as upstream feedstock (for VAR/HIP/HDH). Spherical AM powder is produced via gas atomization or PREP to achieve tight PSD (e.g., 15–45 µm) and high flowability for LPBF/EBM.

2) What impurity limits matter most for Titanium Sponge Powder?

• Interstitials (O, N, H) dominate properties. For CP sponge: O and N must meet ASTM B837 grade limits (e.g., O ≤0.25–0.40 wt% by grade). For AM feedstock derived from sponge, O is typically ≤0.15 wt% (≤0.13 wt% for ELI) and H ≤0.012 wt%.

3) Can Titanium Sponge Powder be used directly for additive manufacturing?

• Generally no. Sponge is usually converted to HDH or melted/atomized into spherical powder with controlled PSD and low satellites. Direct use risks poor flow, high oxidation, and defects.

4) What storage/handling practices reduce safety risk and oxidation?

• Store under inert gas, sealed containers with desiccants; keep away from ignition sources; ground equipment; maintain housekeeping to control dust; follow NFPA 484 and ATEX guidance; monitor O2 and humidity.

5) How do I qualify a new sponge lot for downstream powder production?

• Verify chemistry (ICP/OES), O/N/H (IGF), residual chlorides/Mg, inclusion cleanliness (SEM/EDS), and bulk density. Run pilot HDH or melt trials, measure PSD, flow (Hall/Carney), apparent/tap density, and correlate to downstream process yield and mechanicals.

2025 Industry Trends

• Upstream cleanliness: Producers add inline dechlorination and vacuum dehydrogenation steps, lowering residual Cl/H and improving yield in downstream atomization.
• Near-net consolidation: Increased use of HIP canning of HDH powder derived from sponge for structural billets with lower buy-to-fly.
• Traceability-by-design: QR/Genealogy from sponge lot through atomization to AM build is becoming standard in aerospace/medical audits.
• Sustainability: Argon recovery, scrap-to-sponge circularity, and life-cycle data in EPDs gain importance in procurement.
• Regional capacity shift: Investment in non-sanctioned regions diversifies supply and reduces geopolitical risk exposure.

2025 Snapshot: Titanium Sponge Powder KPIs

KPI	Typical Range/Value (2025e)	Notes/Source
Global sponge output	~300–330 kt/y	Company disclosures, industry reports
CP sponge price (Grade 2)	$9–14/kg	Contract/volume dependent
Oxygen (CP sponge)	0.08–0.40 wt% (grade-specific)	ASTM B837 context
Residual Cl (sponge)	0.10–0.30 wt% typical	Lower favored for melt cleanliness
Conversion yield to HDH <150 µm	75–90%	Process/PSD target dependent
AM-grade Ti-6Al-4V O content	≤0.15 wt% (≤0.13 wt% ELI)	Derived powders after atomization
Safety incidents (fine Ti powders)	Trending down with NFPA/ATEX compliance	Industry safety summaries

Authoritative sources:

• ASTM B837 (Commercially Pure Titanium Sponge), ASTM F2924/F3001 (AM Ti-6Al-4V), ISO/ASTM 52907 (AM feedstock): https://www.astm.org, https://www.iso.org
• ASM Handbook Vol. 7 (Powder Metallurgy), Vol. 2 (Nonferrous Alloys): https://www.asminternational.org
• NFPA 484 (Combustible Metals), ATEX/IECEx directives
• NIST and peer-reviewed journals: Additive Manufacturing, Materials & Design, Acta Materialia

Latest Research Cases

Case Study 1: Reducing Residual Chloride in Titanium Sponge for Improved Atomization Yield (2025)

• Background: An AM powder producer reported nozzle fouling and high oxide inclusions traced to elevated Cl in incoming sponge.
• Solution: Implemented enhanced vacuum dechlorination, additional argon purge during crushing, and ICP/ion chromatography release gates.
• Results: Residual Cl reduced from 0.22% to 0.08 wt%; gas atomization yield to 15–45 µm cut improved by 5.1%; inclusion rate (SEM/EDS) −30%; downstream LPBF density ≥99.7% without HIP.

Case Study 2: HDH-Derived Billet via HIP as a Cost-Down Route for Structural Ti (2024/2025)

• Background: An aerospace Tier-2 sought lower material cost vs. wrought while maintaining properties for non-rotating brackets.
• Solution: Produced HDH powder from certified sponge, vacuum degassed, canned, HIPed, and forged lightly; ultrasonic and CT inspection; Ti-6Al-4V aging per spec.
• Results: Yield strength 900–940 MPa, elongation 10–12%; buy-to-fly ratio −28% vs. wrought bar; cost per kg −18%; passed fatigue screening at R=0.1 with margin.

Expert Opinions

• Prof. Iain Todd, Professor of Metallurgy and Materials Processing, University of Sheffield
• Viewpoint: “Sponge cleanliness—particularly interstitials and halide residues—sets the ceiling for downstream powder quality and AM performance.”
• Dr. John A. Slotwinski, Additive Manufacturing Metrology Expert (former NIST)
• Viewpoint: “Lot genealogy from Titanium Sponge Powder to finished AM part is now a qualification artifact; data-rich CoAs shorten audits and reduce rework.”
• Dr. Sophia Chen, Senior Materials Scientist, Materion
• Viewpoint: “HDH routes derived from clean sponge are unlocking HIP billet solutions that compete with wrought in non-critical aerospace structures.”

Practical Tools/Resources

• Standards: ASTM B837 (Ti sponge), ISO/ASTM 52907 (AM powders), ASTM E1447 (H determination), ASTM E1019 (O/N), ASTM B962 (density)
• Testing/Metrology: ICP/OES for chemistry; IGF for O/N/H; SEM/EDS for inclusions; ion chromatography for residual Cl; Hall/Carney flow; PSD by laser diffraction/sieving; micro‑CT for porosity
• Safety guidance: NFPA 484 combustible metals; ATEX/IECEx zoning and dust hazard analyses; Class D extinguishing protocols
• Process modeling: Thermo-Calc/CALPHAD for alloying from sponge; ANSYS/Fluent for atomization gas flow dynamics
• Market/insight sources: USGS Mineral Commodity Summaries (Titanium), Metal-Powder.net, peer-reviewed AM journals

Implementation tips:

• Specify sponge with tight O/N/H and residual chloride limits; include cleanliness metrics in purchase orders.
• Require CoAs with chemistry, O/N/H, residual Cl, bulk density, and lot genealogy; set acceptance gates before HDH/melting.
• Pilot small-batch conversion (HDH or melt/atomize) to validate yield, PSD, flow, and inclusion levels before scaling.
• Maintain inert handling from sponge crushing through powder packaging; monitor O2 and humidity continuously.

Last updated: 2025-10-13
Changelog: Added 5-question FAQ, 2025 KPI table, two recent case studies (dechlorination for atomization and HDH-HIP billet route), expert viewpoints, and practical tools/resources with implementation tips specific to Titanium Sponge Powder
Next review date & triggers: 2026-04-20 or earlier if ASTM B837/AM standards update, major supply-chain/geopolitical changes affect sponge availability, or new safety guidance for titanium powders is issued