A new, continuous process is proposed for direct manufacture of titanium at very low cost and high energy efficiency. The proposed process is very robust, and could also produce intermetallic TiAl, Ti3Al, TiAl3, and other alloys. The proposed process has inherent economies suitable for making titanium and titanium alloys as inexpensive, commodity metals for general use, rather than as exotic materials to be used only when their high performance is required despite their presently high cost.Anticipated Benefits/Commercial Applications: Titanium and its alloys are important, but costly, materials for aerospace structural and propulsion components. The relatively low density of titanium, combined with its high-temperature properties, high specific stiffness, high strength, high corrosion resistance and relative toughness, are particularly desirable in aerospace systems. Titanium and TiAl are also used, or under development in reinforced composite aerospace components, such as advanced SiC-fiber-reinforced titanium alloy engine and structural components. TiAl automotive valvetrain components also provide improved performance and improved fuel economy, but are prohibitively expensive for general use. A low-cost proess for producing titanium and its alloys would provide enormous savings where it is currently used despite its cost, and would greatly expand the use of the metal and its alloys into general aviation and automotive areas where its cost has been prohibitive.
