Cleaner Production of Ti Powder by a Two-Stage Aluminothermic Reduction Process

A two-stage aluminothermic reduction process for preparing Ti powder under vacuum conditions using Na₂TiF₆ was investigated. An Al-Ti master alloy and a clean cryolite were simultaneously obtained as co-products. The first-stage reduction was an exothermic process that occurred at approximately 660°C. The Al and O contents of the Ti powder product were 0.18 wt.% and 0.35 wt.%, respectively, with an average particle size <74 μm. Ti(IV), Ti(III), and metallic Ti were present in the Ti-containing cryolite produced by the first-stage reduction, at a total content of approximately 3.13 wt.%. After second-stage reduction, the Ti elemental contents of the clean cryolite were reduced to 0.002 wt.%. The Al-Ti master alloy obtained by second-stage reduction was composed of Al and TiAl₃. The mechanisms involved in these reduction processes were also examined.