How Does Particle Size & Mixing Of Titanium Powder Affect Porous Structures? Optimize Your Porous Titanium Production

Strict control over particle size and volume mixing ratios is the deciding factor in creating successful porous titanium structures. To ensure the formation of a fully interconnected network, you must use titanium powder that is significantly finer than the salt particles and mix them at approximately a 50:50 volume ratio.

Core Takeaway The ultimate goal is to achieve a "bicontinuous network" where both the titanium matrix and the salt phase are continuous and interconnected. Failing to maintain a fine particle size for titanium or deviating from the 50:50 volume ratio leads to salt encapsulation, preventing water access and resulting in a failed, non-porous component.

The Mechanics of Network Formation

The Importance of Particle Size Disparity

To successfully create a porous structure, the titanium powder must be significantly finer than the salt particles.

This size difference allows the smaller metal particles to pack densely around the larger salt "space-holders."

If the metal particles were similar in size to the salt, they would not coat the salt surfaces effectively, compromising the structural integrity of the final matrix.

Achieving Bicontinuous Structure via Mixing Ratios

A volume mixing ratio of approximately 50:50 is required to create a bicontinuous network.

In this state, the titanium forms a continuous skeleton for strength, while the salt forms a continuous network of tunnels.

This balance is the threshold required to ensure that the salt is not isolated into discrete islands within the metal.

The Critical Role of Hot Isostatic Pressing (HIP)

Densification and Connectivity

During the Hot Isostatic Pressing (HIP) phase, the mixture is compressed and heated to bond the titanium particles.

Because the mixing ratio is balanced (50:50) and the titanium particles are fine, the densification process locks the materials into an interlocked, two-phase structure.

This step solidifies the geometry that defines whether the final product will be porous or solid.

Understanding the Trade-offs: The Encapsulation Trap

The Risk of Improper Proportions

If the volume of titanium is too high relative to the salt, the metal matrix will completely surround individual salt particles.

This phenomenon is known as encapsulation.

The Dissolution Failure Mode

The creation of pores relies entirely on the ability to wash the salt away with water after densification.

If the salt is encapsulated due to a lack of connectivity in the salt phase, water cannot penetrate the titanium shell to reach the core.

This renders the dissolution process impossible, leaving you with a solid composite part containing trapped salt rather than an open, porous titanium structure.

Optimizing Process Parameters

If your primary focus is ensuring open porosity:

Strictly adhere to the 50:50 volume mixing ratio to guarantee that the salt phase remains interconnected and accessible to water.

If your primary focus is matrix uniformity:

Ensure the titanium powder is significantly finer than the salt to allow for tight packing and consistent coating of the space-holder particles during HIP.

Success in porous titanium fabrication relies on treating the salt not just as a filler, but as a continuous network that must remain unbroken until it is dissolved.

Summary Table:

Parameter	Ideal Specification	Impact on Structure
Titanium Particle Size	Significantly finer than salt	Ensures dense packing and effective coating of salt surfaces
Volume mixing Ratio	Approximately 50:50	Creates a bicontinuous network for both strength and porosity
Salt Phase Status	Fully interconnected	Allows water access for complete dissolution post-HIP
HIP Role	Controlled densification	Bonds titanium particles into a solid skeleton around the salt

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References

Iain Berment-Parr. Dissolvable HIP Space-Holders Enabling more Cost Effective and Sustainable Manufacture of Hydrogen Electrolyzers. DOI: 10.21741/9781644902837-4

This article is also based on technical information from Kintek Press Knowledge Base .