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Abstract
Powder injection moulding is a maturing technology that has proven most useful for the production of complex metallic and ceramic components of modest sizes. Considering the inevitable demand for cost effectiveness in automotive applications, components manufactured from low cost sponge titanium (Ti) powder currently reflect the most advantageous economics among the available Ti powders. This paper describes the net shape fabrication of Ti components and considers the role of iron and zirconium powder additions. Sintering cycle optimisation relied on differential scanning calorimetry to identify a cycle in the 1275–1300°C range for 1–2 h. The sintered material was characterised using tensile and hardness testing and microscopic examinations. The influence of test conditions on densification, microstructure and mechanical properties was analysed.