Evolution of Morphology, Particle Size and Oxidation Resistance of Recycled Ti-6Al-4V Powders Prepared by Planetary Ball Milling

Planetary ball milling is a high-energy ball milling technique that is widely used for the synthesis of alloy and composite powders with micrometer or nanometer particle sizes. The effect of process control agent (PCA) content (wt%) and milling time on the morphology, particle size and distribution, crystallite structure, apparent density and oxidation resistance of recycled T-6Al-4V alloy powders from lathe chips is investigated in this study. To investigate the effect of the PCA on the properties of the Ti-6Al-4V alloy particles, methanol is used as the PCA in various amounts of 0.5, 1 and 2 wt%. The milling is carried out using 20:1 of ball-to-powder ratio (BPR) and 400 rpm of milling speed. A morphological change from scrap form to flake-like shape, from flake-like morphology to irregular and semispherical shape and finally from semispherical form to spherical morphology is observed with increase in milling time for all PCA ratios. The results showed that the average particle sizes (D50) are 20, 18.1 and 21.8 μm after milling of 360 min with 0.5 wt%, 1 wt% and 2 wt% PCA, respectively. Results show that the most suitable recycled Ti-6Al-4V powders for powder-based manufacturing techniques are produced between 180 and 360 min of milling with 2 wt% PCA.