Continuous Melting and Atomisation of Titanium Alloys

Phoenix Scientific Industries Ltd is joined by consortium partners BAE Systems Ltd, Maher Ltd and the University of Greenwich to deliver COLDMELT 2\. The project aligns with the technology enabling 'cross-cutting' focus area within the UK Aerospace Technology Strategy, 'Destination Zero'. AIRBUS Ltd, Spirit Aerosystems Ltd, Rolls-Royce PLC and GKN GKN Aerospace Services Ltd are providing an in-kind contribution in the form a steering input to ensure the requirements of the civil aerospace sector are addressed.

This project will lead to the transformation of titanium powder production via 'cold-crucible' gas atomisation to enable high volume production. The current batch process will be replaced by a continuous process producing high purity, fine, spherical powders which can be sold commercially at a target price substantially below the level offered by existing supply chains (competing production methods being restricted in productivity). This requires sound engineering design, robust manufactured components and innovative utilisation of induction melting technology and the support of advanced multi-physics simulation. The output of this project will be to demonstrate for the first time continuous cold-crucible titanium atomising thereby achieving **TRL6**. During a privately funded subsequent exploitation project, a UK production capability will be established thereby onshoring supply for this critical material. This facility, owned by a UK based company, will be ready for commercial powder production in 2026\.

Increased availability and reduced cost titanium powder will lead to greater adoption of near-net shape manufacturing including additive manufacturing (AM), powder metallurgy hot isostatic pressing (PM/HIP) and thermal spray. Titanium alloys are characterised by high strength-to-weight ratio, excellent corrosion resistance and biocompatibility making them highly desirable in number of applications. The new low-cost, high-volume supply of titanium powder will benefit the aerospace sector through increased sustainability and industrial competitiveness with further spillover into the automotive and medical sectors among others.