Synthesis of Y2O3 Oxide Dispersion-Strengthened Ti-6Al-2Sn-4Zr-2Mo Alloy Powder by In Situ Gas Atomization Method

Oxide dispersion-strengthened (ODS) alloys demonstrate enhanced mechanical properties at elevated temperatures and show potential as next-generation powder materials for additive manufacturing. These alloys can mitigate defects such as micropores and cracks by regulating solidification and grain growth behaviors during the additive manufacturing process. This study investigates the fabrication technology for ODS Ti-6Al-2Sn-4Zr-2Mo (Ti6242) alloy powder to achieve uniform oxide distribution within the alloy powders. Thermodynamic calculations were employed to determine the optimal Ti6242-Y₂O₃ composition for in situ gas atomization, ensuring complete dissolution of the oxide in the Ti6242 molten metal and subsequent reprecipitation upon cooling. A rod-shaped ingot was produced via vacuum arc melting, resulting in coarse Y₂O₃ precipitating along the grain boundaries. The powder was fabricated through an electrode induction gas atomization method, and the ODS Ti6242 powder exhibited a spherical shape and a smooth surface. Cross-sectional analysis revealed the uniform distribution of Y₂O₃ oxide particles, measuring several tens of nanometers in size, within the alloy powder. This research demonstrates the successful synthesis of oxide-integrated ODS Ti6242 alloy powder through the in situ gas atomization method, potentially advancing the field of additive manufacturing for high-temperature applications.