Synthesis of Titanium Carbide Powder by a Non-Vacuum Electric Arc Method and Fabrication of Porous Cermets

Alloy steel scale is a large-tonnage metallurgical waste that represents a potential environmental hazard during storage and disposal. This study investigates its recycling as a component of reactive powder mixtures for producing porous cermets by self-propagating high-temperature synthesis (SHS). Titanium carbide was synthesized from TiO2 and carbon using a non-vacuum electric arc method, while the initial powders were mechanically activated to enhance their reactivity and homogeneity. SHS was performed under air, vacuum, and argon atmospheres. The composition of the reactive mixture and synthesis atmosphere significantly affected phase formation, pore structure, and mechanical properties. Within the investigated range, the most favorable combination of structural characteristics was obtained under argon for the composition FeO-45 wt.%, Al-20 wt.%, Al2O3-7.5 wt.%, Cr2O3-5 wt.%, TiC-10 wt.%, and FeSi-12.5 wt.%, yielding a total porosity of 60%, an average pore diameter of 121 μm, and a permeability of 48%. SEM and XRD analyses revealed a developed porous structure and Fe–Al, Cr–Al, and Ti–Al–C phases. The cermets exhibited a compressive strength of 18 MPa, flexural and yield strengths of 17 MPa, a hardness of 860 HV, and an elastic modulus of 36 GPa. The developed cermets demonstrate potential for lightweight, permeable, and high-temperature engineering applications while providing an effective route for recycling metallurgical waste.