Microstructure and Mechanical Properties of a High-Strength Ti-4Al-2Fe-3Cu Alloy Fabricated by Sintering and Hot Extrusion

A Ti-4Al-2Fe-3Cu (wt pct) alloy containing only low-cost alloying elements was fabricated by vacuum sintering a blend of TiH₂, Al, Fe, and Cu powders at 1200 °C for 1 hour followed by hot extrusion at the same temperature. The as-extruded alloy exhibited a microstructure consisting of mainly α/β lamellar colonies and Ti₂Cu as a minor phase. The average colony size and lamella thickness were 118 and 12 µm, respectively, and Fe and Cu were predominantly distributed in the β lamellae. The as-extruded alloy had a high tensile yield strength (YS) and ultimate tensile strength (UTS) of 1248 and 1270 MPa, respectively, but a limited ductility (elongation to fracture: 2.3 pct). Annealing at 750 °C for 4 hour caused the average colony size and lamella thickness of the alloy to increase to 145 and 17 µm, respectively, and the volume fraction of the β phase decreased with the annealing. These microstructural changes resulted in a slight decrease of the YS and UTS to 1221 and 1253 MPa, but a clear increase of the ductility with the elongation to fracture reaching 4 pct. This work demonstrates that a combination of relatively low-temperature vacuum sintering, hot extrusion, and annealing can be effectively utilized to fabricate a low-cost Ti-4Al-2Fe-3Cu alloy with high strength and appreciable tensile ductility.