Ferrotitanium: A key binary alloy for metallurgical purification and strengthening of high-end steel

I. Core Definition of Titanium Iron Titanium iron is a binary composite alloy formed by titanium (Ti) and iron (Fe), with titanium as the core functional element and iron as the matrix component. Typical titanium content is 25%~75%, and iron content is 20%~65%. It is a high-performance composite deoxidizer, carbonitride forming agent, and grain refiner in the metallurgical industry. Its core value lies in the strong chemical activity and carbonitride affinity of titanium, possessing a triple effect of "deep deoxidation - inclusion purification - dispersion strengthening": it can efficiently remove oxygen and nitrogen impurities from steel, and form stable titanium carbide (TiC) and titanium nitride (TiN) dispersed phases, hindering grain growth and improving material strength and wear resistance. Suitable for high-end steels, special alloys, and other applications, it has become a key functional material connecting traditional metallurgy and high-end manufacturing. II. Development History The industrial production of ferrotitanium (FIG) began in the 1940s. With breakthroughs in titanium metallurgy technology (the mature Krauer process for titanium production), the United States achieved large-scale smelting of binary alloys for the first time. Initially, it was mainly used for quality optimization of steels used in military and aerospace industries (such as turbine disk steel for aircraft engines), solving the problem of traditional deoxidizers being unable to remove trace amounts of oxygen and nitrogen from steel. From the 1960s to the 1980s, the global stainless steel and high-strength steel industries rose, and the advantages of ferrotitanium in improving the corrosion resistance and welding performance of steel quickly became apparent. The production process was upgraded from open electric furnaces to a combined closed submerged arc furnace and aluminothermic furnace process, significantly improving capacity and product stability. Leveraging its titanium ore resource advantages (accounting for 28% of global titanium ore reserves and 35% of production), China achieved large-scale production in the 1990s. In recent years, the "dual-carbon" strategy and high-end manufacturing upgrades have driven industry transformation, accelerating the research and development of low-aluminum, low-phosphorus, high-purity ferrotitanium. Its applications in fields such as nuclear power steel and ultra-supercritical power plant steel have continued to expand, significantly enhancing its strategic position. III. Core Characteristics Analysis

(I) Metallurgical Core Characteristics

The core advantages of ferrotitanium tinplate lie in its strong deoxidation ability and carbonitride strengthening: Titanium's deoxidation ability far exceeds that of silicon and manganese, and is even superior to aluminum (at 20℃, the affinity of titanium for oxygen is 1.2 times that of aluminum). It can form high-melting-point (1840℃) titanium dioxide (TiO₂) with oxygen in molten steel, which is easy to float and separate, and the deoxidation efficiency is more than 50% higher than that of ferrosilicon alone. Titanium has extremely strong bonding force with carbon and nitrogen. The TiC (melting point 3140℃) and TiN (melting point 2950℃) formed are precipitated as nanoscale dispersed phases, which can pin grain boundaries and hinder grain growth, thereby refining the grain size of steel by 30%~40% and increasing the yield strength by 35%~50%. At the same time, it improves the weldability and crack resistance of steel, solving the industry problem of "difficulty in balancing high strength and high weldability". (II) Physical and Chemical Properties Titanium iron appears as a silvery-gray metallic block. Its surface easily oxidizes to form a dense oxide film (containing TiO₂ and FeO). Its density varies with composition, ranging from 4.5 to 5.1 g/cm³, and its melting point ranges from 1480 to 1650℃ (the higher the titanium content, the higher the melting point). It is chemically reactive, easily absorbing moisture and oxidizing at room temperature, requiring sealed storage. At high temperatures (above 1300℃), it dissolves rapidly in molten steel, without reacting harmfully with beneficial elements such as manganese, chromium, and nickel, and without precipitating harmful impurities such as sulfur and phosphorus, exhibiting excellent environmental compatibility. Furthermore, titanium iron has good corrosion resistance, and its stability in acidic and alkaline environments at room temperature is superior to ordinary ferroalloys. (III) Process Adaptability Titanium iron dissolves uniformly and controllably in molten steel, and can be added through various methods such as in-flow addition, injection, and ladle refining, making it suitable for various smelting processes such as converters, electric furnaces, and continuous casting. Different component ratios are precisely matched to needs: high-titanium ferro-titanium (Ti≥60%) is suitable for deep strengthening and purification of special steel and bearing steel; medium-titanium ferro-titanium (Ti40%~60%) is widely used in the production of stainless steel and high-strength structural steel; low-titanium ferro-titanium (Ti25%~40%) is suitable for inoculation modification and casting quality optimization in the casting field. IV. Mainstream Production Processes

(I) Aluminothermic Process (Mainstream Process)
This is currently the core process for the global production of high-titanium iron (Ti≥60%). It uses ilmenite (TiO₂≥45%) or rutile (TiO₂≥90%) and aluminum powder as raw materials, with iron scale as an iron-blending agent and exothermic agent. These are mixed in a specific ratio and then loaded into an aluminothermic reactor. After ignition, the exothermic reaction of aluminum reducing titanium oxides (3TiO₂ + 4Al = 2Al₂O₃ + 3Ti + heat) occurs, reaching a reaction temperature of 2200~2500℃, causing titanium and iron to melt and combine to form an ilmenite alloy. After cooling, the alloy is crushed and screened to a target particle size of 10~50mm. This process is technologically mature, produces high-purity products, and consumes approximately 450~550kg of aluminum per ton of product in traditional processes, with a titanium recovery rate of 80%~85%. (II) Silicon Thermal Method (Auxiliary Process) This method is mainly used to produce low-to-medium titanium ferrophosphate (Ti 25%~40%). It uses ilmenite, ferrosilicon, and lime as raw materials, and a reduction reaction is carried out in an electric arc furnace. The silicon in the ferrosilicon reduces titanium oxides, and the lime acts as a slag-forming agent to remove the silicon dioxide (SiO₂) generated in the reaction, forming a stable slag that separates the alloy from the slag. This process has low raw material costs and is suitable for large-scale continuous production, but the product has a low titanium content, requiring refining processes to improve quality. The traditional process consumes approximately 8500~9500 kWh per ton of product. (III) Technological Upgrading Directions With the upgrading of environmental protection and "dual carbon" requirements, the industry is accelerating technological innovation: First, green electricity coupled smelting, with enterprises in Sichuan (the main titanium ore producing area) and Inner Mongolia introducing green electricity-driven electric arc furnaces, reducing carbon emissions per ton of product by more than 75% and saving 500-600 yuan in electricity costs; Second, high-purity refining technology, using vacuum degassing and electromagnetic induction refining processes to remove impurities such as aluminum, silicon, and phosphorus, producing high-purity titanium iron (total impurities < 0.5%, aluminum content < 0.3%); Third, efficient reduction processes, developing the "aluminothermic-siliconothermic composite reduction method", increasing titanium recovery rate to over 90% and reducing energy consumption by 15%; Fourth, composite modification, developing composite alloys such as titanium iron manganese and titanium iron calcium, integrating multiple functions such as deoxidation, desulfurization, and grain refinement. (IV) Product Form Optimization To adapt to diverse application scenarios, the industry has launched specialized product forms: ferrotitanium powder (particle size < 0.15mm) is suitable for powder metallurgy and 3D printing metal powder formulation; ferrotitanium wire (diameter 13~16mm) is used in continuous casting wire feeding processes for precise control of the addition amount; ferrotitanium blocks (particle size 20~50mm) are suitable for large electric arc furnace steelmaking, improving dissolution uniformity by 20%. V. Core Application Areas

(I) Steel Industry (Traditional Core Area) Globally, over 90% of ferrotitanium is used in steel production, making it an indispensable modifier for high-end steel. In stainless steel production, adding 0.1%~0.3% ferrotitanium can fix the carbon element in the steel, avoiding intergranular corrosion caused by the formation of chromium carbide from carbon and chromium, thus improving the corrosion resistance of stainless steel by more than 40%. It is widely used in chemical equipment, food machinery and other applications. In high-strength structural steel (such as bridge steel and ship hull steel), the carbonitride dispersion strengthening effect of titanium can increase the yield strength of steel to more than 690MPa, while maintaining good weldability. In the production of bearing steel and spring steel, the grain refinement effect of titanium can extend the fatigue life of materials by 30%~50%. In ultra-supercritical power plant steel, titanium can improve the high-temperature strength and oxidation resistance of steel, making it suitable for high-temperature conditions above 600℃. (II) Casting and Alloy Manufacturing (Important Application Scenarios) Titanium iron is a high-quality inoculant and modifier in cast iron production. Its addition refines graphite structure, reduces the tendency for white cast iron, improves the morphology of inclusions in castings, and enhances the mechanical strength and wear resistance of castings. It is widely used in the production of high-precision castings such as automotive engine blocks, machine tool beds, and hydraulic components for engineering machinery, reducing scrap rates by 15%~22%. In high-temperature alloy manufacturing, titanium iron is a core alloying raw material for nickel-based high-temperature alloys, used to manufacture key components such as aero-engine blades and gas turbine rotors, improving the high-temperature creep strength of materials. (III) Emerging High-End Fields (Growth Engines) In the aerospace field, it adapts to the smelting needs of ultra-high strength steel (such as 4340 steel) and titanium alloys, and is used to manufacture aircraft landing gear and rocket body structural components, achieving a balance between lightweight materials and high strength; in the nuclear power field, it is used for the deoxidation and purification of steel used in nuclear reactor cooling pipes, improving the material's radiation resistance and long-term stability; in the new energy field, high-purity ferrotitanium is used in the preparation of titanium-based hydrogen storage materials (titanium hydride hydrogen storage density reaches 4.0wt%), and in the production of high-strength steel for wind power; in the marine engineering field, it is used in the production of corrosion-resistant high-strength steel for ships and structural steel for offshore platforms, resisting seawater corrosion and the impact of wind and waves. VI. Market Development Trends (I) Steady Growth in Demand, Prominent Gap in High-End Products In 2024, China's ferrotitanium production capacity was approximately 850,000 tons, with a market size exceeding 12 billion yuan. It is expected that the average annual compound growth rate will remain at 6.8%~8.3% over the next five years. Among them, the demand for high-purity ferrotitanium (Ti≥70%, total impurities <0.5%, aluminum content <0.3%) is growing the fastest, with its share increasing from 14.5% in 2024 to over 26% in 2029. Currently, the domestic supply-demand gap is 25,000 tons, with an import dependency of about 32%, mainly relying on imports from Russia and Japan. High-end stainless steel, aerospace, and nuclear power are the core driving forces for demand. (II) Optimization of production capacity structure and coordinated regional layout Global ferrotitanium production capacity is mainly concentrated in China (accounting for over 70%), Russia, Japan, and other countries. Domestic production capacity is mainly distributed in Sichuan (the main titanium ore producing area), Inner Mongolia, Liaoning, and Hebei. Affected by energy consumption control and environmental protection policies, traditional high-energy-consuming silicothermic process production capacity is gradually being phased out. Sichuan, Xinjiang, and other regions are taking over incremental production capacity by virtue of their titanium ore resources and green electricity advantages, forming a coordinated layout of "titanium ore producing area + green electricity base". Industry concentration continues to increase, with the top ten companies accounting for 59.2% of the total capacity. Leading companies such as Panzhihua Iron & Steel Group, Sichuan Longmang Baili, and Hebei Jinxi Ferroalloy have built competitive barriers through the integration of the "titanium ore - titanium slag - ferrotitanium" industrial chain. Small and medium-sized enterprises are focusing on niche casting sectors or transforming into composite alloy production. (III) Green and Low-Carbon Driven, Technological Innovation Becomes the Core Barrier The "dual-carbon" strategy is driving the industry's low-carbon transformation, with green electricity smelting and energy efficiency improvement becoming core directions. Policies require that all production capacity that fails to meet energy efficiency benchmarks (comprehensive energy consumption per ton of product in the aluminothermic process ≤ 1.8 tons of standard coal) be phased out by 2025, forcing companies to increase investment in technological upgrades. The adoption rate of vacuum refining and intelligent batching technologies is expected to increase from 36% in 2024 to 60% in 2027. In the medium to long term, the research and industrial application of high-purity, low-impurity production technologies and carbon-free reduction processes (hydrogen-based reduction) will reshape the industry landscape, with "deoxidation + multifunctional composite" alloys (such as titanium-iron-calcium and titanium-iron-manganese) becoming research hotspots. (IV) Price Fluctuations and Strategic Layout The price of titanium-iron is affected by multiple factors: fluctuations in the prices of upstream raw materials such as titanium ore (average price in 2024 was RMB 1280/ton, an increase of 16.4%) and aluminum powder (accounting for 35%~40% of the cost of the aluminothermic process) directly affect production costs; downstream stainless steel production, aerospace orders, and the construction progress of nuclear power projects influence demand; green electricity policies and environmental standards affect supply elasticity. Due to its irreplaceable role in the high-end steel and aerospace industry chains, titanium-iron has been included in the key mineral supply chain management of many countries. Enterprises are strengthening their titanium ore reserves (Sichuan Panzhihua titanium ore reserves account for 60% of the national total) and binding themselves to green electricity, while increasing investment in the research and development of high-purity products to narrow the quality gap with imported products.