Fabrication of low-oxygen Ti powder via CeCl3-assisted molten salt electrolysis under vacuum

Titanium (Ti) powder production via molten salt electrolysis is an environmentally sustainable alternative to the Kroll process, yet achieving precise control over oxygen content remains a significant challenge. This study established a NaCl-KCl-MgCl 2 -TiCl x electrolysis system using titanium sponge as the raw material; moreover, we innovatively introduced CeCl 3 as a deoxidation accelerant. The synergistic effects of anode/cathode current densities, electrolysis temperature, and CeCl 3 concentration on the oxygen content and morphological evolution of Ti powder were systematically investigated. Results indicate that cathode current density exerts a non-monotonic regulatory effect on oxygen content, with an optimal window identified at 1.0 A/cm 2 . While increasing the temperature to 750 °C enhances deoxidation, further heating leads to undesirable grain coarsening. Critically, the addition of CeCl 3 significantly bolsters deoxidation efficiency by modulating the oxygen potential within the melt. Under the optimized parameters (4 wt% CeCl 3 , 750 °C, 0.4 A/cm 2 anode current density, and 1.0 A/cm 2 cathode current density), high-purity Ti powder with an oxygen content as low as 600 ppm was successfully fabricated. This work provides a robust theoretical and technical framework for the green, cost-effective production of high-end, low-oxygen titanium powders.