A nanostructured monolithic titanium boride (TiB) material and methods of
forming such a material are disclosed and described. This material has a
room-temperature four-point flexural strength about three times that of
commercially available titanium diboride (TiB.sub.2). The achievement of
nanostructured internal microstructural arrangement having a network of
interconnected titanium monoboride whiskers affords a very high strength
to this material above some of the best ceramic materials available in
the market. The material contains a small amount of titanium and a
densifier, but it is largely made of TiB phase with substantially no
TiB.sub.2. The nanostructured monolithic titanium boride material can be
formed by high temperature processing of a powder precursor having
carefully selected weight and size distributions of titanium powder,
titanium diboride powder, and densifier powder. Potential applications of
this material can include wear resistant components such as die inserts
for extrusion dies, nozzles, armor, electrodes for metal refining etc. An
important advantage of TiB over other hard ceramics is that TiB can be
cut by electro-discharge machining (EDM) without difficulty, unlike most
ceramics.