P/M Ti-6Al-4V - International Titanium Association

Transcription

Powder Metallurgy Titanium and Titanium Alloy
Components Manufactured from Hydrogenated
Titanium Powders
Georg I. Abakumov, V.S. Moxson , Vladimir Duz, Mykhailo Matviychuk, Viktor Sukhoplyuyev
Georg Abakumov, Director Business Development, ADMA Products, Inc.
October 7‐10, 2012 • Atlanta, Georgia, USA
1
•
•
•
•
•
•
•
INGOT BASED (WROUGHT) TITANIUM
ENORMOUS ENERGY INPUT
EXTENSIVE PROCESSING and MACHINING
HIGH SCRAP RATE – LOW “BUY to FLY” LONG LEAD TIME TO FINISHED PRODUCT
HIGH COST = USE LIMITED to “COST IS NO OBJECT” APLLICATIONS!
As the Commercial Aviation industry grows in the “post recession” economic recovery, strain on the supply of titanium and DRIVE UP THE COST of Titanium and Titanium Components!
•
THE FUTURE OF TITANIUM IS TITANIUM POWDER METALLURGY!
2
•
•
•
•
ADMA HYDROGENATED TITANIUM POWDER BASED COMPONENTS REQUIRE LESS PRECIOUS ENERGY AT EVERY STEP OF PRODUCTION HAVE “BUY to FLY” APPROACHING 1 TO 1 (LITTLE OR NO SCRAP)
SHORT LEAD TIME TO PRODUCTION OF FINISHED COMPONENTS
• WITH NO SACRIFICE INPERFORMANCE • ADMA TiH2 COMPONENTS MEET AND SURPASS ASTM, MIL DTL 46077, AND AMS AT A FRACTION OF THE COST
3
Processing Steps for Blended Elemental
Titanium Alloy Parts Production
ADMA Titanium P/ M “in house” Processes
Die Press
Finished
product
Post-Processing Outside vendors
Rolling
Forging
Flat (foil, sheet, plate)
Round (bar, rod)
Extrusion
Powder
Direct Powder
Rolling
Vacuum
Sintering
Cold Isostatic
Pressing
Vacuum
Sintering
Rotary Forging
Flowform
HIP
Wire drawing
4
Development and Optimization of Rolled Product Forms Using Blended‐Elemental Powder‐Based Ti‐6AL‐4V Alloy
Wednesday June 20, 2012 Dr. Sami El‐Soudani, The Boeing Company
Dr. Kuang‐O (Oscar) Yu and Ernie M. Crist, RTI International Metals, Inc.
Dr. Vladimir S. Moxson and Dr. Vladimir Duz ADMA Products Inc.
The feasibility of rolling process development has been successfully demonstrated at RTI…using initial rolling preforms of blended‐elemental hydrided titanium powder billets fabricated by ADMA using their titanium hydride (“hydrogenated”) powder blended with master alloy aiming at Ti‐6AL‐
4V composition… All elements of the pre‐rolling billet preforms…were within AMS Specification limits…showed equivalent or superior tensile properties as compared to rolling processed wrought ingot‐based Ti‐
6AL‐4V billet materials… The Boeing executed text matrix included processing‐microstructure‐
property correlations of tensile properties, S‐N fatigue life, fatigue crack growth rate…fracture toughness per ASTM‐E399‐K1C…and stress‐corrosion resistance…
5
Wednesday June 20, 2012 Dr. Sami El‐Soudani, The Boeing Company
John Fanning, Megan Harper, Dr. Stephen Fox, Timet, Inc.
Dr. Vladimir S. Moxson and Dr. Vladimir Duz ADMA Products Inc.
The feasibility of rolling process development has been successfully demonstrated at RTI…using initial rolling preforms of blended‐elemental hydrided titanium powder billets fabricated by ADMA using their titanium hydride (“hydrogenated”) powder blended with master alloy aiming at Ti‐6AL‐
4V composition… All elements of the pre‐rolling billet preforms…were within AMS Specification limits…showed equivalent or superior tensile properties as compared to rolling processed wrought ingot‐based Ti‐
6AL‐4V billet materials… The Boeing executed text matrix included processing‐microstructure‐
property correlations of tensile properties, S‐N fatigue life, fatigue crack growth rate…fracture toughness per ASTM‐E399‐K1C…and stress‐corrosion resistance…
6
Boeing/ADMA/RTI/TIMET
Sami M. El‐Soudani, Ti-6Al-4V rolling billets
7
RTI‐Rolled Blended‐Elemental Ti‐6Al‐4V Billets Met Specification Requirements and Matched Properties of Wrought Ingot Alloy Sami M. El‐Soudani, Initial Rolling Passes Were Performed by Straight Rolling ADMA Billets From 4” Down to 2”, 1”, and 0.5”‐Thick Plates at Niagara Specialty Metals, Inc., Then Followed by Final Cross (or Spread) Rolling at RTI International Metals, Inc.
8
RTI‐Rolled Blended‐Elemental Ti‐6Al‐4V Billets Met Specification Requirements and Matched Properties Sami M. El‐Soudani, of Wrought Ingot Alloy Material and Processing History
BE Ti‐6Al‐4V Powder CIP/Sintered then Hot Rolled and Mill Annealed Double‐Arc Remelt Ingot Hot Rolled and Mill Annealed Standard Grade Ti‐6Al‐4V Product Form Sheet / Plate ‐
Optimized
Number of Tests Used in Average Values
Statistical Measure: Average *
Maximum *
Minimum *
UTS
[ksi]
Plate
10
Average
144
130
15
67
Sheet
34
Average
152
135
9
131
Plate
2
Average
138
126
13
79
Average
132
121
10
147
Sheet
YS
[ksi]
Elon. [%]
Fracture Toughness KIC or KC
[ ksi.inch½ ]
8
9
Our Plate Mill Product Processing Optimization at RTI
Demonstrated High Fatigue Endurance Limits Matching DoubleArc-Remelt Wrought Ingot-Based Ti-6Al-4V Standard-Grade Alloy
Similarly Rolled Product Forms
Plate Product Form
Pedigree: Powder
Versus Ingot
Blended-Elemental
Powder-Based
Ti-6Al-4V
Plate Product
Double Arc-Remelt
Ingot-Based Plate
Plate
Identification
and Rolling
Vendor
Plate Geometry
As-Tested per
ASTM E 466
KT = 1 for S/N Fatigue Life
[inches]
Original
As-Sintered
Rolled Billet
Thickness
[inches]
Fatigue
Endurance
Limit
[ksi]
RR4-2A (RTI)
27.7 x 7.2 x 0.480
4.0
88.0
RR2A (RTI)
13.1 x 6.9 x 0.970
4.1
72.5
W1 (RTI)
16.7 x 16.7 x 0.975
4.0
82.0
Sami M. El‐Soudani et al, Metall. and Mat. Trans. A ‐ Vol.41A, 2010
10
Sami M. El‐Soudani, Our Sheet Mill Product Processing Optimization at RTI
Demonstrated High Fatigue Endurance Limits Matching
Double-Arc-Remelt Wrought Ingot-Based Ti-6Al-4V
Standard-Grade Alloy Similarly Rolled Product Forms
Sheet Product Form
Pedigree: Powder
Versus Ingot
Sheet
Identification
and Rolling
Vendor
Sheet Geometry as
Tested per
ASTM E 466 KT = 1 for
S/N Fatigue Life[inches]
Original
As-Sintered Rolled
Billet Thickness
[inches]
Fatigue
Endurance
Limit
[ksi]
Blended-Elemental
Powder-Based
Ti-6Al-4V Sheet
Product
RR1E (RTI)
13.5 x 7.7 x 0.131
4.2
68
RR3D (RTI)
17.2 x 7.5 x 0.065
1.0
81
RR4-2C (RTI)
17.4 x 7.5 x 0.073
4.1
77
W2D (RTI)
16.9 x 8.6 x 0.076
4.0
85.5
W2C (RTI)
14.5 x 8.1 x 0.127
4.0
67
Double Arc-Remelt
Ingot-Based Sheet
11
Timet-Rolled
Blended-Elemental
Ti-6Al-4V
Billets
Met
Requirements and Matched Properties of Wrought Ingot Alloy
Specification
Sami M. El‐Soudani, Material and
Processing History
Product Form
Sheet / Plate Optimized
Number of Tests
Used in Average
Values
Statistical
Measure:
UTS
[ksi]
YS
[ksi]
El.[%]
KIC or KC
[ ksi.inch½ ]
BE
Ti-6Al-4V Powder
CIP/Sintered then
Hot Rolled and Mill
Annealed
Plate
8
Average
142
130
12
63
Sheet
18
Average
148
139
12
128
Plate
2
Average
138
126
13
79
Sheet
8
Average
132
121
10
147
Double-Arc Remelt
Ingot Hot Rolled
and Mill Annealed
Standard Grade
Ti-6Al-4V
12
12
The Boeing Company Goal was Near-Net Sheet Rolling Mill
Product with the Lowest Overall Rolling Reduction Factor, the
Best Property Balance, and Sintered Billets as Thin as 0.75”
Sami M. El‐Soudani The ADMA Hydrogenated Titanium Billet T4-2
(as-Sintered Dimensions 0.709 x 8.5 x 11 inches)
was Rolled Successfully at Timet and Easily Met Tensile,
Fracture Toughness and Fatigue S/N Requirements!
13
13
Our Sheet Mill Product Processing Optimization at Timet
Demonstrated High Fatigue Endurance Limits Matching
Double-Arc-Remelt Wrought Ingot-Based Ti-6Al-4V
Standard-Grade Alloy Similarly Rolled Product Forms
Sheet Product Form
Pedigree: Powder Versus
Ingot
Blended-Elemental
Powder-Based
Ti-6Al-4V Sheet Product
Double Arc-Remelt IngotBased Sheet
Sheet
Identification
and Rolling
Vendor
Sheet Geometry
as Tested per
ASTM E 466 KT = 1
[inches]
Original
As-Sintered
Rolled Billet
Thickness
[inches]
Fatigue
Endurance
Limit
[ksi]
T2.2.2 (Timet)
10.2 x 6.2 x 0.114
1.8
78
T4.2A-9 (Timet)
10.2 x 7.1 x 0.067
0.709
82
W2D (RTI)
16.9 x 8.6 x 0.076
4.0
85.5
W2C (RTI)
14.5 x 8.1 x 0.127
4.0
67
Sami M. El‐Soudani
14
14
General Conclusions on Blended–Elemental Boeing/ADMA/RTI/TIMET Ti‐6Al‐4V Rolled Plate and Sheet Mill Product
The blended elemental RTI and TIMET‐hot‐rolled Ti‐6Al‐4V alloy mill products met the AMS Specification mechanical property requirements for both static loading, as well as damage tolerant fracture toughness and cyclic S/N fatigue endurance limit for aerospace applications. • Encouraging powder‐based rolled mill product form properties of Ti‐6Al‐4V using optimized processing pathways shows static tensile, and fatigue S/N, and fracture properties matching similarly‐processed ingot‐based hot‐rolled product forms. Georg Abakumov, Director Business Development, ADMA Products, Inc.
15
AIRFRAME STRUCTURES
Canless Extrusion Process Development for
B/E Powder-Based Titanium Ti-6AL-4V Alloy
ADMA-fabricated Ti-6AL-4V blended elemental powder-based billets were extruded
successfully by Plymouth Engineered Shapes, Inc.
The Boeing Company and Plymouth Engineered Shapes, Inc.
Extrusions (up to 27 feet length) were
fabricated and analyzed at front, mid-length,
and back and found to be uniform with
respect to oxygen content & microstructure.
Longer and larger cross-section fabrication
is a non-issue in this process.
Sami M. El‐Soudani et al, Metall. and Mat. Trans. A ‐ Vol.41A, 2010
16
AIRFRAME STRUCTURES
Canless Extrusion Process Development for
BE Powder-Based Titanium Ti-6AL-4V Alloy
ADMA-fabricated Ti-6AL-4V blended elemental powder-based billets were extruded
successfully by RTI International Metals, Inc. for The Boeing Company
RTI, International Metals, Inc.
36’-Long Extrusions Cut-up for Shipping and
Laboratory Characterization
Ti-6Al-4V
Ultimate Strength, (psi)
Yield Strength, (psi)
Elongation, %
Reduction of Area, %
ADMA P/M
134,000 – 135,000
156,000 – 157,000
12.5 - 12.9
28.2 - 28.3
Ingot Based
125,000 – 127,000
140,000 – 142,000
12.4 - 12.6
26.9 - 27.6
17
ADMA P/M Ti‐6Al‐4V Commander’s Hatch
“… passed with flying colors, met the forging spec requirements, as well as the plate spec requirements (MIL‐DTL‐46077)… THIS IS THE BEST RESULT WE HAVE SEEN FROM ANY P/M BASED, NO MELT, LOW COST MATERIAL.” (BAE 7‐6‐2010)
Cold Isostatic Pressing
Sintering
Forging
CIP/Sinter
Al
V
Fe
C
N
O
H
Y
Ti
Other, Each
Other, Total
6.16
4.21
0.080
0.009
0.021
0.179
0.0018
<0.0005
Bal.
<0.10
<0.40
Room Temperature Tensile Properties
P/M Ti‐6Al‐4V
UTS, ksi
YS, ksi
Elon., %
RA, %
1.375” thick
143.8 – 149.3
132.1 – 136.3
14.0 – 15.5
34.1 – 37.7
18
P/M Blended Elemental Ti-6Al-4V Commander’s Hatch
Pre-Form Produced from Hydrogenated Ti Powder
(These 220 lb ADMA Titanium Powder Metallurgy plates
can replace 400 lbs of steel plate on the hatch of the Bradley Fighting Vehicle)
ASTM E8 ROOM TEMPERATURE TENSILE TEST
Sample 1
Sample 2
SPEC
UTS (PSI)
146,300
152,500
130,000
0.2% YS (PSI)
131,800
138,900
120,000
ELONGATION, %
13.0
13.0
10.0
R. A., %
26.4
25.2
20.0
19
Large Powder Metallurgy Products
Low-oxygen P/M Ti-6Al-4V Billets from
ADMA Hydrogenated Ti Powder
Chemistry conforms to AMS 4911L
Ti-6Al-4V billet 8.50” x 12.0” x 52.0” 725 lbs
20
ADMA Direct Powder Rolling Mill
- 50 Million Lbs/Year Armor Plate Production
Capacity
0.25” thick plate was
successfully rolled at
ADMA facility
21
P/M Ti-6Al-4V (Low Oxygen) Plates
- ADMA Hydrogenated Ti powder
0.75” thick
0.50” thick
Sintering
Rolling
ST
L
LT
L – Longitudinal
LT – Long transverse
ST – Short transverse
22
ADMA P/M Ti-6Al-4V alloy Bars
for the IBIF Fred Sert Program
ADMA P/M Ti-6Al-4V Extruded bars
Sintering
Extrusion
Rolling
Rotary Forging
Ti-6Al-4V
UTS ksi
YS, ksi
El., %
RA, %
ADMA P/M
148 – 152
142 – 145
19.8 - 22.8 28.2 - 28.3
Ingot Based
140 - 143
125 – 127
19.4 - 21.1 26.9 - 27.6
AMS 4928R
135 Min.
125 Min.
10 Min.
23
Blended ElementalADMA P/M Ti-6Al-4V BARS
Outperform High Cost Ingot Based Products
Fracture Mode:
Extruded Material, Tensile Tested
Fracture initiation location: center of specimen
Fracture mode: microvoid coalescence or dimple
mode
Fatigue Test Results
Maximum Load (lb)
Maximum Stress (ksi)
Cycles to Failure
Diameter (in)
INGOT
5880
119
1,014,725
0.251
ADMA Ti P/M
5880
119
3,716,462
0.250
24
P/M Ti and Ti alloy Hollow Cylinders for
US NAVY Tubes and Pipes
CIP
ADMA Hydrogenated Ti Powder
Vacuum
Sintering
Flowform
25
Low Cost Titanium Pipe for Naval Applications
• Piping for LPD (Titanium CP Grade 2), approx. 20,430 feet per ship, weighing approx. 130,000 lbs
Density
Cu‐Ni 0.323 lb/in3
CP Ti 0.163 lb/in3
• Titanium pipe saves 178,000 lbs per LPD compared to Cu‐Ni pipe system, improving fuel efficiency and reducing life cycle maintenance USS SAN ANTONIO (LPD 17)
cost of the pipe system
26
27
Titanium or Titanium Alloy Components
Die Pressing + Sintering
Near Net Shape
Die Pressing
Sintering
28
Titanium or Titanium Alloy Components for Aerospace Applications Die Pressing + Sintering
Near Net Shape
CP Ti washers
Material
Composition, %
N
C
H
Fe
O
Ti
CP Ti washers
0.015
0.016
0.0014
0.14
0.206
Bal.
ASTM B 348 Grade 2
0.030
0.080
0.015
0.20
0.250
Bal.
Material
Ti-6Al-4V washers
Composition, %
N
C
H
Fe
O
Al
V
Ti
Ti-6Al-4V washers
0.019
0.014
0.0014
0.05
0.263
6.32
4.23
Bal
ASTM B 817-98,
Type I
0.04
0.10
0.015
0.40
max
0.30
5.50 –
6.75
3.50 –
4.50
Bal
29
Die Pressing
Ti-3Al-2.5V Components
for Aerospace Applications
Sintering
30
30
Metal Porous Membrane Sheets by
Direct Powder Rolling Process
Direct Powder Rolling
Metal
Powder
Binder
Filler
BLEND
POWDER ROLLING
SINTER
RE-ROLL
ANNEAL
FINISHED SHEET
31
Direct Powder Rolling of Ti Alloy Foil, Sheet, and
Plate at ADMA
0.010” thick Ti foil
0.25” thick plate
32
Porous Titanium Sheets/Plates
“Cracking Oxygen from Water Life Support Systems for the US NAVY, AIRFORCE, and NASA
33
Porous ADMA Titanium Electrode - High
Capacity Storage of Wind and Solar Energy
• High capacity storage batteries for wind and solar generated
energy
• Improved costs and asset utilization
• Lower maintenance, longer life span, enhanced reliability
• Greater penetration of renewable energy technologies
• Reduction in green house gas emissions
34
Manufacturing Continuously Re-Enforced Ti-6Al-4V
Sheet and Plate by Direct Powder Rolling Ti alloy Blend
with Graphite or Alumina Fibers (S&T)
Preliminary experiments demonstrated the feasibility to produce continuously re-enforced Ti-6Al-4V
plates with Carbon or Alumina fibers (S&T) by using low cost ADMA direct powder rolling or loose
sintering P/M processes.
The fiber loading fraction can be tailored. ADMA can increase the volume % of fibers in composite
material. In some cases a hot temperature consolidation (HIP or hot pressing) is required to
consolidate to full density.
Cold isostatic pressing/Sinter
Direct powder rolling/Sinter
Loose sintering
35
Porous Titanium Tube Sleeve/Flange
Sintering
36
Weapon Components Developments
CIP/Sinter/Rotary Forging
P/M Ti‐6Al‐4V 0.875” Dia x 12ft long round bars produced from ADMA TiH2 powder
Ti‐6Al‐4V
Al
V
Fe
C
N
O
H
Ti
Other, Each
Other, Total
ADMA TiH2
5.83
3.72
0.29
0.017
0.029
0.189
0.012
Bal.
<0.10
<0.40
Sodium Reduced Ti
5.83
3.82
0.13
0.024
0.029
0.160
0.012
Bal
<0.10
<0.40
5.5‐6.75
3.5‐4.5
0.40
0.08
0.05
0.20
0.015
Bal
<0.10
<0.40
ASTM B348
P/M Ti‐6Al‐4V
UTS, ksi
YS, ksi
El., %
RA, %
ADMA TiH2
154 – 155
141 – 142
15.8 – 16.5
38 ‐ 40
Sodium Reduced Ti
139
125 – 126
9.0 – 10.0
19 ‐ 20
AMS 4928R
135 Min.
125 Min.
10 Min.
37
TITANIUM FOR THE MOST CRITICAL DEFENSE,
AEROSPACE AND INDUSTRIAL APPLICATIONS
HYDROGENATED TITANIUM POWDER METALLURGY CAN MEET THE
CURRENT INDUSTRIAL, DEFENSE, AND AEROSPACE APPLICATIONS for
TITANIUM by PROVIDING ANY COMPONENT CURRENTLY MADE.
LOW COST/ HIGHEST PERFORMANCE ADMA HYDROGENATED TITANIUM
POWDER WILL BRING the OVERWHELMING BENEFITS OF TITANIUM TO A
BROADER RANGE OF INDUSTRIAL APPLICATIONS.
THE FUTURE OF TITANIUM IS TITANIUM POWDER METALLURGY!
THANK YOU FOR YOUR INTEREST!
38

P/M Ti-6Al-4V - International Titanium Association

Transcription

Similar documents