AA093 306 WESTINGOUSE ELECTRIC CORP PITTSBURGH PA ADVANCED ENE-ETC F/6 11/6

SU14NARY REPORT ON METAL PROCESSING RESEARCH.CU)AU BFGREIMARTORELL F33615-78-C-5003

UNCLASSIFIED AFWAL-YR-8GO100ALS

E-ENEMEEN

ME

IND

AFWAL-TR-80-4 100

t

SUMAY EPRTON METAL PROCESSING RESEARCH

F. J. GURNEYI. A. MARTORELLWESTINGHOUSE ELECTRIC CORPORATIONADVANCED ENERGY SYSTEMS DIVISIONPITTSBURGH, PENNSYLVANIA 15236

AUGUST 1980

TECHNICAL REPORT AFWAL-TR-80-4100

Approved for public release; distribution unlimited.

MATERIALS LABORATORYAIR FORCE WRIGHT AERONAUTICAL LABORATORIESAIR FORCE SYSTEMS COMMANDWRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

0d

~~80 1229 09

NOTICE

When Government drawings, specifications, or other data are used forany purpose other than in connection with a definitely related Government

procurement operation, the United States Government thereby incurs no re-

sponsibility nor any obligation whatsoever; and the fact that the government

may have formulated, furnished, or in any way supplied the said drawings,specifications, or other data, is not to be regarded by implication orotherwise as in any manner licensing the holder or any other person or

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This technical report has been reviewed and is approved for publication.

ATTLL M. ADAIRProject EngineerMetals Processing Group

FOR T COMMANDER

/HE RY1 GRAHAMChief, Processing andHigh Temperature Materials BranchMetals and Ceramics Division

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Copies of this report should not be returned unless return is required bysecurity considerations, contractural obligations, or notice on a specificdocument.

AIR FORCE/56780/13 Novniber 1980 - 300

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SECURIT * <CI 1FICATION OF THIS PAGE ('wh en D ate En er IF)

9 iqPR REPORT DOCUMENTATION 0AGE PROR MTPRECTIG S

Wes inGOhT ACCES

EOec rO. CtNToS CATALOG NUMBER

PitA4trgh,4 Penslvni 1523 Prjc No 735

I-I.COTOL~ING "'e O', N AND.ADDRE--SS COVERED

Summary Report on Metal Processing Researche 16 Feb 78 AprILPERFORMING ORG. REPV-*HBER

Maeil Lbrtr CONTRACT OR GRANT NUMBER()

itF. J. atGurney i F33615-78-C-5o3h 3L0 . A./Martorell C1 : -

S. PMRFORMING ORGANIZATIO NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASKWetinghuse Electric Corporation / AREA . WORK UNIT NUMBERS

Advanced Energy Systems Division Task No. 735108

Pittsburgh, Pennsylvania 15236 Project No. 7351

IS. CONTROLLING OFFICE NAME AND ADDRESS'eot)

Air Force Wright Aeronautical Laboratories uitMaterials Laboratory 13. NUMBER OF PAG ESWright-Patterson Air Force Base, Ohio 45433 62

14. MONITORING AGENCY NAME & ADDRESS(if different fromn Controllingl Office) 15. SECURITY CLASS. (of this report)

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Approved for public release; distribution unlimited.

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IS. SUPPLEMENTARY NOTES

IS. KEY WORDS (Continue on reverse side If neceaery end idenlify by block number)

Isothermal Forging, Hydrovac, Central Burst

20. ABSTRACT (Continue on revere side It neceseery end Identify by block number)JArhis report summarizes the findings of research conducted on metal processing

over a two 4- year period. The research included the study of the occurrenceof the central burst defect in 7075 Al, the effect of hydrogen on the flow

stress of Ti6AI-4V and other titanium alloys (CP-Ti, Ti-5AI-2.5Sn) and thedesign and use of a high sensitivity load cell. Information derived from thisand past research was applied to the processing of numerous metal workingoperations of other alloys. 4 -- -

DD 'AN73 1473 ITIN wO/,I NOV61 ISIO.SO TE/ SECURITY CLASSIFICATION Of THIS PAGE (mten Do#lB

+LJ0

FOREWORD

This report was prepared by the Westinghouse Electric Corporation,Advanced Energy Systems Division, Pittsburgh, Pennsylvania, under USAFContract No. F33615-78-C-5003. The project was initiated under ProjectNo. 7351, "Metallic Materials", Task No. 735108, "Processing of Metals",and was administered under the direction of the Wright AeronauticalLaboratories, Wright-Patterson Air Force Base, Ohio with Mr. A. M. Adair(AFWAL/MLLM) as Project Engineer.

The work described in this report was carried out between 16 February1978 and 30 April 1980. Forging, Extrusion, Heat Treatments and othertechnical support was provided by the following Westinghouse personnel:

T. M. BrownJ. 0. BrownT. E. JonesM. M. MyersS. E. NashR. A. Sweeney

Typing and editing support was provided by J. F. Hickman.

Accession For

NT IS GRA&IDTIC TAB l

Unannounced D IJust ifica t ion-_ _---

i DistributiJon/Avail i*litY C S

2 *:ci w-orIt

iii

TABLE OF CONTENTS

SECTION PAGE

I INTRODUCTION I

II INVESTIGATION OF METAL PROCESSING OPERATIONS 1

A. Pilot Plant Forging of Hydrogenated Ti-6A1-4V(20) I

B. Experimentaf Forging of Other Titanium Alloys 2Containing Hydrogen"23)

C. Phenomenological Mechanism for the Occurrence of 2the Extrusion Central Burst Defect(2

4)

D. High Sensitivity-Low Capacity Load Cell With 3

Overload Protection

III APPLIED METAL PROCESSING 4

REFERENCES 12

v

If

LIST OF ILLUSTRATIONS

FIGURE PAGE

1. Hydrovac forging advantages. 5

2. Illustration of the rigid ram stop used for the 6partial extrusions.

3. Macrographs of a sequence of longitudinally sectioned 7partially extruded billets showing the development,propagation and repetition of the central burst defect.The above sequence shows a) the development ofthe tangential velocity discontinuity surface, b) theinitiation of the burst at the axial center of thebillet at the tip of the discontinuity surface and c) therapid opening of the defect.

4. The above sequence shows a) the fully developed defect 8exiting the die with metal flow concentrated at the outershell of the product followed by b) the re-establishmentof the metal flow within the die cone and the initiationof a new tangential discontinuity surface beginning atthe outer portion of the billet where the initial entryto the die cone occurs and c) the continued developmentof the discontinuity with concentrated flow in pre-paration for the next burst.

5. Phenomenological mechanism of the development, propagation 9

and repetition of the central burst defect. a) Development oftangential velocity surfaces (1) occurs with bands of local-ized flow. Tangential flow along the discontinuity (2) is

translated to axial flow toward the die exit and resultsin a region of enhanced tensile stress (3) at the billetaxis. b) Initiation of the central burst defect (4) resultsfrom tensile overload. Wavy flow lines (5) develop whilethe deformation zone volume shrinks by movement of theentrance boundary (6) toward the die exit. c) Discontin-uous flow lines develop (7) as the defect propagates alongthe discontinuity surface but propagation becomes lessenergetically favorable as the geometric position of theflow surface proceeds through the deformation zone (8).The defect opens rapidly (9) as flow concentrates (10) atthe outer flow lines. d) As the defect passes through thedie the deformation zone (11) becomes re-established andnew tangential velocity discontinuity surfaces (12) beginat the outer surfaces of the billet near the entrance tothe die cone.

vi

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE PAGE

6. Photograph of the high sensitivity load cell showing 10a) the strain gaged sleeve and the solid core over-load section (note the solid core overload sectionis shown upside down) and also showing b) theassembled sections in the operational arrangement.

7. Flow stress-strain curves for Ti-10V-2Fe-3A1 forged 11isothermally at 3.00 ipm (nominal). Grain Size - 255Um.The forging loads needed for the flow stress calculatedusing the ring compression test(2-5) were measuredusing the load cell previously described.

vii

LIST OF TABLES

TABLE PAGE

1 Extrusion Parameters for Maximum Yield Applications 14

viii

SECTION I

INTRODUCTION

The experimental effort described in this investigation is a continuation

of work(1-19 ) carried out at the Materials Laboratory, Wright-Patterson AirForce Base, Ohio to advance the science and technology of metal deformationprocessing for aerospace applications. The principal objective of this effortwas to determine quantitative metalworking process design procedures for the-selection and control of processing parameters for production of metallicshapes with desired external geometry and internal microstructure. The programconsisted of three tasks which were conducted concurrently at the ExperimentalMetals Processing Laboratory at the Wright-Patterson Air Force Base. The firsttask entailed process design studies for metalworking operations, for theexploitation of processing advantages of alpha or near alpha titanium alloyscontaining hydrogen. The work performed under this task concentrated pri-marily on the effects of hydrogen on the flow stress of Ti-6A1-4V. Some

additional work was also performed on Ti-5Al-2.5Sn and commercially pure Ti-

30A.

The second task entailed the effects of metalworking variables on the

generation of defects during processing. The work conducted under this taskwas performed on extrusion of 7075 Al.

The third task entailed the utilization of optimum processing parametersand techniques, both those developed in the first two tasks and those gained

from previous experience, to process experimental materials from alloydevelopment programs of the Air Force and other government agencies. The aimof this task was to obtain the maximum yield of sound material for metallurgi-cal evaluation. The work performed under the third task included extrusion,forging, rolling, swaging, melting, and heat treatment of experimental alloys.A total of 469 billets and bars were processed for this effort. Tabulateddata on the extrusions carried out under this task are included in thisreport.

The major portion of the research findings have already been presented

in detail in the form of Materials Laboratory Technical Reports. Only

summaries of these studied are presented in this report, together with brief

discussions of work which has not Yet been published.

SECTION II

INVESTIGATION OF METAL PROCESSING OPERATIONS

A. Pilot Plant Forging of Hydrogenated Ti-6Ai-4V(20)

A pilot plant forging program for hydogenated Ti-6AI-4V is described

in this program and was performed on ingot stock which was machined intoring-shaped workpieces. The rings were hydrogenated to obtain hydrogen

content between 0.1 weight percent and 1.2 weight percent. A micro-balancetechnique was used to determine the hydrogen content. A description of theequipment and procedures for hydrogenation of the material and verificationof hydrogen analysis is given(20).

The ring forgings were performed on a hydraulic forge press using iso-thermal techniques. A temperature range between 9220K (12000 F) and 11440 K(16000 F) and deformation rates of 1.26x10-1ms-1 (0.3 ipm) and 1.26xlO-ims -1

(30.0 ipm) were used in the forging evaluation. Two different heats ofmaterial were used. Three to six rings were forged at different reductionsat each condition of temperature, rate and hydrogen content. Non-hydrogenatedrings were also forged at each condition to form a baseline for comparison.Standard techniques were used to analyze the ring forging data.

Results from the program show that a 30 percent reduction in forgingloads resulted when material with 0.4 weight percent hydrogen is utilized. Atlarger hydrogen contents, the deformation loads increase and approximatelyequaled those of non-hydrogenated material when the hydrogen content is 0.8weight percent. Deformation loads for the material with 0.4 weight percenthydrogen which are equivalent to those for non-hydrogenated product occurat processing temperatures between 560K (1000 F) and 83OK (1500 F) lower.These two effects are illustrated in Fig. 1. The application of these re-sults to hydrided titanium powder and to isothermal forging technology isdiscussed(2 0). Information in this report is also applicable to zirconium andhafnium processing technology. Details of this study are included inAFWAL-TR-80-4026.

B. Experimental Forging of Other Titanium Alloys Containing Hydrogen(2 3)

The effort described above for titanium alloy Ti-6AI-4V was expandedto include, in somewhat abbreviated form, other titanium alloys (such ascommercially pure titanium, Ti-30A and alpha titanium Ti-5AI-2.5Sn). Resultsfrom these studies show similar trends with hydrogen content. Load reductionsfor these alloys are somewhat higher, approximately 50 percent. Theseresults support the previously published Russian Data(21-2 2). Details ofthe work on CP-Ti and Ti-5AI-2.5Sn and other alloys will be published in anMaterials Laboratory Technical Report( 23).

C. Phenomenological Mechanism for the Occurrence of the Extrusion CentralBurst Defect(2 4)

An investigation of defect occurrence during metalworking was conductedfor low ratio extrusion billets of 7075 Al partially extruded in a horizontalextrusion press using a three-inch diameter container. Extrusion conditionswere selected such that the central burst defect would occur. A rigidram stop mechanism was employed to halt the extrusion process abruptlyafter selected increments of deformation were achieved in each billet. Thisrigid ram stop mechanism is shown in Fig. 2. Metallographic sections of thepartially extruded billets using the rigid ram stop mechanism illustratingthe development of the defect are shown in Figs. 3 and 4. Metallographic andScanning Electron Microscope analyses were used to identify the developmentof the defect.

2

The occurrence of the defect was found to be preceded by the development of atangential velocity discontinuity surface in the deformation zone. Enhancedmetal flow in the radial direction on the die exit side of this discontinuitysurface caused tensile stresses to develop along the axis of the billetinitiating the defect by a tensile overload mechanism. The defect was foundto propagate along the discontinuity surface but was halted when continuedram motion caused continued plastic flow along this discontinuity surface tobecome diffused. The defect development process is illustrated schematic-ally in Fig. 5. Details of the effort are presented in AFML-TR-79-4031(24 ).

D. High Sensitivity-Low Capacity Load Cell With Overload Protection

A high sensitivity-low capacity load cell was designed and built tosatisfy the need for measurement of loads, representing a small fraction ofthe load capacity of the equipment, that is often encountered in metalworkingoperations. This situation can result from small workpieces because oflimited amounts of experimental materials, prior deformation processing of theingots or constraints on experimental variables. Measurement of small loadscan pose linearity and sensitivity difficulties when using load cells de- -

signed to accommodate full press capacity. The load cell design, shown inFig. 6, has a load measuring capacity of 200,000 lbs and is capable ofaccommodating full press load (l.lxl05 lbs) safely.

The load cell was instrumented with strain gages and calibrated up to200,000 lbs on a certified testing machine. Flow stress-strain curves weredetermined from the forging loads measured with the cell using the RingCompression Test( 8 ).. The stress-strain curves are shown in Fig. 7. Detailsare found in an Materials Laboratory Technical Report in print (25).

A modification to the load cell was accomplished that resulted in anincrease in the linearity range of the cell. The modification consisted ofa change in the free deformation clearance between the measuring cell and thesafety block. This change became necessary due to a misalignment of a 0.004inch thick ring previously used to adjust the deformation characteristics ofthe previously used cell. This modification resulted in a drop of the outputof the cell to a maximum of about 20% at the lower load range. This meansthat a maximum uncertainty of + 10% is possible on the lower load range usedto obtain the flow stress data of Fig. 7.

Changed in the forging method and in the method of data analysis forthe Ring Compression Test are currently underway under Contract No. F33615-79-C-5096 and could have a significant impact on the stress-strain datacomputed from the Ring Compression Test. Corrections to the data in SectionsIIA, liB and IIC will be made as necessary when said data analysis iscompleted.

3

SECTION III

APPLIED METAL PROCESSING

The experience gained during the performance of the experimental pro-grams outlined in Section II, combined with prior expertise and knowledgeof metal forming, has been applied to the processing of more than 469billets and bars of experimental materials related to government alloy devel-opment programs. The processing included extrusion, conventional andisothermal forging, rolling, wwaging and melting. All types of materialswere processed during these studies, ranging from aluminum alloys to tungstenalloys. A variety of starting material forms, cast, powder and wroughtconditions were included in the processing operations. A number of heattreatment operations were also performed in these application studies.

A listing of the billets processed by extrusion for these application

studies are included in Table 1, together with the deformation pressure forthe particular processing conditions and a description of the product quality.

S.. . - l

HYDROVAC FORGING

. 1200 F

DATA POINTS ARE THE PEAKSTRESS VALUES FROM

n 60 -. .FITTED CURVES OF ACTUALLuTEST DATAI- LOAD (PEAK(n S0] ... TRESS) REDUCTON

0r

20Lu

01 1 1I I I I I

0 0.4 0.8 1.2

WEIGHT PERCENT HYDROGEN

30% REDUCTION IN FORGING LOAD

80 0 W/o H DATA POINTS ARE THE PEAK0.3 IPM STRESS VALUES FROM FITTED

CURVES OF ACTUAL TEST0.4 W/o H DATA0.3 IPM

0 /oW H

H 30.0 IPM

4. 0.4 W/o Ho .30.0 IPMM"20- DIE TEMPERA-

TURE REDUCTION-rAT SAME LOAD

w0 (PEPK STRVSS) j 7 '

0 1200 1400 1600 180G

FORGING TEMPERATURE (OF)

150°F REDUCTION IN HOT FORMING TEMPERATURES

Fig. 1. Hydrovac forging advantages.

5

..............

PRESS ARRANGEMENT PRIOR TO EXTRUSION

strsin P ea k

led eadsfe~g

stop Prolina

lockk dip

RIGID STOP YIELDING A PARTIAL EXTRUSION

Fig. 2. Illustration of the rigid ram stop used for

the partial extrusions.

6q

ce taior io

Fig. 3. Macrographs of a sequence of longitudinallysectioned partially extruded billets showing thedevelopment, propagation and repetition of thecentral burst defect. The above sequence showsa) the development of the tangential velocitydiscontinuity surface, b) the initiation of theburst at the axial center of the billet at thetip of the discontinuity surface and c) therapid opening of the defect.

7

.A A

Fig. 4. The above sequence shows a) the fullydeveloped defect exiting the die withmetal flow concentrated at the outer

shell of the product followed by b) there-establishment of the metal flow within

the die cone and the initiation of a newtangential discontinuity surface beginningat the outer portion of the billet wherethe initial entry to the die cone occursand c) the continued development of thediscontinuity with concentrated flow inpreparation for the next burst.

8

A A

!B

((b)

Region 1 - Nondeformed MaterialRegion II - Deformation ZoneRegion III - Product Material

Fig. 5. Phenomenological mechanism of the development, propagation and

repetition of the central burst defect. a) Development of

tangential velocity surfaces (1) occurs with bands of localizedflow. Tangential flow along the discontinuity (2) is translated

to axial flow toward the die exit and results in a region of

enhanced tensile stress (3) at the billet axis. b) Initiationof the central burst defect (4) results from tensile overload.

Wavy flow lines (5) develop while the defrmgation zone volume

shrinks by movement of the entrance boundary (6) toward the die

exit. c) Discontinuous flow lines develop (7) as the defect

propagates along the discontinuity surface but propagation

becomes less energetically favorable as the geometric position

of the flow surface proceeds through the defrmgation zone (8).

The defect opens rapidly (9) as flow concentrates (10) at the

outer flow lines. d).As the defect passes through the die the

deformation zone (11) becomes re-established and new tangential

velocity discontinuity surfaces (12) begin at the outer surfaces

of the billet near the entrance to the die cone.

91

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Fig. 7. Flow stress-strain curves for Ti-10V-2Fe-3A1 forgedisothermally at 3.00 ipm (nominal). Grain Size 255pm.The forging loads needed for th 2 fw stress calculationusing the ring compression test were measured usingthe load cell previously described.

1]

REFERENCES

1. I. Perlmutter and Vincent DePierre, "Extruding Refractory Metals", MetalProgress, November 1963.

2. D. R. Carnahan and V. DePierre, "Process Variables in Metal Extrusion",Part I: Linear Friction During Extrusion", AFML-TR-67-242, July 1967.

3. D. R. Carnahan and V. DePierre, "Process Variables in Metal Extrusion",Part II: Extrusion Die Forces", AFML-TR-67-242, June 1968.

4. V. DePierre, T. D. Cooper and D. R. Carnahan, "Process Variables in MetalExtrusion", Part III: The Effect of Extrusion Temperatures on DeformationLoads and Mechanical Properties of Ti-6A1-4V Titanium Alloy", AFML-TR-67-242, September 1968.

5. Alan T. Male, "Process Variables in Metal Extrusion", Part IV: SummaryAFML-TR-67-242, January i969.

6. F. J. Gurney, A. T. Male and V. DePierre, "Evaluation of DuPont OxalateTreatment for High Temperature Metalworking Lubrication", TM-MAN-69-15,September 1969.

7. Vincent DePierre and Alan T. Male, "Mathematical Calibration of the RingTest for Friction Studies in Flat Forging Operations, Part I: Experi-mental Evaluation, Part II: Computer Solutions", AFML-TR-69-28, October1969.

8. George Saul, Alan T. Male and Vincent DePierre, "A New Method for theDetermination of Material Flow Stress Values Under MetalworkingConditions", AFML-TR-70-19, January 1970.

9. Alan T. Male and Vincent DePierre, "The Use of the Ring Compression Testfor Defining Realistic Metal Processing Parameters", AFML-TR-70-129,June 1970.

10. Vincent DePierre, Alan T. Male and George Saul, "The Relative Validityof Coefficient of Friction and Interface Friction Shear Factor for usein Metal Deformation Studies", AFML-TR-70-243, October 1970.

11. A. T. Male, F. J. Gurney and T. E. Jones, "The Evaluation of Glassesas Forging Lubricants", AFML-TR-71-83, April 1971.

12. F. J. Gurney and A. T. Male, "The Relationship of Microstructure andMechanical Properties of Extruded Titanium Alloy Bars to the PriorDeformation Processing History", AFML-TR-71-28, March 1971.

13. F. J. Gurney, A. T. Male and T. E. Jones, "Evaluation of SelectedCommercial and Experimental Intermediate Temperature Forging Lubricants",AFML-TR-71-139, June 1971.

12

REFERENCES (Cont'd)

14. Alan T. Male and Fred J. Gurney, "Synthesis of Shape, Structure andProperties by Control of Metallurgical Processing Variables", AFML-TR-71-103, September 1971.

15. F. J. Gurney, D. J. Abson and V. DePierre, "The Influence of Extrusion-Consolidation Variables on the Integrity and Strength of the ProductFrom Pre-Alloyed 7075 Aluminum Powder", AFML-TR-73-252, October 1973.

16. D. J. Abson and F. J. Gurney, "Investigation of Parameters Involved inMetal Processing Operations", AFML-TR-73-281, December 1973.

17. D. J. Abson, "Metal Processing Operations", Volume I: Grain Boundaryand Sub-Boundary Strengthening in Aluminum at Room Temperature", AFML-

TR-74-142, July 1974.

18. Gurney, F. J., "Summary Report on Investigation of Metal ProcessingOperations", AFML-TR-77-75, April 1977.

19. Gurney, F. J. and A. M. Adair, "Evaluation of Friction Properties ofSheet Forming Lubricants By Tensile Drawing and By Ring Compression",AFML-TR-78-66, May 1978.

20. Gurney, F. J., I. A. Martorell and W. R. Kerr, "Pilot Plant Forgingof Hydrogenated Ti-6A1-4V", AFWAL-TR-80-4026.

21. Kolachev., B. A., et al., "Effect of Hydrogen on Industrial Plasticityof Ti-9AI", Izvestiya Vysshikh Ucheknykh Zavedeniy TsvetnayaMetallurgiya, Nr. 4, 1972, pp. 137-142, USAF Foreign TechnologyDivision Translation, FTD-ID(RS)I-1076-76, August 1976.

22. Kolachev, B. A., et al., "Evaluation of the Beneficial Effect ofHydrogen on the Deformability of the Titanium Alloy ST4", Kuzechno-Shtampovochnoye Proizvodstvo, Nr. 1, January 1975, pp. 29-32, USAFForeign Technology Division Translation, FTD-ID(RS)I-2347-75, November1975.

23. Gurney, F. J., W. R. Kerr and I. A. Martorell, "Effects of HydrogenContent on Selected Properties of Ti-30A and Ti-5A1-2.5Sn", AFML-TR-,to be published.

24. Gurney, F. J., "A Phenomenological Mechanism for the Occurrence of theExtrusion Central Burst Defect", AFML-TR-79-4031, April 1979.

25. Martorell, I. A. and F. J. Gurney, "High Sensitivity-Low Capacity LoadCell with Overload Protection", AFML-TR-79-4154, in print.

13

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