Manufacturing of Titanium for Critical Applications Hydrogenated … · 2018. 4. 14. · Dr. Vladimir Duz September 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered

Dr. Vladimir DuzSeptember 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered to AS9100

Manufacturing of Titanium Components for Critical Applications from Hydrogenated Titanium Powder

Vladimir Duz1, Vladimir Moxson1, Mykhailo Matviychuk1, Orest Ivasishin21 ADMA Products Inc., 1890 Georgetown Road, Hudson OH 44236, USA2 Institute for Metal Physics, Ukrainian National Academy of Science,

36 Vernadsky St., Kiev 03142, Ukraine

Dr. Vladimir DuzSeptember 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered to AS9100 Registered to AS9100

ADMA Blended Elemental Powder Metallurgy Approach (US Patent 7,993,577 B2)

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TiH2 Powder +

M/A Powder

Simple Consolidation

Sintering Finished Productsor pre-form for post-processing

Hydrogenation followed by simultaneous de-hydrogenation & sintering are twoinnovative aspects of our invented process that are the key in reducing the cycletime to <24 hours (i.e., 5-fold reduction) leading to ~50% energy savings and costreduction of ~20%.

Dr. Vladimir DuzSeptember 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered to AS9100 Registered to AS9100

ADMA TiH2 Powder

• Hydrogen is completely removed from material during sintering

• Finished titanium products meet AMS Specification chemistry requirements

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Material Fraction of total mass of specified impurities, %

Fe N C O H Ti

ADMA TiH2 powder 0.03 – 0.16 0.030 0.010 0.060-0.100 3.80-3.85 Bal

ASTM B348 Grade 2 0.300 0.030 0.080 0.250 0.015 Bal


Ring Rolling

Flowform

Extrusion

Hot Rolling(Flat & Round)

Forging

VacuumSintering

VacuumSintering

Finished ProductsDie Press

Processing Steps for the BE Titanium Alloy Parts Production

TiH2Powder

Post-Processing Outside vendorsADMA Titanium P/ M “in house” Processes

Direct PowderRolling

Cold IsostaticPressing

Ti alloy compositions

• CP Ti

• Ti-6Al-4V

• Ti-3Al-2.5V

• Ti-6-6-2

• Ti-6-2-4-2

• Ti-1Al-8V-5Fe

• Metal Matrix Composites

• TiAl

• Other Ti alloys


Titanium and Titanium Alloys ComponentsDie-press/Sinter

Material Density, % YS, ksi UTS, ksi El. % RA, %CP-Ti, as-sintered 98.5 63 74 26 37

Ti-6Al-4V, as -sintered 99.0 126 142 12 30Ti-6Al-4V, STMB348 Grade 5 - 120 130 10 25Ti-5553, sintered + heat treated 98.5 174 189 6,8 10,3Ti-5553, BMS7-360 specification - 170 180 5 -Ti-1023, sintered + heat treated 98.0 161 181 5,2 11,0

Ti-1023, AMS 4984 specification - 160 173 4 -

Die Pressing

Sintering


Direct Powder Rolling of Ti Alloy Foil, Sheet, and Plate at ADMA

0.005” – 0.250” thick x up to 25” wide


Cold Isostatic Pressing + Sintering

Cold Isostatic Pressing

Sintering

Post-processing

Forging

Extrusion

Flowform

Ring RollingRollingFlat (foil, sheet, plate)

Round (bar, rod)

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P/M Ti-6Al-4V Commander’s Hatch CIP/Sinter/Forging

Al V Fe C N O H Ti Other, Each Other, Total

CIP/Sinter 6.16 4.21 0.080 0.009 0.021 0.179 0.0018 Bal. <0.10 <0.40

ASTM/AMS 5.5 – 6.75 3.5‐4.5 0.30 0.080 0.050 0.20 0.0125 Bal. <0.10 <0.40

Room Temperature Tensile PropertiesP/M Ti‐6Al‐4V Ultimate Tensile Strength, ksi Yield Strength, ksi Elongation, % Reduction of Area, %

1.375” thick 144 – 149 132 – 136 14.0 – 15.5 34 – 38

ASTM 130 120 10 25


Sintering

Forging


“…passed with flying colors, met the forging specification requirements, as wellas the plate specification requirements (MIL‐DTL‐46077)… this is the best result we have seen from any PM based, no melt, low cost material” (BAE 7‐6‐2010 test report)

ADMA P/M Ti-6Al-4V Commander’s Hatch

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P/M Ti-6Al-4V Armor Plates - CIP/Sinter/Hot Rolling

P/M Ti‐6Al‐4V Ultimate Tensile Strength, ksi Yield Strength, ksi Elongation, % Reduction of Area, %

0.75” thick 139 – 147 126 – 136 16 – 17 32 – 36

0.50” thick 142 – 151 129 – 132 15 – 18 33 – 39

ASTM 130 120 10 25

Room Temperature Tensile Properties

Al V Fe C N O H Ti Other, Each Other, Total

CIP/Sinter 5.88 4.23 0.076 0.010 0.008 0.158 0.0054 Bal. <0.10 <0.40

ASTM/AMS 5.5 – 6.75 3.5‐4.5 0.30 0.080 0.050 0.20 0.0125 Bal. <0.10 <0.40


Sintering

Hot Rolling

Dr. Vladimir DuzSeptember 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered to AS9100 11

The powder-based rolled mill Ti-6Al-4V productsform static tensile, fatigue, and fracture propertiesthat match similarly-processed ingot-based Ti-6Al-4Vhot-rolled products

The blended elemental hot-rolled P/M Ti-6Al-4V alloymill products met the AMS Specification mechanicalproperty requirements for both static loading, as wellas damage tolerant fracture toughness and cyclicS/N fatigue endurance limit for aerospaceapplications.

Development and Optimization of Rolled ProductsUsing Blended-Elemental Powder-Based Ti-6AL-4V Alloy

ADMA/BOEING/TIMET/RTIElement %Oxygen 0.143Carbon 0.009Nitrogen 0.012Hydrogen 0.0095Aluminum 6.01Vanadium 4.12Iron 0.085Yttrium 0.0008Chromium 0.022Nickel 0.024Silicon 0.016Total Others < 0.40Titanium Remainder


Ti-6Al-4V UTS (ksi) 0.2% YS (ksi) % El. % RA

ADMA P/M 156 - 157 134 – 135 12 - 13 28

Ingot Based 140 - 142 125 – 127 12 27

Extrusion Process for BE P/M Ti-6AL-4V Alloy

Ti‐6Al‐4V Al V Fe C N O H Ti Other, Each

Other, Total

CIP/Sinter 6.2‐6.4 4.04‐4.30 0.15 0.01 0.01 0.20 0.007‐0.050 Bal. <0.10 <0.40

ASTM B348 5.5‐6.75 3.5‐4.5 0.40 0.08 0.05 0.20 0.0150 Bal <0.10 <0.40

Extrusions up to 36-foot long were fabricated and analyzed at front, mid-length, and back and found to be uniform with respect to oxygen content & microstructure

ADMA/BOEING/Plymouth/RTI

Dr. Vladimir DuzSeptember 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered to AS9100 13

Ti-6Al-4V Round BarsCIP/Sinter/Rotary Forging

0.875” Dia x 12ft long Ti-6Al-4V round bars

P/M Ti-6Al-4V UTS, ksi YS, ksi Elongation, % RA,%

ADMA TiH2 Powder 154 – 155 141 – 142 15.8 – 16.5 38 - 40

AMS 4928R 135 Min. 125 Min. 10 Min.

Room Temperature Tensile Properties

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ADMATALTM

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

ASTM B348 5.5‐6.75 3.5‐4.5 0.40 0.08 0.05 0.200 0.015 Bal <0.10 <0.40

Chemical analysis of P/M Ti‐6Al‐4V CIP/Sinter/Rotary forged bars produced from ADMA TiH2 powder


Corrosion Resistant Heat Exchanger and Chemical Process Seamless Tubing Manufacture Directly from Extruded Titanium Powder

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ADMA Ti Billets Centered and Ready for Hot Extrusion

ADMA CIP Tooling

Extruded Tubes

Ready to Pilger


P/M Ti-6Al-4V CIP/Sinter/Ring Rolling


Sintering

Ring Rolling

Hydrogen content is reduced to safe level 20-60 ppm even at production of components with large cross-sections (16.0” x 13.5” ID x 10.0” LG)

Element Wt. %Aluminum 5.83Vanadium 3.96Iron 0.15Oxygen 0.18 – 0.20Carbon 0.008Nitrogen 0.015Hydrogen 0.0052Yttrium ˂ 0.0005Nickel 0.014Silicon 0.014Chromium 0.013Other elements each ˂ 0.10Other elements total ˂ 0.40Titanium remainder


Ti-1Al-8V-5Fe Round BarsCold Isostatic Pressing

Sintering

Hot Rolling

Room Temperature mechanical properties of Ti-1Al-8V-5Fe (Ti185) alloy round bars rolled in both blended-elemental powder-based and ingot-based double-VAR billet product forms.

Alloy/Billet Ident. Specimen ID

Round‐Bar Rolling Reduction in Diametral Dimension

Ultimate Tensile Strength

0.2% Yield Strength

Elongation Elastic Modulus

Fracture ToughnessKIC (KQ)

[ksi] [ksi] [%] [Msi] [ksi] (inch)1/2

Ti185 Blended‐Elemental Powder‐Based Alloy, CIP /

Sintered and round‐bar rolled

Alloy 1 –T1 4” → 1” 201.3 194.6 17 15.2 33.3

Alloy 1 –T2 4” → 1” 205.2 198.4 16 15.4 22.8

Ti‐185 Ingot‐Based Alloy Double VAR Round‐Bar Rolled

RRR2‐T1 4” → 1” 201.8 194.0 12 17 34.0

RRR2‐T2 4” → 1” 208.0 199.4 10 16.5 31.5


ADMA Capabilities• Titanium Powder Production Units

• Titanium Powder Processing EquipmentTwo Rotap RX-29 screen shakers Rotex screenerVarious blenders with and without intensifier barsWilliams Crusher & PulverizerSteveco Ball Mill1SD AttritorJaw Crusher

• Consolidation EquipmentSix Molding presses with a capacity from 12 to 250 tons;Two Sizing presses with a capacity of 15 and 40 tons;Cold isostatic press with a capacity up to 60,000 psi;

• Rolling MillsStanat 24” wide rolling mill5” wide and 13”wide laboratory direct powder rolling mill12” wide four-high rolling mill26” wide direct powder rolling mill

• Vacuum FurnacesTwo Super VII-TM Vacuum Furnaces up to 2200°C125”long x 52”wide x 28”high Vacuum sintering system

• Analytical InstrumentsMetallography equipmentParticle size analyzer Microtrac S3500Gas Analyzer Leco ROH600 Automated Capillary Flow Porometer


CONCLUSIONSInnovative powder metallurgy processes for manufacturing the titaniumcomponents for critical applications from hydrogenated titanium powder thatincludes various room temperature consolidation techniques (die-pressing, directpowder rolling, and cold iso-static pressing) followed by sintering and hightemperature post processing (forging, rolling, extrusion, ring rolling weredeveloped.

The low cost ADMA patented blended elemental powder metallurgy processes(ADMATALTM) provide the best combination of mechanical properties that meet orexceed the properties obtained on the identical titanium alloys by conventionalingot metallurgy processes.

Documents

Manufacturing of Titanium for Critical Applications Hydrogenated … · 2018. 4. 14. · Dr. Vladimir Duz September 21‐24, 2014 • Hilton Chicago, Chicago, Illinois, USA Registered