Cost-effective Production of Powder Metallurgy Titanium Components

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18 Νοε 2013 (πριν από 3 χρόνια και 6 μήνες)

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1

Cost
-
effective Production
of Powder Metallurgy
Titanium Components


STCU
-
NATO Workshop

11
-
12 October 2006

Kyiv



Prof. Orest Ivasishin

Tel: (044)
-
424
-
22
-
10

E
-
mail: ivas@imp.kiev.ua

Institute for Metal Physics

Kyiv


2

Talk outline



1.
What is needed in the market?

2.
Brief technology description

3.
Stage of development

4.
Who needs it & how many will they need?

5.
What is my unique technology advantage?

6.
Competitive matrix

7.
How will
I

beat the competition?

8.
Opportunity for joint work



3

Problem Description & Market Need


Titanium alloys are attractive construction materials to use
in aerospace, automotive and other industries due to:



high strength



low density



good corrosion resistance


But:

Wider application of these materials is limited by their
relative high cost: $
15/
kg

(
titanium sponge
),
up to

$
150
-
200/
kg

(
components
)


The main trend in titanium materials science is to

expand application of titanium alloys by

development of
new technologies that provide significant cost reduction


4

Problem Description & Market Need

Titanium in Ukraine:

-

significant deposits of raw materials;

-

well developed titanium industry (sponge and ingot production);

-

users of titanium products (aerospace industry)



Titanium is one of the Ukraine`s priorities!

5

Brief Technology Description

Blended elemental powder metallurgy

approach is potentially the lowest
-
cost
process, especially if
additional working
operations (HIP or hot deformation) can
be avoided.


Powder metallurgy

enables
significant reduction in the cost




Blended Elemental
(BE)

Powder Blending

Ti, Alloying Elements


Powders

Powder Blend

BE Compact

Heat Treat

Low Porous Part

Densification

Part

HIP

Up to 90%

95%

99+%

6

Experimental Results

Sintered densities of TiH
2

blends:

-

higher than in equivalent Ti
-
based blends

-

do not noticeably depend on molding pressure




300
400
500
600
700
800
900
1000
95
96
97
98
99
100


Relative density,%
Molding pressure, MPa
TiH
2
Ti
99%
7

Hydrogenated Titanium: Physical
Background



Specific mechanism of
compaction


optimized green
porosity


Shear type phase
transformation TiH
2

Ti (


or

)


high density of crystal
lattice defects



Surface oxide self reducing by
atomic hydrogen


-

f
aster sintering

-

higher sintered density

-

lower impurity content

8

Mechanical Properties

(Ti
-
6Al
-
4V Composition)

Base
powder

Alloying
powder

YS,
MPa

UTS,
MPa

Elong.
%

RA,
%

Oxygen
content,
%

TiH
2

Al
-
V
master
alloy

850
-
930

960
-
990

10
-
12.5

23
-
29

0.11
-
0.25

ASM standard

(ingot material)



828



897



10



20


0.20

9

Cost
-
Effective Production of
Hydrogenated Titanium Powder

MgCl
2

TiCl
4

Reduction


Vacuum separation


Hydrogenation


Vacuum

Hydrogen

Argon

Production in Ukraine:

Zaporozhje Titanium&Magnesium Plant

10

Cost
-
Effectiveness


Integrated production process (in one reactor)


Shortened time of vacuum separation


Energy consumption and labor can be reduced by 12
-
35%

Proposed process : cost of powder
0.9

S (S


cost of titanium sponge)

Conventional process : cost of powder
2

S

Powder production

Part manufacturing

Proposed PM technology: cost of parts
1.4
-
2

S (per kg)

Conventional PM approach(CHIP): cost of parts
5
-
10

S

11

Advantages



Innovative approach



Cost
-
effectiveness



High mechanical properties


12

Stage of Development



Patented in Ukraine (Patents
## 65654 and 70366) and
USA (US Patent
No
6638336B1)



Prototypes (automotive
connecting rods) available for
testing


STCU


IPP partner project (P
-
143) aimed on development of
high
-
volume commercial
application

13

Targeted Market Segment



Automotive industry (connecting rods, valves, etc.)


World production per year : 53 million vehicles


212 million conrods

14

Automotive Components produced
Using Hydrogenated Powder

1.
connected rod with big end
cap

2.
saddles of inlet and
exhaust valves

3.
valve spring plate

4.
distribution shaft driving
pulley

5.
strap tension gear roller

6.
screw nut

7.
fuel pump filter

8.
embedding filter


15

Targeted Market Segment


-

Aerospace industry (components for non
-
critical
application)


-

Medical applications, etc.

16

Competition


-

expensive starting powders
with low impurity content

-
more complicated
processing (including HIP)



high cost

1. Other titanium PM technologies(CHIP)

2. Ingot metallurgy

-

multistep manufacturing

-

low material yield


high cost

17

Competitive Matrix

Important
product or
technology
characteristics

Proposed


PM approach

(TiH2)

Conventional
PM approach

(CHIP)

Ingot approach

Starting
materials

Cost effective
hydrogenated
titanium or scrap

High
-
pure
(expensive!)
titanium powders

VAR or EBM
ingot

Technological
operations

Compaction of
powders,
sintering

Compaction of
powders,
sintering, HIP or
hot deformation

Melting, hot
deformation,
heat treatment

Mechanical
properties

(Ti
-
6Al
-
4V)

UTS: 960
-
990
MPa;

El. 10
-
12%


UTS: 900
-
1000
MPa;

El. 10
-
13%


UTS

896 MPa;

El.


10%

Cost

1.4
-
2 S

5
-

10 S

5
-
13 S

18

Opportunities


Purpose: application of developed technology in
automotive, aerospace and medical industries




Potential customers:

-

automotive companies GM, Ford

-

Antonov, Boeing

-

dental companies (not defined yet)

Partnership:

-

Zaporozhye Titanium&Magnesium Plant


producer of
powders;

-

ADMA Products, Inc. (USA)

producer of titanium PM
parts

19

Contact information

Prof. Orest Ivasishin

Tel: +380
-
44
-
424
-
22
-
10

E
-
mail: ivas@imp.kiev.ua

Institute for Metal Physics

Kyiv