The New Zealand Titanium Technologies Platform - TiTeNZ

Transcription

1 The New Zealand Titanium Technologies Platform - TiTeNZ Ian Brown Jeremy Wu, Geoff Smith, Conrad Lendrum, Bill Owers Advanced Materials Group, Callaghan Innovation Lower Hutt, New Zealand

2 A Brief History of Titanium R&D and Emerging Titanium Enterprises in NZ : First steps in titanium metal powder synthesis at Waikato University, using Al metal to reduce TiO 2 Ar 3TiO Al 3Ti + 2Al 2 O 3 T ( C) ΔH (kj) ΔG (kj) Strategy to use a combination of density separation and dissolution (Al 2 O 3 ) techniques to isolate and purify the titanium

3 Thermodynamic Model of 3TiO Al 3Ti + 2Al 2 O 3 (in Argon) 2.0 TiO 1.5 Moles 1.0 Al2O3(C) AlTi Temperature ( C) Strong competing reactions to form intermetallics Al Ti Al3Ti

4 A Brief History of Titanium R&D and Emerging Titanium Enterprises in NZ : First steps in titanium metal powder synthesis at Waikato University, using Al metal to reduce TiO 2 Ar 3TiO Al 3Ti + 2Al 2 O 3 T ( C) ΔH (kj) ΔG (kj) Ar 3TiO 2 + 7Al 3AlTi + 2Al 2 O 3 T ( C) ΔH (kj) ΔG (kj) The product is more accurately described as Ti,Al(O). Further processing reduced the oxygen content of the intermetallic product phase.

5 A Brief History of Titanium R&D and Emerging Titanium Enterprises in NZ 1997: Establishment of Titanox Developments Ltd to commercialise this process From 1998: Series of investments by Ministry of Research, Science & Technology (then MSI, now MBIE) in: (i) (ii) Univ. Waikato R&D programmes via FRST/MSI/MBIE Titanox via MoRST TechNZ grants and via commercial investors From 2007: NZTE investment in a series of commissioned reports and a commercialisation roadmap 2010: Establishment of the Titanium Industry Development Association (TiDA), transitioned from partial NZTE support to full commercial operation by Oct 2012: MBIE funding of The New Zealand Titanium Technologies Platform

6 Structuring The New Zealand Titanium Technologies Platform - TiTeNZ The TiTeNZ programme targets the opportunities and critical technical and commercial barriers identified in Trilateral Agencies (NZTE, FRST, TEC) reports that define a 10 year roadmap to achieve a NZ-based $1B per year titanium-based export industry. The TiTeNZ research platform expands New Zealand s University and CRI titanium research infrastructure, and integrates this with the industry-focused capability of the Titanium Industry Development Association (TiDA).

7 Structuring The New Zealand Titanium Technologies Platform - TiTeNZ The TiTeNZ Research Aims addressed six critical competency areas identified in the NZTE roadmap: (i) (ii) (iii) (iv) (v) (vi) Thermomechanical Consolidation Powder Metallurgy Metal Injection Moulding Powder Production and Alloy Development Cellular Materials Additive Manufacturing Technologies Surface Treatment and Coatings

8 Obj. 1 Thermomechanical Consolidation Powder Metallurgy. University of Waikato Prof Brian Gabbitas Project Aim: Validate Thermomechanical Powder Compaction (TPC) for economic small scale industrial production. Commercialise the technical know-how for the benefit of New Zealand Technology Goals: Process development for powder compact forging and powder compact extrusion Improved understanding of the relationships between processing conditions, microstructure and mechanical properties for TPC titanium alloy products, with special emphasis on fracture properties.

9 Obj. 1 Thermomechanical Consolidation PM Outcomes to date: Powder compact forging. Investigating powder compaction, vacuum sintering and forging. Prototyping a dive helmet component for Accord Precision Ltd, Auckland, forged in Ti at South Auckland Forgings Engineering. Good tensile properties. Developing processing methods for cost-effective production

10 Obj. 1 Thermomechanical Consolidation PM Outcomes to date: Powder compact extrusion. Researching variables that control extrusion quality and yield, principally the optimum extrusion temperature and extrusion speed for delivering good quality material using a blended elemental approach. Initial target is economic manufacture of high hardness knife blade from a Ti alloy.

11 Obj. 1 Thermomechanical Consolidation PM Outcomes to date: Fracture properties of PM Ti 6Al 4V Conducting a detailed investigation of the fracture behaviour of Ti6Al4V in both the as-forged, as-extruded conditions and after various heat treatments. Charpy impact testing used to obtain data on the relationship between microstructure and toughness and the effect of oxygen content. This will be extended to fracture toughness testing.

12 Obj. 2 Metal Injection Moulding (MIM) University of Auckland Dr Peng Cao TiDA Warwick Downing, Dr Peter Franz Project Aim: Implement a Ti MIM process to achieve maximum commercial benefit. Technology Goals: Binder development aimed at reducing the burnout temperature to below a point where the decomposing binder elements can react with Titanium. Reduction of carbon and oxygen contamination typical for Ti alloy MIM parts. Binder development to meet mould design requirements for fabrication of near net shape parts Maximise mechanical properties and increase density without a HIPping step

13 Obj. 2 Metal Injection Moulding (MIM) University of Auckland Dr Peng Cao TiDA Warwick Downing, Dr Peter Franz Outcomes to date: At least two practical binder choices with one giving good results. Early binder removal reducing contamination; good oxygen levels being recorded. Ongoing research in this area is key to controlling contamination. Parts retain their shape after the solvent debinding. Powder dispersion within the green body. The images show the powder is uniformly dispersed and that the large and small particles have not segregated.

14 Obj. 2 Metal Injection Moulding Solvent debinding of MIM parts Steel retort for thermal debinding Positioning steel retort in furnace Combined debinding/sintering furnace at TiDA

15 Obj. 3 Powder Production and Alloy Development Callaghan Innovation Dr Ian Brown, Dr Jeremy Wu Project Aim: In partnership with Titanox, develop optimised processes for synthesis of commercially significant titanium alloy powders Trial Titanox-sourced alloy powders in hot consolidation, injection moulding, cellular fabrication and/or additive manufacturing demonstrations.

16 Obj. 3 Powder Production and Alloy Development Technology Benefits: There are clear benefits associated with the current Titanox technology approach: The multistep processing associated with current best practice is eliminated Oxygen impurity levels are low in comparison with other commercial powders (typically 1000 ppm, sometimes better; alloy dependent) The ease of processing enables fabrication of multicomponent Ti alloy compositions. The potential for control of particle size distribution and shape to meet the needs of specific body fabrication techniques.

17 Obj. 3 Powder Production and Alloy Development Processing and furnace control enables tailored composition and particle morphology. Prospect of customising shape specific powders for hot consolidation, injection moulding, cellular fabrication and/or additive manufacturing. NiTi alloy NiTi alloy β-ti alloy

18 Obj. 4 Cellular Materials Callaghan Innovation Dr Ian Brown, Dr Jeremy Wu, Dr Geoff Smith, Bill Owers, Dr Conrad Lendrum TiDA Warwick Downing Project Aim: Develop proof-of-concept processes for the fabrication of short range order metal foams and cellular metals with periodic structures, for biomedical applications and as frameworks for catalysed gas or liquid purification, reaction or filtration. Position this proof-of-concept technology before commercial partners to secure ongoing investment with a defined market and product focus.

19 Obj. 4 Cellular Materials Technology Goals: Fabrication of Metal Foam Materials Fabrication of Cellular Materials Engineering Performance of Cellular and Foamed Materials Templating Spaceholder Additive SLM

20 Obj. 4 Cellular Materials - Fabrication of Metal Foam Materials Spaceholder Methods Sacrificial Template Methods 40-75% porous % porous. Voids determined by Hollow struts. size & shape of Cell size & shape chosen spaceholder. determined by organic template.

21 Obj. 4 Cellular Materials - Design and simulation

22 Obj. 4 Cellular Materials - Design and simulation Displacement Stress FEM ANSYS models 5x5x5 cells, unconstrained horizontal cell displacement

23 Obj. 5 Additive Manufacturing Technologies TiDA Warwick Downing Selective Laser Melting (SLM) in New Zealand SLM Solutions SLM280HL Selective Laser Melting instrument operating at the Titanium Industry Development Association (TiDA) laboratories, Tauranga.

24 SLM at work Victory Knives used by Team NZ

25 SLM at work - Weapons suppressors

26 SLM at work Titanium alloy bottle openers for that high tech stocking filler!

27 Obj. 6 Surface Treatment and Coatings GNS Dr Andreas Markwitz, Dr John Kennedy Project Aim: Develop a science and technology capability for advanced Surface Treatment and Coatings in NZ initially to grow and enhance the titanium applications industry. Technology Goals: Demonstrate proof-of-concept for ion beam pipe coating by Oct Ion beam pipe line coating installed in commercial environment by Oct 2014

28 Obj. 6 Surface Treatment And Coatings Proof-of-concept for ion beam pipe coating: Ion beam surface cleaning/coating systems running daily at Page Macrae Engineering, Tauranga

29 Obj. 6 Surface Treatment And Coatings First Testing of CALIS (Circular Anode Layer Ion Source) for Ion Beam Pipe Line Coating Current experimental set-up of CALIS. Number 1 indicates the turbo pump used to create a vacuum in the pipe suitable for striking the ion source and allowing ions to travel from the ion source to the inner wall surface

30 Summary: The New Zealand Titanium Technologies Platform - TiTeNZ is a partnership between: The University of Waikato Callaghan Innovation The Titanium Industry Development Association (TiDA) GNS Science The University of Auckland Our goal is to create a multi-company, multi-sector manufacturing base for high value titanium-based export products. The platform is funded via the MBIE Enabling Technologies investment programme and is supported by a growing number of innovative NZ companies.