Powder Metallurgy Titanium and Titanium Alloy Components Manufactured from Hydrogenated Titanium Powders

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1 Powder Metallurgy Titanium and Titanium Alloy Components Manufactured from Hydrogenated Titanium Powders Georg I. Abakumov, V.S. Moxson, Vladimir Duz, Mykhailo Matviychuk, Viktor Sukhoplyuyev October 7 10, 2012 Atlanta, Georgia, USA 1

2 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! October 7 10, 2012 Atlanta, Georgia, USA 2

3 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 October 7 10, 2012 Atlanta, Georgia, USA 3

4 Processing Steps for Blended Elemental Titanium Alloy Parts Production ADMA Titanium P/ M in house Processes Die Press Finished product Forging Post-Processing Outside vendors Rolling Flat (foil, sheet, plate) Round (bar, rod) Powder Direct Powder Rolling Vacuum Sintering Extrusion Rotary Forging Cold Isostatic Pressing Vacuum Sintering Flowform HIP Wire drawing October 7 10, 2012 Atlanta, Georgia, USA 4

5 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 microstructureproperty correlations of tensile properties, S N fatigue life, fatigue crack growth rate fracture toughness per ASTM E399 K1C and stress corrosion resistance October 7 10, 2012 Atlanta, Georgia, USA 5

6 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 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 microstructureproperty correlations of tensile properties, S N fatigue life, fatigue crack growth rate fracture toughness per ASTM E399 K1C and stress corrosion resistance October 7 10, 2012 Atlanta, Georgia, USA 6

7 Development and Optimization of Rolled Product Forms Using Blended Elemental Powder Based Ti 6AL 4V Alloy Boeing/ADMA/RTI/TIMET Sami M. El Soudani, Ti-6Al-4V rolling billets October 7 10, 2012 Atlanta, Georgia, USA 7

8 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. October 7 10, 2012 Atlanta, Georgia, USA 8

9 Sami M. El Soudani, RTI Rolled Blended Elemental Ti 6Al 4V Billets Met Specification Requirements and Matched Properties 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] YS [ksi] Elon. [%] Fracture Toughness K IC or K C [ ksi.inch½ ] Plate 10 Average Sheet 34 Average Plate 2 Average Sheet 8 Average October 7 10, 2012 Atlanta, Georgia, USA 9

10 Our Plate 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 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 K T = 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 RR2A (RTI) 13.1 x 6.9 x W1 (RTI) 16.7 x 16.7 x Sami M. El Soudani et al, Metall. and Mat. Trans. A Vol.41A, 2010 October 7 10, 2012 Atlanta, Georgia, USA 10

11 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 Blended-Elemental Powder-Based Ti-6Al-4V Sheet Product Double Arc-Remelt Ingot-Based Sheet Sheet Identification and Rolling Vendor Sheet Geometry as Tested per ASTM E 466 K T = 1 for S/N Fatigue Life[inches] Original As-Sintered Rolled Billet Thickness [inches] Fatigue Endurance Limit [ksi] RR1E (RTI) 13.5 x 7.7 x RR3D (RTI) 17.2 x 7.5 x RR4-2C (RTI) 17.4 x 7.5 x W2D (RTI) 16.9 x 8.6 x W2C (RTI) 14.5 x 8.1 x October 7 10, 2012 Atlanta, Georgia, USA 11

12 Timet-Rolled Blended-Elemental Ti-6Al-4V Billets Met Specification Requirements and Matched Properties of Wrought Ingot Alloy 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.- [%] K IC or K C [ ksi.inch½ ] 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 Plate 8 Average Sheet 18 Average Plate 2 Average Sheet 8 Average October 7 10, 2012 Atlanta, Georgia, USA 12

13 Sami M. El Soudani 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 The ADMA Hydrogenated Titanium Billet T4-2 (as-sintered Dimensions x 8.5 x 11 inches) was Rolled Successfully at Timet and Easily Met Tensile, Fracture Toughness and Fatigue S/N Requirements! October 7 10, 2012 Atlanta, Georgia, USA 13

14 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 Ingot- Based Sheet Sheet Identification and Rolling Vendor Sheet Geometry as Tested per ASTM E 466 K T = 1 [inches] Original As-Sintered Rolled Billet Thickness [inches] Fatigue Endurance Limit [ksi] T2.2.2 (Timet) 10.2 x 6.2 x T4.2A-9 (Timet) 10.2 x 7.1 x W2D (RTI) 16.9 x 8.6 x W2C (RTI) 14.5 x 8.1 x Sami M. El Soudani October 7 10, 2012 Atlanta, Georgia, USA 14

15 General Conclusions on Blended Elemental 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. Boeing/ADMA/RTI/TIMET October 7 10, 2012 Atlanta, Georgia, USA 15

16 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 October 7 10, 2012 Atlanta, Georgia, USA 16

17 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, , , , Ingot Based 125, , , , October 7 10, 2012 Atlanta, Georgia, USA 17

18 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 ) Cold Isostatic Pressing Sintering Forging Al V Fe C N O H Y Ti Other, Each Other, Total CIP/Sinter < Bal. <0.10 <0.40 Room Temperature Tensile Properties P/M Ti 6Al 4V UTS, ksi YS, ksi Elon., % RA, % thick October 7 10, 2012 Atlanta, Georgia, USA 18

19 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, , , % YS (PSI) 131, , ,000 ELONGATION, % R. A., % October 7 10, 2012 Atlanta, Georgia, USA 19

20 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 lbs October 7 10, 2012 Atlanta, Georgia, USA 20

21 ADMA Direct Powder Rolling Mill - 50 Million Lbs/Year Armor Plate Production Capacity 0.25 thick plate was successfully rolled at ADMA facility October 7 10, 2012 Atlanta, Georgia, USA 21

22 P/M Ti-6Al-4V (Low Oxygen) Plates - ADMA Hydrogenated Ti powder 0.75 thick 0.50 thick Cold Isostatic Pressing Sintering Rolling ST LT L L Longitudinal LT Long transverse ST Short transverse October 7 10, 2012 Atlanta, Georgia, USA 22

23 ADMA P/M Ti-6Al-4V alloy Bars for the IBIF Fred Sert Program Cold Isostatic Pressing Sintering Extrusion Rolling Rotary Forging ADMA P/M Ti-6Al-4V Extruded bars Ti-6Al-4V UTS ksi YS, ksi El., % RA, % ADMA P/M Ingot Based AMS 4928R 135 Min. 125 Min. 10 Min. October 7 10, 2012 Atlanta, Georgia, USA 23

24 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 ,014, ADMA Ti P/M ,716, October 7 10, 2012 Atlanta, Georgia, USA 24

25 P/M Ti and Ti alloy Hollow Cylinders for US NAVY Tubes and Pipes CIP Vacuum Sintering Flowform ADMA Hydrogenated Ti Powder October 7 10, 2012 Atlanta, Georgia, USA 25

26 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 lb/in 3 CP Ti lb/in 3 Titanium pipe saves 178,000 lbs per LPD compared to Cu Ni pipe system, improving fuel efficiency and reducing life cycle maintenance cost of the pipe system USS SAN ANTONIO (LPD 17) October 7 10, 2012 Atlanta, Georgia, USA 26

27 October 7 10, 2012 Atlanta, Georgia, USA 27

28 Titanium or Titanium Alloy Components Die Pressing + Sintering Near Net Shape Die Pressing Sintering October 7 10, 2012 Atlanta, Georgia, USA 28

29 Die Pressing + Sintering Near Net Shape Titanium or Titanium Alloy Components for Aerospace Applications CP Ti washers Material Composition, % N C H Fe O Ti CP Ti washers Bal. ASTM B 348 Grade Bal. Material Ti-6Al-4V washers Composition, % N C H Fe O Al V Ti Ti-6Al-4V washers Bal ASTM B , Type I max October 7 10, 2012 Atlanta, Georgia, USA 29 Bal

30 Die Pressing Ti-3Al-2.5V Components for Aerospace Applications Sintering October 7 10, 2012 Atlanta, Georgia, USA 30

31 Metal Porous Membrane Sheets by Direct Powder Rolling Process Metal Powder BLEND POWDER ROLLING SINTER RE-ROLL ANNEAL FINISHED SHEET Direct Powder Rolling Binder Filler October 7 10, 2012 Atlanta, Georgia, USA 31

32 Direct Powder Rolling of Ti Alloy Foil, Sheet, and Plate at ADMA thick Ti foil 0.25 thick plate October 7 10, 2012 Atlanta, Georgia, USA 32

33 Porous Titanium Sheets/Plates Cracking Oxygen from Water - Life Support Systems for the US NAVY, AIRFORCE, and NASA October 7 10, 2012 Atlanta, Georgia, USA 33

34 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 October 7 10, 2012 Atlanta, Georgia, USA 34

35 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 October 7 10, 2012 Atlanta, Georgia, USA 35

36 Cold Isostatic Pressing Porous Titanium Tube Sleeve/Flange Cold Isostatic Pressing Sintering October 7 10, 2012 Atlanta, Georgia, USA 36

37 Weapon Components Developments CIP/Sinter/Rotary Forging P/M Ti 6Al 4V Dia x 12ft long round bars produced from ADMA TiH 2 powder Ti 6Al 4V Al V Fe C N O H Ti Other, Each Other, Total ADMA TiH Bal. <0.10 <0.40 Sodium Reduced Ti Bal <0.10 <0.40 ASTM B Bal <0.10 <0.40 P/M Ti 6Al 4V UTS, ksi YS, ksi El., % RA, % ADMA TiH Sodium Reduced Ti AMS 4928R 135 Min. 125 Min. 10 Min. October 7 10, 2012 Atlanta, Georgia, USA 37

38 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! October 7 10, 2012 Atlanta, Georgia, USA 38