Dr.-Ing Jürgen Kiese EBCHR / LIBS Electron Beam Cold Hearth Remelting of Titanium and Scrap Control by LIBS Technology Birmingham, 13th May 2015 Jürgen Kiese, Juri Kazakov, Klaus-Peter Wagner
Dr.-Ing Jürgen Kiese EBCHR / LIBS 2 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Facility Drum feeder Mixing unit - weighing hopper 6 Guns - melting chamber Scrap, sponge, alloying elements EB furnace Slab or ingot
Dr.-Ing Jürgen Kiese EBCHR / LIBS 3 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Scrap revert strategy Since 2008, the VDM performs a successful scrap revert strategy. Feeding material: Titanium sponge Scrap as feedstock, chips (loose or compacted), cobbles, etc. Every ratio of each, sponge and scrap Automatic weighing and mixing systems for sponge, scrap, master alloys, micro components Containers with scrap The scrap ratio is typically 75 %. 100 mm 100 mm 100 mm 100 mm Sponge Cobbles Compacted chips Feedstock
Dr.-Ing Jürgen Kiese EBCHR / LIBS 4 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Melting Feeding EB gun Process control: Automatic Beam Power Distribution Control (ESCOSYS) Process observation by 6 viewing systems Melting Melting rate: up to 1,600 kg/h Refining Crystallization, mould
Dr.-Ing Jürgen Kiese EBCHR / LIBS 5 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Skull of melting and refining Shield Pouring lip to mould Melting area (skull) Metal flow Refining area (skull) Pouring lip
Dr.-Ing Jürgen Kiese EBCHR / LIBS 6 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Grades and Sizes 5390 mm 5300 mm Ti-6Al-4V Dim: 500 x 1050 x 5390 mm, Weight: 12.6 t Ti-6Al-4V Dim: 845 x 5300 mm, Weight: 13.2 t Grades: Grade 1s (low oxygen content) Grade 1 and 2 Ti-0.8Ni-0.3Mo (grade 12) Ti-6Al-4V (grade 5) Ti-6Al-4V ELI (grade 23) Ti-3Al-2.5V (grade 9) Product sizes: Ingots: 845 mm dia x 5.5 m (13.5 t) Slabs: 500 x 1,300 mm x 5.5 m (16 t) Slabs: 500 x 1,050 mm x 5.5 m (13 t) Slabs: 375 x 1,355 mm x 5.5 m (12.5 t) Slabs: 375 x 1,100 mm x 5.5 m (10.2 t)
Dr.-Ing Jürgen Kiese EBCHR / LIBS 7 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Analysis Ti-6Al-4V slab Chemical composition along the slab length 611340E: Aluminum Vanadium Iron Oxygen, Carbon, Nitrogen 611340E, 1050x500mm, 6,2t, Gr.5, Melt Sampling EB 611340E, 1050x500mm, 6,2t, Gr.5, Melt Sampling EB Ti-6Al-4V 1050 x 500 x 2700 mm Weight: 6.2 t
Dr.-Ing Jürgen Kiese EBCHR / LIBS 8 Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Analysis Ti-6Al-4V ingot - EB + VAR Chemical composition along the ingot length 612183E: Aluminum Vanadium Iron Oxygen, Carbon, Nitrogen 612183E, Ø845mm, Gr.5, 12t, Melt Sampling EB, drill VAR 612183E, Ø845mm, Gr.5, 12t, Melt Sampling EB, drill VAR Ti-6Al-4V Ø845mm x 4700mm Weight: 12 t
Dr.-Ing Jürgen Kiese EBCHR / LIBS 9 RETURN Process Chain: Recycling of Titanium Chips RETURN consortium: CeramTec - Cutting materials Cronimet - Recycling Deharde - Machining Institute of Production Engineering and Machine Tools, Uni Hannover - Machining Institute for Material Science, Uni Hannover - Material analysis MAG IAS - Manufacturer of milling machines Premium Aerotec - Machining VDM Metals - Melting Walter - Cutting tools Semifinished product Manufacturing Machining Recycling Titanium chips Closed materials cycle Aim: improvement of the chip quality without decreasing of the component quality component manufacturing
Dr.-Ing Jürgen Kiese EBCHR / LIBS 10 RETURN Process Chain: Recycling of Titanium Chips The role of VDM Metals: building up an innovative scrap/chip control Initial goal: to capture every chip to inspect every chip to analyze every chip Requirements: fast system automatic system Possible solution: LIBS system (laser-induced breakdown spectroscopy) Questions - to capture every chip: is it possible? is it necessary? All results should be transferable to solids (feed stock). In this project the fundamentals and requirements should be developed.
Dr.-Ing Jürgen Kiese EBCHR / LIBS 11 RETURN Process Chain: Recycling of Titanium Chips Feeding hopper Checking or analyzing by LIBS Vibration Channel for chip separation Settling section
Dr.-Ing Jürgen Kiese EBCHR / LIBS 12 RETURN Process Chain: Recycling of Titanium Chips PCA-coordinates, fingerprint of titanium Titanium Brass Silver Copper Zinc Score plot of the principal component analysis: PC0 and PC1
Dr.-Ing Jürgen Kiese EBCHR / LIBS 13 RETURN Process Chain: Recycling of Titanium Chips B A C Fingerprint of titanium WC tool bits A WC tool bits B + C Titanium Score plot of the principal component analysis: PC0 and PC1
Dr.-Ing Jürgen Kiese EBCHR / LIBS 14 RETURN Process Chain: Recycling of Titanium Chips cp-titanium Ti-64 Ti-6246 Score plot of the principal component analysis: PC0 and PC1 In order to clearly distinguish the various Ti-alloys, more work is planed.
Dr.-Ing Jürgen Kiese EBCHR / LIBS 15 RETURN Process Chain: Recycling of Titanium Chips Inspection line provided by PROASSORT LIBS unit provided by SECOPTA An experimental example is shown in a movie: (click picture on the left) Belt speed: 1 m/sec Laser: max. 20.000 shots/sec 7 shots summarized for an analysis 8 msec for an analysis
Dr.-Ing Jürgen Kiese EBCHR / LIBS 16
Thank you for your attention Dr.-Ing Jürgen Kiese EBCHR / LIBS 17