1 cost-effective production of powder metallurgy titanium components stcu-nato workshop 11-12...
TRANSCRIPT
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Cost-effective Production of Powder Metallurgy Titanium
Components STCU-NATO Workshop
11-12 October 2006
Kyiv
Prof. Orest IvasishinTel: (044)-424-22-10
E-mail: [email protected] Institute for Metal Physics
Kyiv
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Talk outline
1. What is needed in the market?2. Brief technology description3. Stage of development4. Who needs it & how many will they need?5. What is my unique technology advantage?6. Competitive matrix7. How will I beat the competition?8. Opportunity for joint work
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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
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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!
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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 Blended Elemental (BE)(BE)
Powder Blending
Ti, Alloying Elements Powders
Powder Blend
BE Compact
Heat Treat
Low Porous PartLow Porous Part
Densification
PartPart
HIPHIP
Up to 90%Up to 90%
95%95%
99+%99+%
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Experimental Results
Sintered densities of TiH2 blends:
- higher than in equivalent Ti-based blends
- do not noticeably depend on molding pressure
300 400 500 600 700 800 900 100095
96
97
98
99
100
Rel
ativ
e de
nsity
,%
Molding pressure, MPa
TiH2
Ti
99%
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Hydrogenated Titanium: Physical Background
• Specific mechanism of compaction optimized green porosity
• Shear type phase transformation TiH2Ti ( or ) high density of crystal lattice defects
• Surface oxide self reducing by atomic hydrogen
- faster sintering - higher sintered density - lower impurity content
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Mechanical Properties (Ti-6Al-4V Composition)
Base powder
Alloying powder
YS, MPa
UTS, MPa
Elong. %
RA, %
Oxygen content, %
TiH2 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
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Cost-Effective Production of Hydrogenated Titanium
Powder
MgCl
2
TiCl
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Reduction Vacuum separation Hydrogenation
VacuumHydrogen
Argon
Production in Ukraine: Zaporozhje Titanium&Magnesium Plant
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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 Proposed process : cost of powder 0.90.9 S (S – cost of titanium S (S – cost of titanium sponge)sponge)
Conventional process : cost of powder Conventional process : cost of powder 22 S S
Powder productionPowder production
Part Part manufacturingmanufacturing
Proposed PM technology: cost of parts 1.4-2 S (per kg)
Conventional PM approach(CHIP): cost of parts 5-10 S
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Advantages
• Innovative approach
• Cost-effectiveness
• High mechanical properties
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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
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Targeted Market Segment
• Automotive industry (connecting rods, valves, etc.)World production per year : 53 million vehicles 212 million conrods
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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
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Targeted Market Segment
- Aerospace industry (components for non-critical application)
- Medical applications, etc.
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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
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Competitive MatrixImportant 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
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OpportunitiesPurpose: 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
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Contact information
Prof. Orest Ivasishin
Tel: +380-44-424-22-10
E-mail: [email protected]
Institute for Metal Physics
Kyiv