computational design and development of new high- … · p. 3 abstract • questek ... – m240l...

Computational design and development of new high-

strength, high-ductility castable titanium alloys

Jason Sebastian, Ph.D.

Jim Wright, Ph.D.

Herng-Jeng Jou, Ph.D.

Sean Backs

18 June 2012

Some images from Nastac, Int. J. of Cast Metals Research, 2006

Computational design and development of new high-strength, high-ductility

castable titanium alloys

AeroMat 2012 Presentation, 18 June 2012

p. 2

Agenda

• Overview of QuesTek Innovations

• Titanium alloy development program background

• Titanium alloy design

• Prototype alloy production and test results

• Next steps




p. 3

Abstract

• QuesTek Innovations has applied its Materials by Design® approach to invent,

design, and develop three new castable titanium alloys with strength and

ductility characteristics similar to wrought titanium (e.g., wrought Ti-6Al-4V).

The development of these alloys has been sponsored by a U.S. Army-funded Small

Business Innovation Research (SBIR) program administered through Picatinny

Arsenal, New Jersey. QuesTek’s titanium alloy computational design has considered

a number of important factors including strength, toughness, alpha/beta

transformation kinetics, and castability/solidification. The new alloys have been

designed to be lower cost in terms of: 1) Near-net-shape formability

(castability); 2) Raw materials (alloying additions); 3) Tolerance to impurities

(e.g., oxygen and/or iron); and 4) Overall ease of processing (e.g., response to

hot isostatic pressing, and overall microstructural and mechanical property

robustness with respect to cooling rate after heat treatment). Results will be

presented from initial prototype wedge castings, further commercial-scale ingot

production, ongoing alloy specification development efforts (ASTM and AMS), and

first-round Army component production and testing. QuesTek is seeking

partnerships (titanium casting designers, titanium alloy producers, titanium

foundries, etc.) to further commercialize its new castable titanium alloy

technologies.




p. 4

QuesTek titanium alloy highlights

• Castable titanium – Near-net-shape processing

– Three new QuesTek alloys (QT-Ti-1A, QT-Ti-2A, QT-Ti-2B)

• Better strength-ductility than cast Ti-6-4 – A higher-performance replacement for existing Ti-6-4 castings

• Similar strength-ductility to wrought Ti-6-4 – Castable (lower cost) replacement for existing Ti-6-4 forgings

• Lower cost – Reduced vanadium (relative to Ti-6-4)

– Tolerance to oxygen

– Can incorporate Ti-6-4 scrap into melting stock

QuesTek seeks partnerships to further commercialize its new titanium alloy technology

(titanium alloy producers, titanium foundries, etc.)




p. 5

Overall SBIR project summary

• Phase I – Base: Initial alloy design and button-scale

production

– Option: 1st round wedge castings

• Phase II – Alloy re-design

– 2nd round wedge castings

– Component casting

– Additional ingot production

– Fluidity mold casting tests

– Testing and characterization

– Test bar mold casting

– Cost modeling

– ALCS casting at RIA

• Further ingot production

• Beyond – Patent pending (full utility filed in April 2011)

– Initial discussions with potential alloy licensees




p. 6

Background - QuesTek Innovations LLC

• Founded 1997

• 17 engineers (10 with PhDs)

• A global leader in computational materials design: – Our Materials by Design® technology and expertise applies

Integrated Computational Materials Engineering (ICME) tools and methods to design new alloys 50% faster and at 70% less cost than traditional empirical methods

– Aligned with President Obama’s Materials Genome Initiative

• Creates IP and licenses it to alloy producers, processors or OEMs

• 30+ patents awarded or pending worldwide

• 4 computationally-designed, commercially-sold alloys

• Designing 10+ new Fe, Al, Cu, Ni, Co, Nb, Ti, Mo and W based alloys for government and industry




p. 7

Serving DoD and others to significantly improve

equipment performance, affordability, and EHS




p. 8

Integrated Computational Materials Design Approach




p. 9

Four new computationally-designed, VIM/VAR steels:

Ferrium S53®

Licensee #1 - Feb. 2007:

Licensee #2 - Dec. 2007:

Ferrium C61™ and C64™

Licensee #1 - Nov. 2009:

Ferrium M54

Licensee #1 - April 2010:

More Licensees are Anticipated QuesTek is creating robust, competitive supply chains

Commercializing New Alloys Thru Licensees

9




p. 10

Titanium System Design Chart

Heat treatment -

(super-solvus)

PROPERTIES STRUCTURE PROCESSING

Raw Material

HIP (sub-solvus)

Cast

Ductility/

Toughness

Strength

α/β substructure

• Interlocking

basketweave

• Retained β

Grain features

• Minimize α film

• Avoid equiaxed α

Grain size

Porosity

Cooling rate




p. 11

Key design feature vs. Ti-64: refined, interlocking

α/β microstructure

QT-Ti-1A QT-Ti-6-4

Both alloys after

vacuum heat

treatment and

gas quench

(~1-2 °C/sec.)

Comparison

microstructures are

shown at equivalent

magnifications

Interlocking,

finer α laths Parallel

α laths




p. 12

SBIR castings and alloy production

• First round of wedge castings (2010)

• QT-Ti-6-4, QT-Ti-1A, QT-Ti-1B, QT-Ti-1C

• Second round of wedge castings (2011)

• QT-Ti-2A, QT-Ti-2B

• Mortar buffer housing component production (2011)

• Two from Ti-6-4

• Four from QT-Ti-2A




p. 13

From buttons to wedges to ingots to components … in three

years

Phase I Base buttons

Phase I Option wedges

Phase II ingots

Phase II component

and test bar castings




p. 14

Strength – Elongation Comparison QuesTek’s cast alloy has higher strength and ductility than cast Ti-6-4

Developed 3 castable titanium alloys under Army SBIR

Currently moving forward with the QT-Ti-1A

Baseline Ti-6-4 cast by QuesTek using

identical methods to 1A, 2A, 2B

Reference: Nastac, Int. J. of Cast Metals

Research, 2006




p. 15

High Temperature Tensile Comparison with Cast Ti-6242 QuesTek’s alloy has higher strength and ductility up to 800 °F

**Ti-6242 data from Aerospace Structural Metals Database




p. 16

High temperature testing summary (left to right: 2A, 1A, 2B; solid lines)

compared with ASMH cast Ti-6242 data (dotted lines)




p. 17

High temperature testing summary (left to right: 2A, 1A, 2B) compared

with ASMH forged Ti-6242 data




p. 18

• Potential applications:

– Lightweight mortar buffer

housings

– M777 Howitzer

– M240L

– Golf clubs

– Aerospace engines &

airframes

– Medical devices?

Potential Applications: Initial applications are for the U.S. Army, who

sponsored the development research

V-22 Future Upgrade

CH-53K

QuesTek seeks partnerships to

further commercialize its new

titanium alloy technology

(titanium alloy producers, titanium

foundries, etc.)




p. 19

Data Development Plan

• Testing is underway of heat

treated specimens for S-basis

analysis for development of an

AMS document

– 3 bar sizes:

0.625” RD, 1” RD, 1.5” RD

• Testing complete Summer 2012

– HIP + HT condition

• Present / submit for AMS and

ASTM




p. 20

QuesTek titanium alloy summary

• Castable titanium – Near-net-shape processing

– Three new QuesTek alloys (QT-Ti-1A, QT-Ti-2A, QT-Ti-2B)

• Better strength-ductility than cast Ti-6-4 – A higher-performance replacement for existing Ti-6-4 castings

• Similar strength-ductility to wrought Ti-6-4 – Castable (lower cost) replacement for existing Ti-6-4 forgings

• Lower cost – Reduced vanadium (relative to Ti-6-4)

– Tolerance to oxygen

– Can incorporate Ti-6-4 scrap into melting stock

QuesTek seeks partnerships to further commercialize its new titanium alloy technology

(titanium alloy producers, titanium foundries, etc.)




p. 21

With commercial partners

interested in pursuing

commercial applications

With platforms/program offices

– DoD

With OEMs/Primes supporting

these platforms/program offices

Relationships sought …




p. 22

Current State of Development

SBIR Milestone TRL Risk-Test Measure of Success TRL Date

Phase 2 – Yr 2 Finalize Alloy Design

and Cast Demonstration

Components

5 Low Achieve properties in initial

casting demonstrations

Nov. 2011

(program

concludes Nov.

2012)

Initial presentation to

ASTM for inclusion in

ASTM B367

5 Low Agreement by ASTM

Committee for QuesTek to

submit full data package for

proposed inclusion in ASTM

B367

May 2012

TRL Required Tests, Demos, and Next Steps Target Date Estimated Funding

Required

Organizations to be

Involved

6 Identify, produce and prototype additional

demonstration components in relevant

environment

2013 TBD TBD

6 ASTM / ASM specifications ~2013 $0 ASTM / ASM

6 Establish initial production license 2012-13 $0 TBD




p. 23

Contact information

For more information, contact:

• Jason Sebastian, Ph.D.

Senior Materials Design Engineer

QuesTek Innovations

847.425.8227

[email protected]

www.questek.com

computational design and development of new high- … · p. 3 abstract • questek ... – m240l...

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