Initiating Low Cost Titanium Parts

Presented by: M. Kamal Akhtar October 6, 2010

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Acknowledgements

Craig Blue, Bill Peter and The Materials Processing Group atOak Ridge National Laboratory

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Introductions – ITP and Cristal Global

Cristal US, Inc.d/b/a International Titanium Powder– Wholly owned subsidiary of Cristal Global

Cristal Global– World’s largest titanium chemicals producer; 2nd largest

TiO2 producer– 8 manufacturing plants & 2 titanium mining operations;

about 4,000 employees– International Titanium Powder: Plant under construction;

R&D and pilot plant

Mining Titanium Tetrachloride

Titanium Dioxide

Titanium Powder

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Commercial Facility at Ottawa, IL

Build a production facility based on the Armstrong Process® to produce commercial levels of titanium and titanium alloy powder– Phase 1 Objectives

• Design, build and operate titanium powder production facility

• Capable of making both CP and Ti-Al-V alloys

• Annual production of 4.4 MM lbs when complete

• Initial production expected in late Q4 2010

June 2010

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The Armstrong Process® Technology

TiNaCl

Flowing Sodium

TiCl4

ContinuousReaction efficiency 100%Low-temperatureDirect alloy production

VCl4AlCl3 - 6Al - 4V

Large volume changeBubble dynamics

KineticsParticle growth

SegregationCrystallization

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Morphology of ITP Powder

Element wt %

Aluminum 6.4

Vanadium 3.8

Oxygen 0.18

Nitrogen 0.004

Carbon 0.016

Hydrogen 0.004

Iron 0.027

Sodium 0.003

Chlorine 0.001

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Process Capability

0.0018 0.0036 0.0054 0.0072 0.0090 0.0108 0.0126

Process Capability for HydrogenProcess Data–––––––––––––––––––––––––Sample Mean 0.006Sample N 96StDev (Within)0.00140StDev (Overall)0.001838

Potential (Within) Capability–––––––––––––––––––––––––Cp *CPL *CPU 1.53Cpk 1.53

Overall Capability–––––––––––––––––––––––––Pp *PPL *PPU 1.17Ppk 1.17Cpm *–––––––––––––––––––––––––

Process Data–––––––––––––––––––––––––Sample Mean 4.053Sample N 69StDev (Within) 0.087StDev (Overall) 0.159

Potential (Within) Capability–––––––––––––––––––––––––Cp 1.90CPL 2.11CPU 1.70Cpk 1.70

Overall Capability–––––––––––––––––––––––––Pp 1.04PPL 1.15PPU 0.93Ppk 0.93Cpm *–––––––––––––––––––––––––

3.60 3.75 3.90 4.05 4.20 4.35 4.5

Process Capability for Vanadium

WithinOverall

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Potential Powder Processing Routes

CIP AddMan

Press CanlessHIP

RollComp

Casting

MIM Extrude

Mill / Sift

SPHEROIDIZE

ROLLCOMPACT

POW

DER

Mill

Pro

duct

Fi

nal P

arts

Powder Modification Powder Consolidation

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Powder

100μm

SEM‐SEI

100μm

SEM‐SEI

Interconnected Porosity Eliminated: Armstrong Process® Ti-6Al-4V

Arm

strong

®HDH

Press + Sinter (100 ksi + 1300oC/1h)

TD: 94.0%OM

100μm

81.1%OM

100μm

Sponsored by DOE –EERE Industrial Technologies Program

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% of Th. Density YS (MPa) UTS (MPa) EL (%)

CPTi 82.4 400  455  6.6  

Ti‐6Al‐4V 94.6 900  991  4.4  

OM 200x

94.2%

OM 200x

T.D.: 82.3%

CPTi, CIP 35 ksi + 1300C/1h Ti‐6Al‐4V, CIP 32ksi + 1300C/1h

CIP & Sinter Approach

ASTM Minimum Requirements for Ti Tensile Properties (Fully Dense)

CP‐Ti, Grade 2 275 345 20

Ti‐6Al‐4V 828 895 10

Low Densities (~80%) Fully Dense Canless Hot Isostatic Pressing

Sponsored by DOE –EERE Industrial Technologies Program

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Roll CompactionRoll-compacted CP-Ti

Powder Feed

Roll Compaction

Rolling

SinteringCoiling

Sponsored by DOE –EERE Industrial Technologies Program

0

20

40

60

80

100

Armstrong Ti-6Al-4V HDH Ti-6Al-4V

Den

sity

, %

GreenCold-rolledCR+ 1300C/1h

Ti-6Al-4V

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Summary

Key process component: control of chemical precursors

ITP powder morphology is unique and challenging

Process routes to mill products and sheet have been demonstrated

Press & sinter, direct HIP, additive manufacturing approaches are in early development stages