scholarly journals FAST-forge of Titanium Alloy Swarf: A Solid-State Closed-Loop Recycling Approach for Aerospace Machining Waste

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 296 ◽  
Author(s):  
Nicholas S. Weston ◽  
Martin Jackson
Keyword(s):  
Titanium Alloy ◽  
Solid State ◽  
Closed Loop ◽  
Hot Forging ◽  
Weight Ratio ◽  
High Strength ◽  
Downstream Processing ◽  
Processing Route ◽  
Aerospace Applications ◽  
Multi Stage

Titanium alloys have excellent properties, but components are very expensive due to the high levels of processing required, such as vacuum melting, multi-stage forging, and machining. As a result, forged titanium alloy components are largely exclusive to the aerospace industry, where a high strength-to-weight ratio, corrosion resistance, and excellent fatigue resistance are essential. However, a typical buy-to-fly ratio for such components is approximately 9:1, as much of the forged billet is machined to swarf. The quantity of waste titanium alloy swarf generated is increasing as aircraft orders, and the titanium components contained within them, are increasing. In this paper, waste swarf material has been recycled using the two-step solid-state FAST-forge process, which utilizes field assisted sintering technology (FAST) followed by hot forging. Cleaned Ti-6Al-4V swarf was fully consolidated using the FAST process at sub-transus and super-transus temperatures, followed by hot forging at sub-transus temperatures at different strain rates. It was demonstrated that swarf-derived Ti-6Al-4V FAST billets have equivalent hot forging flow behaviour and resultant microstructures when directly compared to equivalently processed conventional expensive hydride–dehydride powder, and previously reported Kroll-derived melt-wrought material. This demonstrates that titanium swarf is a good quality feedstock for downstream processing. Additionally, FAST-forge is a viable processing route for the closed-loop recycling of machining waste for next-generation components in vehicles and non-aerospace applications, which is game changing for the economics of titanium alloy components.

scholarly journals FAST-forge of novel Ti-6Al-4V/Ti-6Al-2Sn-4Zr-2Mo bonded, near net shape forgings from surplus AM powder

2020 ◽  
Vol 321 ◽  
pp. 03010
Author(s):  
Oliver Levano ◽  
Nicholas Weston ◽  
Jacob Pope ◽  
Adam Tudball ◽  
David Lunn ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Hot Forging ◽  
Weight Ratio ◽  
High Strength ◽  
Aerospace Sector ◽  
Near Net Shape ◽  
Stress States ◽  
Field Assisted Sintering ◽  
Corrosive Resistance

Titanium alloys are used extensively in the aerospace sector due to the good combination of high strength-to-weight ratio and corrosive resistance. Many aerospace components are exposed to extreme service stress states and temperatures, which in some applications could compromise the component’s performance if a single titanium alloy is used. A potential solution to this issue could be the combination of dissimilar titanium alloys in subcomponent regions, achieved through consolidating powders via field assisted sintering technology (FAST-DB) and subsequent hot forging (FAST-forge). In this paper, near net shape titanium-titanium alloy demonstrator components are produced from oversized AM powders in just two hybrid solid-state steps; FAST-DB and hot forging.

SANDVIK Ti-3Al-2.5V GRADE 9

Alloy Digest ◽  
1997 ◽  
Vol 46 (9) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Endurance Limit ◽  
Weight Ratio ◽  
High Strength ◽  
Strain Ratio ◽  
Bend Strength ◽  
Aerospace Applications ◽  
Excellent Corrosion Resistance ◽  
Titanium Aluminum ◽  
Fatigue Endurance

Abstract Sandvik Ti-3Al-2.5V Grade 9 titanium-aluminum alloy offers excellent corrosion resistance, especially to chloride media, and has a high strength-to-weight ratio, which is especially suitable for use in aerospace applications. Tubing can be produced having a CSR (contractile strain ratio) that enhances the fatigue endurance limit. This datasheet provides information on composition, physical properties, elasticity, tensile properties, and bend strength as well as fatigue. It also includes information on corrosion resistance as well as forming, machining, and joining. Filing Code: TI-109. Producer or source: Sandvik.

Simulation of Deformation Behavior and Microstructure Evolution during Hot Forging of TC11 Titanium Alloy

2018 ◽  
Vol 385 ◽  
pp. 449-454 ◽  
Author(s):  
Artem Alimov ◽  
Dmitry Zabelyan ◽  
Igor Burlakov ◽  
Igor Korotkov ◽  
Yuri Gladkov
Keyword(s):  
Titanium Alloy ◽  
Microstructure Evolution ◽  
Technology Development ◽  
Hot Forging ◽  
Industrial Case Study ◽  
Aerospace Applications ◽  
Heating And Cooling ◽  
Tc11 Titanium Alloy ◽  
Kinetics Of

Finite element method is the most powerful tool for development and optimization of the metal forming processes. Analysis of titanium alloy critical parts should include the prediction of microstructure since their mechanical and technological properties essentially depend on the type and parameters of the microstructure. The technological process of parts production for aerospace applications is multi-operational and consists of deformation, heating and cooling stages. Therefore, it is necessary to simulate the microstructure evolution to obtain high quality parts. In presented paper FE simulation coupled with microstructure evolution during hot forging of TC11 titanium alloy has been performed by QForm FEM code. Constitutive relationships, friction conditions and microstructure evolution model have been established using the experiments. The kinetics of phase transformations has been described by the Johnson-Mehl-Avrami-Kolmogorov (JMAK) phenomenological model. The approach is illustrated by industrial case study that proved its practical applicability and economic advantages for technology development of titanium alloy critical parts.

Multi-Objective Optimization on Drilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Vol 763 ◽  
pp. 29-49 ◽  
Author(s):  
A. Prabukarthi ◽  
V. Krishnaraj ◽  
M. Senthil Kumar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Optimization Technique ◽  
Weight Ratio ◽  
High Strength ◽  
Hole Diameter ◽  
Machining Process ◽  
Multi Objective ◽  
Titanium Alloy Ti6al4v ◽  
Exit Burr

Titanium alloys present superior properties like resistance to corrosion, high strength to weight ratio etc, but possess poor machinability. Titanium alloy Ti-6Al-4V is the most commonly used titanium alloy in aerospace and medical device industries. Titanium and its alloys are notorious for their poor thermal properties and are classified as difficult-to-machine materials. Drilling is an important machining process since it is involved in nearly all titanium applications. It is desirable to develop optimized drilling processes for Ti and improve the hole characteristics such as hole diameter, circularity and exit burr of currently available processes. Due to the low machinability of the alloys under study, selecting the machining conditions and parameters is crucial. The range of spindle speed and feed rate, which provide a satisfactory tool life, is very limited. The hole quality (hole diameter and circularity), thrust force, torque and exit burr were evaluated at various spindle speeds, feed rates combinations. The optimized parameter is chosen using the multi-objective weighted sum optimization technique.

Effect of High Strain-Rate Thermomechanical Processing on Microstructure and Mechanical Properties of Ti-10V-2Fe-3Al Alloy

2013 ◽  
Vol 845 ◽  
pp. 96-100 ◽  
Author(s):  
Piotr Skubisz ◽  
Marek Packo ◽  
Katarzyna Mordalska ◽  
Tadeusz Skowronek
Keyword(s):  
Mechanical Properties ◽  
High Strain Rate ◽  
Strain Rate ◽  
High Strain ◽  
Thermomechanical Processing ◽  
Hot Forging ◽  
High Strength ◽  
Processing Route ◽  
Microstructure And Mechanical Properties ◽  
Processed Material

Results of beta forging of titanium alloy Ti-10V-2Fe-3Al and subsequent thermal treatment are presented, with analysis of the effect of the processing route on the final mechanical properties, correlated with microstructure of thermomechanically processed material. Investigation of response to high strain-rate hot-forging of microstructure and mechanical properties is focused on the effect of the strengthening mechanisms in the material after two common manners of deformation typical of that alloy. The effect of deformation conditions on final microstructure and mechanical properties was analyzed in three crucial stages of thermomechanical processing, e.i. after deformation, quenching and aging. In result, conclusions were formulated as for processing conditions promoting high strength and/or ductility.

Effect of Hot Work on Hardness and Impact Toughness of Heat Treated Low Alloy Steels

2014 ◽  
Vol 1082 ◽  
pp. 197-201
Author(s):  
Mahmoud M. Tash ◽  
Saleh A. Alkahtani ◽  
Khaled A. Abuhasel
Keyword(s):  
Impact Toughness ◽  
Hot Forging ◽  
Weight Ratio ◽  
High Strength ◽  
Extensive Study ◽  
Low Alloy Steels ◽  
Alloying Additions ◽  
Heat Treated ◽  
Alloy Steels ◽  
Effect Of Hot Rolling

The present study was undertaken to investigate the effect of hot work reduction ratio on the hardness and impact toughness of different grades of low alloy steels. The effect of hot rolling and hot forging with different reduction ratios on the hardness and impact toughness properties will be studied. An extensive study will be carried out to investigate the effect of alloying additions and TMT parameters on the hardness and impact toughness of heat-treated low alloy steels. An understanding of the combined effect of TMT and heat treatment on the hardness and impact toughness of the low alloy steels would help in selecting conditions required to achieve optimum mechanical properties and alloy high strength to weight ratio.

High Fugacity Hydrogen Effects in Beta-21S Titanium Alloy

2007 ◽  
Vol 546-549 ◽  
pp. 1355-1360
Author(s):  
Dan Eliezer ◽  
E. Tal-Gutelmacher ◽  
Lothar Wagner
Keyword(s):  
Titanium Alloy ◽  
Weight Ratio ◽  
Thermal Desorption Spectroscopy ◽  
High Strength ◽  
Advanced Materials ◽  
X Ray Diffraction ◽  
Hydrogen Induced Cracking ◽  
Second Phases ◽  
Rolled Condition ◽  
Hot Rolled

Beta-21S titanium alloy is ranked among the most important advanced materials for a variety of technological applications, due to its combination of a high strength/weight ratio, good corrosion behavior and oxidation resistance. However, in many of these technological applications, this alloy is exposed to environments which can act as sources of hydrogen, and consequently, severe problems may arise. The objective of this paper is to investigate the influence of high fugacity hydrogen on Beta-21S alloy in as-received (mill-annealed and hot-rolled) condition. Hydrogen effects on the microstructure are studied using X-ray diffraction and electron microscopy, while the absorption and desorption characteristics are determined respectively by means of a hydrogen determinator and thermal desorption spectroscopy. Preliminary results at room temperature revealed hydrogen-induced straining and expansion of the lattice parameters. However, neither second phases formation (hydrides), nor hydrogen-induced cracking, were observed after hydrogenation. The main characteristics of hydrogen absorption/desorption behavior, as well as hydrogen-induced microstructural changes in both microstructures are discussed in detail.

Investigation of Thrust Forces, Torque and Chip Microstructure during Drilling of Ti-6Al-4V Titanium Alloy

2015 ◽  
Vol 787 ◽  
pp. 431-436 ◽  
Author(s):  
K. Sushinder ◽  
P.R. Shivaram ◽  
S.B. Nivedh Kannaa ◽  
Nisarg Gupta ◽  
K.S. Vijay Sekar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Cutting Tools ◽  
Weight Ratio ◽  
Chip Morphology ◽  
High Strength ◽  
High Reactivity ◽  
Machining Process ◽  
Engine Components ◽  
Thrust Forces

Titanium Alloys are unique due to their high strength-weight ratio,good fracture and corrosion resistance characteristics.They form a significant metal portion of the aircraft structural and engine components. However, their low thermal conductivity and high reactivity with cutting tools during machining, makes them difficult-to-machine materials. In this work, an investigationof the thrust force, torque and chip morphology in drilling of Ti6Al4V, titanium alloy using tungsten carbide tipped drill has been carried out at varying cutting speeds of 19.4, 27.14, 43.41 and 67.82m/min at a constant feed rate of 0.15mm/rev.The machinability, work hardening and thermal softening effects of titanium alloy, during drilling, has been analysed through the effects of the machining process on the thrust force, torque and chip microstructure.

scholarly journals Effect of microstructure and cooling rate on the fatigue performance of TIMETAL® 575

2020 ◽  
Vol 321 ◽  
pp. 12019
Author(s):  
M. Bodie ◽  
M. Thomas ◽  
A. Ayub
Keyword(s):  
Titanium Alloys ◽  
Cooling Rate ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
Electron Backscatter Diffraction ◽  
Material Selection ◽  
Weight Ratio ◽  
High Strength ◽  
Fatigue Performance ◽  
Aerospace Applications

A key design consideration for material selection in the aerospace industry is weight reduction; with excellent strength to weight ratio, high temperature resistance, and fatigue performance, titanium alloys are extensively used. New titanium alloys continue to enhance performance and broaden the range of applications. Titanium Metals Corporation (TIMET) recently developed TIMETAL® 575 (Ti575), a high strength titanium alloy with superior fatigue performance over Ti-6Al-4V, aimed at aerospace applications where these properties are imperative i.e. aerospace turbine discs and blades. [1] [2] This work intends to advance the understanding of the effect of thermal processing of Ti575, by investigating the effect of primary alpha (αp) volume fraction and cooling rate on tensile and fatigue performance in post forged heat-treated microstructures. Microstructural assessment and mechanical performance were completed and are discussed. Three cooling methods from three solution heat-treat temperatures were investigated in this work. The results from these experiments were compared using optical microscopy, electron backscatter diffraction (EBSD), room temperature tensile and high cycle fatigue (HCF) tests.

Nanocrystalline Diamond Coated Tool Performance in Machining of LM6 Aluminium Alloy/Alumina MMC

2015 ◽  
Author(s):  
Ramasubramanian Kannan ◽  
Arunachalam Narayanaperumal ◽  
Mamidanna Sri Ramachandra Rao
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Matrix Composites ◽  
Aerospace Applications ◽  
Coated Tools ◽  
Nano Crystalline ◽  
Improved Performance

Aluminium based metal matrix composites (MMC) gain its importance in automotive and aerospace applications due to their high strength to low weight ratio, which leads to reduced fuel consumption and improved performance. However the usage of MMC is limited due to its poor machinability. The presence of hard reinforcing particles in MMC makes these materials difficult to machine. A cutting tool with high hardness and low coefficient of friction is required for machining this MMC material effectively. In this paper a comparative study on machinability of different coated tools on LM6 aluminum alloy/alumina MMC are conducted and presented. Experimental results on tool wear, cutting force and surface finish indicate that nano-crystalline diamond coated tools (NCD) outperform the other commercially available coated tools for machining this metal matrix composites.

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