Presentation is loading. Please wait.

Presentation is loading. Please wait.

Cost-effective Production of Powder Metallurgy Titanium Components

Similar presentations

Presentation on theme: "Cost-effective Production of Powder Metallurgy Titanium Components"— Presentation transcript:

1 Cost-effective Production of Powder Metallurgy Titanium Components
STCU-NATO Workshop 11-12 October 2006 Kyiv Prof. Orest Ivasishin Tel: (044) Institute for Metal Physics

2 Talk outline What is needed in the market?
   What is needed in the market? Brief technology description Stage of development Who needs it & how many will they need? What is my unique technology advantage? Competitive matrix How will I beat the competition? Opportunity for joint work

3 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 $ /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

4 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!

5 Brief Technology Description
Blended Elemental (BE) Powder Blending Ti, Alloying Elements Powders Powder Blend BE Compact Heat Treat Low Porous Part Densification Part HIP Up to 90% 95% 99+% Powder metallurgy enables significant reduction in the cost Blended elemental powder metallurgy approach is potentially the lowest-cost process, especially if additional working operations (HIP or hot deformation) can be avoided.

6 Experimental Results Sintered densities of TiH2 blends:
- higher than in equivalent Ti-based blends - do not noticeably depend on molding pressure

7 Hydrogenated Titanium: Physical Background
Specific mechanism of compaction  optimized green porosity Shear type phase transformation TiH2Ti ( or )  high density of crystal lattice defects Surface oxide self reducing by atomic hydrogen faster sintering higher sintered density lower impurity content

8 Mechanical Properties (Ti-6Al-4V Composition)
Base powder Alloying powder YS, MPa UTS, MPa Elong. % RA, % Oxygen content, % TiH2 Al-V master alloy 23-29 ASM standard (ingot material)  828  897  10  20 0.20

9 Cost-Effective Production of Hydrogenated Titanium Powder
MgCl2 TiCl4 Reduction Vacuum separation Hydrogenation Vacuum Hydrogen Argon Production in Ukraine: Zaporozhje Titanium&Magnesium Plant

10 Cost-Effectiveness Powder production Part manufacturing
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 0.9 S (S – cost of titanium sponge) Conventional process : cost of powder 2 S Part manufacturing Proposed PM technology: cost of parts S (per kg) Conventional PM approach(CHIP): cost of parts S

11 Advantages Innovative approach Cost-effectiveness
High mechanical properties

12 Stage of Development Patented in Ukraine (Patents ## and 70366) and USA (US Patent No B1) Prototypes (automotive connecting rods) available for testing STCU – IPP partner project (P-143) aimed on development of high-volume commercial application

13 Targeted Market Segment
Automotive industry (connecting rods, valves, etc.) World production per year : 53 million vehicles  212 million conrods

14 Automotive Components produced Using Hydrogenated Powder
connected rod with big end cap saddles of inlet and exhaust valves valve spring plate distribution shaft driving pulley strap tension gear roller screw nut fuel pump filter embedding filter

15 Targeted Market Segment
- Aerospace industry (components for non-critical application) - Medical applications, etc.

16 Competition 1. Other titanium PM technologies(CHIP)
- expensive starting powders with low impurity content more complicated processing (including HIP) high cost 2. Ingot metallurgy - multistep manufacturing - low material yield high cost

17 Competitive Matrix Important 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: MPa; El % UTS: MPa; El % UTS 896 MPa; El.  10% Cost 1.4-2 S 5- 10 S 5-13 S

18 Opportunities Purpose: application of developed technology in automotive, aerospace and medical industries Partnership: Zaporozhye Titanium&Magnesium Plant – producer of powders; ADMA Products, Inc. (USA) –producer of titanium PM parts Potential customers: - automotive companies GM, Ford Antonov, Boeing dental companies (not defined yet)

19 E-mail: Institute for Metal Physics Kyiv
Contact information Prof. Orest Ivasishin Tel: Institute for Metal Physics Kyiv

Download ppt "Cost-effective Production of Powder Metallurgy Titanium Components"

Similar presentations

Ads by Google