Presentation on theme: "Cost-effective Production of Powder Metallurgy Titanium Components"— Presentation transcript:
1 Cost-effective Production of Powder Metallurgy Titanium Components STCU-NATO Workshop11-12 October 2006KyivProf. Orest IvasishinTel: (044)Institute for Metal Physics
2 Talk outline What is needed in the market? What is needed in the market?Brief technology descriptionStage of developmentWho needs it & how many will they need?What is my unique technology advantage?Competitive matrixHow 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 strengthlow densitygood corrosion resistanceBut: 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 toexpand 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 BlendingTi, Alloying Elements PowdersPowder BlendBE CompactHeat TreatLow Porous PartDensificationPartHIPUp to 90%95%99+%Powder metallurgy enables significant reduction in the costBlended 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 porosityShear type phase transformation TiH2Ti ( or ) high density of crystal lattice defectsSurface oxide self reducing by atomic hydrogenfaster sinteringhigher sintered densitylower impurity content
9 Cost-Effective Production of Hydrogenated Titanium Powder MgCl2TiCl4ReductionVacuum separationHydrogenationVacuumHydrogenArgonProduction in Ukraine:Zaporozhje Titanium&Magnesium Plant
10 Cost-Effectiveness Powder production Part manufacturing Integrated production process (in one reactor)Shortened time of vacuum separationEnergy 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 SPart manufacturingProposed 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 DevelopmentPatented in Ukraine (Patents ## and 70366) and USA (US Patent No B1)Prototypes (automotive connecting rods) available for testingSTCU – 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 capsaddles of inlet and exhaust valvesvalve spring platedistribution shaft driving pulleystrap tension gear rollerscrew nutfuel pump filterembedding 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 contentmore complicated processing (including HIP)high cost2. Ingot metallurgy- multistep manufacturing- low material yieldhigh cost
17 Competitive Matrix Important product or technology characteristics ProposedPM approach(TiH2)Conventional PM approach(CHIP)Ingot approachStarting materialsCost effective hydrogenated titanium or scrapHigh-pure (expensive!) titanium powdersVAR or EBM ingotTechnological operationsCompaction of powders, sinteringCompaction of powders, sintering, HIP or hot deformationMelting, hot deformation, heat treatmentMechanical properties(Ti-6Al-4V)UTS: MPa;El %UTS: MPa;El %UTS 896 MPa;El. 10%Cost1.4-2 S5- 10 S5-13 S
18 OpportunitiesPurpose: application of developed technology in automotive, aerospace and medical industriesPartnership:Zaporozhye Titanium&Magnesium Plant – producer of powders;ADMA Products, Inc. (USA) –producer of titanium PM partsPotential customers:- automotive companies GM, FordAntonov, Boeingdental companies (not defined yet)
19 E-mail: email@example.com Institute for Metal Physics Kyiv Contact informationProf. Orest IvasishinTel:Institute for Metal PhysicsKyiv