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Cost-effective Production of Powder Metallurgy Titanium Components

Cost-effective Production of Powder Metallurgy Titanium Components

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Cost-effective Production of Powder Metallurgy Titanium Components

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  1. Cost-effective Production of Powder Metallurgy Titanium Components STCU-NATO Workshop 11-12 October 2006 Kyiv Prof. Orest Ivasishin Tel: (044)-424-22-10 E-mail: ivas@imp.kiev.ua Institute for Metal Physics Kyiv

  2. Talk outline 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$150-200/kg (components) The main trend in titanium materials science is to expand application of titanium alloys bydevelopment 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. Blended Elemental (BE) Ti, Alloying Elements Powders Powder Blending Powder Blend Densification BE Compact Up to 90% Heat Treat Part 95% HIP Low Porous Part 99+% Brief Technology Description 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)

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

  10. Cost-Effectiveness Powder production • 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 1.4-2 S (per kg) Conventional PM approach(CHIP): cost of parts 5-10 S

  11. Advantages • Innovative approach • Cost-effectiveness • High mechanical properties

  12. Stage of Development • Patented in Ukraine (Patents ## 65654 and 70366) and USA (US Patent No 6638336B1) • 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

  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. Contact information Prof. Orest Ivasishin Tel: +380-44-424-22-10 E-mail: ivas@imp.kiev.ua Institute for Metal Physics Kyiv