continuous extrusion of titanium wire from powder feeds-australia.pdf · future manufacturing...

FUTURE MANUFACTURING

Continuous Extrusion of Titanium Wire from Powder Feeds Robert Wilson

December 2013

David Ritchie |Delphine Cantin |Daniel East|

Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary

extruder, or Conform Extruder: process unique

International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson|



• Patent filed March 2012

International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2




• Goal: Continuous mass production process for titanium rod/wire forming from powder-based titanium feed that is competitive against existing processes






• Advantages: Reduction in processing steps, conversion of titanium particulate and powder feeds (including recycled feed) into rod or wire, can tailor product composition







• Applications: Potential for weld wire (e.g., aerospace Additive Manufacturing), custom wire compositions and fastener applications (rod forms ~ 10% mill product volume)








• Achievements: One of the first to continuously extrude Ti of 12, 9, 6 mm f from powder (P2W) and wrought to wrought.








• Achievements: One of the first to continuously extrude Ti of 12, 9, 6 mm f from powder (P2W) and wrought to wrought.

• 6mm f BE Ti64 from powder swagable to 3 mm f



Objectives Developing a Continuous Extrusion Process for Ti Alloy Wire From Powder Continuous mass production of “long forms” from Ti particulate and powder feeds (P2W) and rod (wrought to wrought; W2W), which are currently not mass produced from powders or particulates and current forming methods are costly and have low yields.

Process advantages include:

• Lower cost, higher yields • Large volume production

• Reduction in processing steps

• Conversion of Ti particulate & powder feeds into rod/wire in a single step

• Tailored wire compositions for niche applications such as additive manufacturing

For Additive Manufacturing Applications

• Economics – lower cost, meet requirements for remelting spooling/unspooling

• Markets – allows custom blends for e-beam processes (e.g., Ti74) • Niche market alloys


Intended impact of program

To reduce number of forming and surface conditioning steps to economically

produce Ti rod and wire on a high-volume and continuous basis from titanium

powder feeds Current Ti wire & rod applications are cost-limited to niche applications; aim is to lower cost for current applications and expand into new areas • ~10x price reduction of Ti to compete for price with stainless steel • Target production rates from CSIRO extruder 0.30-1.45 ktonne/yr of rod/wire

• Scaling up feeding capacity to allow 10-20 kg wire lots, currently at feeding limit

• Requires improving tooling life to ~100 kg product per tooling set for economics

Clamping Force

Particulate or Powder feedstock

Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate

Extrusion Die Insert

Rod feed

Coining roll

The process schematic


Continuous extrusion capability BWE Conform rotary extruder modified

from Al/Cu configuration to allow extrusion from Ti

Clamping Force


Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate


Rod feed

Coining roll





CP Ti wires have been produced from flowing pelletised powders and cold isostatically pressed (CIPed) powders and wrought to wrought

Clamping Force


Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate


Rod feed

Coining roll





CP Ti wires have been produced from flowing powders, pelletised powders and cold isostatically pressed (CIPed) powders and wrought to wrought

Blended elemental (BE) Ti-6Al-4V alloy has been extruded, CP Ti matrix is retained during extrusion

Clamping Force


Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate


Rod feed

Coining roll







Process limit: flash gap-extrusion outlet-machine stiffness.

Clamping Force


Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate


Rod feed

Coining roll








Further drawing of extruded wire possible to obtain smaller diameter wire: proven swagable to 3 mm f

Clamping Force


Extrusion Shoe

Grooved Extrusion

Wheel Abutment

Shoe Inserts

Extrudate


Rod feed

Coining roll








Further drawing of extruded wire possible to obtain smaller diameter wire: proven swagable to 3 mm f

Tensile properties of the extruded product are equivalent to properties of the powder feed grade (slightly stronger, elongations equivalent)

Wire/rod conversion cost ~1.2 to 1.25 times typical CP powder price;

~1.5 times sponge granule (if realisable).

– Cost & price advantage for alloy wire using BE approach.

Techno-economics


20

40

60

80

100

120

140

160

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

44

94

144

194

244

294

344

394

0 200 400 600 800 1000 1200 1400

Sell

ing

Pri

ce (

US

$/l

b)

Rod Diameter (mm)

Sell

ing

Pri

ce (

A$/k

g)

Output (Tonnes per year)

CP Ti

BE Ti-64

PA Ti-64

2010-2011 Spot CP2

2010-2011 Spot Ti-64

Wire/rod conversion cost ~1.2 to 1.25 times typical CP powder price;

~1.5 times sponge granule (if realisable).

– Cost & price advantage for alloy wire using BE approach.

– Price competitiveness greater at smaller

diameters (<1mm). Technical target f 3mm.

Techno-economics


20

40

60

80

100

120

140

160

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

44

94

144

194

244

294

344

394

0 200 400 600 800 1000 1200 1400

Sell

ing

Pri

ce (

US

$/l

b)

Rod Diameter (mm)

Sell

ing

Pri

ce (

A$/k

g)

Output (Tonnes per year)

CP Ti

BE Ti-64

PA Ti-64

2010-2011 Spot CP2

2010-2011 Spot Ti-64

0

5000

10000

15000

20000

25000

30000

0 1 2 3 4 5

Pri

ce/k

g (U

S$)

Diameter (mm)

Grade 1/2

Grade 5

ConX Ti gr. 3 rod (CIPped feed) 99.9% TD

ConX CP Ti gr. 3 (mill anneal) 99.9% TD

Extrusion of CP Ti (Powder to Wire: P2W)

ConX CP Ti gr.3 (flowing powder) (99.86% TD)


100 mm

0 1’ 1m

Commercial CP Ti gr.2 rod 100% TD

ConX CP Ti gr. 2 100% TD

Extrusion of CP Ti (from rod)

100 mm 100 mm


W2W

Tensile properties of CP Ti from powder and rod


Run Processing Oxygen

[wt%]

Yield

[MPa]

0.2% Proof

[MPa]

UTS

[MPa]

Ef [%]

ER Preheat

[°C]

6mm 4.0 1100 0.25 354±40 489±10 647±9 23.5±1.3

9mm 1.8 1100 0.35 390±107 528±79 681±23 12.8±6.6

G3 Generic

Extrusion 379 448 18

Description Oxygen [wt%] 0.2% Proof [MPa] UTS [MPa] Ef [%]

Feed 0.18-0.19 389.9±0.8 516.7±0.9 37.8±2.3

800°C 0.19-0.24 410.1±7.3 534.0±6.3 34.1±3.7

1000°C 0.21 411.0±6.7 518.9±5.2 34.7±1.1

1100°C 0.19-0.20 401.7±9.3 512.4±3.0 33.8±3.1

P2W

W2W (9mm)

As extruded BE Ti-64 rod

Swaging of BE Ti-64 extrusion

ConX HT Swage pass 4 (3mm f)


• HT ConX wire swagable from 6mm to 3mm f,

grain refinement. • As extruded breaks up after 3rd swage pass.

Beta-phase field homogenisation anneal BE Ti-64

Al58V42

Summary

• Target is to produce niche composition wire on demand & commercial alloy wire that is cost competitive

• CP Ti extrudable to 6mm f from powder (P2W) and wrought bar feed (W2W)

• CP tensile properties at least equivalent to conventionally extruded material

• BE Ti64 extrudable to 6mm f from BE mixtures and subsequent homogenisation anneals. Can be swaged to 3mm f

• Scaling up feeding capacity to allow 10-20 kg wire lots

• Requires improving tooling life to ~100 kg product per

tooling set


Thank you Dr. Robert Wilson

Ph: +61 3 9545 2840

Email: [email protected] Web: www.csiro.au

continuous extrusion of titanium wire from powder feeds-australia.pdf · future manufacturing...

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