titanium research & development for naval … · 2018-04-14 · titanium 2006 23rditac f &e...
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TITANIUM 200623rd ITA C f & E iti23rd ITA Conference & Exposition 7 – 9 October 2007, Orlando FL
TITANIUM RESEARCH & DEVELOPMENT FOR NAVAL DEVELOPMENT FOR NAVAL
APPLICATIONS
Gerard (Jeff) MercierGerard (Jeff) Mercier
Naval Surface Warfare CenterCarderock DivisionWest Bethesda MarylandWest Bethesda, Maryland
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Navy Platforms
Reduced Surface Ship Signatures Required - RF IR
Hardness Against Underwater E l i (UNDEX) Ai Bl t
Increased Speed & Improved Protection Systems
Signatures Required - RF, IR, Visible, Magnetic, Acoustic
Explosions (UNDEX), Air Blast, Ballistic and Fragment
Penetration JHSV
UUV
DDG 1000
LCS 1
Reduced Submarine and UUV M ti d A ti
ASDS
Magnetic and Acoustic Signatures
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Titanium Usage in USN Ships
Total Weight of TitaniumShip Class
gper Ship (lb)
CVN 68 16,500CVN 68 16,500CG 47 20,800
DDG 51 33,700,SSN 688 31,375
SSBN / SSGN 31,375SSN 21 75,175
SSN 774 31,375LPD 17 136,650
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ASDS Titanium Usage
• High flow stress in tail– Distortion of aluminum alloy– Replaced with Ti (?)
• 14 battery bottles2 ft diameter x 5 ft long
Advanced Seal Delivery System
– 2 ft diameter x 5 ft long– Ti 6-4 ELI
• Ti 5111 fasteners
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Ti-5111 for Naval Applications
Ti-5111 Navy Service ApplicationExtensive evaluation for Submarine Communications Mast StructureMast is welded Ti-5111 structure – plate, bar, & forgingOver 45 Masts deployed / first deployed in 2000
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Navy Titanium R&D Projects
• Advanced Combatant Materials Program– Flow Formed Seamless CP Pipe
LCS E h t G U t k– LCS Exhaust Gas Uptakes• Unmanned Undersea Vehicle (UUV) Pressure Hulls
– Investment Cast Ti-5111 & Ti CP-2LOTi 5111 F i– Ti-5111 Forgings
• Metallic Material Advanced Development & Certification Program– Project on Ti 5111 Evaluation for Critical Applications– Certification of Ti-5111 Fasteners for Shock Applications– Certification of Ti-5111 Fasteners for Shock Applications
• Titanium Welding Fabrication R&D Projects– FSW, Flux-assisted Welding (Including FCAW), GMAW-PA– Laser Peening for Weld Fatigue Improvementg g p
• Technical Support to Low-Cost Ti Program (DARPA)– Evaluation of Solid-State Ti Plate (Armstrong Process)– Ti Applications – Future Navy / Navy After Next
• ALVIN HOV Technical Support– New Pressure Hull (Ti-6Al-4V ELI Forgings)
• CVN 21 MANTECH Project (cancelled)
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CP Titanium Piping Applications
• Low Cost Titanium Piping– Rationale: Reduce Cost of Proven
Titanium Application– Low Cost Powder Preform
» Hollow, Cylindrical Preform
USS SAN ANTONIO (LPD 17)
» Navy Can Benefit from Government/Industry Low Cost Powder Initiatives
» Consolidation Process» Consolidation Process – Flowform Conversion
» Minimal Material Waste» Proven Technology
Issue Limiting Increased Use:High material and fabrication costs
» Proven Technology
Titanium Piping System Fabrication Facility
• High material and fabrication costs• Ti system estimated to saved
$17M/ship if life cycle savings
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Overview CP Titanium Piping
• Rationale:– Reduce Cost of Proven Titanium Application (Seawater Piping)– Navy Can Benefit from Government/Industry Low Cost Powder
InitiativesGoal:• Goal:
– Develop titanium pipe conforming to ASTM B 861 (& B 338) from low-cost powder
• Team: NSWCCD ADMA DFC DuPont and CTC• Team: NSWCCD, ADMA, DFC, DuPont and CTC• Approach:
– Hollow cylindrical preforms via powder metallurgy (PM) routeCIP Si t i f d t h ll li d b ADMA» CIP + Sintering of powder to hollow cylinders by ADMA
» Consolidation of CP Gr 2 powder to hollow cylinders via unique DuPont process (including CIP&HIP)
– Conversion of preforms to pipe via flowforming by DFCp p p g y
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CP Titanium Powder Processes
• ITP Armstrong Process Powder
Courtesy of ITP, J. Sears et al
• ADMA’s Hydride-Dehydride Powder• DuPont-Honeywell’s CP titanium powder via modified• DuPont-Honeywell s CP titanium powder via modified
Hunter Process (?)• DuPont-MER aims for even lower cost Ti under
DARPA programDARPA program
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CP Titanium Pipe Processing
Low Cost CP Ti PowderC ld I t ti P i P fCold Isostatic Pressing Vacuum Sintering Preform
HDH Powder
Courtesy of Dynamic Flowform CorporationCourtesy of Dynamic Flowform Corporation
FlowformingFlowformed PipesSponge Fines
Courtesy of Sam Froes
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Flowforming• Reverse Flowforming for pipe making
Courtesy of Dynamic Flowform Corporation
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Flowforming Facility @ DFC
P fFlowformed titanium pipe PreformsFlowformed titanium pipe
Courtesy of Dynamic Flowform Corporation
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LCS Titanium Uptakes Overview
• Objective: Perform feasibility analysis to determine whether titanium alloys are viable ymaterials to meet the design and performance requirements of the current LCS gas turbines uptakesuptakes.
• Goal: Achieve weight savings, approach a cost-neutral solutionneutral solution
• Current LCS uptake design employs nickel-based Inconel 625
• Evaluate as high temperature replacementtemperature replacementRolls Royce MT30
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LCS Titanium Uptake Feasibility
Tensile Yield Strength
IN 625 Ti1100 IN 625 Ti1100Temp (F)
75 69 5 134 227 9 822 1YS (ksi) YS (ksi)/Density(lb/in3)
75 69.5 134 227.9 822.11200 106 81 347.5 496.91400 79 77 259.0 472.4
Freedom (LCS1)Freedom (LCS1)
Rolls Royce MT30
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LCS Titanium Uptake Feasibility
• Level of substitution– Inner sheath– L-Bracket framingRolls Royce MT30 – L-Bracket framing– Outer sheath
• Critical design criteriaD i h k l d d i i
Rolls Royce MT30
– Design shock load during operation– High-temperature creep resistance– Thermal fatigue– Corrosion resistance– Substitution compatibility with present
materials (YS, % elongation, manufacturability, etc.)manufacturability, etc.)
• Investigate up to 3 candidate materials– Ti-1100, Ti-21S, Other?
D t i i ht i (b d 1 1• Determine weight savings (based on 1:1 substitution)
• Perform FEA on best candidate material
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Cast Titanium & Ti-5111 Alloy
Unmanned Undersea Vehicles (UUV)N t h h ll tiNear net-shape pressure hull castings
Hull Inserts, Penetrations
Hi h S d ShiHigh-Speed Ships(LCS)
Castings (Waterjet
Trial CastingTi CP-2LO UUV Hull
Section
components -impellers, pump casings, ducts)
Trial CastingTi-5111 UUV Hull Section
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SUMMARY
• Titanium is an optimum material for seawater serviceservice
• It has been successfully used in the Navy for decades and continues to be used primarily in p yauxiliary systems
• Increased use and large structural applications are limited by high material & fabrication costs
• Although initial cost may be offset by reduced lif l d d f lif l hi i itilife cycle and end of life value, ship acquisition cost rules
• Opportunities exist for titanium to increased• Opportunities exist for titanium to increased payload, range, stability, and operating cycles