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

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

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 by development of new technologies that provide significant cost reduction

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!

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.

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

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

Mechanical Properties (Ti-6Al-4V Composition) Base powder Alloying powder YS, MPa UTS, MPa Elong. % RA, % Oxygen content, % TiH2 Al-V master alloy 850-930 960-990 10-12.5 23-29 0.11-0.25 ASM standard (ingot material)  828  897  10  20 0.20

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

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 1.4-2 S (per kg) Conventional PM approach(CHIP): cost of parts 5-10 S

Advantages Innovative approach Cost-effectiveness High mechanical properties

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

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

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

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

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

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: 960-990 MPa; El. 10-12% UTS: 900-1000 MPa; El. 10-13% UTS 896 MPa; El.  10% Cost 1.4-2 S 5- 10 S 5-13 S

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)

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