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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: [email protected] Institute for Metal Physics Kyiv. Talk outline. What is needed in the market?

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cost effective production of powder metallurgy titanium components

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: [email protected]

Institute for Metal Physics

Kyiv

talk outline

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

problem description market need
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

problem description market need4
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)

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.

experimental results
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
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
cost effective production of hydrogenated titanium powder
Reduction

Vacuum separation

Hydrogenation

TiCl4

MgCl2

Hydrogen

Vacuum

Argon

Cost-Effective Production of Hydrogenated Titanium Powder

Production in Ukraine:

Zaporozhje Titanium&Magnesium Plant

cost effectiveness
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

advantages
Advantages
  • Innovative approach
  • Cost-effectiveness
  • High mechanical properties
stage of development
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
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
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 segment15
Targeted Market Segment

- Aerospace industry (components for non-critical application)

- Medical applications, etc.

competition
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

opportunities
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)
contact information

Contact information

Prof. Orest Ivasishin

Tel: +380-44-424-22-10

E-mail: [email protected]

Institute for Metal Physics

Kyiv

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