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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| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
• Goal: Continuous mass production process for titanium rod/wire forming from powder-based titanium feed that is competitive against existing processes
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
• 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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
• 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)
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
• 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.
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process: • Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
• Patent filed March 2012
• 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.
• 6mm f BE Ti64 from powder swagable to 3 mm f
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 3
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 4
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
CP Ti wires have been produced from flowing pelletised powders and cold isostatically pressed (CIPed) powders and wrought to wrought
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
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
Particulate or Powder feedstock
Extrusion Shoe
Grooved Extrusion
Wheel Abutment
Shoe Inserts
Extrudate
Extrusion Die Insert
Rod feed
Coining roll
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
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
Process limit: flash gap-extrusion outlet-machine stiffness.
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
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
Process limit: flash gap-extrusion outlet-machine stiffness.
Further drawing of extruded wire possible to obtain smaller diameter wire: proven swagable to 3 mm f
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability BWE Conform rotary extruder modified
from Al/Cu configuration to allow extrusion from Ti
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
Process limit: flash gap-extrusion outlet-machine stiffness.
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 6
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 6
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)
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 7
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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 8
W2W
Tensile properties of CP Ti from powder and rod
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 9
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)
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 10
• 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
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 11