superplastic forming of titanium
TRANSCRIPT
-
5/27/2018 Superplastic Forming of Titanium
1/50
Superplastic forming of titanium
European TitaniumConference 2009Parallel Session D: 11.10am 11.35am
Dr Richard Curtis PhD, DIC, CEng, CSci, FIMMM, FADM
Chair, IOM3 Superplasticity Committee, UK.
Department of Biomaterials, Biomaterials, Biomimetics and
Biophotonics Research Group.
-
5/27/2018 Superplastic Forming of Titanium
2/50
Acknowledgements
Dan Sanders, Boeing Inc
Bill Swale, Aeromet Ltd
Peter Stewart, BAe Systems
Mike Wallis, Rolls Royce
Werner Beck, Formtec AG.
Colleagues at Kings College London,University of Wales Swansea, University
of Kentucky.
-
5/27/2018 Superplastic Forming of Titanium
3/50
A community..
....of superplastic forming practice has
emerged:
- Euro SPF meetings, 2001, 02, 04, 05,
07, 08, 2010 (Bilbao / San Sebastian)- Euro SPF website
- UK IOM3 Superplasticity Committee
- USA Superplastic Forming Committee
- ISO, ASTM and Standards
-
5/27/2018 Superplastic Forming of Titanium
4/50
-
5/27/2018 Superplastic Forming of Titanium
5/50
Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.
SIM-O-SPF will provide a forum to share knowledge and experienceabout SPF process in general and Simulation of SPF in particular.
Will identify limitations of current Simulation capabilities andrecommend future developments
Will create an effective partnership amongst all members fromdifferent background (academia, commercial software and industry)
Providing immediate access to well established simulation tools thatare used by various parties for SPF applications in Aerospace, Railand Automotive
Introduce Simulation-based approach to SPF that would result in
higher quality components, improved design, optimizedmanufacturing parameters and a more cost effective approach
Enhance the capabilities of existing Simulation tools by furtherdevelopments and diversity in applications
For further details contact: [email protected]
SIM-O-SPF - what are the
objectives..?
-
5/27/2018 Superplastic Forming of Titanium
6/50
The Euro-SPF group is a community federating European industries and universitiesinvolved in SuperPlastic Forming. It promotes exchanges between the members as well
as the SPF technology. It also informs about the meetings directly or indirectly linked toSPF and about the positions offered in the universities and in the companies
-
5/27/2018 Superplastic Forming of Titanium
7/50
SPF technology in aerospace
-
5/27/2018 Superplastic Forming of Titanium
8/50
SPF technology in automotive
-
5/27/2018 Superplastic Forming of Titanium
9/50
Induction coil
heating
Ti-6Al-4Vsheet
ceramicdie
argon
gas
Die chamber pre-heatedto 900oC inside the press
Ceramic dieTi-6Al-4V Alloyformed sheet
SPF for Medical ProsthesesTitanium alloys have some of the best biocompatible properties of allmetallic alloys and for this reason many dental and medical implantsand devices are manufactured from both the commercially pure andthe Ti6Al4V alloy forms.
-
5/27/2018 Superplastic Forming of Titanium
10/50
Orbital Floor Fracture Upper face trauma usually results in fractures of the internal orbit,
usually termed Orbital Blowout Fracture.
Patients usually present with pain, swelling & often double vision isexperienced.
Bones in the orbital region play a vital role in the normal function of
the eye.
Therefore, accurate realignment or anatomic reconstruction ofthe bony orbit is essential in maintaining normal function.
Recent advances in diagnosis & treatment of internal orbitalfractures:
CT scanning greater ability to improve implant design andproduction.
-
5/27/2018 Superplastic Forming of Titanium
11/50
Aeromet Forming Division, establishedin 1985 produces Airframe and EngineComponents from Titanium Sheet and Plateby Superplastic, Hot Forming,Chemical Milling and & Laser Trimming.
Aeromet makes a minimum of 150 differentSPF components on a production basis
Superplastic Forming Press
Chemical Milling Plant5 Axis Laser Trimming
-
5/27/2018 Superplastic Forming of Titanium
12/50
Superplastic
Forming
Superplastic Forming at
900C Four components
in one pressing Ti6/4
2,0mm thick
-
5/27/2018 Superplastic Forming of Titanium
13/50
Spherical & Conical shapes
produced by SPF
Size:-600mm diameter x
300mm deep x 0.81mm
skin thicknesses.
Material - Ti 6/4
Assembly of Nine SPF Details
Complex assembly
-
5/27/2018 Superplastic Forming of Titanium
14/50
Tail Cone Section
Superplastic Forming at
900C Two productsTi6/4 0,8mm and one at
1,6mm thick. Size 800mm sq.
-
5/27/2018 Superplastic Forming of Titanium
15/50
Superplastic Forming at
900C from 2.2mm thick
Ti6/4Size 800 x 600 x 300mm
Deep.
Tail Cone Section
-
5/27/2018 Superplastic Forming of Titanium
16/50
Product Examples
Various Firewalls
& Assemblies madefrom Superplastically
Formed components.
-
5/27/2018 Superplastic Forming of Titanium
17/50
Typhoon
Keel Panel
TunnelskinPanel
General view of two sheet SPF/DB keel panel in part assembled rear fuse of Typhoon.
(NB. Single sheet tunnel skins also present)(Courtesy BAe Systems)
-
5/27/2018 Superplastic Forming of Titanium
18/50
TyphoonTop sheet
Lower sheet
Core sheets
Segment of four sheet X core configuration of SPF/DB Typhoonfore-plane.
(Courtesy BAe Systems)
-
5/27/2018 Superplastic Forming of Titanium
19/50
Cellular structure
~1100mm
Four sheet DB/SPF/DB six cell demonstration piece.
(Courtesy BAESystems and MOD)
-
5/27/2018 Superplastic Forming of Titanium
20/50
DB/SPF fan blade - internal structure
Section > 80% Hollow
Membrane
PanelDiffusion
Bond
Superplastic
line core
Rolls-Royce Barnoldswick
-
5/27/2018 Superplastic Forming of Titanium
21/50
An SPF cell with the latest generation
of presses at Rolls-Royce Barnoldswick
-
5/27/2018 Superplastic Forming of Titanium
22/50
The information contained herein is proprietary to FT and shall not be reproduced in whole or part or used for any purpose except when such user processes direct written
08.05.28_ISC Forum.ppt 22
Replacement of forged shells
No final surface machining
Thickness formed to final shape
Schedule reduction
Cost savings ~30% from
Ti-scrap reduction
Production effort
ARIANE V, SPF Hemispheres Ti6-4
Membrane thickness s=0,8 -0/ +0,2mm
Pole/equator zone thickness = 1,8 /2,2mm
Roundness tolerance D= 483 0,2mm
Final strength= 1020 N/mm
-
5/27/2018 Superplastic Forming of Titanium
23/50
The information contained herein is proprietary to FT and shall not be reproduced in whole or part or used for any purpose except when such user processes direct written
08.05.28_ISC Forum.ppt 23
Ti 6-2-4-2 ClosingShell
Closing shell ri./ le. with weird shape
Process and forming tools fully functional
SPF parameters Ti 6-2-4-2 from FTdatabase
Cycle time ~10 mins
-
5/27/2018 Superplastic Forming of Titanium
24/50
The information contained herein is proprietary to FT and shall not be reproduced in whole or part or used for any purpose except when such user processes direct written
08.05.28_ISC Forum.ppt 24
Silent HelicopterExhaust
Materials data beyond current max application
temperature, Ti6-4, Ti6-2-4-2 and Ti beta21S
Temperature simulation
Stress simulation
Design process = f (low mean + peak stresses,heat flow, heat radiation, temperature
dissipation) Process development
Prototype articles
Engine bench test
-
5/27/2018 Superplastic Forming of Titanium
25/50
SPF Standards
-
5/27/2018 Superplastic Forming of Titanium
26/50
26All Content of this presentation, copyright LISTechnology Ltd.
SuperPlastic Laser Integrated Component Equipment
(SPLICE)
Cutting
Blanks from
Sheet Stock
Welding and/or
Diffusion
Bonding
Removal
of Surplus
Material
Hole
DrillingSPF/DB
Raw
Material
Finished
Component
Surface
Preparation
In Process Inspection
LASER
Laser Induced Superplasticity
(LIS)
SPF/DBFatigue
Enhancement
-
5/27/2018 Superplastic Forming of Titanium
27/50
27All Content of this presentation, copyright LISTechnology Ltd.
Laser Induced Superplasticity (LIS)
Double Sided
Forming
-
5/27/2018 Superplastic Forming of Titanium
28/50
28All Content of this presentation, copyright LISTechnology Ltd.
Benefits of the Technology Being Pursued
Quicker
Process should allow a Massive Compression inSPF/DB Cycle Times
Material Preparation75%
Reduction
Heat-up90%
reduction
Forming15%
reduction
Cool Down95%
reduction
Finishing Operations50%
Reduction
Long Cycle Time
Short Cycle TimeSaving of 66%
-
5/27/2018 Superplastic Forming of Titanium
29/50
log
log
Ti-6Al-4V
patient
die
FE meshes
FE-SPFsimulation
Pressure cycle
SP formingprostheses
Superplastic Prosthetic Forming
Simplewaresolution
In this case, Simplewaresoftware allows conversionof 3D images into high qualitymeshes which can be used forFEA, CAD and RP. Enablingimplant design and manufacture.
Said & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
30/50
Provision of Maxillofacial Implants
(Wehmller et al, 2004)
Cranioplasty Orbital Floor Reconstruction Malar Augmentation
Trevor Coward and Richard Curtis, KCL
-
5/27/2018 Superplastic Forming of Titanium
31/50
Contamination in titanium
The alpha case isgenerally known to be
developed by theinterstitials such as carbon,
nitrogen and especiallyoxygen dissolved from
mould materials
from the synthesis of themicrostructure,
the hardness profile, EPMA mapping
and TEM, it could be confirmed that thealpha-case is formed by not onlyinterstitial oxygen atoms but also
substitutional metal atoms dissolved
from mould materials.Materials Science and Engineering A 405 (2005) 173177
-
5/27/2018 Superplastic Forming of Titanium
32/50
32
Die-Ti-6Al-4V surface modification
Forming conditions: 180 minutes @ 900C
Quartz substrateCroform investment
substrate
100 m 100 m
Ammonium Biflouride etch
Atwood & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
33/50
33
Time (min)
0 50 100 150 200
Depth(um)
0
50
100
150Croform-WB
RematitanUltra
Alumina
Zirconia
Silica
800 C
850 C
900 C
Depth of interaction zone
Atwood & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
34/50
Bending Ductility Tests
Determine the ductility or strength of aDetermine the ductility or strength of a
material.material.
AimAim -- produce results of eitherproduce results of either passpass oror failfail..Clause 6Clause 6Shall not show any cracking onShall not show any cracking on
the outside surface of the test piecethe outside surface of the test piecestripstrip
should be bent through an angle of 105should be bent through an angle of 105
around a mandrel.around a mandrel.
Failure of the test pieceFailure of the test pieceplasticplastic
deformation or crack initiationdeformation or crack initiationmay bemay be
attributable to one mode only. In the case ofattributable to one mode only. In the case of
a threea three--point bend test, it is most likely to bepoint bend test, it is most likely to be
due to thedue to the tension on the lowertension on the lower, convex, convexsurface.surface.
InstronInstron 11931193 machinemachine -- produce resultsproduce results
(Load(Load vsvs Deflection graphsDeflection graphs).).
V-block bend
test
Ditta & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
35/50
Load (N)
Deflection (mm)
Load vs Deflection graph
Ditta & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
36/50
- specimens 1 - 3 = die-side in tension.
- specimens 4 - 6 = gas-side in tension.
Bending Test Samples
Ditta & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
37/50
Furnace 20
Deflection (mm)
0 2 4 6 8
Load(N)
0
100
200
300
400
500
12
3
4
5
6
Specimen number
Furnace Samples
Overlap of
graphs
}die
}gas
Ditta & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
38/50
SPF Samples
SPF 30 - (Guys 422)
Deflection (mm)
0 2 4 6 8
Load(N)
0
100
200
300
400
500
1
2
3
4
5
6
Specimen number
4-6 : able towithstandgreater loadbefore failure. 1-3 : failed
earlierthan 4-6.
}die
}gas
Ditta & Curtis et al. KCL
Eff f i h i l
-
5/27/2018 Superplastic Forming of Titanium
39/50
Furnace 20 VS Furnace 120 : Specimens 1-3
Deflection (mm)
0 2 4 6 8
Load(N)
0
100
200
300
400
500
F 20 - 1F 20 - 2
F 20 - 3
F 120 - 1
F 120 - 2
F 120 - 3
Specimen number
Effect ofEffect of timetime on mechanicalon mechanical
properties:properties: furnacedfurnaced samples.samples.
Furnace 120 no plasticregion on
graphs brittlebehaviour.
Furnace 20obviousplastic regionon graphs ductilebehaviour.
(die-side)
Ditta & Curtis et al. KCL
Bioactivity assessment by immersion in SBF using SEM and EDX:
-
5/27/2018 Superplastic Forming of Titanium
40/50
Bioactivity assessment by immersion in SBF using SEM and EDX:
Ti64 (Sanded) SP700 (Sanded)
D1
D3
D7
D7
Ca
P Ca
Mg
Ca
P Ca
Ti64 (NaOH) SP700 (NaOH)
EDX
(D7)
Omar & Curtis et al. KCL
SEM and EDX:
-
5/27/2018 Superplastic Forming of Titanium
41/50
Ti64 (Degu 900C) Ti64 (Wiro 900C) SP700 (Wiro900C)
D1
D7
D3
EDX
(D7) Mg Si
P Ca
Ca
Mg
CaP
CaP
CaSi
SEM and EDX:
Ti Ti Ti
Ti
Omar & Curtis et al. KCL
-
5/27/2018 Superplastic Forming of Titanium
42/50
42
Cp-1 Ti64
G417 20min
G416 120min
TCP control
PVC toxic control
Day 3
Nunclon tissue culture plate
TCP: tissue culture plastic no diskCP-1: unalloyed titanium
Ti64:Ti64-G417 (SPF 900C)Ti64-G416 (SPF 900C)PVC control: Portex +control strips
Cells: primary human osteoblasts
Atwood, DiSilvio & Curtis et al. ongoing project, KCL
-
5/27/2018 Superplastic Forming of Titanium
43/50
43
CP1
Ti64
SP700
20min
120min
tcp
tcp2
pvc
Arb.
Units
0.0
0.1
0.2
0.3
Alamar Blueproliferation - indicates metabolic
activity affected by the number of cells
Atwood, DiSilvio & Curtis et al. ongoing project, KCL
Superplastic Prosthetic Forming samples: g417 (20 min) / g416 (120 min)
human osteosarcoma cells
-
5/27/2018 Superplastic Forming of Titanium
44/50
44
Alkaline phosphatase produced by cells
associated with bone forming tissue (differentiation)
Atwood, DiSilvio & Curtis et al. ongoing project, KCL
ALP expression in cell lysate distrupted cell membranes represents differentiation
-
5/27/2018 Superplastic Forming of Titanium
45/50
Alkaline Phosphatase in Supernatant Solution
0
0.020.04
0.06
0.080.1
0.12
0.140.16
0.18
cp-1
Ti64
sp700
g417
g416
tcp
pvc
m b
Sample type
arb
units
Average
sample set 1
sample set 2
sample set 3
tcp = tissue culture plastic (no sample)
pvc = polyvinyl chloride toxic control disk
m = medium alone (no cells)
b = buffer alone (no cells)
Supernatant meaning fluid from around/abovecells however, cells could be withdrawnfrom the fluid influencing the results. NB. cellsmay not be adhering to surface of the disk.
27 disks: 3 of each type of disk - each point is 4 measurements
..the activity of the enzyme ALP reaches a peak atday 7 on SPF titanium alloy (g417) suggesting thatthe presence of reaction products on the surfacehave a stimulatory effect
Alkaline phosphatase released from cells on
surfaces in media
CellCellCellCell ProliferationProliferationProliferationProliferation
-
5/27/2018 Superplastic Forming of Titanium
46/50
CellCellCellCell ProliferationProliferationProliferationProliferation
Classicalproliferation
profile
----AlamarAlamarAlamarAlamar blueblueblueblue to measure cytotoxicity, proliferation or activation
Omar & Curtis et al. KCL
Recent advances in the understanding of
-
5/27/2018 Superplastic Forming of Titanium
47/50
Recent advances in the understanding of
the chemistry of investment materials? Scrimgeour et al., (2007) with 31P solid-state MAS-
NMR spectroscopy on phosphate bonded investment:
(a) Deguvest
-- setting struvite, amorphous orthophosphate
-- burn-out (900C) farringtonite, Mg
metaphosphate
(b) Wirovest
-- setting struvite, amorphous orthophosphate-- burn-out (1050C) pyrophosphate (dominant),
amorphous orthophosphate.
h k b h
-
5/27/2018 Superplastic Forming of Titanium
48/50
What is known about the titanium
alloy surface?
Titania (TiO2) of 7 8 nm forms a passive and corrosion
resistant film on the alloy surface
Titania is an n-type semiconductor that can be doped withother elements to modify its electronic properties. e.g. Nb5+ ions orP5+ ions
Titania exists in three different crystalline allotropic forms,brookite, anatase and rutile although it may also be amorphous
-
5/27/2018 Superplastic Forming of Titanium
49/50
RutileRutileRutileRutile titaniatitaniatitaniatitania
For Ti-6Al-4V alloy
the transformationto rutile is
suppressed
For Ti-6Al-4V alloythe transformation
to rutile is
suppressed
http://www.fis.unipr.it/phevix/img/tot_disorder.jpg
http://zqlin.public.iastate.edu/TiO2%20Raman%20Spectra.jpg
Omar, Festy & Curtis et al. KCL
Shapes produced by
-
5/27/2018 Superplastic Forming of Titanium
50/50
Shapes produced by
Superplastic Prosthetic Forming
Juszczyk & Curtis et al. KCL