PM Ti base net-shape parts

Production and characterisation of PM netshape parts in titanium base alloys.

Gérard Raisson Aubert et Duval (France)

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PM Ti base net-shape parts

Presentation 1. Introduction 2. Process for production of net-shape parts: 3. TA6-4 parts: - impeller - compressor casing 4. γ-TiAl parts: 5. Conclusion

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SMF – TIG 2009 June 23-24

PM Ti base net-shape parts

Introduction Potentially, production of PM net-shape parts is a way to improve a lot material yield and to save machining specialy for very intricate geometries. Main issues are: - geometrical capability (tolerances) - mechanical properties with effect of net-shape surfaces, - cost.
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PM Ti base net-shape parts

Process (1) Production route
Powder batch Design and dimensioning of tooling tooling HIP Decaning- machining (heat-treatment) NDT
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modeling

PM Ti base net-shape parts

Tooling Design and Dimensioning chart
Customer CAD file of the part Produced part definition Tooling Design Tooling Dimensioning Tooling drawing Tooling making

Modeling Measurement plan

Part production

Dimensionnal measurement

Datas treatment OK 5
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PM Ti base net-shape parts

Production and Characterisation of a partially net-shape Compressor Casing
Co-authors Xinhua Wu, Junfa Mei, Kun Zhang The University of Birmingham Martin Bache, Peter Herley The University of Swansea Wayne Voice Rolls-Royce Plc

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PM Ti base net-shape parts

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PM Ti base net-shape parts
Roundness 0.4 0.3 0.4 0.2 0.5 0.3 0.3 0.7 0.6 0.6

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PM Ti base net-shape parts

Net shape HIPped casing+ light machining Demonstrates 90% reduction in necessary machining
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PM Ti base net-shape parts

Simple internal turning operation was left till required
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Microstructure of HIPped Ti64 powder (taken from samples)

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PM Ti base net-shape parts

Micro 1

Micro 3 Micro 2

Micro 1

Micro 3

Micro 2 Micro 3

Micro 3

Micro 2 Micro 1

Micro 13 1

Micro SMF 2 – TIG 2009 June 23-24

PM Ti base net-shape parts
PHIP V2500 Ti6/4 cut-ups: All Microstructures Similar

Section A Micro 1 Position 1

Section A Micro 1 Position 2

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PM Ti base net-shape parts Fracture toughness of HIPped Ti64 samples: 20ºC, HIPped
Compact tension (CT) specimens
Specimen 1 2 3 KQ (MNm3/2) 94.0 96.5 92.5

BS 7448-1 (1991) Type 1 load vs displacement Plane strain criteria confirmed KQ quoted – loading rates tbc Good consistency

Forged Ti64 KIC ~ 55 MPa√m

KQ values relatively high

Crack path examined
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PM Ti base net-shape parts
Crack path on the side surface of KIC tested sample

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PM Ti base net-shape parts

Liquid H2 Vinci Pump Impeller Co-author Didier Guichard (SNECMA Vernon) Raphaël Salapete (SNECMA Vernon) Sébastien Lesure (SNECMA Vernon)

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PM Ti base net-shape parts
VINCI CRYOTECHNIC ENGINE

• Powers the future cryogenic upper stage of Ariane 5 • Expander cycle engine – turbines driven by heated hydrogen – high engine specific impulse, high payload mass • 180 kN Thrust in vacuum • Snecma Moteurs is prime contractor

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PM Ti base net-shape parts

VINCI HYDROGEN TURBOPUMP PRELIMINARY DESIGN

Main characteristics of VINCI impellers: Outer diameter Channel height Pressure rise per stage Tip speed 110 mm 4.6 mm 140 bar 600 m/s

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PM Ti base net-shape parts

CAD view of 1st and 2nd stages impellers

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PM Ti base net-shape parts

View of the blank before final machining

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PM Ti base net-shape parts

DEVELOPMENT OF METALLURGY (1)

• Choice of TA6.4ELI (Low Intersticial) • Development of a special heat treatment in order to increase ductility and toughness in cryogenic conditions.

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PM Ti base net-shape parts

DEVELOPMENT OF METALLURGY (2)

Condition Forged PM Forged PM

Temperature R.T. R.T. 20 K 20 K

UTS (MPa) 960 960 1675 1660

YS (Mpa) 870 860 1550 1500

El. (%) 14 18 12 15

Toughness (Mpa.?m) 73 100 60 60

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PM Ti base net-shape parts

Development of Metallurgy (3) Negative impact of net-shape surface is reduced by use of patented special steel which suppresses diffusion layer in Ti alloy.

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PM Ti base net-shape parts

THE VINCI IMPELLERS DIMENSIONAL ACCURACY Blades shape ± 0.2mm +/-0.1 mm Inlet diameters ± 0.25 mm Blades thickness ± 0.2 mm +/-0.15mm +/-0.12mm

Channel height ± 0.15 mm +/-0.05 mm
In red: specification In green: measured scatter band (20 parts)

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PM Ti base net-shape parts

NON DESTRUCTIVE TESTING
Dimensional conformity is guaranteed by a few simple measurements and by tooling machining process capability • X Ray or UltraSonic Testing are not sensible enough to guarantee material integrity • Strict process control is the main way to guarantee material integrity

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PM Ti base net-shape parts

γ TiAl Compressor Casing

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PM Ti base net-shape parts

• •

Conclusions Net-shape production of Ti base alloys can be efficient as far as dimensionnal and mechanical requirements are concerned, Economical optimisation requires a concurrent engineering between customer and producer design offices. A dedicated design of the part is more than suitable, An important issue is a as-Hipped material mechanical properties data base, An other important issue is the development time which is also related to the concurrent engineering.

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SMF – TIG 2009 June 23-24

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