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MATERIALS

SCIENCE &
ENGINEERING

ELSEVIER Materials Science and Engineering A213 (1996) 103-114


A

An overview on the use of titanium in the aerospace industry


R.R. Boyer
Boeing Commercial Airplane Group Seattle, ~VA 98124, USA

Abstract

Titanium and titanium alloys are excellent candidates for aerospace applications owing to their high strength to weight ratio
and excellent corrosion resistance. Titanium usage is, however, strongly limited by its higher cost relative to competing materials,
primarily aluminum alloys and steels. Hence the advantages of using titanium must be balanced against this added cost. The
titanium alloys used for aerospace applications, some of the characteristics of these alloys, the rationale for utilizing them, and
some specific applications of different types of actual usage, and constraints, are discussed as an expansion of previous reviews
of fl alloy applications. [i,2]

Keywords: Aerospace applications: Airframe alloys; Aircraft engine alloys; Castings: Forgings: Supe~plastic forming

1. Titanium alloys and characteristics retained at room temperature. (Minor additions of


fl-phase stabilizers are often made to enhance the pro-
There are three titanium alloy types based on the cessing characteristics and to permit greater manipula-
composition of the alloy and the resultant predominant tion of the microstructure of the material.)
room temperature (RT) constituent phase(s), and each The commercially pure grades can be obtained with
of these families of alloys serves a specific role. The minimum yield strengths from 170 to 480 MPa, with
alloy types (only conventional alloys are dealt with; the higher strength grades containing more oxygen and
new systems, such as the aluminides will not be dis- iron. Their primary attributes are good formability,
cussed) include ¢ and near-~ alloys, a/fl alloys and the with the formability decreasing as the strength in-
/3 alloys. Alpha is the low temperature allotrope of creases, and excellent corrosion resistance. Strengths
titanium, and the microstructure of ~ and near-~ alloys are comparable with the annealed 300 series stainless
consists predominantly of the a-phase. The ~/fi alioys steels, but with about a 40% decrease in density. The
are, for the most part, still mostly a at room tempera- commercially pure titanium alloys are not heat treat-
ture, but they do have more of the /?-l~hase, the high able, hence they exhibit good weldability.
temperature allotrope, than the former class of alloys. The a and near-~ alloys (hereinafter referred to as
The definition of/?-alloys is not fully agreed upon, but alloys) include alloys such as Ti-3AI-2.5V (Ti-3-2.5),
in very general terms, they are capable of" retaining Ti-5AI-2.5Sn (Ti-5-2.5), T i - 8 A I - I M o - I V ( T i - 8 -
100%/? when quenched from the/?-phase field. There is i - i ) and T i - 6 A I - 2 S n - 4 Z r - 2 M o (Ti-6-2-4-2S).
some overlap in each of these "families" of alloys. Refs. The "S" is added to the end of the composition for the
[3-5] contain more information on this basic titanium latter alloy to denote the Si addition. Minor Si addi-
metallurgy. tions, in the range of 0.1 to 0.25, and higher, enhance
the creep resistance of the high temperature alloys
i.I. ~ and Near-c~ Alloys [6-9]. Because of their mechanical properties retention
and creep resistance at elevated temperatures, x-alloys
There are two types of alloys in this category, the are preferred for elevated temperature applications.
commercially pure grades of titanium (with oxygen and
iron as the primary alloying elements) and those with 1.2. ~/fl Alloy
intentional additions of a-stabilizers, such as AI and
Sn. Some of these do contain minor additions of fl-sta- These alloys, which include Ti-6A1-4V (Ti-6-4),
bilizers, such as Mo and V, but there is very little fl Ti-6AI-6V-2Sn ( T i - 6 - 6 - 2 ) and T i - 6 A I - 2 S n - 4 Z r -
104 R R. Bo),er / Marerials Sczence a~zd Engineeri~g 4213 (I996) I03-114

6Mo ( T i - 6 - 2 - 4 - 6 ) , are capable of somewhat higher solution treatment is normally done above the/? tran-
strengths than the near-:~ alloys, have good combina- sus. This is not, however, the case with ~ and ~//? alloys
tions of properties, have a wide processing window, which may require careful processing to obtain the
which means that processing requirements are not as correct microstructures for some of the more demand-
stringent as for other alloy types, and, depending on the ing applications. The primary goals in working the /3
alloy, are good for applications up to the range of alloys are to achieve a fine recrystallized microstructure
about 315 to 400 °C. They can be strengthened, usually (which can be challenging), The exception to this is
with a solution treatment below the t3 transus (the T i - 1 0 - 2 - 3 , which is solution treated below the beta
minimum temperature at which the alloy consists of transus, thus retaining some of the microstructural
100% /?-phase) to establish the hardenability, and a effects of the prior working history [17]. Recent experi-
subsequent age. The amount of strengthening which ence with the /?-alloys, however, indicates that the
can be achieved is a function of the alloy and section metallurgy of these alloys is more complicated than it
thickness. Alloys with the lower fl-stabilizing contents, first appears, and the processing steps in fabrication of
such as Ti-6AI-4V, are highly weldable. As the fl-sta- a component need to be carefully considered,
bilizer content increases, the hardenability increases but
welding becomes more difficult.
These alloys can provide a weight savings in place of
the lower strength aerospace type steels and aluminum 2. Primary reasons for using titanium alloys
alloys, and have very superior corrosion resistance to
the aluminum alloys and low alloy steels. The primary justifications for using titanium in the
aerospace industry are:
I..?. /? Allots - Weight savings (primarily as a steel replacement)
- Space limitation (replace A1 alloys)
This alloy class, which includes Ti-10V-2Fe-3A1 - Operating temperature (A1, Ni, steel alloys replace-
(Ti- 10-2-3), Ti- 15V-3Cr--3A1-3Sn (Ti-15-3), ment)
Timetal 21S (Ti-15Mo-2.7Nb-3AI-0.2Si), and Ti- - Corrosion resistance (replace A1 and low alloy steels)
3A1-SV-6Cr-4Mo-4Zr (fl-C), is capable of being - Composite compatibility (replace A1 alloys)
heat treated to high strengths in excess of 1380 MPa. Weight savings is the obvious one with titanium's
They can be heat treated over a broad range of high strength-to-weight ratio. The lower density of tita-
strengths, permitting one to tailor the strength/fracture nium compared with steel permits weight savings re-
toughness properties combination that is desired. They placing steels even though they may be higher strength.
generally have high stress corrosion resistance, with the As the strength of titanium alloys is significantly higher
ratio of the stress corrosion threshold, K,~oo, to the than A1 alloys, weight savings can be achieved in their
fracture toughness, K~¢, being in the range of 0.8 to 1.0 replacement in spite of the 60°,/0 higher density, assum-
in 3.5% NaC1. Some of the/? alloys, such as T i - 1 0 - 2 - ing that the component is not gage limited.
3 [1.2,10-12] and fl-C [13-15] have excellent fatigue Titanium could also replace aluminum when the
properties, while others, such as Ti-15-3, have, in operating temperature exceeds about 130 °C, which is
general, poor fatigue properties relative to their the normal maximum operating temperature for con-
strengths. T i - 1 0 - 2 - 3 is weldable, but electron beam ventional aluminum. These conditions exist, for exam-
welding is recommended as plasma and tungsten inert ple, in the nacelle and auxiliary power unit (APU) areas
gas welding can result in poor ductility and toughness and wing anti-icing systems for airframe structures.
[16]. Alloys such as Ti-15-3 and Beta-21S are readily Steel and nickel-base alloys are obvious alternatives,
weldable, but precautions must be taken to assure good but they do have a density about 1.7 times that of
joint properties. titanium.
Beta alloys offer fabrication advantages, particularly Excellent examples of utilization of titanium because
for producing sheet, owing to their cold rolling capabil- of volume constraints are the landing gear beams on
ities. Owing to the limitations in reductions which can the Boeing 747 and 757. The 747 beam is one of the
be achieved in ~//? alloys, they must be hand rolled, largest titanium forgings produced. The preferable ma-
which is a very labor intensive operation; the/? alloys, terial for this application would have been an alu-
on the contrary, can be strip roiled. In addition, for minum alloy, such as 7075, as the cost would be much
hot-die or isothermal precisior~ forgings, alloys such as lower. However, to carry the required loads, the ma-
Ti- 10-2-3 can be forged at lower temperatures, result- chined aluminum component would not fit within the
ing in lower die costs and forging advantages for some envelope of the wing. Steel could have been used, but it
shapes. would have been heavier owing to the higher density.
Prior processing in terms of obtaining a given mi- Corrosion resistance can be a very important issue.
crostructure is not as important for the /? alloys as The corrosion resistance of titanium is such that corro-
R.R. Boyer / Materials Scieitce and Eizgineerh~g A217 (1996) 103-II4 105

sion protective coatings or paint are not required. Ti-3AI-2.SV has one key application in the
(Paint is applied when titanium comes into contact with aerospace industry, hydraulic tubing. It is used for high
an aluminum or low alloy steel component to prevent pressure hydraulic lines, with operating pressures up to
galvanic corrosion of the contact material.) Much of about 28 MPa. It is used in sizes from 6.3 to 38 mm
the floor support structure under the galleys and lavato- O.D. It replaces 21-6-9 stainless steel tubing with
ries is in a very corrosive environment which dictates about a 40% weight savings. (Sandvik Special Metals
the use of titanium to provide high structural durabil- has recently developed some T i - 6 - 4 hydraulic tubing
ity. which is under evaluation. The higher strength of Ti-
Polymer matrix composite (PMC) compatibility is 6-4 would permit reducing the wall thickness, enhanc-
becoming a bigger issue with higher utilization of com- ing the weight savings.) Since Ti-3-2.5 is strip
posite structure on aircraft. The titanimn is galvanically producible and easily rolled into foil, it is also used for
compatible with the carbon fibers in the composites, the fabrication of honeycomb core where strength
whereas aluminum (and low alloy steels) and carbon greater than that provided by CP is required. (Ti-6-4
generate a significant galvanic potential. The selection is not strip producible, which makes T i - 6 - 4 foil very
of titanium in these instances is related to the criticality expensive.)
of the structure. There are corrosion protection systems Ti-5-2.5, which is also used in the annealed condi-
which are used to isolate aluminum from carbon com- tion, is used for cryogenic applications as it retains
posites to preclude the corrosion problem, but the good fracture toughness and ductility down to cryo-
integrity of the coating over the life of the airframe genic temperatures [18]. The primary use of this alloy
must be taken into account. Titanium has also been today is in the hydrogen side of the high pressure fuel
used with PMC structure due to its relatively good turbo-pump of the space shuttle.
match of coefficient of thermal expansion (CTE), which T i - 8 - 1 - 1 is not a high usage alloy. It was once
will be discussed more fully later. considered for major airframe structure, but was
As mentioned previously, cost is always an important dropped owing to poor stress corrosion resistance. The
consideration. The raw material may cost anywhere alloy's low density and high modulus (for a Ti alloy)
flom 3 to 10 times as much as steel or aluminum, and make it attractive for blades in turbine engines; it is
the machining costs for titanium are generally signifi- used for fan blades for military engines. It is also used
cantly higher than for the other materials (at least 10 for tear straps on commercial airframes. (It is normally
times that to machine AI). Thus the benefits of using used in the duplex annealed condition.)
titanium must outweigh the added cost. Most of the US tonnage for the a-alloys (excluding
CP Ti) in the aerospace industry, is for elevated temper-
ature applications. They have good properties retention
3. Titanium Alloy Applications and creep resistance at elevated temperatures. The pri-
mary alloy for these applications is T i - 6 - 2 - 4 - 2 S , and
Some of the more prominent aerospace applications its chief consumer is the gas turbine engine industry. It
will be discussed. It is beyond the scope of this paper to is used for rotating components such blades, discs and
attempt to cover all the applications and emphasis will rotors at temperatures up to about 540 °C. The RT
be on US aircraft. Missile type applications are not tensile strength is about 930 MPa. (When strength val-
covered. ues are cited, it will refer to ultimate tensile strength
unless otherwise noted.) T i - 6 - 2 - 4 - 2 S is used in the
3.I. ~ Alloys high pressure compressor at temperatures too high for
Ti-6-4, above about 315°C for structural applica-
Commercially pure (CP) titanium, used in the an- tions. In the latter compressor stages, where the temper-
nealed condition, is used primarily for their formability ature is highest, titanium alloys are processed to obtain
and corrosion resistance. The amaealed 300 series stain- the maximum creep resistance. Beyond this point,
less steels have similar characteristics and are lower about 540 °C, the temperatures are too high for tita-
cost, so the lower density of CP is the impetus for its nium, and Ni-based alloys are used owing to: (1) their
usage. It is used for non-structural applications requir- superior elevated temperature properties; (2) the con-
ing the above mentioned traits. Common examples are cern that the titanium will ignite and burn, and (3)
floor support structure in the galley and lavatory areas, oxidation problems with the titanium - - the formation
tubes or pipes in the lavatory system, clips and brack- of an oxygen-stabilized alpha-case or alpha-enrichment
ets, and ducting for the anti-icing and environmental on the surface that results in a substantial decrease in
control systems (ECS). The ECS ducts operate at tem- ductility and fatigue strength. Titanium is used to
peratures up to about 230 °C, which is too high for higher temperatures, up to --- 565 °C, for static compo-
aluminum alloys. Again, stainless steels could be used nents such as compressor cases, brackets, exhaust gas
but the CP offers about a 40% weight savings. mixers, etc. As an example of this type of structure,
t06 R.R. Bo3"er ~ Materia/s Scie/zce atzd Eizgilzeedlzg A213 (1996) 103-114

Fig. 1 illustrates a cast T i - 6 - 4 intermediate case. Ti- tion. It is a forgiving alloy to work with, is normally
6 - 2 - 4 - 2 is just beginning to be used by airframe used at a minimum tensile strength of 896 MPa, has
producer~, in areas~uch as engire mounts and areas of good fatigue and fracture properties (which can be
the exhaust system and exhaust impingement. optimized through heat treatment) and is used in all
IMI has developed two high temperatu,'e alloys, IMI product forms including forgings, bar, castings, foil,
829, Ti-5.5A1-3.5Sn-3Zr-1Nb-0.25Mo-0.3Si [19- sheet, plate, extrusions, tubing and l~tsteners.
21]. which is used at operating tempgrature~up to There are four common heat treatments used for
540 *C. and the newer IMI 834, Ti-5.SA1-4Sn-3.5Zr- Ti-6-4. (1) Mill anneal (MA or A) - - this is the most
0.7Nb-0.5Mo-0.35Si-0.06C, which has a reported common heat treatment, with a strength of about
maximum use temperature of 600 °C [21,22]. These 896 MPa, good fatigue properties, moderate fi'acture
alloys are not being used by U.S. Engine manufactur- toughness (a typical value of about 66 MPa\/m) and
ers, but they are being used by Rolls-Royce (RR), reasonable fatigue crack growth rates FCGR). (2) Re-
which supplies engines to US a:rframe manufacturers. crystallize anneal (RA) - - this is a more damage
The RB-211-535E4 engine, which powers the Boeing tolerant heat treatment condition (usually used with
757, uses IMI 829 in some of the compressor discs, what is termed as an extra low interstitial (ELI)grade
blades and spacers. IMI 829 is used in the fl-solution with a reduced oxygen level to improve the fracture
treated and aged condition (minimum RT tensile properties) which has a slightly lower strength than
strength of 850 MPa). IMI 834 i:~ used in the RR Trent MA, slightly reduced fatigue properties, and improved
800 for compressor discs in the last two stages of the fracture toughness and fatigue growth rate resistance
intermediate pressure compressor, and the first four (the minimum KI~ for RA is usually 77 MP;t\/m). It is
stages of the high pressure compressor. This alloy is used for all fracture critical applications on the B-1 and
used with an :/fl solution treat and age at a minimum B-2 bombers. (3) Beta anneal (BA) - - this is used with
RT tensile strength of 930 MPa. both the standard and ELI grades. For maximum
Timer has developed high temperature ~.-al- damage tolerance properties the ELI grade is used, and
loy,Timetal-lI00, Ti-6AI-2.SSr:-4Zr-0.4Mo-0.4Si, a again, the strength is somewhat reduced, while FCGR
modification of T i - 6 - 2 - 4 - 2 S , which also has a resistance and fracture toughness are maximized (the
claimed use temperature of 600 °C [23]. minimum Klc requirement is 88 MPa x m), but the fa-
Allison Gas Turbine Engines is actively pursuing the tigue strength is significantly degraded. This heat treat-
alloy for higher thrust versions of their T406/ ment is used for damage tolerant components on the
GMA3007/GMA2100 family of engines. F-22 fighter and critical fittings attaching the composite
empennage to the fuselage on the Boeing 777, structure
.3.2. ~.//3 Allo)'s where a flaw of a specified size must be assumed to be
present in the most critical location of the most critical
T i - 6 - 4 is the workhorse of t;'le titanium industry; it component. (4) Solution treated and aged (STA) - -
accounts for about 60% of the total titanium produc- provides the maximum strength, but full hardenability
is limited to about 25 mm. Hundreds of thousands of
titanium fasteners are used on each commercial aircraft,
and they are T i - 6 - 4 used in the STA condition, with a
minimum strength of 1100 MPa (those with diameters
over 19 mm are used at a slightly reduced strength).
The STA heat treatment is not commonly used for
shaped components as the thermal stresses induced by
the required water quenching are not relieved during
the aging treatment, which can result in part warpage
during machining.
It should be noted that a slow cooling rate from
temperatures in the range of about 480 to 620 °C can
cause a significant reduction in the stress corrosion
threshold.
The properties combinations of titanium alloys can
be changed significantly through processing as well as
heat treatment variations. Kuhlman discusses in some
detail the effects of processing on properties of titanium
alloys [24].
Fig. 1 Casty T i - 6 A I - 4 V intermediate compressor case for the E J200 In gas turbine engines T i - 6 - 4 is used for static and
Eurofighter. rotating components. Castings are used to manufacture
R.R. Bo)'er / Materials Scie~tce aizd E~zgmeerhzg .-1213 (1996) i03-114 107

the CTE of the titanium, which more closely matches


,~. , °,% ' ,.~t, f~ ,,, ,
that of the graphite in the PMC better than other
iI~'~[~iF" .....:~;" ~, ~ T TI-6AI-4Vdisks and blades structural materials. The difference in CTE between the
~ . ""~ " ~ ~ ~ ~"
.~.~. "
]J[~ ~- c o m p r l s' , n' g Iow-pressu re
graphite and aluminum would result in loads too high
.~' ' ,
. . " .- *. . .. '., , •t " ' I K i ~ / c o m p r e s s o r assembly
to efficiently use aluminun~.
Beta annealed T i - 6 - 4 machined forgings are also
~ ~ - . ~ : . , , t Ti-6AI-4Vfan disks-
" ~..%e . ; ~ [ . I . . c- blades oot installed used for the critical fittings attaching the composite
Lb.--',NL 1 % horizontal and vertical fins to the fuselage of the 777.
This is owing to the corrosion compatibility between
the titanium and the graphite. Use of titanium pre-
cluded reliance on a corrosion protection system to
prevent a galvanic corrosion problem with the graphite
Fig. 2. Ti-6AI=4V fan disk and low pressure compressor disks and fibers in the PMC empennage structure.
blades. T i - 6 - 4 formed sheet metal is used in the floor
support structure in areas of the galleys and lavatories
for the same reasons. Corrosion in this portion of the
the more complex static components (such as illustrated aircraft can be severe due to the fluids which are
in Fig. i); forgings are typically used for the rotating present. The potential for corrosion was exacerbated on
components. Fig. 2 illustrates the T i - 6 - 4 fan disc and the 777 because PMC floor beams are used, thus
low pressure compressor discs and blades for the Pratt providing the potential for galvanic corrosion as well as
and Whitney 4084 engine. Ti-6AI-4V is used on the general corrosion with aluminum structure.
first 4-5 (cooler) compressor stages, up to temperatures The 777 tail cone (Fig. 5) and APU exhaust duct
of about 315 °C. (Fig. 6) use T i - 6 - 4 owing to the high temperatures
As mentioned before, T i - 6 - 4 has been the associated with the APU. The temperatures are too
workhorse of the titanium industry, and probably high for aluminum and the weight penalty in going to
80%-90% of the titanium used on airframes has been steei or nickel-base alloys was again too high. The tail
this alloy. It is used in all sections of the aircraft - - cone is made from sheet, and owing to some of the
fuselage, nacelles, landing gear, wing, and empennage. sharp contours, much of this structure is superplasti-
The 757 offers an excellent example of the use of cally formed (SPF). ( T i - 6 - 4 sheet has excellent SPF
titanium in the landing gear area, Fig. 3. The rationale characteristics without any special processing. Super-
for utilizing titanium for the landing gear beam, which plastic forming is used throughout the industry to
is about 4.5m long and 375mm wide at its widest produce many complex sheet metal type components
point, and has a forging weight of over 815 kg, has [25].) The exhaust duct is fabricated from a casting.
already been discussed. The other Ti parts shown in Owing to the complexity of the geometry and the
Fig. 3, machined from forgings, are used because of the difficulty of machining, a casting was the most cost
alloy's excellent corrosion resistance with the added effective means of producing this component.
benefit of reduced weight. For other airplane models T i - 6 - 6 - 2 can be used at higher strengths than Ti-
these components are fabricated from low alloy steel; 6-4, up to about 1170 MPa in the STA condition. It
these alloy steels can develop corrosion pits due to the would be used for similar reasons to those of T i - 6 - 4 .
very corrosive environment in the wheel well. These pits and would offer higher weight savings, though the
may become initiation sites tbr subsequent stress corro- fracture toughness and stress corrosion resistance are
sion or fatigue cracks, which means down-time for the reduced. It was used extensively in the landing gear
airlines, and part replacement. Titanium eliminates this support structure of the 747 owing to its superior
issue. It has a higher initial cost, but may provide lower corrosion resistance to the low alloy steels, and it
life cycle costs. provided a weight savings, for applications such as drag
The windshield frames on the 757, 767 and 777 are braces, torsion links, and bell cranks. It has not been
machined from the same BA T i - 6 - 4 forgings, and the used on later models of Boeing aircraft as T i - i 0 - 2 - 3
crown panel just above them is fabricated from formed offers even better weight savings, particularly when the
T i - 6 - 4 sheet (Fig. 4). These components are titanium thickness gets above about 38 to 50 ram, and the frac-
owing to its high strength which is needed to withstand ture toughness and stress corrosion resistance are better
the damage incurred during bird strikes. than that of T i - 6 - 6 - 2 . McDonnell Douglas uses the
The fin deck on the 777, where the composite vertical T i - 6 - 6 - 2 alloy, primarily in the annealed condition, at
fin attaches to the fuselage, uses Ti-6A1-4V hot- about the 1035 MPa strength level. This does not
formed plate, about 5 mm thick, 762 mm wide and provide the weight savings offered by the STA condi-
3.3 m long (Fig. 5). The reason for this application is tion, but it is easier to machine, and has better fracture
108 R.R. Boyer ' Materials Science al~d EizgineerOlg A213 (1996) I 0 3 - I I 4

Yoke
fitting ~ -
Lower
Landing stabilizer
gear beam link
Bearing
housing
Upper
stabilizer
Attach
link - -
fittings

Fig. 3. Titanium forging used in 757 landing gear support structure (from the 757 mockup).

toughness and stress corrosion resistance than the STA advantage. They are not used in place of T i - 6 - 2 - 4 - 2 S
condition. as their creep performance will not match that of
T i - 6 A I - 2 S n - 2 Z r - 2 M o - 2 C r ÷ Si (Ti-6-22-22) Ti-6-2-4-2S.
was developed by RMI in the early i970's as a deep
hardenable alloy. It has recently been resurrected as a
moderate strength-damage tolerant alloy for the Lock-
3.3. fl Al/o),s
heed/Boeing F-22 program [26]. Forgings and plate will
Ti- 13V- 11Cr-3A1 (Ti- 13-11-3) was the first com-
be used at a tensile strength of 1035 MPa with a
mercially significant fl alloy. It was used extensively oll
minimum K~ of 77 MPax/m. A triplex heat treatment
the SR-71 "Blackbird" reconnaissance airplane. About
is used to optimize the damage toIerance properties. It
95% of the structural weight was reported to be tita-
is first solution treated above the fl transus, followed by
nium [2,3[], the bulk of it being Ti-13-11-3. It was
a sub-transus solution treatment, with a controlled
used for wing and body skins, frames, longerons, bulk-
cooling rate, and aged. T i - 6 - 2 2 - 2 2 sheet has excellent
heads, ribs, rivets and essentially the complete main and
SPF characteristics. It can be formed at lower tempera- nose landing gears. Titanium was used as weight was
tures than used for Ti-6-4, and will provide higher critical and it had elevated temperature properties capa-
strength [27,28]. ble of meeting mission requirements. One of the key
T i - 6 - 2 - 4 - 6 was developed by Pratt and Whitney reasons for selection of Ti-13-11-3 was its thermal
(P&W) to provide a high strength alloy which can be stability. Some of the skins had to be spot welded on
used for moderate temperatures, up to about 315 °C. It assembly, and the assembly could not be subsequently
is used primarily for military engines, such as the F-I00 aged so the weld nugget would essentially be in the
and F-119, at a yield strength level of 1035 MPa. The solution treated condition. Ti-13-11-3, the most sta-
damage tolerance characteristics of this alloy are not as ble of the commercial /)' alloys (except for P&W's
good as those of T i - 6 - 4 or T i - 6 - 2 - 4 - 2 so it is not recently developed Alloy C, Ti-35V-15Cr) was the
used in commercial engines owii:g to the shorter inspec- only heat treatable alloy which could be used at the
tion intervals which would be required. operating temperatures, about 250-315°C, which
Ti-5AI-2Sn-2Zr-4Mo-4Cr. Ti-17, is a deep hard- would not embrittle in the weld regions.
enable ~,/fl alloy, minimum slrength of i125 MPa, Ti-13-11-3 was very successful on the SR-71, yet
developed by GE Aircraft Engines which is used below designers today would not consider the properties ac-
400 °C for fan and compressor discs [29,30]. (The tem- ceptable for aircraft structure today, considering the
perature limitation of both Ti-17 and T i - 6 - 2 - 4 - 6 is strength, ductility and fracture toughness properties of
a result of their poor creep resistance above the indi- the alloy. Forgings were used at the 1240 MPa strength
cated maximum use temperatures.) Ti-17 is used for IeveI with a minimum elongation of 2%. It is also very
commercial engines in the//-processed condition - - in difficult to melt (controlling the Cr segregation) and
stages 2-4 of the GE90 high pressure compressor, for fabricate into mill product [32,33]. About the only
example. The titanium blades in the compressor would application for this alloy today is for coil springs, and
be T i - 6 - 4 or T i - 6 - 2 - 4 - 2 S , depending on the temper- it is being replaced there by D'-C.
ature. Titanium is an excellent spring material. With a
Both T i - 6 - 2 - 4 - 6 and Ti-17 are used in place of density about 60% and a modulus about 50% that of
T i - 6 - 4 where the higher strength can be used to steel, weight savings of" up to 70% and volume savings
R.R. Boyer / Materials Science and E~zghzeerhzg A213 (199d) 103-Ii4 [09

strengths. It is presently used at a strength of I035 ksi,


but work is underway to provide coverage for heat
Crown panel treatments to provide strengths of 1170 and 1240 MPa.
Ti-15-3 has excellent cold forming characteristics for
Window simple forming operations, such as brake-forming, or
frame forming it into rectangular, round or oval shapes. For
forgings more complex forming operations, such as bending
tubes, stretch and bulge forming, where tri-axial stresses
are developed, forming difficulties can be encountered.
The alloy e~ibits virtually no work hardening, so once
necking initiates it just continues to thin. There are two
means to minimize, but not eliminate this problem. The
Fig. 4. Window frame forgins used on the Boeing 757, 767, and 777. first is to work at a low strain-rate. It is strain-rate
sensitive, and significant improvements in formability
can be achieved by working at low strain-rates. The
second method, which has not really been proven,
of 50% can be achieved in replacement of steel springs, involves putting some initial cold work into the mate-
at a relatively low cost per kilogram of weight saved rial, or partially aging, to provide a larger spread
[33,34]. In addition there are no corrosion problems between the ultimate and yield strengths, so at least
with the titanium springs. Beta-C is used for springs in some minimal amount of work hardening occurs.
the strength range of 1240 to 1450 MPa. Up- and There are several areas besides springs where T i - I 5 -
down-lock landing gear springs, feel and centering 3 is being used in current generation aircraft. One of
springs for the yoke, pedal return springs for the the large users is the Boeing 777, and the big item is for
brakes, hydraulic return springs, and flight control ECS ducting. About 49 m of 178 mm diameter ducts
springs are common aircraft applications of titanium with a wall thicknesses of 0.5 and 1 ram, with most of
springs [1,2]. it at 0.5 ram, is used per aircraft. Use of this alloy
If there is a volume constraint, square and rectangu- permitted cutting the wail thickness in half in place of
lar wire are available to increase the load carrying the previously used lower strength CP titanium, result-
capacity, though this product form is significantly more ing in a weight savings of about 63.5 kg per airplane. It
costly. For springs made from flat product, such as is also used for fire extinguisher bottles in place of
clock-type springs, Ti-15-3 is used because strip is a 21-6-9 steel, providing a weight savings of about
standard product for this alloy. Examples of springs 23 kg per airplane [1,2]. In addition, it is used for
made from the various product forms can be seen in numerous clips and brackets in the floor support struc-
Fig. 7.
Strip is the primary product form for Ti-15-3. The
advantages of this alloy are strip producibility, cold
formability, and the ability to heat treat to high

gs

.,,. , ...7" ..,. 2 . . ~

Fig. 5. Fin deck for the Boeing 777. Fig. 6. Cast Ti-6AI-4V APU exhaust duct for the 777.
110 R,R. Bo yer ~ ~lat erials Scie~Tce alzd Etzghzeeri~zy¢ A213 (1996) I03-114

strength, ductility, and toughness requirements. The


lower strength levels offer higher fracture toughness
and a less restrictive processing window, Boeing uses
the high strength level to achieve the maximum weight
savings. Ti-10V-2Fe-3A1 also provides excellent fa-
tigue properties: it has only moderate FCGR character-
istics, similar to those of mill annealed Ti-6-4. The
fatigue crack growth rate characteristics are, however,
very predictable - - they are process-microstructure-
strength insensitive. The FCGR are the same at
strength levels from 1035 to 1310 MPa [37], indepen-
dent of microstructure (considering practicaI produc-
tion heat treatments) [38] and the same in air and 3.5%
NaC1 [I0].
The most prominent application of this alloy is on
the landing gear of the 777. As can be seen in Fig. 10,
almost the entire main hmding gear is fabricated from
Ti-10-2-3. The only significant parts of this gear
Fig. 7. Titanium airc,'aft spings. which are not T i - 1 0 - 2 - 3 are the inner and outer
cylinders and the axles. It was used in place of 4340M,
which is used at a minimum strength of 1895 MPa.
ture and other areas of the 777, primarily because of its T i - 1 0 - 2 - 3 applications in the main landing gear re-
strength, corrosion resistance, and formability. For sulted in a weight savings of about 270 kg per airplane
these same reasons P&W uses Ti-15-3 strip to fabri- - - and eliminated the potential of stress corrosion
cate formed brackets for the low temperature regions of cracking associated with the steel. The truck beam
their newer engines. This provides a significant weight shown in Fig. 10 is -,- 3 m long with a 340 mm outside
savings in replacement of steel. Some of the formed dia. T i - 1 0 - 2 - 3 is used throughout the airplane - - the
clips and brackets used in airframes can be imple- other major components would be the larger flap
mented at a relatively cost per kilogram of weight tracks. McDonnell Douglas uses T i - 1 0 - 2 - 3 at the
saved. The parts in Fig. 8 are Lsed without heat treat- 1105 MPa strength level in the cargo door, nacelle,
ment, and no surface finish is required - - the Iow alloy empennage, and other areas of the C-17. (It should be
steel normally used requires Cd plating. pointed out that achievement of the high strength goals
Ti-15-3 castings were also iraplemented on the 777. is very difficult with very large parts, such as the truck
These castings, used at the 1140 MPa strength level, are beam, in that it is difficult to get sufficient work into
used in the cargo handling area and for APU vibration the forgings.)
isolator mounts. The 17-4PH steel castings which these
parts replaced were used at the 1240 MPa strength, but
the lower density of the titanium resulted in a weight
savings of about 35%. Allied Signal-Bendix is using
Ti-15-3 castings for the brake torque tubes for the
F-18EF fighter; they will use it at a minimum tensile
strength of 1045 MPa (Fig. 9). The Ti-15-3 will re-
place a T i - 6 - 4 casting (witla a minimum tensile
strength of about 830 MPa) in this case. The higher
strength enables a reduction of the volume of the
torque tube, allowing them to use a higher volume of
carbon in the brakes, which should result in longer t

brake life. The Ti-15-3 castings exhibit excellent fa-


tigue properties [35,36]. - ,, •

In terms of tonnage, T i - i 0 - 2 - 3 is the most highly


used of the fl_alloys with the production requirements
of the 777. It is a forging alloy which is used at three
strength levels, 965, 1105 and 1190 MPa [24]. The pro-
cessing and heat treatment are adjusted to achieve the
required property level. At the high strength Ievel there Fig. 8. Miscellaneous Ti-15V-3Cr-3AI-3Sn formed sheet compo.
is a fairly narrow processing window to meet the nents.
R.R. Boyer ~Materials Science at~d Enghzeering A213 (I996) I03-II4 Ill

The advantages in fatigue strength of T i - 1 0 - 2 - 3 are k -- Upperlink


also being recognized by the helicopter industry. Bell, Lowerlink
Westland, Sikorsky and Eurocopter are all using T i - ~--4~ Retractarm
10-2-3 in their rotor systems. Westland cited advan-
tages in the properties combinations of superior fatigue Lowersidestrut~ Locklinks
and tensile strength and lower stiffness over competing
alloys [1,2,11].
Timetal 21S (/?-21S)was developed by Timet for the LUo;C~:tt:rr:i:
rr ::ii ~ " ~ ~ ~ ' , , , ~ LUoP~eldragstrut
National Aerospace Plane to provide a strip producible, . -

oxidation resistant alloy to be used as the metal matrix T ruok eam


for metal matrix composite structure. Even though it is
a /? alloy it has reasonably good high temperature Reactionl i n k - " f ~ Brakerods
properties, with creep properties superior to those of
T i - 6 - 4 [39]. (Beta alloys are normally good only to
moderate temperatures.) Beta 21S is being used by Rg. 10. Boeing 777 main landing gear Ti-10V-2Fe-3AI forging
Boeing and P&W at temperatures up to 650 °C, for applications.
short times. The normal operating temperature will be
in the range of 480-565 °C. Two basic heat treatments
are used at Boeing, a solution treat and overage with a
severe embrittlement. Beta 21S is the only titanium
strength requirement of 860 MPa, and a STA heat
alloy which is immune to this attack [1,2,41,42]. The
treatment used at the 1035 MPa strength level. The
resistance is ascribed to the Mo and Nb contents - -
lower strength is used for higher temperature applica-
which seem to have a synergistic effect on corrosion
tions as this heat treatment provides improved thermal
resistance. This enabled the utilization of titanium in
stability [40]. The STA heat treatment is used up to
the nacelle and APU areas, which operate at !empera-
about 480 °C.
tures above 130 °C. Because of the hydraulic fluid issue,
The real advantage of this alloy is its resistance to
titanimn could not be used in these areas previously if
hot hydraulic fluid, which is one of the very few corro-
there was a reasonable possibility of exposure to hy-
sive media for titanium in the aerospace environment.
draulic fluids - - steel or nickel-based alloys were used.
The hydraulic fluid used in commercial aircraft will
Timetai 21S thus provided significant weight savings in
break down and form an organo-phosphoric acid at
the 777 nacelles.
temperatures in excess of ,-~ 130 °C which will etch the
TimetaI 21S is used on the aft cowl and plug and
titanium, reducing the gage, and, more importantly,
nozzle for all three 777 engines, the P&W 4084, GE-90,
pump in large amounts of hydrogen, which can cause
and the Trent 800 (Fig. 11), all skin and stringer type
structures. These applications save about 74 kilorams
per airplane. Pratt and Whitney is specifying fl-21S for
the plug and nozzle of their 4168 engines which will
power the Airbus A-330 which utilizes a honeycomb
sandwich design.

(a) Plug--183-mmdiameterat base


(b) Nozzle--86.5-mmin length
Fig. 9. Ti-15V-3Cr-3A1-3Sn cast torque tube for the F-18EF
fighter. Fig. 11. fl-2lS plug and nozzle assembly for the Trent 800 engine.
112 R.~'. Boyer / Materials Science and Engineerilzg ,,i213 (1996) 103-114

The final alloy to be discussed in this section is enhance the machinability [47]. Ti-3A1-2V connecting
Alloy C, developed by P&W. The advantage this alloy rods are used on some high performance engines: their
offers is ignition resistance. This ignition resistance reduced weight results in an increase in engine speed
enables P&W to use titanium in areas previously of about 700 rpm. This approach, creation of a more
requiring nickel-based alloys, primarily because there free-machining alloy, could potentially be used for
was a real concern of titanium fires in "hot" areas. some of the less demanding aerospace applications, as
The ignition temperature is dependent on a number titanium machining costs are significantly higher than
of factors such as metal gage, ax velocity, gas partial that of steels and aluminum alloys.
pressure and temperature. Pratl, and Whitney limits The Russians have a significant advantage in extru-
the use temperature of Alloy C to about 540 °C. It sion technology. For circle sizes up to about 100 mm
is being used for vectored exhaust structure and they can produce a surface which would not require
some cast compressor components on the Fl19 100% machining. This is very significant in that extru-
engine which powers the Lockheed/Boeing F-22 sions produced in the US, and elsewhere, do require
[43.44]. 100% machining.
NKK has developed an alloy specifically for super-
plastic forming, SP-700 (Ti-4.5AI-3V-2Fe-2Mo)
4. Future considerations [48-50]. This is not a low cost alloy, but it offers
some advantages in SPF characteristics which could
Future titanium technology development efforts provide economic benefits. It can be formed at tem-
should be directed toward lower final component costs peratures as low as 700 °C, though the optimmn form-
for the aircraft manufacturer. Increased emphasis on ing temperature is somewhat higher than this (Ti-6-4
delivery cost will make it more difficult for titanium is typically formed at about 900 °C.) The lower form-
to maintain its share of the structural weight of ing temperature provides an obvious power savings,
aerospace systems unless the co'st of titanium compo- and, the extent of surface contamination is signifi-
nents can be reduced. There are two approaches to cantly reduced, thus requiring less chemical milling,
achieving this, development of lower cost alloys and/ which is a very important consideration in light of the
or processing improvements to reduce the fabrication ecology costs associated with the chemical milling pro-
costs, with the latter probably offering the greatest cess.
potential. The titanium industry is making a concerted effort
Timet has recently developed two low cost alloys to penetrate new markets, such as atttomotive,
with the intent of opening new non-aerospace mar- geothermal, oil, etc. Penetration of these markets,
kets. Timetal 62S (Ti-6AI-I.?Fe-0.1Si) was devel- even if this happens with alloys not suitable for air-
oped as a low cost replacement for T i - 6 - 4 for the craft, could be beneficial to the aerospace industry as
automotive industry [45]. The Fe is a much lower cost the titanium industry would have a broader produc-
alloying addition than V, and the use of an expensive tion base, which could ultimately result in lower, more
master alloy was eliminated. The processing of the stable prices.
alloy was also designed to improve material yield
from the ingot. The other alloy, TimetaI LCB (Ti-
6.SMo-4.5Fe-l.5AI) was developed with automotive 5. Summary
springs in mind. It again takes advantage of low cost
alloying additions, using a low-cost ferro-moly alloy- Titanium alloys play an important role in the
ing addition - - the formulation costs are roughly aerospace industry. They have a high strength-to-
equivalent to that of CP titanium [46]. This alloy is weight ratio, excellent corrosion resistance, and com-
capable of being heat treated to strengths in excess of patibility with composite structure. However, to main-
1500 MPa with reasonable ductility [46]. The proper- tain a prominent position in the industry, future efforts
ties of both of these alloys indicate that they may be must be directed toward the cost reduction of titanium
appropriate for aerospace applications. Timetal LCB structure. In the past the aerospace industry has been
is presently being studied as a high strength fastener performance driven, and it still will be, but, in the
alloy. future, cost will play a more prominent role. Develop-
The other avenue to lower costs consists of alloying ment efforts need to be directed toward new alloys/pro-
or processing changes to reduce the fabrication costs cesses to reduce final component costs. Expansion of
through improved machining ,characteristics, greater the titanium industry into industrial applications, which
utilization of processes such as casting, SPF, super- seems to appear more promising, would also provide a
plastic forming/diffusion bonding, and near-net extru- benefit to the aerospace community by providing a
sions. The Japanese have de~eloped a Ti-3A1-2V more stable production base, which should provide
alloy with minor sulfur and rare-earth additions to greater price stability
R.R. Boyer / Materials Scie~ce a~zd Engineerhzg A213 (I996) I03-114 I13

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