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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
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
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
gs
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
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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