Sintered Titanium Rod Feedstock for High-Strength Large-Part AM
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Solution Overview
Problem
Existing rod feedstocks for titanium alloys used in additive manufacturing are costly and have reduced tensile and fatigue strength compared to wrought processed materials, making them unsuitable for producing large aerospace components like aircraft landing gear.
Innovation Solution
A method involving mixing titanium, iron, vanadium, and aluminum powders, followed by die pressing and sintering to create a rod feedstock with a specific composition and cross-sectional profile, which is then used in additive manufacturing machines to produce high-strength titanium components, eliminating the need for thermomechanical processing and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing rod feedstocks are used for titanium alloy additive manufacturing, then the manufacturing cost is reduced, but the tensile strength and fatigue strength are reduced compared to wrought processed materials
Solution Approach 1:
The patent applies parameter changes by controlling the chemical composition parameters of the powder blend (specific ratios of titanium, aluminum, vanadium, and iron) and processing parameters (sintering temperature range of 900-1600°F, vacuum conditions) to produce rod feedstock that achieves both cost-effectiveness and high strength properties, resolving the contradiction between manufacturing cost and mechanical strength
Solution Approach 2:
The patent uses composite materials by creating a multi-element alloy system (titanium-aluminum-vanadium-iron) through powder blending and sintering, where the combination of different metal powders produces a composite rod feedstock that achieves superior mechanical properties comparable to wrought materials while maintaining additive manufacturing cost benefits
2Device complexity
If conventional melt metallurgy is used to produce titanium alloys, then the production process is simplified, but segregation and macro segregation occur reducing material quality
Solution Approach 1:
The patent applies preliminary action by pre-mixing the powdered metals in precise proportions before sintering, and by controlling the sintering process to achieve homogeneous composition before the additive manufacturing process begins, preventing segregation issues that would otherwise occur during subsequent processing
Solution Approach 2:
The patent replaces conventional melt metallurgy (thermal processing) with a powder metallurgy approach using sintering at lower temperatures (900-1600°F), substituting the melting mechanism with a solid-state diffusion process that avoids macro segregation while maintaining compositional uniformity
3Adaptability or versatility
If powder bed additive manufacturing techniques are used for titanium alloy components, then the manufacturing flexibility is improved, but the technique is unsuited for producing large parts
Solution Approach 1:
The patent applies universality by developing rod feedstock that can be used in rod deposition additive manufacturing processes, which are specifically suited for large part production, while maintaining the flexibility and adaptability benefits of powder-based additive manufacturing through controlled composition and processing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces titanium components with enhanced tensile and fatigue strength at reduced costs, overcoming segregation issues and macro segregation in conventional melt metallurgy, while maintaining structural capabilities for aerospace applications.
Implementation Method 1
sintering the die pressed powder blend to form a rod feedstock
Data Source
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AI summary
A method of forming a rod feedstock for titanium stir friction welding additive manufacturing may comprise: mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend; at least one of die pressing the powder blend to form a die pressed powder or continuously powder rolling the powder blend to form a die pressed powder; and sintering the powder blend to form a rod feedstock having a cross-sectional profile.