Titanium Alloy Composition for Additive Manufacturing

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Solution Overview

Problem

Conventional titanium alloy compositions used in additive manufacturing often result in additively manufactured components with anisotropic material properties due to columnar microstructures, which can be undesirable for certain performance requirements.

Innovation Solution

The development of titanium-based alloy compositions that consist essentially of specific weight percentages of aluminum, vanadium, cobalt, a metallic solute including tin, chromium, iron, copper, and nickel, and titanium, which are optimized to produce equiaxed microstructures and preferred α+β phase structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional titanium alloy compositions are used in additive manufacturing, then the manufacturing process can be completed, but the resulting components exhibit anisotropic material properties due to columnar microstructures

Engineering Contradiction:

Improveadditive manufacturing processabilityVSAvoidisotropic material properties

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by modifying the chemical composition parameters of the titanium alloy, specifically controlling the content of aluminum (4-6.5 wt%), vanadium (1.5-4.5 wt%), cobalt (1.3-2.1 wt%), and metallic solutes (at most 4.5 wt% selected from tin, chromium, iron, copper, and nickel). These compositional parameter changes are designed to alter the solidification behavior and microstructure formation during additive manufacturing, transforming the microstructure from columnar to equiaxed morphology, thereby achieving isotropic material properties while maintaining manufacturing processability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite alloy system by combining titanium with specific amounts of aluminum, vanadium, cobalt, and metallic solutes. This composite material approach leverages the synergistic effects of different elements: aluminum provides solid solution strengthening, vanadium and cobalt contribute to phase stability and microstructure control, and the metallic solutes further refine the equiaxed microstructure. The resulting composite titanium alloy achieves both manufacturability and isotropic properties through the combined effects of its constituent elements

Inventive Principle:

Principle #40Composite materials

2Productivity

If conventional titanium alloy compositions are used in additive manufacturing, then components can be produced, but voids from solidification shrinkage are formed

Engineering Contradiction:

Improvecomponent production capabilityVSAvoidvoid reduction

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent modifies the compositional parameters to control solidification characteristics. By adjusting the alloying elements content, particularly the combination of aluminum, vanadium, cobalt, and metallic solutes, the solidification temperature range and shrinkage behavior are optimized. This parameter optimization reduces solidification shrinkage voids while maintaining efficient component production through additive manufacturing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potentially harmful effect of solidification shrinkage into a beneficial outcome by carefully designing the alloy composition to minimize void formation. The specific compositional parameters are selected to promote complete solidification with minimal shrinkage, transforming what would normally be a defect-prone process into a reliable manufacturing method that produces high-integrity components

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 optimized titanium-based alloy compositions lead to additively manufactured components with isotropic microstructures, reduced voids from solidification shrinkage, and improved material properties, addressing the anisotropic issues of conventional compositions.

Implementation Method 1

during additive manufacturing, metallic materials may exhibit the nucleation and growth of columnar microstructures along a direction that is perpendicular to planes within which the various layers are defined

Methodology Applied

Scientific EffectSolidification: Crystallisation

Implementation Method 2

reduced voids from solidification shrinkage

Methodology Applied

Scientific EffectSolidification shrinkage: Crystallisation

Data Source

PatentUS20250129452A1Titanium-based alloy compositions, additively manufactured components that include the compositions, additive manufacturing systems that utilize the compositions, and methods of additively manufacturing additively manufactured components

Publication Date: 2025.04.24 THE BOEING CO

AI summary

Titanium-based alloy compositions, additively manufactured components that include the compositions, additive manufacturing systems that utilize the compositions, and methods of additively manufacturing additively manufactured components are disclosed herein. The compositions comprising at least 4 weight percent (wt %) and at most 6.5 wt % aluminum, at least 1.5 wt % and at most 4.5 wt % vanadium, at least 1.3 wt % and at most 2.1 wt % cobalt, metallic solutes, and titanium. The composition includes at most 4.5 wt % of the metallic solute, which includes at least two of tin, chromium, iron, copper, and nickel.