Titanium Rod Feedstock for Lower-Cost High-Strength Additive Manufacturing
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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 isostatic pressing and sintering to create a billet, which is then cut into a rod feedstock with a specific cross-sectional profile for use in additive manufacturing, eliminating the need for thermomechanical processing and reducing material costs while maintaining structural integrity.
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 sintering temperature range (900-1600°F or 482-871°C) and vacuum conditions during sintering to achieve optimal density and mechanical properties. The isostatic pressing parameters are also controlled to achieve the desired rod feedstock density (less than 100% of wrought alloy density) while maintaining strength. These parameter optimizations resolve the contradiction between cost reduction and strength maintenance.
Solution Approach 2:
The patent uses composite materials by creating a sintered rod feedstock from a specific composition of titanium hydride powder (4-6% Fe, 0.5-2% Al, 6-9% V). This composite powder blend, when sintered, produces a rod feedstock that achieves the required mechanical properties at lower cost compared to traditional wrought materials, resolving the contradiction between manufacturing cost and strength.
2Adaptability or versatility
If powder bed additive manufacturing techniques are used for titanium alloy components, then manufacturing flexibility is improved, but the technique is unsuited for producing large parts like landing gear
Solution Approach 1:
The patent applies segmentation by dividing the additive manufacturing process into two distinct parts: (1) manufacturing rod feedstock through isostatic pressing and sintering of powder blends, and (2) using rod deposition for additive manufacturing of large parts. This segmentation allows the process to overcome the size limitations of powder bed techniques while maintaining flexibility through the rod deposition approach.
Solution Approach 2:
The patent introduces rod feedstock as an intermediary material that bridges the gap between powder-based manufacturing and large part production. The rod feedstock, created through isostatic pressing and sintering, serves as a mediator that enables rod deposition additive manufacturing, allowing large parts like landing gear to be manufactured with the flexibility and adaptability needed for complex geometries.
3Ease of manufacture
If rod feedstock density is reduced to less than 100% of wrought alloy density, then material costs are reduced, but manufacturing precision may be affected
Solution Approach 1:
The patent applies parameter changes by precisely controlling the sintering temperature (900-1600°F or 482-871°C) and vacuum conditions to achieve the target density range. The isostatic pressing parameters are also optimized to achieve consistent density control. These controlled parameter changes allow the manufacturer to produce rod feedstock with density less than 100% of wrought alloy density while maintaining manufacturing precision and consistent quality.
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
This method produces high-strength titanium alloy components at a lower cost, overcoming segregation issues and enhancing fatigue and ultimate strength, suitable for large aerospace parts like landing gear components.
Implementation Method 1
isostatic pressing the powder blend to form a billet having a cross-sectional profile
Implementation Method 2
sintering the powder blend after the isostatic pressing, wherein the sintering is performed between 900 °F (482 °C) and 1600 °F (871 °C) and under a vacuum
Implementation Method 3
an article of manufacture including a metallic component additively manufactured from a rod feedstock by a stir friction welding additive manufacturing machine
Data Source
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Figure 2B
AI summary
A method of titanium rod additive manufacturing may comprise: mixing a plurality of powdered metals (202) comprising titanium, iron, vanadium, and aluminum to produce a powder blend (204); isostatic pressing the powder blend (204) to form a billet (212) having a crosssectional profile (214); cutting the billet (212) to form a rod feedstock having the first crosssectional profile (214); loading the rod feedstock into an additive manufacturing machine (242) configured to deposit the rod feedstock; and producing a metallic component from the rod feedstock.