Titanium Rod Feedstock Composition for Lower-Cost High-Strength 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 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 (900°F to 1600°F or 482°C to 871°C) and vacuum conditions during sintering to achieve optimal density and mechanical properties. By adjusting these parameters, the rod feedstock achieves tensile and fatigue strength comparable to wrought materials while maintaining cost-effectiveness through powder metallurgy processes.
Solution Approach 2:
The patent uses composite materials by creating a titanium alloy powder blend containing titanium (91-96 wt%), aluminum (0.5-2 wt%), vanadium (6-9 wt%), and iron (4-6 wt%). This specific composite composition, when properly sintered, achieves mechanical properties equivalent to wrought titanium alloys while enabling cost-effective rod feedstock production for additive manufacturing.
2Volume of moving object
If powder based additive manufacturing techniques are used, then large structural components can be manufactured, but the technique is unsuited for producing large parts compared to rod deposition
Solution Approach 1:
The patent applies parameter changes by producing rod feedstock with controlled density (less than 100% of wrought alloy density) through sintering processes. This parameter optimization enables the rod feedstock to be suitable for rod deposition additive manufacturing of large parts, overcoming the limitations of powder bed techniques for large-scale production.
3Productivity
If rod feedstock density is reduced to less than 100% of wrought alloy density, then the additive manufacturing processability is improved, but the material composition deviates from standard specifications
Solution Approach 1:
The patent applies parameter changes by controlling the sintering temperature range (900°F to 1600°F) and holding time to achieve the desired density reduction while maintaining compositional stability. The vacuum sintering process prevents oxidation and maintains the intended alloy composition within specified tolerances despite the reduced density.
Solution Approach 2:
The patent uses an inert environment by performing sintering under vacuum conditions. This prevents oxidation and contamination of the titanium alloy powder during the sintering process, ensuring that the material composition remains conformant to specifications even though the density is reduced for better additive manufacturing processability.
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 enables the production of 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
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
Data Source
AI summary
A method of titanium rod additive manufacturing may comprise: mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend; isostatic pressing the powder blend to form a billet having a cross-sectional profile; cutting the billet to form a rod feedstock having the first cross-sectional profile; loading the rod feedstock into an additive manufacturing machine configured to deposit the rod feedstock; and producing a metallic component from the rod feedstock.