Titanium Rod Feedstock Composition for High-Strength Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
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 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
1Strength
If existing rod feedstocks are used for titanium additive manufacturing, then production cost is reduced, but tensile strength and fatigue strength are reduced compared to wrought processed materials
Solution Approach 1:
The invention changes the chemical composition parameters of the titanium alloy powder blend, specifically controlling Fe (4-6%), V (6-9%), and Al (0.5-2%) content, to achieve superior mechanical properties in the additive manufactured components while maintaining cost-effectiveness
Solution Approach 2:
The invention uses a composite powder blend containing multiple metallic elements (Ti, Fe, V, Al) that work synergistically to enhance the mechanical properties of the final component, with Fe and V providing strength and Al contributing to microstructure control
2Adaptability or versatility
If powder bed additive manufacturing is used for titanium alloy components, then manufacturing flexibility is improved, but the process is unsuited for producing large parts
Solution Approach 1:
The invention segments the manufacturing process by using rod feedstock deposition that can be continuously fed into the build chamber, allowing large parts to be constructed by depositing material in sequential layers without requiring the entire part to fit in the powder bed at once
Solution Approach 2:
The invention transitions from two-dimensional powder bed deposition to three-dimensional rod feedstock deposition, enabling the construction of large-volume parts by adding material in a continuous extrusion process that extends beyond the limitations of powder bed dimensions
3Productivity
If conventional melt metallurgy is used, then production speed is improved, but segregation issues and macro segregation problems occur
Solution Approach 1:
The invention performs preliminary mixing of the powder blend with precisely controlled compositional ratios before deposition, ensuring uniform distribution of alloying elements throughout the rod feedstock, which prevents segregation during the additive manufacturing process
Solution Approach 2:
The invention replaces the thermal field of conventional melt metallurgy with a solid-state deposition process, using controlled material feed and deposition mechanics to build parts without melting, thereby eliminating segregation issues inherent in liquid-phase 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 a lower cost, overcoming segregation issues and macro segregation problems encountered 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 having a cross-sectional profile
Data Source
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.