Titanium Alloy Rod Feedstock for 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
1Strength
If existing rod feedstocks are used for titanium alloy additive manufacturing, then production cost is reduced, but 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 with optimized mechanical properties that achieve high strength comparable to wrought materials
Solution Approach 2:
The patent uses composite materials by creating a multi-element alloy system combining titanium with aluminum, vanadium, and iron in specific proportions. This composite powder blend, when sintered and processed into rod feedstock, produces a material with enhanced mechanical properties that overcomes the limitations of conventional titanium alloys
2Adaptability or versatility
If powder bed additive manufacturing is used for titanium alloy components, then manufacturing flexibility is improved, but large parts cannot be produced
Solution Approach 1:
The patent achieves universality by developing rod feedstock that can be used in multiple additive manufacturing processes including wire arc additive manufacturing and directed energy deposition. This rod-based feedstock system enables the production of large-scale titanium alloy parts while maintaining the flexibility and adaptability of additive manufacturing techniques
3Productivity
If rod feedstock density is reduced to enable additive manufacturing, then manufacturing capability is improved, but material density and structural integrity may be compromised
Solution Approach 1:
The patent applies parameter changes by controlling the sintering process parameters (temperature between 900-1600°F under vacuum) to achieve optimal density in the rod feedstock. This controlled densification process produces material with sufficient structural integrity for additive manufacturing while maintaining the manufacturability benefits of rod-based feedstock
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 approach 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
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.