Titanium Alloy Wire Drawing With Induction Heating and Acoustic Control
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Solution Overview
Problem
Current methods for producing titanium alloy wires for additive manufacturing face challenges such as mechanical anisotropy, high energy consumption, and the inability to produce long, defect-free wires with enhanced mechanical properties, particularly for BT6 titanium alloy, which limits their application in aerospace and other structural components.
Innovation Solution
A method involving induction heating and precise control of temperature and acoustic emission parameters during drawing or rolling, with specific power and frequency settings for different diameters, to achieve uniform temperature distribution and minimize deformation-induced defects, resulting in a wire with reduced mechanical anisotropy and improved strength and ductility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple heat treatment and multi-pass deformation processes are used, then the mechanical properties of the wire are improved, but the production complexity and energy consumption increase, and the wire length is limited
Solution Approach 1:
The patent combines multiple heat treatment operations and multi-pass deformation processes into a single integrated processing step. By performing hot deformation at elevated temperatures (400-700°C) with controlled cooling rates, the method achieves both microstructure refinement and mechanical property enhancement without requiring separate annealing or heat treatment stages, thereby reducing process complexity while maintaining improved strength and ductility
Solution Approach 2:
The patent utilizes parameter changes by controlling the deformation temperature within the range of 400-700°C and adjusting cooling rates to achieve optimal mechanical properties. By varying these parameters during a single processing operation, the method produces wire with enhanced strength and ductility, eliminating the need for multiple discrete heat treatment steps
2Productivity
If traditional heating and multi-pass deformation methods are used, then the wire can be produced, but energy consumption is high and mechanical anisotropy occurs
Solution Approach 1:
The patent implements continuous hot deformation processing where the wire is deformed at elevated temperatures (400-700°C) in a single continuous operation without intermediate cooling or reheating cycles. This continuous processing approach maintains thermal energy throughout the deformation sequence, reducing total energy consumption compared to traditional methods that require repeated heating and cooling between passes
3Manufacturing precision
If conventional drawing methods are used, then wire production is achieved, but mechanical anisotropy and structural inhomogeneity occur along the wire length
Solution Approach 1:
The patent applies local quality control by implementing specific deformation ratios for different passes during hot deformation. Each pass is designed with optimized reduction percentages to ensure uniform microstructure development throughout the wire cross-section and length. The controlled cooling rate further ensures uniform phase transformation, eliminating mechanical anisotropy and structural inhomogeneity that occur in conventional drawing methods
4Reliability
If the wire length is increased to at least 8500 m without weld joints, then the quality for additive manufacturing is improved, but the risk of breaking during manufacture increases
Solution Approach 1:
The patent utilizes parameter changes by controlling deformation temperature (400-700°C) and cooling rates to optimize the microstructure and mechanical properties of the wire. These parameter adjustments enhance the wire's ductility and strength simultaneously, enabling production of extremely long wires (≥8500 m) without weld joints while maintaining integrity during the manufacturing process
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 enables the production of BT6 titanium alloy wires with enhanced mechanical properties and reduced defects, achieving a length of at least 8500 meters without weld joints, thereby improving the quality and efficiency of the manufacturing process.
Implementation Method 1
heating the blank and draw dies (Tz) to a temperature Tz = (400-700)°C... the blank is heated with an induction method using one, two or three induction heating devices
Implementation Method 2
process parameter control using temperature and acoustic emission... control of the wire deformation ratio during drawing or rolling based on acoustic emission energy
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to methods of pressure shaping titanium alloys, when producing wire from (α+β)-titanium alloy for additive manufacturing. The object of the invention is to improve the quality of (α+β)-titanium alloy wire for additive manufacturing and reduce the production cost thereof. The technical result is the reduction of mechanical anisotropy along the length of the wire in a single piece without weld joints, with a length of at least 8500 m, for additive manufacturing. The technical result is achieved by a method, which comprises the deformation of a blank by drawing or rolling in several passes, heating of the blank is carried out using an induction method, deformation of the blank is carried out by drawing or rolling while heating the blank and draw dies (Tz) to a temperature Tz = (400-700) °C, while controlling the deformation temperature tolerance band, which is equal to ±10 °C, with the deformation ratio of the blank µ = (10-50) % in one pass, which is determined using the formula: µ = (d2i-d2(i+1))/d2i × 100, where di and d(i+1) are the wire diameters before and after deformation at the i-th pass, respectively, while controlling the deformation ratio based on the energy parameter of acoustic emission (N) at each pass depending on the diameter (d) and deformation speed (V): V = (10-20) m/min for diameter d = (from 8.0 to 5.5) mm, and for (N) not more than 0.04 × 10-3 mV2/s, V = (20-40) m/min for diameter d = (from less than 5.5 to 2.5) mm, and for (N) not more than 0.03 × 10-3 mV2/s, V = (40-60) m/min for diameter d = (from less than 2.5 to 1.6) mm, and for (N) not more than 0.02 × 10-3 mV2/s. Also, titanium alloy wire is made, comprising, wt %: aluminium 5.50-6.76, vanadium 3.50-4.40, iron ≤ 0.22, carbon ≤ 0.05, oxygen 0.14-0.18, nitrogen ≤ 0.03, hydrogen ≤ 0.015 and titanium - the balance, the wire has a diameter tolerance of -0.05/+0.01 mm.