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Metallurgical and Materials Transactions A

, Volume 44, Issue 2, pp 899–910 | Cite as

Optimization of Blended-Elemental Powder-Based Titanium Alloy Extrusions for Aerospace Applications

  • Sami M. El-Soudani
  • Kuang-O. Yu
  • Ernie M. Crist
  • Fusheng Sun
  • Michael B. Campbell
  • Tony S. Esposito
  • Joshua J. Phillips
  • Vladimir Moxson
  • Vlad A. Duz
Article

Abstract

The process of canless extrusion in ambient environment, using cold isostatic pressed, and vacuum-sintered, direct-consolidated blended-elemental hydrided ADMA titanium powder, mixed with master alloy powder for the Ti-6Al-4V composition, has been successfully demonstrated. However, these initially processed unoptimized powder-based extrusions also exhibited oxygen content of about 3000 ppm, within the ASTM B817 Standard, but exceeding the AMS Specification 4935 maximum limit of 2000 ppm, and with pre-extrusion residual hydrogen within 300–500 ppm resulting in post-extrusion void nucleation aligned with the extrusion direction. Additional optimization of extrusion billets during the CIP-and-sintering steps has been successfully demonstrated reducing both oxygen and hydrogen contents to levels at or below the AMS Specification limits for Ti-6Al-4V composition (oxygen content of 2000 ppm maximum, and hydrogen content of 125 ppm maximum). Processing-microstructure-property correlations of the optimized, AMS-4935-Specification-conformant, Ti-6Al-4V blended-elemental powder-based product form exhibited an overall mechanical property balance matching that of double-arc-remelted ingot-based extrusions. Property matching was not only in terms of static mechanical properties (room-temperature tensile properties, and monotonic fracture toughness K IC (K Q) values), but also in terms of dynamic fatigue properties (combined S/N plus da/dN properties), as well as stress-corrosion resistance, as measured in terms of K ISCC threshold values.

Keywords

Fatigue Crack Growth Rate Titanium Hydride Cold Isostatic Pressing Beta Transus Titanium Hydride Powder 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.

Notes

Acknowledgments

This Development Program was supported by Independent Research and Development (IR&D) activities undertaken by a team led by The Boeing Company including several Boeing Suppliers with The Boeing Company providing: Program Management and Direction, besides IR&D support covering the fabrication of extrusion billets at ADMA Products, Inc., as well as conducting all processing-microstructure-property testing and characterizations of extruded products over a four-year period, in addition to extrusion processing at Plymouth Engineered Shapes, Inc. RTI International Metals, Inc. conducted the initial workability studies on powder-based and ingot-based materials, besides performing the extrusion trials at their Houston Facility, and further contributed the ingot-based double-arc-remelted Ti-6Al-4V extrusion billet for this Program. The authors also wish to thank Dr. Vladislav Telin, Director General of ZTMC (Zaporozhye Titanium-Magnesium Company—in Ukraine) for his help with timely deliveries of the three ZTMC lots of hydrided titanium sponge fines to ADMA Products, Inc., and in sufficient quantities for ADMA’s blended-elemental powder-based Ti-6Al-4V billet fabrication for this investigation. Also the diligent efforts by test engineers and managers at the Westmoreland Mechanical Testing and Research Laboratory., WMT&R, especially by Douglass Bruce, Thomas Fedor, Gerald Boice, and James Becthold are to be gratefully acknowledged.

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Copyright information

© The Minerals, Metals & Materials Society and ASM International 2012

Authors and Affiliations

  • Sami M. El-Soudani
    • 1
  • Kuang-O. Yu
    • 2
  • Ernie M. Crist
    • 2
  • Fusheng Sun
    • 2
  • Michael B. Campbell
    • 3
  • Tony S. Esposito
    • 3
  • Joshua J. Phillips
    • 3
  • Vladimir Moxson
    • 4
  • Vlad A. Duz
    • 4
  1. 1.The Boeing CompanyHuntington BeachUSA
  2. 2.RTI International Metals, Inc.NilesUSA
  3. 3.Plymouth Engineered Shapes, Inc.HopkinsvilleUSA
  4. 4.Advance Materials, Inc.HudsonUSA

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