Continuous Extrusion of Titanium Wire
from Powder Feeds
Robert Wilson
David Ritchie |Delphine Cantin |Daniel East|
December 2013
FUTURE MANUFACTURING
Continuous extrusion process:
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
Goal: Continuous mass production process for titanium
rod/wire forming from powder-based titanium feed that is
competitive against existing processes
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
Goal: Continuous mass production process for titanium
rod/wire forming from powder-based titanium feed that is
competitive against existing processes
Advantages: Reduction in processing steps, conversion of
titanium particulate and powder feeds (including recycled
feed) into rod or wire, can tailor product composition
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
•
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
Goal: Continuous mass production process for titanium
rod/wire forming from powder-based titanium feed that is
competitive against existing processes
Advantages: Reduction in processing steps, conversion of
titanium particulate and powder feeds (including recycled
feed) into rod or wire, can tailor product composition
Applications: Potential for weld wire (e.g., aerospace Additive
Manufacturing), custom wire compositions and fastener
applications (rod forms ~ 10% mill product volume)
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
•
•
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
Goal: Continuous mass production process for titanium
rod/wire forming from powder-based titanium feed that is
competitive against existing processes
Advantages: Reduction in processing steps, conversion of
titanium particulate and powder feeds (including recycled
feed) into rod or wire, can tailor product composition
Applications: Potential for weld wire (e.g., aerospace Additive
Manufacturing), custom wire compositions and fastener
applications (rod forms ~ 10% mill product volume)
Achievements: One of the first to continuously extrude Ti of
12, 9, 6 mm f from powder (P2W) and wrought to wrought.
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Continuous extrusion process:
•
•
•
•
•
•
•
Continuous Ti extrusion process based on a modified rotary
extruder, or Conform Extruder: process unique
Patent filed March 2012
Goal: Continuous mass production process for titanium
rod/wire forming from powder-based titanium feed that is
competitive against existing processes
Advantages: Reduction in processing steps, conversion of
titanium particulate and powder feeds (including recycled
feed) into rod or wire, can tailor product composition
Applications: Potential for weld wire (e.g., aerospace Additive
Manufacturing), custom wire compositions and fastener
applications (rod forms ~ 10% mill product volume)
Achievements: One of the first to continuously extrude Ti of
12, 9, 6 mm f from powder (P2W) and wrought to wrought.
6mm f BE Ti64 from powder swagable to 3 mm f
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 2
Objectives
Developing a Continuous Extrusion Process for Ti Alloy Wire From Powder
Continuous mass production of “long forms” from Ti particulate and powder feeds (P2W)
and rod (wrought to wrought; W2W), which are currently not mass produced from
powders or particulates and current forming methods are costly and have low yields.
Process advantages include:
•
•
•
Lower cost, higher yields
Large volume production
Reduction in processing steps
•
•
Conversion of Ti particulate & powder feeds into rod/wire in a single step
Tailored wire compositions for niche applications such as additive manufacturing
For Additive Manufacturing Applications
•
•
•
Economics – lower cost, meet requirements for remelting spooling/unspooling
Markets – allows custom blends for e-beam processes (e.g., Ti74)
Niche market alloys
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 3
Intended impact of program
To reduce number of forming and surface conditioning steps to economically
produce Ti rod and wire on a high-volume and continuous basis from titanium
powder feeds
Current Ti wire & rod applications are cost-limited to niche applications; aim is
to lower cost for current applications and expand into new areas
• ~10x price reduction of Ti to compete for price with stainless steel
• Target production rates from CSIRO extruder 0.30-1.45 ktonne/yr of rod/wire
• Scaling up feeding capacity to allow 10-20 kg wire lots, currently at feeding
limit
• Requires improving tooling life to ~100 kg product per tooling set for
economics
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 4
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
Particulate or Powder
feedstock
Coining roll
Clamping Force
Extrusion Shoe
Rod feed
Shoe
Inserts
Extrusion
Die Insert
Extrudate
Grooved
Extrusion
Wheel
Abutment
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
 CP Ti wires have been produced from
flowing pelletised powders and cold
isostatically pressed (CIPed) powders and
wrought to wrought
Particulate or Powder
feedstock
Coining roll
Clamping Force
Extrusion Shoe
Rod feed
Shoe
Inserts
Extrusion
Die Insert
Extrudate
Grooved
Extrusion
Wheel
Abutment
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
 CP Ti wires have been produced from
flowing powders, pelletised powders and
cold isostatically pressed (CIPed) powders
and wrought to wrought
 Blended elemental (BE) Ti-6Al-4V alloy has
been extruded, CP Ti matrix is retained
during extrusion
Particulate or Powder
feedstock
Coining roll
Clamping Force
Extrusion Shoe
Rod feed
Shoe
Inserts
Extrusion
Die Insert
Extrudate
Grooved
Extrusion
Wheel
Abutment
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
 CP Ti wires have been produced from
flowing powders, pelletised powders and
cold isostatically pressed (CIPed) powders
and wrought to wrought
 Blended elemental (BE) Ti-6Al-4V alloy has
been extruded, CP Ti matrix is retained
during extrusion
 Process limit: flash gap-extrusion outletmachine stiffness.
Particulate or Powder
feedstock
Coining roll
Clamping Force
Extrusion Shoe
Rod feed
Shoe
Inserts
Extrusion
Die Insert
Extrudate
Grooved
Extrusion
Wheel
Abutment
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
 CP Ti wires have been produced from
flowing powders, pelletised powders and
cold isostatically pressed (CIPed) powders
and wrought to wrought
 Blended elemental (BE) Ti-6Al-4V alloy has
been extruded, CP Ti matrix is retained
during extrusion
 Process limit: flash gap-extrusion outletmachine stiffness.
 Further drawing of extruded wire possible
to obtain smaller diameter wire: proven
swagable to 3 mm f
Particulate or Powder
feedstock
Coining roll
Clamping Force
Extrusion Shoe
Rod feed
Shoe
Inserts
Extrusion
Die Insert
Extrudate
Grooved
Extrusion
Wheel
Abutment
The process schematic
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Continuous extrusion capability
 BWE Conform rotary extruder modified
from Al/Cu configuration to allow
extrusion from Ti
Particulate or Powder
 CP Ti wires have been produced from
feedstock
flowing powders, pelletised powders and
Coining roll
cold isostatically pressed (CIPed) powders
Clamping Force
Extrusion Shoe
and wrought to wrought
Rod feed
Shoe
Inserts
 Blended elemental (BE) Ti-6Al-4V alloy has
been extruded, CP Ti matrix is retained
Extrusion
Die Insert
during extrusion
Extrudate
 Process limit: flash gap-extrusion outletGrooved
Extrusion
machine stiffness.
Abutment
Wheel
 Further drawing of extruded wire possible
to obtain smaller diameter wire: proven
swagable to 3 mm f
 Tensile properties of the extruded product
are equivalent to properties of the powder
The process schematic
feed grade (slightly stronger, elongations
equivalent)
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 5
Techno-economics
 Wire/rod conversion cost ~1.2 to 1.25 times typical CP powder price;
~1.5 times sponge granule (if realisable).
– Cost & price advantage for alloy wire using BE approach.
Rod Diameter (mm)
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
394
CP Ti
BE Ti-64
PA Ti-64
2010-2011 Spot CP2
2010-2011 Spot Ti-64
294
160
140
120
244
100
194
80
144
60
94
40
44
0
200
400
600
800
1000
Output (Tonnes per year)
1200
Selling Price (US$/lb)
Selling Price (A$/kg)
344
20
1400
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 6
Techno-economics
 Wire/rod conversion cost ~1.2 to 1.25 times typical CP powder price;
~1.5 times sponge granule (if realisable).
– Cost & price advantage for alloy wire using BE approach.
Rod Diameter (mm)
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
394
CP Ti
BE Ti-64
PA Ti-64
2010-2011 Spot CP2
2010-2011 Spot Ti-64
140
120
244
100
194
80
144
60
94
40
44
20
1400
0
200
400
600
800
1000
Output (Tonnes per year)
1200
30000
25000
Price/kg (US$)
294
160
Selling Price (US$/lb)
Selling Price (A$/kg)
344
– Price competitiveness greater at smaller
diameters (<1mm). Technical target f 3mm.
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 6
Grade 1/2
20000
Grade 5
15000
10000
5000
0
0
1
2
3
Diameter (mm)
4
5
Extrusion of CP Ti (Powder to Wire: P2W)
100 mm
ConX Ti gr. 3 rod (CIPped
feed) 99.9% TD
ConX CP Ti gr. 3 (mill anneal)
99.9% TD
0
1’
1m
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 7
ConX CP Ti gr.3 (flowing powder)
(99.86% TD)
Extrusion of CP Ti (from rod)
W2W
100 mm
100 mm
Commercial CP Ti gr.2 rod
100% TD
ConX CP Ti gr. 2
100% TD
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 8
Tensile properties of CP Ti from powder and rod
Run
Processing
Oxygen
[wt%]
Yield
[MPa]
0.2% Proof
[MPa]
UTS
[MPa]
Ef [%]
ER
Preheat
[°C]
6mm
4.0
1100
0.25
354±40
489±10
647±9
23.5±1.3
9mm
1.8
1100
0.35
390±107
528±79
681±23
12.8±6.6
448
18
G3 Generic
Extrusion
Description
379
Oxygen [wt%] 0.2% Proof [MPa] UTS [MPa]
Ef [%]
Feed
0.18-0.19
389.9±0.8
516.7±0.9
37.8±2.3
800°C
0.19-0.24
410.1±7.3
534.0±6.3
34.1±3.7
1000°C
0.21
411.0±6.7
518.9±5.2
34.7±1.1
1100°C
0.19-0.20
401.7±9.3
512.4±3.0
33.8±3.1
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 9
P2W
W2W (9mm)
Swaging of BE Ti-64 extrusion
• HT ConX wire swagable from 6mm to 3mm f,
grain refinement.
• As extruded breaks up after 3rd swage pass.
Al58V42
As extruded BE Ti-64 rod
Beta-phase field homogenisation
anneal BE Ti-64
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 10
ConX HT Swage pass 4 (3mm f)
Summary
•
Target is to produce niche composition wire on demand & commercial alloy
wire that is cost competitive
•
CP Ti extrudable to 6mm f from powder (P2W) and wrought bar feed (W2W)
•
CP tensile properties at least equivalent to conventionally extruded material
•
BE Ti64 extrudable to 6mm f from BE mixtures and subsequent
homogenisation anneals. Can be swaged to 3mm f
•
Scaling up feeding capacity to allow 10-20 kg wire lots
•
Requires improving tooling life to ~100 kg product per
tooling set
International Titanium Powder Processing, Consolidation and Metallurgy Conference| Robert Wilson| Page 11
Thank you
Dr. Robert Wilson
Ph:
Email:
Web:
+61 3 9545 2840
[email protected]
www.csiro.au