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Titanium 2015 Orlando FL, USA 1
RECENT DEVELOPMENTS IN MELTING TECHNOLOGIES FOR TITANIUM ALLOYS
Stephen FoxTIMET
Overview
Expansion in melting capacity Cold hearth meltingVacuum arc meltingPowder and Additive ProcessesClosing comments
Titanium 2015 Orlando FL, USA 2
Expansion Drivers - Cost
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Ingot production up 30% since 2005Global revert incorporation rates up significantlyDramatic increase in installed capacity capable of recycling
Source: Andy Bayne. International Titanium Association. Industry Supply Trends. Titanium Revert in 2015, September 2014, Chicago Illinois
Melting of Recycled Titanium
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EB Facility (prior to 2005)
EB Facility with expansion after 2005EB Facility Installed/announced after 2005
PAM Facility with expansion after 2005PAM Facility Installed/announced after 2005 PAM Facility with expansion after 2005Skull Melt Facility (prior to 2005)Skull Melt Facility Installed/announced after 2005
Multiple Public domain sources
Overview
Expansion in melting capacity Cold hearth melting technologyVacuum arc meltingPowder and Additive processesClosing comments
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EB Melting
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VDM Metal Electron Beam Cold Hearth Melting FacilitySource: J. Kiese, International Titanium Association, Titanium Europe, Birmingham, May 13, 2015
http://www.perrymanco.com/capabilities/melting
Skull Melting
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Source: Matteo G. Ricci and Giampiero Santin, “Skull Melting Plant – A Stand Alone Facility for Melting of Titanium and Zirconium” Heat Processing (7) Issue 4, 2009.
Nearer to Shape Casting
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EB Hollow CastingPatented, proprietary process Semi continuous near to shapeHeavy wall hollow ingot
ProductsHollow forging input stockSeamless Rings Extrusions
ApplicationsEnergy – Down hole tubulars, risers, stress jointsIndustrial – large seamless rings
Solidification of EB Ingot
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True 3D problem• Asymmetric metal flow from inlet• Buoyancy driven flows• Momentum• Marangoni effects
Top surface boundary conditions• Cooling to the environment• Electron beam heat input• Evaporation
Side wall Boundary Conditions• Contact and cooling to the mold• Cooling to environment below mold
Solidification of EB Ingot
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Predicted Temperatures during transient solidification stage of validation test ingot
Markers added during transient
Metal InletPredicted Molten pool profile at end of steady state period. Note asymmetry
Model correctly predicts asymmetry of the pool, chemistry and last metal to solidify.
Overview
Expansion in melting capacity Cold hearth meltingVacuum arc meltingPowder and Additive ProcessesClosing comments
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Segregation in hypothetical VAR
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Current Status• Simulation of actual melt data• Assembly of multiple
electrodes• Chemistry prediction• Melt profile development• Post melt process review and
disposition
Potential Future Developments• Integrating with look ahead
control systems• Real time simulation as part
of the quality record• Integration with “through
process” simulation
Dissolution of high nitrogen particles
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• Particles close in density couple with liquid• Residence time depends upon track• High nitrogen feature will grow in size initially• Dissolution controlled by diffusion of nitrogen
0
2
4
6
8
10
0 50 100 150 200 250 300
Size
(mm
)Time(s)
5 mm particle1 mm particle0.5 mm particle
0.5
0.55
0.6
0 5 10
Overview
Expansion in melting capacity Cold hearth meltingVacuum arc meltingPowder and Additive ProcessesClosing comments
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Challenges - Transient Processes
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Gas Atomization - Electrode Induction Gas Atomization
Plasma Rotating Electrode Process
AP&C Plasma Gas Atomization • Rapid Heat input
• Complex and Rapid Heat Transfer• Surface dominated effects• Gas entrapment• Satellites• Shapes• Shrinkage• Size Distribution
AP& C
ALD
Challenges - Transient Processes
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Diverse Processes• Range of Scales• Range of heat sources• Range of heat input• Range of feedstock
Increased Data Fidelity• Physical properties for
liquid and solid• Mechanical properties• Interfacial reactions• Solidification paths
PTA EB-Wire Feed Laser Freeform EB powder bed
Model Outputs• Microstructure• Chemistry• Stresses• Shrinkage
Laser pwder Bed
AIM Challenge: Predict property variation from process data to speed up qualification
Sciaky RPM Innovations ARCAM SiemensWarwick Manufacturing Group
Closing Comments
Melting Capacity has expandedRecycling through cold hearth and skull melt processesComputational methods increasingly important. Challenges for the future
Integrating accurate process informationAccurate prediction of critical structure Rapid and transient events associated with powder and additive processes
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