EP3445888A1 - Procédés améliorés de finition de produits extrudés en titane - Google Patents

Procédés améliorés de finition de produits extrudés en titane

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Publication number
EP3445888A1
EP3445888A1 EP17786791.8A EP17786791A EP3445888A1 EP 3445888 A1 EP3445888 A1 EP 3445888A1 EP 17786791 A EP17786791 A EP 17786791A EP 3445888 A1 EP3445888 A1 EP 3445888A1
Authority
EP
European Patent Office
Prior art keywords
temperature
rolling
shape workpiece
workpiece
beta transus
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP17786791.8A
Other languages
German (de)
English (en)
Other versions
EP3445888C0 (fr
EP3445888B1 (fr
EP3445888A4 (fr
Inventor
Adam Stroud
Dongjian Li
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Howmet Aerospace Inc
Original Assignee
Arconic Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arconic Inc filed Critical Arconic Inc
Publication of EP3445888A1 publication Critical patent/EP3445888A1/fr
Publication of EP3445888A4 publication Critical patent/EP3445888A4/fr
Application granted granted Critical
Publication of EP3445888C0 publication Critical patent/EP3445888C0/fr
Publication of EP3445888B1 publication Critical patent/EP3445888B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/08—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling structural sections, i.e. work of special cross-section, e.g. angle steel
    • B21B1/092—T-sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/002—Extruding materials of special alloys so far as the composition of the alloy requires or permits special extruding methods of sequences
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/32—Lubrication of metal being extruded or of dies, or the like, e.g. physical state of lubricant, location where lubricant is applied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C29/00—Cooling or heating work or parts of the extrusion press; Gas treatment of work
    • B21C29/003—Cooling or heating of work
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C14/00—Alloys based on titanium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/16—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of other metals or alloys based thereon
    • C22F1/18—High-melting or refractory metals or alloys based thereon
    • C22F1/183—High-melting or refractory metals or alloys based thereon of titanium or alloys based thereon

Definitions

  • Titanium alloys are known for their low density (60% of that of steel) and their high strength. Additionally, titanium alloys may have good corrosion resistance properties. Pure titanium has an alpha (hep) crystalline structure at room temperature.
  • the present patent application relates to an improved process for forming a shaped titanium workpiece via a process that couples hot extrusion and one or more rolling steps.
  • the new shaped workpieces may realize improved properties (e.g., improved strength; improved isotropic properties) as compared to conventional titanium materials.
  • a method of creating a titanium alloy workpiece may comprise (a) heating a cast ingot or wrought billet of a titanium alloy to a temperature above its beta transus temperature to yield a heated workpiece, (b) initiating extrusion of the heated workpiece while the heated workpiece is above the beta transus temperature, thereby generating an extruded near net shape workpiece, (c) cooling the extruded near net shape workpiece to a cooled temperature below the beta transus temperature, and (d) rolling the extruded near net shape workpiece one or more times at a rolling temperature to yield a final shape workpiece, wherein the rolling temperature is a temperature below an incipient melting temperature of the alloy and within 600°F (333°C) of the beta transus temperature.
  • the titanium alloy is an alpha-beta alloy, such as Ti-6A1-4V.
  • a thermal treatment such as an anneal (e.g., a stress relief anneal) and/or a heat treatment, may be used before or after any of the extrusion and/or rolling steps to facilitate production of the final shape workpiece.
  • the method may further comprise after the heating step (a), protecting a surface of the heated workpiece with a protectant before the initiating extrusion step (b).
  • the protectant may be a lubricant or parting agent, and in some embodiments the protectant may be removed before the rolling step (d).
  • the cooled temperature may be room temperature.
  • the method may further comprise, after the cooling step (c), cleaning / preparing the near net shape workpiece prior to the rolling step (d) to remove any protectant.
  • the rolling step (d) may further comprise rolling at a strain rate of from 0.1 s "1 to 100 s "1 .
  • the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 1% to 95%, thereby achieving the final shape workpiece.
  • the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 10% to 90%, thereby achieving the final shape workpiece.
  • the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 20%) to 85%), thereby achieving the final shape workpiece. In some embodiments, the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 30%) to 80%>, thereby achieving the final shape workpiece. In some embodiments, the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 40% to 75%, thereby achieving the final shape workpiece. In some embodiments, the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 50% to 70%, thereby achieving the final shape workpiece. In some embodiments, the rolling step may comprise uniformly reducing the near net shape workpiece by a relative reduction of from 55% to 65%, thereby achieving the final shape workpiece.
  • the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 1% to 95%, thereby achieving a final shape workpiece with the first section being reduced. In some embodiments, the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 10% to 90%, thereby achieving a final shape workpiece with the first section being reduced. In some embodiments, the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 20% to 85%, thereby achieving a final shape workpiece with the first section being reduced.
  • the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 30% to 80%, thereby achieving a final shape workpiece with the first section being reduced. In some embodiments, the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 40%) to 75%, thereby achieving a final shape workpiece with the first section being reduced. In some embodiments, the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 50% to 70%, thereby achieving a final shape workpiece with the first section being reduced. In some embodiments, the rolling step may comprise reducing a first section of the near net shape workpiece by a relative reduction of from 55% to 65%, thereby achieving a final shape workpiece with the first section being reduced.
  • the rolling step may further comprise reducing at least a second section (different than the first section) of the near net shape workpiece by a relative reduction of from 1% to 95% thereby achieving the final shape workpiece with at least the first and second sections being reduced. In some embodiments, the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 10% to 90% thereby achieving the final shape workpiece with at least the first and second sections being reduced. In some embodiments, the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 20% to 85% thereby achieving the final shape workpiece with at least the first and second sections being reduced.
  • the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 30% to 80% thereby achieving the final shape workpiece with at least the first and second sections being reduced. In some embodiments, the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 40% to 75% thereby achieving the final shape workpiece with at least the first and second sections being reduced. In some embodiments, the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 50% to 70% thereby achieving the final shape workpiece with at least the first and second sections being reduced. In some embodiments, the rolling step may further comprise reducing at least a second section of the near net shape workpiece by a relative reduction of from 55% to 65% thereby achieving the final shape workpiece with at least the first and second sections being reduced.
  • the rolling temperature may be a temperature above the beta transus temperature and below the incipient melting temperature. In some embodiments, the rolling temperature may be a temperature above the beta transus temperature and within 500°F (278°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature above the beta transus temperature and within 250°F (139°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature above the beta transus temperature and within 100°F (55.6°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature above the beta transus temperature and within 50°F (27.8°C) of the beta transus temperature.
  • the rolling temperature may be a temperature below the beta transus temperature and within 600°F (333°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature below the beta transus temperature and within 300°F (167°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature below the beta transus temperature and within 100°F (55.6°C) of the beta transus temperature. In some embodiments, the rolling temperature may be a temperature below the beta transus temperature and within 50°F (27.8°C) of the beta transus temperature.
  • the rolling temperature is a temperature of more than 600°F (333°C) below the beta transus temperature, the rolling step (d) further comprising limiting a per pass reduction of each rolling step to prevent cracking or development of internal metallurgical defects in the final shape workpiece.
  • a new final shaped workpiece realizes at least 3% higher strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body, where the referenced titanium alloy body has the same composition as the final shape workpiece, and is in the same temper as the final shape workpiece, but is in the form of a sheet, strip or plate (e.g., as per AMS 4911, ⁇ 3.3.1-3.3.2), depending on thickness of the final shape workpiece.
  • the final shape workpiece and the referenced titanium alloy body shall have the same final thickness, within acceptable commercial tolerances (e.g., AMS 2242).
  • AMS 2242 acceptable commercial tolerances
  • a new final shaped workpiece realizes at least 5% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 7% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 9% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body.
  • a new final shaped workpiece realizes at least 11% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 12% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 13% higher tensile yield strength (TYS and/or UTS) (L) as compared to a referenced titanium alloy body.
  • a new final shaped workpiece realizes at least 5% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 7% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 9% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body.
  • a new final shaped workpiece realizes at least 11% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 12% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body. In one embodiment, a new final shaped workpiece realizes at least 13% higher tensile yield strength (TYS and/or UTS) (LT) as compared to a referenced titanium alloy body.
  • a new final shaped workpiece realizes isotropic properties, wherein the tensile yield strength (TYS) in the LT direction is within 10 ksi of the tensile yield strength (TYS) in the L direction.
  • the TYS(LT) is within 8 ksi of the TYS(L).
  • the TYS(LT) is within 7 ksi of the TYS(L).
  • the TYS(LT) is within 6 ksi of the TYS(L).
  • the TYS(LT) is within 5 ksi of the TYS(L).
  • the TYS(LT) is within 4 ksi of the TYS(L). In one embodiment, the TYS(LT) is within 3 ksi of the TYS(L). Similar isotropic properties may also be realized relative to ultimate tensile strength (UTS).
  • a new final shaped workpiece may also realize good ductility.
  • a new final shaped workpiece realizes an elongation (L) of at least 6%>.
  • a new final shaped workpiece realizes an elongation (LT) of at least 6%>.
  • a new final shaped workpiece realizes an elongation (L) of at least 8%.
  • a new final shaped workpiece realizes an elongation (LT) of at least 8%.
  • a new final shaped workpiece realizes an elongation (L) of at least 10%.
  • a new final shaped workpiece realizes an elongation (LT) of at least 10%.
  • a new final shaped workpiece realizes an elongation (L) of at least 12%. In one embodiment, a new final shaped workpiece realizes an elongation (LT) of at least 12%). Any of the above elongations may be realized in both the L and LT directions.
  • the new processes described herein may give the final shape workpieces improved properties, which may have applicability in a variety of product applications.
  • the titanium alloy products may be used in an aerospace structural application.
  • the titanium alloy products may be formed into various components for use in the aerospace industry, such as floor beams, seat rails, and fuselage framing, among others.
  • Many potential benefits could be realized in such components due to the improved tensile properties, improved bearing, and improved resistance to the initiation and growth of fatigue cracks, among others. Improved combinations of such properties can result in enhanced reliability, for instance.
  • the titanium alloy workpieces may also be useful, for instance, in marine, automotive, and/or defense applications.
  • the near net shape workpiece may be produced via an extrusion process.
  • the near net shape workpiece may be a forged product, a shape cast product, or an additively manufactured product instead of an extruded product.
  • Titanium alloys are classified based on microstructures and chemistries into five classes: alpha, near-alpha, beta, near-beta and alpha-beta alloys.
  • Alpha or “alpha phase” refers to a hexagonal close-packed (hep) crystal structure.
  • Beta or “beta phase” refers to a body-centered cubic (bec) crystal structure.
  • Alpha alloys are titanium alloys that have essentially no beta phase and may not be strengthened by heat treatment.
  • Beta alloys are titanium alloys that retain the beta phase on initial cooling to room temperature, which may be heat treated and have high hardenability.
  • Near-beta alloys are titanium alloys that start out as beta alloys but may partially revert to have some alpha phase upon heating or cold working.
  • Near-alpha alloys are titanium alloys that form some limited beta phase on heating, but appear microstructurally similar to alpha alloys.
  • Alpha-beta alloys are titanium alloys that consist of alpha phase and some retained beta phase, the amount of beta phase retained being dependent on the composition of the alloys and/or the presence of beta stabilizers ⁇ e.g., V, Mo, Cr, Cu), the amount of beta phase being more than what is found in near-alpha alloys.
  • Alpha-beta alloys may be strengthened by heat treatment (such as solution heat treatment) and/or aging.
  • Alpha-beta titanium alloys may be classified into a grade based on the composition of the alloy as determined by ASTM B348 ⁇ e.g., grade 5 (which includes titanium alloys having approximately 6% Al and 4% V, such as Ti-6A1-4V), grade 6 (which includes titanium alloys having approximately 5% Al and 2.5% Sn), and grade 9 (which includes titanium alloys having approximately 3% Al and 2.5% V)).
  • Grade 5 which includes titanium alloys having approximately 6% Al and 4% V, such as Ti-6A1-4V
  • grade 6 which includes titanium alloys having approximately 5% Al and 2.5% Sn
  • grade 9 which includes titanium alloys having approximately 3% Al and 2.5% V
  • Alpha-beta titanium alloys may also be directly classified by their chemical composition (e.g., Ti-6A1-4V, Ti-6A1- 6V-2Sn, Ti-Al-2Sn-4Zr-6Mo, Ti-6Al-2Mo-2Cr, and Ti-6Al-2Sn-4Zr-2Mo, among others).
  • Ti-6A1-4V means a grade 5 alpha-beta titanium alloy comprising from about 5.5 wt. % Al to about 6.75 wt. % Al, from about 3.5 wt. % V to about 4.5 wt. % V, a maximum of 0.40 wt. % Fe, a maximum of 0.2 wt. % O, a maximum of 0.015 wt. % H, a maximum of 0.05 wt. % N, a maximum of 0.40 wt. % other impurities, and the balance being Ti. As may be appreciated, similar specifications exist for other titanium grades.
  • the "beta transus” is defined as the lowest equilibrium temperature at which the material is 100% beta phase.
  • titanium alloys may be a mixture of alpha and beta phase depending on the composition of the alloy.
  • FIG. 9 can be found in Tamirisakandala, S., R. B. Bhat and B. V. Vedam. "Recent advances in the deformation processing of titanium alloys.” Journal of Materials Engineering and Performance 12.6 (2003): 661-673.
  • cast ingot means an ingot formed from a molten titanium alloy wherein the alloy may be melted one or more times during formation of the cast ingot.
  • wrought billet means a billet of a titanium alloy formed from a cast ingot of the titanium alloy that has been worked ⁇ e.g., by forging, rolling, or pilger) prior to or during formation of the billet.
  • extrusion or “extruded” shall mean a process to create an extruded titanium alloy workpiece using direct or indirect extrusion.
  • Direct extrusion or “directly extruded” means a process used to create an extruded titanium alloy workpiece by pushing a cast ingot or wrought billet of titanium alloy through a stationary die having a desired cross-section or shape.
  • indirect extrusion or “indirectly extruded” means a process used to create an extruded titanium alloy workpiece by pushing a die having a desired cross section or shape through a stationary cast ingot or wrought billet of titanium alloy.
  • near net shape workpiece means an extruded titanium alloy workpiece, the shape of which, after one or more rolling steps, is sufficient to achieve a final shape workpiece (e.g., in the shape of the final product provided to a customer).
  • NNSWP(z) represents a value for a physical measurement, z, of the near net shape workpiece (e.g., z may be a volume, a width, or a thickness), RR(%) means the percent reduction achieved in the physical measurement by the rolling, and FSWP(z) means a value of the physical measurement in the final shape workpiece.
  • the relative reduction relates to the total reduction of the material's thickness, irrespective of the number of rolling passes required to achieve the relative reduction. Typically, each rolling pass reduces a material's thickness by not greater than 25%.
  • the relative reduction may be non-uniform, meaning the relative reduction may vary for different features or parts of the near net shape workpiece depending on the configuration of the rolling steps, or only one portion of the near net shape workpiece may be reduced.
  • the relative reduction may be uniform across the entire workpiece, meaning the reduction of thickness is the same across the entire workpiece.
  • Relative reduction (R) may mean a reduction of thickness of at least a part of the near net shape workpiece from 1 % to 95 %, such as any of the relative reductions described above.
  • a near net shape workpiece may be a near net shape c- channel shaped workpiece (as seen in FIG.
  • roller means a metal forming process (step) in which an extruded titanium alloy product is passed through one or more rolls of a roller apparatus to reduce a volume or thickness of the product.
  • a roller apparatus 800 may comprise multiple rolls (801), (802), (803) which may be arrayed in a manner so that the roller is configured to reduce a thickness in one or more dimensions of the extruded titanium alloy product.
  • FIG. 8 can be found in Tamirisakandala, S., R. B. Bhat, and B. V. Vedam. "Recent advances in the deformation processing of titanium alloys.” Journal of Materials Engineering and Performance 12.6 (2003): 661-673.
  • final shape workpiece means an extruded and rolled titanium workpiece having a desired volume or thickness and is suitable for its intended end-use purpose. In some embodiments, the final shape workpiece may be additionally finished via machining or surface treatment. Some non-limiting examples of some final shape workpieces include a final shape pi-box final shape C channel. As used herein, "pi-box” means a material having a cross-section generally resembling the Greek letter pi ( ⁇ ).
  • stress relieve anneal means a thermal treatment process at relative low temperature to relieve the stress in the product.
  • heat treatment means a thermal process in which the material is heated to an elevated temperature to change the properties of the material.
  • Some non-limiting examples of heat treatments useful in accordance with the methods described herein include a mill anneal, a near beta transus anneal, a recrystallization anneal, a solution heat treatment, and artificial aging, among others.
  • FIGS. 1-3 are flow charts illustrating an embodiment of a method of creating a titanium alloy workpiece
  • FIGS. 4A-4C demonstrate a C-channel shaped workpiece created by a method in accordance with the present disclosure
  • FIGS. 5A-5C demonstrate a T-bracket shaped workpiece created by a method in accordance with the present disclosure
  • FIGS. 6A-6C depicts an L-bracket shaped workpiece having a uniform relative reduction and a non-uniform thickness created by a method in accordance with the present disclosure
  • FIGS. 7A-7C depicts an L-bracket shaped workpiece having a non -uniform thickness and a non-uniform relative reduction created by a method in accordance with the present disclosure
  • FIG. 8 demonstrates an embodiment of a roller setup having three sets of rolls
  • FIG. 9 illustrates a microstructural deformation mechanism map for a Ti-6A1-4V alloy
  • FIGS. 10A and 10B are graphs demonstrating a relationship between room temperature strength and ductility as a function of cooling from a beta transus region
  • FIGS. 11 A and 1 IB demonstrate yield strengths between workpieces processed at various strain rates and at temperatures above (11 A) and below (11B) a beta transus temperature;
  • FIGS. 12A and 12B demonstrate ultimate strengths between workpieces processed at various strain rates and at temperatures above (12A) and below (12B) a beta transus temperature;
  • FIGS. 13A and 13B demonstrate material elongations between workpieces processed at various strain rates and at temperatures above (13A) and below (13B) a beta transus temperature;
  • FIGS. 14A and 14B demonstrate a reduction of area between workpieces processed at various strain rates and at temperatures above (14A) and below (14B) a beta transus temperature;
  • FIG. 15 illustrates micrographs of materials of Example 2 in the extruded and rolled conditions in the longitudinal (L) and long transverse (T) directions;
  • FIG. 16 illustrates fatigue crack propagation rates of materials of Example 2.
  • FIGS. 1-3 are flow charts of various embodiments of a method for creating a titanium workpiece in accordance with the present disclosure.
  • the workpiece may be any shape capable of being extruded from a titanium alloy.
  • the workpiece may be a C-channel bracket, a T bracket, H or I shapes, or an L bracket.
  • the method comprises a first step of heating (10) a titanium alloy above its beta transus temperature to yield a heated workpiece.
  • the titanium alloy may be an alpha alloy, a beta alloy, or an alpha-beta alloy.
  • the alpha-beta alloy may be Ti-6A1-4V.
  • the titanium alloy comprises a cast ingot or a wrought billet.
  • the method may further comprise, after the heating step (10), a protecting step, wherein a surface of the heated workpiece is coated with a protectant to protect the surface from damage that may occur during extrusion.
  • the protectant may comprise a lubricant (e.g., graphite, glass, a molten salt (e.g., a molten alkaline metal salt)), and/or a parting agent, such as a ceramic material (e.g., a ceramic powder).
  • the method further comprises a step of extruding (20) the heated workpiece to yield an extruded near net shape workpiece.
  • the extruding (20) may comprise direct extrusion.
  • the extruding (20) may comprise indirect extrusion.
  • the extruding step (20) may comprise extruding the heated workpiece at a temperature above the alloy's beta transus temperature.
  • the extruding step (20) may comprise initiating extrusion at a temperature above the alloy' s beta transus temperature, wherein at least a portion of the extruding step (20) may be performed at a temperature below the alloy's beta transus temperature.
  • the method further comprises the step of cooling (30) the near net shape workpiece to a temperature below its beta transus temperature.
  • the cooling step (34) comprises cooling to a temperature within 600°F (333°C) of the alloy's beta transus.
  • the cooling (30) is to a temperature within 500°F (278°C) of the alloy' s beta transus.
  • the cooling (30) is to a temperature of within 400°F (222°C) of the alloy' s beta transus.
  • the cooling (30) is to a temperature of within 300°F (167°C) of the alloy's beta transus.
  • the cooling (30) is to a temperature of within 200°F (1 1 1°C) of the alloy's beta transus. In some embodiments, the cooling (30) is to a temperature of within 100°F (55.6°C) of the alloy' s beta transus. In some embodiments, the cooling (30) is to a temperature of more than 600°F (333°C) below the alloy' s beta transus. In some embodiments, as seen in FIG. 2 and FIG. 3, the cooling step (31) may comprise cooling the near net shape workpiece to any temperature below the alloy's beta transus, and in some embodiments the temperature may be room temperature.
  • the method further comprises, after the cooling step, a cleaning / preparing step, wherein the near net shape workpiece is prepared for rolling by removing any residual protectant via the cleaning / preparing step.
  • the cleaning and/or preparing may comprise sandblasting some or all of the workpiece to remove protectant residue (e.g., residual lubricant or parting agent) and to condition the surface for adherence. Dry powder or wet suspension may be applied to surface. Excess powder or suspension may be removed via mechanical or high velocity air means, leaving a thin layer of protectant.
  • the method further comprises one or more rolling steps (40), wherein the rolling comprises rolling the extruded near net shape workpiece one or more times at a rolling temperature to yield a final shape workpiece.
  • the rolling temperature is the same temperature for each of the one or more rolling steps. In some embodiments, the rolling temperature may be different for each of the one or more rolling steps. In some embodiments, the rolling temperature is a temperature below an incipient melting temperature of the alloy and within 600°F (333°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 500°F (278°C) of the beta transus temperature.
  • the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 400°F (222°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 300°F (167°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 250°F (139°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 100°F (55.6°C) of the beta transus temperature.
  • the rolling temperature is a temperature below the incipient melting temperature of the alloy and within 50°F (27.8°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 600°F (333°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 500°F (278°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 400°F (222°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 300°F (167°C) of the beta transus temperature.
  • the rolling temperature is a temperature below the beta transus temperature and within 250°F (139°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 100°F (55.6°C) of the beta transus temperature. In some embodiments, the rolling temperature is a temperature below the beta transus temperature and within 50°F (27.8°C) of the beta transus temperature.
  • the one or more rolling steps (40) comprise reducing one or more aspects or portions of the near net shape workpiece to yield a final shape workpiece having a relative reduction of from 1% to 95% in the one or more aspects or portions as compared to the near net shape workpiece.
  • only one section of the near net shape workpiece may be reduced.
  • more than one section of the near net shape workpiece may be reduced.
  • the total relative reduction may be from 1% to 95%.
  • the relative reduction may be not greater than 90% in total relative reduction.
  • the relative reduction may be not greater than 85% in total relative reduction.
  • the relative reduction may be not greater than 80% in total relative reduction.
  • the relative reduction may be not greater than 75% in total relative reduction. In some embodiments, the relative reduction may be not greater than 70% in total relative reduction. In some embodiments, the relative reduction may be not greater than 65% in total relative reduction. In some embodiments, the relative reduction may be at least 1% in total relative reduction. In some embodiments, the relative reduction may be at least 10% in total relative reduction. In some embodiments, the relative reduction may be at least 20% in total relative reduction. In some embodiments, the relative reduction may be at least 30% in total relative reduction. In some embodiments, the relative reduction may be at least 40% in total relative reduction. In some embodiments, the relative reduction may be at least 50% in total relative reduction. In some embodiments, the relative reduction may be at least 55% in total relative reduction.
  • the rolling may further comprise rolling at a strain rate of from 0.1 s "1 to 100 s "1 .
  • the strain rate may be a rate of from 1 s "1 to 100 s "1 .
  • the strain rate may be a rate of from 1 s "1 to 50 s "1 .
  • the strain rate may be a rate of from 1 s "1 to 10 s "1 .
  • the relative reduction may be uniform, as may be seen in FIGS. 4A-4C, wherein all portions of the final shape workpiece have uniform relative reduction.
  • FIG. 4A depicts an extruded C-channel bracket prior to the one or more rolling steps (40).
  • FIG. 4B depicts the final shape workpiece, having uniform relative reduction as compared to the near net shape workpiece (as seen in FIG. 4C comparing the two shapes).
  • the relative reduction may be uniform, and an absolute measure of the one or more aspects of the final shape workpiece may be the same across the entire final shape workpiece (e.g., the thickness or volume may be the same throughout the entire final shape workpiece).
  • FIG. 5A depicts an extruded T bracket prior to the one or more rolling steps (40).
  • FIG. 5B depicts the final shape workpiece, having a uniform relative reduction as compared to the near net shape workpiece (as seen in FIG. 5C comparing the two shapes), and also having a uniform absolute measure of thickness throughout all portions of the final shape workpiece as a first section (501) has a same thickness as a thickness of a second section (502).
  • the relative reduction may be uniform across the final shape workpiece, but the absolute measure of one or more aspects may differ (e.g., a percent of reduction in thickness may be the same across the entire final shape workpiece, but the absolute thickness from portion to portion of the final shape workpiece may be different).
  • FIG. 6A depicts an extruded L bracket prior to the one or more rolling steps (40).
  • FIG. 6B depicts the final shape workpiece, having a uniform relative reduction as compared to the near net shape workpiece (as seen in FIG. 6C comparing the two shapes), but having non-uniform thickness throughout portions of the final shape workpiece as a first section (601) has a different thickness from a second section (602).
  • the relative reduction and the absolute measure may be non-uniform across the final shape workpiece.
  • FIG. 7 A depicts an extruded L bracket prior to the rolling steps (40).
  • FIG. 7B depicts the final shape workpiece, having a non-uniform relative reduction as compared to the near net shape workpiece (as seen in FIG. 7C comparing the two shapes), and having non-uniform thickness throughout portions of the final shape workpiece as a first section (701) has a different thickness from a second section (702).
  • the method may further comprise the step of reheating (32) the near net shape workpiece after the cooling step (31), wherein the reheating (32) step comprises heating the extruded near net shape workpiece to a reheated temperature below an incipient melting temperature of the alloy and within 600°F (333°C) of its beta transus.
  • the reheated temperature is a temperature below the incipient melting temperature of the alloy and within 500°F (278°C) of its beta transus.
  • the reheated temperature is a temperature below the incipient melting temperature of the alloy and within 400°F (222°C) of its beta transus.
  • the reheated temperature is a temperature below the incipient melting temperature of the alloy and within 300°F (167°C) of its beta transus. In some embodiments, the reheated temperature is a temperature below the incipient melting temperature of the alloy and within 200°F (1 1 1°C) of its beta transus. In some embodiments, the reheated temperature is a temperature below the incipient melting temperature of the alloy and within 100°F (55.6°C) of its beta transus.
  • the near net shape workpiece may be reheated (32) to allow for a subsequent rolling step to be performed at the reheated temperature.
  • the near net shape workpiece may be alternatively cooled (31) and re-heated (32) between each rolling step of the one or more rolling steps (40).
  • all of the one or more rolling steps (40) may comprise a rolling temperature of more than 600°F (333°C) below the beta transus, wherein each of the one or more rolling steps (40) may further comprise limiting the relative reduction for each rolling step to prevent cracking or development of internal metallurgical defects in the final shape workpiece.
  • various adjustments to the time (e.g., longer times) and/or temperature (e.g., hotter temperatures) of the reheating can be adjusted to relieve residual stress, allow dislocation motion, and relaxation of crystallographic texture. This may ensure that adequate ductility is maintained to tolerate deformation at lower temperatures.
  • the reheating step (33) may comprise heating the extruded near net shape workpiece to a temperature above its beta transus temperature and below its incipient melting temperature, wherein the reheating step (33) may be followed by one or more rolling steps (41) performed at a temperature above the alloy's beta transus temperature.
  • the near net shape workpiece may be reheated (33) if its temperature falls below the alloy's beta transus temperature during any given rolling step of the one or more rolling steps (41).
  • the method further comprises one or more other rolling steps (42), which may be performed below the alloy's beta transus temperature.
  • BT mill measured beta transus
  • the temperature above the beta transus (BT) was limited to 50°F (28°C) above the beta transus to limit grain growth during heat up.
  • the temperature below the beta transus was selected as an attempt to maintain product in the work window promising a globularization type conversion to end at 1775°F (968°C). Below the 1775°F (968°C) temperature the product may still breakdown into a worked structure, but it would be expected that this conversion would be dominated by lamellae kinking.
  • the processing speed of the roll reduction was selected as a high and low speed representing strain rates of 10 s "1 and 2.5 s "1 . Exit speeds of 20-30 inches/second (50.8-76.2 cm/second) in the high speed case, and 5-6 inches/second (12.7-15.2 cm/second) in the low speed case.
  • the furnace was placed immediately adjacent the rolling device.
  • Product was exposed to ambient air for a distance of 15 inches (38 cm) until the roll bite began. This provided a vehicle for cooling of the product, particularly in the final passes when the product was approaching 0.100 inch (2.54 mm) thick.
  • the roller differed from a traditional 2 or 4 high rolling mill.
  • the rollers were arranged to provide contact pressure on the primary (largest) surfaces of the product and be advanced independently to produce gaps between the different rollers.
  • This type of roller design could be modified to produce channels, H's, L's, T's, and a variety of other structural members. With instances of small rollers and certain shapes, an interference will begin to occur with the bearing housings. Placing the bearing within the wheel and having only a powered sprocket on the side will alleviate much instance of interference. This also produces a more rigid structure for applying load. The use of larger wheels will also provide more space and increase the possible reduction per pass.
  • a less common method of secondary hot working of alpha/beta titanium alloys is beta processing.
  • the working occurs above the beta transus temperature.
  • Lamellar microstructure results in higher fracture toughness, fatigue crack propagation resistance and creep resistance. Minor debits occur in strength, ductility.
  • a major benefit of beta hot working which includes beta forging and beta extrusion, is a lowered flow stress and improved die or feature fill.
  • the extrusion of titanium is predominantly performed above the beta transition temperature to achieve the increase in formability of titanium in spite of an increase in grain size.
  • the cooling rate from above the beta transus following recrystallization has significant impact on the formation of the Widmanstatten microstructure.
  • FIGS. 10A and 10B can be found in Siemawski, J., Ziaja, W., Kubiak, K. and Motyka, M., 2013. Microstructure and mechanical properties of high strength two-phase titanium alloys. Titanium Alloys-Advances in Properties Control, pp.69-80.
  • the microstructure of the as-extruded material is characteristic of what is seen from an extrusion. Standard practice of air cooling on significantly thicker product produces a cooling rate in the 2-7°C per second and higher levels of ductility from the Widmanstatten microstructure. It typically takes a water quench to achieve Martensite in Ti-6A1-4V for extruded product. The microstructure after the four pass demonstrated a.) larger prior beta grains and b.) partially Martensitic structure versus the unidirectional bundles of the extrusion. Without being limited to any one theory, it could be as a result of the rapid cooling of the thin sections by both radiation and conduction losses to the rollers.
  • Conduction cooling effects might explain why the effects are more pronounced in the slower processed pieces where the contact time is longer.
  • the loss of ductility is not desirable in aerospace structures, however this could be managed through warmer rolls, higher set point temperature, improved management of environment leading to and from the roll bite.
  • a heated exit zone would allow slowed cooling during the initial cooling to form the desired microstructure.
  • a mixed (below beta transus and above beta transus processing steps) would likely produce the best combination of properties of beta worked material.
  • texture can arise in the material. Texture is the imparting of directionality within the material, and arises from working in one predominant direction.
  • production is enabled by either using alloys with higher cold workability, such as commercially pure grades, or performing a beta anneal following hot working and between cold working passes to relieve directionality.
  • alloys with higher cold workability such as commercially pure grades
  • beta anneal following hot working and between cold working passes to relieve directionality.
  • transverse ductility was un-measurable and brittle behavior was observed in transverse directions compared to lateral direction of rolling.
  • anisotropy in titanium increases the susceptibility to stress corrosion cracking in aqueous solutions.
  • sample materials realize significantly higher strength as compared to conventional Ti- 6A1-4V products (see, e.g., AMS 4928 and AMS 4911). Further, the materials realize isotropic properties with about 65% rolling reduction, realizing less than 5 ksi strength differential between the L and LT directions.
  • FIG. 16 illustrates fatigue crack propagation rates performed in accordance of ASTM E647, under test conditions of a stress ratio of 0.10, a frequency of 10 Hz, room temperature, and laboratory atmospheric air.
  • the fatigue crack growth results are consistent with AMS standards relative to alpha-beta sheet products.

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Abstract

La présente invention concerne des procédés de finition de pièces extrudées en alliage de titane, les procédés consistant à générer une pièce extrudée de forme presque finale, à refroidir la pièce extrudée de forme presque finale à une température abaissée en dessous de la température correspondant au transus bêta, puis à laminer la pièce extrudée de forme presque finale une ou plusieurs fois à une température de laminage pour obtenir une pièce de forme finale ayant des propriétés souhaitées.
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FR3109107B1 (fr) * 2020-04-09 2023-06-23 Airbus Operations Sas Procédé de fabrication d’un profilé par extrusion et forgeage, profilé ainsi obtenu
CN112474851A (zh) * 2020-11-04 2021-03-12 攀钢集团攀枝花钛材有限公司江油分公司 一种不对称截面钛合金tc4异型材的制备方法
CN112718429B (zh) * 2020-12-17 2022-12-13 哈尔滨工业大学 一种减少钛基合金热旋压成形过程中氧化缺陷的方法
CN112845648B (zh) * 2020-12-23 2023-02-03 西部新锆核材料科技有限公司 一种钛或钛合金挤压轧制薄壁型材的制备方法
CN114182186A (zh) * 2021-11-11 2022-03-15 天津职业技术师范大学(中国职业培训指导教师进修中心) 一种提高近β钛合金紧固件棒坯组织均匀性的方法

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JP2019512603A (ja) 2019-05-16
JP6871938B2 (ja) 2021-05-19
KR20180107269A (ko) 2018-10-01
EP3445888C0 (fr) 2023-12-20
CN109072390A (zh) 2018-12-21
CN109072390B (zh) 2021-05-11
US20170306467A1 (en) 2017-10-26
KR102221443B1 (ko) 2021-02-26
RU2709568C1 (ru) 2019-12-18
EP3445888B1 (fr) 2023-12-20
EP3445888A4 (fr) 2019-09-25
UA123406C2 (uk) 2021-03-31

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