electron beam cold hearth remelting of titanium and scrap ......electron beam cold hearth remelting...
TRANSCRIPT
Dr.-Ing Jürgen Kiese EBCHR / LIBS
Birmingham, 13th May 2015Jürgen Kiese, Juri Kazakov, Klaus-Peter Wagner
Electron Beam Cold Hearth Remelting of Titanium and Scrap Control by LIBS Technology
Dr.-Ing Jürgen Kiese EBCHR / LIBS 2
Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Facility
Scrap, sponge,alloying elements
Mixing unit - weighing hopper
Drum feeder
Slab or ingotEB furnace
6 Guns - melting chamber
Dr.-Ing Jürgen Kiese EBCHR / LIBS 3
Electron Beam Cold Hearth Remelting Furnace (EBCHR)- Scrap revert strategy
Since 2008, the VDM performs a successful scrap revert strategy.
Feeding material: Titanium sponge Scrap as feedstock, chips (loose or compacted),
cobbles, etc. Every ratio of each, sponge and scrap Automatic weighing and mixing systems
for sponge, scrap, master alloys, micro components
Sponge FeedstockCompacted chipsCobbles
Containers with scrap
100 mm 100 mm100 mm 100 mm
The scrap ratio is typically 75 %.
Dr.-Ing Jürgen Kiese EBCHR / LIBS 4
Electron Beam Cold Hearth Remelting Furnace (EBCHR) - Melting
Process control: Automatic Beam Power Distribution
Control (ESCOSYS) Process observation by 6 viewing
systems
Melting rate: up to 1,600 kg/h
EB gunFeeding
Crystallization,mould
Refining
Melting
Dr.-Ing Jürgen Kiese EBCHR / LIBS 5
Electron Beam Cold Hearth Remelting Furnace (EBCHR)- Skull of melting and refining
Melting area(skull)
Refining area (skull)
Metal flow
Pouring lipto mould
Pouring lip
Shield
Dr.-Ing Jürgen Kiese EBCHR / LIBS 6
Electron Beam Cold Hearth Remelting Furnace (EBCHR)- Grades and Sizes
Grades: Grade 1s (low oxygen content) Grade 1 and 2 Ti-0.8Ni-0.3Mo (grade 12) Ti-6Al-4V (grade 5) Ti-6Al-4V ELI (grade 23) Ti-3Al-2.5V (grade 9)
5390 mm
Product sizes: Ingots: 845 mm dia x 5.5 m (13.5 t) Slabs: 500 x 1,300 mm x 5.5 m (16 t) Slabs: 500 x 1,050 mm x 5.5 m (13 t) Slabs: 375 x 1,355 mm x 5.5 m (12.5 t) Slabs: 375 x 1,100 mm x 5.5 m (10.2 t)
Ti-6Al-4V
Dim: 500 x 1050 x 5390 mm, Weight: 12.6 t
5300 mm
Ti-6Al-4V
Dim: 845 x 5300 mm, Weight: 13.2 t
Dr.-Ing Jürgen Kiese EBCHR / LIBS 7
Electron Beam Cold Hearth Remelting Furnace (EBCHR)- Analysis Ti-6Al-4V slab
Chemical composition along the slab length 611340E: Aluminum Vanadium Iron Oxygen, Carbon, Nitrogen
Ti-6Al-4V1050 x 500 x 2700 mmWeight: 6.2 t
611340E, 1050x500mm, 6,2t, Gr.5,Melt Sampling EB
611340E, 1050x500mm, 6,2t, Gr.5,Melt Sampling EB
Dr.-Ing Jürgen Kiese EBCHR / LIBS 8
Electron Beam Cold Hearth Remelting Furnace (EBCHR)- Analysis Ti-6Al-4V ingot - EB + VAR
Ti-6Al-4VØ845mm x 4700mm Weight: 12 t
Chemical composition along the ingot length 612183E: Aluminum Vanadium Iron Oxygen, Carbon, Nitrogen
612183E, Ø845mm, Gr.5, 12t,Melt Sampling EB, drill VAR
612183E, Ø845mm, Gr.5, 12t,Melt Sampling EB, drill VAR
Dr.-Ing Jürgen Kiese EBCHR / LIBS 9
RETURN consortium: CeramTec - Cutting materials Cronimet - Recycling Deharde - Machining Institute of Production Engineering and Machine Tools, Uni Hannover - Machining Institute for Material Science, Uni Hannover - Material analysis MAG IAS - Manufacturer of milling machines Premium Aerotec - Machining VDM Metals - Melting Walter - Cutting tools
RETURN – Process Chain: Recycling of Titanium Chips
Closed materials cycle
Semi-finishedproduct
Manufacturing Recycling
Titanium chipsMachining
Aim: improvement of the “chip quality” without decreasing of the component quality component manufacturing
Dr.-Ing Jürgen Kiese EBCHR / LIBS 10
RETURN – Process Chain: Recycling of Titanium Chips
The role of VDM Metals: building up an innovative scrap/chip control
Initial goal: to capture every chip to inspect every chip to analyze every chip
Requirements: fast system automatic system
Possible solution: LIBS system (laser-induced breakdown spectroscopy)
Questions - to capture every chip: is it possible? is it necessary?
All results should be transferable to solids (feed stock).
In this project the fundamentals and requirements should be developed.
Dr.-Ing Jürgen Kiese EBCHR / LIBS 11
RETURN – Process Chain: Recycling of Titanium Chips
Feeding hopper
Vibration Channelfor chip separation
Checking or analyzing by LIBS
Settling section
Dr.-Ing Jürgen Kiese EBCHR / LIBS 12
RETURN – Process Chain: Recycling of Titanium Chips
Score plot of the principal component analysis: PC0 and PC1
Titanium Brass ZincCopperSilver
PCA-coordinates,„fingerprint“of titanium
Dr.-Ing Jürgen Kiese EBCHR / LIBS 13
RETURN – Process Chain: Recycling of Titanium Chips
„Fingerprint“ of titanium
WC tool bits A WC tool bits B + C Titanium
Score plot of the principal component analysis: PC0 and PC1
AB
C
Dr.-Ing Jürgen Kiese EBCHR / LIBS 14
RETURN – Process Chain: Recycling of Titanium Chips
Score plot of the principal component analysis: PC0 and PC1
cp-Titanium
Ti-64
Ti-6246
In order to clearly distinguish the various Ti-alloys, more work is planed.
Dr.-Ing Jürgen Kiese EBCHR / LIBS 15
RETURN – Process Chain: Recycling of Titanium Chips
Inspection line provided by PROASSORT
An experimental example is shown in a movie:(click picture on the left)
Belt speed: 1 m/sec Laser: max. 20.000 shots/sec 7 shots summarized for an analysis 8 msec for an analysis
LIBS unit provided by SECOPTA
Dr.-Ing Jürgen Kiese EBCHR / LIBS 16
Dr.-Ing Jürgen Kiese EBCHR / LIBS 17
Thank you for your attention