recent developments in melting technologies ......titanium 2015 orlando fl, usa 9 eb hollow casting...

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


Expansion Drivers - Cost


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


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


EB Melting


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

Plasma Arc Melting


http://www.retechsystemsllc.com/plasma_melting/

Skull Melting

Titanium 2015 Orlando FL, USA8

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


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

Update on numerical tools for EB cold hearth melting


Solidification of EB Ingot


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


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



Segregation in hypothetical VAR


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


• 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



Challenges - Transient Processes


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


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


recent developments in melting technologies ......titanium 2015 orlando fl, usa 9 eb hollow casting...

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