FAST-forge − A new cost-effective hybrid processing route for consolidating titanium powder into near net shape forged components

Weston, Nicholas J.; Jackson, M.

doi:10.1016/j.jmatprotec.2016.12.013

Cited by 60 publications

(38 citation statements)

References 15 publications

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“…A new hybrid powder metallurgy approach combining accelerated sintering with hot forging, could provide designers with the option to engineer future components with sections containing dissimilar titanium alloys, thus integrating controlled changes in properties across the component. a solid-state powder processing method known as field assisted sintering technology (FAST) or spark plasma sintering (SPS) is emerging as a flexible powder consolidated route for titanium alloys [3][4][5][6][7][8][9][10][11][12][13][14][15]. When compared to conventional powder processing and sintering methods, FAST is advantageous due to an electrical current, which has been shown to provide faster heating rates and consolidation compared to conventional sintering [16,17].…”

Section: Introductionmentioning

confidence: 99%

“…FAST has been demonstrated to be an effective sintering route for complex shapes, most notably a novel deformable interface approach produced fully dense CoNiCrAlY turbine blades [18]. Furthermore, FAST-forge [5] and FAST-DB [19] processing routes have been developed, primarily to provide an alternative route to produce titanium components from particulate feedstocks. The first step of FAST-forge is the consolidation of the titanium feedstock into an optimised forging preform using FAST.…”

Section: Introductionmentioning

confidence: 99%

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FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components

Pope

Jackson

2019

Metals

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Material reductions, weight savings, design optimisation, and a reduction in the environmental impact can be achieved by improving the performance of near-net shape (NNS) titanium alloy components. The method demonstrated in this paper is to use a solid-state approach, which includes diffusion bonding discrete layers of dissimilar titanium alloy powders (CP-Ti, Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr) using field-assisted sintering technology (FAST), followed by subsequent forging steps. This article demonstrates the hybrid process route, firstly through small-scale uni-axial compression tests and secondly through closed-die forging of dissimilar titanium alloy FAST preforms into an NNS (near-net shape) component. In order to characterise and simulate the underlying forging behaviour of dissimilar alloy combinations, uni-axial compression tests of FAST cylindrical samples provided flow stress behaviour and the effect of differing alloy volume fractions on the resistance to deformation and hot working behaviour. Despite the mismatch in the magnitude of flow stress between alloys, excellent structural bond integrity is maintained throughout. This is also reflected in the comparatively uncontrolled closed-die forging of the NNS demonstrator components. Microstructural analysis across the dissimilar diffusion bond line was undertaken in the components and finite element modelling software reliably predicts the strain distribution and bond line flow behaviour during the multi-step forging process.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components

Pope

Jackson

2019

Metals

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“…The initial step uses shaped field assisted sintering to consolidate titanium powder into a pre-forged billet. This is then followed by the second step, in which the FAST billet is then closed die hot forged to achieve a NNS part geometry [72]. This forging step improves the mechanical properties of the FAST titanium by refinement of the microstructure and allows for components to be manufactured with properties similar to those of conventional wrought products.…”

Section: Fast-forgementioning

confidence: 99%

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Childerhouse

Jackson

2019

Metals

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Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

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“…Solid-state consolidation techniques such as the use of field assisted sintering technology (FAST) in conjunction with hot forging are capable of producing shaped metal components with full densities and wrought properties from a powder feedstock. [3] Titanium is currently extracted via the Kroll process, a discontinuous metallothermic reduction process, which involves the reduction of TiCl 4 by Mg to produce a titanium metal sponge. Master alloys are added to the Kroll sponge, before compaction and welding into an electrode for melting.…”

mentioning

confidence: 99%

“…Hence, producing titanium alloy powder directly via the solid-state FFC extraction process, followed by downstream solid-state consolidation using FAST and hot forging (''FAST-forge'' [3] ) to near net shape, will significantly reduce the cost of titanium alloy components. Cost reductions are achieved by directly producing an alloy powder, reducing the number of multistep forging and heat treatment steps, and minimizing both wastage and machining.…”

mentioning

confidence: 99%

On a Testing Methodology for the Mechanical Property Assessment of a New Low-Cost Titanium Alloy Derived from Synthetic Rutile

Benson

Marshall

Weston

et al. 2017

Metall Mater Trans A

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Mechanical property data of a low-cost titanium alloy derived directly from synthetic rutile is reported. A small-scale testing approach comprising consolidation via field-assisted sintering technology, followed by axisymmetric compression testing, has been designed to yield mechanical property data from small quantities of titanium alloy powder. To validate this approach and provide a benchmark, Ti-6Al-4V powder has been processed using the same methodology and compared with material property data generated from thermo-physical simulation software. Compressive yield strength and strain to failure of the synthetic rutile-derived titanium alloy were revealed to be similar to that of Ti-6Al-4V.

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FAST-forge − A new cost-effective hybrid processing route for consolidating titanium powder into near net shape forged components

Cited by 60 publications

References 15 publications

FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components

FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

On a Testing Methodology for the Mechanical Property Assessment of a New Low-Cost Titanium Alloy Derived from Synthetic Rutile

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