Recent Developments in High-Strength Titanium Fasteners For Aerospace Applications

Mission Critical Metallics
Gavin Garside
Greg Vignoul, John Foltz, Walter Vernitsky, Leonard Nowak, Corey Smith
April 3, 2013
2013 ATI. All Rights Reserved.
Outline
Background
Supply Chain and Processing
ATI 425 Alloy
Heading Trials
Mechanical Properties
Direct Age Experiments
Minimum Mechanical Properties of Fastener Alloys

ATI 6-4
Quenching Study
Summary
ATI 2013. All Rights Reserved.
MISSION CRITICAL METALLICS
Background
ATI has vast experience with titanium and titanium alloys
Long Products
Ingot, billet, round & rectangle bar, shapes, rod, wire & coil, extrusions, seamless
tube & pipe, fastener stock
Flat Products
Plate, sheet, coil, foil & precision rolled strip
Alloys
ATI 6-4 Alloy, ATI 425 Alloy, ATI 45Nb Alloy, ATI 3-2.5 Alloy, ATI 3510, ATI
6-2-4-2, ATI 6-2-4-6, and many more
Until recently, ATI has not targeted fastener markets

But has supplied ATI 45Nb Alloy for over 20 years for aerospace
applications including rivets
New to the market, not the materials
Focus on ATI 425 Alloy and ATI 6-4 Alloy

3
Background
Titanium for fastener applications
Similar strength of medium alloy steel
Half the weight of steel
Much more corrosion resistant than steel
Often with no coating
Wide operating temperature range

-350oF to 800oF
ATI Titanium Fastener Stock Processing

Double Melting
(Primary + VAR)
Forging
Hot Rolling
Drawing
Finishing
5
Reliable, Secure, and Redundant Supply Chain

La Porte
Portland
Bolingbrook
Northbrook
Richland
Cudahy
La Crosse
Monaca, Rochester, Zelienople

Lockport
Bagdad, Latrobe, Brackenridge,
Houston, Midland, Washington,
Vandergrift, Oakdale, Waynesboro
Albany
New Bedford
Frackville
Rowley
Waterbury
Wallingford
Windsor
S Windsor
Pittsburgh, PA
(ATI Headquarters)
Louisville
Lebanon
Pico Rivera
Monroe
Irvine
Bakers
Richburg
Walterboro
Primary & Melting
La Vergne
Manufacturing & Fabricating
R&D
Service Centers
Houston
Grant, Gurley, Huntsville, Madison
*Facilities Worldwide*
6
ATI 425 Alloy

Specifications
Composition
AMS 6946, AMS 6947, AMS 6948

MMPDS design allowables
MIL-DTL-46077 class 4
ASTM Ti Grade 38
Advantages
Typical alpha/beta processing

Lower flow stress than Ti-6Al-4V
High Strength
Cold deformable
Beta Transus = 1778oF

7
Heading trials Mill Annealed Material

Trials with no process adjustments
14.6mm bar
ATI 425 Alloy
Warm headed
ATI 425 Alloy
Warm thread
rolled
ATI 425 Alloy
Warm thread
rolled
Ti 6-4 Alloy
Rolled and headed just as well as Ti 6-4 Alloy

8

8
Warm formed
Cold formed
Thread macros
Thread appearance
similar to ATI 6-4 Alloy
Fine thread details were
reproduced in ATI 425 Alloy

9
ATI 425 Alloy Solution Treated and Aged
Both ATI 6-4TM Alloy and ATI 425 Alloy hold the relationship:
10
Standard solution treatment

and ageing conditions
Good correlation between
UTS and double shear
Min. Properties
DS 0.6 UTS
Condition
UTS (ksi)
A-286
STA
130
A-286
DA
180
ATI 425 Alloy

Elevated
Temperature
Testing
Material
Condition
UTS (ksi)
Yield (ksi)
Density (lb/in3)
ATI 425 Alloy
MA
145
135
0.162
ATI 425 Alloy (Typical)
STA
193
171
0.162
STA = Solution Treat and Age; DA = Direct Age; MA = Mill Anneal

11
ATI 425 Alloy Direct Age Experiments
12

Yield Strength vs. Increasing Temperature
% El vs. Increasing Temperature
220
14
13
Low Reduction - 3 Hours
12
200
190
Medium Reduction - 3 Hours
180
170
High Reduction - 3 Hours
160
150
Straightened - 3 Hours
140
Increasing Temperature
% Elongation
Yield Strength, ksi
210
11
10
9
8
Ultimate Tensile vs. Increasing Temperature
% RA vs. Increasing Temperature
13
45
225
43
220
215
210
205
200
195
190
185
Reduction of Area, %
Ultimate Tensile Strength, ksi
230
180
41
39
37
35
33
31
29
27
25

Parameters chosen for comparison
Medium Reduction Draw
Strength - % Elongation Comparison
Strength, ksi
210
36
200
190
31
180
170
160
26
Yield Strength
Ultimate Tensile
Strength
Strength, ksi
41
220
% Reduction of Area
230
230
14
220
13
210
12
200
11
190
10
180
170
160
% Elongation
Strength - % Reduction of Area Comparison
There is a happy medium that needs to be found

14
Minimum Mechanical Properties

Material
Condition
UTS (ksi)
Yield (ksi)
Elong (%)
RA (%)
Density (lb/in3)
A-286
STA
130
85
15
20
0.286
A-286
DA
180
150
10
18
0.286
Alloy 718
STA
180
150
12
15
0.296
Alloy 718
DA
220
200
15
0.296
MP35N
DA
260
230
35
0.304
MP159
DA
260
250
22
0.301
ATI 6-4 Alloy
MA
130
120
10
25
0.160
ATI 6-4 Alloy
STA
165
155
10
20
0.160
ATI 425 Alloy
MA
145
135
15
30
0.162
ATI 425 Alloy
STA
170
150
10
20
0.162
ATI 425 Alloy
STA
193
171
12
44
0.162
DA
213
195
10
34
0.162
(Typical)
ATI 425 Alloy

(Experimental Results)
STA = Solution Treat and Age; DA = Direct Age; MA = Mill Anneal
15
Minimum Mechanical Properties

Material
Condition
UTS (ksi)
Yield (Ksi)
Elong (%)
RA (%)
Density (lb/in3)
A-286#
STA
130
85
15
20
0.286
A-286#
DA
180
150
10
18
0.286
ATI 6-4 Alloy
MA
130
120
10
25
0.160
ATI 6-4 Alloy
STA
165
155
10
20
0.160
ATI 425 Alloy
MA
145
135
15
30
0.162
ATI 425 Alloy
STA
170
150
10
20
0.162
ATI 425 Alloy
STA
193
171
12
44
0.162
DA
213
195
10
34
0.162
(Typical Results)
ATI 425 Alloy

(Experimental Results)
STA = Solution Treat and Age; DA = Cold Work and Age; MA = Mill Anneal
ATI 425 Alloy meets or exceeds A-286 values

ATI 425 Alloy is almost half the density of A-286
#Source:
16
Roach, Thomas SPS Technologies, Inc. Alloy 718 Fasteners: Versatility and Reliability for Aerospace Design

Transverse
ATI 6-4
Alloy
Mill Annealed
Solution Treated and Aged
ATI 425
Alloy
17
Heading trials
Trials with no process adjustments
Warm, high
heading strain
Standard Ti 6-4 Alloy Process
Cold, low
heading
strain
Cold, high
heading
strain
Difficulty of the process

18

18
Quench Study ATI 6-4 Alloy

0.248 fastener stock
Parameters
Time to quench
As fast as possible, 5 second delay, 10 second delay
Water agitation
Agitated and unagitated
Solution treatment time

30, 60, and 90 minutes at temperature (1700oF)
Samples then aged 900oF for 4 hours

Air cooled
Double shear testing

19
Quench Study ATI 6-4 Alloy

Solution Treatment Time
30 min
30 min with water agitation during quench
60 min
90 min
Time to Quench
ASAP
5 sec
10 sec
105.2
102.3
99.6
104.6
101.5
99.7
104.8
102.7
101.1
105.6
102.0
100.5
104.8
103.5
100.5
104.5
104.1
100.4
(Double shear - values in ksi)
Time to quench had a drastic effect on double shear

properties
Water agitation and solution treatment time did not
significantly affect double shear properties
20
Summary
ATI 6-4 Alloy has a great combination of properties for aerospace

fastener applications
o
o
o
ATI 425 Alloy is a highly versatile / titanium alloy with:

o
o
o
o
o
o
21
High strength to weight ratio with good corrosion resistance

ATI produces fastener stock to meet industrial applications
Our material has a uniform fine grain microstructure well suited for aerospace
fasteners
Higher mill annealed strengths than ATI 6-4 Alloy
Excellent formability and ductility
Higher solution treated and aged double shear and ultimate tensile strengths
than ATI 6-4 Alloy
Greater strength especially at >0.5 diameter than ATI 6-4 Alloy
Capability to replace A286 for cold applications
Direct age experiments show potential for higher mechanical properties than
STA treatment

Recent Developments in High-Strength Titanium Fasteners For Aerospace Applications

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Mission Critical Metallics

Mission Critical Metallics

Minimum Mechanical Properties of Fastener Alloys

MISSION CRITICAL METALLICS

Mission Critical Metallics

Until recently, ATI has not targeted fastener markets

Focus on ATI 425 Alloy and ATI 6-4 Alloy

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

Wide operating temperature range

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI Titanium Fastener Stock Processing

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

Reliable, Secure, and Redundant Supply Chain

Monaca, Rochester, Zelienople

Primary & Melting

Manufacturing & Fabricating

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 425 Alloy

AMS 6946, AMS 6947, AMS 6948

Typical alpha/beta processing

Beta Transus = 1778oF

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

Heading trials Mill Annealed Material

Rolled and headed just as well as Ti 6-4 Alloy

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 425 Alloy Solution Treated and Aged

Standard solution treatment

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 425 Alloy

ATI 425 Alloy

ATI 425 Alloy (Typical)

STA = Solution Treat and Age; DA = Direct Age; MA = Mill Anneal

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 425 Alloy Direct Age Experiments

ATI 2013. All Rights Reserved.

MISSION CRITICAL METALLICS

Mission Critical Metallics

ATI 425 Alloy Direct Age Experiments

% El vs. Increasing Temperature

Low Reduction - 3 Hours

Low Reduction - 8 Hours

Medium Reduction - 3 Hours

Medium Reduction - 8 Hours

High Reduction - 3 Hours