Chemical Composition of unalloyed Titanium

Grades

Titanium-rich end of Ti-based binary phase

diagram different types encountered
depending on the type of solute

Production of Ingot
Titanium sponge, fragmented
master alloy, TiO2 and conditioned
scrap being recycled are mixed
homogeneously, cold pressed into
compacts with 65-70% density.
Compacts plasma welded into a
cylindrical electrode
Electrode remelted in a vacuum
arc furnace in a water cooled
crucible.Due to heat caused by
electic arc, titanium at electrode
bottom melts and drops fall into
underlying melting bath.Ingot
formation progresses with
electrode getting consumed
progressively.

SCRAP RECYCLING
Raw materials (Ti sponge, masteralloys etc.) being
very expensive, recycling of scrap generated
during manufacture is of immense commercial
importance.
Both solid and turning scrap is recycled.
Strict quality control necessary while recycling
scrap to ensure product quality.
While recycling turnings generated using WC
tooling, care should be taken to ensure that
tungsten particles do not get into ingot.

Effect of
forging
temperature
on forging
pressure for
three
titanium
alloys and
4340 alloy
steel

Effect of strain rate on flow stress of titanium alloy

Ti-8Al-1Mo-1V at 955C

Effect of strain rate on flow stress of - titanium

alloy Ti-6Al-4V at 900C

Effect of strain rate on flow stress of metastable

titanium alloy Ti-10V-2Fe-3Al at 815C

Closed Die Forging

Closed die forgings are made of titanium alloys
with weight ranging from a few grams to over 1
Tonne
Forge hammers as well as mechanical and
hydraulic presses used for manufacture
Challenge lies in obtaining uniform microstructure
and mechanical properties all over the volume of
forging, considering that large variations in cross
section can occur
Critical parts like rotating compressor blades of
aero-engine are manufactured using closed die
forging

Shear bands in forged blades of Ti 6-2-6-2 S and

processing map of alloy 6-2-4-2 S

TUBE MANUFACTURE
Tube manufacture is largely confined to
commercially pure titanium
Seamless tubes are manufactured by hot extrusion
followed by cold pilgering
Seam welded tubes are used extensively in heat
exchangers in power plants, desalination of sea
water, ship building etc.The starting material is
cold rolled and slit to width strip, 0.4-0.9mm in
thickness depending on application. High
demands are placed on dimensional and surface
quality aspects of the strip
The tubes are manufactured in 15-30mm range

Heat Treatment of Ti, its alloys

Strss relieving treatment
given to relieve residual
stresses developed during
hot working / fabrication
Annealing carried out to
produce an optimum
combination of
mechanical properties,
machinability,
dimensional and structural
stability
Solution treatment and
aging done to increase
strength

Oxidising atmosphere is
used to reduce hydrogen
pick-up. If inspite of it,
unacceptable hydrogen
pick-up occurs, vacuum
annealing is resorted to for
removal of hydrogen
Poor correlation between
strength and hardness.
Hence hardness cant be
used to monitor Heat
Treatment

Pickling of Titanium, its Alloys

Pickling has 2 functions to serve:
Removing the oxide scale
Removing the case layer
Molten salt descaling is an effective method of
removing oxide scale. Grit blasting is also
effective in removing scale
HF-HNO3 acid pickling used to remove
underlying case, once oxide scale is removed.
Bath conditions to be closely controlled to prevent
hydrogen pick-up

Problems in machining titanium

Compared to high strength steels, titanium, due to
its unique physical and chemical properties, poses
the following problems:
Lower thermal conductivity of Ti hinders quick
dissipation of the heat caused by machining,
leading to increased wear of cutting tools.
Lower modulus of elasticity leads to high spring
back, causing Ti parts to move away from the
cutting tool

Lower hardness and high chemical reactivity of

Ti lead to galling with the cutting tool.

WELDING OF TITANIUM
For fabrication of chemical engg. plant & Eqpt.,
commercially pure titanium is used. TIG & MIG
welding methods are used.
Welding of alloy titanium is difficult compared to
welding pure titanium:
alloys are weldable
Among + alloys Ti-6Al-4V has good
weldability
alloys are not weldable
Titanium being a reactive metal, entry of air to the
weldzone is to be strictly prevented through
protection with an inert gas cover to prevent
access to air

ELECTRON BEAM WELDING

In aircraft industry alloy grade Ti is used. Electron
Beam Welding (EBW) is extensively employed.
TIG welding is adopted only in a few cases.
Much better joints can be obtained by EBW of
alloy grade Ti. By welding in a vacuum chamber,
gas absorption is prevented.
The HAZ is very narrow and influence of welding
on structure is minimal.
Complicated work-pieces can be welded without
distortion.
Components with large wall thickness as well as
thin walled components can also be successfully
welded.

Comparison of Ti-6Al-4V TIG and EB welds

Microstructures of the alloy Ti-6Al-4V

Typical microstructure of elevated temperature

titanium alloys: bimodal (TIMETAL 834) and
lamellar (TIMETAL 1100)

Influence of microstructure on creep of

TIMETAL 1100

Influence of microstructure on fracture

toughness of Ti-6Al-4V (J-integral
measurements).

Fatigue crack growth behavior of two

extreme microstructures of Ti-6Al-4V

Creep resistant alloy development : Larsen

Miller Plot showing improvements in last 40
years

Density normalised temperature dependence of

the yield strength of several Ti alloys and a Ni
base superalloy

Metallic Materials used as

biomaterials

Stainless steel, e.g. 316L

Cast CoCr based alloys, e.g. CoCr30Mo6
Wrought CoNiCr alloys, e.g. CoNi35Cr20
cp-titanium and titanium alloys, e.g.
Ti6Al4V
cp-niobium
cp-tantalum

Why titanium is preferred as a

biomaterial
In human body fluid Ti, Ta and Nb show good
corrosion resistance. Stainless steels, CoCr and
CoNiCr alloys behave poorly.
Repair of passive layer occurs fast in Ti, Ta and
Nb. It is slow in stainless steels, CoCr and CoNiCr
alloys.
Ti, Ta and Nb are reported to be biocompatible
because they form protective surface layer.
Titanium shows better bioadhesion (integration of
metallic implants by bone ingrowth) compared to
316L stainless steel

Why titanium is preferred as a

biomaterial contd.
Titanium has youngs modulus closest to
that of bone. Biofunctionality (ratio of
fatigue strength to youngs modulus) is
highest for titanium alloys
Titanium can be processed/fabricated to the
required product shape , size and quality
Titanium is less expensive than Co-base
alloys, niobium and tantalum

Breakdown potential of metallic biomaterials in

Hanks solution and repassivation in 0.9% NaCl
(pH=7.4)

Attractive features of investment

casting of Titanium
Integral structural elements can be
manufactured cost-effectively, with little or
no machining effort
Cast parts show excellent dimensional
accuracy
Castings have an excellent surface quality
Satisfactory levels of mechanical properties
can be guaranteed

Melting of
titanium in
vacuum arc
furnace with a
consumable
electrode

Molding Materials
Should be non-reactive to liquid Ti or at least react
in a delayed way - a challenging task, considering
that Ti is a reactive metal
Conventional molding materials (used in nontianium casting - typical composition Al2O3-SiO2)
not suitable; molten Ti will react and dissolve Al,
Si as well as oxygen
Proprietary non-reactive shell systems have been
developed and patented, incorporating facing of
high melting metals (tungsten) or special ceramic
oxide layers with thermodynamic stability > that
of titanium oxide.

Technological measures adopted to

eliminate casting defects
To overcome the problem of limited
fluidity, centrifuge employed to accelerate
molten metal into mold cavity
Chemical milling of the contaminated
surface layer, a few tenths of a millimeter in
thickness
Hipping at ~1000 bar pressure of an inert
gas atmosphere and ~900C to eliminate
shrinkage cavities, porosity etc.

Examples of cast titanium alloys

Typical mechanical properties of cast

titanium alloys

The Ti-Al phase diagram

TITANIUM ALUMINIDES
Base

Broad composition Density

(At%)
(g/cm3)

Modulus
(Gpa)

Ductility Creep Oxdn.

at Room Limit Limit
Temp.
(C)
(C)

Ti3Al

23-25% Al
11-18% Nb

4.1-4.7

100-145

2-10

760

650

TiAl

48-54% Al

3.7-3.9

160-176

1-4

1000

900

Ti2AlNb

21-25 Al
25-30 Nb
4.5

96-100

20

600

600

Conventional
Ti alloys

Titanium heat exchanger plates

A plate heat
exchanger
being
assembled
out of
unalloyed
titanium
sheets

a) Plate and b)
tube heat
exchangers
manufactured
from titanium

Components
of titanium
alloys
produced by
closed die
forging

The main
landing gear
of the Boeing
777 primarily
uses forged
parts of Ti10V-2Fe-3Al,
among others
the truck
beam Bogie
Beam

Front fans of
commercial
Rolls-Royce
Trent
engines
made of Ti6Al-4V

Titanium
blisks for
compressor
applications

Presently the largest forged titanium blade has a length of

1650 mm (a) and is used for L-0 rows of steam turbines (b)

Open-die
forged
housing rings
for the
engine
RB199:
machining in
progress

Intermediate
casing for
large jet
engines.
(a)Diameter 152
cm, weight
173 kg;
(b)diameter 150
cm, weight
240 kg

Electron beam welded wing-box of the

aircraft type F14

Electron
beam welded
helium gas
container for
the satellite
Symphony

Sequence of
operations
during spin
forming of Ti15-3 half shells

Various investment cast parts for applications in the

low temperature section of a gas turbine engine

Investment cast titanium engine

components

Investment
cast titanium
condenser
rotors

Components of a hip implant made from

cast titanium

Exhaust gas turbocharger rotors made

from TiAl

-TiAl turbine blades

Cost comparison for one design of titanium

alloy aircraft fitting machined from blocks,
forgings and castings

Comparision of weight forged vs. cast

intermediate housing for the engine RB 199