Superplastic Forming of Titanium

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Superplastic forming of titanium

European TitaniumConference 2009Parallel Session D: 11.10am 11.35am

Dr Richard Curtis PhD, DIC, CEng, CSci, FIMMM, FADM

Chair, IOM3 Superplasticity Committee, UK.

Department of Biomaterials, Biomaterials, Biomimetics and

Biophotonics Research Group.


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Acknowledgements

Dan Sanders, Boeing Inc

Bill Swale, Aeromet Ltd

Peter Stewart, BAe Systems

Mike Wallis, Rolls Royce

Werner Beck, Formtec AG.

Colleagues at Kings College London,University of Wales Swansea, University

of Kentucky.


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A community..

....of superplastic forming practice has

emerged:

- Euro SPF meetings, 2001, 02, 04, 05,

07, 08, 2010 (Bilbao / San Sebastian)- Euro SPF website

- UK IOM3 Superplasticity Committee

- USA Superplastic Forming Committee

- ISO, ASTM and Standards


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Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

SIM-O-SPF will provide a forum to share knowledge and experienceabout SPF process in general and Simulation of SPF in particular.

Will identify limitations of current Simulation capabilities andrecommend future developments

Will create an effective partnership amongst all members fromdifferent background (academia, commercial software and industry)

Providing immediate access to well established simulation tools thatare used by various parties for SPF applications in Aerospace, Railand Automotive

Introduce Simulation-based approach to SPF that would result in

higher quality components, improved design, optimizedmanufacturing parameters and a more cost effective approach

Enhance the capabilities of existing Simulation tools by furtherdevelopments and diversity in applications

For further details contact: [email protected]

SIM-O-SPF - what are the

objectives..?


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The Euro-SPF group is a community federating European industries and universitiesinvolved in SuperPlastic Forming. It promotes exchanges between the members as well

as the SPF technology. It also informs about the meetings directly or indirectly linked toSPF and about the positions offered in the universities and in the companies


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SPF technology in aerospace


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SPF technology in automotive


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Induction coil

heating

Ti-6Al-4Vsheet

ceramicdie

argon

gas

Die chamber pre-heatedto 900oC inside the press

Ceramic dieTi-6Al-4V Alloyformed sheet

SPF for Medical ProsthesesTitanium alloys have some of the best biocompatible properties of allmetallic alloys and for this reason many dental and medical implantsand devices are manufactured from both the commercially pure andthe Ti6Al4V alloy forms.


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Orbital Floor Fracture Upper face trauma usually results in fractures of the internal orbit,

usually termed Orbital Blowout Fracture.

Patients usually present with pain, swelling & often double vision isexperienced.

Bones in the orbital region play a vital role in the normal function of

the eye.

Therefore, accurate realignment or anatomic reconstruction ofthe bony orbit is essential in maintaining normal function.

Recent advances in diagnosis & treatment of internal orbitalfractures:

CT scanning greater ability to improve implant design andproduction.


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Aeromet Forming Division, establishedin 1985 produces Airframe and EngineComponents from Titanium Sheet and Plateby Superplastic, Hot Forming,Chemical Milling and & Laser Trimming.

Aeromet makes a minimum of 150 differentSPF components on a production basis

Superplastic Forming Press

Chemical Milling Plant5 Axis Laser Trimming


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Superplastic

Forming

Superplastic Forming at

900C Four components

in one pressing Ti6/4

2,0mm thick


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Spherical & Conical shapes

produced by SPF

Size:-600mm diameter x

300mm deep x 0.81mm

skin thicknesses.

Material - Ti 6/4

Assembly of Nine SPF Details

Complex assembly


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Tail Cone Section


900C Two productsTi6/4 0,8mm and one at

1,6mm thick. Size 800mm sq.


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900C from 2.2mm thick

Ti6/4Size 800 x 600 x 300mm

Deep.

Tail Cone Section


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Product Examples

Various Firewalls

& Assemblies madefrom Superplastically

Formed components.


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Typhoon

Keel Panel

TunnelskinPanel

General view of two sheet SPF/DB keel panel in part assembled rear fuse of Typhoon.

(NB. Single sheet tunnel skins also present)(Courtesy BAe Systems)


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TyphoonTop sheet

Lower sheet

Core sheets

Segment of four sheet X core configuration of SPF/DB Typhoonfore-plane.

(Courtesy BAe Systems)


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Cellular structure

~1100mm

Four sheet DB/SPF/DB six cell demonstration piece.

(Courtesy BAESystems and MOD)


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DB/SPF fan blade - internal structure

Section > 80% Hollow

Membrane

PanelDiffusion

Bond

Superplastic

line core

Rolls-Royce Barnoldswick


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An SPF cell with the latest generation

of presses at Rolls-Royce Barnoldswick


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The information contained herein is proprietary to FT and shall not be reproduced in whole or part or used for any purpose except when such user processes direct written

08.05.28_ISC Forum.ppt 22

Replacement of forged shells

No final surface machining

Thickness formed to final shape

Schedule reduction

Cost savings ~30% from

Ti-scrap reduction

Production effort

ARIANE V, SPF Hemispheres Ti6-4

Membrane thickness s=0,8 -0/ +0,2mm

Pole/equator zone thickness = 1,8 /2,2mm

Roundness tolerance D= 483 0,2mm

Final strength= 1020 N/mm


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Ti 6-2-4-2 ClosingShell

Closing shell ri./ le. with weird shape

Process and forming tools fully functional

SPF parameters Ti 6-2-4-2 from FTdatabase

Cycle time ~10 mins


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Silent HelicopterExhaust

Materials data beyond current max application

temperature, Ti6-4, Ti6-2-4-2 and Ti beta21S

Temperature simulation

Stress simulation

Design process = f (low mean + peak stresses,heat flow, heat radiation, temperature

dissipation) Process development

Prototype articles

Engine bench test


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SPF Standards


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26All Content of this presentation, copyright LISTechnology Ltd.

SuperPlastic Laser Integrated Component Equipment

(SPLICE)

Cutting

Blanks from

Sheet Stock

Welding and/or

Diffusion

Bonding

Removal

of Surplus

Material

Hole

DrillingSPF/DB

Raw

Material

Finished

Component

Surface

Preparation

In Process Inspection

LASER

Laser Induced Superplasticity

(LIS)

SPF/DBFatigue

Enhancement


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Laser Induced Superplasticity (LIS)

Double Sided

Forming


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Benefits of the Technology Being Pursued

Quicker

Process should allow a Massive Compression inSPF/DB Cycle Times

Material Preparation75%

Reduction

Heat-up90%

reduction

Forming15%

reduction

Cool Down95%

reduction

Finishing Operations50%

Reduction

Long Cycle Time

Short Cycle TimeSaving of 66%


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log

log

Ti-6Al-4V

patient

die

FE meshes

FE-SPFsimulation

Pressure cycle

SP formingprostheses

Superplastic Prosthetic Forming

Simplewaresolution

In this case, Simplewaresoftware allows conversionof 3D images into high qualitymeshes which can be used forFEA, CAD and RP. Enablingimplant design and manufacture.

Said & Curtis et al. KCL


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Provision of Maxillofacial Implants

(Wehmller et al, 2004)

Cranioplasty Orbital Floor Reconstruction Malar Augmentation

Trevor Coward and Richard Curtis, KCL


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Contamination in titanium

The alpha case isgenerally known to be

developed by theinterstitials such as carbon,

nitrogen and especiallyoxygen dissolved from

mould materials

from the synthesis of themicrostructure,

the hardness profile, EPMA mapping

and TEM, it could be confirmed that thealpha-case is formed by not onlyinterstitial oxygen atoms but also

substitutional metal atoms dissolved

from mould materials.Materials Science and Engineering A 405 (2005) 173177


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32

Die-Ti-6Al-4V surface modification

Forming conditions: 180 minutes @ 900C

Quartz substrateCroform investment

substrate

100 m 100 m

Ammonium Biflouride etch

Atwood & Curtis et al. KCL


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Time (min)

0 50 100 150 200

Depth(um)

0

50

100

150Croform-WB

RematitanUltra

Alumina

Zirconia

Silica

800 C

850 C

900 C

Depth of interaction zone

Atwood & Curtis et al. KCL


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Bending Ductility Tests

Determine the ductility or strength of aDetermine the ductility or strength of a

material.material.

AimAim -- produce results of eitherproduce results of either passpass oror failfail..Clause 6Clause 6Shall not show any cracking onShall not show any cracking on

the outside surface of the test piecethe outside surface of the test piecestripstrip

should be bent through an angle of 105should be bent through an angle of 105

around a mandrel.around a mandrel.

Failure of the test pieceFailure of the test pieceplasticplastic

deformation or crack initiationdeformation or crack initiationmay bemay be

attributable to one mode only. In the case ofattributable to one mode only. In the case of

a threea three--point bend test, it is most likely to bepoint bend test, it is most likely to be

due to thedue to the tension on the lowertension on the lower, convex, convexsurface.surface.

InstronInstron 11931193 machinemachine -- produce resultsproduce results

(Load(Load vsvs Deflection graphsDeflection graphs).).

V-block bend

test

Ditta & Curtis et al. KCL


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Load (N)

Deflection (mm)

Load vs Deflection graph



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- specimens 1 - 3 = die-side in tension.

- specimens 4 - 6 = gas-side in tension.

Bending Test Samples



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Furnace 20

Deflection (mm)

0 2 4 6 8

Load(N)

0

100

200

300

400

500

12

3

4

5

6

Specimen number

Furnace Samples

Overlap of

graphs

}die

}gas



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SPF Samples

SPF 30 - (Guys 422)

Deflection (mm)

0 2 4 6 8

Load(N)

0

100

200

300

400

500

1

2

3

4

5

6

Specimen number

4-6 : able towithstandgreater loadbefore failure. 1-3 : failed

earlierthan 4-6.

}die

}gas


Eff f i h i l


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Furnace 20 VS Furnace 120 : Specimens 1-3

Deflection (mm)

0 2 4 6 8

Load(N)

0

100

200

300

400

500

F 20 - 1F 20 - 2

F 20 - 3

F 120 - 1

F 120 - 2

F 120 - 3

Specimen number

Effect ofEffect of timetime on mechanicalon mechanical

properties:properties: furnacedfurnaced samples.samples.

Furnace 120 no plasticregion on

graphs brittlebehaviour.

Furnace 20obviousplastic regionon graphs ductilebehaviour.

(die-side)


Bioactivity assessment by immersion in SBF using SEM and EDX:


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Bioactivity assessment by immersion in SBF using SEM and EDX:

Ti64 (Sanded) SP700 (Sanded)

D1

D3

D7

D7

Ca

P Ca

Mg

Ca

P Ca

Ti64 (NaOH) SP700 (NaOH)

EDX

(D7)

Omar & Curtis et al. KCL

SEM and EDX:


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Ti64 (Degu 900C) Ti64 (Wiro 900C) SP700 (Wiro900C)

D1

D7

D3

EDX

(D7) Mg Si

P Ca

Ca

Mg

CaP

CaP

CaSi

SEM and EDX:

Ti Ti Ti

Ti



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42

Cp-1 Ti64

G417 20min

G416 120min

TCP control

PVC toxic control

Day 3

Nunclon tissue culture plate

TCP: tissue culture plastic no diskCP-1: unalloyed titanium

Ti64:Ti64-G417 (SPF 900C)Ti64-G416 (SPF 900C)PVC control: Portex +control strips

Cells: primary human osteoblasts

Atwood, DiSilvio & Curtis et al. ongoing project, KCL


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CP1

Ti64

SP700

20min

120min

tcp

tcp2

pvc

Arb.

Units

0.0

0.1

0.2

0.3

Alamar Blueproliferation - indicates metabolic

activity affected by the number of cells


Superplastic Prosthetic Forming samples: g417 (20 min) / g416 (120 min)

human osteosarcoma cells


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Alkaline phosphatase produced by cells

associated with bone forming tissue (differentiation)


ALP expression in cell lysate distrupted cell membranes represents differentiation


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Alkaline Phosphatase in Supernatant Solution

0

0.020.04

0.06

0.080.1

0.12

0.140.16

0.18

cp-1

Ti64

sp700

g417

g416

tcp

pvc

m b

Sample type

arb

units

Average

sample set 1

sample set 2

sample set 3

tcp = tissue culture plastic (no sample)

pvc = polyvinyl chloride toxic control disk

m = medium alone (no cells)

b = buffer alone (no cells)

Supernatant meaning fluid from around/abovecells however, cells could be withdrawnfrom the fluid influencing the results. NB. cellsmay not be adhering to surface of the disk.

27 disks: 3 of each type of disk - each point is 4 measurements

..the activity of the enzyme ALP reaches a peak atday 7 on SPF titanium alloy (g417) suggesting thatthe presence of reaction products on the surfacehave a stimulatory effect

Alkaline phosphatase released from cells on

surfaces in media

CellCellCellCell ProliferationProliferationProliferationProliferation


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CellCellCellCell ProliferationProliferationProliferationProliferation

Classicalproliferation

profile

----AlamarAlamarAlamarAlamar blueblueblueblue to measure cytotoxicity, proliferation or activation


Recent advances in the understanding of


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Recent advances in the understanding of

the chemistry of investment materials? Scrimgeour et al., (2007) with 31P solid-state MAS-

NMR spectroscopy on phosphate bonded investment:

(a) Deguvest

-- setting struvite, amorphous orthophosphate

-- burn-out (900C) farringtonite, Mg

metaphosphate

(b) Wirovest

-- setting struvite, amorphous orthophosphate-- burn-out (1050C) pyrophosphate (dominant),

amorphous orthophosphate.

h k b h


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What is known about the titanium

alloy surface?

Titania (TiO2) of 7 8 nm forms a passive and corrosion

resistant film on the alloy surface

Titania is an n-type semiconductor that can be doped withother elements to modify its electronic properties. e.g. Nb5+ ions orP5+ ions

Titania exists in three different crystalline allotropic forms,brookite, anatase and rutile although it may also be amorphous


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RutileRutileRutileRutile titaniatitaniatitaniatitania

For Ti-6Al-4V alloy

the transformationto rutile is

suppressed

For Ti-6Al-4V alloythe transformation

to rutile is

suppressed

http://www.fis.unipr.it/phevix/img/tot_disorder.jpg

http://zqlin.public.iastate.edu/TiO2%20Raman%20Spectra.jpg

Omar, Festy & Curtis et al. KCL

Shapes produced by


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Shapes produced by

Superplastic Prosthetic Forming

Juszczyk & Curtis et al. KCL

Documents

Superplastic Forming of Titanium