Low-Cost Titanium Powder For Feedstock

Low-Cost Titanium Powder forFeedstockPrincipal Investigator: Curt LavenderPresenter: Mark T. SmithPacific Northwest National LaboratoryOVT 2008 DOE Peer ReviewFebruary 28, 2008This presentation does not contain any proprietary or confidential information.OutlinePurposeBarriersMotivation – Large potential vehicle mass savingsApproachzSurvey emerging titanium technologies zCost AnalysisEvaluate the product qualityAs-needed develop process parameters to consolidate the new materialsProgresszzzCost Study – ITP PowdersLow Cost TiCl4Powders from Low-Cost TiCl4 zMorphologyMechanical PropertiesSintering behaviorConsolidation by Direct Press and Sinter – Lowest Cost Process High Rate Gear Production TrialsTechnology TransferConclusions – To DateNext Steps – FY 08zzCost analysis of 2 new processesFabrication of high strength beta alloy in rod formPublications21

PurposeThe purpose is to develop and demonstrate technologiesfor producing automotive components out of titanium andtitanium alloys at ever-lower costs.zDevelop low cost titanium powder for use in Powder Metallurgy(P/M) components and EB Hearth Melting zUtilize powders from emerging low cost powder production technologiesand low cost feed stocksDevelop, as-needed, parameters for powder and press and sintertechnology for low cost Ti powders to facilitate commercialization3BarriersTitanium is the only lightweighting material that can be substituted forhigh strength and corrosion resistant steels used in automotiveapplications.z Titanium can be used in suspension, fuel cells, fasteners,reciprocating components etc with individual component masssavings of up to 70% (hollow core springs) over incumbent materials.z Technically titanium has been demonstrated in many automotiveapplications in low-volume highly specialized vehicles.The barriers to realizing the mass savings associatedwith titanium in high-volume vehicles have been:z Raw material costz Secondary processing costPerformance benefits are realz 14 auto OEMs have used titanium components in production vehicles. Ranging from massive springs to small washersReduced cost required for implementation into high production volumevehiclez Powder Metallurgy with powder cost less than 4/kg Can’t be met with current Kroll or Hunter processing42

Overview of Fuel Cell Materials NeedsSuspension, 11%Electrical, 4%Fluids, 4%Interior, 10%Glass/Trim/Hardware, 6%Fuel Cell, 27%Closures, 5%Wheels/Tires, 6%Steering and Brakes, 3% Exhaust, 6%Body in White, 18%StorageBatteryPackaPackagege andControlsControlsHydrogen FuelDelivery SystemFuel CellExhaust SystemFuel Cell StackStackand veBraking MotorsBrakingand DriveDriveSystemHeat ExchangersExchangersand HVACPackageHydrogen FuelFuelStorageProtectionSystemElectricElectric PropulsionPropulsionMotor and PowerElectronicsHydrogen StorageTank(s) andPressure ControlControlSystem5Total Vehicle SavingsWith Ti Intensive Materials SubstitutionMaterialsNeglecting Body-inBody-in-White-WhiteBody-in-WhiteFuel CellPower UnitVehicleStructureTotal FuelCell VehicleSteel orTitanium, kgStainless Steel,kg300197% Savingswith Ti34%81864721%111884425%A 10% mass savings in an automobile can result in fuel economy improvementsfrom 1 to 3% - model dependent.zTitanium impact on US fuel usage is potentially very highA similar study by GM suggested that 60% of the mass of the chassis alonecould be saved. (Kim et al. 2006)zTechnical feasibility demonstrated for many of the applications considered63

ApproachThe approach of this project will be to produce and evaluatelow cost titanium powders using feedstock materials thatallow for the production of commercially pure and alloyedpowders approaching the FreedomCAR cost goals.zzFunding low-cost powder production and processing demonstrationsfor emerging Ti powder technologies.Perform cost analysis of emerging titanium powder technologies. Perform enabling tasks – such as demonstration of low cost powdersproduced from TiCl4 from ilmenitezDevelop process parameters for low cost consolidation.zEvaluate the suitability of low cost powder for feedstock in EBHearth Melting – works very well not discussed. Press/sinter and powder forging7Results - Cost AnalysisAnalysiCan the new Ti technologies meet the automotive hurdle?Contracted Camanoe Associates to analyze selectedprocesseszTechnical cost model that evaluated several emerging powder technologies –up to solid-state consolidation of a slabzSelected International Titanium Powder (ITP) process for further evaluation A sampling from more 20 new technologies (EH Kraft 2005) Potential final powder cost, predicted to be less than the automotive industry hurdlein the “optimistic” scenario The ability to directly produce alloy powders- Continuous low cost conversion process dependent upon raw materialsTiCl4 (v) 4 Na (l ) Ti ( s ) 4 NaCl ( s )FlowingSodiumTiCl4MxClyTi – alloyNaCl84

Impact of TiCl4 Cost on Production Cost1.05Normalized PowderProduction Cost1A reduction of 44% in TiCl4 costreduces Ti powder cost by 21%0.950.90.85Optimistic AnalysisApproaches automotive cost hurdle0.80.750.70.50.60.70.80.911.1Normalized TiCl4 Purchase Price9Low Cost and Highly RefinedTiCl4 Powder ComparisonHighly Refined TiCl4Low Cost TiCl4Low cost TiCl4 contained different trace impurities that were carriedthrough powder – result of fewer refinement steps.zzLittle or no difference observed in powder morphology with TiCl4composition for ITP powder.Observed higher sintered density for powders from low cost grade of TiCl4. zGreater than 96% density for press and sintered powdersObserved swelling in CP grade without the impurities associated with low costTiCl4Typical mechanical properties for both types – when sintered to 96 % 375, 450 MPa yield and ultimate, respectively, with 8 to 15% elongation105

High Production RateTitanium Powder CompactionPressed gears in standardproduction die.zEncountered 2 problems: Interference with punch and dieand liner eject – MillingparametersLamination cracking – as few as3 pressings without lubricationHistorical Ti P/M difficultiesremain with the new powders.11MillingTypical open structure of powderzAfter milling to increase tapped densityMilling parameters were developed to successfully compact theligament structure improving tapped density while reducing oxygen pickup to less than 400 ppm, thereby eliminating die interference126

Gear Pressing StudyLubricationLubrication EffectsEffects31 Tooth Spur Gear PressingImprovement in Green Density with Die and Powder Lubrication0.85Percentage of Theoretical Density0.840.83Powder Lube0.820.81Die cleaning and lubingbetween 080000850009000095000Pressing Pressure, psi13Technology TransferPowders are not produced at PNNL commercialsuppliers are being used and feedback on powdersare directzzInternational Titanium PowderE.I. DuPont Nemours Hunter Fines – batch Na reductionPublication of P/M process developmentzInteraction with Western Sintering for practical highvolume pressing147

Conclusions – To DateDatTitanium can significantly impact the mass of both ICE and FCvehicles.zzPredicted mass reductions of greater than 25% for Fuel Cell vehicles.Up to 60% in Chassis alone.Auto industry understands the performance benefits of titaniumzz14 OEMs have successfully used Ti in selected automobiles.The question is implementation into high volume vehicles.The implementation of Ti to the high volume automobile is limited by:zCost of raw materials zAggressive projects throughout the world; more than 20 processes being evaluatedUnique opportunity in the automotive industry to establish new standards – takeadvantage of new processesCost of component manufacture Move from “Rotating Grade Aerospace Titanium” Triple VAR to lower cost methods- Solid state consolidation – Direct Press and Sinter- Many projects looking at this – many are privately funded and ongoing15Conclusions – To DateDatDirect Press/Sinter Powder Process DevelopmentzSintering of the powders are impacted by small “alloying” additions. zThe high die-friction observed in Ti processing can be overcome blubrication. zIncreased sintered density observed when the onset of sintering is delayed.Opportunity for tailored powder metallurgy alloys.Instrumented die trials show lubricated Ti behaving similar to steel in die pressingIn-die and ad-mixed lubricants have been successfully demonstratedImpurity concerns to be addressed however volatile lubricants have beensuccessfully used both in-die and ad-mixed.Milling of the ITP powder to alternate distributions has been performedwith less than 200 ppm Oxygen pick-up and sintered to greater than 96%dense Attrition milling for very short times with and without milling aid.Tailored powder morphology facilitate die-fill and compaction for fine detailedcomponents.168

Next Step for FY 08There are 2 “New” processes for cost analysiszTiH2 from “ADMA” process – Ukrainian Sponge PlantzDuPont – MER DOE/IPP ProjectElectrowinning process developed at MER licensed by DuPont- DARPA funded processDevelopment of alloys for automotive usezzBeta alloy bar stockBillets to be supplied by DuPont, ADMA using ADMA, ITP andDuPont powdersComplete lubrication developmentzProvide logical selection process and recommend lubricants to bepublished at MPIF June 2008.17Publications/PresentationsLavender CA, KS Weil, MT Smith, and Y Hovanski. 2006. "The Effect of LowCost TiCl4 in Titanium Powder Processing." AeroMat 2006, Seattle, WA.Weil KS, Y Hovanski, and CA Lavender. "Investigation of a Low-Cost TiCl4Source for Use in Titanium Powder Synthesis via the ArmstrongProcess." MS&T'06 Conference, Cincinnati, OH.Weil S, NL Canfield, Y Hovanski, and CA Lavender. 2006. "Development ofLow-Cost Titanium Powders for Automotive Applications." Presented by CurtA. Lavender (Invited) at MPIF 2006, San Diego, CA on June 19, 2006. PNNLSA-50611.Lavender CA (Invited), Y Hovanski, and K Weil. 2007. "Modification andAnalysis of Titanium Powders Synthesized by the ArmstrongProcess." MS&T07, Detroit, MI.Hovanski Y, CA Lavender, K Weil, and LA Jacobsen. 2007. "Net ShapePowder Metallurgy Processing Using ITP Titanium Powder." Presented by YuriHovanski at TMS 2007 Annual Meeting & Exhibition, Orlando, FL on Februar27, 2007.189

z Develop low cost titanium powder for use in Powder Metallurgy (P/M) components and EB Hearth Melting Utilize powders from emerging low cost powder production technologies and low cost feed stocks z Develop, as-needed, parameters for powder and press and sinter technology for low cost Ti p