MATEC Web Conf.
Volume 321, 2020The 14th World Conference on Titanium (Ti 2019)
|Number of page(s)||12|
|Section||Melting and Casting|
|Published online||12 October 2020|
Titanium alloy design and casting process development using an Integrated Computational Materials Engineering (ICME) approach
1 Department of Materials Science & Engineering, The Ohio State University, Columbus, OH 43210, USA
2 Now at National Institute of Standards & Technology, Gaithersburg, MD 20878, USA
3 Global Research and Development, General Motors, Warren, MI 48090, USA
4 Department of Integrated Systems Engineering, The Ohio State University, Columbus, OH 43210, USA
5 Department of Materials Science & Engineering, University of North Texas, Denton, TX 76203, USA
The application of titanium components is generally limited by their high raw material and manufacturing costs. In this paper, a lower cost cast titanium alloy based on the Ti-Al-Fe system has been designed using an ICME approach. The new alloy Ti-6Al-5Fe-0.05B-0.05C (all wt.%) significantly reduces raw material cost and demonstrates improved castability compared with the baseline Ti-6Al-4V alloy. The fine primary and secondary α phase microstructure in the new alloy, due to Fe partitioning, provides exceptionally high strength (1023 MPa yield strength and 1136 MPa ultimate tensile strength) and reasonable ductility (3.7% elongation) for structural applications. On the manufacturing front, the high cost multi-step investment casting process currently used can now be replaced with a low-cost permanent mold casting process using steel molds and a novel ceramic coating. An experimental casting setup, including an induction skull melting (ISM) system, a gravity tilt-pour system and a ceramic-coated H13 steel mold, has been used to produce near-net-shape permanent metallic mold castings with the new titanium alloy developed. Using this setup, and aided by casting process simulation, a prototype automotive connecting rod was cast successfully. The ZrO2 ceramic coating applied to the H13 steel mold was proven effective in minimizing the metal-mold reactions.
© The Authors, published by EDP Sciences, 2020
This is an Open Access article distributed under the terms of the Creative Commons Attribution License 4.0, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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