1 1 Titanium metal production and additive manufacturing – contributing to a vibrant new industry...
-
Upload
rosemary-barnett -
Category
Documents
-
view
214 -
download
1
Transcript of 1 1 Titanium metal production and additive manufacturing – contributing to a vibrant new industry...
1
Titanium metal productionand additive manufacturing –
contributing to a vibrant new industry
Dr Dawie van VuurenMr Hardus Greyling
2
Outlay
• South Africa’s global Ti position• South Africa’s Ti beneficiation strategy• Primary Ti metal production• Large area high speed additive manufacturing
3
South African’s global Ti position in 2006
South Africa World Approximate Value
South Africa World
Reserves 220 Mt TiO2 1300 Mt TiO2
Mineral Production 1090 kt TiO2 5200 kt TiO2 $ 175m p.a. $ 840 m.p.a.
Slag Production 1090 kt TiO2 $ 490m p.a. $ 2500 m.p.a.
Pigment Production ~20 kt TiO2 5100 kt TiO2 $ 37m p.a. $ 10000 m.p.a.
Sponge Production Nil 125 kt p.a. Ti $ 1250 m.p.a.
Ingot Production Nil 145 kt p.a. Ti $ 2600 m.p.a.
Mill Products Nil ~90 kt p.a. Ti $ 4500 m.p.a.
Page 4
Industrialisation & Commercialisation
R&D Platforms
Technology Development
SATi Industry
Supplier Development
Design, Simulation and ModellingCSIR, ULim, Wits, NMMU
Laboratories and R&D FacilitiesCSIR, NLC, SU, UCT, UP, NMMU, UJ, CUT, VUT, Wits, Mintek, Necsa
Physical Metallurgy and CharacterisationUCT, CSIR, UP, VUT
PrimaryMetal
Production
CSIR
PowderConsolidation
CSIRSU
UCT
InvestmentCasting
CSIR
FrictionWelding
NMMU
High SpeedAdditive
Manufacturing
CSIR, NLCAerosud
CUT
High Performance
Machining
SUFh IWUAerosud
SheetForming
AerosudCSIR
R&D Platforms
Developing and commercialisingTechnology Building Blocks
for the South AfricanTitanium Industry
Oil & GasMarine
ChemicalAutomotive
AerospaceMedical
Titanium Centre of Competence
4
5
Cheaper Titanium powder – Changing the industry
Final Products/Components:
USD/kg 150 – 20,000
Ilmenite1 USD/kg Ti
TiO2 Slag1.45 USD/kg Ti
Ti Sponge10 USD/kg Ti
TiCl4
4.4 USD/kg Ti
Ti Ingot20 USD/kg Ti
Ti Mill Products50 USD/kg Ti
TiO2 Pigment5.3 USD/kg Ti
Ti Powder40 USD/kg Ti
Ti Powder10 USD/kg Ti
Typical prices
Current SA industry
66
Titanium Centre of Competence
2011 2012 2013 2014 20162015 2017 2018 2021 202220202019
Primary Ti Production (CSIR Process)
STAGE 2:Basic Development
STAGE 3:Pilot Phase (2kg/h)
STAGE 4 Implementation:Demonstration Plant
500 tpa Commercially Pure (CP) Ti
STAGE 5:World-Class Plant:20 000 tpa CP Ti
R29m R700m – R1bnCompleted
STAGE 4: Feasibility
Phase
R50 - 80m
Commercial partnersCSIR
Industrialisation plan for CSIR-Ti project
Concept designCost estimate & feasibilityBasic designCost estimate & approval Detail designConstructionCommissioningOperation
7
CSIR-Ti pilot plant flow diagram
Metal Melting& Feeding
TiCl4 Transfer
& FeedingReaction
SaltLeaching
Ti PowderClassification
Drying & Packaging
SaltCrystallization
SaltDrying
Molten SaltElectrolysis
UTILITIESCooling water, Steam, Compressed air, Argon, Electricity,
Off-gas scrubbing, Waste disposal, Storage
Reducing Metal
TiCl4
Cl2
Ti
8
CSIR-Ti process advantages
• Continuous operation - 60 years after scaling up the batch Kroll process,
there is still not a commercially proven continuous process.• Economy of scale with lower capital and operating costs• Downstream production and fabrication costs of titanium components are
significantly less for Ti powder than for Ti sponge.• CSIR-Ti process has lowest process temperature of all developments in
the world that is currently being tested on a similar scale of operation.
Scaling up is less risky with less corrosion, less salt entrapment,
reduced reagent and by-product vapour pressures and less hazards.• Closing of metal recycle loop much simpler than in other processes• It is the only direct titanium powder production process that is currently
being considered that gives the means to control Ti powder morphology.
9
Panoramic view of CSIR-Ti pilot plant
Page 10
Additive Manufacturing (or “3D printing”)
10
• Additive manufacturing (AM) is defined by ASTM as “the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.”
Page 11
Additive Manufacturing (or “3D printing”)
Source: Wohler report 2014
11
AM used in final part productionIndustries served
Page 12
Additive Manufacturing in aerospace
12
• Manufacturing of high-value low-volume components
• Reduction of machining and processing time and material waste
• Manufacturing of parts in exotic materials
• Manufacturing of complex 3-D parts • Manufacturing of assemblies • Manufacturing of tools
Page 13
AM in the Aerospace industry
“Composite materials make up 50% of the primary structure of the 787 including the fuselage and wing”
13
Page 14
Ti beneficiation
Ore
Sponge
Ingot Billet
Extensive Machining
Final Part
90+%
Additive Manufacturing
Powder Min Machining
<5%Waste
South African Development
South African Capability
AeroSwift
14
Page 15
Present limitations/opportunities
• Limited production rate
• Inefficient laser manipulation
• Limited energy input
• Serial processing
• Limited part size
• High Cost
• Capital cost
• Production cost
• Material cost
• Aerospace Qualification
15
Page 16
Aeroswift - Objectives
16
• Design and construct a large area, powder bed AM system, for metallic components:o Powder layer manufacturing o High speed system for
Production of large metal parts High throughput
o Versatile to support optimisation of parameter fieldo Build volume:
2m x 0.6m x 0.6m Scalable build volume
o Pre-heating and environmental controlo Materials that can be accommodated
Ti-6Al-4V Stainless Steel alloys Inconel Other metals
Page 17
17
Characteristic Laser Metal Deposition (Direct Energy Deposition)
Selective Laser Melting (Powder Bed Fusion)
Materials Most metals, functionally graded builds Most metals
Part size Depends on handling system
600mm x 500mm x 450 mmAeroswift 2m x 620 mm x 620 mm
Part complexity Limited Nearly unlimited
Build rate 20 -30 mm3/sec Commercial systems 10 -20 mm3 sec, Aeroswift up to 60 mm3/sec
Base Many geometries, also existing parts Flat plate
Surface roughness (Rz) 60 to 100 µm 50 to 70 µm
Laser Metals Deposition vs Selective Laser Melting
Page 18
Part size
Wire depositionsystems
Powder Deposition
systems
Powder bedsystems Aeroswift
<500mm >2000mm
Par
t co
mp
lexi
ty
HIGHER VALUE
Aeroswift in the AM technology landscape
18
Page 19
Aeroswift – Summary of 2014 Achievements
• Phase 1: Machine design and construction completed
• Phase 2: Process development and optimisation started. (Nov 2014)
• Machine testing, evaluation and optimisation• Parameter testing and optimisation• Milestone: End 2017: Flight-ready demonstrator part
• Process development achievements• Consolidation rates up to 60mm3 /sec demonstrated• Low sample porosity (lower than 0.5%)
• Commercialisation strategy develop and presently being implemented
19
Page 20
Progress – Process development
© CSIR 2015 www.csir.co.za
20
Sample
¼ Charpy impact
toughness at 25°C(J)
Vickers Micro Hardness(HV)
Ti6Al4V manufactured by 400W laser powder bed fusion machine
6 370-440
Milled and annealed reference sample
7-8350
Ti6Al4V made by Aeroswift high power laser powder bed fusion technology
8-10 320-390
21
Thank you
Questions?
Hardus Greyling Dr. Dawie v Vuuren