Innovating the Future of Titanium Production at the U.S. Department of Energy Advanced Research Projects Agency-Energy (ARPA-E)

James F. Klausner

Program Director U.S. Department of Energy, ARPA-E 1000 Independence Ave, SW Washington, DC 20585

Titanium 2015, OCT 5th ARPA-E Mission

Catalyze and support the development of transformational, high-impact energy technologies

Reduce Imports Ensure America’s

► Energy Security

► Technological Lead Improve Reduce Efficiency Emissions ► National Security

► Economic Security

1 Approach

Identify fundamentally disruptive technologies with potential to transform the marketplace

steam-powered Cugnot cost (1769) performance Disruptive Benz motorwagen (1885)

Transformational existing technology & Disruptive Ford Model T (1914)

Transformational to Market time ARPA-E Takes on High Risk Technology Development

Strategic Partner or Venture Market Deployment

Military; Govt Pilot Scale System Demonstration Angel High Risk ARPA-E Bench Scale System $3-5 Million Demonstration

Lab Scale Component Demonstration Lab Scale Proof of

Technology ReadinessLevel Technology Concept Science Validated Valley of Death Valley

Investment $

3 What Makes an ARPA-E Project?

IMPACT ‣ High impact on ARPA-E mission areas ‣ Credible path to market ‣ Large commercial application TRANSFORM ‣ Challenges what is possible ‣ Disrupts existing learning curves ‣ Leaps beyond today’s technologies BRIDGE ‣ Translates science into breakthrough technology ‣ Not researched or funded elsewhere ‣ Catalyzes new interest and investment TEAM ‣ Comprised of best-in-class people ‣ Cross-disciplinary skill sets ‣ Translation oriented

4 ARPA-E Programs

ARPA-E has invested in over 380 energy technologies across 20 focused program areas and 2 OPEN solicitations

Transportation Energy Technologies

Transportation and Stationary BEEST Electrofuels RANGE Energy Technologies HEATS AMPED REACT PETRO MOVE REMOTE

METALS SWITCHES Stationary Energy Technologies

Solar GRIDS IMPACCT FOCUS ADEPT

BEETIT GENI ADEPT REBELS

5 ARPA-E METALS Program

Vehicle Lightweighting is the Future

4 Quads (1 Million GWh) Energy Savings Potential in Fuel Economy

Lightweight 26 mpg—Steel 30% less fuel consumption 18 mpg (40% improvement) Global Demand for Aluminum, Magnesium and Titanium Projected to More than Double by 2025

6 Significant Increase in Light Metal Deployment for Ground Vehicle Lightweighting

Ford Launches new Material composition of baseline (1977-2007) aluminum body F150 as a and mass reduced (2020) vehicles production vehicle

Global demand for aluminum projected to more than double by 2025

7 Ti Demand Projected to More than Double Due to Aircraft Lightweighting

● Boeing 787 and 777 lightweight aircraft require 80 and 50 metric tons of titanium per airplane, respectively (enabler of carbon fiber)

● Boeing projects 34,000 new airplanes to be built between 2012-2031

● 2.2 million tons required to meet demand or 116 thousand tons/yr

8 ARPA-E METALS Program: Primary Production

●Light metals enable advanced alternative energy technologies, i.e. lightweight vehicles

●Commercial light metal production processes are energy and emissions intensive

●Domestic light metal production is on the decline due to higher cost of energy, higher cost for labor, and higher cost for importing ore Scaling Law

Thickness Ratio: C2 E2 χ2 ρ1SR2 t1 S2 = = = SAME part = C1 E1 χ1 ρ2SR1 SAME bending strength t2 S1 SR – strength to weight ratio DIFFERENT material C – cost intensity t – thickness E – energy intensity S – yield strength χ - emissions intensity

Goal is Al, Mg parity with steel 9 Ti parity with stainless steel ARPA-E METALS Program

Primary Metal Production 56 kW/kg 44 kW/kg 100 kW/kg 22 kgCO2/kg 7 kgCO2/kg 36 kgCO2/kg 2 $/kg 3.3 $/kg 9 $/kg

Al Mg Ti

20 kW/kg 27 kW/kg 35 kW/kg 7 kgCO2/kg 7 kgCO2/kg 11 kgCO2/kg 1.5 $/kg 2 $/kg 4 $/kg Steel Parity Steel Parity SS Steel Parity10 Domestic Light Metal Production Compared with Global Demand

50 900 45 800 40 700 35 600 US Magnesium 30 US Aluminum 500 Global Magnesium 25 Global Aluminum 400 20 300 15 10 200 5 100 Al Production (Million Production Tons) Al

0 ProductionMg (Thousand Tons) 0 1970 1975 1980 1985 1990 1995 2000 2005 2010 1970 1975 1980 1985 1990 1995 2000 2005 2010

200 United States % share of Global Production (2011) 180 Aluminum 4.7% 160 140 Magnesium 5.6% 120

Titanium 8.7% 100 US Titanium/sponge* 80 Global Titanium 60 Strong interest in small modular 40 Processing, distributed geographically, to 20 leverage regional energy sources 0 Ti Sponge Sponge Ti Production(Thousand Tons) 1970 1975 1980 1985 1990 1995 2000 2005 2010

11 Primary Production of Titanium Powder

Process: hybrid ilmenite carbothermic/electrolysis reduction for Ti powder production

Process: electrowinning of TiCl4 to Ti powder using segmented thin diffusion barriers to prevent bipolarity

Process: hydrothermic

reduction of TiCl4 to Ti powder using plasma reactor

12 Primary Production of Titanium Powder

Process: acid leaching of Ti slag and

MgH2 reduction for TiH2 powder production

Process: high temperature thermal energy storage using flowing ceramic powder

13 Case Western Reserve University: Electrowinning Titanium from TiCl4 Using Segmented Diaphragms Dr. Rohan Akolkar

• Electrowinning process based on utilizing a stack of thin, electrically-isolated diaphragms • Goal is to design diaphragm thickness and quantity to eliminate bipoliarty – a key hindrance in energy efficient titanium electrowinning • Targets: • Steady operation: >200,000 Ahr/m2 Ti plating • Current efficiency: >95% (cathodic) • Mechanical and chemical stability A Vision of an Electrochemical Cell to produce clean Titanium Dr Stephen P. Fox, TIMET Technology Summary Use of domestic ilmenite or perovskite ore (rocks) instead of imported rutile sands Elimination of Kroll process that uses molten magnesium Production of oxycarbide by carbothermic reaction, followed by controlled chlorination to obtain dichloride, then electrowinning to obtain titanium-salt mixture, then classification/ distillation to retrieve titanium Salt and chlorine recycled, CO captured in process Technology Impact CO sequestered as fuel credit Rutile ore (black sand) Ilmenite ore (rock) CP titanium powder Carbon footprint reduced New technology, knowhow created, stepchange from 60 year old techniques Protects and creates jobs in the US Allows domestic ores to be used – additional employment and industry sector increased Proposed Targets Metric State of the Art Proposed

Reduce electricity HEP when 20% reduction in costs and power available, variable operating consumption otherwise fossil costs fuel sources Reduce parasitic heat Kroll Process of reaction used for 60 years Ore reduced to oxycarbide, to chlorinated titanium salt, to pure titanium, with salt and chlorine recycled and CO captured Reduce green house CO2 is captured Produce and gas emissions but unused capture CO instead

Electrochemical Cell to Produce Clean Titanium from Domestic Ores 15 MER: Advanced Titanium Electrowinning using Alternative Ores Jim Withers &Chris Pistorious

• Primary path is to innovate on the direct electrowinning of Ti from TiOC • Process is electrolytic and therefore easily scalable; eliminates magnesium use/regeneration from Kroll process • Process benefits: • Low operating temperature • Low heat loss • Low volatilization University of Utah: Novel Chemical Pathway for Titanium Production Dr. Zak Fang

• Direct reduction of Ti-slag to produce TiH2, , chemically isolating Ti from other impurities

• Purification of TiH2 through conventional extractive metallurgy techniques to physically separate TiH2 from unwanted impurities

• Consolidation of several high temperature energy intensive

processes into one, thus reduce energy consumption of Ti TiH2 and Ti powder produced by direct production by 62% reduction of Ti-slag. SRI International: Direct Low-Cost Production of Titanium Alloys Dr. Jordi Perez

Innovative combination of two disparate technologies: 1) pellet alloy production in fluidized bed and 2) SRI’s multi-arc reactor. . Direct production of metal pellets . Use of atomic hydrogen as reducing agent . Direct production of alloys Low cost, new alloys possible, production flexibility

Fluidized bed reactor to produce alloys by reduction using atomic hydrogen

Ti alloy pellets

Atmospheric-pressure multi-spark fluidized bed reactor in operation

18 What is Metal AM?

Layered addition of material Freeform material addition “Powder Bed” “Directed Deposition” Directed Deposition Types of Powder Bed Metal AM

‣ Laser Sintering/Melting ‣ Electron Beam Melting (DMLS or SLM) (EBM) PROS PROS – Finer features – Very fast – No trapped powder – Built in vacuum – Cheaper – Stress free parts CONS CONS – Internally stressed parts – Expensive – More post processing – Internally sintered powder – Slow optical scan rate – Small company, fewer machines AM Economics Example from ORNL

‣ Part: bracket for hot-side of JSF engine ‣ Material: Ti-6Al-4V ‣ Current Process: – Machining from titanium plate – Buy-to-fly mass ratio 33:1 – Cost: $1000/lb ‣ AM Process: – AM + HIP + final machining – Buy-to-fly mass ratio 1:1 – Cost: $500/lb Near-term (<10yrs) Metal AM Parts

‣ Medical – Many orthopedic implants – Custom surgical tools ‣ Aerospace – Turbine blades (TiAl in GEnx engine) – Injectors – Blisks ‣ Other – Heat exchangers – O&G components – Robotics – Lots more! Challenges

Additive 3D Design Raw Materials Finishing Manufacturing • Human • Quality • Process • Surface limitations • Availability controls roughness • Topology • Cost • Process (internal and external) optimization • Variety simulation • Support • Design for AM • Material • Speed removal characterization • Machine costs • Build size • Sintered particle removal Powder Metallurgy

25 •Theoretical Constitutive Modeling of •Cold , Incremental& Plasticity and Damage Hot Forming •Modeling of Ratcheting •Stamping •MD and FEA Computational Tools •Rolling •Failure Analysis under Complex •Complex loading Loading •Fatigue

Constitutive Understanding of Solid Deformable Bodies

•Discreet Particle Simulation •Continuum Transport Model •Thermal Analysis •Biaxial tester •Fatigue •AFM •ICP Advanced •XRD Powder and Powder Flow, Material Titanium Consolidation, Characterization Research and Sintering Center •High Pressure Consolidation • EDM •Additive Manufacturing • Raman •Laser, Plasma, and induction • Shear Cell Sintering •XRF

Parts and Device Fabrication

•Heat •Brake Rotors Exchangers •Injectors •Transmission •Implants •Valves •Modular reactors •Cams •Turbocharger rotors •Connecting rods ARPA-E METALS Program Recycling Technology

XRF Scrap Metal Sorting Machine

●5 kW Linear X-Ray Tube ●Worlds most powerful industrial x-ray source!

27 ARPA-E METALS Program Recycling Technology Variable Frequency Electrodynamic Sorting Machine ●Discriminates Light Metal Alloys

●High Frequency—High Magnetic Flux Toroid (10 kHz, 600 mTesla) ●Highest Frequency Industrial Electrodynamic Sorter!

28 ARPA-E METALS Program Recycling Technology Electrochemical Sorting of Light Metal Alloys

●2% the cost of XRF gun ●1 sec measurement time as opposed to 1 min for XRF gun

For the first time in the world light metal alloys can be detected with electrochemistry.

Triple-probe tip Used in the Handheld

29 ARPA-E METALS Program Recycling Technology Laser Induced Breakdown Spectroscopy (LIBS)

●In-situ elemental measurement of molten metal ●Self-calibrating ●Signal-to-Noise>3

30 ARPA-E METALS Program

ARPA-E Aims to ARPA-E Aims to Produce the Most Close the Loop on Energy Efficient Light Vehicle Recycling! Metals to Enable Vehicle Lightweighting for Net Energy Savings!

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