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Ti-6Al-4V IPC CASE Manufactured by Trent 900

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Ti-6Al-4V IPC CASE Manufactured by Trent 900 Kobe Steel’s Activities in Aerospace ITA Ti-2007 Annual Con ference October 2007 Shinya Ishigai Titanium Technology De partment KOBE STEEL, LTD. 1 KOBE STEEL, LTD. Proprietary Information Contents Titani um M ark et of A erospace in J apan Development Programs for Airplanes and Jet Engines State of Manufacturinggg Technologies ¾ Die Forging ¾ Near Ne t Ring Ro lling Developed Alloys with Excellent Formability 2 KOBE STEEL, LTD. Proprietary Information Mill Product Shipments by Applications in Japan Total amount of shipment in 2006 was 17,317 tons O thers C onsum er & Chemical 6.2 % Elec tr iic Medical D istribu to rs 9 .4 % 7.3 % 1 1 .6 % Power 14.9 % StS ports E lec tro lysis 3.1 % A u to m o tive 8 .5 % PHE 9 .3 % DlitiD esalination 20. 5 % 1.2 % A erospace Shipsp 6.8%8 % 1.2 % ・Forgings for Engine ・Titanium Alloy Plate & Sheet （Disk，Blade，Shaft，Case etc.) ・CP Tit ani um Sh eet ・Forgings for Airframe （Fittings, Bulkhead) 3 KOBE STEEL, LTD. Proprietary Information Recent Development Programs for Civil Airppgplanes and Jet Engines in Japan 1980’s 1990’s 2000’s Domestic C-X DfDefense P-X B777 Airplane Boeing B787 Regional Jet MRJ Business Jet Honda JET IAE V2500 GE 90 GE GEnx Trent 900 Jet RR Engine Tr ent1000 CF34 Regional Jet Eco Engine Honda HF 120 4 KOBE STEEL, LTD. Proprietary Information Japanese Developed Airplanes Transport Cargo Plane C-X BthlBoth planes were launched in Septem ber 2007 Patrol Plane P-X XF7-10 Engine Designed and Assembled by KHI Photos: Courtesy of Asagumo Shimbunsha Inc. 5 KOBE STEEL, LTD. Proprietary Information Regional Jet ¾Full Composite Wing and Body ¾70 – 90 Passengers ¾Large Cabin Space ¾Comfortable Seats ¾Expected Launch in 2012 Mockup model of MRJ exhibited in 2007 Paris Air-show 6 KOBE STEEL, LTD. Proprietary Information Business Jet HONDA Business Jet Over-the-wing Engine Mount Lower Drag, Larger Cabin Space All Composite Fuselage Original Developed Turbo Fan Engine Photos: Courtesy of Honda R&D Co.,Ltd “HF120” Lightweight, Fuel-efficient, Low-Emission 7 KOBE STEEL, LTD. Proprietary Information Turbo Fan Engines Japanese manufactures of aero-engines have joined new enggppgine development programs for B787 GEnx Engine Trent 1000 Engine -Photo: copyright Rolls-Royce plc 8 KOBE STEEL, LTD. Proprietary Information V2500 Turbo Fan Engine A320 Fan case V2500 LPC disk Photos: Courtesy of Kawasaki Heavy Industries 9 KOBE STEEL, LTD. Proprietary Information Trent 900 Engine A380 Ti-6Al-4V IPC CASE Manufactured by Trent 900 Near Net Ring Rolling Photos: Courtesy of Rolls Royce plc 10 KOBE STEEL, LTD. Proprietary Information Key Points to Grow-up the Amount of Titanium Alloy for Civil Airplane ¾ Reliability, High Quality Stable manufacturing procedure based on sophisticated forging technologies contribute to achieve reliability of material. ¾ Cost Reduction Reduce material input weight by achieving “Near Ne t Shape ” forg ing. Reduce forging cost through using material with excellent formability. 11 KOBE STEEL, LTD. Proprietary Information Titanium Forgings for Civil Aero-engine Fan blade LPC blade Stator bane Fan disk Stub shaft Compr.Case HPC blade Fan case Combustion Turbine 760 dia. HPC disk LPC disk FAN Compressor Titanium alloys used for jet engines; ¾ Ti-64, Ti-811, Ti-6242S, Ti-17, Ti-6246, IMI834 etc. 12 KOBE STEEL, LTD. Proprietary Information Forging Technology of High Strength Ti-6Al-2Sn-4Zr-6Mo HPC Disk ・High strength ・Higher fracture toughness Full acicular microstructure through β ppggrocessed final forging Ti-6246 Forged Disk （700 mm dia.） 25μm 25μm A) Microstructure of conventional B) Microstructure of α＋β forging β-processed forging • High fatigue strength • High fatigue strength • High elongation • Low elongation 9 Low fracture toughness ¾ High fracture toughness 9 High speed crack propagation ¾ Slow crack propagation 13 KOBE STEEL, LTD. Proprietary Information Simulation Analysis for Die Forging ¾ It is important to control material temperature and forging strain during die forging in order to achieve superior material properties. ¾ Forging simulation analyses are very useful and necessary to establish proper forging conditions (Deformation, Temperature, Cooling rate analysis on forging and solution heat treatment) β-processedTid Ti-6-2-4-6dikf6 disk forge dbd by compu ter contlldhtrolled hammer Distribution of equivalent strain Distribution of temperature of forged disk of forged disk 14 KOBE STEEL, LTD. Proprietary Information Example of Simulation Analysis for Die Forggging Change of material temperature distributions during die forging 15 KOBE STEEL, LTD. Proprietary Information Near Net Ring Rolling Fan Case of V2500 Engine (Ti-6Al-4V, 1700mm dia.) IPC Case of Trent 900 Engine (Ti-6Al-4V, 1200mm dia.) 16 KOBE STEEL, LTD. Proprietary Information Example of Simulation Analysis for Near net ringgg rolling 17 KOBE STEEL, LTD. Proprietary Information High Cost-performance Alloys We propose two kinds of developed titanium alloys with superior formability to apply for airframe material, “KSTI-9” and “KS EL-F” 9 Expensive? Are tit ani um all oys diffi cult t o b e roll ed or f orged? Change the image of Titanium alloy by using of our advanced alloys !! ¾ These alloys have excellent formabilities with equal and higher mechanical properties than Ti-6Al-4V ! 1) Coilable alloy; KS TI-9 (Ti-4.5Al-2Mo-1.6V-0.5Fe-0.3Si-0.03C) 2) E asy t o f orge all oy; KS EL-F (Ti-4.5Al-4Cr-0.5Fe-0.2C) 18 KOBE STEEL, LTD. Proprietary Information Coilable Alloy “KS TI-9” ¾Cold Rolled in coil to coil as same as CP titanium ¾Capable of SPF/DB 1400 LdiL direction 1200 T direction KS TI-9 M1000 P a / (ASTM G35) hh t g 800 600 u ms tre n 2.0 t mm 400 Maxim 200 0 1.00E+04 1.00E+05 1.00E+06 1.00E+07 Cycles to failure / cycle 300 mm Smooth axial fatigue properties of SPF/DB KS TI-9 1.2 mm thick sheet Honeycomb structure 19 KOBE STEEL, LTD. Proprietary Information Advantage of KS TI-9 Compared with Ti-6Al-4V Process for Sheets of Ti-6Al-4V 9Low Productivity 9Higher Cost Should be cut Steel Packed and hot rolled with steel pack Ti-6Al-4V Plates Process for Coil Cold rolled in coil to coil by the Strip of KS TI-9 steel mills with high productivity BkdBreakdown Forging Rolling βtransus Hot Ann.& Ann.& Pickling 965Ԩ Rolling Pickling erature Cold Rolling Temp Ingot Bloom Slab Hot Strip Cold Strip 20 KOBE STEEL, LTD. Proprietary Information Advantage of KS EL-F ¾ Extra Low flow stress and excellent hot forge-ability ¾ Easy to make precision net forgings asmm same as steel Reduce material input weight , reheating times in forging, and defects 1200 190 aa mm 1000 High Strength KS EL-F 800 130 gth / MP nn 600 Stre 400 sile Low Flow Stress nn KS EL-F 200 Ti-6Al-4V Te CP-Gr. 2 0 200 400 600 800 1000 1200 Temperature / C Temperature dependence on tensile strength 50 mm compared with KS EL-F and Ti-6Al-4V 21 KOBE STEEL, LTD. Proprietary Information Summary The amount ratio of titanium product shipment fktibt7%iJfor aerospace market is about 7 % in Japan. There are many development programs of civil air- planes and jet engines in Japan . Reliability and high quality required to aerospace material can be achieved by sophisticated forging technologies, such as computer controlled forging and near net ring rolling supported by simulation analysis. Our developed titanium alloys with excellent form- ability h ave great ad vant age on cost red ucti on. 22 KOBE STEEL, LTD. Proprietary Information .
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