Low cost process for the manufacture of near net shape titanium bodies
View Patent ↗A process for manufacturing Ti alloy structures using a SFFF manufacturing process with a welding torch as a high energy source, which comprises using as a feed a feed wire made from Ti sponge and alloying powders, or forming a Ti alloy in-situ in the melt.
1. A process for producing a titanium alloy which comprises mixing ceramic particles, a titanium material consisting of titanium sponge material and selected metallic alloying elements, passing the mixture through compacting rollers to produce a self-bonded wire in which the alloying elements are trapped in compacted titanium sponge material, and feeding the wire to a plasma transferred arc melting process using a non-consumable electrode with a high energy source to produce a titanium alloy containing a dispersion of ceramic particles therein.
2. The process of claim 1 , wherein the ceramic particles are nanosize.
3. The process of claim 2 , wherein the ceramic particles comprise ¼ to 2% by volume of the mixture.
4. The process of claim 1 , wherein the ceramic particles comprise 5 to 30% by volume of the mixture.
5. The process of claim 4 , wherein the ceramic particles comprise about 10% by volume of the mixture.
6. The process of claim 1 , wherein the ceramic particles comprise a material selected from the group consisting of TiB 2 , TiN, TiC, B 4 C and Y 2 O 3 .
7. The process of claim 3 , wherein the ceramic particles interact with the titanium alloy to enhance strength or wear resistance.
8. The process of claim 7 , wherein the ceramic particles comprise B 4 C
9. The process of claim 7 , wherein the ceramic particles comprise TiC and B.
10. The process of claim 1 , wherein the selected metallic alloying elements comprise a mixture of elemental metallic alloying elements in powder form.
11. The process of claim 10 , when the mixture of elemental metallic alloying elements are prealloyed.
12. The process of claim 1 , wherein the alloying elements are selected from the group consisting of AI, V, Mo, B, Fe, Sn and a mixture of two or more of said group.