Development of a new reinforced titanium alloy: Basic research and technological transfer for the Ti-6Al-4V/TiB material Maider García de Cortázar To cite this version: Maider García de Cortázar. Development of a new reinforced titanium alloy: Basic research and technological transfer for the Ti-6Al-4V/TiB material. Material chemistry. Université Sciences et Technologies - Bordeaux I, 2006. English. <tel-00129356> HAL Id: tel-00129356 https://tel.archives-ouvertes.fr/tel-00129356 Submitted on 6 Feb 2007 HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non, lished or not. 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N° d'ordre :3195 THÈSE PRESENTEE A L'UNIVERSITÉ BORDEAUX 1 ÉCOLE DOCTORALE DES SCIENCES CHIMIQUES Par Maider García de Cortázar IngénieurETSII POUR OBTENIR LE GRADE DE DOCTEUR SPÉCIALITÉ : PHYSICO-CHIMIE DE LA MATIÈRE CONDENSÉE Etude de la faisabilité et du transfert de technologie pour l’alliage Ti-6Al-4V renforcé par du monoborure de titane Development of a new reinforced titanium alloy: Basic research and technological transfer for the Ti-6Al-4V/TiB material Thèse soutenue le 18 juillet2006 Après avis de MM: J.TARTERA BARRABEIG Professeur, UPC Barcelone Rapporteur C.ESTOURNES Chargé de Recherche Rapporteur Devant la commission d'examen formée de : MM C.DELMAS Directeur de recherche ICMCB Président Y.LE PETITCORPS Professeur ICMCB Examinateur J.GOÑI DocteurIngénieur INASMET Examinateur S.GOURDET DocteurIngénieur EADS Examinateur -2006- Iñigo, Uxue eta Marinari Familiari Acknowledgements ACKNOWLEDGEMENTS I would like to extend my deepest thank to those who have encouraged, motivated and guided me. Professeur Yann Le Petitcorps and Dr. Javier Goñi for your direction and support, your helpful guidance and suggestions have greatly improved the quality of this work. I also thank you for your generosity,modestyand friendship. In addition I would like to thank INASMET-Tecnalia and the ICMCB-CNRS for the opportunity to do this thesis.Special thanks are due to INASMET-Tecnalia´s employees; Israel, Sonia, Chris, Pedro, Marina, Xabi, Iñigo, Javi,…their experience, knowledgeandsupporthave been very helpful. Finally, the work performed herein would not have happened without the encouragement and confidence provided bymyfriends at INASMET-Tecnalia and my family, thank you very much! i Acronym List ACRONYM LIST BE Blended Elemental CHIP Cold plus Hot Isostatic Pressing CVD Chemical Vapour Deposition EBM Electron Bean Melting EBPVD Electron Beam Physical Vapour Deposition FFF Foil Fibre Foil HIP Hot Isostatic Pressing IHPTET Integrated High Performance Turbine Engine Technology IM Induction Melting IMC Intermetallic Matrix Composites MA Mechanical Alloying MCF Metal Coated Fibre MIG Metal Inert Gas MMC Metal Matrix Composites NASP National Aero-Space Plane PM Powder Metallurgy PVD Physical Vapour Deposition RSP Rapid Solidified Powders SHS Self-propagating High-temperature Synthesis SPS Spark Plasma Sintering TIG Tungsten Inert Gas TMC Titanium Matrix Composites TMCTECC Titanium Matrix Composite Turbine Engine Component Consortium VAR Vacuum Arc Remelting Process ii Table of Contents TABLE OF CONTENTS Acknowledgements...............................................................................................................................i Acronym List........................................................................................................................................ii Introduction......................................................................................................................................1 1 Introduction aux matériaux composites à matrice de titane.........................................................2 2 Contexte de la recherche .............................................................................................................3 3 Organisation du document de thèse ............................................................................................4 1 An Introduction to Titanium Matrix Composites...........................................................................6 2 Motivation for the investigation....................................................................................................7 3 Thesis format...............................................................................................................................8 Chapter 1: Background and literature review......................................................................10 1 Introduction................................................................................................................................11 2 Titanium Matrix Composites TMCs.............................................................................................11 2.1 Continuously reinforced TMCs................................................................................................12 2.1.1 Tow based TMCs............................................................................................................14 2.1.2 Monofilament reinforced TMCs.........................................................................................16 2.2 Discontinuously reinforced TMCs............................................................................................34 2.2.1 Particulate reinforced TMCs.............................................................................................34 2.2.2 In-situ composites ...........................................................................................................35 2.2.3 Economical aspects........................................................................................................44 3 Previous studies of the TMC system assessment......................................................................47 4 Conclusions...............................................................................................................................51 Chapter 2: Production of TiB by SHS.....................................................................................54 1 Introduction................................................................................................................................55 2 Self-propagating High-temperature Synthesis (SHS).................................................................57 2.1 Thermodynamical considerations............................................................................................57 2.1.1 The Boron Titanium system.............................................................................................58 2.2 Variable effects......................................................................................................................61 3 Experimental procedure.............................................................................................................66 3.1 SHS reactions: the synthesis of materials on the Ti-B system...................................................66 iii Table of Contents 3.1.2 Phase identification.........................................................................................................74 3.1.3 Microstructure.................................................................................................................76 3.1.4 Selection criteria.............................................................................................................80 3.2 Simultaneous synthesis and compaction: How to remove the porosity.......................................82 3.2.1 Description of the material obtained.................................................................................87 4 Conclusions...............................................................................................................................92 Chapter 3: In-situ reinforced TMCs produced by investment casting..........................94 1 Introduction................................................................................................................................95 2 Titanium Investment Casting......................................................................................................96 3 Experimental procedure...........................................................................................................100 3.1 Equipment and Process.......................................................................................................100 3.1.1 Induction melting...........................................................................................................103 3.1.2 Centrifugal casting ........................................................................................................104 3.1.3 Mould preparation.........................................................................................................108 3.2 Casting experiments............................................................................................................110 3.2.1 Master compound addition.............................................................................................110 4 Conclusions.............................................................................................................................121 Chapter 4: Technology transfer.............................................................................................122 1 Technology transfer.................................................................................................................123 1.1 Requirements......................................................................................................................123 1.2 Industrial process................................................................................................................124 1.3 Selection of representative components................................................................................125 1.4 Castings .............................................................................................................................127 1.4.1 Definition of the castings................................................................................................127 1.4.2 Results and discussion..................................................................................................128 2 Cost analysis............................................................................................................................134 2.1 Manufacturing processes .....................................................................................................134 2.2 Cost estimate-assumptions ..................................................................................................137 2.2.1 Mass breakdown...........................................................................................................138 2.2.2 Master compound production.........................................................................................139 2.2.3 Moulding and Casting....................................................................................................140 2.2.4 Finishing operations......................................................................................................141 3 Conclusions.............................................................................................................................142 iv Table of Contents Conclusions and future directions.......................................................................................143 1 Conclusions et perspectives....................................................................................................144 1.1 Conclusions ........................................................................................................................144 1.2 Perspectives .......................................................................................................................145 1 Conclusion and future directions.............................................................................................146 1.1 Conclusions ........................................................................................................................146 1.2 Future directions..................................................................................................................148 References...................................................................................................................................150 ANNEX I: Metallurgicalcharacterization procedure.................................................................158 ANNEX II:Tensile test results......................................................................................................159 v