HIGH PERFORMANCE METALLIC MATERIALS FOR COST SENSITIVE APPLICATIONS Edited by: F.H. (Sam) Froes E.Y. Chen R.R. Boyer E.M. Taleff L. Lu D.L. Zhang CM. Ward-Close D. Eliezer HIGH PERFORMANCE METALLIC MATERIALS FOR COST SENSITIVE APPLICATIONS Proceedings of a symposium sponsored by the Structural Materials Committee and the Titanium Committee of the Structural Materials Division (SMD) of TMS (The Minerals, Metals & Materials Society) Held during the TMS 2002 Annual Meeting in Seattle, Washington February 17-21,2002 Partial funding for this publication was provided for by the Seeley W. Mudd Fund Edited by: F.H. (Sam) Froes E.Y. Chen R.R. Boyer E.M. Taleff L. Lu D.L. Zhang CM. Ward-Close D. Eliezer A Publication of TIMS A Publication of The Minerals, Metals & Materials Society 184 Thorn Hill Road Warrendale, Pennsylvania 15086-7528 (724) 776-9000 Visit the TMS web site at http://www.tms.org The Minerals, Metals & Materials Society is not responsible for statements or opinions and is absolved of liability due to misuse of information contained in this publication. Printed in the United States of America ISBN: 0-87339-522-0 Library of Congress Number: 2002100525 Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by The Minerals, Met- als & Materials Society for users registered with the Copyright Clearance Center (CCC) Transac- tional Reporting Service, provided that the base THIS fee of $7.00 per copy is paid directly to Copyright Clearance Center, 27 Congress Street, Salem, Massachusetts 01970. For those organizations that have been granted a photocopy license by Copyright Clearance Center, a separate system of payment has been arranged. ©2002 If you are interested in purchasing a copy of this book, or if you would like to receive the latest TMS publications catalog, please telephone 1-800-759-4867 (U.S. only) or 724-776-9000, EXT. 270. TABLE OF CONTENTS Overview and Titanium Alloys I Cost Effective Synthesis, Processing and Applications of Light-Weight Metallic Materials 3 F.H (Sam) Froes, E. Chen, R.R. Boyer, EM. Taleff, D. Eliezer, CM. Ward-Close, L. Lu and G. Zhang Prospects for Cost Reduction of Titanium Via Electrolysis 19 H. Rosenberg Implementation of Advanced Metal Technologies to Reduce the Cost of Aerospace Systems 27 R.L. Martin Recent Developments in the Manufacturing of Low Cost Titanium Alloys 35 Y. Kosaka and S.P. Fox Lightweight Metals Ale-Finite Element Simulation of "U" Shape Aluminum Profile Extrusion 45 Z Chen, Z. Bao and H. Liu Effect of Reinforcement in Mg Alloy Fabricated by Powder Metallurgy Method 53 M.A. The in, L. Lu and M.O. Lai Light Magnesium Constructions for Transportation Applications 219 A. Ben-Artzy, I. Makover, I. Dahan, M. Kupiec, Y. Salah, A. Heler, A. Shtechman, A. Bussiba and Y. Weinberg Titanium Alloys Using Superplastic Forming as a Means of Achieving Cost Benefits as Well as Enhancing Aircraft Performance 65 L.D. Hefti Superplastic Behavior of Fine Grained Ti-6A1-4V 73 J.P. Escobedo, S.N. Patankar, D.P. Field and F.H. Froes Experimental Study on Tianium Alloy Superplasticity Performance and Processing Parameters 81 Z Tianrui, W. Lijuan and G. Lijin Enhanced Superplastic Forming of Ti-6A1-4V 85 G. Salishchev, R. Galeyev, O. Valiakhmetov, R. Safiullin, R. Lutfullin, P. Comley, S. Patankar, D. Field and F.H. (Sam) Froes Microstructure Evolution in Hydrogenated Ti-6A1-4V Alloys 93 J.I. Qazi, O.N. Senkov and F.H. (Sam) Froes v Kintetics of Decomposition of Martensite in Ti-6Al-4V-xH Alloys 101 J.I. Qazi, J. Rahim, O.N. Senkov and F.H. (Sam) Froes Fabrication of Cost Affordable Components for US Army Systems 109 V.S. Moxson, J.I. Qazi, F. Sun, F.H. (Sam) Froes, S. BoydandJ. Montgomery High Intergrity, Low Cost Titanium Powder Metallurgy Components 117 O.M. Ivasishin, D.G. Savvakin, V.S. Moxson, K.A. Bondareva and F.H. (Sam) Froes Titanium Powder Injection Molding - A Cost Effective Alternative 129 F.H. (Sam) Froes, J. Lombardi, L. LaVoie, J. Fravel and M. Godfrey Cold Spray Process for Cost-Sensitive Applications 137 A.N. Papyrin Laser Induced In-Situ Formation of Ti/TiN Composite 151 Y. Tang, L. Lu, Y.H.J. Fuh, Y.S. Wong M. Gupta and C.H Ng Intermetallics Dispersion Strengthening of Ti-48Al-2Cr-2Nb Alloy with A1 Y 0 Particles 159 2 4 9 P.B. Trivedi, E.G. Baburaj, S.N. Patankar and F.H. (Sam) Froes Processing and Properties of Titanium Aluminide-Ceramic Particulate Composite Materials 167 D.L. Zhang, Z.H. Cai, J. Liang and G Adam Fabrication of TiNiCu Shape Memory Alloy from Elemental Powders 179 Z. Qifei, X. Shuisheng and Y. Guanshen Thermal Stability of Alumina Mold Against Molten Ti-Al Alloys 185 M-G Kim, S-Y. Sung, H-K. Kim, J-L, Lee and Y-J. Kim In-Situ Synthesis of Al-Ti-C Master Alloy Grain Refiners by Different Methods 193 B.Q. Zhang, H.S. Fang, L. Lu and M.O. Lai Fabrication of Cu-Based Functional Parts by Direct Laser Sintering 203 HH Zhu, L. Lu andJ.YH Fuh Synthesis of Ti Si and Ti Si -2Mo Alloys 211 5 3 5 3 F-S. Sun, C. Draney and F.H. (Sam) Froes Author Index 227 Subject Index 229 VI FOREWORD These are the proceedings of the symposium on "High Performance Metallic Materials For Cost Sensitive Applications" held as part of the TMS Annual Meeting in Seattle, WA, February 18-21, 2002. The editors of these proceedings were also the organizers of the symposium, with Dr. E. Chen as the chief organizer. The three most important industries in driving technological changes, national security consider- ations, and economic advances are information/communication systems (computers), biotechnol- ogy and advanced materials and processes. Of these three, advanced materials and processes are the most far-reaching and vital to advances in the other two fields. Advanced materials are charac- terized by enhanced mechanical and physical characteristics compared to traditional materials, such as aluminum and steel, currently manufactured in large-volume assembly line production. These attributes either allow for significant improvements in product or device performance or, of perhaps even greater importance, allow for new technologies that are unachievable using the tradi- tional materials. However, there is another feature of advanced materials - they are almost always more expensive than conventional materials. It is this aspect of lightweight metallic materials, which is addressed in the papers contained in these proceedings. The opening overview paper, by the editors, attempts to present a broad view of the role of ad- vanced processing in the development of light weight metallic materials with the focus on the cost- effectiveness of the processes discussed. The remainder of the papers are divided into the three categories of lightweight metals, titanium, and intermetallics, and the processing routes presented include vapor deposition, laser processing, plasma spraying, gas atomizing, cold spray, rapid so- lidification, injection molding, mechanical alloying, extrusion, superplastic forming, joining, and casting. The organizers of this symposium, would like to thank everyone who helped make the event a success and particularly the session chairmen, the presenters, the authors of the 25 papers repro- duced here and Steve Kendall of TMS who coordinated these proceedings. F.H. (Sam) Froes, E.Y.Chen, R.R. Boyer, E.M. Taleff, L. Lu, D.L. Zhang, CM. Ward-Close and D. Eliezer. VII