Primary

Manufacturing
Raw materials for aeronautical
manufacturing
Aerospace grade metals
Medium Carbon Low Alloys, Maraging
Steel and Precipitation Hardening Stainless

Cu, Zn, Li, Mg, Si, etc.

Aluminum Wrought Alloys

Alpha, Near alpha,

Titanium Alpha-Beta, Beta

Nickel Superalloys Ni, Fe-Ni, Co

High Strength Steels
 “Stone from heaven”
The first iron extracted from the naturally
occurring iron oxide deposits could have
resulted from primitive man building a
wood fire.
This sponge was the iron that remained
after the oxygen had been removed.

The first iron to be developed was wrought iron -

“to shape by hammering or beating”
Iron sponge was produced by carbon reduction of the oxides;
iron products were made by pounding the sponge.
Iron smelting must use carbon in the form of charcoal or coke.
Early iron smelting operations were conducted in chimney
furnaces
Improved blast furnace designs enabled higher Ts to
be reached until the temperature exceeded the melting
point of the iron.

Instead of iron ore and wood, iron ore, coke (made from
coal), and a flux (usually limestone) were used.
Wrought iron is ductile and tough but has little strength,
while pig iron is strong but brittle and lacks toughness.
Wrought iron is highly refined metallic
iron that contains minute, relatively
uniformly distributed insoluble
nonmetallic particles. The individual
particles are termed inclusions.
When inclusions are aligned in the
direction of metal flow during
hammering the groupings of inclusions
are designated as stringers.

Although approximately 1 to 4% of the volume of any wrought iron sample is inclusions, a

typical chemical analysis of wrought iron shows the presence of very little carbon, silicon,
and other elements found in pig iron.
Pig iron can be cast. In fact, carbon levels of pig iron (Table 4.3) approach the eutectic
point of 4.30 wt% C in the iron-carbon system.
Metallurgical Considerations
Steels are alloys of iron and carbon in BCC at RT.
Steel alloys heated above A3 transform to the FCC
austenite structure.
On slow cooling, the structure transforms back
into ferrite + cementite = perlite.
If the steel is austenitized at a temperature above
1333°F for some period of time and then
quenched to RT, it converts to (BCT) martensite.
 Unfortunately, it also makes
the steel extremely brittle;
therefore, the steel is
reheated, or tempered, at
intermediate temperatures to
restore some ductility and
toughness, although the
strength also decrease as the
tempering temperature is
increased.

A key variable is the cooling rate during quenching. The quench rate that will provide the desired
hardness for a given thickness is determines primarily by alloying additions.
Some alloys require a water, others oil quench to form a martensitic structure.

Some steels are hardened by quench and temperature process, others by precipitation hardening.
Ex., the maraging steels, with nickel contents of 18% and carbon contents of 0.03%, will form
martensite on air cooling from the austenitizing temperature. Even very slow cooling of heavy sections
produces a fully martensitic structure.
 However, this low carbon martensite is not the high strength
martensite that forms in the higher carbon alloys steels.

The low carbon martensite that is formed is a tough and ductile

iron-nickel martensite. Since the carbon content is extremely low,
maraging steels are characterized by a combination of high
strength, ductility, and excellent toughness.

The precipitation hardening (PH) stainless steel are classified as

either semiaustenitic or martensitic. The semiaustenitic grades
contain an austenitic structure in the annealed or solution treated
condition.
After fabrication operations are complete, they can be
transformed to martensite by a simple conditioning treatment
followed by precipitation hardening.

The influence of carbon on the strength and hardness of steel

Metallurgical Considerations
High strength steels are available in a variety of
quality levels depending on the type of melting
practice used.
Originally air melted, the trend has been to move to
more advanced melting techniques such as vacuum
degassing, electroslag remelting (ESR), VAR, and
double vacuum melting (vacuum induction melting
followed by vacuum arc remelting (VIMVAR)) for
improved cleanliness and higher quality.
These methods reduce the quality of dissolved
gases (hydrogen, oxygen, and nitrogen) and the non-
metallic inclusions.
Electroslag Remelting Vacuum Arc Remelting
High Strength Steels
While high strength steels normally account for only about 5–15%
of the airframe structural weight, they are often used for highly
critical parts such as landing gear components, control surface
hinges, and helicopter transmissions.
Advantages

Extremely high High density (8

strengths g/cm3 vs Al 2.76 &
and stiffness Ti 4.42)
Yield strenght 1.37- Susceptibility to

Desadvantages
2.06 GPa brittle fracture
Modulus of elasticity Hydrogen
193- 200 GPa embrittlement
Stress corrosion
cracking
F/A 18 Landing Gear
Medium Carbon Low Alloy Steels
● MCLA steels contain carbon in the range of 0.30–0.50%,
with alloying elements added to provide deeper hardening and higher strength
and toughness. Typical alloying elements include Mg, Si, Ni, Cr, Mo, V and Bo.
● Are identified by the American Iron and Steel Institute (AISI) four-digit system
of numbers.
● Are normally hardened to develop the desired strength. Some are also
carburized and then heat treated to produce a combination of high surface
hardness and good core toughness.
● Typical airframe applications include landing gear components, shafts, gears,
and other parts requiring high strength, through-hardening, or toughness.
4130 Steel
● The 41XX series of alloys are classified as chromium–
molybdenum steels containing 0.5–0.95% chromium and
0.13–0.20% molybdenum. Chromium is added to
increase hardenability and strength; however, the
addition of chromium can also make this series
susceptible to temper embrittlement.
● Due to its low-to intermediate hardenability, 4130 must
be water quenched. It has good tensile, fatigue, and
impact properties up to about 700 F; however, the impact
properties at cryogenic temperatures are low.
 4340 Steel
Nickel is added along with chromium
and molybdenum to form the 43XX
class of alloys. Their composition is
about 0.5–0.8% Cr, 0.20% Mo, and 1.8%
Ni.
● Nickel in combination with chromium improves strength and provides greater
hardenability, higher impact strength, and better fatigue resistance.
● The 4340 combines deep hardenability with high strength, ductility, and
toughness. It also has good fatigue and creep resistance. It is often used
where high strength in thick sections is required.
Maraging Steels
● High strength steels with very low carbon contents (0.030% max) and
additions of substitutional alloying elements that produce age hardening of
iron–nickel martensites.
● Nominal composition of 18% Ni, 7–9% Co, 3–5% Mo, less than 1% Ti, and very
low carbon contents.
● During air cooling from the annealing or hot working temperature, MS
transform to soft martensite which can be easily machined or formed. They
are then aged to high strength levels at 850–950 F for 3 to 9 h.
● Can be used for prolonged service at temperatures up to 750°F. MS are also
more resistant to hydrogen embrittlement than MCLA steels. They are less
susceptible to stress corrosion cracking than MCLA steels.
Commercial Maraging Steels

MS are either air melted followed by VAR or vacuum induction melted followed
by VAR. Aerospace grades are tripled melted using air, vacuum induction and
vacuum arc remelting, to minimize the residual elements carbon, manganese,
sulfur, and phosphorous and the gases oxygen, nitrogen, and hydrogen.
Precipitation Hardening Stainless Steels
● Important properties are ease of fabrication, high strength, good ductility, and
excellent corrosion resistance.
● After fabrication operations are completed, they can be
Semiaustenitic transformed to martensite by an austenite conditioning
Austenitic in the heat treatment that converts the austenite to
solution annealed
condition. martensite followed by precipitation hardening.

Martensitic
Martensitic in the ● Only require precipitation hardening after fabrication.
solution annealed
condition
Forging PHSS
● PH grades are the most difficult of the stainless steels to forge. Power drop
hammers are used for open die forgings and mechanical presses for small
forgings. Hydraulic presses are often used for the final forging operations
because there is less chance of overheating due to the slower forging action
than with hammers.
● Due to their low thermal conductivities, it takes longer to heat the PH steels to
the forging temperature, once the forging temperature is reached, they should
be immediately forged.
● Slow furnace cooling, or an equalization temperature hold (e.g., 1900 F for 30
min), during cooling are used to prevent cracking. They convert directly to
martensite on cooling from the austenite range, and too fast a cooling rate
can result in cracking as a result of residual stresses.
Aluminum Alloys
Advantages of Aluminum Alloys
● Relatively low cost, light weight metal that can be heat treated to fairly high
strength levels, and it is one of the more easily fabricated of the high-
performance materials, which usually results in lower costs.
The high strength 2XXX and 7XXX alloys are Strength to
competitive on a strength-to-weight ratio with
the higher strength but heavier titanium and weight ratio
steel alloys

Cryogenic Not embrittled at low temperatures and

become even stronger as the temperature is
properties decreased without significant ductility losses

Among the easiest of all metals to form and

machine. The high strength 2XXX and 7XXX
alloys can be formed in a relatively soft state Fabricability
and then heat treated to much higher strength
levels after forming operations are completed.
Disadvantages of Aluminum alloys
● Low modulus of elasticity, rather low elevated temperature capability, and
susceptibility to corrosion. The modulus of elasticity of aluminum alloys is
generally between 10 and 11 msi, which is lower than competing metals,
such as titanium (16 msi) and steel (29 msi).
● Aluminum alloys can be used for short times at temperatures as high as
400–500 F, but their long-term usage temperatures are usually restricted to
250–300 F.
● Commercially pure aluminum and many
aluminum alloys are very corrosion resistant;
corrosion can be a problem for the highly alloyed
high strength aluminum alloys used in aerospace.
Metalurgical considerations
● Aluminum has FCC structure, melting point at 657.22 °C and density 2.76
g/cm3.
● Only a few elements have sufficient solid solubility to be major alloying
elements. These include Cu, Mg, Si, Zn, and Li; with lower solubility, Cr, Mn
and Zr form compounds that help to control the grain structure.
● Aluminum alloys are normally classified into one of three groups:

○ wrought non-heat treatable alloys (1XXX, 3XXX, 4XXX, 5XXX)

○ wrought heat treatable alloys (2XXX, 6XXX, 7XXX, 8XXX)

○ casting alloys (#XX.0)

Major attributes of wrought aluminum alloys
1XXX: Pure Al
● Strain hardenable
● Exceptionally high formability, corrosion resistance, and electrical conductivity
● Typical ultimate tensile strength range: 10–27 ksi
● Readily joined by welding, brazing, soldering
2XXX: Al–Cu Alloys
● Heat treatable
● High strength, at room and elevated temperatures
● Typical ultimate tensile strength range: 27–62 ksi
● Usually joined mechanically but some alloys are weldable
● Not as corrosion resistant as other alloys
3XXX: Al–Mn Alloys
● High formability and corrosion resistance with medium strength
● Typical ultimate tensile strength range: 16–41 ksi
● Readily joined by all commercial procedures
● Hardened by strain hardening

4XXX: Al–Si Alloys

● Some heat treatable
● Good flow characteristics, medium strength
● Typical ultimate tensile strength range: 25–55 ksi
● Easily joined, especially by brazing and soldering
5XXX: Al–Mg Alloys
• Strain hardenable
• Excellent corrosion resistance, toughness, weldability, moderate strength
• Building and construction, automotive, cryogenic, marine applications
• Typical ultimate tensile strength range: 18–51 ksi

6XXX: Al–Mg–Si Alloys

• Heat treatable
• High corrosion resistance, excellent extrudability; moderate strength
• Typical ultimate tensile strength range: 18–58 ksi
• Readily welded by GMAW and GTAW methods
• Outstanding extrudability
7XXX: Al–Zn Alloys
• Heat treatable
• Very high strength; special high toughness versions
• Typical ultimate tensile strength range: 32–88 ksi
• Mechanically joined

8XXX: Alloys with Al-Other Elements (Not Covered by Other Series).

• Heat treatable
• High conductivity, strength, hardness
• Typical ultimate tensile strength range: 17–60 ksi
• Common alloying elements include Fe, Ni and Li
Precipitation Hardening
The purpose is the formation of submicroscopic precipitates that severely strain the matrix
lattice. This causes an increase in strength by obstructing and retarding dislocation movement.

The strengthening effect is maximized when the atomic arrangement of both the precipitate and
the matrix is the same with no discontinuity in the lattice (coherent); however, the atomic
spacings are different enough to distort the crystal lattice.

Solid Heat
Quenching Aging
Treating
After holding at the solution
The alloy is heated to a During aging, the alloying
treating temperature for some
temperature that is high elements trapped in
time, it is quenched to a lower
enough to put the soluble solution precipitate to form
temperature (RT) to keep the
alloying elements in a uniform distribution of
alloying elements trapped in
solution. very fine particles
solution.
The solute clusters of precipitate are Guinier-Preston (GP) zones.
The progression of precipitation hardening in the Al–Cu system is:
𝑆𝑢𝑝𝑒𝑟 𝑆𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑆𝑜𝑙𝑖𝑑 𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛 →
𝐶𝑙𝑢𝑠𝑡𝑒𝑟𝑖𝑛𝑔 → 𝐺𝑃 𝑍𝑜𝑛𝑒𝑠 → 𝜃′′ → 𝜃′ → 𝜃
Melting and Primary Fabrication
1. Aluminum production starts with the mineral bauxite,
which contains approximately 50% alumina Al2O3.
2. In the Bayer process, pure alumina is extracted from bauxite using a sodium
hydroxide solution to precipitate aluminum hydroxide which is then subjected
to calcination to form alumina.
3. The Hall–Heroult process is then used to
reduce the alumina to pure aluminum.
This is an electrolytic process in which
alumina, dissolved in a bath of cryolite,
is reduced to pure aluminum by high
electrical currents.
Semi-continuous direct chill casting
The molten metal is extracted through the bottom
of a water-cooled mold producing fine grained
ingots with a minimum amount of segregation.

Low melting point elements (Mg, Cu, Zn) are added

pure, while high melting elements (Ti, Cr, Zr, Mn) are
added as master alloys. To prevent hot cracking and
refine the grain size, inoculants (Ti, Ti-B) are added.

The molten aluminum is poured into a shallow water-

cooled cross-sectional shape of the ingot desired.
Typical casting speeds are in the range of 1–5 in./min.
 Typical problems in direct-chill

Cold
Splitting Segregation Liquation Bleeding
shutting

The outer solid shell

Liquid metal in the Deep wrinkles form
contracts fisrt Lower melting Separation of
center melts the on the surface as
creating internal elements solidify at metals due to the
solid outer shell and the solid surface
stresses as the the surfaces rather difference in
runs along the layer contracts
inner metal tries to than at the center melting points
surface toward the center
solidify as well

Therefore, to successfully cast an ingot using the direct-chill process, the ingot must
be cast slow enough to eliminate splitting, bleeding, and liquation, while fast enough
to eliminate cold shutting.
Rolling Plate and Sheet
Hot rolling is conducted at temperatures above the recrystallization temperature to
create a finer grain size and less grain directionality.
● Upper T - the lowest melting point eutectic in the alloy
● Lower T - lowest T that can safely be passed through the rolling mill without cracking.

Sheet is 0.006–0.249 in. thick, while plate is over 0.250 in. thick.
For aircraft applications, typical sheet and plate thicknesses are:
● 0.04–0.40 in. for fuselage skins and stringers
● 1 to 2 in. for wing skins
● up to 8 in. for bulkheads and wing spars.
Extrusions of various angles and shapes (L, J, T, and H) are commonly used for wing
stringers and fuselage frames.
 Hot rolling of as-cast ingots

1 2 3 4 5 6
Reheating to the
Homogenizing Hot rolling to Intermediate Cold rolling and
Scalping of ingots hot rolling
the ingots form a slab annealing annealing
temperature

Scalping of the ingot, in which approximately 0.25–0.38 in. of material is removed from
each surface, to avoid surface defects rolled into the finished sheet and plate.

Homogenizing of the ingots is conducted to remove any residual stresses in the ingots and
improve the homogeneity. The ingots are heated to within 20–40 F of the lowest melting
eutectic in the alloy. (2XXX 4–12 h at 900–950 F & 7XXX 8–24 h at 850–875 F)

An important function of homogenization is to remove non-equilibrium low melting point

eutectics that could cause ingot cracking during subsequent hot working operations.
The ingots can be hot rolled right after removing
them from the soaking pits, or if cooled to RT
after homogenization, they must be reheated for
hot rolling.

Ingots’ size 20x6x2 ft weight of20 tons are hot

rolled back and forth through the rolling mill.
Modern rolling mill facilities can heat the plate,
roll it, spray quench it to harden it, and then
stretch it to relieve stresses.
(2XXX 750–850 F & 7XXX 750–825 F)
Hot rolling helps to break up the as-cast
structure and to provide a more uniform
grain size and a better distribution and
size of constituent particles.
 Initial rolling is done in a four-high reversing mill to breakdown the
ingot.

Then it is removed from the mill, given an intermediate

anneal, and then placed in a five stand four-high mill
to roll to thinner plate or sheet with successive
reductions at each station.

The cold work put into the aluminum during hot rolling
must be sufficient to cause recrystallization during
annealing.
Intermediate anneals are required to keep the sheet from
cracking during cold rolling. The number of anneals
depends on the alloy and the final gage required.
Extrusion
A heated cylindrical billet is pushed under high pressure
through a steel die to produce the desired structural shape.
The extrusion is then fed onto a run-out table where it is
straightened by stretching and cut to length.
During extrusion, metal flow occurs most rapidly at the
center of the ingot resulting in oxides and surface defects
being left in the last 10–15% of the extrusion which is
discarded.
In general, the stronger the alloy, the more difficult it is to
extrude. A profile’s shape factor (the ratio of the perimeter
of the profile to its area) is an approximate indicator of its
extrudability, i.e. the higher the ratio, the more difficult it is to
extrude.
Casting
● Al castings are used for lightly loaded secondary structures
● Can offer significant cost savings by reducing part count and the associated
assembly cost.
● Are tailored to increase the fluidity of the molten metal, be resistant to hot tearing
during solidification, and reproduce the details of the mold shape.

SCC

● Si, greatly improves the fluidity of molten aluminum, especially when the
amount approaches the eutectic (12%).
● In order of decreasing castability: 3XX, 4XX, 5XX, 2XX, 7XX.

● Premium quality castings provide high mechanical properties, low porosity levels as
determined by radiography, dimensional accuracy, and good surface finishes.
● Premium casting alloys: A201.0, A206.0, 224.0, 249.0, 354.0, A356.0, A357.0, and
A358.0.

● The requirements are stablished by specifications

○ SAE-AMS-A-21180: The high strength aluminum alloy castings covered by this

specification are intended for airframe, missile, and other applications where high
strength, ductility, soundness, and uniform composition within each casting are required.
Melting
Al ingots for casting are reheated and melted using one of three types of
furnaces:
● Direct Fuel Fired Furnaces

○ Use hydrocarbon fuels to heat the metal which places the hot combustion gases in direct
contact with the charge being melted.
● Indirect Fuel Fired Furnace

○ Also use hydrocarbon fuels, but the charge is separated by a crucible from direct contact with
the hot combustion gases.
● Electric Furnaces

○ Low frequency induction furnaces, high frequency induction furnaces, and electric resistance
furnaces. The induced electromagnetic field stirs and mixes the melt, thus aiding in
maintaining uniform melt temperatures.
Sand Casting
The oldest casting process known. The molten metal is poured into a cavity shaped
inside a body of sand and allowed to solidify.

Advantages, low equipment costs, design flexibility, and the ability to use a large
number of aluminum casting alloys. It is often used for the economical production of
small lot sizes and is capable of producing fairly intricate designs.

Disadvantages, the process does not permit close tolerances, and the mechanical
properties are somewhat lower due to larger grain sizes as a result of slow cooling rates.
However, the mechanical properties are improving as a result of improvements in
casting materials and procedures.
1. Fabricate a pattern (wood) of the desired part and split it down the
centerline.
2. Place the bottom half of the pattern, called the drag, in a box called a flask.
3. Apply a release coating to the pattern, fill the flask with sand and then
compact the sand by ramming.
4. Turn the drag half of the mold over and place the top half of the flask on
top of it. The top half of the pattern, called the cope, is then placed over
the drag half of the pattern and release coated.
5. Risers and a sprue are then installed in the cope half of the flask. The sprue
is where liquid metal enters the mold. In a complex casting, the sprue is
usually gated to different positions around the casting. The risers are
essentially reservoirs for liquid metal that keep the casting supplied with
liquid metal as the metal shrinks and contracts on freezing.
6. The cope half is then packed with sand and rammed.
7. The two halves are separated and the patterns are removed. If hollow
sections are required, a sand core is placed in the drag half of the mold. A
gating system is then cut into the sand on the cope half of the mold.
8. The two halves are reassembled and clamped or bolted shut for casting.
Plaster and Shell Molding
Plaster mold casting is basically the same as sand casting except gypsum plasters
replace the sand in this process.

Advantages, very smooth surfaces, good dimensional tolerances, and uniformity due to
slow uniform cooling. Surfaces finishes in the range of 250–450in. are typical with shell
molding.

Disadvantages, with the slow solidification rates, the mechanical properties are not as
good as with sand castings. In addition, since plaster can absorb significant moisture
from the atmosphere, it may require slow drying prior to casting. Requires precision
metal patterns and more specialized equipment.
1. A fine silica sand coated with a phenolic resin is placed
in a dump box that can be rotated.
2. A metal pattern is heated to 400–500 F, mold released
and placed in the dump box.
3. The pattern and sand are inverted allowing the sand to
coat the heated pattern. A crust of sand fuses around
the part as a result of the heat.
4. The dump box is turned right side up, the pattern with
the shell crust is removed and cured in an oven at 650–
750 F.
5. The same process is repeated for the other half of the
mold.
6. The two mold halves are clamped together and placed
in a flask supported with either sand or metal shot.
Permanent Mold Casting
Liquid metal is poured into a metal mold and allowed to solidify.

This method is second only to die casting in the number of aluminum castings produced
annually. However, due to the tooling costs, it is usually reserved for high volume.

The castings produced are normally small compared to sand casting and rather simple in
shape. The process produces fairly uniform wall thicknesses but, unless segmented dies
are used, is not capable of undercuts. Compared to sand castings, permanent mold
castings are more uniform and have better dimensional tolerances, superior surfaces
finishes (275–500 µin. are typical), and better mechanical properties due to the faster
solidification rates.
Mold materials include gray cast iron and hot work die steels.
Titanium Alloys
Ti Alloys in aerospace
High strength High melting
Low density point
Excellent Extreme
corrosion reactivity
resistance High cost
The primary reasons for which titanium alloys are
used in aerospace applications include:

● Weight savings. The high strength-to-weight ratio for applications requiring high
strength and fracture toughness. Density 4.54 g/cm3
● Fatigue strength. Used for highly loaded bulkheads and frames in fighter aircraft.
● Operating temperature capability. For Ts above 130 °C alloys are often required.
● Corrosion resistance. Superior to both aluminum and steel alloys.
● Space savings. Used for landing gear components on commercial aircraft to fit within
the landing gear space envelope.
Metallurgical Considerations

882 °C

As alloying elements are added to titanium, they

tend to change the amount of each phase present
and the beta transus temperature.
 Classification

Alpha Alpha - Beta

Two phase alloys
Do not contain beta
containing both alpha
phase at RT
and beta phases

Ti alloys
Near - alpha Beta
Contain mostly alpha Contain mostly beta
with only a small with small amounts of
amount of beta alpha present
Microstructure and Mechanical Properties
Titanium has affinity for interstitial elements, O & N, absorbs them at 700 °C complicating
the processing and increasing the cost. As the amount increases (O&N), the yield and
ultimate strengths increase but ductility and fracture toughness decreases. So, it can be
used for CP grades and ELI. H max. limit allowed is 0.015% because causes embrittlement
(precipitating hydrides).

Ti alloys derive their strength from microstructures produced by the β-α transformation.
If α-β or β alloys are solution heat treated and aged, titanium martensite can form during
quenching; but is not like the extremely hard and strong martensite of steels.
Ti64 tensile strength increases from 890 to 1170 MPa, while 4340 steel, 758 to 1930 MPa.

Grain size does not affect the UTS, the finer grain size gives higher the yield strength,
ductility, and fatigue strength; and larger grain sizes gives creep resistance.
Thermomechanical Treatment
Lamellar structures are a result of cooling from
the beta phase field in which the alpha phase
nucleates at prior beta grain boundaries and then
grows into the beta grains.

A key element, TMT treatments conducted above

or below the beta transus temperature.
 If the cooling rate is fast, then the
microstructure will be fine, but if it is slow, it
will be coarse. Lamellar structures offer the
highest fracture toughness and the lowest
fatigue crack growth rates.

Equiaxed structures are a result of a recrystallization (previous cold

work). This can be accomplished by deformation in the two-phase
alpha + beta field followed by solution treating in the two-phase field.
Equiaxed structures produce the highest strength and ductility and
the best fatigue strength.
Commercially Pure Titanium (CP)
The CP grades have good formability, are readily weldable, and have excellent corrosion
resistance. The CP grades are supplied in the mill annealed condition which permits
extensive forming at room temperature, while severe forming operations can be conducted
at 150–480 °C. However, property degradation can be experienced after severe forming if
the material is not stress relieved.
CP alloys are used for corrosion resistant tubing, tanks, and fittings in the chemical
processing industry. Palladium can be added to further enhance corrosion resistance.
Alpha and Near-Alpha Alloys
5–6% aluminum as the main alloying element with additions of the neutral elements Sn/Zr
and some beta stabilizers. Al is a potent strengthener, increases corrosion resistance and
also reduces density (brittle intermetallic compound Ti3Al).
Cannot be strengthened by heat treatment (no beta phase), have medium formability, are
weldable, and have medium strength, good notch toughness, and good creep resistance
(silicides) in the range of 315-593 °C. These alloys also perform well in cryogenic apps.
Alpha–Beta Alloys
The alpha–beta alloys have the best balance of mechanical properties, wide processing
windows, and can be used in the range of about 315–400 °C. Are heat treatable to
moderate strength. Strengthened by STA but the strength obtainable decreases with
section thickness. The weldability is poor due to their two-phase microstructures, as the
percentage of beta stabilizing elements increases, the hardenability increases and the
weldability decreases.
Beta
Beta alloys contain enough beta stabilizing elements that the beta phase is retained to RT.
The high percentages of the BCC beta phase greatly increase their response to heat
treatment, provide higher ductility in the annealed condition, and provide great formability
at RT. The beta alloys can be STA to higher strength levels than the AB alloys while still
retaining sufficient toughness. In general, they exhibit good weldability (not all), high
fracture toughness, and a good fatigue crack growth rate, but they are limited to about 370
°C due to creep. The drawbacks of beta alloys are increased densities due to alloying
elements such as Mo, V and Nb; and reduced ductility when heat treated to peak strength
levels.
Melting TiO2 TiCl4 Ti

Titanium is extracted from rutile TiO2 ore.

TiCl4 is first produced by reacting TiO2 with
coke and chlorine. Generation of TiCl4
allows purification of the titanium by
distillation.
Next is reduced using either the Kroll
process (Mg), or Hunter process (Na).
In Kroll process, TiCl4 reacts with Mg to
form a porous mass of titanium called
sponge.
Vacuum Arc Remelting
An electrode is made by blending small
diameter (less than 1 cm) sponge particles
with master alloy granules of the same size,
pressing them together into briquettes and
then welding them to form the electrode.
During melting, the electrode is the anode
and the water- cooled copper crucible is the
cathode.
The ingot produced by this process
becomes the starting electrode for
additional VAR.
4.26 m x 0.6 m Ø
 Cold Hearth Melting
By balancing the heat input from a plasma or electron
beam with the heat extracted by water cooling, the melt
can be held in the hearth for longer time with only a solid
layer of titanium (skull) separating it from the copper
hearth.
It has the advantage of
being able to reduce
alloy segregation in the
final product.
 Ingot Defects
Low Density Inclusion High Density Inclusion Beta Flecks
hard-α inclusions are interstitial result from contamination caused by solute segregation, are
defects resulting from high introduced during the electrode regions of microsegregation that
concentrations of N in the original preparation process. essentially have a lower concentration of alpha
sponge that stabilizes the alpha non-deforming at the stress levels and are therefore high in beta
phase and creates local hard spots encountered in titanium alloys, stabilized material. Can be either
with low ductility, essentially an they are sources of strain stronger or weaker than the matrix,
incipient crack that will propagate incompatibility that leads to cause steep local strain gradients
under stress fatigue cracking and can cause early crack initiation.
Primary Fabrication
Titanium alloys are available in most mill
product forms: billet, bar, plate, sheet, strip,
foil, extrusions, wire, and tubing; however, not
all alloys are available in all product forms.

Primary fabrication hot working is used to

refine the grain size, produce a uniform
microstructure, and reduce segregation.

Prior to thermomechanical processing, the as-

cast ingot is conditioned by
grinding to remove surface defects.
Thermomechanical Processing
The first step in deforming as-cast ingots is a series of slow speed steps including upset
forging, side pressing, and press cogging to help homogenize the structure and break-up
the transformed beta structure.
Cogging: open die forging process between flat dies. The ingot is fed through the press in a
series of short bites that reduces the cross -sectional area. Electrically heated air furnaces
are used to preheat the ingot to 700–760 °C and then it is forged at 930–1750 °C in large
presses so that the deformation can be applied slowly to avoid cracking.
Working in the beta transus T is an effective for eliminating grain boundary alpha which
has an adverse effect on fatigue strength. Final hot working must be carried out in AB field
to develop a microstructure that has better ductility and fatigue properties. Cooling must
be fast to prevent alpha phase to precipitate at the prior beta grain boundaries leading to a
decrease in strength and ductility.
Equiaxed Structure
The structure is sufficiently worked to break-up the lamellar structure and then annealed to
cause recrystallization into equiaxed.

The equiaxed structure obtained is a function of:

● the prior microstructure
● the temperature, type, extent
and rate of deformation
● the annealing temperature and time.

In general, the finer the initial microstructure and the lower the deformation temperature
(i.e., greater percent of cold work), the more efficient is the deformation in causing
recrystallization.
After forge
Billets and bars are straightened, annealed, finished by turning or surface grinding to
remove surface defects and alpha case, and ultrasonically inspected.
Slabs from the forging operations are hot rolled into plate and sheet products using two-
and three-high mills. For thin sheet, pack rolling (4-5 sheets) is often used to maintain the
temperatures required for rolling.

Typical hot rolling temperatures for Ti-6-4 are:

● 950–1010 °C for bar
● 930–980 °C for plate
● 900–930 °C for sheet

Typical finishing operations for hot rolled material are annealing, descaling in a hot caustic
bath, straightening, grinding, pickling, and ultrasonic inspection.
Investment Casting
Titanium alloys are difficult to cast due to
their high reactivity; they will react with both
the atmosphere and the casting mold.

The majority of titanium casting is done with

Ti-6-4 (about 90%), with CP-Ti the other 10%.

It should be noted that there are no specific

titanium casting alloys, and the same
compositions that are used for wrought
products are also used for castings.
Investment Casting
As-cast titanium has a
microstructure typical of titanium
alloys worked in the beta field,
which has lower ductility and
fatigue strength than equiaxed
structures.
Due to the slow cooling rate,
titanium castings are often heat
treated to refine the
microstructure and eliminate
grain boundary alpha, large alpha
plate colonies, and individual
alpha plates.
Superalloys
Heat resistant alloys of nickel, iron–nickel
and cobalt that operate at Ts exceeding
537 °C.

Exhibit combinations of high strength,

good fatigue and creep resistance, good
corrosion resistance, and are operational
at elevated Ts for extended periods of
time (i.e., metallurgical stability).

Superalloys are the primary materials

used in the hot portions of jet turbine
engines, such as the blades, vanes and
combustion chambers, constituting over
50% of the engine weight.
Metalurgical Considerations
Nickel has an FCC crystalline structure, a
density of 8.9 g/cm3, and a melting
point of 1454 °C.
While iron has BCC structure and cobalt
HCP at RT, both iron- and cobalt-based
superalloys are so highly alloyed that they
have an austenitic FCC structure at RT.

Nickel and iron–nickel based superalloys

are strengthened by a combination of
solid solution hardening, precipitation
hardening and the presence of carbides
at the grain boundaries.
The compositions of commercial superalloys are complex (some contain as many as a
dozen alloying elements), with the roles of various alloying elements.
Precipitates
The FCC nickel matrix, which is designated
as austenite γ and its most important
precipitate γ’ (Ni,Co)3(Al,Ti) which has only
about an 0.1% mismatch with the matrix;
therefore, γ′ precipitates homogeneously
with a low surface energy and has
extraordinary long-term stability.

γ/γ’=(∼0.05%) spherical; higher it’s cubic.

BCT ordered γ′′ (Ni3Nb) forms the basis for

strengthening Inconel 718
Carbides
Grain boundary strengthening is produced mainly by precipitation
of chromium and refractory metal carbides.
Carbides in superalloys perform three functions.
1. Strengthen the grain boundaries, prevent or retard sliding and
permit stress relaxation.
2. A fine distribution of carbides precipitated within the grains
increases strength.
3. Tie-up certain elements that would otherwise promote phase
instability during service.
Since carbides are harder and more brittle than the alloy matrix,
their distribution along the grain boundaries will affect the high
temperature strength, ductility and creep performance of nickel
based alloys.
Some of the important carbides are MC, M23C6, M6C and M7C3. In
nickel based alloys, M stands for Ti, Ta, Nb or W.
Nickel Based Superalloys
Used in the hottest parts of aircraft engines, constituting
over 50% of the engine weight.
They are either solid solution hardened for lower
temperature use or precipitation hardened for higher
temperature use.
50% Ni, 10–20% Cr, 8% Al and Ti combined, 5–15% Co
and small amounts of boron, zirconium, hafnium and
carbon. Other common alloying additions are
molybdenum, niobium, tantalum, tungsten and rhenium.

An example of a γ′ strengthened alloy is the wrought alloy Waspaloy and the cast alloys
René 80 and Inconel 713 °C. Alloys can also contain both Nb and Ti and/or Al and be
strengthened by a combination γ’’ and γ’, such as Inconel 706.
Iron–Nickel Based Superalloys
Originally evolved from austenitic stainless steels with at least 25% nickel required to
stabilize the FCC austenitic matrix.

25–45% Ni, 15–60% Fe, 15 to 28% Cr (oxidation resistance at high T), 1–6% Mb is added
for solid solution strengthening. Ti, Al and Nb are added for precipitation hardening.

The most common precipitate is γ’ as in the alloy A-286, which contains 26% nickel. In
alloys containing Nb (Inconel 718), the γ′′ precipitate Ni3Nb is main strengthener.

Due to the lower temperature stability of γ′′ compared γ′, the maximum use temperature of
Inconel 718 is about 650 °C; however, Inconel 718 is still the most widely used of all of the
superalloys. It is one of the strongest at low temperatures but rapidly loses strength in the
650 – 815 °C range.
Cobalt Based Superalloys
Co has a HCP matrix below 415 °C that transforms to FCC at higher Ts; however, Ni
stabilizes the FCC austenitic structure between room temperature and the melting point.
50–60% Co, 20–30% Cr, 5–10% W and 0.1–1.0% C. Wrought alloys contain about 40%
cobalt and high nickel contents (∼20%) for increased workability.

Strength increase rely on a combination of solid solution and carbide strengthening, which
limits their use in many applications. In the M23C6 carbides, M is mostly Cr but can also be
Mo or W, when this content exceeds about 5 atomic percent, M6C carbides can form.

The cobalt alloys display good stress rupture properties at hotter than 1000 °C. They also
have superior hot corrosion resistance at high temperature, probably due to their quite high
chromium contents. Examples of important cobalt based alloys are the wrought alloys
Haynes 25 (L605) and Haynes 188 and the cast alloy X-40.
Melting and Primary Fabrication
There are three major types of nickel deposits: nickel–copper–iron sulfides, nickel silicates,
and nickel laterites and serpentines.
1. The nickel– copper–iron sulfide ore is crushed and ground and the iron sulfide is separated
magnetically.
2. The remaining nickel and copper ores are separated by flotation.
3. The nickel concentrate is roasted, smelted in a reverberatory furnace.
4. The copper–nickel matte is cooled under controlled conditions so that discrete crystals of nickel
and copper sulfides and a nickel–copper metallic alloy are formed.
5. The cooled matte is crushed and ground, the metallic alloy is separated magnetically and treated.
6. The remaining copper and nickel sulfides are separated by froth flotation.
7. The nickel sulfide is roasted to produce various grades of nickel oxides which are then converted to
pure nickel and nickel alloys.
Vacuum Induction Melting
In the VIM process, liquid metal is processed
under vacuum in an induction heated crucible,
used to produce the desired alloy composition.
Feedstock includes pure elements, master alloys
and recycled scrap.
Used to reduce interstitial gases (O, N, H), enable
higher and more controllable levels of the reactive
strengthening elements Al and Ti, and eliminate
the slag inherent in air melting. Ceramic filters are
also used to remove large oxide and nitride
inclusions during the final pour.
VIM ingots have coarse and non-uniform grain
sizes, shrinkage and alloying element segregation.
Triple Melting Process
In addition to refining the composition, VAR and ESR refine the solidification structure of
the resulting ingot. The ESR process is inherently capable of producing cleaner metal than
VAR, while VAR is capable of producing larger ingots with fewer segregation defects.
Therefore, a triple melting process (VIM–ESR–VAR) is used for producing large ingots for
forging stock for gas turbine components.
Cast ingots are initially refined by cogging, a forging operation that uses open dies and
hydraulic presses. Automated equipment is used to manipulate the billet and carry out the
deformation producing uniform deformation along the length of the billet. Continued
deformation is conducted at successively lower temperatures to give greater
microstructural refinement.

Producing a fine, uniform

grained billet:
1. lead to fine grained forgings
which improves fatigue life
2. yield lower flow stresses and
uniform reductions during
forging
3. Easier to ultrasonically
inspect assuring increased
levels of cleanliness.
Investment Casting
Since the 60s, the hottest parts of the engine, blades and
vanes, have been manufactured by investment casting.
The original cast blades and vanes were fine grained
polycrystalline structures made using conventional
investment casting procedures. These blades were then
heat treated to coarsen the grain structures for enhanced
creep resistance.

Eventually it became possible to produce directionally solidified (DS) structures with

columnar grains oriented along the longitudinal axis of the blade.
The DS process also creates a preferred low modulus texture, or orientation, parallel to
the solidification direction that helps in preventing thermal fatigue failures.
An extension of the DS process was the development of the single
crystal (SX) process in which a single crystal grows to form the
entire blade.

Since there are no grain boundaries in the SX process, this allowed

the removal of grain boundary control alloying elements that were
detrimental to high temperature creep performance, allowing even
higher operating temperatures

Microstructure of MC2 single-

crystal nickel-based superalloy
observed by TEM (bright field)
after a standard heat treatment.