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Cost reduction of TiAl by alternative production and integration of TiAl scrap recycling - concepts and vacuum-metallurgical equipment

Lochbichler C., Friedrich B., Jarczyk G., Scholz H.

Advances in Materials Science

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2008

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Vol. 8, nr 1(15)

67-74

EN

Due to high corrosion resistance and low density titanium alum in ides show a great potential as material for structural applications in the aerospace and automotive industry. However the high actual production costs for semi-finished products slow down a break through to mass production of TiAl. Current research projects at IME, Aachen funded by AIF "Otto von Guericke" and BMBF aim on cost reduced production methods of TiAl and on the minimisation of downgrading TiAl scrap. This article presents firstly the state of the art of TiAl production by vacuum arc (re)melting (V AR) or induction skull melting (ISM). A comparison of new process routes under special consideration of recycling issues will follow. Innovative processing and equipment concepts are shown by intelligent combination of well known vacuum melting and remelting processes such as vacuum induction melting, specialized using ceramic lining and deoxidisation with e.g. electro slag remelting (ESR). For each process step and accordingly equipment the metallurgical opportunities are pointed out and the way to make use of them within the process route is described. Requirements on input material and final metal quality addicted to the processing route and refining techniques with their adjustment in respect to TiAl are mentioned. Selected results of laboratory and pilot scale experiments done at IME in Aachen and equipment needs therefore are shown.

2

Cost reduction of TiAl by alternative production and integration of TiAl scrap recycling - concepts and vacuum-metallurgical equipment

Lochbichler C., Friedrich B., Jarczyk G., Scholz H.

Advances in Materials Science

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2007

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Vol. 7, nr 4(14)

81-88

EN

Due to high corrosion resistance and low density titanium aluminides show a great potential as material for structural applications in the aerospace and automotive industry. However the high actual production costs for semi-finished products slow down a break through to mass production of TiAl. Current research projects at IME, Aachen funded by AIF "Otto von Guericke" and BMBF aim on cost reduced production methods of TiAl and on the minimisation of downgrading TiAl scrap. This article presents firstly the state of the art of TiAl production by vacuum arc (re)melting (VAR) or induction skull melting (ISM). A comparison of new process routes under special consideration of recycling issues will follow. Innovative processing and equipment concepts are shown by intelligent combination of well known vacuum melting and remelting processes such as vacuum induction melting, specialized using ceramic lining and deoxidisation with e.g. electro slag re-melting (ESR). For each process step and accordingly equipment the metallurgical opportunities are pointed out and the way to make use of them within the process route is described. Requirements on input material and final metal quality addicted to the processing route and refining techniques with their adjustment in respect to TiAl are mentioned. Selected results of laboratory and pilot scale experiments done at IME in Aachen and equipment needs therefore are shown.

3

Nowa technologia odlewania ekonomicznych zaworów silnikowych z aluminidków tytanu.

Jarczyk G., Blum M., Busse P., Scholz H., Laudenberg H.J., Segtrop K.

Inżynieria Materiałowa

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2001

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R. XXII, nr 1

46-49

PL

Analiza cech charakterystycznych materiałów na osnowie gama-TiAl wykazała, że ich doskonałe właściwości predystynują je dla zastosowań w przemyśle motoryzacyjnym, a szczególnie jako tworzywo na zawory spalinowych silników samochodowych. W ALD Vacuum Technologies AG w ramach projektu badawczo-naukowego wspieranego finansowo przez Niemieckie Ministerstwo Nauki i Badań opracowano nowy proces ekonomicznego wytwarzania zaworów. Stosując zmodyfikowaną metodę indukcyjnego topienia w tzw. chłodnym tyglu w powiązaniu z odlewaniem odśrodkowym do gradientowo podgrzanej kokili metalowej, wyprodukowano niewielką serię zaworów silnikowych z aluminidków tytanu. Wyprodukowane części zostały poddane kompleksowym badaniom, m.in. eksploatacyjnym w postaci 500 godzinnego testu silnikowego odpowiadającego żywotności przeciętnego samochodowego silnika benzynowego. W artykule przedstawiono proces technologiczny, jego wyniki oraz perspektywy rozwoju na skalę przemysłową.

EN

Based on the materials characteristics gamma-titanium aluminide has excellent properties for automotive applications, especially as automotive valves. Initiated by ALD Vacuum Technologies AG a new low cost manufacturing process has been developed by a joint research project under the financial support of the German Federal Ministry of Education and Research. Small batch sizes of titanium aluminide automotive valves were produced by using a modified cold wall induction melting and centrifugal casting method in combination with a gradient preheated metallic permanent mold. The parts were extensively tested e.g. in a 500 hours engine test, which corresponds to an average life time cycle of a car engine. The development of the process, the results and upscaling of the equipment will be presented.