Near-To-Net Shape Aerospace Extrusions

Extruded shapes, generally, are ideal for the fabrication of long members of the aircraft that require constant cross sections. Most common aerospace extrusions include seat tracks that are produced using the work horse titanium alloy, Ti-6Al-4V (Ti-64). Typical extrusion temperature for Ti-64 being very high (~2100°F), uses a lubricant during the process resulting in a rough surface, that requires 100% machining. In an effort to reduce the overall costs including the buy-to-fly ratio, the R&D division of Plymouth Engineered Shapes (PES) has successfully developed an innovative process and manufactured near-to-net shape Ti-64 extrusions, about ~30ft. long, on a production scale that included shapes of varying geometries. This paper will present different near-to-net shapes extruded at PES, and provides the advantages in terms of cost savings over the standard extrusions. It will also discuss the mechanical properties, microstructure and the overall dimensional tolerances held over the length of the extrusion.