Advancements in Near-to-Net Extrusion Manufacturing Technology for Aerospace Applications

Aircraft components with long constant cross-sectional areas can utilize extruded shapes in their design. For titanium extrusions, the most common examples are seat tracks produced from the workhorse grade, Ti-6Al-4V (Ti-64). However, outside of aerospace, the applications for titanium extrusions can be more varied ranging from sub-sonic systems to un-manned submarines.

To expand the role of titanium extrusions in aerospace, Plymouth Engineered Shapes (PES) has developed advanced manufacturing techniques for producing near-to-net extrusions. This has been achieved by capitalizing on some of the favorable characteristics of Ti-64, like its low flow stress above beta transus. These shapes can be used in various aero-engine applications together with traditional products. Compared with a conventional part, the near-to-net shape that can be achieved through titanium extrusions allows for significant material yield savings through a closer approximation to the final part. In turn, less machining is required, and the buy-to-fly ratio is improved.

This presentation will provide an overview of various Ti-64 profiles extruded at PES and demonstrate the improvement in buy-to-fly ratio with the use of near-to-net shapes. Furthermore, a summary of relevant mechanical properties, microstructural characterization, and the dimensional tolerances held over the length of the extrusion will be presented. Residual stresses, which play a critical role in the performance, machining, and structural stability of the extruded product, will also be discussed.