Utilizing Near-Net Titanium Extrusions in Aerospace Plate & Forging Applications

Titanium alloys are widely used in aerospace design because of their exceptional design characteristics. Chief among those characteristics is strength to weight ratio, corrosion resistance, and compatibility with composites. On the downside, the use of titanium generally carries a higher cost. This is experienced both in its basic production (raw material and mill processing), and in fabrication/machining. With only four internationally qualified Ti6Al-4V plate producers, and even fewer producers that have the capability of making low residual stress/high flatness plate, demand can far exceed supply. This only further exacerbates cost and lead times. In addition, the war in Ukraine has disrupted the global supply chain and it is becoming more difficult to source large titanium parts.

One solution to meet demand is the exploration of alternative manufacturing solutions to production parts currently being produced from titanium plate. Plymouth Engineered Shapes (PES) has developed a sophisticated method of production to achieve the required plate properties with titanium extruded shapes for parts typically produced from rolled plate. This technique provides an alternative manufacturing source for these products as well as other benefits. Many parts that have been previously produced from joining multiple plates can now be produced via a single near-net extrusion. This improves the overall integrity of the part by simplifying the design while reducing manufacturing time. Also, utilizing a near-net extrusion improves the buy-to-fly ratio and allows for a significant reduction in machining of the final part.

This presentation will provide an in-depth analysis of properties taken from Plymouth produced Ti6Al-4V extrusions while examining the role extrusion ratio plays in fatigue. In addition, an evaluation and comparison of these properties to aerospace requirements of alpha+beta and beta-annealed plate/forgings will be given. The presentation will conclude with a summary of possible applications and considerations that are applicable to this manufacturing methodology.