Recycling of titanium alloy swarf directly into wire using the ConformTM continuous extrusion process

Sarah A Smythe,Xiaoli Fang ,Daniel Suárez-Fernández ,Bethan Thomas ,Benoît Marguet ,Martin Jackson

doi:10.1051/matecconf/202032103028

Sarah A Smythe, Xiaoli Fang + Show 4 more

Open Access

https://doi.org/10.1051/matecconf/202032103028

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Abstract

ConformTM is an extrusion process, which has been in use since the 1970s. Although it is primarily used with aluminium or copper rod/powder feedstocks, work at the Univ. Sheffield over the last decade has involved the use of titanium feedstocks for various applications. This paper expands on this knowledge by utilising low cost, aerospace titanium alloy swarf, which is the largest waste product from the manufacturing of aerospace titanium components. Swarf is fed into a ConformTM extrusion machine at room temperature and is fully consolidated into round wire/rod profiles in one, solid-state step, using modified tooling for titanium. Such wire can be used for additive manufacture or welding wire. To date there has been numerous successful trials in this challenging process, including the production of both 10 mm commercially pure titanium rod (from powder) and, more importantly, the production of 5 mm diameter Ti-6Al-4V wire from swarf. The material produced has since been characterised using light and electron microscopy and mechanical properties determined using tensile testing and microhardness indenting.

Highlights

All trials were completed using an experimental BWE Ltd ConformTM 350i machine based in Ashford, Kent and shown in figure 1
Over the last few years, wire fed addi ve manufacturing routes have received increasing sponsorship, as an alterna ve route to achieve near net shape in fewer processing steps
Such processes include wire-arc addi ve manufacturing (WAAM) [1] and Arconic’s Ampliforge process [2], for example. Such wire fed routes require post or in-situ thermomechanical processing to refine the microstructure. One drawback of such processes is the high cost of the tanium alloy wire feedstock which is produced through the expensive Kroll Process route

Summary

Introduction

All trials were completed using an experimental BWE Ltd ConformTM 350i machine based in Ashford, Kent and shown in figure 1. It’s no surprise that over the last few years there has been more interest the reuse and recycling of tanium alloy machined swarf in order to reduce manufacturing costs. With increasing aircra orders and more tanium alloy components being employed, such recycling technologies are becoming ever important.

Results

Conclusion