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THE VERY BEST IN CASTINGS
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Meeting and exceeding the most
complex casting requirements
We are industry leader in the manufacture of
titanium and aluminium investment casting
products. From our headquarters in Bestwig,
Germany, we supply customers around the
world in the fields of aerospace, electronics,
optics, industrial and medical systems, Formula 1 racing and general motor sports.
Our core competencies and technical capabilities enable us to supply our customers with
assembly-ready investment casting components. We concentrate on high growth market
segments where demands for quality, complexity and product integrity are critical. Our
continued success is driven by our goal to
meet and exceed our customer demands
throughout the supply chain. This customer
focus, combined with our exceptional technical
2
capabilities makes us an ideal development
and production partner for global industry
leaders. For many years we have accepted
the challenge of thinking beyond the boundaries of the possible. Our company culture
thrives on the continuous improvement of our
products, processes and our relationships
with customers, suppliers and staff.
We concentrate on high complexity titanium
and aluminium investment casting products
with dimensions of up to 60 inches. Our patented HERO Premium Casting ® process
allows us to achieve consistent above-average
mechanical properties throughout every aluminium component. You, the customer, are
the focus of all our activities.
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Investment casting components
for aerospace
The aerospace industry is a dynamic marketplace where the highest demands for precision
and quality are commonplace. TITAL® understands these demands and has focused all
processes and procedures to meet and exceed
these important criteria. Our certifications to
EN 9100 and PRI NADCAP (National Aerospace and Defence Contractors Accreditation
Program) clearly underline this. In addition,
TITAL® has been qualified by Airbus as the
world's only investment casting component
producer for supply of critical components to
Casting Factor 1.0 in accordance with FAR
25.621 and JAR 25.621.
Our customer service starts at the conception
phase, in the form of design workshops where
our customers receive real-time product consulting. These design sessions allow an open
forum for material selection, design and manufacturability discussions well in advance of
final designs. Special attention is also devoted
to the design-to-cost strategy to achieve specific component requirements at the minimum
weight and lowest cost possible. Together
with our customers we are able to achieve
key program targets in design, development
and part cost.
This is made possible by our staff's commitment and motivation to continuous process
improvement.
Designed by Techspace Aero
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Technology driving innovation
Aluminium and titanium investment castings
can be found in virtually all commercial airplanes and helicopters as well as in defence
projects like the Eurofighter, A400M, NH90
and the guided missiles, Meteor and Taurus.
TITAL® has long participated in the industry
trend where engine and air frame manufacturers request assembly-ready components.
We have also developed our production system
to adapt to larger and more complex investment castings. Investment castings exceeding
40" are commonplace in today's aerospace
industry.
Cast Frame · TiAl6V4
40.6 x 4.3 x 7.1 inches · 13.2 lbs
A400M
Intermediate Casting · A357
37.8 x 37.8 x 12.2 inches · 174 lbs
GP7000
AFT Canopy Casting · A357
49.21 x 33.46 x 13.78 inches · 46 lbs
Eurofighter
Tail rotor gearbox · A357
20.5 x 11.8 x 18.1 inches · 57.7 lbs
NH90
Track A357
23.43 x 19.88 x 10.04 inches · 21 lbs
Airbus
Rear Main Frame · A357
33.9 x 18.1 x 26.8 inches · 51.8 lbs
TAURUS KEPD 350
In addition, TITAL® has been very successful
in positioning aluminium investment products
ahead of traditional sand casting competitors.
This has been achieved by making larger
components with superior quality, lighter
weight, reliable and repeatable processes at
significantly lower costs.
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Aluminium and titanium in every aerospace platform
Titanium and aluminium investment components manufactured by TITAL® are used in virtually all areas of the aircraft's primary and
secondary structures. Titanium is used for
structural engine components where high temperature and strength-to-weight ratios are
critical. Titanium castings are also used in the
aircraft pylon where thin walls of less than
0.08 inches are important for proper weight
distribution. Smaller titanium castings are
used in the door frame and latch assemblies.
Pipe connections are another area for aluminium and titanium casting products and can
also be found in the air conditioning system
and cabin air management systems as well
as in all actuation areas, e.g. in the area of
airbrakes.
Ti Torsion · 11.7 lbs
13.4 x 5.9 x 10.6 inches
Al Lower Housing · 16.8 lbs
25.6 x 20.1 x 7.5 inches
Ti Cast Frame · 13.2 lbs
40.6 x 4.3 x 7.1 inches
Al Track · 20.9 lbs
23.4 x 19.9 x 10.0 inches
Ti Pylon Fitting · 18.1 lbs
11.4 x 11.0 x 6.7 inches
Ti Door Brackets · 0.4 lbs
5.1 x 2.0 x 3.1 inches
Al Hatch · 4.4 lbs
15.7 x 9.8 x 4.7 inches
Ti Escape Slide Hook · 0.7 lbs
4.1 x 3.7 x 1.6 inches
Al Hand Wheel · 2.4 lbs
15.4 x 7.1 x 3.9 inches
Al Cargo Loading Box · 8.2 lbs
21.7 x 13.8 x 15.7 inches
Al Door Corner · 1.8 lbs
22.0 x 23.0 x 1.6 inches
Al Rudder Pedal · 0.9 lbs
7.1 x 5.9 x 3.9 inches
Al Fairing · 2.9 lbs
18.5 x 7.5 x 6.7 inches
Al Unit door · 1.5 lbs
9,4 x 7,1 x 7,1 inches
Ti Anti Ice Duct · 3.5 lbs
12.2 x 4.7 x 3.5 inches
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Al Seal Corner · 0.9 lbs
11.0 x 10.2 x 2.6 inches
Al Exhaust Duct · 3.5 lbs
28.3 x 11.8 x 7.1 inches
Ti Front Bracket · 15.9 lbs
19.7 x 19.7 x 15.7 inches
Al Front Frame 9strut
70.5 lbs · Ø27.6 inches
Al Vent Door Frame · 1.3 lbs
18.9 x 1.8 x 10.4 inches
Al Housing · 0.7 lbs
10.0 x 4.9 x 3.1 inches
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Design of a casting part using
the Rapid Prototyping process
Batch sizes of one are no longer just a dream.
We provide our customers with a convenient,
high-speed solution for prototype and small
lot production of titanium or aluminium investment castings.
The wax model needed for the casting process
is replaced by a laser generated stereolithography or SLS pattern that allows our customers to significantly reduce the development
time and associated costs. The rapid prototype
casting goes through the same production
process with no sacrifice in product quality.
In addition, we have a separate production
line for rapid prototype castings that allows
for maximum speed and flexibility to meet
the customers aggressive development timelines.
Cost comparison Rapid Prototyping / Series
Total cost
Conventional
tool
Master silicone
tool
Break even 1
Break even 2
approx. 3–5 castings approx. 20–60 castings
SLS model
wax model produced with silicone tool
wax model produced with conventional tool
Engine gearbox with turbine bearing and seven
integrated feeders and waste disposal lines
(Ø 0.47 inches)
Dimensions: 37.8 x 12.2 in
Weight:
174 lbs
Alloy:
GF-ALSi7Mg0,6
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Integration of insertion boxes
in the armature
Design to Cost - our solution
in search of cost savings
Due to the wide array of product configurations
and complexities available using the investment casting process, castings are truly an
economical alternative to other manufacturing
methods. Significant savings are available
when several structural components that are
either welded or mechanically connected are
replaced by a single investment casting.
The component size, weight and cost can also
be optimized by integrating several components into one investment casting. Savings can
be achieved by the reduction of part drawings,
CAD models and associated inspection costs.
With TITAL's HERO Premium Casting® process
for aluminium investment castings, circuit
board slots can be cast with such precision
that no subsequent machining is required.
Self-supporting casting structure
with a wall thickness of < 0.1 inches
Piping for feeding the cooling air
Significant savings can be achieved when
castings replace large component assemblies.
For example, TITAL in conjunction with the
customer converted an extremely complex
cockpit instrument panel assembly into a fully
integrated cast component. Historically, the
instrument panel was assembled from 300
single components with more than 600 rivet
connections. The concurrent engineering effort reduced the 300 single components into
11 investment castings which reduced the
assembly time by 90% and the product cost
by 50%.
TITAL® stays in close communication with the
industry through customer design and manufacturing engineers. Concurrent engineering
workshops with the customers' design and
engineering professionals are held on a
regular basis. The TITAL® hosted "Investment
Casting Seminar" is an in depth look at the
titanium and aluminium casting process from
start to finish with special emphasis on design-to-cost issues and solutions. Dates for
the next "Investment Casting Seminar" can
be found on www.tital.de.
Cost savings of the electronic circuit housing
Sheet Metal Assembly
Concept
Weight
7.9 lbs
1 Casting
4.9 lbs
Approx.
184 Fasteners
Elimination of Fasteners
Overall Cost
12
9 Plates/Bent
Components
8 Milled Parts
42 Plastic Guides
Investment
Casting
100 %
65 %
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HERO Premium Casting® for lightweight, high-strength,
complex aluminium casting parts
with casting factor 1.0
The HERO Premium Casting® process for
aluminium investment castings is a combination of an innovative casting process with
intelligent process-engineering. The results
are light-weight, high-strength complex components that successfully meet tomorrow's
design demands today.
TITAL® A357 Gaussian Distribution of Static Properties, HERO
Premium Casting® and Standard Casting
Frequency
0,040
UTS HERO (CV = 3,0
213 test bars)
0,035
Yield HERO (CV = 4,1
0,030
213 test bars)
UTS Standard (CV = 4,8)
0,025
Yield Standard (CV = 8,1)
0,020
0,015
0,010
The patented HERO Premium Casting® process differs from conventional casting methods with its computer assisted control of
component solidification. In the casting process, the required solidification parameters
are programmed on a process computer which
translates them to repeatable mechanical
properties.
The HERO® aluminium casting process was
developed at TITAL® in 1990 by a five member
engineering team and is a combination of an
innovative casting process with intelligent
process engineering. The HERO® casting process differs from conventional casting methods by using computer-assisted component
solidification. The rapid, controlled solidification achieved with the HERO® casting process
produces an extremely fine metallurgical
structured component that is virtually defectfree with superior mechanical properties.
0,005
0,000
200
250
300
[MPa]
350
400
TITAL® A357 HERO Premium Casting® Fatigue Properties
MPa
180,0
160,0
140,0
120,0
100,0
80,0
60,0
Specimen,
40,0
KT = 1,00 R = 0,1
20,0
Typical
0,0
1,00E+03
1,00E+04
1,00E+05
log
1,00E+06
1,00E+07
TITAL® A357 HERO Premium Casting® Crack Propagation
da/dN [mm/cycles]
1,00E-02
CT Specimen,
R = 0,1
Trend
The patented HERO Premium Casting® process also leads to stable and predictable shrinkage which allows TITAL® to meet our customers toughest dimensional requirements.
Cost-savings throughout the value added
chain by:
• Weight reduction by the use of Casting
factor 1.0
• Minimum variation of shape and positional
tolerances
• High casting quality
• Reduced risk of latent defects
• Automated processes
• Monitored preventative quality assurance
• Reduction of inspection costs
• Reduction of machining costs.
1,00E-03
1,00E-04
1,00E-05
1,0E+00
1,00E+01
∆K [MPa√m]
1,00E+02
TITAL® A357 HERO Premium Casting® Elongation
Frequency
30
Elongation
213 Test Bars
25
20
15
10
5
0
1,0
14
2,0 3,0 3,8 5,3 6,8 8,2 9,8 11,2 12,8 14,2 15,0
Elongation A5 [%]
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Highest customer demands are
met with titanium investment
castings
TITAL® TiAl6V4 Gaussian Distribution Static Properties
TITAL® produces titanium investment casting
parts with a component size of up to 60 inches
and part weight up to 661 pounds for all industry leaders in the European aerospace industry. TITAL® specialized in casting the titanium
alloys TiAl6V4 and TiAl6Sn2Zr4Mo2 and produces cast parts using centrifugal or gravity
pouring processes depending on the size.
Frequency
0,030
In 2008, Airbus Germany approved TITAL® to
manufacture titanium cast parts with a Casting
Factor of 1.0 for the A380 aircraft. This approval
has been preceded by component tests in
order to determine the coefficients of variation
on TiAl6V4 casting parts. This included the
investigation of the influence of chemistry,
weld repair, as well as the level of discontinuities with regard to the variability of static and
mechanical properties.
0,000
620 680
0,025
0,020
UTS (CV = 2,5
170 Test-Bars)
Yield (CV = 1,9
170 Test-Bars)
0,015
0,010
0,005
700 740
780 820 860 900 940 980 1020
MPa
TITAL® TiAl6V4 Open Hole Fatigue Properties
MPa
800
R = 0,1
KT = 2,5
Test Specimen
R = 0,1
KT = 1,00 Calculated
Test Specimen
Batches 1–5
700
600
500
400
300
TITAL® verifies the compliance to required
mechanical properties through regularly scheduled customer specific component testing.
Dynamic properties like fatigue resistance and
crack propagation are being monitored in
addition to static properties like yield strength,
tensile strength and elongation.
The casting process is a superior alternative
to machining and saves precious raw materials
and the final result particularly with titanium
components is more cost efficient than components machined from raw material. The
cost savings achieved when using the nearnet-shape investment casting for titanium
components are so substantial that the conversion costs from machining to castings are
quickly amortized. In addition, for big and
complex assemblies many functions can be
integrated into one single casting which saves
additional weight and assembly costs.
In 2008 TITAL® became involved in the development of state-of-the-art titanium casting technology. Together with renowned universities
and research institutes TITAL® investigates
production technologies for more efficient
casting processes of the intermetallic alloy
γ-TiAl. γ-TiAl has a density of 0.14 lbs/inches3
and is 10 % lighter than conventional titanium
alloys. Besides the advantage in weight γ-TiAl
is heat-resistant and perfectly suited for use
in turbine blades in aircraft engines.
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200
100
0
1,0E+04
1,0E+05
1,0E+06
1,0E+07
Cycles (Nf)
TITAL® TiAl6V4 Crack Propagation
da/dN [mm/cycles]
1,0E-02
Test Specimen
R = 0,1 (4 Batches)
1,0E-03
Trend
1,0E-04
1,0E-05
1,0E-06
1,0E-07
1,0E+00
1,0E+01
1,0E+02
1,0E+03
∆K [MPa√m]
TITAL® TiAl6V4 Elongation 170 Test Bars
Frequency
35
Elongation
30
170 Test Bars
25
20
15
10
5
0
4
5
6
7
8
9
10
11
Elongation A5 [%]
12
13
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Ready for Assembly: Cost
savings with ready for
assembly casting components
For many years TITAL® has offered its clients
the delivery of casting parts ready for assembly. Depending on the customer's requirements the casting parts are delivered directly
to the production line including mechanical
finishing, surface treatment and, if necessary,
mounted purchased parts like rivet nuts, linkages or bolts.
When purchasing machined complete and
ready for assembly products our customers
avoid costly management of parts and supplies
and administrative costs are reduced along
with supplier base reductions. The share of
castings ready for installation at TITAL® has
grown strongly and will prevail as the norm
in the future. TITAL® has laid the foundations
to continue supporting this trend.
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Concurrent Engineering:
Cost advantages from
conception to production
The TITAL® engineering team makes 100% of
it's casting technology expertise available to
our customers to find the best engineering
and cost effective solutions. The concurrent
engineering and joint product development
process is key to maximum cost savings along
the entire product value chain.
As a project moves from development into
production, TITAL® assembles a cross-functional team from Sales, Engineering, Quality
and Manufacturing to ensure a smooth and
seamless product transition. Customer communication is a constant priority through-out
the transition and becomes permanent in the
production manufacturing environment.
As an example of the concurrent engineering
process, a tail rotor gearbox was converted
from an aluminium sand casting to an aluminium investment casting. This project resulted
in significant cost savings and a weight reduction of more than 20%.
Contact us – we are looking forward to your
challenges!
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Materials
Aluminium-Casting-Alloys
Alloy
Material
designation
Chemical composition in %
Qualitygrade
Mechanical characteristics
at 20 °C
Wall
thickness
Heat
treatment
condition
Limits for
technical
use**
Corrosion
resistance
Resistance to
Machin- Electrical Thermal
ability conductivity conductivity
Coefficient of
thermal
expansion
Other
GF-AlSi7Mg0,6
A357
EN-AC-42200
DIN EN 1706
Si
Fe
Cu
Mn
Mg
Zn
Ti
Be
6,5
7,5
0,20
0,20
0,10
0,40
0,70
0,10
0,04
0,20
0,07
each
0,05
AI
Rp0,2
MPa
min.
Rm
MPa
min.
0,15
rest
240
290
2
80
general
T6
250
310
5
85
<3
T6
Al-C-42201
EN 3125*
WL 3.2384 Teil 3
critical
areas
6,5
7,5
0,20
0,20
0,10
0,40
0,70
0,10
0,04
0,20
0,07
0,05
A5 hardness
%
HB
min. min.
total
0,15
rest
mm
°C
240
300
4
85
3-6
T6
240
300
3
85
6-12
T6
240
290
2
85
12-18
T6
230
290
3
85
<3
T6
220
280
3
85
3-6
T6
220
270
3
85
6-12
T6
220
260
2
85
12-18
T6
Climatic
influence
Sea water
-6
m/(Ω · mm2) W/(K · cm) 10 · mm/(mm · K)
20 °C–100 °C
max. dimension
of parts l x b x h
other dimensions
on request
max.
Weight
mm
kg
AMS-A-21180
DAN 2000 Teil 4
other
areas
***Hero Premium 6,5
Casting®
7,5
GF-AlSi5Cu1,2Mg
C355
AMS 4215
GF-AlCu5Ni1,5
MnSbCoTiZr
WL 3.1754 Teil 1
0,20
0,20
0,10
0,40
0,70
0,10
0,04
0,20
0,07
0,05
0,15
rest
all
areas
270
330
3
85
low
effect
T6
0,20
1,0
1,5
0,10
0,40
0,60
0,10
0,20
-
0,08
0,15
rest
general
193
241
2
80
up to max. 10
T6
4,5
5,5
0,20
0,30
1
80
up to max.10
T6
-
-
critical
areas
200
-
0,15
0,25
160
0,30 0,50
other
areas
150
190
1
80
critical
areas
130
185
1
-
other
areas
130
180
1
critical
345
415
3
4,5
5,5
RR350
Ni 1,3
1,8
Zr 0,10
0,30
Co 0,10
0,40
Sb 0,10
0,40
0,05
GF-AlCu4TiMg(Ag) AMS 4229
0,05 0,10
4
5
0,20
0,40
0,15
0,35
-
0,15
0,35
0,15
rest
Ag 0,4
1,0
-
A201
uncritical
0,03
0,1
330
385
B
A
B
B
21-32
1,5-1,8
22
1000 x 1000 x 600
50
max. 150
C
C
C
B
19-22
1,5-1,6
22,4
500 x 300 x 250
20
max. 180
D
D
F
B
19-23
1,4-1,6
22,5
300 x 300 x 300
15
max 150
D
D
F
B
27-32
1,5-1,8
19,3
150 x 150 x 150
5
T6
up to max. 10
T9
up to max. 10
T9
T7
90
max. 100
up to max. 10
1,5
rest
Titanium-Casting-Alloys
Alloy
Material
designation
Chemical composition in %
Max. service
temperature
Mechanical
characteristics
at 20 °C
Weldingability
Machinability
Electrical Thermal
conductivity conductivity
Coefficient of
thermal
expansion
Other
O2
GF-TiAl6V4
N2
H2
Fe
C
Al
V
Sn
0,10
5,50
6,70
3,5
4,5
-
Zr
Mo
Si
-
-
each
total
Ti
Rp0,2
MPa
min.
Rm
MPa
min.
A5
%
min.
°C
0,10
0,40
rest
815
880
5
350
-6
m/(Ω · mm2) W/(K · cm) 10 · mm/(mm · K)
20 °C–600 °C
max. dimension
of parts l x b x h
other dimensions
on request
max.
Weight
mm
kg
EN 3352
WL 3.7264
ASTM B 367-83
Grade C5
MIL-T-81915 Type III
AMS 4992
0,25
0,05 0,015 0,30
-
A
0,58
0,071
9,3
1000 x 1000 x 600
300
-
-
-
750 x 750 x 600
150
BMS 7-310
All reduced cutting speed and
cooling, Ti and Ti-alloys can be
machined without difficulty
MSRR 8670
EMS 54914
MTS 1046
GF-TiAl6Sn2Zr4Mo2
MSRR 8688
0,20
0,05 0,015 0,11
0,10
5,5
6,5
-
1,75
2,25
3,5
4,5
1,75
2,25
0,13
0,10
0,40
rest
847
930
8
450
B
R
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A = excellent
B = good
C = acceptable
D = poor
E = not recommandable
F = unqualified
* Developement stage
** mech. characteristics are depending on temperature and load
*** TITAL® Patent: EP 0571 703B1
AC = Air Cooling
GFQ = Gas Fan Quench
THE VERY BEST IN CASTINGS
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Bielefeld
How to find us:
A2
Paderborn
A33
A44
Dortmund
Kassel
A46
A3
R
Arnsberg
A 46
THE VERY BEST IN CASTINGS
Düsseldorf
A45
A1
A4
Köln
Aachen
A 59
Bonn
Frankfurt
A3
Koblenz
TITAL GmbH
Kapellenstraße 44
59909 Bestwig
Germany
Phone +49 2904 981-0
Fax
+49 2904 981-400
[email protected]
www.tital.de
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