R THE VERY BEST IN CASTINGS I N V E S T M E N T C A S T I N G S F O R A E R O S P A C E 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. R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 3 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 4 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 5 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. 6 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 7 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 8 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 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 9 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 10 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 11 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 % R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 13 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 [%] R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 15 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. 16 200 100 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 14 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 17 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. 18 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 19 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! 20 R R THE VERY BEST IN CASTINGS THE VERY BEST IN CASTINGS 21 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 22 THE VERY BEST IN CASTINGS R 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 23 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