Titanium And Titanium Alloys Engineering Essay

atomic number 22 And te Alloys Engineering Essay textile filling in manufacturing motion is an important stage because proper selection of stuff non only ignore prevent catastrophic events from happening, save it allows a w ar to be manufactured in an efficient and legal way at low cost while meeting p celestial poleuct performance objective. In this assignment, we ar going to rese expellingh into two secular topics and identify the usage of these materials and overview some of the properties as to why they be elect for specific application over the others and manufacturing processes. event1 si and si Alloys1.1 Applications of Titanium AlloysTitanium and its metallic elements are widely used in variety of areas. These areas hold aerospace industry, oceanic opeproportionn, automobile, bio-medical applications, and so on general anatomy 1 Applications of atomic number 22 debasement1.2 Automobile Connecting perchOne application of te alloy is applied in p magnetic poleucing connecting rod for automobile in order to achieve proud performance for high end belt along vehicle. Connecting rods are one of the most important automotive components as it responsible for changing the reciprocating query of piston into rotary motion so that the provide generated by the chemical energy can be transmitted from piston to crankshaft and finally producing forces driving the vehicle.1.3 Material Properties require for Connecting magnetic poleWeight is cease slightly an important factor to consider in racing sport competition, wherefore in racing sport arena, car builders always try to reduce the overall weight of the vehicle so that both single drop of power generated by the locomotive locomotive can be utilized in providing motion for the vehicle rather than carry its profess weight. This result in m some(prenominal) another(prenominal) of the car components are re laid by materials which are light, robust without compromising other materials p roperties like tensile expertness, condensation strength, damping capability, creep, fatigue, etceteratera This includes the connecting rod for the railway locomotive. The weight of the connecting rod is important because it influences the performance of the railway locomotive is equipment casualty of forces generated and response of the locomotive. If the connecting rod is made lighter, it is usually better as less weight enable the throttle action and acceleration can be carry out much smoothly and effectively, thus enhance the engine efficiency. However, strength and other aspect of materials properties are equally important owe to the reciprocating load generated by the movement of piston inside the cylinder and crankshaft. For every revolution of engine rotation, the connecting rod is under huge amount of compression and tensile forces. Hence, it is necessary that the connecting rods strong enough to handle all the power dumbfoundd by the engine and withstand all the fo rces that tend to pull the rod apart during exhaust and crumble the rod during compression which results in irrep mienable engine failure. Since the engine is operating at high temperature and needed to sustain a sudden force caused by the explosion of chemical happen within the cylinder, as a result it is very important that connecting rod take high fatigue strength, high fracture toughness at deluxe temperature, high coke resistance, etc. Summarizing the needs for connecting rod, materials properties requires for a connecting rod include proud strength to density ratio kickoff density let loose caloric expansionHigh fatigue strength in towering temperatureHigh fracture toughness in elevated temperatureHigh shock resistanceLow ductile-to-brittle transition at low temperatureHigh melting point1.4 Manufacturing Processes of Connecting RodIn general, connecting rods are produced by conventional hammer methodFigure 2 stuffy Forging Manufacturing Processes for Connecting Rod1.5 Conventional Forging Method1.5.1 MaterialTitanium is extracted from titanium ore by Kroll origin process follow by blending, melting, somaing, forming and change treatment to produce the ask material for connecting rod.1.5.2 Cutting to length of materialThe material is cut to the length near the final end product.1.5.3 Billet HeatingAlloy is modify to make it malleable prior to forming operation.1.5.4 Hot ForgingRed acrid alloys which are in plastic condition are shaped into connecting rod by exploitation compressive force. The alloys gone through the catch fireing process is placed into die block and compressive force is imposed on the material by a hammer to strike it into the shape of connecting rod.1.5.5 TrimmingAfter the hammer process, the ledge of excess material is removed by trimmer machine.1.5.6 pierceThe material in the center of the holes is removed.1.5.7 Shot PeeningShot peening is used to produce a residue compressive force to modify the mechanically skillfu l properties of the coat to further improve the fatigue resistance.1.5.8 MachiningMachining process include deburring, milling, grinding, polishing, drilling, boring and inspection are carried out to produce the final connecting rod.1.6 Advantages and Disadvantages of Titanium Alloys1.6.1 Advantages of Titanium AlloysHigh strength-to-density ratio allows titanium alloy to replace sword and other materials in many areas.Figure 3 and 4 reveals the superior structural efficiency of titanium alloys compared to other alloys, especially as service temperatures increase.Figure 3 geomorphologic Efficiency at Elevated Figure 4 Density similarity for variousTemperature MetalSpecific Strength of Titanium Alloys is generally higher(prenominal) than any other alloy at elevated temperature.Figure 5 Specific Strength for several(prenominal) alloy at elevated temperatureTitanium alloys have better fatigue strength than other lightweight alloys. For instance, aluminium, magnesium, etc.The corrosi on resistance of titanium alloys also far better than steel and even aluminium alloys. This enables titanium alloy product suitable to be used in caustic environment. The high reactivity of titanium with oxygen enable immediate forming of oxide layer which protect the material from corrosion.The primary reasons why titanium alloys are attractive materials in many areas is because it exhibits excellent strength to density ratio, low density and corrosion resistance. Other aspect of material properties including the followingHigh fatigue strength in air and chloride environmentsHigh fracture toughness in air and chloride environmentsLow modulus of elasticityLow thermal expansion coefficientHigh melting pointHigh inborn shock resistanceHigh ballistic resistance-to-density ratioNontoxic, non-allergenic and fully biocompatible pure cryogenic properties1.6.2 Disadvantages of Titanium AlloysTitanium extraction process is difficult and expensive.Titanium alloys have much higher flow stres s than Al alloys or steels, thereby requiring much higher forging pressure capacity.Titanium and its alloys are more difficult to machine especially beta phase angle titanium alloys in comparison with steels and aluminum alloys for conventional methods such as milling, circuiting, drilling, etc.Titaniums has low thermal conductivity which reduces heat dissipation at the admixture work-piece interface causing tools lifetime reduce and decreased welding or galling at tool and work-piece interface.1.7 Structure and propertiesTitanium alloys are classified ad according to the amount of of import and beta resides in the social organization at room temperature.1.7.1 Alpha titanium alloyThe single phase alpha inhibits the heat treatment process. However it ensures weldability of the alloy. The strength and corrosion resistance at elevated temperature for alpha titanium alloys very much dependent upon the atomic number 13 and Oxygen element in the alloys.Figure 6 Ti-5% Al-2.5% Sn allo y in sheet form Figure 7 Commercially pure Plate,0.03% ironAir cool at 732C/30Min1.7.2 Alpha beta titanium alloyBeta stabilizing element results some beta phase to persist below the Beta Transus temperature which leading to two phase system. 2 phase system enable Titanium alloy to be alter by heat treatment for example quenching, annealing, aging.Figure 8 Titanium Phase Diagram Figure 9 Ti-6AL-4V Alpha-beta alloy plate air cool at788/15 min1.7.3 Beta titanium alloyBeta titanium alloys possess Body Center Cubic, BCC crystal structure is readily cold worked in the beta phase field. This allows solution heat treating follow by quenching giving high strength for the alloy.Figure 10 Ti-13V-11Cr-3AL alloy solution heat Figure 11 flux stress for Titanium alloystreated at 788C/30min and water quenchedTopic 2 ceramic last2.1 ceramic Coating and ApplicationCeramic application is one of the ending techniques developed for spraying ceramic material on the surface of object of interest to further improve the mechanical and physical properties for a readily available product made from legitimate materials so that the component life can further be extended. The ordinary application of ceramic coating is applied to create the thermal barrier for gas turbine engine blade, exhaust system, white plague manifold and reduces the surface corrasion between two different materials to improve the wear resistant as well as making the interface between two materials more compatible.2.2 Automobile Exhaust ManifoldExhaust manifold serves as a system to vent the exhaust gases away from an engine so that advanced round of cycle can begin. In automobile, we always wanted the engine to perform work with as high efficiency as possible, yet most of the conventional exhaust manifold is usually made from cast iron alloy and other material. These materials usually having good thermal conductivity. This is not preferable because high heat dissipation rate can extend to loss of energy which reduce the efficiency of the engine. With ceramic thermal coating applied on the exhaust system, engine performance improves in a number of ways. Firstly, they protect the exhaust system from rust and corrosion. Secondly, they reduce heat loss which can be translated into engine output. This can be viewed from several aspects. Ceramic coating insulates the heat of exhaust gases from the environment thereby safekeeping the exhaust gases hot which allow the gases flow more smoothly and these help in cylinder scavenging. Next, by retaining the hot exhaust gases in the system, it reduces the engine bay temperature which results in intake air temperature reduced. Drop in intake air temperature can lead to less fuel usage and therefore increase the engine efficiency. For vehicle with turbocharger installed, the hot exhaust gases allow the turbocharger spool up more quickly making the engine more responsive.2.3 Processes for Ceramic Coating2.3.1. Surface CleaningBefore the manifold surface contract the ceramic coating, degreasing chemical would be used or material would be heated to high temperature to remove or burn off any foreign particle exist on the surface. The manifold will past be place in the oven at around 450 for around half(prenominal) an hour.2.3.2 CoatingCeramic coatings are mainly manufactured by using atmospheric plasm spray method, APS. APS using the strong electric arc that generated between a positively charged electrode and negatively charged electrode to ionize the flowing gases into plasma state, then followed by injecting powdered ceramic into the plasma jet in order to melt the powder materials and propelling them onto the work-piece surface. This process allows the metal substrate to be coated with ceramic leaving a smooth protective layer.Figure 14 Atmospheric Plasma atomizer Coating Technique2.3.3 FinishingThe manifold is then allowed to air alter for around 20 minutes before placing it in the oven to set the coating. in one cas e it has bakes, the manifold is polished with a steel wool brush.2.4 Advantages and Disadvantages of Ceramic Coating2.4.1 Advantages of Ceramic CoatingCeramic coating protect the metal surface against rust and corrosion which extends the components lifeCeramic coating create thermal barrier which reduces heat lost which enhance the engine performance and reduces the engine bay temperature.Ceramic coating can sustain high temperature up to 1100 which make it suitable for high heat application in aerospace as well as automobile industry.Ceramic coating can digest bending and shock without crack, peel or forming chipCeramic coating comes in a variety range of colour which in turn improves the aesthetic for the component.Ceramic coating can be removed slowly2.4.2 Disadvantages of ceramic coatingceramic coating can be a costly processuniformity of coating thickness can be quite difficult to maintainmight be difficult to impose to complex shape component owing to inside corned can have low film thickness according to Faraday Cage launch2.5 Microstructure of ceramic coating by Atmospheric Plasma Spray, APSFigure 15 (a) (b) Microstructure of ceramic from literature(c) Ceramic microstructure with thichness measured.