Full Analysis of Titanium Standard Parts Processing and Production Technology

I. Core processing technology: double guarantee of accuracy and performance

  1. Precision forging process

    For complex structural parts such as TC18 titanium alloy, the industry generally adopts the multi-stage gradient forging process of parting surface optimization design. By customizing the spindle-shaped block structure, the material utilization rate can be increased from 40% of the process to more than 65%, and at the same time large-scale forming Post-deformation stress.

    In the pre-forging stage, by reserving the transition structure of grooves and curved surfaces, 30% of the subsequent cutting machining allowance can be obtained; In the final forging stage, combined with the primary forming of high bosses and the closed forging technology of U-shaped grooves, the near-net forming of complex geometric characteristics is realized, and the secondary processing does not affect the material fiber streamline, so as to ensure the anti-fatigue performance of the product.

  2. CNC machining

    For brittle and easy-to-crack workpieces such as titanium-aluminum alloy targets, the constant linear speed CNC turning vacuum suction cup stress-free clamping technology is adopted, and the edge breakage rate of brittle materials can be controlled within 0.2% by matching the change of workpiece linear speed through real-time cutting feed.%, ensuring the surface finish of Ra ≤ 0.8 μm and the dimensional accuracy of ± 0.01 mm.

    For special-shaped and complex standard parts, the five-axis turning and milling compound processing technology is adopted, and multi-faceted cutting, drilling and other processes can be completed in one clamping. Compared with the process, the processing efficiency is more than 2 times higher, and the cumulative errors caused by multiple clamping are avoided., greatly improving the dimensional consistency of batch products.

II. Mainstream production process: full-link management and control

  1. Pretreatment of raw materials

    According to the performance requirements of the product, select Gr1, Gr2 pure titanium or Gr5, Gr23 and other titanium alloy grades, smelt ingots with uniform composition through vacuum consumable arc, and then prepare bars that meet the processing requirements through multi-directional forging, opening and rolling, Plate and other blank materials, control the internal inclusions and pore defects of the material from the source, and ensure the uniformity of the raw material structure.

  2. Forming stage

    Hot heading forming: For α-β titanium alloys such as Gr5, heat to the temperature range of 800-950 °C in the two-phase zone for hot heading processing. It is suitable for high-strength bolts, load-bearing forgings and other products that require high mechanical properties. After forming, the grain is refined and uniform, the tensile strength can reach more than 900MPa, and the impact toughness can reach 40J/cm ².

    Cold heading forming: For metastable β-type titanium alloys such as TB2, cold heading forming can be completed directly at room temperature. Compared with the hot heading process, the energy consumption is 40%, the production efficiency is increased by 3 times, and the product surface is better. It is suitable for civil use Production of batch standardized products such as fasteners.

  3. Finishing and surface treatment

    The formed workpiece meets the final dimensional accuracy requirements through CNC turning, milling, grinding and other finishing processes; Subsequent matching of different surface treatment processes according to application scenarios: the polishing process can improve the surface finish, and the biocompatibility requirements of medical implants; The anodizing process can form a dense oxide film on the surface, improving the salt spray corrosion resistance to more than 1,000 hours. At the same time, it can adapt to the needs of different usage scenarios through different appearance colors of oxidation parameters.

III. Materials and product system: covering multiple application scenarios

  1. Classification of materials

    Industrial-grade titanium alloys: represented by Gr5 and TC18, have both high strength and fatigue resistance, and a fracture toughness of more than 40MPa · m1/². It is mainly used in high-end working conditions such as heavy-duty equipment, and can withstand-50 °C to 300 °C wide temperature range service.

    Civil-grade titanium: represented by Gr1/Gr2 pure titanium and TB2 alloy, with excellent processing performance and relatively controllable cost, it is widely used in chemical anti-corrosion, civil hardware, 3C products and other fields, and has a service life in neutral and weak corrosion Up to more than 30 years.

  2. Product matrix

    General standard parts: including outer hexagonal bolts, self-tapping screws, flat gaskets, spring washers, etc., the size meets general standards such as national standards and American standards, and can be used interchangeably in batches, and the assembly requirements of conventional industrial scenarios.

    Customized special-shaped parts: including orthopedic implant connectors, special flanges for chemical reactors, seals for deep-sea exploration equipment, etc., customize material formulas and processing processes according to specific working conditions, personalized use needs, and adapt to special performance under extreme conditions Require.

IV. Application advantages and industry prospects

    The performance advantages of titanium standard parts have been fully verified in the field of high-end manufacturing: in the field, TC18 titanium alloy forgings are widely used in aircraft landing gear, fuselage load-bearing frame and other structures. The specific strength is 1.5 times that of high-strength steel, and the structure can be reduced. The weight is more than 30%, the anti-fatigue cycle life exceeds 10 percent, and the service requirements under extreme working conditions; In the field of chemical industry and shipping, the service life of standard parts such as titanium flanges and titanium valves in acidic corrosive media such as sulfuric acid and hydrochloric acid can reach 5-10 times that of stainless steel, without replacement and maintenance, which greatly improves the full life cycle of chemical plants and marine ships operating cost; In the medical field, Gr1 pure titanium fasteners have excellent biocompatibility, no cytotoxicity, and no rejection after implantation into the human body. They are the preferred materials for medical scenarios such as orthopedic fixation and dental implants.

    The core competitiveness of the current titanium standard parts industry stems from the comprehensive advantages of material formula innovation, process precision control and customized service capabilities. With the improvement of lightweight and corrosion resistance requirements in the high-end manufacturing field, titanium standard parts are gradually replacing steel and stainless steel standard parts. Through further iteration of processing technology in the future, there is still room for a 15%-20% reduction in production costs. The market The penetration rate will expand and become a key basic material industry supporting the upgrading of high-end equipment.