(SANITIZED)UNCLASSIFIED STUDY ON TITANIUM MANUFACTURING METHODS(SANITIZED)

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP81-01043R002500180004-7
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 195
• Document Creation Date: December 23, 2016
• Document Release Date: September 9, 2013
• Sequence Number: 4
• Publication Date: August 29, 1958
• Content Type: REPORT

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TABLE OF CONTENTS
FOREWORD
I. INTRODUCTION
II. OBJECT
III. SUMMARY
IV. CONCLUSIONS
V. RECOMMENDATIONS
VI. DISCUSSION
VII. REFERENCES
VIII. APPENDIX I - Detailed Cost Analysis
Extrusion Process
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FIGURE NO.
LIST OF FIGURES
10 P/N 608118 - Rear Main' Bearing.Support.Cone.Assembly.
P/N 608109 - Rear Main Bearing Vapor Duct Assemb1;y.
30 P/N 608120 - Combustion Chamber Heat Shield Assembly.
? P/N 608569 - Turbine Stator Blade Support Assembly.
5. P/N 226970 - Shaft, Turbine Rotor Front.
STAT
30
31
32
33
34
6. Cutaway View of the Curtiss-Wright QI-65 Turbojet showing 35
the titanium parts and assemblies manufactured under this
program.
P/N 226961 - Rear Flange, Rear Main Bearing Vapor Duct 36
Assembly, Material Ti-A70.
P/N 226956 - Front Flange, Rear Main Bearing Vapor Duct 36
Assembly, Material Ti-A700
9. P/N 226962 - Front Flange, Rear Main Bearing Support Cone 37
Assembly, Material Ti-A70.
10. P/N 226963 - Rear Flange, Rear Main Bearing Support Cone
Assembly, Material Ti-A70.
11. P/N 226964 - Flange Brace, Rear Main Bearing Support Cone
Assembly, Material Ti-A700
12?. P/N 226966 - Flange, Combustion Chamber Heat Shield
? Assembly, Material Ti-A70.
13. P/N 227594 - Rear Flange, Turbine Stator Blade Support 39
P/N 227596 - Front Flange, Turbine Stator Blade Support 39
Assembly, Material Ti-AllO,Wr
37
38
.38
15. P/N 226970 Shaft, Turbine Rotor Front, Material Ti-A110-AT0
vii
t'
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TABLE NO.
LIST OF TABLES
10 Summary Analysis of the Cost of Extruding Ring and
Tubular Titanium Sections through a 4,000 Ton and
a 12,000 Ton Press ((uantity. 100 Units).
110 Detail Cost Breakdown For Contour Forming Extruded
Sections into 360 degree Rings (Quantity - 100.Units).
1110 Detail Cost Breakdown for Flash-Butt Welding Titanium
Rings (Quantity - 100 Units).
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Page No.
23
IV. Detail Cost Breakdown for Sizing Titanium Rings 26
(Quantity - 100 Units).
V. Summary Analysis Showing the Cost Breakdown by Processes 27
for Manufacturing Titanium Components from Cast Ingot
Extrusions (Quantity - 100 Units).
VI. Cost of Detail Titanium Parts by Conventional Manu- 28
facturing Methods.
VII. Detail Cost Comparison Between Titanium Components 29
Manufactured by Conventional Techniques versus
Extruding from Cast Ingots (quantity- 100 Units).
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SCHEMATIC COMPARISON OF MANUFACTURING METHODS FOR TITANIUM
RING SECTIONS DEPICTING THE ADVANTAGES OF EXTRUDING DIRECTLY
FROM CAST INGOTS
!mull llllllll;IIftui,II,pI,il,,ssIutuuilpIlIIu,plIIiiIIII,IIIIIIIIIt
155 LBS
0111111111101.111iiiiiIIIIMMMIIMIOPOWEIHT11011.11011111111111011111111101.11???Illi
115 LBS.
CAST 114G01
COST %5.50/L8.
1
l lll lllllllllllllllllll llll llllll
llll I
10$10,"
BILLET FORGINGWGT, 100 LBS,
COST 111050/LB,
400"1
EXTRUSION OF
DETAIL SHAPE
WAT.. GO LBS,
COST $ 19/LB.
BARS= ROLLING
WGT. 118 LBS.
COST 16/LB
3
?
llllll lllll
?1 10.4
ttttttttt Ohl ttt t ?
tttttttttttttttt ttttttt t
tttttttttt ttt I ttttttttt /.11111111.1 ttttt 44444 1111011111 4444444 444444444444 lllll list ttttt I.1 tttttttt 1111111111E
FOR5MING
1101011.1 tttttt 101101111101,010.'
WELDING
SIZE
tttttt 11.11111t$111 ttttttttt I lllllllll
FINISHED PART WEIGHT 30 LB. UNITS
t1 lll 55550 0 1015051,1 clii,tt II is
CONVENTIONAL FORGING
PART COST 8/13,
(FINISHED WEIGHT)
PART COST 93
(30 LB. UNIT FINISHED WM; )
MATERIAL UTILIZATION %
PROCUREMENT CYCLE (MO
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I. INTRODUCTION
Conventional manufacturing techniques applied to titanium and titanium alloy
jet engine components result in high costs primarily due to low material
utilization and subsequent loss of the expensive material through machining.
For titanium jet engine components applicable to the extrusion process, i0e.
flange and tubular sections, a new production method capable of high
material utilization has been developed. This was accomplished primarily
through the use of the extrusion process. In addition, the use of cast
ingots as the extrusion stock has reduced the end product cost appreciably.
The flow chart presented on the previous page schematically illustrates
the high material utilization and low costs available from cast ingot
extrusions by comparing this method to forging and conventional extrusion
of forged billets.
Consequently, compared to conventional forging, or flash-butt welding rings
from barstock, this new process is capable of reducing the costs of such
components by as much as 40 percent. In addition to reduced costs, through
metallurgical evaluation and engine testing, these components have been
demonstrated to be of equivalent quality to conventionally manufactured
parts.
The results of the engine testing evaluation and a detail analysis of the
economics of the process are presented in this report. Although a
12,000 ton press was used exclusively for the actual extrusions a maximum
pressure requirement of Woo tons was observed for the flange shapes.
Therefore, extrusion cost figures are presented separately for both a
4000 ton and a 12,000 ton press. Lower costs result from the use of
the 4000 ton press due to the lower hourly cost of this unit
($150/hr vs. $600/hr.).
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II. OBJECT
The objective of this final report is to:
1. Present an economic analysis of the developed titanium
manufacturing method 'which utilizes the extrusion process,
and
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Present the results of engine testing of the titanium
parts manufactured by this method.
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III. SUMMARY
4
1. Three sheet metal assemblies and the turbine rotor shaft were
submitted to a 150 hour model engine test. Review of the parts
after engine testing revealed no adverse effect of the test on
the titanium?
The following lists the cost per pound of extruded sections pro-
duced from cast ingots utilizing a 4000 ton press and a 12000
ton press
Part
Number
226956
226961
Name
Flanges, Rear Main
Bearing Vapor Duct
AssUy0 Mat9L. AMS 4921
Rough Cost of Extruded Sections
Weight (l1LsLpund
11111_ Agp ton Press 12000 ton press
402
8 09
226962 Flanges, Rear Main 907
226963 Bearing Support Cone 607
226964 Assuy0 Matol. AMS492/ 5.0
226966 Flange, Combustion
Chamber Heat Shield
Assuy0 Mat10 AMS 4921
17.00
14.00
14.50
15000
18050
26,00
18.00
19 50
20050
27.00
204 20.50 33.00
227594 Flanges, Turbine Stator 804
227596 Blade Support Ass'y. 903
MatuL A1104T
2050.
22.50
27.00
30.00
226970 Shaft-Turbine Rotor 43 50 28.00
Front - A1104T
The range of prices for the AMS 4921 'material using a 4000 ton press
($14000/1b to $20050/ib) is comparable to the cost of round mill
sections. The slightly higher costs for the A1104T sections is
primarily due to the leaser die lite than that obtainable for the
AMS 4921 material.
30 The cost of forming, welding, and sizing of the extruded sections
ranges between $4050/1b and $10/1b0 The higher costs result primarily
from the smaller diameter, heavier cross-section shapes.
STAT
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S.STAT
III* 21121gLiagla
40 The following tabularizes the cost of manufacture of each detail
part for both a 4000 ton and a 12000 ton press.. Also presented
in this table is a comparison to the estimated costa by conven-
tional techniques.
Part
Number Name
Cost.k.glcIngon
(Dollars)
Am.ton Press 12000 tonjoress
Cost
Conventional
TedhlialatE022aEL
? IV. CONCLUSIONS
1. Titanium and titanium alloy components manufactured from
cast ingot extrusionshave properties, as demonstrated by
both metallurgical examination and engine model testing,
which are equivalent to conventionally manufactured parts.
225956 Flanges-Rear. Main 105.00
226961 Bearing Vapor Duct 175000
Assoy.
226962 Flanges-Rear Main
226963 Bearing Support
226964 Cone Ass'yc,
226966 Flange, Combustion
Chamber fieat Shield
Assoy.
182.00
134000
129.00
143000
216.00
152.00
297.00
rettopt
232.00
173.00
171.00
74000 104.00
254.00
200.00
157.00
76000
This newly developed method of extruding directly from
cast ingots is considerably more economical Ulan manu-
facture by conventional techniques such as forging or
flash-butt welding barstock.
In addition to lower costs, considerably less raw mate-
rial is required to manufacture components by this pro-
cess. Consequently, the widespread use of this method
will greatly reduce the procurement cycle and increase
the availability of titanium mill products such as sheet.
227594 Flanges, Turbine 22800
227596 Stator Blade Support 269000
Asey0
284000
337.00
266000
304.00
,
226970 Shaft, Turbine Rotor-
Front
f=")
1294000 1630.00
While a definite advantage exists for most of the larger flange
shapes with the use of a 12000 ton press, a considerably lower
cost would be possible with a 4000 ton press due to the lower press
burden rate.
Compared to conventional manufacturing methods cost reductions as
high as 40 percent are indicated. In.all cases enaverage savings
of 25 percent is indicated.
The procurement cycle for components manufactured from extruded
sections is equivalent to that presently obtainable utilizing
? conventional techniques0 ftowever? with an increase in the volume
of extrusions the cycle time for such components will be considerably
less than that for conventionally manufactured parts?
,
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Disseminate the information presented in this final report,
throughout the aircraft industry for its use for govern-
mental purposes.
Direct all users of titanium for governmental purposes to
review their drawings for components applicable to the
extrusion process to insure minimum cost and maximum mate-
rial utilization?
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VI DISCUSSION
In the following section of this report, Part II, a production method is
described for manufacturing jet engine components such as flanges and tubular
shafts. Both types of parts utilized the extrusion process as the primary
operation to transform cast ingots into the required basic cross-sections.
For the flanges, the extruded shapes were formed into 360 degree rings,
flash-butt welded and sized. These rings were then machined to the detailed
part dimensions and welded to sheet metal components to form a jet engine
assembly. For the shaft, the extruded tube was upset on both ends and
machined to detail part dimensions, thus permitting it to become part of the
turbine rotor assembly. In this manner, the detailed parts were produced
utilizing considerably less material than that required to make these
?
same parts by conventional techniques such as forging or flash-butt welding
rings from barstock.
A. Engine Testing
To manufacture the parts for the production phase, both cas ingots and
forged billets of A70 and AllOAT material were extruded. A metallurgical
analysis was then performed on the extruded lengths and the finished
formed rings. This study revealed the properties of the cast ingot extru-
sions to be equivalent to those made from forged billets. In addition
the mechanical properties of both materials were found to conform to the
applicable specification requirements.
STAT
To permit a further evaluation of the product of this newly developed
manufacturing method, the assemblies, composed of the detail parts, were
engine tested. These units are shown pictorially in Figures 1 through 5
and are listed below:
1, Combustion Chamber Heat Shield Assembly P/N 608120
?2, Rear Main Bearing Vapor Duct Assembly P/N 608109
3. Rear Main Bearing Support Cone Assembly P/N 608118
4. Turbine Rotor Shaft - Front P/N 226970
5. Turbine Stator Blade Support Assembly P/N 608569
The first four units listed above were assembled into a J-65-W-18 model
engine and were submitted to a typical development testing common to the
development of other engine components currently programmed. This testing)
representing an unofficial 150 hour model test, is identical to that em-
ployed in qualifying a part for flight testing or service engines.
This testing was not possible for the Turbine Stator Blade Support Assembly.
This assembly was manufactured to a configuration common only to the J-65-W12
model. Since engine testing of this model is not presently active, the test-
ing of this assembly was deleted from the program,
As previously noted, the assemblies were made of both AMS 4921 and AllQAT
Titanium, In engine operation the AMS 14.921 material was used to replace
carbon and stainless steel, thus providing a lightweight replacement for
mildly stressed, and/or corrosion resistant steel parts for temperatures
11,
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VI DISCUSSION (CONTID
to 700?F. The AllNAT material replaced higher stressed units
made of low carbon or low alloy steels at temperatures to 1000?F.
The locations of these titanium components in the engine are
shown schematically in Figure 6,
The titanium assemblies will be subjected in the future to addi-
tional model testing and, possibly flight testing or service
engines pending continued support by the military.
Economic Analysis
One of the major, if not the most important aspect sof the program
is an economic analysis. The following presents such an analysis
for this manufacturing method for a quantity of 100 units.
Extrusion Operation
The detail cost breakdown for the extruded sections is pre.
sented in Appendix I and summarized in Table I. To under-
stand this analysis it is noted that all flange extrusions
are made from cast ingots. Two and three hole dies are used
for the extrusion of each part except P/N 226961. The cross.
section area of this part is sufficiently large to permit
its extrusion through a single orifice die. The rotor shaft
vat also extruded through a single opening die. The geome-
tries of the finished parts are presented in Figures 7 through
15. The following presents a discussion of each of the major
factors contributing to the cost of the extrusiOn operation
presented in Appendix I and summarized in Nole I.
Cost of Ektrusion Stock
Two factors contribute to the cost of the raw material pro-
cured4 first, and foremost, the cost per pound of the mate-
rial3 and second, the quantity of material required. The
following lists the cost of the titanium extrusion stock for
the quantities considered
AMS 4921
8 inv diae 16 in. dia.
(Flanges) (Rotor Shaft)
$5050/1b
6,15/1b
$5090/1b
S'S TAT
VI DISCUSSION CONT D
The quantity of material procured is determined in this
case, from the extrusion operation yield and the generated
scrap. It was previously established that an extrusion
yield of approximately 70 percent is Obtainable. The mate-
rial lost is primarily attributed to the unextruded butt.
A scrap factor of approximately 15 percent is also required.
This scrap is generated in off-dimension extrusions. There3
fore, the overall yield, i,e, material purchased vs mate-
rial shipped, is between 50 and 6o percent?
Press Costs
All the work on this program was performed on the 12,000 ton
horizontal extrusion press located at Metals Processing Divi-
sion in Buffalo, N.Y. Only the rotor shaft required the
full press capacity. Both the AES 4921 and A110-AT flanges
were extruded through multi-opening dies utilizing the 4,000
ton stage of this press. For the manufacture of production
parts this situation is economically prohibitive due to the
relatively high overhead rate for a 12000 ton press ($600/hr).
It would be more economical to extrude these sections through
multi.opening dies using a 4000 ton press directly. The over-
head rate of this size press is approximately 3150/hr. In
addition, considerably more material can be produced per hour
through a 4000 ton press vs0 the use of the 4000 ton stage of
a 12000 ton press due to the higher cycle rate. For these
reasons, the figures for press costs are quoted separatively
for a 4000 ton press and a 12000 ton press,
TWO cost figures are presented for the 12000 ton press. The
first figures (second column under press costs) represents
the cost actually incurred in manufacturing the parts on this
program. Due to the limited volume of titanium processed and
the intermittent use of the press for steel extrusions only
one of the salt baths was equipped with a low temperature salt
for heating the titanium (1600?F).
It is noted that the salt used to heat steel at approximately
2100?F could not be used at temperatures below 1800?F without
contamination of the salt and eventual attack on the furnace.
Consequently as indicated in Appendix I the number of extrusions
per hour was limited because of the availably heating capacity.
For a sufficiently large volume of titanium extrusions both
salt baths could be converted to the lower temperature salt,
If this was not the case and titanium and steel were extruded
intermittently an additional salt bath would be required to
obtain the optimum use of such a 12000 ton press. The press
cost under the latter conditions is presented in, the third
column,
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VI0 IgLaggaigILDEL
At present, all production suppliers of titanium extrusions
use single opening dies. Consequently, until all the practices
presented in this series of reports are put into practice by
commertial extruders with relatively small units and ring
manufecturers, the values presented for the 12000. ton press
may be the most economical, even considering the relatively
small cross-sections involved9 i.e. less than 1.5 in2.
The rotor shaft, having a cross-section area of approximately
12 1112 cannot be extruded through anything less than a 12000
ton press due to the required pressures.
Dies
Die inserts costing approximately $175/insert are used ex-
clusively for the flanges. The die costs, therefore, are
established by the quantity of inserts required to complete
the order. For the A70 material each insert is capable of
producing a total extrusion length of approximately 100 ft.
The length per each extrusion is a maximum of 20 ft. and 5
extrusions can be made per die. Extruding thA A1104T mate-
rial is considerably rougher on die life. Approximately 15
ft0 of extrusion can be made satisfactorily and each extru-
sion requires the use of a new die.
Miscellaneous Charges
The value indicated in this column is primarily composed of
the cost required to perform the testing for certification
of the extruded sections,
5911144.1r:Fe9A
These columns aresatetplatatory. The. addition of G and
A and profit to the actual cost,. .yield the selling priceg
Based on this selling price the following list of costs per
pound of the extruded sections has been determined.
Cest lb
Part Numberad..?,oRtujitt, hoop Ton 2,2000 Ton
226956
226961
226962
226963
226964
Name
Flanges, Rear Main
Brg. Vapor Duct
Assembly
Flangess, Rear Main
Bearing Support
Cone Assembly
402 17.00
809 l400
907
607
500
14.50
15.00
18.50
26.00
18.00
19.50
20.50
27.00
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VI DISCUSSION CONTID
Part Number Name allEIBLEI?
STAT
000 Ton 1 000 Ton
226966 Flange9 Combustion 204 20050
Chamber Heat Shield
Assembly
227594
227596
Flanges., Turbine
Stator Blade Sup-
port Assembly
33.00
604 200 27.00
903 22.50 30.00
226970 Shaft, Turbine 43050 28.00
Rotor Front
For the most part9 the prices for the 11.000 ton press are
directly competitive with commercially available bar of
comparable cross.section area.
2. Forming, Welding, Sizing & Upsetting
Based on the results obtained from processing theoproduction
phase parts an engineering survey was made by the ring
manufacturing and upsetting vendors to establish the cost
for processing a quantity of 100 units. The eslAblished
costs for these secondary operations iae0 forming9 wld
ing and sizing for the flanges are presented in detail
in Tables 11 through IV for each operation. The total
costfor the ring manufacturing operation are summarized
in Table Va
Formiu
The equipment used to form the extruded sections into
360 degree rings was a Bath Radial Draw Former? Prior
to forming, the extruded ANS 4921 titanium sections
Were heated to the temperature range of 700?F to 1000?F
while the higher temperature range of 1200?F to 1400?F
was required for the AllNAT sections. In general, con.
tour forming was accomplished by three passes on the
machine. The first pass is a rough forming operation
fol,lowed by a second pass which formed the part to the
desired diameter. The final pass was used to round=off
the ends of the ring thus preparing them for subsequent
welding. An end trimming operation and reheating is
required between each forming pass.
A breakdown of the ring forming cost is presented in
Table II. The three items contributing to this cost
axe the machine time9 trimming and inspection time
and the cost for tool maintenance. The overhead rate
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VI EllEallii25.E21
for this equipment is approximately 16.00/hr. Consequentay,
the actual forming cost is a direct function of the time re.
?faired to form eaeh ring. Except for the more complex shape,
namely P/N 226961 and the AllNAT rings, the actual machine
cost is not appreciably effected by minor variations in cross
section. The next largest factor contributing to the cost of
ring forming is the cost of trimming the rings between forming
passes and inspecting ? A nominal tooling maintenance charge
is required to maintain the desired configuration of the die
and rolls. The latter two charges are affected very slightly
by the ring configuration.
Welding
For welding the formed sections, the cost figures are based
on the use of a Thomson Model F-5 welder, Table III. The
two major items contributing to the cost of welding the ex-
truded and formed sections are the machine time and the
cost for flash removal. Indeed, the cost incurred in the
presently utilized method of hand chipping and grinding for
flash removal represent one-half of the cost for this pro-
cess.
In general, considering the variations in cross sections
examined, the finished part cost;were found to be only
slightly effected by material or cross section. Slightly
higher costs, however, did result from the smaller diameter,
heavier cross section rings, (PAT 226961) as considerably
more care was required in their processing. The'actual
welding costs vary from $3/part to $6.50/part
Sizing of all rtngswas accomplished on a 225 ton brake
presto Prior to sizing the ring shapes, both the dies
and rings were heated to the range of 700 to 1250?F. This
permitted the ANS 4921 material to be expanded 2 to 3 per-
cent and the A110-AT rings to be expanded a maximum of
1 1/2 percent? A two step operation was used in sizing
all rings,
The detail cost breakdown for the sizing operation is pre.
sented in Table IV ? The major items contributing to the
sizing cost are the machine charges and the cost for in-
spection. in general, the cost pr sizing is nominal
and ranges fro m $50O/pet t!'e, '605 rto
16
VI pj.m?z2Ejazpl
EILE2212.21.11LE!
In Tables II through IV, the actual costs of forming,
welding and sizing were presented, based on an engine-
ering survey. To establish the selling price for the
ring manufacturing operations, two additional factors
must be considered. These factors are the cost of scrap
and profit and G St A
These items are presented at the end of Table IV. A
scrap factor of 10 percent of the cost of the extruded
section was added to the cost of the actual operations.
This factor is exceedingly high and will remain so until
considerably more experience is gained by the ring manu-
facturers in processing titanium. It is estimated that
this factor need not exceed 2 percent in production pro.
cessing once the vendors have familarized themselves
with the processing of titanium. In the same way as for
the extruded section, the cost of G 8i:A and profit has
been included. In this manner, a realistic cost for the
present day procurement of these sections has been pre-
sented. This total cost is presented in the last column
of Table IV. Prices ranging from approximately $25/part
to $60/part are noted. These prices represent a cost
per pound of approximately $8.00. In general, slightly
higher costs are observed for the A110-AT material com-
pared to the ANS 4921 material.
!i
S.STAT
YE2Y111E
In processing the production phase parts, a 6" Ajax air
forging machine was used to upset the flanges on the ex.
truded tube to produce the turbine rotor shaft. In this
operation, a 3 step pass with intermittent heating to
19001 was used. While this resulted in a successful
upset for the prototype part, the production parts had
a lap at the inner diameter beneath the flange. This
is discussed in detail in Part 2 of this final report.
In performing the engineering survey to obtain the cost
of upsetting 100 shafts, it was decided, due to the lap
which resulted in the 3 pass operation to base the analysis
on a L. pass operation with intermittent heating. This
price has been established at $83.30 per shaft. This
cost is primarily that required to perform the actual
upsetting and therefore, represents a machine burden
charge. In addition to this cost per piece, a fixed
tooling charge of $14,725, is anticipated.
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release
VI EMEMISEER/
3. Finished Detail Part Costs
Table V presents a detail summary analysis of the cost
of manufacturing the complete detail part from cast
ingot extrusions. In this anaTysis? the costsfor both
a 4000 ton and a 12000 ton press are presented.
Considering the use of a 4000 ton press, the finished
part cost is evenly distributed among material, extru.
sion and ring manufacture. The following tebularizes the
finished part costs.
Part Number
eligialawisocos
226956
226961
226962
226963
226964
226966
Name
Flanges, Rear Main
Bearing Vapor Duct
Assembly
Flanges, Bear Main
Bearing Support
Cone Assembly
Flange, Combustion
Chamber Heat
Shield Assembly
227524 Flanges, Tarbine
227596 Stator Blade
Support Assembly
226970 Shaft, Turbine
Rotor Front
Economic Comparison
Finished Part Cost
ton ress 12000 ton press
$105.00 $143x0
175.00 216.00
182.00
134.00
129.00
74.00
228.00
269.00
232.00
173.00
171.00
104.00
284.00
337.00
129)1..00
Prior to the initiation of this development program, three of
the sheet metal assemblies and the turbine rotor shaft were
procured in small quantities for development engine testing.
The cost of these components is listed in Table VI. It is
emphasized that these cost figures are for very small quanti-
ties procured in 1953 and 19540
To enable a direct comparison between the two manufacturing
methods, the cost figures presented in Table VI have been
adjusted for larger quantities at present day material and
labor costs. This comparison is presented in Table VII.
This data indicates savings up to 4o percent and an average
savings exceeding 25 percent of the cost by conventional
methods.
13/09/09 ? CIA-RDP81-01043R002500180004-7
VI EIMEEELIMIZEI
For the four sheet metal assemblies and the rotor shaft,
a total maximum savings of $745.00 has been attained.
This savings considers the use of the 4000 ton press for
the flanges and the 12000 ton press for the shaft. This
savings is for a total of only nine specific components0
Extrapolating this information to applicable shapes, i.e.
rotating shrouds, stator blade carrier rings, etc0 in a
jet engine such as the J-6.5 indicates a total potential
savings per engine in excess of MOO. For a total of
1000 engines, this savings rapidly increases to a value
in excess of $3,500,000.
At present, the procurement cycle for parts manufactured
in this newly developed way is comparable to conventional
techniques. A three month procurement cycle time for ex.
traded sections is readily obtainable. This cycle time
will improve considerably with the widespread utilization
of extrusions.
19
neclassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release
STAT
VII REFERENCES
10 Final Report on "Titanium Manufacturing Methods Development"
Submitted by Metals Processing Division to Wright Aeronautical
Division, January, 1957.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
21
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TABLE II
Detailed Cost Breakdown For Contour FonaingExtruded Section Into 360 Degree Binge (Quantity 100 Units),
Part Number
Name
Material
Bough
Weight
(s.)
lb
Cross
Section
Area
(In. 2)
Bing
Diameter
(In.)
Fpreing
Trimming & Inspection
No. of
passes
per ring
Pieces per
hour per
pass
Total
hears
per ring
Machine
Cost at
$16/hr
($/part)
Time
Enquiredintenance
(brs/part)
Cost at
(t/Z t)
Tooling
Ma
($/part)
Total
Forming Cost
($/part)
Tooling Cbarge
($)
226956
Flanges, Rear Main
AMS 4921
4.2
0.53
12.9
3
8
.375
6.00
.333
2.68
1.50
10.18
4,000
226961
Bearing Vapor Duct
u a
8.9
1.56
9.0
4
5
.800
12.80
.410
3.28
2.30
18.38
5,600
Assembly
226962
Flanges, Bear Maim
is a
9.7
0.96
16.3
3
7.5
.399
6.39
.333
2,68
1.50
10.57
4,000
226963
Bearing Support
MI le
6.7
1.12
7.9
3
7
.426
6.81
.333
2.68
1.60
11.09
4,300
226964
Cone Assembly
a is
5.0
0.70
13.0
3
7.5
.359
6.39
.333
2.68
1.50
10.57
4,000
226966
Flange, Combustion
M M
2.4
0.29
14.4
3
10
.300
4.80
.333
2.68
1.40
8.88
3,800
Chamber Heat
Shield Assembly
227594
Flanges Turbine
AllOAT
6.4
1.04
12.9
4
5
.800
12.80
.410
3.28
2.10
18.18
4,200
227596
Stator lands
TR MI
9.3
0.81
19.5
4
6
.665
10.66
.410
3.28
2.10
16.05
4,200
Support Assembly
NOTEs Equipment - Bath Radial Draw Former
TABLE III
Detail Cost Breakdown For Flash-Butt Welding Extruded Sections (Quantity 100 Units)
N
Part Number
Name
Material
Rough
Weight
(lbs.)
Machine
Set-up
Time
(hrs/part)
Welding
Rate
(parts/hr)
Welding
Time
(hrs/part
Machine
Cost at
$12/hr
($/part)
Cost of
Die
Maintenance
($/part)
Cost of
Flash
Removal
($/part)
Misc. Costs
1.e. X-ray,
Trimming
awal, Ito.
part
Total Welding
Cost
($/part)
Fixed Tooling
Charge
($)
226956
Flanges, Rear
APB 4921
4.2
0.01
20
0.05
0.72
0.15
2.40
0.60
3.87
800
226961
Main Dearing
p m
8.9
0.02
10
0.10
1.414
1.00
3.20
0.90
6.54
2,500
Vapor Duct Assly
226962
Flanges, Rear.
n IN
9.7
0.015
15
0.067
0.98
0.30
2.67
1.20
5.15
1,000
226963
Main Bearing
ti ii
6.7
0.02
15
0.067
1.04
0.30
2.40
0.60
4.34
1,200
226964
Support Cane
si n
5.0
0.01
20
0.05
0.72
0.15 2.67
0.60
4.14
800
Assembly
226966
Flange, Combustkn
" "
2.4
0.01
20
0.05
0.72
0.15 1.60
0.60
3.07
800
Chamber Heat
Shield Assembly
2275914
Flanges, Turbine
Anon'
6.4
0.015
15
0.067
0.98
0.30 2.67
1.20
5.15 1,000
227596
Stator Blade
"
9.3
0.01
20
0.05
0.72
0.15 2.67
0.60 4.05 1,000
Support Assembly
t
NCtTE: Equipment - Thomson Welder Model 7-5
?,
.200 - 400 KV&
40,000 lbs. max. upset force.
100,000 lbs. MR3. clamping force.
2-11-
(D
0
0
0
0
01
0
0
NY
0
0
-
7:1
0
0
01
i\D
0
0
OD
0
0
0
TABLE IV
Detail Cost Breakdown For Sizing Titanium Binge (Quantity 100 Units)
Fart number Name
Material
Rough Weight
(lbs.)
No. of passes
per ring
Pieces/
br/pass
Total
bre/ring
Beehine Cost
at $10/hr
(1)
(Inspection
($/part)
Tooling
Maintenance
($/part)
Total
Sizing Cost
(5/part)
Tooling
Charge
(S/part)
Scrap
Costs
($/part)
0 &A 'Form
&
Profit
Total
Cost
Meld
&Siza
($/part)
226965 Flanges, Bear Main
IMS 4921
4.2
2
a
.25
2.50
1.80
1.08
5.38
3,200
7.23
5.84
32.50
226961 Bearing Vapor Duct
n n
8.9
2
6
.30
3.34
1.80
1.48
6.62
3,200
12.21
9.60
53.35
Assembly
226962 iFlanges, Rear Bain
n 5
9.7
2
8
.25
2.50
1.80
1.08
5.38
3,200
13.91
7.64
42.65
226963 IBearing Support
16 U
6.7
2
8
.25
2.50
1.80
1.12
5.42
3,400
9.85
6.70
37.40
226964 1 Cone Assembly
n
5.0
2
8
.25
2.50
1.80
1.08
5.38
3,200
9.29
6.44
35.82
226966 Flange, Combustion
2.4
2
10
.20
2.00 1.80
.98
4.78
3,100
4.79
4.73
26.25
Chamber Beat Shield
'Assembly
,
2275914 ' Flanges Turbine
227596 ; Stator Flanges,
Sup-
i port Assembly
AllOkT
n
6.4
9.3
2
2
6 .30 3.34 1.80 1.30
6 .30 3.34 1.80 1.30
6.44
6.44
3,300 17.11
3,300 20.99
10.29
10.72
57.17
57.55
I
i
NOTE: Ebleipment - 225 Ton Break Press
Scrap Costs Eratinated At 10% of Value of
Eratruded Section.
TABLE V
Summary Analysis Showing The Cost Breakdown By Processes For Manufacturing Titanium Components From Cast Ingot Rktrusions. (Quantity 100 Unite)
Part Number
Name
Material
Rough
Weight
(lbs.)
Material
Cost
($/part)
Extrusion Cost
($/part)
Bing
Manu-
facturing
coot
($/part)
Upsetting
Cost
(S/Part)
Finished Part Cost
(1
Cost Per Pound
of Material
4000 Ton
press
12000 Ton
press
4000 Ton
press
12000 Ton
press
4000 Tan
press (5)
12000 Ton
press (5)
226956
226961
226962
226963
226964
226966
227594
227596
226970
Flanges, Rear Main
Bearing Vapor Duct
IsseMbay
Flanges, Bear Main
Bearing Support
Cone Assembly
Flange, Combustion
Chamber Heat
Shield Assembly
Flanges, Turbine
Stator Blade
Support Assembly
Shaft, Turbine
Rotor Front
ABS 4921
n
ft
ft
ft
ft ft
AllOAT
ft
4.3
8.9
9.7
6.7
5.0
2.11
6.14
9.3
43.5
/42.00
814.00
89.00
614.00
56.00
25.00
76.00
88.00
570.00
30.00
38.00
50.00
314.00
37.00
23.00
95.00
122.00
68.00
79.00
100.00
72.00
79.00
53.00
151.00
190.00
61&1. 00
33.00
53.00
143.00
37.00
36.00
26.00
57.00
58.00
??????
83.00
105.00
175.00
182.00
134.00
129.00
714.00
228.00
268.00
110.00
216.00
232.00
173.00
171.00
1014.00
284.00
336.00
1294.00
24.50
19.50
19.00
20.00
26.00
31.00
35.50
29.00
33.00
2/4.00
214.00
26.00
314.00
43.50
1411.50
36.00
33.00
a
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE VI
Cost uf Detail T4tanium
r_ts Conventional ManufaoturinK
Part Number
226956
226961
226962
226963
226964
226966
226970
Forging
Cost Per Weight Cost Per
9SABILY PieSti_ 12-ILL1 Pound 1,
2 356,00 8,4 42,50
353 , 00 16 . 5 21,40
1114.00 14.1 79.00
392.00 11.1 35.00
191.00 8.7 22.00
282.00 4.0 70.00
2055 .00 74.0 28.00
8 88
-4g
0 mm
1-4
NM
888 8
IAMM
- anlowpitm luTu - -
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
P/N 226962
P/N 608118
heir Main Bering
Support Coone Assembly
-
FIG. 1,-P/N 608118 "REAR MAIN BEARING SUPPORT CONE ASSEMBLY
STATcr
P/N 226956
/14 608109
REAR MAIN BEARING
VAPOR DUCT ASSEMBLY
FIG. 2- P/N 608109- REAR MAN BEARING VAPOR DUCT ASSEMBLY
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
31
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
P/N 226962
P/N 608118
heir Main Bering
Support Coone Assembly
-
FIG. 1,-P/N 608118 "REAR MAIN BEARING SUPPORT CONE ASSEMBLY
STATcr
P/N 226956
/14 608109
REAR MAIN BEARING
VAPOR DUCT ASSEMBLY
FIG. 2- P/N 608109- REAR MAN BEARING VAPOR DUCT ASSEMBLY
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
31
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,4q
REAR MAIN BEARING SUPPORT CONE
COMBUSTION CHAMBER HEAT SHIELD
TURBINE ROTOR SHAFT-FRONT
S'S TAT
TURBINE STATOR BLADE
SUPPORT
REAR MAIN BEARING
VAPOR DUCT
FIGURE 6
CUTAWAY VIEW OF THE CURTISS-WRIGHT J65 TURBOJET SHOWING
THE TITANIUM PARTS AND ASSEMBLIES MANUFACTURED UNDER
THIS PROGRAM. -
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
N
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09:
.5.1
?29i 0/r7
3.0?\
42.51r.
rrk,t9
? 70S-
041'. -/ .436
(TkP
1.2G9
2.192 (FE r)
FIGURE 7. P/N 226961 - Rear Flange, Rear Main
Bearing Vapor Duct Assembly,
Material Ti-A70.
36
FIGURE 8. P/N 226956 - Front Flange,
Rear Main Bearing Vapor Duct
Assembly, Material Ti -A70.
\51
324
f
917
1.411e,
FIGURE 9. P/N 226962 - Front Flange,
Rear Main Bering Support
Cone AssyV, Material Ti-A70.
37
./50P
7875 27140 /
,37.5
4
S.STAT
FIGURE 10. P/N 226963'- Rear Flange,
Rear main Bearing Support
Cone Asssy, Material Ti-A 70
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
tfi
-1; (ry) 44I4-..
FIGURE 11. P/N 226964 - Flange Brace, Rear
Main Bearing Support Cone Assly,
Material Ti-A70
38
0
FIGURE 12. P/N 226966 . Flange, Combustion
Chamber Heat Shield Au' y,
Material Ti-A70
Declassified in Part - Sanitized Copy Approved for Release
FIGURE 13.
S.STAT
306
*1100(erw7e0)1
-/.2o3 e'redng$9.)--0-
P/N 227594 - Rear Flange, Turbine Stator
Blade Support Assembly, Material Ti-
A 110-AT.
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
39
FIGURE 14. P/N 227596
Front Flange, Turbine
Stator Blade Support
Assembly, Material -
Ti-A110-AT
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
DETAILED COST ANALYSIS OF THE EXTRUSION PROCESS
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VIII, APPENDIX I
DETAILED COST ANALYSIS OF THE EXTRUSION PROCESS
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
I 1,-.1 .
?1-7fIrlf10 I t-Irs7rInvina?n If-N_I ? csnirs rs in I I
.e
.4,000 TOR PRESS
ITEM 1 of 8
MP 9045 EXTRUSION COST ESTIMATE SHEET
VAD ?OD - 275 100 PCS.
Customer Mat. Specs. Quantity Requited Inquiry No
FLANGE -
Part Name Part No. & C/L 226956 Production Rate Date 522-57
MATERIAL 163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.D. Si I.D. LGTH.
541
0.0.1 3 1.0.1 LGTH.
4.9
FIRM DATE BUYER Request 3017
MAT. COST/LB. 5.50/# from Oregon netallurgic.al Corp.
MAT. COST/PIECE 780 A 5-50
WEIGHT/BILLET
4 23
6.5
PIECES/BILLET
10
TOTAL BILLETS REQ. (Incl. ScroP)
12
54 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
780
s YIELD
6-S]
MAT. SCRAP VALUE 780 less 42341..? 357# 4 20?/#
( 71 )
MANUFACTURING DATA
MANUFACTURING COST
4219
255
PUSHES/HR.
7
PIECES/PUSH 2 hole Die
3.0
MANUFACTURING COST/PC. 1.7 bra a $150/lar on .4000 ton presen W
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/HR. Set up
1.0
DEV. & TOOL TRYOUT COST/PC. Set up & prorsted chnnogPosrpt- of 8 i hens - 1_75 0 150/hr
263
PUSHES/DIE CHANGE - MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
'
CHANGE-OVER COST/PC-
BILLET HEATING
1
MACHINING TIME/PC.
.25
MACHINING COST/PC. 25 hys a 10-00
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
.5
PURCHASED SERVICES Mach. Spec.
36.00
PURCHASED SERVICES:
a
56
Interstitial Analysis
20.00
FIRM DATE BUYER
20% Control Check
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Toots First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert - 6 0 $185
DT
1110
25 Pc finsegrt
0
0
0
888
TN st Rn fir Up PI Rip
DT
Inn
Tri. tinl door Reek Pinto,
DT
500
tummy Block
in
400
Extrusion Guide
DT
800
TI4spl at.. lkilma gap
TOTAL MANUFACTURING COST
?4
3710
,S scRAP Included-
-
LABORATORY REQUIREMENTS
* 1,000 Ton Press & Complete Heating raCi1itie5
PACKAGING REQUIREMENTS
-
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS.
TOTAL MANUFACTURING COST
TOTAL TOOLING COST sao
1.512
There Will Be An 6 Hr. Change over
8 s G. & A.
ADDITIONAL EQUIPMENT
Whenever This ur A Group Of These
SUB TOTAL
Parts Are Run
10 s PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUcl TOTAL
7233
Straightness 1/8" In 5'
% RENT
PRICE/LB. 17.10 PRICE/PIECE
7233 each
INSTALLATION
Twist 5upT Max- 20? In 5 irt_
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
Transyer?Q TLAtroi45R 0 025,A3-
MFG. ENG..
SHIPPINGSCHEDULE
Furnished As Extruded & Scaled
WORK STDS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD_ CONT.
TOOLING
ax
Iit
12000?to
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
ped peg!ssepea
-0
4000 TON PRESS
Its 2 of 8
MP 90-6
EXTRUSION COST ESTIMATE SHEET
WAD , 275
Customer Mat. Specs. MPD ? Quantity Require
FLANGE 226962
Port Name Part No. & C/L Production Rate Date
100; PCS
Inquiry No
5-22-57
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
9020
0.0. 8., I.D. LGTH.
10^
0-D-Area-.96 /r.. I.D- LGTH.
6211
FIRM DATE BUYER
WEIGHT/BILLET
82#
WEIGHT/PIECE (Net)
9.7#
MAT. COST/LB. 5..50/-k---
PIECES/BILLET
6
WEIGHT/PIECE (Gross)
11-7#
MAT. COST/PIECE 1640# A5.50
MAT. SCRAP COST
TOTAL BILLETS REQ. (Incl. Scrap)
20
% SCRAP
16.7
TOTAL GROSS WT.
1640
a YIELD
10.1
MAT. SCRAP VALUE 1640# less 970# - 670# 420ti#
MANUFACTURING COST
( 134.
8886
435
MANUFACTURING DATA
PUSHES/HR.
*70
PIECES/PUSH 2 Hole Die
6
MANUFACTURING COST/PC. 2,,9 kr.; /50/1yrn on 44000 ton p-reals./T.W-
DEV. a TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/HR. Sot Up
1 ..e)
DEV. & TOOL TRYOUT COST/PC. set uo-Thr & ororate of Chan e`OVer ? 1.7
-
26
PUSHES/DIE CHANGE -MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
?
CHANGE-OVER COST/PC.
BILLET HEATING
MACHINING TIME/PC.
25
MACHINING COST/PC. 25 hr s sg 10.00
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
?PURCHASED
SERVICESb_ spec
72-00
PURCHASED SERVICES:
Interstitial Analysis
20.00
FIRM DATE BUYER
20% Control Check
FIRM DATE BUYER
? SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Inserts - 8 g $185
DT
/480
Die Back Up Plate
DT
300
15 sci4n Ft f.1"1:
0
-1480
Die Holder Back Piste
TYT
910
r),,,,,,,y Tr 0 eic
DT
Apo
/Extrusion Guide
DT
800
Temo/ates & Gages
DT
--XII--
4080
TOTAL MANUFACTURING COST
=,
% SCRAP Ise/tided above
* 4000 Ton Press & Complete Heating Facilities
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
11406
TOTAL TOOLING COST 8410
4976
% G. & A.
ADDITIONAL EQUIPMENT
SUB TOTAL
SIM TT T
a PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUr3 TOTAL
13910
% RENT
PRICE/LB. 14.34 PRICE/PIECE
139.10 ea
INSTALLATION
RE-ARRANGEMENT
DEPT_ SIGNATURES DATE
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG.
SHIPPING SCHEDULE
WORK STDS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST-
MANUFACTURING
SHIPPING
CONTROLLER
000 Tcl P
Item 3 of 8
MP 9O-5 EXTRUSION COST ESTIMATE SHEET
WAD Mat. Specs. Quantity Required 100 PCS Inquiry No
Customer HE'D ? 275
FLANGE Port No. & C/L 226963 Production Rate Date V22/57
Part Name
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
61468
0.0. Ein 1.0. LGTH.
32.
CLD- I Airea-1-2 Tn. i-D- 1 LGTH.
3/IU
FIRM DATE BUYER
WEIGHT/BILLET
_
98#
WEIGHT/PIECE (14.1)
6-65
MAT. COST/LB. Sap It-Pill #.1
PIECES/BILLET
3-0
WEIGHT/PIECE (Gross)
9.80
MAT. COST/PIECE 1336 la 5_5o
TOTAL BILLETS REQ. (Incl. Scrap)
1.2
5 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
11.76
5 YIELD
67.8
MAT. SCRAP VALUE I176# Less 665# = 511# @ 2004
( 102 )
MANUFACTURING DATA
MANUFACTURING COST
6366
255
263
PUSHES/HR.
*7
PIECES/PUSH
10
MANUFACTURI11.3 COST/PC- 1-7 brs eln5n mach
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/HR.
1.0
DEV. & TOOL TRYOUT COST/PC. set 1 -I hr + 75 ro7...te of ch., ?0.?.r .. 1.7q it $150
PUSHES/DIE CHANGE -MANDREL
q
TIME TO CHANGE DIE & MANDREL/HRS.
-
CHANGE-OVER COST/PC.
250
BILLET HEATING
1.
MACHINING TIME/PC.
.25
MACHINING COST/PC. 115 hrs @ 10-00
MAGNA-FLUX COST/PC.
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
$56.00
D ESCALE
5
PURCHASED SERVICES
20-00
PURCHASED SERVICES:
56
FIRM DATE BUYER
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS-/REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50 ?
3(r)
Die Inserts - 6 a $185
PT
MX)
25 PC/Insert
0
0
a
888
Die Back Do Plate
Die Holder Back Plate
nT
500
Dummy Block
DT
1100
Extrusion Guide
ET
800
i_ Templates St Gages
DT
._O
3700
TOTAL MANUFACTURING COST
.
% SCRAP Inelvided
* 11000 Ton Press & Corgpleto Resting Fneilitise
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
8078
TOTAL TOOLING COST 8410
4532
a G. & A..
ADDITIONALEQUIPMENT
SUB TOTAL
SEE 11r14 1
5 PROFIT
SUL% TOTAL
9851
ADDITIONAL MACHINES OR EQUIPMENT
% RENT
PRICE/LB- glit.81 PRICE/PIECE
913_ 41 en
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG-
? SHIPPING SCHEDULE
WORK STDS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR-
PROCESSING
Same
With
12,J200
Ton
*me.
fis
_
COST EST-
? MANUFACTURING
I
SHIPPING
_
_
_
_

-
CONTROLLER _
-
TTFX It OF A
, --
PIP 90-6 EXTRUSION COST ESTIMATE SHEET -
Customer WAD Mat. Specs. TOT) 275 Quantity Required Inn rns Inquiry No
Port Name FLANGE Port No. S. C/L 226966 Production Rate Date 5/22/57
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 5" I.D_ LOTH.
"
??D?1 Ils..P.om -3n 771-121 LGTH.
; n
FIRM DATE BUYER
WEIGHT/BILLET
65
WEIGHT/PIECE (Net)
MAT. COST/LB. See Item 1
PIECES/BILLET
18
WEIGHT/PIECE (Gross)
_35
3.61
MAT. COST/PIECE . /454# a 5..50
TOTAL BILLETS REQ. (Incl. ScraP)
7
% SCRAP
20.6
MAT. SCRAP COST
25(73
TOTAL GROSS WT.
L55#
% YIELD
65.1
MAT. SCRAP VALUE I155# 3 ,,,,,, 235fy .. 220e e 21-14/#
MANUFACTURING DATA
MANUFACTURING COST
PUSHES/HR.
471 CI
PIECES/PUSH i_ED-EF, 71W
?
?
?
MANUFACTURING COST/PC. 1
8
DEV. & TOOL TRYOUT/HRS.
GEV. & TOOL PUSHES/HR. g '
-.-ar...._-a.-3.,50
DEV. & TOOL TRYOUT COST/PC. ?? ral, , ? ? - ? : - os, a ?
PUSHES/DIE CHANGE -MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
_.
CHANGE-OVER COST/PC.
BILLET HEATING
1
MACHINING TIME/PC.
.25
MACHINING COST/PC. 25 Ars a in_np/ mr.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
?
PURCHASED SERVI cEsNach . Lab. Spec 's
$36.00
PURCHASED SERVICES:
56
V 0/:, 0 % r,
? ? , ?
FIRM DATE BUYER
CHECK
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Raplocooblo Tools Forst)
CODE
COST
PCS./REWORK
NO- OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
.> st..rt - 6 * 185
1100
30 PC TH-
140
a : i.. 'Pi . tp
TYr
300
TN rs 1IO1 rte.?. _Bank _Plate
DT
500
Dummy Block
DT
00
Extrusion Guide
DT
Erin
Templates & Gages
DT
300
3700
TOTAL MANUFACTURING COST
% SCRAP Tnr1iirl,=.4
-e- / WI Thr. Pr...q q Re Cnmp1t. F. Hcoting Pa (-1 "I i ti q
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS t
TOTAL MANUFACTURING COST
3.8
TOTAL TOOLING COST 81110
L.572
% G. & A.
39
SUB TOTAL
ADDITIONAL EQUIPMENT
SEE ITEM 1
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUd TOTAL
4778
% RENT
PRICE/LB- 20.31 PRICE/PIECE
h7 7R ..
INSTALLATION
RE-ARRANGEMENT V
DEPT. SIGNATURES DATE
TOTAL ADDITIONAL EQUIPMENT COST
MFG_ ENG-
SHIPPING SCHEDULE
WORK STDS.
WEEKS
I
2
3
4
5
6
7
8
9
10
11
12
13
14
1Z
16
17
18
19
2C
21
22
23
24
QUALITYON
MATERIAL PROCUREMENT
PROD. CT
TOOLING
PLANT MGR.
PROCESSING
S.80=0'
i .9
Id ith
a
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
Declassified in Part - Sanitized Copy Approved for Release
8
MP 90-6 EXTRUSION COST ESTIMATE SHEET
WAD Mat. Specs. 14117) 775 Quantity Required 1.00 PPS Inquiry No

Customer
FLANGE V Part No. & C/L Production Rate Date 5/22/57
Part Name 22A961
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
85111
13
D.D. 8" 1._ LGTH-
10. 5
0.13..krea *.1./t0 7o21-0- I LGTH-
35n
FIRM DATE BUYER
WEIGHT/BILLET V861_
WEIGHT/PIECE (Net)
8.9
MAT. COST/LB.
PIECES/BILLET '
7 '
WEIGHT/PIECE (Gross)
17.3
MAT. COST/PIECE 15),R a 5.50
TOTAL BILLETS REQ. (Incl. Scrap)
18
9; SCRAP
20.6
MAT. SCRAP COST
TOTAL GROSS WT. V
1q)18
% YIELD
17J,
MAT. SCRAP VALUE 15118 less 890# ?. 658 0 20e/0
( 132 )
MANUFACTURING DATA
MANUFACTURING COST
8382
V0
PUSHES/HR. V
*7
PIECES/PUSH
7
MANUFACTURING COST/PC. 2.A Ars 0
DEV- 8. TOOL TRYOUT/HRS.
DEV. 8. TOOL PUSHES/HR-
1.0
_50
DEV. & TOOL TRYOUT COST/PC. 1.75 0 50
- 263
PUSHES/DIE CHANGE - MANDREL
5.0
TIME TO CHANGE DIE & MANDREL/HRS.
...
CHANGE-OVER COST/PC.
BILLET HEATING
1.0
MACHINING TIME/PC.
.25
MACHINING COST/PC. 25 Its- 0 10-00
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC-
DESCALE
5
PURCHASED SERVICES mar.h,. Tab_ sppc.i,
$72_00
PURCHASED SERVICES:
FIRM DATE BUYER
FIRM DATE BUYER
92
IIITRBqTITTiLL, ANATZSIS 2rep?CONTB.01.
$2100
rt4Frx.
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
'nip Insert - h a $185
DT
714)
nip Thar* Tip Plato
DT
300
35 PC/3215EAT
0
0
0
633
Die Holder Back Plate
TIT
500
itunrrly Mock
DT
400
P:Irt.t-oni on Oni an V
DT
800
TrRatplatFin fir V
DT
200
VW
TOTAL MANUFACTURING COST
_
% SCRAP 7m-winded Above
* h000 Ton Press & Complete Heating Facilities
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING.REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO. N.Y_
REMARKS:
TOTAL MANUFACTURING COST
10,010
TOTAL TOOLING COST - MO a
4073
% G. & A.
ADDITIONAL EQUIPMENT
SUBTOTAL
CRE ITIRM 1
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SU cl TOTAL
12,207
% RENT
PRICE/LB- $13.72 PRICE/PIECE
122.07 ea
INSTALLATION
DEPT- SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG_ ENG._
SHIPPING SCHEDULE
WORK STOS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
,
QUALITY
MATERIAL PROCUREMENT
PROD_ CONT.
TOOLING
PLANT MGR.
PROCESSING
iaine
As_
Trilith
12,0(X)
llon-Eress-
COST EST.
MANUFACTURING
SHIPPING
'-
- --CONTROLLER
-
--
__
,_
1
_,
_
I _
-A.
a
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@ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
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14000 TON PRESS
I= 6 OF 8
MP 90-S EXTRUSION COST ESTIMATE SHEET
Customer WAD Mot_ Specs. ISPD ns Quantity Required -inn Peg Inquiry No
Port Name 'MANGE Port No. & C/L 729A14 Production Rate Date 5/22/57
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 8" I.D. LGTH.
6.5#
0.13.1,-".= 70 TT)2 LD. LGTH.
50n
FIRM DATE BUYER
WEIGHT/BILLET
69
WEIGHT/PIECE (Net)
b.79
MAT. COST/LB.
PIECES/BILLET
8
WEIGHT/PIECE (Gross)
8.62
MAT. COST/PIECE 1-0.35--a-.5-?511_
569.3
TOTAL BILLETS REQ. (Incl. Scrap)
35
% SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS wT.
1035
% YIELD
57.6
MAT. SCRAP VALUE 1/115 1. /197# = 53_8 e 20a#
108
MANUFACTURING DATA
MANUFACTURING COST
5585
PUSHES/HR.
7
PIECES/PUSH 2 Hole Die
MANUFACTURING COST/PC- 7-1 Fi 0 $35.0
315
DEV. & TOOL TRYOUT/HRS.
DEV. 8. TOOL PUSHES/HR. sr up
DEV E. TOOL TRYOUT COST/PC 5 - 0 $350
23
PUSHES/DIE CHANGE -MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS
...
CHANGE-OVER COST/PC.
BILLET HEATING
1
MACHINING TIME/PC.
...
MACHINING COST/PC. 25 RT-g 0 in.no
25-0
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
5
PURCHASED SERVICES mfic1,7 TAR c_pwcirs
tZ2 00
PURCHASED SERVICES.
9
TNTF.RSTTTTAL ANAT.ysTS 2Cg Call TROT
R20-00
FIRM DATE BUYER
CHECK
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS
300
nip Tricrr-t. -
lux)
20 PCJINSE.RT
0
0
0
me)
Di F. Fin r-k 14-1 Plat.p
DT
3m
Die Holder- Bark Plate
DT
sna
flnty Rick
DT
LOO
P,rty-nqinn niii rip
nT
800
Tpmplat.pg .
1Y1
300
TOTAL MANUFACTURING COST
_.3 (JO
% SCRAP
LABORATORY REQUIREMENTS
1000 To r Pres - :.
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, NY_
REMARKS:
TOTAL MANUFACTURING COST
7615
TOTAL TOOLING COST
/1524
% G. & A.
SUB TOTAL
ADDITIONAL EQUIPMENT
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SEP -1= 1
Sire. TOTAL
9287
% RENT
PRICE/LB- 18.69 PRICE/PIECE
97.87 or.
INSTALLATION
RE-ARRANGEMENT
DEPT. SIGNATURES DATE
TOTAL ADDITIONAL EQUIPMENT COST
MFG- ENG_
SHIPPING SCHEDULE
WORK STDS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
___/
PROD- CONT.
TOOLING
PLANT MGR-
PROCESSING
PsaAne?
A.c{
ilitizt
17,000
Toll
press.
COST EST_
MANUFACTURING
SHIPPING
--CONTROLLER
?
OF
MP 90-6 EXTRUSION COST ESTIMATE SHEET
WAD Mat. Specs. ',72 Quantity Required 100 PCS Inquiry No
Customer tinwp
Part FLANGE Port No. & c/L Production Rate Date 4/99/47
Name 227 81,3
(Me lnad -1-.mnrite re t Tire___n a it ht i et nirni 1 o hit.
.-0.-A.t.-4132413013.-t--Taillia-13131y .h
' Additional furnace required
TOTAL.TOOLING COST
?
ADDITIONAL EQUIPMENT
whenever this or a group of these Darts
sus TOTAL
are ran..
z PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
Slid TOTAL
11,187
cti-or-ssi ghtriP55 1/81, Tr. 5,,
Twist 50/f t - Max. 20? In ci
% RENT
PRICE/LB. ii _17 PRICE/PIECE
DEPT. SIGNATURES
133.87
DATE
INSTALLATION
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
i.r5VPT.5P Ti airless ..025n/n
MFG. ENG-
SHIPPING SCHEDULE
Fnrni elte.r1 "As Extanicieti" _end "Des c aIesin
WORK ST?S*
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
QUALITY
MATERIAL PROCUREMENT
__
1
MaIn Pri_e_n nn Minos L 'Ppm Rni-.hst
, PROD. CONT.
- TOOLINGPLANT
MGR.
PROCESSING,_
_
COST EST.
MANUFACTURING
1
SHIPPING
,
CONTROLLER
t
?
-
?
Declassified in Part - Sanitized Copy Approved for Release
12.000 TON PRESS -
rIFF14 2 OF 8
/itP 90-6
Customer
Part Name
WAD
FLANGE
EXTRUSION COST ESTIMATE SHEET
Mat. Specs. 101-1 - 275
Port No. & C/L 226962
Quantity Required
Production Rate
100 POS
Inquiry No.
Date
1.131/57
MATERIAL .163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
Rn 1.13- LGTH.
10 n
0.0.1 Ar.,,, 96 In2i.o_ I LOTH.
6211
FIRM DATE BUYER
WEIGHT/BILLET
142#
WEIGHT/PIECE (Net)
9_7#
MAT. COST/LB.
PIECES/BILLET
6
WEIGHT/PIECE (Gross)
13.7w
MAT. COST/PIECE 16140 a 5.50
9,020
TOTAL BILLETS REQ. (Incl. Scop)
20
S SCRAP
16.7
MAT. SCRAP COST
MAT. SCRAP VALUE .
(
TOTAL GROSS WT.
161in #
S YIELD
7(11
MANUFACTURING
iI-2 BATHS 1 TIA
DATA 66 2/3% Ef f .
8,1)t)
MANUFACTURING COST
PUSHES/HR. Ao
-
PIECES/PUSH 2 Hol... Dia
6
MANUFACTURING COST/PC. ifi-Pm. - fit kr-,Oninr Anon
DEV. EL TOOL TRYOUT/HRS.
30
DEV- & TOOL PUSHES/HR. BET ma
2_0
DEV. & TOOL TRYOUT COST/PC- loon
PUSHES/DIE CHANGE - MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC. 1 fir- _Pnorated_ Changegyer 600
BILLET HEATING .
1
MACHINING TIME/PC. -
MACHINING COST/PC. 2,50
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
-25
MAGNA-FLUX COST/PC.
DESCALE
PURCHASED SERVICES Tocw LLB sppri,
073 j.,0______.
PURCHASED SERVICES: 97
'
-5
TNITF.RSTTTTAT. ANAT:TSTS POI CIONTPOT.
$21.1.__00
FIRM DATE BUYER
K
FIRM DATE BUYER
SPACIAL TOOLING
REPLACEABLE TOOL COST
SPEC/AL TOOLS (Li?t R?ploceabla Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 5n
300
nip TTICIOUT+. R a 1R5
TT
1.16fin
mk
nip Tmaprt sp.,per
nT
120
15 p0/n4sporr
0
0
0
:
Ttrilmny Plex-.1r at- A ass i 1.111 .
Trr
Inn
Ftne.).- P1 at.s= A rinp t.p.r-
TIT
74-1
Flc-t.r-nni on Gni tim
TIT
Ron
nin. Rnok PI ni-.F. -
DT
250
TOTAL MANUFACTURING COST
Tptnpl a+pn X- GAgtott
DT
300
5 SCRAP Tno.l_nrieri Above:
L WO
LABORATORY REQUIREMENTS
-9. Seto T tem 1
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F-O.B. EXTRUSION PLANT. BUFFALO, N.Y.
, REMARKS:
TOTAL MANUFACTURING COST 1R,5nR
. TOTAL TOOLING COST
5366
S G. & A-
EQUIPMENT
SUBTOTALADDITIONAL
96, PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
RPM =14 i
SlIc3 TOTAL - 12,571
SG RENT
PRICE/LB. 21_27 PRICE/PIECE 225.71
INSTALLATION
DATE
RE-ARRANGEMENT
DEPT- SIGNATURES
TOTAL ADDITIONAL EQUIPMENT COST
_
MFG. ENG-
- SHIPPING SCHEDULE
WORK STOS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1$
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD- C0t4T.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
LC...W-4N SYS/ AXIL-P.../ -3.....12171 ..., r
AP 904 EXTRUSION COST ESTIMATE SHEET
Customer WAD Mat. Specs. ISM 275 Quantity Required 11-10 PCS Inquiry No
Part Nome Fla GE Part No. & C/L 226963 Frocluction Rate Date 1/31/57
MATERIAL- ..163
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 13" 1.13. LGTH.
1211
0.0.1Area 1.2 I021.0.1 LGTH.
311"
FIRM DATE BUYER
WEIGHT/BILLET
9R#
WEIGHT/PIECE (Not)
6_65
MAT. COST/LB.
PIECES/BILLET
in
WEIGHT/PIECE (Gross)
9.80
MAT. COST/PIECE 1176 0 5_50/#
614613
TOTAL BILLETS REQ. (Incl. SeraP)
12
5 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
1176#
SI YIELD
67.8
MAT. SCRAP VALUE
( 102 )
MANUFACTURING DATA 66 2/3 % Eff.
.N.2 'BATHS 1 RATH
MANUFACTURING COST
6366
PUSHES/HR.
6 o
3-0
PIECES/PUSH 7 pco e 1,4,,
10
MANUFACTURING COST/PC- 6 NI-R.. a 600
DEV. 8- TOOL TRYOUT COST/PC. 2 Hrs. a 600
-
3600
32nn
DEV. a TOOL TRYOUT/HRS.
DEV. 8. TOOL PUSHES/HR. SFT UP
2.0
PUSHES/DIE CHANGE -MANDREL
5
-TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC- 1 Hr. a 600
,
600
BILLET HEATING
1
MACHINING TINE/PC.
25
MACHINING COST/Pc.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
D ESCALE .
.5
PURCHASED SERVICES " 14nPh- Tab- Rpe,c TA
$36_oo
PURCHASED SERVICES:
56
R.STITTAL. ANALYSIS 20% C.ONTML
$20.00
FIRM DATE BUYER
rarRnic .
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die 'Insert - 6 49 185
PT
1110
25 PC/INSERT
0
0
0
RBB
Die 1-n3e-rt. SpnrP?t"
DT
120
Dummy Block *Available
DT
100
Back PIa.te Adapter .
DT
750
_
Extruisi on Guide
DT
800
Die Back Plate
Trr
250
TOT AL MANUFACTURING COST
Templates & Gages
DT
300
LABORATORY REQUIREMENTS
5 SCRAP -r.?1h.?.1.4.1
41. Snot Ttetm 1 -
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT. BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
12,960
TOTAL TOOLING COST
11_915
5c. G. & A-
? ADDITIONAL EQUIPMENT
SUB TOTAL
S PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SFF TTFM 1
Slid TOTAL
15,805
IC RENT
PRICE/LB. 9-1 77 PRICE/PIECE
-IKfi-n
INSTALLATION ?
DEPT. SIGNATURES
DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG.
SHIPPING SCHEDULE-
WORK STDS.
WEEKS
1
2-
3
4.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING-.
SHIPPING
4
CONTROLLER
?
_
Declassified in Part - Sanitized Copy Approved for Release
-
Declassified in Part - Sanitized Copy Approved for Release
MP 90.6
Customer
Part Nome
WAD
FT.A WOE
EXTRUSION COST ESTIMATE SHEET
Mat. Specs. -Ken 975
Port Na. & 7.96966
t:..X-X) ON PR IMS ITEM Ii CF 8
Qucntity Required (10 P Inquiry No
Production Rate Date
V 1/47
MATERIAL .163
MATERIAL COST
COST
BILLET DATAI.D.
DATA
QUOTATION
4503
0.0. Au 1.0- LGTH.
8"
TART
0.D. 30 T.n2 LGTH.
ly8n
FIRM DATE BUYER
WEIGHT/BILLET
(6/1
WEIGHT/PIECE (Not)
2-3q1
MAT. COST/L13. i
PIECES/BILLET
18
WEIGHT/PIECE (Gloss)
3.61
MAT. COST/PIECE 1155 0 5.50
MAT. SCRAPCOST
TOTAL BILLETS REQ. (Incl. s...p)
7
% SCRAP
20.6
TOTAL GROSS WT.
/1.5.5#
a YIELD
6-5-3
MAT. SCRAP VALUE
MANUFACTURING COST
(
2169
2100
3.2.110
600
MANUFACTURING DATA 66 2/3 Eff.
-it 9 RI1TRS 1 RATH
PUSHES/HR. 6o
3
PIECES/PUSH 3 Baia ni ?
III
MANUFACTURING COST/PC. 3_$ ar, la 60n
DEV. A TOOL TRYOUT COST/PC.
CHANGE-OVER COST/PC-
DEV. & TOOL TRYOUT/HRS.
-n
DEV- & TOOL PUSHES/HR. Trmi srt Hp
9_0
PUSHES/DIE CHANGE - MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
BILLET HEATING
1
MACHINING TIME/PC.
...2,5
MACHINING COST/PC.
MAGNA-FLUX COST/PC. 1
250._L
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
DESCALE
PURCHASED SERVICES itAct: T IRECts
$-36-(10
PURCHASED SERVICES:
56
.5
INTFRCTTPTAT. AUALYSTR 90% /10tITROT.
$211..00
FIRM DATE BUYER
CHFCK
FIRM DATE BUYER
1
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Rsploc?ablo Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
3110
1
Din T/I.Art 6 o 1115
PT
111/0
-
ni f. Tnmet-t SPA.C.P.T
DT
120
311 rni-n,I.s13er
0
0
o
7),0
rimmmy ELI orac it ktrannl-11 r.
DT
boo
Bark Plats Arlanteor
171'
7q0
.c,.--t r-aninn ("fair).
nT
Ron
Tlia Rrusir In a?....
DT
250
TOTAL MANUFACTURING COST
TerttplIt.tAst A- clagen
DT
300
_
% SCRAP
103 mmo
LABORATORY REQUIREMENTS
1
* ?Rol Ttasat 1
PACKAGING REQUIREMENTS
t SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT. BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
71,05
TOTAL TOOLING COST
It-915
z G. & A.
ADDITIONAL EQUIPMENT
SUB TOTAL
a PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SIM- 1::n"d 1
sod TOTAL
9 r3n
91 RENT
PRICE/LE. vt_hl PRICE/PIECE
90.10 ,
INSTALLATION
?
RE-ARRANGEMENT
DEPT. SIGNATURES DATE
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG.
I
SHIPPING SCHEDULE
WORK STOS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
.24
QUALITY
MATERIAL PROCUREMENT
PROC. CONT.
TOOLING
PLANT MGR.
PROCESS/NG
..
COST EST-
MANUFACTURING
SHIPPING_
_
-
_
CONTROLLER
a
12,000 ION PRESS
ram 5 of 8
MP 90-5 EXTRUSION COST ESTIMATE SHEET -
Customer WAD Mot. Specs. MPD- 275 Quantity Required 100 PCS. I nqu iry No
Port Name FLABGE Port No. & C/L 226961 Production Rate Date 1/31/57
MATERIAL
. MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
.
8514
0.0. * 8" LOTH.
/0.5
atkit-likrea 1.56"2 _LD.1 LGTH.
35"
FIRM DATE BUYER
WEIGHT/BILLET
86#
WEIGHT/PIECE (Not)
R.90,
MAT. COST/LB.
PIECES/BILLET
7
WEIGHT/PIECE (Gross)
12.34
MAT. COST/PIECE 151.8 @ 5.50
TOTAL BILLETS REQ.,(Iool. Scrap)
18
% SCRAP
20.6
MAT. SCRAP COST
' TOTAL GROSS WT.
1548#
a YIELD
72.4
MAT. SCRAP VALUE
( 732 )
* 2 Baths TVirACTURI NG DATA 662/37.. Effie.
MANUFACTURING COST
8382
5/.00
PUSHES/HR. An
3.0
PIECES/PUSH
7
MANUFACTURING COST/PC. 9 hr s at 600
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/AIR. Too/ apt. Trp
2.0
DEV. & TOOL TRYOUT COST/PC. 2 W
11200
PUSHES/DIE CHANGE -MANDREL
5
TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC. - 1 "
600
BILLET HEATING
1
MACHINING TIME/PC.
25
MACHINING COST/PC.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
5
PURCHASED SERVICES Hach. Lab specimen
$72.00
PURCHASED SERVICES:
92
Tnter.Sti URI. Ansaargin
On
FIRM DATE BUYER
20% Control Chprir
-20
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Roplocsoblo Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert - 4 @ $185
PT
740
35 PC/Die
0
0
0
- 633
Die Insert Spacer
re
120
Dummy Block *Available
DT
400
Back Plate Adapter.
DT
750
Fri. ir-n al nn Crwl tie.
DT
800
niP RA Pk Pints.
DT
250
TOTAL MANUFACTURING COST
TEM -lates 6. Gazes
300
% SCRAP Included
3660LABORATORY
REQUIREMENTS -
PACKAGING REQUIREMENTS
II: R ee Tt Pm t
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS :.
TOTAL MANUFACTURING COST
1592.4.
TOTAL TOOLING COST
4463
% C. & A.
ADDITIONAL EQUIPMENT
Item I
SUB TOTAL
S PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
Slid TOTAL
A RENT
19420
PRICE/LB. 71_82 PRICE/PIECE
194.20 ea.
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG.
SHIPPING SCHEDULE
WORK STDS.
WEEKS
1
2
3
r 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT.
PROD. CONT.
TOOLING
PLANT NOR.
PROCESSING
COST EST.
MANUFACTURING
r
r
SHIPPING--
-
-
_
CONTROLLER
01
0
0?3
0
0
? ?
. ?-
_
12,000 TON PRESS
'Tint 6 of 8
UP 90-S
Customer
WAD
EXTRUSION COST ESTIMATE SHEET
Mot. Specs. HYD-275 Quantity Required
FT.ANGE Q6
Part NOM& Port No. & 226.4 Production Rate
100 PCS. Inquiry No.
Dote
1-31-57
-
MATERIAL ./63
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
_5693_-_----_
0.0. 6? I.D_ _ LGTH.
8 .5#
1
C.14res-.70 In2----i
CO yr ). LGTH.
50"
FIRM DATE BUYER
MAT. COST/LB,
MAT. COST/P11.:CE 1035 .7,) 5._50
MAT. SCRAP COST
WEIGHT/BILLET
6,4
wetcHT/plece (NsI)
4 97
PIECES/BILLET
6
welotirtetEce (Gr...)
8.62
TOTAL BILLETS REQ. (Incl. ScrnP)
5
% SCRAP
16.7
TOTAL GROSS WT.
1.0350/
% YIELD
57.6
MAT. SCRAP VALUE
* 2 Baths MANUFACTURING DATA 66 2/3 Effie
1 Hset.11
MANUFACTURING COST
5
4500
PUSHES/HR. ' 6 0
3-0
PIECES/PUSH 2 nolo Die
8
MANUFACTURING COST/PC- 7.5 hrs V 600
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/1.5k. Tool 6.et Up
2.0
DEV. & TOOL TRYOUT COST/PC. 2 " 0 WO
CHANGE-OVER COST/PC.
MACHINING COST/PC.
1200
PUSHES/DIE CHANGE - MANDREL
5
TIME TO CHANGE DIE & MANDREL, HRS.
0
BILLET HEATING
1
MACHINING TIME/PC.
.25
STRESS RELIEVE
MAGNA-FLUX TIME/PC
. .
MAGNA-FLUX COST/PC.
r
D ESCAL E
_5
PURCHASED SERVICES /??_kaglx?Lab., Spec.
$72.00
PURCHASED SERVICES:
Interstitial Analysis
20 00
FIRM DATE BUYER
FIRM DATE BUYER
20_1, Control Check
SPECIAL TOOLING .
REPLACEABLE TOOL COST
SPECIAL TOOLS (List R?plocsobls Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert. - 6 at 323_5
PT
1110
20 Pc/Insert
0
0
0
/110
DIP Irsert. Sparer
rhirmy Filark *Avei 1 ntil P
.14(10
ftra rir Pi n te _pcippter
DT
750
Extrusion Guide
DT
BOO
Die Back nate
DT
250
TOTAL MANUFACTURING COST
Ten-17 4-r>rt & rag &e.e
DT
300
% SCRAP Included
f73J
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
* See Iti, f
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
13337
TOTAL TOOLING COST
8207
SOP TS' vim T
% G. 8. A-
ADDITIONAL EQUIPMENT
SLIB TOTAL
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
Slid TOTAL
16265
% RENT
PRICE/LB. 32.73 PRICE/PIECE
162.65 ea
INSTALLATION
RE-ARRANGEMENT
DEPT. SIGNATURES DATE
TOTAL ADDITIOHAL EQUIPMENT COST
MFG. ENG_
SHIPPING SCHEDULE
WORK STOS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20 21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING_
CONTROLLER
12.000 TOW pRESS
ITEM 7 of 8
MP 90-5 EXTRUSION COST ESTIMATE SHEET
100 PCS.
VAD Mal. Specs. MP!) 272 Quantity Required Inquiry No
Customer
r
FLANGE Port No. & CA. 227594 Production Rate Date 1-31-.,?,--
Port Name
MATERIAL .161
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
7673
0.0. 8" 1.0. LGTH.
11.5
AR-IP-Tea-1.04 Iri4-0-1 LGTH.
50"
FIRM DATE BUYER
WEIGHT/BILLET
93#
WEIGHT/PIECE (Not)
8.37
MAT. COST/LB.
PIECES/BILLET
8
WEIGHT/PIECE (Gross)
11.6
MAT. COST/PIECE /395 'AI 5.50
TOTAL BILLETS REQ. (Incl. Scrop)
15
% SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
1395#
% YIELD
72.2
MAT. SCRAP VALUE
1.11
2 Baths TACZACTURING DATA 66 2/3"; Eff.
MANUFACTURING COST
7562
6720
PUSHES/HR.
2
PIECES/PUSH 2 Hole Die
8
MANUFACTURING COST/PC. 11.2 hrs. iia 600
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PUSHES/ Set Up
2.0
DEV. & TOOL TRYOUT COST/PC. 2 " 600
1 ?CIO
PUSHES/DIE CHANGE -MANDREL
1
TIME TO CHANGE DIE & MANDREL/HRS.
CI
CHANGE-OVER COST/PC.. 1 - 600
600
BILLET HEATING
1.5
MACHINING TIME/PC.
.25
MACHINING COST/PC.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
D ESCALE
.5
PURCHASED sERvicEsMach Lab. Specimens
t72.00
PURCHASED SERVICES:
92
Interstitial Analysis
20.00
FIRM DATE BUYER
20`h Control Cheek
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Roplocsablo Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS 50
Die Insert - 30 : $185
PT
5550
I, Pc Insert
Die Insert Spacer
0
Dianmy Block *Ave i 1 J1111P
LOO
Back ?late Adapter
DT
750
Extrusion Cuido
DT
800
DIP fip Mr r 1 At e
DT
250
LABORATORY REQUIREMENTS
TOTAL MANUFACTURING COST
% SCRAP Included
Templ A T.PR Pe Gages
300
8470
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
See Item #1.
REMARKS t
TOTAL MANUFACTURING COST
2/974
TOTAL TOOLING COST
10329
% G. & A.
ADDITIONAL EQUIPMENT
Cee Ttc I
SUB TOTAL
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT .
Slid TOTAL
26798
.
%RENT
PRICE/LB. 32.02 PRICE/PIECE
267.98 ea
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG-
SHIPPING SCHEDULE
WORK STOS.
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
PROD. CONT.
MATERIAL PROCUREMENT
? TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
_
Declassified in Part - Sanitized Copy Approved for Release
01
0
0
0
0
0
-0
0
0
0
0
0
12,000 TON PRESS
ITEM 8 of 8
MP 90-5 EXTRUSION COST ESTIMATE SHEET
,
Mot. Specs. 11PD 272 Quantity Required 100 PCS. Inquiry No
Customer WAD
FLANGI Port No. & C/L 227596 Production Rate Date 1-31-57
Part N Ome
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 8" I.D. LGTH.
10"
2
main.1Area-.81 In I.D.I LGTH.
71"
FIRM DATE BUYER
WEIGHT/BILLET
81#
WEIGHT/PIECE (Net)
9.26
MAT. COST/LB-
PIECES/BILLET
6
WEIGHT/PIECE (Gross)
13.5
MAT. COST/PIECE 1620 @ 5.50
8910
TOTAL BILLETS REQ. ((ncl. Scrap)
20
5 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
1620"
% YIELD
68.6
MAT. SCRAP VALUE
/39
- MANUFACTURING DATA
* 2 Baths i Batla
MANUFACTURING COST
8771
PUSHES/HR. 4.0
2
atEcEs/eusH 2 bole Die
6
MANUFACTURING COST/PC. 5 hrs g 600
9000
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PuskiEsmart.Set Up
2.0
DEV. & TOOL TRYOUT COST/PC.
1200
PUSHES/DIE CHANGE - MANDREL
1
TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC.
600
BILLET HEATING
1.50
MACHINING TIME/PC.
95
MACHINING COST/PC.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
5
PURCHASED SERVICES ms?.4., raivh
$72-00
PURCHASED SERVICES:
99
per1m4
Interstitial Analysis
20.00
FIRM DATE BUYER
Control Check
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First) CODE
COST
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert - 10,0 0 $185. pp7400
3 Pc/Insert
7400
Die Insert spacer
120
Dummy Block * Avallable JYI
400
Back Plate Adapter DT
. 50
Ixtrusion Guide DT
800
I
Die Batik puute DT
250
TOTAL MANUFACTURING COST
Templates & Gages
300
51 SCRAP Trtr-ludc.c1
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
See Item *1
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS'
TOTAL MANUFACTURING COST
5 G. & A.-
27313
?_?/
TOTAL TOOLING COST
I 585
See Item I
SUB TOTAL -
ADDITIONAL EQUIPMENT
S PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SI-la TOTAL
3309
% RENT
PRICE/LB- 35.97 PRICE/PIECE
DEPT- S1GNATuNES
333-09
DATE
INSTALLATION
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MEG. ENG.
SHIPPING SCHEDULE
WORK STDS
WEEKS
1
2
3
-4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
ROO CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
3
AAP 90-5 EXTRUSION COST ESTIMATE SHEET
Cu 1 t omer WAD Mat_ Specs. MPD 272 Quantity Required 24 PCB. Inquiry No. SPIT'vT 1 of 2
Rollill SHAFT
Part Nome Part No. & Cit_ Upset tiniy Production Rate Date
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA 41
QUOTATION 3017
FIRM DATE BUYER
58,115
0.D. .6" I.D. LGTH.
12.0
o.D.1 16 1/4 1.0.1 50. LGTH.
10 i2
WEIGHT/BILLET
386
WEIGHT/PIECE (Net)
320
MAT. COST/LB.
PIECES/BILLET
1
WEIGHT/PIECE (Gross)
386
MAT. COST/PIECE 9850 A 5.90
TOTAL BILLETS REQ. (incl. Scrap)
25
5 SCRAP
47,
MAT. SCRAP COST
TOTAL GROSS WT.
9850
sr. YIELD
83%
MAT. SCRAP VALUE 9850 less 7680 - 2170# g 2CW#
434
MANUFACTURING DATA
1 Batti 2 Bath **
MANUFACTURING COST
57,681
22.500
PUSHES/HR. 1
2
PIECES/PUSH
1
MANUFACTURING COST/PC- 375 hrs. g $600/hr
DEV. & TOOL TRYOUT/HRS.
ximosunemc Set up
2.0
DEV. & TOOL TRYOUT COST/PC- 2 hi-s g 600/hr
1,200
PUSHES/DIE CHANGE -MANDREL
15(riandre/)
TIME TO CHANGE DIE & MANDREL/HRS.
a 0
CHANGE-OVER COST/PC- 2 hrs. 'q 60Q/hr
1.200
BILLET HEATING 3]./2
3 1/2
MACHINING TIME/PC.
Lo
MACHINING COST/PC. 25 DC. g 4hr.- 100 hrs.. g 10.00
? MAGNA-FLUX COST/PC.
1,000
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
DESCALE
PURCHASED SERVICES
PURCHASED SERVICES'
Tntprsfiitial Analysis
20_00
FIRM DA7E BUYER
20
201. Control
FIRM DATE BUYER
. SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS
Die Insert 1 Required
Fir
46 50
Die Back Plate *
25
4
$400
1600
2250
125 -$16. ea
270
Die. ktr0 Owl- Ro Mr Plot. il.
s ?
- itorpr nn H
Mandr..A.A. 2 f red ( 1 avnri
1200.06
.
Pressing ...Mac *
UM
15
I.
720
2880
4080
75 ? 54.40ea
1360
..., .
TOTAL MANUFACTURING COST
* Available (from development programs)
% SCRAP Included above
** AdditiDnal Low Temp. Bath Required
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
% G & A.
85731
TOTAL TOOLING COST 62'1
$2;256.
ADDITIONAL EQUIPMENT
SUB TOTAL
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUES TOTAL
85,231
% RENT
PRICE/LB. 11.10 PRICE/PIECE
3,551.29e
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG..
SHIPPING SCHEDULE
WORK STDS-
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
-
Declassified in Part - Sanitized Copy Approved for Release
0
0
0)
0
0
01
0
0
Declassified in Part - Sanitized Copy Approved for Release
01
0
0
0
0
0
-0
0
0
0
0
0
12,000 TON PRESS
ITEM 8 of 8
MP 90-5 EXTRUSION COST ESTIMATE SHEET
,
Mot. Specs. 11PD 272 Quantity Required 100 PCS. Inquiry No
Customer WAD
FLANGI Port No. & C/L 227596 Production Rate Date 1-31-57
Part N Ome
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 8" I.D. LGTH.
10"
2
main.1Area-.81 In I.D.I LGTH.
71"
FIRM DATE BUYER
WEIGHT/BILLET
81#
WEIGHT/PIECE (Net)
9.26
MAT. COST/LB-
PIECES/BILLET
6
WEIGHT/PIECE (Gross)
13.5
MAT. COST/PIECE 1620 @ 5.50
8910
TOTAL BILLETS REQ. ((ncl. Scrap)
20
5 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
1620"
% YIELD
68.6
MAT. SCRAP VALUE
/39
- MANUFACTURING DATA
* 2 Baths i Batla
MANUFACTURING COST
8771
PUSHES/HR. 4.0
2
atEcEs/eusH 2 bole Die
6
MANUFACTURING COST/PC. 5 hrs g 600
9000
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PuskiEsmart.Set Up
2.0
DEV. & TOOL TRYOUT COST/PC.
1200
PUSHES/DIE CHANGE - MANDREL
1
TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC.
600
BILLET HEATING
1.50
MACHINING TIME/PC.
95
MACHINING COST/PC.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
5
PURCHASED SERVICES ms?.4., raivh
$72-00
PURCHASED SERVICES:
99
per1m4
Interstitial Analysis
20.00
FIRM DATE BUYER
Control Check
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First) CODE
COST
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert - 10,0 0 $185. pp7400
3 Pc/Insert
7400
Die Insert spacer
120
Dummy Block * Avallable JYI
400
Back Plate Adapter DT
. 50
Ixtrusion Guide DT
800
I
Die Batik puute DT
250
TOTAL MANUFACTURING COST
Templates & Gages
300
51 SCRAP Trtr-ludc.c1
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
See Item *1
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS'
TOTAL MANUFACTURING COST
5 G. & A.-
27313
?_?/
TOTAL TOOLING COST
I 585
See Item I
SUB TOTAL -
ADDITIONAL EQUIPMENT
S PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SI-la TOTAL
3309
% RENT
PRICE/LB- 35.97 PRICE/PIECE
DEPT- S1GNATuNES
333-09
DATE
INSTALLATION
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MEG. ENG.
SHIPPING SCHEDULE
WORK STDS
WEEKS
1
2
3
-4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
ROO CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
3
AAP 90-5 EXTRUSION COST ESTIMATE SHEET
Cu 1 t omer WAD Mat_ Specs. MPD 272 Quantity Required 24 PCB. Inquiry No. SPIT'vT 1 of 2
Rollill SHAFT
Part Nome Part No. & Cit_ Upset tiniy Production Rate Date
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA 41
QUOTATION 3017
FIRM DATE BUYER
58,115
0.D. .6" I.D. LGTH.
12.0
o.D.1 16 1/4 1.0.1 50. LGTH.
10 i2
WEIGHT/BILLET
386
WEIGHT/PIECE (Net)
320
MAT. COST/LB.
PIECES/BILLET
1
WEIGHT/PIECE (Gross)
386
MAT. COST/PIECE 9850 A 5.90
TOTAL BILLETS REQ. (incl. Scrap)
25
5 SCRAP
47,
MAT. SCRAP COST
TOTAL GROSS WT.
9850
sr. YIELD
83%
MAT. SCRAP VALUE 9850 less 7680 - 2170# g 2CW#
434
MANUFACTURING DATA
1 Batti 2 Bath **
MANUFACTURING COST
57,681
22.500
PUSHES/HR. 1
2
PIECES/PUSH
1
MANUFACTURING COST/PC- 375 hrs. g $600/hr
DEV. & TOOL TRYOUT/HRS.
ximosunemc Set up
2.0
DEV. & TOOL TRYOUT COST/PC- 2 hi-s g 600/hr
1,200
PUSHES/DIE CHANGE -MANDREL
15(riandre/)
TIME TO CHANGE DIE & MANDREL/HRS.
a 0
CHANGE-OVER COST/PC- 2 hrs. 'q 60Q/hr
1.200
BILLET HEATING 3]./2
3 1/2
MACHINING TIME/PC.
Lo
MACHINING COST/PC. 25 DC. g 4hr.- 100 hrs.. g 10.00
? MAGNA-FLUX COST/PC.
1,000
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
DESCALE
PURCHASED SERVICES
PURCHASED SERVICES'
Tntprsfiitial Analysis
20_00
FIRM DA7E BUYER
20
201. Control
FIRM DATE BUYER
. SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS
Die Insert 1 Required
Fir
46 50
Die Back Plate *
25
4
$400
1600
2250
125 -$16. ea
270
Die. ktr0 Owl- Ro Mr Plot. il.
s ?
- itorpr nn H
Mandr..A.A. 2 f red ( 1 avnri
1200.06
.
Pressing ...Mac *
UM
15
I.
720
2880
4080
75 ? 54.40ea
1360
..., .
TOTAL MANUFACTURING COST
* Available (from development programs)
% SCRAP Included above
** AdditiDnal Low Temp. Bath Required
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
% G & A.
85731
TOTAL TOOLING COST 62'1
$2;256.
ADDITIONAL EQUIPMENT
SUB TOTAL
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUES TOTAL
85,231
% RENT
PRICE/LB. 11.10 PRICE/PIECE
3,551.29e
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG..
SHIPPING SCHEDULE
WORK STDS-
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
-
Declassified in Part - Sanitized Copy Approved for Release
0
0
0)
0
0
01
0
0
Declassified in Part - Sanitized Copy Approved for Release
01
0
0
0
0
0
-0
0
0
0
0
0
12,000 TON PRESS
ITEM 8 of 8
MP 90-5 EXTRUSION COST ESTIMATE SHEET
,
Mot. Specs. 11PD 272 Quantity Required 100 PCS. Inquiry No
Customer WAD
FLANGI Port No. & C/L 227596 Production Rate Date 1-31-57
Part N Ome
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA
QUOTATION
0.0. 8" I.D. LGTH.
10"
2
main.1Area-.81 In I.D.I LGTH.
71"
FIRM DATE BUYER
WEIGHT/BILLET
81#
WEIGHT/PIECE (Net)
9.26
MAT. COST/LB-
PIECES/BILLET
6
WEIGHT/PIECE (Gross)
13.5
MAT. COST/PIECE 1620 @ 5.50
8910
TOTAL BILLETS REQ. ((ncl. Scrap)
20
5 SCRAP
16.7
MAT. SCRAP COST
TOTAL GROSS WT.
1620"
% YIELD
68.6
MAT. SCRAP VALUE
/39
- MANUFACTURING DATA
* 2 Baths i Batla
MANUFACTURING COST
8771
PUSHES/HR. 4.0
2
atEcEs/eusH 2 bole Die
6
MANUFACTURING COST/PC. 5 hrs g 600
9000
DEV. & TOOL TRYOUT/HRS.
DEV. & TOOL PuskiEsmart.Set Up
2.0
DEV. & TOOL TRYOUT COST/PC.
1200
PUSHES/DIE CHANGE - MANDREL
1
TIME TO CHANGE DIE & MANDREL/HRS.
0
CHANGE-OVER COST/PC.
600
BILLET HEATING
1.50
MACHINING TIME/PC.
95
MACHINING COST/PC.
250
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
MAGNA-FLUX COST/PC.
DESCALE
5
PURCHASED SERVICES ms?.4., raivh
$72-00
PURCHASED SERVICES:
99
per1m4
Interstitial Analysis
20.00
FIRM DATE BUYER
Control Check
FIRM DATE BUYER
SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First) CODE
COST
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST TOTAL PCS/TOOL
DESIGN HOURS 50
300
Die Insert - 10,0 0 $185. pp7400
3 Pc/Insert
7400
Die Insert spacer
120
Dummy Block * Avallable JYI
400
Back Plate Adapter DT
. 50
Ixtrusion Guide DT
800
I
Die Batik puute DT
250
TOTAL MANUFACTURING COST
Templates & Gages
300
51 SCRAP Trtr-ludc.c1
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
See Item *1
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS'
TOTAL MANUFACTURING COST
5 G. & A.-
27313
?_?/
TOTAL TOOLING COST
I 585
See Item I
SUB TOTAL -
ADDITIONAL EQUIPMENT
S PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SI-la TOTAL
3309
% RENT
PRICE/LB- 35.97 PRICE/PIECE
DEPT- S1GNATuNES
333-09
DATE
INSTALLATION
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MEG. ENG.
SHIPPING SCHEDULE
WORK STDS
WEEKS
1
2
3
-4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
ROO CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
3
AAP 90-5 EXTRUSION COST ESTIMATE SHEET
Cu 1 t omer WAD Mat_ Specs. MPD 272 Quantity Required 24 PCB. Inquiry No. SPIT'vT 1 of 2
Rollill SHAFT
Part Nome Part No. & Cit_ Upset tiniy Production Rate Date
MATERIAL
MATERIAL COST
COST
BILLET DATA
PART DATA 41
QUOTATION 3017
FIRM DATE BUYER
58,115
0.D. .6" I.D. LGTH.
12.0
o.D.1 16 1/4 1.0.1 50. LGTH.
10 i2
WEIGHT/BILLET
386
WEIGHT/PIECE (Net)
320
MAT. COST/LB.
PIECES/BILLET
1
WEIGHT/PIECE (Gross)
386
MAT. COST/PIECE 9850 A 5.90
TOTAL BILLETS REQ. (incl. Scrap)
25
5 SCRAP
47,
MAT. SCRAP COST
TOTAL GROSS WT.
9850
sr. YIELD
83%
MAT. SCRAP VALUE 9850 less 7680 - 2170# g 2CW#
434
MANUFACTURING DATA
1 Batti 2 Bath **
MANUFACTURING COST
57,681
22.500
PUSHES/HR. 1
2
PIECES/PUSH
1
MANUFACTURING COST/PC- 375 hrs. g $600/hr
DEV. & TOOL TRYOUT/HRS.
ximosunemc Set up
2.0
DEV. & TOOL TRYOUT COST/PC- 2 hi-s g 600/hr
1,200
PUSHES/DIE CHANGE -MANDREL
15(riandre/)
TIME TO CHANGE DIE & MANDREL/HRS.
a 0
CHANGE-OVER COST/PC- 2 hrs. 'q 60Q/hr
1.200
BILLET HEATING 3]./2
3 1/2
MACHINING TIME/PC.
Lo
MACHINING COST/PC. 25 DC. g 4hr.- 100 hrs.. g 10.00
? MAGNA-FLUX COST/PC.
1,000
STRESS RELIEVE
MAGNA-FLUX TIME/PC.
DESCALE
PURCHASED SERVICES
PURCHASED SERVICES'
Tntprsfiitial Analysis
20_00
FIRM DA7E BUYER
20
201. Control
FIRM DATE BUYER
. SPECIAL TOOLING
REPLACEABLE TOOL COST
SPECIAL TOOLS (List Replaceable Tools First)
CODE
COST
PCS./REWORK
NO. OF REWORKS
REWORK COST
REWORK TOTAL
TOTAL TOOL COST
TOTAL PCS/TOOL
DESIGN HOURS
Die Insert 1 Required
Fir
46 50
Die Back Plate *
25
4
$400
1600
2250
125 -$16. ea
270
Die. ktr0 Owl- Ro Mr Plot. il.
s ?
- itorpr nn H
Mandr..A.A. 2 f red ( 1 avnri
1200.06
.
Pressing ...Mac *
UM
15
I.
720
2880
4080
75 ? 54.40ea
1360
..., .
TOTAL MANUFACTURING COST
* Available (from development programs)
% SCRAP Included above
** AdditiDnal Low Temp. Bath Required
LABORATORY REQUIREMENTS
PACKAGING REQUIREMENTS
SHIPPING REQUIREMENTS F.O.B. EXTRUSION PLANT, BUFFALO, N.Y.
REMARKS:
TOTAL MANUFACTURING COST
% G & A.
85731
TOTAL TOOLING COST 62'1
$2;256.
ADDITIONAL EQUIPMENT
SUB TOTAL
% PROFIT
ADDITIONAL MACHINES OR EQUIPMENT
SUES TOTAL
85,231
% RENT
PRICE/LB. 11.10 PRICE/PIECE
3,551.29e
INSTALLATION
DEPT. SIGNATURES DATE
RE-ARRANGEMENT
TOTAL ADDITIONAL EQUIPMENT COST
MFG. ENG..
SHIPPING SCHEDULE
WORK STDS-
WEEKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUALITY
MATERIAL PROCUREMENT
PROD. CONT.
TOOLING
PLANT MGR.
PROCESSING
COST EST.
MANUFACTURING
SHIPPING
CONTROLLER
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0
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TABLE OF CONTENTS
FOREWORD
I. INTRODUCTION
II, OBJECT
III, CONCLUSIONS
IV. RECOMMENDATIONS
V. SUMMARY
VI. DISCUSSION
VII, REFERENCES
VIII. APPENDIX I - MATERIAL & PROCESSING SPECIFICATIONS
IL APPENDIX II - DETAIL EXTRUSION DIE DRAWINGS
STAT
Page No.
iii
3
5
7
9
17
141
159
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LIST OF FIGURES
FIGURE NO.
1. Cutaway view of the Curtiss-Wright J65 Turbojet showing the
titanium parts and assemblies manufactured under this program.
2. P/N 226962 - FrontFlange Rear Main Bearing Support Cone
Assembly, Material Ti-A70,
3. P/N 226963 - Rear Flange, Rear Main Bearing Support Cone
Assembly, Material Ti-A70.
P/N 226964 - Flange Brace) Rear Main Bearing Support Cone 73
Assembly, Material Ti A70.
5. P/N 226956 - Front Flange Rear Main Bearing Vapor Duct Assembly, 73
Material Ti-A70.
STAT
71
6. P/N 226961 - Rear Flange Rear Main Bearing Vapor Duct Assembly, 74
Material Ti-A70.
7. P/N 226966 - Flange) Combustion Chamber Heat Shield Assembly, 74
Material Ti-A70.
8 P/N 227594 - Rear Flange, Turbine Stator Blade Support Assembly, 75
Material Ti A110-AT.
9. P/N 227596 - Front Flange, Turbine Stator Blade Support Assembly, 75
Material Ti-A110-AT.
10. P/N 226970 - Shaft, Turbine Rotor Front, Material Ti-A110-AT. 76
11. P/N 608118 - Rear Main Bearing Support Cone Assembly. 77
12. P/N 608109 - Rear Main Bearing Vapor Duct Assembly. 78
13. P/N 608120 - Combustion Chamber Heat Shield Assembly. 79
14. P/N 608569 - Turbine Stator Blade Support Assembly. 80
15. P/N 226970 - Shaft Turbine Rotor Front 81
16. Several Views of the 12,000 Ton Horizontal Extrusion Press 82
17. Heating curve for an 8 inch Diameter titanium billet heated 89
in a salt bath to 1850?F
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LIST OF FIGURES Cont'd
FIGURE NO.
18. Maximum envelope shape for the extrusion of P/N 226961 - Flaw
Rear. Main Bearing Vapor Duct Assembly.
19. Maximum envelope shape for the extrusion of P/N 226963 - Flange,
Rear-Main Bearing Support Cone Assembly,
20. Photograph's of an extruded section of P/N 226961 shOwing cross-
section and surface quality.
21. Optimistic envelope shape for the extrusion of P/N 226961 Flange,
Rear Main Bearing Vapor Duct Assembly,
22. Optimistic envelope shape for the extrusion
Rear Main Bearing Vapor Duct Assembly.
23. Optimistic envelope shape for the extrusion
Rear Main Bearing Support Cone Assembly.
of P/N 226956, Flange,
of P/N 226962, Flange,
24. Optimistic envelope shape for the extrusion of P/N 226963, Flange,
Rear Main Bearing Support Cone Assembly.
25. Optimistic envelope shape for the extrusion of P/N 226964, Flange,
Rear Main Bearing Support Cone Assembly.
Optimistic envelope shape for the extrusion of P/N 226966, Flange,
Combustion Chamber Heat Shield Assembly.
27. Schematic drawings of the multi-opening dies for the extrusion of
P/N's 226962,226963, 226964) 22956 and 22966
28. Photograph of the multi-opening die for the extrusion of
P/N's 227594 and 227596.
29. Photographs of the optimistic envelope extrusion of P/N's 226961,
956, 962, 963, 964 and 966. Material - Ti-A701 extrusion tempera-
ture - 1500?F.
The effect of extrusion temperature on the tensile properties of.
A70 titanium extruded to the maximum envelope shapes of P/N 226961.
Cross-sections of three A70 flanges indicating the locations of
standard tensile - (.250" Dia,) test specimens (a) and sub-
standard tensile - (.150" Dia.) test specimens (b).
viii
19
90
92
93
94
95
96
97
98
99
101
102
103
104
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LIST OF FIGURE122rItd)
FIGURE NO.
S'S TAT
Page No.
32. Photomacrographs and photomicrograph of a longitudinal section of 105
P/N 226956 (A70 material) extruded with a billet preheat tempera-
ture of 15500F.
33. Photomacrographs and photomicrograph of a longitudinal section 106
of P/N 226961 (A70 material) extruded with a billet preheat tempera-
ture of 1550?F.
34. Photomacrographs and photomicrograph of a longitudinal section
of P/N 226962 (k70 material) extruded with a billet preheat
temperature of 15500F.
35. Photomacrographs and photomicrograph of a longitudinal section 108
of P/N 226963 (A70 material) extruded with a billet preheat
temperature of 15500,F.
360 Photomacrographs and photomicrograph of a longitudinal section of 109
P/N 226964 WO material) extruded with a billet preheat tempera-
ture of 15500F.
107
37. Photomacrographs and photomicrograph of a longitudinal section of
P/N 226966 (A70 material) extruded with a billet preheat tempera-
ture of 1550?F.
38. Photomicrograph of a cross-section through the surface of a 1500?F
A70 extrusion in which freedom from surface contamination is indi-
cated by the uniform microstructure and hardness survey.
39. Etched longitudinal sections of an extruded A70 shape showing the '112
depth of non-uniform flow t the front? end of the extrusion.
110
111
40. Etched longitudinal sections of an A70 extrusion showing the grain
growth penetration due to torch cut-off of the extrusion fro the
butt.
41. The effect of annealing temperatures and cooling rates on the
mechanical properties of A70 titanium extruded with a 15500F
billet preheat temperature.
42. Extrusion shape for P/N 226970 - Shaft) Turbine Rotor Front.
43. Die holder and sub-a
included angle die.
113
114
115
sembly for a re-entrant angle die and a 1300 116
44. Photograph of an extruded ,A110-AT tube. This section was
extruded throu re-entrnt angle die,
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LIST .OF FIGURES Cont 'd),
FIGURE NO.
45. Optimistic envelope shape for the extrusion of P/N 227594, Flange,
Turbine Stator Blade Support Assembly.
46. Optimistic envelope shape for the extrusion of P/N 227596, Flange, 119
Turbine Stator Blade Support Assembly,
47. Photograph showing the surface finish of an extruded .A110-AT flange.
48. Macrostructure of two sections of the re-entrant angle die extrusion
(outer diameter surface to the left), Note coarse grain structure
at the tears.
118
120
121
49. Microstructure of A110-AT titanium extruded through the re-entrant 122
angle die. Note random orientation of structure.
50. Macrostructure of two sections of the steel jacketed extrusion. 123
51. Photomicrograph of the as-extruded steel jacketed tube. Note the 124
alignment of the grains in the flow direction and some recrystalli-
zation.
52. Microstructures of the beta transus studies. Specimens water
quenched after heating one hour at (a) 19200F, (b) 1960?F, and (c)
1970?F. Note the increase in percentage of fine acicular transfor-
mation product as the temperature increases.
125
53. Effect of annealing temperature on the mechanical properties of 126
A1,10-AT titanium extruded with a 19000F billet preheat temperature.
54. View of the tooling mounted in a 25 ton Bath Radial Draw Former. 127
55. Typical contour forming dies) rolls, and common rolls holding yoke
as employed in forming extrusions.
56. Photograph of 360 degree rings of P/N 226966 formed from machined
barstock.
57. a) Beginning of hot contour forming operation. The twist in the
extrusion is corrected in the forming operation.
b) Close-up view of a typical extruded part partially formed in
the contour die in the first roll pass.
127
128
58.? Photograph of P/N 226963 formed in a 360 degree ring. This opti- 130
mistic envelope shape was machined from a maximum envelope extrusion.
LIST OF FIGURES
FIGURE NO.
59. Close-up photograph of P/N 226966 showing the flash-butt weld.
60. P/N 226961 rings formed and flash-butt welded into 360?.
Note the out-of-round condition at the weld joint.
61. Two views of the sizing dies and set-up.
62. Photograph of the six inch Ajax Upsetting Machine.
63. Photomacrograph of a successfully upset flange in AMS 6412
material.
64.
Wooden model used for upset development of plasticine.
S'S TAT
133
134
135
136
65. Schematic drawings of the three step upset cycle used to upset 137
the flanges for the Turbine Rotor Shaft.
66. The upset area of an A110-AT rotor shaft indicating the buckling 138
at the inner diameter.
67. Upset punch design modifications employed to correct the buckling 139
problem in upsetting the rotor shaft flanges.
68. a) Photomacrograph of the upset area of the rotor shafts after the 140
first and second stage.
b) Photomacrograph of the first upset product showing the lap at
the inner diameter.
69. Final design modifications applied to the upset punch to correct
the buckling problem in upsetting the third stage for the rotor
shaft flange.
70. Photograph of the first successfully upset prototype turbine
rotor shaft.
71. Production
72. Production
73. Production
74. Production
75. Production
76. Production
77. Production
extrusion shape for P/N 2269610
extrusion shape for P/N 226956.
extrusion shape for P/N 226962.
extrusion shape for P/N 226963.
extrusion shape for P/N 226964.
extrusion shape for P/N 226966.
extrusion shape for P/N 227594.
xi
141
142
143
145
146
147
148
149
150
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FIGURE NO.
78.
79.
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LIST OF FIGURES Cont'd
Production Extrusion shape for P/N 227596.
Photomicrographs of P/N 226961 extruded from cast
material.
80. Photomicrographs of P/N 226962 extruded from cast
material.
81. Photomicrographs of P/N 226963 extruded from cast
material.
82. Photomicrographs of P/N 226964 extruded from cast
material.
83. Photomicrographs of P/N 226966 extruded from cast
material.
Photomicrographs of P/N 227594 extruded from cast
material.
85. Photograph of sections of several of the finished
rings.
86. Dimensional Inspection Layout of P/N 226962.
87. Close-up photograph of the weld repair zone of the turbine
rotor shaft0
and forged
and forged
and forged
and forged
and forged
and forged
production
`',,00t?
xii
152
153
153
154
1514
155
156
157
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50-Yr
LIST OF TABLES
TABLE NU?
I. Dimensional Inspection Report for
of P/N 226961.
II. Dimensional Inspection Report for
of P/N 226962.
III. Dimensional Inspection Report for
of P/ii 226956.
IV? Dimensional Inspection Report for
of P/N 226963.
Dimensional Inspection Report for
of P/N 226964.
VI? Dimensional Inspection
of P/N 226966.
VII. As Extruded and Annealed Tensile Properties of P/N 226961
kMaximum envelope) Extruded at Various Temperatures.
Several
Several
Several
Several
Several
Report for Several
Prototype Extrusions
Prototype Extrusions
Prototype Extrusions
Prototype Extrusions
Prototype Extrusions
Prototype Extrusions
VIII? The Tensile Properties of A70 Titanium Flanges kuptimistic
envelope) Extruded with a 1550?F Billet Preheat Temperature?
II? Tensile properties of A1104T Tubular Extrusions.
X? The Tensile Properties of RinglIeldments for.Certification of
Machine Settings.
Cleveland Welding Machine Settings and Burn Off Length..
Thomson Welding Machine, Settings and Burn Off Length.
Tensile Properties of the A110-AT Upset Flange.
Dimensional Inspection
of P/N 226961.
IV. Dimensional Inspection
of P/N 226956.
XVI. Dimensional Inspection
of P/N 226962.
XVII. Dimensional Inspection
of P/N 226963.
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Report for Several Production Extrusions
Report for Several Production Extrusions
Report for Several Production Extrusions
Report for several Production Extrusions
STAT,T
21221_220
43
44
46
48
49
50
52
53
54
55
56
57
59
II
r
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LIST OF TABLES cOont
TABLE NO.
XVIII. Dimensional Inspection Report for Several Production
Extrusions of P/N 226966
XIX. D imensional Inspection Report for Several Production
Extrusions of P/N 227594
JLXO Dimensional Inspection Report for Several Production
Extrusions of P/N 227596
XII. Dimensional Inspection Report for Several Production
Extrusions of P/N 226970.
XXII. The Mechanical Properties of Typical Extruded and Annealed
Section from the Production Flange Extrusion.
XIII'. The Tensile Properties of Extruded A110-AT Production Tubing
from Forged billets.
XXIV. The Tensile Properties of the Weld Section and Base Metal
of Formed Rings.
XXV. Comparison of Conventional Manufacturing Methods (Forging
and Flash-tutt Welded Barstock) to Extrusion on the Basis
of Material Utilization.
xiv
Pagp No.
61
62
63
67
68
69
?
INTRODUCTION
In recent years the military, recognizing the potentiality of
titanium for aircraft applications, has made a concerted effort
to develop the "state of the art". Consequently, the develop-
ment of titanium alloys has progressed at a rapid rate far sur-
passing the development of any other structural material. One
obstacle, however, that of economics, must be overcome before
this metal can be used to its full potential. To this end,
the present program was initiated.
The relatively high cost of titanium clearly indicates that an
appreciable savings will result from a high material utiliza-
tion factor, i.e0 the ratio of the finished part weight to that
of the rem material required to produce the part. The extrusion
process is ideally suited as the basic operation for the manu-
facture of parts with a high material utilization factor in
that complex cross sections can be obtained with a minimum of
machining. In addition, for the titanium materials investivted,
extruding directly from a cast ingot provides an additional
cost savings in tAvt both the cost of the forging operation and
the material lost in forging are eliminated.
Specific parts such as flange and tubular shapes are? applicable
to the extrusion process. In the case of the flanges, the basic
cross section is extruded in straight sections. Subsequent form-
ing, welding, sizing operations produce the desired circular con-
figuration. This replaces conventional methods of forging the
ring directly or fabricating rings from barstock. In both these
operations considerable material is lost in machining the detail
cross section. For tubular shapes, conventional forging cannot
compete with extrusion for production of parts with a minimum of
machining and a maximum of material utilization in the process
itself.
Both flange and tubular shapes, typical of such application for
titanium in jet engines were selected for study. These assemblies
are shown schematically in the cutaway ? of a Curtiss-Wright J-65
Turbojet, Figure 1. The materials selected were both unalloyed
(AMS 4921) and the A110-AT titanium alloy.
The results obtained from development directed toward the establish-
ment of a production processing method are presented in this report.
Results of subsequent engine testing of these assemblies and/or
parts and economic analysis of the process were presented in the
previous section of this final report.
S.STAT
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LIST OF TABLES cOont
TABLE NO.
XVIII. Dimensional Inspection Report for Several Production
Extrusions of P/N 226966
XIX. D imensional Inspection Report for Several Production
Extrusions of P/N 227594
JLXO Dimensional Inspection Report for Several Production
Extrusions of P/N 227596
XII. Dimensional Inspection Report for Several Production
Extrusions of P/N 226970.
XXII. The Mechanical Properties of Typical Extruded and Annealed
Section from the Production Flange Extrusion.
XIII'. The Tensile Properties of Extruded A110-AT Production Tubing
from Forged billets.
XXIV. The Tensile Properties of the Weld Section and Base Metal
of Formed Rings.
XXV. Comparison of Conventional Manufacturing Methods (Forging
and Flash-tutt Welded Barstock) to Extrusion on the Basis
of Material Utilization.
xiv
Pagp No.
61
62
63
67
68
69
?
INTRODUCTION
In recent years the military, recognizing the potentiality of
titanium for aircraft applications, has made a concerted effort
to develop the "state of the art". Consequently, the develop-
ment of titanium alloys has progressed at a rapid rate far sur-
passing the development of any other structural material. One
obstacle, however, that of economics, must be overcome before
this metal can be used to its full potential. To this end,
the present program was initiated.
The relatively high cost of titanium clearly indicates that an
appreciable savings will result from a high material utiliza-
tion factor, i.e0 the ratio of the finished part weight to that
of the rem material required to produce the part. The extrusion
process is ideally suited as the basic operation for the manu-
facture of parts with a high material utilization factor in
that complex cross sections can be obtained with a minimum of
machining. In addition, for the titanium materials investivted,
extruding directly from a cast ingot provides an additional
cost savings in tAvt both the cost of the forging operation and
the material lost in forging are eliminated.
Specific parts such as flange and tubular shapes are? applicable
to the extrusion process. In the case of the flanges, the basic
cross section is extruded in straight sections. Subsequent form-
ing, welding, sizing operations produce the desired circular con-
figuration. This replaces conventional methods of forging the
ring directly or fabricating rings from barstock. In both these
operations considerable material is lost in machining the detail
cross section. For tubular shapes, conventional forging cannot
compete with extrusion for production of parts with a minimum of
machining and a maximum of material utilization in the process
itself.
Both flange and tubular shapes, typical of such application for
titanium in jet engines were selected for study. These assemblies
are shown schematically in the cutaway ? of a Curtiss-Wright J-65
Turbojet, Figure 1. The materials selected were both unalloyed
(AMS 4921) and the A110-AT titanium alloy.
The results obtained from development directed toward the establish-
ment of a production processing method are presented in this report.
Results of subsequent engine testing of these assemblies and/or
parts and economic analysis of the process were presented in the
previous section of this final report.
S.STAT
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?
-4.1!
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11101
"Mk
III. CONCLUSIONS
The results obtained on this program permit the follow-
ing generalized conclusions:
1. Detail titanium parts such as end flanges and tubular
sections can be manufactured by extruding the basid
configuration and performing secondary operations
such as ring forming or upsetting for the desired end
configuration? This technique results in considerably
higher material utilization when compared to conven-
tional methods such as forging. A machining envelope
of approximately 0.050 inch has been determined as
satisfactory for such parts?
20 The extrusion of the basic configuration from cast
ingots of A70 and A110-AT titanium will result in
mechanical properties which are equivalent to a forged
section or an extrusion from a forged billet.
30 The following dimensional tolerances are obtainable in
the extrusion operation for extruded lengths of twenty
feet and fifteen feet for the A70 and A1104T titanium
materia1s9 respectively.
Nominal Metal Dimension Extrusion Tolerance
Less then 100 inch 00010
1.0 to 200 inch 0.020
2.0 to 300 inch '0.030
0
4. The present limitation of approximately five extrusions
per die for A70 and one extrusion per die for the A110
-
AT limit the linear footage of extruded material to
approximately 100 and 15 feet, respectively? The use of
multi-opening dies can readily increase this yield by at
least a factor of three.
50 To obtain optimum surface finish on extruded sections and
maximum die life the dextrusion processing variables must
be controlled carefully?
6. Forming of A70 rings should be performed in the temperature
range of 70071000?F, A110-AT rings should be formed in the
temperature range of 12004400?f. In this way small dia
metemand complex cross sections can be formed readily.
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STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
III. CONCLUggnalgEILLL
7. Large variations is cross section (rib ratios of
5031) can be successfully flash butt welded by
closely controlling the heating of the thinner
sections.
8. Sizing of titanium rings should be performed in the
temperature range of 7004250?F. Expand the A70
material 2$ and the A110-AT material a maximum of
1 1/2 %.
9. Conventional steel upsetting techniques and limi-
tations do not apply to titanium.
10. The parts considered in this report cannot be manu-
factured as a production item without considerable
production experience in the specific titanium alloys
and shapes considered.
IV. RECOMMENDATIONS
1. Where applicable, utilize the extrusion operation as the
primary operation in producing titanium parts with a maxi-
, mum of material utilization.
2. For A70 and AllOAT components extrude directly from cast
ingots Where the extrusion ratio is greater than 10:1.
3. Consider additional development along the following lines:
a. Development of a long /ife extrusion die.
b. Development studies on upsetting titanium tubing to
extablish the limitations of the process.
S.STAT
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STAT
V. 8UMmARY
The detail titanium parts studied consisted of end flanges
for sheet metal assemblies and a tubular rotor shaft, see
Figures 2 through 15. The titanium material used was both
AMS 4921 (A70) and A1104T for the shaft. To accomplish the
development objective of utilizing a minimum amount of
material to manufacture the detail components, the minimum
envelope was established, The flanges were manufactured from
extruded sections which were formed into rings and the rotor
shaft was made by extruding a tube and upsetting the flanges.
A* EVAltnItItlIALtt
10 Extrusion
The extrusions were performed on a 12,000 ton horizontal
extrusion press. The extrusion stock was heated in a ,
salt bath located immediately adjacent to the press.
Forged billets were used -exclusively for the extrusion
stock.
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a. Maximum arILLItimistic Enveluejhutg
(1) Ti A70
Initial extrusions had a
1/8 indh0 Several
"maximum" env
19, to
n envelope of approxpately
extrusions were made to this
elope configuration, see Figures 18 and
establish the range of extrusion temperature
quired to obtain maximum mechanical properties and
to provide material for forming envelope studies.
Subsequent extrusions were made of each of the detail
parts, Figures 21 through 269 to an "optimistic
envelope of approximately .030 inch. This represented
the estimated minimum cross section required to suc-
cessfully manufacture a ring.
Multi-opening dies were used to extrude the smaller
cross sections. In this manner the six A70 shapes
were extruded through three dies.
(a) Dimensional Ingastigji
Dimensional inspection of the extrusionsrevealed
the following tolerances
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ilo? O.
V. SUMMA.RY(Cont 'd)
Nominal Metal. Dimension
Less than 1.000 inch
1.000 to 2.000 inch
2 000 to 3p000 inch
Extrusion Tolerance
+0,020
4. 0.030
?0040
Local surface imperfections did not exceed 1/32 inch.
(b) .11.219.111EilL11.112.22LiEaLtaa
Room temperature tensile tests on the optimistic enve-
lope extrusion made at 1850?F revealed the material to
have properties in excess of the minimum specification
requirements. The macrostructure revealed a fine fiber
structure equivalent in uniformity to a rolled ring or
a forging. The microstructure indicated minor struc-
tural variations from equiaxed alpha to bonds of "basket-
weave'
, alpha.
The microstructure and a microhardness survey revealed
the extruded surface to be completely free from contam-
ination. Due to non-uniform flow the first four inches
of each extrusion was scrapped. The rear crop was
approximately one-half inch and was due solely to over-
heating caused by the torch cut-off.
Various annealing cycles performed on the extruded
sections revealed the "as- extruded" properties to be
equivalent to the annealed properties.
(2) Ti-A110-AT
Prior to extruding the tube for the rotor shaft the extru-
sion stock was upset and pierced at 2000?F. Subsequent
extrusions utilizing various lubricants, die designs and
temperature were complete failures in that the extruded tubes
had severe surface tears. Attempts to extrude A110-AT flanges
resulted in similar surface scoring, not quite as severe as
that of the tubes. These results necessitated a study of
A110-AT extrusion conditions. This study is presented in Part
III of this final report.
10
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V. SUMMARY (Cont
TinietallurgLcar
Tensile tests on the sound sections of the tubular
extrusions revealed those sections to be uniform and
to have properties in excess of the minimum specifica-
tion requirements. The macrostructure of the sound
sections was uniform. The microstructure was identi-
fied as elongated alpha grains in a matrix of recrystal-
lized alpha.
A study of the non-uniform flow in the front end of the
extruded tube revealed the front crop to be five inches.
The rear crops necessitated by the torch cut-off, was
established to be one inch.
As for the A70 material the 9as-extrudea" properties for
the A110-AT alloy were Nand to be equivalent to those
obtained by annealing.
20 hia.11EIJAK
The extruded sections were formed into 360 degree rings on a
Bath Radial Draw Former. Initial forming was performed on
machined lengths of P/N 2269660 Rings with envelopes as little
as 0.020' inch were successfully formed at room temperature. Form-
ing the heavier rings in A70 and all the A1104T rings required
heating. These elevated temperature studies were performed:on ex.
truded maximum envelope shapes machined to an optimistic envelope.
Subsequent to these initial forming studies the optimistic envel-
ope extruded sections were formed into 360 degree rings. The dies
and material were heated to 50071100?F for the A70 material and
1200-1400?F for the A1104T alloy, The ,forming of the smaller
diameter rings caused a tlinning, of the inside flange which must
be compensated. for in nature extrusions.
30 Flash-Butt Welding
Welding of the titanium rings was performed at two sources on a
Thomson F-4 Synchromatic and a Swift Welder. Initial welding was
performed on P/N 226966. The machine settings were qualified by
tensile tests. Subsequentlys, the optimistic envelope sections
were welded. Tensile tests on these welded sections established
the weld settings as being capable of passing the strength require-
ments of AMS 7498.
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11
S'S TAT
0
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V,SUMMARXIContld)
The smaller diameter rings, P/N's 226961 and 227594, required a
pre-sizing operation prior to welding to eliminate slippage of
the work in the dies and subsequent distortions.
The titanium rings were sized on a 225 ton press brake. The
expansion of the rings was initially established to be 2 to 3
percent. In sizing the rings,the dies and material were heated
to a temperature of 70042500F0 This was satisfactory for the
A70 rings. The A1104T rings:, however, could not be expanded
beyond 1.5 percent. This required a slightly larger diameter
welded ring for future studies,
5. .7.2?E...ttipl
A 6 inch Ajax Air Forging Machine was used to upset the flanges
in the extruded A110-AT tubing for manufacture of the Turbine
Rotor haft. Initial upsetting of steel tubing indicated that
a 0.450 inch thick wall could be successfully upset in three
passes. Attempts to upset this thickness tube in titanium at
1900coF resulted in a buckling at the inner diameter. Minor
? die modifications and increasing the wall to 0.600 inch, yielded
the first successftlly upset tube.
The tensile properties of the upset flange and adjacent tubular
section were equivalent to that of the original tube.
B. Production Studies
10 Manufacture of Parts
Extrusion
Based on the results obtained on,dimensional inspection of
the finished prototype rings the production extrusion envel-
opes were modified9 see Figures 71 to 78. A development study
of the effect of extrusion processing conditions on the mechan-
ical properties and surface finish of extruded cast titanium
ingots resulted in the use of the following extrusion conditions:
Extrusion Speed
Extrusion Length
Lubricant
Billet Heating
Die Design
Ti-A70
100-500 inbain0
15-20 ft.
Fiske #630
Salt Bath
120 to 140?
included angle
Ti-4110-AT
450 in/Min
12-15 ft.
Fiske #630
Salt Bath
1800 included
angle
Declassified in Part - Sanitized Copy Approved for Release
V. SUMMARY_..1Contedj
Container Temperature
Die Preheat
Die Material
TI-A70 Ti4410-AT
800oF
350 to 750?F 700 to 800?F
5% Chrome, die Vasco Supreme
steel, hard
faced with
Rexweld
Extrusions were made from both cast ingots and forged billets
at extrusion temperatures of 1550?F for the A70 and 185049500F
for the A110 AT.
(1) Quality of the Extrusion
(a) A70
The surface finish ? of these extrusions had heavy
surface scoring due to the run-out guides.
(b) A110-AT
The following tolerances were obtained on the flange
sections:
Nominal Metal Dimeneior
less than 1.000 inch
1 000 to 2e 000 inch
Extrusion Tolerance
L 00010
L0020
In extruding the tubular sections for the rotor shaft
a maximum thickness variation of 0.080 inches on an
eleven foot length was noted.
(2) Extrusion Yield
The extrusion yield was approximately 70 percent.
(3) Die Life ?
The die life for the A70 extrusion was approximately 100
linear feet and for the A1104T 15 linear feet.
(.4) MetallpItisal ? ,gvaluatiop
Tensile tests on the extruded sections from both cast ingots
and forged billets revealed properties which surpassed the
minimum specification requirements,
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S'S TAT
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V. SUMMARY Contod
_p_rm.n?ga_pj,ding and Si zing
The tooling for the ring manufacturing operations was modified
to accommodate the changes in the extrusion envelope and the
production extrusions were processed into 360 degree rings
utilizing the procedure established in the prototype work. The
total machine time required to produce a ring was approximately
30 minutes.
In addition to the qualifying tests for the weld settings,
tensile tests were performed on the weld zone and base metal
of the finished ring. These tests established the finished
product to meet all applicable specifications?
co .11.2P?Ij4RE
Six A110-AT tubes were upset at both ends in the same manner
that resulted in a successful prototype parto All of the shafts
had indications of a lap on the inner diameter immediately under
the upset flange? ,These laps could not be removed by machining
to the finished I.D. dimensions. Consequently, this area was
repair welded.
20 Manufacture of AS
The following list associates the rings with the assemblies and in-
dicates the corresponding assembly vendorss
Part No. Name
608120
608118
608109
608569
Material Flarojos.. Vendor
Combustion Chamber A70 226966
Heat Shield
Rear Main Bearing
Support Cone
Rear Main Bearing
Vapor Duct
A70 226962
226963
226964
A70 226956
Turbine Stator Blade A1104T 227394
Support
227596
Portland Copper
& Tank Works
Smith-Morris Corpo
Midway Company
Alloy Product Co.
a. Weld Approval
Prior to welding the assemblies the vendors facilities were reviewed
and weld samples obtained, Weld approval was granted based on samples
which were required to conform to established WAD specification, see
Appendix I,
V. SUMMARY (ContBd)
130 ProductimlnostEga
Inspection of the final assemblies revealed occasional
dimensional and weld discrepancies. These descrepant areas
were non-critical and when they occurred, the part was pro-
cured through Material Review Action? The repair welding
of the rotor shaft was in a non-critical. stress area and
consequently could be toleratedo
Co Material Utilization
Compared to conventional manufacturing methods, ioe0 forging, etco,
this newly developed method of extruding for the basic cross
section utilizes approximately one-half the raw material. Material
utilization factors in excess of 0.65 were obtained? The highest
material utilization factor obtainable by conventional methods was
0040, see Table XXV?
15
S.STAT
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VI, DISCUSSION
4 0
The detail titanium parts selected for study are shown in Figures 2
through 10. As indicated in these figures, the parts studied con-
sist of end flanges and a tubular shaft. For engine operation, the
detail flanges are welded to sheet metal components to form an
integral part of the assembly, Figures 11 through 15. Major emphasis
was placed on the manufacture of the detailed parts. The assemblies
provided a means of evaluating the parts through engine testing,
The accomplish the development objective of utilizing a minimum amount
of material to manufacture the detail parts in the most economic manner,
the following was required, For the flanges, the minimum machining
envelope, i.e., the stock added to the detail cross-section, had to be
established,/ This envelope must be commensurate with the limitations
of the extrusion, forming, welding, and sizing operations utilized in
the manufacture of the flange rings. For the tubular shaft, the envelope
must be commensurate with the limitations of the extrusion and upset
operations. The limitations of the extrusion operation determined the
machining envelope for most of the rings. Forming and welding limitations
added to this envelope for the smaller diameter parts, The upset oper-
ation limitations established the envelope for the shaft.
Exclusive of the basic studies reported in Part III of this final report,
the initial attempts to establish this machining envelope were concen-
trated around the extrusion operation. Subsequent to the establishment
,of the extrusion limitations, the limitations of the forming, welding,
sizing, and upsetting operations were established by processing parts.
This initial work is described in the following section entitled "Prototype
Studies".
After establishing the limitations for each of the operations, the production
parts were made. These parts were subsequently machined and/or fabricated
into assemblies for engine testing.
A. Prototype Studies
1. Extrusion
a. Equipment
All the extrusions on this program were made on the 12,000 ton
horizontal extrusion press located at Metals Processing Div-
ision, Buffalo, N. Y0, Figure 16. This press is equipped with
three pressure stages capable of delivering 4,000, 8,000, and
12,000 tons. On this program, the flanges were extruded util-
izing the 4,000 ton stage in conjunction with an 8 inch diameter
container. The shaft was extruded from a 16 inch diameter con-
tainer utilizing the full press capacity of 12,000 tons.
STAT
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))
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Declassified in Part - Sanitized C
pyApproved for Release @ 5
4.?
'
VI. DISCUSSION
4 0
The detail titanium parts selected for study are shown in Figures 2
through 10. As indicated in these figures, the parts studied con-
sist of end flanges and a tubular shaft, For engine operation, the
detail flanges are welded to sheet metal components to form an
integral part of the assembly, Figures 11 through 15. Major emphasis
was placed on the manufacture of the detailed parts. The assemblies
provided a means of evaluating the parts through engine testing.
The accomplish the development objective of utilizing a minimum amount
of material to manufacture the detail parts in the most economic manner,
the following was required, For the flanges, the minimum machining
envelope, i.e., the stock added to the detail cross-section, had to be
established. This envelope must be commensurate with the limitations
of the extrusion, forming, welding, and sizing operations utilized in
the manufacture of the flange rings. For the tubular shaft, the envelope
must be commensurate with the limitations of the extrusion and upset
operations. The limitations of the extrusion operation determined the
machining envelope for most of the rings. Forming and welding limitations
added to this envelope for the smaller diameter parts. The upset oper-
ation limitations established the envelope for the shaft.
Exclusive of the basic studies reported in Part III of this final report,
the initial attempts to establish this machining envelope were concen-
trated around the extrusion operation, Subsequent to the establishment
:of the extrusion limitations, the limitations of the forming, welding,
sizing, and upsetting operations were established by processing parts.
This initial work is described in the following section entitled "Prototype
Studies".
After establishing the limitations for each of the operations, the production
parts were made. These parts were subsequently machined and/or fabricated
into assemblies for engine testing.
A. Prototype Studies
1. Extrusion
a. Equipment
All the extrusions on this program were made on the 12,000 ton
horizontal extrusion press located at Metals Processing Div-
ision, Buffalo, No Y., Figure 160 This press is equipped with
three pressure stages capable of delivering 4,000, 8,000, and
12,000 tons. On this program, the flanges were extruded util-
izing the 4,0o0 ton stage in conjunction with an 8 inch diameter
container, The shaft was extruded from a 16 inch diameter con-
tainer utilizing the full press capacity of 12,000 tons.
. IA-RDP81-01043R002500180004-7
STAT
0,1
)
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V10 DISCUSSION (continued)
b. Method of Heating
Heating of the extrusion stock was accomplished in a
barium chloride salt bath immediately adjacent to the
press. Transfer of the billet from the furnace to the
press is accomplished by means of an overhead hoist.
Although the furnace temperature can be controlled quite
closely 9 the transfer of the material does result in a
slight drop in temperature. This drop in temperature WO
determined by using thermocouples to establish cooling
curveWor the billet. Due to the short duration of the
transfer times (approximately I minute), the only temperee
ature drop of any significance is restricted to the outer
surface. Therefore, the actual extrusion temperature
corresponded quite closely to the furnace temperature?
To determine the heating characteristics of the various
size billets and to assure thorough heating 9 heating curves
similar to those presented in Figure 17 were established?
Such curves dictate the time at temperature required to
through-heat the billet?
c. Material
The material for the prototype studies consisted exclusively
of forged billets? This material was purchased to the spec-
ifications shown in Appendix 1. While the specification for
the A70 material indicates a maximum oxygen content of 0020%,
this condition was not maintained as a sole cause for rejection.
This modification was required to expedite the delivery of this
material? In general, the oxygen content was approximately
0.25%.
Maximum and Optimistic Envelope Shapes
(1) Ti470 The initial extrusions of the A70 titanium mater-
ial were to the configurations shown in Figures 18 and 19.
These extrusions are referred to as "maximum envelope"
shapes due to the large machining envelope, approximately
1/8 inch on all surfaces, that was added to the detail
cross-section. The maximum envelope shape of Part No. 226961,
see Figure 18-9 was extruded at temperatures of approximately
17009 16009 15009 and 1450(10 The ram speed was approximately
2 in./sec. A? photograph of sections of one of these extruded
parts is presented in Figure 200 Additional extrusions of
Part No. 226963, see Figure 199 were also made under similar
conditions. This oversize envelope was purposely applied to
these shapes to permit subsequent forming after the extruded
section had been machined to various smaller envelopes. This
S.STAT
VI, DISCUSSION (continued)
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permitted an initial approximation of the limitations
of the subsequent ring producing operations. These
two shapes represent the most complex configuration
as well as the most difficult rings to form due to the
high ratio of cross-section area to ring diameter.
It is interesting to note that these extrusions repre-
sent one of the initial extrusions of titanium at this
facility and certainly the first such extrusions in
equipment of this capacity. They, therefore) also served
as a means of "getting our feet wet" and generally "de
bugging" the equipment. The temperature range for extrud-
ing forged A70 billets was also determined from these
extrusions.
To definitely establish the minimum envelope required) sub-
sequent extrusions were made to an "optimistic envelope" shape.
This envelope represents the initially estimated minimum
cross-section required to successfully manufacture a ring.
The specific cross-sections of each of the six shapes for
this material are presented in Figures 21 through 26.
These shapes are referred to as optimistic envelope shapes
due to the small amount of machining envelope) approximately
0,030 inch) which was applied to the detailed part.
Except for the extrusion of the optimistic shapes of Part
No. 2269611 the balance of the optimistic shapes were ex-
truded through multi-opening dies. These multi-opening dies
are shown schematically in Figure 27. As shown in these
figures) Part Nos. 226962 and 226963 were extruded through
one of these dies while Part Nos. 226956) 2269661 and
226964 were extruded through the other die. A photograph of
the multi-opening die used for the extrusion of Part Nos.
227594 and 227596 is shown in Figure 28, Detail die drawings
are presented in Appendix II.
Based on the experience obtained from the maximum envelope
extrusions) the following conditions were used for the
optimistic envelope extrusions
Billet Temperature
Extrusion Speed
Lubricant
Die Temperature
Container Temperature
Die Material
1550?F
15 ft./sec.
Oil dag, nicrolene) bentone)
lithium carbonate
250-400?F
8000F
rd faced steel
..014 .
Photographs of each of the extruded shapes are presented in
Figure 29.
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VI? DISCUSSION (continued)
(a)
Dimensional Inspection
Dimensional inspection report e for these ex.-
trusions are presented in Tables I through VI.
These reports indicate that the following extrus-
ion tolerances are obtainable.
Nominal Metal Dimension Extrusion Tolerance
Less than 1,0 inch
1.0 to 2.0 inch
2.0 to 300 inch
? 0.020
? 0.030
? 0,040
Local Surface inperfections, in general 9 did not
exceed 1/32 inch. Considerable warpage and twisting
were noted on these extrusions, This is attributed
to the lack of adequate runout guides, Subsequent
straightening operations corrected this condition,
(b) Metallurgical Investigation
i. Mechanical Properties
The results obtained from tensile tests on as
extruded sections of Part No. 226961 extruded
to the maximum envelope shapes at temperatures
from 1450*F to 1700*F are presented graphically
in Figure 28 and are compiled in Table VII.
This data indicates the entire temperature range
to be satisfactory for this extrusion ratio? It
is noted, however, that a considerably more ductile
material, as exhibited in Figure 309 by the values
for elongation and reduction of area and the ten=
sue to yield spread, is obtained by extruding in
the lower part of this temperature range, 1450 to
1600?F. In this range of extrusion temperature, a
more ductile material was obtained by extrusion
than forging as indicated by the vendor's certi-
fied data.
Tensile tests were also performed on the optimistic
envelope shapes. This data? presented in Table
VIII 9 clearly demonstrates, in all cases, that the
tensile properties of the extrusions are superior to
the certified minimum properties submitted by the
supplier. Furthermore, the data indicates a uniform-
ity of properties -within each flange and only a
small variation of properties among the flanges.
It is interesting to note that, except for Part No.
226966 (the smallest cross-section examined), the
tensile properties do not `frary appreciably with
section size, Figure 31. This small cross-section
permitted only the use of sub-standard specimens
which probably accounts for this small difference.
20
VI. DISCUSSION (continued
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ii? Microstructure and Macrostructure
STATcr
Photomicrographs of each of the sections
extruded at 1500?F, Figures 32 to 37,
indicate structural variations from equi-
axed alpha, to bands of "basketweave" alpha.
The equiaxed alpha results from extruding in
the all alpha phase, while the basket weave
alpha is a transformation product, its presence
indicative of extruding in the alpha-beta
region. As the extrusion temperature of approx.
imately 1500?F is close to the lower alpha-beta
transus9 minus variations in temperature through-
out the billet could readily account for BOMB areas
being in the alpha region while others are in the
alpha-beta region. The tensile tests reported in
the previous paragraph clearly establish that
these minor variations in microstructure are not
reflected in the mechanical properties of the
material, These microstructures, therefore, are
concluded to be acceptable for this material?
The macrostructure of these parts, also shown in
Figures 32 to 37, show a fine fibre structure
which is generally more uniform than that obtain-
able with a forging of comparable size and at least
equivalent to that of a rolled ring. These photo-
macrographs dhow a clearly defined narrow band ad.
jacent to the surface of most of the extrusions.
The microstructure of these bands have high per-
centages of the basket weave type alpha structure,
While this structure is less than optimum, no
deleterious effects have been exhibited in tensile
tests or in subsequent forming operations.
Surface Contamination of Extrusions
Sections of Part No, 226961 extruded at 1,500?F
were examined metallographically for surface con-
tamination. A photomicrograph showing a cross-
section adjacent to one of the extruded surfaces
is presented in Figure 38. The lack of surface
contamination is evident by the uniformity of the
microstructure and the results of the 'hardness sur-
vey. Converted, hardness readings to Rockwell C
ranged from 29.5 to 30.0 which is well within the
range of accuracy of the instrument. This work is
in close agreement with previous data20
21
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VI. DISCUSSION (continued)
iv. Front and Rear Crop
Front and rear sections of the extruded A70 flanges
were examined to determine the amount of material
which is not of usable qaality and must be cut off as
scrap? From these shapes, longitudinal sections were
etched for flow lines. Undesirable flow was observed
up to four inches from the front of the extrusion,
Figure 390
The rear crop study was designed to determine stosk
removal necessary due to irregular flaw and overheating
due to torch cutting of the extrusion from the butt?
?An etched section adjacent to the cut-off area, Figure 409
indicates uniform flow from the torch cut forward. Since
the point of cut-off was immediately adjacent to the
unextruded butt, it is evident that non-uniform flow
does not exist in the rear of the extrusions The heat
affected zone due to the torch cut-off extends into the
extrusion for a maximum depth of 1/2 inch, see Figure 40.
IT *,
Extrusion Annealing Cycles
The effect of various annealing temperatures and cooling
rates was determined for extruded A70 material? The
resulting mechanical properties are presented graphically
in Figure 41. As indicated in this figure, the as-extrud-
ed properties were equivalent to those obtained by any
of the annealing conditions examinede
(2) Ti-AllOAT - The initial extrusions with this material were
tubular sections for the turbine rotor shaft? Prior to actual
extrusion9 however, the billet material, which was in the form
of a 12 inch round-cornered square, was subjected to an upset
operation which increased the diameter to 16 inches, Simultan-
eously, the center of the billet was pierced? Initial Attempts
to perform this upset and piercing operation at Omperatures
below 1900?F resulted in severe cracking of the peripheral
upset area. Heating the billet to 2000?F eliminated the crack-
ing and resulted ir a successful upset.
Subsequent to the upset and pierce operation, several tubular
extrusions were attempted to the configuration of Figure 420
In these extr1sions9 both a re-entrant angle and a standard
130* die were used, Figure 43. Both extrusions resulted in
22
VI. DISCUSSION (continued)
? .3.37:e.
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severe surface tearing similar to that shown in
Figure 44. The extrusion temperature in these
tests was approximately 1900?F. A third attempt
to extrude this material into a tubular shape
utilized a steel jacket, i.e., the billet prior
to extrusion was encased in a jacket of steel. Ex-
truding this billet through a 130* die resulted in
surface tearing and cracks similar to those shown
previously, see Figure 44. The purpose of the jacket
was to reduce the friction by lubricating the outer
steel layer rather than the titanium.
Attempts to extrude at temperatures below 1900?F were
unsuccessful in that the press stalled. All the
previous extrusions at 1900?F required forces in
excess of 119000 tons. In several instances s "break
through" forces approached the press maximum of
129000 tons. A beta transus temperature of apprax=
imately 1960?F prohibited the extrusion at higher
temperatures. Results by previous investigators3
indicate that undesirable mechanical properties can
result from extruding above the 1960?F transus temper-
ature or in the "all-beta" region.
STATT
The lubricant for the previously discussed tubular
AllOAT extrusion was a combination of oil dag, nacrolene,
and lithium carbonate. One additional extrusion was
made to this configuration with a coating of Borax as
a lubricant. Although the surface quality of this
extrusion was improved, it is still not satisfactory.
To assure the availability of tubing for subsequent
development studies on upsetting, the dies were opened
to provide for a heavier walled section? This permitted
a machining operation to remove the surface imperfections
and allow subsequent processing.
In addition to the tubular extrusions in this material,
extrusions of Part Nos? 227594 and 227596 to the con-
figuration shown in Figures 45 and 46 were made. While
the surface finish of these extrusions was improved come
pared to the tubular shapes, severe surface scoring did
occur, Figure 470
The above results on AllOAT extrusions clearly established
the need for a development program aimed at establishing
23
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VI. DISCUSSION (continued)
the extrusion conditions required to produce AllOAT
extrusions with an acceptable surface finish. Such
a program was then initiated. The results of this
development program are discussed in detail in Part III
of this finaloreportl.
(a)
Dimensional Inspection
The severe surface tearing and scoring resulting
in all extrusions of this material precluded any
useful dimensional inspection.
(b) Metallurgical Investigation
i. Mechanical Properties
Tensile tests were performed on the sound
sections of two of the tubular extrusions.
These results are compiled in Table IX. As
indicated by the results on this table, the
tensile values of the extruded section were
found to be uniform and considerably more
ductile than that indicated for the base
material by the vendor's certified data. Notch
rupturing testing was also performed. These
results confirm the satisfactory quality of
this material with respect to mechanical pro-
perties.
ii. Microstructure and Macrostructure
A photomacrograph of a section of the re-entrant
angle die extrusion is shown in Figure 48.
While the sound section reveal* an overall
uniform grain distribution pattern, the metal
flow in the tear area is distinctly non-uniform,
yielding a non-uniform coarse grain structure.
A closer examination of the sound area, Figure 49,
reveals a moderately fine, randomly oriented,
recrystallization structure.
The macrostructure of cross-sections of the steel
jacketed extrusion is shown in Figure 50. Un-
like the previous extrusion, the flow lines are
clearly visible and they are generally smooth
with minor turbulences at the irregular surfaces.
Excluding these minor turbulences, the structure
is fairly uniform from inner to outer surface.
The microstructure of a section of this extrusion
VI. DISCUSSION (continued)
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S'S TAT
is presented in Figure 51. This grain
structure is identified as elongated alpha
grains in a matrix of recrystallized alpha?
The variation in grain size between this
and the previous extrusions can probably be
attributed to the upset and pierce temper-
ature which was appreciably lower for the
steel jacketed extrusion. Specifically, the
upset and piercing operation was performed in
the beta region for the first extrusion and
in the alpha-beta region for the latter.
iii. Beta Transus Determination
The beta transus temperature for this heat of
AllOAT material has been metallographically,
determined to be approximately 1960?F, Figure
520 This temperature represents the maximum
at which this material can be extruded or
finished forged3. For although the beta phase
has superior deformation characteristics than
the alpha phase, recrystallization and excessive
grain growth occur when this material is heated
above this temperature.
iv. Front and Rear Crop
A metallographic study of the front end of the
rotor &let extrusions revealed nonuniform
flow back to a distance of five inches from the
front of the extrusion. The rear crop, as was
the case for the A70 material, is approximately
one inch and is required only to remove the heat
affected zone due to torch cut-off.
Extrusion Annealing Cycle
The effect of varied annealing temperatures and
cooling rates on the mechanicaL propertiwbf
extruded AllOAT material is presented in Figure
53.While minor variations in yield strength and
reduction in area were exhibited at various
annealing temperatures, the as-extruded proper-
ties were adequate for further. proceSsingo
25
'
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VI. DISCUSSION (continued)
2. Ring Forming
ao Equipment
The machine utilized to form the extruded sections into
rings is described as a Bath Radial Draw Former, Figure 54.
It consists of a variable speed power driven circular table
and a double acting pressure controlled cylinder. Where
required, a hydraulic ram, capable of applying a side 1:orce
to the section being formed, is utilized.
The contour forming dies were fabricated from AISI 1045
material. They are circular in shape with the general con-
figuration of the part cross-section at the outer periphery.
Suitable contour rolls were fabricated from Ketos die material.
These rolls serve to exert a side force on the length being
formed. A photograph of the rolls and dies used on this pro=
gram is presented in Figure 55.
Initial Forming Studies
In preparation for forming the basic extrusion lengths, a pro-
gram was initiated to utilize machined titanium bar stock for
ring forming development. Initially, titanium bar stock machined
to the configuration of Part No. 226966 with an envelope of
approximately 1/16 inch was formed at room temperature with no
appreciable change in dimension, Figure 560 The enyelope was
then reduced to 0.020 inch and a ring was produced satisfactorily.
The tolerance of 0.020 inch which had been demonstrated to be
adequate for the contour forming operation is considerably less
than permitted by the extrusion operation at this time. Conse-
quently, future sections were machined to the optimistic envelope
(0.030 in.) from either bar stock or maximum envelope extrusions.
The parts studies were Part No. 226961, 226963, and 227594. These
shapes representing both A70 and AllOAT material have small dia-
meters relative to the cross-section area and represent the most
difficult sections in the program based on ring manufacture. At-
tempts to form these rings at room temperature were completely
unsuccessful as the material did not have the required elongation
necessary for this operation.
However, development directed at :hot forming techniques permitted
the satisfactory forming of these shapes to the desired contour,
Figure 579 In this application, both the material and the dies
were heated. A photograph of Part No. 226963 formed in this man-
ner is Shown in Figure 586 The application of hot, forming to
Part No. 226966 resulted in an appreciably better formed section.
VI. DISCUSSION (continued)
The forming temperatures and resulting required forces
for each of the parts followss
Material Temperature
Die Roll Temperature
Force excited through
rolls
Part Number
226977127770671?3
200?F 700?F '700?F
200?F 700?F 700?F
12 1/2 17 1/2 20 ton
ton ton
2275944
800?F
800?F
20 ton
S'S TAT
In all cases, best results were obtained when the forming oper-
ation proceeded as slowly as possible which was a table speed
of .4 RPM. In addition, a two pass operation, working first
with a clockwise rotation of the table and second with a counter-
clockwise rotation yielded the best results.
Optimistic Envelope Extrusions
The forming of extruded sections without any machining presented
an initial problem in that these shapes were twisted and .bowed
whereas the machined shapes were not. For the A70 material,
straightening was possible in the forming operation. For severely
distorted A70 shapes and for all the AllOAT shapes, it was neces-
sary to straighten the parts by hand in an arbor press prior to
forming.
Except for minor die rework required to accommodate the dimen-
sional variations inherent in the extruded section vs0 the
machined sections, these extruded sections were formed with re-
lative ease. The publication, at this time, of DS 7498 (speci-
fication controlling Flash Welded and Titanium Rings) confirmed
the previously established requirement of forming these rings hot.
In general, a temperature range of 5004000?F was established
for the dies and the material. The most difficult A70 ring to form
was Part No. 226963. The side (roll) pressures required to form
this small diameter resulted in a loss of approximately 0.080 ino
on the vertical leg, see Figure 24.
In forming the AllOAT rings, Part Nos. 227594 and 2275969 the high
pressures required to form the ring resulted in a torn surface.
Consequently, to eliminate the surface tearing, the forming temper-
ature was increased to 1200-1400?F and a pre-form operation was
employed. A reduction in thickness of the vertical leg of the
ring of o0)40 inch was noted due to the form4mg forces.
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VI. DISCUSSION (continued)
30 Flash Butt Welding
? Equipment
Welding of the titanium rings was performed at two welding
sources, Thomson Electric Welder Company, Lynn, Massachusetts,
and Cleveland Welding Company, Cleveland, Ohio. The machine
specifications used at each source followss
(1) Thomson Electric Welder Company
Model
Machine Rating
Maximum Upset Force
Maximum Clamping Force
(2) Cleveland Welding Company
Model
Machine Rating
Maximum Clamping Force
Maximum Upset Force
'Welding Formed Shapes
Thomson F44
Synchromatic
250 KVA
32,000 lbs.
23,000 lbs.
Swift Welder
90 K VA
600 KVA
160,000 lbs.
200,000 lbs.
The initial weld settings were based on the result # obtained
Ilva the development studies on maximum rib ratios'. Initial
studies were performed by Thomson Electric Welder on P/N 226966
formed from milled barstock, Figure 59* Several rings were
welded and the machine settings were qualified by tension test-
ing of the veld ring segments. In this manner, weld settings
capable of meeting the strength requirements of ims 7498 were
established*
'Similarly, the weld settings for the remaining shapes formed
from optimistic envelope extrusions were established? The
?tensile properties of the ring weldments are presented in
Table L The welding machine settings and burn off 1Bngths
thus established are indicated in Tables XI and XIIN
\ ?
S.STAT
vl. plEmul (continued)
The welding of P/N vs 226961 and 227594 presented considerable
difficulty in that an out-of-round resulted, Figure 60. The
relatively small diameter of P/N 226961 necessitated a pro
sizing operation prior to welding to eliminate slippage of the
work in the dies during the flashing operation and minimize sub-
sequent distortions. X-ray results on the welds of P/N 227594
revealed a complete lack of bonding. Increasing the flashing
time to overcome the resistance of the AllOAT material during
upsetting corrected the problem.
4* Sizing
Els Equipment
The titanium rings were expanded on a 225 ton press brake lo-
cated at Cyril Bath, A pin centrally located in the expander
fixture engages the punch and the expanding segments. The set
up is shown pictorially in Figure 61.
Sizing Welded Rings
The expansion of the titanium rings was initially set at 2 to
3 percent. This expansion was readily obtained for P/N 226966
at room temperature. Expanding the shape in increments of 0.42
inches resulted in a spring back of approximately 0.080 inches
per increment, or approximately 20 percent. Allowance for this
condition was accomplished by reworking the expanding die seg-
ments. Expansion of the larger cross section rings could only
be accomplished at temperatures in excess of 700?F. The release
at this time, of AMS 7498 established the sizing temperature
range to be 700 to 1250?F for all titanium rings. For P/N 226961
a pre-sizing operation, to eliminate the out-of-round condition
at the weld area was performed
Direct application of the above results obtained for CO titanium
result6d 'in failure when attempted in the AlOOAT rings, This was
due to the considerably lower ductiMy of this alloy as compared
to the A,70 (unalloyed) material. As 4 result, the contour form
circlimference was revised to show a 1.5 percent maximum expansion
instead of the,previously used 2 percent. Subsequent rings were
successfully expanded to this revised dimension.
Upsetting
Equipment
The equipment used to upset the flanges on the extruded AllOAT
"tubing to make the turbine rotor shaft, see Figure 10, was a
6 inch Ajax Air Forging Machine located at the Propeller Divi-
sion, Curtiss-Wright Corporation, Caldwell, New Jersey, A
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29
,
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VI. DISCUSSION (continued)
photograph of this machine is shown in Figure 62,
Heating of the material was performed in a Tocco induction
Heating Unit. This unit was calibrated wpth the use of
thermocouples attached to the tube to insure a uniform
heat pattern.
Upsetting of Tubing
Preliminary development studies for upsetting the ends of
the rotor shaft were performed on low alloy steel tubing,
ANS 6422. This initial work consiited of a three pass
operation on a 0.385 inch.thick wall tube. The temperature
employed was 2200?F. Upsetting of this tube resulted in
a buckling on the I.D. surface? Increasing the wall thick-
ness to 00450 inch resulted in a successfully upset steel
flange, Figure 63.
Concurrent with the steel upset development was a similar
program utilizing plasticine in a scaled down model. Thi7.s
material was laminated in colors to enable a study of the
,,flow of the material under the action of the punch. This
scaled-dawn unit, was constructed of hard wood and is shown
in Figure 64. In performing the upsetting on the plastictne
the material was cooled to a temperature of approximately
300F. This lower temperature permitted a closer approxima-
qon to the real material in that it rendered the plasticl.ne
less ductile. Results of this survey indicated that the
first upset pass can be successfully attempted by using a
tapered punch and a 0.410 inch wall tube.
Based on the above results on steel and plasticine9 tooling
was designed and fabricated to permit the upsetting of a
flange on AllOAT tubing with a 0,410 inch wall, This three
step upsetting cycle is shown pictorially in Figure 65. These
operations affect the dimensions of the upset section as follows:
First Stage: 0.410N wall x 3050N long
upset to 0.7210 wall x 1.62N long
Second Stages 0.7210 wall x 1062N long
upset to 1.053? wall to 10060N long
Third Stages L053" wall x 10060N long
upset to 1.379N wall x 0.62599 long
This upset cycle applied to the AllOAT tubing resulted in
severe buckling at the inner diameter, and incomplete die
fill? Figure 66.
30
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DISCUSSION (continued)
Upsetting of additional AllOAT tubing with a 0.450N
wall was attempted. This did not correct the problem
of the I.D. lap. Die variations, such as tapers on
the first and second stage punch, Figure 6I7k, were also
unsuccessul. Increasing the wall thickness to 0.600
inch solved the buckling problem in the first and second
stages0 A. photamacrograph of a section formed through
the second pass is shown in Figure 68(a). Applying the
third stage operation to this 00600 inch wall tube re=
suited in a serious fold, Figure 68(b). In all the pre-
vious attempts, the tube was heated to 1900?F prior to
the first and second stage operations? In an attempt to
eliminate the fold in the last operation another heating
operation was performed prior to.'-this third upset operation.
This resulted in a considerably improved upset with only
a slight fold,
Finally,? an attempt was made to improve the flow pattern
by removing the restrictive illedgetv from the punch in the
third stage operation, A sketch of the new punch design
is shown in Figure 69. A shaft was then successfully
upset using this 0.600 inch wall tube, three heating cycles
of 1900*F, and a tapered punch, Figure 70. Although a
trace of a fold was detected on close examination all
defects were removed by machining 0b050 inches from the
I010, surface,
(1) Mechanical Properties - Table XIII shows the tensile
properties of the upset area and adjacent tubular
section (heat affected zone). These properties are
equivalent to the original extruded tube. The slightly
law elongation values are probably attributed to the
undersized specimen
Production Studies
1* Manufacture of Parts
a. Extrusion
STAT
Inspection of the prototype rings established the need for
modifications of the extrusion envelope. These modifications
were found necessary primarily due to (1) local thinning of a
section during forming, (2) welding gripper marks, and (3)
dimensional accuracy of the extrusion operation. The final
production extrusion shaposthus established are presented in
Figures 71 to 780 Shown also in these figures are the previous
envelope, the machined detailed part cross-sectionsand the
finished machined assembly cross-sectioneo
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VL. DISCUSSION (continued)
Prior to the actual production extrusions, a development
study aimed at obtaining optimum surface finish and mechafl.
ical properties on extrusions from at ingots was performed.
The results of this Sully are discussed in detail in Part I
? of this final reportl. The following extrusion conditions
resulting from this study were employed on the production
extrusions.
Extrusion Speed
Extrusion Length
Lubricant
Billet Heating
Die Design
Container Temperature
Mie Preheat
Die Material
Ti-A70
100=500 ino/min.
15-20 ft.
Fiske #630
$alt Bath
1200 to 1400
included angle
800?F
350 to 750?F
5% Chrome, hot
worked die steel
t
with a Rexweld
hard face
Ti-AllOAT
450 ino/mino
12-15 ft.
Fiske #630
Salt Bath
180? included
angle
800?F
700 to 8000F
Vasco Supreme
(High Speed
Steel)
At the above condit1ons9 extrusions were made from both cast
ingot and forged billets in both the A70 and AllOAT materials,
An extrusion temperature of 1550?F was used for both the A70
materials while extrusion temperatures of 185049000F were
used for the cast ingot and forged bi11ets9 respectively, in
the AllOAT alloy. As was the case for the prototype extru8i0ns9
multi-opening dies were employed, see Figures 27 and 28.
(1) quality of the Extrusions
? (a) Ti470 Flanges
The surface quality of the production A70 extrusions
? were in general not satisfactory and were inferior
to those obtained in the prototype phase. Heavy
? striations were noted throughout the entire length
? of several of the shapes. These striations are
VI. DISCUSSION (continued)
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at? tributed.to.the run-out guides. These guides
were intended to straighten the twist which occurred
in the extrusions of the prototype parts. A dimen-
sional inspection report of the typical A70 extruded
shapes are presented. in Tables IIV to XVIII.
(b) Ti-AllOAT flange
? The application production extrusion conditions to
the AllOAT Mate4a1 resulted in flange extrusions
with an excellent surface finish? Dimensional in-
spection of these, part's, Tables XIV and XX indicate
the following tolerances are? obtainable.
Nominal Metal Dimension
? less the 14000
19000 to 2,000
Extrusion Tolerance
?/ 0.010
? + 0.020
Comparison of these values to those reported pre-
viously for the prototype A70 shapes reveals a
marked improvement which can be directly attributed
to the close control of the extrusion process variables.
It can logically be expected therefore, that extrusion
tolerances at least as good as those obtainable on the
AllOAT shapes can be realized in A70 material with the
use of properly designed run-out guides.
(c) Ti-AllOAT Shaft
In extruding the tubular sections for, the manufacture
of the rotor shaft the conditions mentioned above were
employed except as follows:
Die Preheat Temperature
Mie Material
Die Design
350 to 4500F
Remeld hard face
210 degrees included angle
The modifications from the optimum conditions pertain
solely to the die. This was necessitated due to the
lengthy procurement cycle associated with new die pro.
curement. Consequently, modifications were made to
existing dies. The die temperature was limited to
33
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VI. DISCUSSION (continued)
450?F due to interference problems associated
with the expansion of the dies upon heating.
The above extrusion conditions resulted in the
first AllOAT tubular extrusion of acceptable
surface quality and minimum die pickup. Slight
intermediate circumferential surface tearing
was noted. Dimensional inspection results are
presented in Table XXI. As indicated in this
table for an eleven foot extruded section the
maximum variation in wall thickness WS 006O
inch, All of these production extrusions were
from forged material due to the lack of cast
ingot of suitable diameter.
(2) Extrusion Yield
The extrusion yield exhibited by the A70 and AllOAT
flanges was approximately 70 percent. The major por-
tion of the lost materials, approximitely 25 percent
represented the unextruded butt. The remaining loss,
5 percent(, was due to the front and rear crops specimen
sampling, and preparation of the billet prior to extrud-
ing,
(3) Die Life
The die life obtained in extruding A70 material was five
extrusion cycles per die. This represents a total extru-
sion length of approximately 100 ft, for a single opening
die. For the AilOAT flanges only one extrusion cycle per
die was obtainable. This represents a total extrusion
length of approximately 15 linear. ft,
Metallurgical Evaluation
The results of tensile tests performed on the extruded
A70 and AllOAT flanges are presented in Table In-
cluded also in this ,table are the chemical compositions
of the ingot and billet materials which were extruded
obtain the shapeso The properties of all the
examined far exceed the mmifp requirement
cable specifications. The specimens
ramdon sampling from front and r
from both cast ingots and f
3
to
specimen
s of the appli-
xamined represent
ear sections of extrusions
rged billets, The extrusion
II
VI. DISCUSSION (continued)
of a forged billet or a cast ingot is not in any way
reflected in these tensile properties.
Typical photomacrographs of the extruded sections are
presented in Figure 79 to 1314 This structure is quite
similar to that obtained in the prototype studies, see
Figures 32 to 37 The microstructure of the A70 mate-
rial is identified as varying from recrystallized alpha
with a slight flow orientation to Widmenstatten alpha
platelets? The microstructure of the AllOAT shapes is
identified as equiaxed grains of Nidmenstatten alpha
platelets.
STAT
The results of tensile tests performed on extruded AllOAT
tubing from forged billets are presented in Table XXIII,
The minimum tensile properties exhibited are in excess
of the minimum specification requirements. The micro-
structure of these tubes are similar to that of the flanges,
see Figure 82,
1) Forming, Welding and Sizing
The tooling for the ring manufacturing operations was reworked
to accommodate the modifications of the production extrusion
envelopes. The procedures established and described in the
prototype studies were employed. These procedures are summar-
ized as follows2
(1) Forming
(a)
Receiving inspection and part identification?
(b) Preheat part and dies to 70040000F for the A70 shapes
and 1200 to 1400?F for the AllOAT parts
(c) Form to 360 degree ring,,
(d) Trims reheat and reroll to required print dimensions.
(a)
Inspect and prepare ring ends for welding.
(2) Welding
(a) Cut back thin segment 0d25 inch to retard heating of
this area during flashing?
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(b) 0.1411fy machine settings,
STAT
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VI. DISCUSSION (continued)
(c) Meld (see Table XI through XII for weld machine
settings).
(d) Stress-relieve (AMS 7498)0
(e) Inspect and remove flash (x-ray).
(3) Sizing
) Preheat work to the range of 700 to 12500F (oil
dag may be used as a lubricant),
(b) Expand to print dimensions (2 to 3% for A70 and
li% expansion for AllOAT).
(c) Inspect and ship.
Photographs of rings produced in this manner are shown
in Figure 85.
The manufacture of a ring from an extruded Section re-
quires approximately 30 minutes of machine time. This
is distributed amont the three operations as follows
Forming 20 minutes welding 5 minutes, and sizing 5
minutes. ,
(4) Inspection of Rings
Inspection layout templates were made for each ring.
A typical layout is shown in Figure 86 for P/N 226962.
As indicated in this layouts the detailed part cross=
section was scribed within the part configuration at
the weld area and 90 degrees from the weld. In general,
most of the rings cleaned up to the detailed part config-
uratiom For some of the A70 rings, which showed heavy
striations due to the run-out guides, the detailed part
cross-section was not obtainable however, these shapes
cleaned up in machining to the final assembly dimensions.
Metallurgical Evaluation
(5)
In addition to the tensile tests perf
welding machine settings, tensil
finished sized rings. The
sented in Table Xliii
36
rmed to qualify, the
e tests were performed on
results of these tests are pre-
VI. DISCUSSION (continued)
Tests were performed on both the meld area and the
metal. All of the rings exhibited tensile proper-
ties in excess of the material requirements and
flash-butt welded ring requirements, AMS 7498.
c. Upsetting
Flanges were upset on both ends of six AllOAT tubes in the
same manner as that which resulted in a successful prototype
parts? The operational sequence follows:
(c)
Machine ends to desired dimensions, see Figure
Heat to 1900?F and upset 1st stage on 1st end.
Heat to 1900?F and upset 2nd stage on 1st end.
(d) Heat to 19000F and urset 3rd stage on 1st end,
(e)
opratio.n b C and d for 2nd, end upset.
(f) Dimensional Inspection
65.
On four of these shafts fairly distinct folds were detected
on visual examination. While the remaining two shafts did
not have a visible fold indications penetrant die inspection
revealed folds on both of these shafts. These laps were
sufficiently deep to preclude their removal by machining the
inner diameter to finished size. Consequentlys repair weld-
ing was performed, This is discussed in greater detail in
the next section.
It is not clear as to the exact cause of the re-occurance of
the lap in the third upset pass. The presence of scoring marks
on the inner diameter of the tube which could not be removed on
machining of these shafts may have helped to contribute to this
lap
Manufacture of Assemblies
The four sheet metal assemblies for which the detail rings were
manufactured were shown previously in Figure 11 through 14. The
following summarizes the various flanges associated with each
assembly and the assembly vendors.
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STAT
1
STA
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VI. DISCUSSION (continued)
(c) Meld (see Table XI through XII for weld machine
settings).
(d) Stress-relieve (AMS 7498)0
(e) Inspect and remove flash (x-ray).
(3) Sizing
) Preheat work to the range of 700 to 12500F (oil
dag may be used as a lubricant),
(b) Expand to print dimensions (2 to 3% for A70 and
li% expansion for AllOAT).
(c) Inspect and ship.
Photographs of rings produced in this manner are shown
in Figure 85.
The manufacture of a ring from an extruded Section re-
quires approximately 30 minutes of machine time. This
is distributed amont the three operations as follows
Forming 20 minutes welding 5 minutes, and sizing 5
minutes. ,
(4) Inspection of Rings
Inspection layout templates were made for each ring.
A typical layout is shown in Figure 86 for P/N 226962.
As indicated in this layouts the detailed part cross=
section was scribed within the part configuration at
the weld area and 90 degrees from the weld. In general,
most of the rings cleaned up to the detailed part config-
uratiom For some of the A70 rings, which showed heavy
striations due to the run-out guides, the detailed part
cross-section was not obtainable however, these shapes
cleaned up in machining to the final assembly dimensions.
Metallurgical Evaluation
(5)
In addition to the tensile tests perf
welding machine settings, tensil
finished sized rings. The
sented in Table Xliii
36
rmed to qualify, the
e tests were performed on
results of these tests are pre-
VI. DISCUSSION (continued)
Tests were performed on both the meld area and the
metal. All of the rings exhibited tensile proper-
ties in excess of the material requirements and
flash-butt welded ring requirements, AMS 7498.
c. Upsetting
Flanges were upset on both ends of six AllOAT tubes in the
same manner as that which resulted in a successful prototype
parts? The operational sequence follows:
(c)
Machine ends to desired dimensions, see Figure
Heat to 1900?F and upset 1st stage on 1st end.
Heat to 1900?F and upset 2nd stage on 1st end.
(d) Heat to 19000F and urset 3rd stage on 1st end,
(e)
opratio.n b C and d for 2nd, end upset.
(f) Dimensional Inspection
65.
On four of these shafts fairly distinct folds were detected
on visual examination. While the remaining two shafts did
not have a visible fold indications penetrant die inspection
revealed folds on both of these shafts. These laps were
sufficiently deep to preclude their removal by machining the
inner diameter to finished size. Consequentlys repair weld-
ing was performed, This is discussed in greater detail in
the next section.
It is not clear as to the exact cause of the re-occurance of
the lap in the third upset pass. The presence of scoring marks
on the inner diameter of the tube which could not be removed on
machining of these shafts may have helped to contribute to this
lap
Manufacture of Assemblies
The four sheet metal assemblies for which the detail rings were
manufactured were shown previously in Figure 11 through 14. The
following summarizes the various flanges associated with each
assembly and the assembly vendors.
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STAT
1
STA
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VII. REFERENCES
?
1. Reynolds, J. E., Ogden, H.R. & Jaffee, R. J., "A Study of the
Air Contamination of Three Titanium Alloys", TML Report No. 10,
Titanium Metallurgical Laboratory, Battelle Memorial Institute,
Columbus, Ohio, July 1955.
Quarterly Progress Report No. 3, "extrusion of New Titanium
Alloys", Contract No. AF 33(600)28322) Submitted by ?z:rvey
Machine Company to Wright Air Development Center) June 1955.
3. WAD Serial Report No. 2006) "Titanium Manufacturing Methods
Development - Part I", Quarterly Progress Report No. 1,
Contract No. AF 33(600)30262, Submitted to .Air Materiel
Command & Wright Air Development Center, August, 1955.
WAD Serial Report No. 2110) 'Titanium Manufacturing Methods
Development, Part I", Quarterly Progress Report No. 2., Contract
No. AF 33 (600)30262, Submitted to Air Materiel Command & Wright
Air Development Center, November, 1955.
WAD Serial Report No. MP.0046, "Titanium Manufacturing Methods
Development, Part I", Quarterly Progress Report No. 3., Contract
No. AF 33(600)30262, Submitted to Air Materiel Command & Wri
Air Development Center, February 1956.
ght
6. WAD Serial Report No. MP.00-31) "Titanium Manufacturing Methods
Development, Part I") Quarterly Progress Report No. 4., Contract
No. AF 33 (600)30262, Submitted to Air Materiel Command & Wright
Air Development Center, May 1956.
WAD Serial Report No. MP.00-461 "Titanium Manufacturing Methods
Development, Part I", Quarterly Progress Report No. 5., Contract
AF 33(600)30262, Submitted to Air Materiel Coumand & Wright Air
evelopment Center, August 1956.
WAD Serial Report No. MP.00-74) "Titanium Manufacturing Methods,
Part I", Quarterly Progress Report No. 6, Contract No. AF 33(600)
30262, Submitted to Air Materiel Command & Wright Air Development
Center, November 1956.
WAD Serial Report No. MP.00-93) "Titanium Manufacturing Methods
Development, Part I") Quarterly Progress Report No. 7., Contract
No. AF 33(600)30262, Submitted to Air. Materiel Command & Wright
Air Development Center, February 1957.
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STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VII. REFERENCELSCont
10. WAD Serial Report No. W.00409) "Titanium Manufacturing Methods
Development) Part I") quarterly Progress Report No. 8) Contract
No, AF 33(600)30262) Submitted to Air Materiel Command & Wright
Air Development Center) May 1957.
11. Final Report on "Titanium Manufacturing Methods Development"
Submitted by Metals Processing Division to Wright Aeronautical
Division) January 1957.
?
TABLE.;- D.TMFNSIONAL IUP.g1pY,REPORT FUR
i
T
SEV.ERAI,t7i6U5LILY4FXTRUSIONSuFiii2269?.11
8'41
I-4-f
Iv 1
1\1:1111ri
.....
__.
Required
Location
Billet No,
Billet No.
Billet No.
Billet No.
Design.
' of
A52-1
A52-2
A53-7
A53-8 '
Dimension
Inspection
Ext. Dim,
Ext. Dim.
Ext, Dim,
__ ....._
,
Front
2.765
2.798
2.781
2.734
,A,
2.737 /.06
Rear ?
2.815
2.785 2.750
2.718
-.03
Variation
A078
71.061 /.044
...019
Front
.576
.564 .562
.567
.561 L.03
Reer
.590
.575 .562
.568
Variation
/4029
/.014
/.001
/.007
Front
.260
.227
.235
.237
C
.220 b02
Rear
.280
.227
.230
. .233
Variation
/.o6o
/.007
/.015
/.017
Front
.268
.264
.265
.269
D
.259 b02
Rear
.283
.266
.266
.267
Variation
7/.024
{.007
A007
71.010
Front
225
.209
.214
..211
.197 i',..02
Rear
.267
.215
.215
.208
.Variation
/470
'.Oi8
A018
/.0.14
Front_
.487.
.470
.469,
.480
462 Z'..03
Rer
. .518
.465
.484
.479
Variation_
/'.056
A008
/.022
/.018
?
Front
1.052
1.040
1.042
1.055
1.037L03
Renr'
1.065.
, 1.045
1.048
1.058, '
?
Variation
/'.028
A008
74.011
/.021.
Front
.250
.243
.234
.239
.231L.02.
Retir
284
.241
.234
.245
Variation
/.053
/.012
/.003
/.014 .
Front:
. 1.202
1.l88
1.179
1.188. -
1.174Z.03
Rear
' 1.220'
1.201
1.188
1.191
W.riation
71.04
A027
7c014 ,
A017
' ?
* ..n.
STAT
.11,1
STAT
14.3
Declassified in Part-Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
??????????????????????????????????? ???????????????????? ???????????????????????.*.....141?11. ???????Ybeid0 do ?????????????????????????????????????? ????????????????? ??? re I ? .1 ? ?????????? ? ? ??? ? 4???????*?????????Y ???????????**????????????????? wow. HMV. 1.1 ? ?? ? l? I
TABLE II. -DIMENSIoNAL INSPECTION REPoRT FOR
SEVER4 PRUToTYPE EXTRUSIONS OF P 226962
Required ikocation
Design : of
Dimension ; Inspection
??????????????*?????
A 1.410L.03
B .220L02
.435/.03
r
D ..395/.03
-.00
.265/.02
- o
Front
RPar
Variation
Front
Rear
Variation
Billet No
!A-53-5
Ext. Dim.
1.422
1.423
/.009
.229
.232
/.012
Front .446
Rear .444
Variation
Front
Rear
Variation
Front
? Rear
Variation
1.406
1.406
/.011
.229
.232
-.036
Billet No. Billet No, Billet No. Billet No.i
A-53-6 A64-1 A64-2 A137F
Ext. Dim. Ext. Dim. Ext. Dim, Ext. Dim.
1.418
1.419
/.009
.223
.221
72.003
1.402
1.408
.008
.218
.219
-.002
.438 .436
.441's .435
71.006 71.001
1.437
1.432
/.042
.287
.292
-.027
4)4
1.402
1.404
/.009
.273
.280
.015
1?????????????
1.410
1.410
.000
.230
.230
.444
.440
71.009
1.428
1.428
7/.033
.282
.281
72,017
1.419
1.424
7/.014
.235
.237
017
.442
.454
/.019
1.408
1.412
/.017
.281
.296
/.031
TABLE II DT.MENIp4L.INSPECTION.REPORT FuR
SEVERAL PRgTOTYPE EXTRUSIONS Ut P 2269 6
Required I LOCPtioft
Design 1 of
Dimension 1 ,Inspection
Font
1.100b03 Rear
;Variation
Front
.178L.02 Retr
iVariation
Front
.298b02 Rear
Variation
Front
.201b02 Rear
Variation
Front
.9877/603 Rear
-.00 Variation
.?????????????????????????????
A
Billet No Billet No.
A64-3 A64-4
Ext. Dim. Ext. Dim.
Billet No.
A64-8
Ext. Dim.
?????????????
Billet No,
A64-9
Ext. Dim.
1.103 1.106 1.115 1.128
1.112 1.109 1.123 1.137
/.012 /.009 /.023 7/.037
??????1
???????????????????????????????:::1
Billet No.
A-136F
Ext. Dim.
1.105
1.122
/.022
.187 .130 .188 .194 .185
.185 .189 .193 .195 .189
A009 /.012 A.015 /.017 71.011
.313 .312 .313 .321 .308
.315 .319 .318 .317 .312
/.0/7 71.021 71.020 /.023 /.014
.223 .219 .230 .208 .210
.227 .236 .240 .215 .210
71.026 /.035 71.039 14.014 /.009
1.002 .995 1.101 1.022 .992
.994 1.002 1.105 1.025 1.005
/.015 710.115 710.118 /.038 1.018
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
STAT
A
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
*MOO .1.????????????OMMO.....11.0?????
TABLE IV - DIMENSIONAL INSPECTION REPORT FUR
SEVERAL Pffiliniiq EXTRUSIONS uF FIN. 2?.161
Required
Design
Dimensions
.457 / o2
-.00
1.732 / .06
- .03
Location.
of
Insoection
Billet No.
A 53-5
Fxt. Dim
Billet No, Billet. No. Bil:!_et No.
A53-6 A64-1 A64-2
Ext Dim. Ext. 'Dim. Eat, Dim,
Front
ReEr
Variation
Front
Rear
VariEtion
Front
.304/.015 Rear
Variation
1.884/ .06
-.03
1.244603
Front
Rear
Variation
Front
Rear
VEriation
.467
.460
1.750
1.765
71.033
.324
.325
.021
1.906
1.906
/.022
46
.472 .457 .464
.470 .455 .466
/.015 -.002
1.789 1.751 1.776
1.792 1.767 1.782
/.035 /.050
.325 .319 .325
.321 .317 .323
/.021 /.015 /.021
1.875 1.898 1.892
1.875 1.896 1.891
-.009 7L.014 ,/.007
1.247 1.248 1.245
1.246 1..24h 1.268
7t.003 /.004 /.024
?????????????ftwaffterft....II ???????fteftft. ft ft.? r,......?????, moore....1 ftftftft...???????????ftwoo.?....??????????
TABLE V - DIMENSIONAL INSPECTION REPORT FOR
IO PN
110111111111101111111110W
I- - A --ON
13,
.DJ?-
MOM P ? ' IM /1.1.1.101..111.0.11.......11.1.1.1.11111.1?191MIIIMMOM MIMOIMMI111.1.1......, I .
,1100.1111?11?010101.1.01/ Mb ft ft I.OM.I.OF tad', , 1 P 1,, MI Po II .00 IOW MO ? ? P 01.10.11???????11111111MMIIMow I NM. NM1.4.011111 ?????11/1101.111?11?1?00.1TIMMINIftIONIIIMMINft Ir.. Ma 11.11$01 ft 1.04? 1111.1.11?11
IIII?ft???ftet
Required Location
Design of
Dimension Inspection
?SaHflNp? 'ASP. 11,i...to HOIONIVOMS.ft I IP/ .11.11,11
1,133.03
Front
Rear
Variation
Front
1.085A,03 Rear
0100 Variation
Rear
.500.015 Front
-.000 ! Variation
! Front
.400/4.015 Rear
-.000 Variation
Front
.140.015 Rear
-.000 Variation
Billet No
A53-9
Ext. Dim.
.0.a?114?1?1111111.....411.1ft
1.083
1.093
-$050
1.078
1.084
.007
.400
.500
-.010
.400
.399
.115
.144
,L.025
Billet No.
A64-3
Ext. Dim.
vane ,??????.T.1.1.1. P.. ,
1.127
1.135
/4.002
eoo6
1,092
1.193
.008
.503
.502
A.003
0418
? .415
11.018
.150
.146
A.010
Billet No
A64-4
Ext. Dim.
Pm
1.140
1.148
1.215
1.203
.030
.546
.538
.0146
.426
.438
A038
.149
.176
Billet No
?A614-8
Ext. Dim,
??101.60.1*1,11TOOMMInlft?ftftftft?
1.132
1.135
A002
1.125
1.108
A.040
.559
.554
.059
.458
.459
/4.059
.111
.162
.022
Billet No.
AS4-9
Ext. Dia.
ftlft????????ftwl. ? 111?1??ftlInftak ? 41.011ft? 1,0111.1
1.162
1.136
/1.029
1.042
1.094
J4.009
..043
.516
.531
X.031
0464
.464
/.064
.154
.189
M149
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
S.STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE VI - DIMENSIONAL INSPECTION REPORT FOR
E L 0 YPE E U IO 0 PN 1?9??
?????00.0.? ???????
Required
Design
Dimension
.980.03
.369/L.02
Location
of
Inspection
Front
Rear.
Variation
Front
Rear
Variation
Front
?330A.03 Rear
.Variation
Front
.174A.02 Rear
Variation
Billet No.
A64-3
Ext. Dim.
.996
.993
.398
.400
A031
03614
.363
A.0314
.185
.190
48
Billet No. Billet No.
A614-4 A614.8
Ext. Dim. Ext. Dim.
.980 1.o48
.981 1.052
A.072
.400 .4140
0430 .14146
,t.061 A.077
.368 .380
.361 .378
It.o38 A.050
.205 .238
.2)41 .260
.0167 A.086
Billet No.
A614-9
Ext. Dim.
1.074
1.093
/.113
.474
.453
.406
.437
.274
.275
/.101
TOLE VII
AS EXTRUDED TENSILE PROPERTIES OF P/N 226961 MAXIMUM ENVELOPE
Billet No. Ultimate
osi
OWV104Wommoloormem....iumws0111~
411111111111.01.40.10?WVIIIIMal
Required 80,000
A 514 100,400
99000
989600
101,200
AVG* 99,500
A 51-3 100,800
101,100
107,200
107,100
AVG ? 1049050
A, 51-4 1029400
103,300
102,000
102,000
AVG. 1020425
A 514 103,000
101,800
? 101,200
? 101,300
AVG. 1019825
A 51-6 102;400
120,1400
102,000
102940
AVG k 107,300
Certified
itysica1 99,800
Properties
EXTRUDED AT VARIOUS TEMPERATURES
Yield
psi
002f, Offset
70,000
'79600
78000
78,000
8oMo
79,000
7140660
72214.0
8196o
79,800
77,190
82,800
829000
819400
809800
81,750
8od400
799700
791,200
78,000
79,325
79,200
82,200
79,200
829080
80,670
78000
STAT
Elongation Reduction of Area Approx.*
Extrusion
%?F
15% MinL
30% Min.
2402 2903
2402 3o03
24.2 2903
2462 2903
2462 2943
26014 4207
2701 4100
2503 35.8
26014 3701
2603 39.6
2507 4006
2507 4402
2507 4302
25,0 4208
2505 424,7
24.2
25.7 3804
2500 3903
250o 4100
2409 39.2
2402
26.4
2305
2604
2501
2109
3705
3902
4503
4108
3i3
*Note: Indicated extrusion temperatures include temperature drop due to
transfer from furnace to press?
1700
1600
11450
1500
1500
, .
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 CIA-RDP81-01043R002500180004-7
TABLE VIII
THE TENSILE PROPERTIES OF A-70 TITANIUM FLANGES oprommummt
Part No.
4IIIMPWIIINVONNONOSIIIRSVOIC
P/N 226956
P/N 226961
Pfil 226962
P/N 226963
P/N 226964
EXTRUDED WITH A 15500F BILLET PREHEAT TEMPERATURE
Test
12.111.
RT
RT
RT
RT
650
650
RT
RT
RT
RT
RT
RT
650
650
RT
RT
RT
RT
RT
RT
650
650
RT
AT
RT
RT
650
650
RT
RT
?RT
RT
650
650
U4T4S., 0.2% Elong. % R.A0 % ?Position* Comment
121212.. IPA/.
106,3o0
106;400
106,000
106,000
47,200
318,0800
1060100
1049900
1060000
106;100
1070100
106,100
4495oo
414700
104500
loo9000
1030mo
lovoo
lot000
lo5p7oo
46/2oo
4154000
1O3 700
lol000
lo3i600
102 700?
45,040o
42xmo
106ploo
lo6Aoo
10791oo
44s)000
449500
85;700
83,600
81000
83;000
32,100
23;600
CC CIO
K,600
8550?
85joo
149600
99500
78,500
78,200
82,500
8Mioo
30p 800
11000
? 80s400
82s3oo
? 82,800
82,900
220100
219400
84,400
84,600
85,500
84,600
239500
21,900
26,7
23.6
23.0
2505
3549
32.1
179
20,9
2$05
2503
2467
266o
3905
3904
140o
2o04
23
25
22
23
36
37
2146o
2366
238
2400
3700
3703
2408
2207
25.5
25014
4002
4804
50
4192111111.111111,111b0MIIMIO
45.2
44.2
32,5
445
64,6
6706
4305
53J
4203
4305
4105
4505
620o
5203
4305
4303
3904
3968
?3908
3965
5241
52.7
38t9
4145
39,5
4107
5308
531
4206
4106
450o
4400
6202
6006
A
A
A
Indications
bf poor tempera-
ture controlo
A
A
A
A Extensometer
A malfunction
A
A
A
A Extensometer
A ?Malfunction
A
A
A
A,
A
A
?
Declassified in Part - Sanitized Copy Approved for Release
TABLE ELIContodl
THE TENSILE PROPERTIES OF A-70 TITANIUM FLANGES (OPTIMISTIC ENVELOPE
EXTRUDED'WTrH A 1550?F BILLET PREHEAT TEMPERATURE
Part No. Test ? M.S. 0.2% YoSo Elong. % R.A0 % Position* Comment
Temp. lull. (psi)
STAT
........
P/N 226966
AMS 4921
RC A-70
RT ? 102,300
RT ? 96,9100
RT 100,300
RT ? 96,100
650 142,600.
650 410.00
650 Limoo
650 )40, boo
RT 8moo
'MCC>
COM
CIO .10
alt,
? 19?2
17.0
18.2
230
3505
3066
3667
ito05
70,000 15
650 hoil000 25,000
MO 0
?3808
4208
4406
4109
?6307
637
6L8
6005
NO NCI
Specification
Rem Cru Data
* Specimens from positions marked A are standard tensile -.25201 diameter - ? test
specimens.
Those from positions marked B are sub-standard tensiles -.15000 diameter? -
test specimens. ?
The locations these specimens are taken from are indicated in Figure 31.
(:??
STAT
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
TABLE VIII
THE TENSILE PROPERTIES OF A-70 TITANIUM FLANGES OPTIMISTIC ENVELOPE)
EXTRUDED WITH A 1.5.500F BILLET PREHEAT TEMPERATURE
Part No.
P/N 226956
Test ILLS., 002% Y.St Elong. % R.A4
...!TeL 12E11.
NICVMONNIIIPITOW11404,60
RT 106300 85;700 2647
Fa 1069400 839600 23.6
RT 1069000 81,000 2340
RT 1069000 839000 2505
650 479200 329100 3549
6050 AM) 2.360o 32.1
RT 1069100 17,19
RT 1049900 MC 2009
P/N 226961 .11T 1660sl000 86400 2565
RT 106400 85,95oo 25.3
-RT. 107400 85400 2407
RT 1069100 85,100 2660
650 14495oo 149600 3965
650. ,1447.00 99500 3904
11.01s500 ? 14.0
RT 100,000 2004
et 226962 'RT 1039000 78,500 23
RT. 103,000 7820p 25
RT 1049700 82,500 22
RT 105's7Oo 80,800 23
60.50 469200 10,800: 36
650 46,000 18,100 37
0 226963 RT 103/00. 80s400 24D0
RT 104-s000' '82300. 23.6
RT. 103600 829800 23.,8-
RT . 1029700 829900 2400
650 45,100 22,100 37.0
650 42,000 219400 370
TO; 226964 AT .106400 84,9400 2408
RT 106400 849600 2267
RT io4800 85s15oo 2505
AIL ?1p7mo 646o0 2504
650 Wow
2
65(1 . 44s5op 21'i? o?6 '1a13$
Position* Comment
45.2 A
4402
32.5 A
4105 A
6o06 A Indications
67,6 A le poor tempera-
4305?B ture control.
53J B
42.3 A
4305 A
4105 A
TABLE VIII Contod
THE TENSILE PROPERTIES OF A-70 TITANIUM FLANGES (OPTIMISTIC ENVELOPE)
EXTRUDED' WITH A 1550?F BILLET PREHEAT TEMPERATURE
Test U.T.S. 0.2% YoS. Elongo % RoA. % Position*
Temp. (psi) ,
RT 1029300 .. 12.2
RT 969100 .. 17.0
RT 100,300 .. 18o2
RT 969100 .. 23.0
650 429600 .. 3505
650 449100 .. 30.6
650 40,200 AC &ID 3607
650 )4O 400 Irt,110 14,5
RT 80s000 70s000 15
'Part No6
P/N 226966
AMS 4921
4545 A Extensometer RC A-70 650 4op000 ?259000 ....,
6200 A Malfunction
52.3 A
005 B
4303 B ?* Specimens from positions marked A. are standard tensile -.252* diameter - test
specimens.
3904 A Those from positions marked B are sub-standard tensiles -01500 diameter .
3968 A test specimens.
3908 A Extensometer The locations these specimens are taken from are indicated in Figure 31.
3965 A Malfunction
52,1 A
5207 A
38t9 A
4L5 A
39,5 A
4107 A
5308 A
531 A
4206 A
4106 A
4500 A
440o A
62.2 A
6006 A
3808 B
42,8
4406 B
4109 B
6307
63.7 B
6148
60.5 B
=IMO
MO '
Comment
Specification
Rem Cru Data
STAT
narlaccifiPrl in Part- Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Extrusion
Number
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE IX
TENSILE PROPERTIES OF AllOAT TUBULAR EXTRUSIONS
Condition Ultimate
Strength
psi
As extruded
1329000
139,000
Average 136,000
Extruded
Annealed
1500li hour
Average
2 As-Extruded
Average
Extruded gt
, Annealed
1500/1 hour
Average
131 000
1349000
1339000
1369000
1339500
1449000
1429500
143,000
1449000
11429000
113 000
1419000
142 000
1147,000
0,2%
Yield Strength
psi
? 127,000
1319000
126,500
1169000
117,000
119,000
129,000
120O00
130,500
130,500
130,500
136,000
1349500
131,000
131,000
?1319000
136,000
Elongation
1805
1805
18
17
16
14
14
14 35
18
18
Reduction
of Area
Remarks
29 Upset & pierced at
27 20000 - Extruded
at 18900 through
28 Reentrant Die
33 Upset & pierced at
31 20000 - Extruded
39 at 18900 through
35 Reentrant Die
32 Upset & pierced at
29 19000 - Extruded
at 18900 - through
18 ?305 1300 die-billet en-
cased steel sheath:
16
lb
43
1414
142
42
43
24
Upset & pierced at
1900? - Extruded at
18900 through 130?
die-billet encased
in steel sheath,
Certified data
from Rem-Cru
rtl
oi)
E-4
cf)
O00
? vO N
ON 0 4
It w
O M 0
O00
H H H
OVVII\N
NNNN
8 ? ?
N N
NICO kOg' 0%47)%4D ONM?ON ()NIA v:po
?
N N N N N N HNHN H ro.1
?$4
O000?
8 0 0 8 000 0000 0
N4Nm (1)0 no 0" C'. ko
co 'C) '0 N 08
?OONNO .ON N44 NNCO LANHH
ft w 0
ft ft
4 NO NO ?1' fg 0 4 P4 ON oN t... 'IA N 0 cry NO
ft w w ft w w 04?ft ft st ft
ON N. CO CO 0 CO N 0 c0 CO N. IA C.-. ON CO Nt's- NCiN
ie
z z HH
O000 00 00 001A 0000 00 00
Huot?-.0) olA ?o.N. ..../pqo OMNM MH kplA
00 00 Ct? 0 .N r4 IA 4
p.
OoNm4 ?40 *co mr-t? m0040 NON
0 CP\ ON 0 ilD\
H ift w A II% A A A A A A
H 4H 00 ON ON ON 0 ON 0 0
4010, 00r; qi, Htt0.2: rir-10,01. tre.../ as
0 ON M M
r-1 1-1
tv9.11;)
E4 E- :g01)
414 ,+4
MO
0000O
eri 'ri $.4 g4 bri
.0 .0
E-4 ega 40eN ee ea
E_401.
?
E-4
E-I
?
STAT
2 1
cy. ON
v? \O
N N
N ? N
53
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1-
TABLE -XI
CLEVELAND WELDING MACHINE SETTINGS AND BURN OFF LENGTHS
part Number ? 226956 226961 226962 226963 226964 226966 227594 227596
Material C.P.-70 C.P.-70 C.P.-70 C.P.-70 C.P.-70 C.P.-70 A-110AT A-110AT
Initial Die Opening 1-5/16 1-3/8 1-5/16 1-1/2 1-5/8 1-3/16 1-9/16
(inch)
Final Die Opening 1/2 1/2 1/2 1/2 3/4 1/2 1/2
(inch)
Flash Burn off 3/8 7/16 13/32 13/32 3/8 5/16 9116
(inch)
Upset Travel 7/16 7/16 13/32 19/32 7/16 3/8 1/2
(inch)
Upset Pressure 42,000 45,600 42,000 42,000 38,000 42,000 451600
(lbs.)
5.8 9.0
.041 .033
.0042 .0087
Voltage 6.87 5.6 6.87 7.5 5.6 5.18 6.87
Burn Off Length 3/4 1-1/8 1-1/8 1 1 3/4 1
(inch)
Flash Time
(sec.)
Initial Velocity
(in./sec.)
Acceleration
(in./sec.2)
6.6
.041
.0098
6.8
.041
.0098
6.8
.041
.0098
7.0
.033
.0073
6.0
.048
.0098
0
(D
0
CD
(/)
(/)
(D
I C
Part Number
Material
TABLE XII
THOMSON WELDING MACHINE SETTINGS AND BURN OFF LENGTHS
226956 226961 226962 226963 226964 226966 227594 227596
C C.P. A-110AT A-110AT
Work Overhang
R. H. 3/8 5/8 9/16 5/8 7/16 9/16 9/16 9/16
L.H. 3/8 5/8 9/16 5/8 7/16 9/16 9/16 9116
Initial Die Opening
(in.) 3/4 li 1 1/8 li 7/8 1 118 1 1/8 1 1/8
Die Opening AT "Ow
(311-)
Final Die Opening
(in.)
Current Cut-Off
After "0" (in.)
3/8 1/62 1/2 1(2 3/8 3/8 1/2
1/8 3/16 NR 3/16 1/8 3/32 NR
1/8 118 3/16 3/16 118 1/8 3/16
1/2
3/16
Flash Time
(sec.) 3 12 53. 7 1/2 5 7 5 1/2 5 1/2
Flow Valve NR 5 5 5 4 5 5
Clamn Pressure
(lbs.) R.H. 23,000 23,000 23,000 23,000 23,000 23,000 .23,000 - 23,000
L.H. 23,000 23,000 23,000 23,000 23,000 23,000 23,000 23,000
Upset Pressure
(lbs.) 20,000 30,000 20,000 30,000 12,000 12,000 213,000 242000
Tap Switch 1 P 85s 4 P 85 1 p 35 4 P 3 P
Burn Off Lengths - - 1 1/8 - - 3/4 1 1
,
Upset Area
(transverse
to shaft
axis)
Heat
Affected
Zone
(Longitu&-
inal speci-
mens)
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Ultimate
Strength
1369000
136,000
1379000
135,900
134,000
1339800
137,000
136,000
128,200
130,000
TABLE XIII
ENSIL PROPERTIES OF THE A110-AT UPSET FLANGE
Yield
Streaki Rala11921
8
10
11
11
15
15
9
10
10
Note & All specimens annealed 15009F/1i2hr/Wir Coo/
00'
56
Reduction In
Area
4105
43
37
33
28.6
28.1
31
29
34
28
Comments
CoarSe
PI
Relatively
Relatively
Grains
Fine Grains
Fine Grains
Coarse Grains-Shear fracture
Coarse Grains-Shear fracture
Shear Fracture
Shear Fracture
Coarse Grains-Shear fracture
Coarse Grains-Shear fracture
Ii
TABLE X/V- DIMENSIoNAL INy.ECTION REPuRT FOR
RS
SEVERAL PROUgIOLUTRUSIoNS OF P N 22 gr
Required
Design
Dimension
2.801
2.707
.687
.593
.346
.252
.354
.260
.323
.229
.588
.494
1.163
1.069
.357
.263
1.269
1.175
2.043
1.949
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
4,8A1
Location Billet No. Billet No.
of A/73-B A173-1
Inspection Ext. Dim. Ext. Dim.
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
2.767
2.800
.626
.600
.266
.261
.263
.263
.228
.225
.503
.515
1.088
1.082
.271
.264
1.200
1.204
1.980
1.986
57
2.737
2.734
.615
.610
.258
.257
.283
.271
.237
.237
.512
.511
1.086
1.084
.276
.264
1.195
1.200
1.972
Billet No. Billet No.
A173-F A173-B
Est. Dim. Ext. Dim.
2.745
2.750
.613
.608
.261
.264
.286
.283
.241
.236
.506
.499
1.103
1.100
.285
.280
1.210
1.208
1.977
1.980
2.770
2.768
.600
.607
,
STAT
t
6.4??????????????????????????
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XV - DIMENSIONAL INSPECTION TITPUjiT FOR
SEVERAL PRODUCTION .glIggf3i?:OF '-226956
Required
Design
Dimensions
A 1.195
1./31
.274
.210
.393
.329
.296
.232
E 1.082
1.018
Location
of
Inspection
Front
Re 6r
Front
Rear
Front
Rear
Front
Rear
Front
Rebr
Billet No.
A171-13
Ext. Dim.
1.157
1.156
.222
.223
.311
.342
.265
.265
1.015
1.035
Billet No.
A171-1
1.137
1.096
.206
.207
.305
.280
.200
.196
1.005
1.017
Billet No.
A179-F
1.164
1.167
, .207
.195
.311
.308
.243
VOW
Billet No
179-1
1.105
1.120
.157
.161
.286
.300
.210
.218
.980
.975
I ii
58
TABLE
FOR
XVI - DIMENSIONA4 INSPECTION
REPORT
uri hul
, Io:?2.
i' HA
...
SEVERAt-PROI5UTION EXTRUSIONS
t y C
1) f:
--4.
1
04--
_
Required
Location
Billet No.
Billet No.
Billet No,
Billet No.
Design
of
A172-11
A173-2
A172-F
A180-1
Dimension
IrIllpection
Ext. Dim.
Ext. Dim.
,
Ext. Dim.
txt. Dim._
Front
1.437
1.432
1.437
1.421
1.474
Rear
1.437
1.447
1.421
1.421
1.380
Front
.240
.238
.236
.234
.345
Rear
.233
.226
.227
.237
.251
Front
.439
.438
.439
?436
.499
Rear
.420
.419
.434
?414
.405
Front
1.421
1.428
1.421
1.421
1.490
Rear
1.437
1.429
1.437
1.453
1.396
Front
.281
? .288
.28/
.281
4391
Rear
.281
.275
.234
.281
.297
,
,
Declassified in Part - Sanitized Copy Approved for Release ?50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
59
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
r
).4
?
STAT
TABqjim 7 DIg;NSIpiiAL INSPECTION REPORT FOR
SEVEIRAL "EXTRUSI6N'S )ffl 226961
TABLE XVIII - DIMENSIONAL INSPECTION REPORT
IOR SEVERAL PRODUCTION EXTRUSIONS OF
6N 226966
Required
Design
Dimensions
Locption
of
Inspection
Billet No,
A172-B
Ext. Dim.
Billet No, Billet No,
A1724 181-B
Ext. Dim. Ext. Dim.
Required
Design
Di mensions
Location Billet No.
of 171-Fl
Inspection Ext. Dim.
Billet No.
171-F
Ext. Dim.
Billet No, Billet No,
171-1 171-B
Ext. Dim, Ext. Dim
6?
6?30:min
.340
.336
.168 .165
.150 .168
6?30 min 6?30 min
6?30 min 6?30 min
t. ?
6o
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
\
I ?
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
?????????????????????????.04=.1.0.10....?????
TABLE XIX DIM.ENST9NAL_LN.V.FCTT.10 REPORT _1
SEVERAL .p..Aglqp)J1 EXTRUS Sfl" .SIOAff ' _227594
Required
Design
Dimension
Loct.tion
of
In
Billet No.
A327-1
Ext. Dim.
Billet No.
A129-11
Ext. Dim.
Billet No.
A323-B
Ext. Dim.
1.335
1.251
B 1.329
1.255
C I 1.784
1.700
D .819
.735
.523
.375
.511
.427
320
284
Front
Rear
Front
Retr
Front
Rear
Front
Retr
Front
Rerr
Front
Retr
Front
Renr
1.250
1.260
1.250
1.245
1.680
1.700
.765
.781.
.438
.436
29?
28?301
62
1.252
1.249
1.260
1.240
1.695
1.695
.781
.765
.415
.409
.434
.434
30?30'
0301
1.249
1.243
1.240
1.240
1.700
1.695
????????
.765
.796
.410
.409
.431
.428
29?301
30?30'
Billet No.
A327-T
Ext. Dim.
1.256
1.237
1.259
1.264
1.696
1.700
.796
.796
.416
.414
.445
.443
30?
30?30e
TABLE X)( D.ImwAmAL.IwEemp REPORT _JR
SEVERAI5DUCTIpITEXWg0gFi?F 22726,
?????????????????????????????????????, ???????????????P ? I ?
Required
Design
Dimension
?????? ...?????????? ?????,.???
1.586
1.502'
1.227
1.153
.408
6334
.492
?418
E 24?301
20?
Location
of
Inspection
Front
Rear
Front
Rear
Front
Rear
Front
Re sr
Front
Rear
Billet No.
A215-F
Ext. Dim.
1.515
1.508
1.160
1.168
.340
.344
.428
240
21?
Billet No. Billet No,
A2/5-B A149-F
Ext. Dim, Ext. Dim.
1.500 1.485
1.483 1.520
1.145
1.140
.330
333
.4.07
.410
23?301
24?301
1.180
1.162
Billet No.
NO Mb gip .
Ext. Dim.
MOWN
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE La - DIMENSIoNAL INSPECT.IoN.REPu_RT FOR
SEVE.RAL_PAvDUSTIoN EXTRU:SIQNS oF_VN 226.970
ACTUAL DIMENSIuNS
LOCATION
I.D.(INCR)
FRONT REAR
FRuNT
FRONT MI
LENGTH
(FFF.T)
4.978 5.024
4.980 5.005
.690 .680
.695 .610
.680 .660
.690 .670
t
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XXIII
THE TENSILE PROPERTIES UF EXTRUDED A-110-AT PRODUCTION TUBING FROM FORGED BILLETS
Ultimate
Ltanat
130,200
126,000
b) Sub-Standard 130,200
(longitudinal) 132,000
Le
a)Standard
(longitudinal)
b)Sub-Standard
(longitudinal)
11.7
13.6
129,000
127,000
133,000
133,200
117,900
116,800
15
14
10.6
1302
Flange
a) Standard
(transverse)
b)Sub-Etcndard
(tvlirwr;ie),
139,000
136,000
139,500
140,900
131,000
133,000
126,200
125,200
15
15
10.9
9.8
10.3
10.3
29
37
33
32
29
28
Coarse grain
Fine groin
Coarse grain
11 U

\
Declassified in Part - Sanitized Copy Approved for Release ? 50 -Yr 2013/09/09 ? CIA RDP8
04-
6
Declassified in Part - Sanitized Copy Approved for Release @ 5 -Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XXIV.
THE TENSILE PROPERTIES OF THE WELD SECTION AND BASE METAL OFJURMED AND WELDED _RINGS
Ident, U.T.S.
A11-B-7-1 108,200
-2 101 000
A173-2-3-1 111,100
-2 114,100
A179-1-3-1 /059300
-2 106,000
A179-1-4-1 104,200
-2 1029800
A181-F-8-1 107,000
-2 107,700
A218-F-5-1 1119800
-2 104,000
1100.111.
41.11111111.12.
1.031.m.
MCP 0=11
mots MN
ONO
a.-
85,500
93,000
88,600
a) Veld joint within the gauge length
% EloPEElla
1403
1703
18.9
18
19.4
17
1409
17,7
24
17
28.5
18.2
1.1111. Comments
40 Weld
3103
40.6 Weld
4305
40 Weld
4105
32.8 Weld
25
4405
46.5 Weld
45.4 Weld
47.5
4
YULE XXV
.4114.4:24ULARffiggiagsWaNTAXTURINGMELInitTigLIIVIM TIOdig WELDED BARSTuaq
TO EXTRUSION UN THE BASIS OF MATERIAL UTILIZATION
Part
No.
Part &
Assembly
Name
Finished
Detail Rough Weight(lbs).
Weight
jbnjConventional rusiot
226966 Fiange-Combusiion 1.0
Chamber Heat 8hie1d
226962 Flanges, Front,
226963 Rear & Brace-Rear
226964 Main Bearing Sup-
port Cone
506
308
3.0
226956 Flanges, Front & 2.8
226961 Rear-Rear main Bear-4.1
ing Vapor Duct
111111
227594 Flange, Front &Rear 4
227596 Turbine Stator B1sde5G4
.8
Support
226970 Shaft, Turbine 19
Rotor-Front
3.0
2.2
906
5c) 8
600
8.4 402
16,5 go3
a.
rib
8 0
902
69O. 3400
13008
7001
*Flash-Butt W elded Rings from barstock or forgings.
Mat,' Utilization
Factor
Conventional*txtrusion
045
.40
057
034
066
ON)
052
.33 .67
.25 .50
a.
.60
.59
.28 .56
STAT
Percentage
of
Weight
gAved
37
32
48
27
50
50
a.
a.
50
45.5
68
69
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
REAR MAIN BEARING SUPPORT CONE
COMBUSTION CHAMBER HEAT SHIELD
TURBINE ROTOR SHAFT-FRONT
FIG I- CUTAWAY VIEW OF THE CURTISS-WRIGHT J65 TURBOJET
THE TITANIUM PARTS AND ASSEMBLIES MANUFACTURED UNDER
THIS? PROGRAM.
Animminimin Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
\
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
4,570 DM,
AO *
86
/26-0-
FIGURE 2. PiN 226962 . Front flange4
Rear Main Bearing Support Cone
Assembly, Material T1-A-70
FIGURE 3. PA 226963 - hear Flange,
Rear main Bearing Support Cone
Assembly, Material T1-A-70.
'
t 32
FIGURE 4. P/N 226964 - Flange Brace,
Rear Main Bearing 8upport
Cone Assembly, Material Ti-A70
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
73
./
/ /
,20 ---->
N440.41pm
13 077
/3,CT2
"
it472
FIGURE 5. P/N 226956 - Front riange, hear
main bearing Vapor Duct Assembly,
Material T1-A7-70
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
./97
070
.3.ey
47g
?Zoo
14417
FIORE 6. P/N 226961 - Rear Flange,
Rear Main Bearing Vapor Duct
Assembly, material T1-A70
FIGURE 7, P/N 226966 - Fiange, Combustion
Chamber Heat Shield Assembly,
Material, Ti-A-70
P/4,
FIGURE 8. 0 227594 - hear Flange,
Turbine btator Blade bupport
Assembly, Material Ti-A110-AT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
75
H.38
YIGURE 9. ell 227596 - Front Flange,
Turbine btator Blade support
Assembly, Material Ti-A110-AT
1 .
STAT
?
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
76
E*4
0
4-1
?ri
$-i
(1)
+3
0
k
0
4-)
(1;
?rl
;-4
4-4
ct
riN 226970
P/N 22 6 96
P/N 6081148
RezIr main Bee,rino
b
support Cone 'Assembly
FIG.11- P/N 608118 - REAR MAIN BEARING SUPPORT CONE ASSEMBLY
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
77
!,I
i
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
111111
STAT
STAT
FIG I4 P/N 608569-TURBINE STATOR BLADE SUPPORT ASSEMBLY.
80
81
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
id
w
a,
:041,,rhot 4,0,4^t4,,,m'oPnrom
0,14$^0",',,vr?-?mm ?. A
'004h,1144004,;Iii
HORIZONTAL
FIG. 16(b)
TOP VIEW OF THE 12,000 TON EXTRUSION PRESS, NOTICE
THE BILLET IN POSITION TO BE TRANSFERRED INTO THE
CONTAINER.?
STAT
83
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
0
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIG. leo
CLOSE-UP VIEW OF THE BILLET IN POSITION FOR EXTRUSION
86
AG. 16 (f)- A BILLET BEING TRANSFERRED FROM THE FURNACE TO
THE BILLET LOADING ?TABLE
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
?
?
Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIG. 16(g)- AN EXTRUDED SECTION MOVING INTO THE RUN-OUT
88
TABLE
24
20
111... ? -4-* -0
for-C."
TEMPERATURE
?????
01.141111111.111111111110011111110
II
?1*-- 8"
CODE
? THERMOCOUPLE # I
0 THERMOCOUPLE # 2
631 THERMOCOUPLE # 3
SALT BATH SET TO CYCLING AT 1850?F.
24
FIGURE 17
TITANIUM BILLET H
12
TIME - MINUTES
voiliMmissffesMINISIMMANNISMIMINIIM=7=34
36 48
EATING CURVE FOR AN 8 INCH DIAMETER
ATED IN A SALT BATH TO I850?F
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
?89
STAT
STAT
NI,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
fiROMPEXTRUSION
MAX, ENVELOPE - 1/8" Average
MATERIAL - AmS 4921 &
WAD 7850 (C.
P. Titanlum)
AREA 1.60 in,
LENGTH 4F3 in.
VOLUME
WEIGHT - 3.07# per Ft.
ACTUAL SIZE
Notes Cross-hatched area indicates
finish-machined detail part.
FIG.I8-MAXIMUM ENVELOPE SHAPE FOR THE EXTRUSION OF P/11226961,
FLANGE, REAR MAIN BEARING VAPOR DUCT ASSEMBLY.
90
,22?*
PRopqm EXTRUSION
MAX. ENVELOPE - 1/8" Average
MATERIAL - AMS 4921 and IAD 7850 (C.P. Titanium
AREA 1.41 In.2
LENGTH ----148 In. ,
VOLUME 67.7 In.'
WEIGHT 2.71# per )'t.
ACTUAL SIZE
Note: Cross-hatched area indiceted
finish-machined detail part.
STAT
f
FIG.19- MAXIMUM ENVELOPE SHAPE FOR THE EXTRUSION OF PM226963,
FLANGE, REAR MAIN BEARING SUPPORT CONE ASSEMBLY.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
A
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
rjypi,optiripwvitlippyrypporpitypqriTlipplITIOTIrrN
?
FIG 20 PHOTOGRAPHS OF AN EXTRUDED
SECTION OF P/N 226961 SHOWING CROSS-
SECTION AND SURFACE QUALITY
4440
.030
P SIG
OPTIMUM ENVELOPE - Approx 1/32"
MATERIAL AMS 492 & WAD-7850 (C.P. Titanium
AREA 1.22 In
LENGTH - - 48 In
VOLUME
58'6 In'
WEIGHT - 2.34 lbs/ft
ACTUAL SIM
bit: Croup-hatched area indicates
finish-machined .detail part.
FIG. 21 - OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF P/N 226961,
FLANGE, REAR MAIN BEARING VAPOR DUCT ASSEMBLY.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
93
STAT
1101WW,04A4o64444.
,"?'7.7!)-;=?Ps;
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
?
PROPOSED EXTRUSION
OPTIMUM ENVELOPE
MATERIAL
AREA
LENGTH
VOLUME
WEIGHT
401
???
MN.
FIG. 22
?
Approx 1/32"
-AMS 491 & WAD7850 (C.P.Titanium
?43 In4
60 in. ,
25.8 In
.83# per ft.
ACTUAL SIZE
Note: Cross-hatched area
indicates finish-machined
detail part.
OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION P/N 226956,
FLANGE REAR MAIN BEARING VAPOR DUCT ASSEMBLY.
94
?
fLOPOSED
OPTIMUM ENVELOPE
MATERIAL - - -
AREA
LENGTH
VOLUME
WEIGHT
EXTRUSIoN
Approx 2/32"
AMS 4924 & WAD-7850 (C.?. Ti)
.88 In
721n 3
63.36 In
1.69 lbs/ft
ACTUAL SIZE
Notet Cross-Hatched area indicates
finish-machined detail oart.
FIG.23 - OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION
OF P/N 226962 FLANGE, REAR MAIN SUPPORT CONE
ASSEMBLY.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
pRoPpgp ExTpsioN
OPTIMUM ENVELOPE - 1/32"
MATERIAL
AREA
LENGTH
VOLUME
WEIGHT
mat tom Mo oft No
(eer)
,/52 4',
AMS 4921 & 1AD-7850 (C.P. Titanium)
1.11 In2
481n
23.i.33 les/ft
ACTUAL SIZE
o?a
/752."()
Notes Cross-hatched area indicates
finish-machined detail part.
FIG. 24 OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF P/N 226963
FLANGE, REAR MAIN BEARING SUPPORT CONE ASSEMBLY,
96
Declassified in Part - Sanitized Copy Approved for Release
UMEER.MNIENI
OPTIMUM ENVELOPE -
MATERIAL
AREA
LENGTH
VOLUME
WEIGHT -
OM all us IA
us
OM ON
Approx. 1/32"
AMS 4921 & 4AD-7
.60 1114
bo
In
n3
36
4.15 lbs/ft
4 oo
noir
1, 179
410 fi
50 (C.F. Titanium)
tfoso
//,u
toir
.000
-0-
SO 0
-I----
I
I
roarivemiff'
Ail
ACTU
4..oso
-'COO
0 09,6"
Note: Cross-hatched area
indicates finish-
machined detail cart.
FIG.25- OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF
P/N 226964, FLANGE, REAR MAIN BEARING SUPPORT CONE
ASSEMBLY.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
!, 020
.087,
PIN 226963
goelet Double Size
OPTIMUM ENVELOPE
PROPOSED _EXTRUSION
- Approx. 1/32"
AMS 494 & WAD-7850 (C.P. Titanium)
.26 in.4
60 in, or in 60" mults.
15.6 in.3
.50# per ft
P/N 226962
Adtual Size
Note: Cross-hetched
area indicates fir4_sh-
machined detail pnrt.
FIG.26 - OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF P/N 226966,
FLANGE, COMBUSTION CHAMBER HEAT SHIELD ASSEMBLY.
FIGURE 272.? SCHDIATIC DRAVING OF THE MULTI-OPENING DIE FOR THE EXTRUSION
OF ?/I'S 226962 AND 226963
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
P/N 225956
P/N 226966
P/N 226964
? FIGURE 2712. SCHEMATIC DRAWING OF THE MULTI-OPENING DIE FOR THE EXTRUSION ,
OF ?/N'S 226956, 226966 AND 226964.
100
STAT
FIG.28- PHOTOGRAPH OF A MULTI-OPENING EXTRUSION FOR
P/N 227594 AND ? PM 227596
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
101
Declassified in Part - Sanitized Copy Approved for: Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
PHOTOGRAPHS OF THE OPTIMISTIC ENVELOPE EXTRUSION 01
6961, 956 962, 963,964,AND966 MATERIAL Tu A70 EX1
TEMPERATURE, 1500 ?F.
102
Declassified in Part - Sanitized Copy Approved for Release
?
100
80
40
Condition: As Extruded
Extrusion Ratiot 33:1
TENSILE
11.10.11111?1111Mis11?11111101111.1.11110
0.2% YIELD
6rus.somrsomemn.
0
1
REDUCTION AREA
0
ELONGATION
1400 1500 1600
Extrusion Temperature -(?F)
FIG.30- THE EFFECT OF EXTRUSION TEMPERATURE ON
THE TENSILE PROPERTIES OF A70 TITANIUM
EXTRUDED TO THE MAXIMUM ENVELOPE SHAPE
OF P/N 226961.
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
103
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Fla31-CR0SS-SECTIONS OF THREE 470 FLANGES INDICATING THE LOCATIONS OF
STANDARD TENSILE - (0.250"DIA.) TEST SPECIMENS (A) AND SUB-STANDARD
TENSILE 1.150"DIA.) TEST SPECIMEN (B).
MAG. - APPROX I X
?????," ,' : ' - ''''4,11,r,'?. ?'.C.i yl.,,,,..,,? ...;',3iv.te? 0. fi,itsi ,,' A.. i,:' .1:,. .:;?,....:"...!..... -.:.,?:. .. - .-. :....i., ;4, . # .:. .., . .,?..,. ,..
ost'\.4%..04Sr/4`;Xittl1...*.iks.j.:? 1".14 ' i ..' ,*'..1,011.p;;.11.414"`J'%%.4041. .4. r...f.?,,- ts - .
."" ? ' ..."- ... 1/4.4.#0..'
r# ?.1.1. , ? , 4 , ? 1.4: .7.
' ? . ? ;?? . .",* ...74 ' m ,..':?? , " ? 4 ' r. ;fly ,:. I litIrtitY4'14^/:,?,)????e? 411cr..41:.!1,..;Rrc ..4. e.`'....."' 441,0'14.?.911i.g: .
:'411',??-?41_,1\-.-4 ' 4'4'i.".,-4....'N :Jo!. -"K?-? l'o!kt't,!7?1, ,:t.i4., 7e, u--:- 41. i
14.,..'''.,..?:'44,?:"47.....;...p,'."...4'146.:'..r:.,17.?.,..\.*' 4,-," , 75, j-...`,0(%:.....1,`-,,: . \,..". ,...., I' 1.,' :?:. 7., :": ; :71: ,' ,,I.. 161 , 1 }:.):. ,7:1 sat:;7 .":,....i,,..:::..
' - - . . . k ' ? ' ,ef ) ?,-;i. :ZA .? ......,,....;
.
...,,,,,.,.. , ?,?.:?.?.4...,?.?.;,,,..,.......?,.....1,........?,\?," ,,,. ? _v., ...,,4747: ,. '''' ,
.. we .,.,?7...., ? , -.5. ' - r. ' .4? V-Cit)i, 14.- i.(1'4 4. ,`' . ' '` `.0.1)1' .r.' ?:.......;..,.../ r". ..6 .0. '' " ........ 7 .. ...,:
%.;"..-...,, '/.t...::::,...'??1:.'..;:::...1?::::`;e-.7..-...:..,\N:11,...7. ,5.4'"7?.?Gt ti" .6 4 (7,.......e: .),..,''',/'..e?i,..,".....,,'
,......, :?,....?.-ii. -.. . , ? ...
4 'r....i
e\v,,, ,\;,,,,,. t.::,,:-. ,,,:\,......r4H...,,,,,,:"7...7.-;..?:-,....,::-..:::?...../.4."."?r.?
I Ie... '':'; 44. 4'4.4" ? ? 1 0.: ; ..,i
?
r.?:7?1\?4.? ::.',...:.?:,L. '' j.7:-'*?!;;Ns,' ..?.:i.cl' N' ?.:,....et.1;:: .. .,....., ? ..>ti4441/\,,,".), ''; 1.;:".:.?:?Nit?.)(? .,.,. ' 14.7$4:-??.'4' ''''\?:, '' ?;:. N .1 ..,..7,711":0
:>.1.1t., . " ???1 ? ?('Y / '4: 1.7'" . '1'.. e'.: V. 4 ., ' ' '? ? "*.-- . ;? ' .... ? ., ' ??' ? irj * ...L. ,A., - ?',,, .. (tCO3
'y'.%".N...S.'"' -. ?,.''',r'tt.'n),),P;':?'' '" . ? . ? ? ?,?-?.'' ''.'' * ,: ?? 'w '''-'-''''' ..'? - i 4 ' .?.1' '''' ? ' .1,''''. tz,?:' '?? .V. .t ?''. $:........ 1
. ,,,":?,'"41..,;;;4y.;?,.?.:,,-0-'' ' ,,,. 5: ?.1\'? "??.11.,????(- .?e I. *-;....,1" ,J: -' .,?.? 4, ?.... .11' ..1,;:l...7:1,4). ...C7itt.....j,,??,...,4 . ? .44.-';.....,-?
' ii?%/?..., .......,'''''.4?..-?.,,,.4...TA'''''' ..,?......".1'46 *,),4%**,..,W? . #.7,,,..7. #: .144*.tr???????,7'4 ?''' ?;:-.....k;??? ???????'. ?? ? ? ' ;21 ???? ?/- ?Oill'????'40.?11 ?1?....ss4."'?e.'..?'?,/ I "' ' ...' ? d?44.? -1 .
.;,,,t,,,:r.iti:', ` .? ` ,\?,,f/' ???v? ,? "?v? ? ? 4X\' \ ? c.. ,. \'\ ? \:. ? - ,,,,,,,."." ,.......,,,..,....,,,,?.,..7?4( N..,..,Pt; ,?.y. 7 . ':,..,,,ti,*?;;fv'":".? .
,
, .. \ : ? .,*, ,. ,,,, . . : ,?A__,. ? , .: /V:/??? _??? ?
:?ri. ' ? ?? .Y'.,.1,. "'t ? (1,41.;_.)' )... ,.)%4\."!,\\ , ; , .,,f-et,,..,/..4?. 2, ..1-.i. -...../ '''.-1'
.:-.,./.....Nt: . - ? 4.- -, ? . .../,. ' i.1'. ..?.. ? ,41, . , .z"',.?''''.:).'14
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...'70;:,'...;.:47(i7;;;;...:.,i?.,:.?4;iW.:77.-Z;4(ii;VP,;;?;?..).1'.4.4.''':;, ...*.'. %
APIY,,, .:'. ??? ?/. ? ....,"! 1.. ,...' ., . ? ".4., .!... t ? ...........r. F., , ,, ? ,,,,.. , , '. ...
....;? ...?????.,:'i, :,
.,....!-.-:,......";',2,;-i':"..:::1.s.;:'''..:.(...".H.:
..i' ::';;.?-Vi.7:f.j.:17?2....''''.:.;:;11.41$1-0..*4.,1*-';')4'.-.'\'').A1 *q1R:1'.'
i\,i'''AG'77)2.:40X-1.--
.,,,,.., .,..r.,?, \ .:,?, 4:.,..,...4,?1/4,N,,ietA,....,4...4,,.,,, -1,;,..,.7.::::.;,,i-pw- . ..........;? ,...,1%,...,4 .-.7 --1'..A4w e41,
FIG. 32 - PHOTOMACROGRAPHS a PHOTOMICROGRAPH OF A LONGITUDINAL
SECTION OF FYN 226956 (470 MATERIAL) EXTRUDED WITH A
BILLET PREHEAT TEMPERATURE OF I550?F.
Declassified in Part -Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
ETCHANT:
95 PARTS- i120
25 HNO3
HCL
- HF
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Fla31-CR0SS-SECTIONS OF THREE 470 FLANGES INDICATING THE LOCATIONS OF
STANDARD TENSILE - (0.250"DIA.) TEST SPECIMENS (A) AND SUB-STANDARD
TENSILE 1.150"DIA.) TEST SPECIMEN (B).
MAG. - APPROX I X
?????," ,' : ' - ''''4,11,r,'?. ?'.C.i yl.,,,,..,,? ...;',3iv.te? 0. fi,itsi ,,' A.. i,:' .1:,. .:;?,....:"...!..... -.:.,?:. .. - .-. :....i., ;4, . # .:. .., . .,?..,. ,..
ost'\.4%..04Sr/4`;Xittl1...*.iks.j.:? 1".14 ' i ..' ,*'..1,011.p;;.11.414"`J'%%.4041. .4. r...f.?,,- ts - .
."" ? ' ..."- ... 1/4.4.#0..'
r# ?.1.1. , ? , 4 , ? 1.4: .7.
' ? . ? ;?? . .",* ...74 ' m ,..':?? , " ? 4 ' r. ;fly ,:. I litIrtitY4'14^/:,?,)????e? 411cr..41:.!1,..;Rrc ..4. e.`'....."' 441,0'14.?.911i.g: .
:'411',??-?41_,1\-.-4 ' 4'4'i.".,-4....'N :Jo!. -"K?-? l'o!kt't,!7?1, ,:t.i4., 7e, u--:- 41. i
14.,..'''.,..?:'44,?:"47.....;...p,'."...4'146.:'..r:.,17.?.,..\.*' 4,-," , 75, j-...`,0(%:.....1,`-,,: . \,..". ,...., I' 1.,' :?:. 7., :": ; :71: ,' ,,I.. 161 , 1 }:.):. ,7:1 sat:;7 .":,....i,,..:::..
' - - . . . k ' ? ' ,ef ) ?,-;i. :ZA .? ......,,....;
.
...,,,,,.,.. , ?,?.:?.?.4...,?.?.;,,,..,.......?,.....1,........?,\?," ,,,. ? _v., ...,,4747: ,. '''' ,
.. we .,.,?7...., ? , -.5. ' - r. ' .4? V-Cit)i, 14.- i.(1'4 4. ,`' . ' '` `.0.1)1' .r.' ?:.......;..,.../ r". ..6 .0. '' " ........ 7 .. ...,:
%.;"..-...,, '/.t...::::,...'??1:.'..;:::...1?::::`;e-.7..-...:..,\N:11,...7. ,5.4'"7?.?Gt ti" .6 4 (7,.......e: .),..,''',/'..e?i,..,".....,,'
,......, :?,....?.-ii. -.. . , ? ...
4 'r....i
e\v,,, ,\;,,,,,. t.::,,:-. ,,,:\,......r4H...,,,,,,:"7...7.-;..?:-,....,::-..:::?...../.4."."?r.?
I Ie... '':'; 44. 4'4.4" ? ? 1 0.: ; ..,i
?
r.?:7?1\?4.? ::.',...:.?:,L. '' j.7:-'*?!;;Ns,' ..?.:i.cl' N' ?.:,....et.1;:: .. .,....., ? ..>ti4441/\,,,".), ''; 1.;:".:.?:?Nit?.)(? .,.,. ' 14.7$4:-??.'4' ''''\?:, '' ?;:. N .1 ..,..7,711":0
:>.1.1t., . " ???1 ? ?('Y / '4: 1.7'" . '1'.. e'.: V. 4 ., ' ' '? ? "*.-- . ;? ' .... ? ., ' ??' ? irj * ...L. ,A., - ?',,, .. (tCO3
'y'.%".N...S.'"' -. ?,.''',r'tt.'n),),P;':?'' '" . ? . ? ? ?,?-?.'' ''.'' * ,: ?? 'w '''-'-''''' ..'? - i 4 ' .?.1' '''' ? ' .1,''''. tz,?:' '?? .V. .t ?''. $:........ 1
. ,,,":?,'"41..,;;;4y.;?,.?.:,,-0-'' ' ,,,. 5: ?.1\'? "??.11.,????(- .?e I. *-;....,1" ,J: -' .,?.? 4, ?.... .11' ..1,;:l...7:1,4). ...C7itt.....j,,??,...,4 . ? .44.-';.....,-?
' ii?%/?..., .......,'''''.4?..-?.,,,.4...TA'''''' ..,?......".1'46 *,),4%**,..,W? . #.7,,,..7. #: .144*.tr???????,7'4 ?''' ?;:-.....k;??? ???????'. ?? ? ? ' ;21 ???? ?/- ?Oill'????'40.?11 ?1?....ss4."'?e.'..?'?,/ I "' ' ...' ? d?44.? -1 .
.;,,,t,,,:r.iti:', ` .? ` ,\?,,f/' ???v? ,? "?v? ? ? 4X\' \ ? c.. ,. \'\ ? \:. ? - ,,,,,,,."." ,.......,,,..,....,,,,?.,..7?4( N..,..,Pt; ,?.y. 7 . ':,..,,,ti,*?;;fv'":".? .
,
, .. \ : ? .,*, ,. ,,,, . . : ,?A__,. ? , .: /V:/??? _??? ?
:?ri. ' ? ?? .Y'.,.1,. "'t ? (1,41.;_.)' )... ,.)%4\."!,\\ , ; , .,,f-et,,..,/..4?. 2, ..1-.i. -...../ '''.-1'
.:-.,./.....Nt: . - ? 4.- -, ? . .../,. ' i.1'. ..?.. ? ,41, . , .z"',.?''''.:).'14
.0'),.,,?10'114) .. '' . ., . .
...'70;:,'...;.:47(i7;;;;...:.,i?.,:.?4;iW.:77.-Z;4(ii;VP,;;?;?..).1'.4.4.''':;, ...*.'. %
APIY,,, .:'. ??? ?/. ? ....,"! 1.. ,...' ., . ? ".4., .!... t ? ...........r. F., , ,, ? ,,,,.. , , '. ...
....;? ...?????.,:'i, :,
.,....!-.-:,......";',2,;-i':"..:::1.s.;:'''..:.(...".H.:
..i' ::';;.?-Vi.7:f.j.:17?2....''''.:.;:;11.41$1-0..*4.,1*-';')4'.-.'\'').A1 *q1R:1'.'
i\,i'''AG'77)2.:40X-1.--
.,,,,.., .,..r.,?, \ .:,?, 4:.,..,...4,?1/4,N,,ietA,....,4...4,,.,,, -1,;,..,.7.::::.;,,i-pw- . ..........;? ,...,1%,...,4 .-.7 --1'..A4w e41,
FIG. 32 - PHOTOMACROGRAPHS a PHOTOMICROGRAPH OF A LONGITUDINAL
SECTION OF FYN 226956 (470 MATERIAL) EXTRUDED WITH A
BILLET PREHEAT TEMPERATURE OF I550?F.
Declassified in Part -Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
ETCHANT:
95 PARTS- i120
25 HNO3
HCL
- HF
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
?.',Vti.ret'????????r I
rp- ? a ? ?x's--4-
\ 0.v)
) r r ? - ?? ' ' ? .*..., ai...
..t oni \..... . Q..?....itl:"TrOe'' ^ li l'...
'
.;,)- `.,-..6....4*Coe
v?., 44)/1 ,
? ..
????. !Ms. .4
erf ? ??
. 4/
r, ,.??? ? ? ,
k 7
-
Ye.-z.r?tr&cY'-' -41 L.7"
? (????;,_
,fc:c
n v
4??"e." " ? I ,;
?? 7
. ?.
""4-4
r\r" T ??:, ? EZ
?
? .
? .
. 17.6 :ije fi
"
? - ? .
1.11. 1,1r.
? .....e$:?4-4 ? ??????1'4'....;.1:77 J '7 A'
MAG. - 250 X
FIG 35
PHOTOMACR ?GRAPHS B PHOTOMICROGRAPH OF A
LONGITUDINAL SECTION OF P/N 226963 (A70 MATERIAL)
EXTRUDED WITH A BILLET PREHEAT TEMPERATURE
OF 1550?F.
FIG .36'- PHOTOMACROGRAPHS & PHOTOMICROGRAPH OF A
LONGITUDINAL SECTION OF PM 226964 (A70
MATERIAL) EXTRUDED WITH A BILLET PREHEAT
TEMPERATURE OF 1550 ?E
ETC HAN T
95 PARTS - H20
2.5 PARTS - H NO3
IS PARTS - HCL
1.0 PARIS H F
108
109
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
HOTOMACROGRAPHS & PHOTOMICROGRAPH OFA
'N 226966 (A70 MATERIAL) EXTRUDED WITH A
IL LET PREHEAT TEMPERATLE ? ?
HARDNESS SURVEY
DEPTH FROM SURFACE
.001"
.0041
.007"
?.010"
.013"
.016"
?.019"
.022"
.025"
.028"
.031"
.034"
CONVERTED ROCK-
WELL C
20.0
20.0
19.5
20.0
19.5
20.0
20.0
20.0
19.5
20.0
19.5
19.5
FIG. 38 PHOTOMICROGRAPH OF A CROSS-SECTION THROUGH THE SURFACE
OF A I500?F A70 EXTRUSION IN WHICH FREEDOM FROM SURFACE
CONTAMINATIONS IS INDICATED BY THE UNIFORM MICROSTRUCTURE AND?
HARDNESS SURVEY.
111
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
HOTOMACROGRAPHS & PHOTOMICROGRAPH OFA
'N 226966 (A70 MATERIAL) EXTRUDED WITH A
IL LET PREHEAT TEMPERATLE ? ?
HARDNESS SURVEY
DEPTH FROM SURFACE
.001"
.0041
.007"
?.010"
.013"
.016"
?.019"
.022"
.025"
.028"
.031"
.034"
CONVERTED ROCK-
WELL C
20.0
20.0
19.5
20.0
19.5
20.0
20.0
20.0
19.5
20.0
19.5
19.5
FIG. 38 PHOTOMICROGRAPH OF A CROSS-SECTION THROUGH THE SURFACE
OF A I500?F A70 EXTRUSION IN WHICH FREEDOM FROM SURFACE
CONTAMINATIONS IS INDICATED BY THE UNIFORM MICROSTRUCTURE AND?
HARDNESS SURVEY.
111
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
50'
10
I
? ? .?????????????
PROPOSED EXTRUDED SECTION 1/5 SIZE
MATERIAL (TITANIUM AellOAT '
SECTIONAL AREA 6.98
LENGTH (Addition incorpoisted 26 5/1611
VOLUME 183.665 cubic inch
WW1 30.121 lbs.
RED.
AREA
FIG. 42 EXTRUSION SHAPE FOR P/N 226970 - SHAFT, TURBINE ROTOR FRONT.
ELONG. . s .
1
?
FIG.4I - THE EFFECT OF ANNEALING TEMPERATURES AND
COOLING RATES ON THE MECHANICAL PROPERTIES
OF A70 TITANIUM EXTRUDED WITH A 1550?F
BILLET PREHEAT TEMPERATURE.
?
114
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115
?
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
? FOR
Plajiti26.222-Rol....01111LVT
B.2.7.9.1=aLlaza1aatt
1300 Included Anele Die
FIG. 43 DIE HOLDER AND SUB-ASSEMBLY FOR A RE-ENTRANT
ANGLE DIE AND A 1300 INCLUDED ANGLE DIE.
116
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STAT
117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
PROPOSED. EXTRUSION
OPTIMUM ENVELOPE -- Approx. 1/32"
MATERIAL
'AREA
LENGTH
VOLUME
WEIGHT
MPD-2711 (A-no-AT)
.87 In-
60,In
52.2 In3
1.67 lbs/ft
2,o/o
.200 --AP-
.1'420
? 5/1
ACTUAL SIZE
Note:
Cross-hatched area Indicatea
finish-machined detail part.
FIG.45 - OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF P/N 227594,
FLANGE,TURBINF. STATOR BLADE SUPPORT ASSEMBLY.
118
PROPOgEAPTRUSION
OPTIMUM ENVELOPE - Approx. 1/32"
MATERIAL
M.:1)6-:1, (A-110-AT)
AREA
LENGTH S 80 InVOLtJME ,
WEIGHT 15.28
2611nsft
.1 ? ? ???
?,030
/, 0 7Z ""4"`
?.03n
/4,58 --JP
????????????????????
4,0f0
/*R ?So?
?000 ?
I
1.3goKife.")
4 000
049..16"
1???????????????????????????????? .??????'?? do ? ? r ? I .????? won. Y.. ? ? i? ????????????? ????????? 1?60..1111,
ACTUAL SIZE
Note: Cross-hatched area indicates
finish-machined detail part.
FIG. 46 - OPTIMISTIC ENVELOPE SHAPE FOR THE EXTRUSION OF P/N 227596,
FLANGE, TURBINE STATOR BLADE SUPPORT ASSEMBLY.
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119
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
FIG 47 - PHOTOGRAPH SHOWING THE SURFACE FINISH OF EXTRUDED AllOAT FLANGES.
I'
120
Declassified in Part - Sanitized Copy Approved for Release
?
\
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
121
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
FIG. 49 MICROSTRUCTURE OF Al10- AT TITANIUM
EXTRUDED THROUGH THE REENTRANT ANGLE DIE
NOTE RANDOM ORIENTATION OF STRUCTURE.
122
,
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STAT
FIG. 50 MACROSTRUCTURE OF TWO SECTIONS OF THE STEEL
JACKETED EXTRUSION. (INSIDE DIAMETER OF TUBE IS ON THE
RIGHT. PHOTOGRAPH SHOSWECSTIATY(PBIC,AL SMOOTH SECTION
AND 'A TYPICAL ROUGH 0N
123
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
FIG. 49 MICROSTRUCTURE OF Al10- AT TITANIUM
EXTRUDED THROUGH THE REENTRANT ANGLE DIE
NOTE RANDOM ORIENTATION OF STRUCTURE.
122
,
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
FIG. 50 MACROSTRUCTURE OF TWO SECTIONS OF THE STEEL
JACKETED EXTRUSION. (INSIDE DIAMETER OF TUBE IS ON THE
RIGHT. PHOTOGRAPH SHOSWECSTIATY(PBIC,AL SMOOTH SECTION
AND 'A TYPICAL ROUGH 0N
123
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0
8
a.
140
120
100
40

20
10
fr 0
?w' 0
?
tr)
4 1?
HR
w
0
0
0
?
TENSILE
?'STRENGTH
..???...e
e e
?
YIELD
STRENGTH
MOON
0?????????????ft, ?
RED--
?
FIG 53 EFFECT OF ANNEALING TEMPERATURE ON THE
MECHANICAL PROPERTIES OF AllOAT TITANIUM
EXTRUDED WITH A 19000F BILLET PREHEAT
TEMPERATURE.
126
FIG. 54-. VIEW OF THE TOOLING MOUNTED IN A 25 TON
BATH RADIAL DRAW FORMER.
TYPICAL CONTOUR FORMING DIES, ROLLS,
COMMON ROLLS HOLDING YOKES AS
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127
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
0
8
a.
140
120
100
40

20
10
fr 0
?w' 0
?
tr)
4 1?
HR
w
0
0
0
?
TENSILE
?'STRENGTH
..???...e
e e
?
YIELD
STRENGTH
MOON
0?????????????ft, ?
RED--
?
FIG 53 EFFECT OF ANNEALING TEMPERATURE ON THE
MECHANICAL PROPERTIES OF AllOAT TITANIUM
EXTRUDED WITH A 19000F BILLET PREHEAT
TEMPERATURE.
126
FIG. 54-. VIEW OF THE TOOLING MOUNTED IN A 25 TON
BATH RADIAL DRAW FORMER.
TYPICAL CONTOUR FORMING DIES, ROLLS,
COMMON ROLLS HOLDING YOKES AS
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127
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
e
FIG. 59 CLOSE-UP PHOTOGRAPH
FIG. 58 PHOTOGRAPH OF P/N 226963 FORMED IN A 360 DEGREE
RING. THIS OPTIMISTIC ENVELOPE SHAPE WAS MACHINED
FROM A MAXIMUM ENVELOPE EXTRUSION,
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Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
4 fb,
,
FIG. 60 P/N 226961 RINGS FORMED AND FLASH BUTT WELDED INTO 360?
NOTE THE OUT-OF-ROUND CONDITION AT THE WELD JOINT,
132
STAT
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
v.
.0
MNSViri.""
?
FIG 62 - PHOTOGRAPH
OF THE SIX-INCH UPSETTING MACHINE.
PHOTOMACROGRAPH OF A SUCCESSFULLY UPSET
FLANGE IN AMS 6412 MATERIAL.
134
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
1
?
87J
i?''
7-0 em/o D/eviems/ews)
FIG.64 WOODEN MODEL USE FOR UPSET DEVELOPMENT OF PLASTICINE.
317?e p45,3 ,....5er"
?
FIGURE 65 SCHEMATIC. DRAWAGS
OF THE THREE STEP UPSET CYCLE USED
TO UPSET 1HE FLANGES FOR THE TURBINE ROTOR SHAFT'
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
66- THE UPSET AREA OF AN AllOAT ROTOR SHAFT INDICATING
THE BUCKLING AT THE INNER DIAMETER.
138
?????? offing
010? /Nkt
-DES IQ A/
FIRST PASS PUNCH
V
?Vm?
L
77
oR/G/NAL
tQ
1701/e if
4-47-ER,47-/oy
p0A/eti
ArER477
N
SECOND PASS PUNCH
FIGURE 67. Upset punch design modifcations employed to correct the buckling
problem in upsetting the rotor shaft flanges. -
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139
STAT
Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Fla681ci) PHOTOMACROGRAPH OF THE ROTOR SHAFTS
AFTER THE FIRST AND SECOND STAGE.
PHOTOMACROGRAPH OF THE FIRST UPSET
PRODUCT SHOWING THE LAP Al THE INNER
DIAMETER.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIG 70 PHOTOMACROGRAPH OF A SECTION OF THE
FIRST SUCCESSFULLY UPSET PROTOTYPE
TURBINE ROTOR SHAFT
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1.3-29
0/A
13 227
/3. 072
4-0
I
.19 ?0-
DETAIL SECTION DETAIL SECTION
(FIN. MACH.) (SEMI-MACH.)
Area - -
Length (Max)
Vol.
Wt.
PIR&,
.--111111.
.49S
OPTIMISTIC ENVELOPE. REVISED ENVEIAPE
(PROPOSED EXTR.) (PROPOSED EXTR.)
2 Area .372 In. 2 Area
Length(Max) 46.66 In. 2Length
Vol. 17.36 In: Vol. -
Wt. 2.76# Wt.
.205 In.
46.34 In.
9.50 In)
1.52#
FIGURE 72. PRODUCTION EXTRUSION SHAPE FoR P
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
145
fts10
.43.1ni Area
??? 411, 00 ???
60 In. Length -
-25.8 In.3 Vol.
4.15# Wt
N 226956.
=NI
011111 ??? ????
.53 In.2
49 In.
26.0In.3
4.19#
STA1
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
14 3-99(
/6. ,ce sph4'
P/Ali
4-
DETAIL SECTION
(FIN. MACH.)
011.???
IC
44
/8.94.
DI4,
3--
.6,144'8
.16
?f2
I. 2
DETAIL SECTION
(SEMI-MACH.)
Area .503 In.2 Area - - -
Length (Max) -59.32 In. Length (Max )
Vol. - - - - 29.84 In.3 Vol.
Wt. - - -4.77# Wt.
14337PIA,
3.0?
uPTIMISTIC ENVELOPE
(PROPOSED Era.),
- -.584 1n.2 Area - -
-59.51 In. Length
34.75 In.3 Vol.
5.56# Wt.
/42(
REVISED ENVELOPE
(PROPOSED EXTR.)
-.88 In.2 Area -
72 In. iLength
63.36Iitt..? Vol.
10.14# Wt
FIGURE 73. PRODUCTION EXTRUSION SHAPE FOR PAI 226962
146
"7 7
2
59.51 In.;
9.58#
Declassified in Part - Sanitized Copy Approved for Release
''''..."1111111111ft
1.4.)
DETAIL SECTION
(FIN. MACH.)
.4117.
Area - - -.565 In.
Length(Max) 35.8 In.
Vol. -20.23 In.3
Wt. 3.24#
????????
ef 9
1,10
OP.
? 08
DETAIL SECTIoN
(SEMI-MACH.)
Area
Length (Ma s . )
Vol.
Wt.
R
2
.656 In.
35.8 In.
23.48 In.
3.76#
7875 .0//9
iNciwo(D Q1.t 0401 irS
.Stie AcE 6w0417 s.
.46'7
15012,--
3Z.cR
/7t)
-
""1-1?266
uPTIMISTIC
(:)RuPoSED
Area
Length -41 Vol.
Wt. -
-
ENVELoPE REVISED DATA
EXTR.)
1.11 In.2 Area
- -35.8 In. Length -
53.3 In.3 Vol.
8.52# Wt. -
.? ????
WM;
FIGURE 74. PRODUCTION EXTRUSIGN? SHAPE FOR P/N 226963
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
147
0.11, ????
*Mr
1.12 In.2
.355. 83. 7261;1 n
STAT
t 4
AI 1
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
W"
DIA
?
DETAIL SECTION
(FIN. MACH.)
Area -
Length(Max
Vol. -
Wt..-
???
-.386 In.2
-47.20 In.
- -18.22 In.3
2.92#
off
C
DETAIL SECTION
(SEMI?MACHINED)
Area -
Length(max)
Vol.
????
Wt.
2
RING?
,179
-.07014
0;)
0
167407
CO.
OPTIMISTIC ENVELOPE REVISED ENVELOPE
(PROPOSED EXTR.) (PROPOSED EXTR.)
-.408 In.
Area - -
--47.38 In., Lerrc;th
19.33 In. Vol.
3.09# Vt. -
2 2
110 - -.60 In. Area - - - r70 In.
-36 In) Vol. - ^ - 53107 1n:3
_ - -60 In. Length
- 5.75# Wt. ------ 5.96#
FIGURE 75. PRoDUCTION EXTRUSION SUPE, FuR P/N 226964.
3.48
/.5a9.1* 014(02EA)
430
.091124-
66.50
.2.apimpf
.422
4- -410
It-rvo
W777"
i)
a-- 96
DETAIL .SECTION
(FIN. MACH)
Area
Vol.
Wt.
DETAIL SECTION
(SEMI4MACH)
.07 In2 Area
OPTIMISTIC ENVELOPE REVISED DATA
(PROPOSED EXTR.)
.13 in2 Area
Length(Max) - - -48.401n 3Length
3,37 Vol. 6.292 In Vol. -
54# Wt. 1.006# Wt.
FIGURE 76. PRODUCTION EXTRUSION SHAPE FUR /IN 226966
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
149
IMO 41.1.?
Mb III=
.26 In2 Area
- 60 In Length .20 In
7
15.6 Id Vol. - - - 13.161n3
2.5# Wt. 2.19#
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
?
R/,VG.
-40.
ID
9
41
6
ti"
ON
,2,411
.20
,I5
.'.3723
(7)
.Q
in
(oh
,;) fty
t 3 .3o
OA.
IL,,::-?..*7
:0065:
11.82
/6
29
154b
2..10
4? tvr
0
N
oYR.,
DETAIL SECTION
(FIN. MACH)
Area - - - -.417 IN2
Length(Max.)50.2 In.
Vol. - - -20.93 In3
W t. ??? ? 3.351/
DETAIL SECTION
(SE4I4MACH.)
Area - - - -.60 In.2
Length(Max.)50.2 In
VOL - - 30.12 In
Wt. - - -4.82#
OPTIMISTIC INNEWPE
(PROPuSED EXTR.)
Area
Length
Vol.
Wt.
RE'VIEED ENVELOPE
(PROA/SED EXTR.)
.87 In.2 Area
.60 In. Length -
52.2 In,.3 Vol.
8.35# Wt.-
4110
FIGURI 77. PRODUCTION EXTRUSION SHAPE FOR P/N 2275914.
MP OW
mi. a..
- -1.04 In2
-.481;0
- 49.9 In,,)
8.0
2 d).74
2/1 0
.03R-
DETAIL SECTION
(FIN. MACH)
Area
Length (Max.
Vol.
Wt.
41??? ???
.367 In.
.68.8 In.
4.04#
4.04#
22,14
220
esQ\
.34
-pm.
DETAIL SECTION
(SEMI-MACH.) ?
0/A
tt -R/A/
22,14
1.07Z-1*
03
Area - - -.482 In.
Length(Max.)69.6 In .
Wt. - -353.3.65; In.
Vol. ... M.
it 26?,3
25
.4? 8
OPTIMISTIC ENVELOPE
(PROPOSED EXTR.)
, REVISED ENVELOPE
(PROPOSED EXTR.)
Area .66 In. Area -
2
AM OM ??? Aft -.81 In.2
Length - - -480 In. Length
Wt. - - - 8.45# Wt. =IP I= WM _9.2701 In.
#
57.5 In.3
- - -52.8 Ins3 Vol.
FIGURE 78. PRODUCTION EVIG' MON .SHAPE FUR P/N 227596
STAT
,
77.77,7771?7,7717.77,r1r7r7t,eL,!5?P
150
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
151
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
7 ":
?
0131,.4s t
. ? y X
04. ? ,V,3
14? 4, 4/*Shilforet:441 .C4444.4,14"..
? 0
?????? "' .,????? ?^ '
? ? ?r..1 ' A, ?
`,'" ? 1,, A ? '
?
?
.4t'
.\?4 A 41. o, ' '"'"4.'
?
S.
I? ?
1 ' .r,
, ? I .(f
".?' .1..1 ?Ita Ari
4;1, i4?.cp,r11.0
,-r? - ,
? ' ?
,
FIG. 79- PHOTOMICROGRAPHS OF P/N 226961 EXTRUDED FROM CAST AND
FORGED MATERIAL.
? . 7'; ,44
4, ?
4,444 / 4.4
44,1
...., 4.
1
,Ais,itat ? .''''.0 . , ....?,. :"
...?.,...41"..I.:'":".? t
,
'...441A7:4.'4.7.4111,,,r, ...4.1C,',,,,,:?4,44,4...44,...,444444444444.4....40?444 1..........,
#:'..,. ' 9.1...4-1,..A ?? r A"'. ' ' , -,T,11".,.",. , ,4 #0fr.::,..
44....W_5.....,....... ?,,,..... .?
FIG.80- PHOTOMICROGRAPHS OF P/N 226962 EXTRUDED FROM CAST AN
FORGED MATERIAL.
Declassified in Part - Sanitized Copy Approved for Release
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
. ?,?$??
*".` , ? '' ????..r???
,
, r wag.,? ^.4 '
girlttrrep, 4". r04?
e ' "
0?44,:41.4. ???
; ; ?
" 44144?, wg..444..4 ,ti.PAt"," t44'''po 044?I.444":4 '?;!.?
',S'A'ht,AX,11t11:40,;" " "10W"44"..40 "
WiVtil*Irjr?61tere4,4, 10,41641.
1'I,46 .1?,4004^',','"*A., ? .1..
'? ir -44
4.0,???;;,' 'TO v
Alteorledr,
. ? 1414 4
4":-"C;t1r/t "444441111:71,.0.41
, 1,xd .0. /0411
;
FIG 84- PHOTOMICROGRAPHS OF P/N 227594 EXTRUDED FROM
FORGED MATERIAL
Declassified in Part - Sanitized Copy Approved for Release
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VIII. APPENDIX I
TITANIUM MATERIAL SPECIFICATIONS
1. MPD 271 - Extrusion Stock (Forged) A110 AT
2. rI'D - 272 - Extrusion Stock (Cast) A110 AT
3, MPD 275 - Extrusion *Stock (Cast) AMS 14.921
4. MPD - 276 - Extrusion Stock (Forged) AMS 14.921
5. WAD 785s Wrou
6.w
? t
t Titanium & Titanium Alloys
7852 - Titanium Alloy - 5A1 2 1/2.8n
Annealed 110,000 psi yield
TITANIUM PROCESSING SPECIFICATIONS
70 AMS 7498 - Rings; Flash Welded - Titanium And
Titanium Alloys
8. WAD 5797E Arc Welding
9. Tenative WAS Titanium Welding Specification
STAT
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1. ACKNOWLEDGEMENT: A vendor shall mention this specification
nurai and a.ts test revision number in all quotations and
when acknowledging purchase orders
APPLICATION:Primarily intended for hot extrusion,.
COMIDSITION;
Carbon .20
Aluminum 4.0 - 6uo
Tin
Oxygen (when analyzed) .20 max
Hydrogen .0175 max
Nitrogen .07 raax
Other elements, total .80 max
L. CONDITION: Vacuum melted, forged or rolled, and machined
c7F-Enartioned to size.l.ocal spot grinding and chipping is
permissible to a maximum depth of 1/211 with well rounded edges.
5. qUALITY: Material shall be uniform in quality and
ceThidT7ti:on, clean, sound, and free from 'foreign materials, and from
internal and external defects.
6.1 MECRANICAL ,In the, annealed condition the properties shall be:
? yield Strength at 01,4 offset,. psi
Elongation, 5 in 41)
Reduction in area, %
Charpy V-Notch at room teMparature
Notched Rupture at room temperature
150,000 cell shall be teetoct to
failure or a maximum 6 20 hours
110)000 mini)
10 min
30 min
Results shall be re;)orted
If
il Of
7.. SAMPLI110 InIVTION AND TEliT
ransverso sartrat'j?iginrorn"?TIEFTWalc-777 supplied hall bo It reduced
to a maximum ratio of 7 to 1. Tentilon and impact test 'specimens Shall
be taken transverse to the direction of major working. This ample
will be the source of test specimens listed below: ?
161
STAT
STAT
.0Wali,N7A
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
7 a2X131.2.0.2a0a The tensile test shall conform to
Federal Specification QQ-M-151a, type The Charpy
specimen shall conform to AS designation E 23.47T, type
A, with radius tolerance of :c 0001"
8, XMENSIOYAL TOLERANCES: Dimensional tolerances shall be
as specified in the order or on applicable drawings, except
as noted in 4 above.
c4,4 AMILLEUTIOD Each billet shall be clearly stamped on
lloth ends with mill heat number and specification number.
10m.? WORTS: The vendor shall furnish with each shipment a
certified report of the results of tests for conformance to
thi3 specification If a heat treatment has been used it
shall be descrited. In addition the report shall include
the purchase order number, heat. number, specification number
size, and quantity from each heat.
ACKNOWLEDGEMENT: A vendor shall mention this specification
E7571737171atest revision number in all quotations and
when acknowledging purchase orders.
APPLIMION: Primarily intended for hot extrusion.
Carbon
Aluminum
Tin
Oxygen (when analyzed)
Hydrogen
Nitrogen
Other elements, total
Iron
Manganese
COND TION: Double vacuum melted rnd rough machined to size
on the O.D. Local spot grinding and chipning is permissable to
a maximum depth of l/4" with well rounded edges. ?
n7ALITY: Ingots or.portions_of ingots purchased to. this spec.-
ificatirn shall be uniform in quality and condition, clean and,
free 'rom foreign materials and e'Aernal defects. ? 'Sonic test-
ing will be .employed to determine the, presence of internal de-
fects and center soundness, The Sonic test observation's shall
be?forwar7ed with the certified test results.
-YECHANICAL TESTS:: The tensile properties apply,when the rate-
'7=M is Maintained through the yield 'strength between the
values of 0,003 in ne r in..per'Min. and 0.007 in.per).n.per min.
. and then increased So as to produce failure in approximately one
additional- minute .' s.Mechanical test results, alone, shall not
.bethe basis for 'reldection. Test specimens obtained from para-
graph 7,1n the annealed condition shall meet the, follbwi0g:
Yield Strength at .2;.; offset, psi
Elongation, % in 4D
Reductidn in area, %
? Charpy V-Notch at room temperature
Notch Tlupture at room temperature
150,000 psi, shall be tested to fail-
ure or a maximum of 20 hours
atilax4.ticc:;acrx7ratmcurrri..rirr :Acurxtrunts-4-..z.ry4 ::!.7.,..lroark.t=onrat ? 01:4P.UCI"..44,47161.4;t:....- .
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:'17.7:733017EM
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
SAMPLING INSPECTION AND TEST PROGEDURESt A transverse sample from the stock
o e supp edlUrr-670=071-G-rMaximum ratio of 71. The vendor
shall supply for6ineAfinishing temperatures and the number of reheats, if
any, to accomplish this reduction, Tension and impact test specimens shall
be taken transverse to the direction of major working. This sample will be
the source of the test specimens listed in 6. One half of this specimen shall be
forwarded to MID for additional testing.
701 Types of Specimens: The tensile test shall conform to Feee:al Specification
QQ-M..151a, Type-4; The Charpy tpecimen si)all conform to ASTM designation E-
23-4?T, 7ype A, with radius tolerance of t ,001 inches.
DIMENSIONAL TOLERANOFS: nimensional tolerances shall be as specified in
the order or on-iiiTtable drawings, except as noted in 4 above,
IDENTIFICATION Rach section shall be clearly stamped on both ends with
the mill heat number and specification number.
100. PuLPORTSr The vendor shall furnish with each shiplent a certified report'
377177-7esults.oftests for conformance to this specification. If a heat
treatment has been used it shall be described. In addition, the report ehall
include the purchase order number, heat number, specification number Size and
quantity from each heat.
Declassified in Part - Sanitized Copy Approved for Release
t.
A
u Ullt4U 6.1.CtIAL Deritt nepom Vo. mr.vu -112
1. ACE11014TAIMENT: A vendor shall mention this specification
number and its latest-revition number in all quotations and .
when ack=aledgins purchase orders.
2. APPLICATION: Primarily intended for hot extrusion.
3. ITION :
.1=411???111?11?411?111??????????????????????????
Carbon
Hydrogen
Oxygen (when analyzed)
Nitrogen
Iron
Manganese
Other elements total (including Fe & Mn) 0.50 max.
Titanium Remainder
0.20 max.
0.0125 max.
0.20 max.
0.07 max.
To be reported
To be reported
CONDITION: Double vacuum melted with both melts employing the
consumable electrode method.. The diameter may be machined.
Local spot grinding and chipping is permittable to a =dna=
depth of 1/4" with well rounded edges.
QUALITY: Ingots or portions of Ingots purchased to this nspeci-
fication shall be uniform in quality and condition, clean and
free from foreign materials and external defects. Sonic test-
ing will be employed to determine the presence of internal de-
fects and center soundness. The sonic test-observations Shall'
be forwarded with the certified test results,
MECHANICAL TESTS: Material_thall,conform to the following re-
quirements, aria-shall be capable .of meeting these requirements_
after being heated to any temperature 416..12009r for,approX-
imately 30 min. in air and cooled in air. Mese properties
apply. when the rate of strain Is maintained -at approximately
0.005 in. per in. per min. to the yield strength.
Tensile Strength., psi .
Yield Strength at 0.2% offset psi
ElOngation, % in 2 in.
Reduction of.. area %
Notch Rupture tests at 752F with an
axial load of 90,000 psi shall
be tested to failure or 4 max-
imum of 10 hours: Hours
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165
80,000 min.
70 000 - :90,000
15 min.
30 min.
5 min.
S.STAT
STAT
ST/-% 1
STAT
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STAT
STAT
STAT
STAT
SANPLING) INSPECTION AND TEST PROCEDURES:' A transverse sample
from the stock to be supplied shall.te hot reduced to a maximum
ratio of 7:1. The vendor shall supply forging, & finishing
temperatures and the number of reheats, if any, to accomplish
this reduction. This sample will be the source of the test
specimens hated in 6. One half of this sample forging shall
be forwarded to MPD.
7.1 Types of Specimens: The tensile test shall conform to Federal
Specification QQ-M-151a, Type 4. Notch rupture specimens shall
have a 0.25 in. diameter with a 60 degree Vee notch of 0.178 in.
root diameter and 0.0C? in. root radius.
DIMENSIONAL TOLERANCES: Dimensional tolerances shall be as
specified in the order or on applicable drawings, except as
noted in 4 above. '
IDENTIFICATION: Each section shall be clearly stamped on both
ends with the mill heat number and specification number.
1 C:NOWI TpMENT,: A vendor shall mention this specification
number anc, its latest revision number in all quotations and
when acknowledeng purchase orders.
4
AiTgalm: Primarily intended for hot extrusion.
30 ME2a111111
Carbon
Hydrogen
Oxygen
Nitrogen
0.20 max.
0,0125 max.
0.20 max.
-0.07 max.
Iron
To be reported
Manganese
REPORTS: The vendor shall furnish with each shipment a certified
report of the results of tests for conformance to this specifica-
tion. If a heat treatment has been used it shall be described.
In addition, the report shall include the purchase order numbers
heat number specification number size and quantity from each
heat.
ACCEPTANCE: Material not conforming to this specification or
to authorized modifications will be subject to rejection.
Materials Laboratory
Manufacturing Engineering
Manufacturing Eng.
,00Oo??????.ot????????????.il??.r..msnsm?om??onr.oWn...o............ir

To be reported
Other elements total (including Fe & Mn) 0.50 max.
Titanium 'Remainder
4. CONDITION:' Double vacuum melted with both melts employing the
consumable electrode method. The diameter may be machined.
Local spot grinding and chipping is pormissable to a maximum
depth of J/4" with well rounded edgel,
5. QUALITY.: Ingots or portions of ingots purhased to this speci-
fication shall be uniform in .quality and condition, clean 'and
free from foreign materials and external defects.. Sonic test- .
ing will be employed to determine the presence of internal de-
fects and center soundness. The sonie test observations shall
be, forwarded with the certified. test.Tesults:
TE0HumligiungENTs: .., Material shall conform to the. follow-'
ing requirements ancIShall.alsb:be:::capableof meeting these'
requirements after being heated to::_any temperature up to 1200,0?
for,apprOximatelY 30 minutes in air-, .cooled Jilair, and descaled.
.G.L Mechanica1:1111AI The tensile properties listed below apply
wnen the rate of strain is maintained through the yield strength
between the values of .,003 in. per. in per min., and ...007 in..
per in. per mm., and then is increased so as to produce fail-
ure in approximately one'additionalminute. In ,the annealed
Condition the 'properties Shall. be: '-
Tensile,Strencth, psi
Yield 'Strength at 0.25 offset psi
Elongation, % in:2 in.
Reduction of area
Notch Rupture tests at 750F with an axial
load of 90 COO si sball be tesed to fail- 5 min'
LINC340041111.100100V ommEamarimaatin of lo.Dours. ours..
80,000 min.
70,000 . 90,000
15 min.
30 min.
166
VWISZW,XM-7472:.
'3P,M;,11'N/A7.6
P'1,70.7M7riror
r
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
....,,,????????????????????????? r+ForWeimoNiortmo 11.0.11111111?11.1110011111114101111 *Ent MP ~lib
SAMP VG INUTXTION.1112.TEST PPOCEDURES: A transverse sample
from the stock to be supplied shall be hot reduced to a maximum
ratio of 7:1. The vendor shall supply forging, & finishing
temperatures and the number of reheats, if any, to accomplish
this reduction. This sample will be the source of the test
specimens listed in 6. One half of, this sample forging shall
be forwarded to MPD.
7.1 Tysof121212=1 Notch rupture specimens shall have a
2 in. diameter with a 60 degree Vee notch of '0.178 in root
diameter and.0.005 in. root radius.
'DIMENSIONAk TOLERANUL. Dimensional tolerances shall be as
specified in the order or on applicable drawings, except as
noted in 4 above,
9. IDENTIFICATION: Each section shall be clearly stamped on
lxih ends with the mill heat number and specification number.
10. 'MEM: The vendor shall furnish with each shipment a certi-
fied report of the results of tests for condormance to this
specification. If a heat treatment has been used it shall be .
described. In additionithe report shall include the pgsrohase
order number, heat number, specification number size and quantity
from each 'heat.
11. ACCEPTSNp.: Material not conforming to this specification or
to.authoriEed,modifications will be subject to rejection.
168
Declassified in Part - Sanitized Copy Approved for Release
ls ACKNONLEDGMENTs A vendor shall menbion this specification number and its revision
letter in all quotations and when acknowledging purchase orders.
APPLICATION: This specification covers certain compositional, technical, and
quality requirements for wrought titanium and titanium alloys and is intended
not to supersede or delet but to supplement the requirements of existing appli-
cable speoificationss
INTERSTITIAL ?OOMPOSITION:
Origen, if determined
Nitrogen
Carbon
Hydrogen
Bar Stock
Sheet Stock
Other Elements, Total
0.20 max
0.07 max
0.20 max
00i25 max
0,0150 max
0,20 max
03.1 For bar stock of AUG AT alloy, the hydrogen content shall be 0.0175 maximum.
3.2 Conformance to teohnical requirements of section 4 shall be achieved by means of
the alloying elements and not be intentional additions of interstitial elements.
TECHNICAL REQUIREMENTS:
4s1 Notched kipLuelests
tests
Bars and forgings shall be capable of meeting the following
401,1 Test spe4mens shell have 0,25 in, diameter with as60-degree 'he notch of
0.178 in, root diameter and 0,005 n, rootsradius?, Maintaining A temperature
of 75 F with an axial load of. 160,000 psiscipplied?, specimens shall not ruptur"
in less than 5 hours, -
401,1,1 For AllQ AT alloy, an axial load of 135,000
401.1.2 For AMS 4921 alloy, an axi
41.13
0
psi shall be applied
al load of 90,000 psi shall be plied.
Unless otherwise specified, AMS 4925 shall have a hardness not
higher than Rockwell C 39 or equivalent.
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STAT
STAT
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
ACKNOLEDGMENT: A vendor shall mention this, specification number,in.all quotations
.and when aCknOwledging.purChase orders.
FORM: Bats and forging stock.
.APPLICATION: Primarily for parts requiring welding and haying ,strength. up to 700 F,
OOMPOSIITON:
Aluminum
Tin
Carbon
Oxygen (if determined
Hydrogen
Nitrogen
Iron
Titaniumse
5. CONDITION: Unless otherwise specified, hot
cold reduction, annealed, and descaled,
6. TECHNICAL REQUIREMENTS:
4,0 - 6.0'
1,5 - 3,5
0.20-max
0.20 max
0.0175 max
0.07 max
?0.50 max
0,20 'max
0.10 max
Remainder
STAT
STAT
STAT
finished, with or without subsequent
6.1 Tensile Properties,: These properties apply when the rate of strain is maintained
through the yield strength between the values of 0.00 in. per in. per min. and
0007/ in. per in. per min., and then it is increased to produce failure in approxi-
mately one additional minute. When a dispute occurs between purchaser and vendor
over the yield strength values, a referee test shall be performed on a test
machine having a strain rate pacer, using a rate of 0.005 in. per in. per min,
through the yield strength.
.Tensile Strength, psi
Yield Strength at 0,2% Offset or at 0....01.82 in.
in 2 in. Etension Under Load (E 15,500,000),psi
,Elongation, ,% in 4D (Section's under 3.in.)
Reduction. of Area, % (SeCtions under:3 in.)
QUALITY:, Material shall be uniform in quality and ,Condition, 'Olean, sound, and
free from foreign materials and from internal and external imperfections detri-
mental to fabrication or to performance of parts. '
170
171
'4,4FiggegOltaem,Atvem.,!,omlvaikm:,,,N,,:4-;;;AtIfom
.r?
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
ACKNOLEDGMENT: A vendor shall mention this, specification number,in.all quotations
.and when aCknOwledging.purChase orders.
FORM: Bats and forging stock.
.APPLICATION: Primarily for parts requiring welding and haying ,strength. up to 700 F,
OOMPOSIITON:
Aluminum
Tin
Carbon
Oxygen (if determined
Hydrogen
Nitrogen
Iron
Titaniumse
5. CONDITION: Unless otherwise specified, hot
cold reduction, annealed, and descaled,
6. TECHNICAL REQUIREMENTS:
4,0 - 6.0'
1,5 - 3,5
0.20-max
0.20 max
0.0175 max
0.07 max
?0.50 max
0,20 'max
0.10 max
Remainder
STAT
STAT
STAT
finished, with or without subsequent
6.1 Tensile Properties,: These properties apply when the rate of strain is maintained
through the yield strength between the values of 0.00 in. per in. per min. and
0007/ in. per in. per min., and then it is increased to produce failure in approxi-
mately one additional minute. When a dispute occurs between purchaser and vendor
over the yield strength values, a referee test shall be performed on a test
machine having a strain rate pacer, using a rate of 0.005 in. per in. per min,
through the yield strength.
.Tensile Strength, psi
Yield Strength at 0,2% Offset or at 0....01.82 in.
in 2 in. Etension Under Load (E 15,500,000),psi
,Elongation, ,% in 4D (Section's under 3.in.)
Reduction. of Area, % (SeCtions under:3 in.)
QUALITY:, Material shall be uniform in quality and ,Condition, 'Olean, sound, and
free from foreign materials and from internal and external imperfections detri-
mental to fabrication or to performance of parts. '
170
171
'4,4FiggegOltaem,Atvem.,!,omlvaikm:,,,N,,:4-;;;AtIfom
.r?
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
ACKNOLEDGMENT: A vendor shall mention this, specification number,in.all quotations
.and when aCknOwledging.purChase orders.
FORM: Bats and forging stock.
.APPLICATION: Primarily for parts requiring welding and haying ,strength. up to 700 F,
OOMPOSIITON:
Aluminum
Tin
Carbon
Oxygen (if determined
Hydrogen
Nitrogen
Iron
Titaniumse
5. CONDITION: Unless otherwise specified, hot
cold reduction, annealed, and descaled,
6. TECHNICAL REQUIREMENTS:
4,0 - 6.0'
1,5 - 3,5
0.20-max
0.20 max
0.0175 max
0.07 max
?0.50 max
0,20 'max
0.10 max
Remainder
STAT
STAT
STAT
finished, with or without subsequent
6.1 Tensile Properties,: These properties apply when the rate of strain is maintained
through the yield strength between the values of 0.00 in. per in. per min. and
0007/ in. per in. per min., and then it is increased to produce failure in approxi-
mately one additional minute. When a dispute occurs between purchaser and vendor
over the yield strength values, a referee test shall be performed on a test
machine having a strain rate pacer, using a rate of 0.005 in. per in. per min,
through the yield strength.
.Tensile Strength, psi
Yield Strength at 0,2% Offset or at 0....01.82 in.
in 2 in. Etension Under Load (E 15,500,000),psi
,Elongation, ,% in 4D (Section's under 3.in.)
Reduction. of Area, % (SeCtions under:3 in.)
QUALITY:, Material shall be uniform in quality and ,Condition, 'Olean, sound, and
free from foreign materials and from internal and external imperfections detri-
mental to fabrication or to performance of parts. '
170
171
'4,4FiggegOltaem,Atvem.,!,omlvaikm:,,,N,,:4-;;;AtIfom
.r?
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
ACKNOLEDGMENT: A vendor shall mention this, specification number,in.all quotations
.and when aCknOwledging.purChase orders.
FORM: Bats and forging stock.
.APPLICATION: Primarily for parts requiring welding and haying ,strength. up to 700 F,
OOMPOSIITON:
Aluminum
Tin
Carbon
Oxygen (if determined
Hydrogen
Nitrogen
Iron
Titaniumse
5. CONDITION: Unless otherwise specified, hot
cold reduction, annealed, and descaled,
6. TECHNICAL REQUIREMENTS:
4,0 - 6.0'
1,5 - 3,5
0.20-max
0.20 max
0.0175 max
0.07 max
?0.50 max
0,20 'max
0.10 max
Remainder
STAT
STAT
STAT
finished, with or without subsequent
6.1 Tensile Properties,: These properties apply when the rate of strain is maintained
through the yield strength between the values of 0.00 in. per in. per min. and
0007/ in. per in. per min., and then it is increased to produce failure in approxi-
mately one additional minute. When a dispute occurs between purchaser and vendor
over the yield strength values, a referee test shall be performed on a test
machine having a strain rate pacer, using a rate of 0.005 in. per in. per min,
through the yield strength.
.Tensile Strength, psi
Yield Strength at 0,2% Offset or at 0....01.82 in.
in 2 in. Etension Under Load (E 15,500,000),psi
,Elongation, ,% in 4D (Section's under 3.in.)
Reduction. of Area, % (SeCtions under:3 in.)
QUALITY:, Material shall be uniform in quality and ,Condition, 'Olean, sound, and
free from foreign materials and from internal and external imperfections detri-
mental to fabrication or to performance of parts. '
170
171
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.r?
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Repairing shall be accomplished by routing to remove the defect and re-welding
by the same method as originally specified fOr that 'particular weld, unless
otherwise permitted.
,APPROVALI
A vendor shall not supply production details or assemblies welded in accordance
with this specification until production approval has been granted, unless such
approval be waived.
A vendor Is facilities,k procedures, and materials used shall be subject to
approval by the Ehgineering Department of W.A.D. - Manufacturing materiald,
procedures, processes, and methods of inspection shall be the same for
production parts as for approved sample parts. If necessary to 'make any
change, a vendor shall obtain permission from purchaser prior to incorporating
such change.
10.3 Automatic fusion welding equipment shall be approved by demonstrating its
0 capability to perform the following:
10.3.1 Controls shall be set to weld a test sample at least 12 in, long and of the
same nominal composition and of thickness representing the mean of the
range of production parts to be welded. Sample shall meet, the quality re-s
quirements of Section 8.
11.1 Personnel-performing-manuallwelding on W.A..D. parts and assemblies shall be
certified in accordance with MIL-T-5021 as competent to do the. particular
- welding operations involved.
12. ACCEPTANCE: Arc-welded 'details and asqemblies not fabricated in accordance
with the Tequirements of this specification or authorized modifications will
be subject to rejection.
ARC AND GAS WELDING SYMBOLS
ROOT OPENING---
(PLUG AND SLOT
WELDS).*
SIZE (EXCEPT
FOR-
PL.UG OR SLOT),
,DETAIL REFERENCE OR
STRENGTH OF
STRUCTURAL. SPOT
WELDS *
SPECIFICATION
TYPE REFERENCE N
FINISH SYMBOL
WHEN USED
INCREMENT LENGTH OR ROOT LENGTH
(FOR PLUG AND SLOT WELDS)*
PITCH OF NON-CONTINUOUS WELDS?
REFERENCE LINE FOR SHOWING
WELD LOCATION
WELD ALL AROUND SYMBOL
ARROW CONNECT-
ING REFERENCE
LINE TO JOINT OR
TO MEMBER TO BE
GROOVED
SIDE OF JOINT TO
WHICH ARROW
POINTS IS ARROW
SIDE AND OPPOSITE
SIDE IS OTHER SIDE
x MAY APPLY TO EITHER SIDE OF REFERENCE LINE DEPENDING ON APPLICATION OF *WELDS.
I. BOTH SIDES OF WELDS OF THE SAME TYPE ARE OF SAME SIZE UNLESS OTHERWISE
SPECIFIED,
2. SYMBOLS APPLY BE ABRUPT CHANGES IN DIRECTION OF JOINT OR AS
DIMENSIONED (EXCEPT WHERE ALL AROUND SYMBOL IS USED)
3, ALL WELDS ARE CONTINUOUS UNLESS OTHERWISE SPECIFIED.
4. DIMENSIONS OF WELDS IN INCHES.
5, WHERE THE SYMBOL / OCCURS, THE WELD 'FINISH SHALL BE EQUIVALENT
IN QUALITY TO THAT REQUIRED FOR THE SURROUNDING .BASE METAL.
? CC-
I
178
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kqt# ?
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. ,
4: ? '! ' ? ?
,,
PPP**
,PV
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artworimitilliUnlinromomw
411P
Figure 2 Illustrative applications of welding symbols:
NAME OF
WELDED
JOINT
SQUARE-BUTT
WELDED
ONE SIDE ,
(PRESENT SYMBOL)
SQUARE-BUTT
WELDED
ONE SIDED si
(OLD SYMBOL)'
SINGLE-V
BUTT JOINT
DOUBLE-V
BUTT JOINT
APPLICATION INTERPRE-
OF TATION OF
SYMBOL SYMBOL
SINGLE BEVEL
BUTT JOINT
OR
DOUBLE BEVEL
BUTT ',JOINT Ti
'Eli
SQUARE EDGE
JOINT
(PRESENT SYMBOL)
SQUARE EDGE
JOINT AL
(OLD SYMBOL)'
NAME OF APTIatit5W-INTE-R-F5FTET.
WELDED OF TATION OF
JOINT SYMBOL SYMBOL
SQUARE ? BUTT
JOINT WITH
BACKING MEMBER
SINGLE
FILLET WELDED
LAP JOINT
DOUBLE
FILLET WELDED
LAP 'JOINT
PLUG
WELDED
LAP JOINT
SLOT
WELDED
LAP JOINT
CORNER JOINT
OUTSIDE
FILLET WELD
J
CORNER JOINT
INSIDE AND -
OUTSIDE
FILLET
WELD
CORNER JOINT
INSIDE AND
OUTSIDE
FILLET WELD
OF UNEQUAL
SIZE
OLD SYMBOL APPEARS ON EARLIER DRAWINGS
1V17,1
VeArt
. .
WV4r47.0,74TAMDMM.MgrrM. Vg**657titiV 'AWM,47iMq.1707i0,4',..arM1:.011
Figure 2 (Continued):
5797j
NAME
OF WELDED
JOINT
APPLICATION
OF .
SYMBOL
INTERPRE7
TATION OF
SYMBOL
NAME
OF WELDED
JOINT
APPLICATION
. OF
SYMBOL
INTERPRE-
TATION OF
SYMBOL
SINGLE,V
CORNER JOINT
CORNER JOINT.
INSIDE .
r
A
311
OR
FILLET WELD
'OR
I
6.
DOUBLE
FILLET
,WELDED
TEE JOIN T
.
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et
FILLET WELD
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(OLD SYMBOL)
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Pe
CORNER JOINT
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i
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FILLET WELD,
OR
V
(PRESENT SYMBOL)
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i .
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' COSINGLE-JR1`.4ER JOINT
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Immima
GROOVED
CORNER JOINT
... ?
FILLET 'WELD .,,
1 OR
r . .1
44
(OLD SYMBOL)'
Si.
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,
SQUARE
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GROOVED,
.
.......
.
BUTT WELD. .
? INCOMPLETE
\A--2O-
.
20R_
STANDARD DIMENSIONS OF U AND J GROOVES .TO BE USED UNLESS OTHERWISE SPECIFIED.
OLD' SYMBOL APPEARS . ON EARLIER DRAWINGS
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STAT
STAT
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4
TENTATIVE WAD SPECIFICATION FOR ARC WELDING OF TITANIUM AND TITANIUM ALLOYS
1. Llai.2122.711Eli.: A vendor shall mention this specification number and
its revision letter in all quotations and when acknowledging purchase
orders.
Application: This specification applies to the process and quality
requirements for. inert gas shielded tungsten arc welding of titanium
and titanium alloys. This specification to be employed only in addi-
tion to the requirements of WAD 5797.
3. General Provisions:
3.1. An inert backup gas of either argon or helium shall be employed to pro-
tect the penetration side of the weld bead.
3.2. Argon and/or helium gas shall be employed in the welding torch nozzle
when joining sheet material 0.080" or less in thickness. Helium shall
be employed for all thicker material.
3.3. In all cases, the largest feasible shielding nozzle shall be used to
insure adequate protection.
3.4. Whenever the part geometry and weld configuration permit, the movement
of ?the welding torch, relative to the area being welded, shall be governed
by mechanical means.
3.5. A trailing shield shall be provided for all machine welds, and shall have
an individual inert gas supply.
3.5.1. The combination of ainozzle and a trailing shield shall be capable of
producing a weld bead which conforms to the requirements of Paragraph 6.
3.6. Manual welding operations must be performed in an inert atmosphere con-
tainer or by other approved methods callable of producing welds which
meet the quality requirements of Paragraph 6.
4. Preparation for Welding:
4.1. Prior to welding, the joint surfaces shall be prepared by
following methods.
1+.1.1. Grind the surfaces with emery ro
remove the tight adhere
Chemic
either of the
.Is or other abrasive material which will
surface-oxide0
al clean in an acid bath as follows:
Bath Analysis
Hydrofluoric Acid
Nitric Acid
Water
Temperature of bath
Immersion Time
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
4
TENTATIVE WAD SPECIFICATION FOR ARC WELDING OF TITANIUM AND TITANIUM ALLOYS
1. Llai.2122.711Eli.: A vendor shall mention this specification number and
its revision letter in all quotations and when acknowledging purchase
orders.
Application: This specification applies to the process and quality
requirements for. inert gas shielded tungsten arc welding of titanium
and titanium alloys. This specification to be employed only in addi-
tion to the requirements of WAD 5797.
3. General Provisions:
3.1. An inert backup gas of either argon or helium shall be employed to pro-
tect the penetration side of the weld bead.
3.2. Argon and/or helium gas shall be employed in the welding torch nozzle
when joining sheet material 0.080" or less in thickness. Helium shall
be employed for all thicker material.
3.3. In all cases, the largest feasible shielding nozzle shall be used to
insure adequate protection.
3.4. Whenever the part geometry and weld configuration permit, the movement
of ?the welding torch, relative to the area being welded, shall be governed
by mechanical means.
3.5. A trailing shield shall be provided for all machine welds, and shall have
an individual inert gas supply.
3.5.1. The combination of ainozzle and a trailing shield shall be capable of
producing a weld bead which conforms to the requirements of Paragraph 6.
3.6. Manual welding operations must be performed in an inert atmosphere con-
tainer or by other approved methods callable of producing welds which
meet the quality requirements of Paragraph 6.
4. Preparation for Welding:
4.1. Prior to welding, the joint surfaces shall be prepared by
following methods.
1+.1.1. Grind the surfaces with emery ro
remove the tight adhere
Chemic
either of the
.Is or other abrasive material which will
surface-oxide0
al clean in an acid bath as follows:
Bath Analysis
Hydrofluoric Acid
Nitric Acid
Water
Temperature of bath
Immersion Time
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APPENDIX II
DETAIL EXTRUSION DIE DRAWINGS
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Declassified in Part - Sanitized Copy Approved for Release
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FOREWORD
I INTRODUCTION
II OBJECT
III SUMMARY
IV CONCLUSIONS
V RECOMMENDATIONS
VI DISCUSSION
VII REFERENCES
TA,BLE OF CONTENTS
Page No .
i
1?
3
5
9
11
13
25
STAT
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Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Photomacrograph of an A70 Titanium Cast Ingot. Note
the Uniform Grain Structure Resulting from the Low
Voltage "Induction Stirring" Coil. Ingot diameter
approximately 7 1/2 inches.
The Notch-Tensile Properties of Low Oxygen (0.20%)
A70 Titanium Extruded from A Cast Ingot (Material Al
Oe 0.33)
The Notch-Tensile Properties of High Oxygen (0.25%)
A70 Titanium Extruded from A Cast Ingot (Material B)
Oe - 0.38)
The Notch-Tensile Properties of High Oxygen (0.25%)
A70 Titanium Extruded from a Forged Billet (Material
CI Oe - 03)
Comparison of the Effect of Interstitial Content on
the Notch-Tensile Properties of A70 Titanium Forged
and Extruded Material at 750F
Comparison of the Effect of Interstitial Content on the
Notch-Tensile Properties of A70 Titanium in Forged and
Extruded Material at -65?F
The Notch-Tensile Properties of AllOAT Titanium Extrud-
ed from a Cast Ingot (Material 13)
The Notch-Tensile Properties of AllOAT Titanium
ed from a Forged Billet (Material E)
The Effect of Extrusion Temperature on the Tensile
Properties of A70 Titanium Extruded from Cast Ingots
of Various Extrusion Ratios
The Effect of Extrusion Ratio on the Tensile Proper-
ties of A70 Titanium Extruded from Cast Ingots at
Various Extrusion Temperatures
The Effect of Extrusion Temperature
structure and Microstructure of A70
ed from Cast Ingots at an Extrusion
The Effect of Extrusion Temperature
structure and Microstructure of A70
ed. from Cast Ingots at an Extrusion
rissified in Pa - Sanitized Uopv App
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LIST OF FIGURES Continued)
13. The Effect of Extrusion Temperature on the Macro-
structure and Microstructure of A70 Titanium Extrud-
ed fromCast Ingots at an Extrusion Ratio of 50:1
14. The Effect of Extrusion Temperature on the Macro-
structure and Microstructure of A70 Titanium Extrud-
ed from Cast Ingots at an Extrusion Ratio of 70:1
15. The Effect of Extrusion Temperature on the Macro-
structure and Microstructure of A70 Titanium Extruded
from Cast Ingots at an Extrusion Ratio of 100:1
16. Rotating Beam Fatigue Results for Smooth and Notched
Ivo Titanium Extruded from, Cast Ingots
17. The Effect of Extrusion Temperature on the Macro-
structure of AllOAT Titanium Extruded from Cast
Ingots at an Extrusion Ratio of 10:1
18. The Effect of Extrusion Temperature on the Macro-
structure and Microstructure of AllOAT Titanium
Extruded from Cast Ingots at an Extrusion Ratio of
25:1
Rotating Beam Fatigue Results for SCLUAT Titanium
Extruded from Cast Ingots
The Effect of Extrusion Ratio on the Pressure
Required to Extrude A70 Titanium from Cast Ingots
at Various Extrusion Temperatures
Photographs of the Various Dies Evaluated Showing
The Condition of the Die After Extruding A70
Titanium
Photographs of the Various Dies Evaluated Showing
The Condition of the Die After Extruding AllOAT
Titanium
Photographs Showing the Surface Finish of Several
AUDAT Titanium Extrusions Utilizing Various
Lubricants
994(9,,
viii
Page No.
63
66
67
68
69
FIGURE NO.
9
LIST OF FIGURES Continued
24. The Effect of Die Angle on the Pressure Required to
Extrude A70 Titanium
25. Typical Fractures of Welded Test Bars Used in the
Maximum Joint Efficiency Study
26. Photomicrograph of the Weld Area of a Flash Butt
Welded Section of AliDAT Titanium
27. Photomicrograph of the Weld Area of a Flash Butt
'Welded Specimen of A70 Titanium
28. Photograph of a Titanium Sample Used to Obtain a
Heat Balance for Welding. Note: The Heat Penetra-
tion is Determinable by the Surface Discoloration.
29. Typical Fractures of Welded Test Bars Used in the
Maximum to Minimum Rib Ratio Study
STAT
Pale No.
714.
75
76
77
78
79
STAT
\
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Declassified in Part - Sanitized Copy Approved for Release
TABLE NO.
!1
LIST OF TABLES
The Notch-Tensile Properties of .A70 Titanium Extruded
from Cast Ingots and Forged Billets
II The Notch-Tensile Properties of AllOAT Titanium Extrud-
ed from Cast Ingots and Forged Billets
III Chemicalknalysis of Cast A70 Titanium Ingots
Iv Chemical Analysis of Cast AllOAT Titanium Billets
V The Tensile Properties of A70 Titanium Extruded from
Cast Ingots at Various Extrusion Temperatures and
Extrusion Ratios
VI The Tensile Properties of AllOAT Titanium Extruded
from Cast Ingots at Various Extrusion Temperatures and
Extrusion Ratios
VII The Pressure Required to Extrude A70 Titanium from
Cast Ingots at Various Extrusion Temperatures and
Ratios
VIII The Pressures Required to Extrude AllOAT Titanium
from Cast Ingots at Various Extrusion Temperatures
and Ratios
STAT
Page No.
27
28
29
30
31
35
38
IX The Effect of Die Preheat Temperature on the Surface
Finish of Extruded A70 and AllOAT Titanium
The Effect of Extrusion Speed on the Surface Finish
of Extruded A70 and AllOAT Titanium
XI ?Experimental Die Materials Evaluated
XII The Effect of Various Die Materials
Finish of Extruded, A70 Titanium
XIII The Effect of Various Lubricants on the
of Extruded AllOAT Titanium
XIV The Effect ? Various Lubricants on the
of ExtrudedA70,and AllOAT Titanium
Surface Finish
Surface Finish
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4
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LIST OF TABLES(Continued)
TABLE NO.
XV The Effect of Die Angle on the Surface Finish of
Extruded A70 and. AllOAT Titanium
XVI Welding Machine Settings at Thomson Welder for the
Study on Maximum Joint Efficiency and Maximum to
Minimum Rib Ratios
The Mechanical Properties of Specimens Welded for the
Study on Maximum Joint Efficiency
The Mechanical Properties of Specimens Welded for the
Study on Maximum to Minimum Rib Ratio
Page No.
46
47
Ii
I INTRODUCTION
Due to the high cost of titanium material the weight advantages gained
by replacing steel with titanium in jet engine applications are ex-
tremely costly. In the manufacture of steel parts the material cost
generally represents a small portion of the end product cost. Conse-
quently, the manufacturing method employed in producing such parts are
governed primarily by the economics of the operation. Thus material
utilization figures become secondary and in most instances run quite
law. For exotic materials such as titanium however) this cannot be
the case. A low material utilization factor for such materials can)
and often does) result in a machining scrap cost which far exceeds the
manufacturing costs.
Conventional forging of jet engine rings in titanium has a low mater-
ial utilization factor and consequently is expensive. The same rings
manufactured by extruding length close to the detail cross-section and
forming and welding for the end product utilizes considerably less
material. In addition, if cast ingots could be utilized instead of
forged billets as the extrusion stock) the cost of the end product
would be lowered considerably. This contract deals with the develop-
ment of such manufacturing techniques toward an economical production
process.
Prior to manufacturing actual parts) however) certain basic studies
were performed. These studies consisted of the following:
A. Material
At present the military specification controlling the quality of
AMS 4921 (T1470) permits a maximum of 0.20% oxygen content. The
titanium, producers will not guarantee the properties of AMS 14.921
and maintain an Oxygen content below-0.20%0' tests were performed
to determine the effects of oxygen contents in excess of 0.20 in
extruded sections.
Extrusion
1. The extrusion of sections directly from cast ingots is a new
concept. Consequently) the effect of extrusion temperature
and ratios on the mechanical properties of A70 and .A110AT
titanium were studied.
Difficulties encountered in initial extrusion of the AllOAT
titanium alloy required a study of theeffects of the extru-
sion proce,aing variables on the surface quality of extruded
sections.
Flash Butt Welding
The limited data available on the flash butt 'welding of titanium
necessitated a study of machine settings for maximum joint efficiency
and maximum to minimum rib ratios when 'welding comPlex cross sections.
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STAT
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STAT
49
19
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11 OBJECT
The objective of this report is to present the results of experimenw
tation dealing with:
The development of mechanical properties in extrusion of A70 and
A110AT titanium cast ingots',
The evaluation of the effect of extxrasion processing variables on
the surface finish of titanium extrusionsR
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11 ?
?
In SUMMARY
A0 Material
1, The A70 and AllOAT titanium cast ingots used for this study were
procured from Cramet, Incorporated. These ingots were melted
utilizing an induction Rstirring coil n which resulted in a homo.
gene= fine grained structure.
Notch-tensile tests were performed on extrusions from Ti-A70 cast
ingots with oxygen contents of approximately 0020% and 0025%0 The
total interstitial content was approximately 0035% oxygen equiva.
lent. These results are summarized as.,follows:
The transition temperature as indicated by this type of test
is below -65?F for both materials.
b. The notch.tensile properties were not effected by the range
of oxygen content examined. (Total interstitial content was
approximately the same)
Notch.-tensile tests were also performed on extrusions from Ti.A70
forged billets with an ovgen content of approximately 0.25%,
(Oe - 0.35%). The results obtained were identical with those
described for the oast ingot extrusion.
Notch.-tensile tests on AllOAT extrusions from both cast ingots
and forged billets indicated a transition temperature well
below .65?F0
Extrusions from Cast Ingots
1. Mechanical Properties and Microstructure
a. Ti.A70
(1) Extrusions were made from cast in ots at extrusion tem.
peratures of 15003 1600 and 170011 and extrusion ratios
ranging from 10s1 to 10021. The minimum specification
requirements of AMS 4921 of 70,000 psi yield strength
and 15% elongation were readily obtained for all extru.
sion conditions except the 1700?F extrusion at a ratio
A
of 10010
(2) The result of the above extrusion conditions on the
microstructure of the extrusion was quite pronounced.
Extruding in the alpha and, low alpha.beta region re-
stilted in a fine grained equiaxed structure. EXtruding
high in the alpha.'oeta region resulted in a coarser
gtained Widmenstatten structure,
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A
III SUMMARY Nontinued)
(3) The endurance limit for titanium extruded from cast in-
got was established to be 40,000 psi and 24,000 psi for
smooth and notched specimens respective370
Ti4110AT
(1) Due to surface tearing of the extrusions the evaluation
of this material was not as thorough as for the A70. The
4a,ta that was obtained, however, Clearly indicate extru-
sion temperatures below 19009F for.ratios of less than
50l to yield desirable properties.
11:
) At an extrusion ratio of 10?,1,,,the range of extrusion
temperatures from' 1650 to 18501' resulted in a similar
Widmenstatten structure? Increasing the ratio to 25:l
appreciably reduced the grain size.
(3) The endurance limit for this material was established
to be 65,000 psi for smooth specimens?
Extrusion Pressures
In general, lower temperatures and higher ratios resulted in
increased pressure. For the range of temperatures and ratios
examined pressure rea.d.ings from 50,000 psi to 130,000 psi were
recorded
Effect of Extrusion Variables on Surface Finish
ao, Die Preheat Temperatures
Maximum die temperatures of 7O ?F resulted in optimum surface
finish9minixrnxm pressures and rrdninrumi die pickup for both A70
and 1)3.10AT materisi?
Extrusion
eed
III UMW! (Continued)
d. Lubricants
Of the lubricants tested, the Fiske #650 resulted in the best
surface finish for both materials. Heating the billet in an
inert gas chamber proved slightly better than heating directly
in salt. Lubrication of the die and chamber was all that was
found to be required.
e. Die Design
Conventional die angles of approximately 110 to 130 degrees
? resulted in an optimum surface finish and minimum pressures
for the A70 material. The best combination of surface finish,
pressure, and die pick-up resulted from a 180 degree die for
the AllOAT material.
Flash Butt Welding
1. ?Minimum Joint Efficiency
The weld settings required to provide mechanical properties in the
weld zone comparable with the base metal were established.
Maximum to Minimum Rib Ratio
Mechanical tests on welded sections with varying rib thicknesses
indicate that rib ratios of 5.3sl can be successfully welded in
AllOAT and A70 material.
STAT
STAT
The extrusion speed had. little effect on die pickmup. However,
minima speeds of 450 .n/min resulted in optMuam surface finish
and required minimum pressures.
Most of the die materials tested with the A70 material stood up
well. ,Minimum die picktAip and minimum die wear were obtained
from the Haynes Stellite and Vasco Supreme dies? In extruding
the. AllOAT material, most of the dies, :broke down? The ,Haynes
Stellite, Rexallab .and Vasco Supreme dies did permit extrusions
of approximately 20 foot lengths with good surface finish?
w..V.V1,41rXraluw,y.etrn,Skail
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IV CONCLUSIONS'
The data assembled in this report permit the
1. The mechanical properties of titanium extrusions from cast ingots of
ANS 4921 with an oxygen content of 002% and a total interstitial
content of approximately 004% 04ygen equivalent are acceptable for
engine operation.
Optimum mechanical properties and microstructure developed in extru-
sions from AZO cast ingota by extruding in the temperature range of
1500 to 1600 F0
Optimum mechanical properties and microstructure developed in extru-
sions from AllOAT cast ingots by extruding at a temperature of ap-
proximately.1850?F and below,
Minimum pressures result from extruding both A70 and AllOAT material
at the high side of the temperature range noted immedAtely above.
The following extrusion processing conditions result in optimum
surface finish:
750
45o inimino
Haynes Stellite
or Vasco Supreme
Fiske # 630
Inert Gas
110 to
130 degrees
Complex cross sections of A70 and AllOAT materials can be flash
butt welded with excellent mechanical properties in the welds0
opy pprov
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IV CONCLUSIONS'
The data assembled in this report permit the
1. The mechanical properties of titanium extrusions from cast ingots of
ANS 4921 with an oxygen content of 002% and a total interstitial
content of approximately 004% 04ygen equivalent are acceptable for
engine operation.
Optimum mechanical properties and microstructure developed in extru-
sions from AZO cast ingota by extruding in the temperature range of
1500 to 1600 F0
Optimum mechanical properties and microstructure developed in extru-
sions from AllOAT cast ingots by extruding at a temperature of ap-
proximately.1850?F and below,
Minimum pressures result from extruding both A70 and AllOAT material
at the high side of the temperature range noted immedAtely above.
The following extrusion processing conditions result in optimum
surface finish:
750
45o inimino
Haynes Stellite
or Vasco Supreme
Fiske # 630
Inert Gas
110 to
130 degrees
Complex cross sections of A70 and AllOAT materials can be flash
butt welded with excellent mechanical properties in the welds0
opy pprov
d for Release @ 50-Yr 2013/09/09 ? CIA-RDP81-01043R002500180004-7
'11'4iVI,0011,40.POVVWWVAM4L4,,i141,1,4,AONWI,ING4.,wo
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VI DISCUSSION
A. Material
The titanium, material used on the program consisted of both the unm
alloyed AMS 4921 (TimA70) grade and the 5% A1m2% Sn titanium allay
(TimAllOAT). Procurement of the material for subsequent extrusions
presented two unique problems. Firs.t? the titanium producers were
reluctant to supply cast ingots. Cast ingots were desired as extrum
siOmmaterial to determine the feasibility of extruding directly from
a cast ingot, thus eliminating the cost ofend.thEV.material lost in
the forging breakmdawn operations Secondly? the titanium producers
would not guarantee a maximum oxygen content of 0.20% required by
military specifications for the strength level of AMS 4921 (Ti.A70
material).
The reluctance on the part of the titanium producers to supply cast
ingots was primarily due to their inability to guarantee a sound in-
got to specified mechanical properties. To expedite the procurement
of this ingot material the requirements for dertified physical propm
erties were waived in lieu of a certified chemical' analysis. This
modification permitted the procurement of both A0.70 and A110AT mater.
ial from Cramet? Incorporated, a newly established facility for
sponge titaaum and cast ingots of lted sizes
The melting technique employed by Cramet utilized a low power in.
duction "stirring" coil. The grain structure of the resulting in.',,
got is presented inTligure 1. As indicated by this photograph the
grains are essentially equiaxed, being both smaller and more uniform
than would be expected from conventionally melted oast ingots.
1. Oxygen content of A70 Material
Titanium producers will not guarantee a minimum yield:stren
of 70,000 psi (AMS 4921) with a corresponding maximum oxygen
content of 0.2N. Unalloyed titanium derives its strength
primarily from interstitial alloying of nitrogen, oxygen, and
carbons. These interstitials strengthen the titanium at MOM
temperature and slightly above p decrease the ductility, and
raise the ductilemtombrittle transition temperatures The
combined effect of these elements can be expressed in
of equivalent oxygen content as given by the following
equation.:
STAT
Declassified in Part - Sanitized Copy Approved for Release
?
At present the in c
ial is limited to the followin
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'11'4iVI,0011,40.POVVWWVAM4L4,,i141,1,4,AONWI,ING4.,wo
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VI DISCUSSION
A. Material
The titanium, material used on the program consisted of both the unm
alloyed AMS 4921 (TimA70) grade and the 5% A1m2% Sn titanium allay
(TimAllOAT). Procurement of the material for subsequent extrusions
presented two unique problems. Firs.t? the titanium producers were
reluctant to supply cast ingots. Cast ingots were desired as extrum
siOmmaterial to determine the feasibility of extruding directly from
a cast ingot, thus eliminating the cost ofend.thEV.material lost in
the forging breakmdawn operations Secondly? the titanium producers
would not guarantee a maximum oxygen content of 0.20% required by
military specifications for the strength level of AMS 4921 (Ti.A70
material).
The reluctance on the part of the titanium producers to supply cast
ingots was primarily due to their inability to guarantee a sound in-
got to specified mechanical properties. To expedite the procurement
of this ingot material the requirements for dertified physical propm
erties were waived in lieu of a certified chemical' analysis. This
modification permitted the procurement of both A0.70 and A110AT mater.
ial from Cramet? Incorporated, a newly established facility for
sponge titaaum and cast ingots of lted sizes
The melting technique employed by Cramet utilized a low power in.
duction "stirring" coil. The grain structure of the resulting in.',,
got is presented inTligure 1. As indicated by this photograph the
grains are essentially equiaxed, being both smaller and more uniform
than would be expected from conventionally melted oast ingots.
1. Oxygen content of A70 Material
Titanium producers will not guarantee a minimum yield:stren
of 70,000 psi (AMS 4921) with a corresponding maximum oxygen
content of 0.2N. Unalloyed titanium derives its strength
primarily from interstitial alloying of nitrogen, oxygen, and
carbons. These interstitials strengthen the titanium at MOM
temperature and slightly above p decrease the ductility, and
raise the ductilemtombrittle transition temperatures The
combined effect of these elements can be expressed in
of equivalent oxygen content as given by the following
equation.:
STAT
Declassified in Part - Sanitized Copy Approved for Release
?
At present the in c
ial is limited to the followin
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
In .general, extruding in the alpha and low alphawbeta regions
results in a fine grained equiaxed alpha structure. Extruding
high in the? alphambeta re .on (1700?P) or in the beta region
results in a coarser grained Uldmenstatten structure? The
super imposed effect of extrusion ratio tends to increase the
grai7n size with increased ratio.
Both the tensile data and the microstructure clearly establish
the extrusion temperature range of 1500 to 1600?P to be optimum
for.extrusion ratios between 1021 and 100:1. This confirms
. the results obtained by previous investigators (4).
,The endurance limit of titanium extruded from cast ingots :was
also determined? This data, presented 'Eraphicai37 in Figure
16, indicates an endurance limit of 48,000 psi and a notch
endurance limit of 24,000 psi. Shown also in this figure are
curves representing the endurance? limit of forged material as
published by the producer (a). As indicated the material exp.
truded from a cast ingot ha S an endurance limit within experi-
mental accuracy of forged barstock.
The'. determination of mechanical properties of extrusions from
AllOAT cast ingots was exceedingly difficult due to the difm
acuity encountered in extruding this material? Conventional
extrusion techniques applied to this material restated in
severe rupturing of the extruded surface. Subsequent studies
were performed to develop a satisfactory extrusion technique.
This is discussed in detail in the following section of this
report.
The tensile data from the available extrusions is compiled in 0
Table V. Rxtrusion temperatures in the range of 1650 and 1950 F
and extrusion ratios ranging from 1021 to 10021 were examined.
Due to occasional rupturing of the extrusions it was not possible
to obtain tensile data for each reduction and temperature. The
data that was obtained however, indicates extrusion temperature
below .1900?F for reductions less than 5081 to yield desirable
properties.
n general, extrusion temperatures above .19O0 0F (approximate;.
o
beta transus temperature 1930 F) result in an extrusion with
varying properties from front to back. Extruding at temperatures
below 1800 results in excessive extrusion pressures with red-
uction ratios in excess of 1081. Consequently, an approximate
extrusion temperature of 1850?F was selected. Tensile tests
on extrusions made at this :temperature and for reduction of
10:1, 25:1 and 48d are all well above the minimum specification
requirements*
M%WPI''Ne:4PW,W4R,1040M',4i!E
,
;94
16
VI DISCUSSION (Continued)
The macro and microstructuresfor some of these extrusions are
presented in Figures 17 End 18. For the 1021 extrusion ratio
and extrusion heat temperatures-between 1650 and 1850?F the
microstructure remains essentially constant, Figure 17. At a
reduction ratio of 25:1, Figure 181 the grain size is appre.0
ciably reduced. Both structures result from extruding in the
alpha-beta, region. The finer grain size results from the ad,.
ditional work imparted by the high reduction ratio.
The endurance limit was also established for AllOAT material
extruded from cast ingots. This data is presented graphically
in Figure 19. The indicated endurance limit of 65,000 psi
coincides quite closely with published data supplied by the
producer (5)0
Extrusion Pressures
Coincident with the determination of the effects of extrusion
temperatures and ratios on the mechanical properties of. extru.-
sions from cast ingots the pressures encountered were also
recorded. These results are compiled in Tables VII and VIII
and presented g37aphical1y in Figure 20 for both the A70 and
,A110AT material. As would be expected higher extrusion ratios
and. lower extrusionctemperatures result in higher pressures.
This is shown graphically in Figure 20 for the A70 material.
A similar plot for the AllOAT material was not possible due
to the erratic readings resulting from the severe surface
tearing, see Table VIII.
rilfect of Extrusion Variables on Surface.Finsih
The application of established extrusion techniques to A70 titan.
ium has resulted in extrusions of acceptable surface quality. The
application of these same extrusion techniques to the .A.110AT alloy
grade was completely unsu.ccessful. In addition to poor surface
finish it was not uncommon to completely tiwash.outit a die on e-
trudimg a length of approximately 10 :_C.eet. Initial
improving the surface of A110A.T extrusions
preheat temperature and decreasin
in a considerably impro
results a pro
Oft
STAT
STAT
V
A
tempts at,
y increasing the die
g the extrusion speed resulted
ved surface. Based on these encouraging
gram was initiated to evaluate the effect of each
he major extrusion variables on the surface finish of ex-
trusions. The variables examined were:
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Die preheat temperature
Extrusion speed
Die material
Lubricant
Die design
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VI rascussION (Continued)
These variables were investigated for both the A70 and 41.110AT
materials.
In order to evaluate these variables most expeditiously the tests
were run as follows. First?,the die preheat temperature was
? varied with all the other variablesteld fixed. The optimum die
? preheat temperature thus established was then applied as a fixed
? variable in the following tests. In a similar manner when the
optimum extrusion speed, die material, etc was determined these,
were also held fixed in subsequent tests. Consequently, each of
the variables was not evaluated independently. The results of
the investigation cleaay, establish this approach to be completely
adequate 'for this prdblem0
??
Die Preheat Temperature
With all other process variables held constant, the die pre-
heat temperature was varied from room temperature up to ap-
proximately 750?F. This upper limit was imposed due to the
consequent expansion of the die. The results of the' investi-
gation. as well as the specific processing conditions are
presented in Table IX.
,(1) Ti-A70
D eo preheat temperature of approximately 300, 4.00 and
750 F were tested. While no appreciable difference re
suited from die preheat temperatures of 300 to 400?F die
? preheat temperature of 750?F resulted in an appreciable
improved surface finish and a minimum of die pick-up.
noted represent that of the extruded section. The accumulated
results are caviled in Table X.
(1) Tit0A70
The variations in. speed had little effect On the die pick-
up or surface finish. The lower, speed, however, did require
considerable less pressure. It is interesting to note that
pressure required. for the 11,50 in/min extrusion is consider-
ably less than that reported in the previous section for
similar processing conditions, see Table IX. This difference
can only be attributed to the slightly higher speed (2,000
in/min) in the first series of tests. If this effect is as
? pronounced as indicated, a-very limited range of speed must
be utilized to take advantage of the lower pressures.
(2) Ti-A110,At
As indicated for the A70 material )lower extrusion pressures
result from low extrusion speeds, Table X. While the low
speed essentially reproduced the results of the previous
section, the fast extrusion resulted in a ftwashed-outil die
and ruptured surface. This slow speed (400 in/min) repre-
sents the miniraun obtainable with the 12,000 ton press.
c. Die Material
Die preheat temperatures ofeapproximately 150, 400 and
750?F Were tested. , The 150 F die resulted in an extrusion
tha+, was severly ruptured and torn. ?CorrespOnci.inglY
heavy die 'pick,-up ,and high extrusion pressures were noted.
While the 4001' extrusion required considerably less
pressure, heavy die pick-up and surface rupturing con-
tinUed. As noted in Table IX. the 750?F die extrusion
required a, minimum of pressure and only slight die pick.?
,u,p., Most important, however, was the improved surface
finish.
. Extrusion Speed
Extrusion speeds of approximately )450 and 10,000 in/min. were
tested.. As previously noted, the optimum die preheat tempera-
ture (750?F) was applied 'to the series of tests. The speeds
kt3,6 ?
The die material for the previously discussed extrusions was a
5% Cr hot-worked steel, heat treated to a hardness of Rc52. The
various die materials evaluated in this section are presented
in Table raco The number of die materia evaluated was neces-
sexily limited due to the excessive procurement cycle for other
die materials.
(1) Ti-A70
The results obtained from extruding through several different
dies are presented in Table XII. All of the dies tested
proved acceptable except a die made of AllOAT titanium.
Slightly better surface finish and minimum die wear resulted
from the Haynes Stellite and the Vasco Supreme die. Photo-
graphs of several of these dies after extrusion are present-
ed in Figure 2l.
(2) Ti-AllOAT
The results obtained from extruding through several differ-
ent des are presented in Table XIII. The Haynes Stellite
held up well for the first 20 feet of the extrusion. This
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VI DISCUSSION (Continued)
die then broke-down resulting in surface tearing over the
remaining length. The Wallex ?Dft Moly Faced, and !MOAT
dies all broke down from the beginning of the extrusion?
The Rexalloy die proved satisfactory for a 24 foot extrud.
ed length. All but one section of the Vasco Supreme die
held up well for a 33 foot extrusion. This broken section
? of the die, however, facedthe surface of the extrusion,
Photographs of several of these dies are presented in
Figure 22.
Lubricants
Previous results have indicated that lubricants applied to the
material are not as effective as lubricating the die and con-
tamer (6). In addition to the standard lubricants, chemical
and metallic 'coatings were applied to the billet. In all cases
severe rupturing occured. Initial extrusions with Fisk #6300 a
calcium base soap with graphite, vermiculite and calcium carbon-
ate, applied to the die, proved encouraging. The lubricant
previously applied was a combination of oil dag? nacroline, and
Lithiuxn-carbonate. In the test to be described all billets were
heated in an inert (argon) chamber submerged in a salt bath un-
less otherwise noted. The extrusion conditions and resulting
surface condition are presented in Table XIV. Due to the pro-
curement time on new dies and the success obtained with the 5%
Cr die, this die was used on all the following studies*
(1) Ti-A70
Fiske #604, Fiske #630 and no lubricant were evaluated.
While lower pressures resulted from the they de? the
Fiske #630 resulted in a much improved surface*
Ta.-AllOAT
Fiske #630 was applied to the die and container with one
ingot heated in argon and a second heated directly in the
salt. As pictured in Figure 23 the inert gas heated billet.
had an excellent surface finish for the first two thirds ,of
the .extrusion* (Extrusion length approximately twenty feet).
..The ingot' heated directly in the salt bath had an acceptable
surface finish throughout the twenty foot lengths, ''ee
Figure 23* The balance of the lubricants were equivalent to
extruding without a lubricant, see Figure 23 and Table XIV.
Die Design
The f inal study determined the, effect of die angle* Previous re.
sults (4) indicate an optimum die angle of approximately lbo de.
.grees for Ti-A700 In this study the range of die angles in.vesti-
Ilm,m0Wp0
"AMAM
7,""TM7T'irmT
2
Declassified in Part - Sanitized Copy Approved for Release
V3: DISCUSSION (Continued)
? gated was 90 to 180 degrees for both A70 and A110,AT materials*
The extrusion conditions and results are presented in Table XV
(1) Ti-A70
Die angles in the range of 110 to 1)40 degrees resulted in
minimum pressure, Figure 24. Based on surface finish and
die pick-up, howevero the range of angles between 110 and
130 degrees proved_optinrum, see Table XV* 1
(2) Tie,A110AT
Minim' um pressures readted from die angles of 1009 110 and
180 degrees, Table XV* Slight die pick-up and optimum sur-
face finish, however, resiiited from the 180 degree die. The
unusual results wen confirmed on subsequent extrusions.
This is discussed in part II of this Final Report*
Flash Butt Welding
At the initiation of this development program only limited data existed
pertaining to the limitations and machine settings required for maximum
properties in flash butt welded titanium sections. To permit the wtld.
ing of ring sections, a study was performed to determine the machine
settings required for maximum mechanical properties and the limiting
rib ratios which can be welded. These studies were performed at Thomson
Electric Welder Company, Lynn, Massachusetts?
1. Maximum Joint Efficiency
11.4110AT
STAT
The initial studies on maximum joint efficiency were performed
on 3/4 inch diameter All,OAT titanium ba,r0 Prior to welding the
ends of the bars were beveled 5 to 10 degrees for approximately
3/32 inch from the end to be weld.ed.. The first variable inves-
tigated was the Upsetting force which was varied from 12,000
to 184).000 pounds. The specific machine settings are listed
in column two of Table XVI()
The results of tensile tes:ting of these bars is presented in
Table XVII, (Part I). All of the upsetting forces examined
resulted in welds with tensile properties comparable to the
base metal. The vendors certified properties are also shown
in this table. In general, the test specimens fractured in
the base metal see Figure 25. This condition obviously in-
dicates the weld area to be of higher strength than the base
metal, A ductile fracture in tlie weld zone also occurred,
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VI DISCUSSION (Continued)
Figure 25a The presence of this type of fracture indicates that
the upsetting pressures did not appreciaay increase the hardness
of the lield area.
Within the present program the maximum cross section area en.-
countered in the ring sections is 1.22 .square inches. With the
'machine capacity limited to 32,000 pounds upset, force, the max..
mum pressure on this part would be 269000 psi. This is equ5Nam
lent to an upset farce of approximate37 12,000 pounds applied
to the 3/4 inch diameter bars, This value therefore represents
a limiting condition?
Drentymfive additional bars were welded at the machine settings
listed in Table XVI,' column three. The resulting mechanical
properties are presented in Table XVII (Part I) for three of
these bars. One of these bars was sectioned through the weld
for metallographic inspection and a microhardness survey. Prior
to sectioning, this bar was stress relieved at 1200?F for 24 hours,
The resulting microstructure is presented in Figure 26.
The results of the Tukon Hardness survey follows:
Parent
Parent Meta
Parent Metal
Parent Metal
Heat Affected Zone
Weld
Heat Affected Zone
Parent Metal
Parent Ffetal
Parent Metal
Parent Metal
Metal
DPH
325
309
?325
334
25
340
317
352
352
352
317
Rc (converted)
33
31
33
34
33
35
32
36
36
36
32
As indicated the scatter observed in this hardness study pre..
eluded the confirmation of the increase in hardness of the weld
zone indicated by the photomicrograph, see Figure 26.
Following the above studymld studies were made on A70 material,
Twentymone bars were weldedosarying the preheat, postheat? forging
delay, flow valve setting; and tap setting. Preheat, postheat, and
forging delay did not improve the quality of the weld, therefore,
their use was discontinued. Nentymeight bars were then welded at
the machine settings listed in Table XVI, column four. The results
of tensile testing these bars is presented in Ihble XVII (Part II)ete
VI DISCUSSION (Continued)
Also presented in this table an; the vendor's certified proper.'
ties for the material. It is noted that materials of two
strength levels were used. Consequently, the low tensile
values exhibited in the weld specimens are not indicatiVe of
low weld quality bat merely reflect the strength level of the
base material. In all the welds examine4 the tensile propel's'
ties were equivalent to the base metal. The specimens tested
were either stress relieved at 1300?F for 1 hour or heated to
?12001' for 24 hours. No appreciable difference in properties
was exhibited by the different stress.-relief cycle()
Table XVII (Part 11)D alsp presents the results of notch
rupture testing? As indicated a stress of 90,000 psi had
been applied for over 15 hours without failure. Mese sped.,
MtDAS were eiper stress relieved by heating to 13000F for 1
hour or 1200 F for 24 hours?
Microhardness studies were performed on both the low and high
strength level materials. As was the case for the AllOAT
material, the scatter in the hardness test did not permit a
confirmation of increased hardness in the weld area indicated
by the microstructure, Figure 27.
Maximum to Minimum Rib Ratios
Bars tock of A70 material machined to the following configurations
was used for this studys
STAT
Initial work consisted of a determination of a satisfactory heat
balance, Figure 28. These specimens used have a 3/1611 minimum rib
thickness. This constitutes a 2.6 rib ratio,
All the edges of the thicker section were beveled 5 to 10 degrees
for approximately 3/329 from the end to be welded. The thinner
section was tapered in such a manner-that the edge of the bar
was 1/411 from the butted ends of the thicker section, The machine
settings for this study are shown in Table XVI9 'Flat tensile spem
cimens were cut from the thicker and thinner sections with the
weld zone in the middle of the test length0 Test results (26:].
ratio) are tabulated in Table XVIII0- These results Clearly
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VI DISCUSSION (Continued)
illustrate the resulting satisfactory mechanical properties*
Figure 29 shows typical tensile fractures for these specimens*
Three welds with 3/32" minimum rib were welded at the settings
listed in Table XVI. This minimum rib represents a 503:1 rib
ratio* These tensile results are also listed in Table XVIII.
The predetermined final die opening on bars #11 and #13 may
account for the low reduction in area of bar #12.
While all the above data were obtained for A70 material exclu-
sively, there is little doubt that the results apply for the
AllOAT material also the only difference being the slightly
higher upsetting forces required by the AllOAT material due
to its higher flow stress.
VII RISFERENCES
1. flier; Feola; N.J. and Sachs; Go, WADC Technical Report 5,325)
"The Effect of Interstitial Contaminants on the NotchmTensile Proper*
ties of Titanium and Titanium Alloys; Part I m. Sponge Titanium";
date July, 1955$
? 2. WAD Serial Report Noo NP. 00Th, "Titanium Manufacturing Methods
Developnent m Part I " Quarterly Progress Report No. 6, Contract No.
I733(600)30262; submitted to AMC and WADC November 25; 1956.
3, Niter; E.P. and Feola; N.J. WADC Technical Report No. 55m325; "The
Effect of Interstitial Contaminants on the Notch.-Tensile Properties
of Titanium and Titanium Alloys m Part II m Alloy Titanium"; dated
October; 19556
40 Ssmbrott, A.M. et. alo; WAX Technical Report 514455, "The Extrusion
of Titanium", dated March 19550
56 Rem Cr Data Sheet.
66 WAD Serial Report No. hP. 00646, "Titanium Manufacturing Methods
Development m Part I" Quarterly Progress Report No. 5 Contract No.
AF33(600)302620 submitted' to AMC AND WAD; August 25 3.9560
???
STAT
70 "Titanium Method Development Program9 Final Report m Part B Materials
and Basic Studies"? submitted by Metal Processing Division to Wright
Aeronautical Diyision; January; 3.957.
80 flier, E.P,) and Gazzara, CO3 "The Tensile and Notch-Tensile Proper*
ties of SeI:oted Titanium"; Syracuse University Research Institute;
8ubmitted to Wright Aeronautical Division, January, 1957.
24
?
R?0 5
,
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
VI DISCUSSION (Continued)
illustrate the resulting satisfactory mechanical properties*
Figure 29 shows typical tensile fractures for these specimens*
Three welds with 3/32" minimum rib were welded at the settings
listed in Table XVI. This minimum rib represents a 503:1 rib
ratio* These tensile results are also listed in Table XVIII.
The predetermined final die opening on bars #11 and #13 may
account for the low reduction in area of bar #12.
While all the above data were obtained for A70 material exclu-
sively, there is little doubt that the results apply for the
AllOAT material also the only difference being the slightly
higher upsetting forces required by the AllOAT material due
to its higher flow stress.
VII RISFERENCES
1. flier; Feola; N.J. and Sachs; Go, WADC Technical Report 5,325)
"The Effect of Interstitial Contaminants on the NotchmTensile Proper*
ties of Titanium and Titanium Alloys; Part I m. Sponge Titanium";
date July, 1955$
? 2. WAD Serial Report Noo NP. 00Th, "Titanium Manufacturing Methods
Developnent m Part I " Quarterly Progress Report No. 6, Contract No.
I733(600)30262; submitted to AMC and WADC November 25; 1956.
3, Niter; E.P. and Feola; N.J. WADC Technical Report No. 55m325; "The
Effect of Interstitial Contaminants on the Notch.-Tensile Properties
of Titanium and Titanium Alloys m Part II m Alloy Titanium"; dated
October; 19556
40 Ssmbrott, A.M. et. alo; WAX Technical Report 514455, "The Extrusion
of Titanium", dated March 19550
56 Rem Cr Data Sheet.
66 WAD Serial Report No. hP. 00646, "Titanium Manufacturing Methods
Development m Part I" Quarterly Progress Report No. 5 Contract No.
AF33(600)302620 submitted' to AMC AND WAD; August 25 3.9560
???
STAT
70 "Titanium Method Development Program9 Final Report m Part B Materials
and Basic Studies"? submitted by Metal Processing Division to Wright
Aeronautical Diyision; January; 3.957.
80 flier, E.P,) and Gazzara, CO3 "The Tensile and Notch-Tensile Proper*
ties of SeI:oted Titanium"; Syracuse University Research Institute;
8ubmitted to Wright Aeronautical Division, January, 1957.
24
?
R?0 5
,
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE II
NOTCH TENSILE PROPERTIES OF A-110 ...AT
TITANIUM EXTRUDED FROM CAST INGOTS AND FORGED BILLETS
Notch
Strength
Ratio
ik.V210.2.
1046 7.13 6075
1046 6020 5041
1.41 5.60 5.06
1.23 2.85 3.06
Cross=
Head Test Tensile
Movement Temp Strength
Material (Inikin) J.?F), 119.PLRELL
2.0 75 133.5
-65 153.2
-100 15201
-320 18900
. 0,O97%
0.017$
? 00010
75
-65
400
75
45
400
-320
12405
14401
15201
19600
135?2
1525
15705
20100
13100
151?5
157?5
208 0
Notch
Strength
11.0.0022.6j14
19700 193,0
2090. 211.0
215.0 214.0
23300 230.0
19205 19500
21000 21400
22200 221.0
260.0 24800
193.5 19000
211.0 201.0
207.0 206.0
214.0 204.0
19i.5 'l89,0
207'0 203 0
218.0 21400
226.0 22800
28
Reduction in Area
(Percent)
Notch 00 Smooth
1056
1.38
1046
1.30
1042
1.35
1.31
1004
1.45
1035
1037
1.09
5010 5037
4052 4055
4080 5009
2067 3009
5011 5077
3.13 4052
3.67 3.63
2.27 2.55
5l0 3.12
3.65'3097
2.85. 2.55
2.00 1.98
2601
23.7
23.0
2203
2406
21.7
2004
1601
3507
2804
27.7
22.9
3304
2304
2404
19.4
Mill Heat Nos. &
Corresponding
Heat Code Noso
Assigned
TABLE III
CHEMICAL ANALYSIS OF CAST A70 TITANIUM INGOTS
0
2
2
2-1145 - Vendor
A141-1 Nat'l Res.
A141-2
A141-2
A141-3 n H
24128 - Vendor
A140-1 Nat'l Res.
vi 11
11 41
It If
A140-2
A140-3
A140-4
2-1105 - Vendor.
A1394 Nat'l Res.
2-59S - Vendor
A137-B Nat'l Res.
Fe Mn Oe*
2
Spec. .20 Max. 00125 Max?
240688 - Vendor
?A136-B Natl'l Res.
.240
024
014*
.26
023
* This
.243
.25
.27
.26
.23
.243
.28
0240
.14
0..263
.26
.0030
.0019
00053
.0017
.07 Max. .20 Max. To Be Reported
.048
0046
0050
.046
.036 .31 .08 .354
00020
may be a misidentification of sample
.0030
.0015
00029
.0030
.0024
.0024
00017
.0041
.0017
.060 .055 033 .08 .388
0048
.048
.046
0047
0052 .037 029 ? 007 0363
.026
0026
.033
STAT
*Oe uxygen Equivalent
%07/ 2% N 7L 2/3% C
Ingot Size - 7 1/2 in. dia.
length 36 in.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
_R.:,-,...r.....7.,.,.,A.A14iM4,A0,,i40,44.,4.,,,,..,.....,,0?:...41,A.,4,A,.,,,,,,,,,,i,,,,,g,?c4?1?,;,',=%.',';WZZ.:ZO';.',.-"-"-
0'
V
\
frl
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
'
STAT
THE TENSILE PROPERTIES OF A70 TITANIUM EXTRUDED 'FROM CAST INGOTS AT
VARIOUS EXTRUSION TEMPERATURES & EXTRUSION RATIOS
Tensile 02% Yield Elongation Reduction Charpy "V" Notched Billet Preheat
Billet Extrusion Strength Strenith In Impact - ft-lbs Temperature
Ratio (PE) 1221.2114ALor
(Painnti.72F
101/ 114,400R
103,80OR
103,200F
1P1.111.25E1
Avg. 106,225
99,930R
99 000R
102,000F
102 000F
An. 100,730
2132S- Vendor
A14.8-B Natgl Res.
MPD
A148-F
4129S - Vendor
A150-B Nato' Res.
MPD
A150-F
25:1 100?100R
99,490R
96
5.2 2.8
5.1 2.9
4095 2.85
? .
,
R - sear
F - Front
84,300 2144 35.8 16.5 11.0
80,400 2208 36.9 16.0 13.5
83,4.00 22.1 35.8 1r11.0 13.0
000 all_ 21,1, 1..4,2, 15.0
82?,.75 22.4 36.7 15.6 13.1
74,700 35.4 14,5
75,000 22.8 3L7 15.5 12,0
76,800 22.8 3345 1.4.5 14.0
77 1,..11L0 ail ILL)
755..900 22.8 33.8 14.0,6 13.1
72,000
72,300
75,300
162222
73;950
78?0
12.5 1700
14.0 12.0
1.7 14.0 14.0
au 14.5 13.5
09 35.5 14.1 13.0
22.8 34..0 15.0 14.0 1500
74,170 ,21.4 32.6 17.0 14.0
480F 74,170 2241, 3800 1905 15.0
Avg. 98,765 75$14(5 ' 22, 02 36.7 . 3503 .9.0 16.0
11.6 14.7
.21,L 71,970 RA
.036 .10 .08
00 .04 .10 .09
5.1 2095
Ingot Size - 7 1/2 i
no Dia. - Length 36 in.
Vendor: Cramet, Inc., Chattanooga, Tenno
30
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
uggigtqtoll=exwauv,
,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
ImILLIcoNTor)
THE TENSILE PROPERTIES UF A70 TITANIUM EXTRUDED FROM CAST INGOTS AT
VARIOUS EXTRUSION TEMPERATURESA EXTRUPON RATIOS
Tensile
Billet Extrusion Strength
Noo? Ratio 12?IL__
A141-3 25:1 101,400R
100,800R
103,800?
1221522Y
Avg. 102475-
A141-2 251 89,500R
105, 600R
109,000F
127.2.522P
Avg. 102,900
A140-3 50:1 114,100R
1080400R
103,200F
102 600F
Avg. 107,075
A140-2 501 108,780R
114,00OR
111,600F
111,300F
Avg. 111,420
.2% Yield
Strength
58,600
77,400;
81,600
g.?00Q
79,650
67,510
73$1800
81,500
22222
75,625
81,600
81,000
80,000
glAR
80975o
77,280
87,000
86,400
86 100
84,195
Elongation
21.4
21.4
22.1
20.7
21.4
27.3
28.6
22.8
22.8
2504
2201
23.5
23.5
23.1
22.8
22.8
20.0
21L4
2/.7
Reduction
In
LPILLitrit
33.0
30.7
3701.
2142.
3404
4007
3701
28.5
34.0
38.9
3903
3907
3907
3904
35.8
3201
2704
28.8
31.0
Charpy "V" Notched Billet Preheat
Impact - ft - lbs
75?F 4o?F
18.5
18.0
16.0
16.0
17.1
18.5
1900
16.5
16.0
17.5
Temperature
oF
13.0
13.5
11.5
12.0
12.5
1600
1700
11.0 1500
15.0
14..0
1421
13.6
1600
Billet
No.
STAT
TABLE11221.)IT0D
THE TENSILE PROPERTIES OF A70 TITANIUM EXTRUDED FROM CAST NGOTS AT
VARIOUS EXTRUSION TEMPERATURES & EXTRUSION RATIOS
Extrusion Tensile .2% Yield Elongation Reduction Charpy. "V" Notched Billet Preheat
Ratio Strength Strength A n Im8act -ft - lbs Temperature
PSI Percent F ?F
1140-4 50:1 101,400R 79,200 2104 38.4 18.0
103 ,500R 75,500 22.8 3704 17.0
96,000F 75,000 220.8 40.2 1900
25.1422f 75.000 24.2 4.0.2 2.....L.9.2
99,075 76,175 22.8 39.0 18.8
Avg.
A137-B 70:1 81,600R 62,400 26.3 43.2 *
81,600R 61,200 26.3 42.8 *
82,200F 61,800 24.2 38.9 16.0
79 800F 60 600 2422 38.? 16.0
81,300 61,500 25.3 40.9 16.0
* Defective Impact Specimens
A1374 70:1 88,800R
85,200R
85,680F
2.4a2.60F
Avg. 86,160
660000
65,520
63,120
62 160
64,200
A137-2 70:1 94,310R 68,980
94,320R 70,800
880800F 69,600
12.1.292:
Avg. 91,832 69,335
24.2
27.1
25.7
aa
25.6
3000
30.0
24.2
27.1
42.8
43.2
40.7
42.0
39.8
3904
38.5
3901
29.0
2805
25.5
21.5_
2701
27.0
27.0
25.5
215_
28.2
1310 1700
13.0
17.0
15.Q.
14.5
18 0 1500
18 5
15.5
16.8
21.0 1600
20.0
19.5
18.5
19.7
27.0 1700
28.0
31,5
29.6
Rear
- Rear
- Front
32
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
t
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
132a1.1922:ilID
THE TENSILE PROPERTIES OF A70 TITANIUM EXTRUDED FROM CAST INGOTS AT
VARIOUS EXTRUSTION TEMPERATURES & giXTRUSION RATIOS
? Billet Extrustion
No. Ratio
A136-B 100:1
A136-1 1061
A136-2 100:1
Tensile
Strength
("Ea _
105,120R
108924OR
103p920F'
1222W
Avg. 1049940
vg
1059000R
106,320R
105,600F
125,11kg
105,570
123,600R
130,200R
119,400F
Avg. 122,700
.2% Yield Elongation Reduction Charpy V! Note e e re eat
Strength ' In Area Impact - ft - lbs Temperature (PAMmt),1?.(Percent) 750 F oF
82,320
82,180
78,240
EL960
80,425
87,600
879400
84,720
15.291.,D
86,182
24.2 41.0
25.7 4302
24.2 3907
,41.1
2404 4100
2305 4302
22.8 4302
22.8 3907
212A 222.,
2206 40.5
102,000 507?
102,480 7.0J. **
87,600 14.2- 14.0
i?.3.4cLo ,31105
94,620 1104 2004
itrx. Tensile Bar Broke In Threads
34
1500
1600
1700
Billet
No.
A146-2
TABLE VI
THE TENSILE PROPERTIES OF AllOAT TITANIUM EXTRUDED FROM CAST INGOTS AT
VARIOUS EXTRUSION TEMPERATURES & EXTRUSION ? RATIOS
? Extrusion
P.atio
10:1
A1474 10:1
A-146-F
A145-1
10:1
10:1
- Rear
.04
Avg.
Avg.
.Avg
Avg.
Front
Tensile
? Strength
? (PSI).
132,00OR
133,80OR
134,2.40F
133,570
125,12OR
123,000
126,660F
120 600F
123,845
1329960F
131,700F
131,14OR
132,100
1229700R
122,70OR
123,600F
1:11E2E.
123,000
STAT
.2% Yield Elongation Reduction Charpy 'IV" Notched Billet Preheat
Strength AIna Im8act - ft - lbs Temperature
(PSI) Percent (Per4enti 25." .40oF oF
120,000
124,200
127,270
126 660
U4,532
15.0
16.3
14.3
15.7,
15.3
27.9
28.4
29.6
atA
28.8
1650
117,280 14.2 ? 21.7 27.0 19.5 1700
113,400 14.2 28.8 28.5 19.0
115,500 ? 14,,.2 26.6 26.0 19.0
1.1.2.011 1.4j4. 2.6 29.0 23.0
116,115 14.2 27.14. 27.6 ? 20.1
125,420
123,900
1249.200
126.000
124.9.880
::194108000
1119300
111,000 20
111,525
1500 31.3
15.0 27;9
1643 32.6
2,1a 24.12
1545 31.4
17.1 31.7
15.7 30.9
15.7 31.4
160.4 12.6
16 2 ? 31.6
28.0
28.0
29.0
29.2
1750
19.0 1850
20.0
20.0
20.0
19,7
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,w,;:a.o.w4a1V.,==M;(4,4W,14MaQW,n4a)4NVXZ
Billet
No.
A145-F
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE VI (CONT' D)
THE TENSILE PROPERTIES OF AllOAT TITANIUM EXTRUDED FROM CAST INGOTS AT
VARIOUS 4TRUSION TEMPERATURES & EXTRUSION RATIOS
? Tensile
Extrusion Strength
atio (PSI)
25:1 118,800*R
118,190*R
124,620 F
12AA20 F
?
Avg. 121,607
.2$ Yield Elongation Reduction Charpy "V" Notched
Strength In Impact - ft - lbs
Percent .(PgatrA1:02.............Z100:
106st200*
110,950*
108,540
11.41.5.M.
110,065
7.1*
7.1*
14.2
14.2
10.6
** - Defective Long Test Bars
A216F 25:1 134,460
136,960
126,000
125,420
122,420
126a/
Avg. 128,931
A2164 25:1 113,330
113,330
126,730
124,240
125,000
?2211PM
Avg. 127,938
A217- 25:1 139,390
130,000
127,430
125,000
126,060
1329000
1299980
123,010
126,660
113,400
114,570
113.9930
1.2.Ajzo.
117,996
121,210
121,810
115,410
112,120
112,800
113)410
116,132
129,090
118,180
115,850
112,800
114,540
120 600
118,430
10.0
8.5
11.4
10.0
11.4
10.0
102
10.0
8.5
10.0
10.0
11.4
10.0
10.0
,1000
10.0
11.4
11.4
12.8
8.5
10.7
36
11.3*
8.2*
3067
30.7
20.2
18.6
17.2
24.0
19.1
25.7
23.1
21.3
17.8
18.7
23.2
21.8
24.2
22.2
21.3
18.7
20.8
23.7
281
18.1
21.9
29.5
29.5
27.5
&Li
28.6
Billet Preheat
Temperature
26.0 1850
25.0
26.0
26.0
25.7
1900
1900
1900
Declassified in Part - Sanitized Copy Approved for Release
STAT
TABLE VI CONT0D
THE TENSILE PROPERTIES OF AllOAT TITANIUM EXTRUDED FIM CAST INGOTS AT
VARIOUS EXTRUSION TEMPERATURES & EXTRUSION RATIOS
Tensile .2% Yield Elongation Reduction Charpy "V" Notched Billet Preheat
Billet Extrusion .Strength Strength In
Area Impact - ft - lbs Temperature
.40oF oF
No. Ratio,:1 PSI) ig2T9Alii..1191nEtl.25vF
A145-3 ? 48:1 127,230R
127023011
? 124,800F
1.?..?AgRE
Avg0 126,465
115,290
114,570
112,200
1,15.,.492
114,315
1402
14.2
1507
15.0
14.7
29.0
28.0
?32.6
31.0
A151-B 70:1 102,600*R ?93,600R?
121,300 108,540 ?1402 ?294
123,010 110,950 ? 12.8 25.1
1222.2. 121221 ILA ? 21.2
Av$. 119,440 108,270 12.6 25.2
* Defective Tensile Bar
A151:1 I00:I 122,420F
122,240F
125,470
?.121.21.700
? Avg. 124,457
-Rear
Front
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
108,540
108,000
112,160
ILLga
110,810
14.2
1507
11..4
11.4
112
3003
3007
22.7
25.2
27.2
30?0
25.5
26.0
26.0
26.8
2305 1850
23.5
23.0
2241
23.3
1950
1950
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
STAT
TABLE VII
TABLE VIII
THE PRESSURE REWIRED TO EXTRUDE A70 TITANIUM FL!L AT VARIOUS
EXTRUSION TEMPERATURES AND RATIOS
Extrusion
Billet Number Ratio
Billet 1?012Lota
THE PRESSURES RE UIRED TO EXTRUDE AllOAT TITANIUM FROM CAST INGOTS AT VARIOUS
EXTRUSION TEMPERATURES AND RATIOS
Extrusion Extrusion
Speed (WILEL pressilnim
A-139-1
A-140-1
A-141-1
10:1
10:1
10:1
1500
1600
1700
58
69
68
68,320
52,140
35,560
A-141-4
A-141-3
A-I41-2
A-140-4
A-I40-3
A-140-2
25:1
25:1
25:1
1500
1600
1700
105
108
134
97,100
86,300
57,540
50:1
50:1
50:1
1500
1600
1700
122
203
144
111,480
100,690
64,730
A-137-B
A-137.1
A-137.2
A-1364
A-136-1
A-136-2
70:1
70:1
70:1
1500
1600
1700
138
250
321
125,900
97,090
61,130
100:1
100:1
100:1
1500
1600
1700
14
127
371
133,050
107,900
71,900
Extrusion Conditions:
(1) Valve - 4
(2) Red.. Ratio - Variable
(3) Billet Size - 71/2 dia.
'4,) Ext. Lgth. - 8'
(5) Lubricant - oil Dag
Necrolene
Lithium
6) Billet Heating - Salt
(7) Die Design - 130? - 90? Incl.Angle
x 14" (8) Die Material - 5% Ch. H.W.
(9) Billet Temperature - as shown
(10) Container Temperature - 800?
(11) Die Preheat - 2800F
Extrusion
Billet Number Ratio
A445-1 10:1
A-145-F 25:1
A-150-B 25:1
A-145-3 50:1
A451-2 50:1
A447-1 5021
A-15I-B 70:1
A4514 100g1
Extrusion Conditions:
Extrusion Extrusion
2111911MIECt9Dt21. .Ipd. inimAd LuggEtIEELL
1850? 63
1850 81
1925 140
1850 162,
1925 225
1950 133
1950 326
1950
57,540
71,920
61,130
125,860
79,110
86,300
79,110
79,110
(I) Valve -4
(2) Red. Ratio - Variable
0) Billet Size - 7 1/2 Mao x 14' L
(4) Ext. Lgth. - 3? - 27?
(5) Lubricant - Oil Dag
Necrolene
Lithium
(6) Billet Heating - Salt
(7) Die Design-. 130? "" 90? Incl. Angle
(8) Dia Mate]. 5.$ Ch. H. M.
(9) Billet Temp. - As shown
(10) Container Temperatgre - 80O ?F..
(11) Die Preheat - 2809F
38
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1,t
Billet
Nol
?????????.r
A.A.424
A-130-B
A-I42-B
r,110
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE IX
THE EFFECT OF DIE TEMPERATURE ON THE SURFACE
FINISH OF EXTRUDED A70-AND A110 AT TITANIUM
Die
Temperature-?
280
Extrusion
Speed
111:01112t0SJ
A70 - Titanium
Extrusion
Pressure
(PSTL?..._
360 79,112
400 480 79,112
750 2,340 82,700
A-245-B 150
A-245-1 400
A 245-T 740
Extrusion Condition:
Extrusion Die
Length ..
A-11043- Titanium
360 106,080
363 79,112
480 57,536
(1) Valve'- 1/4 (Closed)
(2) Reduction Ratio - 25:1
(3) Billet Size - 7 1/2 Dia. x 12n Long
(4) Ext. Lgth - 12" - 15'
(5) Lube - Fiske #630
12?
Heavy
108" Medium
120111" Slight
Surface
Finish
Heavy Stria. (one
side). Fair finish
Slivering last 2'
Med. Stria, Fair
Finish. Sliver-
ing last 3?.
Slight to Med.
Stria, Fair to
good finish.
17'8" Heavy Severe rupturing
and tearing.
169
Heavy Heavy. Stria,
rupturing and
tearing
1508" Slight Medium finish
(6) Billet Heating - Argon - Salt
(7) Die Design - 130? - 90?- Incl. Angle
(8) Die Material - 5% Ch. H.W. Rc-52
(9) Billet Temp. - 1 Hr. 1550? A70
(10) Container Temp. - 800?F
(11) Die Preheat - Variable
40
TABLE X
THE EFFECT OF EXTRUSION SPEED UN THE SURFACE FINISH OF
MIKUMELEELII021=121
Billet Valve
No. Setting
OLIktanium
Die
Temperature - F
A-209-B Closed (t) 700
A-142-T
700
A-246-B Closed ( ) 750
A-247-B 750
Extrustion
Speed
Extrustion
Pressure
112111___.
Extrustion Die
Length Pickup
450 46,748 119 2"
15,6000
75,516
A-1104T Titanium
Extrusion Conditions:
(1) Valve - Variable
(2) Reduction Ratio - 25:1
(3) Billet Size'- 71" dia x 12" long
, 4
(4) Ext. Leng#1 - 121 - 15'
(5) Lute Fiske No. 630
139
Medium
Medium
420 53,940 13 6" Land
Partially
Washed
Out
8,880
STAT
Surface
Finish
Med. to
Heavy stria-
tions. Bad
finish
Med. -first
half, med.
to heavy-
1st half,
fair to
good finish.
Rupt.
tearing con-
dition.
Fair to
good finish.
61,132 12 0 Land Rapt* &
Washout tearing
throughout.
(6) Billet Heating - Argon - Salt
(7) Die Design.,,- 130? - 90? incl. angle
(8) Die Mat. - 5% Ch. H.W. Re-52
(9) Billet Temp. 1 hr. L15500 - A70
11/4 hr. @ 19000 - A-110AT
(3,0) Container. - 8009F
(11) Die Preheat -'700? - 800?
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
Manufacturer
,
,?!Am
1.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XI
EXPERIMENTAL DIE MATERIALS EVALUATED
Trade Name
1. Haynes Stellite #6
Stellite Co,
2. Wall Colmonoy
Corp. Wallex "D"
3. Crucible
Steel
'LTA
imposition Rock "C"
Cast 10, 27Cr, .16Mn, 65 Co, 42-52
41, 3 Fe, 8S1
Cast Tungsten, Chromium,
Cobalt, & Carbon
Rexalloy #33 Cast 2.250, 33Cr, 44Co,17W
4. Beryllium Beryllium
Corp. Nickel
Cast .5Cr, Bal Ni, 2.75Be
Hard Face
Weld
Moly
Faced
Hard .34C, 5Cr, 2.28 Moly,
Faced 20V .30mn, 1.35W? 131,
.025P, ?.0258
emarks
High impact, tough
resistance to hot
dnecking,
48-53 Excellent abrasive
resistance, and
corrosion resis-
tance. Fair impact,
very pot falling,
excellent red.
hardness,
55 63 High red, hardness
superior resist,
to abrasion and
corrosion. Low
coefficient of
frictiom.
50-52 High Strength &
Hardness.
Billet
No.
A-209-T
TABLE XII
THE EFTECT OF VARIOUS DIE MATERIALS ON THE SURFACE FINISH OF
Die
Material
Haynes
Stellite
Extrusion
Speed
minute
840
A-2124 Wallex "D" 480
A-212-T Rexa2loy
A-214-13 Ceramic
Coated
A-213-B Vasco
Supreme
960
A70 Titanium
Extrusion
Pressure Extrusion
(PS') itrat.
82,708
107,880
86,304
Die
Condition
29170 Med. Erosion; Lost
.005" on Dia.;
Prod to Back.
1516" Slight Erosion;
Lost .004" on Dia.;
Die split.
18111u Slight die pickup;
Dia. held constant;
Die cracked.
1914" Slight die pickup;
Lost .0351 Front to
Back.
Surface
Finish
Slight Stria. Last
51 badly torn.
Med. to heavy
Striations finish
good 3/4 of lgth.
Med. to heavy
striations deep
score one area.
Medium to heavy
striations one
area.
STAT
2116" Slight die pickup;
Lost .010" Front to
Back.
InduseCity. Ceramic
Boring Coated
Linde al Si Mag
Hard al. Si Mag.
Faced
Like Resistance to
Diamond Abrasion
A-110-AT
211 L Slight die pickup;
Lost .020m Front to
Back.
Good Finish except
med. to heavy
striations one
area.
Medium to heavy.
striations.
76 Vanadium Vasco Supreme High 1,57 C, 475Cr, 5V, 025 64
Alloys Steel Speed Mn., 5 Co, 1205W, .25Si
Company
High hardness,
hot hardness, wear
resistance.
Extrusion Conditions'
(1) Valve - 1/4 (Closed)
(2) Reduction Ratio 50:1
(3) Billet Size es 7 1/2 Dia. X 12" Long
(4) Ext. Length is 121 . 151
(5) Lube - Fiske #630
(6) Billet Heating - Argon Salt -
(7) Die Design 130 90? Incl.
(8) Die Material - Variable
(9) Billet Temp-,. - 1 hr. 1110 1550?F A70
(10) Container Tamp. 800?F
(1.1) Die Preheat - 550?F
(12) Billet Temp - 1 1/4 hr. g 19000F A-1104T,
42
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043
Manufacturer
,
,?!Am
1.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XI
EXPERIMENTAL DIE MATERIALS EVALUATED
Trade Name
1. Haynes Stellite #6
Stellite Co,
2. Wall Colmonoy
Corp. Wallex "D"
3. Crucible
Steel
'LTA
imposition Rock "C"
Cast 10, 27Cr, .16Mn, 65 Co, 42-52
41, 3 Fe, 8S1
Cast Tungsten, Chromium,
Cobalt, & Carbon
Rexalloy #33 Cast 2.250, 33Cr, 44Co,17W
4. Beryllium Beryllium
Corp. Nickel
Cast .5Cr, Bal Ni, 2.75Be
Hard Face
Weld
Moly
Faced
Hard .34C, 5Cr, 2.28 Moly,
Faced 20V .30mn, 1.35W? 131,
.025P, ?.0258
emarks
High impact, tough
resistance to hot
dnecking,
48-53 Excellent abrasive
resistance, and
corrosion resis-
tance. Fair impact,
very pot falling,
excellent red.
hardness,
55 63 High red, hardness
superior resist,
to abrasion and
corrosion. Low
coefficient of
frictiom.
50-52 High Strength &
Hardness.
Billet
No.
A-209-T
TABLE XII
THE EFTECT OF VARIOUS DIE MATERIALS ON THE SURFACE FINISH OF
Die
Material
Haynes
Stellite
Extrusion
Speed
minute
840
A-2124 Wallex "D" 480
A-212-T Rexa2loy
A-214-13 Ceramic
Coated
A-213-B Vasco
Supreme
960
A70 Titanium
Extrusion
Pressure Extrusion
(PS') itrat.
82,708
107,880
86,304
Die
Condition
29170 Med. Erosion; Lost
.005" on Dia.;
Prod to Back.
1516" Slight Erosion;
Lost .004" on Dia.;
Die split.
18111u Slight die pickup;
Dia. held constant;
Die cracked.
1914" Slight die pickup;
Lost .0351 Front to
Back.
Surface
Finish
Slight Stria. Last
51 badly torn.
Med. to heavy
Striations finish
good 3/4 of lgth.
Med. to heavy
striations deep
score one area.
Medium to heavy
striations one
area.
STAT
2116" Slight die pickup;
Lost .010" Front to
Back.
InduseCity. Ceramic
Boring Coated
Linde al Si Mag
Hard al. Si Mag.
Faced
Like Resistance to
Diamond Abrasion
A-110-AT
211 L Slight die pickup;
Lost .020m Front to
Back.
Good Finish except
med. to heavy
striations one
area.
Medium to heavy.
striations.
76 Vanadium Vasco Supreme High 1,57 C, 475Cr, 5V, 025 64
Alloys Steel Speed Mn., 5 Co, 1205W, .25Si
Company
High hardness,
hot hardness, wear
resistance.
Extrusion Conditions'
(1) Valve - 1/4 (Closed)
(2) Reduction Ratio 50:1
(3) Billet Size es 7 1/2 Dia. X 12" Long
(4) Ext. Length is 121 . 151
(5) Lube - Fiske #630
(6) Billet Heating - Argon Salt -
(7) Die Design 130 90? Incl.
(8) Die Material - Variable
(9) Billet Temp-,. - 1 hr. 1110 1550?F A70
(10) Container Tamp. 800?F
(1.1) Die Preheat - 550?F
(12) Billet Temp - 1 1/4 hr. g 19000F A-1104T,
42
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043
.fty'vqw!OJX!'nV
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
THE EFFECT OF DIE ANGLE- ON TBE SURFACE YINISH OF
EXTRUDED A?
Extrusion
Bi.Uet Die Speed
No. Lat....le. minute)
A-210 1 900
A-210-B 1000
A438-B 1100
A-2184 1200
A-138-1 130?
A-132-B 1400
A-132-1 1500
A-132-F 180?
A-248.4 90?
A-249-B 1009
A-249-1 alo?
A-21494 120?
A -249 ar 130?
A-320-B 140?
- 20.4. ?
A-320-2 180?
333
398
397
591
382
515
405
670
A,70 Titsnitnn
Extrusion
Pressure
(PSI)
102,06
107,880
82,708
71,920
89,900
61,130
89,900
89,900
Extrusion
1314"
1312"
ll!r
i211"
utiol
1316"
18'6"
A 110-AT Titanium
478 133,052
1680 750516
510 79,112
394 104,284
249 118,668
368 1040284
455 100,688
97,092
18114r
14!
129"
15!4n
13!8"
13!
Die
Picku
Light
Medium
Sligh1
Slight
Slight
Heavy
Spotty
Heavy
Heavy
Heavy
Heavy
Heavy
Nedivn
Heavy.
Heavy.
Slight
Surface
Finish
Medium Striations.
Medium to Heavy Striations*
Slight to Medium Striations.
Medium to Heavy Striations.
Medium Striations.
Rupturing and Tearing.
Heavy Striations.
Medium to Heavy.
Rupturing and Tearing?
Rupturing and Tearing.
Rupturing and Tearing.
Rupturing and Tearing.
Medium to Heavy Striations.
Badly Torn.
Badly Torn.
Good Finish.
TABLE XVI
WELDING MACHINE SETTINGS FOR THE STUDYON MAXIMUM JOINT EFFICIENCY
AND MAXIMUM TO 111"6"."1"."""a".** 1"67EVErre-"Ilm1"c."11B RATIOS
25
12,00048, 000 lbs A-110-AT
Upsetting 5/Lt in.
Identification Force dia. bars
Material
Work Overhang
Initial Die Opening 1
Final Die Opening
A-1104,T
1/2
28 max041in.Maxe-Mino
C.P.-70 Study Study
3/4 in. ? 2.6r1 5.30.
dia. bars Ratio Ratio
0,4001WWWWWPWWWWWW. 011101111WMMPOONOMIP1O ?~00100010ftwali ______ '
NR* NR
Current Cut Off 1/8 3/16
After "0"
Flash TimemSeconds 5 it 1/2
Flow Valve Setting 3 1/2 14
Clamping Pressure 23,000 23,000
(lbs
Upset Pressure 12 000-18,000 12 9 000
Tap Switch
14
239 000
Aft70 A-7o
9/16 0
11/8 1
5/16 3/8
? 3/16 146
51/2
5
23,000
STAT
Max 0:sMin,
Study
503:1
Ratio
lica70
1/2
1
5/16
1/106
6
23,000
.10,500 120000
STA
xx 5rd Series
* NR
Not Reported
Machine Specifications:
Model Thomson Fit Synchrmatic
SN. 18777 250 KVA
Max,.Upset Force 32,000 lbs.
Max. Clamping Force 23,000 lbso
(1) Valve 1/14 (Closed)
(2) Reduction Ratio - 25:1
3) Billet Size dill 7 1/2* Dia. X 12N Long
(Li) Ext. Length 12? ma 151
(5) Lube Fiske #630
(6) Billet Heating Argon - Salt
(7) Die Design Variable
(8) Die Material 5% CH. LW. Ro-52
(9) Billet Temp. 1 Hr. 15509F A70
1 1/4 Hr. fi 1900?F A4104T
(10) Container Temp. 8000F
(11) Die Preheat es 7000 m 8000F
46
47
neclassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,
11
,
i;
1
Specimen
Ident.
offii
41
Declassified in Part - Sanitized Copy Approved for Release
1 .1
TABLE XVII PART I
THE MECHANICAL PROPERTIES OF SPECIMENS WELDED FOR TIIE STUDY UN
MAXIMUM JOINT EFFICIENCY
Certified
Rem-Cru
Barstock
1200#
- - -Upset-
Ti 4110AT
1500# 1800#
_ . _ upsetc. - . . gatLet-
Tensile 141.8 13866 136.5 140.2 139.3 139
S trength
(1000 PS I
Yield ? 134.6
Strength
.2% Offset
/000' PSI)
Elongation 1700
(Percent)
Reduction of N.R.
Area
(percent)
Notch: Rupture
Stress (PSI)
Hours
Failure
1,1,0
1
.139 14.005 140.3 1467
of First
A-110 -
Bars !O.
135.
25
AT
ded
137.87
130.5 127.2 129 130.35 131.4 129.3 132.9 130.65 131.15 128.41 127.27
17.1 /5.7 1604 15.7 16.4 17.1 16.4 16.4 17.8 17.1
4002 4109 41.9 3904 4002 1306 400g 40.0 4003 43.6
48
15.7
42.1
135,000
15.6
No Failure
?
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TABLE XVII- PART II
THE MECHANICAL PROPERTIES OF SPECIMENS WELDED FOR THE STUDY ON
MAXIMUM JOINT EFFICIENCY
Ti-A70
Certified 2 of 28
Specimen CP Rem-Cru A70 Welds
Ident. Barstock 1300F1 hr.
Tensile Strength 88 98.2 98.89 83.81
(1000 PSI)
/ of 28
. CP
1200F
1(At
?2 of 28
Barstock A70 Bars 2 of 28
Check 1300F,1 Hr. A70 Bars
82.32 82.43
Yield Strength 68.1 83.8 81.4 62..31 61.2 56.4
.2% Offset .
(1000 PS I)
Elongation
(Percent)
28 24.7 22.8 20.7 19.2 30
Reduction of
Area (Percent) 474
Notch Rupture
(1.000 PSI)
Hours
Failure
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
43.7 474
9
45.7 49.7
nl. I
STATcr
1 of 28
A70 Bars
1200F
.4-11-122.0
90 90 90 90 90
7.5 15.8 77 7.6 12.8
No No No No No
Failure Fail Fail-Fail- Fal
-
ure ure ure ure
4
f'tfiff,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
THE MNRANICAL PROPERTIES uF SPECIMENS WELDED FOR
THE STUDY UN MAXIMUM TO MINIMUM RIB RATIO
Thin Thin Thin
?:MIL...a Spec, #,
Elongation
(Perunt)
j
Specimen
Idento
OT01\44CROGRAPH OF AN A70 TITANIUM CAST IN
NOTE THE UNIFORM GRAIN STRUCTURE RESULTING FROM THE L
VOLTAGE "INDUCTION STIRRING" COIL. INGOT DIAMETER APPR
V2 INS.
Declassified in Part- Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
THE MNRANICAL PROPERTIES uF SPECIMENS WELDED FOR
THE STUDY UN MAXIMUM TO MINIMUM RIB RATIO
Thin Thin Thin
?:MIL...a Spec, #,
Elongation
(Perunt)
j
Specimen
Idento
OT01\44CROGRAPH OF AN A70 TITANIUM CAST IN
NOTE THE UNIFORM GRAIN STRUCTURE RESULTING FROM THE L
VOLTAGE "INDUCTION STIRRING" COIL. INGOT DIAMETER APPR
V2 INS.
Declassified in Part- Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,
r
? u/ 144tiMI/
?P '..1:r;ty." wt.-6. et, ot'of p
'
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
200
1,6
1NTERSTITAL CONTENT
0 N
0.25 0.028 0.04
grata
NOTCH
MOON
SMOOTH
_
LOADING RATE
? 200 IN/MIN
0
0.02 IN/MIN
a
80
40
20
120
A
0
20
15
A,
?
-400 - 200
TESTING TEMPERATURE -0F
NOTCH
FIGURE 4 THE NOTCH -TE
OXYGEN
NSILE PROPERTIES OF HIGH
( O. 25%) 470 TITANIUM EXTRUDED
ROM A FORGED BILLET (MATER(AL C, 0: 034)
514.
200
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01
50
TEST TEMPERATURE- 75?F
Mower
FORGED
MATERIALS
(REF.!)
a
NOTCH
LOADING
a
0.02 IN/MIN
RATE
2.00 rN/MIN
FIGURE 5
CI ?02 0 3 A0 B 04
OXYGEN EQUIVALENT,!/0
0E: %0 4 2`)/oN 4- 2/3 go
0.5 0.8
COMPARISON OF THE EFFECT OF INTERSTITIAL CONTENT
ON THE NOTCH-TENSILE PROPERTIES OF 470 TITANIUM IN
FORGED AND IN EXTRUDED MATERIAL AT 75?F
S.STAT
..'1.11?;',,? I ,.1\,1(4.i
Declassified in Part - Sanitized Copy Approved for Release
, ,
.1*
200
150
cn
50
1.6
1,4
1.2
'4!
50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
TEST TEMPERATURE 0 65*F
1.5 X T . S . ????.,4
FORGED
MATERIALS
, (REF, I)
0 0
60
NOTCH
SMOOT
1?1
LOADING RATE
0 2,00 IN/MIN
0
a o.oe INfitim
Z 0.6
0, 40
0,1 02 0,3 AC B ?
0.5 0,S
I 1
INTERSTITIAL CONTENT,
0 N C AL SN
%?...A
0.097 .017 .04 5,0 3,2
4,_,_....,.
--0------.....,
??...
0 0,
A crA
?
?0
A SMOOTH
'
LOADING
S -2.0
A - 0.2
RATE
IN /MIN.
IN/ MIN.
A 0 ___--------"-
0
A........
0
A
0 ?
0
SMOOTH
A a
,-----8
NOTCH
8
8 a
,
A A
..... o A
8
A A
A
I
1
OXYGEN EQUIVALENT- `)/0
0/00 0. 2%N 092/3 %C
FIGURE 6 COMPARISON OF THE EFFECT OF I NTERSTITIAL CONTENT
IN THE NOTCH -TENSILE PROPERTIES OF A70 TITANIUM IN
FORGED AND IN EXTRUDED MATERIAL AT -5?F
-200
TEST TEMPERATURE- ?F
FIG 7 THE NOTCH TENSILE PROPERTIES OF MIOA'T
TITANIUM EXTRUDED FROM A CAST INGOT (MAT'L-D)
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
,101,,(OLV,
Declassified in Part - Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
300
10
I.
0.
3
2
INTERSTITIAL CONTENT
0 N C AL SN
0,13 003 0,10 5.0 2,5
"".. AA "nu'
0
a",1 owe tag??
...........-i
...,, **ft oft? 4
...fr...
4r.
NOTCH
r".......smooTH
Ii
A..........
LOADING RATE
0 ...
? 2.00 IN/MIN
a .
A 0.02 IN/MIN
1
i
1 :
SMOOTH
6...0
0...0 A
? . ...."''.?w..-?...
I
i p.0_111 ............
J
A
I
?
MOO
FIG. 8
TEST TEMPERATURE -?F.
?
?
200
THE NOTCH TENSILE PROPERTIES OF A-110AT
TITANIUM EXTRUDED FROM A FORGED BILLET
(MATERIAL E)
120
100
0
0
0
80
AMS 4921- T1- A70
TENSILE
?InimoramoomMen.0.??????????10.11.
YIELD
\'"\ S\-\ 7\ 7\ \-\-\ 7".\ SV\ \\-\ \-\"\\ \--\-\ \-7\ S7\ 7\7.-
MINIMUM YIELD STRENGTH
60 EXTRUSION REDUCTION RATIO
? - 10:1
O- 25I
REDUCTION OF AREA
ELONGATION
7A-Th 7-\ v\-Th -7\ \\NN vc\--N \\\\
MINIMUM'ELONGATION
1500 1600
EXTRUSION TEMPERATURE
FIGURE 9
1700
THE EFFECT OF EXTRUSION TEMPERATURES ON THE
TENSILE PROPERTIES OF A70 TITANIUM EXTRUDED
FROM CAST INGOTS OF VARIOUS EXTRUSION RATIOS
STAT
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,101,,(OLV,
Declassified in Part - Sanitized Copy Approved for Release @50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
300
10
I.
0.
3
2
INTERSTITIAL CONTENT
0 N C AL SN
0,13 003 0,10 5.0 2,5
"".. AA "nu'
0
a",1 owe tag??
...........-i
...,, **ft oft? 4
...fr...
4r.
NOTCH
r".......smooTH
Ii
A..........
LOADING RATE
0 ...
? 2.00 IN/MIN
a .
A 0.02 IN/MIN
1
i
1 :
SMOOTH
6...0
0...0 A
? . ...."''.?w..-?...
I
i p.0_111 ............
J
A
I
?
MOO
FIG. 8
TEST TEMPERATURE -?F.
?
?
200
THE NOTCH TENSILE PROPERTIES OF A-110AT
TITANIUM EXTRUDED FROM A FORGED BILLET
(MATERIAL E)
120
100
0
0
0
80
AMS 4921- T1- A70
TENSILE
?InimoramoomMen.0.??????????10.11.
YIELD
\'"\ S\-\ 7\ 7\ \-\-\ 7".\ SV\ \\-\ \-\"\\ \--\-\ \-7\ S7\ 7\7.-
MINIMUM YIELD STRENGTH
60 EXTRUSION REDUCTION RATIO
? - 10:1
O- 25I
REDUCTION OF AREA
ELONGATION
7A-Th 7-\ v\-Th -7\ \\NN vc\--N \\\\
MINIMUM'ELONGATION
1500 1600
EXTRUSION TEMPERATURE
FIGURE 9
1700
THE EFFECT OF EXTRUSION TEMPERATURES ON THE
TENSILE PROPERTIES OF A70 TITANIUM EXTRUDED
FROM CAST INGOTS OF VARIOUS EXTRUSION RATIOS
STAT
STAT
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1500?F.
1600? F
EXTRUSION TEMPERATURES
1700?F.
FIG 13 THE EFFECT OF EXTRUSION TEMPERATURE ON THE MACROSTRUCTURE, AND MICROSTRUCTURE
OF A70 TITANIUM EXTRUDED FROM CAST INGOTS AT AN EXTRUSION RATIO OF 50 = I
I
MICRO MAG. - APPROX. 200X
MACROS- BAR DIA. APPROX 1.1 INCH
63
Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
STAT
STAT
,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
1500?F.
1600? F
EXTRUSION TEMPERATURES
1700?F.
FIG 13 THE EFFECT OF EXTRUSION TEMPERATURE ON THE MACROSTRUCTURE, AND MICROSTRUCTURE
OF A70 TITANIUM EXTRUDED FROM CAST INGOTS AT AN EXTRUSION RATIO OF 50 = I
I
MICRO MAG. - APPROX. 200X
MACROS- BAR DIA. APPROX 1.1 INCH
63
Declassified in Part- Sanitized Copy Approved for Release @50-Yr 2013/09/09 : CIA-RDP81-01043R002500180004-7
STAT
STAT
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
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Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
""'4,11t=t.`117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIGURE 20 THE EFFECT OF EXTRUSION RATIO ON THE
PRESSURE REQUIRED TO EXTRUDE A70 TITANIUM FROM
CAST INGOTS AT VARIOUS EXTRUSION TEMPERATURES
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
""'4,11t=t.`117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIGURE 20 THE EFFECT OF EXTRUSION RATIO ON THE
PRESSURE REQUIRED TO EXTRUDE A70 TITANIUM FROM
CAST INGOTS AT VARIOUS EXTRUSION TEMPERATURES
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
""'4,11t=t.`117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIGURE 20 THE EFFECT OF EXTRUSION RATIO ON THE
PRESSURE REQUIRED TO EXTRUDE A70 TITANIUM FROM
CAST INGOTS AT VARIOUS EXTRUSION TEMPERATURES
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
""'4,11t=t.`117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIGURE 20 THE EFFECT OF EXTRUSION RATIO ON THE
PRESSURE REQUIRED TO EXTRUDE A70 TITANIUM FROM
CAST INGOTS AT VARIOUS EXTRUSION TEMPERATURES
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
""'4,11t=t.`117
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7
FIGURE 20 THE EFFECT OF EXTRUSION RATIO ON THE
PRESSURE REQUIRED TO EXTRUDE A70 TITANIUM FROM
CAST INGOTS AT VARIOUS EXTRUSION TEMPERATURES
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2013/09/09: CIA-RDP81-01043R002500180004-7