LIGHTWEIGHT TITANIUM ALUMINIDE VALVES AND METHODS FOR THE MANUFACTURE THEREOF
Embodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne vale includes a valve element and a flowbody. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted. Embodiments of a method for producing such a lightweight, high temperature airborne valve are also provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.
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This application is a divisional of co-pending U.S. application Ser. No. 12/549,098, filed Aug. 27, 2009.
TECHNICAL FIELDThe present invention relates generally to valves and, more particularly, to embodiments of lightweight valves well suited for use in high temperature airborne applications, such as deployment aboard an aircraft.
BACKGROUNDAirborne valves are commonly deployed aboard aircraft to regulate fluid flow. An airborne valve, and specifically the material from which the flowbody of the airborne valve is cast, ideally has relatively low density, is highly durable, and is highly ductile. When intended to operate in lower temperature environments, airborne valve flowbodies are commonly cast from aluminum and aluminum-based alloys, which generally satisfy the foregoing criteria. However, when the airborne valve is to be utilized within higher temperature environments (e.g., approaching and possibly exceeding approximately 1,200° Fahrenheit), such as when the airborne valve is used to regulate compressor or combustive gas flow from a gas turbine engine, aluminum and aluminum-based alloys are typically unsuitable as flowbody materials due to operational temperature limitations. For this reason, it is conventional practice in aerospace industry to cast high temperature valve flowbodies from high-strength, refractory metal alloys, such as 17-4PH stainless steel or Inconel 718®. Although durable and relatively ductile, such refractory metal alloys have relatively high densities (e.g., the densities of 17-4PH stainless steel and Inconel 718® are approximately 7.74 grams per cubic centimeter (g/cm3) and 8.22 g/cm3, respectively). Airborne valve flowbodies cast from such high temperature materials are consequently undesirably heavy for utilization in airborne applications.
Titanium aluminide alloys have relatively low densities and have been utilized to fabricate certain dynamic components deployed within gas turbine engine, such as air turbine blades. However, titanium aluminide alloys have long been considered excessively brittle for use in the fabrication of high temperature airborne flowbodies, which serve as pressure vessels that conduct highly pressured fluids during operation (e.g., pressured bleed air having pressures exceeding several hundred pounds per square inch (psi) and commonly approaching 600 psi). Titanium aluminide alloys have also been utilized to produce certain non-pressure containing valve components (e.g., poppet-type valve elements) for other ground-based pneumatic systems, such as for automotive internal combustion engines. Titanium aluminide alloys have not, however, been utilized to produce static, pressure-containing valve flowbodies in any context of which the present inventors are aware. Furthermore, in the terrestrial applications set-forth above, the operational requirements, the valve types, and the valve designs are markedly disparate from the high temperature, high pressure airborne valve flowbodies utilized in the aerospace industry.
There thus exists an ongoing need to provide embodiments of a high temperature airborne valve having a reduced weight as compared to conventional airborne valves produced utilizing high density material, such as 17-4PH stainless steel and Inconel 718®. In accordance with embodiments of the present invention, and as described in the subsequent sections of this document, this ongoing need is satisfied by providing airborne valves including lightweight flowbodies formed, at least in part, from titanium aluminide. It would also be desirable to provide one or more methods for manufacturing such lightweight, high temperature airborne valves. Other desirable features and characteristics of the present invention will become apparent from the subsequent Detailed Description and the appended claims, taken in conjunction with the accompanying drawings and this Background.
BRIEF SUMMARYEmbodiments of a lightweight, high temperature airborne valve are provided. In one embodiment, the airborne valve includes a flowbody and a valve element. The flowbody is formed at least partially from a titanium aluminide alloy and has a flow passage therethrough in which the valve element is movably mounted.
Embodiments of a pneumatic avionic system for deployment aboard an aircraft are further provided. In one embodiment, the pneumatic avionic system includes an aircraft duct and a lightweight, high temperature airborne valve fluidly coupled to the aircraft duct. The lightweight, high temperature airborne valve includes a flowbody having a flow passage therethrough, and a valve element movably mounted within the flow passage for modulating fluid flow therethrough. The flowbody is formed at least partially from a titanium aluminide alloy.
Embodiments of a method for producing such a lightweight, high temperature airborne valve are still further provided. In one embodiment, the method includes the steps of forming a lightweight flowbody at least partially from a titanium aluminide alloy, hot isostatically pressing the lightweight flowbody, and machining the lightweight flowbody to desired dimensions.
At least one example of the present invention will hereinafter be described in conjunction with the following figures, wherein like numerals denote like elements, and:
The following Detailed Description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding Background or the following Detailed Description.
In accordance with the teachings of the present invention, flowbody 22 is formed at least partially from a titanium aluminide (TiAl) alloy; and, in a preferred group of embodiments, flowbody 22 is cast substantially entirely from a titanium aluminide alloy. Still more preferably, flowbody 22 is cast from a titanium aluminide alloy that is near-stoichiometric (i.e., has a titanium to aluminum ratio of approximately 1:1 on the atomic scale) and/or that has a density in the range of approximately 3.5 g/cm3 to approximately 5.0 g/cm3. Notably, titanium aluminide alloys have relatively low densities as compared to the high-strength, refractory metal alloys, such as 17-4PH stainless steel and Inconel 718®, conventionally utilized to produce valve flowbodies in the aerospace industry. As a result, flowbody 22 weighs significantly less than a similar flowbody formed from a conventional refractory metal alloy. At the same time, TiAl flowbody 22 is operable in high temperature and high pressure environments; e.g., operational environments characterized by temperatures approaching or exceeding 1200° Fahrenheit and pressures approaching or exceeding several hundred psi. TiAl flowbody 22, and more generally airborne valve 20, is consequently well suited for deployment aboard an aircraft as a means for regulating the flow of a heated and highly pressurized fluid, such as combustive gas flow bled from the combustor of a gas turbine engine.
It will be appreciated that the terms “titanium aluminide alloy” and “TiAl alloy” are utilized to denote an alloy containing titanium and aluminum as the primary constituents. A given titanium aluminide alloy can, and typically will, include lesser amounts of one or more additional metallic or non-metallic constituents. A non-exhaustive list of additional components that may be contained within a particular titanium aluminide alloy includes manganese, boron, niobium, molybdenum, titanium diboride, and the like. Such additive components may be added in powder form to a master alloy during processing to optimize the metallurgical properties of the resulting titanium aluminide alloy.
As previously noted, titanium aluminide alloys have been utilized in the production of dynamic components deployed within gas turbine engine, such as air turbine blades. In addition, titanium aluminide alloys have been utilized to fabricate valve elements in automotive internal combustion engines. However, titanium aluminide alloys have not conventionally been utilized to produce a flowbody or pressure vessel included within an airborne valve. Indeed, it has long been believed within the aeronautical field that titanium aluminide alloys are unsuitable for use in the production of pressure vessels due to the relatively low ductility, and therefore the relative brittleness, of titanium aluminides. However, contrary to this long held belief, the present inventors have discovered that, in principle, certain titanium aluminide alloys can be utilized to produce airborne valve flowbodies capable of operating at elevated temperatures and pressures characteristic of avionic applications. Furthermore, the present inventors have discovered that by producing airborne valve flowbodies from titanium aluminide, in substantial part or in entirety, a substantial weight savings can be realized as compared to airborne valve flowbodies formed from conventional high temperature materials, such as 17-4PH stainless steel and Inconel 718®.
Next, at STEP 48, the particular titanium aluminide alloy that will ultimately be utilized to form the flowbody of airborne valve 42 is selected. As indicated in
After selection of a desired titanium aluminide alloy (STEP 48), the titanium aluminide is heated and melted in an appropriate enclosure substantially devoid of oxidants, poured into mold 46 in molten form, and then allowed to solidify to produce a lightweight TiAl flowbody 50 (STEP 52). TiAl flowbody 50 is then removed, partially or entirely, from mold 46. In the exemplary embodiment illustrated in
Continuing with exemplary method 40 (
During STEP 68 of exemplary method 40 (
To conclude exemplary method 40 (
After fabrication, airborne valve 42 can be installed within a pneumatic avionic system deployed aboard an aircraft. For example, with reference to
Exemplary Embodiments of Titanium Aluminide Airborne Valve Flowbodies Reduced to Practice
By way of illustration and not of limitation, the following table provides the composition of two titanium aluminide alloys utilized to produce airborne valve flowbodies in actual practice. During manufacture, the titanium aluminide alloys were each liquefied and poured into one or more ceramic molds within an appropriate enclosure substantially devoid of oxidants. Then, after solidification of the corresponding flowbodies, the latter were removed from the ceramic molds. The resulting valve flowbodies were then subjected to additional processing steps (e.g., hot isostatic pressing) and subsequently weighed. Two airborne valve flowbodies were cast from the first titanium aluminide alloy (identified as “Example 1” in the table below) and weighed approximately 1,791.83 grams and 1,797.36 grams. By comparison, a nominally identical valve flowbody cast from an Inconel 718® alloy weighed approximately 3,383.14 grams, approximately 89% heavier than the valve flowbodies cast from the first titanium aluminide alloy (“Example 1”). In other words, the TiAl valve flowbodies weighed approximately 47% less than the nominally identical Inconel 718® valve flowbody. Fewer structural defects were detected within the valve flowbodies cast from the first titanium aluminide alloy (“Example 1”) than within the valve flowbody cast from the second titanium aluminide alloy (“Example 2”).
Exemplary valve flowbodies cast from the first TiAl alloy (identified as “Example 1” above) were further machined by mechanical means to create flanges with desired dimensions and properties. A flowbody with the machined flange was connected to a mating flange of a test system, using a V-band clamp, and clamped successfully in place, using standard procedures. No damage to the flange of the TiAl flowbody was visible after this clamping test, and this flange further successfully passed a post-clamping test fluorescent penetrant inspection (FPI) procedure.
In view of the above, it should be appreciated that there has been provided multiple exemplary embodiments of a lightweight, high temperature airborne valve including a flowbody formed, at least partially, from a titanium aluminide alloy. The foregoing has also provided at least one exemplary embodiment of a method for manufacturing such a lightweight, high temperature airborne valve. While, in the above-described embodiments, the airborne valve assumed the form of a cylindrically-shaped butterfly valve, alternative embodiments of the present invention may assume various other forms, including those of a right-angle poppet valve and an inline poppet valve. In certain embodiments, other machined or hot isostatic pressed parts can be bonded or otherwise joined to the titanium aluminide flowbody utilizing, for example, brazing or welding.
While at least one exemplary embodiment has been presented in the foregoing Detailed Description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing Detailed Description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set-forth in the appended Claims.
Claims
1. A method for producing a lightweight, high temperature airborne valve, the method comprising the steps of:
- selecting a near-stoichiometric titanium aluminide alloy having a density between approximately 3.5 grams per cubic centimeter and approximately 5.0 grams per cubic centimeter;
- pouring the selected near-stoichiometric titanium aluminide alloy into a mold in an enclosure substantially devoid of oxidants to form a lightweight flowbody having a flow passage extending therethrough;
- removing the lightweight flowbody from the mold;
- hot isostatic pressing the lightweight flowbody;
- machining the lightweight flowbody to desired dimensions; and
- mounting a valve element in the flow passage of the lightweight flowbody.
2. The method of claim 1 wherein the lightweight flowbody is fabricated to include a radial mounting flange, and wherein the method further comprises installing the lightweight, high temperature airborne valve within a pneumatic avionic system deployed aboard an aircraft and utilized to regulate the flow of pressurized air or combustive gasses bled from a gas turbine engine during operation thereof.
3. The method of claim 1 further comprising applying an oxidation-resistant coating over at least one surface of the lightweight flowbody after machining the lightweight flowbody to desired dimensions.
4. The method of claim 3 wherein applying comprises applying an oxidation-resistant coating over the interior surfaces of the flow passage exposed to hot gas flow during operation of the lightweight, high temperature airborne valve.
5. The method of claim 1 wherein the valve element comprises:
- a butterfly disc rotatably mounted within the flow passage; and
- a wiper seal carried by the butterfly disc and sealingly engaging an inner surface of the lightweight flowbody; and
- wherein the method further comprises applying a wear-resistant coating over the inner surface of the flow passage contacted by the wiper seal during rotation of the butterfly disc.
6. The method of claim 1 further comprises bonding at least one machined or hot isostatic pressured part to the titanium aluminide flowbody after machining.
7. The method of claim 1 wherein selecting comprises selecting a near-stoichiometric titanium aluminide including at least one of the group consisting of manganese, boron, niobium, molybdenum, and titanium diboride and added to a master alloy during processing of the titanium aluminide alloy.
8. The method of claim 1 wherein the selecting comprises selecting a near-stoichiometric titanium aluminide alloy comprising titanium, aluminum, manganese, niobium, and titanium diboride.
9. The method of claim 8 wherein selecting comprises selecting a near-stoichiometric titanium aluminide alloy comprising, by weight:
- about 50.2% titanium;
- about 45.0% aluminum;
- about 2.0% manganese;
- about 2.0% niobium; and
- about 0.8% titanium diboride.
10. The method of claim 1 wherein selecting comprises selecting a near-stoichiometric titanium aluminide alloy comprising titanium, aluminum, niobium, boron, and molybdenum.
11. The method of claim 10 wherein selecting comprises selecting a near-stoichiometric titanium aluminide alloy comprising, by weight:
- about 51.4% titanium;
- about 43.5% aluminum;
- about 4.0% niobium;
- about 0.1% boron; and
- about 1.0% molybdenum.
12. A method, comprising:
- obtaining a high temperature airborne valve, comprising: a lightweight flowbody formed substantially entirely of a near-stoichiometric titanium aluminide alloy having a density between approximately 3.5 grams per cubic centimeter and approximately 5.0 grams per cubic centimeter; and a radial mounting flange extending from the lightweight flowbody; and
- installing the high temperature airborne valve in a pneumatic avionic system deployed onboard an aircraft by clamping the radial mounting flange of the high temperature airborne valve to a duct included in the pneumatic avionic system and conducting pressurized air flow or combustive gas flow bled from a gas turbine engine during operation thereof.
13. The method of claim 12 wherein obtaining comprises obtaining a high temperature airborne valve having a lightweight flowbody formed substantially entirely of a near-stoichiometric titanium alloy comprising titanium, aluminum, manganese, niobium, and titanium diboride.
14. The method of claim 12 wherein obtaining comprises obtaining a high temperature airborne valve having a lightweight flowbody formed substantially entirely of a near-stoichiometric titanium alloy comprising titanium, aluminum, niobium, boron, and molybdenum.
15. A method for producing a lightweight, high temperature airborne valve, the method comprising the steps of:
- selecting a titanium aluminide alloy containing at least one of the group consisting of manganese, boron, niobium, molybdenum, and titanium diboride and added to a master alloy during processing of the titanium aluminide alloy;
- pouring the selected titanium aluminide alloy into a mold in an enclosure substantially devoid of oxidants to form a lightweight flowbody having a flow passage extending therethrough;
- removing the lightweight flowbody from the mold;
- machining the lightweight flowbody to desired dimensions; and
- mounting a valve element in the flow passage of the lightweight flowbody.
16. The method of claim 15 wherein the selecting comprises selecting a titanium aluminide alloy comprising titanium, aluminum, manganese, niobium, and titanium diboride.
17. The method of claim 16 wherein selecting comprises selecting a titanium aluminide alloy comprising, by weight:
- about 50.2% titanium;
- about 45.0% aluminum;
- about 2.0% manganese;
- about 2.0% niobium; and
- about 0.8% titanium diboride.
18. The method of claim 15 wherein selecting comprises selecting a titanium aluminide alloy comprising titanium, aluminum, niobium, boron, and molybdenum.
19. The method of claim 18 wherein selecting comprises selecting a titanium aluminide alloy comprising, by weight:
- about 51.4% titanium;
- about 43.5% aluminum;
- about 4.0% niobium;
- about 0.1% boron; and
- about 1.0% molybdenum.
20. The method of claim 15 wherein selecting comprises selecting a titanium aluminide alloy formulated to have a titanium-to-aluminide ratio of approximately 1:1 on the atomic scale.
Type: Application
Filed: Dec 6, 2012
Publication Date: Jun 6, 2013
Applicant: HONEYWELL INTERNATIONAL INC. (Morristown, NJ)
Inventor: Honeywell International Inc. (Morristown, NJ)
Application Number: 13/706,480
International Classification: B21K 1/20 (20060101);