PROCESSING OF ALPHA-BETA TITANIUM ALLOYS

Abstract

A method for increasing tensile strength of a cold workable alpha-beta titanium alloy comprises solution heat treating a cold workable alpha-beta titanium alloy in a temperature range of Tβ−106° C. to Tβ−72.2° C. for 15 minutes to 2 hours; cooling the alpha-beta titanium alloy at a cooling rate of at least 3000° C./minute; cold working the alpha-beta titanium alloy to impart an effective strain in the range of 5 percent to 35 percent in the alloy; and aging the alpha-beta titanium alloy in a temperature range of Tβ−669° C. to Tβ−517° C. for 1 to 8 hours. Fastener stock and fasteners including solution treated, quenched, cold worked, and aged alpha-beta titanium alloys are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 120 from U.S. patent application Ser. No. 14/948,941, filed on Nov. 23, 2015, the entire disclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE TECHNOLOGY

Field of the Technology

The present disclosure relates to novel methods of processing certain cold workable alpha-beta titanium alloys, to alloys made using such methods, and to articles including such alloys. A particular non-limiting aspect of the present disclosure relates to fasteners and fastener stock including alloys made using the novel methods herein.

DESCRIPTION OF THE BACKGROUND OF THE TECHNOLOGY

Titanium alloys typically exhibit a high strength-to-weight ratio, are corrosion resistant, and are resistant to creep at moderately high temperatures. For those reasons, titanium alloys are used in many aerospace, aeronautic, defense, marine, and automotive applications including, for example, landing gear members, engine frames, ballistic armor, hulls, and mechanical fasteners.

Reducing the weight of an aircraft or other motorized vehicle can provide fuel savings. As such, for example, there is a strong drive in the aerospace industry to reduce aircraft weight. Titanium and titanium alloys are attractive materials for achieving weight reduction in aircraft applications because of their high strength-to-weight ratios and other advantageous mechanical properties.

Ti-6Al-4V alloy (ASTM Grade 5; UNS R56400; AMS 4965), which is an alpha-beta titanium alloy, is used in a number of applications that benefit from the alloy's advantageous combination of light weight, corrosion resistance, and high strength at low to moderate temperatures. For example, many titanium alloy parts used in aerospace applications are made from Ti-6Al-4V alloy. More generally, Ti-6Al-4V alloy is used to produce aircraft engine components, aircraft structural components, high-performance automotive components, components for medical devices, sports equipment, components for marine applications, components for chemical processing equipment, and fasteners. Typical minimum specifications for Ti-6Al-4V alloy small diameter fastener stock (i.e., fastener stock having a diameter less than 0.5 inch (1.27 cm)) are 170 ksi (1,172 MPa) ultimate tensile strength (UTS) (as determined according to ASTM E8/E8M 09 (“Standard Test Methods for Tension Testing of Metallic Materials” ASTM International, 2009)) and 103 ksi (710 MPa) double shear strength (DSS) (as determined according to NASM 1312-13 (Revision 2, 2013) Fastener Test Methods—Double Shear Test (Aerospace Industries Association)).

Iron and nickel based superalloys, such as, for example, A286 iron-base superalloy (UNS S66286), are representative of materials used in aerospace fastener applications having the next tier of strength. Typical specified minimum strengths for cold drawn and aged A286 alloy fasteners are 180 ksi (1,241 MPa) UTS and 108 ksi (744 MPa) DSS.

Alloy 718 nickel based superalloy (UNS N07718) is a material used in aerospace fasteners that represents the uppermost tier of strength. Typical specified minimums for cold drawn and aged Alloy 718 superalloy fasteners are 220 ksi (1,517 MPa) UTS and 120 ksi (827 MPa) DSS. Nickel and steel fastening systems often use a drawing and aging processing route to attain their high strengths. Historically, a drawing and aging process has not been used with Ti-6Al-4V alloy or with other titanium alloys due to the alloys' low ductility at room temperature. This is well known in the industry.

Titanium has considerably lower density than steel or nickel, which results in significant weight savings in aerospace fastener and other applications. However, certain low temperature applications require strength above that typically attainable with current titanium alloy fastener materials. In addition, the heat treatment steps used to produce conventional titanium alloy fasteners can be lengthy, resulting in a process bottleneck during fastener production. For example, conventional aging times for finished titanium alloy fasteners can range from 4 to 12 hours, and typically are 8 to 10 hours. It would be advantageous to provide titanium alloy fastener materials that exhibit high strength, such as the strength obtainable with Ti-6Al-4V alloy fasteners, but without the need for the lengthy aging times currently used to attain desired strength levels.

Ductility is a property of any given metallic material (i.e., metals and metal alloys). The cold formability (also referred to as “cold workability”) of a metallic material is based on the material's near room temperature ductility and ability to deform without cracking. High-strength alpha-beta titanium alloys such as, for example, Ti-6Al-4V alloy, typically have low cold formability at or near room temperature. This limits their acceptance of cold drawing and other low-temperature forming given that the alloys are susceptible to cracking and other breakage when worked at low temperatures. Because of their limited cold formability at or near room temperature, alpha-beta titanium alloys typically are processed by techniques involving extensive hot working. Titanium alloys that exhibit relatively high room temperature ductility generally also exhibit relatively low strength. A consequence of this is that high-strength alloys typically are more difficult to manufacture, requiring extensive working at temperatures above several hundred degrees Celsius to homogeneously deform the HCP and BCC crystal structures.

The HCP crystal structure is common to many engineering materials, including magnesium, titanium, zirconium, and cobalt alloys. The HCP crystal structure has an ABABAB stacking sequence, whereas other metallic alloys such as stainless steel, brass, nickel alloys, and aluminum alloys typically have face centered cubic (FCC) crystal structures with ABCABCABC stacking sequences. As a result of this difference in stacking sequence, HCP metals and alloys have a significantly reduced number of mathematically possible independent slip systems relative to FCC materials. A number of the independent slip systems in HCP metals and alloys require significantly higher stresses to activate, and these “high resistance” deformation modes complete their activation with the formation of cracks. This effect is temperature sensitive, such that below temperatures of several hundred degrees Celsius, titanium alloys exhibit significantly lower malleability.

In combination with the slip systems present in HCP materials, a number of twinning systems are possible in unalloyed HCP metals. The combination of the slip systems and the twinning systems in titanium enables sufficient independent modes of deformation so that “commercially pure” (CP) titanium can be cold worked at temperatures in the vicinity of room temperature (i.e., in an approximate temperature range of −100° C. to +200° C.).

Alloying effects in titanium and other HCP metals and alloys tend to increase the asymmetry, or difficulty, of “high resistance” slip modes, as well as suppress twinning systems from activation. A result is the macroscopic loss of cold-processing capability in alloys such as Ti-6Al-4V alloy and Ti-6Al-2-Sn-4Zr-2Mo-0.1Si alloy. Ti-6Al-4V alloy and Ti-6Al-2-Sn-4Zr-2Mo-0.1S alloy exhibit relatively high strength due to their high concentrations of alpha phase and alloying elements. In particular, aluminum is known to increase the strength of titanium alloys at both room and elevated temperatures. However, aluminum also is known to adversely affect room temperature processing capability.

In general, alloys exhibiting high cold formability can be manufactured more efficiently in terms of both energy consumption and the amount of scrap generated during processing. Thus, in general, it is advantageous to formulate an alloy that can be processed at relatively low temperatures.

Some known titanium alloys have delivered increased room-temperature processing capability by including large concentrations of beta phase stabilizing alloying additions. Examples of such alloys include Beta C titanium alloy (Ti-3Al-8V-6Cr-4Mo-4Zr; UNS R58649), which is commercially available in one form as ATI® 38-644™ beta titanium alloy from Allegheny Technologies Incorporated, Pittsburgh, Pa. USA. ATI® 38-644™ beta titanium alloy and similarly formulated alloys provide advantageous cold formability by limiting or eliminating alpha phase from the microstructure. Typically, these alloys can precipitate alpha phase during low-temperature aging treatments.

Despite their advantageous cold formability, beta titanium alloys, in general, have two disadvantages: expensive alloying additions and poor elevated-temperature creep strength. The poor elevated-temperature creep strength is a result of the significant concentration of beta phase these alloys exhibit at elevated temperatures such as, for example, 500° C. Beta phase does not resist creep well due to its body centered cubic structure, which provides for a large number of deformation mechanisms. Machining beta titanium alloys also is known to be difficult due to the alloys' relatively low elastic modulus, which allows more significant spring-back. As a result of these shortcomings, the use of beta titanium alloys has been limited.

Two beta titanium alloys in use or under consideration as high-strength fastener materials exhibit 180 ksi (1,241 MPa) minimum UTS and 108 ksi (744.6 MPa) minimum DSS. SPS Technologies, Jenkintown, Pa. USA, offers a titanium alloy fastener fabricated from an optimized beta titanium alloy that conforms to the chemistry of Ti-3Al-8V-6Cr-4Zr-4Mo titanium alloy (AMS 4958). The SPS bolts are available in diameters up to 1 inch (2.54 cm). Alcoa Fastening Systems (AFS) has developed a high-strength fastener made from a titanium alloy that conforms to the nominal chemistry of Ti-5Al-5Mo-5V-3Cr-0.5Fe titanium alloy (also referred to as Ti-5553 alloy; UNS unassigned), a near beta titanium alloy. The AFS Ti-5553 alloy fasteners reportedly exhibit tensile strength of 190 ksi (1,309 MPa), greater than 10% elongation, and minimum DSS of 113 ksi (779 MPa) for uncoated parts and 108 ksi (744 MPa) for coated parts.

As discussed, beta titanium alloys generally include a high alloying content, which increases the cost of components and processing compared with alpha-beta titanium alloys. Beta titanium alloys also generally have a higher density than alpha-beta titanium alloys. For example ATI 425® alpha-beta titanium alloy has a density of about 0.161 lbs./in³ (4.5 g/cm³), whereas the beta titanium alloy Ti-3Al-8V-6Cr-4Zr-4Mo alloy has a density of about 0.174 lbs./in³ (4.8 g/cm³), and the near beta titanium alloy Ti-5Al-5Mo-5V-3Cr-0.5Fe alloy has a density of about 0.168 lbs./in³ (4.7 g/cm³). (ATI 425® alpha-beta titanium alloy is a commercial version of Ti-4Al-2.5V alloy (UNS R54250) and is available from Allegheny Technologies Incorporated, Pittsburgh, Pa. USA.) Fasteners made from titanium alloys that are less dense may provide further weight savings for aerospace applications. In addition, the bimodal microstructure that is obtained, for example, in solution treated and aged alpha-beta titanium alloys may provide improved mechanical properties such as high cycle fatigue compared to beta titanium alloys. Alpha-beta titanium alloys also have a higher beta transus temperature (Ta) than beta titanium alloys. For example, the Ta of ATI 425® alpha-beta titanium alloy is about 982.2° C., whereas Ti-5Al-5Mo-5V-3Cr-0.5Fe beta titanium alloy has a Tp of about 860° C. The generally higher Tp of the alpha-beta titanium alloy allows for a larger temperature window for thermomechanical processing and heat treatment in the alpha-beta phase field.

A prior art process for producing alpha-beta titanium alloy fastener stock and fasteners from ATI 425® alloy (UNS R54250) is disclosed in co-pending U.S. patent application Ser. No. 12/903,851, which is hereby incorporated by reference herein in its entirety. Referring to FIG. 1, a process 10 for producing alpha-beta titanium alloy fastener stock and fasteners includes solution treating 12 an alpha-beta titanium alloy, which normally is in the form of a coil, by heating the alpha-beta titanium alloy in the temperature range of 843° C. to 982° C. for 0.5 to 2 hours. After solution treating, the alpha-beta titanium alloy is water quenched 14. Optionally, the solution treated alpha-beta titanium alloy can undergo a process such as hot or cold heading (not shown). The solution treated alpha-beta titanium alloy is then aged 16 by heating the solution treated alpha-beta titanium alloy in a temperature range of 315° C. to 537.8° C. for 2 to 12 hours to provide a solution treated and aged (STA) fastener stock. After aging 16, the STA fastener stock comprising ATI 425® alloy can be subjected to cold deformation 18 processes such as, for example, thread rolling, to form a fastener.

Lower cost titanium products would be possible if existing titanium alloys were more resistant to cracking during cold processing, i.e., if the alloys exhibited increased cold formability. Since alpha-beta titanium alloys represent the majority of all alloyed titanium produced, the costs to process such alloys could be reduced significantly by improving cold formability. Therefore, alloys of commercial interest include high-strength, cold-deformable alpha-beta titanium alloys. Several alloys within this class have been developed recently. For example, in the past 20 years, Ti-4Al-2.5V alloy (UNS R54250), Ti-4.5Al-3V-2Mo-2Fe alloy, Ti-5Al-4V-0.7Mo-0.5Fe alloy (TIMETAL 54M), and Ti-3Al-5Mo-5V-3Cr-0.4Fe alloy have been developed. Ti-4.5Al-3V-2Mo-2Fe alloy, also known as SP-700 alloy (UNS not assigned), is a cold-deformable, high-strength alpha-beta titanium alloy that, unlike Ti-4Al-2.5V alloy, includes relatively high cost alloying ingredients. Similar to Ti-4Al-2.5V alloy, SP-700 alloy exhibits reduced creep resistance due to increased beta phase content. Ti-3Al-5Mo-5V-3Cr-0.4Fe alloy also exhibits good room temperature forming capabilities and, given its significant beta phase content at room temperature, exhibits relatively poor creep resistance.

SUMMARY

It is understood that the inventions disclosed and described in this specification are not limited to the embodiments described in this Summary.

According to a non-limiting aspect of the present disclosure, a method for increasing the tensile strength of an alpha-beta titanium alloy comprises solution heat treating a cold workable alpha-beta titanium alloy by heating the titanium alloy in a temperature range of T_β−106° C. to T_β−72.2° C., where T_β is the beta transus temperature of the titanium alloy, for 15 minutes to 2 hours. In a non-limiting embodiment of the method, after heating the titanium alloy, the titanium alloy is cooled to ambient temperature at a cooling rate of at least 3000° C./minute. In another non-limiting embodiment of the method, after heating the titanium alloy, the titanium alloy is cooled to ambient temperature at a cooling rate at least as great as a cooling rate achieved with water cooling. After cooling the titanium alloy to ambient temperature, the titanium alloy is cold worked to impart an effective strain in a range of 5 percent to 35 percent. Subsequent to cold working the titanium alloy, the titanium alloy is aged by heating in a temperature range of T_β−669° C. to T_β−517° C. for 1 to 8 hours.

In certain non-limiting embodiments of the foregoing method for increasing the tensile strength of an alpha-beta titanium alloy according to the present disclosure, the cold workable alpha-beta titanium alloy comprises, in weight percentages based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium; titanium; and impurities. In a non-limiting embodiment, the sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent.

Another non-limiting aspect of the present disclosure is directed to a method for producing an alpha-beta titanium alloy fastener stock comprising heating an alpha-beta titanium alloy in a temperature range of 866° C. to 899° C. for 15 minutes to 2 hours. The heated alpha-beta titanium alloy is water quenched. After water quenching, the alpha-beta titanium alloy is cold worked to impart an effective strain in a range of 5 percent to 35 percent. The alpha-beta titanium alloy is then aged by heating in a temperature range of 302° C. to 454° C. for 1 to 8 hours.

In certain non-limiting embodiments of the foregoing method, the alpha-beta titanium alloy comprises, in weight percentages based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium; titanium; and impurities. In a non-limiting embodiment, the sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent.

In a non-limiting embodiment of a method for producing an alpha-beta titanium alloy fastener stock according to the present disclosure, cold working comprises drawing the alpha-beta titanium alloy. In another non-limiting embodiment of a method for producing an alpha-beta titanium alloy fastener stock according to the present disclosure, cold working comprises swaging the alpha-beta titanium alloy.

Another non-limiting aspect according to the present disclosure is directed to an article of manufacture selected from: a hot rolled, solution treated, and cold worked alpha-beta titanium alloy fastener; and hot rolled, solution treated, and cold worked alpha-beta titanium alloy fastener stock. In certain non-limiting embodiments, the alpha-beta titanium alloy fastener and the alpha-beta titanium alloy fastener stock according to the present disclosure comprise, in weight percentages based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium; titanium; and impurities. In a non-limiting embodiment, the sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the alpha-beta titanium alloy fastener or the alpha-beta titanium alloy fastener stock is less than 0.5 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present are each less than 0.005 weight percent.

Non-limiting embodiments of a hot rolled, solution treated, and cold worked alpha-beta titanium alloy fastener according to the present disclosure include a bolt, a nut, a stud, a screw, a washer, a lock washer, and a rivet. A non-limiting embodiment of hot rolled, solution treated, and cold worked alpha-beta titanium alloy fastener stock according to the present disclosure is a fastener stock that is in the form of a straight length.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features and characteristics of the non-limiting and non-exhaustive embodiments disclosed and described in this specification may be better understood by reference to the accompanying figures, in which:

FIG. 1 is a flow diagram of a prior art method for making fastener stock and fasteners from an alpha-beta titanium alloy;

FIG. 2 is a flow diagram of a non-limiting embodiment of a method for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure;

FIG. 3 is a flow diagram of a non-limiting embodiment of a method for producing an alpha-beta titanium alloy fastener stock according to the present disclosure;

FIG. 4 is a scanning electron micrograph depicting the microstructure of an embodiment of a fastener stock of a mill annealed ATI 425® alloy;

FIG. 5 is a scanning electron micrograph depicting the microstructure of an embodiment of a fastener stock of ATI 425® alloy that was solution treated and quenched according to a non-limiting method embodiment of the present disclosure; and

FIG. 6 is a scanning electron micrograph depicting the microstructure of an embodiment of a fastener stock of Ti-6Al-4V alloy that was solution treated and quenched according to a non-limiting method embodiment of the present disclosure.

The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive embodiments according to the present disclosure.

DESCRIPTION

Various embodiments are described and illustrated in this specification to provide an overall understanding of the disclosed methods and articles. It is understood that the various embodiments described and illustrated in this specification are non-limiting and non-exhaustive. Thus, the present invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed in this specification. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and/or described in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. The various embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

All percentages and ratios provided herein for an alloy composition are weight percentages based on the total weight of the particular alloy composition, unless otherwise indicated.

Any patent, publication, or other disclosure material that is said to be incorporated, in whole or in part, by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

In this specification, other than where otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term “about”, in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described in the present description should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Also, any numerical range recited in this specification is intended to include all sub-ranges of the same numerical precision subsumed within the recited range. For example, a range of “1.0 to 10.0” is intended to include all sub-ranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0, that is, having a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited herein. All such ranges are intended to be inherently described in this specification such that amending to expressly recite any such sub-ranges would comply with the requirements of 35 U.S.C. § 112, first paragraph, and 35 U.S.C. § 132(a). Additionally, as used herein when referring to compositional elemental ranges, the phrase “up to” includes zero unless the particular element is present as an unavoidable impurity, or unless “up to” is preceded by the wording “greater than zero and”.

The grammatical articles “one”, “a”, “an”, and “the”, as used in this specification, are intended to include “at least one” or “one or more”, unless otherwise indicated. Thus, the articles are used in this specification to refer to one or more than one (i.e., to “at least one”) of the grammatical objects of the article. By way of example, “a component” means one or more components and, thus, possibly, more than one component is contemplated and may be employed or used in an implementation of the described embodiments. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

As used herein in connection with the present invention, “cold working”, “cold worked”, “cold forming”, and like terms, and “cold” used in connection with a particular working or forming technique, refer to working or the characteristic of having been worked, as the case may be, in a temperature range from ambient temperature to no greater than about 677° C. In certain non-limiting embodiments, cold working occurs in a temperature range from ambient temperature to no greater than about 537.8° C. In certain other non-limiting embodiments, cold working occurs in a temperature range from ambient temperature to no greater than about 399° C. In certain other non-limiting embodiments, cold working occurs in a temperature range from ambient temperature to no greater than about 300° C. In a non-limiting embodiment, cold working comprises mechanically working a workpiece without preheating of the workpiece. Non-limiting examples of cold working involve processing a metallic article at such temperatures using one or more techniques selected from rolling, thread rolling, forging, pilgering, rocking, drawing, heading, flow-turning, rocking, bending, flattening, forging, stamping, liquid compressive forming, gas compressive forming, hydro-forming, bulge forming, roll forming, stamping, fine-blanking, die pressing, deep drawing, coining, spinning, swaging, impact extruding, explosive forming, rubber forming, back extrusion, piercing, spinning, stretch forming, press bending, and electromagnetic forming.

As used herein, the term “cold workable”, when referring to a titanium alloy, refers to a titanium alloy that can be cold worked (as defined herein) without deleterious fracturing, macrocracking, and/or microcracking on a titanium alloy workpiece, such as a wire, for example with a preheat, or at a working temperature equal to or less than 398.9° C., or for example, at a working temperature equal to or less than 300° C. It is recognized that when cold working a titanium alloy sheet, a degree of edge cracking may occur, and is acceptable for a cold workable titanium alloy. As used herein, “macrocracking” refers to optically visible cracks and “microcracking” refers to crack formation on the size scale of the grain size of the particular alloy.

Reference herein to a titanium alloy “comprising” a particular composition is intended to encompass alloys “consisting essentially of” or “consisting of” the stated composition. It will be understood that titanium alloy compositions described herein “comprising”, “consisting of”, or “consisting essentially of” a particular composition also may include impurities.

According to a non-limiting aspect of the present disclosure, and referring to FIG. 2, a method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy comprises solution heat treating 22 a cold workable alpha-beta titanium alloy by heating the alpha-beta titanium alloy in a temperature range of T_β−106° C. to T_β−72.2° C. for 15 minutes to 2 hours. All heat treatment times herein and recited in the claims are “time at temperature”, wherein the article is at the indicated temperature or is within the indicated temperature range through its entire thickness. In another non-limiting embodiment, solution heat treating the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of T_β−97.2° C. to T_β−83.3° C. for 30 minutes to 1 hour.

After solution heat treating 22 the alpha-beta titanium alloy, the alloy is cooled 24 at a cooling rate of at least 3000° C./minute. In certain non-limiting embodiments of the method 20, the alpha-beta titanium alloy is cooled 24 by water cooling to achieve the cooling rate of at least 3000° C./minute. In other non-limiting embodiments of the method 20, the alpha-beta titanium alloy is cooled 24 by one of liquid quenching and gas quenching to achieve the cooling rate of at least 3000° C./minute. In certain non-limiting embodiments of the method 20, the alpha-beta titanium alloy is cooled 24 at a cooling rate sufficient to produce martensite upon cooling.

In certain non-limiting embodiments of the method 20, after cooling 24 the alpha-beta titanium alloy, the alloy is cold worked 26 to impart an effective strain in the range of 5 percent to 35 percent, or in the range of 10 percent to 30 percent, or in the range of 13 percent to 23 percent. As used herein, “effective strain” refers to strain that may be achieved during cold working from the combination of tensile, compressive, shear, and/or torsion loading of the alpha-beta titanium alloy. The resultant deformation of the titanium alloy imparts greater strength. The disclosed ranges of effective strain, i.e., 5-35%, or 10-30%, or 13-23%, represent the amount of effective strain that a cold workable alpha-beta titanium alloy of the present disclosure would be capable of withstanding without microcracking occurring in the microstructure. As used herein, effective strain ({dot over (ε)}) is determined by the following equation:

$\stackrel{\_}{\stackrel{.}{\varepsilon }}=\sqrt{\frac{2}{3}}{\left\{{\stackrel{.}{\varepsilon }}_1^2+{\stackrel{.}{\varepsilon }}_2^2+{\stackrel{.}{\varepsilon }}_3^2\right\}}^{1/2}={\frac{2}{3}\left[\frac{1}{2}\left\{{\left({\stackrel{.}{\varepsilon }}_x-{\stackrel{.}{\varepsilon }}_y\right)}^2+{\left({\stackrel{.}{\varepsilon }}_y-{\stackrel{.}{\varepsilon }}_z\right)}^2+{\left({\stackrel{.}{\varepsilon }}_z-{\stackrel{.}{\varepsilon }}_x\right)}^2\right\}+\frac{3}{4}\left({\stackrel{.}{\gamma }}_{\mathrm{xy}}^2+{\stackrel{.}{\gamma }}_{\mathrm{yz}}^2+{\stackrel{.}{\gamma }}_{\mathrm{zx}}^2\right)\right]}^{1/2},$

wherein each of the variables is directed to a normal strain (ε) or a shear strain (γ), and the effective strain is the combination of each of these strains into a single variable. (See, e.g., Kobayashi et al., Metal Forming and the Finite-Element Method, Oxford Series on Advanced Manufacturing (Oxford University Press, New York, N.Y., 1989), p. 48. (ISBN: 0-19-504402-9)). Again referring to method 20, after cold working 26, the alpha-beta titanium alloy is aged 28 by heating in a temperature range of T_β−669° C. to T_β−517° C. for 1 to 8 hours.

In certain non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, the alpha-beta titanium alloy comprises, in weight percentages based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium; titanium; and impurities. An example of an alpha-beta titanium alloy having this composition is disclosed in U.S. Pat. No. 5,980,655, issued Nov. 9, 1999, which is hereby incorporated herein by reference in its entirety.

In certain non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, the alpha-beta titanium alloy comprises, in weight percentages based on total alloy weight: 2.5 to 3.5 aluminum; 2.0 to 3.0 vanadium; up to 0.20 iron; up to 0.15 oxygen; up to 0.050 carbon; up to 0.030 nitrogen; up to 0.015 hydrogen; optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium; titanium, and impurities. In a non-limiting embodiment, the sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.3 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent. An example of an alloy having the foregoing composition is Ti-3Al-2.5V alloy (UNS R56320).

In various non-limiting embodiments of a method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, the alpha-beta titanium alloy is selected from Ti-4.5Al-3V-2Mo-2Fe alloy (also known as “SP-700” alloy; UNS not assigned), Ti-5Al-4V-0.7Mo-0.5Fe alloy (also known as “TIMETAL 54M” alloy), and Ti-3Al-5Mo-5V-3Cr-0.4Fe alloy. A listing of chemical compositions of exemplary alpha-beta titanium alloys that may be processed as described herein follows. This listing provides compositions in weight percentages of the total alloy weight. If the concentration of titanium in a listed alloy is not specified, the alloy's balance is titanium and impurities. In all instances, incidental impurities are expected in the alloys. This listing should not be considered comprehensive and includes: Ti-6Al-4V alloy (UNS R56400) (carbon 0.10 maximum, oxygen 0.20 maximum, aluminum 5.5-6.75, vanadium 3.5-4.5, hydrogen 0.025 maximum, iron 0.30 maximum, others each 0.10 maximum, others total 0.4 maximum); Ti-3Al-2.5V alloy (UNS R56320) (titanium 92.755-95.5, aluminum 2.5-3.5, vanadium 2.0-3.0, iron 0.25 maximum, oxygen 0.15 maximum, carbon 0.1 maximum, nitrogen 0.03 maximum, hydrogen 0.015 maximum, other elements each 0.10 maximum, others elements total 0.40 maximum); Ti-4.5Al-3V-2Mo-2Fe alloy (also known as SP700 alloy) (niobium 6.5-7.5, aluminum 4.0-5.0, vanadium 2.5-3.5, molybdenum 1.8-2.2, iron 1.7-2.3, carbon 0.80 maximum, oxygen 0.15 maximum, nitrogen 0.050 maximum, hydrogen 0.010 maximum, yttrium 0.0050 maximum, other elements each 0.10 maximum, others elements total 0.40 maximum); Ti-5Al-4V-0.7Mo-0.5Fe alloy (also known as “TIMETAL 54M” alloy and disclosed in U.S. Pat. No. 6,786,985, which is incorporated by reference in its entirety herein) (aluminum 4.5-5.5, vanadium 3.0-5.0, molybdenum 0.3-1.8, iron 0.2-1.2, oxygen 0.12-0.25, other elements each less than 0.1, other elements total less than 0.5); Ti-3Al-5Mo-5V-3Cr-0.5Fe alloy (also known as Ti-3553 alloy and disclosed in U.S. Pat. No. 6,632,396, which is incorporated by reference in its entirety herein) (aluminum 2.2 to 3.8, vanadium 4.5-5.9, molybdenum 4.5-5.9, chromium 2.0-3.6, iron 0.2-0.8, zirconium 0.01-0.08, carbon 0.01 to 0.25, oxygen 0.03 to 0.25); and ATI 425® alloy (Grade 38, available from Allegheny Technologies Incorporated, Pittsburgh, Pa. USA) (aluminum 3.5-4.5, vanadium 2.0-3.0, iron 1.2-1.8, oxygen 0.2-0.30, carbon 0.08 maximum, nitrogen 0.03 maximum, hydrogen 0.015 maximum, other elements each 0.10 maximum, others elements total 0.30 maximum).

According to certain non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, cold working 26 the alpha-beta titanium alloy is performed at a temperature less than 676.7° C. In another non-limiting embodiment of the method 20 according to the present disclosure, the alpha-beta titanium alloy is cold worked 26 at a temperature no greater than 300° C. In yet another non-limiting embodiment of the method 20 according to the present disclosure, the alpha-beta titanium alloy is cold worked 26 at a temperature less than 200° C. In still another non-limiting embodiment of the method 20 according to the present disclosure, the alpha-beta titanium alloy is cold worked 26 in a temperature range of −100° C. to +200° C. In still another non-limiting embodiment of the method 20 according to the present disclosure, the alpha-beta titanium alloy is cold worked 26 at a temperature less than 537.8° C.

According to various non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy of the present disclosure, cold working 26 the alpha-beta titanium alloy comprises at least one of rolling, forging, extruding, pilgering, rocking, drawing, flow-turning, liquid compressive forming, gas compressive forming, hydro-forming, bulge forming, roll forming, stamping, fine-blanking, die pressing, deep drawing, coining, spinning, swaging, impact extruding, explosive forming, rubber forming, back extrusion, piercing, spinning, stretch forming, press bending, electromagnetic forming, and cold heading the alpha-beta titanium alloy. In certain non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, cold working 26 the alpha-beta titanium alloy comprises drawing the alpha-beta titanium alloy. In other non-limiting embodiments of the method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, cold working 26 the alpha-beta titanium alloy comprises swaging the alpha-beta titanium alloy.

Again referring to FIG. 2, after cold working 26 the alpha-beta titanium alloy, the alpha-beta titanium alloy is aged 28. In non-limiting embodiments of the method 20, aging 28 the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of T_β−622° C. to T_β−581° C. for 1 to 5 hours. In certain non-limiting embodiments, aging 28 the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of 302° C. to 454° C. for 1 to 8 hours. In other non-limiting embodiments, aging the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of 349° C. to 391° C. for 1 to 5 hours. In various embodiments of the method 20, the aging 28 step can develop significantly higher strength in the alloy, such as 1,450 MPa, for example, while maintaining at least 7% elongation to failure in a 4D tensile gage (4 times the diameter of the specimen) as measured according to specification ASTM E8 2015.

In certain non-limiting embodiments of a method 20 for increasing the tensile strength of a cold workable alpha-beta titanium alloy according to the present disclosure, prior to solution heat treating 22 the alpha-beta titanium alloy, the alpha-beta titanium alloy is hot worked (not shown in FIG. 2). In a non-limiting embodiment of the method 20, hot working (not shown) the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of T_β−83.3° C. to T_β−28° C. In various non-limiting embodiments, the alpha-beta titanium alloy can be hot worked by at least one of rolling, drawing, swaging, equal channel angular pressing, extrusion, thread rolling, forging, flattening, bending, or straightening the alpha-beta titanium alloy.

A person skilled in the art understands that hot working an alpha-beta titanium alloy involves plastically deforming the titanium alloy at temperatures above the recrystallization temperature of the alloy. In certain non-limiting embodiments, the alpha-beta titanium alloy may be hot worked at temperatures in the beta phase field of the alpha-beta titanium alloy. In a particular non-limiting embodiment, the alpha-beta titanium alloy is heated to at least T_β+30° C., and hot worked. In certain non-limiting embodiments, the alpha-beta titanium alloy may be hot worked in the beta phase field of the titanium alloy and subjected to at least a 20 percent reduction in thickness or cross-sectional area. In certain non-limiting embodiments, after hot working the alpha-beta titanium alloy in the beta phase field, the alpha-beta titanium alloy may be cooled to ambient temperature at a cooling rate that is at least as great as the cooling rate achieved from air cooling.

Intermediate the step of cooling 24 the alpha-beta titanium alloy and the step of cold working 26 the alpha-beta titanium alloy, in certain non-limiting embodiments, the alpha-beta titanium alloy is surface conditioned (not shown in FIG. 2). In various non-limiting embodiments, intermediate the step of cold working 26 the alpha-beta titanium alloy and the step of aging 28 the alpha-beta titanium alloy, the alpha-beta titanium alloy is surface conditioned (not shown in FIG. 2). Surface conditioning techniques are known to persons having ordinary skill in the art, and include, for example lathe turning, milling, peeling, sanding, polishing, chemical milling, electrochemical milling, electrodischarge machining, and water-jet techniques.

In various non-limiting embodiments of the method 20, after the step of cold working 26 the alpha-beta titanium alloy and/or the step of aging 28 the alpha-beta titanium alloy, the alpha-beta titanium alloy is finished (not shown). Methods of finishing are known to persons having ordinary skill in the art, and include, for example lathe turning, milling, peeling, sanding, polishing, chemical milling, electrochemical milling, electrodischarge machining, and water-jet techniques. In a particular non-limiting embodiment of method 20, finishing comprises machining the alpha-beta titanium alloy.

Referring now to FIG. 3, another aspect of the present disclosure is directed to a method 30 for producing alpha-beta titanium alloy fastener stock. In a particular non-limiting embodiment of the method 30, the alpha-beta titanium alloy comprises ATI 425® alpha-beta titanium alloy. In various embodiments, the ATI 425® alpha-beta titanium alloy comprises, in percentages by weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; titanium, and impurities. The alloy optionally comprises one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron and yttrium. The sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent.

Non-limiting embodiments of the method 30 for producing an alpha-beta titanium alloy fastener stock comprise heating 32 the alpha-beta titanium alloy in a temperature range of 866° C. to 899° C. for 15 minutes to 2 hours or, alternatively, heating the alpha-beta titanium alloy in a temperature range of 874° C. to 888° C. for 30 minutes to 1 hour. A person having ordinary skill in the art will recognize this heating step to be a solution heat treatment of the alpha-beta titanium alloy, and such person, upon considering the present disclosure, can adjust the heating temperatures and times to suitably solution heat treat different alpha-beta titanium alloys, without undue experimentation.

Again referring to method 30 shown in FIG. 3, after heating 32 the alpha-beta titanium alloy, the alpha-beta titanium alloy is water quenched 34. Other methods of cooling the alpha-beta titanium alloy known to a person of ordinary skill in the art may be used. Any such cooling method preferably provides a cooling rate that is at least a great as the cooling rate needed to form martensite phase in the alpha-beta titanium alloy on cooling. After quenching 34, the alpha-beta titanium alloy is cold worked 36. In various non-limiting embodiments of the method 30, cold working 36 comprises at least one of cold drawing and cold swaging the alpha-beta titanium alloy to impart an effective strain in the range of 5 percent to 35 percent, or in the range of 10 percent to 30 percent, or in the range of 13 percent to 23 percent. In certain non-limiting embodiments of the method 30, cold working 36 the alpha-beta titanium alloy (by a method comprising cold swaging and/or cold drawing, or by another method) comprises working the alpha-beta titanium alloy at temperatures less than 677° C., or less than 537.8° C. In other non-limiting embodiments of the method 30, cold working 36 the alpha-beta titanium alloy (by a method comprising cold swaging and/or cold drawing, or by another method) comprises working the alpha-beta titanium alloy at temperatures no greater than 300° C. In yet other non-limiting embodiments of the method 30, cold working 36 the alpha-beta titanium alloy (whether by cold swaging and/or cold drawing, or by another method) comprises working the alpha-beta titanium alloy at temperatures less than 200° C. In still other non-limiting embodiments of the method 30, the alpha-beta titanium alloy is cold worked 36 by a method comprising cold swaging and/or cold drawing, or by another method, in a temperature range of −100° C. to +200° C.

Again referring to FIG. 3, subsequent to cold working 36 the alpha-beta titanium alloy, the alloy is aged 38. In certain non-limiting embodiments, aging the alpha-beta titanium alloy comprises heating the alloy in a temperature range of 302° C. to 454° C. for 1 to 8 hours. In other non-limiting embodiments, aging 38 the alpha-beta titanium alloy comprises heating the alloy in a temperature range of 349° C. to 391° C. for 1 to 5 hours. In various non-limiting embodiments of the method 30, the aging 38 step can develop significantly higher strength in the alloy, such as 1450 MPa, for example, while maintaining at least 7% elongation to failure in a 4D tensile gage (4 times the diameter of the specimen), as measured according to specification ASTM E8 2015.

In various non-limiting embodiments of the method 30, prior to the step of heating 32 the alpha-beta titanium alloy, the alpha-beta titanium alloy is hot worked (not shown in FIG. 3). In certain non-limiting embodiments, the hot working step comprises at least one of rolling, extrusion, equal channel angle extrusion, drawing, and swaging the alpha-beta titanium alloy. In other non-limiting embodiments, the hot working step comprises hot rolling the alpha-beta titanium alloy to an article having a diameter in the range of 0.25 inch (0.635 cm) to 2.0 inch (5.08 cm). In certain non-limiting embodiments, hot working (not shown) the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of T_β−83.3° C. to T_β−28° C. In non-limiting embodiments of the method 30, the alpha-beta titanium alloy is Ti-4Al-2.5V alloy (UNS R54250), such as ATI 425® alloy, and hot working comprises working the alloy in the temperature range of 888° C. to 943° C.

As noted above, persons skilled in the art understand that hot working an alpha-beta titanium alloy involves plastically deforming the alloy at temperatures above the recrystallization temperature of the alloy. In certain non-limiting embodiments of the method 30, the alpha-beta titanium alloy may be hot worked at temperatures in the beta phase field of the alpha-beta titanium alloy. In certain non-limiting embodiments, the alpha-beta titanium alloy is worked at a temperature of at least T_β+30° C. In certain non-limiting embodiments, the alpha-beta titanium alloy may be hot worked at temperatures in the beta phase field of the titanium alloy so as to provide at least a 20 percent reduction in thickness or cross-sectional area. In certain non-limiting embodiments of the method 30, after hot working the alpha-beta titanium alloy in the beta phase field, the alloy is cooled to ambient temperature at a cooling rate that is at least as great as the cooling rate achieved with air cooling.

In certain non-limiting embodiments of method 30, after hot working (not shown in FIG. 3) the alpha-beta titanium alloy may be cut into short, straight lengths, or may be coiled. If coiled, the alloy may be cut into straight lengths between any two steps of the method 30.

Intermediate the step of quenching 34 the alpha-beta titanium alloy and the step of cold working 36 the alpha-beta titanium alloy, in certain non-limiting embodiments of the method 30, the alpha-beta titanium alloy may be surface conditioned (not shown in FIG. 3). In various non-limiting embodiments, intermediate the step of cold working 36 the alpha-beta titanium alloy and the step of aging 38 the alpha-beta titanium alloy, the alpha-beta titanium alloy is surface conditioned (not shown in FIG. 3). Surface conditioning techniques are known to persons having ordinary skill in the art, and include, for example lathe turning, milling, peeling, sanding, polishing, chemical milling, electrochemical milling, electrodischarge machining, and water-jet techniques.

Another aspect of the present disclosure includes an article of manufacture selected from a titanium alloy fastener and titanium alloy fastener stock. The article of manufacture may be made by a method as described in the present disclosure, for example. In various embodiments, the article of manufacture includes a hot rolled, solution treated, and cold worked alpha-beta titanium alloy comprising, in weight percentages based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; 0.001 to 0.02 nitrogen; titanium; and impurities. The alloy optionally comprises one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron and yttrium. The sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent, wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent, and the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent. In a non-limiting embodiment, the article of manufacture comprising a hot rolled, solution treated, and cold worked alpha-beta titanium alloy is fastener stock that may be in the form, for example, a straight length. In non-limiting embodiments, the article of manufacture comprising a hot rolled, solution treated, and cold worked alpha-beta titanium alloy is in the form of a fastener selected from, for example, a bolt, a nut, a stud, a screw, a washer, a lock washer, and a rivet.

The examples that follow are intended to further describe certain non-limiting embodiments, without restricting the scope of the present invention. Persons having ordinary skill in the art will appreciate that variations of the following examples are possible within the scope of the invention, which is defined solely by the claims.

Example 1

An ingot of ATI 425® alloy was hot forged and subsequently hot rolled to 0.25 inch (6.35 mm) diameter wire for fastener stock. The wire was mill annealed by heating the wire to 760° C. and maintaining at temperature for 60 minutes. The microstructure of the mill annealed ATI 425® alloy wire is shown in the micrograph of FIG. 4. It can be seen from FIG. 4 that the microstructure comprises equiaxed primary alpha grains with small amounts of lenticular secondary alpha.

Example 2

The mill annealed wire fastener stock of Example 1 was solution treated at (760° C.) for 60 minutes (time at temperature), and then water quenched. The microstructure of the solution treated and quenched ATI 425® alloy wire fastener stock is shown in the micrograph of FIG. 5. It can be seen from FIG. 5 that the microstructure comprises a smaller amount of primary alpha grains than in Example 1, and both more numerous and smaller acicular-shaped secondary alpha.

Example 3

Ti-6Al-4V alloy (UNS 56400; available from Allegheny Technologies Incorporated) was hot forged and subsequently hot rolled to 0.25 inch (6.35 mm) diameter wire for fastener stock. The hot rolled wire was solution treated and quenched in the manner used in Example 2. The microstructure of the solution treated and quenched Ti-6Al-4V alloy wire fastener stock is shown in the micrograph of FIG. 6. It can be seen from FIG. 6 that the microstructure comprises primary alpha grains with a matrix of acicular secondary alpha precipitated from a quenched martensite.

Example 4

ATI 425® alloy was hot rolled to a wire having a nominal size of 0.25 inch in diameter. After hot rolling, the wire was either cut into straight lengths or left coiled. Subsequently, the material was solution treated in a furnace at temperatures of 865.6° C., 879.4° C., or 893.3° C. for 1 hour, followed by water quenching. The cooled material was then cold drawn to impart an effective strain of 10%, 15%, and 20%. The effective strain for these samples also corresponded to a percent reduction in cross-sectional area. The material's surface was conditioned after cold drawing to remove any surface imperfections. The surface conditioned material was then aged in a furnace by heating at 350° C., 365° C., or 380° C. for 2, 3, or 4 hours. The process conditions for the samples and mechanical test results are presented in Table 1. Tensile tests were performed in accordance with ASTM E8 2015.

TABLE 1
Tensile Results (mean) for ATI 425 ® alloy Samples
		Effective
		Strain
		(Percent
	Solution	Reduction
Sam-	Treatment	Cross	Aging	Aging			4D
ple	Temp.	Sectional	Temp.	Time	UTS	YS	%	%
#	(° C.)	Area)	(° C.)	(hrs.)	(ksi)	(ksi)	E	RA
1	865.6	10	365	3	208.0	177.6	12.3	37.0
2	865.6	20	365	3	218.5	188.8	12.7	31.3
3	893.3	10	365	3	212.5	187.6	12.3	33.7
4	893.3	20	365	3	215.8	193.5	12.0	33.0
5	879.4	15	350	2	211.9	189.5	12.3	35.3
6	879.4	15	350	4	208.8	183.3	11.3	32.0
7	879.4	15	380	2	205.1	180.5	14.0	37.7
8	879.4	15	380	4	204.2	179.1	12.3	28.0
9	879.4	15	365	3	212.4	189.3	12.3	33.3
10	865.6	15	365	2	214.6	193.8	10.7	28.0
11	865.6	15	365	4	213.5	186.6	11.3	33.3
12	893.3	15	365	2	208.7	181.9	13.3	33.7
13	893.3	15	365	4	213.2	189.4	11.3	33.7
14	879.4	10	350	3	207.8	180.8	14.0	32.0
15	879.4	10	380	3	210.6	188.4	12.5	36.0
16	879.4	20	350	3	223.4	204.7	10.7	28.7
17	879.4	20	380	3	205.5	179.6	11.7	35.3
18	879.4	15	365	3	206.6	181.3	10.0	30.7
19	865.6	15	350	3	211.6	188.8	10.7	35.3
20	865.6	15	380	3	211.6	189.8	13.0	36.0
21	893.3	15	350	3	215.8	197.9	11.3	26.3
22	893.3	15	380	3	214.3	191.4	9.3	26.0
23	879.4	10	365	2	207.2	176.5	12.3	35.7
24	879.4	10	365	4	209.9	185.1	10.7	32.3
25	879.4	20	365	2	210.3	185.5	11.0	36.5
26	879.4	20	365	4	218.5	196.8	11.0	26.0
27	879.4	15	365	3	209.1	188.1	13.0	35.3

It is observed from Table 1 that the aged samples develop significantly higher strength than any commercially available titanium fastener while maintaining at least 7% elongation to failure in a 4D tensile gage. Commercially available titanium fasteners, such as those specified in AMS 4967 rev L, meet a strength requirement of 1137 MPa (165 KSI) and 10% elongation to failure in a 4D tensile gage.

It will be understood that the present description illustrates those aspects of the invention relevant to a clear understanding of the invention. Certain aspects that would be apparent to those of ordinary skill in the art and that, therefore, would not facilitate a better understanding of the invention have not been presented in order to simplify the present description. Although only a limited number of embodiments of the present invention are necessarily described herein, one of ordinary skill in the art will, upon considering the foregoing description, recognize that many modifications and variations of the invention may be employed. All such variations and modifications of the invention are intended to be covered by the foregoing description and the following claims.

Claims

1. A method for producing an alpha-beta titanium alloy fastener stock, comprising:

heating an alpha-beta titanium alloy in a temperature range of 866° C. to 899° C. for 15 minutes to 2 hours;

water quenching the alpha-beta titanium alloy;

cold working the alpha-beta titanium alloy using at least one of cold drawing and cold swaging the alpha-beta titanium alloy to impart an effective strain in the range of 5 percent to 35 percent to the alpha-beta titanium alloy; and

aging the alpha-beta titanium alloy in a temperature range of 302° C. to 454° C. for 1 to 8 hours;

wherein the alpha-beta titanium alloy comprises, in percentages by weight based on total alloy weight: 2.9 to 5.0 aluminum; 2.0 to 3.0 vanadium; 0.4 to 2.0 iron; 0.2 to 0.3 oxygen; 0.005 to 0.3 carbon; titanium; impurities; and

optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron and yttrium;

wherein the sum of the weight percentages of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent;

wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent;

wherein the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent.

2. The method of claim 1, wherein cold working the alpha-beta titanium alloy comprises working the alpha-beta titanium alloy at temperatures less than 676.7° C.

3. The method of claim 1, wherein cold working the alpha-beta titanium alloy comprises working the alpha-beta titanium alloy at temperatures less than 537.8° C.

4. The method of claim 1, wherein cold working the alpha-beta titanium alloy comprises imparting an effective strain in the range of 10 percent to 30 percent to the alpha-beta titanium alloy.

5. The method of claim 1, wherein cold working the alpha-beta titanium alloy comprises imparting an effective strain in the range of 13 percent to 23 percent to the alpha-beta titanium alloy.

6. The method of claim 1, wherein heating the alpha-beta titanium alloy comprises heating the alpha-beta titanium alloy in a temperature range of 874° C. to 888° C. for 30 minutes to 1 hour.

7. The method of claim 1, wherein aging the alpha-beta titanium alloy temperature comprises heating the alpha-beta titanium alloy in a temperature range of 349° C. to 391° C. for 1 to 5 hours.

8. The method of claim 1, further comprising, prior to heating the alpha-beta titanium alloy, hot working the alpha-beta titanium alloy.

9. The method of claim 8, wherein hot working the alpha-beta titanium alloy comprises working the alpha-beta titanium alloy in a temperature range of 888° C. to 943° C.

10. The method of claim 8, wherein hot working the alpha-beta titanium alloy comprises rolling the alpha-beta titanium alloy to a diameter in a range of 0.635 cm to 5.08 cm.

11. The method of claim 8, further comprising, subsequent to hot working the alpha-beta titanium alloy, cutting the alpha-beta titanium alloy into straight lengths.

12. The method of claim 1, further comprising, intermediate quenching the alpha-beta titanium alloy and cold working the alpha-beta titanium alloy, surface conditioning the alpha-beta titanium alloy.

13. The method of claim 1, further comprising, intermediate cold working the alpha-beta titanium alloy and aging the alpha-beta titanium alloy, surface conditioning the alpha-beta titanium alloy.

14. The method of claim 1, further comprising, after at least one of cold working the alpha-beta titanium alloy and aging the alpha-beta titanium alloy, finishing the alpha-beta titanium alloy.

15. The method of claim 14, wherein finishing the alpha-beta titanium alloy comprises machining the alpha-beta titanium alloy.

16. An article of manufacture selected from a titanium alloy fastener and titanium alloy fastener stock, the article of manufacture including a hot rolled, solution treated, and cold worked alpha-beta titanium alloy comprising, in percentages by weight based on total alloy weight:

2.9 to 5.0 aluminum;

2.0 to 3.0 vanadium;

0.4 to 2.0 iron;

0.2 to 0.3 oxygen;

0.005 to 0.3 carbon;

titanium;

impurities; and

optionally, one or more of tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron and yttrium;

wherein the sum of the weight percentages of any tin, zirconium,

molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, cobalt, boron, and yttrium present in the titanium alloy is less than 0.5 weight percent;

wherein the individual concentrations of any tin, zirconium, molybdenum, chromium, nickel, silicon, copper, niobium, tantalum, manganese, and cobalt present in the alloy are each no greater than 0.1 weight percent;

wherein the individual concentrations of any boron and yttrium present in the alloy are each less than 0.005 weight percent.

17. The article of manufacture of claim 16, wherein the alpha-beta titanium alloy is a hot rolled, solution treated, cold worked, and aged alpha-beta titanium alloy.

18. The article of manufacture of claim 16, wherein the article of manufacture is a titanium alloy fastener selected from a bolt, a nut, a stud, a screw, a washer, a lock washer, and a rivet.

19. The article of manufacture of claim 17, wherein the article of manufacture is a titanium alloy fastener selected from a bolt, a nut, a stud, a screw, a washer, a lock washer, and a rivet.

20. The article of manufacture according to claim 16, wherein the article of manufacture is a straight length of fastener stock.

21. The article of manufacture according to claim 17, wherein the article of manufacture is a straight length of fastener stock.