Titanium tube forming
The production journey of titanium begins with extraction from different concentrates, one of the most common being rutile. The concentrate is processed to remove excess iron. From there, the resulting material is put into a reactor along with chlorine and carbon.
The next step involves removing impurities, which is accomplished by vacuum distillation. Once the metal chlorides are removed, the titanium is purified, resulting in a sponge. This will be pressed into blocks and then melted.
Titanium ingots are used to make different products, including titanium tubes. Read on and discover more useful information about the process.
Manufacture of titanium products - welded pipes
In today's modern world, more and more companies are showing interest in the manufacture of titanium products. They have the technology and equipment needed to develop titanium tubes that will be further used in various industries.
The development process has become routine, however, there are some unique aspects worth considering. Titanium tubes must be developed in a completely clean environment. Generally speaking, there is a separate area for the manufacture of titanium products. It is important that this area does not contain any contaminants such as dust and grease. Moisture and airflow must also be absent.
Welded titanium pipes have been used in numerous industries including the chemical industry. Power plants, especially those operating in seawater, rely on titanium pipes. These tubes are also used in heat exchangers in condensers and are appreciated for their high corrosion resistance.
Manufacturers may apply additional tension to the titanium tube wall when noticing insufficient solidification at the weld pool seam. Additionally, to ensure that titanium products remain stable, they may rely on automated diameter measurement systems. In the future, automatic monitoring systems for seam welding conditions may also be introduced.
How are titanium tubes formed?
The formation of titanium is achieved at room temperature in a process similar to that of steel. Given the unique properties of titanium, manufacturers rely on the same technology and equipment. This facilitates the tube formation process.
Titanium is less ductile at room temperature than one of the other structural metals. This automatically translates into reduced stretch formability and wider bend radii. Because of these properties, thermoforming is sometimes used, especially if more severe bending is required (or in the case of stretch forming).
The modulus of elasticity of titanium is half that of steel, which means that the forming process causes significant springback (manufacturers compensate for this property). Additionally, given titanium's tendency to wear—greater than that of steel—lubrication is an important part of the tube forming process.
Preparation before molding
In most cases, titanium requires no additional measures prior to forming operations. Ingots can be used as received, but this may not always work.
Note any marks on its surface, such as gouge marks, these will be removed by different treatments (sanding, pickling, etc.). Also, if there are any sharp edges, they should be smoothed out before the actual tube forming process. Otherwise, there is a risk of edge breakage, which will affect the quality of the final product.
Molding type
Titanium tubes can be formed in two ways: cold forming and hot forming.
cold forming
Considering the elongation of the metal, the titanium tube is formed at low speed and room temperature. For this purpose, a tensile test will be carried out. Manufacturers will eliminate springback by using heat setting on the already formed titanium tube.
Thermoforming
It is known that the ductility of titanium - including bendability and stretch formability - increases with temperature. For this reason, titanium tubes are usually realized at high temperatures. Needless to say, as the temperature increases, the forming operation of the titanium tube becomes easier. Using this method, springback is virtually eliminated when forming grade 5 titanium.
Titanium Tube Bending
Titanium tubes are bent using conventional equipment. Mandrel benders are the first choice for small radius bends. To minimize the wear tendency of titanium alloys, both the tube bending equipment and the wiper die must be properly lubricated. For best results, the bending process should be done at a slow speed.
How is titanium seamless pipe made?
Seamless tubes can be made from commercially pure titanium or one of the existing titanium alloys. Titanium ingots are initially processed at varying temperatures between 850 ºC – 1250 ºC and finally down to 600 ºC – 1100 ºC.
As a result of the machining, a solid blank will be obtained. It is then turned into a hollow piece through a perforation process at temperatures between -100 ºC and 1250 ºC.
Size adjustment occurs through elongation followed by a reduction step. This occurs with a temperature change between 600 ºC and 1100 ºC, resulting in a reduction in the outer diameter. Finally, sizing will take place at temperatures between 550 ºC and 1150 ºC, which will further reduce the outer diameter.
last sentence
The manufacturing methods and equipment for titanium tubes are the same as for other structural metals. Due to its unique properties, it is recommended for use in highly corrosive environments (where steel is not capable). The aerospace industry uses titanium tubes extensively, recognizing the benefits provided.
Manufacturers can offer titanium tubes in a variety of sizes, diameters, and wall thicknesses. Tubes are available in different titanium grades, each with different properties and suitable for a variety of applications. Each titanium grade respects different technical requirements and is suitable for one type of application or another.
