Allegheny Technologies Incorporated announced on June 26, 2006 that its Board of Directors approved a greenfield premium-grade titanium sponge facility to be built in Rowley, UT with an annual capacity of 24 million pounds. This $325 million investment is aimed at increasing ATI’s capacity to produce titanium alloys for aerospace and defense applications.  Premium-grade sponge is essential for many aerospace applications, including rotating quality titanium alloys used for new jet engines and spare parts. ATI expects initial production to begin in the third quarter 2008. 

This Phase IV titanium expansion brings ATI’s projected total annual titanium sponge capacity to approximately 40 million pounds.  ATI previously announced three titanium sponge capacity increases at its Albany, OR facility amounting to 16 million pounds per year.

“ATI’s 40 million pounds of annual titanium sponge capacity provides opportunities for significant revenue and earnings growth and a stable low-cost supply of this vital raw material. Strategically securing a cost-competitive source of titanium sponge is critical to achieving our profitable growth potential. The expected return on this investment is very attractive,” said Patrick Hassey, Chairman, President and Chief Executive Officer of Allegheny Technologies. “With this additional titanium sponge raw material supply, we can confidently meet the growing long-term mill product demand from our customers. We also plan to continue to purchase titanium units in the form of sponge and scrap from our long-term suppliers.”

The Board’s approval of the Phase IV expansion is contingent upon the satisfactory completion of appropriate arrangements relating to the acquisition of and use of property, incentives from the State of Utah and the County of Tooele, and the supply of raw materials and utilities.   

“Looking to the later part of this decade, our customers’ forecast demand for titanium mill products exceeds the titanium industry’s current and announced production capacity,” Hassey said. “ATI is investing to grow profitably and rapidly with this robust demand. ATI is uniquely positioned to grow in the global titanium market with our expanding titanium raw material supply and unequalled melt capabilities. In addition, we have an unparalleled combination of assets for finishing titanium products.”

ATI previously announced a $150 million three-phase titanium products expansion that is expected to yield 16 million pounds of titanium sponge capacity and increase ATI’s annual titanium melt capacity by approximately 25 million pounds:

ATI expects a total of $250-$275 million of capital investments in 2006 in a self-funded growth strategy.

This article contains “forward–looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995. Certain statements in this article relate to future events and expectations and, as such, constitute forward-looking statements. Forward-looking statements are based on management’s current expectations and include known and unknown risks, uncertainties and other factors, many of which we are unable to predict or control, that may cause our actual results, performance or achievements to materially differ from those expressed or implied in the forward-looking statements.  Important factors that could cause actual results to differ materially from those in the forward-looking statements include:

Building the World’s Best Specialty Metals Company™

Allegheny Technologies Incorporated is one of the largest and most diversified specialty metals producers in the world with revenues of $4 billion during the most recent four quarters ending June 30, 2006. ATI has approximately 9,300 full-time employees world-wide who use innovative technologies to offer growing global markets a wide range of specialty metals solutions. Our major markets are aerospace and defense, chemical process industry/oil and gas, electrical energy, medical, automotive, food equipment and appliance, machine and cutting tools, and construction and mining. Our products include titanium and titanium alloys, nickel-based alloys and superalloys, stainless and specialty steels, zirconium, hafnium, and niobium, tungsten materials, grain-oriented silicon electrical steel and tool steels, and forgings and castings. The Allegheny Technologies website is www.alleghenytechnologies.com.

Wah Chang is pleased to announce its sixth international Corrosion Solutions® Conference, which will be held September 9-13, 2007 at Sunriver, Oregon. This conference follows the successful Corrosion Applications Conference held in September 2005 that covered topics ranging from the performance of zirconium, titanium, tantalum, niobium, and specialty steels in corrosive environments to various aspects concerning the design, fabrication, and maintenance of processing equipment. Attendees represented companies from over 20 countries and included participants from chemical and mineral processing plants, fabricators, equipment manufacturers, engineering contractors, and academia.

The 2007 event will provide the latest information working with various materials of construction, such as stainless steels, nickel alloys, titanium, niobium, tantalum, and zirconium, and will cover a broad spectrum of aqueous corrosive applications. At this time, we have preliminary commitments for technical papers from some of the world’s premier chemical companies and major fabricators.

Wah Chang invites you to participate in this unique event by submitting a paper for presentation or joining us as an attendee. We are looking for abstracts discussing the application of alloys in chemical process environments. Potential topics and areas of interest include, but are not limited to:

Interested authors should submit an abstract with the title and author’s name by September 30, 2006 to richard.sutherlin@wahchang.com or submit by fax at 541-924-6892 (attention Rick Sutherlin). All abstracts will be reviewed, and authors will be notified upon acceptance of their papers (Note: there are limited presentation slots, and Wah Chang reserves the right to reject abstracts).

Final manuscripts will be due to Wah Chang no later than May 1, 2007. All selected papers submitted within the deadlines will be included in the conference proceedings. Presenters’ registration as well as selected event fees will be waived. Contact Mr. Sutherlin at 541-967-6924 for more information or to discuss a potential topic.

If you do not plan to present a paper and the conference, but would like to register or reserve a booth (space is limited), contact Ms. Sheryl Renzoni at sheryl.renzoni@wahchang.com, by fax at 541-924-6892, or by phone at 541-926-4211 x6280 for details. Please check out www.corrosionsolutions.com during the coming months for continuing updates on this one-of-a-kind event!

In 1956, the Wah Chang Corporation purchased property just north of Albany, Oregon, and broke ground on a new facility for producing zirconium and other unique metals. What is now called “Building 1” was erected, and the company celebrated the official opening of the Albany Zirconium Plant on April 22, 1957.

In the early 1960s, Wah Chang expanded into the production of “columbium” — now called niobium. The Atomic Energy Commission was exploring uses for nuclear propulsion and hatched the idea of the aircraft nuclear propulsion project. The idea was to design a reactor that could be used to power a large aircraft which could stay aloft without refueling. The metal of choice for constructing the reactor core was niobium. Over 100 niobium and tantalum alloys were manufactured and explored by Wah Chang, and several, such as C-103, Nb-1Zr, WC-129Y, T-111, and T-222, are still used today.

During the 1970s, Wah Chang expanded niobium opportunities into rocket nozzle skirt extensions, satellite orbit thrusters, and development and deployment of Nb47Ti and Nb3Sn, two alloys suitable for superconducting applications. The company’s niobium alloys were soon a material of choice for magnetic resonance imaging equipment (MRIs) for medical diagnostic imaging and particle accelerators for physics research. Commercial nuclear application of zirconium and hafnium grew as Wah Chang supplied material for nuclear power plants.

The 1980s and 1990s were times of diversification. Using six elements (zirconium, hafnium, titanium, niobium, tantalum, and vanadium), Wah Chang melted over 200 alloy combinations and supplied a diverse range of mill products, including ingots, forgings, foil, sheet, strip, plate, billet, bar, rod, wire, tubing, pipe, and pipe fittings. A specialty machine and fabrication shop provided engineered products for defense and civilian applications. Zirconium specialty chemicals went into a range of consumer products from deodorants to ice cream thickeners to paper whiteners. Seamless titanium alloy tubing became the material of choice for aerospace and aircraft hydraulic tubing.

In 1996, Wah Chang became part of Allegheny Teledyne Incorporated, now known as Allegheny Technologies Incorporated (ATI).

Today, ATI Wah Chang continued to innovate and expand product offerings. A zirconium-niobium alloy became the metal of choice for orthopedic implants for knees and hips. Specialty alloy development continues to progress, especially materials based on titanium.

A nickel-titanium alloy, NiTiNOL, originally developed by the Navy in the 1960s, has been adopted for a wide range of medical applications, including arterial stents, catheters and guide wires, and even dental brace wires. A new titanium alloy, ATI 425™, with the strength of industry workhorse Ti-6Al-4V, but with the ability to be cold rolled into continuous strip, is Wah Chang’s latest great development.

ATI Wah Chang will continue to grow core competencies while diversifying both product and market opportunities. The company provides materials to a variety of industries, including aerospace, chemical and mineral processing, consumer goods, electronics, energy, high energy physics, medical, recreation and sporting goods, as well as other niches. The history of ATI Wah Chang is rich with innovations and products that impact the lives of people everyday.



Visit wahchang.com and look at the company’s products and capabilities with an innovative mind set. After-all, Wah Chang’s customers have been key to growth of its product lines… from the day the company broke ground on a zirconium plant 50 years ago through today when it supplies a wide variety of products for life-changing applications.

Allegheny Technologies slogan is “Building the World’s Best Specialty Metals Company,” and we at Wah Chang stand behind that mission and welcome the challenges to come.

By the year 323 BC Alexander the Great, King of Macedonia, had spent eight years moving his massive military to victories across 11,250 miles. His victories were won through superior logistics, achieved by transporting troops and supplies on ships able to carry 400 tons, rather than horses carrying 200 pounds and requiring 20 pounds of food daily. Alexander’s logistical tact continues today. Addressing similar weight and transportation issues, the U.S. Military is employing a “logistical footprint” designed to reduce the vehicle weight of its ground forces. Since 70% of combat vehicle weight comes from vehicle structure and armor,[1] armor engineers, contractors, and material providers are challenged to develop lighter-weight solutions.



Amoring concepts have been rapidly changing since 1999 when the U.S. Department of Defense (DoD) unveiled its future logistics plan called Future Combat Systems (FCS). FCS will transform military logistics through sophisticated intelligence and communication networks designed to integrate highly responsive land, air, and sea operations into a coordinated offensive. The United Kingdom will realize similar types of “network-centric” logistics through its program called Future Rapid Effects System (FRES).

Finding the logistical equivalent to Alexander’s transport ships in its C-130 aircraft, the DoD is restricting FCS combat vehicle weight to 19 tons, permitting these vehicles to be C-130 transportable. This logistical footprint reverses a trend toward heavier armored vehicles, effectively imposing design limitations that will “compel a fundamental shift… in the armor community,” writes Retired Lt. Col. Andrew F. Krepinevich, Jr., “mandating a 70 percent reduction in weight from the Abrams tank and 50 percent less internal volume to fit aboard C-130s.”[2] Additionally, guerilla-style warfare tactics in Iraq are challenging armoring concepts as combat vehicles, and tactical and support vehicles — which are traditionally unarmored — are being exposed to 360º threats from Rocket Propelled Grenades (RPGs) and Improvised Explosive Devices (IEDs).

Unfortunately, the lighter-weight power plant and chassis designs of tactical and support vehicles are quickly taxed by additional armor weight. These facts are compounded by the U.S. Revolution in Military Logistics initiatives requiring a 75 percent reduction in support and supply vehicle fuel consumption.[3] Increased fuel efficiency is logistically critical as fuel comprises 70 percent of the U.S. Army’s total weight shipped to battle zones. Additionally, support and supply vehicles make up eight of the top ten highest consumers of fuel, and the total cost for a gallon of gas in the battle zone rises to between $100 to $400.[4] Under these conditions, armor solutions can yield an immediate return on investment.

To reach weight reduction goals, armor designers are turning to metals with higher mass efficiencies. Em values are used to compare the mass efficiency of armoring materials, with rolled homogeneous armor (RHA) used as a common factor of 1. With an impressive Em value of 1.78, dual hardness steel is being used in U.S. armored light tactical vehicles. It will likely be used to armor support and supply vehicles where dual hardness steel will reduce armor weight by 56 percent over RHA.

Titanium armor also has proven highly successful in several existing applications. BAE Systems Land and Armaments’s Bradley A3/FIST variants take advantage of titanium armor.[5] General Dynamics Land Systems (GDLS) uses titanium on its M1A2 tank’s commander’s hatch, GPS cover, turret blow off panels, CITV cover, and armor skirts to reduce vehicle weight and prevent corrosion.[6] Forged titanium is used in the construction of the M2 Bradley commander’s hatch cover and cast titanium in the Expeditionary Fighting Vehicle (EFV) sprocket and idler wheel. Additionally, the U.S. Army Armament Research, Development and Engineering Center (ARDEC) identifies titanium as an “excellent alternative to steel” because it is 30 percent lighter for the level of threat in the Iraqi theater.[7] Selected for its weight reduction characteristics and structural integrity, titanium is used in the Stryker Fire Support Vehicle (FSV) and Reconnaissance Vehicle (RV) variants’ gunner protection shields. To help reduce the overall weight of the Stryker Mobile Gun System (MGS) and meet C-130 weight limits, titanium has replaced steel armor in several applications on this vehicle. Additionally, CP titanium is used in the construction of explosive reactive armor (ERA) boxes. ERA boxes protect vehicles from RPG threats by exploding outward, effectively redirecting shaped charges away from the vehicle.

Titanium is currently being evaluated for use in FCS vehicles. The U.S. Marines will likely adopt titanium alloy for use in their future combat vehicles. These vehicles will likely weigh in between 10 and 20 tons, and be capable of surviving attacks from ballistic and blast threats.[8] GDLS is actively evaluating titanium (Ti-6Al-4V) as one of its candidate materials. Aluminum and polymer based composites are also being considered as a structural material for its FCS vehicles.[9]

Government research institutes are also working to identify key material characteristics and processing techniques. Advanced Materials Processes Technology (AMPTIAC), a division of DoD, is working to reduce material processing costs, identify more weight efficient ballistic and blast efficient armor, and select better corrosion resistant armoring materials. Meeting these armor material goals is critical to fulfilling the demands placed on FCS and FRES vehicles. Future combat vehicles are expected to be 20-ton combat vehicles with the survivability of 60-ton tanks. Support vehicles, as expected, will have hardened exteriors capable of surviving threats from gunfire and IEDs, and all vehicles should be capable of performing in varied corrosive environments while achieving lifecycles approaching 30 years.

Combat vehicles capable of surviving minefields and direct fire from enemy RPGs are vulnerable to the same threats as poorly armored support vehicles. According to a study by NACE, “corrosion is potentially the number one cost driver in lifecycle costs” for the DoD, costing $20 billion a year. Pressing concerns over corrosion costs have lead the U.S. Deputy Secretary of Defense to appoint a Corrosion Executive responsible for implementing corrosion prevention plans and procedures throughout all branches of the military. “Corrosion impacts vital aspects of the military by reducing combat readiness, increasing maintenance costs, and reducing the morale and training time of soldiers strapped with the responsibility of ‘rust busting’ or tending to rust prevention,” states Rich Hays, U.S. Marine Corrosion Branch Head.[11]

Vehicles are highly susceptible to corrosion during transportation, often being exposed to marine environments while aboard ocean traveling ships. Additionally, several U.S. Marine Corp vehicles, particularly the Expeditionary Fighting Vehicle, are expected to ford the saline waters of ocean shorelines. In order to find better corrosion resistant materials the Office of Naval Research is conducting a six-year study of material corrosion by monitoring material coupons located on 450 vehicles. These test results will assist in material selections that can help achieve the goal of “vehicles capable of more than 20 years’ service with minimal corrosion impact.”[12]

Although lifecycle costs are important to FRES and FCS, securing and protecting highly trained soldiers and field personnel are critical to the functioning of combat technologies and systems. Sensitive to the welfare of their soldiers, western militaries are investing in body armor designed to protect their forces from threats as serious as 7.62 mm armor piercing rounds. However, body armor also posses weight challenges. U.S. Army infantry and U.S. Marines carry between 70 to 85 pounds of gear, equipment and armor into the field, with armor accounting for 16 to 20 pounds of weight.[13,14] Clearly there is a pressing need for lighter-weight, dependable body armor.

Currently, ceramic body armors are used to protect soldiers. Selected for weight efficiency, ceramic body armor is delivered with a paradoxical phrase stamped on the face plate reading “Do not drop,” or “Handle with care.” Invisible stress fractures, caused when a ceramic plate is dropped, significantly compromise ceramic body armor’s ballistic performance. Ceramic body armor plates are prone to these fractures when they are outside of a flack jacket or ballistic vest.

Fortunately, steel body armor maintains integrity when dropped or mishandled. This is an important feature for military tactical tems, who often use body armor plates kept in harnesses, not ballistic vests. Sniper and other tactical teams maneuver through the field differently than other military groups, Often times laying chest down, they must be able to position themselves so they can see targets and fire their weapons with precision. To accomplish this field positioning, tactical teams avoid using bulky ballistic vests. Instead they use stand alone armor plates fitted in harnesses. The entire system is as thin as the armor plate itself. A mass efficient steel alloy, such as dual hardness, is roughly half as thick as ceramic armor.

The evolving armor market is driving metal armor manufacturers to develop targeted solutions. In order to meet the changing needs of the armor market, Allegheny Technologies offers a portfolio of lightweight steel and titanium alloys. Also supplied are cast, near-net shaped, Superplastic Formed (SPF), and engineered armor products. Additionally, ATI offers corrosion testing and laboratory services to aid in material selection decisions. ATI recently upgraded and restarted its titanium sponge plant in Albany, Oregon, USA and is further expanding its armor material capacities by coordinating melting and mill processing capabilities throughout the Corporation (see sidebar).

With its ATI 425™ titanium alloy,[15] ATI successfully addresses the need for a lower-cost, more-workable titanium alloy (see Figure 1). Cost reductions are achieved by taking advantage of Class 4Mil-DTL-46077 open chemistry ranges. ATI 425™ alloy has a higher iron composition compared to the vanadium-rich Ti-6Al-4V. Additionally, ATI 425™ titanium is the only ballistic titanium amenable to cold rolling. Also, high corrosion resistance properties of ATI 425™ titanium to seawater help significantly reduce total lifecycle costs.

ATI further reduces material processing costs by offering titanium ram graphite castings (see page 6), SPF, and near net shape parts. Casting services are making huge financial impacts on the armor market. BAE Systems reduced welding hours by 50 percent, reduced titanium structure part counts by 51 percent, and diminished manufacturing variations by employing titanium casting in its M777A1 Howitzer.[16]

ATI manufactures two high-end mass efficient ballistic steels. Allegheny Technologies is the only U.S. producer of dual hard steel, which it supplies to the market with its K12® alloy. K12® dual hard steel is currently protecting uparmored tactical vehicles in the Iraqi theater and will likely armor support and supply vehicles helping reduce weight by 50 percent compared to RHA steel. ATI also accommodates transportable add-on-armor needs by offering K12® dual hard steel tile forms. ATI also produces mass efficient structural armor with its AL 521™ specialty high hard steel. The armor, with ballistic values greater than RHA, is typically used on the upper hulls of numerous combat and support vehicles. AL 521™ specialty high hard steel is also available in an enhanced form for add-on-armor applications.



ATI has more than 25 years of experience working with corrosion resistance for the chemical processing industry. The ATI Wah Chang Corrosion Laboratory, which has been operating since 1979, is actively evaluating armoring material corrosion issues. Its corrosion and technical laboratories have the ability to replicate a wide range of corrosive environments. Its metallurgical, radio analytical, and corrosion labs and mechanical testing services are also available for contract projects.

Network-centric logistics are complex systems coordinating the actions of foot-soldiers, tanks and aircraft. Undoubtedly, logistics planners recall the wisdom of Alexander the Great, who declared, “Upon the conduct of each depends the fate of all.” With this wisdom in mind, Allegheny Technologies is developing armor solutions for all levels of need: from body armor for the war fighter, to weight saving components and armor solutions for the largest fighting vehicle.

Further information on Allegheny Technologies armor products and services is available through the Business Development department. For details, please contact Larry Martin by phone at 541-924-6896 or by email at larry.martin@wahchang.com, or contact Andy Nichols at 541-917-6716 or andy.nichols@wahchang.com.


RESOURCES

In 1956 the founding fathers of Oremet Titanium built the first commercial titanium foundry; little did they realize that 50 years later this facility would provide quality rammed graphite casting components to the United States Military.

Over the last fifty years the titanium foundry, currently owned and operated by ATI Wah Chang, has grown significantly. Originally designed to produce titanium and zirconium castings for the Chemical Process Industry (CPI), this foundry has grown from producing simple pump bodies, valves and impellers to producing sophisticated components such as torpedo ejection pumps, titanium fire pumps and hatch covers for combat vehicles.

The leap from industrial market cast components to technically sophisticated military castings did not occur overnight. Many years of research and hard work went into the development of titanium and zirconium rammed graphite castings for industrial components. Applications and markets include pump castings for nickel laterite slurries, pulp and paper equipment, cast valve components for Norwegian oil and gas applications and castings for deep sea detection of earthquakes and tsunamis. The lessons learned over the last fifty years have enabled us to smoothly transition into the production of castings for military and defense applications.

The overriding benefit to selecting titanium rammed graphite castings for military applications is cost. Cost advantages can be derived through smarter utilization of the materials, the casting of near net shapes through design efficiencies, and the production of less scrap as compared to machining operations. Casting of titanium into a near net shape holds a distinct advantage for fabricators, contractors and machine shops over traditional forgings or mill products. The ability of cast titanium to conform to the shape of the designed part through a mold presents to the user a cleaner, more dimensionally correct near net shape part without the traditional envelopes that are provided with forged components. Near net shape cast components also eliminate the scrap that is generated by forgings and eliminate long machining times.


THE PROCESS

Titanium rammed graphite castings are made using wood, metal or plastic patterns to produce a mold. Similar to conventional sand castings, titanium rammed graphite castings use the standard cope and drag patterns, with and without cores. Many parts can be cast using the same patterns originally constructed for the casting of other metals.

Because titanium is so reactive in the molten state, graphite is used as a mold medium. Graphite powder is mixed with water, pitch syrup and starch, which act as binders. This mixture is pneumatically tamped and rammed around the pattern to form the mold.

The mold is air dried for approximately 24 hours to achieve a green strength before it is baked at a low temperature to prevent steam generation and cracking during the firing step. The amount of baking time depends on the thickness and shape of the mold. Molds are fired in excess of 1500ºF to develop the final bonds and to burn off binders, resulting in a hard and rigid final product. The molds are then cleaned and assembled and gates and risers are cut into the molds. These must be carefully designed to allow the proper flow of molten material during the casting process and to ensure that shrinkage takes place in the gates and risers rather than the finished casting. The maximum size of a titanium pour is approximately 1800 pounds, although larger castings have been produced by utilizing multiple pours and molds. Dimensionally, 50 inches in diameter by 72 inches is the maximum single pour. Wall thicknesses as thin as 0.1875 inches have been produced using the rammed graphite method.

Titanium rammed graphite castings are currently melted using a vacuum arc skull furnace. This method uses consumable electrodes that are melted into a water-cooled copper crucible; electrodes are either forged billet, consolidated revert or a combination of the two. The mold assembly is placed on a table in the bottom of the furnace where the titanium can be centrifugally or statically cast depending upon the geometry of the casting and specifications that may be imposed by the customer. Extreme care must be used during the melting process since titanium can easily be contaminated by oxygen, hydrogen and nitrogen. The furnace is sealed, a vacuum is drawn and an arc is struck on revert material placed in the crucible and the titanium is then melted. When the proper amount of material is melted the crucible is tipped and the molten material is poured into the mold. The mold assembly is left in the furnace under vacuum until the metal has cooled to proper temperature.

After the mold assembly is removed from the furnace the graphite is removed by traditional “knockout” methods and the gates and risers are removed by oxyacetylene torch. The metal surfaces in contact with the mold will have a carbon-contaminated layer, which must be removed by blasting and/or pickling. The pickling solution is generally 15 to 30 percent nitric acid and 3 to 5 percent hydrofluoric acid with the balance water.

Once the “knockout” has been completed the casting goes through Non-Destructive Testing (NDT) and inspection where necessary finishing processes for the casting are determined. Common finishing processes include sandblasting, grinding and Hot Isostatic Pressing (HIP).

If the casting requires HIP it is shipped offsite to a facility where any internal voids or porosity that may have occurred during pouring can be healed. During the HIP process, the castings are placed in a vacuum chamber, the temperature is raised to 1500ºF and a pressure of approximately 16,000 psi is applied. The voids are “healed” by pressing of the material.

HIP is a process that is used on almost all of the castings that are produced by ATI Wah Chang. In addition to this process, radiographs are often taken of castings to detect if there may be voids or porosity that HIP may have missed. Typical internal defects may include gas hole porosity and shrinkage cavities. If either is found via radiography methods, the casting will be weld repaired. The casting is drilled, cleaned and placed in a weld chamber. A vacuum is drawn in the chamber and backfilled with an inert gas. Filler metal is then welded into the drilled hole and if necessary a post-weld stress relief heat treatment will be performed. Depending on the product and customer specification castings may be visually, dimensionally and dye penetrant inspected. Chemical analysis and mechanical properties are provided if requested by the customer.


THE ADVANTAGES OF RAMMED GRAPHITE CASTINGS

Rammed graphite castings have become a viable alternative to the typical fabrication of titanium plates and components. The labor intensive fabrication methods that previously relied on cutting, machining and fitting plates to be welded are being replaced by the simpler near net shape castings. The titanium foundry has successfully replaced welded fabrications on many occasions and has proven to many military and defense related companies that a near net shaped casting provides a less costly alternative to the fabrication method. Engineers and analysts are realizing that a one piece, near net shaped casting also provides less chance for errors relating to welding because there are less welds on a casting than there are on cut, fitted plates.

The fact that a rammed graphite casting is repeatable is also very desirable to contractors and end users. The low upfront cost of patterns is very desirable and affordable when compared to the tooling that is required for investment castings. Titanium castings use a pattern that is dimensionally correct each and every time, based upon the customers’ drawing requirements. The casting will maintain the dimensions that are designed into the pattern, so the larger envelopes that often accompany forgings, billet and plate stock will be eliminated by requesting castings. A near net shape can eliminate many extra hours of machining and milling as well as solve the problem of what to do with the extra chips and turnings that are generated by machining large amounts of titanium.

Rammed graphite castings often provide the advantage of being more readily available than fabricated or machined components. The current titanium market is experiencing unprecedented lead times when it comes to mill products such as plate, billet and forgings. It is not unheard of to wait 30 weeks for the arrival of the raw materials, and that is before any fabricating or machining can take place. Rammed graphite castings lead times are substantially shorter due to the fact that the melt stock raw materials are generally readily available within the Allegheny Technologies family of companies and do not have to go through the long processing times that plate, billet and forgings require. Generally a prototype casting would be available within a 15 to 20 week lead time, which also includes the production of the patterns. More complex parts may require longer lead times.


CASTINGS FOR THE MILITARY

The demand from the military for engineers to design lighter and more durable military equipment has prompted many companies to seek out alternative processes and products to meet stringent military demands. The titanium foundry has been assisting the military for many years to meet its ever changing requirements. The titanium foundry first developed a relationship with the U.S. Military over thirty years ago due to the demand for pumps that were lightweight and corrosion resistant to seawater. Since that time, titanium rammed graphite castings have been produced at the foundry for numerous applications including titanium fire pumps, balls for seawater valves, pumps for torpedo ejection systems, condenser heads for titanium heat exchangers and cast components for brine and garbage disposal pumps.

The interest in titanium castings is now starting to grow within companies that design tanks and fighting vehicles for the U.S. Military. The lightweight and durable characteristics associated with titanium have made designers consider titanium rammed graphite castings for a growing number of applications on military vehicles. Suspension system components have been reviewed and prototype castings have been produced for a number of companies with very good results. The combination of being lightweight, having good fracture toughness qualities and the ability to produce a near net shape have made some engineers sit up and take notice. Cast idler wheel, idler arms, sprocket carriers and other components suspension systems are ideal candidates for rammed graphite titanium castings.

Titanium rammed graphite castings are cast from any number of grades of titanium. Grades 2 and 3 are commercially pure and most requested for CPI applications. In applications where corrosion is more severe, grades 7 and 12 are often chosen. Ti-6AL-4V is a popular alloy for applications where strength and ballistics are an issue. The most recent alloy the titanium foundry has developed and cast is ATI 425™ titanium for a number of military applications. ATI 425™ titanium has proven to be very castable and much easier to pour than Ti6AL-4V which has historically been requested for military applications. In their short existence, ATI 425™ castings have found their way into a number of military applications and have replaced Ti-6AL-4V in some cases. The advantage in specifying ATI 425™ castings is cost savings. While the properties between Ti6AL-4V and ATI 425™ titanium are similar, there is a marked price difference between the two. There is also an added corrosion benefit with ATI 425™ titanium that isn’t present with Ti-6AL-4V. To date, various customers have selected ATI 425™ titanium for suspension system applications, cast hatch covers and other components for fighting vehicles. Ballistic tests on cast ATI 425™ materials are currently underway to determine what level of threat the ATI 425™ castings can withstand. The ballistic testing efforts currently being performed further demonstrate ATI Wah Chang’s commitment to offering the best quality rammed graphite casting products to our customers.

ATI Wah Chang’s rammed graphite castings play a very important role in the casting marketplace by providing to the end customer a technically sound near net shaped cast part. By selecting and specifying ATI Wah Chang rammed graphite castings for military and defense application, near net shape technology will be utilized; eliminating unnecessary scrap accumulation and the machining of oversized sections. In addition, the end product will be a quality driven casting that has been proven many times over in diverse and challenging applications.

For further information on ATI Wah Chang’s rammed graphite casting capabilities please contact William Budd, Manager of Regional Sales for Castings, at 724-453-3302 or by email at bill.budd@wahchang.com.

This fall, ATI Wah Chang is offering exclusive two-day seminars focused on helping participants make technically and economically sound decisions when selecting and working with specific materials for corrosive applications. The events will be held in in Nanjing, China, September 8-9 and in Paris, France, October 11-12. In addition, Wah Chang will offer a Welding Seminar in Nanjing, September 10-12. Space is limited.

These seminars, presented by professionals in materials engineering, metallurgy and other technical disciplines, will benefit a wide range of participants, including chemical, design, materials, and other engineers, fabricators and maintenance personnel. The course includes the follow sessions:

To register for either or both of the Nanjing events, please contact Xiaofeng Zhu or Zhang Yue at 86.10.6512.0451 or by email at xzhu@alleghenytechnologies.com, fzhu@stellram.com or yzhang@alleghenyludlum.com. The registration fee is not yet determined. If you are interested in signing up for the Paris event, please contact Sheryl Renzoni at 541-926-4211 x6280 or at sheryl.renzoni@wahchang.com. The cost will be $700 euros.

LYNN DAVIS
President

PARRY WALBORN
Vice President — Commercial

ANDY NICHOLS
Director of Marketing

GARY KNEISEL
Director of Sales

KIRK RICHARDSON
Editor

STEPHANIE O'CONNOR
Assistant Editor

Copyright ©2006 Wah Chang. All rights reserved. Reproduction of this newsletter by any means, in whole or in part, without written permission is prohibited by law. Outlook is published quarterly by Wah Chang. The newsletter contains information on reactive and refractory metals, including hafnium, niobium, titanium, vanadium and zirconium, as well as chemicals. The properties listed herein are average values based on laboratory and field test data from a number of sources. They are indicative only of the results obtained in such tests and should not be considered as guaranteed maximums or minimums. The starburst logo and Wah Chang are registered trademarks of ATI Properties, Inc.

ATI Wah Chang
(headquarters)
P.O. Box 460
Albany, Oregon 97321
T 541.926.4211
F 541.967.6990
www.wahchang.com
www.corrosionsolutions.com
www.wahchanglabs.com

Sales/Tech Support
T 541.967.6977
F 541.967.6994
custserv@wahchang.com

CPI Service Center — US
T 541.917.6739
F 541.924.6882
ellen.baumgartner@wahchang.com

CPI Products
T 541.967.6906

Nuclear-Grade Alloys
T 541.967.6914

Ti, V, and Nb Products
T 541.967.6977

ATI Allvac
PO Box 5030
Monroe North, Carolina 28111-5030
T 704.289.4511
www.allvac.com

ATI Allegheny Ludlum
500 Six PPG Place
Pittsburgh, Pennsylvania 15222
T 800.258.3586
www.alleghenyludlum.com