Development of Low Cost Titanium Alloy Feedstock for Casting of Net Shape Combat Vehicle Components Navy SBIR FY2004.2 Sol No.: Navy SBIR FY2004.2 Topic No.: N04-153 Topic Title: Development of Low Cost Titanium Alloy Feedstock for Casting of Net Shape Combat Vehicle Components Proposal No.: N042-153-0 Firm: Dynamet Technology, Inc. Eight A Street Burlington, Massachusetts 01803 Contact: Susan Abkowitz Phone: (781) 272-5967 Web Site: www.dynamettechnology.com Abstract: Dynamet proposes to develop its Low Cost Feedstock Process (LCFP) for producing casting feedstock by the consolidation of processed titanium machine turnings. Dynamet will demonstrate that LCFP has the potential to produce low cost, high quality cast components for combat vehicles. Preliminary analysis indicates that LCFP offers a 27-44% cost savings over current ingot producing methods. This significant cost advantage has the potential of reducing the price of military cast components by 16-30%. LCFP offers other potential advantages including (1) low capital cost, (2) rapid addition of incremental capacity, (3) improved homogeneity, (4) ability to economically modify compositions to specific requirements, and (5) ability to produce small lots. Dynamet will produce Ti-6Al-4V LCFP billets to three density levels. Billets will be assessed through melting and casting trials conducted at Howmet. Test plates will be cast from the billets and compared to standard Ti-6Al-4V plate. LCFP cast plates will be evaluated by radiography, metallography, tensile tests and chemical analyses. Technical and economic analyses will be conducted. During the Phase 1 Option a production-size LCFP billet from optimized process will be manufactured in preparation for Phase II which will include casting and evaluation of a selected vehicle component, e.g. an EFV sprocket carrier. Benefits: This development will benefit the military and industry by providing low cost titanium alloy billet that will significantly lower the cost of titanium alloy castings. Lightweight, low cost titanium castings would then be available for producing sprocket carriers, idler wheels and other EFV track components. In addition low cost titanium castings would be available to produce components for other tracked military vehicles and for wheeled military vehicle undercarriage components. Lower cost titanium castings will promote the increased use of titanium across the Military in applications such as components for aircraft, missiles, ships and land vehicles. Lower cost castings will also meet industry's need for lightweight, low cost titanium for a wide variety of applications. By modifying the composition of LCFP billet high strength titanium alloys and metal matrix composites could be produced with improved mechanical properties while offering the potential for other enhancements such as excellent wear and erosion resistance with higher stiffness. Increased strength and specific modulus would permit further weight reduction of components. Improved wear resistance would offer the potential of providing the Navy with components that could withstand the effects of operating over harsh terrain, in seawater and rivers as well as abuse from sand, mud, rocks, gravel etc. In general this technology will address the Military's need for lightweight, low cost, high performance titanium components. These benefits would also apply to civilian transportation and industrial applications. Return