Manufacture of Light Weight Corrosion Resistant Ti-6Al-4V Deck Components for USVs Using Very Low Cost Raw Materials in a Rapid Manufacturing Process Navy SBIR FY2009.1 Sol No.: Navy SBIR FY2009.1 Topic No.: N091-047 Topic Title: Manufacture of Light Weight Corrosion Resistant Ti-6Al-4V Deck Components for USVs Using Very Low Cost Raw Materials in a Rapid Manufacturing Process Proposal No.: N091-047-0694 Firm: Materials & Electrochemical Research (MER) Corp. 7960 S. Kolb Rd. Tucson, Arizona 85706 Contact: Roger Storm Phone: (520) 574-1980 Web Site: www.mercorp.com Abstract: The Navy has a need to reduce the weight of unmanned surface vehicles (USVs) to improve their operational efficiency. Many of these vessels have an Al hull and supporting structures. While Al alloys have a low density, their strength is very low. The high strength to weight ratio of titanium alloys such as Ti-6Al-4V (Ti64) would allow a significant reduction in thickness which would translate to a significant weight savings. However, the cost of Ti64 structures produced by conventional manufacturing is prohibitively high. In this program, MER will establish the value of manufacturing Ti64 deck components by the PTA additive manufacturing process, resulting in a weight savings of >600 lb. Rather than using commercial Ti64 welding wire at a cost of $60/lb as the feed stock for the PTA process, MER will utilize a very low cost powder derived from Ti sponge powder at a cost of <$10/lb. This will result in lighter Ti64 structures and components which will allow the Navy to meet their weight reduction goals with a manufacturing cost comparable to the Al alloy structures employed in the current design. Benefits: The immediate benefit of the proposed work will be a weight reduction for USVs leading to increased operating capabilities. On a broader basis, a substantial reduction in the cost of Ti components will provide a major benefit to DOD and also to American industry in their efforts to expand the utilization of Ti in new applications. Currently, the cost of Ti components is prohibitively high to gain product acceptance, even though new Ti based products could offer substantial advantages. For example, the use of lightweight Ti components for automotive and truck applications such as valve train and suspension components could provide lower inertia reciprocating components and higher effective engine power, and overall vehicle weight reduction, translating to lower fuel consumption. Return