Rapid Manufacturing of Titanium Components by Consolidating Powdered Titanium in a Near-Net-Shape Tool Through the Application of Pressure and Thermal Cycling using Smart Susceptors.

The Corporate Average Fuel Economy (CAFE) standards for 2025 states that average new vehicle fuel economies to reach 60 miles per gallon for cars and 43 miles per gallon for trucks by 2025. In order to satisfy this problem, innovative processes are required that can produce a weight savings of 30% at a cost of less than $2.00 per pound of weight saved. The focus of this proposal is to generate a lightweight metal forming process that will help reach the CAFE standard. The objective of the proposed Phase I and II research is to prove that inexpensive powdered titanium can be consolidated to greater than 99.9% densification in a near-net-shaped mold. The process cycle time will be less than 3 minutes per part and operate in a cost efficient manner that will exceed the target of $2.00 per pound of weight saved using a comparison format between engine components and vehicle body components that used fuel efficiency as the common dominator. The goal of Phase I is to demonstrate the TiCaD process by demonstrating the consolidation and densification of powdered titanium powder in a exterior shape near net shape mold, using prepackaged titanium powder pucks to a densification of greater than 99.9%. The densification goal will be validated through testing. Commercial Applications and Other Benefits: The TiCaD has the potential to revolutionize the efficiency of engines by making the use of titanium engine components as used in reciprocating mass applications, affordable. This increase in efficiency will correspond to a significant decrease in body mass, resulting in a fuel savings. This could result in a fuel savings of 20% increase in fuel economy, which translates to a reduction in CO2 emissions of 0.4 metric tons per automobile per year. Furthermore, applications of this technology are directly applicable to health care (knees), and sporting goods equipment.