Low Cost Titanium Casting Process and Design for Net Shape Components for the Expeditionary Fighting Vehicle

The use of titanium on the EFV provides significant weight savings and performance benefits. However, titanium is expensive due to high material and processing costs, and there is a strong need to explore low-cost processes to produce net-shape titanium components to control the overall vehicle cost. The objective of this research project is to develop a new cost-effective near-net shape casting process that can be used to produce high-quality titanium components for the EFV. In Phase I, UES in collaboration with Flowserve demonstrated the feasibility of novel casting methodology by integrating three innovative ideas, viz., induction skull melting, permanent mold casting, and trace boron addition. Phase II will pursue continued development and optimization of the casting process to produce identified suspension components such as idler wheel for the EFV. The components produced will be fully evaluated in terms of structural integrity, characterization (microstructure, mechanical properties, and corrosion), process control, quality, dimensional tolerance, and inspectability. The UES team will coordinate with the EFV Prime Contractor through DRPM-AAA to evaluate the low-cost high-quality titanium casting methodology and to perform testing on EFV prototypes.