Development of Low Cost Titanium Alloy Feedstock for Casting of Net Shape Combat Vehicle Components

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.