Low Cost Permanent Die Pressure Casting for Titanium

In this Phase I innovation proposal, MER and THT presses will make use of advanced materials for dies and shot tube liners to develop a permanent die pressure casting technique for high temperature Titanium alloy castings, using automated and high production rate casting facilities at THT for cost effectiveness. THT has developed pressure die casting of Aluminum and Copper, and conducted preliminary Titanium castings to confirm feasibility of our approach. To tolerate the high temperature requirement and reactivity of the Titanium alloys, MER/THT will develop oxidation resistant and high strength at high temperature die materials based on low cost C-C manufactured at MER with silicon Carbide and Hafnium Carbide functionally graded refractory coatings and lubricious Titanium carbonitride die release coatings to be used to replace traditional tool steel permanent dies. MER/THT will measure mechanical properties of the castings made from a Ti-6Al-4V wt% alloy and conduct microstructural characterization of surfaces and internal defects.