Durable Lightweight Track Suspension Components manufacturd by Advanced Processing Technologies

Many of the components for the AAAV track suspension are currently made in steel in order to meet the strength and durability requirements for the vehicle. The use of Ti/6Al/4V has the potential to offer a significant weight reduction in these components,while maintaining a high level of performance and durability. The plasma transferred arc solid free form fabrication process (PTA SFFF) has been demonstrated to produce Ti test shapes which have mechanical properties superior to that of conventionalwrought Ti components. The capital and operating costs of this near net shape process offers the opportunity for the production of cost effective Ti components that meets the requirements of the AAAV program. In the proposed Phase II program, the PTASFFF process will be scaled up to produce full size components for vehicle testing. A database for the PTA SFFF produced Ti/6Al/4V will be established for fabricated test bars as well as test bars cut from fabricated components. NDE methods will beinvestigated to provide a basis for QA/QC for the manufacturing process and scale up. A wear resistant surface layer of Ti with WC which was identified in Phase I will be optimized and incorporated onto the prototype components. At the conclusion of thisPhase II program, MER will be in a position to initiate manufacturing AAAV Ti64 components utilizing state of the art existing equipment already in place at MER.BENEFITS: The demonstration of plasma transferred arc solid free form fabrication of low costtitanium components will enable the utilization of light weight components that meet stringent performance and durability requirements in a variety of military and commercial applications.