Runge_Kutta

From the February 2004 JOM issue, pages 40-44 ( and my own interjections )
( http://www.tms.org/pubs/journals/JOM/contents.html ). Check your
local university library to see an actual issue to read and/or
photocopy

"Titanium in the Family Automobile: The cost challenge"
F.H Froes, H. Friedrich, J. Kiese, and D. Bergoint

[ Froes - University of Idaho ]
[ Friedrich and Kiese - Volkswagen ]
[ Bergoint - Bergoint Engineering ]

1) Material cost (dollars) per pound [ Table 1 ]

Item___Steel____Al_____Mg_____Ti
======================================== =
Ore___$0.02__$0.10__$0.01__$0.30
Metal__$0.10__$0.68__$0.54__$2.00
Ingot__$0.12__$0.70__$0.60__$4.50

2) Table 2: History of titanium usage in production cars

3) Application of Titanium metal-matrix-composites (MMC) to a car engine.
TiC (titanium carbide) [for example: http://www.dynamettechnology.com/titanium_alloys.htm ]
[See also http://www.dynamettechnology.com/ products and applications ]
[ This was presented as a talk in Germany last year. Search for "Bergoint"
in the program http://www.ti-2003.dgm.de/images/program.pdf (pages 18,19) ]

a) Camshaft: 15% TiC with 40% weight reduction
b) Crankshaft: 15% TiC with 44% weight reduction
c) Hollow valves: 55% weight reduction
d) Pistin wrist pins: 15% TiC with 30% weight reduction
e) Valve spring retainer: 12% TiC with 50% weight reduction

For chassis parts

f) Manual Transmission Gearbox Components: 10% TiC with <50% weight reduction
g) Transmission Shafts: 12% TiC with 40% weight reduction
h) Brake caliper pistons: 10% TiC
i) Wheel hubs: 5% TiC with 44% weight reduction

4) TiAl demonstration parts made for Corvette!!
[ http://www.azom.com/details.asp?ArticleID=1548 ]
[ http://202.120.13.87/material/hhgc/TiAl.htm ]

5) Figure 10 is a picture of a titanium MMC crankshaft.

======================================== ==============================

NEW STUFF
http://www.ms.ornl.gov/programs/ener...Titanium-2.pdf
http://www.ai-online.com/issues/arti...ail.asp?id=141
http://www.ai-online.com/ppp_detail.asp?id=275

======================================== ================================

Go to:
http://www.sae.org/congress/

Notice three interesting links in regard to the SAE 2004 World Congress. This
is a meeting held in Detroit (March 8-11) where automotive workers present 30
minute talks on some aspect of automotive design and usually publish an
associated paper. Take a look at the sections

Advanced Propulsion/Powertrain

Lightweight Materials

High-Performance Vehicles

======================================== ==============================

DON'T FORGET:
http://www.sae.org/congress/highperformance/agenda/

Thursday, March 11 - AVL Technology Theater
1:30 p.m. High Performance Cars - A Passion for Performance

Design of the Next Corvette and Cadillac XLR - GM Performance Leaders

Moderator: Dennis Simanaitis, Road & Track Magazine
Dave Hill, Vehicle Line Executive and Chief Engineer, Corvette, General Motors Corp.
Tadge Juechter, Chief Engineer, Chevrolet Corvette, General Motors Corp.
Dave Leone, Chief Engineer, Cadillac XLR / General Motors Corp.

======================================== ==============================

REPEAT STUFF:
http://www.ai-online.com/issues/arti...ail.asp?id=352
http://www.theautochannel.com/F/news...05/179388.html
http://www.sae.org/automag/techbrief...1-112-1-22.pdf
http://www.autonews.com/files/FritzIndra.ppt

======================================== =============

RGGregory

Good information...made this college-trained, but not really used metallurgist teary-eyed. However, it seems that everyone glosses over the shortcomings in Titanium - primarily toughness and brittle fracture problems/concerns. I can tell you the US Navy has taken a hard-line in critical applications (submarine) utilizing titanium due to these concerns. Anyone who wishes to utilize them has pass a rigorous evaluation process and the QA required on the production line for the titanium component(s) results in astronomically-high production costs. MMC may help, but they don't solve the aforementioned concerns.

You continue to find excellent information and research pathS :thumbs:

LittleBoyBlu99

:cool: :cool: :thumbs:

yellow01

Interesting seeing the bit on TiAl since it is used extensively in my industry (semiconductor), ableit in very small amounts :) ... and it is being phased out.

Runge_Kutta

I mentioned this a while ago but it seems worthwhile to
mention it again:
http://www.findarticles.com/cf_dls/m...le.jhtml?term=

"We see growing interest for titanium connecting rods. We see titanium
connecting rods being introduced in more than one vehicle in the
2005-2006 time frame and that is exciting."
http://www.tms.org/Meetings/Annual-0...M03-monday.pdf
page 21 (9:40 AM)
http://www.ald-vt.com/pdf_gb_01_02/A...2_E_gesamt.pdf (page 19)

http://www.ald-ag.de/home/pdf/presae...s_e_intern.pdf (page 7)

From ( http://www.ms.ornl.gov/programs/ener...Titanium-2.pdf )
Page 38: (Mentioned above)

"A pilot plant has been commissioned for production of gamma TiAl
engine valves. The process uses cold wall crucible induction melting
and centrifugal casting with 50 valves / mold. Molds use Nb inserts.
The system has capacity for 600,000 parts / year using one operator.
Over 200 casting trials have been performed on 10 different valve types
for 5 automotive companies. Engine testing is planned."

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OLD STUFF:
http://forums.corvetteforum.com/zerothread?id=546931
http://www.azom.com/details.asp?ArticleID=553
http://www.timet.com/emerging.html
http://www.titanium.org/PDF/Newslett...ch2002News.pdf (pages 2,4)

From ( http://forums.corvetteforum.com/zerothread?id=648162 )
======================================== ==============================
I thought I'd give the highlights from an article that I just
read entitled "Management Justification to Select Titanium
Automotive Components," by Kurt Faller of Titanium Metals Corp. (Timet),
http://www.sae.org/servlets/productD...D=2002-01-0363

Just a bit of background - in January 2002 TIMET created a division
"to optimize the titanium production processes, controls, quality
procedures, and supply channels to meet the needs of automotive
manufacturers." Kurt Faller is the president of Timet Automotive
(TIPRO), Morgantown, PA

( http://www.timet.com/na.html ).
http://www.americanmachinist.com/ful...y.php?WID=4710
http://www.titanium.org/ConfSeminars...ceSpeakers.htm (Scroll down 15%)
http://www.timet.com/applicationsframe.html ( EMERGING )

He remarks that titanium has been limited in it's high-volume
acceptance due to it's cost and the fact that when it is
considered, it is done on a substitution basis rather than
used in a new design where it's full potential may be realized.
Some recent applications include:

1) Toyota Altezza ( Close to Lexus IS200 ) - engine valves
2) Infinity Q45 - engine valves
3) Mitsubishi 1.8L engine - valve spring retainers
4) Chevrolet Corvette Z06 - dual exhausts
5) VW - brake line sealing washers
6) Honda S2000 - shift *****
7) Mercedes S-class - brake caliper guide pins
8) VW Lupo FSI - suspension springs ( http://www.volkswagen.de/lupo/ )

He then lists the attributes of titanium that are particularly
relevant to the automotive industry.

1) Strength - similar to steel alloys
2) Lightweight - density is about 1/2 that of steel
3) Corrosion resistance - essentially immune to corrosion
in the automotive environment
4) Low modulus of elasticity - half that of steels but twice that
of aluminum. Useful for situations where flexibility is required.

EXHAUST SYSTEMS:
================

Z06 exhaust system saved 8.2kg (18.1 pounds). No corrosion means
exhaust system lasts longer than rest of car and no excess material
needs to be added to retain strength in the presence of corrosion.
Ti exhaust systems allow quick "bolt-on" weight savings if needed.
Production equipment is same as that for steel but special tooling
and knowledge are required.

The exact metal used is TIMETAL-LCB = (Ti-1.5Al-6.8Mo-4.5Fe)
That means that it's 1.5% Aluminum, 6.8% Molybdenum, 4.5% Iron
and the remainder is titanium.
http://www.stainless-steel-world.net...timetallcb.asp

SUSPENSION SPRINGS:
===================

Titanium can offer a 35-70% weight savings over steel. In the VW
Lupo FSI, each spring was reduced from 1.1kg to 0.65kg (40%). No coatings
are needed to deal with corrosion. The free height of the Ti springs
can be reduced by 20-50% over similar steel springs freeing up space
and lowering hood heights. The metal used is TIMETAL-LCB. No
mention of valve springs.

CONNECTING RODS:
================

Weight saved on rods allows reduction in size of crankshaft
counterweights. This reduces the interaction of the smaller
crankshaft counterweights with the oil in the oil pan. The
reduced mass of both the crankshaft and connecting rods reduce
frictional forces and also decrease noise vibration and harshness.
Cost for Ti may be offset by no longer needing balance shafts and
special engine mounts.

To date, most connecting rods have been (Ti-6Al-4V)
http://www.timet.com/6-4main.html
http://www.stainless-steel-world.net...um/ams4911.asp

but might be better done using TIMETAL 62S
http://www.timet.com/62smain.html

The primary costs for most Ti-conrod makers is due to finish
machining rather than material costs. Powdered metal Ti rods
are off in the future due to costs.

PISTONS:
========

In diesel engines, aluminum alloy pistons are reaching their limits
and may require a material like titanium.

VALVES:
=======

Lowered valve mass may be used to allow higher RPM limits
or may be used to reduce valve spring loads. When the Toyota
Altezza switched to titanium valves and valve springs, the
valves were 40% lighter, the springs were 16% lighter. RPMs were
increased by 10% while noise was reduced 3 Db at high RPMs. Less
friction reduced required camshaft driving torque by 20%. Intake
valves were (Ti-6Al-4V), which is good to 450 degrees centigrade,
while exhaust valves were TIMETAL 834 with the addition of 5 percent
by volume titanium boride particles to allow operation up to 800
degrees centigrade.
http://www.stainless-steel-world.net...timetal834.asp

Ford took a 1.9 liter 4-cylinder, 2V engine and replaced the
valvetrain with titanium. Mileage went up by 0.7 mpg. For bigger
engines, a 4% gain is estimated. General Motors has pursued
gamma titanium aluminides for exhaust valves. The 2002 Infinity
Q45 uses 40 titanium valves.

VALVE SPRING RETAINERS:
=======================

Saving weight on retainers is just as useful as saving
weight on the valves. By switching from steel to titanium
on their 1.8L and 2.0L engines, Mitsubishi reduced the inertial
mass of their valvetrain by 6%. Faller recommends using
TIMET 15-3.
http://www.timet.com/15-3main.html

TURBOCHARGER WHEELS
===================

Not relevant to C6

BRAKE CALIPER PISTONS AND COMPONENTS:
=====================================

Titanium provides a good thermal barrier between the pad/rotor
and the brake fluid as well as no corrosion.

DRIVESHAFTS/HALF-SHAFTS, VALVE SPRINGS, BUMPER SUPPORTS,
WRIST PINS, CAMSHAFTS, CRANKSHAFTS, DOOR INTRUSION BEAMS,
SWAY BAR FITTINGS, LUG NUTS.
======================================== =================

Not mentioned
http://www.sae.org/automag/material/03-2001/timet.htm
======================================== ==============================





[Modified by Runge_Kutta, 1:26 AM 3/3/2004]

Runge_Kutta

In case anyone wanted to view the links above but couldn't, I
think they're straightened out. From Moscow
http://titanium-valve.com/eng/index_eng.htm
http://titanium-valve.com/archive/alloy_eng.pdf
http://patft.uspto.gov/netacgi/nph-P...FIELD2=&d=ptxt

http://appft1.uspto.gov/netacgi/nph-...DN/20030209218

http://appft1.uspto.gov/netacgi/nph-...DN/20020011228

http://patft.uspto.gov/netacgi/nph-P...S=PN/6,553,956





[Modified by Runge_Kutta, 1:59 PM 3/5/2004]