Current Research

Integrating Light-Weight Automotive Materials: Automotive Component Manufacturing in Titanium

Principal investigators: 

M. Laine Mears, John C. Ziegert and Thomas R. Kurfess

Graduate students:

Mathew A. Kuttolamadom, Joshua J. Jones

Sponsor:

U.S. Department of Energy 

Brief abstract:

The purpose of this project is to explore the use of titanium as an automotive component material in order to reduce vehicle weight and energy consumption. The three project phases consist of:

PHASE 1: Working with a major primary titanium manufacturer (ATW) to identify cost-effective grades of titanium for automotive use and with a major automotive OEM (BMW) to identify potential components for replacement in titanium; a business case is being created to justify experimentation.

PHASE 2: A cost-minimized process plan will be designed in conjunction with a major machine tool manufacturer (OKUMA), including incorporation of titanium strength and flow models to optimize processing; prototype parts will be manufactured and the process validated.

PHASE 3: Prototype components will be tested and measured in the automotive application for functionality and performance.

Impact:

The industry partners selected have an interest in the success of this project throughout the supply chain. Our primary titanium partner (American Titanium Works) is developing lower-cost grades and processing techniques to make titanium available to alternative markets in addition to the aerospace market. Our process development partner (OKUMA) is interested in advancing their machine and process control through the incorporation of physics-based models. Finally, our OEM partner (BMW MC), wants to explore and integrate light-weight vehicle components that will reduce mass and hence energy consumption.

Project schedule:

2009-2010

Publications:

Kuttolamadom, M.A., Jones, J.J., Mears, M.L. & Choragudi, A., "Investigation of the Machining of Titanium Components for Lightweight Vehicles," SAE 2010 World Congress, 2010-01-0022, 2010.

Preliminary Results:

A sample component analysis has been completed successfully.