Titanium Investment Casting: High-Precision Lost Wax Solutions

Titanium Investment Casting: High-Precision Lost Wax Solutions

ForceBeyond specializes in high-precision Titanium Investment Casting (Lost Wax), delivering complex, near-net-shape components with superior surface finishes. Using vacuum melting at appropriately qualified facilities, we produce intricate geometries, including selected wall sections as thin as 0.060 inches (1.5mm), subject to alloy, geometry, and manufacturability review. Dimensional capability depends on alloy, geometry, section size, tooling, process route, and inspection requirements; tolerances near ±0.005 inches per inch may be achievable on suitable features subject to review.

Aerospace Application Specialization

We specialize in components where geometric complexity makes forging or machining from solid billet cost-prohibitive. For flight-critical work, the selected facility’s certification scope and the required material traceability are verified against the drawing, specification, qualification plan, and customer requirements.

• Engine & Propulsion:Fan frames, compressor housings, Titanium Turbine Blades, and exhaust nozzles.
• Environmental Control Systems (ECS):Complex valve bodies, bleed-air ducting, and manifold assemblies.
• Structural Components: Wing-tip ribs, door frames, and nacelle hardware.
• Fuel & Hydraulic Systems:High-pressure pump housings and fuel control bodies.

Engineering Excellence: The VIM + HIP Protocol

ForceBeyond applies project-specific metallurgical controls to support the internal soundness and mechanical-property objectives required by the applicable specification and qualification plan.

Vacuum Induction Melting (VIM)

Titanium’s strong affinity for oxygen requires tightly controlled melting and handling. Vacuum melting and the applicable process controls help limit oxygen-related contamination and alpha-case formation.

Hot Isostatic Pressing (HIP)

HIP may be required for certain flight-critical castings when specified by the drawing, material specification, customer requirements, or qualification plan. The process applies simultaneous high temperature and inert-gas pressure to reduce internal micro-shrinkage and porosity; achievable density and mechanical properties depend on alloy, section thickness, casting quality, HIP parameters, and subsequent heat treatment.

Aerospace Casting Standards & Inspection

Nondestructive testing (NDT) methods and acceptance criteria are selected according to the applicable drawing, material specification, qualification plan, and customer requirements.

Rigorous Quality Verification

• Radiographic Inspection (X-Ray):100% verification of internal soundness to Grade A standards.
• Fluorescent Penetrant Inspection (FPI):Detection of surface-level discontinuities post-machining.
• Mechanical Testing:Destructive and non-destructive testing of accompanying test coupons from the same melt lot.

Multi-Process Optimization: Integrated Solutions

ForceBeyond provides the technical flexibility to pivot between manufacturing methods based on your project’s lifecycle and structural requirements.

Finish Precision: Aerospace Titanium Machining

All aerospace castings are finished in our co-owned CNC centers to achieve the plus or minus 0.005mm tolerances required for mating surfaces. This integrated “Cast-to-Finish” approach reduces supply chain risk.

High-Load Alternative: Titanium Aerospace Forging

For structural parts experiencing extreme unidirectional stress (like wing spars), our Titanium Forging Hub provides the directional grain flow required for maximum fatigue life.

Request an Aerospace Casting Quote

Streamline Your Aerospace Supply Chain with Direct Tier-1.5 Oversight.

Please provide the following for our engineering review:

• Technical Drawings:(Include NDT requirements and critical dimensions)
• Material Specification:(e.g., AMS 4991, Ti-6Al-4V)
• Quality Requirements:(Specify X-Ray and FPI inspection levels)
• Estimated Annual Usage (EAU):To assist in production planning and tooling optimization.