Force Technology, Bentley Motors & Sheffield University obtained research funding for a £1.8m engine lightweighting project.

The 3 year £1.8 million funded project utilises high value alloyed titanium (Ti) swarf as a feedstock to sinter-forge via a new, novel technology FASTforge process into near net shapes for use in high strength and good fatigue life applications typically required within an automotive engine.

A range of engine components of increasing complexity from both a manufacturing and performance perspective will be manufactured and functional bench tested during the project due to start in November 2017.

To achieve this, a new UK supply chain will be developed. Force Technology, chosen for its advanced design & manufacturing capabilities, will coordinate the supply chain as Tier 1 supplier and will also focus on testing and component development.

The process will produce Ti at 20% of the cost of current Ti billet and with minimal waste compared to the 70% waste generated within the aerospace industry.

The Innovate UK competition: Materials and Manufacturing funded project partners include:

  • Bentley Motors (Volkswagen Group)
  • Force Technology
  • Sheffield University
  • Northern Automotive Alliance
  • Plus two other key SME’s

Success will mean:

a) lightweight & lower CO2 & PM emissions for automotive engines. Initially within low volume, but with increasing confidence with the product & developed manufacturing processes it can then move into higher volume applications

b) growth opportunities for the supply chain, initially within the low volume vehicle industry but with the potential to move into the higher volume market and also the wider advanced manufacturing sectors of off-shore, rail, aerospace, non-auto engines, defense & low cost desalination. Exploitation in these other sectors is supported by the 4 components selected

c) the metal forming industry can stay abreast of new technology in alternative metals and use world-leading materials research to halt the decline of an industry within the UK.

d) Product diversification for Force Technology, expanding its advanced knowledge of valve spring applications to other areas of lightweight engine components

 

Project Title – Innovate UK: Materials and Manufacturing  project FAST STEP 3 – Titanium Swarf to Engine Parts in 3 Steps