FAST STEP 3
FAST STEP 3 is a collaborative research project to use titanium in automotive engines with the ultimate aim of lowering vehicle emissions.
Titanium Swarf to Engine Parts in 3 Steps
A consortium including the Northern Automotive Alliance has been successful in obtaining government funding from Innovate UK for a collaborative research project to use titanium in automotive engines.
High value alloyed titanium swarf will be used as a feedstock for the novel hybrid technology of Field Assisted Sintering Technology followed by one-step hot forging – known as the FASTforge process – into near net shapes for use in the high strength and good fatigue life applications typically required within an automotive engine.
FAST STEP 3 Vision
The aims of the FAST STEP 3 project are to:
- Achieve lightweighting for automotive engines in order to lower emissions including CO2, NOx and particulate matter, initially at low volume, potentially moving into higher volume applications when there is increasing confidence with the product and manufacturing processes.
- Provide growth opportunities for the supply chain, not only within the automotive sector, but also in the wider advanced manufacturing sectors of offshore, rail, aerospace, non-automotive engines and defence.
- Enable the metal-forming industry to stay abreast of new technology in alternative metals and use world-leading materials research to assist in halting the decline of the industry within the UK.
FAST STEP 3: The Project
Led by Bentley Motors and pulled together by the Northern Automotive Alliance. The FAST STEP 3 consortium successfully obtained government funding through Innovate UK. Other consortium members are the University of Sheffield, Force Technology, Transition International & W.H. Tildesley.
The project utilises high value alloyed titanium (Ti) swarf as a feedstock to sinter-forge via the 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. Four engine components of increasing complexity from both a manufacturing and performance perspective will be manufactured and functional bench tested.
To achieve this a new UK supply chain will be developed, with diversification for companies within traditional metal manufacturing and ‘know-how’ transfer from the University of Sheffield, combined with multiple areas for IP generation. The FAST process has existed for many years but when combined with forging it can release its untapped potential. The process will produce titanium at 20% of the cost of current titanium billet and with minimal waste compared to the 70% waste typically generated from current processes.
Swarf Recycling Process
Field Assisted Sintering Technology (FAST) or Spark Plasma Sintering (SPS) with a post-sinter forging process, developed by the Sheffield Titanium Alloy Research Group.
The Partners
The FAST STEP 3 consortium is comprised of Bentley Motors, Force Technology Ltd, the Northern Automotive Alliance, The University of Sheffield, Transition International and W.H. Tildesley.
- The University of Sheffield Department of Materials Science and Engineering
The University of Sheffield Department of Materials Science and Engineering is one of the leading materials departments in the UK with a long history in metallurgy and a proven track record in participating in applied research projects in support of UK industry. Having developed the concept on a small-scale, it will provide the fundamental science for FAST STEP 3 and will manufacture the tooling and develop the FAST process on a new 250t FAST furnace in the Henry Royce Institute Discovery Centre in Sheffield.
- Bentley Motors Limited
Bentley Motors is the most sought after luxury car brand in the world. The company’s headquarters in Crewe is home to all of its operations including design, R&D, engineering and production of the company’s four model lines, Continental, Flying Spur, Bentayga and Mulsanne. The combination of fine craftsmanship, using skills that have been handed down through generations, alongside engineering expertise and cutting-edge technology is unique to UK luxury car brands such as Bentley. It is also an example of high-value British manufacturing at its best. Bentley employs around 4,000 people at Crewe, and is a potential end user of titanium produced utilising the method developed during the FAST STEP 3 project.
- Force Technology Limited
Force Technology is IATF16949 approved and was established to pave the way for development and innovation in the high precision, high duty spring markets. The technology leading manufacturing company is focused on continuously improving its products and systems whilst developing its innovative approach to design and development of processes.
- Northern Automotive Alliance
The NAA is a wholly independent, not-for-profit organisation providing support for all companies within the automotive sector in the North of England. As well as business support and provision of funding it provides development and participation support to Innovation consortia, having experience of both project and contract management of large-scale projects.
- Transition International Limited
Transition International Ltd is a bespoke manufacturer of Ferro Titanium. The product is made to order, matching exact customer requirements. Transition’s clients recognise the importance of demanding specifications and ensure they are rigorously adhered to. Transition also prepares titanium scrap for both vacuum and air melt applications.
- W.H. Tildesley Limited
W.H. Tildesley has over 140 years of experience in the Drop Forging industry, servicing many industries worldwide with forged and machined components in many different types of materials ranging from carbon and alloy, nonferrous, stainless, duplex and super alloys. W.H. Tildesley will develop the mould designs and forging dies and tools to enable titanium near-net FAST components to be forged.