AMRC furnace puts UK at forefront of titanium casting

The newly-operational furnace, at the University of Sheffield Advanced Manufacturing Research Centre, has three interchangeable crucibles with the capacity for melting 250kg, 500kg and 1000kg of metal.

This allows it to produce titanium components weighing between 60-500kg.

There are only a few furnaces in the world capable of producing titanium castings of up to 500kg, which requires a molten mass in excess of 1000kg, according to AMRC Castings research and development manager, Mark D’Souza-Mathew.

To produce complex, near-net shape components, the titanium is first melted and then poured into a mould representing the intended part.

But titanium is highly reactive when exposed to atmosphere, so the process must be carried out in a vacuum to prevent explosions, said D’Souza-Mathew.

“There are many safety and cost considerations when casting titanium, and it is for these reasons that foundries don’t tend to go above the 100kg poured mark,” he said.

The researchers are studying the risks and benefits of casting large-scale near-net shape components in titanium. They are also planning to improve the casting process by reducing the amount of material wasted, said D’Souza-Mathew.