Titanium Aerospace Casting: AS9100-Certified Flight-Critical Components

ForceBeyond provides high-integrity Titanium Aerospace Casting for propulsion, structural airframes, and high-pressure fluid systems. Utilizing Vacuum Induction Melting (VIM) and Hot Isostatic Pressing (HIP), we deliver cast components that meet the rigorous AMS 4991 and ASTM B367 standards. Our Tier-1.5 integrated model allows for the production of complex, thin-walled geometries that reduce assembly weight while maintaining the structural reliability required for modern aerospace platforms.

Precision-machined titanium turbine blade for jet engine and aerospace applications on a fully white background.

Aerospace Application Specialization

We specialize in components where geometric complexity makes forging or machining from solid billet cost-prohibitive. Our co-owned AS9100 facilities ensure total traceability for every flight-critical part.

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

Titanium Aerospace Casting Mechanical Properties & HIP Requirements
Titanium Cast Alloy & Condition	Tensile Strength (UTS)	Yield Strength (0.2%)	Elongation / Max Temp	Applicable Standard / Verification
Ti-6Al-4V Cast + HIP (AMS 4991 / C-5)	130 – 145 ksi (896 – 1000 MPa)	120 – 135 ksi (827 – 931 MPa)	8 – 12% / 600°F (316°C)	ASTM E8, AMS 4991, ASTM E1417 (FPI)
Ti-6Al-4V ELI Cast + HIP (Grade 23)	125 – 138 ksi (862 – 952 MPa)	115 – 128 ksi (793 – 883 MPa)	10 – 15% / 600°F (316°C)	ASTM E8 / ASTM E21 elevated temp, AMS 4985
CP Titanium Grade 2 (ASTM B367 C-2)	50 – 70 ksi (345 – 483 MPa)	40 – 55 ksi (276 – 379 MPa)	15 – 25% / 400°F (204°C)	ASTM B367, ASTM E8, ISO 9001:2015
Ti-5Al-2.5Sn Cast + HIP (AMS 4984)	120 – 135 ksi (827 – 931 MPa)	110 – 125 ksi (758 – 862 MPa)	10 – 14% / 800°F (427°C)	AMS 4984, ASTM E1742 (RT X-ray), AS9100D

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

Vacuum Induction Melting (VIM)

Titanium’s extreme affinity for oxygen requires a total vacuum environment during the melt. Our VIM process ensures controls oxygen-related contamination and helps limit alpha-case formation during melting and solidification.

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 subjects castings to simultaneous high temperature and inert gas pressure. This collapses internal micro-shrinkage and gas porosity, transforming the as-cast structure into a fully dense material with mechanical properties approaching wrought levels.

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.

Standard	Description	Application
AMS 4991	Titanium Alloy Castings (6Al-4V)	Primary aerospace investment casting spec.
ASTM B367	Titanium & Titanium Alloy Castings	General engineering and industrial aerospace.
AMS 2175	Classification of Castings	Standard for radiographic and visual inspection levels.

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.

FAQ: Aerospace Titanium Machining

Can cast titanium be used for rotating engine parts?

Yes. When produced via VIM and treated with HIP, cast titanium turbine blades and fan components meet the fatigue requirements for many non-primary rotating applications, offering a significant weight and cost advantage over forged parts.

What is the thinnest wall section you can achieve?

Through our specialized investment casting process, we can achieve wall thicknesses as low as 0.060 inches (1.5mm), depending on the overall part geometry and alloy.

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Sources

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