Abstract
In recent years, both single-melt plasma arc cold hearth melting (PAM) and electron beam cold hearth melting (EBM) followed by a vacuum arc remelting step have emerged as low-cost alternatives for producing single-melt titanium alloy slabs for critical, non-aerospace applications. Technical cost modeling was used to estimate unit cost, identify principal cost drivers, and perform sensitivity analyses for producing 25.4 mm thick Ti-6Al-4V plates for ballistic-shock resistant applications. The results showed that the principal cost drivers are raw material processing, melt processing, and plate rolling. Sensitivity analyses showed that percent revert and process yield could significantly influence or adversely impact the estimated unit cost. A comparison of the estimated unit cost for a worst case of double VAR (2XVAR) with a best case for either PAM- or EBM-processed 25.4 mm thick plate showed a potential cost savings of 57% or 58%, respectively. These results showed the utility of the technical cost modeling approach in enabling process selection and cost control.
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