Prototype plant for the economical mass production of TiAl-valves

Initiated by ALD Vacuum Technologies AG, a technology for the economical production of TiAl-valves has been developed by a joint research project during the last 4 years. The integration of a modified induction cold crucible and a gradient heatable permanent metallic mold in a centrifugal casting furnace under vacuum are the main features of this process. Due to their fine and full lamella as-cast microstructure the valves produced impressively outperform the required mechanical properties of the automotive companies. The valves have successfully passed a 500-h engine test in a BMW M4 engine. As the next step of process development, a new joint research project with the participation of five German automotive companies will evaluate the feasibility of mass production at a competitive price level. Therefore, a prototype plant with a productivity of approximately 600 000 valves/year has been designed and will be built and commissioned during the next 2 years. The current and the precursor project are financially supported by the German Ministry for Education and Research. The quality of the valves will be discussed and the design concept of the prototype plant will be presented.