This step change involved the development of the centrifugal casting process by which the filling of thin sections of large Ti structures was improved so that significantly fewer and smaller defects will be present in the component and a significantly higher production yield rate will be achieved. Further development will be carried out to improve the gravity casting process which is important for casting asymmetrical components such as Ti airframes.

Those developments were closely coupled with the development of computer modelling in terms of better understanding and predicting liquid filling of the mould, defect formation and distribution, control of the dimensional accuracy of the cast component together with the development of a stronger wax and optimum ceramic mould material if required in order to meet the component dimension tolerance specified. The micro structure and mechanical properties including that of heat treated and welded castings must be optimised. If successful, this project will lead to significant cost reduction in producing large Ti components, removal the USA monopoly of supply of aero engine Ti casings and significant reduction of CO2 and of Ti raw material wastage incurred in current manufacturing processes. It will also lead to more application of light Ti structures in aerospace and space, thus weight and fuel reduction by making Ti structure commercially viable.