TITANIUM - A GAME CHANGER IN AUTOMOTIVE PARTS AND MANUFACTURING - HERE'S HOW IT'S MADE.
Titanium, a material synonymous with strength, lightweight properties, and corrosion resistance, has carved out a niche in the automotive industry. From performance-oriented components to luxury finishes, its applications span a wide range of uses. But what makes titanium so special, and how did it become a go-to material for cutting-edge automotive engineering? And why is it so damn expensive? Titanium was first discovered in 1791 by English clergyman William Gregor, who identified it in ilmenite ore in Cornwall, England. However, it wasn’t until 1795 that German chemist Martin Heinrich Klaproth named it "titanium," inspired by the Titans of Greek mythology. Producing pure titanium was a challenge for over a century until in 1910, American chemist Matthew Hunter developed a process to isolate titanium, but it was labour-intensive and costly. The real breakthrough came in 1940 when William Kroll devised the "Kroll Process," which is still the primary method of titanium production today. Titanium is primarily sourced from minerals like ilmenite and rutile. These are mined and processed to remove impurities and for the conversion to Titanium Tetrachloride (TiCl₄), the ore is treated with chlorine gas at high temperatures. For the reduction, the Kroll Process reduces TiCl₄ using magnesium or sodium to produce titanium sponge, a porous form of the metal. The sponge is then melted into ingots, which can be further processed into sheets, bars, tubes or other forms suitable for industrial use. Titanium’s high cost initially confined its use to aerospace and military applications, but advances in manufacturing processes and a growing demand for high-performance materials have made titanium increasingly accessible for automotive purposes. It’s still very expensive, which is why you find it used in the production of supercars and hypercars and also aftermarket exhaust systems for these cars. It’s rare to find a pie-cut full titanium exhaust on something like a Mk7 R.
Titanium is as strong as steel but nearly 45% lighter, making it ideal for reducing vehicle weight without compromising structural integrity, and unlike steel, titanium doesn’t rust, even in harsh environments, making it a long-lasting material for critical components. Titanium can withstand extreme temperatures, which is why it’s the choice for engine components and exhaust systems. You’ll find titanium exhausts on things like the Nissan GT-R and Ferrari F40. The metal also has something many metals don’t have - aesthetic appeal. When heat runs through titanium exhausts the metal turns an amazing blue/purple colour, and because of the way the metal reacts, it works well with anodising - although covering such a good-looking metal seems a bit silly. Titanium is used in valves, conrods, and other parts where strength, weight savings, and heat resistance are critical, you’ll find most of a Formula 1 engine features titanium components. Top-end suspension systems use titanium springs and components to reduce unsprung weight, improving handling and ride quality and bragging rights. Top-tier racecars use lightweight titanium bolts in high-stress areas, particularly in motorsports and supercars. You’ll also find many aftermarket titanium parts like shift knobs, pedals and the like. There would be more, but because the material is so expensive to produce and so hard to work with, not many people specialise in it because niche markets are hard to crack. As manufacturing techniques improve and costs decrease, we’re definitely seeing more titanium bits and pieces popping up, and the fact that there’s a way to 3D print the metal means you companies will soon be able to create just about anything you want. While costs will decrease, things will still be more expensive than steel and other popular alloys.
Take a look at the YouTube video that shows the process of making titanium, a game-changing material that's light, strong and looks amazing when heat has changed the colour - it's also rather expensive and this process sort of explains why: How Is Titanium Made? | History of Simple Things
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