Maybe I am wrong, but I think that it could be hard to obtain such a cost analysis. The manufacturer may not be interested to share a confidential data. I am not a specialist in this field, but I have found the following paper: "Titanium for Automotive Applications: Challenges and Opportunities in Materials and Processing", link: https://link.springer.com/article/10.1007/s11837-012-0310-8 where you can find some information about cost of application of this material ( I am not sure if you are able to see full-text). You can also contact the authors directly. They sould have more detailed data you are looking for.

Regards

Marcin

Oh, I'm sorry. I'm not in the aftertreatment device manufacturing business.

Dear Matteo Tarsi,

Significant growth has been observed in the application of titanium and its alloys to automotive and motorcycle exhaust systems over last decade. Weight saving and visual appeal are the primary benefits of titanium in exhaust applications. Currently motorcycle mufflers and exhaust pipes are primary applications of titanium exhaust. New titanium materials with high temperature capability are expected to expand the application of titanium to vehicles with higher exhaust gas temperatures. TIMETAL®Exhaust XT (Ti-0.45%Si-0.25%Fe) can be developed to meet more stringent requirement where CP titanium cannot be used. Generally , the alloy exhibits superior oxidation resistance to CP titanium or other titanium exhaust alloys. The alloy possesses equivalent cold formability to that of CP titanium Grade 2 and exhibits excellent mechanical properties including fatigue and creep properties. Lightweight and high performance titanium exhaust systems for Porsche sports cars.

Because of the powder particle size issue, this process requires considerable further development. When modifications achieve that objective, then the cost analysis should be modified to reflect those changes. Turner and Hansen estimated the cost elements in production of Ti alloy plate as: 38% raw Ti as sponge, 15% in two arc melting steps, and 47% in fabrication of a one inch thick plate. For investment casting of turbocharger compressor rotors, the cost of raw material is estimated as somewhat less than 30%. While new titanium reduction technologies may have potential to reduce cost by 10 to 15%, major cost reductions will need to be accomplished in component production processes. Cost reduction may be accomplished by either modifying current processes to improve efficiency or by utilizing alternative process routes that reduce the number and complexity of process steps. Simplification may come due to the form of products of the new reduction technologies.

Cost reductions analysis

1. Casting technology

first approach are the efforts currently under way at investment casting operations to modify specifications, reduce shell system costs, and streamline operations for high volume. The opportunity to utilize lower cost, semi-continuous molten Ti alloy should also be studied; processes such as the Ginatta approach discussed in Reference 1 given below may provide a viable option.

2. Powder Metallurgy

The primary obstacle to greater utilization of PM has always been the high cost of powder. The new powder production technologies discussed in Reference 2 given below, offer promise of cost affordable product. Titanium scrap usages maybe one of viable option.

3. Remaining Concerns

As with other processes which rely on the current low prices and relative price stability of sponge and scrap, cost for this process is also subject to future instability in the metal market. This concern would be removed if one of the new powder production processes is commercially successful at the low end of projected cost. Similar to other powder technology, it will be necessary to determine the defect populations and distribution, and the mechanical properties in components with complex shapes. Since the process is apparently ready for commercialization, process demonstration and cost modeling of fabrication of some of the promising heavy vehicle components should be performed.

Refer site for cost analysis

1. An Assessment of Existing Titanium Technologies, P. C. Turner, Jj. S. Hansen; Inter-Agency Titanium Research Committee – Minutes; Washington, DC; July 28, 1999

2. Private Communication; Santoku America, Inc., Phoenix, AZ

Ashish

Dear Matteo Tarsi,

Significant growth has been observed in the application of titanium and its alloys to automotive and motorcycle exhaust systems over last decade. Weight saving and visual appeal are the primary benefits of titanium in exhaust applications. Currently motorcycle mufflers and exhaust pipes are primary applications of titanium exhaust. New titanium materials with high temperature capability are expected to expand the application of titanium to vehicles with higher exhaust gas temperatures. TIMETAL®Exhaust XT (Ti-0.45%Si-0.25%Fe) can be developed to meet more stringent requirement where CP titanium cannot be used. Generally , the alloy exhibits superior oxidation resistance to CP titanium or other titanium exhaust alloys. The alloy possesses equivalent cold formability to that of CP titanium Grade 2 and exhibits excellent mechanical properties including fatigue and creep properties. Lightweight and high performance titanium exhaust systems for Porsche sports cars.

Because of the powder particle size issue, this process requires considerable further development. When modifications achieve that objective, then the cost analysis should be modified to reflect those changes. Turner and Hansen estimated the cost elements in production of Ti alloy plate as: 38% raw Ti as sponge, 15% in two arc melting steps, and 47% in fabrication of a one inch thick plate. For investment casting of turbocharger compressor rotors, the cost of raw material is estimated as somewhat less than 30%. While new titanium reduction technologies may have potential to reduce cost by 10 to 15%, major cost reductions will need to be accomplished in component production processes. Cost reduction may be accomplished by either modifying current processes to improve efficiency or by utilizing alternative process routes that reduce the number and complexity of process steps. Simplification may come due to the form of products of the new reduction technologies.

Cost reductions analysis

1. Casting technology

first approach are the efforts currently under way at investment casting operations to modify specifications, reduce shell system costs, and streamline operations for high volume. The opportunity to utilize lower cost, semi-continuous molten Ti alloy should also be studied; processes such as the Ginatta approach discussed in Reference 1 given below may provide a viable option.

2. Powder Metallurgy

The primary obstacle to greater utilization of PM has always been the high cost of powder. The new powder production technologies discussed in Reference 2 given below, offer promise of cost affordable product. Titanium scrap usages maybe one of viable option.

3. Remaining Concerns

As with other processes which rely on the current low prices and relative price stability of sponge and scrap, cost for this process is also subject to future instability in the metal market. This concern would be removed if one of the new powder production processes is commercially successful at the low end of projected cost. Similar to other powder technology, it will be necessary to determine the defect populations and distribution, and the mechanical properties in components with complex shapes. Since the process is apparently ready for commercialization, process demonstration and cost modeling of fabrication of some of the promising heavy vehicle components should be performed.

Refer site for cost analysis

1. An Assessment of Existing Titanium Technologies, P. C. Turner, Jj. S. Hansen; Inter-Agency Titanium Research Committee – Minutes; Washington, DC; July 28, 1999

2. Private Communication; Santoku America, Inc., Phoenix, AZ

Ashish