FS-Aerospace's advanced FS2S titanium alloy

checks off every mechanical property that an aerospace application requires. Through alloying with aluminum, vanadium, chromium, and other elements, FS2S has improved the mechanical properties for cast titanium to a level significantly higher than that of cast Ti64 (Gr.5), and virtually equivalent to that of machined wrought titanium alloys..

Cast FS2S has ultimate tensile strengths and yield strengths of 148ksi and 135ksi, respectively. With elongation of nearly 40% higher than cast Ti64, FS2S is an ideal material for critical applications where catastrophic mechanical failures might have extreme consequences.

In addition to being on par with fully machined conventional wrought titanium alloys, FS2S has double the strength of typical aluminum alloys, and is 40-50% lighter than conventional steel alloys. These superior properties for aerospace castings are made possible by the unique microstructure of FS2S alloy. Standard Ti64 castings yield a hard and brittle outer layer known as alpha-case, which tends to introduce micro-cracks into the surface structure of castings, and thus can lead to fatigue degradation. The FS2S compound and microstructure, however, yields a beta rich final product which reduces the as-cast alpha case by a factor of two.  This can reduce the amount of costly chemical milling required, as well as reduce the potential for Hydrogen uptake during the chemical milling process.

FS2S Titanium aerospace castings combine Low weight, high strength, and fatigue properties with a cost-effective casting process, while achieving the mechanical properties of fully machined wrought Ti64. With our FS2S titanium alloy, designers can take advantage of every one of these benefits, in the design of a near-net casting.

At Cross Wings, we leverage the exceptional strength-to-weight ratio, corrosion resistance, and fatigue performance of titanium through advanced near-net-shape investment casting. This manufacturing process produces dimensionally accurate components while significantly reducing material waste and minimizing the extensive machining typically required for wrought titanium parts—resulting in lower production costs without compromising quality.

The process begins by creating an exact wax replica of your component using either precision injection molding or advanced 3D printing. The wax pattern is then coated with multiple layers of ceramic slurry to form a durable mold. Once the ceramic shell has cured, the wax is removed, leaving a precise cavity that is filled with molten titanium. After solidification, the ceramic shell is carefully removed to reveal the finished titanium casting.

Following casting, each component undergoes a series of post-processing operations, inspections, and certifications to ensure compliance with stringent aerospace quality requirements before final inspection and shipment.

Engineered for Aerospace Performance

Aerospace components demand exceptional mechanical strength, fatigue resistance, and tight dimensional tolerances. At Cross Wings, every stage of our manufacturing process is designed to consistently meet these critical performance requirements.

Our quality management system is certified to AS9100 and Nadcap standards, and we manufacture components in accordance with industry specifications including AMS 4991, AMS 4992, AMS-T-81915A, as well as customer-specific aerospace requirements.

To maximize structural integrity, castings undergo Hot Isostatic Pressing (HIP), where temperatures and pressures of up to 15,000 psi eliminate internal porosity and enhance material density. Following HIP, we perform in-house chemical milling to remove the alpha-case layer formed during the high-temperature casting process, ensuring superior surface quality and mechanical performance.

Our investment casting process delivers excellent as-cast dimensional accuracy for many applications. When tighter tolerances or precision mating surfaces are required, we also provide complete finish machining services to meet final design specifications.

Quality Without Compromise

Quality is embedded throughout every stage of production. Cross Wings employs advanced Continuous Improvement methodologies and Six Sigma process controls to ensure consistent manufacturing excellence, process stability, and product reliability. Every component is manufactured and inspected to the highest aerospace standards, delivering the confidence required for mission-critical applications.

Maximizing Material Efficiency

Near-net-shape investment casting dramatically improves material utilization compared to conventional machining. Instead of starting with a large titanium billet and removing the majority of the material as scrap, our process produces components that are already close to their final geometry, requiring only minimal machining.

In many conventional manufacturing scenarios, a component weighing just five pounds may require machining from a 100-pound titanium billet, resulting in substantial material waste and unnecessary machining costs. At Cross Wings, our near-net manufacturing approach minimizes waste, reduces production time, lowers overall costs, and maximizes the value of every pound of titanium.