Hifi Ironman Mark II Foam/Cast/3DP/Gold-titanium

[Gee]

Blue Sky Requirements

First establish where I want to be:

• an Ironman armor, made of titanium and steel alloy, or similar (already checked, couldn't source any vibranium nor adamantium on such short notice);
• of model mark II, i.e. NOT weaponised (don't want any issues with MoD);
• powered by a 3 Gj arc reactor, or better (note to self, NO palladium);
• assorted with its own assembly line for easy installation / removal;
• flying range 10,000 km (only one refuel when I go to South-East Asia for the week-end), with a cruise altitude of 20,000 m (to avoid embarassing face to face with commercial airliners);
• full-featured Jarvis OS (to be considered: retail potential to Microsoft to replace Cortana, Google, Amazon);
• general life support and strength augmentation.

And an added feature to face down a hostile boardroom.
<edit> Life support must include the ensuite option as seen in IM2.

Of course, as with any significant project, I might have to scale back a little on some of these requirements over time. Also, not everything might be present from day One, e.g. my wife might have to serve as assembly line for the first few weeks.

And of course, I reserve the absolute right to change my mind and add or remove requirement(s) without notifying anyone on the thread.


That being said, it all start with the following sources:

• reference (IM movies 1,2,3; Hottoy 1:6 replica, CGI rendering, props and costume pix on Marvel-controlled websites and wikis); (*) Important: details vary on the various reference, e.g. rivets bumps vs sunken screws; (http://ironman.wikia.com/wiki/Mark_II and others)
• Dancin_Fool mark II/III model unfolded for foam by JFCustom
• HELMET?
• Cast parts (Dancin_Fool models again, molds by Finhead, castworks by Stealth);
• 3D printed parts of various sources (sources will be confirmed after due diligence and normal procurement processes);
• Nickel, steel, aluminium, titanium, gold and other metals as powders and ingots for casting. The suppliers will be mentioned in case that is of interest to anyone else.

 

[stigmorgan]

This sounds interesting, I look forward to your updates. Subscribed.

 

[Gee]

Following detailed specs and proof of concept, we have selected Ti-6Al-2Sn-4Zr-2Mo as the choice of Titanium alloy for the outer shell of the armor.

This near-alpha alloy contains a small amount of ductile beta-phase, with the 2% molybdenum, which has been preferred to silicon or vanadium. It contains a neutral tin at 2% and 6% aluminium as alpha stabiliser. The zirconium is originally an impurity of the titanium and the tin. It improves the behaviour of the alloy at high-temperatures and aggressive corrosion. It also contains traces of hafnium, which is OK as it behaves similarly to zirconium.

This will make the casting possible, but without a stable beta phase will not allow/require further treatments. As usual it is a trade-off of sort.

The finish will be a-la "brushed steel", a shade halfway between shiny silver and matt gunmetal, with a rough texture.