I think I found a clue regarding the 'titanium mystery' of why Elon is using titanium in the Tesla Pickup Truck, there's been a recent breakthrough in titanium alloys:
"Enhanced strength and ductility in a high-entropy alloy via ordered oxygen complexes."
"The tensile strength is enhanced (by 48.5 ± 1.8 per cent) and ductility is substantially improved (by 95.2 ± 8.1 per cent) when
doping a model TiZrHfNb HEA with 2.0 atomic per cent oxygen, thus breaking the long-standing strength-ductility trade-off"
Fuller article:
Enhanced strength and ductility in a high-entropy alloy via ordered oxygen complexes
Published in Nature.
TL;DR: tensile strength improved by ~50%, ease of manufacturing (ductility, anti-brittleness) increased by 90%. The article was published three weeks ago.
This is a very significant break-through in titanium alloys materials science and probably explains why SpaceX started experimenting with titanium-cast grid fins on the Falcon 9: 50% higher tensile strength moves titanium into the carbon fiber strength class (!), without the numerous disadvantages of carbon fiber. (Unless I'm mis-reading the numbers.)
Titanium alloys have very good properties for rocket technology:
- Titanium has very good high temperature properties and is very good for atmospheric re-entry: small channels can pump water out into the re-entry plasma shock layer and create a steam heat-shield that is opaque to infrared, allowing interplanetary speed atmospheric re-entries. The very dense metal conducts any residual heat very well which can be cooled actively, and also acts as a passive heat sink. This might be the 'delightfully counter-intuitive design' of the SpaceX Starship (used to be BFS) Elon alluded to on Twitter recently. This would save a lot of mass on one of the heaviest components of any re-entry vehicle: the heat shield. With a 'steam heat-shield' on top of a titanium surface would save a lot of mass, as the same titanium would serve as the rocket's regular skin/tank load bearing unibody as well. It would be a fundamentally reusable heat-shield, as it only requires one depleting resource: a small reservoir of water.
- Titanium has very good low temperature (cryogenic) properties, it doesn't get brittle at low temperatures like carbon fiber and I think there are Titanium-Aluminum alloys that don't spontaneously combust in the presence of liquid oxygen, which could form the inner skin of the cryogenic tanks.
- Titanium alloys are very corrosion resistant - so no paint required and no worries from corrosion fatigue. A highly reflective, polished surface would allow effective long term cryogenic rocket fuel storage, such as when coasting ~3-4 months from Earth to Mars. Titanium also doesn't have the really bad stress fatigue properties of the aluminum-lithium alloy SpaceX currently uses for the Falcon 9 (and which problem is also plaguing the airline industry).
Anyway, this also has relevance for Tesla Pickup Truck economics:
- 50% higher tensile strength means ~33% weight reduction for the same strength chassis/frame structure, plus better manufacturing properties mean cheaper, more durable tooling and faster production.
- The Pickup Truck panels would still be aluminum IMHO, because they are not load-bearing - so the nice coloring of titanium alloys would be limited to where the chassis is visible.
- Very little steel to no steel would be used - which again improves corrosion resistance.
- High ductility would actually allow the titanium frame to be repaired/pulled in a much wider range than regular titanium alloys - which would improve serviceability.
Elon gave up a PhD position at Stanford in materials sciences to work on what would become Paypal, so he'd be aware of such developments. (I think there was an interview where he said that he's a materials sciences engineer at heart, but I'm not sure.)
So I think that's one component of Elon's secret Tesla Pickup Truck plan. You heard it here first.