Research

Process Technologies

Current Projects:

136 Improvements in Efficiency of Melting for Die Casting 
146 Die Casting Mechanical Property Improvements through Process Enhancements
149 Reverse Engineering Tools & Productivity Improvements for Spare Part Components
157 HI-MAC
165 MFER&D

 

Research in Action:

Process Technologies - 2008

 

Accomplishments:
  • Various melting and holding furnaces have been benchmarked for energy efficiency. Heat losses during ladle transfer and efficiencies of various lining materials and configurations have been measured. A workshop has been developed for presenting technical and operating efficiency information on various types of energy efficient melting equipment. Productivity improvement opportunity!
  • A design of experiments is being conducted on 6-cylinder and 4-cylider engine block castings at Nemak to determine the impact of cooling, grain refinement dwell time, and other parameters on quality and mechanical properties.

Figure 7 – Specimens for mechanical property testing were taken from the center saddles on the underside of the six-cylinder engine block as indicated with the colored rectangles.

  • Eleven productivity improvement technologies have been identified and are being formulated into implementation strategies. In addition, six reverse engineering methods for converting a part to a solid model been assessed, one has been chosen for casting demonstration and the die inserts are in fabrication. The electronic tool is under construction and will be a user friendly program that provides the user with instructions on using the productivity and reverse engineering technologies. Productivity improvement opportunity!
  • A porosity guideline document has been produced and is available through NADCA Publications.