2010 Strategic Plan & Roadmap - Got Productivity?

Now in its thirteenth year, the NADCA Research & Development Strategic Plan and Roadmap has been established for 2010. NADCA’s R&D Program remains strong despite the current state of the die casting industry. Although the program has been confronted with budget cuts from some funding sources, progress continues to be made at a good pace and results continue to be generated. The program focuses in various strategic areas such as cast materials development, computer modeling, die materials and die surface engineering, process technologies, and other areas identified by the industry as being strategic. Efforts are also focused in advancements areas such as lead-time reduction, productivity improvements, scrap reduction and cost reduction.

Various strategic areas have been highlighted in past overviews of the R&D Strategic Plan and Roadmap. This year, productivity will be highlighted. Productivity is considered to be one of the key elements in staying competitive and profitable, especially in tough economic times. As the portfolio of projects is presented and key accomplishments are shown, kindly keep an eye on which accomplishments may provide an opportunity for productivity improvements in your plant.

Since the full version of the Strategic Plan and Roadmap, which explains the strategic areas and formulation of the roadmap, can be found at: http://www.diecasting.org/research/roadmap.htm, it will suffice to state here that the plan is simply identifying the pertinent areas for which technological advancements should be made and the roadmap is identifying the specific projects for advancing the technology. The full version also provides a statement of objectives for each project. In this overview, only accomplishments stemming from the projects will be presented.

Current Research Projects

The research project portfolio presently consists of 22 projects including the newly approved HyperCAST project which is in the negotiation stage and described below. The total leveraged value (direct funding plus cost share) of the projects is approximately $44,500,000, with $26,000,000 of the total related to HyperCAST. Funding for the projects is provided by the United States Department of Defense (DOD) through the Defense Logistics Agency (DLA) and the American Metalcasting Consortium (AMC), the United States Department of Energy (DOE) through the Industrial Technologies Program (ITP), the Cast Metals Coalition (CMC) and the Vehicle Technology Program, the United States Council for Automotive Research (USCAR)/United States Automotive Materials Partnership (USAMP) Program, and NADCA.

Table 1 – Current R&D projects as related to major strategic areas

Current Project		Products & Markets	Materials	Manufacturing	Environmental	Industry Health
AMC (DOD Funds)
149	Reverse Engineering Tools & Productivity Improvements for Spare Part Components	X	X	X	X	X
150	Computational Tool for Short Run Insert Production and Improved Yield	X		X	X	X
151	Rapid Tooling for Short Run Metal Mold and Increased Productivity	X		X		X
152	High Production Rate Process for Metal Matrix Composite Components	X	X	X		X
153	High Performance Die Casting Alloys	X	X			X
158	Casting Alloy Standards	X	X			X
167	Part Model to Casting Model Conversion Software	X		X		X
CMC (DOE Funds)
132	Mechanical Performance of Dies Continuation	X		X	X	X
133	Design Support for Tooling Optimization	X		X	X	X
134	The Development of Smart Die Coatings	X	X	X	X	X
135	Improved Die Casting Process to Preserve the Life of the Die Casting Dies		X	X	X	X
136	Improvements in Efficiency of Melting for Die Casting			X	X	X
137	Innovative SSM Processing	X	X	X	X	X
USAMP (DOE Funds)
157	HI-MAC	X	X	X	X	X
165	MFER&D	X	X	X	X	X
NADCA Funds
139	Thin Wall Zinc	X	X		X	X
144	Zinc Alloy Properties for Market Development Support	X	X			X
146	Die Casting Mechanical Property Improvements through Process Enhancements	X	X	X		X
155	Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes	X	X	X	X	X
161	Thermal Fatigue Resistance of High Performance Die Steels		X	X	X
168	Die Material Properties at 46-48 HRC		X	X
Vehicle Technology (DOE Funds)
169	HyperCAST	X	X	X	X	X

Table 1 displays the current projects categorized by strategic area and identifies the funding source for each project. Table 2 lists the projects by general topic area. The following provides recent key accomplishments for many of the projects by general topic area.

Table 2 – Current R&D projects as related to general topic area.

Cast Materials
137	Innovative SSM Processing
139	Thin Wall Zinc
144	Zinc Alloy Properties for Market Development Support
152	High Production Rate Process for Metal Matrix Composite Components
153	High Performance Die Casting Alloys
155	Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes
158	Casting Alloy Standards
169	HyperCAST
Computer Modeling and Design Aids
132	Mechanical Performance of Dies Continuation
133	Design Support for Tooling Optimization
150	Computational Tool for Short Run Insert Production and Improved Yield
167	Part Model to Casting Model Conversion Software
Die Materials & Die Surface Engineering
134	The Development of Smart Die Coatings
135	Improved Die Casting Process to Preserve the Life of the Die Casting Dies
151	Rapid Tooling for Short Run Metal Mold and Increased Productivity
161	Thermal Fatigue Resistance of High Performance Die Steels
168	Die Material Properties at 46-48 HRC
Process Technologies
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

 

Cast Materials Accomplishments

• The simplified continuous rheocasting process (CRP) reactor design has been adopted by and is being marketed by Buhler and the LTC (low temperature casting) process. Sound SSM castings have been produced using a variety of commercial alloys. Heat treatment studies are continuing in an attempt to optimize the cycle for –T5 and –T6 conditions. Both conventional and fluidized bed furnaces are being utilized. Productivity improvement opportunity!

Figure 1 – Photograph of the CRP reactor and a resultant SSM microstructure.

• The suitability of a newly developed high fluidity zinc alloy for industrial production has been shown. Lack of fill issues have been resolved and parts with section thicknesses as low as 0.012 inch have been successfully cast. The alloy not only improves die fill but also reduces gas entrapment compared to Alloys 3 & 5. Mechanical properties and casting characteristics have shown to be acceptable. Productivity improvement opportunity!

Figure 2 – This casting had fill issues which were resolved by utilizing the new high fluidity zinc alloy.

• An expanded database of properties has been developed for standard alloys such as Alloys 2, 3, 5, and ZA8, including tensile properties over an extended temperature range, compression at elevated temperatures, impact, rotating fatigue and creep. Only a minor amount of creep testing remains to complete this project.
• Wedge shaped and plate shaped semi-solid metal castings (thixocast) have been produced from SHS aluminum/TiC metal matrix composite material with up to 47% particulate. Wear resistance, hardness, and compression strength measurements show great improvement over standard aluminum and aluminum composite castings and comparable to cast iron.

Figure 3 – Processing route for thixocasting of SHS aluminum wedges for mechanical property testing.

• Three aluminum alloy compositions of thirty-eight formulations have been selected based on property improvement levels noted on laboratory cast specimens. Castings of a production configuration were produced at a member die caster and property measurements show an improvement in quality index.
• Zinc castings have been processed with new coatings and plating and are being prepared for corrosion testing to assess the protective nature of the coatings and platings.
• A magnesium automotive chassis component for test and evaluation has been successfully squeeze cast at two NADCA member die casters. Property enhancements are the current focus.
• A magnesium automotive front end component for test and evaluation has been high vacuum cast at one NADCA member die caster. Although soundness was adequate, focus for this component is also is currently on determining if properties can be enhanced.
• Castings of a production configuration have been produced from three alloy chemistries. Mechanical property testing is in process. A tool was produced for producing as-cast impact and fatigue bars. These properties are being compared to those of separately cast specimens of the same three alloys. A property database is being established.

Computer Modeling and Design Aids Accomplishments

• Information has been generated to assist in providing better ejector side die/platen support for reducing die distortion under load. The largest contributor to the ejector side separation is the unsupported span Characterized by the number, location and size of the pillar supports. Die thickness is the second most important factor. The platen thickness has a negligible effect on the ejector side separation. Major contributors to the cover side separation are the die footprint and platen thickness. The effect of die thickness on the cover side separation is small as compared to its effect on the ejector side. Productivity improvement opportunity!

Figure 4 – Die thickness and die length versus maximum ejector half separation plots for three-platen thicknesses.

• Enhancements to the flow and thermal visualizations have been made and a cooling line sketcher has been incorporated in the program. A modeling methodology has been defined which predicts casting distortion with reasonable accuracy.
• Guidance for the efficient use of modular dies is being developed to assist plants in enhancing their short run capability. A means to assess and enhance the size of the processing window for enhanced quality parts has been established. In addition, methods/suggestions on how to reduce runner volume are being developed. Productivity improvement opportunity!

Figure 5 – Example of how undercuts are flagged on a configuration through the part model to casting model conversion software

• Techniques to flag undercuts and surfaces needing draft have been developed. Current work is focused on automatic identification of sharp edges and conversion to radii.

Die Materials & Die Surface Engineering Accomplishments

• Specimens of wrought copper coated with H13 via the DMD (Direct Metal Deposition) process have been successfully prepared and tested for thermal fatigue resistance. The thermal fatigue performance was similar to that of wrought H13.
• Smart coating development is continuing and generating improved electrical response. Studies found that the insertion of a TiN layer on either side of the AlN piezoelectric layer produced the best piezoelectric effect. Optimized processing parameters have been established for the AlN layer.
• The effect of internal and external cooling of dies on die life has been studied and provides additional insight for die design and operation.

Figure 6 – The cycle time for this casting was reduced by 13% through the use of a core fabricated from high thermal conductivity material.

• The cycle time reduction benefits of utilizing high conductivity alloys in die components have been demonstrated. In one case, the cycle time was reduced from 55 to 40 seconds (13%). In addition, the lead-time reduction benefits of utilizing pre-hardened die steels have been demonstrated. Productivity improvement opportunity!
• Cooling lines have been moved closer to the cavity surface in a die configuration with much historical data. This risk has been taken due to the improved performance of a new die steel as compared to H13 and for faster cooling. The die is currently in operation and a cycle time reduction of 12% has been achieved. Die life is currently being assessed. Productivity improvement opportunity!
• Specimens of four steel grades have been heat treated and testing is currently underway to determine the relationships between thermal fatigue, impact strength and microstructure as compared to Premium Grade H13.
• Measurements on cavity dimensions both before and after heat treatment were made on various die casting configurations as an initial effort to establish better guidelines for machining stock.

Process Technologies 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.

HyperCAST – A New Exciting Project

The purpose of this project is to develop materials and processes for cast high strength light weight frame, body, chassis and powertrain components for fuel efficient passenger cars and both commercial and military trucks to meet the goals of both the FreedomCAR and the 21st Century Truck programs. The advanced materials and processes developed will focus on fuel efficiency and cost effectiveness to offer the potential for 60% weight reduction without compromising component performance, cost, safety or recyclability. The material technology is SHS (self-propagating high-temperature synthesis) also know as auto ignition combustion synthesis for the generation of composite materials. Magnesium based composites are the primary focus.

The scope of the project is five-fold and entails: 1) the develop high strength aluminum and magnesium base composite alloys/materials; 2) defining parameters for robust high volume production rate casting processes for the developed alloys; 3) establishing material design data; 4) the demonstrate and validation of the materials and processes through the production of cast components; and 5) transfer the technology to the industry through appropriate documentation.

To accomplish the tasks defined for the project, researchers from the premier universities and government laboratories with experience in cast materials and processes for the research activities and premier casting companies for demonstration of the research results will be utilized.

The approach to the first scope will be to establish the aluminum and magnesium composite material compositions that yield the most advantageous properties by defining the chemistry of the molten alloy and the volume percent of reactant material to be added to the melt.

The approach to the second scope will be to define processing parameters for the casting of the most promising composite materials via various casting processes in production facilities. Concurrent with the development of processing parameters will be the development of computer models (to aid in cast part design, tooling design and process design), improved die materials and coatings specifically for use in the auto-combustion synthesis casting, and recycling efforts.

The third scope will be approached by producing specimens of the most promising composite materials in the laboratory and in production facilities for mechanical property testing. Subsequently, specimens will be removed from actual castings for testing. Several specimens will be measured in order to provide statistically significant property data for design.

Efforts in the fourth scope will identify a cast component for demonstration and validation or proof-of-concept. This component will be produced in a production facility of the cast composite material and casting process judged to be most viable. Castings of the component will be evaluated and compared to the processing and performance characteristics of the conventionally cast component.

Lastly, material and processing guidelines and computer modeling approaches will be established and transferred to the industry to enable the successful implementation of the material and processing technology.

The expected outcome of this project is a new generation of castable aluminum and magnesium composite materials that represent a major leap in technology and offer opportunities for cost effective light weight components with productivity enhancements of up to 25% and weight savings of 60% compared to current production cast components. Two specific outcomes include ability to replace cast iron and other inserts to eliminate the time involved in placing the inserts as well as the cost and weight of the inserts, and a dual pour technique for preferentially locating the SHS material in a die cavity/cast configuration.

Other Technologies for Productivity Improvement

Through the Research Program, technologies developed by other entities that offer productivity improvements have been identified. Three of these are summarized below.

SPEEDiall
This technology was developed and patented by Buhler and named SPEEDiall for speedy aluminum. It is essentially a core on the cover half of the die that blocks the shot hole after die opening and prior to die closure, thereby allowing aluminum alloy to be poured into the cold chamber earlier than usual. This results in the melt pour time to be shifted from a primary time to a secondary time. Depending on the specific melt feed method and system applied, this enables the cycle time to be cut by an average of 10 to 15 percent.

Figure 8 – Photograph and schematic of the SPEEDiall assembly.

Hot Chamber Pre-Fill
Time can also be eliminated in hot chamber processing. Frech has developed a zinc hot chamber pre-fill technique that allows metal to be delivered to the gate earlier than typical. This assists in shaving up to 5 or more seconds off the hot chamber cycle time, depending on the size of the shot.

Computer Control for Cooling Water Flow
Heat removal from cooling lines can be measured by measuring inlet temperature, outlet temperature, and water flow rate.  Using the water density, specific heat, and machine cycle time, the number of BTU's being removed by the cooling channel can be measured every shot.  Using a personal computer, heat removal can be controlled by making the aforementioned measurements and adjusting a very accurate stepping motor valve to get the desired heat removal.  To restrict heat removal, water flow is reduced and to increase heat removal, water flow is increased. A system to make the appropriate measurements and control water flow via computer interface has been developed and is offered through Die Therm Engineering (DTE).

Closing

Various technologies for improving productivity exist. Some of these have been developed through the NADCA R&D Program and others have been identified through the program. Perhaps there have been some technologies revealed that provide an opportunity for improving productivity in your plant!

Although productivity has been highlighted this year, it should be recognized that several other factors contribute to competitiveness and higher profitability as well. These include: higher performing alloys, improved design aids, longer lasting dies, improved process control, higher quality, lower operating costs, and shortened development and production lead-times. Therefore, the research efforts are also geared toward providing useful results that offering opportunities to improve these and other factors that can enhance competitiveness and profitability.

Notes: The NADCA technical committees are always seeking participants for in-plant trials. If would like to participate in a project, send an e-mail to research@diecasting.org. Additional project ideas are also welcome and may be forwarded to the same address.