Research

Introduction
The 2011 NADCA Research & Development Strategic Plan and Roadmap defines the overall goals and direction of the NADCA R&D Program for the current and upcoming years. The Strategic Plan and Roadmap is reviewed and updated on an annual basis to ensure it continues to evolve with changes in the industry. The strategic plan identifies the strategic areas reflective of the most pertinent needs of the industry. These strategic areas are modified, if necessary, to ensure they identify the current needs of the industry. The roadmap defines the research pathways for enabling technological advancement within the strategic areas. The roadmap is also modified, when necessary, to ensure that projects are being applied to the appropriate strategic areas and that the performance of each project meets minimum expectations. In short, this document charts the course of the die casting research activities for the year 2011 and beyond. The intent of these activities is to produce and transfer results to the industry in order to provide opportunities for profitable growth, enhance the ability of die castings to compete with other processes, and enhance the ability of die casters to compete in the domestic and global marketplace.

Industry Committees
It should be noted that the research and development efforts and transfer of technology are guided by the Technology Administration Group and three technical committees - The Die Materials Committee, The Research and Development Committee and the International Technical Council. In addition, there are task forces or sub-committees that have been formed to assist the R&D and Die Materials Committee in carrying out various tasks. These committees also assist in identifying the needs of the industry. The Technology Administration Group, committees and task forces are comprised of individuals from the NADCA Corporate and Individual membership base, academia and NADCA Headquarters. Due to the die casting industry representation in the form of Corporate and Individual members, the identified needs are viable and the efforts are assured to be focused in a direction to respond to and meet the needs and key challenges of the industry.

Committee Mission Statements
Technology Administration Group Mission: To assist in the overall prioritization of NADCA sponsored technical projects, review requested funding levels and make determinations on the appropriate distribution of funds for the entire portfolio of projects, and ensure that the projects appropriately support the R&D Strategic Plan and Roadmap. The Group also assists in the tracking of current project expenditures and identifies additional/alternate funding sources. This mission allows the technical committees to focus on purely technical issues and avoid administrative project management tasks.

Research & Development Committee Mission: The mission of the NADCA R&D Committee is to: 1) identify research projects that fulfill the NADCA R&D Strategic Plan and Roadmap and assist in procuring funding to accomplish these research projects; 2) identify and maintain liaison with viable research institutions for implementing the research projects; 3) monitor projects to ensure that technical knowledge is provided in a timely and cost-effective way, and; 4) disseminate new technical knowledge to the die casting industry to ensure technological advancement, identify commercial opportunities that are competitive with other processes, and promote profitable growth.

Die Materials Committee Mission: The mission of the Die Materials Committee is to conduct, support and direct research activities and disseminate the resultant information in order to advance the state-of-the-art of dies and shot sleeves. These efforts are targeted to increase die and shot sleeve life, reduce machine downtime, produce higher quality castings and reduce cost.

International Technical Council Mission: The mission of the International Technical Council is to provide continuity to the biennial NADCA Congresses. This committee is a technical reservoir of die casting subject matter experts who, upon request, act as session chairpersons and technical reviewers/editors of the Congress abstracts and papers. All committee members are responsible for maintaining their knowledgebase in their area of die casting expertise and pro-actively solicit potential authors during NADCA’s Call for Papers.

Mission of Task Forces: The mission of the task forces is to: 1) provide input to their respective committee concerning needed research in a specific technical area; 2) ensure the completion of R&D projects in line with established cost and timing targets, and; 3) assure the results of projects are consistent with scientific principles and are relevant to the die casting industry. In addition, task forces establish goals, provide progress reports, and maintain communication between researchers, industry, and commercial applications, as well as provide technical resources and guidance to research projects.

R&D Project Objectives
Research project objectives, such as improving casting integrity, improving alloys, increasing die life, improving quality and lead times through simulation, implementing high integrity casting technology, and energy conservation are aligned with the NADCA Strategic Plan and the Metalcasting Industry Vision Statement and Technology Roadmap. Hence, this plan intends to meet the needs of NADCA and the die casting industry as well as objectives within the entire metalcasting industry vision and roadmap.

Specific items within the strategic areas, to which efforts are intended to be applied, include: aluminum, zinc and magnesium alloy development; base material and coatings/surface treatments for dies and inserts; optimization of hot chamber, cold chamber, SSM and squeeze casting process parameters; metal flow, die design, die deflection and property simulation; rapid tooling, and; environmental friendliness through energy conservation, waste management and pollution prevention.

Focus is placed on developing new technologies and advancing the state of current technologies to increase operational efficiency. Efficiencies in all aspects of the die casting process, including lead-time reduction, productivity improvement, scrap reduction, cost reduction and energy efficiency, are targeted for improvement.

Funding Sources
Projects are funded by various sources. Currently, funds for the majority of projects are provided by the United States Department of Defense (DOD) through the Defense Supply Center Philadelphia, Defense Logistics Agency (DLA), Benet Laboratories, 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 Technologies Program, the United States Council for Automotive Research (USCAR)/United States Automotive Materials Partnership (USAMP) Program, and NADCA.

Metalcasting Industry Vision
Based on input provided by representatives of the various metalcasting industry segments, the most current Metalcasting Industry Vision, although presently eight years old, was constructed and released on May 21, 2002. Identified in the vision are four key challenges, each with corresponding goals and a perspective of what the industry will look like once the goals are achieved. The challenges and goals are summarized below and the Vision in its entirety can be found by clicking on the Metalcasting Industry Vision.

Challenge 1: To communicate the essential value of the metalcasting industry to the U.S economy.

 Goal: By 2020, for society to recognize the metalcaster as a desirable neighbor, a vital player in the U.S. economy, and a supplier of high-performance components. For metal castings to solve challenging performance problems in high technology products and regularly demonstrate outstanding value in common applications.

Challenge 2: To increase the rate and improve the methods of designing castings for new markets and applications while maintaining current markets.

 Goal: Through improved casting design methods, alloy properties, alloy performance data, and casting performance simulation techniques, to grow annual market rates for metalcasting shipments (based on value of shipments) by an average of 3% or more through 2020.

Challenge 3: To improve metalcasting processes through increased understanding, accurate simulation, more finite real-time controls, and improved operating efficiencies.

 Goal: By 2020, to increase significantly, the combination of average melting and mold yield for each metalcasting alloy/process family so that, in aggregate, the metalcasting industry’s yields will increase by 20% from current levels. To cut rejected casting rates by 40% from current industry averages. In addition, on-time/complete delivery performance for the full spectrum of order/release quantities is to be sustained above 95% across the metalcasting industry while the combination of in-process and finished inventory in metalcasting plants is to be reduced by 50%.

Challenge 4: To attract students to the metalcasting industry and retain the brightest, most productive employees.

 Goal: By 2020, through growth in the metalcasting markets and applications, to strengthen the related curricula of at least five leading U.S. metalcasting R&D universities, to add at least three new ones, and to add at least 100 high school and/or vocational metalcasting programs across the U.S. In addition, to have metalcasting related product design, process engineering, and production be among the top 10 career choices of U.S. engineering and vocational graduates.

Subsequent to the Metalcasting Industry Vision, the most current Metalcasting Industry Roadmap, formulated to address the aforementioned key challenges, was released in October of 2003. The two major R&D focus areas are Improved Metalcasting Design Capabilities and Improved Metalcasting Processes. Metalcasting Design Capabilities identifies short, mid, and long term projects for material property data, design-process interrelationships, and design competitiveness. Metalcasting Processes identifies short, mid, and long term projects for innovative processes, variability, intelligent processing, and management issues including whole systems approach. This document can be viewed at: cmc.aticorp.org/roadmap03.pdf.

NADCA Strategic Areas and Roadmap
There are five primary strategic areas and corresponding secondary and tertiary strategic areas that have been identified as those most pertinent to the die casting industry. These define the areas targeted for technological advancements through R&D projects. The primary strategic areas are Products and Markets, Materials Technology, Manufacturing Technology, Environmental Technology, and Industry Health & Profitability. The organizational structure of the strategic areas shown in Figure 1 displays the secondary and tertiary areas. For example, the primary strategic area of materials Technology has two secondary areas – Cast Materials and Die Materials. There are three tertiary areas related to each of these secondary areas. The three areas under Cast Materials are shown as Properties, Processing & Quality, and New Materials.

Figure 1: Organization of the strategic areas.

Many of the strategic areas are in support of the key die casting advancement areas of Lead-time Reduction and Productivity Improvement. Furthermore, the strategic areas are in support of the metalcasting industry vision.

The strategic plan is to ensure that efforts are applied toward further development and advancement in each major strategic area. The roadmap defines the path of the R&D activity by identifying the specific activities required to advance each strategic area. The NADCA roadmap has been populated with current projects as shown in Tables 1 and 3. Table 1 displays current projects spread across the primary strategic areas and Table 3 displays the current projects spread across the targeted advancement areas of Lead-time Reduction, Productivity Improvement, Scrap Reduction, and Cost Reduction. Similarly, recently completed projects are shown in Tables 2 and 4.

 

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
150	Computational Tool for Short Run Insert Production and Improved Yield	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
171	High Performance Nano-Composite Materials	X	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
165	Magnesium Front End R&D	X	X	X		X
Vehicle Technologies (DOE Funds)
169	HyperCAST	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
161	Thermal Fatigue Resistance of High Performance Die Steels	X		X		X
163	Evaluating Soldering Tendencies of Coatings and New Materials for Core Pin Applications	X	X	X		X
168	Die Material Properties at 46-48 HRC	X	X	X		X
170	Ultrasonic Grain Refinement	X	X			X

 

	Table 2.  Recently Completed R&D Projects as Related to Major Strategic Areas.
RECENTLY COMPLETED PROJECT
		Products & Markets	Materials	Manufacturing	Environmental	Industry Health
AMC (DOD Funds)
158	Casting Alloy Standards	X	X			X
167	Part Model to Casting Model Conversion Software	X		X		X
NADCA Funds
162	Generating Data on Die Distortion During Heat Treatment			X		X

 

	Table 3.  Current R&D Projects as Related to Areas Targeted for Advancement.
CURRENT PROJECT		Advancement Area
		Lead-Time Reduction	Productivity Improvement	Scrap Reduction	Cost Reduction
AMC (DOD Funds)
149	Reverse Engineering Tools & Productivity Improvements for Spare Part Components	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
152	High Production Rate Process for Metal Matrix Composite Components	X	X		X
153	High Performance Die Casting Alloys	X		X	X
171	High Performance Nano-Composite Materials	X	X
CMC (DOE Funds)
132	Mechanical Performance of Dies Continuation		X	X	X
133	Design Support for Tooling Optimization	X	X	X	X
134	The Development of Smart Die Coatings		X	X	X
135	Improved Die Casting Process to Preserve the Life of the Die Casting Dies		X	X	X
136	Improvements in Efficiency of Melting for Die Casting				X
137	Innovative SSM Processing		X		X
USAMP (DOE Funds)
157	HI-MAC	X
165	Magnesium Front End R&D	X
Vehicle Technologies (DOE Funds)
169	HyperCAST		X		X
NADCA Funds
139	Thin Wall Zinc			X	X
144	Zinc Alloy Properties for Market Development Support	X
146	Die Casting Mechanical Property Improvements through Process Enhancements			X
155	Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes	X
161	Thermal Fatigue Resistance of High Performance Die Steels		X	X	X
163	Evaluating Soldering Tendencies of Coatings and New Materials for Core Pin Applications		X	X	X
168	Die Material Properties at 46-48 HRC		X	X	X
170	Ultrasonic Grain Refinement			X	X

 

	Table 4.  Recently Completed R&D Projects as Related to Areas Targeted for Advancement.
RECENTLY COMPLETED		Advancement Area
PROJECT		Lead-Time Reduction	Productivity Improvement	Scrap Reduction	Cost Reduction
AMC (DOD Funds)
158	Casting Alloy Standards			X	X
167	Part Model to Casting Model Conversion Software	X			X
NADCA Funds
162	Generating Data on Die Distortion During Heat Treatment	X		X	X

 

In the tables, an X in a box at the intersection of a strategic area or advancement area and a project indicates alignment of a project to that area. Due to the scope of many projects, the support may cut across more than one strategic area as witnessed by the alignment of a project to more than one strategic area. Alignment with a primary strategic area is also indicative of alignment with one or more sub-categories of the primary area. The Design Support for Tooling Optimization project is aligned with Manufacturing Technology because it applies effort to the tertiary area of Design Aids, for instance.

Tabularizing the projects in this fashion shows the level of activity that is being applied to each strategic and advancement area at a glance. From the tables it is seen that the roadmap strongly supports the plan since much effort from multiple projects is being applied to multiple strategic and advancement areas.

Although it is seen that many projects support more than one strategic area, each has a general topical area that it may be categorized under. For ease of reference to topical areas, see the projects as categorized under Cast Materials, Computer Modeling & Design Aids, Die Materials & Technologies, and Process Technologies in Tables 5 and 6.

 

	Table 5.  Current R&D Projects as Related to General Topical 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
169	HyperCAST
170	Ultrasonic Grain Refinement
171	High Performance Nano-Composite Materials
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
Die Materials and 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
163	Evaluating Soldering Tendencies of Coatings and New Materials for Core Pin Applications
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 (High Intergrity Magnesium Automotive Components)
165	Magnesium Front End R&D

 

Table 6.  Recently Completed R&D Projects as Related to General Topical Area.
Cast Materials
158	Casting Alloy Standards
Computer Modeling and Design Aids
167	Part Model to Casting Model Conversion Software
Die Materials & Technologies
162	Generating Data on Die Distortion During Heat Treatment

 

It should be noted that many of the projects support the challenges in the Metalcasting Industry Vision and the R&D focus areas in the Metalcasting Industry Roadmap. It should also be noted that current projects are reviewed and new projects are selected annually to ensure that the best roadmap is established for the amount of available R&D funding.

Current Projects
The NADCA R&D portfolio currently consists of 23 projects. Three projects have been completed and four new projects have been initiated over the past year. The total value (funding level plus industry cost share level) of the current portfolio of projects is approximately $44,000,000.

Although a few of the projects are conducted by members from industry and/or NADCA staff, most of the research projects are conducted by researchers from universities who have a high level of expertise in specific areas directly related to the die casting industry. Coupling the work of these experts with the collaboration of industry assists in ensuring results that are highly beneficial. Titles, researchers, and summaries of research objectives for the current projects are as follows. Highlights of results from select research projects can be found at the end of this section.

Project #132: Mechanical Performance of Dies Continuation (R. Allen Miller, The Ohio State University)

Research Objectives: Main objectives are to: 1) extend the mechanical modeling work to address hot chamber die casting systems; 2) systematically address design of the ejector side of the die; 3) develop parametric information about the relationship between die shoe design, slide carrier design, and the machine; and, 4) continue the efforts to provide design guidelines for the industry addressing the mechanical design of dies and the relationship between die and machine.

Project #133: Design Support for Tooling Optimization (R. Allen Miller, The Ohio State University)

Research Objectives: The basic objectives of this project are to: 1) extend the work on equilibrium temperature calculations to address thermal and cycle management so that cooling channels and the casting cycle can be optimized for thermal performance; 2) improve the fill pattern visualization for high pressure die casting and extend the reasoning techniques used for high pressure casting to include similar issues with permanent mold, squeeze, and semi-solid casting; and, 3) extend the castability assessment work to include “wizards” that incorporate industry-wide (NADCA) or company design standards.

Project #134: The Development of Smart Die Coatings (John Moore, Colorado School of Mines)

Research Objectives: The three primary objectives are: 1) the development of a range of engineered coating systems that will substantially extend the life and performance of dies used in aluminum pressure die-casting; 2) the development of a ‘smart’ die coating system that will indicate the state of condition of the die and provide input as to when the die should be removed prior to catastrophic degradation and wear; and, 3) technology transfer of the optimized and ‘smart’ coatings through the industry partners on this research program that includes both die casting companies and commercial coating companies.

Project #135: Improved Die Casting Process to Preserve the Life of the Die Casting Dies (David Schwam, Case Western Reserve University)

Research Objectives: To study the combined effects of die design, proper internal cooling and efficient die lubricants on die life and develop methods of optimized process control for extended die life.

Project #136: Improvements in Efficiency of Melting for Die Casting (David Schwam, Case Western Reserve University)

Research Objectives: To improve efficiency of melting and molten metal handling in die casting plants by: 1) developing in-plant monitoring methods and procedures of gas and electrical power use in melting and casting operations; 2) training project team and plant personnel in monitoring energy use and identifying potential improvements; and, 3) conducting energy efficiency surveys of melting and holding furnaces and molten metal handling equipment used in die casting operations.

Project #137: Innovative SSM Processing (Diran Apelian, Worcester Polytechnic Institute)

Research Objectives: To optimize the CRP (Continuous Rheocasting Process), develop optimum alloys that are specifically designed for the SSM/CRP process, develop optimum heat treatment schedules that are specifically designed for the SSM/CRP process, and develop a comprehensive constitutive mathematical model that includes the internal microstructural dynamics of SSM slurries and allows better simulation of die filling during the production of SSM parts.

Project #139: Thin Wall Zinc (F. Goodwin, International Lead and Zinc Research Organization)

Research Objectives: To develop and define an approach for producing zinc die castings with wall thicknesses of 0.3 mm or less. Metal chemistry, gate and runner system designs, and the nature of heat transfer in tooling are to be taken into consideration.

Project #144: Zinc Alloy Properties for Market Development Support (Frank Goodwin, International Lead and Zinc Research Organization)

Research Objectives: To develop mechanical property data information that currently does not exist in order to better assist designers. Tensile, fatigue, creep, compressive yield and shear data together with coefficients of thermal expansion are to be determined over a range of temperatures of engineering interest for certain zinc alloys. When possible, the data will be reported in numeric form suitable for use in computer aided design and engineering programs.

Project #146: Die Casting Mechanical Property Improvements through Process Enhancements (David Schwam, CWRU and Andy Karve, Nemak)

Research Objectives: To conduct a design of experiments that will determine the optimized process parameters required to yield the best casting mechanical properties in thick walled aluminum die castings. Process parameters to be considered in the experimental design include gate velocity, gate area, fast shot velocity, fill time and cavity pressure. Casting quality is to be documented with the mechanical property measurements/improvements.

Project #149: Reverse Engineering Tools & Productivity Improvements for Spare Part Components (S. Udvardy, D. Meyer and A. Monroe, NADCA)

Research Objectives: This project is to identify new technologies that can be utilized for improving productivity and develop implementation strategies for the technologies. In addition, the project is to identify and evaluate reverse engineering technologies for the purpose of establishing a 3D solid model and other applicable engineering definitions from an actual component. An electronic tool will be developed to assist one in learning about and applying the productivity improvement technologies and generating rapid tooling directly from the generated 3D model.

Project #150: Computational Tool for Short Run Insert Production and Improved Yield (A. Miller, The Ohio State University)

Research Objectives: This project is to develop a computational tool that will take the insert configuration and determine which die block it would work best with. This would result in providing production ready tooling more quickly and assist in achieving first time success for short runs. Electronic tools currently do not exist that assist the die caster in determining which die casting inserts are the best match for readily available modular holder blocks.

Project #151: Rapid Tooling for Short Run Metal Mold and Increased Productivity (J. Wallace and D. Schwam, Case Western Reserve University)

Research Objectives: In this project, rapid tooling methods will be demonstrated by casting military components via a high integrity casting process. New rapid tooling methods, which may be identified, will be assessed for casting tooling viability. In addition, the utilization of high heat diffusivity alloy inserts and rapid tooling inserts with conformal cooling lines will be assessed for productivity gains.

Project #152: High Production Rate Process for Metal Matrix Composite Components (J. Moore, Colorado School of Mines)

Research Objectives: This project is to determine the applicability of self-propagating reactions to die, semi-solid, and squeeze casting in order to define a combined single step metal matrix composite production process method. The aim is to produce SSM or squeeze cast composite components in which the volume percentage of ceramic phases will range from 20-60% and subsequently measure mechanical properties and provide processing guidelines.

Project #153: High Performance Die Casting Alloys (D. Apelian and M. Makhlouf, Worcester Polytechnic Institute)

Research Objectives: To develop a set of select or premium grade alloys that are optimized for specific properties to meet the high demands that are placed on OEM components with cost-effective cast products. This effort may result in the development of new alloys to improve properties to meet the demand for components with cost-effective cast products. Property information is to be added to the NADCA Product Specification Standards.

Project #155: Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes (Frank Goodwin, International Lead and Zinc Research Organization)

Research Objectives: To identify the most promising processes and types of coatings according to performance, cost, environment and health criteria that are either now available or require further development for application to zinc die castings. For available “next generation” systems, performance data and sources will be reported.

Project #157: HI-MAC (Don Penrod; S. Robison, AFS; S. Udvardy, NADCA; other USAMP participants)

Research Objectives: To develop (existing and new) metal casting process technologies and tools required to manufacture cost effective high integrity cast magnesium chassis components and increase production of cast magnesium automotive components requiring geometries and properties not possible with existing high pressure die casting (HPDC) process limitations. Squeeze casting and technology transfer are the NADCA related tasks.

Project 161: Thermal Fatigue Resistance of High Performance Die Steels (D. Schwam, Case Western Reserve University)

Research Objectives: To generate thermal fatigue data and Charpy V-notch impact behavior of advanced die steels. The relationships between thermal fatigue, impact strength and microstructure will be developed as it was for Premium Grade H13.

Project 163: Evaluating Soldering Tendencies of Coatings and New Materials for Core Pin Applications (Qingyou Han, Purdue University)

Research Objectives: To evaluate the soldering performance of die materials and coatings with a previously developed extremely fast test method. The test method utilizes high frequency ultrasonic vibrations and will also be used to determine if the die cavitation mechanism can be replicated.

Project 165: Magnesium Front End R&D (Bob McCune; S. Robison, AFS; S. Udvardy, NADCA; other USAMP participants)

Research Objectives: To develop existing and new metal casting and forming process technologies and tools required to manufacture cost effective high integrity magnesium front end components not possible with existing high pressure die casting (HPDC) process limitations. High vacuum casting and technology transfer are the NADCA related tasks.

Project 168: Die Material Properties at 46-48 HRC (D. Schwam, Case Western Reserve University)

Research Objectives: To generate impact strength and thermal fatigue data for premium and superior grades of H13 heat treated to a higher hardness and compare the data to that of H13 heat treated to the standard recommended hardness range.

Project 169: HyperCAST (S. Udvardy/D. Meyer/A. Monroe, NADCA and other participants)

Research Objectives: 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. Magnesium based composites are the primary focus.

Project 170: Ultrasonic Grain Refinement (Qingyou Han, Purdue University)

Research Objectives: To determine the impact of ultrasonic (UT) vibrations on grain refinement and porosity reduction in die casting and to define a UT process that is adaptable to the die casting process.

Project 171: High Performance Nano-Composite Materials (S. Udvardy/D. Meyer/A. Monroe, NADCA; D. Apelian, WPI; and J. Moore, CSM)

Research Objectives: To develop castable high performance nano-composite materials that can be used for light weighting weapons systems components. Aluminum and magnesium metal matrix and amorphous matrix composites are the focus. Two processing routes, self-propagating high-temperature synthesis and intelligent distributed processing, are to be pursued.

Future Plans
An important aspect of the R&D Strategic Plan and Roadmap is future planning. The technical committees, which are comprised of members from die casting and supplier companies, consultants, academia, and NADCA staff, routinely seek and provide ideas for future research projects that are in alignment with the strategic areas. These ideas are generated in order to continue the technological advancement of the strategic areas and in preparation for future proposals and future funding. The current portfolio of projects, for instance, is the result of future planning and guidance from previous issues of the Strategic Plan and Roadmap. Therefore, the plan truly charts the future course of research efforts for the die casting industry. The results generated from the research efforts, when utilized, will keep the die casters in North America competitive in the world marketplace.

A sampling of the ideas for future projects is shown below. Update from 2011 Overview

• Heat treatable die castings with properties comparable to other processes
• Non-contact real-time monitor & control/IR vision – Sensor fusion
• Carbon footprint: Optimize melting, holding & ladling/SF6/simulation
• On demand melting - shot by shot
• Lightweight hybrid structures-plastic/metal
• Porosity free homogeneous properties
• Lube free die casting
• Application of lean techniques: vertical integration-smelt/melt/pour
• Hot chamber Al
• Die materials for high temp die casting
• Elimination of trim presses
• Thin wall magnesium and aluminum

Additional project ideas are welcome and may be forwarded to research@diecasting.org.

Higher Performance Alloys

• Aluminum alloy development work at the Worcester Polytechnic Institute (WPI) has identified four alloy compositions, two within the standard A380 range and two outside of the standard range, that provide property improvements. Two compositions show higher room temperature tensile and yield strength (and promise of tensile strength in excess of 50 ksi) as well as higher elevated temperature strength and higher quality indexes as compared to A380. Impact and fatigue strength are comparable to A380, while ductility is slightly lower for the higher strength alloys.
• Two zinc alloy compositions, each yielding a several-fold improvement in creep resistance as compared to the standard commercial alloys were developed through work previously conducted at the International Lead and Zinc Research Organization (ILZRO). An extension of this work by Eastern Alloys has now made the creep-resistant alloys commercially available. Although additional characterization is in process, a few companies have started working with one of the alloys known as EZAC.
• Billets of magnesium with TiC particulate have been successfully produced at the Colorado School of Mines (CSM) via the SHS process. Property measurements, SSM casting of the billets and scale-up of billet size are the next steps. Higher strengths and substantially better wear resistance, as compared to conventional magnesium alloys, are anticipated for this SHS metal matrix composite material.

Improved Design Aids and Shortened Lead Times

• A NADCA-conducted project demonstrated the ability to produce die inserts, and subsequently castings, from a solid model developed through reverse engineering of an actual cast component. The methodology, being incorporated in an electronic guidance tool for the industry to use, is important when castings are needed and 3-D models or drawings for older parts don’t exist and/or the supplier is no longer in business. From receipt of an actual part, reverse engineering to produce a model and fabrication of inserts from the model can be accomplished in weeks as opposed to months. Dimensions of the resultant castings were shown to be surprisingly close to the original part.
• The Ohio State University has established a software program to mark-up a part drawing so that certain features can be identified and converted to die casting friendly features. This is a step toward taking time out of the labor-intensive task of converting a part drawing to a casting drawing, thereby shortening the lead time to production. Current capability includes flagging of undercuts, areas needing draft and sharp edges needing radii, which can be accomplished within seconds. In addition, the software allows the user to indicate the die parting direction and the parting-line location.

Improved Process Control and Quality

• One means of ensuring the die casting process is capable of producing acceptable parts is through PQ2 analysis. Mating the die to an appropriate machine and setting process parameters within the process window of the PQ2 diagram provides for a high degree of success. The Ohio State University has developed a method to select optimum parameters utilizing PQ2 analysis.

Longer Lasting Dies

• Much work has been conducted on die materials at Case Western Reserve University (CWRU). The Extending Die Life for Aluminum Die Casting Report (NADCA Item #308) incorporates most of this work. Select results, including several of the newer die steels, have been incorporated in the latest version of the NADCA Special Quality Die Steel and Heat Treatment Acceptance Criteria (Item #229). Newer die steels have been and continue to be tested and characterized through research projects at CWRU. Because characterization has shown that many of the newer steels provide higher impact strength, they are more resistant to gross cracking. And, because they provide higher thermal fatigue resistance, they are more resistant to heat checking and breakout as compared to Premium Grade H13. The bottom line is longer die life can be realized.
• Additional die life can be obtained through the surface-engineered coating architectures developed at CSM. An example architecture consists of a ferritic nitrocaburized die steel surface, coated with a graded CrN layer, followed by an intermediate layer of a CrN/AlN super-lattice structure and topped off with a working layer of Al2O3. These multi-layer coatings are engineered to manage stress within the layers for improved performance and to provide low wetting, high wear resistance working/outer layers. Working with CSM, one commercial coating company has been able to closely replicate the coatings developed in the CSM laboratory. In-plant trails are in process.

Closing
The Research and Development Program is charged with identifying industry needs and developing results that can be implemented on die casting plant floor. It is to this end that the NADCA Research & Development Strategic Plan and Roadmap, which defines the overall goals and direction of the NADCA R&D Program, has been formulated. Since the roadmap aligns specific research efforts to each of the strategic areas, it yields a sound diverse portfolio of projects that is responsive to the industry’s needs and provides opportunity for appropriate technological advancements. The portfolio has remained strong despite the current state of the economy and budget cuts from some funding sources, Progress continues to be made at a good pace and results continue to be generated.

R&D results emanating from the plan deliver many benefits and provide high value to the die casting industry as well as the funding sources.

The benefits include:

• Improved Alloy Performance
• Longer Die Life
• Reduced Scrap
• Enhanced Dimensional Control
• Reduced Down-Time
• Shorter Development & Lead-Times
• Greater Energy Efficiency
• Enhanced Environmental Management
• Higher Productivity
• Lower Operating Costs
• Increased Profitability

Where are the results found? Congress Sessions! Transactions! Die Casting Engineer Magazine! Text books and electronic documents! Educational courses! Conferences! Software packages! The NADCA Web site! Etc.! Hence, the results of research are found in several places. Whether the form the results take on are new standards and procedures, newly revised educational courses, text books, or software programs, they are to be deployed. Taken advantage of some research results today!

Note: You can assist in the research efforts by participating on one of the technical committees or task forces and by participating in plant trials. This is a great way to help steer the direction of projects and get new information first-hand and hot-off-the-press. Interested parties kindly contact the Research & Technology Department at: research@diecasting.org.

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