Overview

The 2008 NADCA R&D Strategic Plan guides the NADCA R&D Program by defining the strategic areas targeted for technological advancement to which research efforts are applied. The Roadmap aligns specific projects with the strategic areas to ensure that the research efforts are in support of the Strategic Plan.

The areas identified by industry as strategic are shown in Figure 1. Although research efforts are applied in all five of the major strategic areas (Products & Markets, Manufac­turing Technology, Materials Technology, Energy & Environmental and Industry Health & Profitability), the bulk of the research efforts are currently focused on Manufacturing Technology and Materials Technology. The current list of research projects is shown in Table 1, which shows the alignment of the projects, taking into account the primary and secondary foci of the projects, to the major strategic areas. Figure 1a shows the projects grouped by second tier strategic areas of the projects’ primary focus (or general topic) for ease of reference.

Figure 1: Organization of Strategic Areas

Figure 1a: Second Tier Strategic Areas

The total leveraged value (direct funding plus cost share) of the 18-project portfolio is approximately $15,000,000. Funding is provided by the U.S. Department of Defense (DOD) through the Defense Logistics Agency (DLA) and the American Metalcasting Consortium (AMC) and the U.S. Department of Energy (DOE) through the Industrial Technologies Program (ITP), the Cast Metals Coalition (CMC) and the U.S. Council for Automotive Research (USCAR)/U.S. Automotive Materials Partnership (USAMP) Program. Additional funds are provided from NADCA’s own R&D funds. Table 1 shows the funding source(s) for each project.

Technology Transfer

Research results and technical information from the R&D Program are transferred to the industry in several different ways: Die Casting Engineer, text books and electronic documents, educational courses, conferences, software packages, the NADCA website and congress sessions, including the 111^th Metalcasting Congress in Houston, TX, on May 15-17, 2007. Of the papers presented, nine were related to NADCA sponsored research projects, including:

• T07-012: Development of Zinc Die Casting Alloys with Improved Fluidity — Progress in Thin Section Zinc Die Casting Technology

• T07-041: An Accelerated Method for Testing Soldering Tendency of Coated Pins

• T07-043: Review of Reverse Engineering Technologies and Techniques

• T07-052: Optimization of a Graded Multi-layer Die Coating System for use in Al Pressure Die Casting (Selected as the Best Congress Paper for 2007)

• T07-053: Factors that Affect Die Casting Die Life

• T07-061: Rapid Tooling Keynote Address

• T07-072: Heat Losses in Aluminum Holding Furnaces and Transfer Ladles

• T07-101: Finite Element Modeling of Casting Distortion in Die Casting

• T07-112: An Experimental Verification of the Effect of Die Location on Tie Bar Load Imbalance

In addition, over the past year, five Turn Research into Action brochures were compiled and distributed to NADCA corporate members. These special compilations contain project summaries, implementation strategies and case studies from completed research projects in the areas of Cast Materials, Die Materials, Die Coating and Surface Treatments, Computer Modeling and Process Technologies.

Keys to the Future

Technological advancement of the strategic areas is intended to enhance efficiencies in various aspects of the die casting process, including lead-time reduction or faster time to market, productivity improvement, scrap reduction, cost reduction and energy efficiency. Attacking and improving these vitally important aspects will assist in keeping the die casters in North America not only competitive, but the best in the world — die casters that truly embrace and exude the virtues of innovation, integrity, accessibility and reliability.

Several ideas for future projects have been identified by the technical committees and industry participants:

• Cast Material

  • Alloys that facilitate higher productivity.
  • The influence of metal quality on cast part quality.

  • Optimization of magnesium alloys for high pressure die casting.

  • Development of mechanical properties for design, especially finite element design.

• Process Technologies

  • Optimization of the die cast machine cycle time, including die spray and dwell time.

  • Development of relationship between spray lubricant, application technique and surface defects.

  • The effect of die temperature control on quality and dimensional capability.

  • Friction stir welding of castings — eliminate bolted joints.

• Product/Process/Tooling/Design Integration

  • The effects of high intensification.

  • Simulation for defining conditions required to pro­duce high quality surface finishes.

  • Modeling to predict castability of different alloys.

  • Fast and easy-to-use thermal modeling to predict best water/hot oil, spray and cycle time conditions to provide quick solutions for getting faster cycle rates.

• Die Material

  • Improved die designs for improved die life.

  • Dies for improved yield and production rates.

  • Verification of rapid tooling techniques.

  • Methods for improving cycle time through conformal cooling and/or copper cladding of die steel.

Ideas from Industry

We know you’re out there. Are you using what we have? We hope so!

We also know you may have some suggestions for other projects that would provide a benefit to your plant or assist in resolving a technical issue at your plant. If so, this is an op­portunity for you to make suggestions for projects which can be either short term (6-18 months) or long term (2-4 years). Kindly forward suggestions to research@diecasting.org.

Current Research Projects

Interested in knowing a bit about the current projects? If so, the following provides the title of each project and its key accomplishment(s) thus far.

• Project #131: Evaluation of Die Components Made from the Direct Metal Deposition Process (Nao Tsumagari, formerly of Briggs & Stratton)

Key Accomplishment: Specimens of wrought copper coated with H13 via the DMD process have been successfully prepared and tested for thermal fatigue resistance. The test yielded favorable results.

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

Key Accomplishment: The contributions of intensifica­tion pressure and die position on tie bar loading and distortion of the system components have been sorted out. This allows for adjustment of the machine and derating of the machine, if desirable.

Figure 2 – Computer models of an ejector side die half showing the maximum separation and separation plots for four-die support schemes. The impact of die support on deflection can been seen.

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

Key Accomplishment: The computer code for analyses such as flow, fill and thermal by qualitative reasoning has been extended from high-pressure die casting to squeeze casting and other slower fill processes.

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

Key Accomplishments: The architecture and process­ing parameters have been defined for two optimized multi-layer coating systems for improved perfor­mance. A smart coating has been developed and is currently undergoing evaluation. The coating is multi-layer, containing a piezoelectric film which provides an electrical response when stressed and is intended to provide an indication of when reme­dial measures for dies should be taken. Electrical responses are being measured on samples.

Figure 3 – Schematic showing the architecture of a “Smart” coating system which contains a piezoelectric film.

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

Key Accomplishment: The effect that cooling of dies has, especially by die spray lubricant, on die life has been highlighted through this work.

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

Key Accomplishments: Various melting and holding furnaces have been benchmarked for energy effi­ciency. Guidelines for the selection, operation and maintenance of melting and holding furnaces have been developed.

Figure 4 – Thermal fatigue curves showing the effect of die lubricant spraying pressure on die cracking behavior. Higher spraying pressures can overcome the vapor blanket at higher temperatures, increasing the cooling and the temperature. With extremes, however, more cracking can be expected.

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

Key Accomplishments: A simplified continuous rheocasting reactor design has been developed for ease of use on a standard high-pressure die casting machine and demonstrated in plant trials. Preferred chemical constituencies of alloys for SSM process robustness and optimized heat treatment parameters have been established.

Figure 5 – Photograph of a simplified CRP Reactor for SSM processing and a resultant excellent SSM microstructure from a casting produced with the reactor.

• Project #138: The Use of Laser Engineered Net Shaping for Rapid Manufacturing of Dies (J. Brevick, The Ohio State University and J. DuPont, Lehigh University)

Key Accomplishment: A method has been developed for producing material with a copper core and an H13 working layer, providing excellent adhesion between the copper and H13. This provides an opportunity for faster cooling via conformal cooling lines and the higher conductivity of copper.

• 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 will be taken into consideration.

Figure 6 – Cast stepped flow specimens comparing the flow distance of the new high fluidity zinc alloy to Alloy 7.

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

Key Accomplishments: 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.

• Project #146: Die Casting Mechanical Property Improvements through Process Enhancements (Gary Ward, General Motors Powertrain)

Key Accomplishment: This project has been approved but has yet to start. The research objective for this project is 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.

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

Key Accomplishments: Seven productivity improvement technologies have been identified and are being formulated into implementation strategies. Also, two reverse engineering methods (laser and white light) have been assessed.

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

Key Accomplishment: A means of exporting spline representations for gates and runners from the geometric reasoning tool has been developed which allows for uses in other programs, such as CAD, to assist with yield improvement.

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

Key Accomplishment: Lower cycle times have been demonstrated with tungsten-based cores and cores produced from laser deposited H13 on a copper substrate.

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

Key Accomplishments: Reaction systems for aluminum matrix/titanium intermetallic composites have been defined. Cylindrical samples of material up to 3˝ in diameter with up to 47% particulate have been produced for mechanical and physical property analysis.

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

Key Accomplishments: 38 alloy compositions have been produced and assessed. After optimization efforts, nine compositions have been selected for further study.

• Project #154: Development of a Porosity Guideline for Die Casting (J. Brevick, Ohio State University)

Key Accomplishment: A literature survey has been conducted and information collected on the influence of the casting design and process on porosity.

• Project #157: HI-MAC (Bruce Cox, Chrysler; S. Robison, AFS; S. Udvardy and J. Wilkey, NADCA; other USAMP participants)

Key Accomplishments: A magnesium squeeze casting cell has been set up at Contech, and a few shots have been made on a tilt steering housing with AZ91 to test the set-up.

• Project #158: Casting Alloy Standards (S. Udvardy, NADCA and D. Apelian, WPI)

Key Accomplishment: This project has recently started, and its research objective is to establish properties for two premium-grade aluminum die casting alloys — specifically targeted are impact and fatigue properties.

• Project #159: High Production Rate Tooling (J. Wallace and D. Schwam, Case Western Reserve University)

Key Accomplishment: This project was recently started, and its research objective is to evaluate advanced cooling techniques for die casting dies in order to reduce cycle time and to generate revised guidelines for cooling line placement.