Process Technologies

Current Projects:

179	Lube Free Die Casting
192	Methods for Evaluation of Die Lubricants Used in Al Die Casting
193	Evaluation of Pulsed Spray
197	Roadmapping for the Metalcasting Industry
201	Purdue Die Spray Study
205	On-Demand Melting
206	Structural Aluminum Casting Riveting Investigation
209	Splash Test
210	Develop a Better Performance Refractory for Aluminum Die Casters
212	On Demand Casting of Net-Shape Titanium
215	High Pressure Die Casting Process Simulation Development for the Shop Floor
216	Solder is a Symptom of Die Casting Sticking
217	An Initial Evaluation of the Capabilities of CT Scanning
218	High Ductility Die Castings – Part II

Accomplishments of Previous Projects:

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.

Elevenproductivity 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!