NADCA STAFF PROJECTS UPDATE Presentation for R&D Committee Meeting NADCA Headquarters, Wheeling, IL June 14, 2007.

NADCA STAFF PROJECTSUPDATE

Presentation for

R&D Committee MeetingNADCA Headquarters, Wheeling, IL

June 14, 2007

Completed ProjectsCompleted Projects

#106 Design Knowledgebase & Rapid Tooling Techniques

#110 Cost Reduced Magnesium Die Castings Using Heated Runners

#118 Energy and Technology Assessment for Die Casting Plants

#147 Energy and Technology Assessment of Zn and Mg Die Casting Plants

Current ProjectsCurrent Projects

#149 Reverse Engineering Tools & Productivity Improvements for Spare Part Components

#157 HI-MAC

ObjectiveObjective

Problem / opportunity– Drawings for spare parts are

not readily located– 3D solid models don’t exist

precluding use of advanced manufacturing techniques

– Lead times too long– Implementation of

productivity improvement strategies is lacking

Develop an electronic tool that provides methods and guidance for producing tooling/die castings via reverse engineering and strategies for enhanced productivity

Project PlanProject Plan

Reverse Engineering ToolsID and Select Reverse Engineering

Technologies for Evaluation– Point laser – Line laser– White light– X-ray– 2D Interpretation – Digitizing pads

Project PlanProject PlanEvaluate RE Technologies

– Accuracy– Speed– Cost

Demonstrate Most Promising RE Technologies– Produce 3D model – Generate die cast tooling– Cast parts– Compare dimensions of casting to reverse

engineered part or drawing

Project PlanProject Plan

Develop Electronic Guidance Tool for RE Methodology– Brief explanation of technologies– Characteristics– Methodology/instructions for converting to 3D

models– Sources of supply for equipment– Sources of supply for service providers

StatusStatus

Reverse Engineering Tools Received 2 Parts for

Evaluation of RE Technologies from DLA Supply Center through CAST-IT

White Light, Laser and CT Scanning Conducted

Initiated the Design of an Electronic Guidance Tool

Method to be Selected for Insert Production

StatusStatusLine laser

– Scanning and processing : 15 minutes & 10 minutes

White light– Scanning and processing : 20 minutes & 15

minutesCT

– Scanning and processing: 20 minutes & 15 minutes

StatusStatusComments:White light takes additional time compared

to line laser– Need to coat the parts– May need more passes for deep recesses

Sensitivity can be greater for white light when a high resolution camera is used

CT Scanning is best for internal cavities and can differentiate between assembled parts of different densities

Project PlanProject PlanProductivity Improvements for Spare PartsIdentify Latest Die Casting Technologies and

Research Results Related to Productivity– Review past and current research projects– Review literature

Develop Implementation Strategies for each New Technology (Goal – 10)– Brief explanation of the technology or result– Instructions on how to employ/utilize technology – Example benefits and success stories

Project PlanProject Plan

Formulate Into an Electronic Tool for Ease of Deployment– Awareness checklist of technologies/results– Each checklist item linked to implementation

strategy

StatusStatus R&D Project and Literature Review

Completed Supplier Contacts in Process Under Consideration

– Moving cooling lines closer to surface for faster heat removal

– Die spray techniques to ensure maximum cooling

– Articulated spray nozzle for die spray– High thermal diffusivity material in shot block

area

HI-MACHI-MAC (High Integrity Magnesium (High Integrity Magnesium Automotive Components)Automotive Components)

ObjectiveObjective

To develop (existing and new) metal casting To develop (existing and new) metal casting process technologies and tools required to process technologies and tools required to manufacture cost effective high integrity manufacture cost effective high integrity cast magnesium chassis components and cast magnesium chassis components and increase production of cast magnesium increase production of cast magnesium automotive components requiring automotive components requiring geometries and properties not possible with geometries and properties not possible with existing high pressure die casting (HPDC) existing high pressure die casting (HPDC) process limitations.process limitations.

ParticipantsParticipantsFoundries: Foundries: SPX SPX IntermetIntermet Hayes LemmerzHayes LemmerzUniversities: Universities: WPIWPI Georgia Institute of Technology Georgia Institute of Technology University of IowaUniversity of Iowa Mississippi State University Mississippi State University Case Western Case Western University of Windsor University of Windsor National Labs:National Labs: Argonne National LabArgonne National Lab Oak Ridge National LabOak Ridge National Lab Lawrence Livermore National LabLawrence Livermore National LabProfessional Societies: Professional Societies: AFSAFS NADCANADCA

Industrial Partners: Industrial Partners: Advanced Magnesium Advanced Magnesium

TechnologiesTechnologies CANMETCANMET CMI Equipment & EngineeringCMI Equipment & Engineering CMI NovacastCMI Novacast Eck IndustriesEck Industries EKK Inc.EKK Inc. Laempe Core MachinesLaempe Core Machines LightWeight Strategies LLCLightWeight Strategies LLC Magma Foundry TechnologiesMagma Foundry Technologies Manufacturing Services & Manufacturing Services &

Development Inc (Project Development Inc (Project Administrator)Administrator)

Product Development and Product Development and Analysis (LLC) Analysis (LLC)

Task & Budget OverviewTask & Budget Overview Task 1: Squeeze casting process developmentTask 1: Squeeze casting process development Task 2: Low pressure casting process developmentTask 2: Low pressure casting process development Task 3: Thermal treatment of castings including research Task 3: Thermal treatment of castings including research

into stepped heat treatment and fluidized bedsinto stepped heat treatment and fluidized beds Task 4: Microstructure control during casting including Task 4: Microstructure control during casting including

grain refining and property improvementgrain refining and property improvement Task 5: Computer modeling and properties to enable Task 5: Computer modeling and properties to enable

prediction of casting quality and microstructureprediction of casting quality and microstructure Task 6: Development of molten magnesium pump Task 6: Development of molten magnesium pump

materials and technologies materials and technologies Task 7: Investigate emerging casting technologiesTask 7: Investigate emerging casting technologies Total project cost is estimated to be $6.0M consisting of Total project cost is estimated to be $6.0M consisting of

$3.0M cash and $3.0M in-kind. The estimated project time $3.0M cash and $3.0M in-kind. The estimated project time is 48 months. is 48 months.

StatusStatus

Magnesium Squeeze Casting Cell has been Magnesium Squeeze Casting Cell has been Set-up at Contech Set-up at Contech

A Few Shots Made on a Tilt Steering A Few Shots Made on a Tilt Steering Housing with AZ91 to Test the Set-upHousing with AZ91 to Test the Set-up

Control Arm Die Just Arrived for Trial Control Arm Die Just Arrived for Trial CastingCasting