Implementation of Metal Casting Best Practices - EERE - U.S. ...

weight per unit of yield strength. European automakers have made significant progress in the
replacement of aluminum castings with iron castings. However, for cast iron to regain the lost
market from aluminum, it must be better engineered to achieve its full potential. Currently, iron
castings cannot be routinely produced in sand molds with thickness less than 3 mm. With support
from Metal Casting R&D, researchers from the University of Alabama began to develop the
technology for producing commercial iron castings with mold wall thickness less than 3 mm.
The project investigated both the metallurgical treatment required for molten iron and the mold
and core-making techniques needed to reach the project goals.
Iron Foundry-1 participated in this research by running a number of casting trials at its facility,
hoping to obtain technical knowledge ahead of its competitors and have an advantage of being
able to produce the thin-wall castings. However, after the project was completed, Iron Foundry-1
found that the major factor affecting thin-wall mold design is that the mechanical engineering
design software does not utilize the “tensile strength versus section thickness” parameter for gray
iron. Instead, the design engineer enters a plugged figure (e.g., 30,000 psi) for the tensile input
and the finite element analysis software only has that parameter with which to work and does not
use the other much higher values for thinner sections. Although a new product line did not come
out of this research for Iron Foundry-1, the plant personnel now have a good knowledge base and
identified additional hurdles that need to be addressed. This can only help them improve as time
progresses.
Modeling
Iron Foundry-1 actively models all new castings it produces using the AFS Solidcast and Flow
Modeling/Noveacast software tools. Although the DOE-sponsored projects were not intended to
create new software, the results of these individual projects nevertheless were incorporated into
various commercial software applications such as AFS Solidcast and Flow Modeling/Noveacast.
These applications enable the facility to conduct solidification and fluid flow simulations in
order to determine the proper rigging system for the casting. Iron Foundry-1 personnel indicated
that the implementation of these modeling tools has saved them both time and money by
improving casting yield, lowering scrap, and avoiding costly trial and error test pours. The
facility can get the design right the first time. During the site visit, the assessment team received
good testimonials relating to the benefits derived from the modeling tools, yet the plant
personnel were unable to quantify the level of improvement that modeling has had on their
production, energy use, and bottom line.
2. Areas for Improvement
Iron Foundry-1 was determined to be a well-organized, well-engineered plant that produces
high-quality products. The facility has been proactive and seeks ways to gain a technological
competitive advantage by participating in a number of research programs funded by Metal
Casting R&D. However, the assessment team identified certain operational aspects that the
foundry could improve upon to manufacture its products more efficiently and of better quality.
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