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

work yielded a 0.85% reduction in scrap due to porosity and leak (folds) defects for the in-line 6cylinder
blocks it produces. Savings from this scrap reduction were calculated as follows:
Number of block castings produced per day = 1,750
Number of block castings produced/year = 1,750 blocks/day x 220 days/year
= 385,000 block castings/year
Scrap quantity reduced per year for 0.85% scrap reduction = 385,000 x 0.0085
= 3,272 block castings
Energy Consumption 56
(Btu per pound of aluminum)
Electricity 3,810
Natural gas 6,354
Steam 1,343
Compressed Air 1,224
Delivered Molten Aluminum 3,100
Total energy consumed 15,831 Btu/lb of aluminum
Energy savings/yr from 0.85% reduction in scrap = 3,272 block castings x 130 lbs/casting x
15,831 Btu/lb = 6.73 x 10 9 Btu
Therefore, total yearly energy savings from 0.85% scrap reduction in block casting production
is 6.73 x 10 9 Btu.
As demonstrated by these two calculations, the results of research performed at the Lost Foam
Research Center at the University of Alabama – Birmingham are significant. Participating in the
research has enabled the facility to incorporate cutting-edge developments directly into its
operations. Lost Foam Foundry-1, therefore, has benefited substantially from this Metal Casting
R&D, as shown by its energy-savings calculations, and this benefit will only improve with rising
prices for natural gas and electricity.
Source of a Workforce
By participating in Metal Casting R&D efforts, such as the Lost Foam Consortium, Lost Foam
Foundry-1 not only has benefited in terms of energy and financial savings but also in that it has
gained a young, qualified workforce. Over the years, both the facility and its parent company had
trouble in attracting young graduates to work in the foundry. However, the foundry manager and
R&D director explained that more recently they hired a number of engineering students (both in
undergraduate and advanced degree programs) who have participated in the ITP Metal Castingfunded
research. This facility’s management views the student participation in research efforts as
a critical component in encouraging the students to join the metal casting industry. They believe
that the involvement of students in these R&D projects provides the foundation for a well-trained
and highly educated engineering work force for foundries.
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