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

into production resulted from the modeling efforts carried out by WPI as part of their work with
Metal Casting R&D. Furthermore, with the knowledge gained from WPI on SSM, Aluminum
Casting Facility-1 purchased an AEMP SOD technology from GMAC and currently
manufactures a swivel bracket using the process. Another benefit this facility received from
participating in the WPI efforts was that its development engineer for SSM activities was a WPI
graduate with training in SSM technologies. In the words of a senior research director at this
facility, “Thus, it is easy to say that if we had not been introduced to the SSM process at WPI,
and further, if we had not been extensively helped by modeling and fundamental research done at
WPI, and if WPI did not train our key SSM development engineer, this facility would not be in
SOD SSM die casting process, and our future in the die casting industry would not be as
promising. WPI is the Bell Labs of the casting industry!”
Additionally, the research partnership between WPI and Aluminum Casting Facility-1 has
enabled the facility to form a 35-pound slurry of 50% solid-50% liquid in 17 seconds. This slurry
can be transferred to the shot chamber of a HPDC machine to produce a 50-hp block. This block
can be manufactured with a 35% decrease in cycle time using SOD SSM process as compared to
the HPDC process, the manufacturing process used for the preceding five years. The SOD SSM
die casting process can also make the 35-pound block at lower manufacturing costs when
compared to the HPDC process that uses 100% liquid alloy. In the new process, less heat needs
to be removed, which translates into shorter cycle time and lower manufacturing costs, according
to the facility management.
Due to the experience this facility has had with the SOD SSM die casting process, its
management views this development as providing a clear competitive advantage. According to
the plant management, U.S. die casters will have to use SOD in their die casting machines to
remain competitive in the world market. With the increase in productivity and the energy savings
achieved because of reduced energy requirements, SOD SSM die casting has proven to save this
facility money. Using this process has increased die life by five times as compared to the
traditional HPDC process due to the lower heat value of the billet. Aluminum Casting Facility-1
attributes much of this success to working with WPI in support of their efforts with CMC and
ITP.
Melting
Aluminum Casting Facility-1 recently benefited from participating in a research program,
Improvements in Efficiency of Melting for Die Casting, performed by a team from Case Western
Reserve University with funding from the ITP Metal Casting portfolio. This research program
examined multiple aspects of aluminum melting and handling to see how the energy efficiency
of these operations increased while simultaneously improving the quality of the molten metal. As
part of this effort, Aluminum Casting Facility-1 allowed the team from Case Western Reserve
University to come into its plant and examine their melting and molten metal handling operations.
During their site visit, the research team conducted energy efficiency surveys of the melting,
holding, and molten metal handling equipment used in the die casting operation. The team also
trained the plant personnel in how to monitor energy use and identify potential improvements.
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