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

Working with WPI proved critical to this plant in maintaining its competitiveness in the die
casting market by increasing productivity while simultaneously reducing energy consumption.
The facility’s participation in the Case Western’s efforts identified the cause for increased
oxidization in the molten metal, which was a major source for increased porosity in some of their
die castings. Identifying this issue and taking proper corrective measures has decreased the level
of scrap this facility produces.
Not only has the participation and incorporation of the Metal Casting R&D results improved
Aluminum Casting Facility-1’s productivity and reduced its energy consumption, it has also been
a source of needed knowledge. In fact, this facility has relied on the UAB Lost Foam Consortium
and WPI to act much like its own R&D resource. The facility has donated equipment and
provided financial support to cost share Metal Casting R&D. Aluminum Casting Facility-1 has
benefited from this by being a recipient of unbiased research. The facility also views its
participation as an incentive that will attract young engineers.
Finally, Aluminum Casting Facility-1 is a best-practice facility because it proactively seeks ways
to improve its energy efficiency. The plant has an energy management team that is responsible
for identifying potential areas for improvement and designing projects to implement those
improvements. This team also seeks the advice of outside experts that may be able to identify
potential areas for improvement that the team may have overlooked. This was the case when the
facility applied to have an ESA performed through the Save Energy Now initiative. In
combination, these efforts have led to the success and growth experienced by Aluminum Casting
Facility-1.
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