ITP Metal Casting: 2002 Metal Casting Industry of the Future ...

elements on the properties of the die cast product. This permits a tailoring of alloy compositions to
optimize die castings for specific applications. Die casters have utilized the information to improve heat
sinks by enhancing the thermal capability of an alloy and to increase the strength of an alloy. The
increased strength led to reduced section thickness and 7% less alloy needed per casting. For more
information about the publication, please visit http://www.diecasting.org/.
• RSP Tooling – The Rapid Solidification Process (RSP TM ) was developed at the Idaho National
Engineering and Environmental Laboratory under grants from DOE. This process is designed to allow die
casters to build production tooling in the time it usually takes to make prototype
tooling. The RSP TM Tooling process makes high quality production tooling from
virtually any existing tooling metal, for any tooling process. The technique
eliminates the need for any CNC milling, sink EDM, benching, polishing,
engraving and heat treatment. An early application of the technology was the
production of low-carbon steel strip, the industry’s highest volume commodity. A
major advantage of using the RSP TM for producing strip is the significant
reduction in energy use. Producing the strip directly from the molten metal with
accuracy would eliminate the need for hot rolling unit operations, saving time, As-deposited H13 tool steel
money, and energy. The invention received an R&D 100 Award in 1998 and the die for die casting
Federal Laboratory Consortium Award in 2001. In 2002, RSP TM applications.
Tooling, LLC
was formed to design, build, use, and sell machines that manufacture tooling using this process. To learn
more, please visit http://www.oit.doe.gov/metalcast/factsheets/csu_rsp_tooling.pdf.
Exhibit 20
Commercial and Emerging Successes from Metal Casting Research
Commercial Technologies
Emerging Technologies
• Computational fluid dynamics lost foam
casting
• Foundry sand density guidelines for surface
finish in aluminum casting
• Tensile properties database for preliminary
design of metal matrix composites
• Guidelines for critical process variables in
molding accuracy (TWIG) where developed
• Low Cycle fatigue database for 22 cast iron
grades
• Guidelines for gating molds with and without
filters
• Demonstrate increase in beneficial reuse of
foundry byproducts
• Deployment of RSP Tooling Technology
• Squeeze casting techniques more widely
deployed
• Radiographic standards developed
In 2002, the Metal Casting IOF reviewed its portfolio to identify those technologies that are having
commercial success or are emerging as a potential commercial success. IOF “commercial”
technologies are those technologies currently being used in the commercial industry as a result of
program funding. Emerging technologies are those technologies that have achieved laboratory or
in-plant success and are ready to be deployed commercially. Exhibit 20 lists both commercial and
emerging successes from the Metal Casting IOF research.
Partnership Highlights
• A New Vision for the Future - In July of 2002, the Cast Metals Coalition (CMC) published its
new vision, A Vision for the U.S. Metal Casting Industry 2002 and Beyond. A new vision was
created to build upon the past lessons and accomplishments of the program and maintian a
dynamic vision. Achieving the goals set forth in the vision will contribute to improved
productivity and energy efficiency in the industry, and quicken the development and application
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