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

• Beyond the Metal Casting IOF research funding of $23 million received between 1997 and the
present, EERE has leveraged an additional $19 million on current research and technical
assistance relevant to metal casters. (See page 17)
2002- Highlights and Accomplishments
• The metal casting industry is applying the results of cutting edge IOF research (See pages 21-
24). Examples are listed below.
♦ Steel foundries are making improvements in gating systems, including shrouded
pouring. They are reducing scrap and heat treatment requirements in the production
of their castings.
♦ Research has improved yield by 10-25% through development of new feeding
distance rules for risering and pressurization of risers that reduce shrinkage.
♦ Researchers have developed a mathematical tool that will allow an analytical
approach to systematically design EPS pattern molds that will produce higher quality
patterns with reduced lead-time and expenses.
♦ Researchers have developed cost effective non-incineration techniques that will
significantly reduce VOC emissions from foundries.
♦ Research has led to the development of modifications of die steel chemical
composition and heat processing, resulting in die life improvements of 20-30% and
higher.
♦ Researchers have developed a database explaining the effects of key elements on
the properties of the die cast product, permitting a tailoring of alloy components to
optimize die castings for specific applications.
• Through the CMC, the metal casting industry has updated its long-term vision. The new vision
became the basis for the new technology roadmap that will be made available in late 2003. (See
page 24).
• EERE BestPractices and Industrial Assessment Centers are providing hands-on technical
assistance that metal casters can apply immediately, saving them millions annually (See page
25).
♦ MetLab in Wyndmoor, Pennsylvania, with assistance from BestPractices, has
developed a plan that will produce an annual savings of $528,400. One
recommendation included using proper loading and scheduling, and reevaluating
soak times for heat treating processes for long cycles.
♦ A plant-wide assessment at the AMCAST Wapakonet, Ohio plant identified
recommendations that would result in annual savings of $3.7 million. As
implementation began AMCAST identified other cost savings resulting in an annual
savings, of $6 million.
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