NADCA STAFF PROJECTS UPDATE Presentation for R&D Committee Meeting NADCA Headquarters, Wheeling, IL June 14, 2007 Completed Projects  #106 Design Knowledgebase & Rapid Tooling Techniques  #110 Cost Reduced.

Transcript NADCA STAFF PROJECTS UPDATE Presentation for R&D Committee Meeting NADCA Headquarters, Wheeling, IL June 14, 2007 Completed Projects  #106 Design Knowledgebase & Rapid Tooling Techniques  #110 Cost Reduced.

Slide 1

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 2

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 3

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 4

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 5

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 6

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 7

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 8

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 9

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 10

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 11

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 12

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 13

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 14

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 15

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 16

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 17

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

Slide 18

NADCA STAFF PROJECTS
UPDATE
Presentation for

R&D Committee Meeting
NADCA Headquarters, Wheeling, IL
June 14, 2007

Completed Projects


#106 Design Knowledgebase & Rapid
Tooling Techniques
 #110 Cost Reduced Magnesium Die Castings
Using Heated Runners
 #118 Energy and Technology Assessment for
Die Casting Plants
 #147 Energy and Technology Assessment of
Zn and Mg Die Casting Plants

Current Projects


#149 Reverse Engineering Tools & Productivity
Improvements for Spare Part Components
 #157 HI-MAC

Objective
Develop an electronic tool that provides methods
and guidance for producing tooling/die castings via
reverse engineering and strategies for enhanced
productivity
 Problem / opportunity
– Drawings for spare parts are

not readily located
– 3D solid models don’t exist
precluding use of advanced
manufacturing techniques
– Lead times too long
– Implementation of
productivity improvement
strategies is lacking

Project Plan
Reverse Engineering Tools


ID and Select Reverse Engineering
Technologies for Evaluation
–
–
–
–
–
–

Point laser
Line laser
White light
X-ray
2D Interpretation
Digitizing pads

Project Plan


Evaluate RE Technologies
–

Accuracy
– Speed
– Cost


Demonstrate Most Promising RE
Technologies
–

Produce 3D model
– Generate die cast tooling
– Cast parts
– Compare dimensions of casting to reverse
engineered part or drawing

Project Plan


Develop Electronic Guidance Tool for RE
Methodology
–
–
–
–

–

Brief explanation of technologies
Characteristics
Methodology/instructions for converting to 3D
models
Sources of supply for equipment
Sources of supply for service providers

Status
Reverse Engineering Tools
 Received 2 Parts for
Evaluation of RE
Technologies from DLA
Supply Center through
CAST-IT
 White Light, Laser and CT
Scanning Conducted
 Initiated the Design of an
Electronic Guidance Tool
 Method to be Selected for
Insert Production

Status


Line laser
– Scanning and processing : 15 minutes &
10 minutes
 White light
– Scanning and processing : 20 minutes &
15 minutes
 CT
–

Scanning and processing: 20 minutes &
15 minutes

Status
Comments:
 White light takes additional time compared
to line laser
– Need to coat the parts
– May need more passes for deep recesses



Sensitivity can be greater for white light
when a high resolution camera is used
 CT Scanning is best for internal cavities and
can differentiate between assembled parts of
different densities

Project Plan
Productivity Improvements for Spare Parts
 Identify Latest Die Casting Technologies and
Research Results Related to Productivity
–

Review past and current research projects
– Review literature


Develop Implementation Strategies for each
New Technology (Goal – 10)
–

Brief explanation of the technology or result
– Instructions on how to employ/utilize technology
– Example benefits and success stories

Project Plan


Formulate Into an Electronic Tool for Ease of
Deployment
–

Awareness checklist of technologies/results
– Each checklist item linked to implementation
strategy

Status


R&D Project and Literature Review
Completed
Supplier Contacts in Process
Under Consideration



–
–
–
–

Moving cooling lines closer to surface for
faster heat removal
Die spray techniques to ensure maximum
cooling
Articulated spray nozzle for die spray
High thermal diffusivity material in shot block
area

HI-MAC
(High Integrity Magnesium
Automotive Components)

Objective
To develop (existing and new) metal casting
process technologies and tools required to
manufacture cost effective high integrity
cast magnesium chassis components and
increase production of cast magnesium
automotive components requiring
geometries and properties not possible with
existing high pressure die casting (HPDC)
process limitations.

Participants
Foundries:
 SPX
 Intermet
 Hayes Lemmerz
Universities:
 WPI
 Georgia Institute of Technology
 University of Iowa
 Mississippi State University
 Case Western
 University of Windsor
National Labs:
 Argonne National Lab
 Oak Ridge National Lab
 Lawrence Livermore National Lab
Professional Societies:
 AFS
 NADCA

Industrial Partners:
 Advanced Magnesium
Technologies
 CANMET
 CMI Equipment & Engineering
 CMI Novacast
 Eck Industries
 EKK Inc.
 Laempe Core Machines
 LightWeight Strategies LLC
 Magma Foundry Technologies
 Manufacturing Services &
Development Inc (Project
Administrator)
 Product Development and
Analysis (LLC)

Task & Budget Overview










Task 1: Squeeze casting process development
Task 2: Low pressure casting process development
Task 3: Thermal treatment of castings including research
into stepped heat treatment and fluidized beds
Task 4: Microstructure control during casting including
grain refining and property improvement
Task 5: Computer modeling and properties to enable
prediction of casting quality and microstructure
Task 6: Development of molten magnesium pump
materials and technologies
Task 7: Investigate emerging casting technologies
Total project cost is estimated to be $6.0M consisting of
$3.0M cash and $3.0M in-kind. The estimated project
time is 48 months.

Status


Magnesium Squeeze Casting Cell has been
Set-up at Contech
 A Few Shots Made on a Tilt Steering
Housing with AZ91 to Test the Set-up
 Control Arm Die Just Arrived for Trial
Casting

NADCA STAFF PROJECTS UPDATE Presentation for R&D Committee Meeting NADCA Headquarters, Wheeling, IL June 14, 2007 Completed Projects  #106 Design Knowledgebase & Rapid Tooling Techniques  #110 Cost Reduced.

Transcript NADCA STAFF PROJECTS UPDATE Presentation for R&D Committee Meeting NADCA Headquarters, Wheeling, IL June 14, 2007 Completed Projects  #106 Design Knowledgebase & Rapid Tooling Techniques  #110 Cost Reduced.

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