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.
Download ReportTranscript 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 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