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NADCA Headquarters Update

NADCA Headquarters Update. Presentation for R&D Committee Meeting ORNL, Oak Ridge, TN June 14, 2007. Outline. DOE/CMC Update DOD/AMC Update New Proposed Project Miscellaneous. DOE/CMC Update. DOE 2004, 2005, 2006 Cycle: Energy-SMARRT Program $12M Proposal

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NADCA Headquarters Update

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  1. NADCA Headquarters Update Presentation for R&D Committee Meeting ORNL, Oak Ridge, TN June 14, 2007

  2. Outline • DOE/CMC Update • DOD/AMC Update • New Proposed Project • Miscellaneous

  3. DOE/CMC Update • DOE 2004, 2005, 2006 Cycle: Energy-SMARRT Program • $12M Proposal • Actual Funding: $1.4M Y1, $2.4M Y2, $2.0M Y3, ??? Y4 • DOE Congressional Budget Request FY’07 - $982K Initial Request for Metalcasting now suggested at $1.98M • Continuing Resolution

  4. DOE/CMC Update (Cont.) E-SMARRT FUNDS FOR DIE CASTING PROJECTS NADCA Board Approved another $125K of NADCA Funds to be Added to E-SMARRT for Year 4 as they did for Year 3

  5. DOD/AMC PRO-ACT • AMC Phase IV (CIR) • $10M over 4 years, ~$1.4M for Die Casting • Next Review Oct 24 & 25, 2007 in Chicago • Andy Behler - Industry Board Member • AMC Phase IV Add-on (CIDR) • $200K for Die Casting in Year 1 • Casting Alloy Standards: NADCA/WPI $110K • High Production Rate Tooling: CWRU $90K • Contracts Let, Money Available • Could be Funding Available for Out-years

  6. New Proposed Project: HyperCAST • Objective: Develop materials and processes for high strength, light weight cast components for vehicles that are affordable and offer the potential for 60% weight reduction and related improvement in energy efficiency • Based on CSM Auto-ignition Synthesis Material Development • 4-Year Program, Multi-Million Dollar • CSM, CWRU, OSU, WPI, ORNL, Purdue • Industry Partners – Automotive Related

  7. TAG Activities • Review of Current NADCA Projects • Decision: #146 Die Casting Mechanical Property Improvements Through Process Enhancements • Proposed Projects • New submittals: • #155 Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes • #156 SSM Processing Databases for Designers and Metalcasters • Impact and Thermal Fatigue of the New Grades • A Comparative Study on Bainitic and Martensitic Structures • Optimization of the Tempering Process – Times and Temperatures • Funding Allocation for Existing Projects • Alternate Funding Sources • Foreign Technology

  8. 111th Metalcasting Congress • May 15-18, 2007 (Tue-Fri) in Houston, TX, at Hilton Americas • Total Attendance: 1800+, Exhibits: 200 • NADCA Sessions Tue-Thurs • 7 Regular Sessions, 21 Papers • 4 New Format Sessions • Rough Machining of Dies, Rapid Tooling, Energy, Environmental Issues • Session Average Attendance - 55 • Die Casting Competition • NADCA Awards Luncheon

  9. CastExpo’08 • May 17-20, 2008 (Sat-Tue) in Atlanta, GA, at Georgia World Congress Center • NADCA Sessions Days TBD • Exhibits • Call for Papers, Abstracts due Aug 31, 2007 • Die Casting Competition

  10. 2008 NADCA R&D Strategic Plan and Roadmap • Overview Article Written and to be Published in July 2007 DCE Magazine • Full Version of Plan Completed in June 2007 for Posting on the Web

  11. Guidebook Report Compilations • Turn Research Into Action: 1st Round • Die Materials P • Cast Materials P • Computer Modeling P • Process Technologies P • Die Surface Engineering P • 2nd Round to Start Next Quarter • Latest guidebook reports will be added to the compilations above

  12. Plant Management Conference • September 19-21, 2007 • Hilton Milwaukee City Center • Roundtable Discussions • Special Topics: Defect Tracking, Vacuum, Plant Emissions • Tours: Stroh, EST?, Albany Chicago?

  13. New Products • User’s Guide for Relieving Stresses in Die Casting Dies • Guide to Process Monitoring & Control • Rough Machining of Die Casting Dies • Die Casting Safety

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