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Metalcasting Concepts

Metalcasting Concepts. 8:00 Welcome 8:15 Program Overview 8:40 Casting Overview 9:50 Break 10:00 Casting Acquisition 10:20 Casting Quality 10:40 Rapid Prototyping 10:50 Break 11:00 Post-processing 11:10 Casting TDP 11:20 Casting Design 11:50 Reverse Engineering 12:00 Lunch.

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Metalcasting Concepts

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  1. Metalcasting Concepts

  2. 8:00 Welcome 8:15 Program Overview 8:40 Casting Overview 9:50 Break 10:00 Casting Acquisition 10:20 Casting Quality 10:40 Rapid Prototyping 10:50 Break 11:00 Post-processing 11:10 Casting TDP 11:20 Casting Design 11:50 Reverse Engineering 12:00 Lunch 1:00 Sand Casting 1:15 Investment Casting 1:25 Die Casting 2:00 Break 2:10 Alloy Overview 2:40 Aluminum Alloys 3:00 Break 3:10 Magnesium Alloys 3:20 Steel Alloys 3:35 Titanium Alloys 3:50 Q&A 4:00 Adjourn Agenda

  3. Tomorrow’s Agenda Foundry Tour – American Foundry Group Bixby, OK • Aluminum and steel sand foundry • Mainly automotive production • Machining, heat treat, NDT, tooling, welding • Bus departure 7:30 am from the flagpole • Return 3:30 pm

  4. Program Overview Joe Napier

  5. Overview • Castings (and forgings) are essential to all weapon systems. • Design freedom = complex shapes = lightweighting • Alloy selection • Isotropic material properties • High production, low cost

  6. AFS – April 26-28, 2011– Cost Effective Casting Design

  7. Weapons Systems Sustainment Why is this important to DLA?

  8. Weapons Systems Sustainment USAF Weapon Systems F22 Raptor 2005 V22 Osprey 2007

  9. Weapons Systems Sustainment USAF Weapon Systems B2 Spirit 1997 C17 Globemaster 1993 E8 JSTARS 1991

  10. Weapons Systems Sustainment USAF Weapon Systems B1 Lancer 1986 KC10 Extender 1981

  11. C5 Galaxy 1970 Weapons Systems Sustainment USAF Weapon Systems F15 Eagle 1976 E3 Sentry 1977 F16 Falcon 1978 A10 Thunderbolt 1977

  12. T38 Talon 1961 B52 Stratofortress 1962 Weapons Systems Sustainment USAF Weapon Systems

  13. Weapons Systems Sustainment USAF Weapon Systems KC135 Stratotanker 1957 U2 Dragon Lady 1957 C130 Hercules 1957

  14. Weapons Systems Sustainment Necessary hard tooling and fixtures are lost or captive at OEM’s Discontinued and fragmented supply chains Diminishing domestic supply base Obsolete and insufficient technical data (specs, materials) Prescribed process not suitable for sustainment environment Limited casting expertise at DoD / DLA

  15. Weapons Systems Sustainment Castings and forgings represent about 4% of DLA solicitations but 20% of backorders over 180 days.

  16. Weapons Systems Sustainment

  17. Process Application NNS = tolerance, geometric freedom, complexity Performance = strength, integrity

  18. American Metalcasting Consortium (AMC) http://amc.ati.org • Castings for Improved Readiness • DLA ManTech sponsored program with industry cost share • Consortium of four trade associations representing 85% of metalcasting capacity • Integration lead and prime contractor – ATI • Seven universities developing new manufacturing capability • CAST-IT engineering support services for casting design and procurement NO COST!

  19. CAST-IT Engineering Team • Metalcasting consultants totaling 200+ years of casting experience • TDP review • 339 assistance • Access to capable foundries and post-process suppliers • Cast-conversions • Technical assistance to foundries • Proliferate advanced technology within the industry Dick Farrara Albany, NY Jack Church Minneapolis, MN Keith Sturgill Richmond, VA Dave Poweleit Chicago, IL Joe Napier Charleston, SC Gary Burrow Billings, MT Don Joseph Charleston, SC

  20. Website Reference Information • www.dscr.dla.mil/ExternalWeb/UserWeb/aviationengineering/SupplyChainAssistance.asp • NSN casting support • www.amc.ati.org • Technology Reviews, R&D projects • www.sfsa.org • Sources, specifications, tutorials • www.afsinc.org • Sources, literature, CMI classes • www.nffs.org • Sources, tooling and source databases • www.diecasting.org • Sources, die casting design Get involved!

  21. Casting Tools Database www.defensetooling.com • Currently 26,000+ pattern records – 128 foundries • Access restricted to government personnel • By listing patterns, foundries receive e-mail notification each time the government is buying those parts Contact: Ryan Moore Non-Ferrous Founders’ Society (847) 299-0950 ryanm@nffs.org

  22. Casting Suppliers Database www.defensecastingsuppliers.com • Online directory of metalcasters serving the defense industry – 290 foundries • Accessible to government and defense contractors • Receive only open solicitationsthat match your plant capabilities Contact: Ryan Moore Non-Ferrous Founders’ Society (847) 299-0950 ryanm@nffs.org

  23. AMC R&D Premium die casting alloy Modular tooling development Part performance with discontinuities Digital radiography standards Metal mold process improvement Stainless steel weld corrosion resistance Metal matrix composite process Technology transfer

  24. Casting Assistance Cases • F-5 Crossbleed Valve • Worked with foundry to resolve quality problem • Recommended gating change and modification to drawing • A-10 Drain Pylon • Provided casting redesign to reduce maintenance time • Estimated manufacturing cost

  25. Acknowledgement AMC’s Castings for Improved Readiness program is sponsored by the Defense Supply Center Philadelphia, Philadelphia, PA and Defense Logistics Agency, Ft. Belvoir, VA

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