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NADCA Headquarters Update

NADCA Headquarters Update. Presentation for Die Materials Committee Meeting NADCA Headquarters - Wheeling, IL February 11, 2009. Outline. DOE/CMC Update DOD/AMC Update HyperCAST Status Proposals Seeking NADCA Funds Meetings and Expo Miscellaneous. DOE/CMC Update.

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NADCA Headquarters Update

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  1. NADCA Headquarters Update Presentation for Die Materials Committee Meeting NADCA Headquarters - Wheeling, IL February 11, 2009

  2. Outline • DOE/CMC Update • DOD/AMC Update • HyperCAST Status • Proposals Seeking NADCA Funds • Meetings and Expo • Miscellaneous

  3. DOE/CMC Update • Energy-SMARRT Program • Initiated in FY2004 • Originally $12M Proposal Over 3 Years • Actual Funding: $1.4M Y1, $2.4M Y2, $2.0M Y3, $982K Y4, $194K Y5 • FY2009 Y6 – Continuing Resolution • Anticipate Same Funding Level as for FY2008 • May be Higher After Budget Approval

  4. DOD/AMC PRO-ACT • AMC Phase IV (CIR) • FY’09 Funding Approved ~ $2.2M • Money Runs Out Oct 2010 • Planning 12 Month Extension Request • PI’s: ½ Page on Enhancement to Projects, Technical Benefit Bullets, 1-3 Deliverables - $36K-$80K • AMC Phase IV Add-on (CIDR) • Year 2 Funding $170K-200K for Die Casting • No Year 3 FY’09, ATI Pursuing FY’10 Funds • No-Cost Extension Through Oct 2009 • Next Program Review June 24 & 25, 2009 • Annual Report Completed

  5. DOD/AMC PRO-ACT (Cont) • Benet Labs at Watervliet Program for Light Weight Low Cost Parts • AMC Proposal: Superior Weapons Systems through Castings (SWC) Program • Letter Sent to Picatinny 12/15/08 Requesting that SWC be placed under CIDR • Attempted to get $3M/Yr Up To 3 Years, Currently Looks like $1.2M for Year 1: $200K for Die Casting • Suggested NADCA R&D Needs: • Refinement of Casting Alloys for Improved Properties • High Productivity Tooling & Processes • Nano-Composite Materials

  6. HyperCAST Program Status • Passed Authorization • Sought Appropriations for FY’09 • House Mark is at $1.5M for Year 1 • Senate and House Need to Finalize Budget • IBIS Model for Cost and Weight Analysis Completed

  7. TAG Activities • Most Recent Proposal Approved • #168 Die Material Properties at 46-48 HRC • Proposals Removed From Consideration • #160 A Comparative Study on Bainitic and Martensitic Structures • #166 Auto combustion synthesis-die casting (ACS-DC) of amorphous matrix composite (AMC) materials • Recent/Pending Submittals • 3D Laser Scanning to Measure Die Distortion • Ultrasonic Grain Refinement • Evaluation of Chemical Composition and Processing Parameters on the Mechanical Properties of T5 Heat Treated Die Castings

  8. 113th Metalcasting Congress • April 7-10, 2009 (Tues-Fri) in Las Vegas, NV • Papers Reviewed and Selected • 11 NADCA Congress Sessions (Tues-Thurs) • 8 Regular Sessions • 3 Special Format Sessions • Plunger Lubricants • Die Maintenance & Repair • Die Spray • PowerPoint Presentations Due 3/13/09 • Exhibit Floor (Wed, Thurs) • Combined Awards Luncheon (Tues)

  9. Guidebook Report CompilationsTurn Research Into Action • 1st Round • Die Materials P • Cast Materials P • Computer Modeling P • Process Technologies P • Die Surface Engineering P • 2nd Round • Computer Modeling II P • Cast Materials II P • Process Technologies II P • Die Materials II P (Ready for print)

  10. Worldwide Reports • Process Technology (Done) • Die Materials Technology (Done) • Dimensional Report (Done) • Computer Modeling (Done) • Cast Materials (Zn Done, Al Next)

  11. What’s New • New Employee - Alex Monroe • Dust Safety Course • Product Standards • High Integrity Al • Product Design Book • Design Website • http://www.diecastingdesign.org/ • Carbon Footprint Report

  12. Joint Planning Session • Held October 15, 2008 • R&D and Die Materials Committee Members • Brainstorming of Project Ideas/Industry Needs • Input to be Used to Formulate a New Large Program • 48 Ideas Generated and Prioritized • Subsequent Input Provided for Grouping of Ideas

  13. Joint Planning Session Cont. Potential Broad Topics to Encompass Several Ideas/Tasks • Advanced Cast Materials Development • Smart Die Cast Manufacturing • Advanced Processes and Process Improvement • Machine Innovations • Advanced Die Materials • Virtual National Die Casting Center

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