Department of Energy Program A Customer Perspective

1
Department of Energy ProgramA Customer
Perspective

• Presentation for Metal Casting Technology Forum,
  May 18, 2004
• Rock Island Arsenal, Illinois
• By
• Dr Raymond J. Donahue, FASM
• Sr Director Advanced Materials Foundry
  Technology
• MERCURY MARINE
• And
• Original member of DOE INDUSTRIAL ADVISORY BOARD
  (created by public law 101) currently member of
  DOE INDUSTRIAL OVERSIGHT PANEL

2
Most Significant PartnershipDepartment of Energy
Cast Metal Coalition (AFS, NADCA SFSA)

• As a result casting industry has identified
• COMMON CHALLENGES
• COMMON GOALS,
• PRE-COMPETITIVE RESEARCH NEEDS
• To make the casting industry more competitive
  against other technologies

3
The Vision outlining these goals

• Market development
• Materials technology
• Manufacturing technology
• Environmental technologies
• Human resources, education training
• Profitability industry health
• Partnerships collaboration

4
The Roadmap

• Outlines the research pathways necessary to
  achieve those goals
• The cost-shared research, outlined in the
  roadmap, is characterized by
• Open competitive solicitations
• Broad industry participation outreach
• Extensive involvement of university-based centers

5
After the vision, the roadmap, implementation
is logical

• Completed roadmaps catalyze collaborative
  partnerships.
• These partnerships can investigate promising
  technologies too costly for individual firms to
  undertake.
• Note casting industry reviews updates their
  visions roadmaps periodically to reflect new
  trends developments.

6
Metal Casting Industry Overview

• The future holds great potential for the
  industry, because of the 50 million DOE
  investment, since 1990, in 50/50 cost-share
  programs with the casting industry.
• To remain competitive to sustain a viable
  domestic industry, significant challenges must be
  overcome.
• Design, process and material improvements are
  needed for the industry to realize its potential.

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Energy Use in Metal Casting

• 55 of energy costs are in melting.
• Moldmaking, 12 Coremaking, 8 account for 20
  combined.
• Heat Treatment 6.
• Post Cast 7
• Other 12
• Thus, energy costs can be 10-15 of total
  material costs.

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Market Overview

• There are 2950 foundries located in U.S.
  employing 225,000 people.
• 75 of all U.S. casting shipments came from 7
  states Ohio, Indiana, Wisconsin, Alabama,
  Michigan, Pennsylvania Illinois.
• 80 of foundries employ less than 100 people.
• U.S. leads? in shipments with 21 share.
• Other majors include China, India, Mexico Italy

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Tonnage (not value) supply market

• Gray iron 40
• Ductile iron 32
• Aluminum 14
• Steel 7
• Copper 2
• Zinc 1.5
• Other 3.5

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End-Use Markets

• 35 automotive light truck
• 23 other
• 15 pipe fittings
• 5 internal combustion engines
• 5 valves
• 5 railroad
• 3 farm equipment
• 3 municipal castings

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A 2020 Vision For Metal Casting

• U.S. casters will be benchmark for quality
• Industry will employ advanced manufacturing
  technologies processes
• Advanced design manufacturing technologies will
  enable real-time innovation.
• New exotic materials will exist.
• Greater energy self sufficiency will exist.
• New transportation methods will open new markets
• Information technology will increase integration
  between supplier, manufacturer customer.
• Castings may be designed for 100 recoverability

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2020 vision will require progress in four key
areas

• Communicating the essential value of the metal
  industry to the U.S.
• Designing castings for new markets applications
  while maintaining current markets.
• Improving metal casting processes by eliminating
  waste, reducing the cost of production,
  improving product performance.
• Attracting employees students to the metal
  casting industry.

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Communicate the value of metal castings vision
for 2020

• The U.S. casting industry will be recognized as a
  supplier of high quality, precision engineered
  components.
• Castings will be recognized by designers
  customers as the component of choice for their
  manufactured goods.
• Society, government decision makers others will
  equate engineered cast components with quality
  performance.
• They will recognize the importance of healthy
  competitive domestic metal casting industry.
• The industry will be recognized as green clean.
• The industry will continue to be a major recycler
  of materials that would otherwise be landfilled.
• The industry will be a tier one supplier of cast
  metal components
• Broad recognition of the value of cast metal
  components will contribute to the profitability
  competitiveness of the industry.

14
Design castings for new markets 2020 vision

• The quality performance of cast parts will be
  assured in the design stage. Accurate design will
  validate product performance.
• The industry will design castings that reduce
  time-to-part improve manufacturing efficiency
  cost competitiveness.
• Design technologies will enable real-time design
  innovations in both design manufacturing
  stages.
• Enhanced casting design will save energy reduce
  emissions.
• This will open new market to supply high
  performance components.
• Design capabilities will enable castings to
  capture a greater share of total components
  designed.
• Interesting advanced design methods will
  attract a new generation of employees to the
  field of metal casting.

15
Improve metal casting processes 2020 vision

• Metal casting processes will be clean efficient
  with significantly less waste generated.
• Advanced manufacturing technologies process
  improvements will reduce the energy labor
  content of each casting.
• Improved data on materials properties,
  performance will enable high quality castings
  increased yield while opening new markets for
  cast components.
• Improved knowledge control over each step in
  the casting process will improve efficiency,
  reduce scrap, increase output reduce production
  costs.
• The industry will produce deliver high quality,
  high performance castings consistently, cost
  effectively on schedule.
• The industry will have process-related fewer air,
  water solid waste emissions.
• Metal caster may even achieve tool less
  manufacturing.

16
Attract new work force students 2020 vision

• By 2020, the metal casting industry will be home
  to best brightest work force.
• The industry will use innovative strategies to
  attract retain its future workforce.
• Ever worker will be a well-trained, skilled
  technologist employing the latest techniques to
  create high quality metal castings.
• It will be recognized by educators students at
  the K-12, college, and graduate level as a source
  of well-paying, exciting stable careers.
• In 2020, the U.S. metal casting workforce will be
  the most technically competent competitive in
  the world.

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Biography of Raymond J. Donahue

• Received B.S. PhD in metallurgical engineering
  from Illinois Institute of Technology, Chicago,
  Illinois
• Currently Sr. Director of Advanced Materials
  Foundry Technology
• Prior to Mercury, professor of metallurgy at
  University of Connecticut, Storrs, Conn
• Current member Department of Energy, Industrial
  Oversight Panel, and prior to this entity, was an
  original member of the Department of Energy,
  Industrial Advisory Board, created by pubic law
  101
• Past chairman AFS Research Board
• Past chairman WPI Advanced Casting Research
  Consortium
• Member board of directors WPI Metal Processing
  Institute
• Member board of directors Steel Founders Society
  of America
• Chairman of AFS lost foam division 11 research
  committee
• Past chairman AFS division 11 lost foam
• In 1999, awarded AFS division 2 aluminum,
  Hall/Heroult Scientific Merit Award
• In 2000, awarded AFS division 11 lost foam, lost
  foam technical achievement award
• In 2001, awarded ACRC Merton C. Flemings award
• In 2002, ASM International Board of Trustees
  elected Ray, Fellow ASM International
• In 2002, became a Mercury Fellow
• In 2003, awarded AFS division 11 lost foam, lost
  foam technical contribution award