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 Problem / opportunity – Drawings for spare parts are not readily located – 3D solid models dont exist precluding use of advanced manufacturing techniques – Lead times too long – Implementation of productivity improvement strategies is lacking Develop an electronic tool that provides methods and guidance for producing tooling/die castings via reverse engineering and strategies for enhanced productivity

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.

ParticipantsFoundries: SPX SPX Intermet Intermet Hayes Lemmerz Hayes LemmerzUniversities: WPI WPI Georgia Institute of Technology Georgia Institute of Technology University of Iowa University of Iowa Mississippi State University Mississippi State University Case Western Case Western University of Windsor University of Windsor National Labs: Argonne National Lab Argonne National Lab Oak Ridge National Lab Oak Ridge National Lab Lawrence Livermore National Lab Lawrence Livermore National Lab Professional Societies: AFS AFS NADCA NADCA Industrial Partners: Advanced Magnesium Technologies Advanced Magnesium Technologies CANMET CANMET CMI Equipment & Engineering CMI Equipment & Engineering CMI Novacast CMI Novacast Eck Industries Eck Industries EKK Inc. EKK Inc. Laempe Core Machines Laempe Core Machines LightWeight Strategies LLC LightWeight Strategies LLC Magma Foundry Technologies Magma Foundry Technologies Manufacturing Services & Development Inc (Project Administrator) Manufacturing Services & Development Inc (Project Administrator) Product Development and Analysis (LLC) Product Development and Analysis (LLC)

Task & Budget Overview Task 1: Squeeze casting process development Task 1: Squeeze casting process development Task 2: Low pressure 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 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 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 5: Computer modeling and properties to enable prediction of casting quality and microstructure Task 6: Development of molten magnesium pump materials and technologies Task 6: Development of molten magnesium pump materials and technologies Task 7: Investigate emerging casting 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. 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 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 A Few Shots Made on a Tilt Steering Housing with AZ91 to Test the Set-up Control Arm Die Just Arrived for Trial Casting Control Arm Die Just Arrived for Trial Casting