1 NADCA Headquarters Update Presentation for Die Materials Committee Meeting NADCA Headquarters, Wheeling, IL October 18, 2006

2 Outline DOE/CMC Update DOE/CMC Update DOD/AMC Update DOD/AMC Update TAG Activities TAG Activities Miscellaneous Items Miscellaneous Items

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

4 DOE/CMC Update (Cont.) DOE/CMC Update (Cont.) Year 1 Request Actual Year 2 Request Actual Year 3 Request Actual $625K$441K$1,179K$920K$1,200K$450K 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 E-SMARRT Die Casting Tasks Mechanical Performance of Dies Continuation (R. Allen Miller, OSU) Design Support for Tooling Optimization (R. Allen Miller, OSU) The Development of Smart Die Coatings (John Moore, CSM) Improved Die Casting Process to Preserve the Life of the Dies (Jack Wallace & David Schwam, CWRU) Improvements in Efficiency of Melting for Die Casting (Jack Wallace & David Schwam, CWRU) Low Cost Energy Efficient SSM (D. Apelian & Makhlouf, WPI) The Use of Laser Engineered Net Shaping for Rapid Manufacturing of Dies with Protective Coatings and Improved Thermal Management (OSU & Lehigh) Thin Wall Zinc (Frank Goodwin, ILZRO) Investigation of Flow Regimes in High Pressure Die Casting (Jerry Brevick, OSU) Conformal Cooling in Die Casting and Permanent Mold Casting (Kevin McHugh, INEEL) Improved Yield and Production Rates in Metal Mold Casting Processes by Advanced Thermal Management (Jack Wallace & David Schwam, CWRU) Improvement in Die Design to Improve Die Life as Affected both by Thermal Fatigue Cracking, Erosion and Soldering (Jack Wallace & David Schwam, CWRU)

6 DOD/AMC PRO-ACT AMC Phase III (PRO-ACT) Extension AMC Phase III (PRO-ACT) Extension –Ended June 2006, Final Reports July 2006 AMC Phase IV (CIR) AMC Phase IV (CIR) –Kicked-off Meeting March 30 & 31, 2006 –$10M over 4 years ($2.5M), ~$1.4M for Die Casting –JDMTP Review Oct 18, 2006 in D.C. –Andy Behler new Industry Board Member AMC Phase IV Add-on (CIDR) AMC Phase IV Add-on (CIDR) –~$200K for Die Casting in Year 1 –Could be Funding Available for Out-years

7 DOD/AMC PRO-ACT (Cont.) Computational Tool for Short Run Insert Production and Improved Yield (R. Allen Miller, OSU) Rapid Tooling for Short Run Metal Mold and Increased Productivity (Jack Wallace & David Schwam, CWRU) High Production Rate Process for Metal Matrix Composite Components (John Moore, CSM) High Performance Die Casting Alloys (D. Apelian & Makhlouf, WPI) Reverse Engineering Tools & Productivity Improvements for Spare Part Components (NADCA)

8 TAG Activities Review of Current NADCA Projects Review of Current NADCA Projects Review of Proposed Projects Review of Proposed Projects –Newly approved: Project #154 Development of a Porosity Guideline for Die Castings Funding Allocation for Existing Projects Funding Allocation for Existing Projects Alternate Funding Sources Alternate Funding Sources –Die Caster & Supplier Consortia –State Agencies –NADCA ($225K approved for 2007) Foreign Technology Foreign Technology

Plant Management Conference September 20-22, 2006 at the Minneapolis Marriott City Center September 20-22, 2006 at the Minneapolis Marriott City Center Moderator: Bill Butler Moderator: Bill Butler Roundtable Discussions Roundtable Discussions Special Presentations Special Presentations –Energy Efficiency of Melting & Holding, D. Schwam –Quick Die Change, H. Bakemeyer –Die Temperature Control, R. Strohmaier Plant Tours of Twin City Die Castings Co Plant Tours of Twin City Die Castings Co 67 Registrants 67 Registrants

th Metalcasting Congress May 15-18, 2007 (Tue-Fri) in Houston, TX, at Hilton Americas May 15-18, 2007 (Tue-Fri) in Houston, TX, at Hilton Americas NADCA Sessions Tue-Thurs NADCA Sessions Tue-Thurs Exhibits Wed & Thurs Exhibits Wed & Thurs Call for Papers in July, Abstracts due Aug Call for Papers in July, Abstracts due Aug Die Casting Competition Die Casting Competition –Winning Casting on Display at NADCA

NADCA R&D Strategic Plan and Roadmap Overview Article Published in July 2006 DCE Magazine Overview Article Published in July 2006 DCE Magazine Full Version of Plan Completed in June 2006 Now Posted on the Web Full Version of Plan Completed in June 2006 Now Posted on the Web

12 Research in Action Compilation of Guidebook Reports for Distribution to Members Compilation of Guidebook Reports for Distribution to Members –Die Materials (Done) –Cast Materials (Done) –Computer Modeling (Done) –Process Technologies