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 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

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

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

HyperCAST Program Status P assed 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

TAG Activities Most Recent Proposal Approved #168 Die Material Properties at 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

113 th 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)

Guidebook Report Compilations Turn Research Into Action 1 st Round –Die Materials  –Cast Materials  –Computer Modeling  –Process Technologies  –Die Surface Engineering  2 nd Round –Computer Modeling II  –Cast Materials II  –Process Technologies II  –Die Materials II  (Ready for print)

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

What’s New New Employee - Alex Monroe Dust Safety Course Product Standards High Integrity Al Product Design Book Design Website – Carbon Footprint Report

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

Ideas Priority Description Number 1Heat treatable die castings w/properties comparable to other processes 2Non-contact real-time monitor & control/IR Vision – Sensor fusion 3National Die Casting Center 4Carbon footprint: Optimize melting, holding & ladling/SF6/simulation 5On demand melting- shot by shot 6Lightweight hybrid structures-plastic/metal 7Porosity free homogeneous properties 8Smart die cast manufacturing 9Smaller machines for larger castings 10Lube free die casting 11Apply lean techniques vertical integration-smelt/melt/pour 12Coating to eliminate lube 13More cavities per tonnage 14Smart sensor fusion die casting 15Hot chamber Al – materials/coatings for gooseneck/pump/nozzle 16High temp alloys for inserts 17Ti and Ni die casting 18Die materials for high temp die casting 19Die Cast Composite 20Eliminate trim presses 21Thin wall Mg and Al 22Optimize thermal cycling to triple die life 23Models for energy efficient die casting 24Low-no draft, flash free, net shape die casting 25Cost efficient short run production/prototype

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 Joint Planning Session Cont.