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Completed R&D Projects

The following projects have completed their research and development of improved processes and technologies for the Metal Casting Industry of the Future. Project fact sheets for each project are available as Adobe Acrobat PDFs. Download Adobe Reader.

Advanced Melting Technologies

  • Advanced Scalable Clean Aluminum Melting System (SECAT) (PDF 118 KB)

  • Reduction in Energy Consumption and Variability in Steel Foundry Melting and Casting Operations (Iowa State University) (PDF 512 KB)

Environment

  • Performance Data to Increase Reuse by Foundry Bioproducts (PDF 150 KB)

  • Non-Incineration Treatment to Reduce Benzene and VOC Emissions (PDF 445 KB)

  • Steel Foundry Refractory Lining Optimization (PDF 118 KB)

Financial Assistance

  • A Process to Recover and Reuse Sulfur Dioxide in Metal Casting Operations (NICE3) (Adsorption Research, Inc. and Ohio Department of Development) (PDF 87 KB)

  • Ceramic Composite Die for Metal Casting (Inventions & Innovation) (MER Corporation) (PDF 491 KB)

  • Die Casting Copper Motor Rotors (NICE3) (PDF 96 KB)

  • Filtering Molten Metal (Inventions & Innovation) (Palmer Manufacturing and Supply) (PDF 123 KB)

  • Highly Efficient Rapid Tooling Using Optimized Cooling Passages (Inventions & Innovation) (PDF 215 KB)

  • Increasing Productivity and Reducing Control of Die Casting Lubricants (NICE3) (PDF 341 KB)

  • Meta-Lax Stress Relief Process Saves Energy (Inventions & Innovation) (Bonal Technologies, Inc.) (PDF 94 KB)

  • Titanium Matrix Composite Tooling for Enhanced Manufacture of Aluminum Die Castings (Inventions & Innovation) (Dynamet Technology, Inc.) (PDF 541 KB)

Innovative Casting Processes

  • Advanced Steel Casting Technology (University of Alabama-Birmingham) (PDF 490 KB)

  • Castability Assessment and Data Integration (Ohio State University) (PDF 424 KB)

  • Casting Porosity-Free, Grain Refined Magnesium Alloys (Case Western Reserve University) (PDF 164 KB)

  • Characterization of Surface Anomalies from Magnetic Particle and Liquid Penetrant Indications (University of Alabama) (PDF 144 KB)

  • Control of Soldering and Thermal Fatigue During Die Casting (Oak Ridge National Laboratory)

  • Corrosion Testing Practices-High Alloy Corrosion Program (Lehigh University) (PDF 152 KB)

  • Design Support for Tooling Optimization (Ohio State University) (PDF 113 KB)

  • Determination of Bulk Dimensional Variation in Castings (University of North Carolina)

  • Development of Computational Tools for the Assurance of High Strength and Fatigue Resistant Aluminum Castings (General Motors) (PDF 138 KB)

  • Development of Continuous Cooling Transformation (CCT) Diagrams (Iowa State University) (PDF 168 KB)

  • Development of Technical Data to Validate Performance of Foundry Byproducts in Hot-Mix Asphalt and Controlled Low-Strength Material (Pennsylvania State University) (PDF 152 KB)

  • Effect of Design Factors on Thermal Fatigue Cracking of Die Casting Dies (Case Western reserve University) (PDF 112 KB)

  • Evaluation of Heat Checking and Washout of Heat Resistant Super-alloys for Die Insert Applications (Case Western Reserve University)

  • Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based Alloys (CANMET) (PDF 166 KB)

  • Improved Design, Operation, and Durability of Shot Sleeves (Case Western Reserve University) (PDF 470 KB)

  • Improved Die Casting Process to Preserve the Life of the Die Casting Dies (Case Western Reserve University) (PDF 149 KB)

  • Improvements in Efficiency of Melting for Die Casting (Case Western Reserve University) (PDF 206 KB)

  • Light Metals Permanent Mold Casting (CANMET) (PDF 203 KB)

  • Low-Cost and Energy Efficient Methods for the Manufacture of Semi-Solid Metal (SSM) Feedstock (Worcester Polytechnic Institute) (PDF 526 KB)

  • Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology (University of Alabama) (PDF 137 KB)

  • Mechanical Performance of Dies (Ohio State University) (PDF 125 KB)

  • Melting Efficiency Improvement (University of Missouri at Rolla) (PDF 142 KB)

  • Precision Castings (University of Missouri at Rolla) (PDF 142 KB)

  • Quantification and Standardization of Pattern Properties for Control of the Lost Foam Process (Industrial Analytics Corporation)

  • Simulation of Dimensional Changes and Hot Tears during Solidification of Steel Castings (University of Iowa) (PDF 137 KB)

  • Simulation of Distortion and Residual Stress Development During Heat Treatment of Steel Castings (University of Iowa) (PDF 150 KB)

ITP Crosscutting

  • A Bubble Probe for Optimization of Bubble Distribution and Minimization of Splashing/Droplet Formation (Aluminum)

  • Continuous Severe Deformation Processing of Aluminum Alloys (Aluminum) (PDF 210 KB)

  • Coolant Characteristics and Control in Direct Chill Casting (Aluminum) (PDF 135 KB)

  • Degassing of Aluminum Alloys Using Ultrasonic Vibrations (Aluminum)

  • Development of an Innovative Vertical Floatation Melter and Scrap Dryer (Aluminum) (PDF 107 KB)

  • Development of a Two-Phase Model for the Hot Deformation of Highly Alloyed Aluminum (Aluminum) (PDF 103 KB)

  • Effect of Impurities on the Processing of Aluminum Alloys in Casting, Extrusion, and Rolling (Aluminum)

  • Energy Efficient Isothermal Melting (Aluminum) (PDF 403 KB)

  • Fundamental Studies of Structural Factors Affecting the Formability of Continuous Cast Aluminum Alloys (Aluminum)

  • Gating of Permanent Mold Aluminum Casting Phase-II (Aluminum)

  • High Efficiency, Low-Dross Combustion System for Aluminum Remelt Reverberatory Furnaces (Aluminum) (PDF 92 KB)

  • Improved Energy Efficiency in Aluminum Melting (Aluminum) (PDF 213 KB)

  • Molten Aluminum Treatment by Salt Fluxing with Low Environmental Emissions (Aluminum)

  • Reduction of Annealing Times for Energy Conservation in Aluminum Processing (Aluminum)

  • Reduction of Oxidative Melt Loss of Aluminum and its Alloys (Aluminum)

  • Selective Absorption of Salts from Molten Aluminum (Aluminum)

  • Surface Behavior of Aluminum Alloys Deformed Under Various Processing Conditions (Aluminum) (PDF 244 KB)

  • Alloys for Ethylene Cracker (Chemicals) (PDF 142 KB)

  • Improving the Efficiency of Electric Arc Furnace in the United States (Steel) (PDF 76 KB)

  • Optical Sensors for Post Combustion Control in Electric Arc Steelmaking (Steel) (PDF 115 KB)

Manufacturing

  • Advanced Lost Foam Casting (PDF 138 KB)

  • CFD Modeling For Lost Foam White Side (PDF 317 KB)

  • Clean Cast Steel (PDF 131 KB)

  • Die Life Extension: Design Factors (PDF 111 KB)

  • Effect Of Applied Pressure During Feeding Of Critical Cast Aluminum Alloy Components (PDF 1.5 MB)

  • Energy Consumption Of Die Casting Operations (PDF 612 KB)

  • Ergonomic Improvements In Foundries (PDF 108 KB)

  • Gating Of Aluminum Permanent Mold Castings (PDF 186 KB)

  • Heat Transfer At Mold/Metal Interface In Permanent Mold Casting Of Aluminum (PDF 881 KB)

  • Improvements In Sand Mold/Core Technology (PDF 510 KB)

  • Innovative Semi-Solid Metal (SSM) Processing (PDF 470 KB)

  • Modeling The Mechanical Performance Of Die Casting Dies (PDF 448 KB)

  • Optimization Of The Squeeze Casting Process For Aluminum Alloy Parts (PDF 137 KB)

  • Predicting Pattern Tooling And Casting Dimension For Investment Casting (PDF 105 KB)

  • Die Casting Die Deflections: Prediction And Attenuation (PDF 6.7 MB)

  • Integrating RSP Tooling and Rapid Prototyping In Die Casting (PDF 129 KB)

  • Semi-Solid Metal Processing (PDF 316 KB)

  • Sensors For Die Casting (PDF 390 KB)

  • Thin Wall Iron Castings (PDF 115 KB)

  • Unconventional Methods For Yield Improvement (PDF 99 KB)

  • Innovative Semi-Solid Metal (SSM) Processing (PDF 470 KB)

Materials

  • Casting Characteristics of Aluminum Die Casting Alloys (Worcester Polytechnic Institute) (PDF 138 KB)

  • Enhancements in Magnesium Die Casting (Case Western Reserve University) (PDF 110 KB)

  • Macro-Inclusions Atlas (Carnegie Mellon University) (PDF 121 KB)

  • Thin Section Steel Casting (Pennsylvania State University) (PDF 504 KB)

  • Age Strengthening Of Gray Cast Iron Phase III (PDF 663 KB)

  • Creep Resistant Zinc Alloy Development (PDF 108 KB)

  • Die Life Extension: Materials For Critical Applications & Increased Production Rates (PDF 111 KB)

  • Effects Of Externally Solidified Product On Wave Celerity And Quality Of Die Cast Products (PDF 611 KB)

  • Fatigue Properties Database Fatigue (PDF 245 KB)

  • Grain Refinement Of Permanent Mold Cast Copper-Base Alloys (PDF 143 KB)

  • Heat Treatment Procedure Qualification For Steel Casting (PDF 745 KB)

  • Machinable, Thin-Walled, Gray And Ductile Iron Casting Production, Phase III (PDF 601 KB)

  • Metallic Reinforcement In Direct Squeeze Die Casting (PDF 145 KB)

  • Prevention Of Porosity In Iron Castings (PDF 679 KB)

  • Service Performance Of Welded Duplex Stainless Steel Castings (PDF 250 KB)

  • Development Of Surface Engineered Coating Systems For Aluminum Pressure Die Casting Dies (PDF 119 KB)

Technical Assistance

  • AMCAST Industrial Corporation Energy Assessment (PDF 316 KB)

  • Compressed Air System Improvement Project Saves Foundry Energy and Increases Production (PDF 206 KB)

  • Compressed Air System Retrofitting Project Improves Productivity at a Foundry (PDF 193 KB)

  • Lester Precision Die Casting Demonstrates Energy Efficiency and Productivity Improvements (PDF 162 KB)