Metalcasting Industry Funded & Monitored Research
American Metalcasting Consortium/U.S. Dept. of Defense/ Defense Logistics Agency Funded Projects
Castings for Improved Readiness (CIR) Program E-357 Aluminum Statistical Properties
The E-357 Aluminum Statistical Properties Project has re- ceived funding as part of the CIR program. The E-357 proj- ect will produce cast A&B design property allowables for this aluminum alloy for inclusion in the MMPDS (old Mil Spec Handbook 5) to meet FAA requirements. This will allow aero- space design engineers to specify castings without using design safety factors. Various working groups are actively looking at melt practices, test casting gating and filling, heat treatment pa- rameters, testing protocol and weld repair standards. The ini- tial casting trials were conducted for 1.5 x 2.5-in. plate cast in both horizontal and vertical gating approaches, and a heat treat study was conducted at various participating foundries. These plates have been tested for tensile properties and undergone microstructural evaluation. Work is now continuing to obtain the samples for all test plate thickness sizes and begin the me- chanical testing. Test casting for all section thicknesses has be- gun, with targeted completion by October 2011. The status was reviewed at AFS CastExpo’10 and the AMC Annual Technical Review. For more information, contact Steve Robison, AFS, at
stever@afsinc.org.
Casting Standards and Specifications
Accessing state-of-the-market technical, specification and training materials for castings is challenging. AFS is working to provide current and qualified information in a network friendly form to users of castings. The effort includes both archival and recent technical information in searchable da- tabases. Specifications and standards are summarized, and the user is guided in their application. Tutorials covering the fundamental design concerns are also presented. The devel- opment of an online material design property database will greatly enhance the ability for the next generation of com- ponent designer to create the lightest weight and most ef- ficient parts quicker and at lower cost. These tools facilitate more effective and efficient procurement to both DoD and industry in the support of weapon systems. Along with data from various AFS research projects, like the recently com- pleted 08-09#01 & 08-09#03 projects for the Development of Fatigue Properties Database for Use With Modern De- sign Methods, AFS has signed a memorandum of agreement with USAMP to allow it to publish the USAMP Light Metals Materials Database and include this data on the AFS Casting Alloy Data Search (CADS) website:
www.metalcastingvirtu-
allibrary.com/cads/cads.aspx.
International Journal of Metalcasting/Summer 2011
High Strength, High Toughness Cast Aluminum Alloy
There is an ongoing need to reduce the weight and cost of mili- tary weapon systems. High strength, high toughness cast alumi- num alloys could meet this need in applications such as armor and structural components. The objective of the proposed research is to optimize the chemistry of an existing high strength aluminum alloy (BAC 100), which may be suitable for mortar base applica- tions, and develop a mechanical property database for designers. This alloy was developed for military applications as a potential substitute for wrought aluminum alloy 2519 but needs to be opti- mized for specific applications. After optimization, the statistical variation in mechanical properties (strength, toughness) needs to be determined for design purposes. The goal of this material de- velopment program is to produce an aluminum casting alloy with properties that meet MIL-DTL-46192C, aluminum alloy armor, rolled plate and weldable standards. During the development, both high strength and high toughness variants will be developed for specific military applications. The principal investigators for this project are Dr. Robin Foley and John Griffin, University of Alabama at Birmingham.
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For more information, contact Thomas Prucha, AFS, at tpru-
cha@afsinc.org or AFS Information Resource Assistant Katie Doherty at
katie@afsinc.org.
Superior Weapons Thru Casting (SWC) Program
Three new AFS projects will start under the Superior Weapon Systems Thru Castings (SWC) Program. This program has funding secured for both FY09 and FY10 and is under a co- operative agreement obtained by Advanced Technology Insti- tute (ATI) for American Metalcasting Consortium (AMC) with Benet Labs. The AFS projects include High Strength & High Toughness Cast Aluminum Alloy at UAB, Developing an Im- proved Combination of Strength and Permeability for Invest- ment Shells used with Foam Patterns at Missouri University of Science and Technology, and Visual Inspection of Casting (joint sponsorship with Steel Founders’ Society of America and North American Die Casting Association) at Iowa State Uni- versity and Schorn Associates. Updates on these projects and others under this AMC slate of projects was given during the AMC Annual Technology Review held June 23-24, 2010. Those interested in information on the program or attending should contact Thornton C. White, ATI, senior program manager, at
whitet@aticorp.org or visit the ATI website to register online at:
amc.aticorp.org/techreview.html.
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