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Metalcasting Industry Funded & Monitored Research

American Metalcasting Consortium/U.S. Dept. of Defense/ Defense Logistics Agency Funded Projects

Castings Solutions for Readiness (CSR) Program

AFS, as part of their efforts in the American Metalcasting Con- sortium (AMC), has recently secured contracts funded through the U.S. Department of Defense, Defense Logistics Agency, Defense Supply Center Philadelphia and the Defense Logistics Agency, Ft. Belvoir, VA. The group of projects is under an AMC program entitled Castings Solutions for Readiness (CSR). The two new projects are continuations of previous AFS AMC efforts, including one project called Cast High-Integrity Alloy Mechanical Property Standards (CHAMPS) and the other Cast- ing Standards and Specifications.

CHAMPS Project―Additional Alloy Design Data

The CHAMPS Statistical Properties Project goal is incorpora- tion of material property design data for additional cast alloys, A201/206 in the initial phase and then 17-4-PH or Ti6Al4V in second phase, into MMPDS (Metallic Materials Properties De- velopment and Standardization) handbook, which replaced Mil- handbook 5, so that this material can be specified and used to design and manufacture flight critical components in military and civilian aircraft. This builds on the original just completed E357 effort of establishing a framework to design a series of test specimens that encompass the various section thicknesses used in these applications utilizing process simulation software, validate the approach metallographically, coordinate collection of required samples from a consortium of qualified foundries and submit the data for statistical analysis and approval by MMPDS board for incorporation into the MMPDS standards. The benefit to DLA is the development of statistical based property data will permit the use of castings across a broader range of applications and will provide the following benefits. The Engineering Support Activities at the DLA will be able to make cast alloy conversion / replacement decisions with assurance using statistical data on tensile, compressive, shear, and bearing properties from the FAA recognized source, MMPDS Handbook. Also reduced lead times with cast components competing on an equal basis with forging and assemblies from sheet, plate, and extruded mill products.

As with the E-357 project the intended outcome will be cast A&B design property allowables for the alloys selected for inclusion in the MMPDS (old Mil Spec Handbook 5) to meet FAA require- ments. This will allow aerospace design engineers to specify cast- ings without using design safety factors. Various working groups will be actively looking at melt practices, test casting gating and filling, heat treatment parameters, testing protocol and weld re- pair standards. The initial casting trials will follow the approach taken for E357 and 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 will be tested for tensile properties and undergone microstruc-


tural evaluation. The project just is now starting and those wish- ing to participate or want more information should contact Steve Robison, AFS, at

Casting Standards and Specifications

Accessing state-of-the-market technical, specification and train- ing materials for castings is challenging. AFS is working to pro- vide current and qualified information in a network friendly form to users of castings via the Casting Standards and Specifications project. The effort includes both archival and recent technical information in searchable databases. Specifications and standards are summarized, and the user is guided in their application. Tu- torials covering the fundamental design concerns are also pre- sented. The development of an online material design property database will greatly enhance the ability for the next generation of component 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 completed 08-09#01 & 08-09#03 projects for the Development of Fatigue Properties Database, AFS has also incorporated the USAMP Light Metals Materials Database properties and recently strain life fatigue data for CGI Grade 400 and a hi-alloy Class 40 Gray Iron into the AFS Casting Alloy Data Search (CADS) onto the AFS design website: This completes this phase of the project and AFS is working with ASM to create Cast Alloy Material Property Datasheets to be put on the ASM Material Selector and AFS websites. The work planned under this project will add design properties for 4-5 additional cast metal alloys per year, while continuing to up- grade the CADS online database.

For more information, contact Thomas Prucha, AFS, at tpru- or AFS Information Resource Assistant Katie Matticks at

Superior Weapons Thru Casting (SWC) Program

Three new AFS projects were started under the Superior Weap- on 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-

International Journal of Metalcasting/Spring 2012

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