Metalcasting Industry Research
Support of research is critical for North America to maintain a strong, vibrant, healthy and continually advancing metalcast- ing industry. Part of the AFS mission is to promote these activities for the betterment of our membership, our industry and our society.
AFS directly funds research projects from allocation of a por- tion of the annual dues paid by AFS Corporate Membership. The current AFS Funded Research Projects are described be- low. The other projects are funded through research partner- ships, government funding and industry contributions. AFS participates in these projects by securing industry partners and providing technical management and oversight. Current
research funding partnerships include: the U.S. Department of Defense (DOD), Defense Logistics Agency (DLA) Cast- ings Solutions for Readiness (CSR) Program funded through the American Metalcasting Consortium (AMC), the National Network for Manufacturing Innovation and the three current consortium (America Makes—National Additive Manufac- turing Innovation Institute, Lightweight and Modern Metals Manufacturing Innovation-LM3I and Digital Manufacturing and Design Innovation–DMDI), and the New Generation Sand Casting Consortium (NewGen), which is a partnership between AFS and the National Industrial Sand Association (NISA) investing in metalcasting research relating to improv- ing and advancing sand casting.
AFS Funded & Monitored Research
Eight active projects are currently being funded through the allocation of a portion of the AFS Corporate Member Dues in FY2013-2014.
Magnesium Melt Cleanliness (11-12#04)
Coordinator: Dr. C. (Ravi) Ravindran, Ryerson University, and AFS Magnesium Division (6)
High-volume application of lightweight materials is key to in- creasing fuel efficiency and vehicle performance and decreasing exhaust emissions to address environmental concerns. Current- ly, Mg alloys, which are the lightest structural materials, repre- sent only ~ 0.3% of the vehicle weight. The proposed research is part of an ongoing effort to increase the use of Mg alloys at a significant level in the automotive industry.
One of the most important parameters in controlling the properties of Mg and its alloys for various applications is melt cleanliness with respect to inclusions. The presence of such inclusions will strongly influence the mechanical properties and corrosion resistance of structural parts. The project seeks a better understanding of the origin of defects and inclusions in order to improve melt cleanliness and effectively improve the mechanical properties of Mg alloys. The proposed project aims at carrying out an analysis of the inclusions in Mg cast- ings currently produced, with the ultimate objective to reduce or eliminate/remove them. This project constitutes a first step for the improvement of Mg melt cleanliness. It will provide a clear picture of the current Mg melt quality in the industry. In the future, the project will have an important impact on the productivity through quality improvement and consequently
reduction of defective castings. As a result, it will lead to cost reduction and enhancement of foundry competitiveness.
Ultimately, the project will help improve the melt quality and lead to reduction of scrap, cost reduction and enhancement of foundry competitiveness. It will also lead to an increase of Mg competitiveness as compared to other materials. The consequent improved mechanical properties of Mg castings will lead to an increase of their structural applications in au- tomobiles. It is the aim of the principal investigator and the Steering Committee to ensure broad diffusion of the project results. The project results will be presented in several scien- tific articles and presented in chapter meetings, Casting Con- gresses or in international peer-reviewed journals. Finally, a two-page foam board poster on current Mg melt cleanliness will be developed.
Status Update: The project is ongoing with sampling be- ing conducted at several Mg metalcasting facilities. The work is now being monitored by the AFS Aluminum Division (2) and the AFS Research Board. An update report will be given during the Tuesday, April 8, 2014, 3:45 p.m. Mg ses- sion at the 118th
Metalcasting Congress in Schaumburg, IL.
Ryerson is actively seeking additional Mg metalcasting facilities to supply samples to analyze and those wishing more informa- tion about the project or participation should contact Dr. Ravi Ravindran at
rravindr@ryerson.ca.
International Journal of Metalcasting/Volume 8, Issue 2, 2014
87
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