ing, which will enable designers to locate specifi c properties in specifi c areas of a part to meet service loading conditions. When load paths are clearly defi ned, the research group also plans on establishing topol- ogy optimization techniques to enhance design optimization. In the fi rst three months of
the project, the group has se- lected the baseline alloy (A380) and identifi ed an experimental high strength aluminum alloy for structural casting develop- ment for aerospace and auto- motive applications. A concept design on a thin-wall casting die also has been started. T e die is based on a thin-walled zinc die casting, which is being rede- signed for aluminum. Researchers have begun mechanical property evaluation and ICME model validation in thin- wall casting development. Key real-world applications, such as an aerospace wing fuel door, to demonstrate the benefi ts of vacuum diecasting and ICME have been identifi ed. “What we are doing here is bridging the gap between
great research in laboratories and great manufacturing skills in private industry,” Brown said. “Once you bring these in- novations into production, the results just multiply.” Lightweight aluminum diecast components have a
significant market to fill, particularly in the transporta- tion industries, including aerospace, automotive, military and marine. Industry partners from these markets include Eaton Corp., Comau and Nemak. On the research side, Worcester Polytechnic Institute, Southwest Research Institute, the University of Michigan and Massachusetts Institute for Technology have joined the effort, while the American Foundry Society and North American Die Casting Association are assisting with modeling, technol- ogy oversight and dissemination of knowledge on how to manage the new thin-wall aluminum diecasting process in a production environment. LIFT is operated by the American Lightweight Mate-
rials Manufacturing Institute and was selected through a competitive process led by the U.S. Department of Defense. It is one of the founding institutes in the National Network for Manufacturing Innovation, a federal initiative to create regional hubs to accelerate the development and adoption of cutting-edge manufacturing technologies. After the two-year project is concluded, the group plans to deliver design guidelines and property specifica- tions for thin-walled aluminum diecasting and ICME models for thin-wall casting design with location-specific properties. As these technologies and guidelines are incorporated into production diecasting operations, the options for aluminum components in structural applica- tions will expand. ■
26 | METAL CASTING DESIGN & PURCHASING | Nov/Dec 2015
This wing fuel access door is a potential application for vacuum diecasting to achieve thinner walls.
WHAT IS NNMI AND LIFT?
The National Network for Manufacturing Innova- tion (NNMI) is a federal program started in February 2014 that focuses on creating development hubs that use public and private funds to propel American manufacturing forward. The hubs bring together product developers, researchers, manufacturers, institutes, universities and training institutions to advance high tech manufacturing. So far, NNMI has established seven institutes, with
two more pending. Of the seven, three institutes have programming involving cast metal parts. LIFT, or Lightweight Innovations for Tomorrow, is
aimed at providing commercial and military sectors solutions for lightweight subsystem design, com- ponent-level manufacturing, joining and assembly processes. It’s fi rst two projects focus on thin-walled diecasting and thin-walled gray iron casting. America Makes is the national accelerator for
additive manufacturing and 3-D printing. This institute is currently undertaking the research proj- ect “Accelerated Adoption of Additive Manufactur- ing Technology in the American Foundry Industry,” which supports the transition of binder jet additive manufacturing to the small business metalcasting industry. The Digital Manufacturing and Design Innovation
Institute (DMDII) encourages factories to deploy digi- tal manufacturing and design technologies. Seven of the 13 initial projects started by this institute contain a metalcasting component, including online design tools and adaptive machining of large castings. ■
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