AFS NEWS First LIFT Technology Project to
Focus on Thin-Wall Iron Casting parts from molten iron is a well-established process that has been transformed recently by techno- logical advances. LIFT, (Lightweight Innovations for Tomorrow) formerly ALMMII (American Lightweight Materials Manufacturing Innovation Institute) has chosen to investigate those innovations in melt process- ing as its first technology acceleration project. Grede, Southfield, MI and Michigan Technological Univer- sity, Houghton, MI, are the industry and research lead partners on the project, which will focus on reducing the amount of metal used in an automotive transmission differential case. AFS is involved in the project to ensure that workers in the industry have opportunities to learn how to use the new materials and techniques that will come out of the project.
By integrating and implementing improved manufac- turing methods with different available alloys, there is potential to decrease the wall thicknesses of ductile iron cast parts by up to 50%. That, in turn could lead to 30- 50% weight savings, depending on the load requirements of the part.
Associate Professor of Materials Science and En- gineering at Michigan Technological University Paul Sanders said, “Iron alloys have high stiffness and good strength. We will optimize composition and cooling rate utilizing Grede’s new high precision molding machines to create thin-wall ductile iron components while main- taining desired microstructures and performance. We look forward to integrating upfront modeling with local cast properties to design optimized component geom- etries. We hope to bring this lightweight design method- ology into Grede’s production facility.” LIFT is one of two national manufacturing innovation institutes supported by the federal government that AFS is involved with. LIFT receives its funding from the U.S. Department of Defense administered by the U.S. Navy Offi ce of Naval Research. Approximately 44% of the esti- mated $1.34 million costs for this melt processing tech- nology acceleration project will be paid for by the federal government while the other 56% will be shared by industry and research partners.
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METALCASTINGDESIGN.COM The focus of the fi rst LIFT will be thin-walled iron castings. August 2015 MODERN CASTING | 55
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