Metalcasting Industry Roadmap


allowed the industry to employ materials such as aluminum, magnesium, titanium, zinc, advanced copper-based, and advanced iron and steel alloys to produce thin wall, high-strength castings with higher precision and more complex shapes. But to remain competitive and maintain a viable domestic industry, challenges must be overcome in casting design, processing efficiency, industry recognition, and employment attractiveness.


Increasingly, the U.S. metalcasting industry will need to reduce its cost of production to remain globally competitive. As long as non-U.S. manufacturers are able to benefit from low-cost labor and lax environmental constraints, U.S. manufacturers will continue to be at a disadvantage. Dramatic increases in U.S. metalcasting productivity and product and process technology are the economic answer to competition from commodity castings produced outside the U.S. Design, process, and material improvements to open new markets and applications, enhance metalcasting practices, advance alloy and component performance, and attract employees and students are all needed for the U.S. industry to realize its potential.


American Metalcasting Consortium (AMC)


AMC was established in 1992 to solve metalcasting procurement issues for the Department of Defense (DoD). $0& LQWHJUDWHV WKH QDWLRQ¶V WRS DFDGHPLF metalcasting


researchers with the four THE NUMBERS leading


metalcasting industry associations (American Foundry Society, Non-)HUURXV )RXQGHUV¶ 6RFLHW\ 1RUWK American Die Casting Association, and the Steel )RXQGHUV¶ 6RFLHW\ RI $PHULFD DQG WKHLU PHPEHUV These


four metalcasting challenges and industry associations


represent members from over 95% of U.S. foundries. $0& LV WKH QDWLRQ¶V OHDGLQJ SURYLGHU RI WHFKQLFDO DQG enterprise


solutions for metalcasting supply chain the only


existing metalcasting


$130Msavings projected by DoD $2.6M saved using existing tooling 2,950 cast parts improved 2130 foundries accessible 2100 personnel trained in seminars 135 weapons systems enhanced 85 seminars conducted 82 DoD & AMC partners 27 leading research institutions 1 AMC metalcasting partnership


partnership providing access to the U.S. metalcasting industry. AMC has developed numerous successes for DoD, and DoE as the Cast Metals Coalition (CMC), through the development and enterprise-wide implementation of new technologies, best practices, and engineering expertise to facilitate and enhance capability, affordability, and sustainability of weapons system readiness (see Figures 3 and 4).


Figure 3: AMC Success Statistics3


SCRA, a private, non-profit, proven world-leader in consortia management, is responsible for the day-to-day operations management of AMC.


15


Overview


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