Metalcasting Industry Roadmap
6. Melt-Pour-Cast ± This relates to the improvement of metalcasting manufacturing processes via reductions in variation, reductions in handling, and creating more repetitive production approaches to transform the metalcasting industry.
require strenuous and repetitive motions. The use of robotics and other dedicated equipment has helped alleviate some of these issues but its implementation is still not widespread, especially in lower volume applications and in the small-to-medium enterprises.
7. Advanced Metalcasting Technology ± To revolutionize the approaches used to manufacture castings, collaboration is needed among the various stakeholders which includes researchers at universities, the equipment manufacturers, material suppliers, the metalcasters, and the end customers. The future metalcasting operations will look more like mini-mills with the use of engineered cooling and thermal management or potentially on-demand melting and molding technologies.
8. Quality ± To improve reliance on cast products as the most cost-effective solution, dramatic reductions in variability and improved yields are needed. Efforts should be directed to supplant qualitative Non-Destructive Evaluation (NDE) techniques (based upon international / national comparison standards that do not reflect the loads applied and performance expected from the product) with those that are quantitative.
Within each major category, the following areas were identified: Additive Manufacturing and Rapid Subtractive Manufacturing in Metalcasting
AM holds the potential to be both a transformative and disruptive technology. The current approaches have been more on applications in new product development and specialty production.
Efforts are needed to integrate the various methods of AM into a more
manufacturing-based approach, which could include core and mold production via 3D Sand Printing (3DSP), printed investment cast patterns, and 3D printed die and tools. These efforts will move the technologies from Rapid Prototyping towards Rapid Production.
Key Tasks
x Integrate AM into current metalcasting manufacturing stream x Develop higher speed milling, turning, and CNC approaches x Print pattern / tooling as disposable tooling using AM
24 Process
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