Metalcasting Industry Roadmap


x Workforce retention and creation of desirable workplaces x Higher consistency of product quality x Adoption of cross-cutting technologies from outside the metalcasting industry x Implementation of automation into lower-volume manufacturing x Autonomous communication between resources x Integration of information from sensors as well as mechatronic data x Reaching Zero Discharge x Improved profitability


Melt-Pour-Cast


Improving metalcasting manufacturing processes via reductions in variation, reductions in handling, creating more repetitive production approaches, and movements away from the traditional approaches used to melt, transfer metal, pour, and cast components will transform the industry.


This can lead to reduced chemistry and process variation, improved mechanical


properties, reductions in scrap, improved yields, higher repeatability and predictability of casting performance, and higher efficiency. These are just some of the benefits from reducing variation in metal chemistries and other manufacturing process variables. Efforts should be made to identify the sources of variation and reduce them.


Key Tasks


x Reduce chemistry and molten metal-related process variations x Improve pouring processes x Understand shrinkage and various interaction aspects x Utilize on-line in-situ chemical analyses and quality checks x Implement molten metal on-demand (small batches) x Eliminate ladles


Target Outcomes


x Scrap reductions x More accurate process and predictive models x Improved mechanical properties x Higher repeatability and predictability of casting performance


29 Process


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