Metalcasting Industry Roadmap Materials


Research, data, and tools are needed to improve the materials used in the production of metalcastings. Material R&D can improve quality and performance, reduce weight, reduce lead times, and improve the cost-effectiveness of cast parts. In developing a metalcasting roadmap to address the area of materials, the roadmapping development workshop participants identified three major categories in which to group the new technologies and processes needed for metalcasting materials. The three major categories are:


1. Cast Materials ± These are the liquid metals that are poured or injected into molds, then allowed to cool to produce solidified metal castings. This category includes enhancing properties / quality and sustainability of monolithic metals as well as hybrid materials, such as metal-matrix composites.


2. Mold, Die, and Tooling Materials ± This refers to the materials that are used to contain the molten metals that are poured into them and form the shape of the casting once the metal is solidified. This category includes the materials used to make the molds / dies (sand, steel, ceramic, etc.) including the binder material, coatings, and the design / simulation of molds.


3. Furnace Refractories ± These are the heat-resistant materials that constitute the linings for the furnaces and ladles used in metalcasting.


Within each major category, the following areas were identified: Cast Materials


a. Optimization of Properties ± This area deals with optimizing the mechanical properties and quality of current casting materials to reduce variability and defects. Part of this


32 Materials


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