Metalcasting Industry Roadmap Key Tasks


x Utilize expendable cores x Develop improved die coatings and lubricants x Employ modeling and design criteria x Use smart coatings


Target Outcomes


x Reduced cycle / production lead times x Higher quality cast parts x Reduced porosity x Reduced gas related defects x Improved surface finish x Improved dimensional repeatability x Elimination of veining and erosion defects x Less scrap and re-work x Environmental improvements


b. Sand ± This refers to the material improvements involving sand molds. It includes the reclamation-beneficial reuse-disposal of


Key Tasks


x Enhance binders / coatings x Improve reclamation-beneficial reuse-disposal x Use modeling to design sand molds and test sand properties x Develop alternatives for silica, olivine and zircon sands


Target Outcomes


x Reduced production lead times x Higher quality cast parts x Improved surface finish x Improved dimensional repeatability x Less scrap and re-work x Environmental improvements x Alternative resources if materials are unavailable or in short supply


c. Investment Cast Wax - In the investment casting process, a ceramic slurry is applied or ³LQYHVWHG´ around a disposable wax pattern, and allowed to harden to form a disposable


casting mold. The wax pattern is lost when it is melted out from the disposable ceramic mold which is later destroyed to recover the casting. This R&D area would involve


35 sand, binders, and coatings used in the


production of sand molds, developing alternatives for silica, olivine and zircon sands, and also modeling / simulation in the design of sand molds.


Materials


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