Metalcasting Industry Roadmap


Andrew D. Behler is a third generation die caster, literally having grown up in the die casting industry. His extensive die casting experience is a result of the opportunity to work in every phase of the die cast business and a lifetime of participation in die cast association activities. He is trained as an engineer, holding B.S. degrees in Engineering Science and Mechanical Engineering from Lafayette College. In addition, he is a licensed Professional Engineer in the state of Pennsylvania.


Behler spent his career in attempting to apply engineering principles to the solution of die cast problems. In the area of zinc die casting his work includes conducting the field work for the NJZ LQ WKHLU ³7KLQ :DOO =LQF 'LH &DVWLQJ 'HPRQVWUDWLRQ 3URMHFW´ 7KLV YHU\ HDUO\ ZRUN LQFOXGHG development of machine instrumentation and characterization, thermal analysis and temperature control, application of Ilzro-Battelle gating techniques, and process optimization through statistical methods. Result of this work was shared with the industry through publication and demonstration. Efforts in brass die casting include; die material analysis of both refractory base materials and conventional hot work steels, alloy development in minimizing the effects of hot shortness through element control in manganese bronze. The work he did on closed form analysis of machine and die deflection provided the basis for almost twenty years of NADCA UHVHDUFK E\ 'U $O 0LOOHU DQG KLV WHDP DW 268 :RUNLQJ ZLWK WLHU RQH 2(0¶V RQ DOXPLQXP GLH cast designs, Behler provides guidance and training in the integration of finite element analysis and fatigue analysis utilizing safe load methods for fatigue avoidance. Understanding the inherent die cast defects and their impact on fatigue, toughness and pressure tightness, he provides a design guideline where none exists.


Inspired by his dad to participate in industry association activities he quickly learned the benefit of being an active member at both the local and national level. Participating as both a student and a leader he has had the opportunity to both learn and lead. His tenure dates to 1973 and the NADCA predecessor organizations, where he served as chairman of the R&D committee, and culminated with a position on the NADCA Board of Governors. During his time on the board he served as secretary / treasurer, vice president and chairman of the board. Committee activities have included R&D committee, Finance committee, and Government Affairs. As chairman of the Finance Committee his conservative fiscal policy helped steer the Association back to a position of financial strength. In addition, he has served on many sub committees helping evolve the technology roadmaps, strategic plans and industry liaisons which have guided our industry through an ever changing landscape. Behler remains a most ardent fan of NADCA and its role in the die cast industry.


Andy Bonczkowski Manufacturing Specialist, Wisconsin Manufacturing Extension Partnership, Madison, WI Bonczkowski@wmep.org (414) 403-4716


Andy comes to WMEP with over 15 years of operations experience in manufacturing. He has successfully led Lean transformations and Six Sigma project teams throughout his career,


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