melt pillar overview: technology projects by themes … · control & draft thinner wall for...
TRANSCRIPT
IND
UST
RY Aerospace
Automotive light vehicle
Commercial heavy vehicles
Military vehicles
Rails
Ships
O�shore platform
Overview: Technology Projects by ThemesM E LT P I L L A R
HIGH INTEGRITYCASTINGS
MULTI-MATERIALCASTINGS
THIN WALLCASTINGS
2016 2017 >2018
Developing & Deploying Thin Wall Ductile Iron Castings For High Volume Production
R1-5
a
Overcasting: multi-material manufacturingR2
-1
Themes
Proj
ects
Proj
ects
Proj
ects
R1-5
b Thin-Wall Aluminum Die Casting Development
R3-1 Thin-Wall cast high strength steel
LIGHTWEIGHTINNOVATIONS
Controlled Di�usion Solidi�cation
R1-1
In-situ Manufacturing of Nanoparticle Reinforced Aluminum Matrix Composites
R2-2
Fluidized HydroSolidi�cation
R2-
4
Integrated AdvancedInvestment Casting
R3-3
>2018
Applications: Technology Projects by themesM E LT P I L L A R
HIGH INTEGRITYCASTINGS
MULTI-MATERIALCASTINGS
THIN WALLCASTINGS
2017
R1-5
a Developing & Deploying Thin Wall Ductile Iron Castings For High Volume Production
Di�erential case; knuckles, frames, doors, crank, cam shafts, vehicle body castings, control arms, wind turbines, housing, covers, cases, heat exchangers
Proj
ects
Proj
ects
Proj
ects
Controlled Di�usion Solidi�cation
R1-1
In-situ Manufacturing of Nanoparticle Reinforced Aluminum Matrix Composites
R2-2
Fluidized HydroSolidi�cation
R2-
4
Integrated Advanced Investment Casting
R3-3
Knuckles suspension components, wheels universal joints, control arms, drivetrain castings, etc.
Oil & gas tooling, defense matrix composites, heavy truck frames & suspension
Thick & thin structural casting for various industries
A P P L I C AT I O N
A P P L I C AT I O N
A P P L I C AT I O N
Thick & thin structural casting for various industries
A P P L I C AT I O N
Overcasting: multi-material manufacturing
R2-1
Structural casting for various industries
A P P L I C AT I O N
A P P L I C AT I O N
R1-5
b
Thin-Wall Aluminum Die Casting Development Knuckles suspension components, wheels universal joints, control arms, drivetrain castings, etc.
A P P L I C AT I O N
R3-1 Thin-Wall cast high
strength steel
Themes
LIGHTWEIGHTINNOVATIONS
Applications: Possible applications each project can translate to across industries when brought to the market.
Programmatic Areas: Technology Projects By ThemesM E LT P I L L A R
HIGHINTEGRITYCASTINGS
MULTI-MATERIALCASTINGS
THIN WALLCASTINGS
2016Themes
Dimensional/tolerancecontrol & draft
Thinner wall for strength-limited applications
Distortion control of thin-wall casting
Thin-wall Ti casting
LEG
END Potential projects within program
3D printed molds/cores for structural castings
High-temp yield strength improvements (alloy optimization, etc.)
Next-G HPDC (melt control, novel melt control, LIBS, non-turbulent �ow, robust new alloy optimization, ICME, defect control, etc.)
Recon�gurable/�exible tooling
High integrity Ti castings (e.g., permanent mold casting)
Surface-functionalized casting (Surface-reactive spray or coating)
Dual-pour casting In-situ reactions/casting between ceramic and molten metal
Substrate surface treatment for multi-material casting
Selectively-reinforced multi-material castings or MMCs
LIGHTWEIGHTINNOVATIONS
ACTI
ON
IT
EMS R1-1 Controlled Di�usion Solidi�cation
Theme #1 Action Items: High Integrity CastingsM E LT P I L L A R
NON-FERROUS
FERROUS
2017 2018 >2019
R1-2 In-situ Manufacturing of Nanoparticle Reinforced Aluminum Matrix Composites
R2-4 Fluidized Hydro Solidi�cation
R3-3 Integrated Advanced Investment Casting
Sub-Themes
1
1
1
1
2
2
2
2
3
3
3
Lab-scale development& modeling
Foundry demonstration& testing
Lab-scale development& modeling
Casting trials, testing & ICMEdevelopment
Composite casting demonstration on production tool Characterization of production castings
Lab-scale development& modeling
Casting trials, testing & ICMEdevelopment
Casting demonstrationon production tool Characterization of production castings
Lab-scale development& modeling
Casting trials, testing & ICMEdevelopment
Casting demonstrationon production tool Characterization of production castings
ACTI
ON
IT
EMS R2-1 Overcasting: multi-material manufacturing
Theme #2 Action Items: Multi-material CastingsM E LT P I L L A R
NON-FERROUS
FERROUS
2018 >2019Sub-Themes
1 2 3Lab-scale development& modeling
Casting trials, testing & ICMEdevelopment
Casting demonstrationon production tool characterization of production castings
ACTI
ON
IT
EMS R1-5a Overcasting: multi-material manufacturing
R1-5b Overcasting: multi-material manufacturing
Theme #3 Action Items: Thin Wall CastingsM E LT P I L L A R
NON-FERROUS
FERROUS
2016 2017 2018 >2019
R3-1 Thin-Wall Cast High Strength Steel
Sub-Themes
Lab-scale development& modeling1
Casting trials, testing /ICME development2
Casting demonstrationproduction toolcharacterization ofproduction castings
3
LIGHTWEIGHTINNOVATIONS
Process Baseline De�nition1
Product Design & Development2
Tool build & Development3
Tooling build & dev/tryout run4
Trials & Validation @ Grede5
Generic prototype die design & simulation1
Casting process modeling2
Heat treatment process development3
Heat treatment process simulation4
Generic prototype die (H13 steel) Mfg.5
Super vacuum die casting (SVDC) trials6
ICME tool integration7
Thin-wall casting design using local properties8
Mechanical property testing and ICME validation9
Thin-wall casting demonstration10
Technical cost modeling11
Incorporation of results in Materials Commons12