wisconsin metalcasting roadmap - seventhwavebuilding wisconsin’s metalcasting future sponsored by...

Building Wisconsin’s Metalcasting Future

SPONSORED BYU.S. Department of Energy—Industries of the Future

Department of Administration’sDivision of energy

Energy Center of Wisconsin

Wisconsin Focus on Energy

IN COOPERATION WITHAmerican Foundrymen’s Society (AFS)

Non-Ferrous Founders’ Society (NFFS)

Steel Founders’ Society of America(SFSA)

Wisconsin Cast Metals Association(WCMA)

COORDINATED BYEnergy Center of Wisconsin

WisconsinMetalcastingRoadmap

WisconsinMetalcastingRoadmapA referencedescribing resourcesand long-termcompetitive needsidentified byWisconsinmetalcasters

Publication320-1

Wisconsin Metalcasting Roadmap

November 2000

Prepared by

595 Science DriveMadison, WI 53711-1076

Phone: 608.238.4601Fax: 608.238.8733

Email: [email protected]

Copyright © 2000 Energy Center of WisconsinAll rights reserved

This document was prepared as an account of work sponsored by the Energy Center of Wisconsin (ECW). NeitherECW, participants in ECW, the organization(s) listed herein, nor any person on behalf of any of the organizationsmentioned herein:

(a) makes any warranty, expressed or implied, with respect to the use of any information, apparatus, method, orprocess disclosed in this document or that such use may not infringe privately owned rights; or

(b) assumes any liability with respect to the use of, or damages resulting from the use of, any information,apparatus, method, or process disclosed in this document.

Acknowledgements

Thanks to all the Wisconsin metalcasters that participated in the roadmap process. It would not have been a successwithout your help. We are especially grateful to the following members of the steering committee:

Ray Donahue, Mercury Marine

Ryan Leiterman, Metal-Technologies

Jim Mallory, Non-Ferrous Founders’ Society

Brian Mitchell, Wisconsin Cast Metals Association

Ray Monroe, Steel Founders Society of America

Roy Pickhard, Milwaukee Valve

Bill Powell, Waupaca Foundry

Robert Purgert, Thompson Aluminum

Rod Riek, Harley Davidson

Pradeep Rohatgi, UW-Milwaukee

Preston Schutt, Wisconsin Department of Administration Division of Energy

Mike Slawny, Wisconsin Electric Power Company

Michael Stroh, Stroh Controls

Ed Wabiszeski, Maynard Steel Casting

David Weiss, Eck Industries

Bob Wolfe, Madison Kipp

John Wright, Foundry Magazine

Contents

Introduction ...................................................................................................................................................................1

What is in this Roadmap? .....................................................................................................................................1

Next Steps .............................................................................................................................................................2

Frequently Asked Questions..........................................................................................................................................3

What is a “Metalcasting Roadmap”? .........................................................................................................................3

How has Wisconsin’s Metalcasting Roadmap been created? ....................................................................................3

What will this document give you?............................................................................................................................3

An industry voice..................................................................................................................................................3

A comprehensive reference tool for the metalcasting industry .............................................................................3

A directory of resources available to Wisconsin metalcasters ..............................................................................3

How do I take action on a need identified in this roadmap? ......................................................................................4

Why are energy organizations assisting the metalcasting industry? ..........................................................................4

Problems lead to increased energy intensity .........................................................................................................4

The traditional approach to energy efficiency.......................................................................................................4

A new approach to reducing energy intensity.......................................................................................................4

So why the metalcasting industry?........................................................................................................................4

Wisconsin Metalcasting Needs......................................................................................................................................5

1. Manufacturing Needs .............................................................................................................................................5

A. Reduce Process Labor Needs ...........................................................................................................................8

B. Rapid Prototyping for Foundry Industry ..........................................................................................................8

C. Thin Wall Casting ............................................................................................................................................8

D. Lost Foam Process for Steel.............................................................................................................................8

E. Heat Treatment Improvements .........................................................................................................................8

F. Melting Atmosphere Control & Reduced Emissions........................................................................................9

G. Best Practices Equipment Guide for Metal Casters .........................................................................................9

H. Filling & Solidification Modeling....................................................................................................................9

I. Reduction of Metalcasting Lead Time...............................................................................................................9

J. Die Casting Quality Improvement.....................................................................................................................9

K. Metal Casting Product Competitiveness ........................................................................................................10

L. Metal Casting Development Program ............................................................................................................11

2. Materials Technology...........................................................................................................................................13

M. Materials Improvement .................................................................................................................................15

N. Clean Metal Technology................................................................................................................................15

O. Low Shrinkage on Solidification....................................................................................................................15

ii

P. Casting Research Center.................................................................................................................................15

Q. Materials Research for Metal Casting............................................................................................................16

3. Environmental Regulatory and Technical Needs .................................................................................................17

R. Solve Silica Dilemma.....................................................................................................................................20

S. Use and Reuse of Byproducts.........................................................................................................................20

T. Regulation ......................................................................................................................................................20

4. Energy Reliability Needs .....................................................................................................................................21

U. Improved Reliability and Supply ...................................................................................................................23

V. Improved Communication between Foundries ..............................................................................................23

5. Products and Market Needs .................................................................................................................................25

W. Product Design..............................................................................................................................................28

X. Communication of New Technologies...........................................................................................................28

6. Human Resource Needs .......................................................................................................................................29

Action on Wisconsin Metalcasting Priorities ..............................................................................................................33

Action Items for Wisconsin Metalcasters ................................................................................................................33

Action Teams ...........................................................................................................................................................34

Metalcasting Resource Directory.................................................................................................................................35

Funding Opportunities .............................................................................................................................................35

Department of Energy – Office of Industrial Technologies................................................................................35

Energy Center of Wisconsin ...............................................................................................................................35

Metalcasting Trade Association...............................................................................................................................36

Other Wisconsin Metalcasting Organizations..........................................................................................................37

Technical Assistance................................................................................................................................................37

Wisconsin Manufacturing Extension Partnership ...............................................................................................38

Administrative Assistance to Pursue Needs Identified in the Roadmap .............................................................38

Energy Efficiency Assistance ..................................................................................................................................38

U.S. Department of Energy – Office of Industrial Technologies........................................................................38

Industrial Assessment Centers ............................................................................................................................39

National Metalcasting Roadmap..................................................................................................................................41

The Wisconsin Metalcasting Industry – A Snapshot ...................................................................................................43

How Wisconsin’s Metalcasting Roadmap Was Developed.........................................................................................51

Tables and Figures

Table 1: Wisconsin Metalcasters by Type ...................................................................................................................44

Figure 1: Reported sales volume .................................................................................................................................45

Figure 2: Wisconsin metalcasters ................................................................................................................................46

Figure 3: Number of national comparison – number of employees.............................................................................47

Figure 4: Wisconsin to national comparison – type of metal cast ...............................................................................47

Figure 5: Wisconsin to national comparison – casting method ...................................................................................48

Figure 6: Wisconsin to national comparison – major metals.......................................................................................48

Figure 7: Wisconsin to national comparison – melting equipment plants ..................................................................49

Figure 8: Wisconsin to national comparision – melting equipment units....................................................................49

Figure 9: Wisconsin to national comparions – coremaking method............................................................................50

Figure 10: Wisconsin to National Comparison – jobbing/captive status .....................................................................50

1

Introduction

Metalcasting is one of the nine industries identified by U.S. Department of Energy (DOE) that together consumeover 65 percent of industrial energy in the United States. The Energy Policy Act of 1992 catalyzed these nineindustries with DOE assistance to develop technology visions and research agendas. The visions and researchagendas identified what was needed to insure the industry remained competitive and viable into the year 2020. Theresulting Metal Casting Agenda 2020 and National Metalcasting Roadmap provides a common vision for theindustry. It also:

• Provides alignment about strategic goals

• Enhances the industry’s ability to conduct research and implement new technology

• Provides leverage to gain funding and assistance

• Improves individual companies’ global competitiveness

The metalcasting industry is important to Wisconsin’s economy. Wisconsin metal casting companies employ over25,000 people, bring in over $3 billion of revenue and consume over eight percent of the industrial energy in thestate.

In December of 1999 the Wisconsin Metal Casting Roadmap Initiative1 was started. Participation in the Initiativeis voluntary. The initiative is industry driven – guided by a steering team of industry and metal casting associationrepresentatives.

The first goal of the initiative was to identify the needs of Wisconsin metalcasters. These needs are described in thisWisconsin-based Metalcasting Roadmap. Although this Wisconsin Metalcasting Roadmap parallels the NationalMetalcasting Roadmap, it also identifies unique needs of Wisconsin metalcasters that must be addressed to insurethe industry’s long-term viability. The second goal of the initiative is to identify resources to address these needs andto facilitate partnerships between industry and funding organizations to find solutions that will help Wisconsinmetalcaster’s competitiveness.

At the first Wisconsin Metalcasting Roundtable June 1, 2000, fifty-eight Wisconsin metalcasters and representativesfrom their associations identified common needs and goals to remain competitive and viable into the year 2020. Theresulting product of that effort, the Wisconsin Metalcasting Roadmap, lists the needs and identifies any recent orongoing research and demonstrations that addresses each of the needs.

On September 14, 2000 Wisconsin metalcasters met to 1) learn of resources available to help them address theirneeds and goals, and 2) form action teams to address priority needs. Wisconsin metalcasters and other interestedparties formed 14 action teams within five broad categories to address priority needs (see Section III).

What is in this Roadmap?

This Metalcasting Roadmap includes a list of frequently asked questions that describe how this document wascreated, what value it has for you, and how you can help get your critical needs addressed. Next, the Roadmap

1 This initiative is funded by the US DOE, Wisconsin Department of Administration’s(DOA) Focus on Energy and administered by the Energy Center of Wisconsin (ECW), aprivate non-profit energy research and education organization.

2

includes a list of the needs identified by Wisconsin metalcasters and their associations, sorted in six broadcategories. This section includes a brief description and contact information on recent or current research anddemonstrations related to the needs. Finally, the last section of this roadmap is a reference section that includes:

• A list of resources to help you identify potential funding sources, technical resources and other assistanceavailable to you.

• A description of the National Metalcasting Industries of the Future Initiative

• A summary of the metalcasting industry in Wisconsin. This summary includes a breakdown of the number andtypes of metal casting companies, number of employees, reported sales volumes, type of process and meltingequipment. Review this section to see how your company compares with other Wisconsin metal casting firms!

Next Steps

Take action on your industry’s priority needs. You can be part of the solution by joining fellow metalcasters inpursuing one of the priority needs. The Energy Center will provide administrative assistance such as coordinating,communicating, and writing funding proposals for the action teams. Identified action teams are already developingstrategies to address the 14 priority needs. Time commitment depends upon your interests. You can lead the team,serve as a participant, or serve as a team advisor. For further information, contact Sherry Benzmiller (608.238.8276ext 121 or [email protected]).

You can help make your industry more competitive and viable. Be a part ofWisconsin’s metalcasting future!

mailto:[email protected]

3

Frequently Asked Questions

What is a “Metalcasting Roadmap”?

A “roadmap” is a communication tool which describes long term competitive needs identified by industry. Findingsolutions to these needs is critical to improve future industry strength. This application of the term “roadmap” wascoined by the U.S. Department of Energy’s – Industries of the Future Program.

With the U.S. Department of Energy’s support, nine industrial sectors have developed national roadmaps. Thedocument you are reading is one of the first state-based roadmaps. This state roadmap identifies competitive needscommon to all metalcasters, as well as needs unique to the metalcasters in Wisconsin. (To find out more about thenational metalcasting roadmap, see the reference section of this document.)

How has Wisconsin’s Metalcasting Roadmap been created?

Following the creation of a National Metalcasting Roadmap, Wisconsin began a state-based roadmapping initiative.The purpose of the state initiative is to bring together metalcasters, funding, and other resources to address local andnational metalcasting industry needs. The needs presented in this roadmap have been identified by metalcasters andtheir associations who volunteered their time. Fourteen metalcasters participated in detailed interviews and 58metalcasters met at the first metalcasting roundtable to generate this list. Additional input was provided throughfollow-up mailing to all metalcasters in Wisconsin.

What will this document give you?

An industry voice

This roadmap brings together metalcasters with the resources needed to increase the competitiveness of theirindustry. The advantage of creating a consolidated “needs list” is that it serves as a tool for individual metalcastersand their trade organizations to communicate their goals to local, state and national organizations who can helpthem. By working collectively to meet these needs we can help insure a viable metalcasting industry.

A comprehensive reference tool for the metalcasting industry

The roadmap provides a comprehensive listing of the Wisconsin metalcasting industry needs and the work that iscurrently underway around the country to address all or parts of those needs.

A directory of resources available to Wisconsin metalcasters

There are many resources available to assist Wisconsin metalcasters. The difficulty is in knowing what they are andhow to contact them. Use the resources section of this document as a quick reference to make these resourcesaccessible when the need arrives.

4

How do I take action on a need identified in this roadmap?

Determine that action must be taken and find others interested in taking part. Metalcasting trade associations are oneway to find others interested in taking action. ECW, through the Wisconsin Metalcasting Roadmap Initiative, willhelp individual metalcasters and their associations accomplish their goals.

Why are energy organizations assisting the metalcasting industry?

Problems lead to increased energy intensity

Problems in industrial plants tend to increase the amount of energy that goes into each product produced. Evenproblems that are not directly related to hardware typically result in an increase in energy consumption per unit ofproduct produced.

The traditional approach to energy efficiency

Organizations promoting efficient use of energy have traditionally developed or identified technologies andtechniques which get the same job done with less energy. Demonstration of these technologies has been widely usedas a method to improve industry confidence in using the technology. The drawback of the technology-basedapproach is that, although the technology may make solid economic sense, cost reduction through energy efficiencyis currently not a priority of many industrial plants. Energy efficiency projects that are adopted by industry typicallyfulfill a particular need, in addition to cutting energy costs.

A new approach to reducing energy intensity

Since the barrier to implementing energy efficiency concepts has been finding a willing audience, the energyefficiency community is pursuing the approach of partnering with industrial sectors to assist them in resolvingindustry-identified needs. By resolving these needs, an expected side-effect will be the reduction of energy per unitof product produced.

So why the metalcasting industry?

The metalcasting industry is important to the state's economy. Metalcasting industries employ 25,000 people inWisconsin and consume over eight percent of the industrial energy in the state. About 20 to 30 percent of theproduction cost for a metalcaster is energy. With this energy intensity, the amount of energy likely to be reduced isgreater than other industrial sectors, where energy is three to ten percent of production costs.

5

Wisconsin Metalcasting Needs

The needs identified by Wisconsin metalcasters are organized into six categories. These categories are the same asthose identified in the National Metalcasting Roadmap.

1. Manufacturing

2. Materials Technology

3. Environmental – Regulatory and Technology

4. Energy Reliability

5. Products & Markets

6. Human Resources

For each of the six categories a matrix describes whether the need is a state or national priority and whether thesolution to that need involves technology. In addition, we have identified recent efforts that may address all or partof a need. Following the matrix is a detailed description of the need and related efforts, including contactinformation.

1. Manufacturing Needs

The needs identified in this section impact the process of manufacturing a metalcast product.

There are 26 individual needs which have been grouped into five subcategories. The subcategories are:

• Cost control

• Process flow improvement

• Tooling technology

• Continuous improvement

• Promotion

Next to each individual need are six columns:

“National Roadmap” = this is a national need on the National Roadmap

“National” = this is a national need, although not on the National Roadmap

“Wisconsin” = this is a Wisconsin only need

“Technology” = this is a need whose solution relates to technology

“Policy” = this is a need whose solution does not relate to technology

“Currently Addressed” = some part of this need is currently being addressed

Project names and contact information associated with each action being addressed are found after the needs matrix.

6

Manufacturing National

Roadmap

National Wisconsin Technology Policy Currently

Addressed

COST CONTROL

minimize time/temperature in solution heat treatment x x E1

lost foam in steel x x D1

modeling for filling and solidification with foam decomposition product x x H2

cost effective atmosphere control in melting x x

develop polymer quenchant technology x x A1, A2

improve automation in low to mid production volumes x x A1, A2

reduce labor hours per ton of production x x

reduce energy cost per ton of production x x

improve ability to quantify technology impact on quality and cost x x

PROCESS FLOW IMPROVEMENT

increase throughput x x

synchronous flow / flexible manufacturing x x

reduce time from concept to final product x x

reduce scrap and rework x x K1 - K7

automate data collection x x

TOOLING TECHNOLOGY

need better sand aggregate materials x x

need thin wall near net shapes x x B1, B2

need low cost, dimensionally accurate, rapid tooling x x B1

need consumer report on new equipment x x

need solidification modeling to predict microstructure and properties x x

improve furnace thermal efficiency x x

7

Manufacturing National

Roadmap


Addressed

CONTINUOUS IMPROVEMENT

integrate manufacturing process control x x

summarize metalcasting best practices x x G1

improve internal quality of die casting x x J1 - J16

develop high integrity die casting technology x x

PROMOTION

create a business development program to encourage expansion and new plants x x

need assistance to reduce energy consumption in compressed air systems x x

8

Manufacturing

A. Reduce Process Labor Needs

Action/Contact

A1. Ergonomic Improvements for Foundries, Iowa State University (DOE Project Contacts: P.E. Peterson; F.E.Peters, Iowa State University (515.294.5933)

A2. Ergonomics Laboratory, University of Wisconsin-Milwaukee. Contacts: A. Garg, Industrial & ManufacturingEngineering Department, College of Engineering & Applied Science (414.229.6240)

B. Rapid Prototyping for Foundry Industry

Action/Contact

B1. “Improved Readiness through Fast Freeform Fabrication”, Northwest University. Contact J. Santer(800.537.4237)

B2. “Rapid Prototyping Consortium,” Milwaukee School of Engineering. Contact John Choren, Tom Bray(414.277.7384)

C. Thin Wall Casting

Action/Contact

C1. Thin Wall Iron Casting, CMC Project. Contact Tom Piwonka, University of Alabama (205.348.1585)

C2. Thin Wall Steel Castings, Penn State. Contact R. Voigt (814.865.7601)

C3. Thin Wall Steel Castings, Steel Foundries Society. Contact R. Monroe (847.382.8240)

D. Lost Foam Process for Steel

Action/Contact

D1. Lost Foam Castings Technology Project, University of Alabama at Birmingham Contacts: Charles Bates(205.975.8120); Joe Santner, AFS (847.824.0181)

E. Heat Treatment Improvements

Action/Contact

E1. CMC Project with AFS Support on “In Stream Inoculation for Aluminum Casting Processes,” Oak RidgeNational Laboratory. Contact S. Viswanathan (423.576.9917) or J. Santner, AFS (847.824.0181)

9

F. Melting Atmosphere Control & Reduced Emissions

Action/Contact

F1. Industrial Heating Magazine. Article summaries addressing these needs:www.industrialheating.com/article_database.htm

G. Best Practices Equipment Guide for Metal Casters

Action/Contact

G1. AFS Publishes a Buyer’s Directory for Metal Casting Industry. Contact AFS at www.afsinc.org or1.800.537.4237

H. Filling & Solidification Modeling

Action/Contact

H1. There is a NIST Darpa and Howmet Corporation project on improving modeling to predict microstructure ofcastings. Contact B. Boettinger, NIST

H2. “Solidification Design and Control Consortium.” AFS with NASA-MFC and Auburn University. Contact J.Santner- AFS (847.824.0181)

H3. “Thermophysical Property Measurement for Casting Process Design.” Auburn University. Contact TonyOverfelt (334.844.5894)

I. Reduction of Metalcasting Lead Time

Action/Contact

I1. “American Metal Casting Consortium: Reduced Lead Time and Cost Reduction Phase I & II.” Contact DennisAllen, AMC Program (843.760.3215), J. Santner, AFS (847.824.0181)

J. Die Casting Quality Improvement

Action/Contact

J1. “Preventing Die Solding in Zinc Die Casting” Frank Goodwin, International Lead Zinc Research Organization

J2. Enhancements in Magnesium Die Casting. Contact Steve Udvardy, NADCA (847.292.3600 x219 or219.288.7552)

J3. Mechanical Properties of Squeeze and Semisolid A356 – Case Western Reserve. Contact J. Wallace(216.368.4222)

J4. Semisolid Metal Processing Consortium. Worcester Polytechnic, Oak Ridge National Laboratory and MIT.Contact D. Appelian, WPI (508.831.5222)

http://www.industrialheating.com/article_database.htm

http://www.afsinc.org/

10

J5. “Rapid Tooling for Functional Prototyping of Metal Mold Processes.” Contact Larry Quimet, GMI USAMP,Robert E. Eppich

J6. “Casting Die Life Extensions through Preventative Maintenance.” Contact Jack Wallace, Case Western Reserve(216.368.4222)

J7. Optimization of Composition and Heat Treatment of Die Steels. Contact Jack Wallace, Case Western Reserve(216.368.4222)

J8. “Influence of Thickness and Surface Coatings on Magnesium Properties.” Contact Carol Mobley, Ohio StateUniversity (614.292.5770)

J9. “Evaluation of Coatings for Die Surfaces.” Ragir Shirpari, Ohio State University

J10. “Development and Evaluation of Sensor Systems.” Contact Carol Mobely, Ohio State University(614.292.5770)

J11. “Die Casting Defects Causing Rejection during Machining.” Contact Jerald Brerick or Carol Mobley, OhioState University (614.292.5770)

J12. “Die Casting Part Distortion: Predictors and Control.” Contact R. Allen Miller, Ohio State University(614.292.6351)

J13. “Dimensional Control of Die Castings.” Contact R.A. Miller, Ohio State University (614.292.6351)

J14. “Computer Modeling of Short Sleeve Distortion.” Contact Jerry Brerick, Ohio State University (614.292.6351)

J15. “Deflection of Die Casting Dies.” Contact R.A. Miller, Ohio State University (614.262.6351)

J16. “High Speed Milling of Dies.” Contact Ohio State University (614.262.6351)

K. Metal Casting Product Competitiveness

A number of projects are currently being worked on which contribute to the above needs. These include projects onsolidification modeling (which have been listed elsewhere) and projects which deal with a) methodizing—includinggating, risering, and feeding; b) development of filtering techniques; c) on line sensing and control of processes andd) nondestructive inspection, both on line and off line.

Action/Contact

K1. “Gating of Aluminum Permanent Mold Castings.” Contact Jack Wallace, Case Western Reserve University(216.368.4222)

K2. “Process Parameters for Lead Free Copper Based Engineering Alloys in Permanent Molds.” Contact M. Sahoo,Canmet (613.992.5475)

K3. Technology for the Production of Clean, Thin Wall, Machinable Gray and Ductile Iron Castings.” ContactCharles Bates, University of Alabama-Birmingham (205.975.8120)

11

K4. “Heat Transfer at the Mold – Metal Interface in Permanent Mold Casting of Aluminum Alloys.” Contact R.Pahlke, University of Michigan (313.936.1295)

K5. “Aluminum Gating Study.” Contact Dan Groetke, QC Designs, (616.983.6859)

K6. “Clean Metal Casting.” DOE. Contact Dr. D. Appelian, Worcester Polytechnic Institute (508.831.5222)

K7. “Quality Improvement Expert System.” Contact Dr. H. Roshan, Maynard Steel Casting (414.645.0440)

L. Metal Casting Development Program

Action/Contact

L1. Wisconsin Department of Commerce. The Wisconsin Department of Commerce is the state’s primary agencyfor delivery of integrated services to businesses.

The purpose of the Wisconsin Department of Commerce is to:

• Foster the retention and creation of new jobs and investment opportunities in Wisconsin

• Foster and promote economic business expert and community development

• Promote the public health, safety and welfare through effective and efficient regulations, education andenforcement

Business Helpline – 1.800. HELP-BUSExport Helpline – 1.800.XPORT-WIwww.commerce.state.wi.us/com/com

L2. The Wisconsin Economic Development Association (WEDA) is a statewide, nonprofit organization dedicatedto expanding the economy of Wisconsin. Founded in 1975, WEDA represents more than 400 economicdevelopment professionals and active volunteers. Contact Brenda Ralph (608.255.5666) for more information.

http://www.commerce.state.wi.us/com/com

13

2. Materials Technology

The needs identified in this section are based on developing new raw materials or predicting the properties ofexisting raw materials, in addition to improving the quality of castings through reduction of defects.

There are 21 individual needs which have been grouped into three subcategories. The subcategories are:

• New materials

• Reliability

• Database









14

Materials Technology National

Roadmap


Addressed

NEW MATERIALS

develop cost effective composite materials x x M1 - M4

develop alloys free from toxic materials x x

develop AL-Si compositions to eliminate eutectic modifiers x x

develop alloys with low shrinkage on solidification x x

reduce casting weight x x

need long lived tooling materials for die casting x x

need materials that melt with less heat x x

need cheaper materials x x M1 - M4,

Q1 -Q4

RELIABILITY

need faster defect analysis x x

need low-cost, clean metal technology to control non-metallics and gas x x N1 - N3

need to reduce inclusions in steel castings and oxides in aluminum x x N1 - N3

need rapid scrap analysis x x

improved quality and reduced cost x x

improve soundness and yield of casting x x

elimination of dangerous/difficult jobs x x

DATABASE

need national database on material characteristics x x

improve materials together with vendors and research facilities x x

determine effects of adding elements to metals x x

establish a casting research center to assist with R&D x x

develop low-cost, high-performance secondary alloy x x Q1 - Q4

need efficient communication for industry advances to be shared x x x

15

Materials Technology

M. Materials Improvement

Action/Contact

M1. Eck Industries. Contact David Weiss (920.682.4618)

M2. “Mechanical Properties – Structure Correlation for Commercial Specification of Cast Metal MatrixComposites.” University of Wisconsin-Milwaukee. Contact Pradeep Rohatgi (414.229.4987)

M3. AFS Committee for Metal Matrix Composites. Contact J. Santner, AFS (847.824.0181)

M4. Thompson Aluminum Castings, Cleveland Ohio. Contact Robert Purgert (216.761.7533)

N. Clean Metal Technology

Action/Contact

N1. Clean Metal Casting Project of Cast Metals Consortium on Aluminum, Wooster Polytechnic Institute. ContactDr. Diran Appelian (508.831.5222); Joe Santner, AFS ( 847.824.0181)

N2. Clean Cast Steel Projects funded by US DOE-Office of Industrial Technology

Clean Cast Steel – Flow of Steel in Sating Systems. Contact Dr. Charles S. Bates, University of Alabama-Birmingham; Dr. Robin D. Griffin

Steel Macroinclusions Atlas. Contact Ray Monroe, Steel Founders Society (847.382.8240)

N3. Clean Steel Technology – Accelerated Transfer of Clean Steel Technology to Steel Industry. Contact R.Monroe, Steel Founders Society (847.382.8240)

O. Low Shrinkage on Solidification

Very little work is going on to develop new alloy compositions which have low shrinkage on solidification, whileyielding acceptable properties. This will require long term research but the results can lead to sound castings andincreased casting yields.

P. Casting Research Center

Action/Contact

P1. Foundry and Solidification Processing Laboratory, UW-Milwaukee. Contact Pradeep Rohatgi (414.229.4987)

P2. Casting Development Center, Cleveland, OH. Contact R. Purgert (216.761.7533)

16

Q. Materials Research for Metal Casting

Action/Contacts

Q1. AFS Funded “Mechanical Properties of Sebialoy I and Sebialoy II” and “Effect of Bismuth and Selenium onProperties of Leaded Red Brasses.” Canmet. Contact M. Sahoo (612.992.5475)

Q2. DOE “Lead Free Copper Graphic Alloys.” UW-Milwaukee. Contact Pradeep Rohatgi (414.229.4987)

Q3. Effect of Selected Elements in Cast Iron and Aluminum, UW-Madison. Contact C. Loper (608.262.2562)

Q4. “New Aluminum-Silicon Alloy,” Mercury Marine. Contact R. Donahue (920.929.5421)

17

3. Environmental Regulatory and Technical Needs

The needs identified in this section relate to achieving regulatory compliance. The needs address reducing theburden to meet environmental regulatory compliance and developing needed technology to reduce emissions at theirsource.

There are 39 individual needs, which have been grouped into eight subcategories. The subcategories are:

• Regulations

• Use and reuse of byproducts

• Technologies needed

• Cooperation

• Simplified regulation / uniformity

• Permits

• Assistance

• Improvement









18

Environmental National

Roadmap


Addressed

REGULATIONS

need to reduce cost of regulatory communication x x x

need to be able to plan for environmental standards x x x

need to review CAA of 1990 for practicality x

need ability to cost effectively expand business x x

prove compliance testing methods before regulation in effect x x

level regulatory requirements for all metalcasters x x x

reduce air permit turnaround time to a few weeks x x

need efficient, coordinated, clear regulation x x

USE AND REUSE OF BY PRODUCTS

need sources for use of byproducts x x M1 - M4

need regulatory endorsement to use byproducts x x

TECHNOLOGIES NEEDED

reduce baghouse costs / increase reliability x x

need zero discharge systems (all materials used) x x

need C12-free melt treatment x

need inorganic binder system x x

need technology to improve internal cleanliness x x

need zero-emission riser cutting x x

need reduced emission aluminum melting x x

need non-hazardous lubes x x

need affordable, practical air emission monitoring x x F1

solve the silica dilemma x x R1

need means to share environmental technology information x x x

19

COOPERATION

need predictable properties and time lines for future regulation x x x

need greater industry involvement in regulatory process x x x

need trust between industry and regulators x x x

need frequent regulatory / industry communication x x x

SIMPLIFIED REGULATION / UNIFORMITY

establish uniform state and federal regulation for safety and environment x x x

need single agency to interact with x x

need clear divisions between regulators x x x

validate Wisconsin's non-attainment status x x x

PERMITS

need faster permitting process x x

ASSISTANCE

need information sharing on byproduct reuse x x x

need collaboration with vendors to reduce emissions x x x

need waste stream coordination assistance x x x

need proactive industry effort with government x x x

need funding for pollution reduction actions x x x

IMPROVEMENT

need more realistic emission calculation instead of maximum theoretical x x

reduce regulatory paperwork x x x

need clear regulation x x x

establish compliance science before regulation x x x x

20

Environmental Regulatory and Technical Needs

R. Solve Silica Dilemma

Action/Contact

R1. Silica Coalition. Contact Robert Glen, National Industrial Sand Association (301.595.5550); Gary Mosher AFS(847.824.0181)

S. Use and Reuse of Byproducts

Action/Contact

S1. FIRST (Foundry Industry Reuse Starts Today) – Phase II through IV. Contact Elizabeth Olenbush, EOAssociates (516.472.9187); Gary Moster, AFS (847.824.0181)

S2. “Development of an Information Database on Beneficial Reuse of Foundry By-products.” Contact BrianMitchell, WCMA (414.271.5900)

S3. “Non-Incineration Treatment to Reduce Benzene and VOC Emissions from Green Sand Molding Systems.” R.Voigt, Penn State University (814.863.7290); Joe Santner, AFS (847.824.0181)

S4. Reuse of Waste Foundry Sand and Slag in Construction Center for By-products Utilization.” Contact Dr. Naik,UW-Milwaukee (414.229.6696)

S5. State Programs for Disposal of Waste Foundry Sand and other Foundry By-products in the states of WestVirginia, Michigan, Iowa, Pennsylvania.” Contact Harvey Wong, DOE-OIT State Program on Metal Casting(202.586.9235)

T. Regulation

Action/Contact

T1. “Maximum Achievable Control Technology – MATC.” Ajax & Associates. Contact Robert Ajax,(919.362.7123)

T2. “Foundry Industry Air Emissions Database – Phase I – IV.” Foundry Association of Michigan. Contact TedPalpass (616.536.2261)

T3. “Environmental Management System Pilot Project.” Contact Brian Mitchell, WCMA (414.271.5900), SusanLindem, Wisconsin DNR (608.267.0567)

21

4. Energy Reliability Needs

The needs identified in this section relate to being able to predict energy availability and pricing for businessplanning purposes. In addition, this category includes minimizing energy resources cost through educatedpurchasing and minimizing consumption.

There are 10 individual needs which have been grouped into four subcategories. The subcategories are:

• Supply and reliability

• Education and strategy development

• Energy cost and cost predictability

• Communication between metalcasters









22

Energy Reliability National

Roadmap


Addressed

SUPPLY AND RELIABILITY

communicate future so industry can plan x x

need reliable supply at reasonable price x x

EDUCATION AND STRATEGY DEVELOPMENT

need education to prepare for open market x x

need open market for pricing and reliability x x

ENERGY COST AND COST PREDICTABILITY

need stable energy costs x x

need long-term, predictable costs x x

need competitive price x x

need cost comparison between states x x

COMMUNICATION BETWEEN METALCASTERS

need benchmarking within industry x x x V1 - V3

need sharing of energy management strategies x x x V1 -V3

23

Energy Reliability

U. Improved Reliability and Supply

Action/Contact

U1. A draft Strategic Energy Assessment for Wisconsin is available on the Wisconsin Public Service Commissionof Wisconsin's website: http://www.psc.state.wi.us/cases/sea/seadraft.htm

Hard copies of the draft SEA may be requested by submitting a written request to:

Records ManagementPublic Service Commission of Wisconsin

P.O. Box 7854Madison, WI 53707

608.261.8524e-mail: [email protected].

There is no charge for hard copies of the draft SEA.

V. Improved Communication between Foundries

Action/Contact

V1. “The Foundry Industry: Review of Process Energy Use, Markets and Information Resources.” Energy Center ofWisconsin. Contact Karen Meadows (608.238.8276 x146)

V2. “Energy Audit Studies of Selected Foundries.” UW-Milwaukee. Contact Umesh Saxena (608.229.4052)

V3. “Energy Audits of Industries.” DOE. Contact Charles Glasser (202.586.1298 or [email protected])


25

5. Products and Market Needs

The needs identified in this section relate to increasing the efficiency and speed of producing and delivering ametalcasting product. This category also includes retaining and growing existing markets.

There are 21 individual needs which have been grouped into eight subcategories. The subcategories are:

• Education

• Competitive advantage

• Design

• Attract and retain customers

• World market

• Third party support

• Cost issues

• Distribution









26

Products and Markets National

Roadmap


Addressed

EDUCATIONimprove user specification / design of castings x xcreate user awareness of casting benefits x x

COMPETITIVE ADVANTAGEreduce concept to production time x xcommunicate with user to understand needs x xrespond quickly to user needs x x

DESIGNimprove designs to optimize manufacturability x x W1need standardized specification and standards x xredesign fabrications into castings x xmake it easy to design and use castings x x W1

ATTRACT AND RETAIN CUSTOMERSretain in-state business x xattract new customer base x x

WORLD MARKETimprove language skills x xcombat internet coalitions x xthink as a world wide supplier x xcompensate for goods produced with greater emissions x xincrease export marketing knowledge x x

27

3RD PARTY SUPPORTsingle source for metalcasting buyer assistance x xneed metalcasting promoter similar to plastics x x

COST ISSUESneed a stable international currency valuation x x

DISTRIBUTIONneed better transportation to markets x x xneed better distribution channels x x x

28

Products & Markets

W. Product Design

W1.AFS Magazine “Engineered Casting Solutions” is a tool developed to present opportunities for optimal productdesign and function. Contact AFS 1.800.537.4237, www.afsinc.org or www.castsolutions.com

X. Communication of New Technologies

Action/Contact

X1. Wisconsin Metal Casting Associations have websites containing updated technology information.

American Foundrymen Society, www.afsinc.comSteel Founders’ Society of America, www.sfsa.org

Non-Ferrous Founders’ Society, www.nffs.orgWisconsin Cast Metals Association. Contact Brian Mitchell (414.227.1292)

X2. U.S Department of Energy – Industries of the Future. Metal casting is one of seven designated areas that theDOE has supported to improve technology and the industry. Contact Harvey Wong (202.586.9235)www.oit.doe.gov/metalcast

http://www.afsinc.org/

http://www.castsolutions.com/

http://www.afsinc.com/

http://www.sfsa.org/

http://www.nffs.org/

http://www.oit.doe.gov/

29

6. Human Resource Needs

The needs identified in this section relate to maintaining a quality labor force for both manual labor and technologypositions.

There are 12 individual needs which have been grouped into two subcategories. The subcategories are:

• Labor supply

• Education









30

Human Resources National

Roadmap


Addressed

LABOR SUPPLY

need reliable labor force with ability to gain skills x x

need skilled labor with education in metalcasting x x

need to make metalcasting industry more attractive x x x

need labor and management to work together x x

need metalcasting to be an attractive career x x x

need metalcasting to be accepted by local community x x x

EDUCATION

need metalcasting curriculum increased in university and tech schools x x x

increase students' hands on experience with metalcasting x x x

need ongoing metalcasting employee education x x x

need funding to support metalcasting education infrastructure x x x

educate public on importance of metalcasting x x x

need more safety training materials for metalcasting work x x x

31

Human Resources

There are no identified actions in this area.

33

Action on Wisconsin Metalcasting Priorities

Wisconsin metalcasters participating in the second Metalcasting Roundtable identified the following 14 actionitems. This list is a subset of the needs identified at the first roundtable.

Action Items for Wisconsin Metalcasters

Manufacturing

1. Improve efficiency of small run production

2. Reduce cost of heat treating

3. Improve process flow

Human Resources

4. Attract and retain technical labor

5. Attract and retain non-technical labor

6. Improve future metalcasting labor supply

Energy

7. Improve knowledge of supply reliability, purchase strategy, and future cost predictability

Environmental

8. Improve regulation permitting process

9. Improve use and reuse of foundry waste

Materials Technology

10. Develop cost effective composites

11. Develop improved cast iron alloys

12. Develop alloys free from toxic materials

13. Develop metal matrix composites

14. Improve understanding of filling/solidification characteristics to increase yield of cast iron, aluminum, and steelalloys

Our plan is to address these needs based on metalcasters’ interest. Items with the greatest number of interestedmetalcasters will be pursued first.

34

Action Teams

To address these priorities, ECW will review how other U.S. metalcasters are addressing these needs, solicit inputfrom Wisconsin metalcasters, and create team plans. We will then assemble action teams. The teams will revise theplans and develop a schedule. We suggest that teams communicate on a monthly basis to review progress, reviseplans, and set monthly goals. ECW will provide a progress report to all Wisconsin metalcasters twice a year.

We suggest the following steps for developing action plans:

1. Establish goals

2. Identify barriers to reaching these goals

3. Develop ways to overcome the barriers

4. Identify resources needed to implement the action plan

5. Develop a schedule

6. Develop a list of members and contact information

In order to maximize time and resources, the metalcasting initiative will provide assistance to the action teams. Wewill provide logistical support and identify and bring together the resources needed to pursue their goals. Actionteams will then be able to focus on issues that only they, with their extensive experience and insight, can address.

To keep participants informed on progress toward meeting their goals, we will provide e-mail updates on at least asemi-annual basis. We also plan to arrange an annual meeting where metalcasters can discuss the initiative.

To find out more about action teams or how to participate, contact the Energy Center of Wisconsin at 608.238.4601.

35

Metalcasting Resource Directory

Funding Opportunities

Department of Energy – Office of Industrial Technologies

Industries of the Future (IOF) Vision Teams

DOE has been placing special emphasis on working with energy and waste-intensive industries to develop theresearch and technologies that will make a vision of clean, competitive Industries of the Future (IOF) a reality. Thenine industries being addressed are: agriculture, aluminum, chemicals, forest products, glass, metalcasting, mining,petroleum refining, and steel.

For further information on these programs you can contact the Energy Efficiency and Renewable EnergyClearinghouse (EREC) at 1.800.DOE.EREC (1.800.363.3732) or OIT Clearinghouse at 1.800.862.2086. Each year,the Industries of the future program teams with industry to pursue needs identified in the national metalcastingroadmap. In recent years, IOF provided significant matching project funding to the metalcasting industry.www.oit.doe.gov/metalcast

The National Industrial Competitiveness Through Energy, Environment, & Economics (NICE3) Program

NICE 3 is an innovative, cost-sharing DOE grant program designed to promote energy efficiency, clean production,and economic competitiveness in industry. The program provides grants to state and industry partnerships thatdevelop and demonstrate new energy efficiency and clean production technologies. If you have an innovativetechnology that you want to demonstrate, you should contact your state agencies responsible for energy, pollutionprevention, or business development to explore the possibility of developing a grant proposal. Federal funds cancover 45 percent of project costs (up to $425,000). www.oit.doe.gov/metalcast

Inventions and Innovation

The only federal program devoted to providing financial and technical assistance to small businesses andindependent inventors. The Inventions and Innovation program will fund up to $200,000 for well-developedinventions moving towards prototype development or commercialization. At a minimum, engineering analysisand/or a bench scale model must be complete for an invention to be considered. www.oit.doe.gov/metalcast

Plant Wide Energy Efficiency Assessments

Plant-Wide Energy Assessment Opportunity - OIT will share up to 50 percent of the assessment cost (up to$100,000) and provide technical assistance, tools, and resources. The solicitation opened on August 1, 2000 and willclose on November 22, 2000. www.oit.doe.gov/metalcast

Energy Center of Wisconsin

Funding to pursue concepts, tools, and information on energy efficiency in industry

The Energy Center of Wisconsin has an annual solicitation to identify projects which lead to industrial energyefficiency improvement. Projects typically combine financial and technical resources from several sources toachieve the desired goals. Industry-endorsed initiatives are a priority for this funding. Annual energy intensity

http://www.oit.doe.gov/metalcast




36

benchmarking for Wisconsin’s metalcasting industry is a project currently underway. The Energy Center ofWisconsin also has case studies, fact sheets, software, and other resources for industry. Email: [email protected]: www.ecw.org

Metalcasting Trade Associations

American Foundrymen’s Society (AFS)

Stateline Chapter

Marc Vuletich

302 Peoples Avenue

Rockford, IL 61104-7092


Wisconsin Chapter

Gene O’Kelly

Maynard Steel Casting Company

2856 S. 27th Street

Milwaukee, WI 53215


Northeast Wisconsin Chapter

Bruce Prellwitz

Rice Industries, Inc

W2516 County Road J

Green Lake, WI 54941

American Society Metals International

(formerly American Society for Metals)

9639 Kingsman Road

Materials Park, OH 44073

Non-Ferrous Founders Society (NFFS)

Jim Mallory

1480 Renaissance Drive #310

Park Ridge, IL 60068

North American Die Casting Association (NADCA)

Steve Udvardy

9701 West Higgins Road, Suite 880

Rosemont, IL 60018

Steel Founders’ Society of America (SFSA)

Raymond Monroe

205 Park Avenue

Barrington, IL 60010-4332


http://www.ecw.org/

37

Wisconsin Cast Metals Association (WCMA)

Brian Mitchell

600 East Mason

Milwaukee, WI 53202

Other Wisconsin Metalcasting Organizations

UW-Milwaukee, Metalcasting Department

Dr. Pradeep Rohatgi

1401 East Fairmount Street

Milwaukee, WI 53217

UW-Madison, Cast Iron Research

Carl Loper

227 Materials Science and Engineering Building

1509 University Avenue

Madison, WI 53706

Foundry Magazine

John Wright

1100 Superior Avenue

Cleveland, OH 44114

Modern Casting Magazine

American Foundrymen’s Society

505 State Street

Des Plains, IL 60016

Technical Assistance

A Laboratory Coordinating Council (LCC) has been formed to expedite industry's access to the vast science andtechnology capabilities and expertise of DOE’s National Laboratories. The LCC also facilitates collaborationbetween the labs and industry and can assist in matching industrial technology needs with the appropriatecapabilities and assets of the DOE's National Lab System. The following labs have the technology capabilities andexpertise to meet the technology needs of the metalcasting industry.

• Albany Research Center

• Ames National Laboratory

• Argonne National Laboratory

• Federal Energy Technology Center

• Idaho National Engineering and Environmental Laboratory

• Los Alamos National Laboratory

38

• Lawrence Berkeley National Laboratory

• Lawrence Livermore National Laboratory

• National Renewable Energy Laboratory

• Oak Ridge National Laboratory

• Pacific Northwest National Laboratory

• Sandia National Laboratory

Wisconsin Manufacturing Extension Partnership

WMEP is the manufacturer's resource for improving productivity, profitability, and competitiveness. Their missionis to improve manufacturing in Wisconsin. WMEP provides manufacturing, technical and management assistance toWisconsin's small and midsize manufacturers, in order to deliver bottom line improvements. Drawing on real worldexperience of manufacturing specialists, WMEP assists companies to modernize their manufacturing operation andeffectively manage business. E-mail: [email protected] Fax: 608.240.1744, Phone: 608.240.1740 or1.800.637.4634

Administrative Assistance to Pursue Needs Identified in the Roadmap

The Wisconsin Metalcasting Roadmap initiative has administrative resources to provide support and coordinationfor groups pursuing needs identified in the Wisconsin Metalcasting Roadmap. This support can include coordinationof the work team, identification of additional expertise needed for the work team, and pursuit of funding.

Energy Efficiency Assistance

U.S. Department of Energy – Office of Industrial Technologies

BestPractices Programs

The Motor Challenge Program

The program provides case histories, technical tools, and training based on products that have been developed withindustry. A Motor Challenge Clearinghouse has been established: 1.800.862.2086 and their web sitewww.oit.doe.gov/bestpractices/motors provides additional information. This is a valuable source of information onall of your questions related to motors and motor driven systems.

The Steam Challenge Program

If you are a steam owner, you can join the ranks of industry leaders who have improved productivity and increasedprofits by using BestPractices tools for your facility today. Steam system equipment and service providers canbenefit by allying with the message of steam system improvement and promoting the use of BestPractices tools. Forsteam system information call 1.800.862.2086 or get information immediately on DOE’s website atwww.oit.doe.gov/bestpractices/steam/steam.shtml.


39

The Compressed Air Challenge Program

The mission of the CAC is to develop and provide resources that educate industry on the opportunities to increasenet profits through compressed air system optimization. Training and resources can be found by calling1.800.862.2086, or get information on their website at www.knowpressure.org.

Industrial Assessment Centers

These centers provide "no cost" industrial assessments, energy, waste, and productivity surveys for small- andmedium-size manufacturing plants. To be eligible for an IAC assessment, a manufacturing plant must meet thefollowing criteria:

• Within Standard Industrial Codes (SIC) 20-39

• Within 150 miles of a host campus

• Gross annual sales below $75 million

• Fewer than 500 employees at the plant site

• Annual energy bills more than $75,000 and less than $1.75 million

• No professional in-house staff to perform the assessment

In Wisconsin contact: University of Wisconsin-Milwaukee, Dr. Umesh Saxena, 414.229.4052, E-mail:[email protected]


41

National Metalcasting Roadmap

Industries of the Future

Sponsored by U.S. Department of Energy

DOE is doing business in a new way. The Industries of the Future is a fundamentally different approach to thedevelopment of new industrial technology. The process aligns federal investments in technology research,development, and deployment with the needs of the technology users in the metalcasting industry. All referencedinformation can be received by calling 1.800.862.2086 or going to their website at www.oit.doe.gov/metalcast.

Based on the vision document “Beyond 2000,” American Foundry Society (AFS), Steel Founder’s Society ofAmerican (SFSA) and North American Die Casting Association (NADCA) developed the Metal Casting IndustryTechnology Roadmap, which outlines a specific path for accomplishing the vision. The Cast Metals Coalition(CMC) was established by AFS, SFSA, and NADCA to provide direct partnership with DOE. Today, some specificaccomplishments include the following:

Vision Developed

In September 1995, chief executive officers and presidents from the foundry, die casting, and foundry supplyindustries developed “Beyond 2000: A Vision for the American Metal Casting Industry.”

Compact Signed

During October 1995, the American Foundrymen’s Society (AFS), Steel Founders’ Society of America (SFSA) andNorth American Die Casting Association (NADCA) signed a Compact establishing a voluntary collaborative effortbetween industry and the U.S. Department of Energy. The compact provided the framework for identifyingappropriate areas for joint research, development, and technology demonstrations.

Technology Roadmap

Published January 1998, the CMC recently finalized the Technology Roadmap. The roadmap sets out the strategyfor pursuing near-, mid-, and long-term goals set out by industry and for carrying out the cooperative agreementbetween the U.S. Department of Energy and industry. The roadmap outlines key goals in the areas of Products andMarkets; Materials Technology; Manufacturing Technology; Environmental Technology; Human Resources; andIndustry Health.

Vision Implementation

The CMC also manages R&D activities through the Metalcasting Industries of the Future program. Through anExecutive Board and Technical Committees, the CMC operates with input and guidance across the metal castingindustry, drawing on existing metal casting Industrial Oversight Panel (IOP) and numerous technical committees inthe metalcasting associations, as well as relying on the input and advice from corporations, academia, andgovernment agencies. The CMC Technical Committees select candidate R&D based on the goals and objectivesidentified in the metalcasting vision. The CMC Executive Board, composed of representatives from the threeassociations, OIT, and the metal casting IOP, work together to ensure that the candidate R&D projects correspond tothe vision's objectives and goals, and make the final project selection.

http://cmc.scra.org/

43

The Wisconsin Metalcasting Industry – A Snapshot

The metal casting industry is one of the most energy-intensive industries in Wisconsin. According to 1997 study,foundries (a subset of the metal casting industry) account for one-eighth of all the energy supplied to Wisconsinindustries (Energy Center of Wisconsin, 1997 – The Foundry Industry). The industry is also important to theWisconsin economy, accounting for between 30,000 and 60,000 jobs and more than 3 billion dollars in sales(Foundry Management).

The purpose of this appendix is to provide a snapshot of some of the characteristics of the Wisconsin metalcastingindustry. Specifically, we look at the size and types of metalcasting businesses in Wisconsin, including the processesthat they use and the metals that are cast.

Overall, we find that the Wisconsin metalcasting industry is varied and on many characteristics is a microcosm ofthe U.S. metalcasting industry. This wide variety makes addressing Wisconsin metalcaster’s needs a challenge, sincefew businesses share many common characteristics. We display these characteristics in a series of tables and graphs,many that compare Wisconsin to national data.1

The data sources often provided inconsistent information regarding the number, size and types of WisconsinMetalcasters. We believe the inconsistencies exist for two reasons. First, the metalcasting industry is a movingtarget. Mergers, acquisitions and business closings appear to be reducing the number of firms. This is an important(although elsewhere documented) finding by itself. Second, depending on the listing source, some firms maymisidentify the types of activities in which they engage, causing some secondary SIC/NAIC codes to be mis-assigned.

1 We defined the metalcasting industry as those businesses with the SIC codes listedin Table 1. To compile the statistics on Wisconsin Metalcasters we used a variety ofsources. The primary data sources were the Harris Selectory, 2000 obtained throughWisconsin Manufacturers and Commerce and data from Foundry Management. We used avariety of other references too.

44

Table 1: Wisconsin Metalcasters by Type

(data source - Harris Selectory, 2000)

1 Sum is greater than 100 percent because firms could report more than one activity.

All SIC codes Primary SIC codes

SIC Description Number ofFirms

% of Firms1 Number ofFirms

% of Firms1

3321 Gray andDuctile IronFoundries

46 25.3 37 26.6

3322 Malleable IronFoundries

18 9.9 3 2.2

3324 SteelInvestmentFoundries

10 5.5 8 5.8

3325 SteelFoundries, not

elsewhereclassified

20 11.0 10 7.2

3363 AluminumDie-Castings

25 13.7 14 10.2

3364 Nonferrous De-Castings,Except

Aluminum

7 3.8 3 2.2

3365 AluminumFoundries

50 27.5 23 16.5

3366 CopperFoundries

40 22.0 10 7.2

NonferrousFoundries,

ExceptAluminum and

Copper 67

67 36.8 31 22.3

45

We compared the characteristics of 151 Wisconsin metalcasters to 2,967 metalcasters nationally on data provided byFoundry Management and Technology. These data show that for the most part, Wisconsin metalcasters are amicrocosm of the nation’s metalcasters. In other words, Wisconsin’s metalcasters are casting the same materials,using the same processes and melting equipment in the same proportions as the nation’s metalcasters. Wisconsinmetalcasters, on the other hand, are comprised of a greater percentage of larger (as measured by number ofemployees) firms. Also, 10 percent of Wisconsin metalcasters are casting stainless steel – as compared to fivepercent for the nation as a whole. Still, this represents a small percentage of metal casters in Wisconsin.

Figure 1: Reported sales volume

Number of employees 58,716

Square footage of plant space 18,700,000 +

Reported Sales Volume

based on 184 firms in Harris Selectory, 2000

15%

8%9%

25%

11%

19%

8%

4%3%

0%

5%

10%

15%

20%

25%

30%

Notprovided

Under$500K

$500-$999K

$1MM-

$4.9MM

$5MM-

$9.9MM

$10MM-

$24.9MM

$25MM-

$49.9MM

$50MM-

$99.9MM

$100MM-

$499.9MM

Sales Volume

46

Figure 2: Wisconsin metalcasters

47

Figure 3: Number of national comparison – number of employees

Figure 4: Wisconsin to national comparison – type of metal cast

Number of EmployeesWisconsin to National Comparison

10% 10%

18% 17%

25%

15%

5%

1% 0%

18%

15%

24%

16% 16%

7%

3%1% 0%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

1 to 9 10 to 19 20 to 49 50 to 99 100 to 249 250 to 499 500 to 999 1,000 to2,500

over 2,500

Number of Employees

Wisconsin

Nation

Type of Metal CastWisconsin to National Comparison

16%14%

4%2%

9% 8%

13%

25%

0%

4% 4%

13%

10%

2% 1%

9%8%

15%

27%

1%

7% 6%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

Type of Metal Cast

Wisconsin

Nation

48

Figure 5: Wisconsin to national comparison – casting method

Figure 6: Wisconsin to national comparison – major metals

Casting MethodWisconsin to National Comparison

38%

12%

9%8%

3%

7%5%

16%

3%1% 0%

39%

10%11%

6%

3%

7%

4%

15%

2% 2%

0%0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

Casting Method

Wisconsin

All Records

Major MetalsWisconsin to National Comparison

21%

7%

0%1%

10% 10%

13%

34%

0%1% 2%

17%

7%

0% 1%

10%

5%

14%

38%

1%

4%6%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

Major Metal

Wisconsin

Nation

49

Figure 7: Wisconsin to national comparison – melting equipment plants

Figure 8: Wisconsin to national comparision – melting equipment units

Melting Equipment - PlantsWisconsin to National Comparison

7%

10%12%

32%

25%

15%

6%

10%9%

28%

36%

12%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

cupuloa electric arc channel induction coreless induction crucible reverberatory

Melting Equipment - Plants

Wisconsin

Nation

Melting Equipment UnitsWisconsin to National Comparison

2%

6%

12%

28%

34%

18%

2%

7% 7%

23%

48%

13%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

cupuloa electric arc channel induction coreless induction crucible reverberatory

Melting Equipment - Units

Wisconsin

Nation

50

Figure 9: Wisconsin to national comparions – coremaking method

Figure 10: Wisconsin to National Comparison – jobbing/captive status

Coremaking MethodWisconsin to National Comparison

16%

12%

20%

5%

10%

13%

8%

1%

3%

13%14% 13%

24%

3%

6%

14%

7%

2% 1%

15%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

oil sand CO2Process

Shell Hot box Cold Box No-bake air setting other selfcuring

warm box other

Coremaking Method

Wisconsin

Nation

Jo b bing /C ap tive S ta tusW isc on s in to N ation a l C om pariso n

80%

12%

7%

1%

79%

12%

7%

2%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

fo r sa le on ly fo r sa le and ow n w ith > 50%fo r sa le

fo r ow n us e on ly fo r sa le and ow n use w ith> 50% ow n use

Jo bb in g /C aptive S ta tu s

W isco nsin

N a tio n

51

How Wisconsin’s Metalcasting Roadmap Was Developed

Early in 1999, the Department of Energy’s Industries of the Future Program solicited states to propose industrialsectors that would benefit by developing a “state-based” roadmap and establishing a mechanism to carry out theneeds identified in the roadmap.

The Department of Administration’s Division of Energy (Wisconsin Energy Bureau) and the Energy Center ofWisconsin proposed the Wisconsin metalcasting industry as a candidate and was awarded the project in the fall of1999. A group of metalcasters in Wisconsin volunteered to serve on a project steering committee and met for thefirst time in December of 1999.

We interviewed upper management in 14 of the states’ metalcasters to identify the general needs of Wisconsinmetalcasters. Following this sampling, 58 Wisconsin metalcasters participated in a First Metalcasting Roundtableheld in Kohler, Wisconsin on June 1, 2000. From the input received this day, we identified a list of 375 needs. Wesent this list to Wisconsin metalcasters for their input on missed needs and known actions. After we incorporatedtheir input, a second version was distributed.

This final needs list was then integrated into the Wisconsin Metalcasting Roadmap. A draft Roadmap was sent to allmetalcasters attending the Second Metalcasting Roundtable in Milwaukee, Wisconsin on September 14, 2000. Theparticipants’ comments on the draft roadmap were incorporated into this final version.

An electronic version of the roadmap will be available at the Energy Center of Wisconsin website atwww.ecw.org/products/commindu.html or by calling 608.238.8276 x 121 and asking for a copy of the WisconsinMetalcasting Roadmap.

AFK Corporation • Badger Alloys, Inc. • BerntsenFoundry • Bremer Manufacturing • Case Corporation• Century Casting • Wisconsin Cast MetalsAssociation • Eck Industries • Electric MeltingServices Co., Inc. • EMTEC • Energy Center ofWisconsin • Falk Corporation • Foundry Magazine •Grede Foundries, Inc. • International Truck &Engine Corporation • Kohler Company • LincolnHills School • Madison Kipp Corporation • ManitowocGrey Iron Foundry • Maynard Steel • MercuryMarine • Metal Masters • Metal-Technologies, Inc. • Miller Compressing • MilwaukeeMalleable and Grey Iron • Milwaukee Valve • Modern Equipment Company • MotorCastings Company • Neenah Foundry Company • Precision Metalsmiths, Inc. •Richland Center Foundry Co. • Roloff Manufacturing Corporation • Rooy & Associates• Slinger Manufacturing Company • Steel Founders Society of America • Stroh DieCasting Company, Inc. • The C.A. Lawton Company • Thompson Aluminum CastingCompany, Inc. • U.S. Department of Energy, Chicago Regional Support Office • U.S.Filter Castalloy • University of Wisconsin–Milwaukee–Metalcast Program • WaukeshaCherry Burrell • Waupaca Foundry • Winsert, Inc. • Wisconsin Centrifugal • WisconsinElectric • Wisconsin Energy Bureau, Dept. of Administration • Wisconsin ManufacturingExtension Partnership • Wisconsin Public Service Corporation

Thank you to all of the Wisconsin metalcasaters that have participated in the roadmapprocess. Identification of Wisconsin metalcasting needs would not have been a successwithout your help.

ENERGY CENTEROF WISCONSIN

595 Science DriveMadison, WI 53711

Phone: 608.238.4601Fax: .608.238.8733

E-mail: [email protected]

Copyright © 2000 Energy Center of Wisconsin

1100/2505 • Publication number 320-1

wisconsin metalcasting roadmap - seventhwavebuilding wisconsin’s metalcasting future sponsored by...

Documents