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NADCA Headquarters Update Presentation for Die Materials Committee Meeting NADCA Headquarters - Wheeling, IL NADCA Headquarters Update Presentation for Die Materials Committee Meeting NADCA Headquarters - Wheeling, IL February 11, 2009

Outline • • • DOE/CMC Update DOD/AMC Update Hyper. CAST Status Proposals Seeking NADCA Outline • • • DOE/CMC Update DOD/AMC Update Hyper. CAST Status Proposals Seeking NADCA Funds Meetings and Expo Miscellaneous

DOE/CMC Update • Energy-SMARRT Program – Initiated in FY 2004 – Originally $12 M DOE/CMC Update • Energy-SMARRT Program – Initiated in FY 2004 – Originally $12 M Proposal Over 3 Years – Actual Funding: $1. 4 M Y 1, $2. 4 M Y 2, $2. 0 M Y 3, $982 K Y 4, $194 K Y 5 • FY 2009 Y 6 – Continuing Resolution – Anticipate Same Funding Level as for FY 2008 – May be Higher After Budget Approval

DOD/AMC PRO-ACT • AMC Phase IV (CIR) – FY’ 09 Funding Approved ~ $2. DOD/AMC PRO-ACT • AMC Phase IV (CIR) – FY’ 09 Funding Approved ~ $2. 2 M – Money Runs Out Oct 2010 – Planning 12 Month Extension Request • PI’s: ½ Page on Enhancement to Projects, Technical Benefit Bullets, 1 -3 Deliverables - $36 K-$80 K • AMC Phase IV Add-on (CIDR) – Year 2 Funding $170 K-200 K for Die Casting – No Year 3 FY’ 09, ATI Pursuing FY’ 10 Funds – No-Cost Extension Through Oct 2009 • Next Program Review June 24 & 25, 2009 • Annual Report Completed

DOD/AMC PRO-ACT (Cont) • Benet Labs at Watervliet Program for Light Weight Low Cost DOD/AMC PRO-ACT (Cont) • Benet Labs at Watervliet Program for Light Weight Low Cost Parts • AMC Proposal: Superior Weapons Systems through Castings (SWC) Program • Letter Sent to Picatinny 12/15/08 Requesting that SWC be placed under CIDR • Attempted to get $3 M/Yr Up To 3 Years, Currently Looks like $1. 2 M for Year 1: $200 K for Die Casting • Suggested NADCA R&D Needs: – Refinement of Casting Alloys for Improved Properties – High Productivity Tooling & Processes – Nano-Composite Materials

Hyper. CAST Program Status • Passed Authorization • Sought Appropriations for FY’ 09 – Hyper. CAST Program Status • Passed Authorization • Sought Appropriations for FY’ 09 – House Mark is at $1. 5 M for Year 1 – Senate and House Need to Finalize Budget • IBIS Model for Cost and Weight Analysis Completed

TAG Activities • Most Recent Proposal Approved • #168 Die Material Properties at 46 TAG Activities • Most Recent Proposal Approved • #168 Die Material Properties at 46 -48 HRC • Proposals Removed From Consideration • #160 A Comparative Study on Bainitic and Martensitic Structures • #166 Auto combustion synthesis-die casting (ACSDC) of amorphous matrix composite (AMC) materials • Recent/Pending Submittals • 3 D Laser Scanning to Measure Distortion • Ultrasonic Grain Refinement • Evaluation of Chemical Composition and Processing Parameters on the Mechanical Properties of T 5 Heat Treated Die Castings

113 th Metalcasting Congress • April 7 -10, 2009 (Tues-Fri) in Las Vegas, NV 113 th Metalcasting Congress • April 7 -10, 2009 (Tues-Fri) in Las Vegas, NV • Papers Reviewed and Selected • 11 NADCA Congress Sessions (Tues-Thurs) – 8 Regular Sessions – 3 Special Format Sessions • Plunger Lubricants • Die Maintenance & Repair • Die Spray • Power. Point Presentations Due 3/13/09 • Exhibit Floor (Wed, Thurs) • Combined Awards Luncheon (Tues)

Guidebook Report Compilations Turn Research Into Action • 1 st Round – – – Guidebook Report Compilations Turn Research Into Action • 1 st Round – – – Die Materials P Cast Materials P Computer Modeling P Process Technologies P Die Surface Engineering P • 2 nd Round – – Computer Modeling II P Cast Materials II P Process Technologies II P Die Materials II P (Ready for print)

Worldwide Reports • • • Process Technology (Done) Die Materials Technology (Done) Dimensional Report Worldwide Reports • • • Process Technology (Done) Die Materials Technology (Done) Dimensional Report (Done) Computer Modeling (Done) Cast Materials (Zn Done, Al Next)

What’s New • • • New Employee - Alex Monroe Dust Safety Course Product What’s New • • • New Employee - Alex Monroe Dust Safety Course Product Standards High Integrity Al Product Design Book Design Website – http: //www. diecastingdesign. org/ • Carbon Footprint Report

Joint Planning Session • • Held October 15, 2008 R&D and Die Materials Committee Joint Planning Session • • Held October 15, 2008 R&D and Die Materials Committee Members Brainstorming of Project Ideas/Industry Needs Input to be Used to Formulate a New Large Program • 48 Ideas Generated and Prioritized • Subsequent Input Provided for Grouping of Ideas

Ideas Priority Number Description 1 • Heat treatable die castings w/properties comparable to other Ideas Priority Number Description 1 • Heat treatable die castings w/properties comparable to other processes 2 • Non-contact real-time monitor & control/IR Vision – Sensor fusion 3 • National Die Casting Center 4 • Carbon footprint: Optimize melting, holding & ladling/SF 6/simulation 5 • On demand melting- shot by shot 6 • Lightweight hybrid structures-plastic/metal 7 • Porosity free homogeneous properties 8 • Smart die cast manufacturing 9 • Smaller machines for larger castings 10 • Lube free die casting 11 • Apply lean techniques vertical integration-smelt/pour 12 • Coating to eliminate lube 13 • More cavities per tonnage 14 • Smart sensor fusion die casting 15 • Hot chamber Al – materials/coatings for gooseneck/pump/nozzle 16 • High temp alloys for inserts 17 • Ti and Ni die casting 18 • Die materials for high temp die casting 19 • Die Cast Composite 20 • Eliminate trim presses 21 • Thin wall Mg and Al 22 • Optimize thermal cycling to triple die life 23 • Models for energy efficient die casting 24 • Low-no draft, flash free, net shape die casting 25 • Cost efficient short run production/prototype

Joint Planning Session Cont. Potential Broad Topics to Encompass Several Ideas/Tasks – Advanced Cast Joint Planning Session Cont. Potential Broad Topics to Encompass Several Ideas/Tasks – Advanced Cast Materials Development – Smart Die Cast Manufacturing – Advanced Processes and Process Improvement – Machine Innovations – Advanced Die Materials – Virtual National Die Casting Center