Speakers and Presentation Information
Cast Magnesium Alloys: Processing, Properties and Applications
In recent years, the demand for magnesium alloys has seen a rapid increase due to increased efforts of the automotive industry to achieve improved fuel economy and lower emission levels. Magnesium alloys are the lightest structural metals commercialized to date, and have excellent specific strength and elastic modulus together with a low density of 1.74 g/cm³. According to a recent industry survey sixty different automotive components, totaling over 150 lbs use magnesium or are under development. The use of magnesium in automotive parts is predicted to increase globally at an average rate of 15% per year. This presentation will review casting methods, key properties and applications of magnesium alloys. Recent magnesium casting development programs will be highlighted.
Dr. Schwam is a Research Associate Professor in the Department of Materials Science and Engineering at Case Western Reserve University and Director of the Case Metal Casting Laboratory. He also serves as the Foundry Educational Foundation Key Professor for Case Western Reserve University. Dr. Schwam has over twenty-five years of experience in theoretical and experimental investigations related to casting and solidification, heat treating, squeeze casting and powder metallurgy. His recent research activities include energy efficiency studies, die casting and squeeze casting of aluminum and magnesium alloys, evaluation of die materials, rapid prototyping, recycling and computer simulation of flow and solidification. He has published over 200 papers and technical publications and is a member of the North American Die Casting Association, American Foundry Society, American Society of Metals, Materials Research Society and Laser Institute of America.
Thixomolding® of Magnesium Components
Thixomat, Inc. holds the worldwide patents on the ThixomoldingÒ process, a new one-step process for the production of near-net shape, injection molded, magnesium parts. The entire ThixomoldingÒ process – from solid magnesium chips to finished molded parts – takes place in a single step. ThixomoldingÒ eliminates the need for metal foundries and their associated safety and environmental issues. The process combines the lightweight, high strength, high ductility and EMI/RF shielding characteristics of magnesium with a safe, simple process that allows manufacturing of even thin-wall components (less than 1 mm.) to tight tolerances. Applications for ThixomoldedÒ parts are in the automotive, consumer, and electronics/communications industries. There are currently over 300 machines in use worldwide processing magnesium alloys. A description of the process will be presented including an examination of structure-property relationships. Examples of current production parts, particularly the explosive growth in consumer electronics, and recent developments in the automotive markets are reviewed. Basic design concepts will be presented along with case studies of current commercial applications.
Dr. LeBeau has spent his entire career in the areas of manufacturing and materials processing development. He holds degrees in Metallurgical and Materials Engineering from Michigan Technological University, Rensselaer Polytechnic Institute and the University of Wisconsin-Madison. Dr. LeBeau has previously held positions with USX Steel, Caterpillar Tractor, Babcock & Wilcox and Peerless Metal Powders. He is currently President & CEO of Thixomat, Inc. Dr. LeBeau is a Fellow of ASM, and member at-large of TMS-AIME, SME, NADCA and SAE.
The presentation and discussion will address the origin, evolution and future of the Precision Sand Process. This will include:
- Process pioneers
- Significant process milestones
- Process capability
- Process advantages
- Future potential
Robert J. Bend, Technical Manager of Formed Light Alloys LLC (FLA) of Plymouth Michigan has in excess of 30 years experience in the casting industry, predominantly in aluminium. FLA specializes in the development and technical support of aluminium cylinder blocks and heads produced in the Precision Sand Process. Their clients include automotive OEM’s and tier one casting suppliers.
Prior to the formation of Formed Light Alloys LLC Bob held positions with the University of Warwick, Cosworth and Nemak where he was instrumental in the development of their Precision Sand Processes for the production of cylinder heads and blocks. Bob is a member of the Society of Automotive Engineers and the American Foundry Society.
Principles of Direct Chill Casting of Beryllium Copper Alloys
The direct chill (D.C.) semi-continuous casting process is an attractive production technology for moderately high production rates and the associated relatively fast freezing (solidification) rates which tend to produce a fine and uniform grain size in as-cast billets/ingots. The direct chill casting process is used at Brush Wellman’s Elmore, Ohio, plant to cast copper based beryllium containing alloys having round & rectangular cross-sections. Fundamental aspects of D.C. semi-continuous casting will be presented. Solidification behavior of narrow and wide freezing range alloys will be described including effects on macro- and micro- segregation of alloying elements. The surface and the interior quality of the billets produced via this method generally depend on several process variables e.g., mold length, alloy composition, casting size, tundish metal temperature, alloy freezing range and casting speed. As-cast macro- & micro- structures for narrow and wide freezing range alloys of Be-Cu alloys will be shown and the implications of these structures on further mechanical & thermal treatments described.
Dr. Sabit Ali is Process Engineer for Primary Operations at Brush Wellman Inc. focused on production of copper-beryllium alloys. Dr. Ali earned his Ph.D. Degree in Materials Engineering from Drexel University and his Masters Degree in Metallurgy & Materials Science from University of Pennsylvania, both located in Philadelphia. He was Visiting Assistant Professor, teaching Metallurgical Thermodynamics and Extractive Metallurgy at Drexel University. He has been with Brush Wellman since 1985, is widely published internally and has been a major contributor to process improvements, basic research of solidification dynamics, hot working and alloy development. Dr. Ali is a member of ASM International.
Solidification and Process Design in the Metal Casting Industry
The metal casting process is thousands of years old. Casting allows shapes to be created in metal that would be difficult or uneconomical to produce by other methods.
Understanding of solidification and its impact on process design and part design has progressed from an art to a science. Designing parts as castings, and designing processes to produce high-quality castings, requires consideration of the following aspects:
- Effects of metal contraction during solidification (or expansion in some alloys)
- Directional solidification
- Basic design rules for castings: Tapers, fillets, section thicknesses
- Basic design rules for the process: Gating and risering
- The role of computer simulation in part and process design
The more part designers and foundry engineers share understanding about the casting process, the more successful they can be in designing parts for castability.
Lawrence E. Smiley received his BSME in 1975 from the University of Cincinnati. He is the Founder and President of Finite Solutions, Inc., a provider of simulation and process design tools for the metal casting industry. Larry developed the first PC-based casting simulation program in 1985. Prior to forming Finite Solutions in 1993, he worked as Project Engineer for Republic Steel and Enerfab Corporation, and as Executive Vice President for Reliable Castings Corporation. Larry is a Registered Professional Engineer in the State of Ohio.
This talk will give an overview of investment casting including:
- History
- Processing Steps
- Types of products and where the method is competitive
- Examples of use in the gas turbine industry
- Trends in casting analysis (modeling)
Dr. Graham received his B.S., M.S., and Ph.D. degrees in Metallurgical Engineering from Lehigh University. He received his Ph.D. in 1965. Upon graduation, he joined the staff of TRW’s Colwell Research Center as a Research Engineer and Section Manager, working in the areas of solidification and casting of superalloys for gas turbine engine applications. From 1974 to 1983, he was assigned to TRW’s Minerva Casting Plant where his responsibilities included various management positions. These positions ranged from Laboratory Manager, Quality Control Manager, Manufacturing Manager for a portion of the plant and Master Metal Product Manager. From 1983 to present, he has held Division R&D positions, first for TRW, and then for PCC Airfoils, Inc., beginning in 1986 with its acquisition of the former TRW Aircraft Components Group. During this timeframe, he has been responsible for conducting and managing development efforts in ceramic mold and core materials, solidification, physical metallurgy, manufacturing processing, automation, and solidification modeling. He has 20 patents in the casting field. He has been intimately involved with PCC activities related to the externally and internally-funded programs on single crystal castings. He has managed several government cooperative programs for PCC where suppliers, competitors and customers successfully worked together. This included a DARPA program to introduce computer modeling of solidification and an AF program directed at process improvement and cost savings. He is a Fellow of ASM.
A brief overview of all commercial Metal Casting Processes will be presented. Recommendations will be given for which processes should be utilized for specific casting applications. This presentation will conclude with a condensed, rapid-fire version of “How to Buy a Casting.”
Tom Cobett has over 35 years of experience within the Primary Metals Industries. As an R&D specialist, Tom has worked closely with major companies who produce or utilize metals, helping them to solve design, application and cost problems. He has developed several unique products and processes resulting in 2 US Patents and 2 European Patents. In addition to his R&D activities, Tom has over 20 years of teaching experience at the university level. He is a graduate of Kent State University, the Chairman of the Education Committee for the Foundry Educational Foundation, a member of AFS, ASM, AIST, an active participant in the ASM Material Camps and the R&D Manager of OmniSource Corporation, the largest metals recycling company in North America.
Analysis Using ProCAST Software
An explanation of the ProCAST FEA software package will be given along with analyses of several casting problems. A demonstration of the software will be given at the breaks.
Scott Hayward, Manager, and Adi Sholapurwalla, Technical Director of Engineering, are from ESI Group.