Wisconsin Metalcasting Roadmap

A reference describing resources and long-term competitive needs identified by Wisconsin metalcasters

Building Wisconsin’s Metalcasting Future

SPONSORED BY U.S. Department of Energy— Industries of the Future Department of Administration’s Division of energy Energy Center of Wisconsin Wisconsin Focus on Energy

IN COOPERATION WITH American Foundrymen’s Society (AFS) Non-Ferrous Founders’ Society (NFFS) Steel Founders’ Society of America (SFSA) Wisconsin Cast Metals Association (WCMA)

COORDINATED BY Energy Center of Wisconsin

Publication 320-1

Wisconsin Metalcasting Roadmap

November 2000

Prepared by

This document was prepared as an account of work sponsored by the Energy Center of Wisconsin (ECW). Neither ECW, participants in ECW, the organization(s) listed herein, nor any person on behalf of any of the organizations mentioned herein:

(a) makes any warranty, expressed or implied, with respect to the use of any information, apparatus, method, or process 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 success without 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 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

ii 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

Introduction

Metalcasting is one of the nine industries identified by U.S. Department of Energy (DOE) that together consume over 65 percent of industrial energy in the United States. The Energy Policy Act of 1992 catalyzed these nine industries with DOE assistance to develop technology visions and research agendas. The visions and research agendas identified what was needed to insure the industry remained competitive and viable into the year 2020. The resulting Metal Casting Agenda 2020 and National Metalcasting Roadmap provides a common vision for the industry. 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 over 25,000 people, bring in over $3 billion of revenue and consume over eight percent of the industrial energy in the state.

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

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

At the first Wisconsin Metalcasting Roundtable June 1, 2000, fifty-eight Wisconsin metalcasters and representatives from their associations identified common needs and goals to remain competitive and viable into the year 2020. The resulting product of that effort, the Wisconsin Metalcasting Roadmap, lists the needs and identifies any recent or ongoing 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 their needs and goals, and 2) form action teams to address priority needs. Wisconsin metalcasters and other interested parties 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 was created, 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), a private non-profit energy research and education organization.

1 includes a list of the needs identified by Wisconsin metalcasters and their associations, sorted in six broad categories. This section includes a brief description and contact information on recent or current research and demonstrations 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 assistance available 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 and types of metal casting companies, number of employees, reported sales volumes, type of process and melting equipment. 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 in pursuing 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 developing strategies 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 (608.238.8276 ext 121 or [email protected]).

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

2 Frequently Asked Questions

What is a “Metalcasting Roadmap”?

A “roadmap” is a communication tool which describes long term competitive needs identified by industry. Finding solutions to these needs is critical to improve future industry strength. This application of the term “roadmap” was coined 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. The document you are reading is one of the first state-based roadmaps. This state roadmap identifies competitive needs common to all metalcasters, as well as needs unique to the metalcasters in Wisconsin. (To find out more about the national 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 and national metalcasting industry needs. The needs presented in this roadmap have been identified by metalcasters and their associations who volunteered their time. Fourteen metalcasters participated in detailed interviews and 58 metalcasters met at the first metalcasting roundtable to generate this list. Additional input was provided through follow-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 their industry. The advantage of creating a consolidated “needs list” is that it serves as a tool for individual metalcasters and their trade organizations to communicate their goals to local, state and national organizations who can help them. 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 is currently 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 and how to contact them. Use the resources section of this document as a quick reference to make these resources accessible when the need arrives.

3 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 one way to find others interested in taking action. ECW, through the Wisconsin Metalcasting Roadmap Initiative, will help 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. Even problems that are not directly related to hardware typically result in an increase in energy consumption per unit of product produced.

The traditional approach to energy efficiency Organizations promoting efficient use of energy have traditionally developed or identified technologies and techniques which get the same job done with less energy. Demonstration of these technologies has been widely used as a method to improve industry confidence in using the technology. The drawback of the technology-based approach is that, although the technology may make solid economic sense, cost reduction through energy efficiency is currently not a priority of many industrial plants. Energy efficiency projects that are adopted by industry typically fulfill 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 energy efficiency community is pursuing the approach of partnering with industrial sectors to assist them in resolving industry-identified needs. By resolving these needs, an expected side-effect will be the reduction of energy per unit of product produced.

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

4 Wisconsin Metalcasting Needs

The needs identified by Wisconsin metalcasters are organized into six categories. These categories are the same as those 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 the solution to that need involves technology. In addition, we have identified recent efforts that may address all or part of a need. Following the matrix is a detailed description of the need and related efforts, including contact information.

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.

5 National National Wisconsin Technology Policy Currently Manufacturing Roadmap 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 xx 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

6 National National Wisconsin Technology Policy Currently Manufacturing 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

7 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 & Manufacturing Engineering 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 Ridge National Laboratory. Contact S. Viswanathan (423.576.9917) or J. Santner, AFS (847.824.0181)

8 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 or 1.800.537.4237

H. Filling & Solidification Modeling

Action/Contact H1. There is a NIST Darpa and Howmet Corporation project on improving modeling to predict microstructure of castings. 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 Tony Overfelt (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 Dennis Allen, 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 or 219.288.7552)

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)

9 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 State University (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, Ohio State 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 on solidification modeling (which have been listed elsewhere) and projects which deal with a) methodizing—including gating, risering, and feeding; b) development of filtering techniques; c) on line sensing and control of processes and d) 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.” Contact Charles Bates, University of Alabama-Birmingham (205.975.8120)

10 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 agency for 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 and enforcement Business Helpline – 1.800. HELP-BUS Export Helpline – 1.800.XPORT-WI www.commerce.state.wi.us/com/com L2. The Wisconsin Economic Development Association (WEDA) is a statewide, nonprofit organization dedicated to expanding the economy of Wisconsin. Founded in 1975, WEDA represents more than 400 economic development professionals and active volunteers. Contact Brenda Ralph (608.255.5666) for more information.

11 12 2. Materials Technology

The needs identified in this section are based on developing new raw materials or predicting the properties of existing 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

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.

13 National National Wisconsin Technology Policy Currently Materials Technology 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

14 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 Matrix Composites.” 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. Contact Dr. 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, while yielding acceptable properties. This will require long term research but the results can lead to sound castings and increased 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)

15 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 on Properties 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)

16 3. Environmental Regulatory and Technical Needs

The needs identified in this section relate to achieving regulatory compliance. The needs address reducing the burden to meet environmental regulatory compliance and developing needed technology to reduce emissions at their source.

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

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.

17 National National Wisconsin Technology Policy Currently Environmental 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

18 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

19 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, EO Associates (516.472.9187); Gary Moster, AFS (847.824.0181)

S2. “Development of an Information Database on Beneficial Reuse of Foundry By-products.” Contact Brian Mitchell, 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 West Virginia, 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 Ted Palpass (616.536.2261)

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

20 4. Energy Reliability Needs

The needs identified in this section relate to being able to predict energy availability and pricing for business planning purposes. In addition, this category includes minimizing energy resources cost through educated purchasing 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

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.

21 National National Wisconsin Technology Policy Currently Energy Reliability 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

22 Energy Reliability

U. Improved Reliability and Supply

Action/Contact U1. A draft Strategic Energy Assessment for Wisconsin is available on the Wisconsin Public Service Commission of 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 Management Public Service Commission of Wisconsin P.O. Box 7854 Madison, WI 53707 608.261.8524 e-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 of Wisconsin. 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])

23 24 5. Products and Market Needs

The needs identified in this section relate to increasing the efficiency and speed of producing and delivering a metalcasting 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

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.

25 National National Wisconsin Technology Policy Currently Products and Markets Roadmap Addressed

EDUCATION improve user specification / design of castings x x create user awareness of casting benefits x x

COMPETITIVE ADVANTAGE reduce concept to production time x x communicate with user to understand needs x x respond quickly to user needs x x

DESIGN improve designs to optimize manufacturability x x W1 need standardized specification and standards x x redesign fabrications into castings x x make it easy to design and use castings x x W1

ATTRACT AND RETAIN CUSTOMERS retain in-state business x x attract new customer base x x

WORLD MARKET improve language skills x x combat internet coalitions x x think as a world wide supplier x x compensate for goods produced with greater emissions x x increase export marketing knowledge x x

26 3RD PARTY SUPPORT single source for metalcasting buyer assistance x x need metalcasting promoter similar to plastics x x

COST ISSUES need a stable international currency valuation x x

DISTRIBUTION need better transportation to markets x x x need better distribution channels x x x

27 Products & Markets

W. Product Design W1.AFS Magazine “Engineered Casting Solutions” is a tool developed to present opportunities for optimal product design 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.com Steel Founders’ Society of America, www.sfsa.org Non-Ferrous Founders’ Society, www.nffs.org Wisconsin 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 the DOE has supported to improve technology and the industry. Contact Harvey Wong (202.586.9235) www.oit.doe.gov/metalcast

28 6. Human Resource Needs

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

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

• Labor supply • Education

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.

29 National National Wisconsin Technology Policy Currently Human Resources 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

30 Human Resources There are no identified actions in this area.

31 32 Action on Wisconsin Metalcasting Priorities

Wisconsin metalcasters participating in the second Metalcasting Roundtable identified the following 14 action items. 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 steel alloys

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

33 Action Teams

To address these priorities, ECW will review how other U.S. metalcasters are addressing these needs, solicit input from Wisconsin metalcasters, and create team plans. We will then assemble action teams. The teams will revise the plans and develop a schedule. We suggest that teams communicate on a monthly basis to review progress, revise plans, 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. We will provide logistical support and identify and bring together the resources needed to pursue their goals. Action teams 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 a semi-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.

34 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 the research and technologies that will make a vision of clean, competitive Industries of the Future (IOF) a reality. The nine 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 Energy Clearinghouse (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 metalcasting roadmap. 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 that develop and demonstrate new energy efficiency and clean production technologies. If you have an innovative technology that you want to demonstrate, you should contact your state agencies responsible for energy, pollution prevention, or business development to explore the possibility of developing a grant proposal. Federal funds can cover 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 and independent inventors. The Inventions and Innovation program will fund up to $200,000 for well-developed inventions moving towards prototype development or commercialization. At a minimum, engineering analysis and/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 will close 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 energy efficiency improvement. Projects typically combine financial and technical resources from several sources to achieve the desired goals. Industry-endorsed initiatives are a priority for this funding. Annual energy intensity

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

Metalcasting Trade Associations American Foundrymen’s Society (AFS) Stateline Chapter Marc Vuletich 302 Peoples Avenue Rockford, IL 61104-7092

American Foundrymen’s Society (AFS) Wisconsin Chapter Gene O’Kelly Maynard Steel Casting Company 2856 S. 27th Street Milwaukee, WI 53215

American Foundrymen’s Society (AFS) 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

36 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 and technology capabilities and expertise of DOE’s National Laboratories. The LCC also facilitates collaboration between the labs and industry and can assist in matching industrial technology needs with the appropriate capabilities and assets of the DOE's National Lab System. The following labs have the technology capabilities and expertise 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

37 • 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 mission is to improve manufacturing in Wisconsin. WMEP provides manufacturing, technical and management assistance to Wisconsin's small and midsize manufacturers, in order to deliver bottom line improvements. Drawing on real world experience of manufacturing specialists, WMEP assists companies to modernize their manufacturing operation and effectively manage business. E-mail: [email protected] Fax: 608.240.1744, Phone: 608.240.1740 or 1.800.637.4634

Administrative Assistance to Pursue Needs Identified in the Roadmap The Wisconsin Metalcasting Roadmap initiative has administrative resources to provide support and coordination for groups pursuing needs identified in the Wisconsin Metalcasting Roadmap. This support can include coordination of 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 with industry. A Motor Challenge Clearinghouse has been established: 1.800.862.2086 and their web site www.oit.doe.gov/bestpractices/motors provides additional information. This is a valuable source of information on all 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 increased profits by using BestPractices tools for your facility today. Steam system equipment and service providers can benefit by allying with the message of steam system improvement and promoting the use of BestPractices tools. For steam system information call 1.800.862.2086 or get information immediately on DOE’s website at www.oit.doe.gov/bestpractices/steam/steam.shtml.

38 The Compressed Air Challenge Program The mission of the CAC is to develop and provide resources that educate industry on the opportunities to increase net profits through compressed air system optimization. Training and resources can be found by calling 1.800.862.2086, 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- and medium-size manufacturing plants. To be eligible for an IAC assessment, a manufacturing plant must meet the following 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]

39 40 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 the development 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 referenced information 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 of American (SFSA) and North American Die Casting Association (NADCA) developed the Metal Casting Industry Technology 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 specific accomplishments include the following:

Vision Developed

In September 1995, chief executive officers and presidents from the foundry, die casting, and foundry supply industries 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) and North American Die Casting Association (NADCA) signed a Compact establishing a voluntary collaborative effort between industry and the U.S. Department of Energy. The compact provided the framework for identifying appropriate 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 strategy for pursuing near-, mid-, and long-term goals set out by industry and for carrying out the cooperative agreement between the U.S. Department of Energy and industry. The roadmap outlines key goals in the areas of Products and Markets; Materials Technology; Manufacturing Technology; Environmental Technology; Human Resources; and Industry Health.

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

41 42 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 Wisconsin industries (Energy Center of Wisconsin, 1997 – The Foundry Industry). The industry is also important to the Wisconsin 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 metalcasting industry. Specifically, we look at the size and types of metalcasting businesses in Wisconsin, including the processes that 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 of the U.S. metalcasting industry. This wide variety makes addressing Wisconsin metalcaster’s needs a challenge, since few 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 Wisconsin Metalcasters. We believe the inconsistencies exist for two reasons. First, the metalcasting industry is a moving target. 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 may misidentify 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 listed in Table 1. To compile the statistics on Wisconsin Metalcasters we used a variety of sources. The primary data sources were the Harris Selectory, 2000 obtained through Wisconsin Manufacturers and Commerce and data from Foundry Management. We used a variety of other references too.

43 Table 1: Wisconsin Metalcasters by Type

(data source - Harris Selectory, 2000)

All SIC codes Primary SIC codes

SIC Description Number of % of Firms1 Number of % of Firms1 Firms Firms

3321 Gray and 46 25.3 37 26.6 Ductile Iron Foundries

3322 Malleable Iron 18 9.9 3 2.2 Foundries 3324 Steel 10 5.5 8 5.8 Investment Foundries

3325 Steel 20 11.0 10 7.2 Foundries, not elsewhere classified

3363 Aluminum 25 13.7 14 10.2 Die-Castings

3364 Nonferrous De- 73.832.2 Castings, Except Aluminum

3365 Aluminum 50 27.5 23 16.5 Foundries

3366 Copper 40 22.0 10 7.2 Foundries

Nonferrous 67 36.8 31 22.3 Foundries, Except Aluminum and Copper 67

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

44 We compared the characteristics of 151 Wisconsin metalcasters to 2,967 metalcasters nationally on data provided by Foundry Management and Technology. These data show that for the most part, Wisconsin metalcasters are a microcosm 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. Wisconsin metalcasters, on the other hand, are comprised of a greater percentage of larger (as measured by number of employees) firms. Also, 10 percent of Wisconsin metalcasters are casting stainless steel – as compared to five percent for the nation as a whole. Still, this represents a small percentage of metal casters in Wisconsin.

Figure 1: Reported sales volume

Reported Sales Volume

based on 184 firms in Harris Selectory, 2000

30%

25% 25%

19% 20%

15% 15%

11%

10% 9% 8% 8%

5% 4% 3%

0% Not Under $500- $1MM- $5MM- $10MM- $25MM- $50MM- $100MM- provided $500K $999K $4.9MM $9.9MM $24.9MM $49.9MM $99.9MM $499.9MM

Sales Volume

Number of employees 58,716 Square footage of plant space 18,700,000 +

45 Figure 2: Wisconsin metalcasters

46 Figure 3: Number of national comparison – number of employees

Number of Employees Wisconsin to National Comparison 50%

Wisconsin 45% Nation

40%

35%

30%

24% 25% 25%

20% 18% 18% 17% 15% 16% 16% 15% 15%

10% 10% 10% 7% 5% 5% 3% 1% 1% 0% 0% 0% 1 to 9 10 to 19 20 to 49 50 to 99 100 to 249 250 to 499 500 to 999 1,000 to over 2,500 2,500 Number of Employees

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

Type of Metal Cast Wisconsin to National Comparison 50%

45% Wisconsin Nation 40%

35%

30% 27% 25% 25%

20% 16% 15% 14% 15% 13% 13% 10% 9%9% 10% 8%8% 7% 6% 5% 4% 4% 4% 2% 2% 1% 1% 0% 0%

Type of Metal Cast 47 Figure 5: Wisconsin to national comparison – casting method

Casting Method Wisconsin to National Comparison 50%

45% Wisconsin

39% All Records 40% 38%

35%

30%

25%

20% 16% 15% 15% 12% 11% 10% 9% 10% 8% 7%7% 6% 5%4% 5% 3% 3% 3%2% 2% 1% 0%0% 0%

Casting Method

Figure 6: Wisconsin to national comparison – major metals

Major Metals Wisconsin to National Comparison 50%

45% Wisconsin

40% 38% Nation

35% 34%

30%

25% 21% 20% 17% 14% 15% 13% 10%10% 10% 10% 7%7% 5% 6% 4% 5% 1% 1% 2% 0%0% 1% 0%1% 0%

Major Metal 48 Figure 7: Wisconsin to national comparison – melting equipment plants

Melting Equipment - Plants Wisconsin to National Comparison 50% Wisconsin 45% Nation

40% 36%

35% 32%

30% 28%

25% 25%

20%

15% 15% 12% 12% 10% 10% 10% 9% 7% 6% 5%

0% cupuloa electric arc channel induction coreless induction crucible reverberatory Melting Equipment - Plants

Figure 8: Wisconsin to national comparision – melting equipment units

Melting Equipment Units Wisconsin to National Comparison

50% 48%

45% Wisconsin Nation 40%

35% 34%

30% 28%

25% 23%

20% 18%

15% 13% 12%

10% 7% 7% 6% 5% 2% 2%

0% cupuloa electric arc channel induction coreless induction crucible reverberatory Melting Equipment - Units

49 Figure 9: Wisconsin to national comparions – coremaking method

Coremaking Method Wisconsin to National Comparison 50%

45% Wisconsin

Nation 40%

35%

30%

24% 25%

20% 20%

16% 15% 14% 13% 14% 15% 13% 13% 12% 10% 10% 8% 7% 6% 5% 5% 3% 3% 1%2% 1% 0% oil sand CO2 Shell Hot box Cold Box No-bake air setting other self warm box other Process curing Coremaking Method

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

Jobbing/Captive Status Wisconsin to National Comparison 100% Wisconsin 90% Nation

80% 79% 80%

70%

60%

50%

40%

30%

20% 12% 12% 10% 7% 7% 1% 2% 0% for sale only for sale and own with > 50% for own use only for sale and own use with for sale >50% own use Jobbing/Captive Status

50 How Wisconsin’s Metalcasting Roadmap Was Developed

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

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

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

This final needs list was then integrated into the Wisconsin Metalcasting Roadmap. A draft Roadmap was sent to all metalcasters attending the Second Metalcasting Roundtable in Milwaukee, Wisconsin on September 14, 2000. The participants’ 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 at www.ecw.org/products/commindu.html or by calling 608.238.8276 x 121 and asking for a copy of the Wisconsin Metalcasting Roadmap.

Thank you to all of the Wisconsin metalcasaters that have participated in the roadmap process. Identification of Wisconsin metalcasting needs would not have been a success without your help. AFK Corporation • Badger Alloys, Inc. • Berntsen Foundry • Bremer Manufacturing • Case Corporation • Century Casting • Wisconsin Cast Metals Association • Eck Industries • Electric Melting Services Co., Inc. • EMTEC • Energy Center of Wisconsin • Falk Corporation • Foundry Magazine • Grede Foundries, Inc. • International Truck & Engine Corporation • Kohler Company • Lincoln Hills School • Madison Kipp Corporation • Manitowoc Grey Iron Foundry • Maynard Steel • Mercury Marine • Metal Masters • Metal-Technologies, Inc. • Miller Compressing • Milwaukee Malleable and Grey Iron • Milwaukee Valve • Modern Equipment Company • Motor Castings 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 Die Casting Company, Inc. • The C.A. Lawton Company • Thompson Aluminum Casting Company, Inc. • U.S. Department of Energy, Chicago Regional Support Office • U.S. Filter Castalloy • University of Wisconsin–Milwaukee–Metalcast Program • Waukesha Cherry Burrell • Waupaca Foundry • Winsert, Inc. • Wisconsin Centrifugal • Wisconsin Electric • Wisconsin Energy Bureau, Dept. of Administration • Wisconsin Manufacturing Extension Partnership • Wisconsin Public Service Corporation

ENERGY CENTER OF WISCONSIN