Cafe Standards �Corporate Average Fuel Economy�

SSM/Squeeze Casting| 2013 Safety Awards| MAY 2014

SEMI�SOLID METAL CASTING TO MEET CAFE STANDARDS �CORPORATE AVERAGE FUEL ECONOMY�

ALSO INSIDE: 2013 SAFETY AWARDS

NORTH AMERICAN DIE CASTING ASSOCIATION VOLUME 58 NUMBER 3 NADCA® and the NADCA logo above are both registered trademarks of the North American Die Casting Association. MAY 2014

FEATURES DEPARTMENTS 02 Chairman’s Note Introducing an Improved Process for Semi-Solid Metal 16 03 Letter From the Editor Casting of High Integrity Parts 04 Washington Insights – A. Koch, K. Tenzek 08 NADCA Reports 10 Dr. Die Cast 12 OSHA + EPA Awareness Update 20 Fire Incident Prevention for NADCA 15 Ask the Experts – R. Block 47 New Corporate Members 48 Corporate Member List 22 Energy Conservations in Die Castings Industry 52 Chapter News & New Members – Some Practical Examples 59 New Products, Services & Solutions – A. Pari 60 Industry News & Information 62 People in Die Casting 64 Classi�ed Advertising 28 The Role of Temperature During Semi-Solid Metal Processing 64 Advertising Index – Dr. F. Czerwinski

33 NADCA’s David Laine Scholarship Program Awards Record-Breaking 17 Students – D. Hutchins

38 Wage & Bene�t Survey – Executive Summary

40 2013 Safety Awards

41 2014 Exhibitor Spotlight

The NADCA logo was hidden here this month. Did you find it?

PUBLISHER Daniel L. Twarog Die Casting Engineer (ISSN 012-253X ) is published bimonthly, six times per year, by the North EDITOR American Die Casting Association, 3250 N. Arlington Heights Rd., Ste. 101, Arlington Heights, Illinois Andrew Ryzner 60004. Periodicals postage paid at Arlington Heights, Illinois 60004 and at additional mailing ADVERTISING & PROMOTIONS MANAGER office. POSTMASTER: Send address changes to address listed above. Athena Catlett GRAPHIC DESIGNER Non-member subscription rates: $60 one year U.S., Canada & Mexico; $135 one year other countries Kristen Castillo (international airmail). Single copies $15 each, except for Suppliers Directory, $35 (Single issues EDUCATION & MEETINGS MANAGER available in North America only). Melisa Ryzner, CMP EXECUTIVE OFFICES All material copyright 2014 by the Nor th American Die Casting Association. All rights reserved. 3250 N. Arlington Heights Rd., Ste. 101 Nothing in this magazine may be reproduced or utilized in any form or by any means, electronic Arlington Heights, Illinois 60004 or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from the publisher. NADCA is not responsible for any material Phone: 847.279.0001 published in this magazine unless it has been explicitly approved by the NADCA Board of Governors. Fax: 847.279.0002 Email: [email protected] Web site: www.diecasting.org/dce Chairman’s Note

Mark Your Calendars

Te 2014 Executive Conference was held in late February in Marco Island, Flor- ida. And what a conference it was. Te overall attendance of 110+ was believed Eric Treiber, President & CEO to be the highest ever (though there was some debate that back in the 1990’s, the Chicago White Metal Casting Inc. CEO conference attendance was even higher). Tose who did attend were treated NADCA Chairman to a world class conference at an amazing venue. If you did not have the opportunity to attend this year, please mark your calendar now for 2015 - February 22-25 at the Marco Island Marriott Beach Resort, Marco Island, FL. Te presentations were excellent, and included topics such as: pricing trends in aluminum, magnesium and zinc (with a spirited discussion on the status of the LME and NASAAC aluminum); navigating the Affordable Healthcare Act as a small business owner; political, regulatory and legal updates from Washington; and “This is typically a preliminary view of the 2014 NADCA die casting benchmarking survey. Again, these were just a few of the informative presentations given. a sign that I was able to talk with most of the conference attendees, including a number of individuals for the first time. Repeatedly, I was told that there seemed to be a “buzz” business levels about this year’s conference, and many indicated it was the best NADCA Executive Conference they had attended. are growing and Te North American die casting industry is healthier today than it has been in quite a few years, as evidenced by a number of indicators. Te strong attendance at management this year’s Executive Conference is certainly an example. In addition, so far in 2014, NADCA members are registering for various education offerings at double the rate is training new that was forecasted. Tis is typically a sign that business levels are growing and management is training new associates, while also making sure that existing team associates.” members are exposed to additional training. So let’s strike while the iron is hot. What’s next on the horizon? Te Plant Man- agement Conference is scheduled for May 21-23 in Charlotte, NC. Included as part of the conference will be a plant tour of Cascade Die Casting’s world class facility in High Point, NC. You won’t want to miss out on an opportunity to tour this S 16949 registered facility. Te Government Affairs Briefing will be held June 10-11. For those who attended the Executive Conference and heard the presentation by Te Franklin Group (NAD- CA’s Washington Representatives), you know that there is much going on in Wash- ington that warrants our attention and requires our voices to be heard on Capitol Hill. And finally, mark your calendar now for the Die Casting Congress & abletop that will be held September 22-24 at the Wisconsin Center in Milwaukee. Not only is this expected to be a very widely attended event due to the Midwest location, but with the Wisconsin Center being located in the heart of downtown Milwaukee, attendees will never be far from a cold beer and a brat!

 From the Editor’s Desk

NADCA Launches Its New Website

NADCA has recently launched a new, updated website at www.diecasting.org. Several months in the making, I think that the improvements that you can see are substantial. You will notice updated sections on the front page – News & Head- lines, Quick Links, Featured opics, Upcoming Events, Classiﬁeds, and updated Advertisements and Ad sizes for those of you who advertise with us. Overall I think it makes for a much more aesthetic experience to better match current web standards – and as you know those standards can and do change every few years. I Andrew Ryzner feel it is important to evolve with those trends. Editor North American Die Casting Association Tis issue of DCE magazine includes NADCA’s yearly Safety Awards for the year 2013. Safety in the workplace is not only important for the obvious reason of keeping your employees free of harm, but it also makes your facility a more attractive place to work. Te Safety Awards honor NADCA Corporate Members that both “I feel it is exceed and meet the average U.S. national safety standards for all of the manufacturing industry in a given year. Congratulations to all the companies that were important to awarded the Perfect and Outstanding Safety Awards.

evolve with Finally, be ready for the next issue (July) of DCE magazine, as it includes the Suppliers Directory, which is only printed every other year, and serves as the Show those trends.” Preview for the 2014 Die Casting Congress & abletop, which will take place September 22-24, 2014. Te city for this year is another Midwestern location – Milwaukee, WI at the Wisconsin Center. Make sure to mark the date on your calendar. I hope to see you there!

 NADCA Government Aﬀairs

Three Aluminum Price-Fixing ronmental Protection Agency (EPA) to establish energy Cases to Move Forward efficiency best practices for commercial tenants rent- ing space in commercial buildings and creates a new A U.S. District Court Judge ruled three plaintiffs groups ENAN SAR certification program, which the bill may move forward for now with separate class-action law- models on the existing ENERGY SAR certification suits against Goldman Sachs Group Inc., JPMorgan Chase program. he provision establishes a voluntary, cost- & Co., their warehousing businesses and the London free certification and recognition program to promote Metal Exchange (LME) for fixing aluminum prices by energy efficiency during design and occupancy of conspiring to reduce the supply of aluminum. leased space. he bill also directs federal agencies to On March 6, 2014, U.S. District Judge Katherine implement strategies to increase the energy efficiency Forrest directed purchaser plaintiffs, commercial end- of federal data centers, remove a regulatory barrier to user plaintiffs and consumer end-user plaintiffs to file manufacturing large scale water heaters, and would separate complaints seeking class-action status. Te establish a benchmarking and disclosure process for defendants will have the right to object to the filings. energy consumed in federally leased buildings. In her order, Judge Forrest designated the law firms Te bill, introduced by Rep. David McKinley (R-WV) that will act as co-counsel for each plaintiff group and and Rep. Peter Welch (D-V), is the first significant appointed nine other law firms to a “steering commit- bipartisan energy initiative approved by the House in the tee” for the direct purchaser plaintiffs. 113th Congress. “It is important that U.S. manufacturers have access Te House also passed H.R. 3826, Te Electricity to globally priced raw materials in a timely manner,” said Security and Affordability Act, by a vote of 229-183. Rep. NADCA President Daniel warog. “Long lead times, Ed Whitfield (R-KY) developed the bill in response to supply shortages, outmoded contract terms, and illogical Environmental Protection Agency’s new greenhouse gas pricing contribute to instability in the aluminum market. emissions standards. Te standards, as introduced by the Tis drives down manufacturing productivity and encour- EPA, are unattainable with currently available technology ages customers to seek overseas suppliers,” said Mr. and would effectively ban coal for use in energy produc- warog. tion, affecting the cost and reliability of energy. Judge Forrest’s ruling comes on the heels of a December H.R. 3826 requires the EPA to set emissions targets 2013 decision by the U.S. Judicial Panel on Multidistrict based on commercially viable technology and requires Litigation to consolidate 26 lawsuits filed nationwide over Congress to review and set a start date for the EPA’s aluminum price-fixing allegations. new standards for existing power plants, giving energy Te North American Die Casting Association suppliers time to make necessary compliance invest- (NADCA) is at the forefront of this important issue, ments and maintain coal and natural gas as viable power submitting testimony to the Senate Banking Subcom- plant fuels while keeping prices low. mittee on Financial Institutions and Consumer Protec- Te EPA introduced the new power plant standards in tion in January and meeting with representatives of the September 2013 and rules for existing plants are expected LME to discuss concerns last year. out in June 2014.

House Passes Two Industry NADCA Signs Letter to Supported Energy Bills Congress on Workforce

Te U.S. House of Representatives passed two energy bills In March, NADCA joined with other leaders from supported by manufacturers and other industry groups. manufacturing, education, and non-proﬁts by sending a H.R. 2126, the Energy Efficiency Improvement Act letter to the U.S. House and Senate supporting work- of 2014, was passed by the chamber on March 5, 2014 force develop and job training programs. In a recent by a vote of 375-36. he legislation directs the Envi- survey, 88% of NADCA members reported they cur- NADCA GOVERNMENT AFFAIRS

rently have skilled job openings. file incident/accident reports electronically on an annual “Many of our members face significant challenges basis (those with more than 250 employees file quarterly) recruiting qualified employees,” said NADCA President which they will make public. Te comments state that the Daniel warog. “Our industry is growing but we can’t proposed rule does nothing to advance safety, but rather expand if we can’t find the right workers.” increases regulatory burdens and removes confidentiality A study conducted by Deloitte and the Manufacturing of employer/employee regulatory information. Institute showed there are 600,000 skilled manufactur- Te NADCA coalition believes that workplace safety ing positions open in the United States. Te challenges is everyone’s concern and improving safety can only coming from Washington do not only surround decreased happen when all parties—employers, employees, and federal funding for job training initiatives, but also that OSHA—have a strong working relationship. Without Congress has not updated some of these programs since providing the data with meaningfu l context, the infor- 1998. NADCA is working with House and Senate leaders mation is not a reliable measure of an employer’s safety on moving a bill to reauthorize the Workforce Investment record or its efforts to promote a safe work environment. Act (WIA), which expired in 2004. OSHA is expected to finalize the proposed rule shortly.

NADCA Coalition Comments NLRB Revives Ambush Elections Rule on OSHA Reporting Rule After their defeat on Capitol Hill and the courts, supporters NADCA oﬃ cially signed comments with its partners, of the NLRB “Ambush Election” rule recently reissued the the Coalition for Workplace Safety (CWS), opposing a proposal. Trough the Coalition for a Democratic Work- proposal released by OSHA late in 2013. Te proposed place, NADCA supported oﬃcial comments opposing the rule requires businesses with 20 or more employees to rule which shortens the time between when a union election NADCA GOVERNMENT AFFAIRS

is called and the vote to as little as 7-10 days. (PCBs), asbestos, radon and lead-based paint. Tere is Originally part of the Employee Free Choice Act bill considerable pressure on policymakers to update SCA; which failed on Capitol Hill, this is the second attempt with some sides calling for the inclusion of more chemi- by the NLRB to implement the Ambush Election rule cals on the controlled list, while others seek ing are a after a court ruled last year it violated the law. Te more updated approach. NLRB is expected to ﬁnalize the rule in the coming months; however, numerous court challenges are again expected by its opponents.

U.S. House Passes Environmental Regulatory Reform Bill Climate Change Champion to Chair Te U.S. House passed a bill supported by manufacturers Senate Clean Air Subcommittee to reform the environmental regulatory process and help speed up permits for businesses seeking to create jobs and After Sen. Max Baucus (D-M) resigned his seat to expand. Te Responsibly and Professionally Invigorating become the U.S. Ambassador to China, a game of musical Development Act (RAPID) seeks to expedite the per- chairs began throughout the Senate. His departure created mitting process by requiring the lead agency to provide a a vacancy at the powerful Senate Finance Committee as schedule with deadlines, which all participating agencies well as affecting the Senate Environment and Public Works must also adhere to in their review process. If an agency Committee, which has overseas the EPA and other impor- does not comply, the permit is deemed approved. tant regulatory agencies. aking over the Clean Air and Te bill targets delays at the local level generated as a Nuclear Energy Subcommittee is Sen. Sheldon Whitehouse result of compliance with federal laws and requirements (D-RI) while Freshman Sen. Cory Booker (D-NJ) will such as completion of an Environmental Impact Statement chair the Oversight Subcommittee. (EIS) or Environmental Assessment under the National Te shuffl e will have a significant impact on regula- Environmental Policy Act (NEPA). Te bill places time tions and actions under the Clean Air Act, including the limits on these various actions to streamline the process. National Ambient Air Quality Standards (NAAQs). Te new Clean Air Subcommittee Chair Whitehouse led the effort among 28 Democratic Senators in March to hold the �oor all night to discuss climate change. Te Senator is the leading voice in the Senate for action on this issue. Senate Report Focuses on EPA’s Use of “Secret Science” Republicans on the Senate Environment and Public Works Committee released a report in March titled, New Toxic Substances Control “EPA’s Playbook Unveiled: A Story of Fraud, Deceit, Act Bill; Hearing Held and Secret Science.” Te report spends considerable time on an employee’s manipulation during EPA’s deci- he Chairman of the House Energy and Commerce sion process in 1997 to establish National Ambient Air Subcommittee on Environment and the Economy, Quality Standards (NAAQs) for fine Particulate Matter Rep. John Shimkus (R-IL), released a draft proposa l (PM2.5) and ozone. Regulators and lawmakers have to update the oxic Substances Controls Act (SCA). based virtually all of their Clean Air Act and air quality he bill, the Chemicals in Commerce Act (CICA), proposals since 1997 on the NAAQs data. is based on a bipartisan Senate proposal, S. 1009, the Te report found that the EPA rushed the NA AQs Chemical Safety Improvement Act (CSIA), champi- review process, relied on data deemed too week even by oned by the late Sen. Frank Lautenberg (D-NJ) and their own standards, and exaggerated the health bene- Sen. David Vitter (R-LA). fits of the proposed regulation. Late last year, NADCA Te House Subcommittee has held roughly a half submitted formal comments to several states in the dozen hearings on SCA. Te law provides the EPA process of recommending which areas within their with the authority to require reporting, record-keeping boundaries the EPA should designate as not attaining and testing requirements, and restrictions relating to new air quality standards being developed. If states do chemical substances and/or mixtures. While SCA not meet the new standards by 2020, non-attainment excludes certain substances such as food, drugs, cosmet- areas will face similar restrictions on manufacturing ics and pesticides; hundreds of items used in manufac- and economic activity as are in place today. turing are covered including polychlorinated biphenyls  NORTH AMERICAN DIE CASTING ASSOCIATION Webinar Schedule

Attending a webinar is an excellent way to obtain information without the hassle or cost of travel! These 60 minute presentations will not only address vital information on the topic but also provide adequate time for questions, answers, and discussion.

For a complete list of webinars, including cost and start time or to register please visit: www.diecasting.org/webinar.

Date Webinar Time Host Die Design and Process Control 5/2/14 1pm CDT Scott Kirkman Part 8 - Thermal Design Example 2 Operator Training 5/6/14 2pm CDT JeffB rennan Part 9 - Recognizing and Controlling Flow Defects SMED Series 5/7/14 12pm CDT Alex Monroe Part 3 - SMED Analyzing and Improving Operator Training 5/7/14 2pm CDT JeffB rennan Part 10 - Recognizing and Controlling Porosity Operator Training 5/13/14 2pm CDT JeffB rennan Part 11 - Eliminating Solder and Flash Defects Porosity Management 5/14/14 12pmC DT EdH erman Part 1- Understanding Porosity Die Design and Process Control 5/16/14 1pm CDT Scott Kirkman Part 9 - Thermal Control Porosity Management 5/21/14 12pmC DT EdH erman Part 2 - Die Design Porosity Management 5/28/14 12pmC DT EdH erman Part 3 - Casting Design Porosity Management 6/4/14 12pmC DT EdH erman Part 4 - Process Control Die Design and Process Control 6/6/14 1pm CDT Scott Kirkman Part 10 - Basic Die Casting Die - Holders and Locking Metallurgy of Aluminum Die Cast Alloy 6/11/14 12pmC DT DavidN eff Part 1 - Alloy Effects, Phase Diagrams, Microstructure Metallurgy of Aluminum Die Cast Alloy 6/18/14 12pmC DT DavidN eff Part 2 - Impurities and Melt Treatment Die Design and Process Control 6/20/14 1pm CDT Scott Kirkman Part 11 - Basic Die Casting Die - Inserts and Fit NADCA Reports

market-expanding potential. Winning castings will be dis- NADCA NEWS played during the 2014 Die Casting Congress & abletop in Milwaukee, WI and winners will be honored during the NADCA and NAM Partner to Achieve Goal Die Casting Awards Luncheon. NADCA’s Die Casting of 500,000 Industry Certi�cations Engineer Magazine, NADCA’s Website and the NADCA Design Website will also feature the winning castings. Arlington Heights, IL - Te Manufacturing Institute and Tis competition helps promote increased use of die its partners in the Skills Certification System, including castings by recognizing and publicizing outstanding the North American Die Casting Association (NADCA), designs. For more information on the 2014 International announced significant progress toward achieving a five- Die Casting Design Competition please visit, www.die year goal to award 500,000 industry-based certifications to casting.org/castings/competition or email Daniel warog individuals. Over the past year, the certification partners at [email protected]. have issued 117,189 certifications, an increase of over 30 percent, bringing the total to 294,478 certifications issued Te deadline to submit your casting is June 30, 2014. since 2011. With 80 percent of manufacturers citing a Don’t hesitate! moderate to severe shortage of skilled workers, this is an important step in closing the skills gap and increasing the competitiveness of U.S. manufacturing. Correction From NADCA’s March DCE Magazine “NADCA is using our die casting educational resources to create certificate programs which complement the cur- Page A9 from the March issue of riculum developed for the Manufacturing Skills certification Die Casting Engineer magazine system,” said Daniel warog, president of the North Ameri- contained a misprint of a photo- can Die Casting Association. “We are working with some graph of a casting award winner. community colleges, and would like to work with more, in Te Aluminum Die Casting 1 order to integrate the die casting resources into the standard to 10 Lb category had the cor- courses on basic manufacturing skills. Any die caster inter- rect credit given to Don Carter ested in partnering with a local community college or trade - Shiloh Industries, for the school should contact NADCA so we can work with that part - Clutch Retainer Annulus. organization to incorporate die casting in their training.” However, the photograph shown o view the rest of this press release please visit www. was not correct. Te image on the diecasting.org/newsletter/2014/031914/21.htm. left is the correct photograph. NADCA encourages comments, suggestions and/or complaints regarding errors that warrant correction. If you see anything you would ever like to comment on, Innovative Die Castings Wanted - Submit Your Entry to please contact Andrew Ryzner, Editor of DCE magazine the International Die Casting Design Competition at [email protected]. Arlington Heights, IL - o be a winner in today’s economy, you must meet and even exceed expectations. In a competitive global market, customers take notice of the best. NADCA knows that competition improves the competitor. With its annual Die Casting Competition, it recognizes and UPCOMING EVENTS rewards the outstanding casting designs of the year. Entering and winning is one of the best ways to gain visibility with leading decision-makers. Te competition is NADCA to Host 2014 Die Casting Congress & Tabletop open to aluminum, magnesium, zinc die castings and other in Milwaukee, WI alloy families. Any number of castings may be entered. Arlington Heights, IL - Te 2014 Die Casting Congress However, a separate entry form is required for each cast- & abletop will be held September 22-24, 2014, at the ing or assembly of castings. In addition, the metal surface Wisconsin Center in Milwaukee, WI. Tis event will cannot be improved or concealed by tumbling, shot blast- include three days of Congress sessions. Te Congress ing, coating or other surface treatments. session schedule for 2014 has been adjusted to create more Judging is conducted by an independent panel of experts time for those attending sessions to also attend the show from the die casting industry, with no ties to eligible exhibits. In addition, the Design Awards Luncheon has companies. Te four equally weighed criteria are ingenuity been combined with the Industry Awards Luncheon to of casting/product design; overall quality; cost savings; and provide a united complimentary awards event. NADCA REPORTS

“Te technical presentations at this year’s congress ses- Updated NADCA Publications Available sions were among the best ever to accompany a abletop Via iTunes and Amazon show. Investigators demonstrated a unique understanding of Arlington Heights, IL - With the continued growth of applicable scientific principles and practical die cast issues. eReaders such as the iPad, Kindle and Nook, NADCA is In addition, all the sessions I attended were void of annoying continuing the process of making various publications avail- attempts at salesmanship. Session attendance was very good, able on these devices. NADCA has recently updated the with few empty seats even in the late afternoon,” said Andrew following publication available for purchase on Amazon and D. Behler, P. E., Vice President, Blue Ridge Pressure Cast- iunes. Tis publication can be purchased for just $9.99. ings Inc. at the 2013 Die Casting Congress & abletop. In addition to the Congress sessions, this tabletop show • Extending Die Life: Maintenance & Welding Strategies will feature more than 70 exhibitors and the International Die Casting Design Competition. Previously released titles include: “Te tabletop shows are a great value for exhibitors. I • Porosity Management: Advanced Analysis received high quality leads that are industry specific. By exhibiting I have the opportunity not only to reach the die • Evaluation of Surface Finishes on Aluminum Die Castings casting industry but also to support the association,” said • Die Casting Defects - Causes and Solutions Michael Hicks, Vice President, DMS, at the 2013 abletop. • Die Casting Defects - roubleshooting Guide Te 2013 Die Casting Congress & abletop attracted over 780 attendees (over 334 different companies were represented) • Porosity in Die Castings: An Overview and Analysis and 110 companies showcased the latest technology, research • Safe & Reliable Die Clamping and services available to the die casting industry. NADCA expects another fantastic turnout at the 2014 Die Casting • Die Casting Porosity Guidebook Congress & abletop held in Milwaukee, WI! • Die Casting Shipment Report 2011 • Energy Saving Manual • High Integrity Die Castings • Master Die Casting Process Modeling TOOLS & RESOURCES As NADCA continues to convert publications we will make sure to keep you posted on the newest developments NADCA Launches New Website with and availability on other devices. Upgraded Features for Members  Arlington Heights, IL - NADCA has recently transi- tioned to its newly designed website. Tis newly designed site offers members a sleek new look, updated content, new Calendar of Events advertising options and a more user-friendly registration area for webinars and events. As with any major overhaul May 15, 2014 September 23, 2014 Committee Meetings Committee Meetings there may be a few bugs to work out here and there. Arlington Heights, IL Milwaukee, WI Please contact [email protected] if you encoun- ter an error or have any issues operating the new site. May 21-23, 2014 September 24, 2014 Plant Management Conference Board of Governors Meeting Charlotte, NC Milwaukee, WI June 10-11, 2014 October 15, 2014 Government Affairs Brie�ng Die Materials Meeting Washington, D.C. Arlington Heights, IL June 10, 2014 October 16, 2014 Board of Governors Meeting R&D Meeting Washington, D.C. Arlington Heights, IL June 11, 2014 October 19-25, 2014 Die Materials Meeting Italy Delegation TBD Sirmione, Italy June 12, 2014 February 22-25, 2015 R&D Meeting Executive Conference TBD Marco Island, FL September 22-24, 2014 October 5-7, 2015 Die Casting Congress & Tabletop Die Casting Congress & Exposition Milwaukee, WI Indianapolis, IN Dr. Die Cast Training Our Customers?

Anyone serving the current group 6. ighter tolerances will insure I 5. Low volume products that of customers will experience get better quality. involve lots of close tolerance numerous “itle Block Standards” as-cast cores that could be 7. olerances are free. that are a mismatch for the die more cost effective as machined casting drawing. Te standards 8. Die/tooling life is not related to features. will have been copied word for tolerances. 6. Non-standard, tighter tolerances word from a die casting drawing 9. Te size of the casting has noth- cost extra. Either in additional somewhere within the customer’s ing to do with the tolerances. tool maintenance, higher scrap, company. Sometimes this is due lower productivity. to company mergers when two 10. Te annual volumes have noth- or more companies engineering ing to do with development 7. Accelerated tool replacement standards are somehow morphed costs. due to lack of allowances for normal tool heat checking. together instead of doing a thor- 11. Didn’t have time to review the ough review and consolidation of options. 8. X-ray standards that create the standards. How can we as sup- extra processing and inspection pliers address this condition? In a 12. Didn’t have the authority to costs with little improvement in phrase, by “training our customers”. change (top down). functionality. Experienced senior engineers that 13. Add your own… 9. Notes that refer to “External are slightly “younger than dirt” Customer Standards Documents” must train our emerging customer What are some of the problems asso- that are either obsolete or not base. Now before you start dust- ciated with copying standards? readily available to the supplier. ing off your books and courses on persuasion, you might want to ask 1. Surface finish require- 10. Material standards that are the customer why they chose that ments are inappropriate for a “non-standard” materials (such procedure in the first place. mechanical die casting prod- as specifying an extrusion or uct especially die castings. sand cast alloy for die castings.) (Chrome polished surface or What are some of the misconcep- 11. Tread and tap sizes that are tions that would lead a designer to “Class A call out” on an oth- “British Standard” confused copy title blocks? erwise functional casting.) with “English Standard” i.e. 1. Die castings are similar to 2. As-cast tolerances require fre- U.S. or S.A.E. plastic parts and therefore have quent core replacement and/or 12. Designer needs to specify similar dimensional capabilities. tool repair and/or replacement whether the die casting “draw- 2. All alloy casting processes 3. Die castings with dimensional ing” or the “3D casting model” are similar. tolerances similar to plastic takes precedent. injection molding. Increased 3. All die casting products can 13. CPK on non-critical features tool maintenance costs to both that add costs, especially when produce the same tolerances the die caster and customer. regardless of the alloy. variable gaging is required to 4. Aluminum die casting dimen- validate. 4. Didn’t ask. sional tolerances that are the same 14. Low draft conditions that 5. Previous experience with as zinc or magnesium increasing increase the diffi culty to cast/ a die casting. the tool maintenance costs. eject and decrease tool life.

Who’s Dr. Die Cast? Bob McClintic & Associates [email protected] Robert P. McClintic 2544 Almar Street www.drdiecast.com Die Casting Consultant Jenison, MI 49428-9108 616.669.2932 DR. DIE CAST

15. Incorrect revision level. Fea- Te time to address design and What about existing castings, tures added after the quote tolerance concerns is “sooner rather sometimes referred to as “legacy that increase tooling and than later”. Te time to initially cri- castings”? Most customers today castings costs. tique the drawing is during the quot- are looking for ways to reduce 16. Packaging or dunnage that ing process. For many companies, costs. By the time you have worn may be defined on the drawing the design still has some �exibility out a die cast die you and your that is assumed as “free”. during the quoting process. staff are the resident experts on the What is a good reference tem- strengths and weaknesses of their 17. Etc. plate when critiquing drawing castings. Why not be proactive and When is the appropriate time to notes? In Section 8 of the 2009 suggest changes that could not only address the notes? It is not as one E-606 “NADCA Product Speci- increase reliability but reduce costs? die caster commented, “After they fications Standards for Die Cast- Rather than just doing a form letter receive the purchase order.” In the ings” there is a Checklist that stating that the cavities are reach- life cycle of the design this is nearly outlines the “cost effect” of various ing the end of their life, how about too late to reopen the conversa- specifications and tolerances. Every reopening the conversation on the tion. Most designers are already sales engineer should be intimately current operating standards? Tey working on the next project by the familiar with these pages. Be might just be grateful, and wouldn’t time the tooling order is placed prepared to discuss the real costs that be a welcome improvement to and are reluctant to revisit the associated with each level. Don’t be the business relationship. design. What if the design was by afraid to challenge the standards an outside design source? Tey may with something like, “Do you really not even be present by the time the need that for your customer or the tooling P.O. is placed. functionality of the casting?” 

NORTH AMERICAN DIE CASTING ASSOCIATION    In conjunction with NAM’s 6th   

June 10-11, 2014 –    OSHA + EPA Awareness Update

OSHA + EPA Update Seven Planning Steps Tere are seven planning steps for crisis management, as Crisis Management Impacts, Prerequisites, outlined below: and Business Continuity for Enterprise 1. Treat Assessment - Te organization must perform a process/functional assessment on what may be Risk Management impacted by a crisis. Examples include manufacturing When it comes to crisis and enterprise risk management, equipment/process, raw material supply, inventory of are you prepared? And just how do business managers product, shipping/receiving, I, ﬁnance, customer data, determine their organization’s preparedness? safety, environmental releases, utilities, and logistics.

2. Business Impact Assessment - Management must Crisis Management Standards and Guidelines rate and rank the business impacts to determine those First, it is important to review the standards and guide- needing mitigation. Te assessment will determine lines used for the development of an effective crisis the significance of each event to the business. Man- management program: agement should then determine mitigation plans. Where an emergency program does not exist, a new program should be developed. GUIDELINE REQUIREMENT(S) 3. Emergency Response Plans - Emergency response • The organization shall establish, implement and plans are to be developed to the degree necessary ISO/OSHAS maintain a procedure(s) to identify potential emer- to ensure that the organization will survive a crisis. Management gency situations. A typical emergency plan includes strategic plan, System • The organization shall periodically review and revise emergency response, prevention, mitigation, recovery, its emergency preparedness and response plans. and continuity. Plans must also include the process for managing leadership, communication, the �ow of • 5.3 Risk Assessment: The entity shall identify & moni- information, and direction of recovery. tor hazards, determine likelihood of their occurrence 4. Business Recovery Plans - Te recovery plans must and the vulnerability of people, property, the environ- include short- and long-term priorities for restoration of ment and the ENTITY itself to those hazards. functions, services, resources, facilities, programs, and NFPA 600 • 5.5 Mitigation: The entity shall develop and imple- infrastructure. It is very important for an organization ment a mitigation strategy that includes the mea- to make short-term timeline decisions prior to a crisis: sures to be taken to limit or control the consequences, • Determine what must be done and by whom in the extent or severity of an incident that cannot be first two hours, six hours, twelve hours, twenty-four reasonably prevented. hours, two days, and beyond • 11.1.2 Perform Risk Assessment • Assign senior management for oversight/ decision-making duties ASIS: Business • 11.1.3 Conduct Business Impact Analysis Continuity • Nominate/train a crisis management team Guidelines • 11.2.2 Develop Mitigation Strategies • 11.3.5 Execute the Plan • Develop needed controls to effectively ensure response/recovery OSHA + EPA AWARENESS UPDATE

• Verify and validate measures to establish risk benefits • Verification that warning systems are known of responses developed and understood • Assure maintenance of alert guides and contact lists • Completion of trials for each emergency plan • Include legal and professional advice readiness prior • Completion of actions and impacts lists development to needing service During an audit, it can be good to shake things up. • Determine internal trained/assigned communication Always complete a post-incident review after any incident resource for all external communication required occurs. Auditors must verify management meetings, review after an event to give one consistent voice of each emergency plan, and results of each exercise. Use a corrective/preventive action program to document continu- 5. raining - All employees and outside contractors ous improvement of your crisis management program. must be trained on all applicable emergency plans; management should also consider including training 7. Maintenance - You must have an ongoing review of for community emergency response support teams. the emergency procedures and work instructions, and raining should be documented, and competency of continually improve them using management by walk- those trained must be verified. Allow for employee ing around techniques. suggestions/improvement during training exercises. • Update/review plans yearly with employees • Update/review threat assessment and plans as new 6. Auditing & Evaluation of Plans - Each emergency building, processes, or equipment are added to facility plan must be audited for: • Verify that emergency plans meet all legal requirements • Inclusion of all possible scenarios • Use internal auditing and corrective/preventive • Completeness of tasks action programs for improvement • raining and understanding by employees • Verify status of emergency plans in management and outside contractors meeting sessions

The DOEHLER AWARD is presented annually for outstanding contributions to the advancement of the die casting industry or to the art of die casting as represented by:

NORTH AMERICAN DIE CASTING ASSOCIATION Technical Achievement – As measured by signi�cant scienti�c contributions of a metallurgical or engineering nature relating to the die casting process, including casting alloys, die steels and die practices, �nishing 2014 methods, machine design and related subjects. Advancement in Plant Operations – Of a management or administrative nature and related to the operational Doehler Award phases of the industry; safety procedures, devices, and techniques; practical mechanical advances and other accomplishments directly related to eﬃciency, economy Nominations and safety of plant operation. Other Activities – Not primarily of a scienti�c or operational nature that result in the enhancement of the reputation and acceptability of die castings. All contributions to the art of die casting and advancement of the industry are to be evaluated on the applicability of Submit Nomination to: the contribution to the die casting industry as a whole.

North American Die Casting Association Your response should detail the nominee’s contributions to the die 3250 N. Arlington Heights Rd., Ste. 101 casting industry that meet the criteria and include the names of Arlington Heights, IL 60004 any other NADCA members who are in support of the nomination. The deadline for nominations is Monday, June 30, 2014. All P: 847.279.0001 • F: 847.279.0002 nominations received will be submitted, in con�dence, to the E: [email protected] NADCA Awards Committee for consideration. OSHA + EPA AWARENESS UPDATE

Getting Started on Crisis Management • Claims, accidents, and workers compensation Where does an organization start? • Business , property, and special premiums You should begin by reviewing current emergency plans, expe- • Policy consolidation options rience with any prior events, and industry/market situations. • Formal emergency response and loss prevention programs • Policy costs and payment terms How does an organization know if its plans are adequate? • Low-incident, high-risk potential Ask yourself: • Are there plans for every possible scenario? • Claims and credit history • Policy document management • Do the plans include all steps required for mitigation? • Loss prevention scenarios • Do the plans include internal communication and information updates to employees and external sources? • Contractor insurance liability and company listing on contractor policy How does an organization know its plans will work? • Comparison of coverages to risk and loss levels All emergency plans must be trialed and reviewed by management upon completion of trial for verification. How do you know if your coverage is current/comprehensive? • What is your company’s process? • Conduct a review/consider use of specialized resources or assessment guide • Are roles and responsibilities known, understood, and documented? • Fully examine all possible risks • Does each employee know his/her role and demon- • Determine all crisis scenarios strate competence during trials and audits? • Quantify loss potential • How are back-up roles deployed, trained and verified? • Update and outline crisis management plans and options • Rate, rank, and prioritize the plans How does the organization communicate crisis management information? • Update plans to both highlight and remediate your risk concerns • Is there a communication plan in place that includes all employees and external parties (i.e., emergency • Establish a compliance plan for all safety and loss responders, regulators, suppliers, insurance, customers standards that apply to your business and financial institutions)? Finally, conduct a continuous Plan-Do-Check-Act cycle until you are satisfied with the cost benefits of your planning. By following these steps, your organiza- Enterprise Risk Management tion will help ensure itself of being prepared for and o help ensure the overall enterprise risk management of surviving a crisis incident. your organization, you need to review the following: 

Kestrel Management Services, LLC is a proud member of NADCA and an independent consultancy providing industry with compliance support services in development of Regulatory Compliance and Enterprise Risk Management programs and systems including safety and health, environmental protection, sustainability, quality and operational eﬀectiveness. Our advisory and strategic focused practice is led by a team of senior consultants and principles averaging over 30 years of direct industry experience. We have both the capability and Kestrel Management Services, LLC know-how to understand and meet the needs of our clients. 199 East Badger Road, Suite 200 We focus on business-centric results. Madison, WI 53713 Contact NADCA or Bill Bremer, the NADCA member Phone: 608.226.0531 contact of Kestrel Management at: Fax: 608.226.0536 [email protected] for additional information. www.kestrelmanagement.com Ask the Experts...

What advantages of SSM and squeeze casting should be considered (as compared to standard HPDC) when designing cost-eﬀective parts?

Te primary advantage of (typically 1+ minute for squeeze versus Te following are the both the SSM and squeeze 30 seconds + for HPDC) and is also advantages of the SSM A: casting processes is their limited to thicker cast sections (5 or 6 A: and Squeeze castings ability to employ low-Fe alloy of the mm or more for squeeze versus 1-2 mm over the Standard HPDC: A356, A357 types to make sound cast- for HPDC) and therefore higher cast • Less air entrainment. ings that can be solution heat treated weight; the rheocasting version of SSM, • Less shrinkage. (for the -4, -6 or -7 tempers) with- on the other hand, can easily employ • Less porosity. out blistering, thus both are suitable both primary and secondary alloys, and • Higher pressure tightness. for production of structural castings is capable of cycle times and cast section • More sound casting. for a variety of automotive, military thicknesses equal to or even less than • Fine and homogenous and aerospace applications. Tere are, HPDC, so can be very cost eﬀective for microstructure. however, important diﬀerence between reducing the weight of crash sensitive • Improved mechanical strength. SSM and squeeze; Squeeze tends to be and other automotive parts where mini- • Less cost on parts with above a higher-cost process in terms of input mum weight is paramount to reduced requirements. material (primary for squeeze versus fuel consumption and CO2 emissions. - Director secondary for HPDC) and cycle time - Consultant  Introducing an Improved Process for Semi-Solid Metal Casting of High Integrity Parts

Alan Koch, Development Consultant Kristen Tenzek, Development Engineer Ajax-TOCCO Magnethermic Ajax-TOCCO Magnethermic Warren, Ohio Warren, Ohio

Abstract Some factors limiting commercialization of SSM processing historically have been: A process has been developed that can produce high integ- 1. Te expense and complexity of the processing and rity parts to meet the new CAFE standards and higher billet heating equipment. performance requirements in the marketplace. Moreover, 2. Te absence of the means to measure the fraction the new process can be set up to produce both 10-20% solid of material during processing, particularly fraction solid (fs) slurry that can be poured directly into in view of recent information on the in�uence of the shot sleeve of a die casting machine to reduce casting melt chemistry on Process Stability.1 (Kaufmann & porosity and other part defects in castings, and produce Uggowitzer p. 226) semi-solid slugs (40-50% fs) that can be poured directly into 3. Tere are many variables in the SSM production process a shot sleeve for forming into high integrity components. and the high pressure casting processes that are either Te process features a non-contact, continuous method to not easily controlled, or cannot be accurately measured monitor the development of the slurry structure. Te process with a view to the control of the overall process. is able to sense, and can be adjusted for, variation in the melt chemistry to ensure delivery of consistent fraction solid material to the casting machine. Te process can be added to an existing HPDC cell. Te features of this process address shortcomings that have limited the commercialization of semi-solid processes in the past.

Introduction

Since the late 1960’s and early 1970’s, when the initial research was done at MI, Semi-Solid Metal (SSM) processing and casting has been a topic of interest in the metals industry. With the new CAFE standards and higher performance requirements in the marketplace, further development of SSM processes looks to be a promising method Figure 1a – Low fs 380 Alloy Slurry being poured from the by which to create parts to meet those standards, thereby AM processor. increasing commercialization opportunities.

Some of the advantages of SSM processing are: 1. Reduction of shrinkage porosity since the material is already partially solidified. 2. Reduction of dwell/curing time in the mold, again, since the material is partially solidified. 3. Ability to be able to fill a mold cavity in a laminar �ow regime, thus minimizing turbulence and the associated entrapment of gases. 4. Potential increase in die life due to reduced thermal cycling and less heat that has to be absorbed and dis- sipated through the casting mold. 5. Semi-solid material can fill both thin sections and thick sections with reduced defects; thus, allowing Figure 1b – Slice est of an A-356 Semi-Solid “slug” poured maximized physical properties to be achieved. from the AM Processor. o utilize the advantages and minimize the concerns Te unit is powered by a dual frequency induction power of SSM processes up to this point, this new process supply. A Load Analyzer module in the induction unit addresses features that are desirable in a controllable sends coil feedback to the system’s data acquisition pack- SSM casting process. For example, process stability is age. Tis coil feedback is used to sense the occurrence of the key issue in determining future investment in new the liquidus point of the alloy and monitor the cooling of processes. Te most important parameter allowing the semi-solid metal to the desired condition for casting. control of the SSM processes is the alloy composition. (Kaufmann & Uggowitzer, p. 254). Te fraction solid of a batch or charge of slurry material at a specific temperature is extremely sensitive to the chemical composition of the melt. An example given by the cited reference indicates that A356 alloy at 586° C at the extremes of the chemical composition spec limits for Silicon can be at 47% fs or 37%fs, which can significantly alter the mold filling behavior of the material. Most SSM systems rely on temperature feedback to control the process. If melt chemistry cannot be controlled or at least re�ected in some manner, then melt temperature alone Figure 2 – Chart showing the relationship of the liquidus of is not a reliable process control parameter.1 (Kaufmann the metal temperature (red) with the slope change of the Load R & Uggowitzer, p. 236-256) Signal (blue) during consecutive cooling cycles. raceability of a formed part back to the material processing and casting parameters is a desirable and Te system has a small footprint that allows it to be oftentimes necessary quality system requirement in incorporated into most existing die cast cells. Standard the production of high performance and high liability holding or dosing furnaces can be used as molten metal components. If a monitoring system for key parameters sources. Te process requires good incoming molten metal can identify when a process is outside of acceptable temperature control. Incoming metal temperatures that control limits, then “out of spec” parts can be rejected at have been used for A356 alloy have been in a range from the production cell instead of at downstream operations, 625° C to 650° C. with +/- 2° C control point repeatabil- after additional work and expense has been expended. ity. Te system can deliver slurry to a standard die cast Previous technology was often hard to operate due machine or to an HVSC machine. to complexity of the equipment or to the previously mentioned lack of reliable process feedback and process instability. Terefore, a process that was well-defined and relatively easy to operate would be beneficial. Some systems have multiple charges in process at a time in order to meet production rate targets or to allow sufficient time for the necessary spherical microstructure to develop (ripen). Tese types of systems typically incurred a high loss of material in process if an interruption was experienced either in the processing of the SSM material or at the casting machine. An interruption in the thixocasting case usually resulted in an expensive loss of slugs “in process” with additional downtime expense for recovery and restart of the system. A single charge processor unit that can deliver a repeatable slurry or slug charge to a casting machine at a typical die casting cycle time would be advantageous.

Discussion

A new system has been developed at Ajax -OCCO Magnethermic that addresses these concerns. Te AM system consists of a single crucible based, metal processing unit that is able to control the cooling/heating of metal delivered to it.3 Te induction coil is closely coupled to the crucible, which allows for a rapid response in both cooling and heating of the system as needed for rapid cycle times. As mentioned above, previous SSM methods have not had a means, other than temperature, to determine the process conditions of the charge. emperature is not a good indicator of fs since it is sensitive to the chemistry of the alloy. In Europe, a Laser Induced Plasma Spec- troscopy, LIPS system has been used to continuously monitor melt chemistry. Tis points out the importance of controlling chemistry for consistent melt properties and downstream processes. Te AM unit uses the coil feedback of the load to sense the liquidus point of the molten metal as it cools. When this point is determined, a value of the pouring point can be calculated on the basis of a predetermined resistance change in the load. Tis method links the active process to any changes in the alloy chemistry that would be seen as a shift of the liquidus point. Figure 4b – Microstructure of Alloy 380 Slurry processed in the AM System.

Figure 3 – Liquidus emperature vs. Si % of 380 Alloy; Casting rial Data.

Figure 5a – Spheroid microstructure from Slurry 02/09/2012.

Summary

380 and 356 Alloys have been successfully processed in the unit. Examples of the typical microstructures are shown in Figure 4. Moreover, the process was able to produce similar, spheroid microstructure in both the low fs and high fs test runs.

Figure 5b – Spheroid microstructure from Semi-Solid Slug 06/04/2013. During initial casting trials using 380 alloy with the same casting equipment and mold, parts were made using both the standard die casting parameters and separately groups were cast using slurr y material and process settings. ensile results averaged 1.5% Elonga- tion for the standard HPDC samples and 3.5% for the Figure 4a – Microstructure of 356 Alloy Slurry Processed in the slurry samples. Also, cycle times were comparable to the AM System HPDC cycle time due to the reduction in dwell. Comparisons were made of parts costs using several casting methods. Tese comparisons were made consider- ing the same casting (7lbs suspension arm) and standard equipment and parameters typical to the individual processes. Te relative trimmed part costs are shown below: + + 1.H PDC 100%( $11.64) 2. AM Slurry 104% NADCA + + + 3. Squeeze Cast 125% 4. Perm. Mold 115% six station 5. Perm. Mold 190% single station MARKET All trimmed parts; 356 Alloy. HPDC included as a reference for part rate, all the other processes usually considered high integrity processes. PLACE+

+ Conclusion +

Te AM system is a state of the art process and equipment package. Te system provides a method to monitor the What is the Marketplace? development of the fs and reference it to the melt chemistry, a critical variable in metal casting processes. Metal condi- The Marketplace is NADCA’s new tion is traceable through the data acquisition and monitor- online store. You can purchase the + ing system, and can be linked to a cell part quality system. items below. Trying to register for Te system provides a method to provide high integrity parts at a competitive cost; a signiﬁcant factor in terms of someone else? No problem! This is new CAFE standards and higher performance require- also an option in the new Marketplace. ments in the marketplace. • Purchase Publications References • Register for Conferences 1. Kaufmann, Helmut, and Uggowitzer, Peter J., Metallurgy • Register for Courses and Processing of High Integrity Light Metal Pressure Cast- • Register for Webinars + ings. Berlin: Schiele & Schön, 2007. Published Book 2. de Figueredo, Anaceleto ed. Science and echnology of Semi- Solid Metal Processing. Worcester, MA: Worcester Polytech- nic Institute, 2001. Published Book 3. US 8241390.B2 Patent, Semi-Liquid Metal Processing and How to Buy? Sensing Device and Method of Using Same. published 2009- Simply add the item or items to 04-16, granted 2012-08-14, �led 2008-10-10, inventor your shopping cart and proceed Koch, Alan A, assigned Ajax-OCCO Magnethermic. to checkout! To view more details Additional Information on items available in the Marketplace For more information about the AM Slurry System, visit: www.diecasting.org/store. + contact Bob Riccardi at Ajax-OCCO Magnethermic at 330.372.8511, [email protected]. + 

About the Authors Alan Koch has been involved in metal processing, casting and related support activities for over 30 years. He is currently a development consultant with Ajax-OCCO Magnethermic in Warren, Ohio.

Kristen Tenzek is a development engineer at Ajax OCCO

Magnethermic. She has a Bachelor’s of Science degree in Phys- NORTH AMERICAN DIE CASTING ASSOCIATION ics from Kent State University, and has taken graduate-level www.diecasting.org/store classes in Optics and Materials at Cleveland State University. Fire Incident Prevention for NADCA

Randy Block Kestrel Management Services, LLC Madison, Wisconsin

Kestrel Management Services, LLC was asked to observe Not only is each organization required to follow multiple NADCA member sites looking for ways to help these requirements, but they are also required to train members identify issues of concern within their own employees, verify that outside contractors are meeting organizations concerning fire prevention. Tis report is a these requirements, and show evidence of a valida- guide to help members to better understand what to look tion activity by management. Management must verify for, how to assess compliance, and, ultimately, how to training, as appropriate, and document that daily, reduce the likelihood of a fire incident. weekly, monthly, semi-annual, and annual actions of employees and management meet all applicable legal Legal Requirements - Te first step for any NADCA requirements as stated by regulations. See member is to verify that they know and understand all legal www.osha.gov for further information on these critical requirements that apply to their organizations. Below are requirements for fire prevention and what constitutes the OSHA requirements for fire prevention, which include: governance under the General Duties clause. • Industrial Fork ruck - 29 CFR 1910.178 - Not utilizing a daily fork truck checklist. Not securely attaching Management Responsibilities - Only management can molten metal crucible to forks by chain or screw. determine acceptable actions by employees. Management • Hot Work - 29 CFR 1910.252 - Not utilizing required must make its desires and requirements known, under- Hot Work Permit. Not training or identifying the Fire stood, and followed by all onsite personnel. In many cases, Watch personnel. Not clearing fire area for minimum management has worked very hard to earn S/ISO certifi- of 35 feet. Not using a tarp to prevent possible fire. cations. Each organization should use the fundamentals of a management system for fire prevention. A management • Walking/Working Surfaces - 29 CFR 1910.22 - Rail- system approach would include: ings insufficient. No three inch toe guards for plat- forms greater than four feet off of �oor. • Internal audits of facility and legal requirements • Personal Protective Equipment (PPE) - 29 CFR 1910.132 focusing on fire prevention. - PPE not being utilized by employees; no eye protection, • Verification of training. no safety vest and face shield while working around molten • Verification on outside contractors meeting legal metal. No purchasing specifications for PPE defined. No requirements; based on job functions and duties. Hazard Assessment for determining required PPE. • Use of corrective/preventive action (CAPA) • Electrical Safety - 29 CFR 1910.303 - Floor space program for fire prevention, including timeline clearance requirements not defined from power panels, and identification of responsibilities. based on Voltage. No labels on power panels. • Verification activity by management of actions identi- • Explosive Dust - 29 CFR 1910 Subpart R & S and fied by CAPA as meeting internal requirements. www.osha.gov/publications/combustiblesdustposter. pdf - Poor housekeeping to remove dust from overhead • Management review topic on fire prevention activities. piping, light fixtures and ceiling fans. • Accountability of supervisors and management • National Fire Protection Association (NFPA) - 70 (e) to meet all legal requirements. - No Arc Flash study. No PPE requirements for those • Improved and documented preventive performing electrical work. No Termo Imaging of maintenance programs. electrical circuits. In addition, an organization needs to have a strong “near • Process Safety Management (PSM) - 29 CFR miss” program. Once management knows and understands 1910.119 - Management not reviewing if under the legal requirements to follow, it will be easier for super- requirements per Appendix A. visors and management to identify when and where a near • Hand and Power ools - 29 CFR 1910.242 - Must miss (which may now not even be considered) is occurring. purchase Square D logo safe power tools. Must repair Near miss information will guide an organization towards any frayed power cords. rectification activities to prevent an actual occurrence in • Pressurized Cylinders - 29 CFR 1910.110 - Pressur- the future. Management and hourly workforce must define ized cylinders not stored correctly. Pressurized cylinders a fire incident in the same manner. Otherwise many fires stored near power panels. Pressurized cylinders allowed may not be reported to management for inclusion as an on manufacturing �oor, not chained and secured. issue of concern to rectify. Five S Program – Many of the NADCA members’ loca- Maintenance - It appears that many maintenance depart- tions lacked a comprehensive 5S workplace organization ments are understaffed and not capable of meeting preventive program. Implementation of a workplace organization maintenance requirements. Te workload is not adjusted program must be driven from the very top of manage- and prioritized against any criteria other than safety requirement. Only top management can create the environment ments. Why would fire prevention not also get a high priority needed and give visibility and importance to the program from management? Of note, maintenance does not appear needs for long-term viability. Tis workplace organiza- to be able to keep up with equipment oil leaks. Management tion program creates a fundamental difference between a should review the practice of allowing hosing to be on �oor. successful fire incident prevention program and a com- Tis action hinders cleaning the �oor and determining the pany waiting for the next incident to occur. Without the location of oil leaks, and prematurely shortens the life of every ability of management and hourly workforce employees hose being rubbed against equipment during cycling process. to define their workplace organization tasks, nothing will Who is responsible and verifies that equipment repairs are improve. Once workplace organization program structure completed in a manner that is acceptable and correct? When has been defined, the first task is to sort everything in the has somebody in management been reprimanded or disci- workplace. Determine proper quantities of items to keep plined for shoddy work being performed? in workplace. Next is to set in order and determine how to organize what is left. Storage should include �oor, rack- Random Observations - Tere are a number of observa- ing, cabinets, carts and storage bins. Shine the workplace tions made - some small, yet important tasks - that com- includes more than just cleaning. One must clean �oor, panies should address and incorporate into daily practices equipment, walls, ceiling, bathrooms, light fixtures and to prevent fires: even ceiling fans. Management must maintain this appear- • Eliminate home blindness by management. ance after completion and develop preventive measures • Improve cleanliness of facility. to keep it clean. o maintain the improved appearance of the facility will require paint, lighting, dust removal, • Place lids on all garbage cans. minimizing spills and improved maintenance of equipment • Place rags in auto-close fire prevention containers. and building. Standardize every location and tool used. • Develop PM and cleaning program for all ceiling Put a system in place to ensure everybody does their work ventilation fans and all �oor fans. in same manner. Management must train, complement employees and train again. Management must support • Develop specific locations for propane tanks on and sustain this workplace improvement program for it to molding equipment and storage of all propane remain successful over time. tanks used for pre-heating of molds. Workplace disorganization examples include: • Define �oor space clearance requirements for each • Pallets and cardboard strewn about instead of given a power panel and maintain clearance requirements. specific location. • Verify location of �ammable pressurized cylinders • Pallets and cardboard leaning against power panels and their proximity to a power panel. instead of lying �at. • Clean and organize maintenance shop and all • Cardboard used as improvised shields on equipment. work benches. • Floors cluttered with unused materials and oily. • Define cleaning of overhead piping to remove dust, zinc, and magnesium to assure this is not a gateway • Propane tanks not stored properly. path for a fire to move quickly through a building. • ools and cleaning supplies not stored correctly. • Give all wood and cardboard used by manufacturing an assigned location. Culture - It is important for management to accurately assess the culture of their organization - without wearing • Eliminate use of two or more power cords to supply power. rose-colored glasses. Many organizations spend time and • Hard pipe location to supply power, as required. resources on quality, environmental, health, and safety • Ensure �ammable metal filings are stored in bucket requirements. Most do not spend the same resources with lid. needed to elevate fire prevention as a worthy component of a successful organization. It is not until there is a fire or • Pallets should be stored laying �at instead of catastrophic incident that management looks at prevention. standing on edge. By then it is too late. Te best time to review fire preven- • Bar lube containers should not be placed on hot oil units. tion efforts is before a fire incident ever occurs. It is hard to • Propane tanks stored inside the building should be moved quantify fire incident savings until a facility burns down. outside and stored in an approved locked storage system. Te actual building and equipment costs are just one small • Storage racks must be labeled to define weight limits - component of the actual damage. A company’s sterling vertical and horizontal. reputation may take a big hit. Te insurance company will evaluate the organization differently. Customers will wonder Fire incident prevention should - and must - be a high if they should move their molds and business elsewhere. Te priority for management. By focusing resources on this supply chain may invoke change against the organization. important aspect of the business, the long-term survival of the Employees will wonder if management is competent and is organization and the safety of its employees will be enhanced. capable and assured of meeting their safety needs.  Energy Conservations in Die Castings Industry - Some Practical Examples

A.Pari, Director CRP (India) Private Limited Chennai, India

Abstract Instead this paper will highlight some interesting examples of practical energy conservation solutions adapted, their simplicity and their beneﬁts. Tis will be very useful not Te manufacturing sector is undergoing a serious chal- only to our fellow die casters, but to the industry as a whole. lenge amidst the global economic slowdown. We need to look at the internal, as the external environment is out of our control. Te major areas that the industry could look into are cost cutting measures and energy conservation, with the latter being the most signiﬁcant amongst them. Te die casting industry is highly energy intensive, and Examples there is a lot of potential for energy conservation. Tis paper will highlight some of the measures implemented successfully, thereby helping fellow die casters in Te following examples explain the many approaches towards the application of various energy conservation order to apply the same ideas in their organizations. solutions in the die casting facilities.

Example 1: Use of Natural Light Natural light is one of the significant sources of energy and Introduction it is often ignored at many shop �oors and offices. In tropi- cal countries like India, this can be augmented for up to 12 CRP (India) Private Limited is a leading manufacturer hours thus leading to substantial saving of energy. of High Pressure Die Casting Products in India. It was Te buildings and offi ces were designed and some modi- founded in the year 1975 by Mr. N. Kunchithapatham, fied so as to allow the natural light to come in. Depending one of the pioneers in the country, in the field of die cast- on the need, the intensity of light was reduced by making ing in terms of design and manufacturing of HPDC dies use of vertical blinds in the offices. If the heat input to the as well as production of castings. room is too high (east and west walls) then a double glazed CRP is a one-stop solution provider for the HPDC glass is used to prevent the excess heat from entering into Products, having expertise in product design, die design, the room. Tis becomes more important in the case of air die manufacturing, die casting, machining, surface finish- conditioned rooms. ing, powder coating, assembly and testing. CRP has joined with win City Die Castings Company (USA) in September 2009 to promote a joint venture in India called “CRP-CDC Die Castings India Private Limited (CI)” to cater to the growing needs of technical and engineered die castings. Te adaptation/implementation and effective use of newer technologies in the field of die casting has made CRP a cost-effective and preferred source for the customers. Te Figure 1 – Shop �oors with natural light rooftops. most important of these implemented technologies are those pertaining to energy conservation. Most of the power In the shop �oors, the number of natural roof panels is consumed by the melting furnaces and the die casting is decided by the exact need of lighting levels and machines themselves. Recent technological developments, locations. Tese roof panels are made of fiberglass or such as energy efficient tower furnaces and the all-electric polycarbonate material - having ver y good light trans- die casting machines are already available to the die casting mission with up to 99% UV shielding, stabilized, strong community to adopt and solve. Te efficienc y of this equip- and lightweight. Tese panels are weather and tempera- ment has improved significantly due to global competitions ture resistant. Tese panels are also incorporated into and continual improvements. Numerous solutions are being the side walls to allow more natural light. In addition to provided in this regard from a huge list of suppliers and being natural and energy efficient these lights improve hence are not included in this paper. the ambience of the workplace. North American Die Casting Association’s

Figure 2 – Die casting shop �oor with natural roof panels. Whenever there is a �uctuation of light in the day time, Technical the automatic light sensors are introduced into the circuit to on/off/dim the lights. Tis is ensuring the ideal light with optimum power consumption. Te less frequently used areas such as rest rooms and corridors are fitted with Archive motion sensors with auto on/off and daylight sensing features to further save the otherwise wasted energy.

Example 2: Use of Natural Ventilation Tere are several sources of heat, fumes, smoke and vapors Search NADCA’s published in the foundry and they are necessary to be exhausted out information on any industry of the shop �oors continuously and eﬃ ciently. Generally a topic, available in the Technical lot of energy is used for this purpose. Archive. This library of information includes Congress Transactions and technical papers, as well as articles published in Die Casting Engineer and LINKS magazine.

Archive Includes: Figure 3 – Roof extractors over the die casting shop �oor. • Congress Transactions since 1960 • DCE articles from 1988 Extractors are ﬁtted on to the high points on the roof at periodic intervals and also over some speciﬁc hot spots • LINKS articles from 2001 such as furnace areas. Tese roof extractors use the natural �ow of air on the surface of the roof coupled with the • Research reports �ow of air through the extractors, in order to rotate. No • Technical papers power is needed here thereby saving substantial energy. Tey seldom need to be maintained.

Example 3: Natural Draught Cooling Towers Cooling towers are one of the utilities that are switched on FREE TO MEMBERS! first and switched off last. In colder countries they are not switched off even during the holidays so as to prevent the circulating water from freezing. Any small saving of energy here is going to be of great significance over the years. Te natural draught cooling towers use special nozzles to atomize the water and coupled with the natural �ow of air, it tends to bring down the water temperature. It uses the circulating pump pressure itself for this purpose thereby eliminating the power used for the www.diecasting.org/technology/archive forced �ow fan motor. We found that our leakage was more than 20% and the following remedial means were taken: • Replacing the leaking components - pipes, fittings, etc. • Replacing the rust prone GI pipes with aluminum and plastic pipes. • Introducing air foot switches to the air gauges, which otherwise will leak the air constantly. • Periodic replacement of effective parts in time. It is suggested from the above study that every die casting plant should include an air audit in their system. Tey may also use an in-line electronic air �ow measuring equipment to monitor and control on an ongoing basis. Over and above these, we also saved a significant amount of air through many initiatives, such as optimization of the spray systems (another major area), re-engineering of the pipe lines in terms of size and friction. Te cost of the generation of compressed air also needs to be addressed as it is very energy intensive as well as a constant source of energy dissipation. Hence we have benchmarked and invested in the makes and models from international brands, with very optimum specific energy consumption. Only a few brands in the market are prepared to share their specific energy consumption charts, Figure 4 – Natural draught cooling tower near the die cast- and we have not considered for investment, those who do ing shop floor. not share these inputs. Tey are simple in construction (FRP), and easy to repair Another key area of focus should be the sizing and and clean. Maintenance is almost none. Te return on invest- number of the compressors. It is advisable to split the ment is typically around 6 months. capacity of the compressors into multiple units so that we However they need a high footprint in terms of area, as will have the �exibility to run the capacity close to the well as the height, but they could be accommodated in any demand. Te efficiency is maximum when the compres- open space such as gardens, roofs, etc. Te energy saving sors are running close to the full capacity. Also, we can outweighs this simple shortcoming. apply a master-slave system, which is available today with most of the leading manufacturers, in order to manage the demand vs. capacity. Example 4: Compressed Air Management Compressed air is an expensive and power consuming input to the die casting shop but is quite often ignored. One CFM (cubic feet per minute) is equivalent to approxi- mately 0.25KW. Tere is a huge potential for the conservation of energy through the optimization of the air usage and the cost of generating the compressed air. Also, the compressed air utilities are similar to the cooling towers, as Figure 5 – Compressor bank (left) connected and controlled by they are kept switched on as long as the plant is running. an air manager (right). On a casual visit to a manufacturing facility which produces doors for an automobile, we found heavy sounds of equipment based on compressed air. Our CRP has invested in an air manager to manage three scrutiny revealed that the installed capacity of 3000 compressors with different capacities - 100, 200,400 CFM for the compressed air far outweighs their actual CFMs and one 200 CFM Variable speed (SFC). Tis needs and the team suspected an excessive leak from the helps in managing the optimum energy consumption by components in the air circuit. We suggested their plant ensuring the correct status of each of the four compressors maintenance team to test it out on a holiday. in the bank depending on the ever changing air demand. Te test was conducted by switching off all equipment and running as many compressors as required to compensate for the leaks. By observing the loading and Example 5: Wind Energy unloading time cycles of the running compressors we Te alternate forms of renewable energy have been a arrived at their leaking capacity, which was as high as subject of debate for the last few decades. Its time has 1500 CFM, more than 50% of overall consumption. already come with changed scenarios, as some of the Tis was an eye-opener and we decided to make the sources of renewable energy are not only green but eco- same study in our own company. nomical as well. Leading this pack is wind energy and it is growing very Tere are several free tools (i.e. Calculux) along with fast in terms of percentage of share in energy generation excellent support, and they are available over the web, and number of installations. India is a leading player here, particularly with luminaire manufacturers. Tese tools use and CRP has utilized this opportunity by regularly invest- the product libraries of various brands around the world, ing in wind energy. oday 75% of our need is harnessed to readily pick and place the appropriate combinations of through wind energy. Tey are located about 500 km away, lights and fittings. where optimum potential for the wind exists.

Figure 6 – Wind turbine installation.

Te local energy distribution company, owned and oper- ated by the state government, takes care of the management of absorbing the generated power and compensating the same for our plants. Te responsibility of the upkeep and maintenance of these equipment are with the supplier. Tese initiatives are ensuring us not only that the energy is available, but is also economical.

Example 6: Lighting Optimizations Te shop �oor lighting needs to be adequate. Inappro- priate lighting will lead to eye strain and fatigue to the employees. Te excess lighting will contribute to power loss which otherwise can be saved. Generally the shop �oors will contain lots of imbalances in lighting at different areas in terms of poor or excess illumination with pockets of areas with appropriate lighting. ime and time again, die casters have used and mas- tered various simulation techniques for the design of the part and the process. When it comes to shop �oor design they tend to depend on external experts with little knowledge of the die caster’s perspective. oday the lighting industry has highly matured and offers a numer- Figure 7 – Proposed 2D-layout with location of �ttings (top) ous easy-to-learn and to apply software tools. and ISO contours of light distribution (bottom). CRP has tried to adopt these tools by conducting a sample • Durable towards vibrations and shocks study. A conference room with known light fittings is mod- • Long life and low maintenance. eled and simulated. Te results were correlated with actual • Very low heat generation, more than 25 times less than measurement with a simple lux meter and found within a incandescent lamps and close to 10 times less than CFLs. difference of 2%. Tis has encouraged the team to use these In a recent project for a sister concern of CRP, we tools in the future projects to optimize the illuminations in replaced the metal halide fittings with LED fittings. the shop �oors and offi ces. In one of the immediate projects Tough cost of the fittings was almost 2.5 times, it reduced the contractor suggested 24 fittings for a particular shop the energy cost by half and doubled the illumination. �oor, whereas the analysis optimized it to just 14 fittings with balanced lighting. A saving of more than 40% (2.5 KWh) on power consumption and as well as investment are achieved. Te steps are as follows: • Input the simple 2D sketches/dimensions of the shop �oor layout into the software. • Define the measurement plane/working height. • Choose appropriate products from the libraries from the manufactures available online. • Define the fitting height of the luminaires. • Mark the areas with the recommended illumination in terms of lux. • Run the simulation. Te professional output gives a detailed report which includes: • Te proposed layout with location of fittings. • Various views. • ISO contours of light distribution. • extual and graphical tables. • Mountain plot. • Detailed Costing sheet. Te detailed costing sheet is very accurate with necessary financial inputs - cost of power, burning hours, investment cost, maintenance cost, etc. Te precision can be further improved by defining the life of bulbs, maintenance factors, and so on. One can learn these simple tools in about a day and finish the projects within few hours. Tis gives adequate opportunity for multiple iterations and optimizes the illumination and cost. For those who are serious about lighting and need a detailed analysis much more advanced tools Figure 8 – Proposed 3D-layout with location of �ttings (top) are available in the public domain. All that is required is and ISO contours of light distribution (bottom). the will to try, apply and save on energy costs. Again for this project, the same software tools were used to compare the traditional and LED options in terms of Example 7: LED Illuminations layout and economy. It is time for all our shop �oors are illuminated with As a continuation of the previous example there are plenty LED lights, saving energy and cost. of opportunities to further reduce the cost of lightings by replacing the traditional luminaires with LED. LED luminaires have come of age in terms of their applications, availability, reliability and economy. Despite being a costly option, its advantages outweigh the shortcomings: Conclusion • Consumes very little energy, less than 10% of incandescent lamps and less than 50% of CFLs. Tis is testing time for the economy the world over and it • Power demand and infrastructure cost is important for all the organizations to look inwards in proportionally reduces. terms of saving cost and stay competitive. Te purpose of this paper is to rekindle the fellow die • Environmental friendly with low CO2 emission and no use of Mercury. casters to look for energy saving opportunities. • Works at wide range of temperatures including Energy conservation is the key as die casting is an very low temperature. energy intensive sector. By saving energy, this sector not only saves cost but also gives an immense value to the • No sensitivity towards humidity. corporate social responsibility and mitigates so much of • Instant switch on/off. damage already done to the environment. • No effect on life due to frequent switching on/off. 

The Role of Temperature During Semi-Solid Metal Processing

Dr. Frank Czerwinski, Group Leader, Senior Research Scientist CanmetMATERIALS, Natural Resources Canada Hamilton, Ontario, Canada

Introduction energy savings, the full manufacturing cycle should be considered. As explained in Figure 1, the total energy required depends on the processing route. Historically, rheocasting When semi-solid metal processing was invented in the early (rheo-route) was the first method invented and it is based 1970s, it was seen as a very promising technology with great on a molten alloy as the precursor. o generate a thixotropic potential applications and capabilities to revolutionize the structure during solidification, many methods of a liquid manufacturing industry. After over four decades of research alloy treatment were developed over years, based mainly on and despite impressive findings at a laboratory scale, its mechanical, ultrasound or magnetic agitations. Other concepts commercialization progress remains relatively low 1. For a of generating thixotropic structures from a liquid precoursor new technology to achieve the commercial acceptance in include swirl enthalpy equilibration, continuous conversion, today’s market, clear advantages of lower cost and superior sub-liquidus casting or new rheocasting process1. Processing product properties must be demonstrated. Te commercial- following the Tixo-route 1 takes place at rather lower tem- ization complexity is magnified by the fact that the semi- perature than rheocasting but the amount of energy involved is solid processing concept has to compete with new and old, substantially higher. At the first stage, a billet is manufactured already well-established technologies. Tus at present, it is by employing similar techniques of molten alloy treatment as frequently stated that semi-solid processing still requires used in rheocasting. Ten, in the second step the billet is re- research and that the critical breakthrough is still expected. heated and a component is formed in semi-solid state, e.g. by Semi-solid processing is portrayed as the technique being thixo-forging. A substantially lower energy requirement could capable to produce in a single step the net-shape product at 2 be during thixoprocessing following Tixo-route 2. In this the low cost similar to casting with the wrought alloy quality . concept, a solid alloy is subjected to so-called stress-induced In practice, however, there are many criteria based on which melt activation, which involves cold or warm deformation or semi-solid processing is evaluated such as energy savings, net a combination of different deformation techniques. Te idea shape and intricate shape capabilities, high part integrity with of stress-induced melt activation generates fine grains after absent porosity and high mechanical properties. Although recrystallization during preheating prior to semi-solid forming. the original experiment was carried out with the Sn-15%Pb ypical deformation methods include rolling, extrusion, equal system, numerous alloys were further involved, most fre- channel angular pressing or their combinations3. Tere is a quently aluminum and magnesium based grades. Te present limitation, however, on the billet size that is possible to prepare industrial focus of semi-solid processing is oriented towards through deformation and typical dimensions are usually too the net or near-net shape capability and internal integrity of small for many industrial components. the final product. However, for structural components, typical for transportation applications, an improvement in mechanical properties that benefits from semi-solid nature of the alloy at casting or forming temperatures, is the priority. Among all processing parameters, the reduced temperature of the alloy is seen as the key difference while comparing semi-solid methods to conventional casting that employs fully molten alloys. Although the reduced temperature is generally seen as the positive factor, in practice, its beneficial effect is not entirely universal. Some aspects of the critical and complex role of temperature during semi-solid processing of metallic alloys are described in this paper.

Temperature and Processing Route

Casting and forming in the solidus-liquidus range create an impression of reduced energy consumption. However, when Figure 1 – Schematics explaining steps of semi-solid processing assessing benefits of the reduced temperature and related based on rheo- and thixo-routes. Role of Temperature in formed at lower temperatures of the semi-solid range will achieve better dimensional accuracy due to lower overall Hardware Performance shrinkage, it may still develop serious internal deficiencies due to incomplete filling. Te process economy is affected by the hardware required Additional avenues to modify properties of alloys and its service life with the hardware failure being the processed in semi-solid state are post-manufacturing main reason causing the downtime of production lines. treatments, e.g. heat treatment or deformation. Te high Te processing temperature affects not only thermal attack part integrity achieved through semi-solid methods but also chemical reactivity or in practice for crucibles or improves properties in as-cast state and also allows their furnace liners, simultaneous thermal and corrosive attacks. modification by exploring heat treatment. It is known that Te chemical reactivity depends on molten alloy chemistry porosity excludes components from thermal exposures and there is an essentail difference in chemical reactivity since it generates blisters. Te heat treatment allows for between magnesium and aluminum alloys that require dif- microstructure modifications, which may compensate a ferent materials being in contact with them. An additional reduction in properties resulted from semi-solid process- factor affecting hardware degradation is a pressure of the ing. For example, heat treatment changes properties of molten or semi-solid alloy, affecting strength and lead- the matrix as well as the phase composition, morphology ing to high temperature fatigue. Examples of hardware and distribution of precipitates. Since for a given chemical experiencing high pressure include shot sleeves, pressure composition, an alloy after semi-solid processing has dif- pump elements, high pressure casting dies or machine ferent microstructure, also heat treatment would be dife- nozzles. Moreover, the slurry �ow contributes to wear of rent than that used after conventional casting. It is known the processing equipment. It is generally concluded that a that in the case of Mg-Al alloys, a 4 treatment leads to reduction in processing temperature is universally positive increased properties, especially at increased temperatures4. and sometimes lowering tempearture by 20-30°C makes If the Al content is high enough to generate precipitation substantial difference in service life of the hardware. hardening, the 6 treatment, which follows part forming reduces the creep rate. Te post-processing deformation is mainly focussed on introducing cold work by a single step method or using a complex thermo-mechanical treatment to refine the grain size. As in the case of heat treatment, high internal integrityof the component is beneficial for Role of Temperature in thermo-mechanical processing. Component Integrity

Te evident concern during conventional casting is an internal integrity of the product. Based on simple analysis, semi- solid processing having only a fraction of the liquid alloy, additionally with lower tempeature than typical overheated melt, should have reduced porosity due to lower shrinkage (Figure 2). An additional improvement is due to better �ow characteristics of the thixotropic alloy during die ﬁlling; laminar �ow versus turbulent �ow during conventional casting. While this is true, the lower temperature causes also some reduction in heat content of the alloy, thus reducing the �ow length and intensifying freezing. Tus, the product

Figure 2 – In�uence of temperature during semi-solid processing on component integrity and microstructure. Role of Temperature in ing in the solid state and then experiences sharp coarsen- ing just prior and during early stages of alloy melting. Alloy Microstructure Although there is some reduction during advanced stages of melting, the final particle size is many times larger than A reduction of the processing temperature in�uences a the initial grain, reaching typically over 100 µm (5). Such number of factors changing solidification characteristics a large size is detrimental to material properties. and the final microstructure. While some factors cause an improvement in product properties, others have clearly negative contribution. Te essential difference of the microstructure after semi-solid processing is expressed through a replacement of dendritic forms with globular morphologies having thixotropic characteristics (Figure 3). According to the general rule, refining microstructural components leads to improved properties and is highly desirable. For the liquid fraction, a refinement is achieved by an increased cooling rate. Te cooling rate, however, does not affect the size of primary solid particles. During rheocasting, the size of the primary solid is controlled by the nucleation rate. Terefore, through increasing a number of nucleation sites available, the primary solid size may be refined. In general, the size of the primary solid after rheo-route is smaller than after Figure 4 – Schematics explaining an in�uence of processing thixo-route. For thixo-route, the size of the solid glob- temperature on strength and ductility of alloys during semi-solid ules originates from the grain size in the solid state after processing. For comparison, there are also shown properties after recrystallization. Tere is no obvious correlation with the casting of completely liquid alloys. primary solid size since first the grain grows during heat-

Role of Temperature in Material Properties

Tere is an expectation that semi-solid processing causes the substantial increase in mechanical properties, being critical for all structural applications. So far, there is no consistent evidence to support that thesis (Figure 4). For present magnesium alloys, there are examples showing exactly the opposite behaviour6. o reverse this trend, recent efforts within both the industry and academia focus on identifying opportunities at different stages of the manufacturing cycle that could create the beneficial microstructure. Since thixotropic mixtures represent a form of reversed composites with the primary solid being a softer phase than the matrix, minimizing the globule size is of crucial importance. For thixo-routes, exploring solid precursors, there are attempts to refine the globule size through the solid-state deformation prior to re-melting 7. Another effort is oriented towards strengthening the solid-liquid interface. As documented by fractographic observations8, the interface between the primary solid and subsequently solidified liquid fraction represents a weak region, coinciding with the crack propagation path during tensile failure.

How to Select the Figure 3 – A comparison of microstructure after casting of Processing Temperature molten alloy resulting in dendritic morphology and porosity (a) with that after semi-solid processing showing globular mor- Based on the above description, the processing temperature phologies with no prorosity (b). Magnesium-based alloy. is aﬀected by a number of factors related to the process, hardware, alloy and product charactersitics. Te above discussion shows that the reduction of the processing temperature within the semi-solid range is not universally satisfying all elements of manufacturing to lead to improvement. It has to be rather an optimum established for particular process conditions. For example, wall thickness will aﬀect the solid fraction required. While for thin wall components, low solid fraction, i.e. high temperatures, are preferable to achieve high �ow length, for thick walls, high solid fractions, i.e. lower tempeartures, are needed to achieve the low shrinkage and dimentional accuracy. For magnesium alloys, the latter is not aligned with improvement of material strength.

Conclusions

During semi-solid processing of metallic alloys, temperature is the key parameter affecting not only the component integrity, microstructure and properties but also the hardware performance and process economy. While a reduction in the processing temperature leads to better hardware performance and longer tool service life, it does not universally lead to the beneficial microstructure and accompanied properties. Tere- fore, for each processing route, manufacturing technique details, alloy used and product specifications, the optimum value of the processing temperature should be established.

References • 1F. Czerwinski, Magnesium Injection Molding, New York: Springer, 2008. • 2F. Czerwinski, “Te basics of modern semi-solid metal processing,” Te Journal of Te Minerals, Metals and Mate- rials Society, vol. 57, no. 6, pp. 17-20, 2006. • 3L. Rogal and J. Dutkiewicz, “Heat treatment of thixo- formed hypereutectic X210CrW12 tool steel,” Metallurgical and Materials ransactions A, vol. 43, pp. 5009-5018, 2012. • 4 Y. Wang, G. Liu and Z. Fan, “Microstructural evolution of rheo-diecast AZ91D magnesium alloy during heat treatment,” Acta Materialia, vol. 54, no. 3, pp. 689-699, 2006. • 5 F. Czerwinski, “On the generation of thixotropic structures during melting of the Mg-9Al-1Zn alloy,” Acta Mate- rialia, vol. 50, no. 12, pp. 3265-3281, 2002. • 6Z. Fan, “Semi-solid metal processing,” International Materials Reviews, vol. 47, no. 2, pp. 49-85, 2002. • 7 Z. Huang, R. Chen and E. Han, “Preparation of semi-solid billet of ZW61 alloy by equal channel angular extrusion,” Materials Science Forum, Vols. 610-613, pp. 806-809, 2009. • 8 F. Czerwinski, A. Zielinska-Lipiec, P. Pinet and J. Over- beeke, “Correlating the microstructure and tensile properties of a thixomolded AZ91 magnesium alloy,” Acta Materialia, vol. 49, no. 7, pp. 1225-1235, 2001.

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Cast Materials III: Metal Matrix Cast Materials IV: Magnesium 3:45 pm - 5:15 pm Composites (2 paper Session) (2 Paper Session) NADCA’s David Laine Scholarship Program Awards Record-Breaking 17 Students

Donna Hutchins, Membership Services North American Die Casting Association Arlington Heights, IL

NADCA is proud to announce that 17 students were recog- ent areas within the engineering department and worked nized by the David Laine Intern and Scholarship Program on projects including cycle time studies, creating gating in 2013. Tis is the highest amount of students that have prints and shadowing engineers in the process depart- been awarded in one year since the program’s inception, ment. His favorite part of the internship was learning how as well as the largest overall dollar amount given, with the many departments it takes to make quality parts. Previ- scholarships totaling $41,250.00. ously, Bossong served an internship at RCM Industries “I was excited to see that 17 interns were selected for Inc. - Inland Die Casting Company in Wheeling, IL. Laine Scholarships this year,” stated NADCA President Daniel warog. “Te program has grown over the past 10 years and has placed dozens of engineers into the die casting industry. Most of the applicants received $2,500 JACOB BOWERMAN scholarships, which are the highest scholarships awarded PURDUE UNIVERSITY throughout the entire metalcasting industry. Die casting is RCM INDUSTRIES INC. � AALLIED DIE CASTING COMPANY � FRANKLIN PARK a metalcasting process with a bright future.” Te scholarship fund was established in 1975, and requires Jacob Bowerman was also that students complete an internship or co-op at a die casting an intern at RCM Industries company or supplier to the die casting industry prior to apply- Inc. - Aallied Die Cast- ing for the scholarship. Te prerequisite allows students to ing Company in Franklin experience hands-on training in the die casting industry, with Park, IL, and this was his the hope that the learning experience will encourage students third year working for the to continue on in the ﬁeld after graduation. company. Bowerman is a Scholarship winners cited experience gained in areas such Mechanical Engineering as die casting machine re-builds, process development, qual- echnology major at Purdue ity engineering and die maintenance on their application University and plans to essays. “Companies that have invested in these interns not graduate in 2015. In his most recent internship, Bower- only reaped the beneﬁts of the students’ talents for an entire man spent most of his time in the company’s mainte- summer, but also developed an inside track in hiring the nance department. He was instrumental in a die casting next generation engineers into the industry. Investing in the machine rebuild – helping to strip the machine, while future is what internships are all about,” warog said. identifying parts that needed repair or replacement and Te association is pleased to recognize the following he worked on sourcing and pricing the parts. Bowerman 2013 Laine Scholarship winners, their universities, and the also became involved in the company’s safety committee companies that provided them the opportunity to work in and helped the safety coordinator complete audits. the die casting industry.

JACK BOSSONG CHRISTOPHER CARBERRY UNIVERSITY OF ILLINOIS URBANA�CHAMPAIGN UNIVERSITY OF ILLINOIS AT URBANA�CHAMPAIGN RCM INDUSTRIES INC. � AALLIED DIE CASTING COMPANY � FRANKLIN PARK CAST PRODUCTS, INC.

Jack Bossong, an Indus- Christopher Carberry is trial Engineering major a Computer Engineering at University of Illinois major at University of Illi- Urbana-Champaign served nois at Urbana-Champaign. his internship for RCM 2013 marks his third year Industries Inc. - Aallied interning at Cast Products, Die Casting Company in Inc. in Norridge, Illinois. Franklin Park, IL. During Based on his previous expe- his time at Aallied, Bossong rience with the company, in was involved in many differ- this year’s internship, he had a solid foundation and was ADAM FETTIG able to work with many different personnel at the plant, MARQUETTE UNIVERSITY including the operations manager, engineering manager, STRATTEC COMPONENT SOLUTIONS quality control manager, I manager, plant engineering manager, production manager and the die casting Adam Fettig is a junior at manager. He noted that he “thoroughly enjoyed working Marquette University, study- with the entire ‘Cast Crew’”, and that most of his proj- ing Mechanical Engineering. ects were directly related to the 5S initiative. 5S is a set Fettig worked as an intern of industry standards for the workplace that promote: at SRAEC Security cleanliness, happiness, functionality and profitability. Corporation, Milwaukee, WI, for eight months and reported that he worked on several different projects over KEVIN COVENY the course of his term, but no two projects were the same, so he learned something UNIVERSITY OF DAYTON different from each of them. Areas he focused on included RCM INDUSTRIES INC. � AALLIED DIE CASTING COMPANY � FRANKLIN PARK process control, automation and quality. One of his favorite projects involved automating an inspecting process, from A Mechanical Engineer- studying the issue to developing method sheets on proper ing echnology major at procedures. Fettig estimated implementing his modifica- University of Dayton, Kevin tions could save the company over $9,000. Coveny has worked two internships for RCM Indus- tries. In 2012, he interned at Inland Die Casting CRAIG HART Company in Wheeling, IL and in 2013, spent 13 WRIGHT STATE UNIVERSITY weeks working at Aallied FORT RECOVERY INDUSTRIES INCORPORATED Die Casting Company in Franklin Park, IL. Coveny Wright State University reported directly to the engineering manager, and student Craig Hart is a was tasked with projects like transitioning AutoCAD Computer Science and Engi- files into Solid Works files. He also spent time in the neering major. He works at tool room and was able to visit some area tool shops. Fort Recovery Industries in Coveny enjoyed being part of team meetings where Fort Recovery, Ohio. Hart specific parts were discussed in detail and any defects started as a “clean-up guy” in or issues were identified. 2011, but has worked his way up to the machining department. He enjoys working on the CNC machines doing tool changes, adjustments and ALEXANDER DAAR other operations. Hart also works security, where he is UNIVERSITY OF ARIZONA responsible for watching for leaks, furnace �uctuations and RCM INDUSTRIES INC. � INLAND DIE CASTING COMPANY prepping machines for third-shift. He hopes to one day use his degree to write programs and set-up computers that Alexander Daar studies help increase the effi ciency and production of a company. Mechanical Engineering at the University of Arizona. He has interned at RCM Indus- tries Inc. - Inland Die Cast- TYLER HOLLAND ing Company, in Wheeling, WILKES UNIVERSITY IL, for the past two years, BLUE RIDGE PRESSURE CASTINGS INC. where he spent time in the process engineering, quality yler Holland is a Wilkes and CNC departments. He University Student, and learned about metal quality testing, understanding die cast studies Mechanical Engi- parameters, operating CNC machines and even working neering. Holland has with outside vendors. One of his special projects was learn- interned for three years at ing how to design, price and implement a fall protection Blue Ridge Pressure Cast- system to improve plant safety. Daar appreciated learning ings Inc. in Lehighton, so many skills pertinent to his future as a mechanical engi- PA. He became very adept neer, and he feels the experience provided him “a greater at using SolidWorks and understanding of what it takes to be a die caster.” learned how to model different parts, while factoring in material usage. One of his most important projects was the conversion of a two-piece die to a three-piece. “Tis experience allowed me to apply concepts taught in subjects such as �uid Ever Thought of mechanics, heat and mass transfer, and both static and dynamic systems,” Holland said. “Although knowledge acquired inside the classroom is essential, there are just things that cannot be taught in class.” ADVERTISING IN DCE? CAITLIN LAHEY UNIVERSITY OF ILLINOIS AT CHICAGO MAGMA FOUNDRY TECHNOLOGIES INC.

Caitlin Lahey studies Civil 2013 DCE could be a powerful mber o ys| 2013Sho w Wrap|No ve Ad vanced Technologies| All Engineering at University of marketing tool for your Illinois at Chicago and served company! In queue for two summer internships at 2014 we have the Annual MAGMA Foundry echnologies, Inc., in Schaumburg, Report in March, the IL. She was trained on how Suppliers Directory in July, to run simulations using the our September issue which will act as the Die Casting MAGMASOF, and quickly S TI NG learned that while minimiz- B L E TO P Congress and Tabletop ing the porosity and hot spots was a general goal, it was RA P show guide (extra copies Ma gnesium | 2013 International DieCasting Comp etition | 2013 Show Guide | SEPT EMBER2013 : ALSO INSIDE not an easy task! She enjoyed working with customer’s S TECHNOLOGIE will be printed and given AD VANCED designs, setting them up in the system and then interpret- away free at the show) and ing the results in a way that the customers could under- other great topics like: stand. “Using the software to simulate such a complex process gave me a great understanding and appreciation for T E RNAT IONAL • Die Casting Components/ the die casting industry,” Lahey noted. E CAS Equipment & Die T ING Casting Machines IGN COMPE T IT ION • Die Materials BRENDAN MELNICK

13 • SSM/Squeeze Casting 20 lting & Holding | JANUAR Y Furnaces/Energy| Me ALSO INSIDE::: PURDUE UNIVERSITY 2013 SHOW GUIDE CHICAGO WHITE METAL CASTING INC. • Defects

Brendan Melnick is a • Die Coatings and Surface S TA T E O F T H E Purdue University Mechan- NI D U S T R Y Treatments & Post Casting/ ical Engineering senior and Secondary Operations recently served an intern- A R E YO U I N ship for Chicago White CO M P LIA NC E ? • Aluminum Metal Casting, Inc. in Bensenville, IL. Melnick

: helped with AutoCAD ALSO INSIDE Computer Modeling & Simulati | WinnoneRr&DPs lan | 2013Show Preview | JULY 2013 model work, customer part Laine Scholarship

: analysis, project manage- 1 / / 12 : ment and f low simulations. He enjoys working with For more information and CAD and especially enjoys problem solving. During pricing, please contact his internship, he worked on transitioning core pin PROBLE M SOLV ING W IT H Athena Catlett at: sketches to CAD files and updating the cooling line sketches. He also troubleshot how to get around metal P: 847.808.3153 shortages, and described a project where he needed E: [email protected] a “crash-course in furnace-ology!” Melnick said the experience changed his opinion of manufacturing, and specifically, the die casting industry. “he industry ALSO INSIDE: 2013 SHOW PREV IEW offers the fast-paced, technical, problem solving that I www.diecasting.org/dce/mediakit/MediaKit.pdf so often seek in my spare time,” he said.

SAMUEL MOSER processes within the low and high pressure die divi- MISSOURI UNIVERSITY OF SCIENCE AND TECHNOLOGY sions at Honda. He also learned AutoCAD so that he SPARTAN LIGHT METAL PRODUCTS INC. was able to design parts, develop layouts and prepare multiple options for a future metal transfer process. Te Samuel Moser is a Mechanical experience provided Province with a “newfound under- Engineering student at Missouri standing of die casting.” He commented that learning University of Science and ech- all of the processes involved has laid the groundwork for nology. During his internship at his engineering future. Spartan Light Metal Prod- ucts’ Hannibal facility, Moser assisted in process development, quality evaluation and customer submissions. During the THOMAS H. RING summer, he was able to watch TENNESSEE TECHNOLOGICAL UNIVERSITY the entire product manufacturing process take place, as four WALKER DIE CASTING INC. new dies were coming in at the beginning of his internship. He learned the process of testing a new die, part testing, inspec- Engineering echnology tion, machine modifications and further communication with student Tomas Ring has the toolmaker, if warranted. Moser helped produce a manufac- held internships at Walker turing process report for the die casters to use with a part. He Die Casting, Inc. in Lewis- appreciated the opportunity to learn, and remarked that the industry is very competitive, fast growing, and innovative. burg, KY since 2012. He is a junior at ennessee echno- logical University, and had the opportunity to work for DAVID PROROK the production, quality and UNIVERSITY OF ILLINOIS AT URBANA�CHAMPAIGN engineering departments NORTH AMERICAN DIE CASTING ASSOCIATION during his tenure. Before serving an actual internship, Ring worked as a trimmer on the production �oor, in David Prorok studies Com- quality control as an X-ray inspector and as a Layout puter Science at University of CMM operator. While shadowing project engineers Illinois at Urbana-Champaign. during his internship, tasks included die maintenance, Prorok worked at NADCA, die storage and handling. Ring also had the opportunity in Arlington Heights, IL with to run special diagnostic projects for big clients. Ring a goal of improving methods says he is fascinated by the complexities of aluminum for the die casting industry to die casting and is grateful to have learned how to con- access information and technology. He designed two iPhone duct business in the real world, outside of class. applications, one to assist die casting designers and the other contains a searchable directory of thousands of webinars, articles, and other publications. Prorok’s other projects included optimizing NADCA’s weekly JOSEPH SCHWARTZ eNewsletter for smart phones and converting NADCA publications so they can be sold on iunes and Amazon. NADCA UNIVERSITY OF ILLINOIS hopes to bring Prorok back next summer to development more RCM INDUSTRIES INC. � INLAND DIE CASTING COMPANY engineering App’s and calculations for its Member Plus area and to further develop its iunes App for Android systems. Joseph Schwartz is an Engineering student at University of Illinois Urbana-Champaign. He JOSH PROVINCE was granted an intern- UNIVERSITY OF CINCINNATI ship at RCM Industries HONDA OF AMERICA MANUFACTURING Inc. - Inland Die Casting Josh Province is a student Company in Wheeling, IL, at University of Cincin- where he worked on proj- nati studying Mechanical ects including maintenance Engineering. Province has work orders, preventative maintenance, 5S and prepar- completed t wo co-ops for ing/reviewing work instructions. Schwartz realized as Honda of America Manu- he worked with different vendors how every facet of a facturing’s Anna Engine plant was tied together. “I developed a greater under- Plant, in Anna, OH. Prov- standing of how the machines worked and how vital ince received training on even the smallest part or process is to the success of each of the manufacturing plant operations,” Schwartz said. LINDSEY TWAROG development of a safety program, which was adopted by OHIO STATE UNIVERSITY the institute in 1945. Laine also helped to found the Die EMPIRE DIE CASTING COMPANY INC . Casting Research Foundation. oday, the Laine rust- ees come from die casting companies and suppliers of Lindsey warog studies the industry from across the U.S. Industrial and Systems Engi- “Tere may not be a better investment to make than neering at Te Ohio State bringing in interns for the summer,” warog said. University. Empire Die Cast- “Every die caster should spend the resources to do this. ing Company Inc., based in It would pay dividends in the near-term when all these Macedonia, Ohio provided students graduate and have some practical experience an internship for her this past and exposure to die casting.” summer. warog spent time working on process improvement, daily time studies for different secondary and aluminum foundry machines and Are you ready to find a die casting intern for the summer? tracking machine downtime. One special project was NADCA can reach out to local universities or technical helping to reconfigure the plant to include new equip- schools, and has a database of current student resumes ment that was being purchased. She credits her intern- available online at: www.diecastingdesign.org/interns. ship experience for teaching her how she can apply what NADCA also offers guidance on what companies should she is learning in her classes to real life situations. expect when hiring an intern on its Web site at www.die casting.org/scholarship/laine. Finally, the David Laine Intern & Scholarship Program is supported entirely by contributions and pledges from DANIEL WINLAND the die casting community. Your help is appreciated, and goes directly into helping emerging engineers finance UNIVERSITY OF DAYTON their education, while spending time in our industry. Visit RIMROCK CORPORATION www.diecasting.org/scholarship/laine to find out how you or your company can help. Daniel Winland is a  Mechanical Engineering student going into his senior year at University of Dayton. Winland interned in the Applications Engineering department at Rimrock Cor- poration in Columbus, OH. He assumed he would basi- cally be the “coffee boy”, but learned this could not be more opposite of what happened at Rimrock! His work focused on learning SolidWorks, developing his AutoCAD skills and learning robotic simulation software for automation cells. Winland was given the opportunity to work with current clients and even potential customers. Although Winland did not realize he would be granted so much responsibility as an intern, he valued he experience of getting to learn the business and engineering side of the company and was invited to return for a second semester.

About the David Laine Scholarship

Te David Laine Scholarship program was established in 1975 in tribute to David Laine, who served as Sec- retary of the American Die Casting Institute (ADCI), a forerunner of NADCA, for 29 years. Laine was instrumental in eﬀecting many advancements for the beneﬁt of the die casting industry. Among these was the Wage & Bene�t Survey – Executive Summary

North American Die Casting Association Arlington Heights, Illinois

The results of the 2013 Survey representing 58 companies Participating Companies nationally have recently been published. The 2013 report covers information based on the month of September 2013 The survey represents 58 companies in the die casting that was collected during October and November 2013. The industry nationwide. The participating companies table report is organized by category of information (i.e. fringe defines the group of facilities in terms of annual sales, benefits, wage rates, etc.). number of die casting machines, number of employees, etc. Information is provided both nationally and by region. This year, the typical participating company had annual sales of $44.45 million per year; utilized 19 die casting machines, and employed 145 full-time direct labor employees. Nine The Summary (16%) were union shops. 22% of the total production employees reported were temporary. Almost 80% of the survey partici- The summary provides a tabulated analysis of the major pants’ total employees were hourly production employees. A good indication of a company’s productivity can be facets of the reported information. In all cases, the informa- established by analyzing the level of sales per total employ- tion provided by participants has been analyzed as finely as ees. The median increased since 2012 from $192,000 to possible within the limits of the sample provided. $198,000 sales per total employees.

Minimums, Maximums, Wage Rate Information Summary Medians and Averages This table covers information relating to work week, meth- The information is analyzed in terms of minimum and od of payment, overtime policy and miscellaneous other information. National and regional analyses are included. maximum to provide an idea of the range of values reported by the participants. Both median and average values are provided. Median values may be more indica- tive of the typical response and may not be as subject to distortion as an average value. The median value is General Wage Adjustments defined as the value of a ranking from low to high above and below, which there are an equal number of responses More than half the companies (71%) reported a general of greater and lesser value. In some cases, dividing the wage adjustment in the last 12 months, but a smaller per- information into segments does not allow meaningful centage (66%) plan to make a general wage adjustment in analysis. In those instances, the symbol “*” is used to the next 12 months. The median value of adjustment in the indicate insuf ficient data. last 12 months was equal to the amount in 2012. Insurance Information Summary ORDER FORM: 2013 Wage & Fringe Bene�t Survey These tables provide summaries of insurance benefits including life insurance, hospitalization, surgical, medical Name (�rst, middle initial, last) NADCA Member Number care and catastrophic/major medical. Accident/sickness policies and other insurance coverage are also covered. Title

Company

Fringe Bene�t Information Summary Street Address

Cost of benefits, vacation policy, paid leave policy, pen- City State/Province sion plans, bonus plans and profit sharing plans are sum- marized in these tables. The trends in cost of benefits are shown below: Zip/Postal Code Country NADCA CORPORATE MEMBER?  Yes ($50/copy)  All Others ($100/copy)  Please send membership information

NON�PARTICIPATING COMPANIES No, I did not participate in this year’s Wage & Fringe Bene�t Survey, but I would like to receive a copy of the Wage & Fringe Bene�t Survey.  NADCA Corporate Member ($100/copy) The number of companies providing pension/retirement  NADCA Individual Member ($150/copy) plans increased to 56% overall, and the percent providing  All Others ($200/copy) insurance for retirees was 7%. While most unions do not provide these benefits directly, union shops tend to have PAYMENT OPTIONS a much higher participation for these types of programs compared to non-union shops. Report Cost $ ______United States Shipping (add $10.00) $ ______International Shipping (call NADCA) $ ______ Illinois Residents: Add 9.0% State Sales Tax $ ______Total Cost $ ______The 2013 NADCA Annual Wage & Fringe Benefit  Check/Money Order (payable to NADCA in U.S. Dollars only) Survey is specifically designed for the die casting industry. This report gives you:  Company Purchase Order (Corporate Members in good standing only) • Detailed summaries for direct labor employees  Credit Card:  VISA  MasterCard  American Express • Wage rates for 13 key direct labor employees Total (payable to NADCA in U.S. Dollars only) • Analysis of insurance coverage

• Executive summary with annual trends Credit Card Number Expiration Date • Is now completely downloadable containing all individual company surveys. Cardholder’s Name (�rst, middle initial, last) The 2013 Survey will be a valuable resource for: Cardholder’s Signature (required for processing) • Determining compensation standards • Selecting fringe beneﬁt plans and insurance MAIL FORM & PAYMENT TO: • Leading labor negotiations. North American Die Casting Association 3250 N. Arlington Heights Rd., Ste. 101 – Arlington Heights, IL 60004 Make sure this survey becomes an indispensable tool P: 847.279.0001 F: 847.279.0002 on your desk. ORDER YOUR COPY TODAY! E: [email protected] SAFETY AWARDS 2013 The North American Die Casting Association is pleased to recognize Corporate Members with operations which have a strong focus on their employee’s safety and well being. NADCA’s Safety Award Program was developed to honor Corporate Members that both exceed and meet the average U.S. national safety standards for all manufacturing in a given year. Companies that have maintained a safety record during 2013 with 0 lost days/transfers/restrictions are awarded with a “Perfect” award. Companies with records equal to, or less than 4.4%, the national average for all manufacturing, are recognized with an “Outstanding” award.

Perfect Awards A&B Die Casting Meridian Lightweight Technologies Inc. Rimrock Corporation Hercules, CA Strathroy, ON, Canada Columbus, OH Basic Resources Inc. Metal Mechanics, Inc. Spartan Light Metal Products Knoxville, TN Schoolcraft, MI Hannibal, MO DeCardy Diecasting Company North American Casting Corp. The Hill and Griﬃ th Company Chicago, IL Trussville, AL Cincinnati, OH Gibbs Die Casting - Audubon Tool Pace Industries, Harrison Div. Versevo Henderson, KY Harrison, AR Hartland, WI Gibbs Die Casting - Corporate Portland Casting Plant, Fort Recovery Industries, Inc. Wheelabrator Henderson, KY Portland, IN LaGrange, GA KenWalt Die Casting Company Production Castings, Inc. Whitehead Die Casting Co., Inc. Sun Valley, CA Fenton, MO Gainesville, GA Lakeside Casting Solutions RCM Industries Inc. - Imperial Die Casting Company Wilkast Inc. Monroe City, MO Liberty, SC Grand Rapids, MI Outstanding Awards Ahresty Wilmington Corporation Dynacast Patterson Mold and Tool Wilmington, OH Elgin, IL St. Charles, MO Alloy Die Casting Empire Die Casting Company RCM Industries Inc. - Inland Die Casting Company Buena Park, CA Macedonia, OH Wheeling, IL Audubon Metals LLC General Die Casters, Inc. RCM Industries Inc. - Aallied Die Casting Co. of North Carolina Henderson, KY Twinsburg, OH Rutherfordton, NC Bohler Uddeholm Corp. Honeywell International, Inc. Ryobi Die Casting Elgin, IL San Diego, CA Shelbyville, IN BuhlerPrince Inc. International Die Casting, Inc. SENSUS, PDC Holland, MI Gardena, CA Bowling Green, KY Canada Metal (Paci�c) Ltd. Joyner’s Die Casting & Plating, Inc. Shiloh Industries, Inc. - Auburn Delta, BC, Canada Brooklyn Park, MN Auburn, IN Cascade Die Casting Group, Inc./Atlantic Kason Industries, Inc. Shiloh Industries, Inc. - Pleasant Prairie High Point, NC Newnan, GA Pleasant Prairie, WI Cascade Die Casting Group, Inc./Great Lakes Meridian - Magnesium Products of America Spartan Light Metal Products Sparta, MI Eaton Rapids, MI Sparta, IL Cascade Die Casting Group, Inc./Mid-State Pace Industries, Airo Division Spartan Light Metal Products Grand Rapids, MI Loyalhanna, PA Mexico, MO Cast Products, Inc. Pace Industries, Cambridge Division Superior Aluminum Alloys Norridge, IL North Billerica, MA New Haven, IN Castool Tooling Systems Pace Industries, Grafton Division TEAM Industries - Detroit Lakes Uxbridge, ON, Canada Grafton, WI Detroit Lakes, MN Chicago White Metal Casting, Inc. Pace Industries, Product Tech Division The Schaefer Group, Inc. Bensenville, IL Maple Lake, MN Dayton, OH Pace Industries, St. Paul Division Arden Hills, MN Exhibitor Spotlight 2014

01 4

AV+R Die Casting 330 For over 30 years we have used the latest in application technology, MetaLLife (Compressive Stress Surface Engineering) and TerMaLLife (Termal Diff usion 1203 Marie Victorin of Nitrogen and Carbon) are the most cost effective St-Bruno, QB J3V 6C3 Canada Phone: 450.676.4622 surface treatments that are used extensively in the tool- Fax: 450.656.7871 ing industry for proactive and reactive die maintenance. www.avr-diecasting.com Tese processes can be applied separately or in combination (ooLLife) to provide the many needed benefits AV&R Die Casting will present its innovative line of high- that extend and improve die life by 50%. speed, cold chamber, Aluminum die casting machines that offer low cost solutions for small Aluminum castings. Te CADENCE 100 machine features multiple-slide closing Bohler-Uddeholm Corp. 305 system and a proprietary inclined injection system designed to reduce air entrapment in the shot sleeve. Production speeds are up to 7 shots per minute with a significant reduc- 2505 Millennium tion in porosity for castings of up to 500 grams. Elgin, IL 60124 Phone: 630.883.3020 AV&R Die Casting is part of the AV&R group that Fax: 630.883.3101 supplies complete automated turnkey systems, includ- www.bucorp.com ing mold design & manufacture, testing, preproduction runs, robotic finishing, automated visual inspection, Bohler-Uddeholm Corporation is part of the Special automated post casting operations, training and after Steel Division of voestalpine AG. We are a worldwide sales service and support. leader in the production of hot work tool steels for the die casting industry. Bohler-Uddeholm’s first operation in North America was established in 1925 and has since B & L Information Systems Inc. 312 expanded into a network of warehouses, service centers, steel stores, a manufacturing facility in South Boston, 4707 Rambo Road Virginia, and a coatings division, Eifeler Coatings Bridgman, MI 49106 echnology. Our goal is to provide the best steel, coat- Phone: 269.465.6207 ings and service to our customers. Fax: 269.465.6686 www.blinfo.com BuhlerPrince Inc. 302 B&L Information Systems is a global leader in providing integrated enterprise resource planning (ERP) for metal casters. All B&L products, whether client server applica- 670 Windcrest Drive tion or Software as a Service (SaaS), are designed with the Holland, MI 49423 specific needs of metalcasters in mind. For more informa- Phone: 616.394.8201 tion, visitwww.BLInfo.com. Fax: 616.394.1250 www.buhlerprince.com

Badger Metal Tech Inc. 315 Die Casting Machines and systems made by Buhler- Prince are ideal for the most varied processes, including N169 W21010 Meadow Lane aluminum, magnesium, zinc, vacuum, structural, engine Jackson, WI 53037 block and lost core die casting. Customers are supported Phone: 262.252.3804 throughout the life-cycle of their equipment with global Fax: 262.677.5111 services including process optimization, �ow simula- www.badgermetal.com tions, remanufacturing, retroﬁts and upgrades. 2014 EXHIBITOR SPOTLIGHT

Castool01 4 Tooling Systems 208 DMS 212

2 Parratt Road 1875 Blackacre Drive Uxbridge, ON L9P 1R1 Oldcastle, ON N0R1L0 Canada Canada Phone: 519.737.6743 Phone: 905.852.0121 Fax: 519.737.6744 Fax: 905.852.2300 www.dmscomponents.com www.castool.com DMS is a leading supplier of tooling/die-cast components. Castool is a knowledge-based company that provides pro- We also represent Kool�ow water manifolds, ICS full duction tooling and technical advice to leading aluminum colour tooling plaques, REDE VAUL 8 gb on board extruders and die casters, as well as die casting equipment tooling management device, Boride polishing products, and extrusion equipment throughout the world. HMMSolutions hydraulic locking systems and may other quality products and companies. We are a proud corporate Castool exports more than 90% of its sales, with custom- member of NADCA. ers in Western Europe and the Orient, as well as the US, Mexico, and South America. East River Solutions 220

Chem-Trend Ltd. Partnership 405 700 Gillard Street Wallaceburg, ON N8A 4Z5 1445 McPherson Park Drive Canada Howell, MI 48843 Phone: 855.372.6201 Phone: 517.546.4520 Fax: 888.595.4762 Fax: 517.546.6850 www.ercnc.com www.chemtrend.com East River Solutions embodies a fresh vision in custom Chem-rend, is a global leader in developing, producing and machining - including rim Dies, Fixtures, Mold Com- supplying specialized process chemicals, focusing on release ponents, and Prototypes. We oﬀer value to our customers technology. Within the die cast industry, Chem-rend’s through our unique, gutsy and collaborative approach customers rely on our highly specialized products to protect to our work, making sourcing easy from data transfer to their investments and keep production running eﬃ ciently. delivery. East River is located in Wallaceburg, Ontario, 40 Chem-rend develops and produces advanced die and miles northwest of Detroit. plunger lubes along with a range of ancillary products. Our technology is used by some of the biggest names in the casting of aluminum, magnesium, zinc and related alloys. EKK, Inc. 417

37682 Enterprise Court Die Cast Press Manufacturing Co. 410 Farmington Hills, MI 48331 Phone: 248.624.9957 56480 Kasper Drive Fax: 248.876.4075 Paw Paw, MI 49079 www.ekkinc.com Phone: 269.657.6060 Fax: 269.657.9302 EKK Inc., a metal casting process simulation software and www.diecastpress.com consulting services company, provides software that oﬀers the most accurate solutions to a wide variety of metal cast- Die Cast Press is a supplier to the die casting industry. ing concerns. EKK’s Finite Element Method (FEM) based Our products include new, remanufactured, and rebuilt EKKcapcast software includes Solidiﬁcation, Termal , die cast machines, and trim presses, and new “ DCP” Fluid �ow, Stress and Porosity analysis tools which can high – velocity close coupled shot systems. We also accurately identify your casting defects and help you opti- supply automated cell packages, parts and service for mize your casting process. all makes of die casting machinery. DCP emphasizes complete customer service and quality by addressing EKKcapcast includes essentially everything you need to our customers immediate needs. We warranty and take improve your casting processes. Over the years our excel- pride in all we do. We are proud of the reputation that lence in software development and technical support have we have developed over the past 50 years. gained the trust of the casting industry. EXHIBITOR SPOTLIGHT 2014

Ellwood Specialty Steel Co. 319 Frech USA 011094

499 Honeybee Lane 6000 S. Ohio Street New Castle, PA 16105 Michigan City, IN 46360 Phone: 724.856.5730 Phone: 219.874.2812 Fax: 724.654.9550 Fax: 219.874.2434 www.ess.elwd.com www.frechusa.com Ellwood Specialty Steel is a premier producer of tool steels for die casting dies. H13 Superior, Hot Die, and uf Die Frech products include a complete line of Hot and Cold are alloys engineered to stand up to the rigors of the die Chamber Die Casting Machines ranging from 20 to casting environment and SURVIVE! Knowledgeable 4400 ons. Additional product lines include Meltec steelmaking, forging, and heat treatment result in die steel Dosing Furnaces, Robamat Heating and Cooling units, you can count on to perform. We stock it and deliver it Spesima Automation and VDS Vacuum systems. Frech FAS. Quality steel…made in the USA! USA has a complete service team located in the US and stocks all spare and wear parts for our equipment.

ESI North America 404

32605 W 12 Mile Road, Suite 350 GW Smith & Sons Inc: A Quaker Chemical Company 211 Farmington Hills, MI 48234 Phone: 248.381.8040 1700 Spaulding Road Fax: 248.381.8998 www.esi-group.com Dayton, OH 45432 Phone: 610.832.7807 USA- based ESI North America provides a unique offer www.gwsmithandsons.com to the metal casting industry. G.W. Smith & Sons, a Quaker Chemical Company, is ESI’s �agship casting solution, ProCAS, celebrating its recognized as the leading innovator in the die casting 25th year, offers unmatched accuracy and detailed func- industry through our advanced technology solutions. tionality across all casting processes. ProCAS, a proven We provide process expertise and customized support finite element based software, provides the full physics of services at the local level, for every thing covering your the casting process, from the key information of filling die casting needs from DIE SLICK® mold release with and solidification, to a comprehensive evaluation of stress Smart Polymer™ technology to plunger lubricant and and microstructure, no matter the casting size or shape. specialty hydraulic �uids. ESI also offers QuikCAS, an entry level solution that guides the engineer through the basic needs of understanding filling and solidification, while maintaining high accuracy in result. Hill & Griffi th Co. 216

Flow Science Inc. 204 1085 Summer Street Cincinnati, OH 45204 683 Harkle Road Phone: 513.921.1075 Santa Fe, NM 87505 www.hillandgriffi th.com Phone: 505.982.0088 Fax: 505.982.5551 Die Casting, Squeeze Casting & Permanent Mold www.�ow3d.com/cast Lubricant products that represent the latest in technology and ongoing research in die casting, squeeze Flow Science’s metal casting simulation software, FLOW-3D casting and permanent mold-release techniques that Cast is designed for modeling virtually all casting processes. will enhance your competitiveness. Cleaner dies while FLOW-3D Cast’s highly-accurate �ow and solidification results capture critical casting defects, including tracking sur- increasing productivity. Custom blended die lubricants face oxides, air entrainment, and micro-porosity. If you want for your specif ic application: Diluco™ 100 Series to improve the accuracy of your simulations and the quality water-base, 300 Series for squeeze casting, Concote™ of your cast products, then FLOW-3D Cast is the simulation low pressure die casting or permanent mold coating tool for you. Flow Science offers exceptional support and has and Plunger Lube™ water-based for cleaner and more dedicated support engineers for metal casting customers. efficient cooling. 2014 EXHIBITOR SPOTLIGHT

Midland echnologies is your premier resource for Valve- Lindberg/MPH01 4 107 Less Vacuum and Vent echnology to reduce air porosity, High Velocity Jet Cooling echnology to combat shrink 3827 Riverside Road porosity, and peripheral mold components. PO Box 131 Riverside, MI 49084 • Vacuum or vent blocks, jet coolers, slides, Phone: 269.849.2700 and mold components Fax: 269.849.3021 www.lindbergmph.com • Calculation of the required air evacuation area for your casting at no cost Lindberg/MPH manufactures a complete line of gas and • Exit runner layout at no charge with purchase electric melting and holding furnaces both aluminum and of a valve-less block zinc die casting including: • stack melters, dry hearth and wet hearth • Vacuum systems and filters reverberatory melting furnaces • Pre-cut and ground to length ejection pins • electric resistance (glowbar-type) melting • Core pins with detail and holding furnaces • launder systems • immersion melters and holders Modern Equipment Company 217 • metal treatment furnaces • electric and gas crucible furnaces-all sizes 369 W. Western Avenue Quality construction and refusal to compromise means you Port Washington, WI 53074 can count on superior performance. Phone: 262.284.9431 Fax: 262.284.9433 www.ModernEQ.com MAGMA Foundry Technologies 304 Modern Equipment Company, Inc. has been serving the 10 N Martingale Rd metal casting industr y since 1919. Our aluminum melt- Schaumburg, IL 60173 ing furnaces (JetMelt and MicroJet melters), aluminum Phone: 216.524.2363 holding furnaces and launder systems provide energy Fax: 216.524.9594 saving capacity to our customers. Foundry Ladles and www.magmasoft.com other molten metal handling systems, as well as the parts to keep them in good running order, form another MAGMA® Foundry echnologies, Inc. is the indus- key portion of our product and service offering. Call try leading supplier of casting process simulation and us at 262-284-9431, email [email protected], or optimization software, as well as related education and www.ModernEQ.com for Foundry Products. engineering services. MAGMA® has been the paceset- ter in defining a new direction for the diecasting industry. Besides MAGMASOF’s capability of simulating nearly any alloy and process the MAGMAhpdc and Paulo Product Company 115 MAGMAdielife modules were specifically developed to consider the specific process conditions of diecastings. 5711 West Park Avenue MAGMA5 Release 5.3 sets a new standard in ease-of- St. Louis, MO 63110 use, accuracy, and simulation speed. Phone: 314.450.4366 Fax: 314.450.4566 www.paulo.com Midland Technologies 210 Paulo Products Company offers a variety of Heat reating 14800 James Road services including Batch IQ , Continuous Belt, Vacuum, Rogers, MN 55374 and Metal Finishing. Paulo currently consists of 5 plants, Phone: 763.428.4229 located in St. Louis, MO, Cleveland, OH, Kansas City, Fax: 763.428.4720 MO, Murfreesboro N, and Nashville, N. Please visit us www.midlandtechnologies.com at www.paulo.com to learn more. EXHIBITOR SPOTLIGHT 2014

Rimrock Corporation is dedicated to manufacturing RAYTEQ LLC 202 01 4 high quality automation solutions to help our customers reduce their production cost. Rimrock’s product line, PO Box 1343 including ladles, reciprocators, extractors, and a com- Healdsburg, CA 95448 plete line of spray equipment, is designed to withstand Phone: 510.638.2000 harsh environments, while keeping you up and running www.rayteq.com 24/7. Rimrock also provides robot systems for a variety of applications including, material handling, metal • High powered, compact crucible-type electric ladling, die spray, and part ﬁnishing. resistance furnaces for melting aluminum, magnesium and zinc right at the die casting machine. Unique hybrid digital/analog power Schmolz & Bickenbach USA Inc. 207 controls shipped factory ready for Rayteq’s KW demand management software 365 Village Drive • Interactive KW demand management software Carol Stream, IL 60188 (IDMS) for reducing electric furnace utility Phone: 630.682.3900 demand charges www.schmolz-bickenbach.us • Retroﬁt kits and software for adapting most makes of electric resistance melting furnaces SCHMOLZ+BICKENBACH is a leading supplier of to Rayteq interactive KW demand management s Hot Work Die Steels engineered for maximum tough- ystems (IDMS). ness and thermal fatigue resistance under extreme con- • Exact replacement, long-life dual-refractory ditions. Te company operates seven service centers in heating elements for most popular makes of North America, including one heat treatment facility. electric resistance melting furnaces SCHMOLZ+BICKENBACH USA supplies the following die steels in rounds and �ats: 2343 (H11), 2344 ESR • Portable and compact compressed-air driven, (H13), 2367 ESR, 2714, 2999 ESR and E38K. Vacuest hydrogen porosity checker • Non-contact molten metal level sensors for accurate level sensing and control StrikoWestofen America 409

501 E. Roosevelt Avenue Regloplas Corp. 402 Zeeland, MI 49464 Phone: 616.772.3705 1088 Miners Road Fax: 616.772.5271 Saint Joseph, MI 49085 www.strikodynarad.com Phone: 269.428.1100 Fax: 269.428.1155 StrikoWestofen America is a manufacturer of melting, www.regloplasusa.com dosing, and holding furnaces for the light metal casting industry. Energy eﬃ cient solutions for die casting, gravity Regloplas manufactures emperature Control Units for casting (sand and permanent mold) and low pressure cast- the Die Cast Industry. Tey are extremely energy eﬃcient ing. Te StrikoMelter® is a tower melter that boasts 2% due to the cutting edge design and available green technol- or lower metal loss. Te Westomat® is a dosing/holding ogy. Models range from water units up to 400°F and oil furnace with a dosing accuracy of +/- 1.5%. Te Dynarad® units up to 660°F. A complete line of accessories is avail- line includes crucible and non-crucible furnaces, launder able for a safe and simple installation. Chillers and Cool- systems, and furnace support products. ing Systems are available through Regloplas/Schreiber.

Techmire 230 Rimrock Corporation 116 185 Voyageur 1700 Jetway Boulevard Pointe-Claire, QB H9R 6B2 Columbus, OH 43219 Canada Phone: 614.471.5926 Phone: 514.694.4110 Fax: 614.471.7388 Fax: 514.694.2634 www.rimrockcorp.com www.techmire.com 2014 EXHIBITOR SPOTLIGHT

echmire is the world leader in the design and manufac- Versevo 411 ture01 of4 multiple-slide die-casting systems for precision components in zinc, lead and magnesium alloys, including: 1055 Cottonwood Ave. Hartland, WI 53029 • design, manufacture and testing of die-casting Phone: 262.912.7154 machines and tooling Fax: 262.369.7793 • training of customers’ operators and maintenance www.versevo.com personnel Versevo, ISO 9001:2008 certified, the moniker for Versa- • full after-sales service tility, Service, Evolution. World class services provider to • machine retrofitting and refurbishing the cast metals industry. Offerings include process & tool • annual maintenance & support program design, prototype & production tooling, iron & aluminum castings, machining, in support of “First Shot Success” for echmire provides cost-effective solutions to manu- High Pressure & Low Pressure Die Cast, Lost Foam Cast, facturers of die cast components to cast complex parts and Sand Cast. Te exclusive US & CAN sales agents for with faster cycle speed, higher material utilization and Kurtz Gmbh foundry equipment, including low pressure superior part quality. permanent mold, and trimming machines.

The Schaefer Group Inc. 311 Visi-Trak Worldwide LLC 205

1500 Humphrey Avenue 8400 Sweet Valley Drive Dayton, OH 45410 Suite 406 Phone: 937.253.3342 Valley View, OH 44125 Phone: 216.524.2363 Fax: 937.937.2503 Fax: 216.524.9594 www.theschaefergroup.com www.visi-trak.com Te Schaefer Group, Inc. will be displaying their Visi-rak is the leader in process automation in the die- furnaces at booth #311 at the NADCA Die Casting casting industry - increasing customer’s efficiency, quality Congress & abletop in September. In the booth will be level, and profitability. Our 33 year history of monitoring and information on electric immersion element holding fur- shot control applications has provided industry with the tools naces, transfer ladles along with pictures and informa- needed to increase quality and throughput while decreasing tion on a large variety of furnaces, launders and melting cost. From high integrity aluminum die-casting, to high-reso- furnaces. Stop by and see our new Schaefer Shield. Te lution sensor technologies, to (PLC) interfaces, to production best refractory coating on the market! reporting and process control software - Visi-rak combines them all into complete process automation solutions. Toshiba Machine 227 Zitai USA 105 755 Greenleaf Avenue Elk Grove Village, IL 60007 5133 W. Camino Dr. Manana Phone: 847.709.7000 ucson, AZ 85742 Fax: 847.593.0897 Phone: 520.579.0485 www.toshiba-machine.com Fax: 520.579.0486 www.zitai.com oshiba Machine has been manufacturing die casting machines since 1953. With over 12,000 installed Zitai USA is the North American agent for Zitai Precision around the world and more than 13,000 installed Machinery Company of aichung,aiwan. Zitai Precision around the world and more than 500 in North America, Machinery Company has been manufacturing cold chamber it’s no wonder that quality has grown to be synonymous die casting machinery and automation equipment since 1981 with the oshiba name. We offer a complete turn- and has thousands of machines installed worldwide. Zitai key system with cold chamber machines ranging from Precision Machinery offers a complete turnkey solution to die 150-4500 US ons. With our centrally located Illinois casters including tooling design, build and sampling in addi- headquarters, and strategic locations throughout North tion to world class equipment utilizing the latest technology and South America, we can back our quality machines including servo shot technology in cooperation with Visitrak. with quality support and ser vice.  NADCA Welcomes Its Newest Corporate Members

East River Solutions Ltd. In the summer of 2013, long-time toolmaker Jason Everaert merged his existing business with serial entrepreneur and industry veteran Otto Kjeldsen - to create East River Solutions Ltd. East River Solutions embodies a fresh vision in custom machining. We offer value to our customers through our unique, gutsy and collaborative approach to our work. East River aims to be recognized by our customers and our peers as the better supplier. We leverage the latest in technology and apply a fresh approach to machining through innovation in set-up and cutting methodology. We are skilled in creating prototypes, trim dies, fixtures and mould components. We are located in a brand new 4,000 sq. ft. facility in picturesque Wallaceburg, Ontario - nestled into the extreme southwest of the province - (40 miles) northeast of Detroit, Michigan. Tis picturesque small town is a little known center of tooling and design expertise, long utilized by the “Big Tree” automotive companies in Detroit. Visit our website at www.ercnc.com to find out more about who we are and what we do!  2014 Corporate Members

CORPORATE DIE CASTERS Cascade Die Casting Group Inc. E - Corp. HQ Grand Rapids, MI Empire Die Casting Macedonia, OH A Cascade Die Casting Group Inc. A & B Die Casting Inc. - Great Lakes Div. Hercules, CA Sparta, MI F ABCO Die Casters Inc. Cascade Die Casting Group Inc. Fielding Mfg.-Zinc Diecasting Inc. Newark, NJ - Mid-State Div. Cranston, RI Grand Rapids, MI Able Die Casting Corp. Fort Recovery Industries Inc. Schiller Park, IL Cast Products Inc. Fort Recovery, OH Norridge, IL ACE Precision International, LLC FT Precision Marshalltown, IA Cast-Rite Corporation Fredericktown, OH Gardena, CA Acme Alliance LLC Future Die Cast & Engineering Inc. Northbrook, IL Cast Specialties Inc. Shelby Township, MI Ahresty Wilmington Corp. Warrensville Heights, OH Wilmington, OH Chicago White Metal Casting Inc. Alloy Die Casting Bensenville, IL G Buena Park, CA CompX Security Products General Die Casters Inc. Apex Aluminum Die Casting Co. Grayslake, IL Twinsburg, OH Piqua, OH Congress Drives LLC Gibbs Die Casting Corporation Auto Cast Inc. Ennis, TX Henderson, KY Grandville, MI Cottam Diecasting Ltd. GM Powertrain Bedford Tecumseh, ON Canada Bedford, IN B Crecocast – A Div. of Creco Corp. GM Powertrain HQ Seville, OH Pontiac, MI Blue Ridge Pressure Castings Inc. Lehighton, PA Cuprum SA De CV Green�eld Industries Inc. Sac Nicolas De Los Garza, Nuevo Leon, Mexico Freeport, NY Briggs & Stratton Corp. - Milwaukee Milwaukee, WI Briggs & Stratton Corp. - Murray D H Murray, KY DeCardy Diecasting Co. Heritage Die Casting Co. Briggs & Stratton Corp. - Poplar Bluﬀ Chicago, IL Denver, CO Poplar Bluﬀ, MO Deco Products Co. Honda Engineering North America EGA - Briggs & Stratton Corp. - Statesboro Decorah, IA Tool Block: Powertrain Equipment Statesboro, GA Dwyer Instruments Inc. Anna, OH Brillcast Inc. Kingsbury, IN Honda Manufacturing of Alabama LLC - Grand Rapids, MI DyCast Specialties Corp. Engine Plant: ALDC Starbuck, MN Lincoln, AL C Dyersville Die Cast - Div. of Joseph L. Ertl Honda North America Services LLC - Dyersville, IA Powertrain: Engineering Center California Die Casting Inc. Marysville, OH Ontario, CA Dynacast de Mexico Cuautitlan Izcalli, Mexico Honda of America Mfg. - Callen Die Casting LLC Anna Engine Plant: ALDC Fountain Inn, SC Dynacast Inc. Anna, OH Charlotte, NC Callen Manufacturing Corp. Honda of America Mfg. - Northlake, IL Dynacast Elgin North American Purchasing Canada Metal (Paci�c) Limited Elgin, IL Anna, OH Delta, BC, Canada Dynacast Germantown Honda of Canada Mfg. Inc. - Carteret Die Casting Corp. Germantown, WI Engine Plant: ALDC Somerset, NJ Dynacast Lake Forest Alliston, ON, Canada Cascade Die Casting Group Inc. Lake Forest, CA Honda Power Equipment - - Atlantic Div. Dynacast Ltd. Aluminum Die Cast High Point, NC Peterborough, ON, Canada Swepsonville, NC 2014 CORPORATE MEMBERS

Honda Precision Parts Georgia LLC - Meridian Technologies Mexico PECO Manufacturing Company Aluminum Die Cast Ramos Arizpe, Coahuila, Mexico Portland, OR Lincoln, AL Micro Industries Inc. PHB - Die Casting Div. Honda R&D America - Rock Falls, IL Fairview, PA O: Aluminum Division Microcast Technologies Phillips Magnesium Injection Molding Raymond, OH Linden, NJ Eau Claire, WI Honda South Carolina - Midwest Die Casting Corp. Pittsburgh Die & Casting Co. Aluminum Die Cast Pittsburgh, PA Timmonsville, SC Milwaukee, WI Muskegon Castings Corp. Port City Group Honda Transmission Manufacturing Inc. Muskegon, MI Russells Point, OH Muskegon, MI Honeywell International Premier Die Casting Co. Avenel, NJ San Diego, CA N Premier Lakewood Inc. Nebraska Aluminum Castings Inc. Lakewood, NY Hastings, NE I Premier Tool & Die Cast Corp. International Die Casting Inc. Nemak Alabama Berrien Springs, MI Gardena, CA Sylacauga, AL Prestige Casting Inc. Nemak Kentucky Englewood, CO Glasgow, KY J Production Castings Inc. Joyner’s Die Casting & Plating Nemak Wisconsin Fenton, MO Brooklyn Park, MN Sheboygan, WI Proto Labs Inc. North American Casting Corp. Maple Plain, MN K Trussville, AL Kason Industries Inc. Northern Iowa Die Casting Inc. R Lake Park, IA Shenandoah, GA Rangers Die Casting Company KenWalt Die Casting Corporation Lynwood, CA Sun Valley, CA O RCM Industries Inc. Kinetic Die Casting Inc. Omni Die Casting Inc. - Aallied Die Casting Co. of IL North Hollywood, CA Massillon, OH Franklin Park, IL Kirby West Corporation RCM Industries Inc. Andrews, TX - Aallied Die Casting Co. of NC P Rutherfordton, NC L Pace Industries - Airo Div. RCM Industries Inc. Loyalhanna, PA - Imperial Die Casting Co. Lakeside Casting Solutions Pace Industries - B&C Div. Liberty, SC Monroe City, MO Harrison, AR RCM Industries Inc. Laurel Manufacturing LLC - Inland Die Casting Co. Elk Grove Village, IL Pace Industries - Cambridge Div. North Billerica, MA Wheeling, IL Littler Diecast Corp. Regal Beloit Corporation Albany, IN Pace Industries - Chihuahua Div. Chihuahua Chih, Mexico Beloit, WI Pace Industries - Corp. Oﬃ ce Regal Beloit Corporation M Fayetteville, AR El Paso, TX Madison-Kipp Corp. Pace Industries - Grafton Div. Regal Beloit Corporation Madison, WI Grafton, WI Marsh�eld, MO Mag-Tec Casting Corp. Pace Industries - Harrison Div. Rheocast Co. Jackson, MI Harrison, AR Germantown, WI Mercury Castings Pace Industries - Product Tech Div. Ryobi Die Casting (USA) Inc. - Div. of Mercury Marine, WI Maple Lake, MN Shelbyville, IN Fond Du Lac, WI Pace Industries - Saltillo Div. Ryobi Die Casting Mexico Meridian Lightweight Technologies Inc. Saltillo, Mexico Irapuato, Guanajuato, Mexico Strathroy, ON, Canada Meridian Lightweight Technologies Inc. Pace Industries - St. Paul Div. - GTC Saint Paul, MN S South�eld, MI Paci�c Die Casting Corporation SDC Incorporated Meridian Technologies Inc. Commerce, CA Sullivan, MO - Magnesium Products of America Paci�c Die Casting Corporation SENSUS Precision Die Casting Inc. Eaton Rapids, MI Vancouver, WA Russellville, KY 2014 CORPORATE MEMBERS

Shiloh Industries Wilkast, Inc. C Alma, MI Grand Rapids, MI CANMET Materials Technology Shiloh Industries Wrex Products Inc. Hamilton, ON, Canada Auburn, IN Chico, CA Casting Impregnators Inc. Shiloh Industries Franklin Park, IL Clarksville, TN CORPORATE OEM Castool Tooling Systems Shiloh Industries Uxbridge, ON, Canada Pierceton, IN ASSA Abloy-Interlock Reno, NV Chemtool Incorporated Shiloh Industries Rockton, IL Pleasant Prairie, WI Sundaram - Clayton Limited Deer�eld, IN Chem-Trend Ltd. Partnership Simalex Manufacturing Company Ltd. Howell, MI Langley, BC, Canada Colosio Die-Casting Machines & Accessories SKS Die Casting & Machining Inc. CORPORATE SUPPLIERS Fort Mill, NC Alameda, CA CRD Enterprises, Inc. Soldy Manufacturing Company A Lake Zurich, IL Schiller Park, IL A Finkl & Sons Spartan Light Metal Products Inc. Chicago, IL Sparta, IL D AarKel Tool & Die Inc. Daido Steel Co. Ltd. Spartan Light Metal Products LLC Wallaceburg, ON, Canada Hannibal, MO Florence, KY Allied Metal Co. Delaware Dynamics LLC Spartan Light Metal Products LLC Chicago, IL Mexico, MO Muncie, IN Alltherm Services Inc. Die Cast Press Manufacturing Co. St. Clair Die Casting - An EPI Company Highland, IN Saint Clair, MO Paw Paw, MI STRATTEC Component Solutions American Die Cast Releasants LLC Die Casting Design & Consulting Milwaukee, WI Fenton, MI Milwaukee, WI Stroh Precision Die Casting LLC American Metal Chemical Corp. Die Process Control Systems Mauston, WI Medina, IL Manitowoc, WI Audubon Metals LLC Die Therm Engineering LLC T Henderson, KY Grand Rapids, MI Automatic Anodizing Diversi�ed Machine Inc. Team Industries - Detroit Lakes Chicago, IL Bristol, IN Detroit Lakes, MN AV&R Die Casting DME Company LLC Technical Die-Casting Inc. Saint-Bruno, QC, Canada Madison Heights, MI Stockton, MN DMS Tek-Cast Inc. Oldcastle, ON, Canada Bensenville, IL B TESLA Motors B & L Information Systems Inc. DTP Diecast Solutions LLC Florence, AL Fremont, CA Bridgman, MI Thomas & Betts Monterrey Badger Metal Tech Inc. Guadalupe, Nuevo Leon, Mexico Jackson, WI E TRU Die Cast Corp. Basic Resources Inc. East River Solutions Ltd. New Troy, MI Knoxville, TN Wallaceburg, ON Canada TVT Die Casting Die Casting & Manufacturing Bedford Machine & Tool Inc. Eastern Alloys Inc. Portland, OR Bedford, IN Maybrook, NY Twin City Die Castings Co. Blasch Precision Ceramics EDCO Inc. Minneapolis, MN Albany, NY Toledo, OH Twin City Die Castings Co. Bob McClintic & Associates EKK, Inc. Monticello, MN Jenison, MI Farmington Hills, MI Twin City Die Castings Co. Bodycote Thermal Processing Inc. Ellwood Specialty Steel Watertown, SD Sturtevant, WI New Castle, PA Bohler-Uddeholm United States W Elgin, IL F Walker Die Casting Inc. Brach Machine Inc. Fisa North America Inc. Lewisburg, TN Batavia, NY Elk Grove Village, IL Whitehead Die Casting Co. Inc. BuhlerPrince Inc. Flow Science Gainesville, GA Holland, MI Santa Fe, NM 2014 CORPORATE MEMBERS

Frech USA Inc. MAGMA Foundry Technologies Inc. The Schaefer Group Inc. Michigan City, IN Schaumburg, IL Dayton, OH Fremar Industries Metal Conversions Ltd. Schmolz & Bickenbach Canada Brunswick, OH Mans�eld, OH Mississauga, ON, Canada Metal Mechanics Inc. Schmolz & Bickenbach USA, Inc. G Schoolcraft, MI Carol Stream, IL Midland Technologies, Inc. Sorel Forge Godfrey & Wing Inc. Rogers, MN Aurora, OH St-Joseph-De-Sorel, QC Canada Modern Equipment - An Alco Industries Co. Spectro Alloys Corp. Gosiger High Volume Port Washington, WI Brook�eld, WI Rosemount, MN Mokon StrikoDynarad Corp. GW Smith - a Quaker Chemical Company Buﬀalo, NY Dayton, OH Zeeland, MI MORESCO USA Inc. Superior Aluminum Alloys Ann Harbor, MI H New Haven, IN Swiss-Tek Coatings Inc. Henkel Corp. - Adhesives Technologies New Berlin, WI Madison Heights, MI N Hill & Griﬃ th Co. New Century Heaters Ltd. Cincinnati, OH Bay City, MI T HPM North America Corp. Techmire Marion, OH O Pointe-Claire, QC, Canada Oerlikon Balzers Coating USA Therm-Tech of Waukesha I Rock Hill, SC Waukesha, WI Toshiba Machine Co. America IDRA North America Elk Grove Village, IL Kokomo, IN P Imperial Zinc Corp. Tra�gura AG Paulo Products Company Stamford, CT Chicago, IL Saint Louis, MO Italpresse Industrie, SpA PCS Company Englewood, OH Fraser, MI U PiQ2 UBE Machinery Inc. J Livonia, MI Ann Arbor, MI J&S Chemical Corp. Ultraseal America Inc. Canton, GA Q Ann Arbor, MI Just In Time Technical Personnel Quad Steel Corporation Solon, OH Brighton, MI V VERSEVO Inc. K R Hartland, WI Kestrel Management Services RAYTEQ LLC Visi-Trak Worldwide LLC Lisle, IL Healdsburg, CA Valley View, OH Kuka Robotics Corp. Regloplas Corporation Shelby Township, MI Saint Joseph, MI W Reis Robotics USA Inc. Wheelabrator Group Canada L Elgin, IL Burlington, ON, Canada LK Machinery Inc. Rike Equipment Corp. Wheelabrator Group USA Holland, MI Ivy, VA LaGrange, GA Leco Corp. Rimrock Corp. Wollin USA Saint Joseph, MI Columbus, OH Plymouth, MI Lincoln International, LLC Roberts Sinto Corp. New York, NY Lansing, MI Z Lindberg MPH Zitai USA Riverside, MI S Tucson, AZ Sanyo Special Steel USA Inc. M New York, NY M & I Machine Saran Industries LP Benton Harbor, MI Indianapolis, IN  Chapter News & New Members

Chapter 3 - W. Michigan Die Casting at a Golf Course? Yes, it happened! Not much else goes on at a Golf Course in West Michigan in March! As reported ear- lier Western Michigan Professor, Dr. Sam Ramrattan and his students conceived an idea to design and build a miniature working and portable Cold Chamber Die Cast Machine. After accomplishing the task and furnishing a report to Chapter 3, Dr. Ramrattan “upped the ante” on his students. He proposed a challenge to them, to bring Chapter 3 – NADCA Chapter 3 attendees listen intently and the machine on the road (which is the intent of the project) learn about the “Die Cast in a Box” project. to the NADCA Chapter 3 March meeting, they accepted the challenge. Over the last couple of months his students have made many improvements to the machine, including; updating the hydraulic controls, moving platen redesign, improved metal melting system and the addition of a shot monitoring system donated by Visi-rak Worldwide. Not only did the students step up to the plate with all the updates and bring the machine to our March meeting at Tornapple Point golf course, they made parts.

Chapter 3 – Te die cast machine ready to make the �rst shot at Tornapple Point Golf Course, notice the snow on the fairways!

Chapter 3 – Dr. Ramrattan of Western Michigan University addresses March dinner attendees.

Chapter 3 – Students ready the machine in preparation for the �rst shot. During Happy Hour and Dinner the machine was available for viewing for the 50 attendees of the meeting. Dr. Ramrattan opened the presentation with a brief overview of the project and then turned the presentation Chapter 3 – Ryan Niewoonder, “Die Cast in a Box” senior over the 2013 project leader Ryan Niewoonder who is project team, reviews the “Die Cast in a Box” project. now employed by Parker. Ryan presented a history of the CHAPTER NEWS & NEW MEMBERS

Please visit the Chapter’s Web site www.diecasting.org/ chapter/03 for details on upcoming events.

- Submitted by Rob McInerney, BuhlerPrince, Inc. Chapter 3 Chairman

New Members: Joe Bowen, Shiloh Industries - Alma Plant; William Burdue, GM Powertrain HQ; Raymond F. Decker, Tixomat, Inc.; Dustin McDonald, Shiloh Industries - Alma Plant; Joel Ramsey, Baker College of Jackson; Dan Stahl, Shiloh Industries - Alma Plant

Chapter 5 - Chicago NADCA Chapter 5 held its annual State of the Indus- Chapter 3 – Dr. Sam oversees the extraction of the �rst part. try Meeting on Tursday, February 6, 2014 at Colletti’s Dining & Banquets. Over 80 members braved cold and snowy winter weather to attend and learn more about what they can expect from the economy and the outlook for the industry in the year to come. Attendees were treated to two very informative presentations. Te ﬁrst was by our own Eric reiber. Eric gave an informative look at what the NADCA Board of Governors does for the die cast industry and introduced us to OSHA’s new Injury and Illness Prevention Program (I2P2). We also

Chapter 3 – Success, the �rst part is made. project and commented on the updates to the machine. But, now it was time to make good on the promise made by Dr. Ramrattan and his students. Te machine was rolled to the veranda, plugged in (literally 110VAC) and allowed to heat up for 15 minutes. Without any further delays the ﬁrst casting ever made at Tornapple Point Golf Course was accomplished. o further enhance the accomplishment 3 more shots were made and the parts Chapter 5 – Attendees smile for the camera. were passed around for all to inspect. As part of the requirement for passing the Die Casting Course and running the machine at the March meeting, the students now have to prove that the machine will run 10 consecutive shots. Shot data must be collected and analyzed to show machine capability. NADCA Chapter 3 would like to thank Dr. Ramrat- tan and his students for all the hard work and congratulate them on the success on this project. Many of the die casters in attendance couldn’t believe the accomplishment of the “Die Casting in a Box” project and the comment “they did it” was heard may times. Te next task involves adding more safety features to the machine so the machine can be taken on a Road Show to High Schools and echnology Schools in the area to Chapter 5 – NADCA Chairman Eric reiber converses with promote the art of Die Casting. attendees. CHAPTER NEWS & NEW MEMBERS

Chapter 6 - Cleveland Please visit the Chapter’s Web site www.diecasting.org/ chapter/06 for details on upcoming events.

New Members: Ned Stockdale, Northern Iowa Die Casting Inc

Chapter 7 - New York Leonard Cordaro is president of Premier Die Casting and was our speaker who presented a preview of Dan warog’s Chapter 5 – Members enjoy a nice dinner. State of the Industry which is featured in the January issue of Die Casting Engineer Magazine. It would be to your advantage for the die casting industry, members and associates to read Dan warog’s entire report and beneﬁt from a great amount of valuable information contained in this report.

Chapter 5 – Mr. reiber addresses the crowd.

Chapter 7 – Dean Fuschetti, President, Microcast echnologies Leonard Cordaro, President, Premier Die Casting Joseph Dapsis, President, Carteret Die Casting Corp Joe Hoﬀman, President, Hoﬀman Die Casting Steve Vitollo Representing Joseph Vitollo, President, ABCO Die Casting; Santa Claus, President, North Pole.

Chapter 5 – Jeff Brennan speaking to everyone. heard from Jeff Brennan, the echnology Manager for NADCA. He provided us with an overview of the State of the Industry with a focus on re-shoring and what we can expect in the months to come. A big thanks to Eric, Jeff, and all who came out to attended this very informative meeting. Please join us on June 13 for our annual golf outing and lunch. Te outing will be held at the Bloomingdale Golf Club this year and it will be an 8:30 am shotgun start. If you are interested in being a spon- sors of the event or need more information, please feel free to contact Max Gondek at [email protected]. Chapter 7 – John Mudrak, Vice President of Sales; Charles We look forward to seeing you there. Silvera, Casting Manager, Carteret Die Casting; James K Please visit the Chapter’s Web site www.diecasting.org/ Him, Quality Manager, Carteret Die Casting; Joseph Dapsis, chapter/05 for details on upcoming events. President, Carteret Die Casting Corp. CHAPTER NEWS & NEW MEMBERS

Chapter 9 - Central NY Please visit the Chapter’s Web site www.diecasting.org/ chapter/09 for details on upcoming events.

Chapter 10 - Ontario Please visit the Chapter’s Web site www.diecasting.org/ chapter/10 for details on upcoming events. Chapter 7 – Charles Silvera, Casting Manager, Carteret Die New Members: Jason Everaert, East River Solutions Ltd; Casting; James K Him, Quality Manager, Carteret Die Cast- Ian Robinson, Imacro Inc ing; Vito M oto, President, VM Design. Tis meeting was our annual President’s Night where we honor our die casting member presidents to receive a warm recognition and appreciation for their continued Chapter 12 - Wisconsin service to our industry. Dan warog, President of NADCA, made note that he “You can’t be everywhere at once.” Someone, somewhere, a will be speaking on our next President’s Night in Decem- long sometime ago muttered those words for the very first ber 2014. Tis was accomplished via telephone call with time, most likely out of an uncomfortable mix of anxiety, John Mudrak, our Chapter 7 Chairman. frustration and a sprinkle of resignation. Unbeknownst to Chapter 7 Sponsored a webinar seminar and all chapter the mutterer, that mutterance would go on to spawn an 7 die casters had company members partake in this. I (Vito era, one whose tide has risen well above our heads and gets oto) was invited by Carteret Die Casting to attend at deeper with every hat we wear. Like it or not, for better or their facility in Somerset, NJ. worse, life has made us all slaves to the Era of Burden. Steve Udvardy, Director of Education and echnology at “Dude – what the �ash does this have to do with Chapter NADCA National was our speaker. His presentation is called 12 news?” Ahhh – that is the question, isn’t it. Tank you “Extending Die Life” which covered die design features, for keeping me focused, and trust me – I’m getting there. operational factors and care maintenance. Here are some of I myself felt the whip of Burden come lashing down upon the highlights of his presentation: Steve said “good casting my �esh one day before Chapter 12’s most recent meeting. design” incorporates easy fill, quick cool and easy ejection. He It pitted two lives against each other, one personal, the stresses avoiding sharp corners and heavy wall sections. other professional, something every single one of us can Sharp corners create hot spots causing undue stress. Tick relate to in one way or another. In most cases – and this walls cause high heat �ux with fatigue. Inadequate draft one in particular – the urgency of my personal issue far promotes soldering and extracting heat becomes harder. Steve said you need “robust die design”. Adequate support with proper clamping to offset injection forces. Support is needed under die cavities too. You also need proper metal �ow to avoid surface erosion and proper heat removal to avoid die fatigue. Steve also discussed the importance of minimizing variations, cycle times, metal temperatures, die spray, minimizing die solder, minimizing scrap, die care and maintenance, stress relieving, micro-precision shot peen, weld-repair and storage. Steve gave us a great presentation. He is very knowledgeable and detailed. He covered a lot of subject matter during the one hour time slot. We all learned a lot. Please visit the Chapter’s Web site www.diecasting.org/ chapter/07 for details on upcoming events.

- Submitted by Vito M. oto, VM Design Chapter Program Chairman

New Members: John W Burk, Carteret Die Casting Corp; Chapter 12 – People gathered around a machine listening to Gregory Clark, Premier Die Casting Company; Quanyi Li, a Busch representative explain the process. Noticeably absent: Duchan echnology (HK) Co. Ltd; Burkhard Weber, Lincoln me. I’ll give you three guesses where the guy in the plaid shirt International, LLC works. Make that two guesses. CHAPTER NEWS & NEW MEMBERS

ogy by none other than our very own Dr. Ray Donahue. o summarize in one word: awesome. If my life should become another motley con�agration of idiomatic drama within the days leading up to this one, I may very well have to reshuffl e my personal & professional priorities. One way or another, I will be there. Don’t forget about the Chapter 12 golf outing on Friday, June 6. Tis year’s event looks to be the basis by which all other outings (specific to organizations within the die cast industry located in the Midwest) will be compared. We’re already taking reservations for golfers, but it’s limited to the first 144 registrants. Wait, is it registrars? Or maybe registrationists? Let’s just go with golfers and leave it at that. ake a look at the �yer on the Chapter 12 website, round up a few buddies and prepare yourselves for golf like you’ve never known it before. Yeah – it’s that good. Please visit the Chapter’s Web site www.diecasting.org/ Chapter 12 – Same guy saying something more about the chapter/12 for details on upcoming events. company. Wish I knew what that was. Impressively clean and shiny concrete �oor, by the way. - Submitted by Steve Grall, Shiloh Industries Chapter 12 Secretary

New Members: Dave L. Bandy, Nemak Wisconsin; Dan Bazar, Shiloh Industries; John Carroll, Stotek Inc; Randy Fry, Stroh Precision Die Casting LLC; Zakk Geyer, Stroh Precision Die Casting LLC; Kathy Gilleran, A. Finkl and Sons; Scott Harden, Shiloh Industries; Mike Howe, Shiloh Industries; Larry Kubisiak, Shiloh Industries; Steve Mayer, Promontory Point Capital; John S. Moch, AI Ladish Diecast ooling; Jim Paulsen, Innovation Mold and Design; Chuck Reed, Stroh Precision Die Casting LLC; Chris Scheider, Stroh Precision Die Casting LLC Chapter 12 – Members and guests enjoying their meal without me. How could they?! outweighed the importance of the professional one, and it made for an easy but unfortunate choice. Chapter 14 - S. Ohio I say unfortunate because I REALLY wanted to attend this meeting, mainly because it wasn’t really a Southwest OH Chapter 14 had the privilege of hosting meeting at all, but I couldn’t be there. On March 12, Mr. Bob McClintic, AKA Dr. Die Cast, to their Feb- Chapter 12 held its ﬁrst plant tour in more years than ruar y meeting that was held at LaPiazza in roy, OH I’ve been a member, and I couldn’t be there. Busch Pre- on February 11. Bob was asked to use his industrial cision was kind enough to open its doors, explain what they do and how they do it, even arrange for an on-site dinner, and I couldn’t be there. From what I hear, it was a great tour – well organized, informative and even included representatives from three other companies related to the industry. And I couldn’t be there. Any details I would give from the tour & dinner would be blatant, purely fabricated (though probably entertain- ing) lies. Why? C’mon, you know this…that’s right, because I couldn’t be there. Te good news is, this pity party I’m throwing for myself will be very short lived. My one saving grace will come in May when Chapter 12 has its second plant tour and last dinner meeting of the year. Tis one’s gonna be at Mercury Marine and will include a visit to their newly-opened museum, dinner on the lakeshore and an explanation of salt core technol- Chapter 14 – Dr. Die Cast speaks to the attendees. CHAPTER NEWS & NEW MEMBERS

knowledge in die casting to lead a round table discussion on “How to Increase Plant Productiv ity”. With 30+ folks in attendance the discussions were lively and informative. As expected Bob was able to lead the group into productive conversations. he attendees were vocal and willing to share their experiences as well which made for a great evening. opics discussed included costs of compressed air, how to lengthen the life of furnace liners, common causes of part defects, pros and cons of plunger lubrication methods and future of die spray technologies. On uesday March 11, Chapter 14 welcomed Mr. Rainer Herrmann as a special guest speaker. Rainer educated the audience on how structural castings came to be and why there is so much talk about them today. Of special interest were the technologies behind this reﬁned die casting process and how the need for process control is paramount. All in attendance left with a much better understanding of the “ins” and the “outs” of Chapter 14 – Enjoying dinner and a presentation. making structural parts and the impact that these parts are making on the automotive marketplace as a whole. Rainer’s German heritage made for an insightful and fun ﬁlled evening and much interaction was experienced with the audience which was not shy in participating.

Chapter 14 – Te crowd listens attentively.

Chapter 14 – Members smile for a photo. Your Chapter 14 executive staﬀ looks forward to working with our members in 2014 and beyond. Please feel free to contact me or any of our executive team ww w.diecasting.org/chapter/14 with your ideas on how we can become an even more eﬀective chapter for you, your workmates and your respective companies. Please visit the Chapter’s Web site www.diecasting.org/ chapter/14 for details on upcoming events.

- Submitted by Monte Swigart, Combined echnologies Group Chapter 14 Chairman

New Members: Chris A. Daugherty, Chrysler Group LLC; James Kreitzer, Honda Engineering North America EGA - Chapter 14 – Dr. Die Cast giving his presentation. ool Block: Powertrain Equipment CHAPTER NEWS & NEW MEMBERS

Chapter 15 - Southeastern meeting notice, and the entry form for the 2014 Golf Outing, which will be on Friday, September 26 again at Te Links of Please visit the Chapter’s Web site www.diecasting.org/ Dardenne. Please plan to join us in September. chapter/15 for details on upcoming events. Please visit the Chapter’s Web site www.diecasting.org/ chapter/17 for details on upcoming events. New Members: Kris Oakley, Honda Power Equipment - Aluminum Die Cast - Submitted by Pete Schiavone, Gateway Metals, Inc. Chapter 17 Secretary Chapter 16 - Minnesota New Members: Stephen Fall, Nidec Motor Corporation; Marc Scher, Shapiro Metals Please visit the Chapter’s Web site www.diecasting.org/ chapter/16 for details on upcoming events. Chapter 25 - Indiana New Members: Alan Oppegaard, Northern Iron & Machine Please visit the Chapter’s Web site www.diecasting.org/ chapter/25 for details on upcoming events. Chapter 17 - St. Louis New Members: Rex R. Fish, Linamar; John Hime, Audu- Chapter 17 members and advertisers should have received the bon Metals LLC; Keith Martin, Briggs & Stratton Corp - 2014 Chapter Yearbook a few weeks ago. Congratulations to Murray; Victor Steele, SENSUS Precision Die Casting Inc. committee chairman Randy Tomas, Hellebusch ool and Die, on a job well done once again!! NADCA National’s Steve Udvardy was the featured speaker for our March 11 Chapter 29 - South Central Membership meeting. Steve discussed die failure and will deliver part two of his presentation on April 22. We appreci- Please visit the Chapter’s Web site www.diecasting.org/ ate Steve’s eﬀorts to enlighten us. Chapter 17 will dispense chapter/29 for details on upcoming events. with formal Chapter activities through the summer months. Please watch your email for the September Membership New Members: Michael Castle, Shiloh Industries - Clarksville Plant; Brian Devening, Te Fred Jones Companies, LLC; Marshall Reeske, exas State University - San Marcos; Eric Wallace, oshiba

Chapter 30 - Los Angeles Please visit the Chapter’s Web site www.diecasting.org/ chapter/30 for details on upcoming events.

New Members: Abraham Amaya, ESLA Motors; Matt Kallas, ESLA Motors; Danielle Meenach, Pyrotek Inc

Chapter 39 - SW Michigan Please visit the Chapter’s Web site www.diecasting.org/ chapter/39 for details on upcoming events.

New Members: Tomas Dailey, Metal Mechanics Inc; Kurt Flesher, Shiloh Industries - Auburn Plant; Michael Harris, Shiloh Industries - Auburn Plant; Bernard Jaeger, Shiloh Industries - Pierceton; Randy Kinsey, Shiloh Industries - Pierceton; Bryan Osslelaer, Superior Aluminum Alloys; Justin uransky, Superior Aluminum Alloys; Shawn Williams, Shiloh Industries - Pierceton

Members at Large New Members: Gang Chen, Shanghai Yadelin Non Ferrous Metal Co., Ltd.; Tomas Fritsch, Foundry-Planet Ltd.; David Hsu, Dynacast; Worawit Lalitkiattikool, riumph Motor- cycles Tailand Ltd; Victor Manea, SHW Automotive Pumps and Engine Components; Chen Mingsheng, ripod (Ningbo) Alloy Manufacturing Co., Ltd.; S.J. Oh, H YUNDAI POW- ERECH; Lee L. Song, Motorola Solutions  New Products, Services & Solutions

StrikoWestofen Chicago White Metal GW Smith and Sons Introduces Mobile Launches Fresh Introduces HFC Water Website and System- Website Redesign Glycol Hydraulic Fluid Speci�c QR Code for Die Casters Identi�cation

Offering Product Design Resources to Engineers Out of the many types of fire resis- Te StrikoWestofen Group (Gum- Chicago White Metal, Inc. unveiled tant hydraulic �uids available, the mersbach, Germany) offers faster sys- its redesigned website, www.cwmdi- more popular type of �uids are water tem-specific support to their customers. ecast.com. Te website will serve as glycol hydraulic �uids, or “HFC Tis is made possible by the new mobile a resource for OEM product design- �uids”. o address the needs of the website of the company, providing the ers, engineers, design consultants, die casting industry, GW Smith and necessary contact options. A QR code purchasing managers and buyers of Sons, a Quaker Chemical Company retrofitted to all existing systems allows die cast components. has introduced a water glycol �uid, service technicians to give targeted Te new website features two QUINOLUBRIC 702 46 RD to counselling. Te rapid evaluation of relevant sections: information about its line of products. error messages sent via contact form Chicago White Metal’s operations QUINOLUBRIC 702-46 RD is makes a distinct contribution towards and the Die Cast Design Center a premium water glycol (HFC) fire- increased system availability. (DC2), a free educational hub with resistant �uid that has been approved Which spare part will improve one of the industry’s largest collection by Factory Mutual (FM) Global for the effi ciency of my system? What of technical die casting content. Its FM approval. QUINOLUBRIC does a certain error message mean? purpose is to assist design engineers 702-46 RD is designed to provide Why is there a drop in the effi ciency and buyers through the die casting optimum performance in hydraulic of my system? Tere are a number design and purchasing processes. systems where fire-resistant �uids are of reasons why operators of melting required. Key benefits include excellent and dosing systems require rapid and Features include: fire-resistance, minimal foaming, high system-specific support from compe- • A new die casting blog viscosity index and extended pump life tent service partners. • A totally reorganized Die in systems operating under high pres- “At StrikoWestofen, service does not sure or in overloaded hydraulic systems. stop after the planning and delivery of Cast Design Center (DC2) with new content Please visit www.gwsmithandsons. the systems,” explains Holger Stephan, com for more information. manager of the Service and Spare Parts • Links to multiple CWM department at StrikoWestofen. “Even social media sites our process-reliable melting and dosing • FAQ pages with eight different Don’t See Your Company’s systems are subject to wear. In case of categories of die casting information Products in DCE? need, a rapid system-specific reaction is important as every minute literally costs • Rep locater with interactive map All NADCA Corporate Members money. Te new range of services we Chicago White Metal has further are allowed one complimentary offer via our mobile website increases plans to add new content including listing per issue and NADCA the system availability in particular.” videos, case studies, webinar record- Individual Members may submit one StrikoWestofen is now offering a ings and other reference material to free listing per year. For all others, mobile website which is available at: engage visitors on an ongoing basis. there is a small fee. Don’t delay, www.strikowestofen.com/mobile. Te site’s integration with social submit today! Visit www.diecasting. Tis service allows targeted counsel- media provides additional options org/dce/products to learn how to ling, thus increasing the availability for the engineering community to put your company’s new products, of the melting and dosing systems. access information. services and solutions in print. 

Industry News

SHILOH INDUSTRIES, INC. ANNOUNCES STRATEGIC PARTNERSHIP WITH VELOCYS

Valley City, OH - Shiloh Industries, Inc. has entered into a strategic manufacturing agreement with Velocys, to be the preferred fabricator of microchannel cores and future products being explored. Te cores are an integral component of Velocys’ modular reactors that enable small scale distributed gas-to-liquid systems that convert unconven- tional, remote and problem gas into valuable liquid fuels. “Shiloh will be utilizing our advanced laser welding technology to manufacture the cores for Velocys,” said Ramzi Hermiz, president and CEO of Shiloh. “As a preferred supplier, Shiloh’s engineering focus on lightweight- ing will be applied to the development and manufacturing of future products being designed by Velocys.” Te two companies have been working together since 2012 to develop and implement economic, high quality mass-manufacturing capabilities for the Velocys Fischer-ropsch (F) reactors, based on state-of-the-art manufacturing technology and quality systems from the automotive industry. ogether with Shiloh, Velocys’ supply chain can support annual F reac- tor orders suffi cient for 10,000 bpd of production, and has plans enabling expansion to 40,000 bpd in time for order growth. Velocys provides complete smaller scale GL solutions that address an untapped market of up to 25 million bar- rels of fuel a day. As the gas-oil arbitrage remains at an all- time high and as more global regulations ban the practice of �aring, Shiloh and Velocys expect to see a substantial increase in demand for distributed scale GL technolo- in the effort to provide young professionals an honorable gies. A significant opportunity exists for converting low- career. Tao shared that he is very much enjoying his apprenticeship and being a part of the Matzel team, stat- value gas into high-value, clean synthetic oil. ing that he hopes to join Matzel as a full-time employee Shiloh will be manufacturing these products out of its once he completes his apprenticeship. When asked what Innovation Drive Plant in Valley City, Ohio. he likes most about Matzel, he added “the different skills and processes I am learning on different machines”. Senator Johnson stated that he believes the foundation of our local economy is founded in our area employers SENATOR RON JOHNSON AND ALDERMAN and workforce coming together to create a stronger com- JOE DAVIS VISIT MATZEL MANUFACTURING munity. Alderman Davis echoed this message by compli- Milwaukee, W I - Wisconsin Senator Ron Johnson (Rep) menting companies like Matzel Manufacturing for their and District 2 Alderman Joe Davis (Dem) met together innovative solutions when engaging the younger work- on March 26 to tour Milwaukee based, Matzel Manufac- force. Davis went on to show favor in Senator Johnson’s turing, as they discussed cross party solutions for creating willingness to reach across party lines to share ideas and a pro-hire environment for local manufactures. One of create solutions that benefit the public interests. those solutions is to work with Wisconsin youth appren- Matzel Manufacturing co-owners, Brian Nuetzel and ticeship programs which allow young professionals to Wayne Matthiesen, were pleased to have been the site gain real world experience. Te goal is to build capacity of Senator Johnson and Alderman Davis visit. Nuetzel in the workforce by teaching emerging professionals a is especially pleased to see offi cials from the city, state, strong work ethic and drive to succeed. and federal levels actively talking about the issues most Bradley ech Senior, Anthony Tao, is an example of pressing to businesses like Matzel. “I’m happy to see our how the efforts of Matzel Manufacturing, working with elected offi cials getting to the root cause of issues that local and state offi cials, are making a positive difference affect each and every one of us”, said Matthiesen. INDUSTRY NEWS

RIMROCK EARNS PRESTIGIOUS ROBOTIC INDUSTRIES class to be held at the B&L office in Bridgman, Michi- ASSOCIATION DESIGNATION gan. Te new training class will be called “Odyssey Boot Camp” and will focus on providing both a high-level Columbus, OH - Rimrock Corporation has received the overview of the Odyssey ERP software’s holistic system Robotic Industries Association (RIA) Certified Robot and an interactive demonstration of the software’s use. Integrator designation. Te certification process included Additionally, class trainers will answer any company a review of Rimrock’s robotic integration business prac- specific questions attendees may have. tices and individual employee hands-on skill level testing Craft noted, “Tis is a hands-on, kick-starter class focused in robot operation and programming. Seven employees on key Odyssey modules to get new staff off to a productive were tested and passed with a level of “Expert” and start. Te overview of Odyssey business processes will also “echnician” based on the number of robots installed. be beneficial for those Odyssey software users who may not “We are delighted to welcome Rimrock Corporation be familiar with the complete ERP package.” as our seventeenth Certified Robot Integrator,” said Jeff Te Odyssey Boot Camp will be held on May 15 -16 2014. Burnstein, President of RIA. “Te Certified Robot Inte- Tere is also a stand-alone Crystal Reports class May 13 -14 grator program strengthens the overall integrator channel at B&L’s Bridgman office. Advanced registration for either and allows integrators to benchmark their own pro- class is required as space is limited. More information may be cesses against best industry practices. Based on industry found at B&L’s website www.blinfo.com/BootCamp. feedback, we have found that achieving certification has proven to be valuable for integrators looking to showcase their capabilities to both users and suppliers.” “Rimrock has been integrating robots for over 25 years, with FLOW SCIENCE ANNOUN CES ITS 2014 FLOW�3D hundreds of successful installations into harsh casting and forg- AMERICAS USERS CONFERENCE ing environments. Tis experience, coupled with RIA’s integrator certification, can give manufacturers great confidence in Santa Fe, NM - Flow Science, Inc. has announced that it our ability to increase their production with robot automation,” will hold its 2014 FLOW-3D Americas Users Conference said Mark Reikert, Manager – Applications Engineering and on September 9-10, 2014 in oronto, ON at the Courtyard Project Management of Rimrock Corporation. Marriott Downtown oronto. Advanced training for the For more information, please visit www.rimrockcorp.com. water & environmental industry will be held September 8. All FLOW-3D, FLOW-3D/MP, and FLOW-3D Cast users—and anyone interested in the FLOW-3D product suite—are invited to attend the conference. DME BRINGS MOLD TECHNOLOGIES EXPERTISE CLOSER Te conference will feature customer presentations and TO MOLDERS AND MOLDMAKERS IN MEXICO posters from both industry and academia that focus on validations, benchmarks and case studies, as well as the Madison Heights, MI - Molders and moldmakers in Mex- latest developments for FLOW-3D presented by Flow ico’s fast-growing plastics industry will have greater access Science’s Michael Barkhudarov, VP of R&D, and John to the advanced mold technologies expertise and support of Ditter, VP of Software Engineering. global mold technologies supplier DME, as the company For more information, contact visit: www.�ow3d.com or has established a permanent presence within Milacron’s contact Amanda Ruggles at: info@�ow3d.com. integrated High Impact echnology Center in Querétaro. “As plastics companies in Mexico take on more complex applications and challenging demands, they’re looking for more support than ever from their suppliers,” said Dave WHEELABRATOR CELEBRATES ONE MILLION Lange, DME Director of Sales for the Americas. “While SAFE WORK HOURS other providers continue to use independent distribution channels, DME’s �agship Mexican facility will bring our LaGrange, GA - Wheelabrator Group reached a major engineering expertise – along with the widest selection safety milestone during the first quarter of 2014 with of quality mold technologies - bases, plates, components, 1,000,000 work hours (nearly four years of operation) hot runners, temperature controllers, and much more – without a lost time incident. directly to our customers.” Over 200 Wheelabrator employees and guests marked this special event during a safety luncheon at their LaGrange facility on March 13, 2014. On March 13, 2014 an American Flag �ew over the Wash- B&L INFORMATION SYSTEMS ANNOUNCES ington D.C. Capitol in recognition of the 1,000,000 work ODYSSEY BOOT CAMP hours for Wheelabrator. Tis �ag was then sent to Wheela- brator with a certificate in recognition for the 1,000,000 work Bridgman, MI - As part of B&L Information Systems’ hours without a lost time incident. Te �ag will be displayed re-envisioned training initiative, Kristine Craft, Manager in the Wheelabrator customer lobby in LaGrange, GA. – Professional Services, has announced a new two-day  People in Die Casting

Godfrey & Wing tion. Godfrey & Wing experienced ees through personal development, Announces Multiple record growth in 2013, and these providing a quality product through Promotions three leaders will help the company improved manufacturing processes continue its strategic growth into and continuous improvements of 2014 and beyond. products through strategic research As General Manager, Service and development. Sim has over 10 years of experi- Nick Chapman Operations, Chapman is responsible for leading and managing ence in the aluminum and magne- Godfrey & Wing daily operations in all the service sium die casting industry and has worked for Godfrey & Wing for is pleased to facilities of the Company. His seven years, where he was previ- announce the focus will be on optimizing the service operations and establishing ously the Quality Manager at the promotion of Nick Aurora, Ohio facility. Chapman to Gen- a stable, viable supply base for the manufacturing industry. As Director of Business Develop- eral Manager of Chapman has over 25 years of ment, Boaz is responsible for leading Service Operations, Han Sim experience within the manufactur- and managing the sales and market- the promotion of ing industry in Canada, Mexico and ing team to execute strategic initia- Han Sim to Gen- the U.S.A. He spent the last three tives. He will focus on developing eral Manager of years as Site Operations Manager for strategies to grow the business in the Sealant Divi- Godfrey & Wing at both the oledo, existing markets and expand Godfrey sion and the hiring Ohio impregnation and Deﬁance, & Wing’s reach into parts of Asia. of Zach Boaz as Ohio X-ray service centers. Boaz has more than 10 years of Director of Busi- As General Manager, Sealant experience in the automotive and ness Development. Zach Boaz Division, Sim’s mission is to under- aerospace industries in roles rang- Chapman, Sim and Boaz will stand and satisfy customers’ vacuum ing from Program Manager to Sales play instrumental roles in man- impregnation sealant needs while Director. Most recently, Boaz led aging teams focused on innova- providing excellent customer service. the sales and marketing team for a tion and excellence, and ensuring His focus will be on enhancing the key international capital equipment customer involvement and satisfac- safety and security of his employ- supplier in the tire industry.

NADCA’s Melisa (CIC). Tis distinguished credential, for this designation continues to Ryzner Becomes recognized throughout the meetings, increase as both employers and Certi�ed Meeting conventions, and exhibitions indus- meeting professionals recognize the Planner try, demonstrates an individual’s high standards of knowledge and comprehensive knowledge of meet- professionalism it embodies. Since ing management as well as a com- its inception, the CMP designation mitment to the profession. has been earned by more than 14,000 Established in 1985, the mission of individuals in 51 countries and ter- Te North American Die Casting the CMP program is to elevate and ritories worldwide. Association’s Education and Meet- enhance the professionalism of the NADCA is very proud of Melisa’s ings Manager, Melisa Ryzner, has meetings, conventions, exhibitions accomplishment and congratulates been offi cially named a Certified and events industry and the dedi- her on her new title of Certified Meeting Professional (CMP) by cated individuals who are responsible Meeting Planner. the Convention Industry Council for meeting management. Demand PEOPLE IN DIE CASTING

NADCA Remembers

John Matthew Biel earned his Bachelor’s degree from Robertsdale Chamber of Commerce 1937 - 2014 St. Joseph’s College in Rensselaer, for an unprecedented 5 terms. Indiana. He was a Staﬀ Sergeant After his 35 year career in the Die in the U.S. Army, and was a very Cast Industry, Biel retired with his active member of St. John the Baptist wife in Harvest, AL in 2007. Jack Catholic Parish in Whiting. is survived by his wife of 47 years, He was a lifetime member of the Lucy Einhorn Biel, his children, his Knights of Columbus. Biel was a two sisters, his eight grandchildren, John “Jack” Matthew Biel, 77, of Distinguished Life Member of the many nieces, nephews, and a host of Harvest, Alabama passed away Sat- North American Die Casting Asso- family and friends. urday, February 15, 2014 peacefully ciation (NADCA) where he served In lieu of �owers, the family sug- at his residence. Formerly of Whit- on multiple committees including gests donations be made in memory ing, Indiana, Mr. Biel graduated the Board of Governors, with one of Jack Biel to St. Jude Children’s from St. John the Baptist Catholic term as President (1982-1984). He Research Hospital or Wounded School, Whiting High School, and also was president of the Whiting- Warriors Program. 

NADCA eBooks

With the continued growth of eReaders such as the iPad, Kindle and Nook, NADCA is continuing the process of making various publications available on these devices. The following NADCA publications are available for purchase on Amazon and iTunes for $9.99 each.

• Extending Die Life: Maintenance • Evaluation of Surface Finishes on • Porosity in Die Castings: An & Welding Strategies Aluminum Die Castings Overview and Analysis

• Porosity Management: Advanced Analysis • Die Casting Shipment Report 2011 • Energy Saving Manual

• Die Casting Defects - Troubleshooting Guide • Safe & Reliable Die Clamping • High Integrity Die Castings

• Die Casting Defects - Causes and Solutions • Die Casting Porosity Guidebook • Master Die Casting Process Modeling

Available on the ADVERTISERS INDEX WWW.DIECASTING.ORG/DCE/MEDIAKIT CLASSIFIEDS Brach Machine Inc. brachmachine.com 31 Classi�ed advertisements are accepted for publication in DIE CASING ENGINEER for sale of equipment and notice of services and employment BuhlerPrince Inc. buhlerprince.com OBC available or wanted. Te net rate is $60 per inch or fraction thereof (for NADCA members, individual Chem-Trend chemtrend.com 15 and corporate) and $70 per inch for all others, 1 in the 2 /8 in. wide column, payable with order. Please make remittance payable toDIE CASING Dalton Electric Heating Co., Inc. daltonelectric.com 58 ENGINEER , and send with copy to: NADCA, 3250 N. Arlington Heights Rd., Ste. 101, Arling- Godfrey & Wing Inc. godfreywing.com 5 ton Heights, IL 60004. Contact Athena Catlett at 847.808.3153 or email [email protected]. LK Machinery, Inc. lkadvantage.com 27

HELP WANTED M&I Machine shotendtooling.com 29

MAGMA Foundry Technologies magmasoft.com IFC

NADCA WANED – Salesperson for used 2014 Awards Nominations 13 die casting machines and equipment. 2014 Casting Competition IBC Beta Die Casting Equipment 2014 Die Casting Congress & Tabletop 32 Phone: 416.707.0326 Advertise in DCE 35 Government Aﬀairs Conference 11 HELP WANTED Laine Scholarship 47 Production Castings is seeking a Zinc Die NADCA eBooks 63 Cast Manager who is well organized and has NADCA Marketplace 19 extensive current knowledge in the zinc die casting – injection molding ﬁeld, including NADCA Techinical Archives 23 secondary related operations. Te candidate NADCA Webinar Schedule 7 should have a minimum of 3-5 years experience managing all of the duties and aspects of a zinc Onsite Machining Inc. onsitemachine.com 17 die cast department, such as establishing and monitoring production processes and evaluating them to reduce waste, excessive handling and Rocklin Manufacturing Co. rocklinmanufacturingco.com 37 to “Lean Out” current processes. Also assist in the design of new tooling and equipment and recommend improvements to our existing HELP WANTED CONSULTING SERVICES tooling to increase productivity. NEED HELP? We are a zinc and aluminum die cast Sales Rep Wanted! oshiba Machine Co., raining of all personnel, operator to engi- company which has been in business since America – Die Ca sting is currently look ing neer; casting, tooling and process design, 1976. For general information about our for a sales representative to handle our ever development and procurement. Simulation company and it’s capabilities you may go growing territory. oshiba Machine has of metal and heat flow. to our website, productioncastings.com. been manufacturing die casting machines since 1953. With over 13,00 0 installed Resumes may be mailed or sent by email to around the world and more than 500 in [DC]2 Die Casting Design & Consulting [email protected], please North America. Our machines range in Henry Bakemeyer and Associates include salary requirements when applying. size from 150-4500 US ons. We are an Equal Opportunity Employer 924 Currie Place, Milwaukee, Wi. 53213 and participate in E-Verify. Send your resume to: Ph. 414.259.8982 [email protected]. Production Castings, Inc Email: [email protected] 1410 West Lark Industrial Park Fenton, MO 63026 CONSULTING SERVICES FOR SALE Multi-slide to 1,200 ton zinc hot chamber, cold chamber to 4,000 ton. Process, tooling SERVICES WANTED and machine training, process optimization and scrap reduction projects Project and Midwest precision machining company program management Infrastructure is looking to partner with or purchase a review and optimization high pressure aluminum die caster. Bob McClintic, Die Casting Consultant Used Die Casting Equipment For Sale Up to 1800 ton, $7-25M revenue 2544 Almar St. and EBIDA > $500K. Jenison, MI 49428 See the latest additions to our huge Cell: 616.292.0454 inventory at www.betadiecasting.com Contact Steve Mayer at Fax: 616.669.7884 [email protected] – 414.225.0484 ��:4 E-mail: [email protected] el: 519.621.0799 www.promontorypointcapital.com Web: ww w.DrDieCast.com Email: [email protected] 2014 INTERNATIONAL DIE CASTING DESIGN C OMPETITION

www.diecasting.org/castings/competition

Aluminum Under 1 lb. Aluminum Over 10 lb. Magnesium Over 2 lb.

Strip Cut Stripper Housing – Upper Dual / Lower Dual Light Engine Enclosure

Zinc, Any Size with Decorative Finish Aluminum 1 to 10 lb. Magnesium Under 2 lb.

Base Cabinet Door Clutch Retainer Annulus Ultrasound System Electronics Enclosure & Power Supply Shield

Aluminum Over 10 lb. - Squeeze Casting Aluminum Over 10 lb. - Structural Casting Zinc Over 6 oz. Non-Electroplated

Clutch Housing B Pillars (Left and Right) Top Cast, RH Univ. Gear OCL