ATI Corporate Headquarters

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ATI Metalcasting Energy Savings RD
ProgramsThornton WhiteATI Metalcastings Program
ManagerOctober 16, 2006

• ATI Corporate Headquarters
• Trident Research Center, N. Charleston, SC

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ATI

• 18 years of experience building and managing gt 20
  National and International RD Consortia
• 501(c)3 Not-for-Profit
• Portfolio of models and processes
• Our experience helps build collaboration
  businesses to suit each customers needs
• Knowledge of typical barriers and how to
  anticipate solve each
• Ala Carte selection of sophisticated or simple
  elements
• User-led structures to keep implementers in the
  drivers seat
• Proven toolkits for building new RD
  collaborations
• Responsive, rapid and flexible contracting of RD
  portfolios
• Government approved accounting systems with
  flawless audit record
• One-stop full service shopping (legal, PR, etc.)
• Reliable protection of members IP and
  proprietary data
• Diversified business base across many industries
  and federal agencies

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Program Overview

• Mission of DOE Industrial Technologies Program
• Develop technologies to improve energy
  efficiency
• Industrial partnerships, technology transfer,
  education

E-SMARRT - Seeking maximum energy savings in -
Mold / Core Processes - Melting Processes - Alloy
Families - Finishing Processes
CMC DOE / Industry Associations partnership to
assure effective RD technology transfer
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Uniqueness of E-SMARRT Project

• A large award of over 11 million (typical range
  is 0.5 to 3 million), matching cost share
  of over 50
• Bundle of 29 independent projects, many energy
  saving avenues - 26 under way
• RD work to be performed by 13 organizations,
  mostly universities with strong metal casting
  programs and two national laboratories
• Strong participation of metalcasting industry
• Guidance from American Foundry Society, North
  American Die Casting Association and Steel
  Founders Society of America
• Over 90 companies providing plant facilities,
  materials, testing and training as cost share

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Roles and Responsibilities

• ATI Contract Prime
• Project Management
• Financial and Technical reporting to DOE
• DOE/ITP Sponsor and Monitor
• Approve SOW and budget, Provide funds and
  guidance, Monitor progress
• Industry Associations (AFS, NADCA, SFSA)
• Coordination with industry (needs, technology
  transfer, cost share)
• RD Performing Organizations
• Perform work per plan to achieve DOE/Industry
  objectives, prepare and submit reports in time
• Industry Partners Evaluators and Users
• Provide facilities, materials and services to
  develop and test commercialization potential

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Project Organization Chart
AFS, NADCA SFSA
DOE

ATI
RD Companies
National Laboratories
Universities
Metal Casting Companies
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13 Foremost MetalcastingRD Organizations
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93 E-SMARRT IndustryCost Share Partners
Detail Upper Midwest
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Energy Content U.S. Industry
Source DoE BCS
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Energy Content Casting Industry
Source GM Powertrain
Source DoE BCS
Energy Savings Casting Applications
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COMPARATIVE BTUsMetalcasting Process vs-
Metalcasting Application
Castings Impact on Energy Savings
Growing share of lightweight castings in
automotive platforms
2003 (e1) Process Energy Consumption 0.31 Quad
(1015 BTUs)
2003 (e2) Gasoline BTUs Saved 0.63 Quad (1015
BTUs)
1 Based on 1997 DoE data revised for estimated
process energy savings 2 From Lightweight
Castings Improving Fuel Economy in 2003 BCS/US
Dept of Energy
Source DoE BCS
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RD Areas

• Improve Melt Efficiency
• Innovative Casting Processes for Yield
  Improvement / Revert Reduction
• Instrumentation and Control Improvement
• Material Properties for Casting or Tooling Design
  Improvement

AN INTEGRATED RD PORTFOLIO
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Improved Melt Efficiency

• Improvements in Efficiency of Melting for Die
  Casting
• Increasing the energy efficiency of aluminum
  melting and handling in die casting operations
• Melting Efficiency Improvement
• Develop new melting technologies and processes to
  improve the energy efficiency of melting in steel
  foundry operations

Example Evaluating energy efficient die casting
equipment
Example Evaluating thermal properties of newly
developed ceramics for steel ladle linings
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Innovative Casting Processes for Yield
Improvement / Revert Reduction

• Design Support for Tooling Optimization
• Developing optimization thermal management
  techniques to aid in the die cooling system
  design

Minimizing Tooling Deflection
Improve Gating to Improve Fill
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Innovative Casting Processes for Yield
Improvement / Revert Reduction

• Manufacturing Advanced Engineered Components
  Using Lost Foam Casting Technology
• Advance the Lost Foam Casting technologies to
  improve production efficiency and mechanical
  properties

Cast aluminum engine blocks and heads made
without cores Lighter Cooler
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Innovative Casting Processes for Yield
Improvement / Revert Reduction

• Simulation of Distortion and Residual Stress
  Development During Heat Treatment of Steel
  Castings
• Develop a model for predicting the distortions
  and residual stresses that develop during heat
  treatment of steel castings

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Instrumentation and Control Improvement

• Energy Efficiency Instrumentation
• Improve the manufacturing system at metalcasting
  plants through better instrumentation and process
  control to reduce energy consumption and waste

Time-temperature profiles to examine the
variability in soak times after ramp completion
for various section sizes in a load.
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Material Properties for Casting or Tooling
Design Improvement

• The Development of Surface Engineered Coating
  Systems for Aluminum Pressure Die Casting Dies
  Towards a Smart Die Coating
• Development of a range of engineered coating
  systems that will substantially extend the life
  and performance of dies used in aluminum pressure
  die-casting

500 oC
800 oC
1000 oC
1150 oC
ESEM microphotographs of CrAlN (22 Al) film
annealed at different temperatures
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Material Properties for Casting or Tooling
Design Improvement

• Development of Elevated Temperature Aluminum MMC
  Alloy and Process Technology
• Develop a production capable cast aluminum Metal
  Matrix Composite (MMC) alloy with a high
  operating temperature capability

Photomicrograph of MMC produced from alloy 13 and
7 micron diameter alumina