Light Metals Market Overview/

Vehicle Light-Weighting Session

ARPA-E Metals Meeting

Detroit, MI - August 24-25, 2016

Steve Udvardy

NADCA

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Introduction

• What is NADCA?– Voice of the die casting industry and is committed to

promoting industry awareness, domestic growth in the

global marketplace and member exposure

– 7 full-time and 2 part-time people

• Profile

– Over 2,200 Individual & 235 Corporate Members

– Die casting employs 56,000

– Average sales of $165K per employee

NADCA Activities

• Research & Technology Development

• Industry Marketing

• Meetings & Exposition

• Education

• Design Assistance & Standards

• Government Affairs

• Chapter Relations

• Technology Transfer

Information Dissemination-Communications-Networking

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End Market Use of Die Castings

• Automotive applications still drive the die casting market

• Home construction is an indicator as to where most of the

remaining markets are heading.

68% Automotive 32% Housing and Other

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Automotive Castings Driving Foundry Growth

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HPDC Growing, Other Methods Stagnant

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Longer Term Auto to Slow Rate of Growth

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7063.7

75.3 78.3

88.697.6

112

0

20

40

60

80

100

120

2007 2009 2011 2012 2014 2016 2025

World Motor Vehicle Production (million)

40% Growth in Automobile Production Worldwide

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Aluminum Content in Automotive

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Aluminum Content in Automotive

Source: Ducker Worldwide

/ CRU

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Die Castings in Vehicles Worldwide and

the U.S. Total Die Castings (2007-2025)

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Suspension arm in Magsimal®-59 in F temper in the Porsche

Cayenne, Audi Q7, VW Touareg

A Shift in U.S. HPDC is NecessaryStructural Die Castings

UTS: 194.31 Mpa

YS: 129.46 Mpa

%E: 14.12%

Actual Values

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Steel parts (10 parts) Aluminum – die casting (1 part) Integration of chassis components

Cadillac CTS RH/LH

Front Shock Towers

Aluminum design: 4.1 kg

Steel design: 10.4 kg

BMW X5/X6 RH/LH

Front Shock Towers

Aluminum design: 3.2 kg

Steel design: 8.2 kg

Tesla Model S RH/LH

Rear Shock Towers

Aluminum design: 2.7 kg

Steel design: 6.8 kg

Single Unitized Shock Towers

Jaguar

Structural Die Castings

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Door & window frames

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Structural Die Castings

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What We Need

• Low embedded energy low cost feed stock

• Flexibility in offering multiple alloys

• High strength high ductility alloys

• Thinner wall capability

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Where We’re At

• Low iron modifications for Al alloys

• On-demand melting

• Heat treatment of HPDC

• Modeling of flow distance

• Process definition for thin wall casting

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On-Demand Melting

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Heat Treatment

T5 Mechanical Properties

0.29% Mg

Cast Bars

Best T5:

4 Hrs at

355F/180C

Elong

UTS

Quality Index

0.2% YS

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T6* Mechanical Properties of Cast Bars

• Low-iron conventional die castings can provide an outstanding combination of strength and ductility

• Better than all Al-Si based sand castings

• Equivalent to best Al-Si based permanent mold castings

*-Short term salt bath solution treatment

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Alloy UTS (ksi) YS (ksi) % Elong.

A380 Standard 47.0 23.0 3.5

F380-T6 61.0 49.0 2.9

B360-T6 53.0 41.0 5.8

Heat Treatment

DOD/DLA Thin Wall Al Project

• Previous version developed by Lindsey-Wallace assumed the

desired temperature at end of fill is liquidus temperature

• However, metal can still flow below the liquidus temperature

(ie. semi-solid casting)

Tgate = Tliquidus

Gate Spd = 1600

in/s

10 lb casting

1

s

g

m f

VA

v t

New Gating/Fill Time Equation

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Solution

where

, , ,s s

p p g p g

f gate s m gate s f gate s

c c A c Amx g T f v g T f t g T f

h P h P h P

&

ln

, 0 1,

ln,

1

liquidus die s liquidus solidus

gate die liquidus gate

sliquidus die s liquidus solidusf

gate s liquidus diep liquidus solidus

f

p liquid

T T f T T

T T T T

fT T f T TLg T f T Tc T T

L

c T

ln ,

1

solidus gate liquidus

liquidus die s liquidus solidus

liquidus gate

sgate dieus solidusliquidus solidus

T T TT T f T T

T TfT TT

T T

DOD/DLA Thin Wall Al Project

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Project kickoff on July 30, 2015 (2-year project)

Selected a baseline alloy (A380), a new die casting alloy (Alcoa EZCast), and LIFT380

Preparing for casting of specimens at OSU

Project kickoff meeting at LIFT

NADCA design for thin-wall Zn die casting

(to be resigned for Al in this project)

Alcoa specialty alloy for structural components

(to be evaluated and validated in this project)

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LIFT Thin Wall High Vac Al Project

Summary

• NADCA has efforts focused on energy efficiency

and light-weighting

• NADCA assists with the development and

implementation of new technologies

• Member companies participate by conducting in-

plant trials on production equipment

• Cost points for new technologies to be adopted

by small business die casters <$100,000

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