Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating

Technical Report · Tue Jul 31 00:00:00 EDT 2012

DOI:https://doi.org/10.2172/1050628· OSTI ID:1050628

Moore, John J

The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).

• Research Organization: Advanced Technology Institute
• Sponsoring Organization: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Technology Development (EE-20)
• DOE Contract Number: FC36-04GO14230
• OSTI ID: 1050628
• Report Number(s): NA; TRN: US201218%%1050
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
36 MATERIALS SCIENCE
ALUMINIUM
CARBON
CASTING
COATINGS
DESIGN
LUBRICANTS
MAINTENANCE
MANUFACTURING
MARKET
MELTING
METRICS
PROCESSING
PRODUCTION
RESEARCH PROGRAMS
SCRAP
THERMAL FATIGUE
TOLERANCE
WASTES
WEAR RESISTANCE
Die Casting
Coatings
Aluminum Die Casting
Permanent Mold Casting: Die Life Extension