Metalcasting Industry Research
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vibrant, healthy and continually advancing metalcasting industry. AFS participates in these projects by securing industry partners and providing technical management and oversight. AFS is currently active in two metalcasting research funding partnerships.
American Metalcasting Consortium/Defense Logistics Agency Funded Projects AFS is a partner in the American Metalcasting Consortium (AMC.) AMC is funded through the U.S. Department of Defense (DOD), Defense Logistics Agency (DLA). The American Metalcasting Consortium provides direct support to the DLA through new technology, improved processes, and technical expertise in the procurement of metal castings to ensure warfighter readiness. AFS is managing two projects under the current AMC program, Innovative Casting Technology.
Casting Alloy Data Search (CADS) AFS through AMC/DLA has developed a very effective web-based tool called Casting Alloy Data Search (CADS) for design engineers and ICME professionals, which has been used for over 5 years by the foundry industry and is accessible through their website. CADS needs to further expand to accommodate more ICME relevant data generation for optimization and more accurate predictions of thermo-physical and thermomechanical properties for materials beyond casting alloys, for example, molding media. The goal of this research project is to enhance the current CADS and create an additional module of CADS for the nonmetallics, such as molding and core materials, and populate it by generating and validating data useful to ICME professionals. CADS is developed in partnership with Product Development & Analysis (PDA).
Integration of ICME Tools in Casting Design and Process Optimization for Intelligent Manufacturing The project will develop an effective and integrated ICME framework as an approach to make more efficient casting designs and improved manufacturing approaches. Current physics-based simulation tools are limited to simulate for a few, finite known process variables, but do not account for many more, including dimensional, compositional and section thickness variability inherent to the metalcasting process. A comprehensive approach of physics-based simulation with probabilistic metamodeling using historic data is unique and will allow for rapid and more accurate predictions.
Advanced Casting Research Center (ACRC)—RELOCATES TO UCI August 19, 2020 The Advanced Casting Research Center (ACRC) has moved to the University of California, Irvine (UCI) from its 30-year home base at Worcester Polytechnic Institute (WPI) in Worcester, Massachusetts. A research arm for the metalcasting industry, ACRC complements the work of AFS by (1) educating and reproducing new leaders and (2) acting as a source of knowledge creation to benefit the
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entire industry. UCI is investing $2 million to renovate space for a new state-of-the-art metal processing facility and an additional $2 million for equipment including a modern foundry (ferrous and nonferrous), vacuum arc melting, atomization unit, a complete Buehler Center for metallog
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