The majority of metal casters are small businesses. They are not positioned to perform the research necessary to remain competitive. Collaborative research partnerships, which bring together industry, universities, and government, are proving vital to conducting the research needed to raise the technology of metalcasting products and processes.

Metal casting is one of the most energy-intensive industries. Approximately 55% of energy costs are consumed in melting. Mold making, core making, heat treatment and post-cast operations also use significant energy. Research to improve these operations and reduce melting requirements will help the industry save energy and improve competitiveness.

Metal castings play a critical role in all sectors of the economy. Yet, many of us are not aware of castings, the benefits they provide over alternative-manufactured components, and their role in everyday life. Further, some manufacturers, management and technical professionals do not understand the difference that metal castings can make in their product compared to components made by other techniques. The result is missed market opportunities for metal casters. Many government decision makers and the public at large are not familiar with the casting industry and not aware of its importance to a healthy and vibrant economy.

To remain profitable, maintain a viable number of producers, and expand into new markets, the industry is increasing awareness on the part of manufacturers and the public regarding the value of engineered cast components.

Improving design capabilities in metal casting is critical to the industry's ability to produce cast products that will be competitive in world markets. Improved design capabilities can enable metal casters to manufacture parts not currently possible with current design constraints, opening new markets for metal casters. Maintaining existing markets and opening new markets is critical to the financial viability of metal casting companies. Improvements in casting design will reduce testing and tryout on the shop floor and replace it with computer-based design and analysis.

This will significantly reduce energy and environmental impacts. Improved design capabilities will also reduce defects, post casting operations, and rejected castings - also saving energy and reducing environmental emissions. The casting industry already uses a number of strong design tools and employs basic design principles. However, design capabilities are not at the level necessary to remain competitive over the long term. The principles of casting design are still not well known and there is a lack of published data on tolerances as well as validated, widely available data on material properties and performance.



The industry is trying to develop additional data and tools, which are needed to improve casting design methods. This includes alloy properties and performance data as well as the accurate simulation of casting performance based on alloy properties, stress levels, and solidification integrity. These improvements can increase the value of metal components, reduce component weight, reduce manufacturing lead-times, and assure product performance. They will assist manufacturers to build better products with less cost and less energy.