SSM/Squeeze Casting | 2013 Safety Awards | MAY 2014

ALSO INSIDE:
2013 SAFETY AWARDS
SEMI-SOLID METAL
CASTING TO MEET
CAFE STANDARDS
(CORPORATE AVERAGE FUEL ECONOMY)
NORTH AMERICAN DIE CASTINGASSOCIATION
NADCA

and the NADCA logo above

are both registered trademarks of the
North American Die Casting Association.
VOLUME 58 NUMBER 3
MAY 2014
PUBLISHER
Daniel L. Twarog
EDITOR
Andrew Ryzner
ADVERTISING & PROMOTIONS MANAGER
Athena Catlett
GRAPHIC DESIGNER
Kristen Castillo
EDUCATION & MEETINGS MANAGER
Melisa Ryzner, CMP
EXECUTIVE OFFICES
3250 N. Arlington Heights Rd., Ste. 101
Arlington Heights, Illinois 60004
Phone: 847.279.0001
Fax: 847.279.0002
Email: dce@diecasting.org
Web site: www.diecasting.org/dce
FEATURES
16 Introducing an Improved Process for Semi-Solid Metal
Casting of High Integrity Parts
A. Koch, K. Tenzek
20 Fire Incident Prevention for NADCA
R. Block
22 Energy Conservations in Die Castings Industry
Some Practical Examples
A. Pari
28 The Role of Temperature During Semi-Solid Metal Processing
Dr. F. Czerwinski
33 NADCAs David Laine Scholarship Program Awards
Record-Breaking 17 Students
D. Hutchins
38 Wage & Beneft Survey Executive Summary
40 2013 Safety Awards
41 2014 Exhibitor Spotlight
Die Casting Engineer (ISSN 012-253X) is published bimonthly, six times per year, by the North
American Die Casting Association, 3250 N. Arlington Heights Rd., Ste. 101, Arlington Heights, Illinois
60004. Periodicals postage paid at Arlington Heights, Illinois 60004 and at additional mailing
office. POSTMASTER: Send address changes to address listed above.
Non-member subscription rates: $60 one year U.S., Canada & Mexico; $135 one year other countries
(international airmail). Single copies $15 each, except for Suppliers Directory, $35 (Single issues
available in North America only).
All material copyright 2014 by the North American Die Casting Association. All rights reserved.
Nothing in this magazine may be reproduced or utilized in any form or by any means, electronic
or mechanical, including photocopying, recording or by any information storage and retrieval
system, without permission in writing from the publisher. NADCA is not responsible for any material
published in this magazine unless it has been explicitly approved by the NADCA Board of Governors.
DEPARTMENTS
02 Chairmans Note
03 Letter From the Editor
04 Washington Insights
08 NADCA Reports
10 Dr. Die Cast
12 OSHA + EPA Awareness Update
15 Ask the Experts
47 New Corporate Members
48 Corporate Member List
52 Chapter News & New Members
59 New Products, Services & Solutions
60 Industry News & Information
62 People in Die Casting
64 Classifed Advertising
64 Advertising Index
The NADCA logo was hidden here this month. Did you find it?
Eric Treiber, President & CEO
Chicago White Metal Casting Inc.
NADCA Chairman
Chairmans Note
Mark Your Calendars
Te 2014 Executive Conference was held in late February in Marco Island, Flor-
ida. And what a conference it was. Te overall attendance of 110+ was believed
to be the highest ever (though there was some debate that back in the 1990s, the
CEO conference attendance was even higher). Tose who did attend were treated
to a world class conference at an amazing venue. If you did not have the opportu-
nity to attend this year, please mark your calendar now for 2015 - February 22-25
at the Marco Island Marriott Beach Resort, Marco Island, FL.
Te presentations were excellent, and included topics such as: pricing trends in
aluminum, magnesium and zinc (with a spirited discussion on the status of the
LME and NASAAC aluminum); navigating the Afordable Healthcare Act as a
small business owner; political, regulatory and legal updates from Washington; and
a preliminary view of the 2014 NADCA die casting benchmarking survey. Again,
these were just a few of the informative presentations given.
I was able to talk with most of the conference attendees, including a number of
individuals for the frst time. Repeatedly, I was told that there seemed to be a buzz
about this years conference, and many indicated it was the best NADCA Executive
Conference they had attended.
Te North American die casting industry is healthier today than it has been in
quite a few years, as evidenced by a number of indicators. Te strong attendance at
this years Executive Conference is certainly an example. In addition, so far in 2014,
NADCA members are registering for various education oferings at double the rate
that was forecasted. Tis is typically a sign that business levels are growing and
management is training new associates, while also making sure that existing team
members are exposed to additional training.
So lets strike while the iron is hot. Whats next on the horizon? Te Plant Man-
agement Conference is scheduled for May 21-23 in Charlotte, NC. Included as part
of the conference will be a plant tour of Cascade Die Castings world class facility
in High Point, NC. You wont want to miss out on an opportunity to tour this TS
16949 registered facility.
Te Government Afairs Briefng will be held June 10-11. For those who attended
the Executive Conference and heard the presentation by Te Franklin Group (NAD-
CAs Washington Representatives), you know that there is much going on in Wash-
ington that warrants our attention and requires our voices to be heard on Capitol Hill.
And fnally, mark your calendar now for the Die Casting Congress & Tabletop
that will be held September 22-24 at the Wisconsin Center in Milwaukee. Not only
is this expected to be a very widely attended event due to the Midwest location, but
with the Wisconsin Center being located in the heart of downtown Milwaukee,
attendees will never be far from a cold beer and a brat!

This is typically
a sign that
business levels
are growing and
management
is training new
associates.
From the Editors Desk
Andrew Ryzner
Editor
North American Die Casting Association
NADCA Launches Its New Website
NADCA has recently launched a new, updated website at www.diecasting.org.
Several months in the making, I think that the improvements that you can see are
substantial. You will notice updated sections on the front page News & Head-
lines, Quick Links, Featured Topics, Upcoming Events, Classifeds, and updated
Advertisements and Ad sizes for those of you who advertise with us. Overall I
think it makes for a much more aesthetic experience to better match current web
standards and as you know those standards can and do change every few years. I
feel it is important to evolve with those trends.
Tis issue of DCE magazine includes NADCAs yearly Safety Awards for the year
2013. Safety in the workplace is not only important for the obvious reason of keep-
ing your employees free of harm, but it also makes your facility a more attractive
place to work. Te Safety Awards honor NADCA Corporate Members that both
exceed and meet the average U.S. national safety standards for all of the manu-
facturing industry in a given year. Congratulations to all the companies that were
awarded the Perfect and Outstanding Safety Awards.
Finally, be ready for the next issue (July) of DCE magazine, as it includes the
Suppliers Directory, which is only printed every other year, and serves as the Show
Preview for the 2014 Die Casting Congress & Tabletop, which will take place
September 22-24, 2014. Te city for this year is another Midwestern location
Milwaukee, WI at the Wisconsin Center. Make sure to mark the date on your
calendar. I hope to see you there!

I feel it is
important to
evolve with
those trends.
NADCA Government Afairs
Three Aluminum Price-Fixing
Cases to Move Forward
A U.S. District Court Judge ruled three plaintifs groups
may move forward for now with separate class-action law-
suits against Goldman Sachs Group Inc., JPMorgan Chase
& Co., their warehousing businesses and the London
Metal Exchange (LME) for fxing aluminum prices by
conspiring to reduce the supply of aluminum.
On March 6, 2014, U.S. District Judge Katherine
Forrest directed purchaser plaintifs, commercial end-
user plaintifs and consumer end-user plaintifs to fle
separate complaints seeking class-action status. Te
defendants will have the right to object to the flings.
In her order, Judge Forrest designated the law frms
that will act as co-counsel for each plaintif group and
appointed nine other law frms to a steering commit-
tee for the direct purchaser plaintifs.
It is important that U.S. manufacturers have access
to globally priced raw materials in a timely manner, said
NADCA President Daniel Twarog. Long lead times,
supply shortages, outmoded contract terms, and illogical
pricing contribute to instability in the aluminum market.
Tis drives down manufacturing productivity and encour-
ages customers to seek overseas suppliers, said Mr.
Twarog.
Judge Forrests ruling comes on the heels of a December
2013 decision by the U.S. Judicial Panel on Multidistrict
Litigation to consolidate 26 lawsuits fled nationwide over
aluminum price-fxing allegations.
Te North American Die Casting Association
(NADCA) is at the forefront of this important issue,
submitting testimony to the Senate Banking Subcom-
mittee on Financial Institutions and Consumer Protec-
tion in January and meeting with representatives of the
LME to discuss concerns last year.
House Passes Two Industry
Supported Energy Bills
Te U.S. House of Representatives passed two energy bills
supported by manufacturers and other industry groups.
H.R. 2126, the Energy Efficiency Improvement Act
of 2014, was passed by the chamber on March 5, 2014
by a vote of 375-36. The legislation directs the Envi-
ronmental Protection Agency (EPA) to establish energy
efficiency best practices for commercial tenants rent-
ing space in commercial buildings and creates a new
TENANT STAR certification program, which the bill
models on the existing ENERGY STAR certification
program. The provision establishes a voluntary, cost-
free certification and recognition program to promote
energy efficiency during design and occupancy of
leased space. The bill also directs federal agencies to
implement strategies to increase the energy efficiency
of federal data centers, remove a regulatory barrier to
manufacturing large scale water heaters, and would
establish a benchmarking and disclosure process for
energy consumed in federally leased buildings.
Te bill, introduced by Rep. David McKinley (R-WV)
and Rep. Peter Welch (D-VT), is the frst signifcant
bipartisan energy initiative approved by the House in the
113th Congress.
Te House also passed H.R. 3826, Te Electricity
Security and Afordability Act, by a vote of 229-183. Rep.
Ed Whitfeld (R-KY) developed the bill in response to
Environmental Protection Agencys new greenhouse gas
emissions standards. Te standards, as introduced by the
EPA, are unattainable with currently available technology
and would efectively ban coal for use in energy produc-
tion, afecting the cost and reliability of energy.
H.R. 3826 requires the EPA to set emissions targets
based on commercially viable technology and requires
Congress to review and set a start date for the EPAs
new standards for existing power plants, giving energy
suppliers time to make necessary compliance invest-
ments and maintain coal and natural gas as viable power
plant fuels while keeping prices low.
Te EPA introduced the new power plant standards in
September 2013 and rules for existing plants are expected
out in June 2014.
NADCA Signs Letter to
Congress on Workforce
In March, NADCA joined with other leaders from
manufacturing, education, and non-profts by sending a
letter to the U.S. House and Senate supporting work-
force develop and job training programs. In a recent
survey, 88% of NADCA members reported they cur-
NADCA GOVERNMENT AFFAIRS
rently have skilled job openings.
Many of our members face signifcant challenges
recruiting qualifed employees, said NADCA President
Daniel Twarog. Our industry is growing but we cant
expand if we cant fnd the right workers.
A study conducted by Deloitte and the Manufacturing
Institute showed there are 600,000 skilled manufactur-
ing positions open in the United States. Te challenges
coming from Washington do not only surround decreased
federal funding for job training initiatives, but also that
Congress has not updated some of these programs since
1998. NADCA is working with House and Senate leaders
on moving a bill to reauthorize the Workforce Investment
Act (WIA), which expired in 2004.
NADCA Coalition Comments
on OSHA Reporting Rule
NADCA of cially signed comments with its partners,
the Coalition for Workplace Safety (CWS), opposing a
proposal released by OSHA late in 2013. Te proposed
rule requires businesses with 20 or more employees to
fle incident/accident reports electronically on an annual
basis (those with more than 250 employees fle quarterly)
which they will make public. Te comments state that the
proposed rule does nothing to advance safety, but rather
increases regulatory burdens and removes confdentiality
of employer/employee regulatory information.
Te NADCA coalition believes that workplace safety
is everyones concern and improving safety can only
happen when all partiesemployers, employees, and
OSHAhave a strong working relationship. Without
providing the data with meaningful context, the infor-
mation is not a reliable measure of an employers safety
record or its eforts to promote a safe work environment.
OSHA is expected to fnalize the proposed rule shortly.
NLRB Revives Ambush Elections Rule
After their defeat on Capitol Hill and the courts, supporters
of the NLRB Ambush Election rule recently reissued the
proposal. Trough the Coalition for a Democratic Work-
place, NADCA supported of cial comments opposing the
rule which shortens the time between when a union election
NADCA GOVERNMENT AFFAIRS
is called and the vote to as little as 7-10 days.
Originally part of the Employee Free Choice Act bill
which failed on Capitol Hill, this is the second attempt
by the NLRB to implement the Ambush Election rule
after a court ruled last year it violated the law. Te
NLRB is expected to fnalize the rule in the coming
months; however, numerous court challenges are again
expected by its opponents.
Climate Change Champion to Chair
Senate Clean Air Subcommittee
After Sen. Max Baucus (D-MT) resigned his seat to
become the U.S. Ambassador to China, a game of musical
chairs began throughout the Senate. His departure created
a vacancy at the powerful Senate Finance Committee as
well as afecting the Senate Environment and Public Works
Committee, which has overseas the EPA and other impor-
tant regulatory agencies. Taking over the Clean Air and
Nuclear Energy Subcommittee is Sen. Sheldon Whitehouse
(D-RI) while Freshman Sen. Cory Booker (D-NJ) will
chair the Oversight Subcommittee.
Te shuf e will have a signifcant impact on regula-
tions and actions under the Clean Air Act, including the
National Ambient Air Quality Standards (NAAQs). Te
new Clean Air Subcommittee Chair Whitehouse led the
efort among 28 Democratic Senators in March to hold the
foor all night to discuss climate change. Te Senator is the
leading voice in the Senate for action on this issue.
New Toxic Substances Control
Act Bill; Hearing Held
The Chairman of the House Energy and Commerce
Subcommittee on Environment and the Economy,
Rep. John Shimkus (R-IL), released a draft proposal
to update the Toxic Substances Controls Act (TSCA).
The bill, the Chemicals in Commerce Act (CICA),
is based on a bipartisan Senate proposal, S. 1009, the
Chemical Safety Improvement Act (CSIA), champi-
oned by the late Sen. Frank Lautenberg (D-NJ) and
Sen. David Vitter (R-LA).
Te House Subcommittee has held roughly a half
dozen hearings on TSCA. Te law provides the EPA
with the authority to require reporting, record-keeping
and testing requirements, and restrictions relating to
chemical substances and/or mixtures. While TSCA
excludes certain substances such as food, drugs, cosmet-
ics and pesticides; hundreds of items used in manufac-
turing are covered including polychlorinated biphenyls
(PCBs), asbestos, radon and lead-based paint. Tere is
considerable pressure on policymakers to update TSCA;
with some sides calling for the inclusion of more chemi-
cals on the controlled list, while others seeking are a
more updated approach.
U.S. House Passes Environmental
Regulatory Reform Bill
Te U.S. House passed a bill supported by manufacturers
to reform the environmental regulatory process and help
speed up permits for businesses seeking to create jobs and
expand. Te Responsibly and Professionally Invigorating
Development Act (RAPID) seeks to expedite the per-
mitting process by requiring the lead agency to provide a
schedule with deadlines, which all participating agencies
must also adhere to in their review process. If an agency
does not comply, the permit is deemed approved.
Te bill targets delays at the local level generated as a
result of compliance with federal laws and requirements
such as completion of an Environmental Impact Statement
(EIS) or Environmental Assessment under the National
Environmental Policy Act (NEPA). Te bill places time
limits on these various actions to streamline the process.
Senate Report Focuses on EPAs
Use of Secret Science
Republicans on the Senate Environment and Public
Works Committee released a report in March titled,
EPAs Playbook Unveiled: A Story of Fraud, Deceit,
and Secret Science. Te report spends considerable
time on an employees manipulation during EPAs deci-
sion process in 1997 to establish National Ambient Air
Quality Standards (NAAQs) for fne Particulate Matter
(PM2.5) and ozone. Regulators and lawmakers have
based virtually all of their Clean Air Act and air quality
proposals since 1997 on the NAAQs data.
Te report found that the EPA rushed the NAAQs
review process, relied on data deemed too week even by
their own standards, and exaggerated the health bene-
fts of the proposed regulation. Late last year, NADCA
submitted formal comments to several states in the
process of recommending which areas within their
boundaries the EPA should designate as not attaining
new air quality standards being developed. If states do
not meet the new standards by 2020, non-attainment
areas will face similar restrictions on manufacturing
and economic activity as are in place today.

Webinar
Schedule
di ti / bi
NORTH AMERICAN DIE CASTING ASSOCIATION
Date Webinar Time Host
5/2/14
Die Design and Process Control
Part 8 - Thermal Design Example 2
1pm CDT Scott Kirkman
5/6/14
Operator Training
Part 9 - Recognizing and Controlling Flow Defects
2pm CDT Jef Brennan
5/7/14
SMED Series
Part 3 - SMED Analyzing and Improving
12pm CDT Alex Monroe
5/7/14
Operator Training
Part 10 - Recognizing and Controlling Porosity
2pm CDT Jef Brennan
5/13/14
Operator Training
Part 11 - Eliminating Solder and Flash Defects
2pm CDT Jef Brennan
5/14/14
Porosity Management
Part 1- Understanding Porosity
12pm CDT Ed Herman
5/16/14
Die Design and Process Control
Part 9 - Thermal Control
1pm CDT Scott Kirkman
5/21/14
Porosity Management
Part 2 - Die Design
12pm CDT Ed Herman
5/28/14
Porosity Management
Part 3 - Casting Design
12pm CDT Ed Herman
6/4/14
Porosity Management
Part 4 - Process Control
12pm CDT Ed Herman
6/6/14
Die Design and Process Control
Part 10 - Basic Die Casting Die - Holders and Locking
1pm CDT Scott Kirkman
6/11/14
Metallurgy of Aluminum Die Cast Alloy
Part 1 - Alloy Efects, Phase Diagrams, Microstructure
12pm CDT David Nef
6/18/14
Metallurgy of Aluminum Die Cast Alloy
Part 2 - Impurities and Melt Treatment
12pm CDT David Nef
6/20/14
Die Design and Process Control
Part 11 - Basic Die Casting Die - Inserts and Fit
1pm CDT Scott Kirkman
Attending a webinar is an excellent way to obtain information without the hassle or cost of travel! These 60 minute presentations
will not only address vital information on the topic but also provide adequate time for questions, answers, and discussion.
For a complete list of webinars, including cost and start time or to register please visit: www.diecasting.org/webinar.
NADCA NEWS
NADCA and NAM Partner to Achieve Goal
of 500,000 Industry Certifcations
Arlington Heights, IL - Te Manufacturing Institute and
its partners in the Skills Certifcation System, including
the North American Die Casting Association (NADCA),
announced signifcant progress toward achieving a fve-
year goal to award 500,000 industry-based certifcations to
individuals. Over the past year, the certifcation partners
have issued 117,189 certifcations, an increase of over 30
percent, bringing the total to 294,478 certifcations issued
since 2011. With 80 percent of manufacturers citing a
moderate to severe shortage of skilled workers, this is an
important step in closing the skills gap and increasing the
competitiveness of U.S. manufacturing.
NADCA is using our die casting educational resources
to create certifcate programs which complement the cur-
riculum developed for the Manufacturing Skills certifcation
system, said Daniel Twarog, president of the North Ameri-
can Die Casting Association. We are working with some
community colleges, and would like to work with more, in
order to integrate the die casting resources into the standard
courses on basic manufacturing skills. Any die caster inter-
ested in partnering with a local community college or trade
school should contact NADCA so we can work with that
organization to incorporate die casting in their training.
To view the rest of this press release please visit www.
diecasting.org/newsletter/2014/031914/21.htm.
Innovative Die Castings Wanted - Submit Your Entry to
the International Die Casting Design Competition
Arlington Heights, IL - To be a winner in todays economy,
you must meet and even exceed expectations. In a com-
petitive global market, customers take notice of the best.
NADCA knows that competition improves the competitor.
With its annual Die Casting Competition, it recognizes and
rewards the outstanding casting designs of the year.
Entering and winning is one of the best ways to gain
visibility with leading decision-makers. Te competition is
open to aluminum, magnesium, zinc die castings and other
alloy families. Any number of castings may be entered.
However, a separate entry form is required for each cast-
ing or assembly of castings. In addition, the metal surface
cannot be improved or concealed by tumbling, shot blast-
ing, coating or other surface treatments.
Judging is conducted by an independent panel of experts
from the die casting industry, with no ties to eligible
companies. Te four equally weighed criteria are ingenuity
of casting/product design; overall quality; cost savings; and
market-expanding potential. Winning castings will be dis-
played during the 2014 Die Casting Congress & Tabletop
in Milwaukee, WI and winners will be honored during the
Die Casting Awards Luncheon. NADCAs Die Casting
Engineer Magazine, NADCAs Website and the NADCA
Design Website will also feature the winning castings.
Tis competition helps promote increased use of die
castings by recognizing and publicizing outstanding
designs. For more information on the 2014 International
Die Casting Design Competition please visit, www.die
casting.org/castings/competition or email Daniel Twarog
at twarog@diecasting.org.
Te deadline to submit your casting is June 30, 2014.
Dont hesitate!
Correction From NADCAs March DCE Magazine
Page A9 from the March issue of
Die Casting Engineer magazine
contained a misprint of a photo-
graph of a casting award winner.
Te Aluminum Die Casting 1
to 10 Lb category had the cor-
rect credit given to Don Carter
- Shiloh Industries, for the
part - Clutch Retainer Annulus.
However, the photograph shown
was not correct. Te image on the
left is the correct photograph.
NADCA encourages comments, suggestions and/or
complaints regarding errors that warrant correction. If
you see anything you would ever like to comment on,
please contact Andrew Ryzner, Editor of DCE magazine
at ryzner@diecasting.org.
UPCOMING EVENTS
NADCA to Host 2014 Die Casting Congress & Tabletop
in Milwaukee, WI
Arlington Heights, IL - Te 2014 Die Casting Congress
& Tabletop will be held September 22-24, 2014, at the
Wisconsin Center in Milwaukee, WI. Tis event will
include three days of Congress sessions. Te Congress
session schedule for 2014 has been adjusted to create more
time for those attending sessions to also attend the show
exhibits. In addition, the Design Awards Luncheon has
been combined with the Industry Awards Luncheon to
provide a united complimentary awards event.
NADCA Reports
Te technical presentations at this years congress ses-
sions were among the best ever to accompany a Tabletop
show. Investigators demonstrated a unique understanding of
applicable scientifc principles and practical die cast issues.
In addition, all the sessions I attended were void of annoying
attempts at salesmanship. Session attendance was very good,
with few empty seats even in the late afternoon, said Andrew
D. Behler, P. E., Vice President, Blue Ridge Pressure Cast-
ings Inc. at the 2013 Die Casting Congress & Tabletop.
In addition to the Congress sessions, this tabletop show
will feature more than 70 exhibitors and the International
Die Casting Design Competition.
Te tabletop shows are a great value for exhibitors. I
received high quality leads that are industry specifc. By
exhibiting I have the opportunity not only to reach the die
casting industry but also to support the association, said
Michael Hicks, Vice President, DMS, at the 2013 Tabletop.
Te 2013 Die Casting Congress & Tabletop attracted over
780 attendees (over 334 diferent companies were represented)
and 110 companies showcased the latest technology, research
and services available to the die casting industry. NADCA
expects another fantastic turnout at the 2014 Die Casting
Congress & Tabletop held in Milwaukee, WI!
TOOLS & RESOURCES
NADCA Launches New Website with
Upgraded Features for Members
Arlington Heights, IL - NADCA has recently transi-
tioned to its newly designed website. Tis newly designed
site ofers members a sleek new look, updated content, new
advertising options and a more user-friendly registration
area for webinars and events. As with any major overhaul
there may be a few bugs to work out here and there.
Please contact webmaster@diecasting.org if you encoun-
ter an error or have any issues operating the new site.
Updated NADCA Publications Available
Via iTunes and Amazon
Arlington Heights, IL - With the continued growth of
eReaders such as the iPad, Kindle and Nook, NADCA is
continuing the process of making various publications avail-
able on these devices. NADCA has recently updated the
following publication available for purchase on Amazon and
iTunes. Tis publication can be purchased for just $9.99.
Extending Die Life: Maintenance & Welding Strategies
Previously released titles include:
Porosity Management: Advanced Analysis
Evaluation of Surface Finishes on Aluminum Die Castings
Die Casting Defects - Causes and Solutions
Die Casting Defects - Troubleshooting Guide
Porosity in Die Castings: An Overview and Analysis
Safe & Reliable Die Clamping
Die Casting Porosity Guidebook
Die Casting Shipment Report 2011
Energy Saving Manual
High Integrity Die Castings
Master Die Casting Process Modeling
As NADCA continues to convert publications we will
make sure to keep you posted on the newest developments
and availability on other devices.

Calendar of Events
May 15, 2014
Committee Meetings
Arlington Heights, IL
May 21-23, 2014
Plant Management Conference
Charlotte, NC
June 10-11, 2014
Government Afairs Briefng
Washington, D.C.
June 10, 2014
Board of Governors Meeting
Washington, D.C.
June 11, 2014
Die Materials Meeting
TBD
June 12, 2014
R&D Meeting
TBD
September 22-24, 2014
Die Casting Congress & Tabletop
Milwaukee, WI
September 23, 2014
Committee Meetings
Milwaukee, WI
September 24, 2014
Board of Governors Meeting
Milwaukee, WI
October 15, 2014
Die Materials Meeting
Arlington Heights, IL
October 16, 2014
R&D Meeting
Arlington Heights, IL
October 19-25, 2014
Italy Delegation
Sirmione, Italy
February 22-25, 2015
Executive Conference
Marco Island, FL
October 5-7, 2015
Die Casting Congress & Exposition
Indianapolis, IN
NADCA REPORTS
Whos Dr. Die Cast?
Robert P. McClintic
Die Casting Consultant
Bob McClintic & Associates
2544 Almar Street
Jenison, MI 49428-9108
rmcclintic@ameritech.net
www.drdiecast.com
616.669.2932
Dr. Die Cast
Training Our Customers?
Anyone serving the current group
of customers will experience
numerous Title Block Standards
that are a mismatch for the die
casting drawing. Te standards
will have been copied word for
word from a die casting drawing
somewhere within the customers
company. Sometimes this is due
to company mergers when two
or more companies engineering
standards are somehow morphed
together instead of doing a thor-
ough review and consolidation of
the standards. How can we as sup-
pliers address this condition? In a
phrase, by training our customers.
Experienced senior engineers that
are slightly younger than dirt
must train our emerging customer
base. Now before you start dust-
ing of your books and courses on
persuasion, you might want to ask
the customer why they chose that
procedure in the frst place.
What are some of the misconcep-
tions that would lead a designer to
copy title blocks?
1. Die castings are similar to
plastic parts and therefore have
similar dimensional capabilities.
2. All alloy casting processes
are similar.
3. All die casting products can
produce the same tolerances
regardless of the alloy.
4. Didnt ask.
5. Previous experience with
a die casting.
6. Tighter tolerances will insure I
get better quality.
7. Tolerances are free.
8. Die/tooling life is not related to
tolerances.
9. Te size of the casting has noth-
ing to do with the tolerances.
10. Te annual volumes have noth-
ing to do with development
costs.
11. Didnt have time to review the
options.
12. Didnt have the authority to
change (top down).
13. Add your own
What are some of the problems asso-
ciated with copying standards?
1. Surface f inish require-
ments are inappropriate for a
mechanical die casting prod-
uct especially die castings.
(Chrome polished surface or
Class A call out on an oth-
erwise functional casting.)
2. As-cast tolerances require fre-
quent core replacement and/or
tool repair and/or replacement
3. Die castings with dimensional
tolerances similar to plastic
injection molding. Increased
tool maintenance costs to both
the die caster and customer.
4. Aluminum die casting dimen-
sional tolerances that are the same
as zinc or magnesium increasing
the tool maintenance costs.
5. Low volume products that
involve lots of close tolerance
as-cast cores that could be
more cost efective as machined
features.
6. Non-standard, tighter tolerances
cost extra. Either in additional
tool maintenance, higher scrap,
lower productivity.
7. Accelerated tool replacement
due to lack of allowances for
normal tool heat checking.
8. X-ray standards that create
extra processing and inspection
costs with little improvement in
functionality.
9. Notes that refer to External
Customer Standards Documents
that are either obsolete or not
readily available to the supplier.
10. Material standards that are
non-standard materials (such
as specifying an extrusion or
sand cast alloy for die castings.)
11. Tread and tap sizes that are
British Standard confused
with English Standard i.e.
U.S. or S.A.E.
12. Designer needs to specify
whether the die casting draw-
ing or the 3D casting model
takes precedent.
13. CPK on non-critical features
that add costs, especially when
variable gaging is required to
validate.
14. Low draft conditions that
increase the dif culty to cast/
eject and decrease tool life.
DR. DIE CAST
15. Incorrect revision level. Fea-
tures added after the quote
that increase tooling and
castings costs.
16. Packaging or dunnage that
may be defned on the drawing
that is assumed as free.
17. Etc.
When is the appropriate time to
address the notes? It is not as one
die caster commented, After they
receive the purchase order. In the
life cycle of the design this is nearly
too late to reopen the conversa-
tion. Most designers are already
working on the next project by the
time the tooling order is placed
and are reluctant to revisit the
design. What if the design was by
an outside design source? Tey may
not even be present by the time the
tooling P.O. is placed.
Te time to address design and
tolerance concerns is sooner rather
than later. Te time to initially cri-
tique the drawing is during the quot-
ing process. For many companies,
the design still has some fexibility
during the quoting process.
What is a good reference tem-
plate when critiquing drawing
notes? In Section 8 of the 2009
E-606 NADCA Product Speci-
fcations Standards for Die Cast-
ings there is a Checklist that
outlines the cost efect of various
specifcations and tolerances. Every
sales engineer should be intimately
familiar with these pages. Be
prepared to discuss the real costs
associated with each level. Dont be
afraid to challenge the standards
with something like, Do you really
need that for your customer or the
functionality of the casting?
What about existing castings,
sometimes referred to as legacy
castings? Most customers today
are looking for ways to reduce
costs. By the time you have worn
out a die cast die you and your
staf are the resident experts on the
strengths and weaknesses of their
castings. Why not be proactive and
suggest changes that could not only
increase reliability but reduce costs?
Rather than just doing a form letter
stating that the cavities are reach-
ing the end of their life, how about
reopening the conversation on the
current operating standards? Tey
might just be grateful, and wouldnt
that be a welcome improvement to
the business relationship.

Covetumeul A||olts btleug

In conjunction with NAMs 6
th
Auuuo| |ouu|oclutlug Summll
NORTH AMERICAN DIE CASTING ASSOCIATION
June 10-11, 2014 woshluglou, 0.C..
www.dlecosllug.otg/meellugs/gob
OSHA
+
EPA
Awareness Update
OSHA + EPA Update
Crisis Management Impacts, Prerequisites,
and Business Continuity for Enterprise
Risk Management
When it comes to crisis and enterprise risk management,
are you prepared? And just how do business managers
determine their organizations preparedness?
Crisis Management Standards and Guidelines
First, it is important to review the standards and guide-
lines used for the development of an efective crisis
management program:
Seven Planning Steps
Tere are seven planning steps for crisis management, as
outlined below:
1. Treat Assessment - Te organization must per-
form a process/functional assessment on what may be
impacted by a crisis. Examples include manufacturing
equipment/process, raw material supply, inventory of
product, shipping/receiving, IT, fnance, customer data,
safety, environmental releases, utilities, and logistics.
2. Business Impact Assessment - Management must
rate and rank the business impacts to determine those
needing mitigation. Te assessment will determine
the signifcance of each event to the business. Man-
agement should then determine mitigation plans.
Where an emergency program does not exist, a new
program should be developed.
3. Emergency Response Plans - Emergency response
plans are to be developed to the degree necessary
to ensure that the organization will survive a crisis.
A typical emergency plan includes strategic plan,
emergency response, prevention, mitigation, recovery,
and continuity. Plans must also include the process
for managing leadership, communication, the fow of
information, and direction of recovery.
4. Business Recovery Plans - Te recovery plans must
include short- and long-term priorities for restoration of
functions, services, resources, facilities, programs, and
infrastructure. It is very important for an organization
to make short-term timeline decisions prior to a crisis:
Determine what must be done and by whom in the
frst two hours, six hours, twelve hours, twenty-four
hours, two days, and beyond
Assign senior management for oversight/
decision-making duties
Nominate/train a crisis management team
Develop needed controls to efectively ensure
response/recovery
GUIDELINE REQUIREMENT(S)
ISO/OSHAS
Management
System
The organization shall establish, implement and
maintain a procedure(s) to identify potential emer-
gency situations.
The organization shall periodically review and revise
its emergency preparedness and response plans.
NFPA 600
5.3 Risk Assessment: The entity shall identify & moni-
tor hazards, determine likelihood of their occurrence
and the vulnerability of people, property, the environ-
ment and the ENTITY itself to those hazards.
5.5 Mitigation: The entity shall develop and imple-
ment a mitigation strategy that includes the mea-
sures to be taken to limit or control the consequences,
extent or severity of an incident that cannot be
reasonably prevented.
ASIS: Business
Continuity
Guidelines
11.1.2 Perform Risk Assessment
11.1.3 Conduct Business Impact Analysis
11.2.2 Develop Mitigation Strategies
11.3.5 Execute the Plan
OSHA + EPA AWARENESS UPDATE
Verify and validate measures to establish risk benefts
of responses developed
Assure maintenance of alert guides and contact lists
Include legal and professional advice readiness prior
to needing service
Determine internal trained/assigned communication
resource for all external communication required
after an event to give one consistent voice
5. Training - All employees and outside contractors
must be trained on all applicable emergency plans;
management should also consider including training
for community emergency response support teams.
Training should be documented, and competency of
those trained must be verifed. Allow for employee
suggestions/improvement during training exercises.
6. Auditing & Evaluation of Plans - Each emergency
plan must be audited for:
Inclusion of all possible scenarios
Completeness of tasks
Training and understanding by employees
and outside contractors
Verifcation that warning systems are known
and understood
Completion of trials for each emergency plan
Completion of actions and impacts lists development
During an audit, it can be good to shake things up.
Always complete a post-incident review after any incident
occurs. Auditors must verify management meetings, review
of each emergency plan, and results of each exercise. Use a
corrective/preventive action program to document continu-
ous improvement of your crisis management program.
7. Maintenance - You must have an ongoing review of
the emergency procedures and work instructions, and
continually improve them using management by walk-
ing around techniques.
Update/review plans yearly with employees
Update/review threat assessment and plans as new
building, processes, or equipment are added to facility
Verify that emergency plans meet all legal requirements
Use internal auditing and corrective/preventive
action programs for improvement
Verify status of emergency plans in management
meeting sessions
2014
Doehler Award
Nominations
The DOEHLER AWARD is presented annually for outstanding
contributions to the advancement of the die casting industry or
to the art of die casting as represented by:
Technical Achievement As measured by signifcant
scientifc contributions of a metallurgical or engineering
nature relating to the die casting process, including
casting alloys, die steels and die practices, fnishing
methods, machine design and related subjects.
Advancement in Plant Operations Of a management
or administrative nature and related to the operational
phases of the industry; safety procedures, devices, and
techniques; practical mechanical advances and other
accomplishments directly related to efciency, economy
and safety of plant operation.
Other Activities Not primarily of a scientifc or
operational nature that result in the enhancement of
the reputation and acceptability of die castings. All
contributions to the art of die casting and advancement
of the industry are to be evaluated on the applicability of
the contribution to the die casting industry as a whole.
Your response should detail the nominees contributions to the die
casting industry that meet the criteria and include the names of
any other NADCA members who are in support of the nomination.
The deadline for nominations is Monday, June 30, 2014. All
nominations received will be submitted, in confdence, to the
NADCA Awards Committee for consideration.
NORTH AMERICAN DIE CASTING ASSOCIATION
Submit Nomination to:
North American Die Casting Association
3250 N. Arlington Heights Rd., Ste. 101
Arlington Heights, IL 60004
P: 847.279.0001 F: 847.279.0002
E: twarog@diecasting.org
OSHA + EPA AWARENESS UPDATE
Kestrel Management Services, LLC
199 East Badger Road, Suite 200
Madison, WI 53713
Phone: 608.226.0531
Fax: 608.226.0536
www.kestrelmanagement.com
Kestrel Management Services, LLC is a proud member of
NADCA and an independent consultancy providing industry
with compliance support services in development of Regulatory
Compliance and Enterprise Risk Management programs and
systems including safety and health, environmental protection,
sustainability, quality and operational efectiveness.
Our advisory and strategic focused practice is led by a team
of senior consultants and principles averaging over 30 years of
direct industry experience. We have both the capability and
know-how to understand and meet the needs of our clients.
We focus on business-centric results.
Contact NADCA or Bill Bremer, the NADCA member
contact of Kestrel Management at:
bbremer@kestrelmanagement.com for additional information.
Getting Started on Crisis Management
Where does an organization start?
You should begin by reviewing current emergency plans, expe-
rience with any prior events, and industry/market situations.
How does an organization know if its plans are adequate?
Ask yourself:
Are there plans for every possible scenario?
Do the plans include all steps required for mitigation?
Do the plans include internal communication and
information updates to employees and external sources?
How does an organization know its plans will work?
All emergency plans must be trialed and reviewed by man-
agement upon completion of trial for verifcation.
What is your companys process?
Are roles and responsibilities known, understood,
and documented?
Does each employee know his/her role and demon-
strate competence during trials and audits?
How are back-up roles deployed, trained and verifed?
How does the organization communicate crisis management
information?
Is there a communication plan in place that includes
all employees and external parties (i.e., emergency
responders, regulators, suppliers, insurance, customers
and fnancial institutions)?
Enterprise Risk Management
To help ensure the overall enterprise risk management of
your organization, you need to review the following:
Claims, accidents, and workers compensation
Business , property, and special premiums
Policy consolidation options
Formal emergency response and loss prevention programs
Policy costs and payment terms
Low-incident, high-risk potential
Claims and credit history
Policy document management
Loss prevention scenarios
Contractor insurance liability and company listing
on contractor policy
Comparison of coverages to risk and loss levels
How do you know if your coverage is current/comprehensive?
Conduct a review/consider use of specialized resources
or assessment guide
Fully examine all possible risks
Determine all crisis scenarios
Quantify loss potential
Update and outline crisis management plans and options
Rate, rank, and prioritize the plans
Update plans to both highlight and remediate
your risk concerns
Establish a compliance plan for all safety and loss
standards that apply to your business
Finally, conduct a continuous Plan-Do-Check-Act
cycle until you are satisfed with the cost benefts of
your planning. By following these steps, your organiza-
tion will help ensure itself of being prepared for and
surviving a crisis incident.

Ask the Experts...

What advantages of SSM and squeeze casting should be considered (as compared
to standard HPDC) when designing cost-efective parts?
Te primary advantage of
both the SSM and squeeze
casting processes is their
ability to employ low-Fe alloy of the
A356, A357 types to make sound cast-
ings that can be solution heat treated
(for the T-4, T-6 or T-7 tempers) with-
out blistering, thus both are suitable
for production of structural castings
for a variety of automotive, military
and aerospace applications. Tere are,
however, important diference between
SSM and squeeze; Squeeze tends to be
a higher-cost process in terms of input
material (primary for squeeze versus
secondary for HPDC) and cycle time
(typically 1+ minute for squeeze versus
30 seconds + for HPDC) and is also
limited to thicker cast sections (5 or 6
mm or more for squeeze versus 1-2 mm
for HPDC) and therefore higher cast
weight; the rheocasting version of SSM,
on the other hand, can easily employ
both primary and secondary alloys, and
is capable of cycle times and cast section
thicknesses equal to or even less than
HPDC, so can be very cost efective for
reducing the weight of crash sensitive
and other automotive parts where mini-
mum weight is paramount to reduced
fuel consumption and CO
2
emissions.
- Consultant
Te following are the
advantages of the SSM
and Squeeze castings
over the Standard HPDC:
Less air entrainment.
Less shrinkage.
Less porosity.
Higher pressure tightness.
More sound casting.
Fine and homogenous
microstructure.
Improved mechanical strength.
Less cost on parts with above
requirements.
- Director

A: A:
Introducing an Improved Process for Semi-Solid
Metal Casting of High Integrity Parts
Kristen Tenzek, Development Engineer
Ajax-TOCCO Magnethermic
Warren, Ohio
Alan Koch, Development Consultant
Ajax-TOCCO Magnethermic
Warren, Ohio
Abstract
A process has been developed that can produce high integ-
rity parts to meet the new CAFE standards and higher
performance requirements in the marketplace. Moreover,
the new process can be set up to produce both 10-20%
fraction solid (fs) slurry that can be poured directly into
the shot sleeve of a die casting machine to reduce casting
porosity and other part defects in castings, and produce
semi-solid slugs (40-50% fs) that can be poured directly into
a shot sleeve for forming into high integrity components.
Te process features a non-contact, continuous method to
monitor the development of the slurry structure. Te process
is able to sense, and can be adjusted for, variation in the
melt chemistry to ensure delivery of consistent fraction solid
material to the casting machine. Te process can be added
to an existing HPDC cell. Te features of this process
address shortcomings that have limited the commercializa-
tion of semi-solid processes in the past.
Introduction
Since the late 1960s and early 1970s, when the initial
research was done at MIT, Semi-Solid Metal (SSM) pro-
cessing and casting has been a topic of interest in the metals
industry. With the new CAFE standards and higher per-
formance requirements in the marketplace, further devel-
opment of SSM processes looks to be a promising method
by which to create parts to meet those standards, thereby
increasing commercialization opportunities.
Some of the advantages of SSM processing are:
1. Reduction of shrinkage porosity since the material is
already partially solidifed.
2. Reduction of dwell/curing time in the mold, again,
since the material is partially solidifed.
3. Ability to be able to fll a mold cavity in a laminar
fow regime, thus minimizing turbulence and the
associated entrapment of gases.
4. Potential increase in die life due to reduced thermal
cycling and less heat that has to be absorbed and dis-
sipated through the casting mold.
5. Semi-solid material can fll both thin sections and
thick sections with reduced defects; thus, allowing
maximized physical properties to be achieved.
Some factors limiting commercialization of SSM process-
ing historically have been:
1. Te expense and complexity of the processing and
billet heating equipment.
2. Te absence of the means to measure the fraction
solid of material during processing, particularly
in view of recent information on the infuence of
melt chemistry on Process Stability.
1
(Kaufmann &
Uggowitzer p. 226)
3. Tere are many variables in the SSM production process
and the high pressure casting processes that are either
not easily controlled, or cannot be accurately measured
with a view to the control of the overall process.
Figure 1a Low fs 380 Alloy Slurry being poured from the
ATM processor.
Figure 1b Slice Test of an A-356 Semi-Solid slug poured
from the ATM Processor.
To utilize the advantages and minimize the concerns
of SSM processes up to this point, this new process
addresses features that are desirable in a controllable
SSM casting process. For example, process stability is
the key issue in determining future investment in new
processes. Te most important parameter allowing
control of the SSM processes is the alloy composition.
(Kaufmann & Uggowitzer, p. 254). Te fraction solid of
a batch or charge of slurry material at a specifc temper-
ature is extremely sensitive to the chemical composition
of the melt. An example given by the cited reference
indicates that A356 alloy at 586 C at the extremes of
the chemical composition spec limits for Silicon can
be at 47% fs or 37%fs, which can signifcantly alter
the mold flling behavior of the material. Most SSM
systems rely on temperature feedback to control the pro-
cess. If melt chemistry cannot be controlled or at least
refected in some manner, then melt temperature alone
is not a reliable process control parameter.
1
(Kaufmann
& Uggowitzer, p. 236-256)
Traceability of a formed part back to the material
processing and casting parameters is a desirable and
oftentimes necessary quality system requirement in
the production of high performance and high liability
components. If a monitoring system for key parameters
can identify when a process is outside of acceptable
control limits, then out of spec parts can be rejected at
the production cell instead of at downstream operations,
after additional work and expense has been expended.
Previous technology was often hard to operate due
to complexity of the equipment or to the previously
mentioned lack of reliable process feedback and process
instability. Terefore, a process that was well-defned
and relatively easy to operate would be benefcial.
Some systems have multiple charges in process at
a time in order to meet production rate targets or to
allow suf cient time for the necessary spherical micro-
structure to develop (ripen). Tese types of systems
typically incurred a high loss of material in process if
an interruption was experienced either in the process-
ing of the SSM material or at the casting machine. An
interruption in the thixocasting case usually resulted
in an expensive loss of slugs in process with addi-
tional downtime expense for recovery and restart of the
system. A single charge processor unit that can deliver a
repeatable slurry or slug charge to a casting machine at a
typical die casting cycle time would be advantageous.
Discussion
A new system has been developed at Ajax -TOCCO
Magnethermic that addresses these concerns. Te ATM
system consists of a single crucible based, metal process-
ing unit that is able to control the cooling/heating of metal
delivered to it.
3
Te induction coil is closely coupled to the
crucible, which allows for a rapid response in both cooling
and heating of the system as needed for rapid cycle times.
Te unit is powered by a dual frequency induction power
supply. A Load Analyzer module in the induction unit
sends coil feedback to the systems data acquisition pack-
age. Tis coil feedback is used to sense the occurrence of
the liquidus point of the alloy and monitor the cooling of
the semi-solid metal to the desired condition for casting.
Te system has a small footprint that allows it to be
incorporated into most existing die cast cells. Standard
holding or dosing furnaces can be used as molten metal
sources. Te process requires good incoming molten metal
temperature control. Incoming metal temperatures that
have been used for A356 alloy have been in a range from
625 C to 650 C. with +/- 2 C control point repeatabil-
ity. Te system can deliver slurry to a standard die cast
machine or to an HVSC machine.
Figure 2 Chart showing the relationship of the liquidus of
the metal temperature (red) with the slope change of the Load R
Signal (blue) during consecutive cooling cycles.
As mentioned above, previous SSM methods have not
had a means, other than temperature, to determine the
process conditions of the charge. Temperature is not a
good indicator of fs since it is sensitive to the chemistry
of the alloy. In Europe, a Laser Induced Plasma Spec-
troscopy, LIPS system has been used to continuously
monitor melt chemistry. Tis points out the importance
of controlling chemistry for consistent melt properties
and downstream processes.
Te ATM unit uses the coil feedback of the load to
sense the liquidus point of the molten metal as it cools.
When this point is determined, a value of the pouring
point can be calculated on the basis of a predetermined
resistance change in the load. Tis method links the
active process to any changes in the alloy chemistry that
would be seen as a shift of the liquidus point.
Summary
380 and 356 Alloys have been successfully processed in
the unit. Examples of the typical microstructures are
shown in Figure 4. Moreover, the process was able to
produce similar, spheroid microstructure in both the
low fs and high fs test runs.
During initial casting trials using 380 alloy with the
same casting equipment and mold, parts were made
using both the standard die casting parameters and
separately groups were cast using slurry material and
process settings. Tensile results averaged 1.5% Elonga-
tion for the standard HPDC samples and 3.5% for the
slurry samples. Also, cycle times were comparable to the
HPDC cycle time due to the reduction in dwell.
Figure 4a Microstructure of 356 Alloy Slurry Processed in the
ATM System
Figure 4b Microstructure of Alloy 380 Slurry processed in the
ATM System.
Figure 5a Spheroid microstructure from Slurry 02/09/2012.
Figure 5b Spheroid microstructure from Semi-Solid Slug
06/04/2013.
Figure 3 Liquidus Temperature vs. Si % of 380 Alloy; Casting
Trial Data.
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What is the Marketplace?
The Marketplace is NADCAs new
online store. You can purchase the
items below. Trying to register for
someone else? No problem! This is
also an option in the new Marketplace.
Purchase Publications
Register for Conferences
Register for Courses
Register for Webinars
How to Buy?
Simply add the item or items to
your shopping cart and proceed
to checkout! To view more details
on items available in the Marketplace
visit: www.diecasting.org/store.
NORTH AMERICAN DIE CASTING ASSOCIATION
www.diecasting.org/store
+
+
+
+
+
+
NADCA
MARKET
PLACE
Comparisons were made of parts costs using several
casting methods. Tese comparisons were made consider-
ing the same casting (7lbs suspension arm) and standard
equipment and parameters typical to the individual pro-
cesses. Te relative trimmed part costs are shown below:
1. HPDC 100% ($11.64)
2. ATM Slurry 104%
3. Squeeze Cast 125%
4. Perm. Mold 115% six station
5. Perm. Mold 190% single station
All trimmed parts; 356 Alloy. HPDC included as a ref-
erence for part rate, all the other processes usually consid-
ered high integrity processes.
Conclusion
Te ATM system is a state of the art process and equip-
ment package. Te system provides a method to monitor the
development of the fs and reference it to the melt chemistry,
a critical variable in metal casting processes. Metal condi-
tion is traceable through the data acquisition and monitor-
ing system, and can be linked to a cell part quality system.
Te system provides a method to provide high integrity
parts at a competitive cost; a signifcant factor in terms of
new CAFE standards and higher performance require-
ments in the marketplace.
References
1. Kaufmann, Helmut, and Uggowitzer, Peter J., Metallurgy
and Processing of High Integrity Light Metal Pressure Cast-
ings. Berlin: Schiele & Schn, 2007. Published Book
2. de Figueredo, Anaceleto ed. Science and Technology of Semi-
Solid Metal Processing. Worcester, MA: Worcester Polytech-
nic Institute, 2001. Published Book
3. US 8241390.B2 Patent, Semi-Liquid Metal Processing and
Sensing Device and Method of Using Same. published 2009-
04-16, granted 2012-08-14, fled 2008-10-10, inventor
Koch, Alan A, assigned Ajax-TOCCO Magnethermic.
Additional Information
For more information about the ATM Slurry System,
contact Bob Riccardi at Ajax-TOCCO Magnethermic at
330.372.8511, rriccardi@ajaxtocco.com.

About the Authors

Alan Koch has been involved in metal processing, casting and related
support activities for over 30 years. He is currently a development
consultant with Ajax-TOCCO Magnethermic in Warren, Ohio.
Kristen Tenzek is a development engineer at Ajax TOCCO
Magnethermic. She has a Bachelors of Science degree in Phys-
ics from Kent State University, and has taken graduate-level
classes in Optics and Materials at Cleveland State University.
Fire Incident Prevention for NADCA
Randy Block
Kestrel Management Services, LLC
Madison, Wisconsin
Kestrel Management Services, LLC was asked to observe
multiple NADCA member sites looking for ways to help
members identify issues of concern within their own
organizations concerning fre prevention. Tis report is a
guide to help members to better understand what to look
for, how to assess compliance, and, ultimately, how to
reduce the likelihood of a fre incident.
Legal Requirements - Te frst step for any NADCA
member is to verify that they know and understand all legal
requirements that apply to their organizations. Below are
the OSHA requirements for fre prevention, which include:
Industrial Fork Truck - 29 CFR 1910.178 - Not utiliz-
ing a daily fork truck checklist. Not securely attaching
molten metal crucible to forks by chain or screw.
Hot Work - 29 CFR 1910.252 - Not utilizing required
Hot Work Permit. Not training or identifying the Fire
Watch personnel. Not clearing fre area for minimum
of 35 feet. Not using a tarp to prevent possible fre.
Walking/Working Surfaces - 29 CFR 1910.22 - Rail-
ings insuf cient. No three inch toe guards for plat-
forms greater than four feet of of foor.
Personal Protective Equipment (PPE) - 29 CFR 1910.132
- PPE not being utilized by employees; no eye protection,
no safety vest and face shield while working around molten
metal. No purchasing specifcations for PPE defned. No
Hazard Assessment for determining required PPE.
Electrical Safety - 29 CFR 1910.303 - Floor space
clearance requirements not defned from power panels,
based on Voltage. No labels on power panels.
Explosive Dust - 29 CFR 1910 Subpart R & S and
www.osha.gov/publications/combustiblesdustposter.
pdf - Poor housekeeping to remove dust from overhead
piping, light fxtures and ceiling fans.
National Fire Protection Association (NFPA) - 70 (e)
- No Arc Flash study. No PPE requirements for those
performing electrical work. No Termo Imaging of
electrical circuits.
Process Safety Management (PSM) - 29 CFR
1910.119 - Management not reviewing if under
requirements per Appendix A.
Hand and Power Tools - 29 CFR 1910.242 - Must
purchase Square D logo safe power tools. Must repair
any frayed power cords.
Pressurized Cylinders - 29 CFR 1910.110 - Pressur-
ized cylinders not stored correctly. Pressurized cylinders
stored near power panels. Pressurized cylinders allowed
on manufacturing foor, not chained and secured.
Not only is each organization required to follow
these requirements, but they are also required to train
employees, verify that outside contractors are meeting
these requirements, and show evidence of a valida-
tion activity by management. Management must verify
training, as appropriate, and document that daily,
weekly, monthly, semi-annual, and annual actions of
employees and management meet all applicable legal
requirements as stated by regulations. See
www.osha.gov for further information on these critical
requirements for fre prevention and what constitutes
governance under the General Duties clause.
Management Responsibilities - Only management can
determine acceptable actions by employees. Management
must make its desires and requirements known, under-
stood, and followed by all onsite personnel. In many cases,
management has worked very hard to earn TS/ISO certif-
cations. Each organization should use the fundamentals of
a management system for fre prevention. A management
system approach would include:
Internal audits of facility and legal requirements
focusing on fre prevention.
Verifcation of training.
Verifcation on outside contractors meeting legal
requirements; based on job functions and duties.
Use of corrective/preventive action (CAPA)
program for fre prevention, including timeline
and identifcation of responsibilities.
Verifcation activity by management of actions identi-
fed by CAPA as meeting internal requirements.
Management review topic on fre prevention activities.
Accountability of supervisors and management
to meet all legal requirements.
Improved and documented preventive
maintenance programs.
In addition, an organization needs to have a strong near
miss program. Once management knows and understands
the legal requirements to follow, it will be easier for super-
visors and management to identify when and where a near
miss (which may now not even be considered) is occurring.
Near miss information will guide an organization towards
rectifcation activities to prevent an actual occurrence in
the future. Management and hourly workforce must defne
a fre incident in the same manner. Otherwise many fres
may not be reported to management for inclusion as an
issue of concern to rectify.
Five S Program Many of the NADCA members loca-
tions lacked a comprehensive 5S workplace organization
program. Implementation of a workplace organization
program must be driven from the very top of manage-
ment. Only top management can create the environment
needed and give visibility and importance to the program
needs for long-term viability. Tis workplace organiza-
tion program creates a fundamental diference between a
successful fre incident prevention program and a com-
pany waiting for the next incident to occur. Without the
ability of management and hourly workforce employees
to defne their workplace organization tasks, nothing will
improve. Once workplace organization program structure
has been defned, the frst task is to sort everything in the
workplace. Determine proper quantities of items to keep
in workplace. Next is to set in order and determine how to
organize what is left. Storage should include foor, rack-
ing, cabinets, carts and storage bins. Shine the workplace
includes more than just cleaning. One must clean foor,
equipment, walls, ceiling, bathrooms, light fxtures and
even ceiling fans. Management must maintain this appear-
ance after completion and develop preventive measures
to keep it clean. To maintain the improved appearance
of the facility will require paint, lighting, dust removal,
minimizing spills and improved maintenance of equipment
and building. Standardize every location and tool used.
Put a system in place to ensure everybody does their work
in same manner. Management must train, complement
employees and train again. Management must support
and sustain this workplace improvement program for it to
remain successful over time.
Workplace disorganization examples include:
Pallets and cardboard strewn about instead of given a
specifc location.
Pallets and cardboard leaning against power panels
instead of lying fat.
Cardboard used as improvised shields on equipment.
Floors cluttered with unused materials and oily.
Propane tanks not stored properly.
Tools and cleaning supplies not stored correctly.
Culture - It is important for management to accurately
assess the culture of their organization - without wearing
rose-colored glasses. Many organizations spend time and
resources on quality, environmental, health, and safety
requirements. Most do not spend the same resources
needed to elevate fre prevention as a worthy component
of a successful organization. It is not until there is a fre or
catastrophic incident that management looks at prevention.
By then it is too late. Te best time to review fre preven-
tion eforts is before a fre incident ever occurs. It is hard to
quantify fre incident savings until a facility burns down.
Te actual building and equipment costs are just one small
component of the actual damage. A companys sterling
reputation may take a big hit. Te insurance company will
evaluate the organization diferently. Customers will wonder
if they should move their molds and business elsewhere. Te
supply chain may invoke change against the organization.
Employees will wonder if management is competent and is
capable and assured of meeting their safety needs.
Maintenance - It appears that many maintenance depart-
ments are understafed and not capable of meeting preventive
maintenance requirements. Te workload is not adjusted
and prioritized against any criteria other than safety require-
ments. Why would fre prevention not also get a high priority
from management? Of note, maintenance does not appear
to be able to keep up with equipment oil leaks. Management
should review the practice of allowing hosing to be on foor.
Tis action hinders cleaning the foor and determining the
location of oil leaks, and prematurely shortens the life of every
hose being rubbed against equipment during cycling process.
Who is responsible and verifes that equipment repairs are
completed in a manner that is acceptable and correct? When
has somebody in management been reprimanded or disci-
plined for shoddy work being performed?
Random Observations - Tere are a number of observa-
tions made - some small, yet important tasks - that com-
panies should address and incorporate into daily practices
to prevent fres:
Eliminate home blindness by management.
Improve cleanliness of facility.
Place lids on all garbage cans.
Place rags in auto-close fre prevention containers.
Develop PM and cleaning program for all ceiling
ventilation fans and all foor fans.
Develop specifc locations for propane tanks on
molding equipment and storage of all propane
tanks used for pre-heating of molds.
Defne foor space clearance requirements for each
power panel and maintain clearance requirements.
Verify location of fammable pressurized cylinders
and their proximity to a power panel.
Clean and organize maintenance shop and all
work benches.
Defne cleaning of overhead piping to remove dust,
zinc, and magnesium to assure this is not a gateway
path for a fre to move quickly through a building.
Give all wood and cardboard used by manufacturing
an assigned location.
Eliminate use of two or more power cords to supply power.
Hard pipe location to supply power, as required.
Ensure fammable metal flings are stored in bucket
with lid.
Pallets should be stored laying fat instead of
standing on edge.
Bar lube containers should not be placed on hot oil units.
Propane tanks stored inside the building should be moved
outside and stored in an approved locked storage system.
Storage racks must be labeled to defne weight limits -
vertical and horizontal.
Fire incident prevention should - and must - be a high
priority for management. By focusing resources on this
important aspect of the business, the long-term survival of the
organization and the safety of its employees will be enhanced.

Energy Conservations in Die Castings Industry - Some

Practical Examples
A.Pari, Director
CRP (India) Private Limited
Chennai, India
Abstract
Te manufacturing sector is undergoing a serious chal-
lenge amidst the global economic slowdown. We need to
look at the internal, as the external environment is out of
our control. Te major areas that the industry could look
into are cost cutting measures and energy conservation,
with the latter being the most signifcant amongst them.
Te die casting industry is highly energy intensive, and
there is a lot of potential for energy conservation.
Tis paper will highlight some of the measures imple-
mented successfully, thereby helping fellow die casters in
order to apply the same ideas in their organizations.
Introduction
CRP (India) Private Limited is a leading manufacturer
of High Pressure Die Casting Products in India. It was
founded in the year 1975 by Mr. N. Kunchithapatham,
one of the pioneers in the country, in the feld of die cast-
ing in terms of design and manufacturing of HPDC dies
as well as production of castings.
CRP is a one-stop solution provider for the HPDC
Products, having expertise in product design, die design,
die manufacturing, die casting, machining, surface fnish-
ing, powder coating, assembly and testing.
CRP has joined with Twin City Die Castings Company
(USA) in September 2009 to promote a joint venture in
India called CRP-TCDC Die Castings India Private
Limited (CTI) to cater to the growing needs of technical
and engineered die castings.
Te adaptation/implementation and efective use of newer
technologies in the feld of die casting has made CRP a
cost-efective and preferred source for the customers. Te
most important of these implemented technologies are
those pertaining to energy conservation. Most of the power
is consumed by the melting furnaces and the die casting
machines themselves. Recent technological developments,
such as energy ef cient tower furnaces and the all-electric
die casting machines are already available to the die casting
community to adopt and solve. Te ef ciency of this equip-
ment has improved signifcantly due to global competitions
and continual improvements. Numerous solutions are being
provided in this regard from a huge list of suppliers and
hence are not included in this paper.
Instead this paper will highlight some interesting exam-
ples of practical energy conservation solutions adapted, their
simplicity and their benefts. Tis will be very useful not
only to our fellow die casters, but to the industry as a whole.
Examples
Te following examples explain the many approaches
towards the application of various energy conservation
solutions in the die casting facilities.
Example 1: Use of Natural Light
Natural light is one of the signifcant sources of energy and
it is often ignored at many shop foors and of ces. In tropi-
cal countries like India, this can be augmented for up to 12
hours thus leading to substantial saving of energy.
Te buildings and of ces were designed and some modi-
fed so as to allow the natural light to come in. Depending
on the need, the intensity of light was reduced by making
use of vertical blinds in the of ces. If the heat input to the
room is too high (east and west walls) then a double glazed
glass is used to prevent the excess heat from entering into
the room. Tis becomes more important in the case of air
conditioned rooms.
In the shop foors, the number of natural roof panels
is decided by the exact need of lighting levels and
locations. Tese roof panels are made of fberglass or
polycarbonate material - having very good light trans-
mission with up to 99% UV shielding, stabilized, strong
and lightweight. Tese panels are weather and tempera-
ture resistant. Tese panels are also incorporated into
the side walls to allow more natural light. In addition to
being natural and energy ef cient these lights improve
the ambience of the workplace.
Figure 1 Shop foors with natural light rooftops.
Whenever there is a fuctuation of light in the day time,
the automatic light sensors are introduced into the circuit
to on/of/dim the lights. Tis is ensuring the ideal light
with optimum power consumption. Te less frequently
used areas such as rest rooms and corridors are ftted with
motion sensors with auto on/of and daylight sensing fea-
tures to further save the otherwise wasted energy.
Example 2: Use of Natural Ventilation
Tere are several sources of heat, fumes, smoke and vapors
in the foundry and they are necessary to be exhausted out
of the shop foors continuously and ef ciently. Generally a
lot of energy is used for this purpose.
Extractors are ftted on to the high points on the roof
at periodic intervals and also over some specifc hot spots
such as furnace areas. Tese roof extractors use the natu-
ral fow of air on the surface of the roof coupled with the
fow of air through the extractors, in order to rotate. No
power is needed here thereby saving substantial energy.
Tey seldom need to be maintained.
Example 3: Natural Draught Cooling Towers
Cooling towers are one of the utilities that are switched on
frst and switched of last. In colder countries they are not
switched of even during the holidays so as to prevent the
circulating water from freezing.
Any small saving of energy here is going to be of great
signifcance over the years. Te natural draught cool-
ing towers use special nozzles to atomize the water and
coupled with the natural fow of air, it tends to bring
down the water temperature.
It uses the circulating pump pressure itself for this
purpose thereby eliminating the power used for the
forced fow fan motor.
Figure 3 Roof extractors over the die casting shop foor.
Figure 2 Die casting shop foor with natural roof panels.
Technical
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Tey are simple in construction (FRP), and easy to repair
and clean. Maintenance is almost none. Te return on invest-
ment is typically around 6 months.
However they need a high footprint in terms of area, as
well as the height, but they could be accommodated in any
open space such as gardens, roofs, etc. Te energy saving
outweighs this simple shortcoming.
Example 4: Compressed Air Management
Compressed air is an expensive and power consuming
input to the die casting shop but is quite often ignored.
One CFM (cubic feet per minute) is equivalent to approxi-
mately 0.25KW. Tere is a huge potential for the conserva-
tion of energy through the optimization of the air usage
and the cost of generating the compressed air. Also, the
compressed air utilities are similar to the cooling towers, as
they are kept switched on as long as the plant is running.
On a casual visit to a manufacturing facility which
produces doors for an automobile, we found heavy
sounds of equipment based on compressed air. Our
scrutiny revealed that the installed capacity of 3000
CFM for the compressed air far outweighs their actual
needs and the team suspected an excessive leak from the
components in the air circuit. We suggested their plant
maintenance team to test it out on a holiday.
Te test was conducted by switching of all equip-
ment and running as many compressors as required to
compensate for the leaks. By observing the loading and
unloading time cycles of the running compressors we
arrived at their leaking capacity, which was as high as
1500 CFM, more than 50% of overall consumption.
Tis was an eye-opener and we decided to make the
same study in our own company.
We found that our leakage was more than 20% and the
following remedial means were taken:
Replacing the leaking components - pipes, fttings, etc.
Replacing the rust prone GI pipes with aluminum
and plastic pipes.
Introducing air foot switches to the air gauges,
which otherwise will leak the air constantly.
Periodic replacement of efective parts in time.
It is suggested from the above study that every die
casting plant should include an air audit in their system.
Tey may also use an in-line electronic air fow measuring
equipment to monitor and control on an ongoing basis.
Over and above these, we also saved a signifcant
amount of air through many initiatives, such as optimiza-
tion of the spray systems (another major area), re-engineer-
ing of the pipe lines in terms of size and friction.
Te cost of the generation of compressed air also needs
to be addressed as it is very energy intensive as well as
a constant source of energy dissipation. Hence we have
benchmarked and invested in the makes and models from
international brands, with very optimum specifc energy
consumption. Only a few brands in the market are pre-
pared to share their specifc energy consumption charts,
and we have not considered for investment, those who do
not share these inputs.
Another key area of focus should be the sizing and
number of the compressors. It is advisable to split the
capacity of the compressors into multiple units so that we
will have the fexibility to run the capacity close to the
demand. Te ef ciency is maximum when the compres-
sors are running close to the full capacity. Also, we can
apply a master-slave system, which is available today with
most of the leading manufacturers, in order to manage
the demand vs. capacity.
CRP has invested in an air manager to manage three
compressors with diferent capacities - 100, 200,400
CFMs and one 200 CFM Variable speed (SFC). Tis
helps in managing the optimum energy consumption by
ensuring the correct status of each of the four compressors
in the bank depending on the ever changing air demand.
Example 5: Wind Energy
Te alternate forms of renewable energy have been a
subject of debate for the last few decades. Its time has
already come with changed scenarios, as some of the
sources of renewable energy are not only green but eco-
nomical as well.
Figure 4 Natural draught cooling tower near the die cast-
ing shop floor.
Figure 5 Compressor bank (left) connected and controlled by
an air manager (right).
Leading this pack is wind energy and it is growing very
fast in terms of percentage of share in energy generation
and number of installations. India is a leading player here,
and CRP has utilized this opportunity by regularly invest-
ing in wind energy. Today 75% of our need is harnessed
through wind energy. Tey are located about 500 km away,
where optimum potential for the wind exists.
Te local energy distribution company, owned and oper-
ated by the state government, takes care of the manage-
ment of absorbing the generated power and compensating
the same for our plants. Te responsibility of the upkeep
and maintenance of these equipment are with the supplier.
Tese initiatives are ensuring us not only that the energy
is available, but is also economical.
Example 6: Lighting Optimizations
Te shop foor lighting needs to be adequate. Inappro-
priate lighting will lead to eye strain and fatigue to the
employees. Te excess lighting will contribute to power
loss which otherwise can be saved. Generally the shop
foors will contain lots of imbalances in lighting at dif-
ferent areas in terms of poor or excess illumination with
pockets of areas with appropriate lighting.
Time and time again, die casters have used and mas-
tered various simulation techniques for the design of
the part and the process. When it comes to shop foor
design they tend to depend on external experts with
little knowledge of the die casters perspective. Today the
lighting industry has highly matured and ofers a numer-
ous easy-to-learn and to apply software tools.
Tere are several free tools (i.e. Calculux) along with
excellent support, and they are available over the web,
particularly with luminaire manufacturers. Tese tools use
the product libraries of various brands around the world,
to readily pick and place the appropriate combinations of
lights and fttings.
Figure 6 Wind turbine installation.
Figure 7 Proposed 2D-layout with location of fttings (top)
and ISO contours of light distribution (bottom).
CRP has tried to adopt these tools by conducting a sample
study. A conference room with known light fttings is mod-
eled and simulated. Te results were correlated with actual
measurement with a simple lux meter and found within a
diference of 2%. Tis has encouraged the team to use these
tools in the future projects to optimize the illuminations in
the shop foors and of ces. In one of the immediate projects
the contractor suggested 24 fttings for a particular shop
foor, whereas the analysis optimized it to just 14 fttings with
balanced lighting. A saving of more than 40% (2.5 KWh) on
power consumption and as well as investment are achieved.
Te steps are as follows:
Input the simple 2D sketches/dimensions of the shop
foor layout into the software.
Defne the measurement plane/working height.
Choose appropriate products from the libraries from
the manufactures available online.
Defne the ftting height of the luminaires.
Mark the areas with the recommended illumination
in terms of lux.
Run the simulation.
Te professional output gives a detailed report which includes:
Te proposed layout with location of fttings.
Various views.
ISO contours of light distribution.
Textual and graphical tables.
Mountain plot.
Detailed Costing sheet.
Te detailed costing sheet is very accurate with necessary
fnancial inputs - cost of power, burning hours, investment cost,
maintenance cost, etc. Te precision can be further improved
by defning the life of bulbs, maintenance factors, and so on.
One can learn these simple tools in about a day and
fnish the projects within few hours. Tis gives adequate
opportunity for multiple iterations and optimizes the illu-
mination and cost. For those who are serious about light-
ing and need a detailed analysis much more advanced tools
are available in the public domain. All that is required is
the will to try, apply and save on energy costs.
Example 7: LED Illuminations
As a continuation of the previous example there are plenty
of opportunities to further reduce the cost of lightings by
replacing the traditional luminaires with LED.
LED luminaires have come of age in terms of their appli-
cations, availability, reliability and economy. Despite being a
costly option, its advantages outweigh the shortcomings:
Consumes very little energy, less than 10% of incan-
descent lamps and less than 50% of CFLs.
Power demand and infrastructure cost
proportionally reduces.
Environmental friendly with low CO
2
emission
and no use of Mercury.
Works at wide range of temperatures including
very low temperature.
No sensitivity towards humidity.
Instant switch on/of.
No efect on life due to frequent switching on/of.
Durable towards vibrations and shocks
Long life and low maintenance.
Very low heat generation, more than 25 times less than
incandescent lamps and close to 10 times less than CFLs.
In a recent project for a sister concern of CRP, we
replaced the metal halide fttings with LED fttings.
Tough cost of the fttings was almost 2.5 times, it reduced
the energy cost by half and doubled the illumination.
Again for this project, the same software tools were used
to compare the traditional and LED options in terms of
layout and economy.
It is time for all our shop foors are illuminated with
LED lights, saving energy and cost.
Conclusion
Tis is testing time for the economy the world over and it
is important for all the organizations to look inwards in
terms of saving cost and stay competitive.
Te purpose of this paper is to rekindle the fellow die
casters to look for energy saving opportunities.
Energy conservation is the key as die casting is an
energy intensive sector. By saving energy, this sector not
only saves cost but also gives an immense value to the
corporate social responsibility and mitigates so much of
damage already done to the environment.

Figure 8 Proposed 3D-layout with location of fttings (top)

and ISO contours of light distribution (bottom).
The Role of Temperature During Semi-Solid
Metal Processing
Dr. Frank Czerwinski, Group Leader, Senior Research Scientist
CanmetMATERIALS, Natural Resources Canada
Hamilton, Ontario, Canada
Introduction
When semi-solid metal processing was invented in the early
1970s, it was seen as a very promising technology with great
potential applications and capabilities to revolutionize the
manufacturing industry. After over four decades of research
and despite impressive fndings at a laboratory scale, its
commercialization progress remains relatively low
1
. For a
new technology to achieve the commercial acceptance in
todays market, clear advantages of lower cost and superior
product properties must be demonstrated. Te commercial-
ization complexity is magnifed by the fact that the semi-
solid processing concept has to compete with new and old,
already well-established technologies. Tus at present, it is
frequently stated that semi-solid processing still requires
research and that the critical breakthrough is still expected.
Semi-solid processing is portrayed as the technique being
capable to produce in a single step the net-shape product at
the low cost similar to casting with the wrought alloy quality
2
.
In practice, however, there are many criteria based on which
semi-solid processing is evaluated such as energy savings, net
shape and intricate shape capabilities, high part integrity with
absent porosity and high mechanical properties. Although
the original experiment was carried out with the Sn-15%Pb
system, numerous alloys were further involved, most fre-
quently aluminum and magnesium based grades. Te present
industrial focus of semi-solid processing is oriented towards
the net or near-net shape capability and internal integrity of
the fnal product. However, for structural components, typical
for transportation applications, an improvement in mechani-
cal properties that benefts from semi-solid nature of the alloy
at casting or forming temperatures, is the priority. Among all
processing parameters, the reduced temperature of the alloy is
seen as the key diference while comparing semi-solid meth-
ods to conventional casting that employs fully molten alloys.
Although the reduced temperature is generally seen as the
positive factor, in practice, its benefcial efect is not entirely
universal. Some aspects of the critical and complex role of
temperature during semi-solid processing of metallic alloys
are described in this paper.
Temperature and Processing Route
Casting and forming in the solidus-liquidus range create an
impression of reduced energy consumption. However, when
assessing benefts of the reduced temperature and related
energy savings, the full manufacturing cycle should be con-
sidered. As explained in Figure 1, the total energy required
depends on the processing route. Historically, rheocasting
(rheo-route) was the frst method invented and it is based
on a molten alloy as the precursor. To generate a thixotropic
structure during solidifcation, many methods of a liquid
alloy treatment were developed over years, based mainly on
mechanical, ultrasound or magnetic agitations. Other concepts
of generating thixotropic structures from a liquid precoursor
include swirl enthalpy equilibration, continuous conversion,
sub-liquidus casting or new rheocasting process
1
. Processing
following the Tixo-route 1 takes place at rather lower tem-
perature than rheocasting but the amount of energy involved is
substantially higher. At the frst stage, a billet is manufactured
by employing similar techniques of molten alloy treatment as
used in rheocasting. Ten, in the second step the billet is re-
heated and a component is formed in semi-solid state, e.g. by
thixo-forging. A substantially lower energy requirement could
be during thixoprocessing following Tixo-route 2. In this
concept, a solid alloy is subjected to so-called stress-induced
melt activation, which involves cold or warm deformation or
a combination of diferent deformation techniques. Te idea
of stress-induced melt activation generates fne grains after
recrystallization during preheating prior to semi-solid forming.
Typical deformation methods include rolling, extrusion, equal
channel angular pressing or their combinations
3
. Tere is a
limitation, however, on the billet size that is possible to prepare
through deformation and typical dimensions are usually too
small for many industrial components.
Figure 1 Schematics explaining steps of semi-solid processing
based on rheo- and thixo-routes.
Role of Temperature in
Hardware Performance
Te process economy is afected by the hardware required
and its service life with the hardware failure being the
main reason causing the downtime of production lines.
Te processing temperature afects not only thermal attack
but also chemical reactivity or in practice for crucibles or
furnace liners, simultaneous thermal and corrosive attacks.
Te chemical reactivity depends on molten alloy chemistry
and there is an essentail diference in chemical reactivity
between magnesium and aluminum alloys that require dif-
ferent materials being in contact with them. An additional
factor afecting hardware degradation is a pressure of the
molten or semi-solid alloy, afecting strength and lead-
ing to high temperature fatigue. Examples of hardware
experiencing high pressure include shot sleeves, pressure
pump elements, high pressure casting dies or machine
nozzles. Moreover, the slurry fow contributes to wear of
the processing equipment. It is generally concluded that a
reduction in processing temperature is universally positive
and sometimes lowering tempearture by 20-30C makes
substantial diference in service life of the hardware.
Role of Temperature in
Component Integrity
Te evident concern during conventional casting is an inter-
nal integrity of the product. Based on simple analysis, semi-
solid processing having only a fraction of the liquid alloy,
additionally with lower tempeature than typical overheated
melt, should have reduced porosity due to lower shrinkage
(Figure 2). An additional improvement is due to better fow
characteristics of the thixotropic alloy during die flling;
laminar fow versus turbulent fow during conventional cast-
ing. While this is true, the lower temperature causes also
some reduction in heat content of the alloy, thus reducing
the fow length and intensifying freezing. Tus, the product
formed at lower temperatures of the semi-solid range will
achieve better dimensional accuracy due to lower overall
shrinkage, it may still develop serious internal defciencies
due to incomplete flling.
Additional avenues to modify properties of alloys
processed in semi-solid state are post-manufacturing
treatments, e.g. heat treatment or deformation. Te high
part integrity achieved through semi-solid methods
improves properties in as-cast state and also allows their
modifcation by exploring heat treatment. It is known that
porosity excludes components from thermal exposures
since it generates blisters. Te heat treatment allows for
microstructure modifcations, which may compensate a
reduction in properties resulted from semi-solid process-
ing. For example, heat treatment changes properties of
the matrix as well as the phase composition, morphology
and distribution of precipitates. Since for a given chemical
composition, an alloy after semi-solid processing has dif-
ferent microstructure, also heat treatment would be dife-
rent than that used after conventional casting. It is known
that in the case of Mg-Al alloys, a T4 treatment leads to
increased properties, especially at increased temperatures
4
.
If the Al content is high enough to generate precipitation
hardening, the T6 treatment, which follows part forming
reduces the creep rate. Te post-processing deformation is
mainly focussed on introducing cold work by a single step
method or using a complex thermo-mechanical treatment
to refne the grain size. As in the case of heat treatment,
high internal integrityof the component is benefcial for
thermo-mechanical processing.
Figure 2 Infuence of temperature during semi-solid process-
ing on component integrity and microstructure.
Role of Temperature in
Alloy Microstructure
A reduction of the processing temperature infuences a
number of factors changing solidifcation characteristics
and the fnal microstructure. While some factors cause
an improvement in product properties, others have clearly
negative contribution. Te essential diference of the
microstructure after semi-solid processing is expressed
through a replacement of dendritic forms with globular
morphologies having thixotropic characteristics (Figure
3). According to the general rule, refning microstructural
components leads to improved properties and is highly
desirable. For the liquid fraction, a refnement is achieved
by an increased cooling rate. Te cooling rate, however,
does not afect the size of primary solid particles.
During rheocasting, the size of the primary solid is
controlled by the nucleation rate. Terefore, through
increasing a number of nucleation sites available, the
primary solid size may be refned. In general, the size of
the primary solid after rheo-route is smaller than after
thixo-route. For thixo-route, the size of the solid glob-
ules originates from the grain size in the solid state after
recrystallization. Tere is no obvious correlation with the
primary solid size since frst the grain grows during heat-
ing in the solid state and then experiences sharp coarsen-
ing just prior and during early stages of alloy melting.
Although there is some reduction during advanced stages
of melting, the fnal particle size is many times larger than
the initial grain, reaching typically over 100 m (5). Such
a large size is detrimental to material properties.
Role of Temperature in
Material Properties
Tere is an expectation that semi-solid processing causes the
substantial increase in mechanical properties, being critical
for all structural applications. So far, there is no consistent
evidence to support that thesis (Figure 4). For present magne-
sium alloys, there are examples showing exactly the opposite
behaviour
6
. To reverse this trend, recent eforts within both
the industry and academia focus on identifying opportunities
at diferent stages of the manufacturing cycle that could create
the benefcial microstructure. Since thixotropic mixtures
represent a form of reversed composites with the primary
solid being a softer phase than the matrix, minimizing the
globule size is of crucial importance. For thixo-routes, explor-
ing solid precursors, there are attempts to refne the globule
size through the solid-state deformation prior to re-melting
7
.
Another efort is oriented towards strengthening the solid-liq-
uid interface. As documented by fractographic observations
8
,
the interface between the primary solid and subsequently
solidifed liquid fraction represents a weak region, coinciding
with the crack propagation path during tensile failure.
How to Select the
Processing Temperature
Based on the above description, the processing temperature
is afected by a number of factors related to the process,
Figure 3 A comparison of microstructure after casting of
molten alloy resulting in dendritic morphology and porosity (a)
with that after semi-solid processing showing globular mor-
phologies with no prorosity (b). Magnesium-based alloy.
Figure 4 Schematics explaining an infuence of processing
temperature on strength and ductility of alloys during semi-solid
processing. For comparison, there are also shown properties after
casting of completely liquid alloys.
hardware, alloy and product charactersitics. Te above dis-
cussion shows that the reduction of the processing tempera-
ture within the semi-solid range is not universally satisfying
all elements of manufacturing to lead to improvement. It has
to be rather an optimum established for particular process
conditions. For example, wall thickness will afect the solid
fraction required. While for thin wall components, low solid
fraction, i.e. high temperatures, are preferable to achieve
high fow length, for thick walls, high solid fractions, i.e.
lower tempeartures, are needed to achieve the low shrinkage
and dimentional accuracy. For magnesium alloys, the latter
is not aligned with improvement of material strength.
Conclusions
During semi-solid processing of metallic alloys, tempera-
ture is the key parameter afecting not only the component
integrity, microstructure and properties but also the hardware
performance and process economy. While a reduction in the
processing temperature leads to better hardware performance
and longer tool service life, it does not universally lead to the
benefcial microstructure and accompanied properties. Tere-
fore, for each processing route, manufacturing technique
details, alloy used and product specifcations, the optimum
value of the processing temperature should be established.
References

1
F. Czerwinski, Magnesium Injection Molding, New York:
Springer, 2008.

2
F. Czerwinski, Te basics of modern semi-solid metal
processing, Te Journal of Te Minerals, Metals and Mate-
rials Society, vol. 57, no. 6, pp. 17-20, 2006.

3
L. Rogal and J. Dutkiewicz, Heat treatment of thixo-
formed hypereutectic X210CrW12 tool steel, Metallurgical
and Materials Transactions A, vol. 43, pp. 5009-5018, 2012.

4
Y. Wang, G. Liu and Z. Fan, Microstructural evolution of
rheo-diecast AZ91D magnesium alloy during heat treat-
ment, Acta Materialia, vol. 54, no. 3, pp. 689-699, 2006.

5
F. Czerwinski, On the generation of thixotropic struc-
tures during melting of the Mg-9Al-1Zn alloy, Acta Mate-
rialia, vol. 50, no. 12, pp. 3265-3281, 2002.

6
Z. Fan, Semi-solid metal processing, International
Materials Reviews, vol. 47, no. 2, pp. 49-85, 2002.

7
Z. Huang, R. Chen and E. Han, Preparation of semi-solid
billet of ZW61 alloy by equal channel angular extrusion,
Materials Science Forum, Vols. 610-613, pp. 806-809, 2009.

8
F. Czerwinski, A. Zielinska-Lipiec, P. Pinet and J. Over-
beeke, Correlating the microstructure and tensile properties
of a thixomolded AZ91 magnesium alloy, Acta Materialia,
vol. 49, no. 7, pp. 1225-1235, 2001.

DIE CASTING
C ONGRE S S
&TABLETOP
2014
September 22-24, 2014
Wisconsin Center in Milwaukee, WI
TAKING THE
NEXT STEP FORWARD
TIME MONDAY TUESDAY WEDNESDAY
8:00 am - 9:30 am Advanced Technologies Die Materials I Computer Modeling I
Exhibits Open
(10:00 am - 5:00 pm)
Exhibits Open
(10:00 am - 5:00 pm)
Exhibits Open
(10:00 am - 2:00 pm)
9:45 am - 11:15 am Cast Materials I Die Surface Engineering Computer Modeling II
11:15 am - 2:00 pm Die Casting Awards Luncheon
2:00 pm - 3:30 pm Cast Material II: Zinc Process Control Machine & Equipment Technologies
3:45 pm - 5:15 pm
Cast Materials III: Metal Matrix
Composites (2 paper Session)
Cast Materials IV: Magnesium
(2 Paper Session)
LIMITED BOOTH SPACE AVAILABLE!
NADCAs David Laine Scholarship Program
Awards Record-Breaking 17 Students
Donna Hutchins, Membership Services
North American Die Casting Association
Arlington Heights, IL
NADCA is proud to announce that 17 students were recog-
nized by the David Laine Intern and Scholarship Program
in 2013. Tis is the highest amount of students that have
been awarded in one year since the programs inception,
as well as the largest overall dollar amount given, with the
scholarships totaling $41,250.00.
I was excited to see that 17 interns were selected for
Laine Scholarships this year, stated NADCA President
Daniel Twarog. Te program has grown over the past
10 years and has placed dozens of engineers into the die
casting industry. Most of the applicants received $2,500
scholarships, which are the highest scholarships awarded
throughout the entire metalcasting industry. Die casting is
a metalcasting process with a bright future.
Te scholarship fund was established in 1975, and requires
that students complete an internship or co-op at a die casting
company or supplier to the die casting industry prior to apply-
ing for the scholarship. Te prerequisite allows students to
experience hands-on training in the die casting industry, with
the hope that the learning experience will encourage students
to continue on in the feld after graduation.
Scholarship winners cited experience gained in areas such
as die casting machine re-builds, process development, qual-
ity engineering and die maintenance on their application
essays. Companies that have invested in these interns not
only reaped the benefts of the students talents for an entire
summer, but also developed an inside track in hiring the
next generation engineers into the industry. Investing in the
future is what internships are all about, Twarog said.
Te association is pleased to recognize the following
2013 Laine Scholarship winners, their universities, and the
companies that provided them the opportunity to work in
the die casting industry.
JACK BOSSONG
UNIVERSITY OF ILLINOIS URBANA-CHAMPAIGN
RCM INDUSTRIES INC. - AALLIED DIE CASTING COMPANY - FRANKLIN PARK
Jack Bossong, an Indus-
trial Engineering major
at University of Illinois
Urbana-Champaign served
his internship for RCM
Industries Inc. - Aallied
Die Casting Company in
Franklin Park, IL. During
his time at Aallied, Bossong
was involved in many difer-
ent areas within the engineering department and worked
on projects including cycle time studies, creating gating
prints and shadowing engineers in the process depart-
ment. His favorite part of the internship was learning how
many departments it takes to make quality parts. Previ-
ously, Bossong served an internship at RCM Industries
Inc. - Inland Die Casting Company in Wheeling, IL.
JACOB BOWERMAN
PURDUE UNIVERSITY
RCM INDUSTRIES INC. - AALLIED DIE CASTING COMPANY - FRANKLIN PARK
Jacob Bowerman was also
an intern at RCM Industries
Inc. - Aallied Die Cast-
ing Company in Franklin
Park, IL, and this was his
third year working for the
company. Bowerman is a
Mechanical Engineering
Technology major at Purdue
University and plans to
graduate in 2015. In his most recent internship, Bower-
man spent most of his time in the companys mainte-
nance department. He was instrumental in a die casting
machine rebuild helping to strip the machine, while
identifying parts that needed repair or replacement and
he worked on sourcing and pricing the parts. Bowerman
also became involved in the companys safety committee
and helped the safety coordinator complete audits.
CHRISTOPHER CARBERRY
UNIVERSITY OF ILLINOIS AT URBANA-CHAMPAIGN
CAST PRODUCTS, INC.
Christopher Carberry is
a Computer Engineering
major at University of Illi-
nois at Urbana-Champaign.
2013 marks his third year
interning at Cast Products,
Inc. in Norridge, Illinois.
Based on his previous expe-
rience with the company, in
this years internship, he had a solid foundation and was
able to work with many diferent personnel at the plant,
including the operations manager, engineering manager,
quality control manager, IT manager, plant engineer-
ing manager, production manager and the die casting
manager. He noted that he thoroughly enjoyed working
with the entire Cast Crew, and that most of his proj-
ects were directly related to the 5S initiative. 5S is a set
of industry standards for the workplace that promote:
cleanliness, happiness, functionality and proftability.
KEVIN COVENY
UNIVERSITY OF DAYTON
RCM INDUSTRIES INC. - AALLIED DIE CASTING COMPANY - FRANKLIN PARK
A Mechanical Engineer-
ing Technology major at
University of Dayton, Kevin
Coveny has worked two
internships for RCM Indus-
tries. In 2012, he interned
at Inland Die Casting
Company in Wheeling,
IL and in 2013, spent 13
weeks working at Aallied
Die Casting Company in Franklin Park, IL. Coveny
reported directly to the engineering manager, and
was tasked with projects like transitioning AutoCAD
files into Solid Works files. He also spent time in the
tool room and was able to visit some area tool shops.
Coveny enjoyed being part of team meetings where
specific parts were discussed in detail and any defects
or issues were identified.
ALEXANDER DAAR
UNIVERSITY OF ARIZONA
RCM INDUSTRIES INC. - INLAND DIE CASTING COMPANY
Alexander Daar studies
Mechanical Engineering at
the University of Arizona. He
has interned at RCM Indus-
tries Inc. - Inland Die Cast-
ing Company, in Wheeling,
IL, for the past two years,
where he spent time in the
process engineering, quality
and CNC departments. He
learned about metal quality testing, understanding die cast
parameters, operating CNC machines and even working
with outside vendors. One of his special projects was learn-
ing how to design, price and implement a fall protection
system to improve plant safety. Daar appreciated learning
so many skills pertinent to his future as a mechanical engi-
neer, and he feels the experience provided him a greater
understanding of what it takes to be a die caster.
ADAM FETTIG
MARQUETTE UNIVERSITY
STRATTEC COMPONENT SOLUTIONS
Adam Fettig is a junior at
Marquette University, study-
ing Mechanical Engineering.
Fettig worked as an intern
at STRATTEC Security
Corporation, Milwaukee,
WI, for eight months and
reported that he worked on
several diferent projects over
the course of his term, but
no two projects were the same, so he learned something
diferent from each of them. Areas he focused on included
process control, automation and quality. One of his favorite
projects involved automating an inspecting process, from
studying the issue to developing method sheets on proper
procedures. Fettig estimated implementing his modifca-
tions could save the company over $9,000.
CRAIG HART
WRIGHT STATE UNIVERSITY
FORT RECOVERY INDUSTRIES INCORPORATED
Wright State University
student Craig Hart is a
Computer Science and Engi-
neering major. He works at
Fort Recovery Industries in
Fort Recovery, Ohio. Hart
started as a clean-up guy in
2011, but has worked his way
up to the machining depart-
ment. He enjoys working on
the CNC machines doing tool changes, adjustments and
other operations. Hart also works security, where he is
responsible for watching for leaks, furnace fuctuations and
prepping machines for third-shift. He hopes to one day
use his degree to write programs and set-up computers that
help increase the ef ciency and production of a company.
TYLER HOLLAND
WILKES UNIVERSITY
BLUE RIDGE PRESSURE CASTINGS INC.
Tyler Holland is a Wilkes
University Student, and
studies Mechanical Engi-
neering. Holland has
interned for three years at
Blue Ridge Pressure Cast-
ings Inc. in Lehighton,
PA. He became very adept
at using SolidWorks and
learned how to model dif-
ferent parts, while factoring in material usage. One of
his most important projects was the conversion of a
two-piece die to a three-piece. Tis experience allowed
me to apply concepts taught in subjects such as fuid
mechanics, heat and mass transfer, and both static and
dynamic systems, Holland said. Although knowledge
acquired inside the classroom is essential, there are just
things that cannot be taught in class.
CAITLIN LAHEY
UNIVERSITY OF ILLINOIS AT CHICAGO
MAGMA FOUNDRY TECHNOLOGIES INC.
Caitlin Lahey studies Civil
Engineering at University of
Illinois at Chicago and served
two summer internships at
MAGMA Foundry Technol-
ogies, Inc., in Schaumburg,
IL. She was trained on how
to run simulations using the
MAGMASOFT, and quickly
learned that while minimiz-
ing the porosity and hot spots was a general goal, it was
not an easy task! She enjoyed working with customers
designs, setting them up in the system and then interpret-
ing the results in a way that the customers could under-
stand. Using the software to simulate such a complex
process gave me a great understanding and appreciation for
the die casting industry, Lahey noted.
BRENDAN MELNICK
PURDUE UNIVERSITY
CHICAGO WHITE METAL CASTING INC.
Brendan Melnick is a
Purdue University Mechan-
ical Engineering senior and
recently served an intern-
ship for Chicago White
Metal Casting, Inc. in
Bensenville, IL. Melnick
helped with AutoCAD
model work, customer part
analysis, project manage-
ment and f low simulations. He enjoys working with
CAD and especially enjoys problem solving. During
his internship, he worked on transitioning core pin
sketches to CAD f iles and updating the cooling line
sketches. He also troubleshot how to get around metal
shortages, and described a project where he needed
a crash-course in furnace-ology! Melnick said the
experience changed his opinion of manufacturing, and
specif ically, the die casting industry. The industry
offers the fast-paced, technical, problem solving that I
so often seek in my spare time, he said.
ASTING
ABLETOP
WRAP
Advanced Technologies | Alloys | 2013 Show Wrap | November 2013
ALSO INSIDE:
ADVANCED TECHNOLOGIES
WWRAP
Magnesium | 2013 International Die Casting Competition | 2013 Show Guide | SEPTEMBER 2013
ALSO INSIDE:
2013 SHOW GUIDE
TERNATIONAL
IE CASTING
SIGN COMPETITION
D :: EEEEEE: EEE
UUUIIIDDD U
Furnaces/Energy | Melting & Holding | JANUARY 2013
ALSO INSIDE:
Laine Scholarship Winners
STATE OF THE
INDUSTRY
ARE YOU IN
COMPLIANCE?
12/5/2012 9:38:07 AM
Ever Thought of
ADVERTISING
IN DCE?
DCE could be a powerful
marketing tool for your
company! In queue for
2014 we have the Annual
Report in March, the
Suppliers Directory in July,
our September issue which
will act as the Die Casting
Congress and Tabletop
show guide (extra copies
will be printed and given
away free at the show) and
other great topics like:
Die Casting Components/
Equipment & Die
Casting Machines
Die Materials
SSM/Squeeze Casting
Defects
Die Coatings and Surface
Treatments & Post Casting/
Secondary Operations
Aluminum
For more information and
pricing, please contact
Athena Catlett at:
P: 847.808.3153
E: catlett@diecasting.org
Computer Modeling & Simulation | R&D Plan | 2013 Show Preview | JULY 2013
ALSO INSIDE:
2013 SHOW PREVIEW
PROBLEM SOLVING WITH
www.diecasting.org/dce/mediakit/MediaKit.pdf
processes within the low and high pressure die divi-
sions at Honda. He also learned AutoCAD so that he
was able to design parts, develop layouts and prepare
multiple options for a future metal transfer process. Te
experience provided Province with a newfound under-
standing of die casting. He commented that learning
all of the processes involved has laid the groundwork for
his engineering future.
THOMAS H. RING
TENNESSEE TECHNOLOGICAL UNIVERSITY
WALKER DIE CASTING INC.
Engineering Technology
student Tomas Ring has
held internships at Walker
Die Casting, Inc. in Lewis-
burg, KY since 2012. He is a
junior at Tennessee Techno-
logical University, and had
the opportunity to work for
the production, quality and
engineering departments
during his tenure. Before serving an actual internship,
Ring worked as a trimmer on the production foor, in
quality control as an X-ray inspector and as a Layout
CMM operator. While shadowing project engineers
during his internship, tasks included die maintenance,
die storage and handling. Ring also had the opportunity
to run special diagnostic projects for big clients. Ring
says he is fascinated by the complexities of aluminum
die casting and is grateful to have learned how to con-
duct business in the real world, outside of class.
JOSEPH SCHWARTZ
UNIVERSITY OF ILLINOIS
RCM INDUSTRIES INC. - INLAND DIE CASTING COMPANY
Joseph Schwartz is an
Engineering student at
University of Illinois
Urbana-Champaign. He
was granted an intern-
ship at RCM Industries
Inc. - Inland Die Casting
Company in Wheeling, IL,
where he worked on proj-
ects including maintenance
work orders, preventative maintenance, 5S and prepar-
ing/reviewing work instructions. Schwartz realized as
he worked with different vendors how every facet of a
plant was tied together. I developed a greater under-
standing of how the machines worked and how vital
even the smallest part or process is to the success of
plant operations, Schwartz said.
SAMUEL MOSER
MISSOURI UNIVERSITY OF SCIENCE AND TECHNOLOGY
SPARTAN LIGHT METAL PRODUCTS INC.
Samuel Moser is a Mechanical
Engineering student at Missouri
University of Science and Tech-
nology. During his internship at
Spartan Light Metal Prod-
ucts Hannibal facility, Moser
assisted in process development,
quality evaluation and cus-
tomer submissions. During the
summer, he was able to watch
the entire product manufacturing process take place, as four
new dies were coming in at the beginning of his internship. He
learned the process of testing a new die, part testing, inspec-
tion, machine modifcations and further communication with
the toolmaker, if warranted. Moser helped produce a manufac-
turing process report for the die casters to use with a part. He
appreciated the opportunity to learn, and remarked that the
industry is very competitive, fast growing, and innovative.
DAVID PROROK
UNIVERSITY OF ILLINOIS AT URBANA-CHAMPAIGN
NORTH AMERICAN DIE CASTING ASSOCIATION
David Prorok studies Com-
puter Science at University of
Illinois at Urbana-Champaign.
Prorok worked at NADCA,
in Arlington Heights, IL with
a goal of improving methods
for the die casting industry to
access information and technol-
ogy. He designed two iPhone
applications, one to assist die
casting designers and the other contains a searchable direc-
tory of thousands of webinars, articles, and other publications.
Proroks other projects included optimizing NADCAs weekly
eNewsletter for smart phones and converting NADCA publi-
cations so they can be sold on iTunes and Amazon. NADCA
hopes to bring Prorok back next summer to development more
engineering Apps and calculations for its Member Plus area
and to further develop its iTunes App for Android systems.
JOSH PROVINCE
UNIVERSITY OF CINCINNATI
HONDA OF AMERICA MANUFACTURING
Josh Province is a student
at University of Cincin-
nati studying Mechanical
Engineering. Province has
completed two co-ops for
Honda of America Manu-
facturings Anna Engine
Plant, in Anna, OH. Prov-
ince received training on
each of the manufacturing
development of a safety program, which was adopted by
the institute in 1945. Laine also helped to found the Die
Casting Research Foundation. Today, the Laine Trust-
ees come from die casting companies and suppliers of
the industry from across the U.S.
Tere may not be a better investment to make than
bringing in interns for the summer, Twarog said.
Every die caster should spend the resources to do this.
It would pay dividends in the near-term when all these
students graduate and have some practical experience
and exposure to die casting.
Are you ready to fnd a die casting intern for the summer?
NADCA can reach out to local universities or technical
schools, and has a database of current student resumes
available online at: www.diecastingdesign.org/interns.
NADCA also ofers guidance on what companies should
expect when hiring an intern on its Web site at www.die
casting.org/scholarship/laine.
Finally, the David Laine Intern & Scholarship Program
is supported entirely by contributions and pledges from
the die casting community. Your help is appreciated, and
goes directly into helping emerging engineers fnance
their education, while spending time in our industry. Visit
www.diecasting.org/scholarship/laine to fnd out how you
or your company can help.

LINDSEY TWAROG
OHIO STATE UNIVERSITY
EMPIRE DIE CASTING COMPANY INC.
Lindsey Twarog studies
Industrial and Systems Engi-
neering at Te Ohio State
University. Empire Die Cast-
ing Company Inc., based in
Macedonia, Ohio provided
an internship for her this past
summer. Twarog spent time
working on process improve-
ment, daily time studies for
diferent secondary and aluminum foundry machines and
tracking machine downtime. One special project was
helping to reconfgure the plant to include new equip-
ment that was being purchased. She credits her intern-
ship experience for teaching her how she can apply what
she is learning in her classes to real life situations.
DANIEL WINLAND
UNIVERSITY OF DAYTON
RIMROCK CORPORATION
Daniel Winland is a
Mechanical Engineering
student going into his senior
year at University of Dayton.
Winland interned in the
Applications Engineering
department at Rimrock Cor-
poration in Columbus, OH.
He assumed he would basi-
cally be the cofee boy, but
learned this could not be more opposite of what happened
at Rimrock! His work focused on learning SolidWorks,
developing his AutoCAD skills and learning robotic
simulation software for automation cells. Winland was
given the opportunity to work with current clients and
even potential customers. Although Winland did not
realize he would be granted so much responsibility as an
intern, he valued he experience of getting to learn the
business and engineering side of the company and was
invited to return for a second semester.
About the David Laine Scholarship
Te David Laine Scholarship program was established
in 1975 in tribute to David Laine, who served as Sec-
retary of the American Die Casting Institute (ADCI),
a forerunner of NADCA, for 29 years. Laine was
instrumental in efecting many advancements for the
beneft of the die casting industry. Among these was the
Wage & Beneft Survey Executive Summary
North American Die Casting Association
Arlington Heights, Illinois
The results of the 2013 Survey representing 58 companies
nationally have recently been published. The 2013 report
covers information based on the month of September 2013
that was collected during October and November 2013. The
report is organized by category of information (i.e. fringe
benets, wage rates, etc.).
The Summary
The summary provides a tabulated analysis of the major
facets of the reported information. In all cases, the informa-
tion provided by participants has been analyzed as nely as
possible within the limits of the sample provided.
Minimums, Maximums,
Medians and Averages
The information is analyzed in terms of minimum and
maximum to provide an idea of the range of values
reported by the participants. Both median and average
values are provided. Median values may be more indica-
tive of the typical response and may not be as subject
to distortion as an average value. The median value is
dened as the value of a ranking from low to high above
and below, which there are an equal number of responses
of greater and lesser value. In some cases, dividing the
information into segments does not allow meaningful
analysis. In those instances, the symbol * is used to
indicate insufcient data.
Participating Companies
The survey represents 58 companies in the die casting
industry nationwide. The participating companies table
denes the group of facilities in terms of annual sales,
number of die casting machines, number of employees, etc.
Information is provided both nationally and by region.
This year, the typical participating company had annual sales
of $44.45 million per year; utilized 19 die casting machines,
and employed 145 full-time direct labor employees. Nine
(16%) were union shops. 22% of the total production employ-
ees reported were temporary. Almost 80% of the survey partici-
pants total employees were hourly production employees.
A good indication of a companys productivity can be
established by analyzing the level of sales per total employ-
ees. The median increased since 2012 from $192,000 to
$198,000 sales per total employees.
Wage Rate Information Summary
This table covers information relating to work week, meth-
od of payment, overtime policy and miscellaneous other
information. National and regional analyses are included.
General Wage Adjustments
More than half the companies (71%) reported a general
wage adjustment in the last 12 months, but a smaller per-
centage (66%) plan to make a general wage adjustment in
the next 12 months. The median value of adjustment in the
last 12 months was equal to the amount in 2012.
Insurance Information Summary
These tables provide summaries of insurance benets
including life insurance, hospitalization, surgical, medical
care and catastrophic/major medical. Accident/sickness
policies and other insurance coverage are also covered.
Fringe Beneft Information Summary
Cost of benets, vacation policy, paid leave policy, pen-
sion plans, bonus plans and prot sharing plans are sum-
marized in these tables. The trends in cost of benets are
shown below:
The number of companies providing pension/retirement
plans increased to 56% overall, and the percent providing
insurance for retirees was 7%. While most unions do not
provide these benets directly, union shops tend to have
a much higher participation for these types of programs
compared to non-union shops.

ORDER FORM: 2013 Wage & Fringe Beneft Survey

Name (frst, middle initial, last) NADCA Member Number
Title
Company
Street Address
City State/Province
Zip/Postal Code Country
NADCA CORPORATE MEMBER?
Yes ($50/copy)
All Others ($100/copy)
Please send membership information
NON-PARTICIPATING COMPANIES
No, I did not participate in this years Wage & Fringe Beneft Survey, but
I would like to receive a copy of the Wage & Fringe Beneft Survey.
NADCA Corporate Member ($100/copy)
NADCA Individual Member ($150/copy)
All Others ($200/copy)
PAYMENT OPTIONS
Report Cost $ ___________
United States Shipping (add $10.00) $ ___________
International Shipping (call NADCA) $ ___________
Illinois Residents: Add 9.0% State Sales Tax $ ___________
Total Cost $ ___________
Check/Money Order (payable to NADCA in U.S. Dollars only)
Company Purchase Order (Corporate Members in good standing only)
Credit Card: VISA MasterCard American Express
Total (payable to NADCA in U.S. Dollars only)
Credit Card Number Expiration Date
Cardholders Name (frst, middle initial, last)
Cardholders Signature (required for processing)
MAIL FORM & PAYMENT TO:
North American Die Casting Association
3250 N. Arlington Heights Rd., Ste. 101 Arlington Heights, IL 60004
P: 847.279.0001 F: 847.279.0002
E: publications@diecasting.org
The 2013 NADCA Annual Wage & Fringe Beneft
Survey is specifcally designed for the die casting
industry. This report gives you:
Detailed summaries for direct labor employees
Wage rates for 13 key direct labor employees
Analysis of insurance coverage
Executive summary with annual trends
Is now completely downloadable containing
all individual company surveys.
The 2013 Survey will be a valuable resource for:
Determining compensation standards
Selecting fringe beneft plans and insurance
Leading labor negotiations.
Make sure this survey becomes an indispensable tool
on your desk. ORDER YOUR COPY TODAY!
The North American Die Casting Association is pleased to recognize Corporate Members with operations which have a strong focus on their employees safety and
well being. NADCAs Safety Award Program was developed to honor Corporate Members that both exceed and meet the average U.S. national safety standards
for all manufacturing in a given year. Companies that have maintained a safety record during 2013 with 0 lost days/transfers/restrictions are awarded with a
Perfect award. Companies with records equal to, or less than 4.4%, the national average for all manufacturing, are recognized with an Outstanding award.
Perfect Awards
SAFETY AWARDS 2013
Outstanding Awards
A&B Die Casting
Hercules, CA
Basic Resources Inc.
Knoxville, TN
DeCardy Diecasting Company
Chicago, IL
Gibbs Die Casting - Audubon Tool
Henderson, KY
Gibbs Die Casting - Corporate
Henderson, KY
KenWalt Die Casting Company
Sun Valley, CA
Lakeside Casting Solutions
Monroe City, MO
Meridian Lightweight Technologies Inc.
Strathroy, ON, Canada
Metal Mechanics, Inc.
Schoolcraft, MI
North American Casting Corp.
Trussville, AL
Pace Industries, Harrison Div.
Harrison, AR
Portland Casting Plant, Fort Recovery Industries, Inc.
Portland, IN
Production Castings, Inc.
Fenton, MO
RCM Industries Inc. - Imperial Die Casting Company
Liberty, SC
Rimrock Corporation
Columbus, OH
Spartan Light Metal Products
Hannibal, MO
The Hill and Grif th Company
Cincinnati, OH
Versevo
Hartland, WI
Wheelabrator
LaGrange, GA
Whitehead Die Casting Co., Inc.
Gainesville, GA
Wilkast Inc.
Grand Rapids, MI
Ahresty Wilmington Corporation
Wilmington, OH
Alloy Die Casting
Buena Park, CA
Audubon Metals LLC
Henderson, KY
Bohler Uddeholm Corp.
Elgin, IL
BuhlerPrince Inc.
Holland, MI
Canada Metal (Pacifc) Ltd.
Delta, BC, Canada
Cascade Die Casting Group, Inc./Atlantic
High Point, NC
Cascade Die Casting Group, Inc./Great Lakes
Sparta, MI
Cascade Die Casting Group, Inc./Mid-State
Grand Rapids, MI
Cast Products, Inc.
Norridge, IL
Castool Tooling Systems
Uxbridge, ON, Canada
Chicago White Metal Casting, Inc.
Bensenville, IL
Dynacast
Elgin, IL
Empire Die Casting Company
Macedonia, OH
General Die Casters, Inc.
Twinsburg, OH
Honeywell International, Inc.
San Diego, CA
International Die Casting, Inc.
Gardena, CA
Joyners Die Casting & Plating, Inc.
Brooklyn Park, MN
Kason Industries, Inc.
Newnan, GA
Meridian - Magnesium Products of America
Eaton Rapids, MI
Pace Industries, Airo Division
Loyalhanna, PA
Pace Industries, Cambridge Division
North Billerica, MA
Pace Industries, Grafton Division
Grafton, WI
Pace Industries, Product Tech Division
Maple Lake, MN
Pace Industries, St. Paul Division
Arden Hills, MN
Patterson Mold and Tool
St. Charles, MO
RCM Industries Inc. - Inland Die Casting Company
Wheeling, IL
RCMIndustriesInc.-AalliedDieCastingCo.ofNorthCarolina
Rutherfordton, NC
Ryobi Die Casting
Shelbyville, IN
SENSUS, PDC
Bowling Green, KY
Shiloh Industries, Inc. - Auburn
Auburn, IN
Shiloh Industries, Inc. - Pleasant Prairie
Pleasant Prairie, WI
Spartan Light Metal Products
Sparta, IL
Spartan Light Metal Products
Mexico, MO
Superior Aluminum Alloys
New Haven, IN
TEAM Industries - Detroit Lakes
Detroit Lakes, MN
The Schaefer Group, Inc.
Dayton, OH
Exhibitor Spotlight
2014
2014
AV+R Die Casting 330
1203 Marie Victorin
St-Bruno, QB J3V 6C3 Canada
Phone: 450.676.4622
Fax: 450.656.7871
www.avr-diecasting.com
AV&R Die Casting will present its innovative line of high-
speed, cold chamber, Aluminum die casting machines that
ofer low cost solutions for small Aluminum castings. Te
CADENCE 100T machine features multiple-slide closing
system and a proprietary inclined injection system designed
to reduce air entrapment in the shot sleeve. Production
speeds are up to 7 shots per minute with a signifcant reduc-
tion in porosity for castings of up to 500 grams.
AV&R Die Casting is part of the AV&R group that
supplies complete automated turnkey systems, includ-
ing mold design & manufacture, testing, preproduction
runs, robotic fnishing, automated visual inspection,
automated post casting operations, training and after
sales service and support.
B & L Information Systems Inc. 312
4707 Rambo Road
Bridgman, MI 49106
Phone: 269.465.6207
Fax: 269.465.6686
www.blinfo.com
B&L Information Systems is a global leader in providing
integrated enterprise resource planning (ERP) for metal
casters. All B&L products, whether client server applica-
tion or Software as a Service (SaaS), are designed with the
specifc needs of metalcasters in mind.For more informa-
tion, visitwww.BLInfo.com.
Badger Metal Tech Inc. 315
N169 W21010 Meadow Lane
Jackson, WI 53037
Phone: 262.252.3804
Fax: 262.677.5111
www.badgermetal.com
For over 30 years we have used the latest in application
technology, MetaLLife (Compressive Stress Surface
Engineering) and TerMaLLife (Termal Difusion
of Nitrogen and Carbon) are the most cost efective
surface treatments that are used extensively in the tool-
ing industry for proactive and reactive die maintenance.
Tese processes can be applied separately or in combina-
tion (TooLLife) to provide the many needed benefts
that extend and improve die life by 50%.
Bohler-Uddeholm Corp. 305
2505 Millennium
Elgin, IL 60124
Phone: 630.883.3020
Fax: 630.883.3101
www.bucorp.com
Bohler-Uddeholm Corporation is part of the Special
Steel Division of voestalpine AG. We are a worldwide
leader in the production of hot work tool steels for the
die casting industry. Bohler-Uddeholms frst operation
in North America was established in 1925 and has since
expanded into a network of warehouses, service centers,
steel stores, a manufacturing facility in South Boston,
Virginia, and a coatings division, Eifeler Coatings
Technology. Our goal is to provide the best steel, coat-
ings and service to our customers.
BuhlerPrince Inc. 302
670 Windcrest Drive
Holland, MI 49423
Phone: 616.394.8201
Fax: 616.394.1250
www.buhlerprince.com
Die Casting Machines and systems made by Buhler-
Prince are ideal for the most varied processes, including
aluminum, magnesium, zinc, vacuum, structural, engine
block and lost core die casting. Customers are supported
throughout the life-cycle of their equipment with global
services including process optimization, fow simula-
tions, remanufacturing, retrofts and upgrades.
2014
2014
EXHIBITOR SPOTLIGHT
Castool Tooling Systems 208
2 Parratt Road
Uxbridge, ON L9P 1R1
Canada
Phone: 905.852.0121
Fax: 905.852.2300
www.castool.com
Castool is a knowledge-based company that provides pro-
duction tooling and technical advice to leading aluminum
extruders and die casters, as well as die casting equipment
and extrusion equipment throughout the world.
Castool exports more than 90% of its sales, with custom-
ers in Western Europe and the Orient, as well as the US,
Mexico, and South America.
Chem-Trend Ltd. Partnership 405
1445 McPherson Park Drive
Howell, MI 48843
Phone: 517.546.4520
Fax: 517.546.6850
www.chemtrend.com
Chem-Trend, is a global leader in developing, producing and
supplying specialized process chemicals, focusing on release
technology. Within the die cast industry, Chem-Trends
customers rely on our highly specialized products to protect
their investments and keep production running ef ciently.
Chem-Trend develops and produces advanced die and
plunger lubes along with a range of ancillary products. Our
technology is used by some of the biggest names in the cast-
ing of aluminum, magnesium, zinc and related alloys.
Die Cast Press Manufacturing Co. 410
56480 Kasper Drive
Paw Paw, MI 49079
Phone: 269.657.6060
Fax: 269.657.9302
www.diecastpress.com
Die Cast Press is a supplier to the die casting industry.
Our products include new, remanufactured, and rebuilt
die cast machines, and trim presses, and new DCP
high velocity close coupled shot systems. We also
supply automated cell packages, parts and service for
all makes of die casting machinery. DCP emphasizes
complete customer service and quality by addressing
our customers immediate needs. We warranty and take
pride in all we do. We are proud of the reputation that
we have developed over the past 50 years.
DMS 212
1875 Blackacre Drive
Oldcastle, ON N0R1L0 Canada
Phone: 519.737.6743
Fax: 519.737.6744
www.dmscomponents.com
DMS is a leading supplier of tooling/die-cast components.
We also represent Koolfow water manifolds, ICS full
colour tooling plaques, REDE VAULT 8 gb on board
tooling management device, Boride polishing products,
HMMSolutions hydraulic locking systems and may other
quality products and companies. We are a proud corporate
member of NADCA.
East River Solutions 220
700 Gillard Street
Wallaceburg, ON N8A 4Z5
Canada
Phone: 855.372.6201
Fax: 888.595.4762
www.ercnc.com
East River Solutions embodies a fresh vision in custom
machining - including Trim Dies, Fixtures, Mold Com-
ponents, and Prototypes. We ofer value to our customers
through our unique, gutsy and collaborative approach
to our work, makingsourcing easy from data transfer to
delivery. East River is located in Wallaceburg, Ontario, 40
miles northwest of Detroit.
EKK, Inc. 417
37682 Enterprise Court
Farmington Hills, MI 48331
Phone: 248.624.9957
Fax: 248.876.4075
www.ekkinc.com
EKK Inc., a metal casting process simulation software and
consulting services company, provides software that ofers
the most accurate solutions to a wide variety of metal cast-
ing concerns. EKKs Finite Element Method (FEM) based
EKKcapcast software includes Solidifcation, Termal ,
Fluid fow, Stress and Porosity analysis tools which can
accurately identify your casting defects and help you opti-
mize your casting process.
EKKcapcast includes essentially everything you need to
improve your casting processes. Over the years our excel-
lence in software development and technical support have
gained the trust of the casting industry.
2014
2014
EXHIBITOR SPOTLIGHT
Ellwood Specialty Steel Co. 319
499 Honeybee Lane
New Castle, PA 16105
Phone: 724.856.5730
Fax: 724.654.9550
www.ess.elwd.com
Ellwood Specialty Steel is a premier producer of tool steels
for die casting dies. H13 Superior, Hot Die, and Tuf Die
are alloys engineered to stand up to the rigors of the die
casting environment and SURVIVE! Knowledgeable
steelmaking, forging, and heat treatment result in die steel
you can count on to perform. We stock it and deliver it
FAST. Quality steelmade in the USA!
ESI North America 404
32605 W 12 Mile Road, Suite 350
Farmington Hills, MI 48234
Phone: 248.381.8040
Fax: 248.381.8998
www.esi-group.com
USA- based ESI North America provides a unique ofer
to the metal casting industry.

ESIs fagship casting solution, ProCAST, celebrating its
25th year, ofers unmatched accuracy and detailed func-
tionality across all casting processes. ProCAST, a proven
fnite element based software, provides the full physics of
the casting process, from the key information of flling
and solidifcation, to a comprehensive evaluation of stress
and microstructure, no matter the casting size or shape.

ESI also ofers QuikCAST, an entry level solution that guides
the engineer through the basic needs of understanding flling
and solidifcation, while maintaining high accuracy in result.
Flow Science Inc. 204
683 Harkle Road
Santa Fe, NM 87505
Phone: 505.982.0088
Fax: 505.982.5551
www.fow3d.com/cast
Flow Sciences metal casting simulation software, FLOW-3D
Cast is designed for modeling virtually all casting processes.
FLOW-3D Casts highly-accurate fow and solidifcation
results capture critical casting defects, including tracking sur-
face oxides, air entrainment, and micro-porosity. If you want
to improve the accuracy of your simulations and the quality
of your cast products, then FLOW-3D Cast is the simulation
tool for you. Flow Science ofers exceptional support and has
dedicated support engineers for metal casting customers.
Frech USA 109
6000 S. Ohio Street
Michigan City, IN 46360
Phone: 219.874.2812
Fax: 219.874.2434
www.frechusa.com
Frech products include a complete line of Hot and Cold
Chamber Die Casting Machines ranging from 20 to
4400 Tons. Additional product lines include Meltec
Dosing Furnaces, Robamat Heating and Cooling units,
Spesima Automation and VDS Vacuum systems. Frech
USA has a complete service team located in the US and
stocks all spare and wear parts for our equipment.
GW Smith & Sons Inc: A Quaker Chemical Company 211
1700 Spaulding Road
Dayton, OH 45432
Phone: 610.832.7807
www.gwsmithandsons.com
G.W. Smith & Sons, a Quaker Chemical Company, is
recognized as the leading innovator in the die casting
industry through our advanced technology solutions.
We provide process expertise and customized support
services at the local level, for everything covering your
die casting needs from DIE SLICK mold release with
Smart Polymer technology to plunger lubricant and
specialty hydraulic fuids.
Hill & Grif th Co. 216
1085 Summer Street
Cincinnati, OH 45204
Phone: 513.921.1075
www.hillandgrif th.com
Die Casting, Squeeze Casting & Permanent Mold
Lubricant products that represent the latest in tech-
nology and ongoing research in die casting, squeeze
casting and permanent mold-release techniques that
will enhance your competitiveness. Cleaner dies while
increasing productivity. Custom blended die lubricants
for your specific application: Diluco 100 Series
water-base, 300 Series for squeeze casting, Concote
low pressure die casting or permanent mold coating
and Plunger Lube water-based for cleaner and more
efficient cooling.
2014
2014
EXHIBITOR SPOTLIGHT
Lindberg/MPH 107
3827 Riverside Road
PO Box 131
Riverside, MI 49084
Phone: 269.849.2700
Fax: 269.849.3021
www.lindbergmph.com
Lindberg/MPH manufactures a complete line of gas and
electric melting and holding furnaces both aluminum and
zinc die casting including:
stack melters, dry hearth and wet hearth
reverberatory melting furnaces
electric resistance (glowbar-type) melting
and holding furnaces
launder systems
immersion melters and holders
metal treatment furnaces
electric and gas crucible furnaces-all sizes
Quality construction and refusal to compromise means you
can count on superior performance.
MAGMA Foundry Technologies 304
10 N Martingale Rd
Schaumburg, IL 60173
Phone: 216.524.2363
Fax: 216.524.9594
www.magmasoft.com
MAGMA Foundry Technologies, Inc. is the indus-
try leading supplier of casting process simulation and
optimization software, as well as related education and
engineering services. MAGMA has been the paceset-
ter in defning a new direction for the diecasting indus-
try. Besides MAGMASOFTs capability of simulating
nearly any alloy and process the MAGMAhpdc and
MAGMAdielife modules were specifcally developed to
consider the specifc process conditions of diecastings.
MAGMA5 Release 5.3 sets a new standard in ease-of-
use, accuracy, and simulation speed.
Midland Technologies 210
14800 James Road
Rogers, MN 55374
Phone: 763.428.4229
Fax: 763.428.4720
www.midlandtechnologies.com
Midland Technologies is your premier resource for Valve-
Less Vacuum and Vent Technology to reduce air porosity,
High Velocity Jet Cooling Technology to combat shrink
porosity, and peripheral mold components.
Vacuum or vent blocks, jet coolers, slides,
and mold components
Calculation of the required air evacuation area
for your casting at no cost
Exit runner layout at no charge with purchase
of a valve-less block
Vacuum systems and flters
Pre-cut and ground to length ejection pins
Core pins with detail
Modern Equipment Company 217
369 W. Western Avenue
Port Washington, WI 53074
Phone: 262.284.9431
Fax: 262.284.9433
www.ModernEQ.com
Modern Equipment Company, Inc. has been serving the
metal casting industry since 1919. Our aluminum melt-
ing furnaces (JetMelt and MicroJet melters), aluminum
holding furnaces and launder systems provide energy
saving capacity to our customers. Foundry Ladles and
other molten metal handling systems, as well as the
parts to keep them in good running order, form another
key portion of our product and service ofering. Call
us at 262-284-9431, email Sales@ModernEQ.com, or
www.ModernEQ.com for Foundry Products.
Paulo Product Company 115
5711 West Park Avenue
St. Louis, MO 63110
Phone: 314.450.4366
Fax: 314.450.4566
www.paulo.com
Paulo Products Company ofers a variety of Heat Treating
services including Batch IQ, Continuous Belt, Vacuum,
and Metal Finishing. Paulo currently consists of 5 plants,
located in St. Louis, MO, Cleveland, OH, Kansas City,
MO, Murfreesboro TN, and Nashville, TN. Please visit us
at www.paulo.com to learn more.
2014
2014
EXHIBITOR SPOTLIGHT
RAYTEQ LLC 202
PO Box 1343
Healdsburg, CA 95448
Phone: 510.638.2000
www.rayteq.com
High powered, compact crucible-type electric
resistance furnaces for melting aluminum,
magnesium and zinc right at the die casting
machine. Unique hybrid digital/analog power
controls shipped factory ready for Rayteqs KW
demand management software
Interactive KW demand management software
(IDMS) for reducing electric furnace utility
demand charges
Retroft kits and software for adapting most
makes of electric resistance melting furnaces
to Rayteq interactive KW demand management s
ystems (IDMS).
Exact replacement, long-life dual-refractory
heating elements for most popular makes of
electric resistance melting furnaces
Portable and compact compressed-air driven,
VacuTest hydrogen porosity checker
Non-contact molten metal level sensors for
accurate level sensing and control
Regloplas Corp. 402
1088 Miners Road
Saint Joseph, MI 49085
Phone: 269.428.1100
Fax: 269.428.1155
www.regloplasusa.com
Regloplas manufactures Temperature Control Units for
the Die Cast Industry. Tey are extremely energy ef cient
due to the cutting edge design and available green technol-
ogy. Models range from water units up to 400F and oil
units up to 660F. A complete line of accessories is avail-
able for a safe and simple installation. Chillers and Cool-
ing Systems are available through Regloplas/Schreiber.
Rimrock Corporation 116
1700 Jetway Boulevard
Columbus, OH 43219
Phone: 614.471.5926
Fax: 614.471.7388
www.rimrockcorp.com
Rimrock Corporation is dedicated to manufacturing
high quality automation solutions to help our customers
reduce their production cost. Rimrocks product line,
including ladles, reciprocators, extractors, and a com-
plete line of spray equipment, is designed to withstand
harsh environments, while keeping you up and running
24/7. Rimrock also provides robot systems for a vari-
ety of applications including, material handling, metal
ladling, die spray, and part fnishing.
Schmolz & Bickenbach USA Inc. 207
365 Village Drive
Carol Stream, IL 60188
Phone: 630.682.3900
www.schmolz-bickenbach.us
SCHMOLZ+BICKENBACH is a leading supplier of
Hot Work Die Steels engineered for maximum tough-
ness and thermal fatigue resistance under extreme con-
ditions. Te company operates seven service centers in
North America, including one heat treatment facility.
SCHMOLZ+BICKENBACH USA supplies the follow-
ing die steels in rounds and fats: 2343 (H11), 2344 ESR
(H13), 2367 ESR, 2714, 2999 ESR and E38K.
StrikoWestofen America 409
501 E. Roosevelt Avenue
Zeeland, MI 49464
Phone: 616.772.3705
Fax: 616.772.5271
www.strikodynarad.com
StrikoWestofen America is a manufacturer of melting,
dosing, and holding furnaces for the light metal casting
industry. Energy ef cient solutions for die casting, gravity
casting (sand and permanent mold) and low pressure cast-
ing. Te StrikoMelter is a tower melter that boasts 2%
or lower metal loss. Te Westomat is a dosing/holding
furnace with a dosing accuracy of +/- 1.5%. Te Dynarad
line includes crucible and non-crucible furnaces, launder
systems, and furnace support products.
Techmire 230
185 Voyageur
Pointe-Claire, QB H9R 6B2
Canada
Phone: 514.694.4110
Fax: 514.694.2634
www.techmire.com
2014
2014
EXHIBITOR SPOTLIGHT
Techmire is the world leader in the design and manufac-
ture of multiple-slide die-casting systems for precision
components in zinc, lead and magnesium alloys, including:
design, manufacture and testing of die-casting
machines and tooling
training of customers operators and maintenance
personnel
full after-sales service
machine retroftting and refurbishing
annual maintenance & support program
Techmire provides cost-efective solutions to manu-
facturers of die cast components to cast complex parts
with faster cycle speed, higher material utilization and
superior part quality.
The Schaefer Group Inc. 311
1500 Humphrey Avenue
Dayton, OH 45410
Phone: 937.253.3342
Fax: 937.937.2503
www.theschaefergroup.com
Te Schaefer Group, Inc. will be displaying their
furnaces at booth #311 at the NADCA Die Casting
Congress & Tabletop in September. In the booth will be
information on electric immersion element holding fur-
naces, transfer ladles along with pictures and informa-
tion on a large variety of furnaces, launders and melting
furnaces. Stop by and see our new Schaefer Shield. Te
best refractory coating on the market!
Toshiba Machine 227
755 Greenleaf Avenue
Elk Grove Village, IL 60007
Phone: 847.709.7000
Fax: 847.593.0897
www.toshiba-machine.com
Toshiba Machine has been manufacturing die cast-
ing machines since 1953. With over 12,000 installed
around the world and more than 13,000 installed
around the world and more than 500 in North America,
its no wonder that quality has grown to be synonymous
with the Toshiba name. We ofer a complete turn-
key system with cold chamber machines ranging from
150-4500 US Tons. With our centrally located Illinois
headquarters, and strategic locations throughout North
and South America, we can back our quality machines
with quality support and service.
Versevo 411
1055 Cottonwood Ave.
Hartland, WI 53029
Phone: 262.912.7154
Fax: 262.369.7793
www.versevo.com
Versevo, ISO 9001:2008 certifed, the moniker for Versa-
tility, Service, Evolution. World class services provider to
the cast metals industry. Oferings include process & tool
design, prototype & production tooling, iron & aluminum
castings, machining, in support of First Shot Success for
High Pressure & Low Pressure Die Cast, Lost Foam Cast,
and Sand Cast. Te exclusive US & CAN sales agents for
Kurtz Gmbh foundry equipment, including low pressure
permanent mold, and trimming machines.
Visi-Trak Worldwide LLC 205
8400 Sweet Valley Drive
Suite 406
Valley View, OH 44125
Phone: 216.524.2363
Fax: 216.524.9594
www.visi-trak.com
Visi-Trak is the leader in process automation in the die-
casting industry - increasing customers ef ciency, quality
level, and proftability. Our 33 year history of monitoring and
shot control applications has provided industry with the tools
needed to increase quality and throughput while decreasing
cost. From high integrity aluminum die-casting, to high-reso-
lution sensor technologies, to (PLC) interfaces, to production
reporting and process control software - Visi-Trak combines
them all into complete process automation solutions.
Zitai USA 105
5133 W. Camino Dr. Manana
Tucson, AZ 85742
Phone: 520.579.0485
Fax: 520.579.0486
www.zitai.com
Zitai USA is the North American agent for Zitai Precision
Machinery Company of Taichung,Taiwan. Zitai Precision
Machinery Company has been manufacturing cold chamber
die casting machinery and automation equipment since 1981
and has thousands of machines installed worldwide. Zitai
Precision Machinery ofers a complete turnkey solution to die
casters including tooling design, build and sampling in addi-
tion to world class equipment utilizing the latest technology
including servo shot technology in cooperation with Visitrak.

NADCA Welcomes Its Newest Corporate Members

East River Solutions Ltd.
In the summer of 2013, long-time toolmaker Jason Everaert merged his existing business with serial entrepreneur and
industry veteran Otto Kjeldsen - to create East River Solutions Ltd.
East River Solutions embodies a fresh vision in custom machining. We ofer value to our customers through our
unique, gutsy and collaborative approach to our work. East River aims to be recognized by our customers and our peers
as the better supplier. We leverage the latest in technology and apply a fresh approach to machining through innovation
in set-up and cutting methodology. We are skilled in creating prototypes, trim dies, fxtures and mould components.
We are located in a brand new 4,000 sq. ft. facility in picturesque Wallaceburg, Ontario - nestled into the extreme
southwest of the province - (40 miles) northeast of Detroit, Michigan. Tis picturesque small town is a little known
center of tooling and design expertise, long utilized by the Big Tree automotive companies in Detroit.
Visit our website at www.ercnc.com to fnd out more about who we are and what we do!

2014 Corporate Members

CORPORATE DIE CASTERS
A
A & B Die Casting Inc.
Hercules, CA
ABCO Die Casters Inc.
Newark, NJ
Able Die Casting Corp.
Schiller Park, IL
ACE Precision International, LLC
Marshalltown, IA
Acme Alliance LLC
Northbrook, IL
Ahresty Wilmington Corp.
Wilmington, OH
Alloy Die Casting
Buena Park, CA
Apex Aluminum Die Casting Co.
Piqua, OH
Auto Cast Inc.
Grandville, MI
B
Blue Ridge Pressure Castings Inc.
Lehighton, PA
Briggs & Stratton Corp. - Milwaukee
Milwaukee, WI
Briggs & Stratton Corp. - Murray
Murray, KY
Briggs & Stratton Corp. - Poplar Bluf
Poplar Bluf, MO
Briggs & Stratton Corp. - Statesboro
Statesboro, GA
Brillcast Inc.
Grand Rapids, MI
C
California Die Casting Inc.
Ontario, CA
Callen Die Casting LLC
Fountain Inn, SC
Callen Manufacturing Corp.
Northlake, IL
Canada Metal (Pacifc) Limited
Delta, BC, Canada
Carteret Die Casting Corp.
Somerset, NJ
Cascade Die Casting Group Inc.
- Atlantic Div.
High Point, NC
Cascade Die Casting Group Inc.
- Corp. HQ
Grand Rapids, MI
Cascade Die Casting Group Inc.
- Great Lakes Div.
Sparta, MI
Cascade Die Casting Group Inc.
- Mid-State Div.
Grand Rapids, MI
Cast Products Inc.
Norridge, IL
Cast-Rite Corporation
Gardena, CA
Cast Specialties Inc.
Warrensville Heights, OH
Chicago White Metal Casting Inc.
Bensenville, IL
CompX Security Products
Grayslake, IL
Congress Drives LLC
Ennis, TX
Cottam Diecasting Ltd.
Tecumseh, ON Canada
Crecocast A Div. of Creco Corp.
Seville, OH
Cuprum SA De CV
Sac Nicolas De Los Garza, Nuevo Leon, Mexico
D
DeCardy Diecasting Co.
Chicago, IL
Deco Products Co.
Decorah, IA
Dwyer Instruments Inc.
Kingsbury, IN
DyCast Specialties Corp.
Starbuck, MN
Dyersville Die Cast - Div. of Joseph L. Ertl
Dyersville, IA
Dynacast de Mexico
Cuautitlan Izcalli, Mexico
Dynacast Inc.
Charlotte, NC
Dynacast Elgin
Elgin, IL
Dynacast Germantown
Germantown, WI
Dynacast Lake Forest
Lake Forest, CA
Dynacast Ltd.
Peterborough, ON, Canada
E
Empire Die Casting
Macedonia, OH
F
Fielding Mfg.-Zinc Diecasting Inc.
Cranston, RI
Fort Recovery Industries Inc.
Fort Recovery, OH
FT Precision
Fredericktown, OH
Future Die Cast & Engineering Inc.
Shelby Township, MI
G
General Die Casters Inc.
Twinsburg, OH
Gibbs Die Casting Corporation
Henderson, KY
GM Powertrain Bedford
Bedford, IN
GM Powertrain HQ
Pontiac, MI
Greenfeld Industries Inc.
Freeport, NY
H
Heritage Die Casting Co.
Denver, CO
Honda Engineering North America EGA -
Tool Block: Powertrain Equipment
Anna, OH
Honda Manufacturing of Alabama LLC -
Engine Plant: ALDC
Lincoln, AL
Honda North America Services LLC -
Powertrain: Engineering Center
Marysville, OH
Honda of America Mfg. -
Anna Engine Plant: ALDC
Anna, OH
Honda of America Mfg. -
North American Purchasing
Anna, OH
Honda of Canada Mfg. Inc. -
Engine Plant: ALDC
Alliston, ON, Canada
Honda Power Equipment -
Aluminum Die Cast
Swepsonville, NC
2014 CORPORATE MEMBERS
Honda Precision Parts Georgia LLC -
Aluminum Die Cast
Lincoln, AL
Honda R&D America -
O: Aluminum Division
Raymond, OH
Honda South Carolina -
Aluminum Die Cast
Timmonsville, SC
Honda Transmission Manufacturing Inc.
Russells Point, OH
Honeywell International
San Diego, CA
I
International Die Casting Inc.
Gardena, CA
J
Joyners Die Casting & Plating
Brooklyn Park, MN
K
Kason Industries Inc.
Shenandoah, GA
KenWalt Die Casting Corporation
Sun Valley, CA
Kinetic Die Casting Inc.
North Hollywood, CA
Kirby West Corporation
Andrews, TX
L
Lakeside Casting Solutions
Monroe City, MO
Laurel Manufacturing LLC
Elk Grove Village, IL
Littler Diecast Corp.
Albany, IN
M
Madison-Kipp Corp.
Madison, WI
Mag-Tec Casting Corp.
Jackson, MI
Mercury Castings
- Div. of Mercury Marine, WI
Fond Du Lac, WI
Meridian Lightweight Technologies Inc.
Strathroy, ON, Canada
Meridian Lightweight Technologies Inc.
- GTC
Southfeld, MI
Meridian Technologies Inc.
- Magnesium Products of America
Eaton Rapids, MI
Meridian Technologies Mexico
Ramos Arizpe, Coahuila, Mexico
Micro Industries Inc.
Rock Falls, IL
Microcast Technologies
Linden, NJ
Midwest Die Casting Corp.
Milwaukee, WI
Muskegon Castings Corp.
Muskegon, MI
N
Nebraska Aluminum Castings Inc.
Hastings, NE
Nemak Alabama
Sylacauga, AL
Nemak Kentucky
Glasgow, KY
Nemak Wisconsin
Sheboygan, WI
North American Casting Corp.
Trussville, AL
Northern Iowa Die Casting Inc.
Lake Park, IA
O
Omni Die Casting Inc.
Massillon, OH
P
Pace Industries - Airo Div.
Loyalhanna, PA
Pace Industries - B&C Div.
Harrison, AR
Pace Industries - Cambridge Div.
North Billerica, MA
Pace Industries - Chihuahua Div.
Chihuahua Chih, Mexico
Pace Industries - Corp. Of ce
Fayetteville, AR
Pace Industries - Grafton Div.
Grafton, WI
Pace Industries - Harrison Div.
Harrison, AR
Pace Industries - Product Tech Div.
Maple Lake, MN
Pace Industries - Saltillo Div.
Saltillo, Mexico
Pace Industries - St. Paul Div.
Saint Paul, MN
Pacifc Die Casting Corporation
Commerce, CA
Pacifc Die Casting Corporation
Vancouver, WA
PECO Manufacturing Company
Portland, OR
PHB - Die Casting Div.
Fairview, PA
Phillips Magnesium Injection Molding
Eau Claire, WI
Pittsburgh Die & Casting Co.
Pittsburgh, PA
Port City Group
Muskegon, MI
Premier Die Casting Co.
Avenel, NJ
Premier Lakewood Inc.
Lakewood, NY
Premier Tool & Die Cast Corp.
Berrien Springs, MI
Prestige Casting Inc.
Englewood, CO
Production Castings Inc.
Fenton, MO
Proto Labs Inc.
Maple Plain, MN
R
Rangers Die Casting Company
Lynwood, CA
RCM Industries Inc.
- Aallied Die Casting Co. of IL
Franklin Park, IL
RCM Industries Inc.
- Aallied Die Casting Co. of NC
Rutherfordton, NC
RCM Industries Inc.
- Imperial Die Casting Co.
Liberty, SC
RCM Industries Inc.
- Inland Die Casting Co.
Wheeling, IL
Regal Beloit Corporation
Beloit, WI
Regal Beloit Corporation
El Paso, TX
Regal Beloit Corporation
Marshfeld, MO
Rheocast Co.
Germantown, WI
Ryobi Die Casting (USA) Inc.
Shelbyville, IN
Ryobi Die Casting Mexico
Irapuato, Guanajuato, Mexico
S
SDC Incorporated
Sullivan, MO
SENSUS Precision Die Casting Inc.
Russellville, KY
2014 CORPORATE MEMBERS
Shiloh Industries
Alma, MI
Shiloh Industries
Auburn, IN
Shiloh Industries
Clarksville, TN
Shiloh Industries
Pierceton, IN
Shiloh Industries
Pleasant Prairie, WI
Simalex Manufacturing Company Ltd.
Langley, BC, Canada
SKS Die Casting & Machining Inc.
Alameda, CA
Soldy Manufacturing Company
Schiller Park, IL
Spartan Light Metal Products Inc.
Sparta, IL
Spartan Light Metal Products LLC
Hannibal, MO
Spartan Light Metal Products LLC
Mexico, MO
St. Clair Die Casting - An EPI Company
Saint Clair, MO
STRATTEC Component Solutions
Milwaukee, WI
Stroh Precision Die Casting LLC
Mauston, WI
T
Team Industries - Detroit Lakes
Detroit Lakes, MN
Technical Die-Casting Inc.
Stockton, MN
Tek-Cast Inc.
Bensenville, IL
TESLA Motors
Fremont, CA
Thomas & Betts Monterrey
Guadalupe, Nuevo Leon, Mexico
TRU Die Cast Corp.
New Troy, MI
TVT Die Casting Die Casting & Manufacturing
Portland, OR
Twin City Die Castings Co.
Minneapolis, MN
Twin City Die Castings Co.
Monticello, MN
Twin City Die Castings Co.
Watertown, SD
W
Walker Die Casting Inc.
Lewisburg, TN
Whitehead Die Casting Co. Inc.
Gainesville, GA
Wilkast, Inc.
Grand Rapids, MI
Wrex Products Inc.
Chico, CA
CORPORATE OEM
ASSA Abloy-Interlock
Reno, NV
Sundaram - Clayton Limited
Deerfeld, IN
CORPORATE SUPPLIERS
A
A Finkl & Sons
Chicago, IL
AarKel Tool & Die Inc.
Wallaceburg, ON, Canada
Allied Metal Co.
Chicago, IL
Alltherm Services Inc.
Highland, IN
American Die Cast Releasants LLC
Fenton, MI
American Metal Chemical Corp.
Medina, IL
Audubon Metals LLC
Henderson, KY
Automatic Anodizing
Chicago, IL
AV&R Die Casting
Saint-Bruno, QC, Canada
B
B & L Information Systems Inc.
Bridgman, MI
Badger Metal Tech Inc.
Jackson, WI
Basic Resources Inc.
Knoxville, TN
Bedford Machine & Tool Inc.
Bedford, IN
Blasch Precision Ceramics
Albany, NY
Bob McClintic & Associates
Jenison, MI
Bodycote Thermal Processing Inc.
Sturtevant, WI
Bohler-Uddeholm United States
Elgin, IL
Brach Machine Inc.
Batavia, NY
BuhlerPrince Inc.
Holland, MI
C
CANMET Materials Technology
Hamilton, ON, Canada
Casting Impregnators Inc.
Franklin Park, IL
Castool Tooling Systems
Uxbridge, ON, Canada
Chemtool Incorporated
Rockton, IL
Chem-Trend Ltd. Partnership
Howell, MI
Colosio Die-Casting Machines & Accessories
Fort Mill, NC
CRD Enterprises, Inc.
Lake Zurich, IL
D
Daido Steel Co. Ltd.
Florence, KY
Delaware Dynamics LLC
Muncie, IN
Die Cast Press Manufacturing Co.
Paw Paw, MI
Die Casting Design & Consulting
Milwaukee, WI
Die Process Control Systems
Manitowoc, WI
Die Therm Engineering LLC
Grand Rapids, MI
Diversifed Machine Inc.
Bristol, IN
DME Company LLC
Madison Heights, MI
DMS
Oldcastle, ON, Canada
DTP Diecast Solutions LLC
Florence, AL
E
East River Solutions Ltd.
Wallaceburg, ON Canada
Eastern Alloys Inc.
Maybrook, NY
EDCO Inc.
Toledo, OH
EKK, Inc.
Farmington Hills, MI
Ellwood Specialty Steel
New Castle, PA
F
Fisa North America Inc.
Elk Grove Village, IL
Flow Science
Santa Fe, NM
2014 CORPORATE MEMBERS
Frech USA Inc.
Michigan City, IN
Fremar Industries
Brunswick, OH
G
Godfrey & Wing Inc.
Aurora, OH
Gosiger High Volume
Brookfeld, WI
GW Smith - a Quaker Chemical Company
Dayton, OH
H
Henkel Corp. - Adhesives Technologies
Madison Heights, MI
Hill & Grif th Co.
Cincinnati, OH
HPM North America Corp.
Marion, OH
I
IDRA North America
Kokomo, IN
Imperial Zinc Corp.
Chicago, IL
Italpresse Industrie, SpA
Englewood, OH
J
J&S Chemical Corp.
Canton, GA
Just In Time Technical Personnel
Solon, OH
K
Kestrel Management Services
Lisle, IL
Kuka Robotics Corp.
Shelby Township, MI
L
LK Machinery Inc.
Holland, MI
Leco Corp.
Saint Joseph, MI
Lincoln International, LLC
New York, NY
Lindberg MPH
Riverside, MI
M
M & I Machine
Benton Harbor, MI
MAGMA Foundry Technologies Inc.
Schaumburg, IL
Metal Conversions Ltd.
Mansfeld, OH
Metal Mechanics Inc.
Schoolcraft, MI
Midland Technologies, Inc.
Rogers, MN
Modern Equipment - An Alco Industries Co.
Port Washington, WI
Mokon
Bufalo, NY
MORESCO USA Inc.
Ann Harbor, MI
N
New Century Heaters Ltd.
Bay City, MI
O
Oerlikon Balzers Coating USA
Rock Hill, SC
P
Paulo Products Company
Saint Louis, MO
PCS Company
Fraser, MI
PiQ2
Livonia, MI
Q
Quad Steel Corporation
Brighton, MI
R
RAYTEQ LLC
Healdsburg, CA
Regloplas Corporation
Saint Joseph, MI
Reis Robotics USA Inc.
Elgin, IL
Rike Equipment Corp.
Ivy, VA
Rimrock Corp.
Columbus, OH
Roberts Sinto Corp.
Lansing, MI
S
Sanyo Special Steel USA Inc.
New York, NY
Saran Industries LP
Indianapolis, IN
The Schaefer Group Inc.
Dayton, OH
Schmolz & Bickenbach Canada
Mississauga, ON, Canada
Schmolz & Bickenbach USA, Inc.
Carol Stream, IL
Sorel Forge
St-Joseph-De-Sorel, QC Canada
Spectro Alloys Corp.
Rosemount, MN
StrikoDynarad Corp.
Zeeland, MI
Superior Aluminum Alloys
New Haven, IN
Swiss-Tek Coatings Inc.
New Berlin, WI
T
Techmire
Pointe-Claire, QC, Canada
Therm-Tech of Waukesha
Waukesha, WI
Toshiba Machine Co. America
Elk Grove Village, IL
Trafgura AG
Stamford, CT
U
UBE Machinery Inc.
Ann Arbor, MI
Ultraseal America Inc.
Ann Arbor, MI
V
VERSEVO Inc.
Hartland, WI
Visi-Trak Worldwide LLC
Valley View, OH
W
Wheelabrator Group Canada
Burlington, ON, Canada
Wheelabrator Group USA
LaGrange, GA
Wollin USA
Plymouth, MI
Z
Zitai USA
Tucson, AZ

Chapter News & New Members

Chapter 3 - W. Michigan
Die Casting at a Golf Course?
Yes, it happened! Not much else goes on at a Golf
Course in West Michigan in March! As reported ear-
lier Western Michigan Professor, Dr. Sam Ramrattan
and his students conceived an idea to design and build a
miniature working and portable Cold Chamber Die Cast
Machine. After accomplishing the task and furnishing a
report to Chapter 3, Dr. Ramrattan upped the ante on
his students. He proposed a challenge to them, to bring
the machine on the road (which is the intent of the project)
to the NADCA Chapter 3 March meeting, they accepted
the challenge. Over the last couple of months his students
have made many improvements to the machine, including;
updating the hydraulic controls, moving platen redesign,
improved metal melting system and the addition of a
shot monitoring system donated by Visi-Trak Worldwide.
Not only did the students step up to the plate with all the
updates and bring the machine to our March meeting at
Tornapple Point golf course, they made parts.
During Happy Hour and Dinner the machine was
available for viewing for the 50 attendees of the meet-
ing. Dr. Ramrattan opened the presentation with a brief
overview of the project and then turned the presentation
over the 2013 project leader Ryan Niewoonder who is
now employed by Parker. Ryan presented a history of the
Chapter 3 Dr. Ramrattan of Western Michigan University
addresses March dinner attendees.
Chapter 3 Ryan Niewoonder, Die Cast in a Box senior
project team, reviews the Die Cast in a Box project.
Chapter 3 NADCA Chapter 3 attendees listen intently and
learn about the Die Cast in a Box project.
Chapter 3 Te die cast machine ready to make the frst shot at
Tornapple Point Golf Course, notice the snow on the fairways!
Chapter 3 Students ready the machine in preparation for the
frst shot.
CHAPTER NEWS & NEW MEMBERS
project and commented on the updates to the machine.
But, now it was time to make good on the promise made
by Dr. Ramrattan and his students. Te machine was
rolled to the veranda, plugged in (literally 110VAC) and
allowed to heat up for 15 minutes. Without any further
delays the frst casting ever made at Tornapple Point
Golf Course was accomplished. To further enhance the
accomplishment 3 more shots were made and the parts
were passed around for all to inspect.
As part of the requirement for passing the Die Casting
Course and running the machine at the March meeting,
the students now have to prove that the machine will run
10 consecutive shots. Shot data must be collected and
analyzed to show machine capability.
NADCA Chapter 3 would like to thank Dr. Ramrat-
tan and his students for all the hard work and congratulate
them on the success on this project. Many of the die cast-
ers in attendance couldnt believe the accomplishment of
the Die Casting in a Box project and the comment they
did it was heard may times.
Te next task involves adding more safety features to
the machine so the machine can be taken on a Road Show
to High Schools and Technology Schools in the area to
promote the art of Die Casting.
Please visit the Chapters Web site www.diecasting.org/
chapter/03 for details on upcoming events.
- Submitted by Rob McInerney, BuhlerPrince, Inc.
Chapter 3 Chairman
New Members: Joe Bowen, Shiloh Industries - Alma Plant;
William Burdue, GM Powertrain HQ; Raymond F. Decker,
Tixomat, Inc.; Dustin McDonald, Shiloh Industries - Alma
Plant; Joel Ramsey, Baker College of Jackson; Dan Stahl,
Shiloh Industries - Alma Plant
Chapter 5 - Chicago
NADCA Chapter 5 held its annual State of the Indus-
try Meeting on Tursday, February 6, 2014 at Collettis
Dining & Banquets. Over 80 members braved cold and
snowy winter weather to attend and learn more about
what they can expect from the economy and the outlook
for the industry in the year to come. Attendees were
treated to two very informative presentations. Te frst
was by our own Eric Treiber. Eric gave an informative
look at what the NADCA Board of Governors does for
the die cast industry and introduced us to OSHAs new
Injury and Illness Prevention Program (I2P2). We also
Chapter 3 Dr. Sam oversees the extraction of the frst part.
Chapter 3 Success, the frst part is made.
Chapter 5 Attendees smile for the camera.
Chapter 5 NADCA Chairman Eric Treiber converses with
attendees.
CHAPTER NEWS & NEW MEMBERS
heard from Jef Brennan, the Technology Manager for
NADCA. He provided us with an overview of the State
of the Industry with a focus on re-shoring and what we
can expect in the months to come. A big thanks to Eric,
Jef, and all who came out to attended this very informa-
tive meeting. Please join us on June 13 for our annual
golf outing and lunch. Te outing will be held at the
Bloomingdale Golf Club this year and it will be an 8:30
am shotgun start. If you are interested in being a spon-
sors of the event or need more information, please feel
free to contact Max Gondek at mgondek@cwmtl.com.
We look forward to seeing you there.
Please visit the Chapters Web site www.diecasting.org/
chapter/05 for details on upcoming events.
Chapter 6 - Cleveland
Please visit the Chapters Web site www.diecasting.org/
chapter/06 for details on upcoming events.
New Members: Ned Stockdale, Northern Iowa Die Casting Inc
Chapter 7 - New York
Leonard Cordaro is president of Premier Die Casting and
was our speaker who presented a preview of Dan Twarogs
State of the Industry which is featured in the January issue
of Die Casting Engineer Magazine.
It would be to your advantage for the die casting
industry, members and associates to read Dan Twarogs
entire report and beneft from a great amount of valuable
information contained in this report.
Chapter 5 Members enjoy a nice dinner.
Chapter 5 Mr. Treiber addresses the crowd.
Chapter 5 Jef Brennan speaking to everyone.
Chapter 7 Dean Fuschetti, President, Microcast Technolo-
gies Leonard Cordaro, President, Premier Die Casting Joseph
Dapsis, President, Carteret Die Casting Corp Joe Hofman,
President, Hofman Die Casting Steve Vitollo Representing
Joseph Vitollo, President, ABCO Die Casting; Santa Claus,
President, North Pole.
Chapter 7 John Mudrak, Vice President of Sales; Charles
Silvera, Casting Manager, Carteret Die Casting; James K
Him, Quality Manager, Carteret Die Casting; Joseph Dapsis,
President, Carteret Die Casting Corp.
CHAPTER NEWS & NEW MEMBERS
Tis meeting was our annual Presidents Night where
we honor our die casting member presidents to receive a
warm recognition and appreciation for their continued
service to our industry.
Dan Twarog, President of NADCA, made note that he
will be speaking on our next Presidents Night in Decem-
ber 2014. Tis was accomplished via telephone call with
John Mudrak, our Chapter 7 Chairman.
Chapter 7 Sponsored a webinar seminar and all chapter
7 die casters had company members partake in this. I (Vito
Toto) was invited by Carteret Die Casting to attend at
their facility in Somerset, NJ.
Steve Udvardy, Director of Education and Technology at
NADCA National was our speaker. His presentation is called
Extending Die Life which covered die design features,
operational factors and care maintenance. Here are some of
the highlights of his presentation: Steve said good casting
design incorporates easy fll, quick cool and easy ejection. He
stresses avoiding sharp corners and heavy wall sections.
Sharp corners create hot spots causing undue stress. Tick
walls cause high heat fux with fatigue. Inadequate draft
promotes soldering and extracting heat becomes harder.
Steve said you need robust die design. Adequate
support with proper clamping to ofset injection forces.
Support is needed under die cavities too. You also need
proper metal fow to avoid surface erosion and proper
heat removal to avoid die fatigue. Steve also discussed the
importance of minimizing variations, cycle times, metal
temperatures, die spray, minimizing die solder, minimiz-
ing scrap, die care and maintenance, stress relieving,
micro-precision shot peen, weld-repair and storage.
Steve gave us a great presentation. He is very knowl-
edgeable and detailed. He covered a lot of subject matter
during the one hour time slot. We all learned a lot.
Please visit the Chapters Web site www.diecasting.org/
chapter/07 for details on upcoming events.
- Submitted by Vito M. Toto, VMT Design
Chapter Program Chairman
New Members: John W Burk, Carteret Die Casting Corp;
Gregory Clark, Premier Die Casting Company; Quanyi Li,
Duchan Technology (HK) Co. Ltd; Burkhard Weber, Lincoln
International, LLC
Chapter 9 - Central NY
Please visit the Chapters Web site www.diecasting.org/
chapter/09 for details on upcoming events.
Chapter 10 - Ontario
Please visit the Chapters Web site www.diecasting.org/
chapter/10 for details on upcoming events.
New Members: Jason Everaert, East River Solutions Ltd;
Ian Robinson, Imacro Inc
Chapter 12 - Wisconsin
You cant be everywhere at once. Someone, somewhere, a
long sometime ago muttered those words for the very frst
time, most likely out of an uncomfortable mix of anxiety,
frustration and a sprinkle of resignation. Unbeknownst to
the mutterer, that mutterance would go on to spawn an
era, one whose tide has risen well above our heads and gets
deeper with every hat we wear. Like it or not, for better or
worse, life has made us all slaves to the Era of Burden.
Dude what the fash does this have to do with Chapter
12 news? Ahhh that is the question, isnt it. Tank you
for keeping me focused, and trust me Im getting there.
I myself felt the whip of Burden come lashing down upon
my fesh one day before Chapter 12s most recent meeting.
It pitted two lives against each other, one personal, the
other professional, something every single one of us can
relate to in one way or another. In most cases and this
one in particular the urgency of my personal issue far
Chapter 7 Charles Silvera, Casting Manager, Carteret Die
Casting; James K Him, Quality Manager, Carteret Die Cast-
ing; Vito M Toto, President, VMT Design.
Chapter 12 People gathered around a machine listening to
a Busch representative explain the process. Noticeably absent:
me. I ll give you three guesses where the guy in the plaid shirt
works. Make that two guesses.
CHAPTER NEWS & NEW MEMBERS
outweighed the importance of the professional one, and it
made for an easy but unfortunate choice.
I say unfortunate because I REALLY wanted to
attend this meeting, mainly because it wasnt really a
meeting at all, but I couldnt be there. On March 12,
Chapter 12 held its frst plant tour in more years than
Ive been a member, and I couldnt be there. Busch Pre-
cision was kind enough to open its doors, explain what
they do and how they do it, even arrange for an on-site
dinner, and I couldnt be there. From what I hear, it
was a great tour well organized, informative and even
included representatives from three other companies
related to the industry. And I couldnt be there.
Any details I would give from the tour & dinner would
be blatant, purely fabricated (though probably entertain-
ing) lies. Why? Cmon, you know thisthats right,
because I couldnt be there. Te good news is, this pity
party Im throwing for myself will be very short lived.
My one saving grace will come in May when Chapter 12
has its second plant tour and last dinner meeting of the
year. Tis ones gonna be at Mercury Marine and will
include a visit to their newly-opened museum, dinner on
the lakeshore and an explanation of salt core technol-
ogy by none other than our very own Dr. Ray Donahue.
To summarize in one word: awesome. If my life should
become another motley confagration of idiomatic drama
within the days leading up to this one, I may very well
have to reshuf e my personal & professional priorities.
One way or another, I will be there.
Dont forget about the Chapter 12 golf outing on Friday,
June 6. Tis years event looks to be the basis by which all
other outings (specifc to organizations within the die cast
industry located in the Midwest) will be compared. Were
already taking reservations for golfers, but its limited to
the frst 144 registrants. Wait, is it registrars? Or maybe
registrationists? Lets just go with golfers and leave it at
that. Take a look at the fyer on the Chapter 12 website,
round up a few buddies and prepare yourselves for golf like
youve never known it before. Yeah its that good.
Please visit the Chapters Web site www.diecasting.org/
chapter/12 for details on upcoming events.
- Submitted by Steve Grall, Shiloh Industries
Chapter 12 Secretary
New Members: Dave L. Bandy, Nemak Wisconsin; Dan
Bazar, Shiloh Industries; John Carroll, Stotek Inc; Randy Fry,
Stroh Precision Die Casting LLC; Zakk Geyer, Stroh Precision
Die Casting LLC; Kathy Gilleran, A. Finkl and Sons; Scott
Harden, Shiloh Industries; Mike Howe, Shiloh Industries;
Larry Kubisiak, Shiloh Industries; Steve Mayer, Promontory
Point Capital; John S. Moch, ATI Ladish Diecast Tooling; Jim
Paulsen, Innovation Mold and Design; Chuck Reed, Stroh
Precision Die Casting LLC; Chris Scheider, Stroh Precision
Die Casting LLC
Chapter 14 - S. Ohio
Southwest OH Chapter 14 had the privilege of hosting
Mr. Bob McClintic, AKA Dr. Die Cast, to their Feb-
ruary meeting that was held at LaPiazza in Troy, OH
on February 11. Bob was asked to use his industrial
Chapter 12 Same guy saying something more about the
company. Wish I knew what that was. Impressively clean and
shiny concrete foor, by the way.
Chapter 12 Members and guests enjoying their meal without
me. How could they?!
Chapter 14 Dr. Die Cast speaks to the attendees.
CHAPTER NEWS & NEW MEMBERS
knowledge in die casting to lead a round table discus-
sion on How to Increase Plant Productivity. With
30+ folks in attendance the discussions were lively
and informative. As expected Bob was able to lead the
group into productive conversations. The attendees
were vocal and willing to share their experiences as
well which made for a great evening. Topics discussed
included costs of compressed air, how to lengthen the
life of furnace liners, common causes of part defects,
pros and cons of plunger lubrication methods and
future of die spray technologies.
On Tuesday March 11, Chapter 14 welcomed Mr.
Rainer Herrmann as a special guest speaker. Rainer
educated the audience on how structural castings came
to be and why there is so much talk about them today.
Of special interest were the technologies behind this
refned die casting process and how the need for pro-
cess control is paramount. All in attendance left with a
much better understanding of the ins and the outs of
making structural parts and the impact that these parts
are making on the automotive marketplace as a whole.
Rainers German heritage made for an insightful and
fun flled evening and much interaction was experienced
with the audience which was not shy in participating.
Your Chapter 14 executive staf looks forward to
working with our members in 2014 and beyond. Please
feel free to contact me or any of our executive team
www.diecasting.org/chapter/14 with your ideas on how
we can become an even more efective chapter for you,
your workmates and your respective companies.
Please visit the Chapters Web site www.diecasting.org/
chapter/14 for details on upcoming events.
- Submitted by Monte Swigart, Combined Technologies Group
Chapter 14 Chairman
New Members: Chris A. Daugherty, Chrysler Group LLC;
James Kreitzer, Honda Engineering North America EGA -
Tool Block: Powertrain Equipment
Chapter 14 Te crowd listens attentively.
Chapter 14 Dr. Die Cast giving his presentation.
Chapter 14 Enjoying dinner and a presentation.
Chapter 14 Members smile for a photo.
CHAPTER NEWS & NEW MEMBERS
Chapter 15 - Southeastern
Please visit the Chapters Web site www.diecasting.org/
chapter/15 for details on upcoming events.
New Members: Kris Oakley, Honda Power Equipment -
Aluminum Die Cast
Chapter 16 - Minnesota
Please visit the Chapters Web site www.diecasting.org/
chapter/16 for details on upcoming events.
New Members: Alan Oppegaard, Northern Iron & Machine
Chapter 17 - St. Louis
Chapter 17 members and advertisers should have received the
2014 Chapter Yearbook a few weeks ago. Congratulations to
committee chairman Randy Tomas, Hellebusch Tool and
Die, on a job well done once again!! NADCA Nationals
Steve Udvardy was the featured speaker for our March 11
Membership meeting. Steve discussed die failure and will
deliver part two of his presentation on April 22. We appreci-
ate Steves eforts to enlighten us. Chapter 17 will dispense
with formal Chapter activities through the summer months.
Please watch your email for the September Membership
meeting notice, and the entry form for the 2014 Golf Outing,
which will be on Friday, September 26 again at Te Links of
Dardenne. Please plan to join us in September.
Please visit the Chapters Web site www.diecasting.org/
chapter/17 for details on upcoming events.
- Submitted by Pete Schiavone, Gateway Metals, Inc.
Chapter 17 Secretary
New Members: Stephen Fall, Nidec Motor Corporation;
Marc Scher, Shapiro Metals
Chapter 25 - Indiana
Please visit the Chapters Web site www.diecasting.org/
chapter/25 for details on upcoming events.
New Members: Rex R. Fish, Linamar; John Hime, Audu-
bon Metals LLC; Keith Martin, Briggs & Stratton Corp -
Murray; Victor Steele, SENSUS Precision Die Casting Inc.
Chapter 29 - South Central
Please visit the Chapters Web site www.diecasting.org/
chapter/29 for details on upcoming events.
New Members: Michael Castle, Shiloh Industries - Clarksville
Plant; Brian Devening, Te Fred Jones Companies, LLC; Marshall
Reeske, Texas State University - San Marcos; Eric Wallace, Toshiba
Chapter 30 - Los Angeles
Please visit the Chapters Web site www.diecasting.org/
chapter/30 for details on upcoming events.
New Members: Abraham Amaya, TESLA Motors; Matt
Kallas, TESLA Motors; Danielle Meenach, Pyrotek Inc
Chapter 39 - SW Michigan
Please visit the Chapters Web site www.diecasting.org/
chapter/39 for details on upcoming events.
New Members: Tomas Dailey, Metal Mechanics Inc; Kurt
Flesher, Shiloh Industries - Auburn Plant; Michael Harris, Shiloh
Industries - Auburn Plant; Bernard Jaeger, Shiloh Industries -
Pierceton; Randy Kinsey, Shiloh Industries - Pierceton; Bryan
Osslelaer, Superior Aluminum Alloys; Justin Turansky, Superior
Aluminum Alloys; Shawn Williams, Shiloh Industries - Pierceton
Members at Large
New Members: Gang Chen, Shanghai Yadelin Non Ferrous
Metal Co., Ltd.; Tomas Fritsch, Foundry-Planet Ltd.; David
Hsu, Dynacast; Worawit Lalitkiattikool, Triumph Motor-
cycles Tailand Ltd; Victor Manea, SHW Automotive Pumps
and Engine Components; Chen Mingsheng, Tripod (Ningbo)
Alloy Manufacturing Co., Ltd.; S.J. Oh, HYUNDAI POW-
ERTECH; Lee L. Song, Motorola Solutions

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submit today! Visit www.diecasting.
org/dce/products to learn how to
put your companys new products,
services and solutions in print.

StrikoWestofen
Introduces Mobile
Website and System-
Specifc QR Code
Identifcation
Te StrikoWestofen Group (Gum-
mersbach, Germany) ofers faster sys-
tem-specifc support to their customers.
Tis is made possible by the new mobile
website of the company, providing the
necessary contact options. A QR code
retroftted to all existing systems allows
service technicians to give targeted
counselling. Te rapid evaluation of
error messages sent via contact form
makes a distinct contribution towards
increased system availability.
Which spare part will improve
the ef ciency of my system? What
does a certain error message mean?
Why is there a drop in the ef ciency
of my system? Tere are a number
of reasons why operators of melting
and dosing systems require rapid and
system-specifc support from compe-
tent service partners.
At StrikoWestofen, service does not
stop after the planning and delivery of
the systems, explains Holger Stephan,
manager of the Service and Spare Parts
department at StrikoWestofen. Even
our process-reliable melting and dosing
systems are subject to wear. In case of
need, a rapid system-specifc reaction is
important as every minute literally costs
money. Te new range of services we
ofer via our mobile website increases
the system availability in particular.
StrikoWestofen is now ofering a
mobile website which is available at:
www.strikowestofen.com/mobile.
Tis service allows targeted counsel-
ling, thus increasing the availability
of the melting and dosing systems.
Chicago White Metal
Launches Fresh
Website Redesign
Ofering Product Design Resources to Engineers
Chicago White Metal, Inc. unveiled
its redesigned website, www.cwmdi-
ecast.com. Te website will serve as
a resource for OEM product design-
ers, engineers, design consultants,
purchasing managers and buyers of
die cast components.
Te new website features two
relevant sections: information about
Chicago White Metals operations
and the Die Cast Design Center
(DC2), a free educational hub with
one of the industrys largest collection
of technical die casting content. Its
purpose is to assist design engineers
and buyers through the die casting
design and purchasing processes.
Features include:
A new die casting blog
A totally reorganized Die
Cast Design Center (DC2)
with new content
Links to multiple CWM
social media sites
FAQ pages with eight diferent
categories of die casting information
Rep locater with interactive map
Chicago White Metal has further
plans to add new content including
videos, case studies, webinar record-
ings and other reference material to
engage visitors on an ongoing basis.
Te sites integration with social
media provides additional options
for the engineering community to
access information.
GW Smith and Sons
Introduces HFC Water
Glycol Hydraulic Fluid
for Die Casters
Out of the many types of fre resis-
tant hydraulic fuids available, the
more popular type of fuids are water
glycol hydraulic fuids, or HFC
fuids. To address the needs of the
die casting industry, GW Smith and
Sons, a Quaker Chemical Company
has introduced a water glycol fuid,
QUINTOLUBRIC 702 46 RD to
its line of products.
QUINTOLUBRIC 702-46 RD is
a premium water glycol (HFC) fre-
resistant fuid that has been approved
by Factory Mutual (FM) Global for
FM approval. QUINTOLUBRIC
702-46 RD is designed to provide
optimum performance in hydraulic
systems where fre-resistant fuids are
required. Key benefts include excellent
fre-resistance, minimal foaming, high
viscosity index and extended pump life
in systems operating under high pres-
sure or in overloaded hydraulic systems.
Please visit www.gwsmithandsons.
com for more information.
Industry News
SHILOH INDUSTRIES, INC. ANNOUNCES
STRATEGIC PARTNERSHIP WITH VELOCYS
Valley City, OH - Shiloh Industries, Inc. has entered into
a strategic manufacturing agreement with Velocys, to be
the preferred fabricator of microchannel cores and future
products being explored. Te cores are an integral compo-
nent of Velocys modular reactors that enable small scale
distributed gas-to-liquid systems that convert unconven-
tional, remote and problem gas into valuable liquid fuels.
Shiloh will be utilizing our advanced laser welding
technology to manufacture the cores for Velocys, said
Ramzi Hermiz, president and CEO of Shiloh. As a pre-
ferred supplier, Shilohs engineering focus on lightweight-
ing will be applied to the development and manufacturing
of future products being designed by Velocys.
Te two companies have been working together since 2012
to develop and implement economic, high quality mass-man-
ufacturing capabilities for the Velocys Fischer-Tropsch (FT)
reactors, based on state-of-the-art manufacturing technology
and quality systems from the automotive industry. Together
with Shiloh, Velocys supply chain can support annual FT reac-
tor orders suf cient for 10,000 bpd of production, and has plans
enabling expansion to 40,000 bpd in time for order growth.
Velocys provides complete smaller scale GTL solutions
that address an untapped market of up to 25 million bar-
rels of fuel a day. As the gas-oil arbitrage remains at an all-
time high and as more global regulations ban the practice
of faring, Shiloh and Velocys expect to see a substantial
increase in demand for distributed scale GTL technolo-
gies. A signifcant opportunity exists for converting low-
value gas into high-value, clean synthetic oil.
Shiloh will be manufacturing these products out of its
Innovation Drive Plant in Valley City, Ohio.
SENATOR RON JOHNSON AND ALDERMAN
JOE DAVIS VISIT MATZEL MANUFACTURING
Milwaukee, WI - Wisconsin Senator Ron Johnson (Rep)
and District 2 Alderman Joe Davis (Dem) met together
on March 26 to tour Milwaukee based, Matzel Manufac-
turing, as they discussed cross party solutions for creating
a pro-hire environment for local manufactures. One of
those solutions is to work with Wisconsin youth appren-
ticeship programs which allow young professionals to
gain real world experience. Te goal is to build capacity
in the workforce by teaching emerging professionals a
strong work ethic and drive to succeed.
Bradley Tech Senior, Anthony Tao, is an example of
how the eforts of Matzel Manufacturing, working with
local and state of cials, are making a positive diference
in the efort to provide young professionals an honorable
career. Tao shared that he is very much enjoying his
apprenticeship and being a part of the Matzel team, stat-
ing that he hopes to join Matzel as a full-time employee
once he completes his apprenticeship. When asked what
he likes most about Matzel, he added the diferent skills
and processes I am learning on diferent machines.
Senator Johnson stated that he believes the foundation
of our local economy is founded in our area employers
and workforce coming together to create a stronger com-
munity. Alderman Davis echoed this message by compli-
menting companies like Matzel Manufacturing for their
innovative solutions when engaging the younger work-
force. Davis went on to show favor in Senator Johnsons
willingness to reach across party lines to share ideas and
create solutions that beneft the public interests.
Matzel Manufacturing co-owners, Brian Nuetzel and
Wayne Matthiesen, were pleased to have been the site
of Senator Johnson and Alderman Davis visit. Nuetzel
is especially pleased to see of cials from the city, state,
and federal levels actively talking about the issues most
pressing to businesses like Matzel. Im happy to see our
elected of cials getting to the root cause of issues that
afect each and every one of us, said Matthiesen.
INDUSTRY NEWS
RIMROCK EARNS PRESTIGIOUS ROBOTIC INDUSTRIES
ASSOCIATION DESIGNATION
Columbus, OH - Rimrock Corporation has received the
Robotic Industries Association (RIA) Certifed Robot
Integrator designation. Te certifcation process included
a review of Rimrocks robotic integration business prac-
tices and individual employee hands-on skill level testing
in robot operation and programming. Seven employees
were tested and passed with a level of Expert and
Technician based on the number of robots installed.
We are delighted to welcome Rimrock Corporation
as our seventeenth Certifed Robot Integrator, said Jef
Burnstein, President of RIA. Te Certifed Robot Inte-
grator program strengthens the overall integrator channel
and allows integrators to benchmark their own pro-
cesses against best industry practices. Based on industry
feedback, we have found that achieving certifcation has
proven to be valuable for integrators looking to showcase
their capabilities to both users and suppliers.
Rimrock has been integrating robots for over 25 years, with
hundreds of successful installations into harsh casting and forg-
ing environments. Tis experience, coupled with RIAs integra-
tor certifcation, can give manufacturers great confdence in
our ability to increase their production with robot automation,
said Mark Reikert, Manager Applications Engineering and
Project Management of Rimrock Corporation.
For more information, please visit www.rimrockcorp.com.
DME BRINGS MOLD TECHNOLOGIES EXPERTISE CLOSER
TO MOLDERS AND MOLDMAKERS IN MEXICO
Madison Heights, MI - Molders and moldmakers in Mex-
icos fast-growing plastics industry will have greater access
to the advanced mold technologies expertise and support of
global mold technologies supplier DME, as the company
has established a permanent presence within Milacrons
integrated High Impact Technology Center in Quertaro.
As plastics companies in Mexico take on more complex
applications and challenging demands, theyre looking for
more support than ever from their suppliers, said Dave
Lange, DME Director of Sales for the Americas. While
other providers continue to use independent distribution
channels, DMEs fagship Mexican facility will bring our
engineering expertise along with the widest selection
of quality mold technologies - bases, plates, components,
hot runners, temperature controllers, and much more
directly to our customers.
B&L INFORMATION SYSTEMS ANNOUNCES
ODYSSEY BOOT CAMP
Bridgman, MI - As part of B&L Information Systems
re-envisioned training initiative, Kristine Craft, Manager
Professional Services, has announced a new two-day
class to be held at the B&L of ce in Bridgman, Michi-
gan. Te new training class will be called Odyssey Boot
Camp and will focus on providing both a high-level
overview of the Odyssey ERP softwares holistic system
and an interactive demonstration of the softwares use.
Additionally, class trainers will answer any company
specifc questions attendees may have.
Craft noted, Tis is a hands-on, kick-starter class focused
on key Odyssey modules to get new staf of to a productive
start. Te overview of Odyssey business processes will also
be benefcial for those Odyssey software users who may not
be familiar with the complete ERP package.
Te Odyssey Boot Camp will be held on May 15 -16 2014.
Tere is also a stand-alone Crystal Reports class May 13 -14
at B&Ls Bridgman of ce. Advanced registration for either
class is required as space is limited. More information may be
found at B&Ls website www.blinfo.com/BootCamp.
FLOW SCIENCE ANNOUNCES ITS 2014 FLOW-3D
AMERICAS USERS CONFERENCE
Santa Fe, NM - Flow Science, Inc. has announced that it
will hold its 2014 FLOW-3D Americas Users Conference
on September 9-10, 2014 in Toronto, ON at the Courtyard
Marriott Downtown Toronto. Advanced training for the
water & environmental industry will be held September
8. All FLOW-3D, FLOW-3D/MP, and FLOW-3D Cast
usersand anyone interested in the FLOW-3D product
suiteare invited to attend the conference.
Te conference will feature customer presentations and
posters from both industry and academia that focus on
validations, benchmarks and case studies, as well as the
latest developments for FLOW-3D presented by Flow
Sciences Michael Barkhudarov, VP of R&D, and John
Ditter, VP of Software Engineering.
For more information, contact visit: www.fow3d.com or
contact Amanda Ruggles at: info@fow3d.com.
WHEELABRATOR CELEBRATES ONE MILLION
SAFE WORK HOURS
LaGrange, GA - Wheelabrator Group reached a major
safety milestone during the frst quarter of 2014 with
1,000,000 work hours (nearly four years of operation)
without a lost time incident.
Over 200 Wheelabrator employees and guests marked
this special event during a safety luncheon at their
LaGrange facility on March 13, 2014.
On March 13, 2014 an American Flag few over the Wash-
ington D.C. Capitol in recognition of the 1,000,000 work
hours for Wheelabrator. Tis fag was then sent to Wheela-
brator with a certifcate in recognition for the 1,000,000 work
hours without a lost time incident. Te fag will be displayed
in the Wheelabrator customer lobby in LaGrange, GA.

People in Die Casting

Godfrey & Wing
Announces Multiple
Promotions
Godfrey & Wing
is pleased to
announce the
promotion of Nick
Chapman to Gen-
eral Manager of
Service Operations,
the promotion of
Han Sim to Gen-
eral Manager of
the Sealant Divi-
sion and the hiring
of Zach Boaz as
Director of Busi-
ness Development.
Chapman, Sim and Boaz will
play instrumental roles in man-
aging teams focused on innova-
tion and excellence, and ensuring
customer involvement and satisfac-
tion. Godfrey & Wing experienced
record growth in 2013, and these
three leaders will help the company
continue its strategic growth into
2014 and beyond.
As General Manager, Service
Operations, Chapman is respon-
sible for leading and managing
daily operations in all the service
facilities of the Company. His
focus will be on optimizing the
service operations and establishing
a stable, viable supply base for the
manufacturing industry.
Chapman has over 25 years of
experience within the manufactur-
ing industry in Canada, Mexico and
the U.S.A. He spent the last three
years as Site Operations Manager for
Godfrey & Wing at both the Toledo,
Ohio impregnation and Defance,
Ohio X-ray service centers.
As General Manager, Sealant
Division, Sims mission is to under-
stand and satisfy customers vacuum
impregnation sealant needs while
providing excellent customer service.
His focus will be on enhancing the
safety and security of his employ-
ees through personal development,
providing a quality product through
improved manufacturing processes
and continuous improvements of
products through strategic research
and development.
Sim has over 10 years of experi-
ence in the aluminum and magne-
sium die casting industry and has
worked for Godfrey & Wing for
seven years, where he was previ-
ously the Quality Manager at the
Aurora, Ohio facility.
As Director of Business Develop-
ment, Boaz is responsible for leading
and managing the sales and market-
ing team to execute strategic initia-
tives. He will focus on developing
strategies to grow the business in
existing markets and expand Godfrey
& Wings reach into parts of Asia.
Boaz has more than 10 years of
experience in the automotive and
aerospace industries in roles rang-
ing from Program Manager to Sales
Director. Most recently, Boaz led
the sales and marketing team for a
key international capital equipment
supplier in the tire industry.
NADCAs Melisa
Ryzner Becomes
Certifed Meeting
Planner
Te North American Die Casting
Associations Education and Meet-
ings Manager, Melisa Ryzner, has
been of cially named a Certifed
Meeting Professional (CMP) by
the Convention Industry Council
(CIC). Tis distinguished credential,
recognized throughout the meetings,
conventions, and exhibitions indus-
try, demonstrates an individuals
comprehensive knowledge of meet-
ing management as well as a com-
mitment to the profession.
Established in 1985, the mission of
the CMP program is to elevate and
enhance the professionalism of the
meetings, conventions, exhibitions
and events industry and the dedi-
cated individuals who are responsible
for meeting management. Demand
for this designation continues to
increase as both employers and
meeting professionals recognize the
high standards of knowledge and
professionalism it embodies. Since
its inception, the CMP designation
has been earned by more than 14,000
individuals in 51 countries and ter-
ritories worldwide.
NADCA is very proud of Melisas
accomplishment and congratulates
her on her new title of Certifed
Meeting Planner.
Nick Chapman
Han Sim
Zach Boaz
PEOPLE IN DIE CASTING
NADCA Remembers
John Matthew Biel
1937 - 2014
John Jack Matthew Biel, 77, of
Harvest, Alabama passed away Sat-
urday, February 15, 2014 peacefully
at his residence. Formerly of Whit-
ing, Indiana, Mr. Biel graduated
from St. John the Baptist Catholic
School, Whiting High School, and
earned his Bachelors degree from
St. Josephs College in Rensselaer,
Indiana. He was a Staf Sergeant
in the U.S. Army, and was a very
active member of St. John the Baptist
Catholic Parish in Whiting.
He was a lifetime member of the
Knights of Columbus. Biel was a
Distinguished Life Member of the
North American Die Casting Asso-
ciation (NADCA) where he served
on multiple committees including
the Board of Governors, with one
term as President (1982-1984). He
also was president of the Whiting-
Robertsdale Chamber of Commerce
for an unprecedented 5 terms.
After his 35 year career in the Die
Cast Industry, Biel retired with his
wife in Harvest, AL in 2007. Jack
is survived by his wife of 47 years,
Lucy Einhorn Biel, his children, his
two sisters, his eight grandchildren,
many nieces, nephews, and a host of
family and friends.
In lieu of fowers, the family sug-
gests donations be made in memory
of Jack Biel to St. Jude Childrens
Research Hospital or Wounded
Warriors Program.

Extending Die Life: Maintenance

& Welding Strategies
Porosity Management: Advanced Analysis
Die Casting Defects - Troubleshooting Guide
Die Casting Defects - Causes and Solutions
NADCA eBooks
With the continued growth of eReaders such as the iPad, Kindle and Nook, NADCA is continuing the process
of making various publications available on these devices. The following NADCA publications are available for
purchase on Amazon and iTunes for $9.99 each.
Evaluation of Surface Finishes on
Aluminum Die Castings
Die Casting Shipment Report 2011
Safe & Reliable Die Clamping
Die Casting Porosity Guidebook
Porosity in Die Castings: An
Overview and Analysis
Energy Saving Manual
High Integrity Die Castings
Master Die Casting Process Modeling
Available on the
|
C L A S S I F I E D S
Classifed advertisements are accepted for publica-
tion in DIE CASTING ENGINEER for sale of
equipment and notice of services and employment
available or wanted. Te net rate is $60 per inch or
fraction thereof (for NADCA members, individual
and corporate) and $70 per inch for all others,
in the 2
1
/
8
in. wide column, payable with order.
Please make remittance payable to DIE CASTING
ENGINEER, and send with copy to: NADCA,
3250 N. Arlington Heights Rd., Ste. 101, Arling-
ton Heights, IL 60004. Contact Athena Catlett at
847.808.3153 or email catlett@diecasting.org.
ADVE RT I S E RS I NDE X
WWW.DIECASTING.ORG/DCE/MEDIAKIT
Brach Machine Inc. brachmachine.com 31
BuhlerPrince Inc. buhlerprince.com OBC
Chem-Trend chemtrend.com 15
Dalton Electric Heating Co., Inc. daltonelectric.com 58
Godfrey & Wing Inc. godfreywing.com 5
LK Machinery, Inc. lkadvantage.com 27
M&I Machine shotendtooling.com 29
MAGMA Foundry Technologies magmasoft.com IFC
NADCA
2014 Awards Nominations
2014 Casting Competition
2014 Die Casting Congress & Tabletop
Advertise in DCE
Government Afairs Conference
Laine Scholarship
NADCA eBooks
NADCA Marketplace
NADCA Techinical Archives
NADCA Webinar Schedule
13
IBC
32
35
11
47
63
19
23
7
Onsite Machining Inc. onsitemachine.com 17
Rocklin Manufacturing Co. rocklinmanufacturingco.com 37
WANTED Salesperson for used
die casting machines and equipment.
Beta Die Casting Equipment
Phone: 416.707.0326
HELP WANTED
NEED HELP?
Training of all personnel, operator to engi-
neer; casting, tooling and process design,
development and procurement. Simulation
of metal and heat flow.
[DC]2 Die Casting Design & Consulting
Henry Bakemeyer and Associates
924 Currie Place, Milwaukee, Wi. 53213
Ph. 414.259.8982
Email: henry.bakemeyer@sbcglobal.net
CONSULTI NG SERVI CES
Multi-slide to 1,200 ton zinc hot chamber,
cold chamber to 4,000 ton. Process, tooling
and machine training, process optimization
and scrap reduction projects Project and
program management Infrastructure
review and optimization
Bob McClintic, Die Casting Consultant
2544 Almar St.
Jenison, MI 49428
Cell: 616.292.0454
Fax: 616.669.7884
E-mail: RMcClintic@DrDieCast.com
Web: www.DrDieCast.com
CONSULTI NG SERVI CES
Used Die Casting Equipment
For Sale
See the latest additions to our huge
inventory at www.betadiecasting.com
Tel: 519.621.0799
Email: sales@betadiecasting.com
FOR SALE
Production Castings is seeking a Zinc Die
Cast Manager who is well organized and has
extensive current knowledge in the zinc die
casting injection molding feld, including
secondary related operations. Te candidate
should have a minimum of 3-5 years experience
managing all of the duties and aspects of a zinc
die cast department, such as establishing and
monitoring production processes and evaluating
them to reduce waste, excessive handling and
to Lean Out current processes. Also assist
in the design of new tooling and equipment
and recommend improvements to our existing
tooling to increase productivity.
We are a zinc and aluminum die cast
company which has been in business since
1976. For general information about our
company and its capabilities you may go
to our website, productioncastings.com.
Resumes may be mailed or sent by email to
rebecca@productioncastings.com, please
include salary requirements when applying.
We are an Equal Opportunity Employer
and participate in E-Verify.
Production Castings, Inc
1410 West Lark Industrial Park
Fenton, MO 63026
HELP WANTED
Sales Rep Wanted! Toshiba Machine Co.,
America Die Casting is currently looking
for a sales representative to handle our ever
growing territory. Toshiba Machine has
been manufacturing die casting machines
since 1953. With over 13,000 installed
around the world and more than 500 in
North America. Our machines range in
size from 150-4500 US Tons.
Send your resume to:
dcsales@toshiba-machine.com.
HELP WANTED
Midwest precision machining company
is looking to partner with or purchase a
high pressure aluminum die caster.
Up to 1800 ton, $7-25M revenue
and EBITDA > $500K.
Contact Steve Mayer at
SLM@promcp.com 414.225.0484 ex:4
www.promontorypointcapital.com
SERVI CES WANTED
2014 INTERNATIONAL
DIE CASTING DESIGN
COMPETITION
www.diecasting.org/castings/competition
CastingsDue onJune 30 2014
AluminumUnder 1lb.
Strip Cut Stripper
MagnesiumOver 2lb.
Light Engine Enclosure
Zinc, Any SizewithDecorativeFinish
Base Cabinet Door
Zinc Over 6oz. Non-Electroplated
Top Cast, RH Univ. Gear OCL
Zi O 6 N El t l t d
MagnesiumUnder 2lb.
Ultrasound System Electronics
Enclosure & Power Supply Shield
Aluminum Over 10 lb. - Squeeze Casting
Clutch Housing
Aluminum Over 10 lb.
Housing Upper Dual / Lower Dual
Aluminum Over 10 lb. - Structural Casting
B Pillars (Left and Right)
Aluminum 1 to 10 lb.
Clutch Retainer Annulus
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