NADCA Headquarters Update Presentation for Die Materials Committee Meeting NADCA Headquarters - Wheeling, IL June 10, 2009

Outline DOE/CMC Update DOD/AMC Update HyperCAST Status Proposals Seeking NADCA Funds Congress and Exposition Miscellaneous

DOE/CMC Update Energy-SMARRT Program –Initiated in FY2004, Planned $12M Over 3 Years –Actual Funding: $1.4M Y1, $2.4M Y2, $2.0M Y3, $982K Y4, $194K Y5 FY2009 Y6 –Initially Under Continuing Resolution –Budget Approval for $552K, leaving $3.4M unfunded FY2010 –$2M Initially in Budget, President’s Request $0 –Congress May Change This

DOD/AMC Update AMC Phase IV (CIR) –FY’09 Funding Approved ~ $2.2M –Money Runs Out Oct 2010 –12 Month Extension Request Pending AMC Phase IV Add-on (CIDR) –Year 2 Funding $170K-200K for Die Casting –No Year 3 FY’09, ATI Pursuing FY’10 Funds –No-Cost Extension Through Oct 2009 Next Program Review June 24 & 25, 2009

DOD/AMC Update (Cont) Proposal Submitted by AMC to Benet Labs: Superior Weapons Systems through Castings (SWC) Program Focus: Light Weight Low Cost Parts Attempted to get $3M/Yr Up To 3 Years $1.2M for Year 1 Available = $200K for Die Casting NADCA Project Selected: Nano-Composite Materials Aniticpated Start Date: July 1, 2009

HyperCAST Program Status Appropriations for FY’09 –House Mark was at $1.5M for Year 1 –Now defined as a 5-Year Program –Senate and House Finalized Budget at $1.5M DOE HQ Approved as Sole Source Project Letter Received from Contracting Office, NETL, Requesting Paperwork Info Received from Researchers One Year Contract in Negotiation Stage Anticipated Start in July

TAG Activities Group Had Not Met Since Before Last Meeting Although Proposals have been Submitted, NADCA Budget for 2009 May not Allow for More than ~$2000

113 th Metalcasting Congress April 7-10, 2009 (Tues-Fri) in Las Vegas, NV 11 NADCA Congress Sessions (Tues-Thurs) –8 Regular Sessions –3 Special Format Sessions Plunger Lubricants Die Maintenance & Repair Die Spray Session Attendance: 17-50, Ave. 35 Total Attendance: 1215 Awards Luncheon –Safety Awards –Casting Competition Awards –Special Recognition Awards (TCM for 2009: J. Brennan)

CastExpo’10 Sat-Tues, March 20-23, 2010, Orange County Convention Center, Orlando FL 11 Sessions, 3-4 Special Format Sessions Theater on Show Floor for Training and Short Special Presentations (20 Minutes) Classroom for Short Courses (4 Hours) Call for Papers is Out!

Guidebook Report Compilations Turn Research Into Action 1 st Round –Die Materials  –Cast Materials  –Computer Modeling  –Process Technologies  –Die Surface Engineering  2 nd Round –Computer Modeling II  –Cast Materials II  –Process Technologies II  –Die Materials II 

Worldwide Reports Process Technology (Done) Die Materials Technology (Done) Dimensional Report (Done) Computer Modeling (Done) Cast Materials (Zn Done, Al in Layout)

R&D Plan 2010 Overview Scheduled for July DCE Full Version to be Posted on Web Shortly Thereafter Productivity Focus Results of Joint Planning Session Included

What’s New Dust Safety Course English & Spanish Extending Die Life for Al Die Casting Die Casting Porosity Guidebook