1 NADCA Headquarters Update Presentation for R&D Committee Meeting ORNL, Oak Ridge, TN June 14, 2007

2 Outline DOE/CMC Update DOE/CMC Update DOD/AMC Update DOD/AMC Update New Proposed Project New Proposed Project Miscellaneous Miscellaneous

3 DOE/CMC Update DOE/CMC Update DOE 2004, 2005, 2006 Cycle: Energy-SMARRT Program DOE 2004, 2005, 2006 Cycle: Energy-SMARRT Program –$12M Proposal –Actual Funding: $1.4M Y1, $2.4M Y2, $2.0M Y3, ??? Y4 DOE Congressional Budget Request FY’07 - $982K for Metalcasting now suggested at $1.98M DOE Congressional Budget Request FY’07 - $982K Initial Request for Metalcasting now suggested at $1.98M Continuing Resolution Continuing Resolution

4 DOE/CMC Update (Cont.) DOE/CMC Update (Cont.) Year 1 Req Actual Year 2 Req Actual Year 3 Req Actual Year 4 $625K$441K$1,179K$920K$1,200K$450K+$125K$225K+$125K E-SMARRT FUNDS FOR DIE CASTING PROJECTS NADCA Board Approved another $125K of NADCA Funds to be Added to E-SMARRT for Year 4 as they did for Year 3

5 DOD/AMC PRO-ACT AMC Phase IV (CIR) AMC Phase IV (CIR) –$10M over 4 years, ~$1.4M for Die Casting –Next Review Oct 24 & 25, 2007 in Chicago –Andy Behler - Industry Board Member AMC Phase IV Add-on (CIDR) AMC Phase IV Add-on (CIDR) –$200K for Die Casting in Year 1  Casting Alloy Standards: NADCA/WPI $110K  High Production Rate Tooling: CWRU $90K –Contracts Let, Money Available –Could be Funding Available for Out-years

6 New Proposed Project: HyperCAST Objective: Develop materials and processes for high strength, light weight cast components for vehicles that are affordable and offer the potential for 60% weight reduction and related improvement in energy efficiency Objective: Develop materials and processes for high strength, light weight cast components for vehicles that are affordable and offer the potential for 60% weight reduction and related improvement in energy efficiency Based on CSM Auto-ignition Synthesis Material Development Based on CSM Auto-ignition Synthesis Material Development 4-Year Program, Multi-Million Dollar 4-Year Program, Multi-Million Dollar CSM, CWRU, OSU, WPI, ORNL, Purdue CSM, CWRU, OSU, WPI, ORNL, Purdue Industry Partners – Automotive Related Industry Partners – Automotive Related

7 TAG Activities Review of Current NADCA Projects Review of Current NADCA Projects –Decision: #146 Die Casting Mechanical Property Improvements Through Process Enhancements Proposed Projects Proposed Projects –New submittals:  #155 Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes  #156 SSM Processing Databases for Designers and Metalcasters  Impact and Thermal Fatigue of the New Grades  A Comparative Study on Bainitic and Martensitic Structures  Optimization of the Tempering Process – Times and Temperatures Funding Allocation for Existing Projects Funding Allocation for Existing Projects Alternate Funding Sources Alternate Funding Sources Foreign Technology Foreign Technology

8 111 th Metalcasting Congress May 15-18, 2007 (Tue-Fri) in Houston, TX, at Hilton Americas May 15-18, 2007 (Tue-Fri) in Houston, TX, at Hilton Americas Total Attendance: 1800+, Exhibits: 200 Total Attendance: 1800+, Exhibits: 200 NADCA Sessions Tue-Thurs NADCA Sessions Tue-Thurs –7 Regular Sessions, 21 Papers –4 New Format Sessions  Rough Machining of Dies, Rapid Tooling, Energy, Environmental Issues –Session Average Attendance - 55 Die Casting Competition Die Casting Competition NADCA Awards Luncheon NADCA Awards Luncheon

9 CastExpo’08 May 17-20, 2008 (Sat-Tue) in Atlanta, GA, at Georgia World Congress Center May 17-20, 2008 (Sat-Tue) in Atlanta, GA, at Georgia World Congress Center NADCA Sessions Days TBD NADCA Sessions Days TBD Exhibits Exhibits Call for Papers, Abstracts due Aug 31, 2007 Call for Papers, Abstracts due Aug 31, 2007 Die Casting Competition Die Casting Competition

NADCA R&D Strategic Plan and Roadmap Overview Article Written and to be Published in July 2007 DCE Magazine Overview Article Written and to be Published in July 2007 DCE Magazine Full Version of Plan Completed in June 2007 for Posting on the Web Full Version of Plan Completed in June 2007 for Posting on the Web

11 Guidebook Report Compilations Turn Research Into Action: 1 st Round Turn Research Into Action: 1 st Round –Die Materials  –Cast Materials  –Computer Modeling  –Process Technologies  –Die Surface Engineering  2 nd Round to Start Next Quarter 2 nd Round to Start Next Quarter –Latest guidebook reports will be added to the compilations above

12 Plant Management Conference September 19-21, 2007 September 19-21, 2007 Hilton Milwaukee City Center Hilton Milwaukee City Center Roundtable Discussions Roundtable Discussions Special Topics: Defect Tracking, Vacuum, Plant Emissions Special Topics: Defect Tracking, Vacuum, Plant Emissions Tours: Stroh, EST?, Albany Chicago? Tours: Stroh, EST?, Albany Chicago?

13 New Products User’s Guide for Relieving Stresses in Die Casting Dies User’s Guide for Relieving Stresses in Die Casting Dies Guide to Process Monitoring & Control Guide to Process Monitoring & Control Rough Machining of Die Casting Dies Rough Machining of Die Casting Dies Die Casting Safety Die Casting Safety