Energy-Saving Melting and Revert Reduction (E-SMARRT): Energy Efficiency Instrumentation

As with any manufacturing operation, the metalcasting processes have several sources of variation. Additionally, the metalcasting industry routinely produces a wide variety of complex shaped components, which often exacerbates the problem of determining the source of variation. The goals of this project were to develop better tools and strategies to collect and manage process and product information. Based on industry feedback, five areas were selected based on the amount of variation caused by this source or the potential for improvement in terms of energy, emissions and competitiveness. These five areas were: 1. Heat Treatment Control Strategies 2. Semi-Automated Grinding 3. Surface Mapping Software 4. Study of Impact of Repairs via Weld Gouges 5. Rapid Pattern Making Machine This project collectively looked at areas of the steel casting production process which could help reduce the rework, scrap and energy consumption required. Through these efforts, casting producers are better equipped to control their processes and specify processes that better meet their customers’ needs