• Energy Resources - North American Die Casting Association

    This guide focuses on building a culture of energy awareness by using a continuous improvement process to incorporate employees in assessing and improving energy use throughout the facility. The main area of focus is on low/no cost process improvements. NADCA is working on tailoring this process to the die casting industry.

  • METALS Program Overview - arpa-e.energy.gov

    provide benchmark performance targets for light metal production. These are the basis for the establishment of the cost targets for Al, Mg, and Ti described in Section I.E. Table 3: Energy, emissions, and cost requirements for parity with steel and stainless steel (current values taken from Tables 1 and 2). Aluminum Magnesium Titanium

  • Metal Casting | US EPA ARCHIVE DOCUMENT

    Most of the energy use in the metal casting sector (approximately 55% of total energy costs) can be attributed to the melting of metals, but moldmaking and coremaking also utilize significant amounts of energy.9 Opportunities to improve energy efficiency include updating old gas-fired equipment and substituting water for lubricant to cool heated die surfaces.10

  • 89 questions with answers in METAL CASTING | Science topic

    Oct 05, 2020· 3- Is there any way to calculate fuel wise energy intensity values in a metal casting plant by only having total energy consumption and total production capacity values and further breakdown of ...

  • Energy Efficiency and Cost Saving Opportunities for Metal ...

    This Guide provides information to identify cost-effective practices and technologies to increase energy efficiency in each of three industrial metal casting segments: iron, steel and aluminum. It focuses on the most important systems, processes, and practices that account for the bulk of energy consumption.

  • 4. Process for High Integrity Castings, AFML TR-74-152 ...

    Metal projections in the form of elongated areas in the direction of mold assembly Crush A 220: Projections with rough surfaces A 221(a) Projections with rough surfaces on the cope surface of the casting Mold drop or sticker A 222(a) Projections with rough surfaces on the drag surface of the casting (massive projections) Raised core or mold ...

  • The Metal Casting Operation - Manufacturing

    The Metal Casting Operation Pouring, Fluidity, Risers, Shrinkage And Other Defects In the previous section the fundamentals of the metal casting process, as the basic starting point for metal fabrication and part manufacture, were covered. Setup and design of a system to perform a casting …

  • Frequently Asked Questions (FAQs) | Building Energy Codes ...

    In the 2015 IECC, Section C402.1.1 Low-energy buildings – low energy buildings or portions separated from the remainder of the building by a building thermal envelope complying with the code, can be exempt from the building thermal envelope...

  • METAL CASTING GUIDEBOOK - Focus on Energy

    May 24, 2006· The Metal Casting Industry Energy Best Practice Guidebook provides Wisconsin metal casters a reference for reducing process energy used in metal casting. The guidebook contains individual best practice descriptions as well as tips for overcoming the most common barriers encountered during implementation of these practices.

  • Energy Audit Uncovers Major Energy Savings for Paper Mill

    Focus on Energy’s Best Practice provides specialized support for the pulp and paper, metal casting, plastics, food/dairy and water/wastewater industries. These services improve the energy efficiency of manufacturing processes. Services include walk-through audits, project

  • How to Improve Mental Focus to Help You Achieve Your Goals

    Step 1: Choose Your Area of Focus. Once you have blocked out a specific amount of time to work on your goal, it’s important that you get very clear about how this time will be used. In other words, you must specify what your area of focus will be. Let’s say that you have allocated a couple of hours today to work on accomplishing your goal.

  • Metalcasting | Department of Energy

    The metal casting industry is vital to the U.S. economy and national security. Cast metal components are used in the energy, automotive, aerospace, railroad, electronics, manufacturing, plumbing, construction, and other industries. In the metal casting industry, the melting of metal accounts for approximately 55% of total energy costs.

  • Energy and material efficiency metrics in foundries ...

    Jan 01, 2018· Material flows are expressed in kg and energy flows in GJ. 424 Emanuele Pagone et al. / Procedia Manufacturing 21 (2018) 421–428 4 Author name / Procedia Manufacturing 00 (2017) 000–000 3. The shape casting process steps Metal casting encompasses a large and diverse family of processes that can be categorised in different ways.

  • CleanTech Partners

    We know energy consumption and we know the key Wisconsin end-user industries – pulp & paper, metal-casting, plastics and food processing – that would benefit most from increased energy efficiency. We also know that these key industry end-users often identify energy savings opportunities but lack the financing, industry knowledge or both, to ...

  • Guidebook on Energy Management for SMEs

    Guidebook on Energy Management 4 Chemical Electricity 35% Heating 45% Sewage 8% Fresh water 12% 1.3 Characteristics of different industries The following table gives an overview of energy intense industries and the proportion of energy costs as a percentage of total costs: Mining 8,7 % Metal production and processing 6,2 %

  • DEVELOPMENT OF ENERGY STAR® ENERGY PERFORMANCE …

    May 17, 2017· ENERGY STAR Focus on Energy Efficiency in Metal Casting, as well as input from the American Foundry Society (AFS), Steel Founder’s Society of America (SFSA) and North American Die Casting Association (NADCA).

  • PROJECT ASSESSMENT INCENTIVE - Focus on Energy | Focus …

    Focus on Energy works with eligible Wisconsin residents and businesses to install cost effective energy efficiency and renewable energy projects. Focus on Energy information, resources, and financial incentives help to implement projects that otherwise would not be completed, or to complete projects sooner than scheduled.

  • The Metal Casting Process Explained | General Kinematics

    energy prices are not "right", energy consumption decision makers cannot be counted on to make the correct resource mix choices. In short, energy is underpriced, because of a combination of improper supply incentives, market failures, and social costs. As a result, the cost per BTU paid in the market is a poor indicator ofthe true

  • Investigating the energy consumption of casting process by ...

    Investigating the energy consumption of casting process by multiple life cycle method Binxu Zeng1, Mark Jolly1, Konstantinos Salonitis1 1Cranfield University, Cranfield, Bedfordshire, MK43 0AL, UK [email protected] Abstract The Constrained Rapid Induction Melting Single Shot Up-Casting(CRIMSON) process is an alternative casting process to conventional casting that can be …

  • Metal casting | US EPA ARCHIVE DOCUMENT

    The most energy-intensive process in metal casting is the melting of metal, which accounts for approximately 55% of total energy costs.6Other energy-intensive processes include core making, mold making, heat treatment, and post-casting activities.

  • ITP Metal Casting: Theoretical/Best Practice Energy Use in ...

    Home » ITP Metal Casting: Theoretical/Best Practice Energy Use in Metalcasting Operations doebestpractice_052804.pdf OFFICE of ENERGY EFFICIENCY & RENEWABLE ENERGY

  • ENERGY STAR Focus on Energy Efficiency in Metalcasting ...

    The “metalcasting focus” is a partnership between EPA’s ENERGY STAR program, the American Foundry Society, and metalcasting companies to improve energy efficiency within their operations. Tools are available here to help improve manufacturing energy efficiency, save money, and reduce greenhouse gas emissions.

  • Energy Consumption in Metal Additive Manufacturing ...

    Mar 28, 2019· Joule Printing™ is the most energy efficient end-to-end metal AM process, followed by Binder Jetting and Laser Powder Bed Fusion. Wire DED is the least energy efficient mostly due to its high material waste. LPBF wastes the most energy in the printing process. All these processes are dominated by the energy consumed in primary metal production.

  • MnTAP – Resources & Associations

    Focus on Energy Guidebook: Metal Casting Industry Energy Best Practice Guidebook (2006) [PDF 463KB]. DOE Summary: Ford Cleveland: Inside-Out Analysis Identifies Energy and Cost Savings Opportunities at Metalcasting Plant (2003) [PDF 265KB]. Sixteen projects were identified at this facility and have a combined potential annual savings of $3.3 ...

  • Tapping Hot Slag for Energy | Primetals Technologies

    Thomas Fenzl: Research on dry slag granulation processes actually started decades ago, but without the focus on energy recovery. With energy prices on the rise and regulations on efficiency getting tougher, the steel industry was looking for possibilities to recapture energy that was being wasted in its processes.

  • Impacting Energy Through Smart Manufacturing

    Dec 03, 2020· Honeywell (Metal Additive Manufacturing): 5% energy savings can be derived from Yield Improvement, reduced transportation and Energy savings relative to traditional casting and forging processes. Current AM metal processing yields are 90% at best.

  • Note on the Rate and Energy Efficiency Limits for Additive ...

    Nominal primary energy values for sand and die casting are generally in the range of 10 to 20 MJ/kg (Dalquist and Gutowski 2004a, 2004b). The minimum energy required to melt aluminum from room temperature to the melt temperature is about 1.4 MJ/kg and will vary slightly from this value depending upon alloy content.

  • Metal Castings - an overview | ScienceDirect Topics

    The casting process involves the following general steps: patternmaking, molding, melting, pouring, ejection, cleaning, fettling, and inspection. A majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. There are ferrous (iron or steel) and nonferrous (aluminum, brass, bronze, copper, etc.) foundries.

  • Doug Presny - Energy Engineer - Process Optimization ...

    High temperature processes such as Metal Casting and Heat Treating are highlighted areas of expertise. Principal ... Focus on Energy. 1999 – 2005 6 years. www.focusonenergy.com.

  • Energy Efficiency and Cost Saving Opportunities for Metal ...

    Nov 08, 2016· Energy costs typically account for 5-7% of the overall operating costs in a metal casting foundry. Energy waste is found in all plants, and improving energy efficiency goes …

  • Waste Heat Recovery - Energy.gov

    Metal Casting ... energy efficiency focus on reducing the energy consumed by the equipment used in manufacturing (e.g., boilers, furnaces, dryers, reactors, separators, motors, and pumps) or changing the processes or techniques to manufacture products. A valuable alternative approach to improving overall energy efficiency is to

  • Overcoming Barriers to Energy Efficient Process ...

    Focus on Energy program promotes savings and technologies through trade allies and how this relationship benefits both entities. Overview of the Foundry Industry As of 2004, there were about 2,480 metal casting facilities in the United States. This industry employs approximately 161,000 people. Six states comprise over 60% of shipments (Table 1).