ALSO INSIDE

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Die Materials | 2013 Annual Report | MARCH 2014
Improved
resIstance to
Heat cHeckIng
ALSO INSIDE:
2013 AnnuAl RepoRt

NORTH AMERICAN DIE CASTING ASSOCIATION
Volume 58 Number 2
NADCA® and the NADCA logo above
are both registered trademarks of the
North American Die Casting Association.
MARCH 2014
FEatURES dEPaRtMEntS
02 Chairman’s note
17 2013 annual Report 03 Letter From the Editor
06 Washington Insights
08 nadCa Reports
10 dr. die Cast
32 Qualification of additive Manufacturing Processes and Procedures 12 oSHa + EPa awareness Update
for Repurposing and Rejuvenation of tooling 48 Corporate Member List
– D. Schwam, P. Denney, M. Kottman, S. Udvardy 52 Chapter news & new Members
59 new Products, Services & Solutions Die Materials | 2013 Annual Report | MARCH 2014
60 Industry news & Information
38 die Materials 62 People in die Casting
– B. Andresen 64 Classified advertising
64 advertising Index
40 Put a Check on Heat Checking with an Enhanced die Steel
– J. Price
44 Exhibitor Spotlight
The NADCA logo was hidden here this month. Did you find it?
PUBLISHER
Daniel L. Twarog
Die Casting Engineer (ISSN 012-253X) is published bimonthly, six times per year, by the North ManagIng EdItoR
American Die Casting Association, 3250 N. Arlington Heights Rd., Ste. 101, Arlington Heights, Illinois Andrew Ryzner
60004. Periodicals postage paid at Arlington Heights, Illinois 60004 and at additional mailing
adVERtISIng & PRoMotIonS ManagER
office. POSTMASTER: Send address changes to address listed above.
Athena Catlett
gRaPHIC dESIgnER
Non-member subscription rates: $60 one year U.S., Canada & Mexico; $135 one year other countries Kristen Castillo
(international airmail). Single copies $15 each, except for Suppliers Directory, $35 (Single issues EdUCatIon & MEEtIngS ManagER
available in North America only). IMPROVMelisa RyznerED
EXECUtIVE oFFICES
All material copyright 2014 by the North American Die Casting Association. All rights reserved. 3250 N. Arlington Heights Rd., Ste. 101
Arlington Heights, Illinois 60004
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 Phone: [phone]
published in this magazine unless it has been explicitly approved by the NADCA Board of Governors. Fax: [phone]
Email: [email protected]
REWeSb site: ISwww.dTiecastinAg.org/dce NCE TO
www. diecasting.org/dce MARCH 2014 1DIe CAStInG enGIneeR | 1
HEAT CHECKING
ALSO INSIDE:
2013 ANNUAL REPORT
Chairman’s Note
Where Have We Been and
Where are We going?
This is the time of year when NADCA focuses on the State of the Industry. Where
have we been (in 2013) and where are we going (in 2014)? The discussion centers
around the financial metrics for the industry as you would expect. I would like to
take this time to put a little spin on the typical dialogue, and instead focus on safety. Eric Treiber, President & CEO
“Where have we been and where are we going?” Chicago White Metal Casting Inc.
There can be no dispute that the most important issue all die casters must focus NADCA Chairman
on every day is the safety of every associate in our facility. Die casters overall, with
support from NADCA, have done a tremendous job of improving safety levels in
the last 10 years. Specifically, from 2002 – 2011, the industry has realized a 65%
reduction in “lost work day injuries and illnesses”. Our efforts though are a journey
that continues forever with the ultimate goal of creating a “Zero Incident” culture.
“ OSHA ... is
OSHA continues down this path as well, and is currently looking to implement an
Injury and Illness Prevention Program (I2P2) at the Federal level. Fifteen states already
have some form of I2P2 programs, including the following states with significant die cast- currently looking
ing facility populations: California, Michigan, Minnesota, North Carolina, and New York.
The I2P2 model starts with OSHA’s 1989 Safety and Health Guidelines, but takes it to to implement
a higher level. There are 6 principles at the heart of I2P2, which are: Management Lead-
ership, Worker Participation, Hazard Identification and Assessment, Hazard Prevention an Injury and
and Control, Education and Training, and Program Evaluation and Improvement.
NADCA is working very closely with OSHA, through our Washington Repre- Illness Prevention
sentatives (The Franklin Partnership – TFP) to have an industry representative sit
on an I2P2 Small Business Review Panel which provides input to federal regulators Program (I2P2) at
on the impact of this new rule on businesses.
The efforts of NADCA’s Government Affairs arm often go unnoticed and under-
the Federal level.”
appreciated, but this is a clear example of how this committee is working to help
shape federal policies and rulemaking in support of the membership. You can show
your support for NADCA’s Government Affairs efforts by attending the Washing-
ton Briefing June 10 - 11, 2014.
You can expect to hear much more in the coming months about OSHA’s I2P2 initia-
tive and how it could affect your operations. If you would like to learn more about the
details of I2P2, and each of its six principles, type the following link into your browser:
http://goo.gl/vmpB9E, and then click on “Download Free I2P2 White Paper”.
In addition to all the other activities NADCA is currently engaged in with respect
to promoting a safe working environment for the industry, NADCA is also going
to begin work on creating a safety manual that is specific to die casting operations.
This would be a very comprehensive document that could serve as the framework for
a new, robust safety program, and also would be a solid reference to compare against
an existing safety program. Look for more on this in the latter part of 2014.
This issue of Die Casting Engineer is focused on Die Materials and contains excel-
lent information on research that is ongoing in this area, including a great article that
reminds us of the responsibility we have to our customers when it comes to choosing the
proper tool steel as well as a fascinating investigation on Repurposing and Rejuvenation
of Tooling. Near the conclusion of the “Repurposing” article, die casters are encouraged
to contact NADCA to learn how they can get involved in this experimental program
during the qualification and evaluation phase. Don’t miss out on this great opportunity.
NADCA has so much to offer its members. I hope your company is taking advan-
!
tage of all that is available.
2 | DIe CAStInG enGIneeR 1MARCH 2014 www. diecasting.org/dce
From the Editor’s Desk
Using nadCa’s online
Education Services
Andrew Ryzner
As many of you probably know, my duties involve more than just being the Managing
Managing Editor
Editor of Die Casting Engineer magazine for NADCA. I delve into various parts of
North American Die Casting Association
NADCA Membership, some portions of our web site, and other various tasks, one
of the most important being helping out with online education and audio/visual at
NADCA. Everyone at NADCA is involved in this in some way or another, and it is
“W ebinars have one of the most important things that we do.
become one of I am reminded of the topic of education as I am writing this because of some edu-
cational material that NADCA is preparing for a member right now. NADCA
NADCA’s most can customize education for your company’s needs, and it can be done in-plant
by a visiting instructor, or it can be done via the online avenue through online
popular ways to courses and webinars. Webinars have become one of NADCA’s most popular
ways to deliver educational content to its members. Available either live or for
deliver content.” purchase after the fact, NADCA’s webinars can be found at the following www.
diecasting.org/education/webinars.
NADCA webinars can even be customized for your company’s educational needs. It
is a great way to get a number of your employees in the same room to be exposed to
educational material to aid your company. With a live question and answer section at
the end, any of those present can get their questions answered by the instructor, live
over the web. Contact NADCA for more information on education.
Thank you for reading, and I hope you as a NADCA member can take advantage of
all we have to offer you.
!
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NORTH AMERICAN DIE CASTING ASSOCIATION
Plant Management Conference
May 21 - 23, 2014 – Charlotte, North Carolina
Wednesday, May 21, 2014 Friday, May 23, 2014
7:00 - 8:00 pm Reception 7:00 - 7:45 am Breakfast

8:00 am Round Table Discussion
Thursday, May 22, 2014
9:15 am Die Casting Success Stories
7:00 - 7:30 am Breakfast Select Attendees
7:30 am Registration 10:00 am Break
8:00 am Welcome, Opening Remarks, 10:15 am Round Table Discussion
Round Table Discussion
11:15 am Presentation - TBD
9:15 am Presentation - TBD
12:00 am Lunch
10:00 am Break
1:00 pm Round Table Discussion
10:15 am Round Table Discussion
2:30 pm Break
11:15 am Boxed Lunch
2:45 pm Round Table Discussion
11:30 am Plant Tours
3:30 pm Discussion of the 2014 Plant
5:00 pm Return from Plant Tour Management Conference
6:30 pm Leave Hotel for Group Dinner 3:45 pm Adjourn
www.diecasting.org/meetings/pm
Plant Management Conference
May 21-23, 2014 – Charlotte, North Carolina
Plant Tour:
Type or print clearly all information below. One registration for per person.
If you need additional forms, you may make photocopies.
Cascade Die Casting - High Point, NC
Registrant Information
Registration Fees:*
NAME (FIRST, MIDDLE INITIAL, LAST)
(Please Check Appropriate Box)

 Corporate Member $495 SPOUSE/GUEST’S NAME

Individual Member $595

Member Spouse/Guest $100
 COMPANY NAME
Non-Member $995

Non-Member Spouse/Guest $175
STREET ADDRESS (INCLUDE P.O. BOXES AND/OR MAIL DROPS)
* If registering more than one person from the same
company, contact NADCA for discount pricing.
CITY STATE/PROVINCE ZIP/POSTAL CODE & COUNTRY

Registration fee includes a reception on the
first evening, breakfast, lunch, and dinner on
BUSINESS PHONE (INCLUDE AREA/COUNTRY CODE)
the second day, breakfast and lunch on the
third day and all breaks and handout material.
If you require special dietary arrangements to BUSINESS EMAIL (IF APPLICABLE)  Check here if you do not wish to share email address with the conference attendees
participate fully in this event, please contact
NADCA at 847.808.3161 with your requests.
Method of Payment - Select One
NADCA Cancellation Policy:
 Company/personal check or money order payable to NADCA in U.S. dollars only.
Notice of cancellation must be in writing and  ACH (U.S. dollars only Routing: 071000013 Account: 800334625)
received at NADCA by April 30, 2014 for a full  Company purchase order (NADCA corporate members in good standing only).

refund. There will be no refunds after April 30, 2014.  Credit card - choose type: Visa® Mastercard® American Express®

TOTAL AMOUNT ENCLOSED ($)
Hotel:

DoubleTree Suites CREDIT CARD NUMBER EXPIRATION DATE
by Hilton Charlotte - SouthPark
6300 Morrison Boulevard
CARDHOLDER’S NAME (AS IT APPEARS ON THE CARD)
Charlotte, NC 28211

P: 704.364.2400 CARDHOLDER’S SIGNATURE (REQUIRED FOR PROCESSING)
Rates: $159 + tax per night
Mailing Information
Reservation Procedure:
Mail your registration form with payment (faxed registrations require credit card
Call the hotel at 704.364.2400. You must identify
yourself as part of the NADCA group to receive the information) to:
group rate or visit www.diecasting.org/meetings/pm
for the online hotel reservation link. The room block North American Die Casting Association
will be held until Wednesday, April 28, 2014 or until 3250 N. Arlington Heights Rd., Ste. 101 • Arlington Heights, IL 60004
it is sold out, whichever occurs first. P: 847.808.3161 • F: 847.279.0002 • E: [email protected]
www.diecasting.org/meetings/pm
NADCA Government Affairs
NADCA Submits Testimony to Senate
submitted a redesignation request to the EPA to reclas-
Committee on Aluminum Pricing and Supply sify Rome under the 1997 annual PM2.5 NAAQS
along with a plan to maintain those standards through
On January 15, 2014, NADCA submitted formal 2023. The EPA is seeking comments on this proposal by
testimony to the Senate Banking Subcommittee on February 24, 2014.
Financial Institutions and Consumer Protection for the NADCA is working with regulators, members of
hearing titled, “Regulating Financial Holding Compa- Congress, and industry allies on new PM2.5 stan-
nies and Physical Commodities.” dards under consideration by the EPA. PM2.5 includes
This is the second Senate hearing investigating own- emissions and releases related to sulfur dioxide, nitro-
ership of metals warehouses by banks and holding com- gen oxide, ammonia, and volatile organic compounds,
panies and their relationship with the London Metals among other particles. Late last year, NADCA submit-
Exchange (LME). Aluminum is one of the metals ted formal comments to several states in the process of
central to the warehousing investigations and subject of recommending which areas within their boundaries the
three lawsuits against holding companies such as Gold- EPA should designate as non-attainment zones. The
man Sachs, which own metals warehouses. EPA is expected to make final decisions on designation
In February 2013, according to data from the LME, areas for the entire country in December 2014. If states
the queue to remove metal from warehouses they oversee do not meet the new standards by 2020, non-attainment
in Detroit reached 400 days. In June 2013, some users areas will face similar restrictions on manufacturing and
reported 16-month wait times for aluminum from order to economic activity as are in place today.
delivery. In May 2013, NADCA met with representatives
of the LME to discuss concerns over wait times, among
other issues, with the North American Special Aluminum
Alloy Contract (NASAAC). The Association considered
withdrawing its support of the NASAAC and remains Bipartisan Bill Limits EPA
concerned about terms applied to aluminum contracts.
Actions on Greenhouse Gas Emissions
NADCA is working with the Aluminum Users Coali-
tion on additional ways to address this important issue.
To view the NADCA testimony submitted to the Senate A bipartisan bill in the House and Senate would provide
Banking Subcommittee, please visit: www.diecasting.org/ guidelines to the U.S. EPA on how it can regulate green-
government/rawmaterials and view the link “NADCA house gas emissions from stationary sources. The Adminis-
Statement to Senate Banking Committee on Aluminum tration must issue draft regulations by June 2014 and final
Pricing and Supply.” regulations by summer 2015. The EPA has already issued
its proposed standards for new power plants.
Most in the manufacturing sector, including NADCA
coalition partners, contend that the EPA is imposing
techniques and standards which are not currently techno-
EPA Proposes to Change Rome, Georgia logically feasible. Manufacturers are not only concerned
the new regulations will increase energy costs, but may be
to a PM2.5 Attainment Area
expanded to cover industries beyond energy companies.
On January 23, 2014, the U.S. Environmental Protec-
tion Agency released a proposal to redesignate the
Rome, Georgia area as an “attainment” zone under the
National Ambient Air Quality Standards (NAAQS)
EPA Releases RCRA
for Particulate Matter (PM2.5). This important change
“e-Manifests” Rule
from a “non-attainment area” designation will remove
a number of restrictions currently in place on manufac-
turing facilities and other businesses throughout Floyd The U.S. EPA issued a rule on January 15 formally
County, Georgia, which encompasses the Rome PM2.5 authorizing the use of “e-Manifests”, which Congress
Attainment Area. In June 2012, the state of Georgia created in 2012 to track hazardous waste. The new
6 | DIe CAStInG enGIneeR 1MARCH 2013 www. diecasting.org/dce
NADCA GovERNMENT AFFAIRS
system replaces the paper manifest system tracking Since its inclusion in the Dodd-Frank Wall Street
waste under the Resource Conservation and Recovery Reform Act, NADCA has closely tracked develop-
Act (RCRA). The rule covers all federal and state-regu- ment of the SEC Conflict Minerals Rule. Today, the
lated waste requiring manifests, which track shipments NADCA lobbying firm in Washington is an active
of hazardous waste from its origin to the disposal site. participant in the Conflict Minerals Compliance Task
The Hazardous Waste Electronic Manifest Establish- Force. To better help its members prepare for inquiries
ment Act requires that a system be up and running by from their customers.
October 2015. The rule paves the way for “e-Manifests”
which the EPA estimates will save over 300,000 labor
hours. This is part of a broader government-wide initia-
tive to move to electronic reporting systems where much
of the information will become public.
NADCA Coalition Officially
Defeats NLRB Poster Rule
The National Labor Relations Board (NLRB) officially
West Virginia Spill Impacting Toxic saw its efforts to implement the “Poster Rule” defeated
during the first week of the new year. The agency proposed
Substance Control Act Debate
a rule requiring employers to post a notice in their facilities
informing employees of their right to form or join a union.
The spill in West Virginia is impacting the debate in
Multiple courts held in favor of NADCA coalition
Washington, D.C. over efforts to reform the Toxic
partners, finding that the Poster Rule violated an employ-
Substance Control Act of 1976 (TSCA). Sen. Lauten-
er’s right to free speech by compelling them to post a
berg (D-NJ), prior to his passing, was working with
notice with which they might not agree. The NLRB
Sen. Vitter (R-LA) on a TSCA reform bill supported
faced a January 2 deadline to petition the U.S. Supreme
by industry and some in the environmental community.
Court to hear their appeal of a lower court’s finding that
However, Senate Environment Chair Boxer (D-CA),
the NLRB Poster Rule is unconstitutional.
long slow to embrace the bill’s approach, now feels ener-
gized to move her own more restrictive measure in light
of the West Virginia water situation. Chair Boxer, along
with the two West Virginia Senators, is promoting the
Chemical Safety and Drinking Water Protection Act.
Supreme Court Justices Leery of
Industry, environmental groups, and lawmakers alike
agree TSCA is in need of significant reform and updat- Recess Appointments
ing, but recognize the new bill may derail some of the
progress negotiators had made the past year.
In early January, the U.S. Supreme Court heard oral
arguments in a case challenging the President’s recess
appointments of controversial members to the NLRB.
The case centers on whether the Senate was in “recess”
at the time of the appointments as the Administra-
Court Hears NADCA Coalition
tion contends. This is shaping up as a landmark case
Conflict Minerals Challenge focusing on the powers of the Executive Branch and is
being closely watched by the business community and
On January 7, the U.S. Court of Appeals for the D.C. constitutional scholars alike. The Justices, including
Circuit heard oral arguments on the Security and the Court’s more liberal members, poised very pointed
Exchange Commission’s implementation of the Con- questions to the Administration about the President’s
flict Minerals Rule. The judges expressed significant recess appointment authority. Most experts believe the
skepticism over the SEC’s broad regulation covering the oral arguments were more in favor of our coalition than
inclusion of Tin, Tungsten, Tantalum, and Gold from supportive of the Administration. NADCA is part of
the Congo and surrounding countries in manufactured a coalition which initiated the challenge to the NLRB
products. The court also questioned the impact on a appointments in 2012.
business’s first amendment rights and stated the Con-
flict Mineral Rule unduly compels speech by forcing
an employer to post their report on their own web-
site. Most expect the court to render a decision before
publicly traded companies must file their first conflict
!
minerals reports by May 31.
www. diecasting.org/dce MARCH 2013 1DIe CAStInG enGIneeR | 7
NADCA Reports
nadCa nEWS NADCA to Host 2014 Die Casting Congress
& Tabletop in Milwaukee, WI
NADCA Releases 2014 Spring Education Schedule
Arlington Heights, IL - The 2014 Die Casting Congress
& Tabletop will be held September 22-24, 2014, at the
Arlington Heights, IL - NADCA has released the 2014
Wisconsin Center in Milwaukee, WI. This event will
Spring Education schedule. Don’t miss out on your chance
include three days of Congress sessions. The Congress
to gain valuable knowledge about die casting parts and
session schedule for 2014 has been adjusted to create more
processes. For more information on the courses being
time for those attending sessions to also attend the show
offered please refer to page 16 of this magazine or visit
exhibits. In addition, the Design Awards Luncheon has
www.diecasting.org/education/schedule.htm.
been combined with the Industry Awards Luncheon to
If you would like to learn about other education services
provide a united complimentary awards event.
NADCA offers please visit: www.diecasting.org/education
or contact Melisa Ryzner at [email protected]. “The technical presentations at this year’s congress ses-
sions were among the best ever to accompany a Tabletop
show. Investigators demonstrated a unique understanding of
UPCoMIng EVEntS applicable scientific 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,
Learn to Reduce Costs and Enhance Productivity
with few empty seats even in the late afternoon,” said Andrew
at NADCA’s Plant Management Conference
D. Behler, P. E., Vice President, Blue Ridge Pressure Cast-
ings Inc. at the 2013 Die Casting Congress & Tabletop.
Arlington Heights, IL - Register today for NADCA’s annual
Plant Management Conference. This year’s conference will be In addition to the Congress sessions, this tabletop show
held in Charlotte, NC on May 21-23 at the DoubleTree Suites will feature more than 70 exhibitors and the International
by Hilton Charlotte - SouthPark. The conference will feature Die Casting Design Competition.
special presentations and plant tour of Cascade Die Casting. “The tabletop shows are a great value for exhibitors. I
Benefits derived from the exchange of information received high quality leads that are industry specific. By
include: innovation and product integrity through alternate exhibiting I have the opportunity not only to reach the die
ways of resolving problems, improved control of processes, casting industry but also to support the association,” said
reduced costs, increased quality and enhanced productiv- Michael Hicks, Vice President, DMS, at the 2013 Tabletop.
ity. As always, the conference will also have plenty of The 2013 Die Casting Congress & Tabletop attracted over
round table discussions and chances for networking. 780 attendees (over 334 different companies were represented)
For additional information, please visit www.diecasting. and 110 companies showcased the latest technology, research
org/meetings/pm. The housing block closes April 28, 2014 and services available to the die casting industry. NADCA
so act soon. If you have any questions, please feel free to
expects another fantastic turnout at the 2014 Die Casting
contact Melisa Ryzner at [email protected]. We look
Congress & Tabletop held in Milwaukee, WI.
forward to seeing you in Charlotte.
Save the Date for NADCA’s Annual
Government Affairs Briefing tooLS & RESoURCES
Arlington Heights, IL – Plan to join NADCA in Washing-
2013 Wage and Fringe Benefit Survey - 20% Increase in
ton, D.C. for the industry Government Affairs Briefing June
Companies Providing Pension/Retirement Plans
10-11, 2014. During this 2-day event, NADCA members can
take part in the NAM Summit which includes legislative and
Arlington Heights, IL - The results of the 2013 Wage
regulatory updates on critical manufacturing issues, as well as
& Fringe Benefit Survey have been published. The 2013
Congressional speakers and reception. NADCA will be host-
NADCA Annual Wage & Fringe Benefit Survey is
ing a separate policy briefing and scheduling your congres-
specifically designed for the die casting industry. This
sional visits with your Representatives and Senators, as well
as their staff. The conference will be held at the Renaissance survey represents 58 companies in the die casting indus-
Washington, D.C. Downtown Hotel, located at 999 9th Street try nationwide with detailed summaries for direct labor
Northwest, Washington, D.C. 20001. employees. In addition, the survey includes: wage rates
For additional information please visit: www.diecasting.org/ for 13 key direct labor employees, analysis of insurance
meetings/gab. Make your voice heard and plan on joining your coverage, determining compensation standards and
colleagues for the 2014 NADCA Government Affairs Briefing. selecting fringe benefit plans and insurance.
8 | DIe CAStInG enGIneeR 1MARCH 2014 www. diecasting.org/dce