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| Issue 16 | AFS Metal Casting Congress Edition, Spring 2007 | Print Version | ||||||
AFS Metal Casting Congress Edition, Spring 2007
Alternative Energy
Future of America and the Future For the the Casting Industry
Casting requests are coming from the fuel cell industry, wind-mill expansion, new motor
development, new power generation methods, heat energies and transfers, solar energy
systems, even more efficient lighting technologies - all new markets for metal castings! |
The United States must reduce dependence on foreign oil for its primary source of energy. The President of
the United States has made it a high priority to develop and deploy advanced technologies for nurturing
sources of alternative energy. In light of the environmental and security issues with oil, let’s look at
our energy options and then some examples of how we, the casting industry might play a role in
the energy industry of the future: |
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FUSION:
Fusion power holds unlimited potential as a clean source of energy,
one that does not produce radioactive waste as the current nuclear technology
does. Fusion is the process that the sun uses to produce energy. buyCASTINGS
wrote the winning proposal and built the team that is now in production of the 12,000
lb complex shaped steel castings that are currently being assembled to produce
the fusion reactor. Details of this project were covered in buyCASTINGS Newsletters
(Issue 6, Spring/Summer 2003 and Issue 9, 2004
which are available at buyCASTINGS.com.) Shown here are some
examples of castings produced by the buyCASTINGS project team: |
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We have seen a flurry of activity in energy related casting
applications including: Fuel cells, solar, heat transfer applications,
reclamation of lost mechanical energy in power generation, precision
self sustaining engine applications, windmills, engine applications
eliminating part ware. Parts are high precision, quantities range from several hundred large
parts to many tens of thousands of parts of the smaller sizes. However,
most of the buyers for this technology are from Europe, Japan, and
the Baltic. Unfortunately, the US is still clutching the old technology of
consumption, while other countries are embracing new forms of energy
generation.As part of commercial and government programs to develop alternative energy sources and the manufacturing capabilities, “US foundries really have a great opportunity to impact our future and help build technologies that can meet all of our energy needs”, says Mr. Neil Chaudhry, COO, buyCASTINGS.com Inc. By using buyCASTINGS assembled team of experts to model, optimize process, manage the project, and coordinate all suppliers activities, tasks, schedules and budgets, there are tremendous cost savings benefits to the buyers and sponsors of such projects. The exact nature of our buyer projects and the exact dollar amounts of potential savings for each project are kept proprietary. Call Dave Rauen, the Casting Project Manager at 937-424-4778 if you would like to build a project team for your innovative energy and casting projects. |
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On March 21, 2007, buyCASTINGS' president Bob Dzugan made the
titled presentation to the International 3D Stereolithography Users
Group (3D SUG) in Daytona, Florida.
Bob has been involved in the 3D SUG conference since 1995 and has made many presentations in the past. In addition, Bob has worked with many of the companies involved in the Rapid Prototyping community to assist them with procurement of castings using the best prototype and casting combination for given applications.  The presentation that was given to the full conference entailed a look
at what types of prototyping processes should be used for specific
applications. The process for selecting the correct prototyping process
starts with a somewhat different approach, looking at what metal is
needed and beginning the down-select from there. Bob stated: "It's the same process we use at
buyCASTINGS to determine what casting process
and foundry we want to go to. We always start
with the metal needed." When you start with the
metal needed you automatically eliminate several
processes and foundries that you can work with on the project.The presentation included weighing factors such as quantity, complexity, cost and rapid prototyping process including Stereolithography (SLA), Quickcast, Selective Laser Sintering (SLS), ThermoJet (TJ) as well as ProMetal and FOPAT. FOPAT is a new investment casting pattern material replacing wax patterns and can be used in the prototyping process or limited production runs when more than a few castings are needed. If you have any questions about the presentation or would like a copy, please email Bob Dzugan at rdzugan@buyCASTINGS.com |
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GEOTHERMAL: An 18-member panel led by MIT recently released a 400-page
study, titled “The Future of Geothermal Energy” (PDF, 14.1 MB). Sponsored by the
U.S. Department of Energy, it is the first study in some 30 years to take a new look at geothermal system
(EGS) technology which has been mostly ignored so far, for its potential of larger scale
deployment. EGS or heat mining has the potential to supply a significant
amount of the country’s electricity. Unlike conventional fossil-fuel power plants
that burn coal, natural gas or oil, no fuel would be required. And unlike
wind and solar systems, a geothermal plant works night and day, offering
a non-interruptible source of electric power. According to experts
“…energy capture and extraction is contained entirely underground, and the surface
equipment needed for conversion to electricity is relatively compact.” The drilling must reach depths of 5,000
feet or more. Still, “the possibility of drilling into these rocks, fracturing them and pumping water in to
produce steam has already been shown to be feasible.”
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