Industrial Technologies Program — Boosting the Productivity and 

Competitiveness of U.S. Industry 

Industry consumes 33 percent of all energy used in the United States. By developing and adopting more 

energy efficiency technologies, U.S. industry can boost its productivity and competitiveness while 

strengthening national energy security, improving the environment, and reducing emissions linked to global 

climate change. 

The U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) works in 

partnership with U.S. industry to increase the efficiency of energy and materials use, both now and in the 

future. EERE’s Industrial Technologies Program (ITP) is working to build the Industries of the Future through 

a coordinated program of research and development (R&D), validation, and dissemination of energy 

efficiency technologies and operating practices to reduce energy intensity in the industrial sector. ITP 

develops, manages, and implements a balanced portfolio that addresses industry requirements throughout 

the technology development cycle. The primary long-term strategy is to invest in high-risk, high-return R&D. 

Investments are focused on technologies and practices that provide clear public benefit but for which market 

barriers prevent adequate private sector investment. 

ITP focuses its resources on a small number of energy-intensive materials and process industries that account 

for over 55 percent of industrial energy consumption. 

• Aluminum 

• Chemicals 

• Forest Products 

• Glass 

• Metal Casting 

• Mining 

• Steel 

ITP uses a leveraging strategy that maximizes the energy and environmental benefits of its process-specific 

technology investments by coordinating and cooperating with energy-intensive industries. By working 

closely with the private sector, ITP is able to effectively plan and implement comprehensive R&D agendas and 

help disseminate and share best energy management practices throughout the United States. The ITP publicprivate partnerships also facilitate voluntary efforts, such as the President’s Climate VISION initiative, to 

encourage industry and government to reduce greenhouse gas emissions. ITP also conducts R&D projects on 

enabling technologies that are common to many industrial processes such as industrial energy systems, 

combustion, materials, and sensors and process control systems. In addition, ITP funds technical assistance 

activities to stimulate near-term adoption of best energy-saving technologies and practices within industry. 

These activities include plant assessments, tool development and training, information dissemination, and 

showcase demonstrations. 

New technologies that use energy efficiently also lower emissions and improve productivity. By leveraging 

technical and financial resources of industry and government, the ITP partnerships have generated 

significant energy and environmental improvements that benefit the nation and America’s businesses. 

Energy-intensive industries face enormous competitive pressures that make it difficult to make the necessary 

R&D investments in technology to ensure future efficiency gains. Without a sustained commitment by the 

private and public sectors to invest in new technology R&D and deployment, the ability to close the gap 

between U.S. energy supply and demand will be severely compromised. 
CONTENTS 

Executive Summary ............................................................................................................................................ i


Industry Overview ............................................................................................................................................. 1


Metal Casting In Brief ......................................................................................................................................... 1


Metal Casting Industry Shipments ...................................................................................................................... 1


2002 World Casting Production .......................................................................................................................... 3


Energy Use in Metal Casting................................................................................................................................ 4


The Challenge ..................................................................................................................................................... 6


Key Pathways ..................................................................................................................................................... 6


FY 2004 Highlights & Accomplishments .......................................................................................................... 8


Broad Industry Partnership ................................................................................................................................. 8


A Diverse Research Portfolio ................................................................................................................................ 9


Integrated Assistance for the Metal Casting Industry ......................................................................................... 9


Applying R&D Results ........................................................................................................................................ 12


New Project Awards ............................................................................................................................................ 14


Improving Energy Efficiency Today ................................................................................................................... 15


Energy Analysis – Targeting Energy Efficiency ................................................................................................... 15


University-Based Research .................................................................................................................................. 15


Disseminating Research Results to Industry ...................................................................................................... 15


Tools, Publications, and Resources Available ................................................................................................. 16


Tools and Publications ....................................................................................................................................... 16


Fact Sheets ........................................................................................................................................................ 16


How To Get Involved and Contact Information ............................................................................................ 17


Partnership Information ................................................................................................................................... 17


Access to Resources and Expertise....................................................................................................................... 17


Where to Go to Get More Information............................................................................................................. 18


EXHIBITS 

1. Metal Casting Supply and End-Use Markets ................................................................................................ 1


2. U.S. Producers’ Shipments of Nonferrous and Ferrous Castings ................................................................. 2


3. Value of Shipments of Nonferrous and Ferrous Castings ............................................................................ 2


4. 2002 World Ferrous Casting Production ...................................................................................................... 3


5. 2002 World Nonferrous Casting Production ................................................................................................ 3


6. Energy Use in Metal Casting ........................................................................................................................ 5


7. Process & Technology Improvements Target Energy Efficiency ....................................................................7


8. Broad Industry Partnership Metal Casting Research Performers and Project Partners ................................. 8


9. Research Funding ......................................................................................................................................... 9


10. Examples of EERE Technical and Financial Assistance ................................................................................. 9


11. Metal Casting Portfolio by Focus Area ........................................................................................................10


12. Additional Industrial Technologies Research Related to Metal Casting .....................................................11

EXECUTIVE SUMMARY 

The metal casting industry purchases an estimated 328 trillion Btu annually to manufacture components for 

transportation, aerospace, medical, national defense, and many other manufacturing industries. In fact, 90 

percent of all manufactured goods contain one or more cast metal components. Energy-intensive processes 

include melting, moldmaking, coremaking, and post-casting operations. 

The U.S. metal casting industry is diverse, employing a variety of casting processes and alloys to make a wide 

range of products. Because the majority of metal casters are a small business — 80 percent of the 2,700 metal 

casters operating in the United States employ fewer than 100 people — most metal casters cannot assume the 

high cost and risk associated with research and development (R&D), particularly long-term R&D. Publicprivate research partnerships, such as the Cast Metals Coalition (CMC), have proven vital for performing 

long-term research needed to maintain a productive and healthy U.S. metal casting industry. 

Transformational R&D, such as that funded by the U.S. Department of Energy (DOE), Office of Energy 

Efficiency and Renewable Energy (EERE), Industrial Technologies Program (ITP), is critical to maintaining 

the global competitive position of the U.S. metal casting industry. Studies sponsored by EERE have 

quantified the opportunity for saving energy in metal casting (defined as the difference between today’s 

energy use and the practical minimum energy use). DOE’s goal in this area is to develop transformational 

technologies that will reduce the energy required to produce a ton of castings by 20 percent - 65.6 trillion 

Btu per year in 2020. 

A Successful Strategy with Industry 

DOE’s Office of Energy Efficiency and Renewable Energy leads federal development of advanced energyefficient and environmentally-friendly industrial technologies. Metal casting industry R&D is a component 

of the overall EERE strategy, contributing to a reduction in energy intensity of industry, a goal outlined in 

the National Energy Policy. 

EERE/ITP is working to build the Industries of the Future through a strategy that is based on multi-year 

planning, industry involvement and input during the planning process, and careful analysis and data-based 

decision making. This strategy not only takes into consideration the interests of the industry as described in 

their R&D Technology Roadmaps, but also consists of an agenda of analytical studies that provide the basis 

for decision making. For instance, the Metalcasting Industry Technology Roadmap: Pathway for 2002 and Beyond, 

published in 2003 and the Metalcasting Industry Technology Roadmap published in January 1998, have provided 

the basis for focusing the R&D by identifying industry research interests. The Metal Casting Energy and 

Environmental Profile, Bandwidth study, and Footprint study were developed using both government and 

industry data and information, and industry expertise to provide the next level of prioritization for the 

portfolio. By using these studies, the portfolio is able to design a multi-year R&D plan based on the focus 

area, barrier, and pathway approach. In this approach, a limited number of critical technology focus areas 

are identified along with the technical barriers preventing their successful implementation. A multi-year plan 

(called a “Pathway”) is then developed that will guide the R&D activities leading to a successful development 

of the focus area technology. The “Pathways” are then the basis for solicitations of pre-competitive R&D 

that addresses both energy efficiency goals outlined in the National Energy Policy and metal casting industry 

research priorities. This successful strategy has now evolved to a point where it provides focus on potentially 

high-impact research to make revolutionary improvements in metal casting. 

Strong industry involvement ensures direct application of research results and testifies to the importance of 

this cost-shared research partnership. Broad industry and university participation (over 270 active R&D 

partners) in the Metal Casting portfolio is facilitated through the Cast Metals Coalition, which is composed 

of the American Foundry Society (AFS), the North American Die Casting Association (NADCA), and the Steel 

Founders’ Society of America (SFSA). Collectively, this coalition represents approximately 80 percent of the 

U.S. metal casting industry. Involving industry in the early R&D stages helps accelerate the development and 

application of energy efficiency technologies. The ITP Metal Casting portfolio also emphasizes universitybased research in order to tap into the technical resources of our nation’s educational institutions and ensure 

a well-trained, well-educated work force. 

i

Achieving Energy Savings: Portfolio Strategy 

The ITP Metal Casting portfolio, comprised of pre-competitive research, addresses technological needs that 

have broad applicability throughout the metal casting industry. The program fosters both revolutionary 

technologies and incremental improvements to existing processes, thereby addressing long-term goals 

without neglecting short-term opportunities to improve energy efficiency. ITP also strives to expand the 

industry’s fundamental base of knowledge to optimize key processes and resource efficiency. 

As the Metal Casting portfolio continues to shift towards supporting a smaller number of high-impact 

projects, research activities are organized into the following categories: Advanced Melting and Innovative Casting 

Processes. The FY 2004 portfolio of 35 metal casting research topics (see Exhibit 11, p. 10) is performed in 

partnership with 270 university, industry, and national laboratory partners across the United States. The FY 

2004 portfolio leverages 14 percent of research funding to the “Advanced Melting” focus area and 86 percent 

to the “Innovative Casting” focus area. The ITP Metal Casting portfolio also maintains a healthy balance of 

research targeted at both ferrous and nonferrous alloys with 17 percent of the funds addressing ferrous issues, 

33 percent nonferrous, and 50 percent crosscutting. 

FY 2004 Highlights 

•	 Researchers have developed an advanced high-temperature rheological measurement system that can help 

to improve the accuracy and capabilities of various simulation tools used to determine flow patterns 

during die filling while using Semi-Solid Metal (SSM). This project will expand the use of SSM 

technology because the billets require a lower temperature (as compared to traditional casting 

operations), thereby reducing the amount of energy expended. 

•	 Steel foundries generally have 10 times the process inventory workload in comparison to traditional iron 

foundries. These high inventory levels inhibit the ability to detect quality problems and lead to extended 

delivery times. Researchers at Iowa State University have been able to identify the problems leading to 

these high inefficiencies and are developing recommendations that will reduce the amount of heat 

treatment, scrap castings, and casting reworks. 

•	 Quantitative gas evolution measurements taken at the University of Alabama - Birmingham have assisted 

in the development of a new model that is heated by molten metal. This model recognizes the formation 

of undercut in lost foam patterns. The model enables the user to correctly predict the filling speed and a 

weak thickness dependence. General Motors is using this model to make production decisions to improve 

the quality of its lost foam casting lines. 

•	 ITP conducted a solicitation for competitive cost-shared research proposals which resulted in four newlyawarded research topics. These research topics will make advances in the melting systems and innovative 

casting processes for the metal casting industry. 

•	 EERE’s BestPractices and Industrial Assessment Centers provide hands-on technical assistance that metal 

casters can apply immediately, saving them thousands of dollars annually. For example, a plant-wide 

assessment at Sawbrook in Ohio identified 15 plant and process modifications that would result in an 

annual savings of $169,000 per year in costs and energy. 

•	 In FY 2004, the ITP published two reports, Energy Use in Selected Metal Casting Facilities - 2003 and 

Theoretical/Best Practice Energy Use In Metalcasting Operations. These two studies evaluate energy use in 

casting operations, taking into consideration the diversity of the industry in terms of casting processes, 

facility size, and other factors. These reports will assist the ITP to direct efforts to high-impact, 

revolutionary processes research. 

•	 In October 2003, ITP conducted a survey of all university participants in the Metal Casting portfolio to 

determine the level of student participation. The results concluded that over 326 students participated in 

ITP Metal Casting portfolio research. Of these students, 152 are now working in the metal casting 

industry, and 52 are in the process of pursuing advanced degrees. 

ii

INDUSTRY OVERVIEW 

The metal casting industry has been integral to U.S. growth and has helped the United States become the 

world benchmark in fields such as manufacturing, science, medicine, and aerospace. This industry, 

dominated by small businesses, continues to fuel the nation’s prosperity and national defense into the 21st 

century. 

The metal casting industry consists of 2,700 facilities located in all 50 states. Eighty percent of these facilities 

employ fewer than 100 people, 14 percent employ between 100 and 250 people, and only 6 percent employ 

more than 250 people.1 The industry employed approximately 199,000 people, providing $9.4 billion in 

wages.2 

Metal Casting In Brief 

Metal casting enables the production of simple and complex parts that meet a wide variety of needs. Nearly


all manufactured goods contain one or more cast components. Major end-uses include power generation


equipment, defense systems and machinery, motor vehicles, transportation equipment, oil field machinery,


pipelines, industrial machinery, construction materials, and other products vital to our economic and


national security. Oil field machinery and equipment sales alone represent approximately $259 million in


casting sales per year.

3 Exhibit 1


illustrates raw material supplies and Exhibit 1


end-use markets for metal castings. Metal Casting Supply and End-Use Markets 

The basic metal casting process 

consists of pouring or injecting 

molten metal into a mold or die 

containing a cavity of the desired 

shape. The most commonly used 

method for small- and medium-sized 

castings is green sand molding, 

accounting for approximately 60 

percent of castings produced. Other 

methods include die casting, shell 

molding, permanent molding, 

investment casting, lost foam 

casting, and squeeze casting. 

Supply 

Gray Iron 36% 

Ductile Iron 34% 

Aluminum 17% 

Steel 5% 

Copper 3% 

Zinc 2% 

Other 2% 

Source: 

of Commerce, Bureau of 

Census, Current Industrial 

Reports MA331E(02) and 

MA331A(02)-1.-

End-Use Markets 

Automotive & Light Trucks 35% 

Pipe & Fittings 15% 

Construction, Mining, Oil Field Machinery 6% 

Railroad 5% 

Internal Combustion Engines 5% 

Valves 5% 

Farm Equipment 3% 

Municipal Castings 3% 

Other 23% 

Source: Facts & Figures 

About the U.S. Foundry Industry, 

http://www.afsinc.org/trends/factsandfigures.htm 

U.S. Department 

American Foundry Society 

Markets for metal castings are increasingly competitive and casting customers are placing greater emphasis on 

high-quality, competitively priced castings. There is an increasing demand for lighter-weight, high-strength 

ferrous and nonferrous cast metal components and castings that meet demanding design specifications. 

Casting processes must continually evolve and improve to remain competitive in today’s marketplace. 

Metal Casting Industry Shipments 

As shown in Exhibit 2, in 2002, the metal casting industry shipped a total of 11.9 million short tons of 

castings valued at $16.2 billion (shown in Exhibit 3). This was a 2.5 percent decrease in total tonnage 

shipped and a 9.6 percent decrease in the value of castings shipped from the previous year. Over the period 

1996-2001, there has been an average annual decline of 3 percent in casting shipments.4 

1 American Foundry Society, AFS Trends Facts and Figures, www.afsinc.org/Trends/FactsandFigures.htm
 2 U.S. Department of Commerce, Bureau of Census, Annual Survey of Manufactures 2001, Table 3 NAICS code 3315.
 3 Lessiter, Michael J. Modern Casting “Oil Field Equipment & Machinery,” November 2002, pg. 36.
 4 U.S. Department of Commerce, U.S. Census Bureau, Current Industrial Reports, Iron and Steel Castings 2002, MA331A(02)-1, Table 3; Non-Ferrous Castings


2002, MA331E(02)-1, Table 1. 

1
Exhibit 2


U.S. Producers’ Shipments of Nonferrous and Ferrous Castings (short tons)


Nonferrous Castings 1996 1997 1998 1999 2000 2001 

Aluminum and aluminum-based alloy Copper and copper-based alloy Magnesium and magnesium-based alloy 

Zinc and zinc-based alloy Sub-Total Nonferrous 

1,521,081 

284,560 

25,724 

221,543 

2,052,908 

1,593,876 

276,480 

19,257 

228,933 

2,118,546 

1,921,137 

286,360 

20,741 

239,169 

2,467,407 

1,976,343 

310,449 

21,956 

225,058 

2,533,806 

2,037,213 

273,739 

29,599 

225,528 

2,566,079 

1,942,930 

351,389 

24,378 

207,948 

2,526,645 

6% 4% 1% 

-2% 

4% 

2001 2000 1999 1998 1997 1996 Ferrous Castings 

4,312,000 6,198,000 

263,000 

1,271,000 

12,044,000 

4,325,000 5,938,000 

272,000 

1,218,000 

11,753,000 

4,583,000 6,047,000 

247,000 

1,325,000 

12,202,000 

4,658,000 5,955,000 

207,000 

1,202,000 

12,022,000 

4,599,000 5,606,000 

186,000 

972,000 

11,363,000 

4,194,000 4,803,000 

135,000 779,000 

9,887,000 

-1% -5% -11% 

-10% -4% 

Total Nonferrous and Ferrous 14,096,908 13,871,546 14,669,407 14,555,806 13,929,079 12,194,400 -3% 

Avg. % change 

(96-02) 

Avg. % change 

(96-02) 

Ductile iron Gray iron Malleable iron 

Steel1 Sub-Total Ferrous 

2002 

2,079,903 

337,264 

24,378 

199,949 

2,641,493 

2002 

4,066,000 4,401,000 

127,000 

660,000 

9,254,000 

11,895,493 

Exhibit 3


Value of Shipments of Nonferrous and Ferrous Castings (‘000 dollars)


Nonferrous Castings 1996 1997 1998 1999 2000 2001 

Avg. % change 

(96-02) 

Aluminum and aluminum-based alloy Copper and copper-based alloy Magnesium and magnesium-based alloy 

Zinc and zinc-based alloy Sub-Total Nonferrous 

$4,724,290 

983,955 272,842 

809,127 

$6,790,214 

$5,172,590 

991,974 225,685 818,963 

$7,209,212 

$5,669,532 

1,053,833 

256,852 

914,648 

$7,894,865 

$5,556,386 

1,120,292 

245,677 

928,341 

$7,850,696 

$6,028,183 

1,089,881 

256,274 

873,831 

$8,248,169 

$5,604,727 

1,311,793 

191,462 

787,215 

$7,895,197 

4% 4% 

-4% 

-2% 

3% 

Avg. % change 

(96-02) 2001 2000 1999 1998 1997 1996 Ferrous Castings 

Ductile iron Gray iron Malleable iron 

Steel1 Sub-Total Ferrous 

$3,971,500 

4,463,000 

266,100 

2,295,600 

$10,996,200 

$4,148,900 

4,719,500 

272,400 

2,343,500 

$11,484,300 

$4,428,400 

4,635,100 

257,900 

2,499,000 

$11,820,400 

$4,299,000 

4,446,000 

238,000 

2,161,000 

$11,144,000 

$4,381,100 

4,406,200 

229,400 

1,806,800 

$10,823,500 

$3,928,800 

3,817,900 

176,300 

1,587,200 

$9,259,100 

-3% -4% -8% 

-9% -5% 

Total Nonferrous and Ferrous $17,786,414 $18,693,512 $19,715,265 $18,994,696 $19,071,669 $17,895,197 -1% 

2002 

$5,982,421 

1,184,796 

201,853 

688,229 

$8,057,299 

2001 

$3,325,500 

3,345,800 

156,800 

1,285,100 

$8,113,200 

$16,170,499 

Sources: U.S. Department of Commerce, U.S. Census Bureau, Current Industrial Reports, Iron and Steel Castings, MA331A(02)-1, and Non-Ferrous Castings, MA331E(02)-1. Does not include steel investment castings. 1 

2
2002 World Casting Production 

As shown in Exhibit 4, the United States was second in world ferrous casting production, with 16 percent of 

the world market. China continued to lead the world in ferrous casting production with 26 percent of the 

world market. From 2001 to 2002, China experienced a 9 

percent growth in ferrous casting shipments, while the United 

States experienced a 0.5 percent decline in casting shipments in 

2002.5 

As shown in Exhibit 5, the United States was the leader in 

nonferrous casting production across nearly all alloy types, with 

26 percent of the world market, up slightly from 24 percent 

during 2001. Japan followed the United States with 13 percent 

of the world market. Aluminum represented 97 percent of 

Japan’s nonferrous casting shipments, whereas the United 

States was more diversified, with aluminum accounting for 77 

percent of the nonferrous casting shipments. China held 11 

percent of the world market. Mexico continued to have strong 

nonferrous production with 6 percent of the world market. 

This is a significant increase from 1995, when Mexico held only 

2.9 percent of the world market.6 

Although the United States is one of the largest producers of 

metal castings, its manufacturing sector is dependent upon 

imports to meet the casting demand. It is estimated that in 

2004, the United States will rely on imports to meet 18 percent, 

Exhibit 4


2002 World Ferrous Casting


Production


(Share of Tonnage Produced) 

China 26% 

Canada 1% 

France 4% 

Germany 6% 

India 5% 

Italy 2% 

Japan 7% 

Korea 3% 

Mexico 2% 

Russia 10% 

Spain 2% 

Taiwan 2% 

U.S. 16% Great Britain 1% 

Other 10% 

Brazil 3% 

Exhibit 5


2002 World Nonferrous Casting


Production


(Share of Tonnage Produced) or 2.6 million tons, of its total casting demand. The United 

States will rely on imports to supply 29 percent of its gray iron 

casting demand, and 13 percent of steel casting demand. 

Moreover, the United States will rely on imports to meet 18 

percent of its total demand for aluminum castings and 20 

percent of its requirements for bronze castings.7 

5 Stratecast, Inc., AFS Metalcasting Forecast & Trends 2004 American Foundry Society, Des Plaines, October 2003, pg. 32.
 6 Ibid.


7 Ibid pg. 35.


U.S. 26% 

Other 

Brazil 1% 

China 11% France 4% 

Germany 8% 

India 2% 

Italy 9% 

Japan 13% 

Mexico 6% 

Russia 6% 

Spain 3% Taiwan 3% 

8% 

3
Energy Use in Metal Casting 

The metal casting industry requires more than 460 trillion Btu annually.

10 This includes an estimated 328 

trillion Btu consumed in metal casting operations, and an estimated 132 trillion Btu lost in off-site power 

generation and distribution losses. Non-captive foundries consume 70 percent of the energy, and captive 

foundries consume the remaining 30 percent. [Note: A “captive” foundry is one where the cast products are 

consumed on-site by the company, usually as the parts are incorporated into higher value-added products.] 

The major energy-consuming processes in metal casting include melting of metal, coremaking, moldmaking, 

heat treatment, and post-cast activities.11 The industry spent $1.3 billion in 2001 on purchased fuels and 

electricity. Energy purchases equalled about 11 percent of the material cost and 5 percent of the value of 

shipments. Energy costs were highest in iron foundries (13 percent of material costs) and lowest in 

nonferrous die casting foundries (6 percent of material costs).12 Purchased fuels and electricity on average 

represented about 10 percent of the value of shipments in 2002. The amount of energy that is consumed by a 

typical casting foundry is equivalent to the energy consumption of 100 residential homes per year.

13 Exhibit 

6 shows the industry’s energy use by fuel type and electricity. A majority of the industry’s on-site energy (73 

percent) is supplied by fuels (83 percent natural gas, 16 percent coke and breeze, and 1 percent other fuel 

sources). Electricity provides the remaining 27 percent of the industry’s on-site energy needs with 89 trillion 

Btu being consumed.14 The onsite electric energy demand requires nearly 221 trillion Btu, of which nearly 

132 trillion Btu are needed for the generation and transmission of power to the industry. 

10 Using AFS 2002 Metalcasting Forecast & Trends, the ratio of metal casting shipments (NAICS 3315) to captive foundry casting production was calculated. This 

ratio was applied to industry energy consumption for NAICS 3315, 1998 Manufacturing Consumption of Energy Report, U.S. Department of Energy, Energy 

Information Administration Tables N.11.1, to estimate energy consumption in captive foundries. The tacit energy was then calculated based on EIA tacit energy 

conversion factors. 

11 U.S. Department of Energy, Energy Efficiency and Renewable Energy, Office of Industrial Technologies, Metal Casting Industry of the Future, Energy and 

Environmental Profile of the U.S. Metal Casting Industry, 1999, pg. 10. 12 U.S. Department of Commerce, U.S. Census Bureau, 2001 Annual Survey of Manufactures, Manufacturing Industry Series, Tables 2 and 4, Detailed Statistics by 

Industry: 2000 for NAICS codes 3315, 331511, 331512, 331513, 331524, 331525, 331528, 331521, and 331522. 13 Used the U.S. Department of Energy, Energy Information Administration, Residential Energy Consumption Surveys, to find the average Btu consumption in a year 

per house. Divided the number of foundries by the annual Btu consumption and found the average Btu consumption in a foundry. Calculated the ratio of number 

of houses to energy consumed in average foundry. 14 U.S. Department of Energy, Energy Information Administration, 1998 Manufacturers Energy Consumption, Table N1.2. “First Use of Energy for All Purposes,” NAICS 

code 3315; 331511; 331521; 331524. 

4
Exhibit 6


Energy Use in Metal Casting


Metal Casting Industry 

• Of the total 2,700 metal casting facilities located 

throughout the 50 states, 80 percent employ fewer than 100 people, 14 percent employ between 100 and 250 people, and only 6 percent employ more than 250. 

• The average metal casting facility consumes an 

amount of energy equivalent to 100 households per year. 

• The industry purchased 328 trillion Btu in 1998, 

which was valued at $1.3 billion. 

• The industry employed approximately 199,000 people 

in 2000, providing $9.4 billion in wages. 

• The industry’s value of shipments in 2001 was $16.2 

billion. 

• The industry’s carbon dioxide emissions were 10.79 

million metric tonnes of CO2 annually. 

132 trillion Btu 

Electricity Received at Plant 

Fuels 

Melting 55% 

Heat Treatment 6% 

Post Casting 

Moldmaking 12% 

Coremaking 8% 

Process Energy Cost

Other 12% 

Natural Gas 83% 

Coke & 

Breeze 16% 

Other 1% 

Electricity 

221 trillion Btu 

89 trillion Btu 

Off-site Power Generation Losses 

The Metal Casting portfolio will reduce the energy 

required to produce a ton of castings by 20 

percent - 65.6 trillion Btu per year in 2020. 

328 trillion Btu 

239 trillion Btu 

7% 

5
THE CHALLENGE


The metal casting industry is critical to the U.S. economy, as 90 percent of all manufactured goods contain 

one or more cast metal components. Metal castings are integral in U.S. transportation, energy, aerospace, 

manufacturing, and national defense. Metal casting is also one of the only major U.S. manufacturing 

industries that is dominated by small businesses. Moreover, the industry is widely dispersed throughout the 

country, limiting opportunities for geographic-based, intra-industry coordination. These unique 

characteristics have helped drive the need for public-private R&D collaboration. 

The U.S. metal casting industry is diverse, employing a variety of casting processes and alloys to make a wide 

range of products. Because the majority of metal casters are small businesses, many lack the resources to 

perform high-risk, high-impact research on their own. Public-private research partnerships, such as the Cast 

Metals Coalition (CMC), have proven vital for performing long-term research needed to maintain a 

productive and healthy U.S. metal casting industry. 

The U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Industrial 

Technologies Program (ITP), supports these partnerships by sponsoring cost-shared R&D funding to improve 

energy efficiency in metal casting. This partnership is encouraged by ITP in collaboration with the CMC. 

The CMC is composed of the American Foundry Society (AFS), the North American Die Casting Association 

(NADCA), and the Steel Founders’ Society of America (SFSA). Collectively, this coalition represents 

approximately 80 percent of the U.S. metal casting industry. 

The partnership emphasizes university-based research with strong industry participation. This strategy taps 

into the technical resources of our nation’s educational institutions, and positions industry partners to 

quickly apply the results of metal casting research, thereby saving energy and improving U.S. competitiveness 

in world markets. The involvement of industry in the early R&D stages helps to speed the pace of 

technology transfer. 

Strong industry involvement ensures direct application of research results and gives evidence to the 

importance of this cost-shared research partnership. ITP’s Metal Casting portfolio research partners 

represent the diversity of the metal casting industry, including suppliers, end-users, designers, ferrous and 

nonferrous foundries, and die casters. The partnership is also introducing hundreds of students to the 

industry and helping to sustain vital casting-related curricula at the U.S. universities. Since the inception of 

the Metal Casting portfolio, approximately 326 students participated in Metal Casting portfolio research, of 

which 152 are now working in the metal casting industry. Ensuring a well-educated and well-trained 

workforce is imperative for the metal casting industry to remain innovative and competitive in world 

markets. 

Key Pathways 

The ITP Metal Casting portfolio strategy was designed to foster government-industry partnerships in 

economically imperative, energy-intensive U.S. industries, including metal casting. This strategy has fostered 

industry partnerships and created the impetus for industry to develop long-term visions and roadmaps. 

Visions assist in the development of long-term goals for the future, while roadmaps provide an outline of the 

R&D pathways to achieve vision goals. The Metal Casting vision and roadmap, along with in-depth analysis 

of energy use in the industry, are the pillars for open and competitive solicitations for pre-competitive R&D 

that addresses both energy efficiency goals outlined in the National Energy Policy, as well as industry research 

priorities. This successful government-industry partnership is now focusing on high-impact research to make 

revolutionary improvements in the energy efficiency of the metal casting process. 

The Metal Casting portfolio has been successful in improving energy efficiency and market competitiveness 

in the industry. For example, research in lost foam casting, co-funded by the ITP Metal Casting portfolio 

and in partnership with the Lost Foam Casting Consortium, has resulted in significant improvements in the 

lost foam process; these results have been implemented throughout the industry. Currently, the Metal 

Casting portfolio is targeting additional opportunities for high-impact research. ITP conducted in-depth 

analyses to map energy consumption in the industry by evaluating energy demand in each of the various 

6
processes and technologies used in metal casting. Further analysis revealed the theoretical/best practice 

energy use that may be attainable in the industry. The results of these analyses are assisting the ITP Metal 

Casting portfolio in identifying areas of focus for 

high-impact research, and setting the groundwork 

for future research solicitation. 

The Metal Casting portfolio also participated in 

the ITP Corporate Peer Review that was held 

March 9-10, 2004. This Peer Review brought 

industry stakeholders and government partners 

together to review the mission, strategies and 

future direction of the Industrial Technologies 

Program, including a strategic overview of the 

metal casting R&D portfolio. The participants of 

the meeting provided useful suggestions that can 

be used to strengthen the Metal Casting portfolio. 

Examples of some of the feedback ITP received 

from the portfolio review included: 

1. More R&D efforts required on molten metal 

containments, and 

2. 	R&D efforts required to provide more 

properties data to support casting design. 

Research Categories of the Metal Casting Portfolio 

The success of the Metal Casting portfolio is the result of a strong partnership 

between the Cast Metals Coalition (CMC) and EERE. This partnership is directing 

its efforts to address high-impact research to make revolutionary improvements in 

energy efficiency in metal casting. Research is grouped into three categories: 

• 

• 

• 

Advanced Melting: Research that establishes new melting practices, and/or 

new design methodologies to significantly improve the energy efficiency of 

melting and save costs for metal casters. Research in this area will improve 

melt efficiency, reduce metal transfer heat loss, reduce scrap/revert, and 

improve mold yield. 

Innovative Casting: Research that advances energy-efficient casting 

processes and practices that will increase yield and reduce scrap. Research in 

this area is developing: accurate simulation tools, the ability to produce thinwall, high-performance castings, real-time sensors and controls, improvements 

in rapid prototyping, and expanding the knowledge base of various material 

properties and performances. 

R&D Integration and System Analysis: Integration of applicable ITP 

technologies for improving energy efficiency and reducing emissions in metal 

casting practices. This includes other ITP portfolios and ITP’s BestPractices 

program for energy demand management. 

In FY 2004, ITP reorganized its Metal Casting research portfolio into three categories: Advanced Melting, 

Innovative Casting Processes, and R&D Integration and System Analysis. These research categories align with 

the Metalcasting Industry Technology Roadmap: Pathway for 2002 and Beyond. Exhibit 7 shows the target areas for 

each of these research categories. Advanced Melting and Innovative Casting Processes formed the basis for 

the ITP Metal Casting portfolio solicitation offered in March 2003, of which four new projects were awarded 

in the fall of 2004. (More information on these projects is provided in the Highlights & Accomplishments 

section). 

Research in the Advanced Melting focus area is not only concentrating on new melting technologies, but 

also includes upstream processes such as the chemistry and purity of the melt stock and alloying ores, and 

the role they play in efficiency factors. Research is also examining ways to improve melt loss, which directly 

affects the net melting energy consumption. 

Exhibit 7


Process & Technology Improvements Target Energy Efficiency


Impact Targets • Yield Improvement/Scrap Reduction - Achieve 10 percent combined yield increases and scrap reduction by 2020. 

• Melting Efficiency - Improve melting efficiency to achieve a 10 percent energy savings industry-wide by 2020. 

• Environmental Benefits - Save energy and associated emissions by 20 percent by 2020. 

Advanced Melting 

Yield Improvement 

Scrap Reduction 

New Melting Technologies 

R&D Integration and Analysis 

Casting Facility Practices 

Plant Systems 

Energy Guidelines 

Emissions Reduction 

By-product Reduction 

Critical Baseline Metrics 

Energy Benchmark Study 

Theoretical Minimum Study 

Innovative Casting Processes 

Thin Wall/High Strength 

Alloy Diversification for Lost Foam 

Steel Foundry Practices 

Materials Properties and Performance 

Low-Cost Semi-Solid Metal Feedstock 

Machining: Inclusions and Porosity Reduction 

Die Casting Practices 

Computer-Based Modeling Tools 

7
FY 2004 HIGHLIGHTS & ACCOMPLISHMENTS 

The ITP Metal Casting portfolio supports a diverse portfolio of cost-shared, pre-competitive research. 

Research projects address high-risk/high-impact needs that have broad application throughout the metal 

casting industry. 

All metal casting research projects are selected through a competitive review process. ITP’s Metal Casting 

portfolio research must address both the priorities outlined in the Metal Casting Industry Technology Roadmap, 

as well as DOE’s national energy efficiency goals. Solicitations are announced in trade society publications 

and meetings, the Commerce Business Daily, FedBizOpps, the Metal Casting portfolio Web site, and industry 

Web sites. In FY 2004, the metal casting portfolio began to transition to fewer, yet larger, research projects 

(with higher impact per project) that will have the opportunity to produce revolutionary improvements in 

metal casting energy efficiency. 

Maintaining a strong and well-balanced portfolio requires careful attention throughout the competitive 

solicitation, evaluation, and selection process. The FY 2004 ITP Metal Casting portfolio consists of 35 active 

projects, addressing the diverse research needs of the industry. Four are newly-awarded projects that resulted 

from the Metal Casting IOF solicitation in March, 2004. Many of the projects in the portfolio have 

applications across various casting processes and alloys. All projects address the need to improve energy 

efficiency in the industry. 

Broad Industry Partnership 

One of the strengths of the Metal Casting research portfolio is the large participation of both industry and 

universities, providing both cost-share and in-kind support. Currently, the portfolio is partnering with 270 

industry members, universities, and national laboratories in 33 states across the United States. The 

geographic reach of the Metal Casting portfolio is illustrated in Exhibit 8. 

Exhibit 8


Broad Industry Partnership


Metal Casting Research Performers and Project Partners


Primary Research Performers 

1 Advanced Technology Institute


2 CANMET


3 Case Western Reserve University


4 Climax Research Services


5 Colorado School of Mines


6 Colorado State University


7 Copper Development Assoc., Inc.


8 ECK Industries


9 General Motors Powertrain


10 GKS Engineering Services


11 Idaho National Engineering and Environmental


Laboratory 

12 Industrial Analytics Corporation 

13 Intl. Lead Zinc Research Organization 

14 Iowa State University 

15 Lehigh University 

16 Oak Ridge National Laboratory 

17 Ohio State University 

18 Pennsylvania State University 

19 SECAT, Inc. 

20 Tennessee Technological University 

21 Tri-State University 

22 University of Alabama 

23 University of Alabama - Birmingham 

24 University of Iowa 

25 University of Michigan 

26 University of Missouri - Rolla 

27 University of North Carolina -Charlotte 

28 University of Tennessee 

29 Worcester Polytechnic Institute 

Industry Partners 

1 

2 

21 

8 

3 

4 

6 

7 

5 

13 

11 

10 

9 

12; 16 20 

15 

22 

24 14 

20 17 

29 

26 

18 

19 

25 

28 27 

The Metal Casting Industry of the Future is partnering with 270 university, 

industry, and laboratory partners in 33 states across the U.S. 

8
A Diverse Research Portfolio 

Exhibit 9 illustrates ITP’s Metal Casting portfolio funding by alloy and its focus areas. As illustrated, the 

program maintains a healthy balance of research targeted at both ferrous and nonferrous alloys. However, 

the majority of research in the program’s portfolio crosscuts all alloy types, further leveraging research 

investment. Exhibit 9 also illustrates how the Metal Casting portfolio leverages funds within its focus areas 

of Advanced Melting and 

Innovative Casting Processes. In 

FY 2004, 86 percent of the funds 

were allocated to the Innovative 

Casting area. Because ITP leverages 

funds to melting in other 

portfolios, the Metal Casting 

portfolio allocates a majority of its 

funds to various casting processes 

other than melting. Still, 

recognizing the energy-saving 

potential, the Metal Casting 

portfolio leverages approximately 

14 percent of their budget to 

advancing melting R&D. 

Exhibit 9


Research Funding


By Primary Alloy By Focus Area 

Non-Ferrous 33% Crosscutting 

Ferrous 17% 

Advanced Melting 

14% 

Innovative Castings 

86% 

50%

On page 10, Exhibit 11 displays a list of metal casting projects organized by focus area. Lead research 

organizations are shown in italics. Those projects identified as “Energy SMARRT” are tasks under the newlyawarded Energy SMARRT project led by Advanced Technology Institute (ATI). This project consists of 28 tasks 

that address both the Advanced Melting and Innovative Casting Processes focus areas. 

Integrated Assistance for the Metal Casting Industry 

The ITP Metal Casting portfolio has funded $22 million in research, with an additional $27 million provided 

by industry cost-share over a period of seven years. 

A number of other EERE program activities have performed research related to metal casting, including 

Inventions & Innovation, and the Aluminum and Steel portfolios. Combined, they have provided an 

additional $20 million in funding on current research and technical assistance relevant to metal casters and 

leveraged an additional $20 million in cost-share. 

Beyond the research funding provided by the Metal 

Casting portfolio, many EERE technical and 

financial assistance programs and services are 

available to the metal casting industry to improve 

energy efficiency and competitiveness in casting 

processes. Exhibit 10 provides a couple of examples 

of EERE program assistance. Exhibit 12 lists recent 

examples of research performed by other ITP 

portfolios that pertain to the metal casting 

industry. 

In addition to those portfolios listed in Exhibit 10, 

EERE provides funding for research on cutting-edge 

enabling technologies, including Sensors & 

Automation, Industrial Materials, Combustion, 

Exhibit 10 

Examples of EERE Technical and Financial Assistance 

• Weatherization’s I&I Subprogram: Inventions and Innovation (I&I) 

provides financial assistance for conducting early development and 

establishing technical performance of innovative, energy-saving ideas and 

inventions. 

• IAC: Industrial Assessment Centers enable eligible small and mediumsized manufacturers to receive comprehensive industrial assessments 

performed at no cost to the manufacturer. 

• Plant-Wide Assessments: Plant-Wide energy assessments investigate 

overall energy use in industrial facilities, which can account for 10 percent 

or more of an industry’s total operating costs, and highlight opportunities for 

best energy management practices for industry, including the adoption of 

new, efficient technologies. 

and others. The program enables risk-sharing on industry-specific, pre-competitive, long-term high-impact 

research available through other ITP portfolios, such as Aluminum and Steel. The program also provides 

financial assistance for small businesses through Small Business Innovative Research grants. In addition, the 

Metal Casting portfolio is working with Allied Partners to help deploy the results of metal casting research 

9
and improve energy efficiency in the industry. Allied Partners are manufacturers, trade associations, industrial 

service and equipment providers, utilities, and other organizations that agree to promote increased energy 

Exhibit 11


Metal Casting Portfolio by Focus Area


(Fact sheets are available at: http://www.eere.energy.gov/industry/metalcasting/active_rd.html) 

Advanced Melting 

• Improvement in Melt Efficiency for Die Casting (Case Western Reserve 

University)) - Energy SMARRT 

• Advanced, Scalable Clean Aluminum Melting System (SECAT, Inc.) 

• Advanced Steel Casting Technology (University of Iowa) 

• Simulation of Dimensional Charges & Hot Tears During Solidification of Steel 

Castings (University of Iowa) - Energy SMARRT 

• Melting Efficiency Improvement (University of Missouri-Rolla) - Energy 

SMARRT 

Innovative Casting Processes 

• Clean Steel Casting Production (CANMET)- Energy SMARRT 

•	 Feasibility of Producing Lost Foam Casting in Aluminum and Magnesium 

Based Alloys (CANMET)- Energy SMARRT 

• Light Metals Permanent Mold Casting (CANMET)- Energy SMARRT 

•	 Casting Porosity-Free, Grain Refined Magnesium Alloys (Case Western 

Reserve University)- Energy SMARRT 

•	 Effects of Die Design & Dimensional Features on Thermal Fatigue Cracking 

of Die Casting Dies (Case Western Reserve University) 

•	 Gating of Permanent Mold Aluminum Casting (Phase II) (Case Western 

Reserve University) 

•	 Evaluation of Heat Checking and Washout of Heat Resistant Superalloys 

for Die Insert (Case Western Reserve University) 

•	 Improved Die Casting Process to Preserve the Life of the Inserts (Case 

Western Reserve University)- Energy SMARRT 

•	 Improvement in Die Design to Improve Die Life as Affected by Thermal 

Fatigue Cracking, Erosion and Soldering (Case Western Reserve University)­

Energy SMARRT 

•	 Improved Yield and Production Rates in Metal Mold Casting Processes by 

Advanced Thermal Management (Case Western Reserve University)­

Energy SMARRT 

•	 Metallic Reinforcement of Direct Squeeze Die Cast Aluminum Alloys for 

Improved Strength and Fracture Resistance (Case Western Reserve 

University) 

• Prevention of Porosity in Iron Casting (Climax Research Services) 

•	 Development of a Fatigue Properties Database for Use in Modern Design 

Methods (Climax Research Services) 

•	 Development of Surface Engineered Coating Systems for Aluminum 

Pressure Die Casting Dies: Towards a “Smart” Die Coating (Colorado 

School of Mines) - Energy SMARRT 

•	 Development of Surface Engineered Coatings for Die Casting Dies 

(Colorado School of Mines) 

•	 Integration of RSP Tooling with Rapid Prototyping for Die Casting 

Applications (Colorado State University) 

•	 Grain Refinement of Permanent Mold Cast Copper Base Alloys (Copper 

Development Association) 

•	 Development of Elevated Temperature Aluminum MMC Alloy and Process 

Technology (Eck, Industries) - Energy SMARRT 

•	 Prediction of Wax Pattern Tooling and Final Investment Casting Dimensions 

(EMTEC and Oak Ridge National Laboratory - Energy SMARRT 

•	 Tools for the Assurance of High Strength and Fatigue Resistant Aluminum 

Castings (General Motors Powertrain) 

•	 Development Program for Natural Aging Aluminum Alloys (GKS 

Engineering Services) 

•	 Conformal Cooling in Die Casting and Permanent Mold Casting (Idaho 

National Engineering and Environmental Laboratory)- Energy SMARRT 

•	 Quantification and Standardization of Pattern Properties for the Lost Foam 

Casting Process (Industrial Analytics Corporation) 

•	 Development of Thin-Section Zinc Die Casting Technology (International 

Lead Zinc Research Organization)- Energy SMARRT 

• Development of CCVT Diagrams (Iowa State University)- Energy SMARRT 

• Energy Efficient Instrumentation (Iowa State University)- Energy SMARRT 

•	 Reduction in Energy Consumption and Variability in Steel Casting (Iowa 

State University) 

•	 Control of Soldering and Thermal Fatigue During Die Casting (Oak Ridge 

National Laboratory) 

•	 Castability Assessment and Data Integration for Die Casting Design (Ohio 

State University) 

•	 Computer Modeling of the Mechanical Performance of Die Casting Dies 

(Ohio State University) 

•	 Design Support for Tooling Optimization (Ohio State University) - Energy 

SMARRT 

•	 Effects of Externally-Solidified Product on Wave Celerity and Quality of 

Die Cast Products (Ohio State University) 

•	 Improvements in Sand/Mold/Core Technology: Effects on Casting Finish 

(Ohio State University) 

•	 Investigation of Flow Regimes in High-Pressure Die Casting (Ohio State 

University) - Energy SMARRT 

• Prediction of Part Distortion in Die Casting (Phase III) (Ohio State University) 

• Energy Consumption of Die Casting Operations (Ohio State University) 

• Mechanical Performance of Dies (Ohio State University) - Energy SMARRT 

•	 Understanding the Relationship Between Pattern Filling and Part Quality in 

Die Casting (Ohio State University) 

•	 The Use of Laser Engineered Net Shaping for Rapid Manufacturing of Dies 

with Protective Coatings and Improved Thermal Management (Ohio State 

University) - Energy SMARRT 

•	 Development of Technical Data to Validate Performance of Foundry 

By-products in Hot-Mix Asphalt and Controlled Low-Strength Material 

(Pennsylvania State University) 

•	 Heat Treatment Procedure Qualification for Steel Castings (Pennsylvania 

State University) 

•	 In-Situ Real-Time Monitoring and Control of Mold Making and Filling 

Processes (Tennessee Technological University) 

• Investment Shell Cracking (Tri-State University) 

• Metallic Recovery and Ferrous Melting Processes (Tri-State University) 

• Thin Wall Cast Iron: Phase 2 (University of Alabama) 

•	 Advanced Lost Foam Casting, Phase V (University of Alabama -

Birmingham) 

• Advanced Steel Casting Technology (University of Alabama-Birmingham) 

•	 Manufacturing Advanced Engineered Components Using Lost Foam Casting 

Technology (University of Alabama-Birmingham) - Energy SMARRT 

•	 Surface/Near Surface Indications - Characterization of Surface Anomalies 

from Magnetic Particle and Liquid Penetant Indications (University of 

Alabama-Birmingham) - Energy SMARRT 

•	 Simulation of Dimensional Changes and Hot Tears During Solidification of 

Steel Castings (University of Iowa)- Energy SMARRT 

•	 Simulation of Distortion and Residual Stress Development During Heat 

Treatment of Steel Castings (University of Iowa)- Energy SMARRT 

•	 Yield Improvement and Defect Reduction in Steel Castings (University of 

Iowa) 

•	 Investigation of Heat Transfer at the Mold/Metal Interface in Permanent 

Mold Casting of Light Alloys (University of Michigan) 

• Aging of Graphite Cast Irons and Machinability (University of Missouri-Rolla) 

- Energy SMARRT 

• Precision Castings (University of Missouri-Rolla) - Energy SMARRT 

•	 Determination of Bulk Dimensional Variation in Castings (University of 

North Carolina at Charlotte) 

•	 Service Performance of Welded Duplex Stainless Steel Castings and 

Wrought Materials (University of Tennessee) 

•	 Innovative Semi-Solid Metal (SSM) Processing (Worcester Polytechnic 

Institute) - Energy SMARRT 

10
efficiency and productivity for those industries that participate in the Industries of the Future strategy. The 

metal casting industry is working with the technical societies, state casting associations, research institutes, 

and others to formalize Allied Partnership agreements. Through Allied Partners, EERE will be well equipped 

to deliver the results of research programs and technical assistance. 

Currently, ITP and the Metals Processing Institute at Worcester Polytechnic Institute have an Allied 

Partnership. The objectives of this partnership are to increase knowledge and end-user awareness of 

opportunities in the operation and/or design of metal processing systems, leading to improved productivity, 

energy efficiency and reliability, and reduced life-cycle costs for industrial customers. 

Exhibit 12


Additional Industrial Technologies Research Related to Metal Casting


(Fact sheets are available at http://www.eere.energy.gov/industry/metalcasting/completed_rd.html) 

Financial Assistance 

• A New “Pour-In-Mold” (DPI) Technology for Producing Ductile and Compacted Graphite Iron Castings (Inventions & Innovation) 

• Casting Quality Measurements for Polystyrene Foam Patterns (Inventions & Innovation) 

• Ceramic Composite Die for Metal Casting (Inventions & Innovation) 

• Computer Process Model for the Cupola Furnace (Inventions & Innovation) 

• High-Frequency Eddy-Current Separator for Foundry Sand (Inventions & Innovation) 

• Highly Efficient Rapid Tooling Using Optimized Cooling Passages (Inventions & Innovation) 

• Lost Foam Casting Quantifier Program (Inventions & Innovation) 

• Meta-Lax Stress Relief Process (Inventions & Innovation) 

• Method and Apparatus for Production of Three-Dimensional Objects by Photosolidification (Inventions & Innovation) 

• Titanium Matrix Composite Tooling Material for Enhanced Manufacture of Aluminum Die Castings (Inventions & Innovation) 

Crosscutting Applications 

• A Bubble Probe for Optimization of Bubble Distribution and Minimization of Splashing/Droplet Formation (Aluminum) 

• Continuous Severe Deformation Processing of Aluminum Alloys (Aluminum) 

• Coolant Characteristics and Control in Direct Chill Casting (Aluminum) 

• Degassing of Aluminum Alloys Using Ultrasonic Vibrations (Aluminum) 

• Development of an Innovative Vertical Floatation Melter and Scrap Dryer (Aluminum) 

• Development of a Two-Phase Model for the Hot Deformation of Highly-Alloyed Aluminum (Aluminum) 

• Effect of Impurities on the Processing of Aluminum Alloys in Casting, Extrusion, and Rolling (Aluminum) 

• Energy-Efficient Isothermal Melting (Aluminum) 

• Fundamental Studies of Structural Factors Affecting the Formability of Continuous Cast Aluminum Alloys (Aluminum) 

• Gating of Permanent Mold Aluminum Casting Phase-II (Aluminum) 

• High-Efficiency, Low-Dross Combustion System for Aluminum Remelt Reverberatory Furnaces (Aluminum) 

• Improved Energy Efficiency in Aluminum Melting (Aluminum) 

• Molten Aluminum Treatment by Salt Fluxing with Low Environmental Emissions (Aluminum) 

• Reduction of Annealing Times for Energy Conservation in Aluminum Processing (Aluminum) 

• Reduction of Oxidative Melt Loss of Aluminum and its Alloys (Aluminum) 

• Selective Absorption of Salts from Molten Aluminum (Aluminum) 

• Surface Behavior of Aluminum Alloys Deformed Under Various Processing Conditions (Aluminum) 

• Alloys for Ethylene Cracker (Chemicals) 

• Improving the Efficiency of Electric Arc Furnace in the United States (Steel) 

• Optical Sensors for Post Combustion Control in Electric Arc Steelmaking (Steel) 

Technical Assistance 

• BestPractices - Plant-Wide Assessments and Hands-on Technical Assistance 

- AMCAST 

- Sawbrook 

- Techni-cast 

• Industrial Assessments 

- Over $12 million in energy-saving recommendations implemented in the metal casting industry since 1992 

The ITP Metal Casting portfolio posted a number of important accomplishments in FY 2004. The following 

describes accomplishments in several key areas: 

• Applying R&D Results 

• Newly-Awarded Projects 

• Improving Energy Efficiency Today 

11

• Energy Analysis – Targeting Energy Efficiency 

• University-Based Research 

• Disseminating Research Results to Industry 
Applying R&D Results 

Industry is rapidly adopting ITP Metal Casting portfolio research results in their casting operations. The 

following provides examples of metal casting research developments and applications. 

•	 CastView Assists in Designing the Xlerator Hand Dryer – Researchers at the Ohio State University 

developed a software tool, “CastView,” to help die casters predict the complex metal flow within metal 

dies. This tool has assisted in the designing of dies by providing a simulation of die filling conditions. 

Recently, this software has been used in improving the design of an Xlerator Hand Dryer. This hand 

dryer is a seven-pound zinc die casting that is manufactured by Excel Dryer. The hand dryer is designed 

to be the most efficient and fastest hand dryer available, with the ability to dry hands in less than 10 

seconds. The product also uses only one-third the energy used in standard hand dryers, and one-tenth 

of the energy used to make paper towels. This software tool is expected to significantly reduce defects 

and improve yield in die casting. ITP estimates that this tool will save 2.61 trillion Btu and $14.72 

million in energy cost-savings in 2020. To learn more about this tool and ITP’s involvement, please visit: 

http://www.eere.energy.gov/industry/metalcasting/pdfs/vistool.pdf. 

•	 Surface-Engineered Coatings for Die Casting Dies – Researchers at the Colorado School of Mines have 

made significant strides with the development of multi-layer graded die coating systems that extend the 

life of dies. The researchers examined the major mechanisms leading to premature die failure including 

heat checking, gross cracking, erosive-wear soldering, and corrosion/oxidation. This research 

concentrated on developing a coating system for dies used in aluminum die casting. The research has 

yielded promising coating systems which are now undergoing in-plant trials with five aluminum pressure 

die casting plants. Ultimately, these coating systems developed by this research will increase die life, 

increase surface quality of die cast components, and decrease downtime during scheduled production 

due to die failure. ITP estimates that these coating systems will save 30 billion Btu and $140 thousand in 

energy costs in 2020. To learn more about this tool and ITP’s involvement, please visit: 

http://www.eere.energy.gov/industry/metalcasting/pdfs/csm_surfacecoating.pdf. 

•	 Semi-Solid Metal Transient Rheological Behavior Characterization: A New Approach – Commercial 

Semi-Solid Metal (SSM) forming operations take place in seconds or fractions of seconds. Therefore, the 

transient rheological behavior of SSM is critical in determining the flow patterns during die filling. At 

present, there is no standard technique or rheological measurement instrument available for the SSM 

community. Researchers at Worcester Polytechnic Institute developed an advanced high-temperature 

rheological measurement system, and corresponding methodologies with ITP Metal Casting portfolio 

funding. The new system consists of a high-temperature rheometer coupled with an optimized rotating 

vane in cup geometry. Thus far, validation experiments with the standard materials indicate that the 

system can be used to characterize the rheological behavior of SSM under both steady and transient 

shear conditions. Specifically, the optimized vane-cup design circumvents some critical problems 

encountered in traditional methods, such as the wall slip effect. Using the system, a vast set of transient 

rheological data of commercial MHD A356 alloy has been generated. These valuable data are being 

employed to improve the accuracy and capabilities of the simulation tools developed by the research 

team. This project will expand the use of SSM technology because the billets require a lower temperature 

(as compared to traditional casting operations), thereby reducing the amount of energy expended. 

Researchers estimate that this research program has the potential to save 2.54 trillion Btu per year. To 

learn more about this tool and ITP’s involvement, please visit: http://www.eere.energy.gov/industry/ 

metalcasting/pdfs/wpi_ssm.pdf. 

•	 Service Performance of Welded Duplex Stainless Steel Castings and Wrought Materials – Duplex 

stainless steels are used because of their excellent corrosion resistance and high strength. To meet the 

specification requirements and to provide confidence to the user, a specification test (ASTM A923) was 

developed for wrought material. The purpose of the screening test was to identify if intermetallic 

precipitates have a detrimental effect on mechanical properties and corrosion resistance. Their presence 

can lead to premature failure and unscheduled shutdowns of industrial equipment with consequential 

energy losses. Researchers at the University of Tennessee with ITP Metal Casting portfolio funding, 

developed a data package that demonstrated that cast material responded in a similar manner. The data 

package included information on three heats of material compared to the one from the wrought 

12
material. In addition, the researchers showed that the impact test was a much better discriminator than 

the corrosion test in ASTM A923. This data was submitted as a ballot item to ASTM and was approved 

within six months, providing efficient technical transfer of these research findings. These findings 

increase yield, thus saving the energy associated with remelting. ITP estimates that this research will save 

approximately 700 million Btu and $470 thousand in energy costs in 2020. For more information, please 

visit: http://www.eere.energy.gov/industry/metalcasting/pdfs/ut_welded_duplex.pdf. 

•	 Heat Treatment Procedure Qualification – Heat treatment is underdeveloped in the national and 

international specifications currently in use. There is a need to develop a method to bring this process 

step under control. Equipment failures due to inadequate heat treatment are unpredictable and costly in 

terms of energy and lost production. A procedure is being developed to document the critical control 

issues and the hurdles that must be cleared. To date, this work has been split into two sections, one 

dealing with carbon and low-alloy steels and the other dealing with high-alloy steels. Researchers at 

Pennsylvania State University, with ITP Metal Casting portfolio support, have identified an easy way to 

deal with the carbon and low-alloy steels. These same researchers are now addressing the issues 

surrounding the high-alloy steels. The most critical goal here is to gain industry acceptance by producer 

and users. Presentation of the scope of this work at ISO has ensured that a specification will be 

developed. ITP estimates that this research will save 900 billion Btu and $900 thousand in energy cost 

savings in 2020. To learn more, please visit: http://www.eere.energy.gov/industry/metalcasting/pdfs/ 

psu_heat_treat.pdf. 

•	 Reduction in Energy Consumption and Variability in Steel Casting – Steel foundries generally have 10 

times the process inventory workload in comparison to iron foundries. These high inventory levels 

inhibit the ability of the foundry to detect quality problems, leading to extended delivery times. The 

quality issue causes the foundry to use more energy as the amount of substandard product grows due to 

the slow reaction time of the process. Researchers at Iowa State University set out to gain an 

understanding of the reasons for these high inventory levels. Researchers determined that the largest 

problem that was leading to the high inventory levels has been the inability of operators to understand 

quality level requirements. Due to this lack of knowledge, the researchers realized that many cleaning 

rooms were only operating at a 20 percent efficiency level. This inefficiency forced many steel foundries 

to use heat treat castings or scrap castings for reworking, or to provide excess cleaning rooms, thus 

consuming more energy. Researchers at Iowa State University have developed recommendations that will 

reduce the inefficiencies. Researchers estimate that this research will save 1.78 trillion Btu. To learn 

more, please visit: http://www.eere.energy.gov/industry/metalcasting/pdfs/ui_yield_def.pdf. 

•	 A Model for the Mechanics of Foam Decomposition in Contact Mode – There are two problems with 

the traditional lost foam pattern decomposition model. First, the calculated filling speeds are slow by an 

order of magnitude, and second, there is a strong thickness dependence. A new model was developed that 

recognizes the formation of an undercut in the foam pattern while it is heated by the melt. This 

phenomenon is able to correctly predict the filling speed and a weak thickness dependence. GMC has 

used this understanding to make production decisions to improve the quality of its lost foam casting 

lines. This insight would not have been possible without the quantitative gas evolution measurements 

made at the University of Alabama-Birmingham through their lost foam research supported by ITP’s 

Metal Casting portfolio. ITP estimates that this research will save 8.07 Trillion Btu and $48.5 million in 

energy cost savings in 2020. To learn more, please visit: http://www.eere.energy.gov/industry/ 

metalcasting/pdfs/uab_lostfoam.pdf. 

•	 Predicting Wax Pattern Distortion for Investment Casting – In the investment casting industry, 

tooling dimensioning is based on proprietary and plant experience, with very few industry guidelines. 

The work on wax and shell systems is an important step toward predicting the tooling dimensions for 

geometric features in a new casting during the first casting run. For the first time, researchers from Oak 

Ridge National Laboratory, with ITP Metal Casting portfolio funding, have developed a computational 

tool that can be used to predict the tooling dimensions, as well as the casting dimensions. The computer 

tools enable the designers to develop castings with high structural efficiency and avoid energy-intensive 

processes such as using mechanical fasteners, welding, and brazing. ITP estimates that this research will 

save 3.62 Trillion Btu and $14.1 million in energy cost-savings in 2020. To learn more, please visit: http:// 

www.eere.energy.gov/industry/metalcasting/pdfs/ornl_predict_patrn_tool.pdf. 

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•	 Machinable Thin-Wall Ductile Iron Research Incorporated by Dura-Bar – There is a growing demand 

for ductile iron castings with a consistent machinability at high speed. Foundries that produce 

machinable castings occasionally encounter batches that are extremely “hard-to-machine” or cause rapid 

tool wear. Under ITP Metal Casting portfolio funding, a technique was developed by researchers at the 

University of Alabama-Birmingham to accurately measure tool wear as a function of metallurgical 

variables and machining conditions. The improved technique provides a rate of tool wear and volume 

of metal removed as a function of casting variables. This technique consistently ranked different iron 

grades regardless of the machining operations. Dura-Bar has incorporated these findings into their 

manufacturing process. By doing this, Dura-Bar has been able to give their customers confidence that 

they are controlling variables that affect machinability, but can also directly benefit their customers’ 

profits by reducing their machining operations. ITP estimates that this research will save 1.37 Trillion 

Btu and $18.4 million in energy cost-savings in 2020. 

New Project Awards 

The Industrial Technologies Program, Metal Casting portfolio solicitation for competitive cost-shared 

research proposals resulted in four awards. The ensuing research projects will make important contributions 

to ongoing efforts to address both Vision targets and national energy efficiency goals. These projects will 

make advances in the melting systems and innovative casting processes for the metal casting industry. The 

four selected projects are: 

•	 Energy-Saving Melting and Revert Reduction Technology (Energy SMARRT) – The Advanced 

Technology Institute of Charleston, South Carolina is leading a research team that includes University of 

Alabama, University of Iowa, University of Missouri - Rolla, CANMET, Case Western Reserve University, 

Eck Industries, Worcester Polytechnic Institute, Idaho National Energy and Environmental Laboratory, 

Ohio State University, Colorado School of Mines, Iowa Sate University, Lehigh University, International 

Lead Zinc Research Organization, and Edison Materials Technology Center. The project, known as 

Energy SMARRT, is a balanced portfolio of tasks to reduce energy consumption in the metal casting 

industry by 49 trillion Btu per year over ten years. The portfolio will improve existing technologies, as 

well as develop breakthroughs to revolutionize casting production. Maximum energy savings from the 

“as is” environment are realized in these tasks, while the theoretical minimum energy inputs are 

researched for existing and new melting technologies. 

•	 In-Situ, Real-Time Monitoring and Control of Mold Making and Filling Processes – Tennessee 

Technological University will lead a research team from Oak Ridge National Laboratory, Walford 

Technologies, and nine other partners in developing an innovative approach to introduce technologies 

for real-time characterization of sand molds, lost foam patterns, and monitoring of the mold filling 

process. The proposed technology will enable better control over the casting process and reduce scrap 

and variances in casting quality. 

•	 Development of Computational Tools for the Assurance of High-Strength and Fatigue-Resistant 

Aluminum Castings – General Motors Powertrain will lead a team of researchers from Oak Ridge 

National Laboratory, the University of Wisconsin, ComuTherm, EKK, and Worcester Polytechnic Institute 

on a project to develop computational techniques for alloy design, melt treatment, microstructure 

control, and heat treatment optimization of aluminum castings. With computational tools, designers of 

aluminum cast components and casting engineers will be able to optimize the alloy, as well as the casting 

and heat treatment processes to achieve strength and fatigue life requirements with minimal lead-time 

and cost. 

•	 Advanced, Scalable Clean Aluminum Melting Systems – SECAT, Inc., will lead a team of researchers 

from Oak Ridge National Laboratory, the DOE Albany Research Center, University of Kentucky, E3M, and 

nine other partners on a project to develop and integrate the technologies necessary to substitute 

immersion heating for the conventional radiant burner methods used in reverberatory furnaces. 

Specifically, the project will couple heater improvement with furnace modeling to enable cost-effective 

retrofits to a range of existing furnaces, thus reducing the economic barriers to the application and 

reducing the energy and environmental impact of aluminum melting. 

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Improving Energy Efficiency Today 

Within ITP, there are other services that help the metal casting industry save energy. These include software 

tools, training, and energy-saving resources from EERE BestPractices and Industrial Assessment Centers. 

Recommendations by these groups have the potential to save metal casters millions of dollars annually. For 

example, a plant-wide assessment performed by the BestPractices program for Sawbrook, Ohio identified 15 

plant and process modifications that would result in an annual savings of $169,000 per year in costs and 

energy savings. Another plant-wide assessment conducted at Techni-Cast, California, identified 

improvements in the compressed air systems that allowed the foundry to reduce its compressor capacity by 50 

percent, thus saving annual energy of 242,000 kWh and costs of $24,000. To learn more about plant-wide 

assessments, please visit: http://www.oit.doe.gov/bestpractices. 

Energy Analysis – Targeting Energy Efficiency 

In FY 2004, ITP published two reports, Energy Use in Selected Metal Casting Facilities – 2003 and Theoretical/Best 

Practice Energy Use In Metalcasting Operations. The Energy Use in Selected Metal Casting Facilities – 2003 provides 

an energy benchmark for various metalcasting processes. It describes process flows and energy use by fuel type 

and processes for selected casting operations. It also provides recommendations for improving energy 

efficiency in casting. The Theoretical/Best Practice Energy Use In Metalcasting Operations report evaluates the 

potential for reducing the energy needed to produce molten metal (cast iron, steel, aluminum, magnesium, 

zinc and copper). It also includes energy-saving opportunities beyond melting, as well as an analysis of the 

potential for combined heat and power in metal. These reports will assist the Metal Casting IOF and the 

CMC to direct efforts to high-impact, revolutionary processes research. These reports are available at: http:// 

www.eere.energy.gov/industry/metalcasting/analysis.html. 

University-Based Research 

The availability of a well-trained workforce in the U.S. metal casting industry has been one of the industry’s 

top priorities. Addressing this concern, the Metal Casting IOF places a strong emphasis on university-based 

research. Metal Casting IOF-funded research is performed at nearly 18 universities across the United States. 

U.S. students are being exposed to cutting-edge technology and material research critical to the future health 

of the U.S. economy. In addition, well-trained students are moving toward productive careers in the metal 

casting industry. In October 2003, ITP conducted a survey of all university participants in the portfolio since 

the inception of the Metal Casting portfolio. The survey was used to determine the number of students that 

participated in ITP Metal Casting portfolio-funded research, and of those that participated, how many now 

work in the metal casting industry. The results concluded that over 325 students participated in Metal 

Casting portfolio-funded research; 150 are now working in the metal casting industry. These students have 

been able to translate their education in the advanced technologies, materials, and processes into improved 

energy efficiency and productivity for the metal casting industry. 

Disseminating Research Results to Industry 

The ITP Metal Casting portfolio performs various outreach activities to disseminate R&D results and enable 

the U.S. metal casting industry to implement energy-saving practices and technologies. This includes 

participating in trade shows and maintaining an up-to-date Web site that highlights Metal Casting portfolio 

activities. In addition, through trade publications such as Die Casting Engineer and Modern Casting, research 

funded by the ITP Metal Casting portfolio is often highlighted, exposing metal casters to research that can 

save them energy and reduce their costs. Examples of trade shows in which the ITP participates include: 

• CastExpo hosted by AFS (http://www.afsinc.org) 

• Die Casting Congress & Exposition hosted by NADCA (http://www.diecasting.org) 

• Technical and Operating Conference hosted by SFSA (http://www.sfsa.org) 

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TOOLS, PUBLICATIONS, AND RESOURCES AVAILABLE 

The Metal Casting Industry of the Future offers a wide array of tools and publications to help metal casters 

improve productivity and energy efficiency. These resources are available online at the Metal Casting Web 

site at: http://www.eere.energy.gov/industry/metalcasting/analysis.html. 

Tools and Publications 

The tools and publications available from the ITP Metal Casting portfolio include: 

•	 A Vision for the U.S. Metal Casting Industry: 2002 and Beyond: This document outlines the broad 

goals and challenges identified by industry leaders that must be addressed over the next 20 years. 

Achieving the goals set forth in the vision will improve productivity and energy efficiency in the industry 

and quicken the development and application of advanced, clean technologies in metal casting 

processes. 

•	 Metal Casting Industry Technology Roadmap: Pathway for 2002 and Beyond (2003): The Metal 

Casting Industry Technology Roadmap establishes the industry’s R&D priorities, performance targets, and 

milestones for attaining the goals set forth in the vision. This roadmap identifies specific research 

challenges and needs in the areas of Improved Metalcasting Design Capabilities and Improved Metalcasting 

Processes. 

•	 Gateway to Metal Casting Resources: This application is available both online and 

in CD-ROM form. It provides abstracts of Metal Casting portfolio projects along 

with links to both fact sheets and technical reports of these projects. Projects are 

categorized by alloy, casting method, and step in the casting process. This 

application provides both links to the technical societies and other resources 

available from DOE. 

•	 Energy Use in Selected Metalcasting Facilities – 2003: This report represents an 

energy benchmark for various metal casting processes. It describes process flows and 

energy use by fuel type and processes for selected casting operations. It also provides 

recommendations for improving energy efficiency in casting. 

•	 Energy and Environmental Profile of the Metal Casting Industry: This detailed 

report benchmarks the energy and environmental characteristics of the key 

technologies used in the major processes of the metal casting industry. 

•	 Theoretical/Best Practice Energy Use In Metalcasting Operations: With U.S. 

energy costs increasing, this timely report evaluates the potential for reducing the 

energy needed to produce molten metal (cast iron, steel, aluminum, magnesium, 

zinc and copper). It also includes energy-saving opportunities beyond melting, as 

well as an analysis of the potential for combined heat and power in metal casting. 

To view these documents and application, please visit: http://www.eere.energy.gov/ 

industry/metalcasting/analysis.html 

Fact Sheets 

The Metal Casting IOF disseminates information on current and past projects through project fact sheets. 

The information provided in each fact sheet includes the objective, accomplishments, benefits, principal 

investigator, and project partners. All metal casting fact sheets are available online at: http:// 

www.eere.energy.gov/industry/metalcasting/portfolio.html and on the Gateway to Metal Casting Resources. 

16
HOW TO GET INVOLVED AND CONTACT INFORMATION 

Partnership Information 

Public-private partnerships are the foundation of ITP’s technology delivery strategy. ITP includes its partners 

in every phase of the technology development process to focus scarce resources where they can have the 

greatest impact on industrial energy efficiency. To learn more, please visit our Web site at http:// 

www.eere.energy.gov/industry. 

•	 Collaborative, cost-shared research and development projects are a central part of ITP’s strategy. 

Annual solicitations provide technology development opportunities in a variety of energy-intensive 

industries. 

•	 Industries of the Future Partnerships increase energy efficiency in the most energy-intensive 

industries. In addition to cost-shared research and development projects, industry partners participate in 

the development of vision and roadmap documents that define long-term goals, technology challenges, 

and research priorities. 

•	 Allied Partnerships provide an opportunity for ITP to reach a broad audience of potential customers by 

allying with corporations, trade associations, equipment manufacturers, utilities, and other stakeholders 

to distribute industrial energy efficiency products and services. By becoming an Allied Partner, an 

organization can increase its value to clients by helping them achieve plant efficiencies. 

•	 State energy organizations work with ITP in applying technology to assist their local industries. ITP 

assists states in developing partnerships to mobilize local industries and other stakeholders to 

improve energy efficiency through best practices, energy assessments, and collaborative research and 

development. 

•	 EERE’s technical programs (ITP is one of 11) give manufacturers access to a diverse 

portfolio of energy efficiency and renewable energy technologies and bring advanced manufacturing 

technology to the renewable energy community. For more information, access the EERE home page at 

http://www.eere.energy.gov. 

•	 The President’s Climate VISION (Voluntary Innovative Sector Initiatives: Opportunities Now) effort also 

offers opportunities for manufacturers to pursue cost-effective actions that will reduce greenhouse gas 

emissions. See www.climatevision.gov for details. 

Access to Resources and Expertise 

The Industrial Technologies Program provides manufacturers with a wide variety of industrial energy 

efficiency resources to help your company reduce energy expending right away. Visit our Web site at: http:// 

www.eere.energy.gov/industry or call the EERE Information Center at 877-337-3463 to access these resources 

and to get more information. 

•	 ITP offers energy management best practices to improve energy efficiency throughout plant 

operations. Improvements to industrial systems such as compressed air, motors, process heat, and steam 

can yield enormous savings with little or no capital investment. 

•	 Our suite of powerful system optimization software tools can help plants identify and analyze energysaving opportunities in a variety of systems. 

•	 Training sessions are held several times per year at sites across the country for companies interested in 

implementing energy-saving projects in their facilities. DOE software tools are used as part of the 

training sessions. 

17
•	 ITP’s qualified industrial energy specialists will work with your plant personnel to identify savings 

opportunities and train staff in the use of ITP software tools. 

•	 Our extensive library of publications gives companies the resources they need to achieve immediate 

energy savings. 

•	 Plant-wide energy assessments are available to manufacturers of all sizes interested in cutting their 

energy use. Cost-shared solicitations are available each year for plant-wide energy assessments. In 

addition, no-cost, targeted assessments are provided to eligible facilities by teams of engineering faculty 

and students from 26 university-based Industrial Assessment Centers around the country. 

•	 The DOE Regional Offices provide a nation-wide network of capabilities for implementing ITP’s 

technology delivery strategy. Regional Offices are located in the Southeast, Northeast, Midwest, Central, 

Mid-Atlantic, and Western regions. Visit http://www.eere.energy.gov/rso.html for more information. 

Where to Go to Get More Information 

Visit our Web site: http://www.eere.energy.gov/industry/metalcasting 

Learn about all EERE programs: http://www.eere.energy.gov 

EERE Information Center answers questions on EERE’s products, services and 11 technology programs, refers 

callers to the most appropriate EERE resources, and refers qualified callers to the appropriate expert networks. 

You may contact the EERE Information Center by calling 1-877-EERE-INF (1-877-337-3463) or by completing 

the form at this site: http://www.eere.energy.gov/informationcenter. A customer service specialist or energy 

expert at the EERE Information Center will respond to your inquiry. 

For print copies of DOE, EERE and ITP Publications, contact the


Energy Efficiency and Renewable Energy Information Center


P.O. Box 43165


Olympia, WA 98504-3165


http://www.eere.energy.gov/informationcenter/


For questions regarding Metal Casting portfolio activities, please contact: 

Ehr-Ping HuangFu


Industrial Technologies Program/Rm. 5F059


Office of Energy Efficiency and Renewable Energy


U.S. Department of Energy


1000 Independence Avenue SW


Washington, DC 20585-0121


Phone: 202-586-1493


Fax: 202-586-6507


E-mail: ehr-ping.huangfu@ee.doe.gov


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A Strong Energy Portfolio for a Strong America 

Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and great energy 

independence for America. By investing in technology breakthroughs today, our nation can look forward to a more 

resilient economy and secure future. 

Far-reaching technology changes will be essential to America’s energy future. Working with a wide array of state, 

community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and 

Renewable Energy invests in a portfolio of energy technologies that will: 

• Conserve energy in the residential, commercial, industrial, government, and transportation sectors 

• Increase and diversify energy supply, with a focus on renewable domestic sources 

• Upgrade our national energy infrastructure 

• Facilitate the emergence of hydrogen technologies as a vital new “energy carrier” 

The Opportunities 

Biomass Program 

Using domestic, plant-derived resources to meet our fuel, power, and chemical needs 

Building Technologies Program 

Homes, schools, and businesses that use less energy, cost less to operate, and ultimately, generate as much power as 

they use 

Distributed Energy & Electric Reliability Program 

A more reliable energy infrastructure and reduced need for new power plants 

Federal Energy Management Program 

Leading by example, saving energy and taxpayer dollars in federal facilities 

FreedomCAR & Vehicle Technologies Program 

Less dependence on foreign oil, and eventual transition to an emissions-free, petroleum-free vehicle 

Geothermal Technologies Program 

Tapping the Earth’s energy to meet our heat and power needs 

Hydrogen, Fuel Cells & Infrastructure Technologies Program 

Paving the way toward a hydrogen economy and net-zero carbon energy future 

Industrial Technologies Program 

Boosting the productivity and competitiveness of U.S. industry through improvements in energy and environmental 

performance 

Solar Energy Technology Program 

Utilizing the sun’s natural energy to generate electricity and provide water and space heating 

Weatherization & Intergovernmental Program 

Accelerating the use of today’s best energy-efficient and renewable technologies in homes, communities, and 

business 

Wind & Hydropower Technologies Program 

Harnessing America’s abundant natural resources for clean power generation 

To learn more, visit: www.eere.energy.gov 

Metal Casting Industry of the Future 

Industrial Technologies Program 

Boosting the productivity and competitiveness of U.S. industry 

Published February 2005