WSU Energy Program Logo
Bonneville Power Administration Logo
  • Home
  • About
  • Database
      • Browse
      • Energy Systems
        • Building Envelope
        • Electronics
        • HVAC
        • Irrigation
        • Lighting
        • Motors & Drives
        • Multiple Energy Systems
        • Power Systems
        • Process Loads & Appliances
        • Refrigeration
        • Transportation
        • Water Heating
      • Sector
        • Agricultural
        • Commercial
        • Industrial
        • Residential
        • Utility
  • TAG Portal
      • 2017 Residential Lighting TAG (#14)
      • 2016 Multifamily Building TAG (#13)
      • 2015-1 Commercial HVAC TAG (#11)
      • 2014 Residential Building TAG (#10)
      • 2014 Commercial Building TAG (#9)
      • 2013 Information Technology TAG (#8)
      • 2013 ALCS TAG (#7)
      • 2012 Smart Thermostat TAG (#6)
      • 2012 LED Lighting TAG (#5)
      • 2011 Energy Management TAG (#4)
      • 2010 HVAC TAG (#3)
      • 2009 HVAC TAG (#2)
      • 2009 Lighting TAG (#1)
  • Webinars
    • Webinar Archives
  • Glossary
>

Summary

Near-Net-Shape Casting

Casting: Near-Net-Shape vs. Conventional

Refers to multiple techniques available to reduce the amount of machining and surface finishing required for the final cast part.

Synopsis:

Casting is a manufacturing process that is used for making complex shapes that would otherwise be difficult or uneconomical to make.  Casting takes many forms, including sand, continuous and die casting.  A liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.

Near-net-shape casting (NSC) is a family of techniques where the initial part production provides a quality surface finish and is close to the final (net) shape. Reducing the need for machining and grinding can eliminate more than two-thirds of the production cost in some industries.  NSC techniques include investment casting, spray forming (deposition), polymer blow molding, vacuum forming, compressed air forming, laser forming, rapid prototyping and nanotechnology manufacture.

With NSC, very close tolerances can be achieved with material waste reduced to a minimum.  NSC techniques can be used with ferrous and non-ferrous materials such as Titanium, Aluminum, Copper, Magnesium, and Zinc and ceramics.  Currently, most steel is continuously cast into slabs, billets or blooms, which later have to be reheated and rolled into final shape. Direct or NSC or thin-strip casting integrates the casting and hot-rolling of steel into one step, reducing the need to reheat the steel before rolling it (IEA, 2008). With a direct continuous steel casting approach, liquid steel can be directly cast into semi-finished products, which eliminates the need for primary rolling of ingots.

Prediction of energy savings is difficult as NSC is not a "one size fits all" approach.  Generally, a consultant works with a foundry to design an approach that addresses specific requirements of the material being cast.     

Energy Savings: 25%
Energy Savings Rating: Not rated.  What's this?
LevelStatusDescription
1Concept not validatedClaims of energy savings may not be credible due to lack of documentation or validation by unbiased experts.
2Concept validated:An unbiased expert has validated efficiency concepts through technical review and calculations based on engineering principles.
3Limited assessmentAn unbiased expert has measured technology characteristics and factors of energy use through one or more tests in typical applications with a clear baseline.
4Extensive assessmentAdditional testing in relevant applications and environments has increased knowledge of performance across a broad range of products, applications, and system conditions.
5Comprehensive analysisResults of lab and field tests have been used to develop methods for reliable prediction of performance across the range of intended applications.
6Approved measureProtocols for technology application are established and approved.

Status:

Details

Near-Net-Shape Casting

Casting: Near-Net-Shape vs. Conventional

Refers to multiple techniques available to reduce the amount of machining and surface finishing required for the final cast part.
Item ID: 183
Sector: Industrial
Energy System: Process Loads & Appliances--Industrial Processes

Synopsis:

Casting is a manufacturing process that is used for making complex shapes that would otherwise be difficult or uneconomical to make.  Casting takes many forms, including sand, continuous and die casting.  A liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.

Near-net-shape casting (NSC) is a family of techniques where the initial part production provides a quality surface finish and is close to the final (net) shape. Reducing the need for machining and grinding can eliminate more than two-thirds of the production cost in some industries.  NSC techniques include investment casting, spray forming (deposition), polymer blow molding, vacuum forming, compressed air forming, laser forming, rapid prototyping and nanotechnology manufacture.

With NSC, very close tolerances can be achieved with material waste reduced to a minimum.  NSC techniques can be used with ferrous and non-ferrous materials such as Titanium, Aluminum, Copper, Magnesium, and Zinc and ceramics.  Currently, most steel is continuously cast into slabs, billets or blooms, which later have to be reheated and rolled into final shape. Direct or NSC or thin-strip casting integrates the casting and hot-rolling of steel into one step, reducing the need to reheat the steel before rolling it (IEA, 2008). With a direct continuous steel casting approach, liquid steel can be directly cast into semi-finished products, which eliminates the need for primary rolling of ingots.

Prediction of energy savings is difficult as NSC is not a "one size fits all" approach.  Generally, a consultant works with a foundry to design an approach that addresses specific requirements of the material being cast.     

Baseline Example:

Baseline Description:

Manufacturer's Energy Savings Claims: Currently no data available.
Best Estimate of Energy Savings:

"Typical" Savings: 25%
Low and High Energy Savings: 25% to 50%

Comments:

An analysis of advanced lost foam NSC casting processes (such as Pressure Assisted Solidification and Vacuum Assisted Mold Filling) reported a 27% energy savings, a 46% improvement in labor productivity and 7% less material usage compared to other casting processes.  At the same time, mechanical properties, such as fatigue resistance for Aluminum alloys, were improved. (Druschitz, 2009).

The U.S. DOE has sponsored research for the aerospace industry using net shape casting with Titanium powders (Peter, ORNL, 2013).  They state that:  The aerospace industry, which consumes over half of the U.S. titanium production, has very high scrap generation rates. On average, eight pounds of raw material must be machined to produce one pound of final product, with seven pounds of machinings discarded as waste. This low material efficiency results in high machining costs and significant energy consumption per pound of finished  product.  Their research further shows that:  "Titanium components fabricated from powder metallurgy could have less than 5% to 10% scrap. When compared to conventional processes, the new titanium powders offer a 25% to 50% reduction in energy consumption".

Energy Use of Emerging Technology:
Currently no data available.
Technical Potential:
Currently no data available.
First Cost: Currently no data available.

Cost Effectiveness:

Simple payback, new construction (years): N/A

Simple payback, retrofit (years): N/A

What's this?

Cost Effectiveness is calculated using baseline energy use, best estimate of typical energy savings, and first cost. It does not account for factors such as impacts on O&M costs (which could be significant if product life is greatly extended) or savings of non-electric fuels such as natural gas. Actual overall cost effectiveness could be significantly different based on these other factors.

Reference and Citations:

ORNL, 11/22/2000. Scenarios for a Clean Energy Future, Chapter 5, The Industrial Sector
Oak Ridge National Laboratory

EERE, 02/28/2007. Research Advances Application of Semi-Solid Metal Processing, Enables High Quality Die Cast Parts
Energy Efficiency & Renewable Energy

EPA, 09/06/2012. Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Iron and Steel Industry
Environmental Protection Agency

NADCA, 01/01/2013. About Die Casting
North American Die Casting Association

William Peter, ORNL, 05/01/2013. Near Net Shape Manufacturing of New Titanium Powders for Industry
U.S. DOE Advanced Manufacturing Office

A Druschitz, 01/01/2009. Advanced Lost Foam Casting Processes and Materials
SAE International Journal of Material Manufacturing , 2

Rank & Scores

Near-Net-Shape Casting

There is no TAG available for this technology.
Contact
Copyright 2023 Washington State University
disclaimer and privacy policies

Bonneville Power Administration Logo