In this Issue

Increased Capacity
Rapid Prototype Cores
Next Generation DS/SC Material Development
DAI Website

Summer 2012

Hard to believe that half the year has come and gone already. It has been busy at DAI over the last several months with new development work as well as increased production along with procuring some new equipment. As you will read in this newsletter we have promising news about our next generation DS/SC material as well as rapid prototype cores for new and redesigned parts. All of that to better service our customers.

Increased Capacity

Over the last several months DAI has made a major investment to increase our overall capacity in a couple of departments. Late last year we took delivery of two new large batch kilns, which are on line, that increased our firing capacity by around 35 percent. That has helped alleviate any potential bottlenecks at our firing operation. Around that same time we took delivery of a new 220 ton high pressure injection machine to increase our capacity in producing larger high pressure cores for both aero and IGT parts. This July DAI will be taking delivery on a new low pressure injection machine to increase our capacity in making IGT and larger aero and commercial cores. With the new equipment, as well as the new transformer that was required for the increased power demand, the ancillary work and material needed to complete these projects, DAI has invested over $1 million back into the business to better serve our customers. We are poised to take on new production and development work without impacting current customer commitments.

Rapid Prototype Cores

DAI understands the need to be able to bring new parts and designs to the customer fast in order to be able to prove out new designs and to get a jump on the casting process. In order to do that you need to be able to get cores made quickly. At DAI we have sources that can build rapid prototype aluminum tooling in as little as 4 weeks depending on the complexity of the part. The tooling would be good for a couple dozen pieces to a couple hundred pieces, depending on the complexity, in order to prove out the part and get the core and casting process in place while production tooling is being built. We also work with a company that can produce an actual core without any tooling. This would be for a very limited number of parts, but no tooling is required. All we need to get any of this started is a core model and we can take it from there. If you have any new development programs or want to try a modified design on a current part give us a call and see how we can help.

Next Generation DS/SC Material Development

Last year DAI engineering started development work on an improved DS/SC core material. To date a screening DOE with sixteen runs has been completed to evaluate key material and process parameters that effect high temperature creep (also known as sag or slump). Results of the initial DOE proved very promising; with one of the test materials having a creep value that is 35% less than our current D-200 production material. The hot strength of this material was also greatly enhanced. Hot strength of the test material at 1475 C was 22% higher than the current D-200 production material. A second DOE is currently underway to optimize the results of what was generated in the initial DOE. It is expected that creep performance will be even further enhanced in this second round of experiments. So what does this all mean for the foundry? Better dimensional stability on thin wall castings, less core break, and less casting scrap. Upon finalizing material chemistry and processing parameters, DAI engineering will be working with several validation partners to prove the new materials higher performance out in the field prior to the material going into full production. Proving trials are slated for late Q4 2012 / early Q1 2013. If you would like to be a validation partner and take advantage of the enhanced performance of this new material, please contact DAI sales.

More About DAI

We have been serving the investment casting industry since 1986. Our experienced staff stands ready to help with any of your ceramic core needs.

If you need a quote you can fax, mail or email your requirements for preformed ceramic or extruded cores. Or better yet you can go to our website and click on the RFQ icon to send a quote. The next time you are in the area you are invited to stop by and tour our facility and see first hand how we can help your company. You can also take a virtual tour of DAI on our website.