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The North American Die Casting Association's Die Casting Congress & Exposition was held on October 5-7 at the Indiana Convention Center in Indianapolis, IN. This premier event for the North American die casting industry continues to gain momentum as indicated by record-breaking attendance numbers. The event attracted over 2,500 attendees and 202 companies showcased the latest technology, research and services available to the die casting industry.
“The NADCA's Congress & Exposition proved to be one of the best ever. A sold out floor and record attendance at the Congress sessions proves that the industry is extremely prosperous and forward thinking in terms of applying new technology with new equipment. Our goals for exhibitors, attendees and the awards luncheon were exceeded by a significant percentage due to the interest the die casting industry has shown,” said NADCA President Daniel Twarog. “Moving forward, the changes in our industry's' machines, supplies and alloys will demonstrate our ability to produce the best die castings in the world. Thanks to everyone that exhibited and attended this signature event for the industry.”
“This year’s NADCA Congress & Exposition hit a home run for both exhibitors and attendees,” said Eric Treiber, NADCA Chairman and President & CEO, Chicago White Metal. “The exhibition space was sold out and the traffic on the show floor was very strong. Indianapolis continues to shine as the most favored location for this triennial convention.”
The exhibit hall housed the 202 companies who were eager to educate attendees on their products, services, capabilities and implementation of new technologies
“Great job NADCA, for hosting a tremendous event this year in Indy! By all accounts, this show was one of the best we’ve been involved with since participating. The quantity and quality of attendees and sessions were tremendous, and really generated great excitement and enthusiasm for the future of the die casting industry in the U.S. and around the world. Versevo’s team is proud to be recognized and affiliated with this tremendously important manufacturing community,” Terry Moon, President & CEO, Versevo Inc.
Jeff Walters, Regional Sales Manager, BuhlerPrince Inc. added, “The 2015 Die Casting Exhibition exceeded our expectations. The energy in our booth was electric and customers just kept coming. We also enjoyed the awards luncheon that celebrated the success of die casters across North America. We are proud that Bühler customers received 5 of the 10 available awards. Thanks to the NADCA team for hosting such a great event that shows the strength of the North American Die Casting Industry!”
“This show was no hassles-in and out. There was good customer traffic and very professionally run by NADCA,” Andy Bodnar, President, Kelm Acubar.
Dave Lee, U.S. Foundry Sales Division Manager, Pyrotek Inc. said, “We were really impressed with the substance and depth of both the exposition and the quality of conversations we were able to have with the attendees. We can’t wait for NADCA 2018! Indianapolis is a great place to host this show as well.”
“I talked to many suppliers in the various booths who were very happy with the location of the exposition and the amount of traffic through the show. They all believe Indianapolis is a great venue and strategically located for easy access by the attendees,” said Leonard Cordaro, President, Premier Die Casting Company and this year’s Herman H. Doehler Award recipient.
The Die Casting Congress sessions also took place in conjunction with the exposition. These sessions expose participants to top tier technical and management presentations, given by experts from around the world. These presentations address the latest technology, ongoing research and successful management tools to assist companies in enhancing their competitiveness. The 2015 Die Casting Congress featured over 30 presentations. The popularity of the sessions this year continued to far surpass all expectations with attendance of some presentations topping over 150 individuals!
The papers and presentations, which are available to session attendees online, expose a variety of new technologies, case studies and success stories. These presentations offered sessions in several different fields of metalcasting including: structural & MMC, process control & engineering, cast materials, die materials, die surface engineering, energy, computer modeling and die lubricants.
“The sessions of the 2015 Die Casting Congress were met with historic attendance levels. Among the top attended sessions were Structural & MMC, Cast Materials, Die Materials and Computer Modeling. Attendance for these were in excess of 100, with the highest hitting an attendance level of above 160. The attendance levels were in part sparked by the excellent papers that were presented. Highlights include heat treatment of castings to achieve high ductility, development and characteristics of new die steels, and enhanced computer modeling techniques. Rounding out the topics for the session were Process Control & Engineering, Die Surface Engineering, Energy, and Testing of Die Lubricants, the latter two of which had panel discussions. This was a great forum for transferring the latest research results and technologies to the industry,” said NADCA Director of Research, Education & Technology, Steve Udvardy.
This year NADCA hosted two special events. On Monday, October 5, attendees were invited to the Die Casting Congress & Exposition’s Happy Hour - After Hours with the Exhibitors. This gave attendees an extra opportunity to spend time visiting with exhibitors on the show floor. Exhibitors and attendees alike raved about the success of this event and the time they got to spend conversing and networking. A special thanks goes out to our Sponsors for this specific event: BuhlerPrince Inc, Versevo, GH Tool & Mold Inc and Industrial Innovations.
On Tuesday, October 6 NADCA hosted the Die Casting Awards Luncheon. This complimentary lunch allowed attendees to honor the winners of this year’s Industry Awards. The following awards were presented during this special event:
• Herman H. Doehler Award
• Edward A. Kruszynski Supplier Excellence
• Nyselius Award
• Gullo & Treiber Award
• Austin T. Lillegren Award
• 2014 Safety Awards
• 2015 International Die Casting Design Awards
• Instructor of the Year
• Emphasis on Education Award
• Technical Committee Member of the Year Award
• Best Congress Paper Award
Displayed prominently in the NADCA Online Education area and NADCA Bookstore were the winners of NADCA’s International Die Casting Competition. NADCA’s 34th International Die Casting Design competition award included:
Briggs & Stratton Corporation
Second Place Aluminum Die Casting 1 to 10 lb
Aluminum Die Casting 1- 10 lb
Aluminum Die Casting Over 10 lb
Fiat Chrysler Automobiles Canada
Aluminum Die Casting: Structural
Chicago White Metal
Aluminum Die Casting Under 1 lb
Chicago White Metal Casting Engineering Team
Magnesium Die Casting Over .5 lb
Magnesium Die Casting Under .5 lb
Lakeside Casting Solutions
Zinc Die Casting Under 6 oz
Zinc Die Casting Decorative
“The 2015 International Die Casting Competition saw many strong entries,” said NADCA Project Manager, Beau Glim. “Winning castings ranged from an aircraft seat armrest to a frame for a 3-D printer and a structural front cross-member for a car to a pawl for an electronic key tether. These castings displayed ingenuity by the casters to solve challenges in casting complex parts for unique applications. Also, these castings open new markets for die castings, such as the aerospace, medical and bicycle markets. As industry and technology move forward die casting is well suited to produce the highly detailed components required for more efficient, light weight products.”
INSTRUCTOR OF YEAR
Martin Hartlieb was presented with the Instructor of the Year Award. This award is presented to an individual com-mitted to continuing education in the field of die casting, both for themselves and their students. Individuals winning this award feature qualities such as flexibility, high understanding of a topic and ability to teach it, favorable com-ments from evaluations requested and unsolicited reviews from students at chapter courses, national courses and in-plant courses.
After his bachelor and master degree in Industrial Engineering and Economics/Marketing at the University of Stuttgart (Germany), Martin started his career in 1995 in Germany and then in Spain at Behr GmbH & Co KG (heat exchangers, engine cooling, HVAC). In 2000 he joined Alcan Inc. first in Markt Schwaben (Germany), where he was in charge of Sales and Engineering of their Engineered Shaped Products Division (Die castings including structural castings, forgings, thixocastings). In 2003 he was transferred to Montreal (Canada) to take over the global market development for Alcan (later Rio Tinto Alcan) Primary Metals, where he conducted market studies, launched new alloys, products and technologies (including high vacuum die casting and semi-solid forming technologies and alloys), and developed new international markets. He subsequently also held positions in Marketing and Product Management at RTA. During this time he became a recognized aluminum industry expert and speaker at many conferences and seminars around the globe.
Since 2012 he is working full time in his own company, Viami International Inc., where he works with a number of different producers of aluminum alloys, products and process technologies in developing (international) markets, launching new products and process technologies, etc.. He also offers consulting and training in sourcing of aluminum, equipment and technologies as well as process improvement. His company also represents various producers of innovative technologies in the aluminum foundry/die casting sector in Canada.
EMPHASIS ON EDUCATION
RCM Industries - Franklin Park, Illinois received the Emphasis on Education Recognition Award, which recognizes a die casting company that has had a specific focus on die casting education and training for their workforce. The award was chosen by NADCA Education Staff and Educational Committee Chairmen. The selection criteria for outstanding contribution to the promotion of die casting education includes the number of NADCA courses held over the past year, the total number of employees exposed to the courses, and consistency in offering courses over the past three years.
or over 60 years, RCM Industries has been one of the largest custom aluminum die casting suppliers in North America. As the parent company to four of the most reputable, established names in die casting, RCM has the capabilities to meet the strict casting and machining standards of customers around the globe amongst varied and unique industries.
RCM’s family of companies include Aallied Die Casting Company of Illinois in Franklin Park, IL, Inland Die Casting Company in Wheeling, IL, Aallied Die Casting Company in Rutherfordton, NC, and Imperial Die Casting in Liberty, SC. Investing in continued education through our valued employees leads to improvement and growth within our internal operations, setting RCM Industries up for sustainable success in the die casting industry.
TECHNICAL COMMITTEE MEMBER OF THE YEAR
Rob McInerney II was awarded the Technical Committee Member of the Year Award. The person chosen for NADCA’s Technical Committee Member of the Year award is subject to several sets of criteria. The award, chosen by NADCA’s technical staff and Technical Committee Chairmen, is given based on participation in committees, contribution to committee/task force, and applicability of efforts to industry.
Rob has a Mechanical Engineering background, having worked in the Die Cast Industry for 31 years. Twelve of these years were spent with Rimrock Corporation, a leading supplier of automation for the Die Cast Industry. He held positions of various capacities including Director of Engineering.
Rob is an author of articles for the Die Cast Engineer Magazine, and is currently the Chairman of the NADCA Computer Modeling Committee and NADCA Chapter 3. He now is serving as a Director of Sales for BuhlerPrince, Inc., his extensive experience in the Die Cast industry has brought new insights into the sales force and product development.
R. Allen Miller was presented with the award for Best Congress Paper. The Best Congress Paper is selected by paper reviewers and session chairpersons from NADCA’s International Technical Council and NADCA’s Technical Staff. Papers that are chosen demonstrate a high degree of technical achievement and excellence in the advancement of die casting.
R. Allen Miller received the B.M.E. degree from Union College, the S.M. degree in Mechanical Engineering from the Massachusetts Institute of Technology, and the Ph.D. degree in Control and Systems Engineering from Case Western Reserve University in 1966, 1967 and 1971 respectively. He has been with Ohio State since 1971, currently holding the rank of Professor Emeritus of Industrial and Systems Engineering. His research is in the areas of design for manufacture, die casting part and die design, and design environments for part and die/mold design including CAD/CAM/CAE integration.
R. Allen Miller’s paper, The “Gating Equation” Updated, is featured in this issue of Die Casting Engineer magazine.
Stephen P. Udvardy was presented with the Nyselius Award. This award is given in recognition of exceptional technical contributions to the industry. The award was established In 1965 by the Nyselius Foundation.
Stephen (Steve) P. Udvardy is the Director of Research, Education & Technology for the North American Die Casting Association where he has held this position for the past 19 years. His responsibilities include: coordinating research & development efforts between member companies, government agencies, government laboratories and universities; enhancing and implementing the NADCA educational program as well as instructing courses; further developing the level and quality of technology and information transfer between NADCA and its members; providing opportunities for enhancing competitiveness and profitability of members; and, responding to various inquiries from die casters, suppliers, designers and original equipment manufacturers.
Steve joined NADCA after serving 2 years as Vice President of Engineering & Technology for Teledyne Casting Service in La Porte, IN. This foundry is a producer of large gray and ductile iron castings.
Prior to his position at Teledyne, Steve managed the Materials Engineering Group and Materials Laboratory at Honeywell’s (formerly, AlliedSignal Aerospace Company) Aircraft Landing Systems in South Bend, IN where he spent 15 years. Aircraft Landing Systems is a manufacturer of aircraft wheels and brakes.
Steve holds both a B.S. and M.S. degree in Metallurgical Engineering & Materials Science from the University of Notre Dame.
Gullo & Treiber Award
Ryan Winter was presented with the Gullo & Treiber Award which is given in recognition of successful marketing activity resulting in the expansion of knowledge of die casting. The award was established in 1969 by Chicago White Metal Casting Inc.
Ryan is the Vice President of Engineering Services at Eastern Alloys. He received a bachelor’s degree in Metallurgical Engineering and an MBA from the University of Utah. He has been with Eastern Alloys since 1999, providing technical and marketing services to Eastern’s die casting customers. Some of his typical activities include:
• Using metallurgical techniques to analyze die casting defects – helping determine the root cause of defects.
• Providing plant audits and consultation to help improve die casting operations.
• Performing marketing and sales seminars to Eastern’s die casting customers (sales reps, etc.) and potential end users of die casting alloys to help educate and promote the advantages of the die casting process.
• General marketing for Eastern Alloys, including website SEO, advertising, NADCA chapter liaison, etc.
• Zinc bar stock sales for prototyping.
Ryan is the main developer and marketer of one of Eastern’s new zinc based alloys called EZAC, which is a high strength, creep resistant alloy used in the die casting industry. EZAC has found much success in converting new applications to zinc due to these improved properties.
Outside of work, Ryan is very involved with his family, including coaching his three son’s basketball teams, lots of scouting activities, sporting events, fishing and hiking in Utah’s trails and streams, and too many wrestling matches to count.
Edward A. Kruszynski Supplier Excellence Award
Chem-Trend LP was presented with the Edward A. Kruszynski Supplier Excellence Award. This award recognizes a supplier to the die casting industry that has demonstrated a long-standing record of NADCA membership, participation in and furthering of NADCA’s education efforts, longevity as an exhibitor in the International Congress & Exposition and DIE CASTING ENGINEER advertiser, and participation in NADCA committees and boards. Originally introduced as the Achievement Award in 1960, it was renamed the Edward A. Kruszynski Achievement Award in 1987 and the Edward A. Kruszynski Supplier Excellence Award in 1991.
Chem-Trend LP provides value, performance and dependability to the Die Casting industry through:
• More than 50 years of experience developing customized solutions for Die Lubricants, Plunger Lubricants, Hydraulic Fluids, and other ancillary die casting products,
• Manufacturing excellence
• Extensive Die Casting manufacturing knowledge
• Dedicated Die Casting industry laboratory
• Vast production floor experience through committed technical and sales teams Chem-Trend LP was founded in 1960 with two major innovations in the release agent industry:
• Water-based die lubricant for the Die Casting industry
• Release agent for the Polyurethane industry
Since that time Chem-Trend has evolved into a global leader in developing, producing and supplying chemical specialties, singularly focused on the development of release agents designed to provide process improving solutions to a variety of industries. We serve seven major industries, each of which has an individual laboratory specifically for that industry.
Within the die cast industry, Chem-Trend’s customers rely on our highly specialized products to protect their investments and keep production running efficiently. Chem-Trend develops and produces advanced die and plunger lubes along with a range of ancillary products. Our technology is used by some of the biggest names in the casting of aluminum, magnesium, zinc and related alloys. Chem-Trend is customer driven; it is our policy to provide only the highest-quality products and service, working toward a goal of uncompromised customer satisfaction.
Chem-Trend is also committed to sustainable environmental practices and ensuring the health and safety of our employees, customers and the public. We consider this in the development, manufacturing and marketing of chemical specialty products at our facilities worldwide.
They have offices, manufacturing facilities and laboratories and in the USA, Europe, Brazil, China, India and Korea along with a network of distribution partners to reach customers worldwide.
Chem-Trend LP is certified to all major quality, safety, and environmental standards including QS-9001, ISO 14001, OHSAS 18001, and AS9100, the aerospace quality standard for which we are the only release agent company certified to this standard.
They also innovate in the area of specialized equipment for process control in several of the industries we serve, allowing us to offer further process improvement and cost savings to our customers.
Austin T. Lillegren Award
Eric Treiber received the Austin T. Lillegren Award which is presented biennially to members in recognition of loyal and extraordinary service. This award was established in 1960 in memory of Austin T. Lillegren, whose devotion and leadership exemplifies unselfish service.
Eric, named Chief Executive Officer of CWM in 2010, was appointed President and COO in February, 2005, becoming the third generation to head the company, founded by his German immigrant grandfather in 1937.
Prior to his appointment as President and then CEO, he had direct responsibility for management of CWM’s Contract Manufacturing division, coordinating with the CWM sales-marketing, engineering, purchasing and assembly departments, and performing key client contact on major CM programs.
Among his client service responsibilities, Eric was charged with empowering Chicago White Metal’s customer service team, and facilitating work with all CWM departments to enhance the level of service provided to customers. He was responsible for negotiating supply contracts with key clients and providing support to CWM client representatives in quickly resolving questions in areas of policy, procedures, pricing and delivery.
His background embraces in-depth training in all of the disciplines within CWM, joining the company in 1990. A graduate of the University of Illinois, he holds an MBA from the Kellogg School of Graduate Management of Northwestern University. He is currently serving as Chairman to the NADCA Board of Governors. In addition, he is a member of NADCA’s Finance and Government Affairs Committees.
Herman H. Doehler Award
Leonard Cordaro was presented with the Herman H. Doehler Award in recognition of his outstanding contributions to the advancement of the die casting industry, the art of die casting as represented by technical achievement, advancement in plant operation and other activities.
Leonard Cordaro began his career on a path that is rare among executives. Having earned his Bachelor of Science degree in mechanical engineering from one of the nation’s top schools, University of Notre Dame in South Bend, Indiana he also received a Masters in Management Science from Rensselear Polytechnic Institute in Troy, NY. Leonard’s goal was to complement his natural technical savvy with a strong foundation in business.
During his work at Rennsalear Leonard was fortunate to be tutored by the Dean of the Management School, Dr. Harry Smith, an authority in statistics having written several books in statistics and regression analysis. Dean Smith wanted to apply statistical techniques to trading egg white futures on the Chicago Mercantile Exchange and Leonard developed a predictive statistical model for his thesis. The Dean had worked at Proctor & Gamble where egg whites were purchased for use in shampoos and a price hedging model was needed.
Leonard tailored his education to be able to manage and operate the family die casting business – Premier Die Casting Company which was started in 1945 by his grandfather. The business has grown from a small tool shop with a sand foundry to 12 robotic die casting machines, 12 CNC machines and finishing capability in house.
Today Leonard is responsible for all operations at Premier Die Casting Company, including but not limited to all sales activities, production management, and strategic planning.
In 1994 Leonard formed a joint venture with a NJ painting company and started a die cast plant in Juarez, Mexico. The company, MicroCast Technologies, has grown to over 30 die casting machines, over 50 CNC machines, painting, plating, and assembly. MicroCast services various industries in the US and Mexico and is growing very rapidly today.
Leonard has been active in the die casting industry for the past 43 years serving as Chairman for the North American Die Casting Association for two years during the challenging economy in 2010 and 2011. He is also a member of the NADCA Government Affairs Committee for the past 39 years and is very active in Washington DC. Leonard also serves on the NADCA Finance Committee for the past 24 years and regularly attends the NADCA Board of Governors’ meetings.
On the personal level Leonard works part time job in the music industry with various musicians at the “Jersey Shore” area, home of Springsteen, Southside Johnny, and Bon Jovi. He had a cover band for a few years, “One Track Mind”, that performed at various local establishments in New Jersey. He has recently worked in a jazz project “The Sharp 5 Trio”.
Leonard plans to continue working in the die cast community and enjoys traveling, sailing, biking, and skiing in his off time with no plans to slow down.
NADCA also acknowledged the 2014 Safety Awards Winners. These awards recognize companies within the die casting community that have exceeded or met the industry criteria to operate a safe working environment for their employees. Only NADCA Corporate Members in North America are eligible. There are two award levels: the Perfect Award recognizes the facilities that operated all of 2014 without a reportable injury or illness, and the Outstanding Award honors operations whose reportable injury or illness level was below the national average for all manufacturing of 4.4%. To view a complete list of the 2014 Safety Award winners please visit <URL> www.diecasting.org/docs/congress/2014SafetyAwards.pdf.
NADCA would like to thank everyone involved in this year's show, including exhibitors, authors, speakers and all the attendees who contributed to the success of the 2015 Die Casting Congress & Exposition. A special thanks goes out to all of our sponsors as well: BuhlerPrince Inc, L K Machinery Inc, MAGMA Foundry Technologies, MORESCO USA, Strattec Component Solutions, Techmire, B&L Information Systems, Casting Guru International LLC, Chem-Trend L.P., Italpresse, Iwatani Corp of America, Q.C. Designs, Inc, Quaker Chemical Corp-GW Smith & Sons, Stotek Inc, Toshiba Machine Co. America, Visi-Trak worldwide, Versevo, GH Tool & Mold Inc and Industrial Innovations. We will continue to work hard to provide the best shows possible for our industry. We look forward to seeing you next year in Columbus, OH September 26-28, 2016 for the Die Casting Congress & Tabletop.