Case Western Reserve rededicates foundry program.

With the renovation of its metalcasting laboratory, Case Western Reserve University (CWRU) has recommitted itself to teaching and research in support of the foundry industry.

The university, located in Cleveland, officially dedicated the newly refurbished laboratory on May 12 with a tour of the remodeled and expanded facility, along with presentations by several top industry executives from the Midwest.

"This renovation consists of two parallel efforts--the rebuilding of a strong program of foundry and metalcasting education and research, and the renovation of the facilities to support these activities," said Thomas Kicher, dean of the Case School of Engineering. "The goal is to rebuild a world-class program at Case."

The overall facility has been renamed the Case Metal Casting Laboratories.

Several industry executives initiated the renovation program after the Foundry Educational Foundation (FEF) Board of Directors met in 1991 at CWRU. The board toured the facilities, which had become seriously out of date due to lack of support and changes in the university's educational direction.

The casting laboratory's condition prompted several of those on tour to form the CMCL Industrial Advisory Committee to start a program to solicit donations for modernizing the facility.

They were joined by CWRU's Dept. of Materials Science and Engineering, the Case School of Engineering, the Case Alumni Assn. and the CWRU Development Office to raise funds for completing the laboratory.

The three-phase renovation was begun in June 1992 and the first two stages were completed in May 1994. To date, $802,000 in cash and equipment has been received from various companies and individuals. Total renovation cost of the laboratory, which originally opened in 1961, is expected to be $1.25 million.

The renovation's first phase consisted of cleanup and disposal of obsolete equipment and materials, renovation of the physical plant and installation of a new ventilation system. Phase two consisted of acquiring and installing basic foundry equipment, including a 350 kW induction melting system.

The third phase will involve acquiring and installing equipment to increase the facility's capabilities and provide research on world-class castings well into the next century.

"The mission of the Case Metal Casting Laboratories," said Robert Aikin, who will direct the CMCL, "is to support the foundry education programs, conduct long-term graduate-oriented research, and provide resources for industrial support projects."

The newly renovated foundry will be called the John F. Wallace Foundry in honor of Professor Emeritus Jack Wallace, who has headed the university's casting program since 1954.

In addition, the facility will include a new simulation and modeling laboratory named in honor of Ray H. Witt, president of CMI International, and a 1951 graduate of what was then called Case Institute of Technology. Witt helped initiate the renovation and provided significant financial support for the project.

Gary Ruff, executive vice president of CMI International and CWRU alumnus, served as chairman of the CMCL Industrial Advisory Committee.

Featured speakers at the dedication program included Witt, who called the work force "the lifeblood of our companies." He stressed the need for empowering employees, and providing them with tools (such as statistical process control) to meet the growing demands of business.

Witt said "success is a function of the intellect of the individuals in an organization. With a talented, empowered work force, you don't need supervisors."

George Booth, general manager, Casting Operations/Ford Motor Co., discussed the challenges ahead for automotive foundries. The two major driving forces confronting the U.S. automotive industry and casting producers are their customers and government regulations, he said. To meet the demands created by these drivers of change, the automotive industry is pursuing joint research in four primary areas:

* advanced manufacturing processes aimed at reducing production costs and product development time;

* technologies that will increase the efficiency of standard vehicle designs;

* increased use of lightweight, high-strength materials for vehicle weight reduction;

* development of a revolutionary new class of vehicles with up to three times the fuel efficiency of today's cars.

Pointing to the need for a strong industry-university relationship, Booth specifically addressed the CWRU staff when he said: "We are looking to you to provide us with assistance in developing new technologies and applications. And most importantly, we are looking to you to provide us with the most valuable resource for tomorrow--highly trained, highly skilled men and women to operate and manage our industry.

"It is with people--some of whom are still in school today--that those of us in metalcasting can look to the future with confidence, knowing full well that we will have what it takes to meet every challenge."

Other speakers included: Donald Hurtuk, president and CEO, Ellwood Engineered Castings; Frank Demeo, president, General Casting Co.; Bill Sorensen, FEF executive director; Diana Waterman, AFS Washington office; Bill Tordoff, vice president and general manager, Ashland Chemical/Foundry Products Div.; Larry Semersky, Foseco, Inc.; and Agnar Pytte, CWRU president.

In addition to Ruff, other Industrial Advisory Committee members were: Ray Carcione, Equipment Merchants International; William Emling, LTV Steel Technology Center; Walter Evans, Ford Motor Co.; Donald Hurtuk, Ellwood Engineered Castings; Vinod Gupta, Ohio Cast Products; Thomas Kolakowski, PCC Airfoils; Jack Miske, Foundry Management & Technology; Peter Petto, Jr., Arrow Aluminum Castings; Larry Semersky, Foseco, Inc.; and David Trudel, Alcoa.