Using R&D to maintain American metalcasting.

There is an emerging debate about the wisdom of funding research in the U.S. metalcasting industry because some believe it will be offshored out of existence in the near future. Some even have suggested that the U.S. government should fund research in the foreign countries where the castings will be made. I'm suggesting our government spend our money at home.

The American foundry sector is a collection of primarily small businesses employing hundreds of thousands of workers at a living wage. It is one that deserves to be saved.

While the outsourcing of low-end casting business to foreign countries will continue, opportunities exist for U.S. foundries in new applications via new materials and casting techniques. These innovative products and castings that replace higher-cost fabrication methods can keep our industry strong. The ability of the U.S. foundry industry to take advantage of those opportunities will depend on the availability of funding to develop those materials and techniques into affordable products for our customers.

Unfortunately, traditional research and development (R&D) funding from the government has been cut. The U.S. now ranks sixth in R&D spending as a percentage of gross domestic product. In contrast, China and India are increasing research spending by double-digit growth rates a year. These countries are moving into position to rise as they await our inevitable decline.

R&D spending, whether public or private, determines where we will find the foundry industry in the future.

The AFS Magnesium Div. has proposed a multi-tiered program that would help put hundreds of pounds of affordable magnesium castings on automobiles (see "Charting a Course for Magnesium" p. 39). The project has wide support, consisting of foundries, equipment manufactures, national labs and universities. This venture would reduce weight, increase gas mileage and improve the performance of our vehicles.

However, this proposal is thought to be too ambitious. Yet consider this: Improving fuel economy of cars and trucks to 40 mpg would save 6 million barrels of oil a day. Also, increasing mileage to 60 mpg worldwide would stabilize the amount of carbon entering our atmosphere, significantly slowing global warming and decreasing our dependence on foreign fuel.

The U.S. military can benefit, as well. The objective of the Future Combat System (FCS), which will form the centerpiece of the Army's ground combat force, is to develop vehicles that weigh 50% less that the existing force structure. High integrity, high strength, lightweight castings are the solution to many FCS problems. I would prefer to develop those parts with U.S. dollars in U.S. foundries. All this can be done affordably with better castings if research projects that focus on these goals are funded.

We can save the casting industry with some bold and ambitious ideas. The AFS Technical Committee structure is the ideal forum for exchanging new ideas. Contact our elected officials and let them know how important funding of metalcasting research is. Tell everyone that you work tot one of the most important industries in the U.S., an industry whose demise would threaten both our economic and military well-being.

DAVID WEISS VICE PRESIDENT-SALES/ENGINEERING ECK INDUSTRIES, INC.