Advisor(s) Mark Plichta/Doug Swenson

Sponsor: Materials Science & Engineering

Team Members                       Joseph Licavoli

                                              Brent Fogal

                                              Paul Nelson

                                              Brian Szwejkowski

                                              David Stafford

Project Title: Ford Cylinder Head Riser Optimization

Sponsor: Ford Motor Company Nemak Engineering of Canada

Project Summary    A riser provides feed metal to accommodate shrinkage in a casting and eliminates porosity that may lead to poor performance and failure of parts. Ford Motor Company requested that the Michigan Tech design team reduce the volume of the riser used for their 5.4 liter 3 valve V8 cylinder head casting. This will make their casting operation more efficient. In addition to satisfying other constraints, the team reduced the volume of the riser without causing an increase in porosity of the casting. MAGMAsoft casting simulation software was used to verify all results.

Advisor(s) Stephen Hackney

                  Materials Science & Engineering

Team Members                       Aaron Lueker

                                                Andrew Zeagler

                                                Eric Morgan

                                                Sandra Reister

                                                Jenny Collins

Project Title    Characterization of Surface Contaminants on Deep Drawn Battery Cans

Sponsor         Heitkamp & Thumann

Project Summary   Heitkamp and Thumann (H&T) uses a deep drawing operation for producing battery cans. Their process uses a multiple-stage punch and die draw in order to produce the final shape. In order to perform this drawing operation, a lubricating oil must be used in the process. Since these products are ultimately going to be used in the assembly of consumer batteries, cleanliness is extremely important. Any residue left on the finished battery could be detrimental to the battery’s performance. Heitkamp and Thumann has requested details regarding the amount, composition, and distribution of the residue left on the finished cleaned battery can.

Advisor(s)   Calvin White

                    Materials Science & Engineering

Team Members                       Jess Barden

                                              Erin Gancer

                                              Brian Maness

                                              Tim Wong

                                              Dan Seguin

Project Title   Fatigue Properties of Fluidized Bed Heat Treated A319 Aluminum Engine Blocks         

Project Summary    The heat treatment of aluminum castings is an important, yet time consuming, step in the manufacturing process. Fluidized Bed Heat Treatment (FBHT) presents a significant cost savings in the processing of cast aluminum as compared heat treatment in conventional air furnaces. Before an FBHT process can be implemented, it must be shown that the final product will have reasonable mechanical properties. Our senior design team has been tasked with investigating the fatigue properties yielded with a FBHT process.