The influence of helium injection on the cooling rate and productivity of an aluminum permanent mold casting process was previously investigated by Doutre at Alcan International Limited. This experimental work indicated that the production rate of a large intake manifold could be increased by 25 percent. While some small-scale industrial trials have been attempted, no organized plan that would correlate plant trials with production tooling and controlled experiments in the laboratory have been conducted. The goal of the project is to provide a new and innovative accessory to permanent mold casting processes, which would provide the industry with marked increases in productivity and energy savings. The phase of the project is intended as an industrial prove-out of the technical merits of the approach is being coordinated by Prof. Kyle Metzloff, University of Wisconsin–Platteville.

Status Update: Plant trials have been conducted at an AFS member foundry. Those results are been compiled into a final report which will be presented at the 2009 Metalcasting Congress. Those wishing information or how to participate with the AFS Permanent Mold Committee (2E) on this project should contact Brian Began, Foseco Metallurgical Inc., at This e-mail address is being protected from spam bots, you need JavaScript enabled to view it