Integrated Assessment and Improvement of the Quality Assurance System for the Cosworth Casting Proces

The purpose of this study was to improve the Quality Assurance (QA) System at the Nemak Windsor Aluminum Plant (WAP). The project used Six Sigma method based on Define, Measure, Analyze, Improve, and Control (DMAIC). Analysis of in process melt at WAP was based on chemical, thermal, and mechanical testing. The control limits for the W319 Al Alloy were statistically recalculated using the composition measured under stable conditions. The "Chemistry Viewer" software was developed for statistical analysis of alloy composition. This software features the Silicon Equivalency (SiBQ) developed by the IRC. The Melt Sampling Device (MSD) was designed and evaluated at WAP to overcome traditional sampling limitations. The Thermal Analysis "Filters" software was developed for cooling curve analysis of the 3XX Al Alloy(s) using IRC techniques. The impact of low melting point impurities on the start of melting was evaluated using the Universal Metallurgical Simulator and Analyzer (UMSA).