Delphi, D.O.E., and ORNL Implement Energy Saving Heat-Treat Furnace

    TROY, Mich., April 30 Delphi Automotive Systems
and the Department of Energy (D.O.E.) celebrate today the
successful implementation of nickel aluminide heat-treat fixtures developed
jointly under a cooperative research and development agreement (CRADA).  Use
of nickel aluminide fixtures instead of traditional steel fixtures at Delphi
has extended the fixture life by more than two times, dramatically enhancing
manufacturing productivity.
    
    The development enables a more reliable, energy-efficient manufacturing
process for Delphi and other U.S. manufacturers who have similar needs,
thereby helping D.O.E. to meet its goals of improving energy efficiency,
decreasing industrial process waste and improving worldwide competitiveness.

    The D.O.E.'s Oak Ridge National Laboratory (ORNL) researchers invented the
nickel aluminide alloy in an effort to develop heat resistant materials
leading to more energy efficient processes.  The alloy has a highly ordered
structure, which contributes to an unusual property where the alloy gets
stronger as it is heated to around 900 degrees centigrade.  The next step was
to develop a specific commercial application for this material.

    "Delphi is one of the largest producers of heat-treated products in the
world, so it was of great interest to us to develop the nickel alloy further
in partnership with D.O.E. and ORNL," stated Paul J. Tosch, president of
Delphi Saginaw Steering Systems and vice president of Delphi Automotive
Systems.  "The benefits to be realized for Delphi and other industries are
significant and worthy of the investment."

    Delphi engineers worked with ORNL to apply the material in Delphi's heat
treat facilities, replacing steel rack assemblies that over time were less
tolerant of high heat and resulted in production delays.  The assemblies hold
automotive parts to be heat-treated and consist of trays, support posts, and
fixtures.  Together, Delphi and ORNL developed a nickel aluminide fixture
casting process, modified the alloy to optimize its manufacturability and
performance under typical heat-treating furnace operating conditions, and
tested and evaluated prototype parts.

    "We are pleased to have worked with Delphi, leveraging the strengths of
industry and government, to develop this technology for a win-win
application," said Denise Swink, deputy assistant secretary for industrial
technologies, D.O.E., Office of Industrial Technologies (OIT).  "The
commercialization of nickel aluminide for heating trays and fixtures will
clearly give the United States global leadership with now-proven, advanced
materials for these types of applications."

    The typical life of a steel tray used today approaches 12-15 months.
Using nickel aluminide trays and fixtures significantly lengthens the life of
the product.  Delphi tested six trays in batch furnaces and 65 trays in pusher
furnaces in January 1998.  The trays are still in use today, thirty-nine
months later, with no failures.  The component life has been extended by more
than two times the life of the steel tray.

    "The implementation of nickel aluminide into the heat-treating furnace has
large potential for energy savings through enhanced component life, a major
objective of D.O.E.-supported research," stated Swink.