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April 12-22, 2021 | Streaming Live & On-Demand
METALCASTINGCONGRESS
125 ANNIVERSARY TH
Virtual shows.
Virtual shows.
2021
METALCASTING CONGRESS
SHOW GUIDE
ADVOCAT
E. E
DU
CA
TE
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NOVATE.
ii | 2021 METALCASTING CONGRESS SHOW GUIDE 2021 METALCASTING CONGRESS SHOW GUIDE | 1
Real service. Real people. Really gifted.
Real service. Real people. Really gifted.
Real service. Real people. Really gifted.
(C) r)eIcH 2021
(C reIcH 2021
(C) reIcH 2021
2 | 2021 METALCASTING CONGRESS SHOW GUIDE 2021 METALCASTING CONGRESS SHOW GUIDE | 3
SQUEEZE
MOLDING
April 12-22, 2021 | Streaming Live & On-Demand
METALCASTINGCONGRESS
125 ANNIVERSARY TH
READY TO JUMP INTO
AUTOMATIC TABLE OF CONTENTS
MOLDING? LETTER FROM THE AFS CEO
5
SUPPLIER DIRECTORY
48 - 54
NOW OFFERING A KEYNOTE AND CAST IN NORTH
ROBUST, COST EFFECTIVE SOLUTION HOYT MEMORIAL SPEAKERS AMERICA DIRECTORY
6-7 54
with the purchase of a
FDNX MOLD HANDLING SYSTEM THANK YOU TO OUR SPONSORS CASTING TECHNOLOGY
8-9 SHOWCASE 2021
56 - 61
ABOUT METALCASTING
AUTOMATE YOUR FINISHING ROOM WITH THE BARINDER CONGRESS 2021 DIVISION CHAIRS
11 63 - 64
reduce manpower and increase productivity, consistency and profit
MONDAY, APRIL 12 2021 AWARDS
12 - 15 67 - 69
TUESDAY, APRIL 13 AFS AND THE INSTITUTE
15 - 18 2020 - 2021 BOARD OF DIRECTORS
70
WEDNESDAY, APRIL 14
18 - 23 AFS AND THE INSTITUTE NATIONAL
OFFICER & DIRECTOR NOMINEES
easy to quick part ePVS industry THURSDAY, APRIL 15 71
program changeover 4.0 analytics 23 - 27
CORPORATE MEMBERS
MONDAY, APRIL 19 73 - 76
28 - 32
UPCOMING AFS EVENTS
TUESDAY, APRIL 20 82
VISIT US VIRTUALLY AT METALCASTING CONGRESS AND ASK ABOUT ePVS, 33 - 38
AFS INSTITUTE COURSES
SINTO’S INDUSTRY 4.0 ANALYTICS PLATFORM FOR ALL PLC DRIVEN MACHINES
WEDNESDAY, APRIL 21 84
TM
TM
39 - 43
www.sinto.com
THURSDAY, APRIL 22
SINTO AMERICA 44 - 47
SINTOKOGIO, LTD.
www.sintoamerica.com sales@sintoamerica.com
150 Orchard St. Grand Ledge, MI 48837 Tel 517.371.2460 Fax 517.371.4930
4 | 2021 METALCASTING CONGRESS SHOW GUIDE 2021 METALCASTING CONGRESS SHOW GUIDE | 5
METALCASTING
CONGRESS
To Our Members and Friends,
We are pleased to present this guide to the 2021 virtual Metalcasting Congress. In this
guide, you’ll find summaries of more than 60 research papers, panel presentations, and
buyer/designer sessions that comprise the heart of Metalcasting Congress.
The guide also includes valuable information about the industry suppliers and
foundries that are virtual exhibitors, and we trust that registrants will take full
advantage of the chance to learn about exhibitors’ offerings. Plus, there are tips on
how to make the most of the virtual Metalcasting Congress 2021 experience.
Whether you are a foundry representative, supplier to the industry, casting buyer/
designer, or AFS student member, there is much for everyone to visit, learn and enjoy.
With all that it has to offer, Metalcasting Congress 2021 is an industry event unlike any
other.
We salute our session presenters and panelists, event sponsors, exhibitors and
registrants. Enjoy the experience and thank you for your involvement!
Sincerely, ADVOCAT
E. E
DU
CA
TE
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NOVATE.
Doug Kurkul
Chief Executive Officer
American Foundry Society
6 | 2021 METALCASTING CONGRESS SHOW GUIDE 2021 METALCASTING CONGRESS SHOW GUIDE | 7
KEYNOTE & HOYT MEMORIAL
LECTURE SPEAKERS
MONDAY, APRIL 12 TUESDAY, APRIL 20
HOYT LECTURE KEYNOTE SPEAKER HOYT LECTURE KEYNOTE SPEAKER
SPONSORED BY LAEMPE REICH
GREG MISKINIS TOM PRUCHA
Retired, Waupaca Foundry President, Metal Morphasis LLC
Editor-in-Chief, International Journal of Metalcasting
“Transformation of the Modern Foundry”
“Metalmorphasis Change and Transition”
The foundry industry has been in a state of transformation
for over 2,600 years. From shapes carved into stone, to Change is constant, as nothing stays the same. Consider
topologically optimized and additive manufacturing- the words of the Chinese philosopher Lao Tzu: “Life is a
facilitated creations, the evolution of metalcasting is easily series of natural and spontaneous changes. Don’t resist
witnessed. Whether this change has come about by man, them—that only creates sorrow. Let reality be reality. Let
method, material or market is debatable. With the gradual things flow naturally forward in whatever way they like.”
shift from personal vehicles with internal combustion engines to semi- or fully Some changes are the result of biology and the passage of time, within the natural
autonomous electric vehicles, competing in these shrinking markets will likely require cycle or order of things. Others are self-generated, under our own control and willful
agile and novel foundry solutions. This Hoyt Lecture will examine how foundries have effort, or dependent upon encounters with significant others—family, friends, col-
been transformed primarily by shifts in the workforce, market pressures brought by leagues, and others close to us. Still, other changes occur because of circumstance or
global flattening (competition), environmental, health and safety changes and even fate, a proverbial “date with destiny” and often beyond what we feel is in our control.
by disaster. Whether it is our personal life or occupation, like metalcasting, this change can facil-
itate transition and transformation. Prucha has coined the term metalmorphasis, and
this lecture is a reflection of how to embrace change and use it as a vehicle for new
opportunities. Beyond the philosophical, this lecture looks at how we as metallurgists
MONDAY, APRIL 19 and metalcasters apply change (time, temperature, pressure, chemical reactions, etc.)
KEYNOTE SPEAKER to transform metals and create metalmorphasis.
HARRY MOSER
Founder, Reshoring Initiative
ADVOCAT
E. E
“How to Benefit From Shorter Supply Chains” DU
CA
Reshoring and foreign direct investment (FDI) have
TE
. IN
brought back over 700,000 U.S. manufacturing jobs in
the last 11 years. At the same time, the COVID crisis has
NOVATE.
demonstrated the risk of long supply chains. In fact, a
recent BDO survey showed that 24% of companies are
planning to change the country in which they source or
produce, and 22% plan to reshore to the U.S.
Harry Moser, president of Reshoring Initiative, will explore how U.S. foundries can
take advantage of the trend toward shorter supply chains and what that means for
reshoring and FDI. Plus, discover how Reshoring Initiative’s Total Cost of Ownership
Estimator and the Import Substitution Program can help your company land
contracts that otherwise would have gone overseas.
8 | 2021 METALCASTING CONGRESS SHOW GUIDE 2021 METALCASTING CONGRESS SHOW GUIDE | 9
THANK YOU TO OUR
PLATINUM SPONSORS!
®
10 | MONDAY, APRIL 12 2021 METALCASTING CONGRESS SHOW GUIDE | 11
ABOUT METALCASTING
CONGRESS 2021
Metalcasting Congress 2021 is a virtual event that allows you to participate from any-
where in the world – all you need is a web browser and an Internet connection. Here
are a few things to know.
ACCESSING METALCASTING CONGRESS
Log in with your email address at
https://afs.6connex.us/event/MetalcastingCongress/login.
Ready to
You will receive detailed login instructions via email prior to the show.
Not registered?
Purchase a pass at www.metalcastingcongress.org.
do things
PARTICIPATION & SCHEDULES
Metalcasting Congress is open to visitors 24/7 from April 12-22, 2021, with live events
happening Mondays through Thursdays. To view a presentation, visit the Exhibit Hall,
differently?
or take part in other activities, simply click the corresponding area in the Metalcasting
Congress lobby, where you’ll be directed after logging in.
• Most booths in the Exhibit Hall will be staffed by representatives from 9 a.m. to 4
p.m. CDT, April 12-15 and April 19-22. Exhibits are on display 24/7.
• Live support will be available 9 a.m. to 4 p.m. CDT, April 12-15 and April 19-22.
• Schedules of presentations and other live events are shown in this guide. Unless
otherwise noted, times reflect the North American Central Time Zone (Chicago).
VIEWING ON DEMAND
Discover the secret of successful metal casters. Many Congress sessions will be recorded and made available to stream at any time.
You can view all on-demand presentations after they go live through May 17, 2021.
Just log in with your registration credentials to stream this content.
MORE INFORMATION & WAYS TO CONTACT US
MAGMASOFT ®
You can view a list of FAQs at www.afsinc.org/frequently-asked-questions. Need more
metal casting quality, optimizing process conditions and reducing production costs.
help? If you’re an exhibitor, please contact us at exhibits@metalcastingcongress.org.
Attendees and others should email customerservice@afsinc.org.
MAGMA Foundry Technologies, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173
Phone: 847-969-1001 | info@magmasoft.com | www.magmasoft.com The following schedule is subject to change.
12 | MONDAY, APRIL 12 MONDAY, APRIL 12 | 13
10:30 a.m. | Auditorium 1 p.m. | Innovation Theater
MONDAY, APRIL 12 HOYT LECTURE CASTING DESIGNERS AND BUYERS
TRANSFORMATION OF THE TRENDS IN REDUCING
9 a.m. | Auditorium 9 a.m. | Innovation Theater
ALUMINUM & LIGHT METALS DIVISION INNOVATION THEATER MODERN FOUNDRY (21-126) WEIGHT WITH METAL CASTINGS
RELATION BETWEEN THE SPONSOR PRESENTATION: (2021-137)
Greg Miskinis
POROSITY LEVEL AND THE PRACTICAL EXAMPLES OF Retired, Waupaca Foundry Andrew Halonen, Mayflower Consulting
RADIOGRAPHIC QUALITY IN HOW FOUNDRIES BENEFIT LLC, Calumet, MI
ALUMINUM A356 CASTINGS FROM DIGITALIZATION The foundry industry has been in a state
(2021-007) of transformation for over 2,600 years. Opportunities for lightweighting with
From shapes carved into stone, to topo- metal castings abound through material
Franco Chiesa, Jean-Nicolas Rousseau, logically optimized and additive manu- choice and smart designs. Examples in
David Levasseur, Quebec Metallurgy facturing-facilitated creations, the evolu- iron and aluminum will be shared, along
Center, Trois-Rivières, QC, Canada tion of metalcasting is easily witnessed. with current trends and future opportu-
Whether this change has come about nities for reducing weight in cast compo-
Aluminum A356 stepped castings, with by man, method, material or market is nents.
plates 6mm, 19mm and 38mm in thick- 9:30 a.m. | Auditorium debatable. With the gradual shift from
ness, were sand cast from melts with ALUMINUM & LIGHT METALS DIVISION personal vehicles with internal combus- 1 p.m. | Auditorium
three gas contents, providing a wide HOT TEARING SUSCEPTIBILITY tion engines to semi- or fully autonomous COPPER DIVISION
range of casting conditions and solidifi- OF AL-ZN ALLOYS (2021-011) electric vehicles, competing in these LEAD CONTRIBUTORS IN
shrinking markets will likely require agile
cation times varying from 0.6 min to 15
and novel foundry solutions. This Hoyt DRINKING WATER AND
min. The plates were radiographed and Kumar Sadayappan, CanmetMaterials, BEYOND—WHAT THE SCIENCE
the local microporosity distribution mea- Hamilton, ON, Canada; Amanada Aguiar, Lecture will examine how foundries have
sured so the level of microporosity could Sumanth Shankar, Light Metal Casting been transformed primarily by shifts in IS SAYING (2021-133)
be related to the radiographic quality ex- Research Centre, Mechanical the workforce, market pressures brought
pressed by a frame number per standard Engineering, McMaster University, by global flattening (competition), en- Justine Parker, Cardno Chemrisk,
ASTM E155 reference radiographs. This Hamilton, ON, Canada vironmental, health and safety changes, Boulder, CO
made predicting the radiographic quality and even by disaster.
of a casting by solidification modeling Hot Tearing Susceptibility of aluminum The continued appearance of lead in
possible. alloys was investigated using a con- SPONSORED BY: drinking water is likely due to a variety
strained rod hot tearing test apparatus of conditions besides the 0.25% in the
9 a.m. | Auditorium to simulate and characterize hot tearing. newer brass fittings. This talk will look at
CAST IRON DIVISION The test apparatus and procedure were the range of possible lead sources that
could be significant contributors to lead
PANEL: NON-SILICA validated using Al-Si-Mg and Al-Cu fam-
in drinking water and how this compares
SANDS (2021-106) ilies of alloys. Subsequently, the test was
used to characterize new structural Al-Zn to brass fitting data. We will also take
alloys being developed for high-pressure a broader view and discuss what the
Scott Giese, University of Northern Iowa, current science is saying regarding the
Cedar Falls, IA; Jerrod Miller, Wear-Tek, die casting application. It was found that
introducing small amounts of Fe that pro- sources of lead contributions to elevated
Spokane, WA; Chris Barnes, Caterpillar blood lead levels in children.
Inc., Deerfield, IL motes evolution of eutectic phases can
alleviate the hot tearing problem. In this
Iron casting experiments were performed presentation, the details of the investiga-
to observe the effect of a high- and tion are presented and discussed.
low-thermal diffusivity ceramic sand on
graphite morphology and ferrite/pearl-
ite ratio. When compared to baseline KEYNOTE SPEAKERS
silica sand, observable differences in me-
chanical properties were noted as a result TECHNICAL TRACK
of the thermal behavior of the ceramic
sands. Panelists from both academia and MANAGEMENT TRACK
industry will speak to the challenges and
considerations when operating a foundry CASTING DESIGNERS
using non-silica sands. AND BUYERS TRACK
14 | MONDAY, APRIL 12 MONDAY, APRIL 12 | 15
2 p.m. | Auditorium Lobby
WOMEN IN METALCASTING CASTING OF THE
2020 HINDSIGHT: REFLECT ON YEAR COMPETITION
DIVERSITY, EQUALITY, AND
INCLUSION (2021-135) View the best in foundry achievements in
the Casting of the Year gallery. Presented
Sandy Calabrese, General Motors, by AFS and Casting Source magazine,
Defiance, OH this annual competition recognizes man-
ufacturing excellence by North American
The social movements that defined 2020 metalcasters and designers/users of
are causing companies to identify and metal castings.
address barriers to creating and sustain-
ing a more diverse and inclusive work- SPONSORED BY:
force. What steps can individuals take to
nurture diversity, equality, and inclusion?
Join us for a presentation on how we can
champion ourselves and others toward
achieving professional milestones and
progressing equal-access opportunities.
Lobby
PRODUCT SHOWCASE
Gain in-depth insight into a selection of
curated products and services for found-
ry customers in the Product Showcase,
accessible 24/7 from the virtual lobby.
TUESDAY, APRIL 13
9 a.m. | Auditorium sprue bushing during the filling of the
ALUMINUM & LIGHT METALS DIVISION mold cavity. While the final quality of
SPRUE BUSHING FILTER the casting is strongly affected, among
BENEFITS IN THE LOW many other variables, by the mold filling
process, the efficiency and throughput of
PRESSURE CASTING PROCESS the process is negatively influenced by
(2021-078) operational issues encountered around
mold filling factors induced by using
Rafael Gallo, Spencer Bishop, steel filters, such as erosion of the sprue
Pyrotek Inc., Aurora, OH bushing and the spreader, need of special
handling of sprue returns, more frequent
The intention of this paper is not to delve mold changes, lack of casting process
in all the engineering and metallurgical consistency, etc. A filter technology is
intricacies of the low pressure casting introduced to assist in eliminating and/or
process but rather to concentrate in reducing the mentioned issues. Detailed
one specific area, which is sometimes qualitative and quantitative analysis of
neglected: the filter being used in the the benefits are provided.
16 | TUESDAY, APRIL 13 TUESDAY, APRIL 13 | 17
9 a.m. | Auditorium 9:30 a.m. | Auditorium 9:30 a.m. | Auditorium historical production data and applying
CAST IRON DIVISION ALUMINUM & LIGHT METALS DIVISION CAST IRON DIVISION modern tools, such as physics-based
EFFECT OF THE TYPE OF MELT-REFRACTORY THE HISTORY AND EVOLUTION virtual simulation, ICME, machine learn-
INOCULANT ON THE SHRINKAGE INTERACTIONS DURING OF INOCULANTS (2021-038) ing and artificial intelligence, to develop
meta models for better casting designs
POROSITY OF HIGH SILICON ALUMINUM MELT and an intelligent manufacturing system,
SG IRON (2021-028) PROCESSING (21-041) Cathrine Hartung, Elkem Foundry
Products, Kristiansand, Norway; Robert will be presented. This Industry 4.0 big
Logan, Elkem, Mooresville, NC; Leander data project demonstrates how to opti-
Gorka Alonso, Jon Sánchez, Gorka Emre Cinkilic, Michael Moodispaw, mize design and solve quality issues and
Zarrabeitia, Ramon Suarez, IK4-Azterlan, The Ohio State University, Columbus, OH; Michels, Elkem Silicon Products,
Kristiansand, Norway is capable of real time process control
Durango, Spain; Dr. Doru Stefanescu, Yeou-Li Chu, Ryobi Die Casting, with further integration. Both research
The Ohio State University and University Shelbyville, IN; Xinyan Yan, Alcoa projects are funded by AMC/DLA, man-
of Alabama, Dublin, OH Technical Center, New Kensington, PA; Historically, inoculation has been around
since the 1930s. Over the years, many aged by AFS and led by PDA LLC.
Francis Caron, Alcoa Technical Center,
High-silicon spheroidal graphite (SG) Deschambault, QC, Canada different theories have evolved to explain
how inoculation works. At the same time, 1 p.m. | Innovation Theater
irons present significant challenges to the CASTING DESIGNERS AND BUYERS
production of sound castings as it is par- Molten aluminum processing is crucial to many different inoculation compositions
have been developed for use in foundry WORKING WITH YOUR
ticularly susceptible to significant shrink- energy and melt efficiency and product
age defects. The critical phase is the end quality (chemistry and cleanliness) in operations. In today’s foundry, the inoc- FOUNDRY TO DESIGN FOR
of solidification when, as the amount of the casting industry. Many materials are ulation process utilizes a typical addition MANUFACTURABILITY (2021-141)
eutectic graphite generated decreases, involved in aluminum melt processing, in- of between 0.05 to 1% of a specialized
graphite expansion may become insuf- cluding refractory and flux materials. The FeSi alloy containing controlled amounts Andy Mastalir, The C.A. Lawton Co.,
ficient to compensate the solidification fundamental thermodynamic reactions of one or more elements, including Al, De Pere, WI
shrinkage, increasing the risk of micro- among these materials in melt process- Ca, Ba, Sr, Ce, La, Mn, Bi, S, O, and Zr.
shrinkage (microporosity) formation. The ing determine the energy efficiency and The inoculant provides nucleation sites Small but important changes to a com-
goal of this industrial research was to throughput (melt recovery) of the melt- that promote graphite precipitation and ponent’s design can lead to significant
assess the efficiency of eight commercial ing and casting operations. Currently, growth, together with iron solidifica- cost, weight, and time savings. Early de-
inoculants in minimizing porosity occur- most of the process control and optimi- tion based on a stable Fe-C system. In sign discussions with a qualified casting
rence in a 3.45%C, 3.75%Si SG iron. Metal- zation in molten aluminum processing is this session, the history and evolution source will pay dividends.
lographic analysis was conducted on the conducted using traditional trial-and-er- of inoculation will be presented, along
TA cups to evaluate the nodule count and ror and design of experiment methods, with a description of the common under- 1 p.m. | Auditorium
size distribution. SEM analysis was used with limited use of analytical tools avail- standing of what an inoculant is, how the COPPER DIVISION
to study the type of nuclei, and tomog- able to the industry. This session presents effect and performance of an inoculant INVESTIGATING THE EFFECTS OF
can be measured, and what factors can
raphy to quantify the amount of porosity fundamental thermodynamic modeling
affect inoculation performance. TURBULENT GATING ON C89833
in each TA cup. An attempt was made for aluminum melt processing involving MATERIAL (2021-110)
to correlate the graphite formation rate refractory materials. Various ingredients
during eutectic solidification with the po- of refractory materials were evaluated for 10:30 a.m. | Auditorium
METALCASTING RESEARCH Andy Shea, A.Y. McDonald
rosity level. Inoculants rich in Zr seemed higher melt recovery rates, and the mod- Manufacturing Co., Dubuque, IA
to produce the best results. eling results were validated in lab-scale DATA DRIVEN
experiments. DESIGN & INTELLIGENT Brass foundries have seen an increase
9 a.m. | Innovation Theater MANUFACTURING (2021-156) in leaker scrap when pressure testing
INNOVATION THEATER brass castings since the switch to no-lead
SPONSOR PRESENTATION: Jiten Shah, PDA LLC, Naperville, IL materials. This investigation examines the
LAEMPEARSM impact of turbulent gating on pressure
Shah will give an update on a newly up- tightness and mechanical properties for
When being there soon is not soon graded, user-friendly, web-based Cast- the C89833 material.
enough. KEYNOTE SPEAKERS ing Alloy Data Search (CADS V 3.0) tool
for casting design engineers with over
350 engineering properties data sets of
TECHNICAL TRACK
commonly used ferrous and nonferrous
MANAGEMENT TRACK alloys with pedigree information, such as
the molding process, section thickness
CASTING DESIGNERS and composition. Also, another ongoing
AND BUYERS TRACK research project focused on data mining18 | TUESDAY, APRIL 13 WEDNESDAY, APRIL 14 | 19
2:30 p.m. | Auditorium Leadership Self-Awareness
FUTURE LEADERS OF METALCASTING John Wiesbrock, Waupaca Foundry, Visit our Virtual Booth
PANEL: FOUNDRY EXECUTIVES Waupaca, WI
SHARE KEY LESSONS — A Q&A Your Partner in Finding
AFS Future Leaders of Metalcasting pres-
SESSION (2021-136) ents an interactive session of metalcast- Innovative Foundry Solutions
ing leaders sharing their stories with at-
Your 1st Year in Metalcasting tendees through panel discussions. Bring
JB Brown, BCI Solutions Inc., Bremen, IN your questions and share your stories in
these worthwhile mentoring discussions.
3 C’s- Culture, Connection and
Dana Cooper-Hayes, Cooper Hayes LLC, Offering Innovative Alloys for...
Stevensville, MI SPONSORED BY:
How to Influence Without Authority
Denny Dotson, Dotson Iron Castings,
Madison Lakes, MN
The Importance of Data Driven Goals
Henry Lodge, Lodge Mfg. Co., South
Pittsburg, TN
Gray Iron Ductile Iron
WEDNESDAY, APRIL 14
Chill and Carbides Eliminated
Less Casting Porosity
Higher Magnesium Recoveries
with Fewer Emissions
9 a.m. | Auditorium for PSCP engine blocks. The results in- Improved Nucleation and
Improved Mechanical
ALUMINUM & LIGHT METALS DIVISION dicated artificial age temperature dif- Graphite Structure
Properties
NOVEL APPROACH TO THERMAL ferences of as little as 4C (within CQI-9 Less Casting Porosity
for furnace temperature specification of Lower Scrap Rates
PROCESSING DEVELOPMENT ±5C) can produce significantly different Lower Scrap Rates
Better Machinability
FOR PRECISION SAND CASTING casting properties. Mechanical properties, Improved Machinability
PROCESS (PSCP) IN ALUMINUM the Quality Index, and cryogenic stress Lower Total Costs
Lower Total Costs
319 ALLOY (2021-070) testing were all measured to determine
casting suitability for service. The work
Robert Mackay, Glenn Byczynski, Nemak finally outlines a more effective protocol
US/CAN Business Unit, Windsor, ON, for the selection of artificial age tempera-
Canada; Abdallah Elsayed, University of ture which produces an optimized and Elkem’s innovative alloys include specialty inoculants, nodulizers, cover alloys for ductile-
functional engine block casting. iron treatment pockets, and preconditioners.
Guelph, Guelph, ON, Canada
For More Information:
The latest generation of high-perfor- Visit Elkem’s virtual booth at the 2021 AFS Metalcasting Conference or the contact below.
mance cylinder blocks are produced Your Elkem technical-sales representative will work with you to select the product and alloy-
with the precision sand casting process addition practice that is most suitable for your foundry conditions.
(PSCP). To achieve the required prop-
erties, integrated chills are incorporat-
ed and can result in large variations in KEYNOTE SPEAKERS Elkem Silicon Products
secondary dendrite arm spacing (l2)
U.S.A.: P.O. Box 266; Pittsburgh, PA 15230; Tel: +1-412-299-7234;
throughout the casting, providing unique TECHNICAL TRACK Toll-Free: +1-800-848-9795; Fax: +1-412-299-7238; E-Mail: customerservice@elkem.com
challenges to optimizing the heat treat-
ment (T7 temper) and complying with MANAGEMENT TRACK Canada: Tel: +1-905-570-2783; E-Mail: chris.lisso@elkem.com
existing automotive requirements. This
work proposes a new way to fully assess CASTING DESIGNERS
the appropriate heat treat development AND BUYERS TRACK
www.elkem.com/foundry20 | WEDNESDAY, APRIL 14 WEDNESDAY, APRIL 14 | 21
9 a.m. | Auditorium 9:30 a.m. | Auditorium
CAST IRON DIVISION ALUMINUM & LIGHT METALS DIVISION
HONORARY LECTURE: MACHINABILITY
TECHNOLOGY TRENDS AND CHARACTERISTICS OF
CHALLENGES FOR IRON ALUMINUM CAST ALLOYS
FOUNDRIES (2021-090) (2021-029)
Patricio Gil, MAPPSA, Dr. Yasser Zedan; Marawn Hamid, British
Ramos Arizpe, Mexico University in Egypt, Cairo, Egypt; Yasser
Zedan, ETS-Montreal, Canada,
Understand the current world market Montreal, QC, Canada; Herbert Doty,
trends in terms of manufacturing technol- General Motors, Pontiac, MI; Salvador
ogy and how those changes are affecting Valtierra Gallardo, Nemak, S.A.,
the iron foundry industry and questioning Garza Garcia, N.L., Mexico
the traditional business models. Gil will
review the main variables that influence The present study was carried out to
the iron foundry’s performance from a study the machinability, i.e., milling
management perspective and discuss characteristics, of an Al-6%Cu-0.7%Si
how those variables are linked to our alloy (in the as-cast, T5 and T7 aging
technical infrastructure and our market conditions) and compare these charac-
decisions. teristics to those of well-defined B319.0
(as-cast, T7-treated) and A356.0 (as-
9 a.m. | Innovation Theater cast, T6-treated) alloys. Wet milling was
INNOVATION THEATER carried out on 15 blocks prepared from
SPONSOR PRESENTATION: each alloy using new carbide inserts for
LEARN HOW INDUSTRY 4.0 AND about 120m machining distance. Thir-
ARTIFICIAL INTELLIGENCE HELP ty-five blocks (12 in x 7 in x 1.5 in) were
employed. The experiment comprised the
CUT SCRAP BY 40% CNC machine, the blocks to be machined,
a table dynamometer with piezoelectric
Starting your digital journey doesn’t have sensors that are responsible for detecting
to be complicated. You can start small and measuring the cutting forces, a sig-
with Industry 4.0 tools to centralize all nal amplifier and an A/D converting unit.
your foundry data, and then apply AI to New and dull cutting inserts were used
consistently cut scrap. We will show you for each alloy group. Thirteen layers of
how a green sand foundry cut scrap by material were removed from each block,
40% using AI-driven recommendations to where each layer consisted of 10 paths,
identify process optimization across the and the depth of cut was 1.35 mm.
entire casting process.
Over 70 years of experience means the heavy-duty, custom built foundry
equipment developed by Carrier Vibrating Equipment is engineered to
KEYNOTE SPEAKERS withstand the harsh environment of a foundry while being reliable, easy
to maintain, and produce the best quality castings possible.
TECHNICAL TRACK
MANAGEMENT TRACK CarrierVibrating.com
CASTING DESIGNERS
AND BUYERS TRACK 502.969.317122 | WEDNESDAY, APRIL 14 WEDNESDAY, APRIL 14 | 23
10 a.m. | Auditorium sis can be problematic. The widespread 1 p.m. | Auditorium AFS is focused on ensuring that poli-
CAST IRON DIVISION practice of estimating nodularity via GOVERNMENT AFFAIRS DIVISION cies crucial to the metalcasting industry
UNDERSTANDING THE comparator chart is highly subjective and KEY METALCASTING ISSUES remain front and center of the new 117th
EFFECT OF BORON IN GRAY prone to unacceptably high variation. An MOVING THROUGH THE U.S. Congress and Biden Administration. Hear
improvement over visual metallographic critical updates on the most recent advo-
IRON (2021-073) estimates is digital image analysis (IA) CONGRESS AND KEY AGENCIES cacy efforts related to AFS priority issues
by which subjectivity can be greatly (2021-139) in Washington, D.C., on pandemic relief,
Laura Bartlett, Simon Lekakh, Suyash reduced, but the more reliable results infrastructure, trade and safety.
Pawaskar, Missouri University of Science obtained from IA are time consuming Eric Meyers, Oil City Iron Works Inc.,
and Technology, Rolla, MO and difficult to implement in a production Corsicana, TX; Stephanie Salmon, AFS
environment. For this session, the use of Washington Office, Washington, D.C.
Increasing usage of boron in automotive ultrasonic velocity testing via a standard
THURSDAY, APRIL 15
steels progressively contaminates cast coupon was evaluated as a possibly more
iron charge mixtures. Many controversial reliable technique for determining front-
opinions are held about boron’s effect on end (real time) nodularity. Major results
the structure and properties of cast iron 9 a.m. | Auditorium 9 a.m. | Innovation Theater
will be presented, along with details STEEL DIVISION INNOVATION THEATER
with no agreement about acceptable crit- necessary for implementation of front-
ical concentrations of this element in cast end ultrasonic nodularity determination
THE VALUE OF SCRAP, SPONSOR PRESENTATION:
iron. Therefore, an experimental study using standard coupons (FEUNDUSC) as REWORK AND YIELD AT AUTOMATED TECHNOLOGIES
was performed to uncover the effects of standard practice. STEEL FOUNDRIES (2021-036) FOR TODAY’S MELT SHOP
boron in Class-30 gray iron. Ferro-boron
additions were used to increase boron 1 p.m. | Innovation Theater Roy Stevenson, Daniel Coyle, Gerald Having been at the forefront of the ther-
up to 130 ppm in several laboratory CASTING DESIGNERS AND BUYERS Richard, MAGMA Foundry Technologies, mal processing industry for close to 70
heats. Thermal analysis was utilized to Schaumburg, IL years—Inductotherm knows how to take
determine the effect of boron on phase FINDING A SOLUTION WITH
foundry automation to the next level.
transformations during solidification and LOST FOAM: AN ALUMINUM By providing melt shops with efficient,
Steel foundries seeking to survive and
the eutectoid transformation. Mechanical CASE STUDY (2021-142) thrive in difficult economic environments customized equipment for their induction
property tests and microstructural anal- must consider both internal and external melting, heating, holding and pouring
ysis were conducted to determine the Curtis Taylor, BRP, Spruce Pine, NC opportunities and threats when plan- requirements while employing the latest
effect of boron at different carbon equiv- ning for the short- and long-terms. While “end-to-end” automated technology like
alents. The results showed that the effect Hear the story of how the two-stroke external threats, such as sharp decreases IoT and robotics for virtually any metal or
of boron in cast iron was significantly 300HP V-6 marine engine block called in steel casting demand, are outside of material, we are able to provide foundries
affected by carbon equivalent. Prelimi- the G2 Snipe came to be cast in alu- the control of steel foundry management, with advanced solutions. Please watch
nary discussion about the mechanisms of minum via the lost foam method. The opportunities are present within all steel our presentation to learn how technolo-
boron effects on phase transformations one-piece design eliminated the need for foundries to reduce costs, improve on- gy is shaping the future of the melt shop
and properties of gray cast iron will be multiple castings, weldments, and their time delivery performance and shorten and what it can do for you.
presented. assembly. Casting such a complicated lead times. This session will investigate
part may seem like more trouble than it’s the impact inconsistent as-cast quality
10:30 a.m. | Auditorium worth, but the cost savings from eliminat- has on scrap and rework costs and how
CAST IRON DIVISION ing individual parts were considerable. inconsistent as-cast quality makes it diffi-
DUCTILE IRON FRONT-END cult for steel foundries to remain respon-
ULTRASONIC NODULARITY sive while trying to win new work and/or
DETERMINATION USING meet customer delivery requirements. A
model will be used to estimate the cost
STANDARD COUPONS
of scrap, rework and yield for different
(2021-009) size steel foundries and case studies will
KEYNOTE SPEAKERS help to highlight the potential that exists
James Cree, Mike Robles, Jr., Adam for each of these categories.
Hoover, Grede - New Castle,
New Castle, IN TECHNICAL TRACK
Ductile iron nodularity is of critical im- MANAGEMENT TRACK
portance to its quality, but nodularity
determination by metallographic analy- CASTING DESIGNERS
AND BUYERS TRACK24 | THURSDAY, APRIL 15 THURSDAY, APRIL 15 | 25
9:30 a.m. | Auditorium 10:30 a.m. | Auditorium
STEEL DIVISION STEEL DIVISION
SAND CASTING OF POTENTIAL APPLICATIONS
SURFACE-ALLOYED OF PATENTED LIGHTWEIGHT
BUTTERFLY VALVE WITH STEEL IN ARMORED
IMPROVED HARDNESS AND VEHICLES (2021-019)
CORROSION RESISTANCE BY
INCORPORATING METAL Hathibelagal Roshan, Maynard Steel
Casting Co., Milwaukee, WI
POWDERS IN-MOLD COATINGS
(2021-093) Development of lightweight steel for use
in armored vehicles has been the subject
Kaustubh Rane, Michael Beining, matter of research by several institutions
Swaroop Behera, Amir Kordijazi, Ajay for many years. Maynard Steel Casting
Kumar, Radeep Rohatgi, University of Company in Milwaukee has invented
Wisconsin-Milwaukee, Milwaukee, WI lightweight steel weighing up to 70%
We are an international market less than solid steel on an industrial scale
and technology leader of induction A cost-effective procedure to surface using a sand casting process. Two U.S.
systems for melting, pouring and alloy WCB steel butterfly valve sand cast- patents have been granted for this inven-
holding of ferrous and nonferrous ings using mold coatings incorporating tion. In order for a material to be used to
metals. metal and ferroalloy powders was stud- make components in armored vehicles,
ied in this research. it needs to have ballistic- and blast-re-
Our success is based on our more sistant properties listed in military spec-
than 400 dedicated employees. 10 a.m. | Auditorium ifications. The designers of components
They provide the perfect combination STEEL DIVISION in military vehicles expect optimization
of proven and innovative technology. TITANIUM MASTER ALLOY of the behavior of the component based
EFFECT ON 1030 (2021-018) on computer simulations using appropri-
ate failure models. There is a paradigm
Robert Tuttle, Saginaw Valley State shift from design-make-shoot and eval-
University, University Center, MI uate concept to model-simulate-opti-
mize-make-shoot and evaluate. Various
The work presented in this session uses requirements of components used in
two different TiC master alloys in casting armored vehicles and the research efforts
experiments. The goal was to determine to meet these requirements will be pre-
whether these master alloys could pro- sented and discussed.
duce grain refinement. Metallography,
mechanical testing, and thermal analysis
were employed to understand the role of
these master alloys on the microstructure
of 1030. The mechanical properties of the
treated steels were lower than the base-
line, yet the macrostructure was finer
in the treated steels. Thermal analysis
found no change in solidification reac-
tions. It appears that TiC is likely formed
at the end of solidification and acts as a KEYNOTE SPEAKERS
grain growth restrictors while the casting
cools. TECHNICAL TRACK
MANAGEMENT TRACK
CASTING DESIGNERS
ABP Induction LLC · 1460 Livingston Ave. · North Brunswick, NJ 08902 · Phone: +1 732-932-6400 · www.abpinduction.com AND BUYERS TRACK26 | THURSDAY, APRIL 15 THURSDAY, APRIL 15 | 27
11 a.m. | Auditorium 1 p.m. | Auditorium 1 p.m. | Innovation Theater 2:30 p.m. | Auditorium
STEEL DIVISION ALUMINUM & LIGHT METALS DIVISION CASTING DESIGNERS AND BUYERS MARKETING DIVISION
QUANTIFYING THE EFFECT PREDICTIVE ANALYSIS OF 3D PRINTING: FROM PROTOTYPE MODERN DAY PROSPECTING
OF FILLING CONDITIONS ON WATER WETTABILITY AND TO PRODUCTION (2021-143) AND SELLING FOR ELITE
8630 STEEL CASTING CORROSION RESISTANCE OF PERFORMANCE (2021-155)
QUALITY (2021-079) SECONDARY AlSi10MnMg(Fe) Dave Rittmeyer, Hoosier Pattern Inc.,
Decatur, IN Rich Austin, Corporate Strategies,
ALLOY MANUFACTURED BY
Laura Bartlett, Koushik Karthikeyan A Sandler Training Center, Naperville, IL
VACUUM ASSISTED HIGH Advancements in additive sand technol-
Balasubramanian, Missouri University of
Science and Technology, Rolla, MO; Zach PRESSURE DIE CASTING ogy have fostered its emergence from a Selling in the COVID era has not changed
Henderson, Doug Imrie, Southern Cast (2021-048) prototype-only process to a process what we sell; it has changed how we sell
Products, Jonesboro, AR; Mingzhi Xu, viable for production casting applica- it. Twenty-five years ago, salespeople
Georgia Southern University, Statesboro, Swaroop Behera, Amir Kordijazi, Arthur tions. This presentation will provide a thrived by developing expertise in their
GA Jamet, Pradeep Rohatgi, University of view of how the use of additive sand for products and services and furthermore,
Wisconsin-Milwaukee, Milwaukee, WI; production castings will grow in the the features and benefits associated
Gating system design plays an import- Ana Fernández-Calvo, AZTERLAN, coming years. with both. Today, prospective clients are
ant role in determining the quality and Basque Research and Technology savvy, sophisticated, and well-educated.
mechanical properties of castings. Re- Alliance (BRTA), Durango, Spain 1:30 p.m. | Auditorium They are no longer looking for features
cently developed naturally pressurized ALUMINUM & LIGHT METALS DIVISION and benefits; they crave value-added,
gating systems have been proclaimed by An Artificial Neural Network was devel- THERMODYNAMIC MODELING customized, efficient interactions that
some to completely eliminate defects in oped to investigate the effect of section OF SOLID FLUX INTERACTIONS are personally impactful. With furloughs,
steel castings; however, this has not been size and type of AlSi10MnMg alloys (pri- WITH MOLTEN ALUMINUM budget freezes, and work-from-home
quantitatively studied. In the current mary or secondary) on water wettability policies, getting prospective deci-
of the cast samples. Additionally, corro- (2021-034) sion-makers to engage is indefinitely
study, the efficiency of different gating
systems on reduction of inclusions and sion resistance was studied using a linear harder and every opportunity needs to
polarization experiment. The developed Michael Moodispaw, Emre Cinkilic, be re-qualified in each step of the sales
the corresponding mechanical proper- Alan Luo, The Ohio State University,
ties was studied in quenched and tem- model was able to predict CA values with process. It is no wonder that salespeople
the Pearson correlation coefficient of Columbus, OH are reluctant to hunt for new business
pered SAE 8630 steel castings using a
combination of computational modeling 0.96. The section size of the casting did and fear their approach is intrusive or
not appear to have a measurable effect The total melt loss generated during inappropriate in the current environment.
coupled with experimental evaluation melt processing can be greatly reduced
of industrially produced test castings. A on the contact angle. However, the sec-
ondary alloy exhibited significantly higher by efficient use of flux, particularly for Re-envisioning the psychology that
novel mold design allowed for the simul- melting aluminum scrap or secondary
taneous comparison of four different best contact angles than the primary alloy; as drives salesperson and prospect behav-
demonstrated by confocal microscopy alloys. Effective use of cover fluxes can ior today provides striking data toward
practices and gating systems. Inclusion significantly reduce dross generation and
analysis revealed presence of mainly images, the secondary alloy exhibited process change for the success of both
higher surface roughness than the pri- the amount of metallic aluminum trapped parties. This session will peer behind the
Al2O3, complex Al2O3-MnS inclusions, within the dross, while drossing fluxes
and eutectic type II MnS. The naturally mary alloy when polished under identi- curtain of the adaptation of modern sales
cal conditions, presumably due to more can return up to 50% of the trapped alu- and give attendees a glance at not only
pressurized system provided the cleanest minum. To evaluate flux ingredients used
castings with the highest notch tough- intermetallic compounds. The primary what overperforming salespeople are
alloy possesses more corrosion resis- in the casting industry, computational doing right now, but the technology they
ness. Eutectic type II MnS that formed thermodynamic software was used to
during solidification negatively affected tance than the secondary alloy, possibly are leveraging to change the game.
due to the larger fraction of intermetallic calculate the driving force for reactions
toughness and this obscured the effect of between 15 flux ingredients and 15 com-
pre-existing alumina inclusions. compounds in the microstructure of the Attendees will learn:
secondary alloy serving as galvanic sites mon alloying and impurity elements in • The top five psychological anchors
in the corrosion reaction. foundry alloys. The thermodynamic cal- that hamper salespeople.
culations, combined with other proper- • How to engage in ethical prospecting
KEYNOTE SPEAKERS ties, were used to provide a desirable list practices.
of cover and drossing ingredients, which • Habits of consistently overperforming
TECHNICAL TRACK are being experimentally validated. salespeople.
• How to leverage a predictable pro-
MANAGEMENT TRACK cess for sales efficiency during unpre-
dictable times.
CASTING DESIGNERS
AND BUYERS TRACK28 | MONDAY, APRIL 19 MONDAY, APRIL 19 | 29
MONDAY, APRIL 19
9 a.m. | Auditorium polylactic acid (PLA), then placed in plas-
ENGINEERING DIVISION ter to form the molds. The plaster molds
CASTING COOLING were sintered, then pressure infiltrated
TECHNOLOGY: NEW SOLUTIONS with a magnesium alloy, AZ91E, to form
foams. Simulations were performed
AND APPLICATIONS (2021-032) for compression response of foams for
varying beam and pore sizes and shapes.
Gaetano Coraggio, A simulated foam compressed 0.23mm
Magaldi Technologies LLC, Atlanta, GA under loading that cortical bone can
withstand, 150MPa. The experimental
Over the years, the casting procedures and simulated results show that a low-
for steel and aluminum alloy products cost magnesium foam can be cast with a
have developed distinctive features in controlled porosity and strength similar
terms of casting practices, machinery, to bone.
process, and quality control methodolo-
gies. This session will discuss the casting 9:30 a.m. | Auditorium
cooling curves that affect the material MOLDING METHODS
properties and how it is possible to cool & MATERIALS DIVISION
down the castings per client requests
through accurate cooling system design. ROOT-CAUSE ANALYSIS AND
The combined use of analytical methods PROBLEM SOLVING OF SHRINK
(i.e., CFD analysis), experimental tests, DEFECTS IN ALUMINUM ALLOY
an in-house built test rig, and on-field BY SOLIDIFICATION RATE STUDY
measurements allow setting the correct (2021-013)
parameters to obtain an effective cooling
process. Sritama Kar, ASK Chemicals LP,
Dublin, OH
9 a.m. | Auditorium
MOLDING METHODS In order to investigate the root cause of
& MATERIALS DIVISION shrink defects in aluminum alloy A319,
CAST MAGNESIUM FOAM FOR the solidification rate of this alloy in the
ENERGY ABSORPTION AND sand molds prepared by a Cold Box sys-
BONE REGROWTH (2021-052) tem, has been studied. A statistical analy-
sis is done on the time-temperature data
Hannah Ullberg, Kaustubh Rane, Amir collected during the solidification pro-
Kordijazi, Pradeep Rohatgi, University of cess in the range of 650C to 583C right
Wisconsin-Milwaukee, Milwaukee, WI before the liquid metal loses its ability to
flow as it reaches the critical fraction of
In this work, a critical review of the solid. This analysis predicts the factors
casting of metal foams for biomedical that would affect the rate of solidification
applications is presented, outlining the of the castings by a certain percentage.
opportunities for markets for castings. The order of impact of the factors found
Additionally, this work presents a nov- in this study is different than that of the
el, low-cost pressure infiltration casting previous study based on the temperature
technique which enables the synthesis range of 650C-400C degrees - 400 and
of magnesium foams for use as bone conclusive for finding a solution to shrink
scaffolds. Foam and mold shapes were defects.
designed to take into account the re-
quirements of bone cell regrowth. These
designs were 3D printed usingVisit us at The Metalcasting Congress
30 | MONDAY, APRIL 19 MONDAY, APRIL 19 | 31
10:30 a.m. | Auditorium reduce this limitation. Accurately model-
KEYNOTE SPEAKER ing the filling and solidification processes
HOW TO BENEFIT FROM for these complex castings is of utmost
SHORTER SUPPLY CHAINS importance. This session will show that
a geometrically flexible finite element
IL O T
(2021-144)
S O SI
method mesh is particularly suitable for
M
3D printed sand mold casting simulation,
Harry Moser
O L
compared to the more commonly used
Reshoring Initiative, Kildeer, IL
R O
orthogonal structured mesh. A demon-
stration of a novel advanced mesh coars-
F
Reshoring and foreign direct investment ening scheme will be included.
(FDI) have brought back over 700,000
U.S. manufacturing jobs in the last 11 1:30 p.m. | Auditorium
years. At the same time, the COVID crisis ADDITIVE MANUFACTURING DIVISION
has demonstrated the risk of long sup-
ply chains. In fact, a recent BDO sur- WIRELESS FOUNDRY PROCESS
vey showed that 24% of companies are SENSORS FOR IOT
planning to change the country in which APPLICATIONS (2021-096)
they source or produce, and 22% plan to
reshore to the U.S. Jerry Thiel, University of Northern Iowa,
Cedar Falls, IA; Eric MacDonald,
Harry Moser, president of Reshoring University of Texas at El Paso, El Paso, TX
Initiative, will explore how U.S. found-
ries can take advantage of the trend Molding process variation has been the
toward shorter supply chains and what source of casting defects and ultimately
that means for reshoring and FDI. Plus, delays in product delivery. It is estimat-
discover how Reshoring Initiative’s Total ed that quality issues including casting
AND EVERYTHING Cost of Ownership Estimator and the Im-
port Substitution Program can help your
defects resulting from process variation
can cost manufacturers millions in reject-
IN BETWEEN company land contracts that otherwise
would have gone overseas.
ed parts or delivery delays. Determining
variations in the molding and casting
processes can provide valuable infor-
1 p.m. | Auditorium mation to improve the casting process.
ADDITIVE MANUFACTURING DIVISION This information can form the basis for
THE PREFERRED NUMERICAL foundries to advance into manufacturing
METHOD FOR PROCESS 4.0. Data from the molding and casting
process can aid metalcasters in refining
SIMULATION OF 3D PRINTED their processes to higher levels than ever
SAND MOLD CASTINGS before possible. Sensors within molds
(2021-058) can collect process data which includes
temperature, pressure, moisture, and gas
Ken Siersma, Mahfuj Ahbab, Chung-Whee chemistries. Temperature as well as mold
Kim, EKK, Inc., Farmington Hills, MI gas emissions are used to determine
the degree of sand curing by measuring
Product designs created with topology volatile organic compounds released
optimization or generative design in- during polymerization. Sensors in areas
clude geometrical features that are lean or rooms of the foundry can measure
and organically derived. Metalcasting environmental conditions as well as respi-
continues to be a practical process for rable dust.
manufacturing, but traditional casting
New Harmony >> New Solutions
TM
processes are often incapable of cre-
ating parts with such complex organic
geometries. 3D printed sand mold cast-
TINKER OMEGA SINTO, LLC. SINTOKOGIO GROUP www.sinto.com ing technology can eliminate or greatly
P.O. Box 328
Springfield, OH 45501
Tel 1.937.322.2272 Fax 1.937.322.2256
www.tinkeromega.com32 | MONDAY, APRIL 19 TUESDAY, APRIL 20 | 33
2:30 p.m. | Innovation Theater Ductile iron is desirable for lightweighting
CASTING DESIGNERS AND BUYERS as it has an optimum specific strength TUESDAY, APRIL 20
THE UNDERUTILIZED when cost is considered. This is espe-
COMPETITIVE ADVANTAGE: cially true for its heat-treated variation, 9 a.m. | Auditorium 9 a.m. | Auditorium
austempered ductile iron (ADI). The ADDITIVE MANUFACTURING DIVISION LOST FOAM DIVISION
BENEFITING FROM LIFE CYCLE authors report on U.S. Department of
ANALYSES (2021-025) PANEL: RESEARCH, SUPPLIER, LOST FOAM STAINLESS STEEL
Energy funded research for thin-walled
ductile iron. The influence of chemistry OPERATOR, A LOOK AT THE (2021-063)
Jeremy Lipshaw, Unaffiliated, for 65-45-12, 80-55-06, and 100-70-03 FUTURE OF AM4MC (2021-091)
Ferndale, MI was studied across various thicknesses Marshall Miller, Tesserract4D, Irving, TX
for ductile iron cast in lost foam and resin Brandon Lamoncha, Humtown Products,
The casting supply chain has an opportu- bonded nobake sand. Carbide-free re- Columbiana, OH; Kelley Kerns, While successful in the production of
nity to leverage the inherent strengths of sults in sections as thin as 0.76mm were HA-International LLC, Westmont, IL; aluminum base, copper base, irons and
its product into a competitive advantage obtained. Lost foam casting’s dimension- Travis Frush, University of Northern Iowa, carbon steel, the lost foam process has
by embracing sustainability assessments al tolerance control was also investigated. Cedar Falls, IA been unable to produce lower carbon
based on Life Cycle Analysis (LCA). While content stainless steels such as CF8M
classical vehicle sustainability metrics 3 p.m. | Auditorium The panel, made up of researchers, mate- (0.08C maximum) due to carbon pick up
primarily consider how materials affect LOST FOAM DIVISION rial suppliers and operators, will discuss and non-uniform carbon distribution. The
fuel economy via lightweighting, LCA where we were, where we are and where session will demonstrate the success-
HOW ANY FOUNDRY CAN ful production of CF8M stainless steel
accounts for the entire life cycle of the we are going in additive manufacturing
material or product, including the pro- DIVERSIFY INTO LOST FOAM in the foundry Industry. The presenta- through the application of the latest in
duction, use, and end-of-life. Due to their CASTING AT NEGLIGIBLE COST tion will cover the latest advancements bead technology for patterns and gating,
recyclability and lower embodied energy, (2021-067) in materials and equipment for 3D sand gating design, aggregate permeability
castings have the potential to be more printing. and LOI impact and coating as developed
sustainable in this framework compared Sarah Jordan, Mark DeBruin, by the lost foam process products sup-
to other metals manufacturing methods. Skuld, LLC, Gahanna, OH ply chain in the actual operating foundry
However, the casting industry is current- environment.
ly underprepared to compete in LCA- Decades ago, it was predicted that lost
based evaluations. There is a significant foam would take over nearly 30 percent
shortage of LCA literature for castings of the casting industry. Yet despite its
compared to other material processes. advantages, the process has a negligible
Furthermore, the well-documented and market share. This presentation will ad-
inaccurate perception problem with- dress the idea that lost foam is unsuitable
in industry that castings are heavy and for small volumes. Many hold the belief
outdated discourages researchers from that lost foam casting requires expen-
considering this line of study. This pre- sive tooling and specialized equipment.
sentation speaks about how the casting This large upfront investment in tooling
industry would benefit from LCA-based and equipment then has to be amor-
sustainability metrics. tized across large production volumes.
However, lost foam casting can be done
2:30 p.m. | Auditorium by machining foam and manual com-
LOST FOAM DIVISION paction. This method still maintains the
THIN-WALLED DUCTILE IRON tight dimensional tolerances of lost foam
WITH CARBIDE-FREE casting: typically 0.002 per inch toler-
ance plus the machined foam tolerance.
MICROSTRUCTURE DOWN TO Process details on how any foundry can
UNDER ONE MILLIMETER IN LOST diversify into lost foam casting as well as
FOAM AND NOBAKE CASTING common defects to avoid will be shared.
(2021-068) The design benefits of lost foam, includ-
ing the latest research showing the ability
Sarah Jordan, Mark DeBruin, Skuld, LLC, for as-cast threads, will also be covered.
Gahanna, OH; Alan Luo, Emre Cinkilic,
The Ohio State University, Columbus, OH34 | TUESDAY, APRIL 20 TUESDAY, APRIL 20 | 35
10:30 a.m. | Auditorium
HOYT MEMORIAL LECTURE
1 p.m. | Innovation Theater
CASTING DESIGNERS AND BUYERS
SHAPING THE FUTURE OF INDUCTION
HOYT MEMORIAL LECTURE: IRON CASTING CONVERSION Global
Sales &
METALMORPHASIS CHANGE CASE STUDY (2021-138) Service
AND TRANSITION (2021-127)
Tom Prucha
Mark Mundell, Lethbridge Iron Works Co.
Ltd., Lethbridge, AB, Canada Induction
Melting
Metal Morphasis LLC, Editor-in-Chief,
International Journal of Metalcasting, In this case study presentation on the
Rochester Hills, MI 2020 Casting of the Year, Mundell will
Change is constant, as nothing stays the
talk about the process of manufacturing
an opener main body casting — a text- Solutions
same. Consider the words of the Chinese book example for a casting conversion
philosopher Lao Tzu: “Life is a series of from a steel fabrication.
natural and spontaneous changes. Don’t
resist them—that only creates sorrow. Let 1 p.m. | Auditorium
reality be reality. Let things flow naturally MOLDING METHODS
& MATERIALS DIVISION Service, Support, & Manufacturing World Headquarters
forward in whatever way they like.” Some 1745 Overland Avenue
changes are the result of biology and the SILVER ANNIVERSARY LECTURE: Coreless & Channel Furnaces Power Supplies Coil Repair Warren, Ohio USA 44483
+1-330-372-8511
Ferrous & Non-Ferrous Installation & Retrofits & Rebuilds
passage of time, within the natural cycle AIR FLOW VARIATIONS WITHIN Construction
+1-330-372-8608 Fax
or order of things. Others are self-gener- Melting, Holding, & Duplexing Parts & Service
A COREBOX: A STUDY OF
ated, under our own control and willful
effort, or dependent upon encounters VENT OPEN AREA AND
24/7 Customer Service: 800-547-1527
SAND VARIABLES (2021-121)
®
with significant others—family, friends,
colleagues, and others close to us. Still,
other changes occur because of circum- David Gilson, SinterCast Inc., www.ajaxtocco.com
stance or fate, a proverbial “date with Naperville, IL
destiny” and often beyond what we feel
is in our control. Whether it is our per-
sonal life or occupation, like metalcast-
This Silver Anniversary Lecture provides
a timely update on a paper originally pre- Induction Melting Equipment Solutions
ing, this change can facilitate transition sented at Metalcasting Congress in 1996,
and transformation. Prucha has coined “Air Flow Variations Within a Corebox:
A Study of Vent Open Area and Sand Non-Ferrous
the term metalmorphasis and this lec- Melting Systems
ture is a reflection of how to embrace Variables” by D.M. Gilson, K.B. Horton,
and P.B. Carr of Ashland Chemical Co. in Ferrous Melting
change and utilize it as a vehicle for new Systems
opportunities. Beyond the philosophical, Columbus, Ohio. This study confirmed
some generally accepted venting guide- Precious Metal
this lecture looks at how we as metal- Melting Systems
lurgists and metalcasters apply change lines, but also contradicted some expect-
ed outcomes. Gilson will provide new Specialty Applications
(time, temperature, pressure, chemical
insights into this research on the air flow Furnaces &
reactions, etc.) to transform metals and Power Supplies
create metalmorphasis. characteristics of common foundry vents.
Retrofits & Rebuilds
Field Service
& Coil Repair
With over 50 years of excellence,
BLACK
Pillar is your partner for induction melting solutions.
KEYNOTE SPEAKERS
For more information
TECHNICAL TRACK please contact Pillar at PMS 294
800-558-7733
MANAGEMENT TRACK Pillar Induction
21905 Gateway Road Brookfield, WI 53045 262-317-5300
CASTING DESIGNERS
AND BUYERS TRACK www.pillar.com WHITEYou can also read
