122nd Metalcasting Congress
2018 Metalcasting Congress Logo


Designers and buyers, make connections at Metalcasting Congress 2018

Casting designers and buyers! This is the time and the place to move your business forward at Metalcasting Congress, April 3-5 in Fort Worth, Texas.

Professionals in the field of component design and purchasing, Metalcasting Congress offers a wide range of alloys and processes, lots of foundry expertise packed into a small footprint, and perhaps most importantly, an educational track focused on designing, specifying, and buying metal castings. Network with other industry leaders, make new important contacts, and gather intelligence from your business connections with classroom experiences specifically for you!

The AFS Design & Purchasing Track at Metalcasting Congress includes a lengthy list of events geared toward designers and buyers to help you better understand the metalcasting process and identify foundry best practices for the products you purchase.

Register here to take advantage of the following:

Design & Purchasing Track

Tuesday, April 3, 1:30-3 p.m.
Evaluation of A New High Temperature Cast Aluminum Alloy for Cylinder Head Applications
Qigui Wang, Devin Hess, General Motors, Pontiac, MI; Xinyan Yan, Alcoa Technical Center, New Kensington, PA; Francis Caron, Alcoa Technical Center, Deschambault, QC, Canada

Tuesday, April 3, 1:30-3 p.m.
An Aluminum Casting Alloy for High Performance Engines
David Weiss, Eck Industries, Inc., Manitowoc, WI

Tuesday, April 3, 1:30-3 p.m.
Solidification Pattern of Silicon Alloyed Ductile Cast Irons
Stelian Stan, Iulian Riposan, Mihai Chisamera, Politehnica University of Bucharest, Romania, Bucharest; Michael Barstow, Consultant Metallurgist, Napa, CA

Tuesday, April 3, 1:30-3 p.m.
Modelling the Variation of Tensile Properties of High Silicon Ductile Iron
Peter Hammersberg, Kenneth Hamberg, Chalmers University of Technology, Goteborg, Sweden; Henrik Borgstrom, Swerea SWECAST AB, Jonkoping, Sweden; Joachim Lindkvist, Volvo Powertrain, Goteborg, Sweden; Lars-Erik Bjorkegren, LEB Casting Technology, Jonkoping, Sweden

Tuesday, April 3, 1:30-3 p.m.
Stop Name Calling - Identify Casting Defects by Appearance to Reduce Scrap
Dr. Sudesh Kannan, Co-Power LLC, Schaumburg, IL; Abhishek Pathak, Kautex Textron Inc., Muskegon, MI; Tom Cobett, Tom Cobett and Associates, Strongsville, OH

Wednesday, April 4, 8:00-9:00 a.m.
AFS Research: New Tools for Casting Design and Simulation Engineers
Jiten Shah, Product Development & Analysis LLC, Naperville, IL

Wednesday, April 4, 1:30-3 p.m.
Challenges in the Design and Manufacture of Efficient, Downsized ICE Cylinder Heads (For Future Vehicles)
Remi Martinez, Linamar Montupet Light Metalcasting, Livonia, MI

Wednesday, April 4, 1:30-3 p.m.
Thermal Treatment of Al-Mg-Ce Alloys
David Weiss, Eck Industries, Inc., Manitowoc, WI

Wednesday, April 4, 1:30-3 p.m.
Casting of the Year Case Study from Aristo-Cast
Paul Leonard, Aristo-Cast Inc., Almont, MI

Thursday, April 5, 8:00-9:00 a.m.
Forced Cooling of Semi-Permanent Molds for Fine Grain Ferrous Castings
Nick Moroz, Pedro Guillen, Detroit Materials, Wixom, MI; Rish Mitra, ESI-NA, Farmington Hills, MI

Thursday, April 5, 8:00-10:15 a.m.
Panel: Additive Manufacturing
Marshall Miller, Flowserve, Irving, TX; Travis Frush, University of Northern Iowa, Cedar Falls, IA; Tom Mueller, Mueller AMS, New Berlin, WI; Jiten Shah, Product Development & Analysis LLC, Naperville, IL; Jerry Thiel, University of Northern Iowa, Cedar Falls, IA

Thursday, April 5, 9:15 - 10:15 a.m.
Effect of Nonmetallic Inclusions on Impact Toughness in High Strength Lightweight Steels with Different Sulfur Additions
Rairu Vaz Penna, Laura Bartlett, Trevor Constance, Missouri University of Science Technology, Rolla, MO


Institute Courses
Virtual Casting Process
Tuesday, April 3, 1:30-4:45 p.m. 
This course provides participants with a basic overview of the metalcasting process. It will trace the path of a casting from quoting through shipping. This course covers common metalcasting terms and highlights the activities inside the major departments of a metalcasting production facility. At the end of this course you will be able to:

  • Define key industry terms.
  • Describe the major departments in a metalcasting facility.
  • Chronologically track a casting through the metalcasting facility from quoting to shipping.

Identifying the Correct Casting Defect
Wednesday, April 4, 1:30-4:45 p.m. 
Learning a systematic procedure for defect root cause identification supports the business goal of designing, producing and selling quality castings that are made in a timely manner and in a safe environment for a profit. This course provides participants with a path and process for correctly identifying a casting defect. At the end of this course you will be able to:

  • List the 10 steps used in casting defect analysis.
  • State the benefits of using a consistent approach.
  • Identify a good problem statement.
  • Collect process data using the process sheet.
  • State the importance of evaluating data.
  • Use the International Atlas of Casting Defects classification system.

Creating a Culture of Respect Through Feedback
Thursday, April 5, 8:00-10:15 a.m. 
Today, it’s more critical than ever to develop a culture of respect and safety for all employees.  Senior leaders have one role in creating a workplace that promotes tolerance and collaboration.  But the fact is that we all have a stake in driving a safe and enjoyable work climate, whether you’re a man or a woman, salaried or hourly, experienced or brand-new.  One way that you can support a thriving workplace is through your ability to deliver and receive feedback.  We get a lot of feedback from bosses, colleagues, spouses, parents, neighbors, and customers — and it’s never easy to accept.  Why?  Because even though we all want to learn and develop, we have a conflicting and fundamental need to be accepted and respected.  Learn about three triggers of feedback and how to defuse the triggers before they impact your credibility, reputation, and a workplace that works for everyone.  Through the unique Leading Edge blend of research and best practices, improvisational comedy, and interaction, you’ll walk away more open and ready to learn.     

  • Identify your own reactions to feedback and how they may get in the way of growth and change.
  • Build awareness around the three feedback triggers that shut you and others down.
  • Respond with curiosity — even when you feel defensive.
  • Recognize when psychological safety is compromised and take action to help others learn.
  • Deliver feedback to others using five steps.

Tuesday Keynote Speaker/Honorary Lecture
Jean Bye, Dotson Iron Castings, Mankato, MN
"Disaster Recovery—Everyone’s Worst Nightmare"
Sponsored by the AFS Cast Iron Division
Tuesday, April 3, 10:30—11:30 a.m.
In the early morning hours of Sept. 23, Dotson Iron Castings experienced a fire that would destroy all of its molding capabilities, completely shut down its operation and require a recovery effort beyond what could ever have been detailed in a disaster recovery plan. Bye will talk about the many twists, turns, and lessons learned throughout the recovery process relating to disaster preparedness.

Hoyt Memorial Lecture
Dan Oman, Haley & Aldrich Inc., Ann Arbor, MI
"Changing Perceptions: The Need for an 'Unbalanced Force'"
Wednesday, April 4, 10:30—11:30 a.m.
Perceptions are a function of information received from many different sources. These perceptions become firmly held beliefs that rarely, if ever, change. Today, the typical perception of the metalcasting industry is that of a smokestack industry utilizing low technology and lacking in challenging career opportunities. This perception remains virtually unchanged since the 1970s. According to Newton’s First Law of Motion, an object moving in space continues to move in the same direction at a constant velocity in the absence of an unbalanced force. In the absence of an unbalanced force, perceptions also will not change. Over the past 40 years many individuals have acted as an unbalanced force to change perceptions. This presentation will examine the common aspects of these efforts so that each of us can have an impact on perceptions.

Thursday Keynote Speaker
Stephen Moore, economist
Economic and Political Update 
Thursday, April 5, 10:30—11:30 a.m.
Serving as Keynote Speaker on the morning of April 5 will be respected economist Stephen Moore, who was Senior Economic Adviser to the Trump Campaign in 2016.
"Stephen Moore is one of the foremost experts on tax policy and one of the most influential advocates for economic growth," said Doug Kurkul, CEO of the American Foundry Society. "The insight and perspective he offers will benefit Metalcasting Congress attendees in their business planning and decision-making."

Moore is currently the Distinguished Visiting Fellow for the Project for Economic Growth at the Heritage Foundation. In prior roles, he was the Founder of the Club for Growth, a member of the Wall Street Journal editorial board, and Founder of the Free Enterprise Fund. Moore was the Co-Founder of the Committee to Unleash Prosperity, alongside Arthur Laffer, Steve Forbes and Larry Kudlow.
The author or co-author of several books, Moore earned a Bachelor of Arts degree from University of Illinois at Urbana-Champaign. He holds a Master of Arts in economics from George Mason University. Moore's commentary has often been featured on CNN, Fox News, and other news outlets.