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MCTV Videos

  • Webinar: Early Evaluation of Manufacturability:

    The separation between product designers and the manufacturing community has greatly increased over the years, especially for cast components. As the demand for lighter and new designs with new materials and alloys has increased, the pressure on the entire supply chain to be profitable and efficient continues to build.


    To watch the recording of this webinar, click here.

    This free webinar is sponsored by solidThinking.

  • Control Foundry Sand Temperature to Reduce Cost, Improve Quality (Sponsored Webinar from Solex):

    By adopting an innovative heat exchanger technology that has been used in different industries, the metalcasting industry can solve some of the similar challenges they faced. Plate heat exchanger technology can increase efficiency and improve casting quality through precise sand temperature control.

    The presenter is Andy Nix, North America Sales Manager, Solex Thermal Science. Nix uses a consultative approach to provide solutions based on available space, required performance and budget. He has been involved in the development of many technologies for material flow sciences, thermal processing and discharge feeders.

  • Iron Casting From a Customer's Viewpoint:

    In this video from 360 Yield Center, the ag manufacturer showcases its lost foam ductile iron stalk roll. This part is integral to the company's unique approach to nitrogen management in crops. 

  • Osco Delivers: August 2017 Modern Casting:

    AFS Corporate Member Osco Industries has finetuned its business to deliver quality parts with a short lead time by committing to gray iron, adding flexibility through inventory, and conservative revenue management. 

  • Webinar: Combining Cores With 3-D Printing:

    Combining four individual cores into a single piece can have a huge impact on downstream costs. It is often difficult to determine what “not having” 3-D printing can cost. In this sponsored webinar, a metalcaster shares a real world example of how progressive thinking can save money downstream.

    Since 1936, Prospect Foundry has been a market-leading supplier of complex cored gray and ductile iron castings in low to medium volumes. It combines modern casting technologies, engineering expertise, and a focus on craftsmanship to produce high quality, complex pressure tight, porosity free castings. Prospect Foundry castings have been used by major OEM customers in the construction, mining, agricultural equipment and industrial markets.

    The webinar is presented by Greg Colosimo and Bob Gruidl, of Prospect Foundry, as well as Terry Senish, director technology applications for ExOne.

  • Batesville Products Inc.: September Modern Casting:

    The aluminum permanent mold casting business relies on measurement and analysis to propel its continuous improvement projects. (Video from Batesville Products Inc.)

  • Soucy Invests in Metalcasting:

    A manufacturer of track systems, parts, accessories and other industrial components spent more than $30 million to build a new plant next to the casting facility it just purchased, converting it from a local supplier to one of North America’s largest, most automated plants for large castings.

    Read more.

  • 2017 Metalcasting Congress:

    More than 2,100 metalcasters, suppliers, casting users, and students participated in the 121st Metalcasting Congress, April 25-27 in Milwaukee. The show was marked by brisk attendance, featuring more than 220 exhibitors – including 15 first-time exhibitors – and a standing-room-only keynote address that drew well over 400 attendees.

  • New Melting at Fonderie Laperle:

    Fonderie Laperle (Saint-Ours, Quebec, Canada) completed the installation of a new melting department in 2016, making the switch from cupola to induction melting. For more about Fonderie Laperle, read the article in the March issue of Modern Casting.  

  • Pouring a Crankcase in a 3-D Mold:

    The crankcase being poured in this video is featured in the April 2016 issue of Modern Casting magazine.

  • Busche Builds Its Platform:

    Busche Performance Group, seeking to become a competitive Tier-1 automotive supplier, acquired an aluminum casting operation as its first order of business.  Read more.

  • Webinar: Trade Policies in the Trump Administration:

    In this recorded webinar, Alan Price, chair-international trade practice at Wiley Rein, highlights how the potential new Trump trade policies will affect domestic metalcasters.

    This webinar gives an overview of U.S. trade law, presents trade remedies opportunities for U.S. manufacturers, discusses the future of the World Trade Organization (WTO), dispute settlement, and trade agreements, and gives potential uses of U.S. trade laws to aid U.S. manufacturing, exports, and infrastructure spending.

  • Customer Success Story (Sponsored Video From General Kinematics):

    From General Kinematics: A customer shares its story.

  • Webinar: OSHA s New Injury Illness Reporting Rule:

    The Occupational Safety and Health Administration (OSHA) issued its final rule to improve tracking of workplace injury and illness data earlier this year. The rule requires most metalcasters to electronically submit their injury and illness data to OSHA. And for the first time, OSHA plans to make this information publicly available on the Internet through a new searchable database. Beyond the electronic reporting, particularly controversial is the impact of OSHA’s new rule on employers’ policies for post-injury drug testing, safety incentive programs, and executive compensation and bonuses.

    In this recorded webinar, presenters outlined the key requirements of the final rule and explained what employers must do to comply.

  • Manufacturing Day 2016 at AFS:

    On Friday, Oct. 7, the American Foundry Society (AFS) hosted more than 250 students and adults at its 3rd Annual National Manufacturing Day event. As one of 17 national sponsors, AFS hosted Foundry in a Box demonstrations, gave a metalcasting trivia contest and received a proclamation from Illinois Governor's office.

    “Across the country, hundreds of manufacturers opened their doors on National Manufacturing Day to demonstrate modern manufacturing,” said AFS CEO Doug Kurkul. “AFS was proud to help represent the metalcasting industry in this endeavor.”

  • Webinar: On Demand Skills Training With the AFS Institute:

    Take a peek at the AFS Institute’s new e-learning program launched July 1 with Jennifer Morton, AFS e-learning project manager, and Leo Baran, AFS director of membership. This webinar will explore how to integrate e-learning into your company's education program, show the e-learning interface, walk you through an e-learning module, and tell you how you can subscribe to a year of unlimited access to all modules or purchase one module at a time. The AFS Institute currently offers 20 modules covering casting defects, green sand molding, cast iron, and an introduction to metalcasting principles.

    The new online courses provide the following benefits:

     Interactive practical skills to use on the shop floor.
     Real world scenarios.
     Flexible time management (each module ranges from 15 minutes to 1 hour+).

    Find more information at www.afsinc.org/elearning.

  • Webinar: Integrating 3D Sand Printing Technologies Into Traditional Foundry Tooling Processes:

    The advent of 3-D sand printing is a “game changer” in the metalcasting industry and will alter the way in which metalcasters address their tooling and casting needs in the future. No longer an “emerging technology,” 3-D sand printing must be seriously considered as a valuable tool in the development of engineered cast components. 

    This sponsored webinar from Craft Pattern and Mold focuses on when, and how, to incorporate 3-D sand printing technologies with traditional tooling methods to deliver cost effective, innovative solutions to today’s engineered metal casting challenges.

  • Saguenay Foundry's Pattern for Success:

    Saguenay Foundry’s innovative and envelope-pushing philosophy has led to a thriving business with a clear path into the company’s next phase.

  • What to Do When OSHA Shows Up:

    This webinar is presented by Jim Barry, industrial hygiene consultant and the AFS 10-Q Health and Safety Committee.

  • Lead Part 2: Control of Lead Exposure in the Foundry:

    This webinar is presented by Robert Scholz, RMT Inc. and the AFS 10-Q Health and Safety Committee.

  • OSHA's Revision to Its Hazard Communication Standard:

    Kay Rowntree, Industrial Hygiene Sciences, provides information on revisions to the hazard communication standard from the U.S. Occupational Safety and Health Administration.

  • Webinar: Hexavalent Chromium Part 1: OSHA’s Standard:

    Part 1 of this series, given by Kay Rowntree, Industrial Hygiene Sciences, will cover OSHA's Hexavalent Chromium Standard (1910.1026) as it applies to foundry exposures. Exposures to hexavalent chromium (Cr+6) can occur during the melting of stainless steel and other higher chromium alloys and when thermal processes such as plasma cutting, arc gouging or welding are used in the processing of castings made from these alloys. You will learn about the OSHA requirements and where to focus your efforts to comply with the Standard. Part 2 of this series, to be held in September, will address reducing exposures to hexavalent chromium.

  • Miami Dolphins Sun Life Stadium Restoration:

    Cast iron seat components produced by Atlas Foundry for American Seating are apparent in this video on the Sun Life Stadium restoration. 

  • Webinar: High Performance Aluminum Casting Alloys for Engine Applications:

    In this sponsored webinar from Eck Industries, learn about a new range of aluminum alloys that boast superb casting characteristics coupled with high mechanical properties, opening up new applications for aluminum castings.

    In the early 1980s, promising research and development efforts focused on powder metallurgy revealed that aluminum alloys containing 4 wt% cerium exhibit high temperature mechanical properties exceeding those of the best commercial aluminum casting alloys currently in production. Cerium oxide is an abundant rare earth oxide that is often discarded during the refining of more valuable rare earths.

    More recently, the Critical Material Institute and Eck Industries developed a series of binary aluminum-cerium alloys with and without traditional elemental additions. This webinar will discuss the casting characteristics, mechanical properties and unique opportunities afforded from these innovative new alloys.

  • Atlas Foundry Charts Its Path:

    With a memorable niche and commitment to upgrades, Atlas Foundry is looking to continue its strong tradition of service and growth.

  • Webinar: Chemical Data Reporting Rule:

    The Chemical Data Reporting (CDR) rule that EPA issued pursuant to the Toxic Substances Control Act (TSCA) requires manufacturers and importers of chemical substances (including byproducts that are not intentionally produced) to report information to EPA regarding these chemical substances. This webinar summarizes the reporting threshold levels and other requirements and provide updates on the rule since the last reporting date in 2012.

  • E-Learning Demo:

    This short video gives a demo of the new e-learning modules from the Institute. Find out more at www.afsinc.org/elearning.

  • Cast Football Face Masks Case Study:

    Zuti Facemasks and Acra Cast are producing a new face mask for football helmets that looks cool and might help the sport reduce concussions. Watch this video from Steinbrink Engineering for more information. 

  • Webinar: Introduction to 3D Sand Printing for the Metalcasting Industry:

    This sponsored webinar from Hoosier Pattern covers the basics of additive manufacturing as well as explains the technology used to create molds and cores with a 3D printer. Led by Dave Rittmeyer and Steve Murray, both of Hoosier Pattern, the webinar gives full access to two industry veterans who have worked in metalcasting for a combined 50 years. The webinar covers the basics and explores how to utilize 3D printed sand components on your next project.

  • 2016 Metalcaster of the Year: Production Castings:

    Aluminum and zinc diecaster Production Castings has built a reputation and strong business model on offering its customers added value from tooling to assembly.

  • Webinar: Are You Ready? Preparing for the Final OSHA Hazard Communication 2012 Deadline:

    The final Hazard Communication 2012 deadline is June 1, 2016. By this date, employers must be sure that their Hazard Communication Program is updated to comply with the Standard and that all employees are trained for newly identified hazards. This webinar will help foundries learn about:

    • The key requirements of the Standard that must be addressed in your program
    • Recent OSHA interpretations of the Standard, especially those that relate to chemical labeling
    • Challenges in complying with the requirements

    Presenter:
    Kay Rowntree, CIH
    Industrial Hygiene Sciences, LLC
    Waterford, WI

    Kay Rowntree is the owner of the industrial hygiene consulting firm Industrial Hygiene Sciences, LLC. She has over 37 years of experience in the field of industrial hygiene conducting air and noise surveys, training employees and management, investigating occupational disease claims, preparing Safety Data Sheets and assessing the risks associated with chemical, noise and biological exposures to workers. She is certified by the American Board of Industrial Hygiene in comprehensive practice and holds a B.S. degree in Bacteriology from the UW-Madison and a M.S. degree in Environmental Health-Industrial Hygiene specialty from the University of Minnesota.

  • Sponsored Video: New Resin-Coated Sand From Fairmount:

    This sponsored video from Fairmount Santrol covers resin-coated shell sand. It’s a new, safer shell and core casting system that dramatically lowers in-plant smoke, odor and emissions while delivering superior performance. 

  • CastExpo'16:

    CastExpo'16 was a successful show bringing together the metalcasting supply chain for technology transfer and networking.

  • Webinar: Foundry Sand Beneficial Reuse Part 2:

    AFS presented this FREE webinar series covering U.S. EPA’s recent study on the beneficial use of foundry sand. The idea of beneficial use for metalcasters has gained continued traction across the country, and the release of U.S. EPA’s Risk Assessment of Spent Foundry Sands in Soil Related Applications provides significant opportunity for the metalcasting industry to promote and reform beneficial use rules.

    This second webinar focuses on identifying and promoting opportunities at the foundry level through best management practices, educating your customers by marketing your byproduct in a positive light, and providing valuable resources and tools to help facilitate reuse program success.

  • Webinar: OSHA's Sweeping Final Silica Rule: What is the Impact on Metalcasting:

    OSHA published its sweeping final crystalline silica rule on March 25. Join us for a live webinar on April 12, when Tom Slavin, CIH, CSP, CSHM, Slavin OSH Group, will outline what is included in the final silica rule, how the final rulemaking differs from the proposed rule, and how to begin to prepare for compliance.

    Find more information about the rule at www.afsinc.org/silica.

  • Webinar: A Case Study in Optimizing Casting Design Using 3 D Printing:

    In this sponsored webinar, presenters Jeff Shepler, the ExOne Corp., and Scott Chapman, Applied Technology Integration Inc. (ATI), illustrate the design optimization of a cast component utilizing 3D sand printing and various software technologies.

    The ExOne Design and Re-Engineering for Additive Manufacturing Center, in conjunction with the ATI engineering team, conceived and created the unique casting solution that resulted in a 33% weight reduction while maintaining the structural requirements demanded by the application.

    Using 3D modeling, topology optimization, shape optimization, and finite element analysis, the team was able to verify the redesigned casting's performance and show the full design freedom afforded by 3D printing.

  • New Roof Construction at Arthur Ashe Stadium:

    From the U.S. Open Tennis Championships, this video shows the new roof constructed for Arthur Ashe stadium. Cast steel connectors were used as structural support for the new retractable roof built for the Arthur Ashe stadium, home of the U.S. Open's biggest tennis matches.

  • Casting the Future:

    This video is a great resource to show students the exhilarating careers to be found in metalcasting. For more information on how to reach out to students and the next generation of metalcasters, visit Melting Point.

  • AFS Staff Presents Foundry in a Box at GEMS 2016:

    Staff from the American Foundry Society took Foundry in a Box on the road to James B. Conant High School, Schaumburg, Illinois, on Feb. 7 to share the metalcasting industry with fifth and sixth grade girls as part of the District 211 Girls in Engineering, Math and Science (GEMS) Conference.

    Click here to read more.

  • Metalcasting Is Advanced Technology:

    This video highlights the technological aspects of the metalcasting industry.

  • The Gearbox Inside the Biggest BAF Fan:

    Check out the cast gearbox inside Big Ass Fans' biggest commercial fan. Besides the sand cast gearbox, BAF utilizes many U.S.-sourced diecastings in its products.  

  • Screencap

    Webinar: Foundry Sand Beneficial Reuse Part 1:

    This webinar covers the EPA risk assessment and advancing beneficial use of spent metalcasting sand in your state.

    For more information on beneficial use, click here. 

  • Using Sponsored Webinars to Attract New Customers:

    Watch this webinar to see how using this medium can help communicate with potential customers.

  • Webinar: Reducing Cleaning Costs With an Environmentally Safe Method:

    Traditional cleaning methods can involve a lot of time-consuming disassembly, be ineffective, costly, involve environmentally harmful cleaning methods, and cause damage to expensive tooling and equipment. This presentation provides details for attacking and reducing the costs associated with cleaning applications in the foundry industry. More importantly, it will help participants position their companies for increased profitability.

    In this recorded webinar, learn about in situ cleaning with environmentally friendly non-destructive dry ice. Cold Jet’s Environmental Cleaning and Surface Preparation Systems utilize high speed MicroParticles of dry ice to clean and prepare patterns, core boxes, shell molds, permanent molds, and other tooling resulting in less down-time, a better clean, higher quality parts, improved tool utilization, and longer asset life.

  • Robotic Demolition Equipment:

    Considering the rigid materials used in metalcasting, one of the serious challenges many facilities face is the damaging effects of repetitive and extended use of pneumatic hand-held tools. Robotic machines serve as a means to a safer, more worker-friendly operation with far-reaching improvements in productivity.


    This sponsored webinar, led by Peter Bigwood, vice president of sales, Brokk Inc., provides educational information and quantifiable results, explaining how remote-controlled equipment boosts productivity and increases safety for foundry personnel. The machines allow operators to stay out of harm's way while easily tackling challenging process applications - from the cleaning and de-bricking of furnaces, ladles and cupolas to removing baked-on sand from large castings.

  • The Truth About Carbon:

    Without carbon there would be no cast iron or steel, as it has been the reducing agent used to liberate metallic iron from its ores since the earliest times. A few tenths of a percent difference in carbon content can have a dramatic effect on the mechanical properties of iron and steel, so its accurate measurement is critical to ferrous metallurgy. 

    OES using an electric spark source is one of the most popular methods to measure carbon in iron and steel, however, this method can be prone to errors traceable to the granular nature of the material and the presence of particles of “free” carbon in the form of graphite. These errors can be overcome by careful sample preparation techniques, but a high degree of skill and experience is required to achieve reproducible and reliable results. 

    In this sponsored webinar, Dan Soisson, Field Product Manager, discusses new developments in OES technology to detect and analyze suboptimal samples to achieve results comparable to “total carbon” measuring techniques such as combustion analysis. Techniques and methods will be explained for detection of “free” carbon in the sample to help make the process more efficient.

  • Lodge's Recipe for Growth:

    With sales doubling in the last six years, Lodge Manufacturing Co. is rising to the challenge of fulfilling customer cravings for cast iron cookware. Read more in the December 2015 issue of MODERN CASTING.

  • Manufacturing Day 2015 at AFS:

    AFS hosted more than 400 students, neighbors and local dignitaries in an open house Oct. 2 at its headquarters in Schaumburg, Ill. National Manufacturing Day is an annual event with the aim of encouraging students to pursue careers in metalcasting. 

    Click here for more information.

  • Talladega Pattern's Plunge Into Automation:

    A small green sand nonferrous job shop answered the pull of customer demand with its first automatic molding line and sand system. 

  • Aluminum Structural Die Castings in Lightweight Concept Car:

    This video highlights the main structural aluminum die castings designed for the Ford Fusion Concept Car to reduce weight for lower emissions. 

  • Webinar: The Link Between T&D and World Class Status:

    Workforce training and development is a must for any organization hoping to be a world-class manufacturer. Those companies that excel in this area are far more likely to achieve world-class status for their operations. So where do you fit in- are you already world-class or working towards it? Join us as Jennifer Head, director of education for the AFS Institute, explores the connection between training and development and world-class status, and look at concrete ways you can improve your training and development programs.

  • Webinar: Cost Savings Opportunities in the Metal Casting Industry:

    Tom Kayser teaches how to identify and implement cost reduction opportunities with your castings. Tom has a systematic approach and a check list he shares. It doesn't matter if you buy, sell, design, machine or assemble castings you will benefit from this webinar. 

    Tom has been pricing castings for Osco Industries for over 15 years and has a passion of working with his partners to identify ways to lower cost.

  • The Fun of GIFA:

    Modern Casting Publisher and Editor Al Spada shows us the fun side of GIFA, the international metalcasting trade fair held June 2015 in Dusseldorf, Germany.

  • Eagle Alloy’s Innovative Approach to Sustainability:

    Eagle Alloy Inc., a steel casting facility in Muskegon, Mich., has a proven history of finding unique methods of improving its overall operation. From recycling methane from a local landfill to its recently opened onsite employee health clinic, Eagle Alloy is dedicated to improving sustainability, which led to being named Modern Casting’s 2015 Metalcaster of the Year.

    For the full story, click here

  • Design Details: 2015 Casting of the Year:

    Design Details columnist Jiten Shah points out the casting features of the 2015 Casting of the Year--space frame nodes for the Acura NSX designed and produced by Honda of America utilizing the ablation casting process developed by Alotech Ltd.

  • Rochester Metals's Experience With DISA:

    Sponsored video from DISA: Rochester Metals has had a long relationship with DISA, and it continues today with the recent purchase of a new piece of equipment.

  • Prospect Foundry's Experience With Guardian Software:

    Sponsored video from Guardian Software: Prospect Foundry details its use of software to manage its inventory and production scheduling.

  • Bremen Casting's Use of B&L Software:

    Sponsored video from B&L Information Systems: Bremen Casting's successful implementation of B&L software. 

  • Webinar: Veining Reduction Project--A Thermo Mechanical Approach:

    Dr. Sam Ramrattan, Western Michigan University, delivers this presentation on veining reduction for castings as part of AFS's Technology Transfer Thursday.

  • AFS: Innovate:

    AFS offers several programs to offer guidance and resources for established and emerging methods for better energy management, human relations, safety, government advocacy, marketing presence and casting and metallurgical procedures, and casting design and sourcing.

  • AFS: Educate:

    AFS exists in part to meet the career and educational needs of its members. Through Institute classes, in-plant training, the Education Solutions program, Metalcasting Career Center, reference and resource material, and various workshops, seminars and conferences, AFS helps drive the sustainability and growth of the metalcasting industry.

  • Webinar: Evaluating Steel Casting Process Cleanliness:

    Presented by Robert Tuttle, Saginaw Valley State University, this webinar covers how to evaluate the cleanliness of your steel casting process. Background on common analysis techniques used and methodologies are given. Emphasis is on a specific strategy to setup as part of a continual inclusion monitoring approach that allows metalcasters to identify the inclusion formation portion of their process. This approach allows a metalcaster to determine which clean steel techniques are needed to improve their operation. An example from an actual foundry in how this approach helped them target improvements is given.

  • Webinar: Automated SEMEDX Analysis of Steel Quality Capture:

    Detailed analysis of non-metallic inclusions (NMI) in steel castings is important for improving foundry processing and casting quality. Automated SEM/EDS with integrated design (ASPEX system) provides fast analysis and accurate reliable data (size, number, shape, distribution and chemistry of MNI population). The samples were collected at different steel producers and NMI were analyzed. This webinar covers:

    • Cast steel quality problems caused by NMI
    • Basic principles of automated SEM/EDS for NMI analysis
    • Several industrial cases for mini-mills and steel foundries. 

    The Aspex technology has been widely reported as a proven method in solving NMI problems in large scale steel production (integrated plants and mini-mills) and can be very useful for solving quality problem in steel foundries. Missouri University of Science and Technology offers ASPEX NMI analysis for steel foundries.

  • Webinar: Hexavalent Chromium Part 2:

    As a follow-up to Part 1 in this series, Bob Scholz, Senior Project Manager, TRC Environmental Corp., will discuss successful controls of Hexavalent Chromium.

  • AFS: Advocate:

    AFS is the leading voice for the metalcasting industry with federal and state lawmakers, as well as regulators.

  • What Is AFS?:

    The American Foundry Society (AFS) is a non-profit association serving members of the metalcasting industry both in the United States and abroad. Through various resources, AFS provides members with advocacy coordination and efforts in Washington, D.C., ongoing technical education through its Institute, as well as the transfer of innovative research and technology to the industry.

  • Elevating Workplace Safety With 5S:

    Glenn Huneycutt, Charlotte Pipe & Foundry, discusses understanding 5S, getting started at your facility, its impact within work areas, auditing to motivate improvement, and additional benefits of 5S.

  • 2014 AFS Manufacturing Day Open House:

    AFS hosted a Manufacturing Day open house on Oct. 3, complete with metalcasting demonstrations to local businesses, students, families and neighbors.

  • Brillion Iron Works' Rejuvenation:

    Once bankrupt, Brillion Iron Works is now a lean, profitable iron casting facility, thanks to the “Fix and Grow” strategy of parent company Accuride Corp.

  • Consolidating Features in an Investment Cast Prototype:

    Jiten Shah, Product Development & Analysis, points out the unique casting features of an electronics mount produced by Aristo-Cast, Almont, Mich.

  • Metal Casting at the Dunn County Fair:

    From Univ. of Wisconsin-Stout: Faculty from UW-Stout demonstrated metal casting techniques for excited crowds at the Dunn County Fair. The young participants got to form, file and finish their own souvenirs while learning about the age-old process.

  • GIFA 2015:

    Sponsored video from Messe Dusseldorf: GIFA is the one of the most important trade fairs for foundry technology in the world. It runs June 16-20, 2015 in Dusseldorf, Germany. Click here for more information. 

  • Tour the Metalcaster of the Year: Aristo Cast:

    See what it means to be 2014 Metalcasting Facility of the Year.

  • Design Details: Cast Ductile Iron Oil Pan by Aarrowcast Inc.:

    Metal Casting Design & Purchasing magazine columnist Jiten Shah points out the unique casting features of the winner of the 2014 Casting of the Year competition.

  • AFS Metalcasting Congress:

    The AFS Metalcasting Congress is an annual technical conference and trade show event that brings together suppliers, foundries and casting customers for the biggest industry event of the year.

    For more information, go to www.metalcastingcongress.org

  • Webinar: Enhancing Aluminum Castings for Structural Applications:

    356 has been the primary aluminum alloy for structural applications in aluminum castings. However, there are easy to cast alloys that can outperform 356 in many applications. This webinar will explore higher strength and higher ductility 300 series alloys, 200 series alloy systems and the exciting development of aluminum casting alloys containing nanoparticles. 

    Presenter: David Weiss-Eck Industries

  • Webinar: To Offshore or Reshore? How to Objectively Decide:

    Harry Moser of the Reshoring Initiative discusses total cost estimating for cast components that takes into consideration research and development, inventory carrying costs and travel costs associated with checking on foreign suppliers. For more information on reshoring castings, click here.

  • 3D Printing at Ford:

    From Ford: See how additive manufacturing(3D printing) is used at Ford Motor Co.

  • AFS's Role in the National Network of Manufacturing Innovation:

    AFS has significant roles in two major manufacturing initiatives announced in February 2014 by President Obama as part of his National Network for Manufacturing Innovation. The new programs are backed by more than $300 million of public and private funds and aim to propel American manufacturing forward by bringing together product developers, researchers, manufacturers, universities and training institutions into regional hubs. The hubs will connect private businesses with research institutions to advance high tech manufacturing. For more information: http://www.afsinc.org/news/news.cfm?ItemNumber=16038

  • What Does Manufacturing Mean to You?:

    From NAM: This video demonstrates the comeback of American manufacturing and the future it holds for all Americans.

  • Performance of Road Bases Using Foundry Sand:

    An EPA-funded research study investigated the use of foundry sand and crushed concrete recycled into road base. Hear the results from the case study.

  • Design Details Transmission Housing:

    Jiten Shah discusses the design features of an aluminum sand cast transmission housing produced by Denison Industries, Denison, Texas.

  • O'Fallon Casting's Growth:

    In its 10 years as O'Fallon Casting, the nonferrous investment caster's annual sales have grown from $10 to $25 million.

  • Performance of Road Bases Using Foundry Sand:

    An EPA-funded research study investigated the use of foundry sand and crushed concrete recycled into road base. Hear the results from the case study.

  • O'Fallon Casting's Growth:

    In its 10 years as O'Fallon Casting, the investment caster's annual sales have grown from $10 to $25 million.

  • 3-D Sand Printing:

    From Hoosier Pattern: The pattern shop's additive manufacturing system selectively dispenses foundry-grade resin into thin layers of specially engineered sand. The process produces accurate, uniform cores and molds rapidly, significantly reducing lead time.

  • Institute's Million Dollar Pledge:

    The AFS Institute has pledged one million dollars to the metalcasting industry to develop and rework its courses and content. The work was ignited by a desire to increase the Institute’s relevance and respond to the industry’s request for shorter, more interactive courses and continue to improve education for the industry.

    Classes for Casting Designers and Buyers

    AFS Institute Page

  • Overview of Designing for Castings:

    Jiten Shah, Product Development & Analysis, discusses methods for designing for metal castings.

  • Busche Machining on Casting Purchasing:

    A CNC machining company discusses its casting supplier relationships. Busche specializes in design, tooling, gauging, and engineering.

  • Casting Design & Purchasing at Bosch Corporation:

    Edward Vinarcik of Bosch Corp., Gerlingen, Germany, discusses his company's casting design and purchasing policies and philosophies and their presence in Europe.

  • Overview of Metalcasting Processes:

    The presentation covers a varity of casting methods including lost foam, green sand and many more.

  • Madison Kipp Hosts Students on Manufacturing Day:

    From Madison Kipp Corporation: Madison-Kipp Corporation,Madison, Wis., hosted a day for area high school students to see how high pressure diecasting transforms molten aluminum into everyday recognizable products as was part of the National Manufacturers Day. The day was established to engage, promote, and encourage young people to choose a career in manufacturing. The students were very interested in the wide range of opportunities available to them as they contemplated their future work and career plans.

  • Wisconsin Lt. Governor Visits Metcast:

    From Wisconsin Lt. Governor Rebecca Kleefisch: Kleefisch visited Metcast, New Berlin, Wis., in September after its announcement of 15 new jobs and a 20,000 sq ft addition. The visit was one of several Kleefisch has planned as a ramp up for October: National Manufacturing Month.

  • What Is AFS?:

    The American Foundry Society (AFS) is a non-profit association serving members of the metalcasting industry both in the United States and abroad. Through various resources, AFS provides members with advocacy coordination and efforts in Washington, D.C., ongoing technical education through its Institute, as well as the transfer of innovative research and technology to the industry.

  • Waukesha Foundry Observes Its Centennial Year:

    From JS Online: As Waukesha Foundry enters its 100th year in business, defense contracting has slowed but the company remains busy making other castings. Video by Mark Hoffman

  • Watts Water Technologies' Lead-Free Facility:

    From Watts Water Technologies: Watts' new lead-free casting facility was completed this summer. This video discusses the construction of the lead-free copper-base alloy plant.

  • Volvo Trucks Cast Iron Hook:

    From Volvo, the president of Volvo Trucks puts his neck on the line in his own exciting stunt showcasting the strength of metalcasting. No trick filming. Just Claes Nilsson, testing the new Volvo FMX.

  • Tonkawa Foundry Profile:

    From Oklahoma HORIZON: Oklahoma is burning hot -- not from the weather, but rather from a golden liquid that creates new and better objects. Tonkawa Foundry is profiled.

  • The Olivine Replacement Project:

    Vic LaFay, research and technical development manager for S&B Industrial Minerals, Cincinnati, outlines three major alternatives to olivine sand for nonferrous sand casters in this video.

  • The Next Generation Thermal Distortion Tester:

    Researchers at Western Michigan University have developed an improved thermal distortion test for nobake molds.

  • Spotlight on Metalcasting:

    The documentary, which currently airs on PBS, educates the audience on the metalcasting process and the positive ways metal castings affect society.

  • Sponsored Video Tour of Premier Aluminum:

    Sponsored video from Premier Aluminum: Premier is an ISO 9001-2008 certified permanent mold aluminum casting and machine shop with a reputation of partnering with its customers to find flexible and cost-effective solutions to a variety of product problems.

  • Social Media With BCI's Wayne Drescher:

    Bremen Casting Inc.'s Wayne Drescher spoke with MCTV at CastExpo'13 in St. Louis about how metalcasters can utilize social media to promote their business.

  • Sivyer Steel's Big Change:

    Sivyer Steel is in the midst of a dramatic transformation. The strategy behind a nearly $12 million capital expenditure begun in 2010 was to become a technological leader through modernization.

  • Simplifying and Improving a Complex Welded Assembly:

    Monarch Industries, Winnipeg, Manitoba, Canada, recently worked with its customer Morris Industries, Saskatoon, Saskatchewan, Canada, to convert a family of six weldments into machined D65-45-12 ductile iron castings.

  • Science Achievers Meet Metalcasting:

    From Colin Parsons on vimeo: Students from a program through the Museum of Science and Industry in Chicago work with the AFS Foundry in a Box kit.

  • Saguenay Foundry on Business Day with Terry Bradshaw:

    From Saguenay Foundry: The metalcasting facility and its Nopatech® process were showcased on Business Day with Terry Bradshaw.

  • Respirator Safety:

    From the U.S. Department of Labor: When employees must wear a respirator to protect against airborne contaminants, they should follow the proper procedures for putting it on and taking it off.

  • Process Knowledge:

    Failed castings, whether occurring as internal or external scrap or rework, become a significant operating cost that could be reduced by controlling the variables critical to specific parts. Dr. Hathibelagal Roshan, Maynard Steel Casting Co., discusses how to acquire process knowledge to reduce costs in this video.

    For more on the subject, read Roshan's article in Modern Casting.

  • Pricing and the CEO:

    MODERN CASTING columnist Dan Marcus, TDC Consulting Inc., shares his views on pricing castings for the market.

  • Precision Sand Casting:

    From General Foundry Service, San Leandro, Calif., this video illustrates its precision sand casting process.

  • Pittsburg State's 12th ICI Certification Course:

    From Pittsburg State University: The 30 participants in the 12th annual Investment Casting Institute's industry certification course at Pittsburg State came from all over the U.S. and countries such as New Zealand, Belgium, Turkey and Mexico in June 2012. Read the rest of the story at www.pittstate.edu/news/casting-institute-draws-from-around-the-world.

  • O'Fallon's Casting of the Year:

    The elegant investment cast electronics housing incorporates dozens of as-cast features and serves as a stunning example of what is possible in design.

  • Nondestructive Testing Methods:

    See how ultrasonic, magnetic particle and liquid penetrant dye inspection methods are performed.

  • Modified Cone Jolt Test:

    Researchers at Western Michigan University demonstrate the modified cone jolt test.

  • MIT Introduction to Lean Six Sigma Methods:

    From Massachusetts Institute of Technology: Two MIT OPENCOURSEWARE sessions introduce students to six sigma methods.

  • Metalcasting Pouring:

    MODERN CASTING shares molten metal pouring shots from various staff visits to metalcasting facilities across North America.

  • ME Elecmetal In Demand:

    MODERN CASTING profiled ME Elecmetal in its January 2013 issue. The steel casting company has recently completed a $42 million plant optimization to meet the demand in the mining and minerals processing industries.

  • May/June 2013 MCDP Editorial:

    Al Spada, publisher of Metal Casting Design & Purchasing, gives a video editorial for the May/June 2013 issue.

  • Linear Mold Handling at Buck Co.:

    From Hunter Foundry Machinery, the linear mold handling line in operation at Buck Company in Pennsylvania.

  • Kinze 4900 Series Planter:

    From Kinze Manufacturing: This brand new planter helps farmers plant seeds more accurately and at faster speeds. Its planter row unit features a new ductile iron cast design and was converted from a 30 stamped steel parts to six castings.

  • June 2013 Modern Casting Editorial:

    Publisher Alfred Spada discusses the magazine's new Actable app features.

  • Installing Cast Aluminum Halves of Plasma Dynamo Experiment:

    From University of Wisconsin-Madison: Professor Cary Forest and his team supervise as the two cast aluminum halves of the plasma dynamo experiment are moved into Sterling Hall. The experiment will investigate how magnetic fields are generated.

  • Hunter HLM10:

    Sponsored video from Hunter Foundry Machinery: the New HLM-10 Linear Motion Machine, the first of Hunter's new product line.

  • Global Casting Trends:

    Alfred Spada, AFS director of marketing and publisher of MODERN CASTING, gave a presentation on global casting trends and markets at Metals China 2012.

  • Foundry by Composer John Mackey:

    Composer John Mackey created this musical piece that middle and high school bands could play with found percussion. The result invokes plenty of metalcasting imagery.

  • FANG Challenge:

    From DARPA TV, The U.S. Defense Advanced Research Projects Agency (DARPA) launched a challenge to design a next generation military ground vehicle. The winning design will be built by the DARPA Instant Foundry Adaptive through Bits program.

  • Engaging Your Workforce:

    Dennis Dotson, chairman for Dotson Iron Castings, Mankato, Minn., discusses how to engage your workforce to improve operations.

  • Electronics Housing's Design Details:

    Design engineering consultant and author Jiten Shah, Product Development and Analysis, points out design elements in an investment cast aluminum electronics housing that aided in improved castability and resulted in multiple features cast into the part.

  • Diecasting:

    SME produced this short overview of the diecasting process as part of the organization's Fundamental Manufacturing Processes video series.

  • Coordinate Measurement Machine (CMM) Inspection:

    From General Foundry Service, San Leandro, Calif., this video shows coordinate measurement machine (CMM) inspection of an aluminum casting that has been machined on a CNC vertical machining center and a CNC lathe to very close tolerances.

  • Coldbox Coremaking at Waupaca:

    From Waupaca Foundry: This video shows the coldbox coremaking process in detail that is used at Waupaca Foundry's iron casting facilities.

  • Changes in Steel Scrap Charge Material:

    Current steel alloy trends may have an impact on cast iron metallurgy.

  • CFD Modeling of Da Vinci's Horse:

    For 17 years, Leonardo Da Vinci researched how to produce Il Cavallo, a huge equine statue to be made out of bronze in a single pour. But when he finally had the clay model built and ready to be cast, all the needed bronze was taken to be used for a war against France. The mold and model were destroyed, and the statue was Da Vinci’s “horse that never was.” Despite Da Vinci’s confidence in the design, however, many engineers believed the casting would never have been successful any way. Recent advances in casting simulation technology provided a way to prove Da Vinci right. The Institute and Museum of the History of Science in Florence, Italy, sought to test DaVinci’s design and worked with XC Engineering (an Italian associate of Flow Science, Santa Fe., N.M.) and IMSS - Museo Galileo to conduct a casting simulation for the artwork. The result: Da Vinci’s 24-ft.-high, 70-ton bronze horse would have been successfully cast in a single pour in 165 seconds.

  • Casting Buyers Speak Out:

    Casting purchasers Rex Harrison, Oshkosh Corp., and Roberta Brecheisen, Haldex Corp., discuss their sourcing strategies with Metal Casting Design & Purchasing magazine.

  • Casting 200 Series Aluminum:

    David Weiss of Eck Industries discusses control methods for casting 200 series aluminum and how they can improve properties of 300 series aluminum castings, as well.

  • CastExpo Man on the Street:

    Hear what a few CastExpo attendees had to say about this year's show in St. Louis.

  • CastExpo '13 Exhibitor News:

    Vulcan's VTS robotic technology, Bruker's radiation detection device and Hunter's new molding machine are highlighted.

  • Automatic Sand Molding at Bremen Castings:

    From Bremen Castings Inc., Bremen, Ind., this video shows a cored job running on a Hunter match plate 20x24 at its green sand molding facility.

  • Automated Molding at General Foundry:

    From General Foundry Service, San Leandro, Calif., this video shows its automated sand molding process using a Hunter molding machine.

  • An Alternative Method to the Methylene Blue Clay Test:

    Researchers at Western Michigan University developed a new test to measure active clay content in green sand using spectrophotometry.

  • 2013 AFS/MCDP Casting Competition:

    Who won this year's casting competition? Who were best-in-class and honorable mention honorees? Watch the video to find out.

  • 116th Metalcasting Congress:

    More than 2,200 metalcasters convened in Columbus, Ohio, April 17-20, 2012, for the 116th Metalcasting Congress to touch base with suppliers and peers, hear the latest research and trends reports, and congratulate industry award winners.

Metalcasting is Advanced Technology

Congress Screen Cap

 

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