Developing/Advanced Technology

Saturday, April 16 Sunday, April 17 Monday, April 18

Saturday, April 16

8 a.m.-9 a.m.

3D Fused Filament Forming of Lost Foam Tooling (16-158)
Iron and aluminum • Lost foam
Marshall Miller, Flowserve

Gain insight into the potential of using printed polymers for lost foam equipment through the use of additive manufacturing.

1:30 p.m.-3 p.m.

Accelerated Adoption of Additive Manufacturing Technology in the American Foundry Industry (16-061)
All metals • All processes
Jerry Thiel, University of Northern Iowa, Metal Casting Center; Jiten Shah, Product Development & Analysis LLC; Brandon Lamoncha, Humtown Products 

The panel will share the progress of America Makes, a collaborative teaching, learning, and additive manufacturing center, focused on introducing additive manufacturing throughout the foundry industry, with a primary objective of achieving enhanced economic development. 

Sunday, April 17

8 a.m.-9 a.m.

Microwave Reclamation of Foundry Sand (16-031)
All metals • Sand
Milt Mathis, M-Wave Consulting; Joseph Plunger, Midwest Metal Products Inc.

Microwave technology potentially offers the metalcasting industry an energy efficient and low emission system for sand reclamation while leaving the sand relatively cool. Prototype units are currently being run for nobake and green sand reclamation and both methods will be discussed, as well overall efficiency and robustness of the concept.

9:15 a.m.-10:15 a.m.

Evaluating a High Production Eco-Friendly Core Binder System for Aluminum (16-067)
Aluminum • Sand
Sam Ramrattan, Western Michigan University; Tatsuyuki Aoki, Hiroyasu Makino, Sintokogio Ltd.

A sustainable polysaccharide sand binder system was developed for a modified injection molding process. The injection molded cores are designed for aluminum casting technology. This presentation will relate the physical, mechanical, and thermo-mechanical properties of disc-shaped core specimens. 

3:15 p.m.-4:45 p.m.

Alternative Modification of A356 Hypoeutectic Alloy by Ca-Si-Ba Additions (16-086)
Aluminum • All metals
Alexandre Bois-Brochu & Gheorghe Marin, Quebec Metallurgy Centre; Francis Breton, Rio Tinto Alcan

Hypoeutectic aluminum alloys such as A356.0 (Al-7Si-0.3Mg) are usually subjected to strontium additions in order to obtain a chemically modified eutectic morphology. In research shared in this session, it has been found that a fully modified microstructure can be obtained through Ca-Si-Ba additions.  

Metallurgical Properties Inside a Sand Molded Aluminum 206 Casting (16-002)
Aluminum • Sand
Franco Chiesa, David Levasseur & Jeremy Carignan, Centre de Métallurgie du Québec; Bernard Duchesne, Collège de Trois-Rivières 

This presentation will share the results of a  metallurgical study of aluminum alloy 206 in the T4 and T7 condition.

Effect of Bismuth and Calcium Additions on the Performance of B319 Al Cast Alloy (16-096)
Aluminum • All processes
Waleed Khalifa, Cairo University; Herbert Doty, General Motors; Salvador Valtierra Gallardo, Corporativo Nemak, S.A.; Fawzy Samuel, Université du Québec à Chicoutimi 

The effect of bismuth and calcium additions on the microstructural characteristics and the tensile properties of the modified and grain-refined B319-alloys as well as that of solution and aging treatments on the same will be shared. Based on the results of recent research, bismuth was found to be an efficient solid-solution strengthening element for these alloys.

The Background, Use and Application of the Cast Iron Strain Life Fatigue Database (16-090)
Iron • Sand
John Tartaglia, Element Materials Technology; Jiten Shah, Product Development & Analysis LLC; Tony Lindert, Oshkosh Corporation 

Over many years, the Strain Life Fatigue database has been populated to aid design engineers in the development of new product. Panelists will present on the data collection and testing process used to create the database. They also will cover how to use this information in design applications along with OEM practical examples.

Monday, April 18

8 a.m.-9 a.m.

On the Nucleation of Graphite in Lamellar Graphite Cast Iron (16-020)
Iron • Sand
Gorka Alonso, Pello Larranaga & Esther De la Fuente, IK-4 Azterlan;; Ramon Suarez & Doru Stefanescu, University of Alabama & The Ohio State University; Ramon Suarez, IK4-Azterlan & Veigalan Estudio

Quenching experiments at successive stages during solidification of gray cast iron with various sulfur and titanium levels were carried out to determine the effect of these elements on the nucleation of graphite in its lamellar and superfine morphology.

Demystifying the Role of Sulfur in Cast Irons (16-080)
Iron • Sand
Iulian Riposan, Mihai Chisamera, Stelian Stan, Valentin Uta, Ion Cuza Stefan, & Mihail Ciprian Firican, POLITEHNICA University of Bucharest; Rodney Naro & David Williams, ASI International Ltd.

Sulfur is a key element in graphite nucleation in all cast irons, and its effect varies greatly depending on the presence of Group IIA, IIIB, IVB and III A elements in the periodic table. This presentation will summarize much technical literature on the effects of sulfur in cast irons plus new, experimental work on the inter-relationships between sulfur with other graphitizing elements.

9:15 a.m.-10:15 a.m.

Influence of Mn and S on the Microstructure of Cast Iron, an AFS Funded and Monitored Research (16-163) 
Iron • Sand
Richard Gundlach, Element Materials Technology.

A recent review of the literature suggests that, to achieve optimum strength and resistance to chill, manganese and sulfur should be balanced according to MnS solubility. 

Maintenance and R&D Cost Recovery (16-147)
All metals • All processes
Lester Cook, KBKG; Michael Maroney, KBKG, Inc.; Brian Reinke, TDI Energy Solutions

The panel will review and discuss an alternative approach that may allow you to take such expenses as furnace relining, maintenance and other capital equipment in the year they are incurred.

Expanding the Envelope of Precision Casting (16-079) 
All metals • Investment casting
James Collins, Castings Technology International

This session will give an introduction of an advanced investment casting process and technology. The research can be used to manufacture large-scale ceramic shell investment castings in both ferrous and nonferrous alloys.

1:30 p.m.-3 p.m.

LIFT (Lightweight Innovation for Tomorrow) Thin Wall Ferrous Casting Project (16-165) 
Iron • Sand
Thomas Prucha, AFS

This project is investigating very thin-walled ferrous castings (<2mm wall), focusing on the manufacturing process development required to bring thin wall, vertically-molded green sand ductile iron castings to high volume production. 

Improving Casting Quality and Productivity Through the Application of a High Efficiency, Engineered Lustrous Carbon Former (16-057) 
All metals • Sand
Nick Richardson; Vic LaFay, IMERYSA properly designed lustrous carbon former for the foundry industry can be engineered through the selection and blending of high efficiency coals.

This presentation will demonstrate how the conversion of a sand system was performed, resulting in improved casting quality measured in scrap reduction and improved productivity.

Non-Standard Testing to Qualify 3D Printed Sands (16-066) 
All metals • Sand
Sam Ramrattan, Western Michigan University; Terrence Senish & Mihaela Nastac, ExOne 

Three-dimensional (3D) printing provides the flexibility and ease of reproducing the sand mold directly from CAD models. This eliminates the laborious pattern making steps, thus reducing total time to casting. The purpose of this study is to characterize post cured 3D printed silica sand specimens with non-standard tests designed to measure the physical, mechanical and thermo-mechanical properties as required for castability. 

New Method for Measuring Gas Evolution in Chemically Bonded Sands (16-058) 
All metals • Sand
Sairam Ravi & Jerry Thiel, University of Northern Iowa, Metal Casting Center 

The gas evolution test has been a valuable tool in determining the volume and pressure of gas emitted by chemically bonded sands during the pouring operations. In this research, a new method was developed which uses a thermos gravimetric analysis unit in conjunction with the atomic weights of the gaseous products to calculate the gas volume and associated gas pressure based on the mold or core permeability. 

Strengthening Mechanism in 1030 Steel by Niobium Oxides (16-021) 
Steel • Sand
Robert Tuttle, Saginaw Valley State University

Previous work and theoretical considerations have indicated that niobium oxides could act as a heterogeneous nuclei for plain carbon steels. However, niobium has been well documented to increase steel strength by a precipitation hardening mechanism. This work was done to confirm earlier results and determine if the strengthening mechanism was from grain refinement or another mechanism. 

Steel-Refractory Interactions and Elimination of Phosphorous Pickup During Melting of High Manganese and Aluminum Steels (16-047) 
Steel • Sand
Riazur Rahman & Laura Bartlett, Texas State University 

High manganese and aluminum steels are up to 18% less dense than quenched and tempered chromium and molybdenum steels, with comparable strengths and up to seven times the dynamic fracture toughness. The current study investigates the interaction between two commercially available refractories and a high manganese and aluminum steel during melting and casting. 

The Use of Specialty Sand Blends to Reduce Veining Defects in Steel Castings (16-060) 
Steel • Sand
Sairam Ravi & Jerry Thiel, University of Northern Iowa, Metal Casting Center

It’s been well established that molding materials such as chromite, zircon, and mullite all exhibit low expansion leading to fewer casting defects related to expansion and better dimensional accuracy. They also have refractory values significantly higher than silica sands. Although some casting applications require the use of 100% specialty sands, a significant amount requires only modest improvements to yield significant casting quality benefits.

3:15 p.m.-4:45 p.m.

Characterization of Cast Al-Si Alloys (16-146)
Aluminum • All processes
Robin Foley, Charles Monroe & John Griffin, University of Alabama at Birmingham; David Neff, retired

The importance and application of microstructural characteristics—grain size, silicon modification, and SDAS—of cast aluminum silicon alloys will be discussed as these factors pertain to the understanding of casting properties.

Metallographic Studies on the Intermetallic Phases in the Al-Si Near Eutectic and Eutectic Alloys (16-095) 
Aluminum • All processes 
Agnes Samuel & Fawzy Samuel, Université du Québec à Chicoutimi; Herbert Doty, General Motors; Salvador Valtierra Gallardo, Corporativo Nemak, S.A. 

This research was performed on experimental Al-Si near eutectic cast alloys, with different additives, mainly Fe, Mg, Mn, Cr, Sr and P. The alloys were cooled at 0.8C/s, precipitated phases were examined and chemical composition of each phase was confirmed using electron probe microanalyzer. 

Castability Improvements of Stainless Steels Within the Material Specifications (16-013) 
Steel • Sand
Delin Li, CanmetMATERIALS; Clayton Sloss, Wescast Industries Inc.

General effects of alloying elements in stainless steels are well documented, and the lower and upper limits of chemical compositions are specified in the material specifications for stainless steels. In the present work, two grades of cast stainless steels CF8C and HF were taken as an example to review the discrepancies among the material specifications and to investigate the influences of the lower and upper specification limits within the specifications.