Casting Design & Purchasing

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

Saturday, April 16

1:30 p.m.-3 p.m. 

Roundtable: Casting Defects in Copper Based Alloys (16-109)
Copper • Sand and permanent mold
Michael Jones, Ford Meter Box Co. Inc.; Geary Smith, G & W Electric Co.; Andy Shea, A.Y. McDonald Mfg. Co.; Jeff Sorenson, I Schumann & Co. 

Bring your defect or a picture of it and our selected panelist will attempt to solve it along with participation from the audience.

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. 

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

Roundtable: Defect Solution Forum (16-102)
Iron • Sand
Andrew Adams, Foseco; Courtney Burden, Waupaca Foundry-Tell City; Tyler Ferrell, Pier Foundry; Lizeth Medina-Alatorre, Neenah Enterprises, Inc.; Ron Spencer, Rochester Metals Products; Mark Osborne, American Castings LLC; Josh Keller, Bremen Castings Inc. 

The participants in this forum will present defects they have combatted and solutions they have found to anticipate and minimize or eliminate the future formations of the defect.

PANEL: 10 Questions Buyers Should Be Asking Casting Suppliers to Find the Right One for Them (16-152)
All metals • All processes
Tom Kayser, Osco Industries Inc.; Chris Witt, Dotson Iron Castings; Vasko Popovski, Applied Process Inc. 

Casting buyers can make better deals by asking the right questions of their current and potential casting suppliers. This panel will help buyers get the answers they need for more optimal sourcing of castings.

Sunday, April 17

8 a.m.-9 a.m.

Significantly Reducing Common Casting Issues in Permeable Molds by Casting Under Pressure (16-115) 
All metals • Permanent mold
Randy Oehrlein, Carley Foundry Inc.

In porous media molds, solidifying under gas pressure is a little used yet powerful way to address fundamental quality issues in castings. When the technique is coupled with conductive inert gasses, its effectiveness is increased due to faster solidification times and partial suppression of burning elements in the mold. 

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

Reduction of Oxide Inclusions in Aluminum Cylinder Heads Through Autonomous Design of Experiments (16-093) 
Aluminum • Sand
Steve Sikorski, MAGMA Foundry Technologies Inc.

In the case of aluminum cylinder heads, the utilization of advanced software technology allowed for an autonomous design of experiments (autonomous DOE) to be carried out, which provided the basis for the evaluation and subsequent optimization of process parameters and geometry in the melt transport, pouring process and gating layout. 

Methods for the Improvement of Ductility in an E357 Aluminum Alloy (16-145) 
Aluminum • Sand
David Weiss, Eck Industries, Inc.; Thomas Wood, Michigan Technological University

This presentation will explore the use of manganese and cobalt to modify the morphology of the iron-rich phases in aluminum-silicon alloys (357 type) as well as the relationship of silicon modification with strontium and silicon level to intermetallic formation and ductility.

Austempered Ductile Iron—Beyond the Standard (16-098) 
Iron • Sand
John Keough, Kathy Hayrynen, & Vasko Popovski, Applied Process Inc.; Justin Lefevre, Joyworks LLC

The authors will explore the critical issues related to substandard and properly made austempered ductile iron (ADI) so both the engineering and technical purchasing communities may benefit from properly specified and certified ADI components in order to avoid the potential downside risks associated with substandard components.

High Strength Ductile Iron Produced by Engineered Cooling: Application for Different Casting Processes (16-048) 
Iron • Sand
Simon Lekakh, Brenton Hrebec, Robby Scott, & Joshua Schlobohm, Missouri University of Science and Technology

The development of high strength ductile iron castings in as-cast conditions by applying an engineered cooling will be investigated in this session. The possible strengthening level as well as process limitations will be discussed.

Additive Manufacturing (16-151)
All  metals • All processes
Oliver Johnson, Tooling and Equipment International Corp; Aaron Kepler, Caterpillar Inc.; Jerry Thiel, University of Northern Iowa, Metal Casting Center

Practical use of additive manufacturing currently used in the metalcasting facility and what’s coming in the future will be discussed.

Predicting Casting Dimensions With Computer Process Modeling (16-076) 
All metals • All processes
Jerry Thiel, Sairam Ravi, University of Northern Iowa, Metal Casting Center

Research has detailed a methodology using computer process modeling to accurately determine casting dimensions from room temperature pattern dimensions. As the ability of creating castings true to designs improves, reductions in machine stock can be made to decrease cost, improve reliability and speed production.

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

Workshop on Aluminum and Aluminum Casting Alloys (16-126) 
Aluminum • All processes
Geoffrey Sigworth, GKS Engineering Services

This workshop is intended for casting buyers and design engineers who wish to learn more about the production and casting of aluminum, and the properties of aluminum castings. It will provide a detailed overview of alloys, including the effects of impurities and undesirable “tramp” elements, heat treatment and temper designations. 

Honorary Lecture: The Stuff Matters (16-114) 
Iron • All processes
John Keough, Applied Process Inc.

The concept of “green” has morphed into a catch-all category for anything that either reduces human consumption or effluent into the air or water. The author will use real-world case studies from familiar fields of investigation (including cast iron) to foster a “life cycle” energy perspective and, perhaps, positively affect the thinking of engineers and designers in their work. 

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

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.

3D Scanning: Developing Industry Accepted Methodology (16-149)
All metals • All processes
Nick Fox, Galesburg Castings Inc.; Shaun Thomas, Dotson Foundry; Ron Spencer, Rochester Metals Products

This panel will give an update on the development of a uniform method of implementing 3D scanning technology throughout the industry. By understanding the issues in repeatability and reporting, the technology can be an even more valuable tool for dimensional reporting and comparison of tooling, castings and cores.  

Monday, April 18

8 a.m.-9 a.m.

Autonomous Optimization of Die Casting Processes (16-040) 
Nonferrous • Diecasting
Deepika Gaddam, MAGMA Foundry Technologies Inc.

Autonomous optimization is a new casting process simulation tool that can complement, and potentially replace, traditional manual simulation options. This session will show examples of high pressure die castings where autonomous optimization options were utilized to resolve casting defect issues.

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

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.

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. By integrating and implementing improved methods and alloys, wall thicknesses of ductile iron cast parts can potentially be decreased by up to 50%, thus enabling light weighting of transportation components by 30%-50%, depending on component loading.

Application of Resonance Inspection to Cast Iron—Literature Review (16-053) 
Iron • Sand
Siddhartha Biswas & Charles Monroe, University of Alabama at Birmingham

Resonance inspection is gaining popularity in the cast iron industry for its faster result output. To understand the current status and achieve future developments, the existing literature containing the application of resonance inspection of cast iron will be reviewed and critical issues for future research in the area of resonance inspection and defect identification will be discussed.

Casting of the Year—Optimized Casting Design (16-153)
All metals • All processes
John Grassi, Alotech Inc.; James Clifford, Aarrowcast Inc.; Duane Rice, Pier Foundry & Pattern Shop 

Every year, AFS recognizes excellence in casting design and production with the Casting of the Year award. These metalcasters have produced innovative casting designs that showcase the capabilities of the industry.

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. 

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. 

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

Casting Inspection Measurement and Machining (16-150)
All metals • All processes
Frank Peters, Iowa State University; Jiten Shah, Product Development & Analysis LLC; Andy Bowman, Caterpillar Inc.

The panel will discuss visual casting inspection, how good it is and the development of inspection standards and adaptive machining fixtures. A scanned casting versus a coordinate measuring machine dimensional layout of a casting will be compared for PPAP. 

Factors and Trends in Casting Sourcing (16-154)
All metals • All processes
Chuck Denn, DeZurik Inc.; Tom Edwards, Gardner Denver Inc.; Keith Wetzel, Bradley Pulverizer Co.

Purchasing professionals from medium-sized U.S. manufacturers will describe their experiences and concerns in sourcing castings. Topics will relate to reduced domestic options, tradeoffs in off-shoring, and how domestic suppliers can promote their “non-price reasons to buy.”  

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. 

Autonomous Optimization of Gating and Risering Design for Steel Castings (16-039) 
Steel • Sand
Roy Stevenson, MAGMA Foundry Technologies Inc.

Casting engineers use process simulation technology to design tooling and select process parameters for the steel casting process. This session will detail a novel simulation software, autonomous optimization which greatly reduces the amount of time required to set up and analyze individual simulations.