Ferrous Track

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

Saturday, April 16

8 a.m.-9 a.m.

Energy Conservation at Grede Foundry (16-174)
All metals • All processes
Larry Foreman, Grede Holdings LLC

This presentation will describe how Grede reduced energy use and provide practical suggestions for saving energy in melting and other foundry processes.

Channel Furnace Start-up—“Controlling” Predictability During Commissioning (16-072)
Iron and steel • All processes
Timothy Hoyt, Allied Mineral Products Inc.; Richard Falkowski, United Refractories

This presentation is an overview of the basics regarding form design and refractory composition, selection and properties, including the importance of refractory conditioning and proper introduction of the metal.

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

Steel Produced by the Lost Foam Casting Method (16-101) 
Iron and aluminum • Lost foam
Mark DeBruin, Flowserve Corp.; Sarah Jordan, DeBruin Consulting 

Proper lost foam casting technology process adjustments to compensate for the higher melting point of steel results in zero degradation in properties and improved surface roughness and dimensionality compared to green sand or resin-bonded sand methods. 

Thin-Walled Ductile Iron Produced by Lost Foam Casting (16-159) 
Iron • Lost foam
Sarah Jordan, DeBruin Consulting

Continual pressure to reduce the weight of engineered casting designs has led to significant investment into various methods of making thin walled ductile iron. Several production examples will be reviewed.

Melt Safety 2016—Keeping It Real! (16-111)
All metals • All processes
Michael Looby, Inductotherm Corp.; Johnny Hill, Martin Foundry; Mark Muszynski, Waupaca Foundry Inc.

The melting, transfer, holding, and pouring of molten metal create numerous safety challenges 24/7. These panel presentations will discuss key criteria for coreless, channel and cupola furnace operation. 

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

Graphite Morphology (16-110)
Iron • Sand 
Dileep Singh, Argonne National Laboratory; Serge Grenier, Rio Tinto Iron and Titanium, Technology Center

The morphology of graphite plays a critical role in determining the physical properties of cast irons. This panel discussion will explore two modern methods for determining graphite morphology, computer aided image analysis and high energy X-ray tomography. 

Cupola Horizons: Topics for Future Discussions (16-112)
All metals • All processes
Kyle Metzloff, University of Wisconsin/Platteville; Jeet Radia, McWane Inc.; Robert Fechner, Kuttner North Americ

As metalcasting technology evolves, the future of cupola melting remains bright. This panel will discuss the managerial and economic decisions to implement state of the art cupola technologies focusing on investment returns, energy efficiency and low cost iron production. 

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. 

Participants will present defects they have combatted and solutions they have found to anticipate and minimize or eliminate the future formations of the defect.

Practical Coreless Induction Furnace Issues (16-113)
Iron • Sand
Michael Becker, Allied Mineral Products Inc.; Todd Lyles, Specialty Foundry Products Inc.; Jerry Holcombe, Reno Refractories Inc.; David Williams, ASI International Ltd. 

This panel will discuss coreless induction melting topics with an emphasis on safe furnace operation. 

Sunday, April 17

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

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 engineering and technical purchasing communities may benefit from properly specified and certified ADI 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.

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

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

The presenter 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. 

Best Practices—Make Your Refractory Coating Work for You (16-097)
All metals • Sand
Jeffrey Cieplewski, Prince Minerals LLC; Tim Maurina, C A Lawton Co.; Fritz Meyer, ASK Chemicals; Mitchell Patterson, HA International LLC

Join this interactive discussion about refractory coating use in the foundry with emphasis on production considerations in optimizing a core and mold coating operation. At the end, a confidential industry information survey on the use of refractory coatings will be collected for future work by the AFS 4F Committee.

Veining Test Castings and Effects of Process Variables (16-014) 
Nonferrous • Sand
Paula Vivas, Eric Scheller & Ralph Showman, ASK Chemicals

This panel will explore the impact of typical casting-process variables on veining and other casting defects. Comparative tests conducted on different binder systems and strength levels will provide insights into controlling veining defects.

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

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 

Panelists will present on the data collection and testing process used to create the Strain Life Fatigue 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. It can be a valuable tool for dimensional reporting and comparison of tooling, castings and cores.  

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.

The research presented here will summarize technical literature on the effects of sulfur in cast irons and cover  new, experimental work on the inter-relationships between sulfur amd 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. 

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

Non-Destructive Testing for Aging in Gray Cast Iron (16-017) 
Iron • Sand
Kevin Kuehl, Matthew Schultz & Nickolas Meyer, Waupaca Foundry

While prior research has indicated an increase in strength from aging in gray cast iron, tensile testing does not have the precision required to detect small changes in value. Non-destructive techniques of resonant frequency and ultrasonic velocity testing demonstrated very good precision, and were able to detect small changes resulting from room temperature aging. 

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. 

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. Existing literature on the application of resonance inspection of cast iron will be reviewed and critical issues for future research will be discussed.

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, IMERYS

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 

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 

In this research, a new gas evolution test 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 Universit

Previous work and theoretical considerations have indicated that niobium oxides could act as a heterogeneous nuclei for plain carbon steels. 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 

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

Molding materials such as chromite, zircon, and mullite all exhibit low expansion leading to fewer casting defects related to expansion and better dimensional accuracy. Although some applications require 100% specialty sands, a significant amount needs only modest improvements to yield significant benefits.

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

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

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.