Molding & Finishing Track

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 (AM).

Thermo-Physical Properties of Some Lost Foam Glues (16-160) 
Iron and aluminum • Lost foam
John Griffin, University of Alabama at Birmingham

Thermo-physical analysis of lost foam glues can provide quantitative information on the characteristics during decomposition. If the specific characteristics that identify an acceptable glue can be established, this information can be used for quality control and to improve glue performance in the future.

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. Lost foam casting has been shown to result in carbide free, normal nodularity microstructures with section sizes down to 0.100 in. with a potential to be even thinner. Several production examples will be reviewed.

Lost Foam Casting of Magnesium Based Alloys (16-157)
Magnesium • Lost foam
Yemi Fasoyinu, CanmetMATERIALS

A project focusing on the development of a lost foam casting process for magnesium alloys established the effects of various casting process variables.

Molding Methods & Materials Silver Anniversary Lecture: Methylene Blue Determination of Clay: It’s Not Your Father’s Test Anymore (16-004) 
All metals • Sand
Vic LaFay & Stephen Neltner, IMERYS

The evaluation of foundry clays has come a long way since 1990 when the original paper was presented at the AFS Casting Congress. The evaluation of green sand molding properties with the additional contribution of the Methylene Blue testing protocol has allowed metalcasting facilities to apply laboratory information to the successful running of their operations.

Traceability of Height Measurements on Green Sand Molds Using 3D-Optical Scanning (16-033) 
All metals • Green sand
Kamran Mohaghegh, Seyed Alireza Yazdanbakhsh, Niels Skat Tiedje & Leonardo De Chiffre, Technical University of Denmark

The surface of the green sand mold is not suitable for measurements using a tactile coordinate measuring machine. A metrological approach for measurement on green sand molds using an optical 3D scanner will be presented. 

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

Applications of an Inorganic Geopolymer Binder System for a Sustainable Future (16-063) 
All metals • Sand
Andrew Tagg, John Winter & Co., Ltd.

Geopol, a unique geopolymeric modified sodium silicate nobake binder system, contains no VOCs, resulting in virtually no emissions to the metalcasting environment during molding, pouring or shakeout. The presentation will explain the technology of the process and share recent developments in sand reclamation, with case studies in Europe and North America.

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.

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. 

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.

Data on the Performance Effect of Blow Tube Design (16-052) 
All metals • Sand
Andrew Pike, Jesus Benavente & Kathleen Lowe, ASK Chemicals

Cores blown with both straight and neck-down blow tubes under controlled laboratory conditions were analyzed and compared by high speed photography, core weight recordings, and visual observations. The data gathered shows that minimal design choices, such as blow tube type, can have a significant impact on core quality.

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

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.

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. 

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.

Benefits of the Amine Recovery Process for Sustainable Foundries (16-044) 
All metals • Sand
Sritama Kar, Greg Sturtz & Matthew Hartman, ASK Chemicals

Amine catalyzed cold box coremaking systems are the most popular high productivity core making processes in the world but comes with an objectionable odor. Today, recovery of amines from spent scrubber solutions is widely practiced. The purpose of this presentation is to explain how the amine recovery process technology operates and how foundries can efficiently run their amine scrubber.

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. Topics will include preparation and handling, control and application, results and troubleshooting. 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

Recent years have shown major advances in our understanding of veining and related casting defects. 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.

PANEL: 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.

Low Pressure Diecasting Simulation Discovery Through Short Shot (16-045) 
Nonferrous • Permanent mold, diecasting
Melissa Carter, Flow Science Inc.; Tim Kauffung, Lucas Weyenberg & Chris Peters, Versevo Inc.

The low pressure diecasting (permanent mold) process is used for high yield and high mechanical properties for various types of parts. This paper will focus on how to apply the correct assumptions and boundary conditions to the simulation software in order to accurately predict the correct input parameters.

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.

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

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

A 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. 

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.

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.