Nonferrous Track

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


Saturday, April 16

8 a.m.-9 a.m.

Clean Metal Processing (16-107)
Copper • All processes
Gregory Svoboda, I Schumann & Co.; David Williams, ASI International Ltd. 

This panel will go over quality melting procedures to ensure your copper alloys are melted and poured as clean as possible.

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

Quality Pouring Practices to Achieve Clean Castings (16-108)
Copper • Sand and permanent mold
Sam Scott, ESI North America, Farmington Hills, Mich.; James Schmahl, Selee Corp.

This panel will discuss the effects of turbulence on the quality of a casting as well as the proper selection and use of filters.

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.

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

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.

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

Concepts and Experiences With Thermal Analysis of Aluminum Alloys for Assessing Grain Refinement and Eutectic Modification Effectiveness (16-105)
Aluminum • All processes
Brian Began, Foseco; Geoffrey Sigworth, GKS Engineering Services 

In this panel, the history of thermal analysis and its practical applications will be reviewed. Suggestions will also be given for possible future improvements in the technology.

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 • Sand, investment and lost foam
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. 

A Novel Approach for the Assessment of Eutectic Si Modification and Tensile Properties of Al-Si Cast Alloys (16-116) 
Aluminum • All processes
Mohammadreza Zamani, Jönköping University

The author will present a correlation between the depression in eutectic growth temperature as a result of modification, and the tensile properties of Al-Si cast alloys. 

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.

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. This presentation will relate the physical, mechanical, and thermo-mechanical properties of disc-shaped core specimens. 

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 about 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.

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.

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. The technology can be a 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.

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 in low pressure diecasting (permanent mold).

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

This session will show examples of high pressure die castings where autonomous optimization options were utilized to resolve casting defect issues.

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.