Technical and Management

Research & Development

Support of research is critical for North America to maintain a strong, vibrant, healthy and continually advancing metalcasting industry. Part of AFS' mission is to promote these activities for the betterment of our membership, our industry and our society.

AFS directly funds research projects from allocation of a portion of the annual dues paid by AFS Corporate Membership. The current AFS Funded Research Projects are described below. The other projects are funded through research partnerships, government funding and industry contributions. AFS participates in these projects by securing industry partners and providing technical management and oversight.

AFS Funded & Monitored Research

Nine projects are currently being funded through the allocation of a portion of the AFS Corporate Member Dues in FY2014-2015:

  • New Technique for Measurement of Active Clay in Green Sand
  • Advanced Metrics to Assess Sand Binder Emission
  • High Strength Cast Iron Castings Produced by Engineered Cooling
  • Reclamation of Investment Casting Shell Materials
  • Development of Ultra-High Strength Light Weight Al-Si Alloys
  • Helium-Enhanced Semi-Permanent Mold Aluminum Casting
  • Reducing Energy Costs through Real-Time Monitoring and Assessment
  • Influence of Mn and S on the Mechanical Properties of Cast Iron
  • NDT & Microsstructure Correlations to Gray Iron Aging

Metalcasting Industry Funded & Monitored Research

Metalcasting Research Foundation

AFS has established the Metalcasting Research Foundation as a mechanism to fund metalcasting research, support educational efforts and help ensure our future and legacy. It is time to take our fate out of the hands of politicians and special interest groups. By creating a not-for-profit foundation, we have established the mechanism to advance metalcasting technology, support educational institutions, and provide our members a competitive edge in the marketplace. For more information or to donate, visit the Metalcasting Research Foundation webpage.

National Network of Manufacturing Innovation

America Makes: National Additive Manufacturing Innovation Institute

America Makes is the nation’s leading collaborative partner in additive manufacaturing and 3-D printing technology research, discovery, creation and innovation. AFS is partnering with Youngstown Business Incubator (YBI), which has been named a recipient of funds from America Makes. The research project “Accelerated Adoption of AM Technology in the American Foundry Industry” will support the transition of binder jet AM to the small business casting industry by providing increased access to the use of binder jet equipment and the development of design guidelines and process specifications.

American Lightweight Materials Manufacturing Innovation Institute (ALMMII)

AFS is part of a 60-member consortium that will pair leading aluminum, titanium and high strength steel manufacturers with universities and laboratories pioneering new technology development and research. The long-term goal of the ALMMII will be to expand the market for and create new consumers of products and systems that utilize new, lightweight, high performing metals and alloys by removing technological barriers to their manufacture, according to the White House. AFS will champion the role of the metalcasting industry as a key metals manufacturing sector in this effort.

ALMMII Fact Sheet

Digital Labs for Manufacturing (Digital Lab)

The Digital Lab has been established to increase the successful transition of digital manufacturing and innovative design technologies through advanced manufacturing, create an adaptive workforce capable of meeting industry needs, further increase domestic competitiveness, and meet participating defense and civilian agency requirements. As it relates to the metalcasting industry, the use of these technologies will assist in the more rapid development and production of lighter weight cast metal components for military, energy, transportation and commercial applications. 

Digital Labs Fact Sheet

American Metalcating Consortium/U.S. Department of Defense/Defense Logistics Agency Funded Projects

Casting Solutions for Readiness Program

AFS, as part of their efforts in the American Metalcasting Consortium (AMC), has recently secured contracts funded through the U.S. Department of Defense, Defense Logistics Agency, Defense Supply Center Philadelphia and the Defense Logistics Agency, Ft. Belvoir, VA.  The group of projects is under an AMC program entitled Castings Solutions for Readiness (CSR).  The two new projects are continuations of previous AFS AMC efforts, including one project called Cast High-Integrity Alloy Mechanical Property Standards (CHAMPS) and the other Casting Standards and Specifications.

CHAMPS Project - Additional Alloy Design Data 

Casting Standards and Specifications 

Accessing state-of-the-market technical, specification and training materials for castings is challenging. AFS is working to provide current and qualified information in a network friendly form to users of castings via the Casting Standards and Specifications project. The effort includes both archival and recent technical information in searchable databases. Specifications and standards are summarized, and the user is guided in their application. Tutorials covering the fundamental design concerns are also presented. The development of an online material design property database will greatly enhance the ability for the next generation of component designer to create the lightest weight and most efficient parts quicker and at lower cost. These tools facilitate more effective and efficient procurement to both DoD and industry in the support of weapon systems. Along with data from various AFS research projects, like the recently completed 08-09#01 & 08-09#03 projects for the Development of Fatigue Properties Database, AFS has also incorporated the USAMP Light Metals Materials Database properties and recently strain life fatigue data for CGI Grade 400 and a hi-alloy Class 40 Gray Iron into the AFS Casting Alloy Data Search (CADS) onto the AFS design website: www.metalcastingvirtuallibrary.com/cads/cads.aspx.  This completes this phase of the project and AFS is working with ASM to create Cast Alloy Material Property Datasheets to be put on the ASM Material Selector and AFS websites. The work planned under this project will add design properties for 4-5 additional cast metal alloys per year, while continuing to upgrade the CADS online database.

For more information, contact Thomas Prucha, AFS vice president of technical services or AFS technical and information services coordinator Katie Matticks.

U. S. Department of Energy - Advanced Manufacturing Office (AMO) / Energy-Saving Melting and Revert Reduction (E-SMARRT)-Cast Metals Consortium Program

The Department of Energy program under its Advanced Manufacturing Office (AMO) supported various R&D projects to promote energy efficiency through SCRA and its partners that included the Energy-Saving Melting and Revert Reduction (E-SMARRT)-  CMC (Cast Metals Coalition) lead program.   The CMC consisted of AFS, NADCA, SFSA and performing research organizations. The nine-year technical program ended March 31, 2014.

Click here for links to the final reports.

AFS and National Industrial Sand Assoc. (NISA) Sand Casting Consortium

NewGen Consortium
AFS Library Search Results - Dimensional Accuracy and Repeatability

Advanced Casting Research Consortium (ACRC) at Worcester Polytechnic Institute (WPI)

AFS participates as a member of the as part of the Advanced Casting Research Consortium (ACRC) at Worcester Polytechnic Institute (WPI).  The ACRC is part of the Metal Processing Institute (MPI) at Worcester Polytechnic Institute and is a leading industry-university alliance dedicated to advancing the field of materials science. Through research in the areas of metal casting, heat treating, and resource recovery and recycling, MPI has earned awards, recognition, breakthrough patents, and industry accolades. At the Advanced Casting Research Center (ACRC) we collaborate on research addressing the global foundry industry.  The focus is to bring fundamental understanding to existing processes, develop new methods and address management-technology interface issues with our industrial partners. Some call ACRC the finest foundry-related industry-university research consortium in the world. Working together, industry leaders and university researchers solve business challenges and improve manufacturing processes that save energy, reduce cycle time, increase productivity, and eliminate environmental waste.  http://wp.wpi.edu/acrc/?shortURL=acrc&redirector=plus.wpi.edu

AFS Technology Transfer

International Journal of Metalcasting
Conferences

Technical Resource
AFS Library Website

Technology Transfer Thursdays Webinars
American Metalcasting Coalition Website

Forms

To download one of the research forms, click on the appropriate link.

If you are interested in participating in an AFS project or committee activity, contact the AFS Technical Department at research@afsinc.org, or Tom Prucha, vice president of technical services, at tprucha@afsinc.org