2023 Cast Iron Production Conference

Hilton Charlotte Airport
February 27 - 28, 2023

Overview

The 2023 Cast Iron Production Conference is a can’t miss event for any ferrous foundry, supplier or end user of ferrous castings. Sessions will cover a broad range of topics including melting practice and charge makeup, inoculation, treatment, gating and risering, quality control and finishing considerations. This conference will benefit those who have responsibilities for areas listed above or are more focused and need to understand cross functional interactions. Attendees will hear several practical talks with ideas and concepts that can readily be put to use. There will be opportunities to network across the industry and with subject matter experts. Join the AFS Cast Iron Division in Charlotte this February!

Location

  • Hilton Charlotte Airport
  • Charlotte, North Carolina
  • February 27 - 28, 2023
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Hotel Information

  • Hilton Charlotte Airport
  • Charlotte, North Carolina
  • $139 per night

Room rate cutoff is February 6, 2023. 

Conference Agenda

Monday, February 27, 2023
INTRODUCTION/KEYNOTE
1 p.m.
Welcome/Introduction

Eric

 

 

 

Eric Nelson
Cast Iron Division Chair, Dotson Iron Castings, Mankato, MN

1:15 p.m.
KEYNOTE: TBD

Chip Keough
LightSpeed Concepts Inc., Albion, MI

MOLTEN METAL/INOCULATION
2:15 p.m.
Panel: Scrap Stream (Individual Presentations then combined Q&A)

Brandon

 

 

 

Brandon Kacko
PrimeTrade Inc., Finleyville, PA

Mike Dunn
OmniSource Corp., Brookville, OH

Jiten

 

 

 

Jiten Shah
PDA LLC, Naperville, IL

Global Pig iron update, Sourcing options for pig iron moving forward, pig iron demand increasing due to mini Mills. The war in Ukraine and how it will effect the pig iron market for years to come.

Recent research outcome on AI/ML driven meta modeling for high-strength ductile iron sand castings to predict yield strength using historical data with detail chemistry will be presented. During this panel, the effects and influences of lesser-known elements will be discussed and demonstrated for potential impact on yield strength.

  • Growth of EAF mill production
  • How much new production is here and coming?
  • How does this affect prime grades availability?
  • Is the Quality of prime scrap changing for foundry consumption?

 

3:15 p.m.
Break
3:30 p.m.
Panel: Least Cost Charge (Flexibility and Adaption)

Brad

 

 

 

Brad Steinkamp
Charter Dura-Bar, Woodstock, IL

Justin

 

 

 

Justin Hall
John Deere Foundry Waterloo, Waterloo, IA

william

 

 

William Koshut
TMS International, Beaver Falls, PA

As clean scrap continues to become more difficult to source, the need to diversify scrap purchases in order to identify least cost charges that meet tighter customer specifications becomes more and more demanding. Today’s software can help simplify the mathematics required to optimize raw material purchases. By making the software fully capable of automatically interfacing with ERPs, company servers, spectrometers, electronic scales, bar codes and other interfaces, the technology continues to focus on minimizing operator interaction while reducing process variances.

4:30 p.m.
Panel: What are the Top 3 Process Control Parameters for Metal that I Should be Monitoring in My Cast Iron Production?

Jacob

 

 

 

Jacob Gerdt
Waupaca Foundry Inc., Waupaca, WI (Ductile Furnace)

Matt Calcutt
Rochester Metal Products, Rochester, IN (Induction Ductile Iron/Melt)

Emily Ballinger
Caterpillar Inc., Mapleton, IL (CGI)

Trevor

 

 

 

Trevor Beach
Betz Industries, Grand Rapids, MI (Large Producer)

This panel will discuss the top requisite process control parameters in monitoring cast iron production. Panelists representing a variety of melting methods including cupola, electric, and induction melting will speak on their shared experiences on a variety of iron grades including gray, ductile, and CGI irons. The differences and unique considerations for each melting method and iron grade will be discussed from a list of leading industry practitioners.

5:45 p.m.
Day 1 Concludes
6 p.m.
Networking Reception (Drinks, appetizers, etc.)
Tuesday, February 28, 2023
7 a.m.
Breakfast
MOLTEN METAL/INNOCULATION (continued)
8 a.m.
Inoculation/Treatment

Rob

 

 

 

Rob Logan
Elkem Foundry Products, Mooresville, NC

Back to basics? Methods? Elements in the iron (gray or ductile).

9 a.m.
Panel: Quality Control? Gray & Ductile Iron?

caesar

 

 

 

Cesar Braga
Aarrowcast Inc., Shawano, WI

Ben Keith
Neenah Foundry Co., Neenah, WI

Jim

 

 

 

Jim Barlow
Caterpillar Inc., Mapleton, IL

This panel will discuss options of controlling mechanical properties and correlation of casting mechanical property to separately cast samples including in-mold treatment and in-stream inoculation processes. Also, one OEM’s take on how to factor in separately cast test bars to their specifications.

  • Process Control
  • Quality Verification
  • Casting Correlation
10 a.m.
Break
10:15 a.m.
Panel: What are the Top 5 Defects I Should be Aware of in Cast Iron Production? Case Studies? Walkthrough on Resolutions of Defects?

Kramer

 

 

 

Kramer Pursell
Metals Technologies Auburn LLC, Auburn, IN

Leo

 

 

 

Leonard Winardi
Charlotte Pipe & Foundry Co., Charlotte, NC

Dickey

 

 

 

Andrew Dickey
Neenah Foundry Co., Neenah, WI

Panelists will discuss defects they have seen in their foundries. They will provide practical insights and case studies into defect detection, analysis and resolution.

GATING & RISERING
11 a.m.
Advancements in Gating Cast Iron

Speaker TBD
Magma Foundry Technologies, Schaumburg, IL

11:30 a.m.
New Consideration/Theories in Gating Cast Iron

Kyle Metzloff
University of Wisconsin-Platteville, Platteville, WI

Noon
Lunch
1 p.m.
Case Study 1: Gating & Risering Cast Iron

Alan Crawford
Waupaca Foundry Inc., Waupaca, WI

1:30 p.m.
Case Study 2: Gating & Risering Cast Iron

Chris Slinger and Derek Orlikowski
Neenah Foundry Co., Neenah, WI

FOUNDRY PROCESSES
2 p.m.
Smart Manufacturing of Ductile Iron Using Artificial Intelligence and Uncertainty Quantification

Shah

 

 

 

Jiten Shah
Product Development & Analysis LLC, Naperville, IL

Ductile iron casting design and manufacturing is a multi-variable complex process that often is found inadequate in spite of extensive experience, well controlled operation and a traditional trial & error approach to solve periodic shrinkage porosity and poor properties not meeting the requirements. A framework and methodology consisting of machine learning and AI tools, coupled with ICME (casting process simulation) will be presented to develop meta model predictors with uncertainty quantification using historical production data and selective DOE based data with an example. Application of such meta models applied in near real-time intelligent process control will be presented with positive outcomes. This approach is applicable to solve any such complex problems encountered in the foundry and machining operations.

2:45 p.m.
Industry 4.0? Smart Technology?

Nathaniel Bryant
University of Northern Iowa, Cedar Falls, IA

3:15 p.m.
Break
3:30 p.m.
Panel: Lessons Learned in Automated Casting Iron Processing Finishing/Automation of Grinding Cells (Needs in Foundry, Concerns in Finishing Area)

Sean McCormick
Buck Co. Inc., Quarryville, PA

Josh

 

 

 

Josh Jaycox
Dotson Iron Castings, Mankato, MN

Jason Torrence
Grede-St. Cloud, St Cloud, MN

Grinding castings has historically been a danger and bottle neck in the foundry. With today’s labor shortage, the difficulty in getting castings through finishing is greater than ever. These three presenters will discuss the challenges and improvements they have made to their facilities in the area of Finishing throughput and automation.

5 p.m.
Conference Concludes

Registration

Cancellations & Substitutions

AFS presents a variety of technical and management conferences (in both in-person and virtual formats). The refund policy for AFS conferences is as follows: 1) Substitutions are accepted at no charge at any time up until the start of the conference; 2) Full refunds are offered if AFS is notified in writing of cancellation at least 30 days in advance of the conference. No refunds or credits are available for less than 30 days written notice.

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