Session Chair:
Buddy Barnhill Jr.
Lee Bras Co., Anniston, AL

Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada

The basic metallurgy copper alloys is presented. Starting with an introduction to copper, followed with various major and minor alloying elements and their impact on properties. Copper alloy families are introduced with common applications.  

Chris Greenfield
The Federal Metal Co., Bedford, OH

Michelle Ring
Norican Group, Carmel, IN

Susan Bernard
Battery Council International, Chicago, IL

The Occupational Safety and Health Administration (OSHA) last year published its Advanced Notice of Proposed Rulemaking (ANPRM) on Blood Lead Level for Medical Removal. The last time OSHA updated this standard was in 1978 and they agency is looking to make significant changes in the updated standard. The entire rulemaking process is likely to take six-to-eight years and OSHA is keen to publish a proposed rule in 2024 or 2025.  Industry experts are anticipating new triggering activities and thresholds that will expand the number of workers covered by the rule. Susan will discuss how these changes may affect industries outside of the traditionally-covered lead workers and the impact it could have on your business.

Ted Schorn
Enkei America Inc., Columbus, IN

There is a strong current of excitement over autonomous inspection using machine vision coupled with artificial intelligence. Before a foundry jumps into such a project, a few words of caution are in order. Ted will describe what characteristics make sense for inspections without humans and those that continue to need direct human involvement.

Ted Schorn
Enkei America Inc., Columbus, IN

Some authors in the safety field have offered the opinion that setting a “zero defect” goal for safety programs is not only not achievable, but harmful. Others insist that we must target zero injuries in our efforts to manage safety. Ted will review this controversy, offering an overview of the issues and why such a question matters practically as we try to reduce injury rates in our foundries.

Session Chair:
Gerald Richard
MAGMA Technologies, Schaumburg, IL

Gerald Richard
MAGMA Foundry Technologies, Schaumburg, IL

In this talk we will begin by reviewing traditional gating methods and how to calculate them. Then, we will move to more advanced gating design practices including pouring basin design, parabolic sprues and vortex surges. The goal is to understand which set of practices will help minimize defects such as misrun, sand inclusions, and leakers.

Paul Clements
Sloan Valve Co., Augusta, AR

This presentation will cover basic gating and risering principles for range of copper based alloys. Instruction will be supported with the aid of fluid flow and solidification modeling results to demonstrate root cause analysis of common filling and solidification defects. Emphasis will be put on understand molding and pour system constraints to maximize yield as it applies to casting quality.

Andy Shea
AY McDonald Mfg. Co., Dubuque, IA

Some casting designs become difficult for foundries to make. This presentation identifies some good designs for no lead brass castings with green sand molds and goes through gating changes that have reduced casting scrap.

All Presenters & Attendees 

TopGolf
2050 Progress Pkwy
Schaumburg, IL

Session Chair:
Jeff Sorenson
Lee Brass, Anniston, AL

Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada

Principles and best practices of copper melting will be discussed. Topics include Charge materials, Oxidation, gas content, melt protection and processing (deoxidation, degassing, grain refinement). Presentation includes tests for melt and metal quality.

Tom Prucha
Metal Morphasis LLC, Rochester Hills, MI

Marshall Miller
3D Systems, Rock Spring, GA

Customers rarely, if ever, tell us the molding equipment arrived so quickly and was so inexpensive they were astounded. Today, the technology is here to deliver resilient molding equipment more quickly and less expensively than conventional purely subtractive methods.

This presentation will provide comparisons between additively manufactured molding equipment and traditional methods for green sand, no-bake, lost foam and investment casting tooling and how additive manufacturing drives down cost and delivery dramatically.

Jeremy FIscher
Foseco, Pittsburgh, PA

This presentation will introduce the basics of induction furnace linings for copper alloys. This includes how induction melting works, what types of linings are available, when each type of lining is used, how to properly install them, common mistakes made, and the cause of common lining failure modes. This will provide a basis of knowledge for attendees to better understand linings usage in their induction furnaces.

Panelists:

Leigh Omerz
H. Kramer & Co., Chicago, IL

Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada

Jeff Sorenson
Lee Brass Co., Anniston, AL

Jim Valentine
Neptune Technology Group, Inc., Tallassee, AL

Have you ever had a scrap problem that you just cannot find a solution for? If so, we have a panel session that can help with that problem. Come join Industry Experts in this panel session that will focus on scrap issues and how to fix that problem casting that always seems to show up. You can bring that casting with you to the Copper Workshop on September 27th and 28th at AFS Headquarters in Schaumburg, IL. If you are worried about getting on the plane with your casting, you can send it to AFS attention Brian Began and we will make sure that it makes it to the session. Please include any specifics on molding process, alloy, sand properties, etc. - anything that can help the panel members and others in the session to help come up with a solution or solutions.