2023 Copper Alloys Workshop

AFS Headquarters
September 27 – 28, 2023


This workshop is tailored for new and experienced copper alloy manufacturing professionals. Featuring 15 sessions scheduled over two days, each session will be led by industry experts in their respective fields. Topics include green sand systems, gating and risering, metallurgy, additive manufacturing, quality inspection, foundry safety, and -- back by popular demand -- a panel on casting defects.

Please join us in expanding the shared knowledge in the copper alloy industry.

Don’t forget to ship us a casting with defects or bring it with you for discussion during the defect panel!

For information about sponsorship opportunities at the event, please contact Kim Farrugia at kfarrugia@afsinc.org or click here.


  • AFS Headquarters
  • Schaumburg, IL
  • September 27 – 28, 2023
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Hotel Information

Holiday Inn
  • Holiday Inn Chicago Schaumburg
  • Schaumburg, IL
  • $95.00/night + tax

Standard room rate of $95.00/night + tax. Attendees can also reserve directly with the hotel room reservation department by calling (847) 885-0101 and request the AFS room block. The hotel’s check-in time is 4 p.m. Check-in prior to the hotel’s published check-in times are subject to availability. Check-out time is 11 a.m. 

Conference Agenda

Wednesday, September 27, 2023
Session 1: Basics/Introductions

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

7 a.m.
8 a.m.
8:15 a.m.
Metallurgy Part #1 (Review)


Kumar 120

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.  

9:15 a.m.
Mega-Trends or Copper Uses for Today & Tomorrow






Chris Greenfield
The Federal Metal Co., Bedford, OH

10:15 a.m.
10:30 a.m.
Green Sand Primer/Sand Systems






Michelle Ring
Norican Group, Carmel, IN

11:15 a.m.
How OSHA's Lead Rule May Effect Non-Lead Industries






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.

1 p.m.
Perspectives on Autonomous Inspection for Castings

Schorn 120

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.

1:30 p.m.
What is the Goal of Safety Management Programs?

Schorn 120

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 2: Gating & Risering

Session Chair:
Gerald Richard
MAGMA Technologies, Schaumburg, IL

2:15 p.m.
Advanced Gating Techniques

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.

3 p.m.
Introduction to Copper Alloy Gating Practices

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.

3:30 p.m.
3:45 p.m.
Gating Changes to Improve 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.

4:15 p.m.
Q & A/Panel

All Presenters & Attendees 

4:30 - 4:45 p.m.
Day 1 Concludes
5:30 p.m.
Networking Reception (Drinks, appetizers, & golf!)

2050 Progress Pkwy
Schaumburg, IL

Thursday, September 28, 2023
Session 2: Advanced Metallurgy & Technologies

Session Chair:
Jeff Sorenson
Lee Brass, Anniston, AL

8 a.m.
Metallurgy Part #2


Kumar 120

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.

9 a.m.
IJMC Research Update

Tom Prucha
Metal Morphasis LLC, Rochester Hills, MI

9:30 a.m.
9:45 a.m.
Extrusion Technology Applications for Foundry Tooling: Half the Cost & Time






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.

10:15 a.m.
10:45 a.m.
Induction Furnace Linings and Practices






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.

11:30 a.m.
12:30 p.m.
Panel: Casting Defects







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


Kumar 120

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.

2 p.m.
Workshop Concludes


Registration Fees

Non-member: $825.00
AFS Member: $550.00

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.