AFS directly funds research projects from the allocation of a portion of annual dues paid by AFS Corporate Membership. Current AFS-funded research projects are described below.
Updated May 2023
19-20#02 Effect of Ceramic Sand on Cast Iron Mechanical Properties
Principal Investigators: Dr. Scott Giese, University of Northern Iowa
Steering Committee Chair: Brandon Reneau, Caterpillar
Due to the OSHA Silica Rule under enforcement in the foundry industry today, many foundries are considering changing from silica sand to a ceramic sand/media to alleviate the issue. Many questions are associated with this change, but one that is of primary importance is understanding the effect, if any, in microstructure and the associated mechanical properties that might accompany the use of the ceramic sand/media.
The purpose of this project is to evaluate the effect of ceramic sand/media on the mechanical properties for Class 30 iron and 80-55-06 ductile iron.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
19-20#07 LFC Molds Produced Using Additive Manufacturing
Principal Investigator: Marshall Miller, Tesseract4D
Steering Committee Chair: Jeff Prickett, Metals Alloys & Refractories
Tooling constructed of T6061-T6 is considered expensive and requires special software and skilled programmers.
The purpose of this project is to determine the applicable metal additive manufacturing method and material for medium and high-volume production considering material durability, material costs, cycle time, equipment costs, and skill level required for production as compared to conventional methods.
The project is being monitored by the AFS Lost Foam Division and Additive Division. For more information about the project, contact AFS Senior Technical Associate Bo Wallace (bwallace@afsinc.org) or AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
19-20#08 LFC Molds Produced Using Polymer FDM & SLA Additive Manufacturing
Principal Investigator: Marshall Miller, Tesseract4D
Steering Committee Chair: Jeff Prickett, Metals Alloys & Refractories
Tooling constructed of T6061-T6 is considered expensive and requires special programing software and skilled programmers.
The purpose of this project is to determine the applicable FDM (fused deposition modeling) polymer additive manufacturing and SLA (stereolithographic additive) method and material for low- and medium-volume production considering material durability, material costs, cycle time, equipment costs, and skill level required for production as compared to conventional methods.
The project is being monitored by the AFS Lost Foam Division and Additive Division. For more information about the project, contact AFS Senior Technical Associate Bo Wallace (bwallace@afsinc.org) or AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
19-20#09 PVD Coatings to Aid Release for Permanent Mold Castings
Principal Investigators: Dr. Stephen Midson, Colorado School of Mines
Steering Committee Chair: Randy Oehrlein, Carley Foundry Inc.
Aluminum often strongly solders to uncoated steel dies when cast in permanent metal molds. To address this problem, metalcasters use lubricants, which often need to be applied to the die prior to the production of each casting. For high-pressure diecasting, organic lubricants are sprayed onto the die, while for permanent mold casting, ceramic coatings and graphite are used. Although the application is necessary, they cause various problems, such as reducing the quality of the castings and the creation of costly housekeeping issues. In addition, they are expensive and add to the cost of the casting.
The purpose of this project is to develop and utilize a laboratory test that can provide a quantitative measurement of the impact of different PVD coatings on the level of adhesion and force required to extract long cores from aluminum coatings.
The project is being monitored by the AFS Permanent Mold Committee. For more information about the project, contact AFS Vice President of Metalcasting Technical Services (bbegan@afsinc.org).
20-21#02 Quantifying Aluminum Casting Quality Through H Gas - (Phase 2)
Principal Investigators: Daniel Hoefert, Eck Industries, Inc.
Steering Committee Chair: Adam Kopper, Mercury Marine
Foundries producing gravity pour aluminum castings have several gating concepts to choose from. Phase 1 (Quantifying Casting Quality Through Filling Conditions) compared three systems that provided different filling conditions ranging from tranquil bottom filling to semi-tranquil side filling to turbulent top filling. The results of the top and side filling gating systems repeatedly exhibited less shrinkage porosity and improved the general tensile properties over the bottom filling system. While bottom filling did avoid turbulence and oxide films associated with buoyant bubbles and non-buoyant flow tubes. Tranquil filling did not reduce the overall shrinkage porosity in the castings and did not improve tensile properties. However, other observations suggested that a relationship may exist between hydrogen gas levels in melts and subsequent interdendritic porosity. It also suggested hydrogen gas levels may reduce bubble formations.
The purpose of this project is to gain additional understanding regarding the solidification and filling dynamics that common defects are associated with, such as porosity (micro and macro), bubbles, flow tubes, and hydrogen gas.
The project is being monitored by the AFS Aluminum and Light Metals Division. For more information about the project, contact AFS Vice President of Metalcasting Technical Services (bbegan@afsinc.org).
20-21#03 Low CRI, High CSR Coke Cupola Trials
Principal Investigators: Steve Hay, Hay Melting Solutions; Bruce Blatzer
Steering Committee Chair: Alex Croll, Waupaca Foundry
Higher CSR (coke strength after reactivity) coke has higher hot strength--implying that coke with those properties will travel farther down the cupola shaft, which can enhance metal temperature and carbon pick up. Furthermore, the stronger coke in the presence of heat and CO2 will better support the burden in the cupola. Furthermore, lower ash fusion temperatures of blast furnace coke imply higher carbon pickup from such coke. Research is needed to determine if coke for cupola melting with a lower CRI (coke reactivity) and higher CSR can enhance performance and cost for cupola melting.
The purpose of this project is to reduce coke per ton of iron melted with no change in melted iron properties and no detrimental changes in the melting operation.
The project is being monitored by the AFS Melting Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
20-21#06 Machinability of Solution Strengthend Ferritic Ductile Iron
Principal Investigators: Dave Labyak and Paul Sanders, Michigan Technological University
Steering Committee Chair: Mark Osborne, Wabtec
Lack of machining knowledge has impeded the growth of solution strengthened ferritic ductile iron (SSFDI) in North American markets due to machining shops using machining costs associated with conventional ductile iron grades.
The purpose of this project is to understand the machinability of SSFDI grades compared to conventional grades to help expand the market for SSFDI grades.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
21-22#03 Multi-axial Measurement of Casting Wall Movement During SGI Solidification and Cooling in In-Molding
Principal Investigators: Dr. Mingzhi Xu, Georgia Southern University; Dr. Simon Lekakh, Missouri University of Science and Technology
Steering Committee Chair: Jiten Shah, PDA LLC
Casting wall movement during metal solidification and cooling causes external surface distortion on complex ductile iron castings. Casting wall movement is also related to internal porosity formation within the castings.
The purpose of this project is to develop an experimental apparatus to perform multi-axial measurement of casting wall movement during ductile iron solidification and cooling. A full set of variables will be systematically studied, including mold strength, pouring temperature, riser condition, metalhead pressure, CE, nodularity, and inoculation.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
21-22#05 Digital Active Clay Measurement in Green Sand
Principal Investigators: Dr. James Springstead and Dr. Sam Ramrattan, Western Michigan University
Steering Committee Chair: Brian Rachwitz, EJ
Casting defects are consistently attributed to variations in green sand systems and limitations of the clay control methods for green sand. A better clay measurement technique is necessary to improve green sand systems.
The purpose of this project is to create a novel optimized method for the measurement of active clay in green sands that will be tested in multiple working foundries and is ready to be implemented as a standardized method.
The project is being monitored by the AFS Molding Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
22-23#01 Refining Austenite in Gray Irons
Principal Investigators: Jingjing Qing, Georgia Southern University
Steering Committee Chair: Leonard Winardi, Charlotte Pipe
It’s well known that the properties of cast iron are related to the fineness of the microstructure features, such as graphite particle size, eutectic cell (GI) size, and pearlite lamellar spacing. Good attentions were paid onto refining sizes and distributions of graphite (nodule, flake and compacted) via inoculations, or refining pearlite structures using alloy additions, but much less effort was put into the study of refining austenite in cast irons, especially evaluating the effects of inoculant on austenite grain size.
The purpose of this project is to study the effects of different types of inoculants on the austenite grain size and mechanical properties of the differently inoculated cast irons. Heterogeneous nucleation to refine austenite in cast irons will also be explored.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
22-23#03 Effects of Si in High-Cr White Cast Irons
Principal Investigators: Richard Gundlach, Gundlach Consulting Services
Steering Committee Chair: Brian Bendig, Penticton Foundry
Silicon is a common alloying element that cannot be avoided in High-Cr white irons (HCWI). It has unique attributes that influence the microstructure and hardenability of heat-treated castings, and industry does not know how to adjust for variations in silicon.
The purpose of this project is to study the effects of different types of inoculants on the austenite grain size and mechanical properties of the differently inoculated cast irons. Heterogeneous nucleation to refine austenite in cast irons will also be explored.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).
22-23#04 Biobased Polymer Foam Pattern for Lost Foam Casting
Principal Investigators: Jacob Belke, Mercury Marine
Steering Committee Chair: Marshall Miller, 3D Systems
Lost foam patterns are made of expanded polystyrene (EPS) which is derived from crude oil. The negative environmental impact of the oil and gas industry has been well documented and is not sustainable.
The purpose of this project is to identify an environmentally sustainable biopolymer(s) that can become an alternative to the current petroleum-derived polystyrene.
The project is being monitored by the AFS Lost Foam Division. For more information about the project, contact AFS Senior Technical Associate Bo Wallace (bwallace@afsinc.org).
22-23#06 Understanding and Mitigating the Effect of Boron in Ductile Iron
Principal Investigators: Laura Bartlett, University of Missouri Science & Technology
Steering Committee Chair: Kramer Pursell, Metal Technologies Inc.
Boron has shown to cause multiple effects on microstructure and mechanical properties of ductile iron castings, causing an increase in problems for ductile iron foundries.
The purpose of this project is to quantitatively evaluate the effect of different boron additions in the range of 8 to 60 ppm on the microstructure and mechanical properties of pearlitic and ferritic ductile irons.
The project is being monitored by the AFS Cast Iron Division. For more information about the project, contact AFS Director of Technical Metalcasting Services Travis Frush (tfrush@afsinc.org).