A Year After OSHA Began Silica Enforcement: What Savvy Foundries Have Learned?
Kay Rowntree, Eric Pylkas & Daniel Engling | Recorded Sept. 12, 2019 | Click here to view
Come gain know-how from foundries and consultants that have been devising creative solutions to attain compliance with the silica regulations. Learn strategies to deal with traditionally high exposure areas/tasks such as baghouse changes and furnace relining. Industrial Hygienists will share the difference between performance monitoring and periodic sampling, and when enough sampling is enough
Update: Proposed Overtime Rule & Navigating the New EEO-1 Pay Data Requirements
James A. Paretti, Jr. | Recorded Aug. 22, 2019 | Click here to view
Earlier this year, the U.S. Department of Labor (DOL) published a proposed rule that would make nearly a million workers eligible to receive overtime pay. If adopted, these new regulations among other things, raise the salary threshold to qualify as overtime exempt from $23,660 to $35,308. It’s important to not wait until the rule is finalized to begin reviewing your practices.
AFS Research: Pre-Firing Time/Temperature effect on Investment Shells
Mingzhi Xu | Recorded Aug. 13, 2019 | Click here to view
This AFS-sponsored research demonstrates the importance of firing parameters on the thermo-mechanical properties of investment shells. With this knowledge in hand, foundries are one step closer to achieving shells that provide sufficient mechanical strength with fewer layers. This could translate into a marked reduction in operating costs.
How to apply 3 Fluid Flow properties that impact your Gating System
Dr. Sudesh Kannan | Recorded Aug. 6, 2019 | Click here to view
Fluid flow in your gating system plays a significant role in getting the desired quality in your casting. Key concepts of turbulence, momentum and fluidity will be discussed as part of understanding molten metal fluid flow and the impact they have on gating design and practice. Videos and case studies will be shared to explain basic gating principles.
AFS Research - Quantifying Casting Quality Through Filling Conditions
Dan Hoefert | Recorded July 16, 2019 | Click here to view
Presented by Dan Hoefert, explore the research behind quantifying casting quality through filling conditions.
Process & Data Automation for Mid-Sized Foundries
Jim Lagrant | Recorded July 9, 2019 | Click here to view
Foundries are one of the core businesses many people tend to think of when imagining industrial manufacturing. As a result, it’s often considered an old-fashioned industry without a lot of room for improvement.
The AFS Corporate Member Advantage
Ben Yates | Recorded June 21, 2019 | Click here to view
Learn how a small investment in an AFS Corporate Membership can pay dividends throughout your organization by driving innovation, reducing costs, developing employees, and connecting with customers.
3D Sand Printing-Operation/Maintenance Considerations
Travis Frush | Recorded June 4, 2019 | Click here to view
Faster, higher quality at lower cost/higher value. Focus on operational sustainability and materials that offer increased process flexibility and deliver higher quality castings.
Effect of Filling Conditions on Steel Casting Qualities
Dr. Laura Bartlett | Recorded May 14, 2019 | Click here to view
Recent understanding on the effect of filling conditions on casting surface and performance of aluminum castings has resulted in design of new gating systems that eliminate damaged metal, greatly increasing casting quality and yield. It has been proposed by recent researchers that nearly all surface and internal defects in steel castings result from air entrainment during turbulent filling conditions causing unnecessary weld repair, low mechanical properties, and customer rejections.
Additive Sand Manufacturing – Path to Production
Ron Walling | Recorded May 7, 2019 | Click here to view
Recent advancements in additive sand technology have fostered its emergence from a prototype-only process to a process that is viable for particular production casting applications. But, the benefits of additive sand are best applied to specific categories of castings. Also, the availability of printed sand in the foundry industry is currently limited. This presentation will provide a casting customer’s perspective of how the use of additive sand for production castings will grow in the coming years.
Why Lost Foam?
Marshall Miller | Recorded May 2, 2019 | Click here to view
The webinar explains the steps of the Lost Foam Casting (LFC) process and shares examples of project successes derived through LFC. We cover which countries are using the Lost Foam process and how prevailing it is on the global scene. You also learn the type of parts Lost Foam is best for and review the benefits of using this method. For each limitation identified for the process, we also identify remedies being developed through AFS research.
Guidance for Foundry Heat Stress Management
Bob Scholz | Recorded April 11, 2019 | Click here to view
This webinar is intended to provide information and reference to resources that can be useful in managing heat stress in foundries.
Purpose & Description of Failure Analysis
John Tartaglia | Recorded April 2, 2019 | Click here to view
This talk will start by defining failures and cracks. This will then discuss the general failure causes of design, material and manufacturing. The role of the customer will then be outlined, i.e., when you should consider purchasing a fracture or failure analysis, what you should expect to learn, and what information and samples that you should collect. The failure analysis steps will be described and some failure analysis examples will be included.
EU’s Registration, Evaluation, Authorisation & Restriction of Chemicals (REACH)
Bing C. Xu | Recorded March 20, 2019 | Click here to view
Does the European Union’s Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH) Affect Your Foundry? Many foundries are receiving letters from their European customers asking for certification that their castings are REACH compliant. The REACH regulation was written to protect human health and the environment from chemical substances that are produced in or imported into EU member nations.
Design Principles for Effective Casting Production
Mike Gwyn | Recorded March 5, 2019 | Click here to view
Can OEMs analyze their own aluminum structural casting designs for castability and solidification integrity with software they already have?Yes! Join us for Design Principles for Effective Casting Production to find out how.
Nadcap & the Foundry Industry
Dave Weiss | Recorded February 26, 2019 | Click here to view
Nadcap is an accreditation program for special processes and products in the aerospace industry. The author who managed the task group which established the Conventional Machining as a Special Process accreditation program and who is a current auditor will provide insight into Nadcap. This includes background on the history of Nadcap and an overview of the process.
Demonstration of the Impact of Thermomagnetic Processing on Cast Aluminum Alloys
Dave Weiss | Recorded February 7, 2019 | Click here to view
A number of alloys were processed via thermomagnetic processing (TMP) including 242, 355, and Al-8Ce-10Mg alloys. Mechanical property results from cast tensile samples heat treated in ORNL’s 5-inch superconducting magnet system clearly indicate a 10 to 65% increase in yield strength (YS) and 16 to 37% increase in ultimate tensile strength (UTS) over reported conventional heat treatment practice values depending on the alloys system.
Ed Foulke | Recorded January 23, 2019 | Click here to view
Understanding what is considered a recordable case under OSHA’s injury and illness recordkeeping rule has never been more important. Most foundries are now required to annually electronically submit their injury and illness data to OSHA as part of the electronic recordkeeping rule. The agency is using this data to target its enforcement efforts.
Update on Prop. 65
David Sarvadi & Javaneh Nekoomaram | Recorded January 17, 2019 | Click here to view
As of August 2018, new, more specific labeling and signage requirements are being required. Any foundry with 10 or more employees, that sells castings that could be used, machined, or processed in California, could potentially be affected by these amendments. Learn more about who the regulations apply to and how the new requirements could affect your business.
What is an Inoculant and What Does it Do?
Catherine Hartung | Recorded January 15, 2019 | Click here to view
Presentation of the concept inoculation and what can be an inoculant covering typical composition and elements used in inoculants along with emphasis on FeSi-based inoculants with controlled chemistries. And that same specification does not mean the same performance.
OSHA's Crystalline Silica Rule - 6 Months After Implementation (FAQs)
Brad Hammock | Recorded January 10, 2019 | Click here to view
This webinar will look at how OSHA has been enforcing the new Respirable Crystalline Silica Standard (or rules) in the metalcasting industry, six months after its implementation, and provide a detailed overview of the new Frequently-Asked-Questions (FAQs) that have been developed in conjunction with AFS, the National Association of Manufacturers (NAM) and OSHA to provide additional clarification on several key portions of the rulemaking. OSHA anticipates formally releasing the FAQs in early January 2019.
Scanning & Eliminating Slow Moving Patterns
Carl Berube | Recorded January 8, 2019 | Click here to view
A lot of warehouse space is devoted to storage of old, seldom used foundry patterns. When you factor auxiliary storage space, insurance and other factors, the process can be quite costly. Ever wonder if there’s a way to just eliminate the old patterns that are rarely used for production parts?
Best of Congress 2018 - Reuse of Foundry Sand
Robert Voight | Recorded November 14, 2018 | Click here to view
Early studies have established the foundation for our current understanding of sand reclamation. AFS has played a key role in early sand reuse and reclamation technology deployment. What’s new in sand reclamation?
2018 Midterm Elections: What will Divided Government Mean for the U.S. Metalcasting Industry?
Stephanie Salmon | Recorded November 8, 2018 | Click here to view
Stephanie Salmon of the AFS Washington office discusses the results of the 2018 midterm elections and what they mean for the metalcasting industry.
Preview: AFS Marketing & Sales Conference
Alexandria Trusov, Richard Jefferson | Recorded October 30, 2018 | Click here to view
This year’s AFS Marketing & Sales Conference offers superb speakers covering topics of interest to all marketing and sales people in the metalcasting industry. Our webinar tells you why this conference in December is great preparation to best execute your marketing and sales in 2019.
Influence of Rare Earth Additions on the Structure of HY 100
Robert Tuttle | Recorded October 5, 2018 | Click here to view
This Best of Congress 2018 webinar covers a series of plate casting experiments which examined the impact of rare earth additions on the structure and properties of HY100. The heats were produced in an induction furnace under an air atmosphere and poured into green sand molds. These plates were then cut into tensile bar and metallurgical samples. Some tensile bars were quench and tempered.
Best of Congress 2018 - Aluminum Casting Alloy for High Performance Engines
Dave Weiss | Recorded September 18, 2018 | Click here to view
Automotive design engineers are looking for higher performance engines. Whether this translates into more horsepower on the racing circuit, or improved fuel economy in passenger cars, the end result is increased stress and higher temperatures in the engine. Especially problematic are conditions in the dome area of cylinder heads.
Silica Q&A Panel
Tom Slavin, Kay Rowntree, Bob Scholz, Eric Pylkas | Recorded August 30, 2018 | Click here to view
Join Tom Slavin, Kay Rowntree, Bob Scholz and Eric Pylkas as they field questions about silica.
Best of Congress 2018 - What Impact will 3D Metal Printing have on Investment Casting?
Tom Mueller | Recorded August 14, 2018 | Click here to view
In the past few years, the number of manufacturers of metal additive manufacturing systems has ballooned from less than ten to more than thirty and new ones seem to appear every month. Some have forecast that metal printing will become the dominant method of creating metal parts. Will metal printing make investment casting obsolete?
Best of Congress 2018 - An Update on the Latest Trends in Ferrous Charge Material
Lenny Basaj, Gene Halloway, David Borsuk | Recorded July 31, 2018 | Click here to view
Do you have questions on what the latest trends in ferrous charge material mean for your operation? Highlighting the popular panel from Metalcasting Congress, three panelists host a Q&A session on the newest charge material trends you should know about for your iron foundry.
Housekeeping and Silica Exposure Control Plans
Eric Pylkas | Recorded July 26, 2018 | Click here to view
AFS has a Members Only Webinar to help you with your Silica Exposure Control Plan. You'll gain the skills to build your own plan that includes all the required information using a new template AFS is releasing. You'll also explore results from the latest research on rider sweepers and input from those who've purchased new ones with HEPA filters.
Best of Congress 2018 - Hoyt Lecture
Dan Oman | Recorded July 10, 2018 | Click here to view
Perceptions are a function of information received from many different sources. These perceptions become firmly held beliefs that rarely, if ever, change. Hear Dan Oman's Hoyt Lecture from this year's Metalcasting Congress on using an unbalanced force to change perceptions.
Control of Silica Exposures: Part 2
Bob Scholz | Recorded June 28, 2018 | Click here to view
Learn what needs to be documented in your Silica Exposure Control Plan. Document everything, even ventilation systems you've installed prior to the passing of the revised silica rules.
AFS Trade Webinar: Update on Section 232 Steel & Aluminum Tariffs and Retaliation Measures
Teresa Polino, Aman Kakar | Recorded June 21, 2018 | Click here to view
Join expert trade attorneys from Arent Fox for an informative webinar as they dive into the Trump Administration’s Section 232 Steel and Aluminum tariffs and the recently announced retaliatory tariffs by the EU, Canada & Mexico.
Getting the Most from the New AFS Website
Doug Kurkul, Mike Lakas | Recorded June 20, 2018 | Click here to view
AFS CEO Doug Kurkul and Vice President of IT and Operations Mike Lakas present on how you can get the most out of the new AFS website. Launched on April 17, the new website serves the needs and advances the interests of the modern metalcasting industry.
Countdown to Compliance Under OSHA’s Final Silica Rule
Brad Hammock | Recorded June 19, 2018 | Click here to view
Learn the latest on OSHA’s Silica Standard – AFS has been in discussions with OSHA about developing over 50 Frequently Asked Questions (FAQs) to provide clarification on several key areas of the rule.
The Metalcasting World at your Fingertips: The AFS Library
Mike Lakas | Recorded June 13, 2018 | Click here to view
Hear from AFS Vice President of IT and Operations Mike Lakas on how you can use the AFS library to advance your metalcasting needs.
Design and Engineering for Toolingless Sand and Investment Castings
Jiten Shah | Recorded June 5, 2018 | Click here to view
Are you thinking about using additive manufacturing with your tooling-less sand and investment castings? Hear what additive manufacturing for your conventional sand and investment casting methods can do for you. Jiten Shah will discuss what you need to know ranging from the basic to highly complex casting configurations.
Control of Silica Exposures: Part 1
Bob Scholz | Recorded May 30, 2018 | Click here to view
Know your silica sources and learn how to reduce concentrations of respirable crystalline silica. Bob Scholz discusses elements of a program to control silica exposures in foundries.
Reduction of Coating Related Casting Defects
Stacey Clifford | Recorded May 29, 2018 | Click here to view
Mold and core coating related defects are discussed. Topics include veining, penetration, erosion, gas defects, spalling, scabs, inclusions, orange peel, brush marks, teardrops, cratering, coating retention and excess coating. The AFS Mold-Metal Interface Reactions Committee has also designed a poster that is available for purchase outlining these defects.
Veining & Penetration Reduction
Sam Ramrattan | Recorded May 16, 2018 | Click here to view
Does the interaction of chemically bonded sand cores and molds with molten metal create challenges for your castings? Hear how you can accomplish near-net-shape castings with minimal veining and penetration defects. Dr. Sam Ramrattan will walk you through the steps to understand the thermal-mechanical effect suffered by the cores and molds when different binders, additives and coatings are used.
Respiratory Protection and Medical Surveillance for Silica
Kay Rowntree | Recorded April 26, 2018 | Click here to view
Respiratory protection is a key component of most silica compliance programs. Hear all you need to know about silica filtering respirators and OSHA's newly required medical surveillance programs. Industrial hygienist Kay Rowntree hosts this webinar geared toward small to mid-size foundries.
Finite Element Analysis of Low-Alloy Steel Castings
Patrick Severson | Recorded April 24, 2018 | Click here to view
Do you need to determine if a low-alloy steel casting is adequately designed for an anticipated duty cycle? Hear how proper FEA drives important engineering decisions for your low-alloy steel castings. Patrick Severson of Komatsu will outline key steps to constructing a proper finite element model you can use for your business.
How to Select an Industrial Hygienist and What to Expect When They Come
Kay Rowntree, Juliette Garesche | Recorded March 29, 2018 | Click here to view
What can you expect when an industrial hygienist comes to visit? Find out with this AFS Members Only Webinar.
Casting Alloy Data Search (CADS) Tool
Jiten Shah | Recorded March 27, 2018 | Click here to view
Are you frustrated with having to reply on potentially obsolete material property data? CADS is an online casting material database tool that offers easy access to critical design properties for casting designers and buyers at no cost to you. This AFS Members Only Webinar will explore CADS features and how they benefit you.
Prediction of Core Gas Pressure from Chemically Bonded Sand Molds using Process Simulation Software
Jerry Thiel, Sairam Ravi | Recorded March 13, 2018 | Click here to view
Did you know the University of Northern Iowa is conducting research into developing advanced API software for foundries? Its purpose is to predict gas porosity defects based on mold and core material properties. Hear about research, the methodology used to determine critical core gas pressure using API code, and case studies showing the application of the algorithm in process simulation software.
Silica Substitutes - Will They Work for Your Foundry?
Juliette Garesche, William G. Johnston, Steve Gates, Jerry Thiel, Jeff Morrell | Recorded February 28, 2018 | Click here to view
Are you interested in transitioning to non-silica media for the new silica standard, but not sure if it will work for your business? Hear who is already using these products, the pros and cons of non-silica media, and a panel to field questions.
Predictive Analytics in Metal Casting Industry - A Case Study
Hathibelagal Roshan | Recorded February 23, 2018 | Click here to view
How can your business benefit from using predictive analytics? By identifying meaningful patterns in data, metalcasters are using predictive analytics to create an advantage over the competition. Jerry Thiel and Sairam Ravi will explore the four types of predictive analytics and how you can apply them to your foundry for a competitive advantage.
Exploit the Industrial Internet of Things (IIOT) for Increased Productivity & Lower Costs
Jamie Wiczer, Brian Reinke | Recorded February 13, 2018 | Click here to view
Did you know that using new Industrial Internet of Things (IIOT) technologies can give you productivity and efficiency benefits? New smart sensors combined with world-wide connectivity analyze your metalcasting operations and immediately alert you when abnormal conditions occur. Dr. James Wiczer and Brian Reinke will explore how you can use IIOT technologies to increase production, lower costs, and increase your profits.
Casting Uncommon Aluminum Alloys
David Weiss | Recorded January 22, 2018 | Click here to view
Have you faced challenges casting uncommon aluminum alloys? Casting defects caused by difficult alloys can affect your bottom line. Dave Weiss of Eck Industries will explore difficult aluminum alloys and techniques you can use to improve the quality of your castings.
Tax Reform is Here
David Sites | Recorded January 22, 2018 | Click here to view
Now that the Tax Cuts and Jobs Act has been signed by President Trump, what do you need to know? Participants will hear from expert David Sites, international tax partner at Grant Thornton in Washington, D.C., on a number of topics important to the metalcasting industry, including changes to marginal tax rates; pass-through taxation of sole proprietorships, partnerships, and corporations; expensing of new and used equipment; new rules related to estate tax; and more.
A New Look at Mn-S Balancing in Gray Cast Iron
Rick Gundlach | Recorded January 9, 2018 | Click here to view
Did you know the sulfur content in cast gray irons can be as high as 0.16%? When manganese is not balanced with sulfur, this high concentration can produce hot-tears and embrittlement in your iron castings. Rick Gundlach of Element Materials Technology will present findings and offer ideas on balancing Mn-S to maximize the strength of cast gray iron.
Case Studies in Additive Manufacturing for Metalcasting
David Rittmeyer | Recorded December 5, 2017 | Click here to view
Did you know some foundries have applied additive manufacturing to their existing processes? Find out how foundries are able to do this with an AFS Members Only Webinar. Dave Rittmeyer, Hoosier Pattern Inc., and Brandon Lamoncha, Humtown Products, will explore case studies and answer your questions on how you can grab the low-hanging fruit while minimizing your risks.
Practical Steps to Maximizing Refractory Performance
Pete Satre | Recorded November 28, 2017 | Click here to view
The refractory used in the melting furnace is an important part of the foundry process and can greatly affect furnace performance, energy costs and profitability. New technologies have made great advancements in refractory effectiveness, and selecting the correct refractory is an important first step. However, foundry procedures such as installation, maintenance and start up process still play a significant role in furnace refractory life. This webinar will provide practical insights that can help improve refractory performance in your operation.
Get Ready for OSHA's Electronic Recordkeeping Rule
Brad Hammock | Recorded November 27, 2017 | Click here to view
You might have recorded your OSHA injury and illness data the same way for years, but now that's changing. As of Dec. 1, 2017, many companies will be required to submit their 300A form to OSHA electronically. Brad Hammock, attorney and occupational safety and health law expert, will guide you through what you need to know about this new rule.
Update on Respirable Silica—What you Should be Doing Now?
Tom Slavin | Recorded November 7, 2018 | Click here to view
Join us for an update on OSHA's new, fast-approaching crystalline silica standard. Hosted by industry expert Tom Slavin, you'll go through the steps to better prepare you and your business for meeting this new, burdensome rule.
Reshoring Metalcasting: How to Compete More Effectively vs. Imports
Harry Moser | Recorded October 4, 2017 | Click here to view
Do you and your customers compare domestic and offshore casting quotes correctly? Interpreting the data correctly can mean the difference between losing work to an overseas competitor. In this webinar, Harry Moser, founder of the Reshoring Initiative, will share how reshoring can help your business. Moser uses real-world examples to demonstrate the success of reshoring. Does reshoring really work? In the past seven years, reshoring and FDI (Foreign Direct Investment) have brought back 330,000 manufacturing jobs to the U.S.