Predicting the Impact on Green Sand Emissions as a Function of the Concentration of Carbonaceous Additives
Liam Miller, Ray Vakili, Jason St. Onge & Dr. Zhen Wang | Recorded June 22, 2021 | Click here to view
Commercial sands contain different concentrations and ratios of carbonaceous materials and bentonite clays that a given facility uses to prepare their molding sands. Design of Experiment methodology was used in combination with Analysis of Variance (ANOVA) to show that carbonaceous additives seacoal and causticized lignite in the bentonite-based pre-blend are statistically significant factors in predicting emissions output as measured using pyrolyzer Gas Chromatography Mass Spectrometry (pyrolyzer/GC-MS) analytical methods. Hazardous Air Pollutants (HAPs) were measured in a laboratory setting. A model was generated from the results of the ANOVA to predict emissions of molding sands as a function of their seacoal and causticized lignite concentrations.
AFS Corporate Member Advantage
Doug Kurkul, Ben Yates & Steve Robison | Recorded June 16, 2021 | Click here to view
Explore the benefits of AFS Corporate Membership, including technical benefits and expertise, discounts, and other resources for growing your business with AFS.
Marketing to Manufacturer Representatives
Skylar Cardott | Recorded May 20, 2021 | Click here to view
Learn how marketers can boost their companies' bottom lines by marketing directly to their own manufacturer sales reps. Get tips on effective communication within teams, how to create co-branded campaigns, and more.
Effect of Defect Size on Tensile Elongation in Aluminum Castings
Anthony Koprowski, Dr. Qigui Wang, Dr. Peggy Jones & Dr. Thomas Gustafson | Recorded May 14, 2021 | Click here to view
In order to better understand the effect of defect size on tensile elongation, 4 groups of tensile specimens were collected and studied in this work from cast aluminum products made of different cast aluminum alloys and heat-treatments.
Casting Design and Process Optimization for Intelligent Manufacturing with Industry 4.0
Jiten Shah | Recorded March 23, 2021 | Click here to view
This webinar explores an AMC/DLA funded research project, managed by AFS and led by PDA LLC, into Industry 4.0 technologies and their use for casting design and process optimization in the foundry.
Work-Life Balance: Perspectives and Real-Life Solutions
Alexandria Trusov, Kathy Hayrynen, Towanda Long, and Michelle Ring | Recorded March 2, 2021 | Click here to view
Balancing your professional and personal life can be challenging, but it’s essential. Work-life balance is the state of equilibrium where a person equally prioritizes the demands of one's career and the demands of one's personal life. Moderator Alexandria Trusov (Alpha Resources Inc.) will kick off this webinar by asking 3 panelists – Kathy Hayrynen (Applied Process Inc), Towanda Long (Charlotte Pipe & Foundry), and Michelle Ring (American Colloid Co) – to introduce themselves and define what success looks like for them. From there panelists will field questions about their definitions, their support systems, and the implications of the pandemic.
USEPA's Compliance and Emissions Data Reporting Interface (CEDRI) and Electronic Data Tool (ERT)
Theresa Lowe & Kevin McGinn | Recorded February 18, 2021 | Click here to view
Beginning on March 10, 2021, and thereafter, iron and steel foundries with reporting requirements associated with either the Foundry MACT or Foundry GACT (Area Source Rule) must begin using USEPA’s Compliance and Emissions Data Reporting Interface (CEDRI) and associated Electronic Data Tool (ERT) when submitting documents such as required notifications, semiannual compliance reports, semiannual visible emissions monitoring results, test plans and stack test reports. This webinar explains how to use CEDRI and ERT to submit these documents as well as offer tips.
Industry 4.0 Process Control & Traceability in the Foundry Industry
David Gilson | Recorded February 9, 2021 | Click here to view
Industry 4.0 is transforming production methods through the digitization of manufacturing. To meet increasing demands for process efficiency, product traceability, and profitability, foundries must be able to measure every step of the production process. Learn how modern technology can identify and collect the traceable data needed for improvements in the casting process.
Metalcasting Congress 2021 Preview
Doug Kurkul, Ben Yates & Mike Lakas | Recorded February 2, 2021 | Click here to view
Get an early look at the exciting opportunities coming to the all-new Virtual Metalcasting Congress 2021! Learn about exhibit options, registration, programming and more.
Application of AI in the Metal Casting Industry
Dr. Hathibelagal Roshan | Recorded Jan. 19, 2021 | Click here to view
This webinar will explore the use of artificial intelligence and machine learning in foundries.
New COVID-19 Relief Package: Key Provisions Impacting U.S. Metalcasters
Angela Styles & Zachary Rudisill | Recorded January 15, 2021 | Click here to view
This webinar covers what's important for U.S. metalcasters to know about the coronavirus relief and government spending package.
Steel Casting Specifications
Mike Porfilio | Recorded December 15, 2020 | Click here to view
Learn the latest insights for achieving high-quality steel castings. This webinar covers contract review, major factors of order specifications, material specifications, drawing requirements, and more.
Best of Congress 2020: Further Evaluating Iron Filter Print Designs
Tony Midea | Recorded December 8, 2020 | Click here to view
With tighter customer requirements and new challenges in an ever-changing industrial landscape, many foundries have had to utilize new technologies in creative ways to improve their process quality, cost, and efficiency to compete in the global economy. Properly filtering iron castings involves utilizing the most optimally engineered filter print and gating system designs to ensure delivery of the cleanest and least turbulent metal to the mold cavity.
Achieving Crystalline Silica Compliance With a Payback - A Story of Enriched Water
Eric Nelson & E. Jay Zins | Recorded November 3, 2020 | Click here to view
Join presenters Eric Nelson and Jay Zins of Dotson Iron Castings (Mankato, MN) as they discuss their system changes and approach to achieving compliance with the latest OSHA silica regulation. The team will cover system considerations, implementation and engineering as well as the challenges experienced in bringing the system online.
SEO 101: Beginners Guide to Search Engine Optimization
Caterina Romano & Matt Babiarz | Recorded September 30, 2020 | Click here to view
Know your company needs to rank higher on Google, but not sure where to start? SEO is a science. And it’s squarely centered on user experience. Gone are the days of stuffing keywords into your copy to get a #1 Google ranking. Today, achieving sustained top-rankings for your content requires completely rethinking how you choose the content you write about in the first place, how you format and present the content, and how you methodically elevate awareness of the content.
Grain Refinement and Hydrogen Control of Cast Aluminum Alloys
Brian Began | Recorded September 15, 2020 | Click here to view
Hear the latest developments in sand molds, permanent molds, and low pressure molds with aluminum alloys, and learn the latest advancements and case studies on the use of grain refining in cast aluminum alloys.
Best of Congress 2020: Thermal Analysis and Properties of 1030 with Mg & Ti Additions
Dr. Robert Tuttle | Recorded September 8, 2020 | Click here to view
Learn about new research studying additions of titanium and magnesium on their own and together in 1030, and their effect on mechanical properties.
5 Ways to Get The Most Out of Your Media Coverage
Towanda Long | Recorded August 27, 2020 | Click here to view
Media attention is good for your company; handling it well can earn you more positive attention. This webinar explores five ways to turn your 15 minutes of fame into much more.
Lessons Learned & New Development: OSHA's Crystalline Silica Rule 2 Years After Implementation
Brent Charlton, Kay Rowntree & Mary Kay Crowley | Recorded August 18, 2020 | Click here to view
Looking at the OSHA silica rule in retrospect, this webinar will provide foundries with practical lessons learned about the silica standard and maintaining compliance.
Leadership & Career Development: A Case Study
Lindsay Hamner | Recorded August 13, 2020 | Click here to view
This webinar will provide you with practical, actionable steps to navigate your professional journey, and further career development for you and others, while showing you how to foster a culture of learning and mentorship. Told through the narrative of the presenter and her experience in coursework focusing on personal career development, leadership skills, and mentoring.
Employer Branding is for Everyone
Sara Timm | Recorded July 30, 2020 | Click here to view
Join branding expert Sara Timm of Waupaca Foundry to learn how a positive reputation supports your business plan and encourages productivity.
Best of Congress 2020: Wireless Sensor Measurement in 3D Printed Sand Molds
Eric MacDonald, Ph.D | Recorded July 28, 2020 | Click here to view
Additive manufacturing is enabling the casting of complex geometries directly from digital design data and including 3D-scanned and reversed-engineered structures and even functionally-graded lattices. By inkjetting binder into a bed of sand layer-by-layer, dimensionally-precise sand molds and cores can be printed to serve as soft tooling for sand casting. However, the related increase in geometry complexity can lead to challenges in ensuring casting quality and yield. One recently-explored remedy is to introduce sensors (the Internet of Things) to enable the collection of a diversity of data at difficult-to-access locations in molds and includes measuring temperature, pressure, moisture, and detecting core shift. This webinar will describe work in wirelessly measuring temperature, humidity, magnetic field, metal velocity, and most recently, in barometric pressure, to monitor the pressures that accumulate within cores due to binder decomposition.
Latest on U.S. Trade Actions, USMCA, China Tariffs
Nicole Bivens Collinson | Recorded July 16, 2020 | Click here to view
Hear the latest on key trade policy developments affecting metalcasters and predictions on what may happen for the remainder of the year.
Use of Mull-to-Energy Strategies for Improved Control of Green Sand Systems
Dr. Paul David Paulsen | Recorded July 14, 2020 | Click here to view
Learn how some foundries have used mulling-to-energy as an alternative for better sand consistency and increased throughput.
Cast Metal-Ceramic Composite Lattice Structures for Energy Absorbing Penetration Resistant Application
Dr. Alan P. Druschitz & Manuel Umanzor | Recorded June 30, 2020 | Click here to view
This webinar profiles a project which demonstrates how different foundry alloys, cast into several lattice structure panels, are able to resist penetration from different caliber projectiles.
Earn the Right to Close the Deal: Qualify Before Present
Rich Austen | Recorded June 24, 2020 | Click here to view
Sales professional Rich Austin will provide essential ingredients for your sales success in the new normal. Austin’s presentation will demonstrate how personality and Intuition, also known as the ‘Wing-It’ model, is the most commonly used sales methodology in the world today. Unfortunately, most buyers do not share your personality, and intuition leads to assumptions which can prove devastating in a selling environment.
Parameters that Matter When Evaluating Inoculants
Lizeth Eloisa Medina Balliet | Recorded June 17, 2020 | Click here to view
Effective inoculation has an effect in a wide variety of factors in liquid and solid state. Inoculants are the source of inoculation. As we strive for continuous improvement, lean practices and cost savings, we often look at making changes in our process. Inoculants are some of these changes; these changes can potentially result in disruptions to the process (aka SCRAP). This talk will address how we can practically evaluate inoculants and the effect in process.
Addressing Mental Health Concerns for Employee and Organization Success
Kevin Beaver | Recorded June 11, 2020 | Click here to view
To ensure companies have a workforce prepared to meet the demands of the ever-evolving foundry industry, they must be prepared to effectively respond to workplace mental health and substance use concerns. This session will provide background information on mental health and substance use issues in the workplace, and how to most effectively address these concerns at an individual and organizational-level.
Best of Metalcasting Congress 2020: Tellurium Coating and Control in the Foundry
Kramer Pursell | Recorded June 4, 2020 | Click here to view
This presentation discusses Dalton Foundry’s experience and lessons learned from the use and management of tellurium coatings. Dalton has effectively used tellurium coatings on a variety of gray iron castings to eliminate shrinkage defects when gating or risering is not possible.
Best of Metalcasting Congree: Foundry 4.0 -- Driving Change with Your Data; Use Cases, Best Practices and the Goal of Implementing an Industry 4.0 Strategy
Jim Wenson | Recorded June 2, 2020 | Click here to view
Data and information are valuable (and we have more than ever before), but companies will be able to differentiate themselves by the people, tools and execution utilizing that data.
Social Media Marketing: Best Practices, Tips and Tricks
Skylar Finkelstein | Recorded May 27, 2020 | Click here to view
Simpson Technologies Corp. Marketing Manager Skylar Finkelstein discusses social media marketing, popular platforms, social content, and tips and tricks for getting the most out of your social media campaigns.
Non-metallic Inclusions in Inoculated Spheroidal Graphite Iron
Simon Lekakh & JingJing Qing | Recorded May 21, 2020 | Click here to view
Inoculation of spheroidal graphite cast iron (SGI) is used for improving casting performance and eliminating solidification microporosity by controlling graphite nodule nucleation. In this seminar, we will discuss basic of thermodynamic predictions of non-metallic inclusion formation during ductile iron liquid metal processes, describe a new methods of automated SEM/EDX inclusion analysis, how to get information about graphite nuclei family. High resolution TEM will show you complicated structure of individual nuclei, you will see atomic interfaces in great details. We will also introduce method of 3D micro CT visualization of graphite nodules in cast structure and demonstrate advantages of 3D methods compare to 2D analysis. Finally, we will shear with you the results of study effect of melt inoculation on microporosity in casting.
Best of Metalcasting Congress 2020: A New Measure for Active Clay in Green Sand
Andreas Decher & Sam Ramrattan | Recorded May 12, 2020 | Click here to view
An alternative approach to measure active clay in green sand has been developed. The new technique is based on dye absorption and uses a spectrophotometer to detect the amount of active clay present in a green sand sample. This study investigated a commercially available, organic and nonhazardous dye. The test procedure can discriminate among various levels of sodium and calcium Bentonite standards in silica sand. Results with the new approach shows repeatability with acceptable test-to test variability when measuring standard active clay levels from 2 to 12% and on samples of green sand from working foundries.
Best of Metalcasting Congress 2020: Quantifying Casting Quality through Filling Conditions
Dan Hoefert | Recorded May 6, 2020 | Click here to view
Focused concern and education related to filling damage and oxide inclusions has been widely promoted among the foundry industry in the past three decades; with special regards to aluminum. However, predicting the quantifiable damage that oxide film may cause to the quality of aluminum castings during the filling process remains largely theoretical, due to a lack of supporting data. The purpose of this experiment was to turn on and turn off turbulent filling conditions consistent with bifilm entrainment, in order to obtain the needed data required to predict the actual porosity and tensile damage these conditions may cause to aluminum castings.
3D Sand Printing: Production-Ready
Brandon Lamoncha | Recorded April 28, 2020 | Click here to view
This webinar is a discussion on 3D printing opportunities to go into full production.
Best of Metalcasting Congress 2020: Ultrasonic Cavitation Based Dispersion for Nano-Composites Casting
David Weiss | Recorded April 16, 2020 | Click here to view
The presentation describes work over the last year on development of materials and foundry technology for the production of aluminum based nanocomposites. Highlighted are techniques for both adding particles into the melt and the development of nano particles within the melt using reactive chemistry. A proposed plan for the transition from bench and small scale testing to the production of full scale components is detailed.
A New Look at Protecting Foundry Workers from Heat-Related Illness
Bob Scholz P.E., CIH | Recorded April 14, 2020 | Click here to view
Learn how you can review your own heat stress management program and see practices of other foundries in protecting their workers from heat-induced illness.
AFS Institute Webinar: E-Learning Onboarding
Jen Christian | Recorded April 7, 2020 | Click here to view
The purpose of this 30-minute webinar is to demonstrate how the AFS suite of e-Learning modules may be used to support and add value to the onboarding of employees.
COVID-19 Stimulus Law: New Federal Loan Options for Small and Medium-Sized Metalcasters -- Are You Eligible, How Do You Apply, and What are the Key Terms/Benefits?
Arent Fox LLP | Recorded April 6, 2020 | Click here to view
Learn about the Coronavirus Aid, Relief, and Economic Security Act’s (CARES Act) provisions relating to business loan programs for small and medium-sized metalcasters. This webinar will focus on assisting small and medium-sized businesses in determining eligibility and securing loans under the programs established by the CARES Act.
AFS Institute Webinar: E-Learning Best Practices
AFS Institute Staff | Recorded March 31, 2020 | Click here to view
The purpose of this 30-minute webinar is to share the best practices for the delivery of e-Learning at your company (using the AFS e-Learning platform and modules).
COVID-19 and OSHA Compliance
Brent Charlton & Kay Rowntree | Recorded March 26, 2020 | Click here to view
This webinar explains the necessary elements of a COVID-19 safety program for your foundry. The information is appropriate for health and safety professionals.
COVID-19 Practical Guidance for Metalcasters
Edwin Foulke & Howard Mavity | Recorded March 19, 2020 | Click here to view
This webinar reviews recent COVID-19 developments and federal legal guidance targeted for manufacturers, including strategies to prevent workplace exposure, PPE, OSHA guidance, and employee leave.
AFS Institute Webinar: Custom On the Job Training
Clarence Trowbridge | Recorded March 17, 2020 | Click here to view
During this 60-minute webinar participants will discover how to develop and dramatically improve custom on the job training programs for their manufacturing jobs/positions!
What Will The Rise of Electric Vehicles Mean for Metalcasters?
Richard Jefferson | Recorded March 4, 2020 | Click here to view
Automotive manufacturers have decided it’s time to offer consumers more electric vehicles (EVs), and as a result, fundamental change could be coming to automotive industry suppliers, including metalcasters.
Empirical Methods for Estimating Heat Treatment Parameters and Evaluating Quench Severity
Dr. David C. Van Aken | Recorded February 19, 2020 | Click here to view
The webinar reviews the basic function of the Missouri S&T hardenability calculator. This excel spreadsheet calculator uses traditional empirical relations based on steel chemistry to determine heat treatment parameters, prior austenite grain size, hardenability, quenched hardness profile, and tempered hardness.
Websites for Foundries: What Helps and Doesn't Help the Customer
John Grabel | Recorded January 28, 2020 | Click here to view
How does a “no quote” response make you feel? Can it be avoided? The right information on your website can eliminate most of that problem. Does your website help potential customers find you or are you unwittingly erecting barriers? Who is your true customer and what information do they really need from your website? Find out at this webinar presented by industry expert John Grabel.
Work Is Flowing Out Of China: How To Get Your Share Now!
Harry Moser | Recorded January 21, 2020 | Click here to view
Rising labor costs, tariffs, and the high cost of offshoring are prompting manufacturing jobs to leave China. This webinar from Harry Moser of Reshoring Initiative shows how to capitalize on this trend through reshoring and Foreign Direct Investment. Resources covered include the Total Cost of Ownership (TCO) Estimator and the Import Substitution Program.
Coming into Compliance with the DOL’s New Salary Requirements Thresholds for the Overtime Exemption
Mitchell W. Quick & Elizabeth A. Odian | Recorded December 10, 2019 | Click here to view
The U.S. Department of Labor (DOL) recently published its final rule changes to the salary threshold requirements for the “white collar” overtime exemptions under the Fair Labor Standards Act (FLSA). The DOL increased the minimum salary levels by almost 50%. Attorneys Mitchell Quick and Elizabeth Odian of Michael Best & Friedrich LLP will go over the new rules in detail, and advise how employers can achieve compliance by the January 1, 2020 deadline.
The Synergistic Effects of Refractory Coatings and Sand Additives in Controlling Veining, Metal Penetration and Surface Finish in PUCB Systems
Dr. Paula Vivas, Matt Shoffner, Marek Simon, E. Rivera & Lee Horvath | Recorded December 3, 2019 | Click here to view
The development of more effective engineered sand additives and refractory coatings has significantly helped to reduce or eliminate casting defects such as veining, metal penetration and surface finish for castings made using chemically-bonded molds/cores. The goal here is to systematically understand/quantify the contribution that each of these materials has during the casting process. However, this process is a multi-variable one so in order to gain deeper insight of the overall effects of these materials, the individual variables/parameters need to be analyzed simultaneously.
Consideration of Material, Labor and Production Costs in Steel Casting Tooling
Roy Stevenson | Recorded November 15, 2019 | Click here to view
This webinar highlights a steel casting case study, utilizing material, labor and production costs, which were integrated into the casting process simulation software interface. Having the costs associated with producing the casting when using each tooling design, along with the predicted quality level of each tooling design, gives the foundry engineer a much better idea of the true overall costs associated with a given tooling design.
A Primer: Silica Compliance Made Easy!
Juliette Garesche | Recorded November 13, 2019 | Click here to view
This webinar will serve to clarify, in plain language, the requirements of OSHA’s Respirable Crystalline Silica (RCS) standard. It will cover the basic and necessary definitions of silica related terms and review the resources available on the AFS website.
Opioids/Cannabis Workplace Drug Testing: What Should Metalcasters Know?
Nancy Delogu | Recorded November 7, 2019 | Click here to view
The opioid crisis has escalated dramatically across the country. At the same time, the marijuana legalization movement has grown, and a number of states now not only permit medical marijuana but also recreational marijuana. What can metalcasters do to maintain a safe workplace? What restrictions are there for testing employees for drug use?
A Conversation with an OEM Strategic Commodity Manager
Serhan Yener & Richard Jefferson | Recorded October 23, 2019 | Click here to view
- How do you select a manufacturing process for required OEM parts?
- How does cost figure in the decision to purchase parts, as compared to quality, lead times, etc.?
- What is your perspective on surcharges?
Serhan Yener, Strategic Commodity Manager for AGCO Corp., answers these and other key supply chain questions during an exclusive web event for Casting Source magazine.
Best of CastExpo 2019—Welding of Aluminum Castings: An Overview and Recommendations
David Weiss, Mike Gwyn & Keith Sturgill | Recorded October 23, 2019 | Click here to view
In-process weld rework during finishing of as-cast surfaces on many kinds of castings is widely misunderstood by casting materials engineers, manufacturing engineers, and inspectors. In some cases, welding is prohibited, or restricted, or significant burdens are imposed to document welded castings. This reviews current specifications and the results of testing done over the years on aluminum castings for aerospace, military and commercial applications. Proper welding technique and post processing recommendations are also discussed for welding of aluminum alloy castings.
Best of CastExpo 2019—Sand Distribution Effect on Three-Dimensional Printed Sand Properties
Kip Woods, Dr. Scott Giese and Sudhir Trikha | Recorded October 8, 2019 | Click here to view
This webinar assesses the impact that screen distribution has on the final properties of 3D printed silica sand.
Best of CastExpo 2019—Evaluation of Emissions in Green Sand & Casting Comparison
Sairam Ravi, Jerry Thiel & Victor LaFay | Recorded September 24, 2019 | Click here to view
For many years, researchers in the foundry industry and universities have been developing testing protocols to evaluate the emission characteristics of prepared green sand during pouring, cooling and shakeout. This paper will review the testing protocol and methods used in the collection and evaluation of these emissions that is the result of the entire metalcasting process.
A Year After OSHA Began Silica Enforcement: What Savvy Foundries Have Learned?
Kay Rowntree, Eric Pylkas & Daniel Engling | Recorded September 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 August 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 August 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 August 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, 2017 | 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.