Session Chair: Ryan Showalter, AFS’ Copper Workshop Chair, Fresno Valves & Castings Inc., Selma, CA 

Ryan Showalter, AFS’ Copper Workshop Chair, Fresno Valves & Castings Inc., Selma, CA 

The basic metallurgy of copper and its alloys is presented. Starting with an introduction to copper, possible alloying elements including major and minor, and their impact on properties are discussed. Copper alloy families are introduced with possible applications.   

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

Leigh Omer, H. Kramer & Co., Chicago, IL: Ryan Showalter, Fresno Valves & Castings Inc., Selma, CA

Session Chair: Eric Sivill, Neptune Technology Group, Inc., Tallassee, AL 

TBD

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 and help avoid common pitfalls that lead to decreased metal throughput.

Session Chair: Jeff Sorenson, Neptune Technologies Group, Lincoln, AL

Al Jacobson, American Colloid Co., Hoffman Estates, IL 

The presentation will discuss the benefits of tightly controlling the key independent variables of:

Compactability, Active Clay and AFS Washed Aggregate Sizing.  These three variables are independent of other greensand properties and are controlled primarily with a system’s major inputs of: water, clay, and sand.  Also presented will be ideas to define and track a system’s current level of variation, so as changes are implemented their effect on variation can be statistically evaluated.

TBD

Kay Rowntree, Industrial Hygiene Sciences LLC, Waterford, WI

• TopGolf Schaumburg
  • 2050 Progress Parkway, Schaumburg, IL, 60173

Session Chair: Gerald Richard, MAGMA Foundry Technologies, Schaumburg, IL

David Halm, Project Success, Atlanta, Georgia

Gerald Richard, MAGMA Foundry Technologies, Schaumburg, IL

Ryan Showalter, Fresno Valves & Castings, Inc., Selma, CA

Paul Clements, Sloan Valve Co., Augusta, AR

Dr. Jerry Kovacich EWI, Columbus, OH

The domestic copper alloy casting industry is experiencing supply shortages and long lead times, especially for large castings. One promising avenue for increasing productivity and alleviating shortages is by reducing reject rates through weld repair of casting defects. If undertaken with care, repair welding can fill casting voids or defects that would normally lead to part rejection. This talk will focus on the welding metallurgy of copper alloys, candidate processes for repair welding of copper alloys, and the current state of the art in welding automation and digital manufacturing for weld repair. Strategies for welding of common copper alloy families will be discussed, with an emphasis placed on historic best practices for cast alloys and methods to test feasibility of new weld repair applications. Common welding process attributes such as deposition rate, joint accessibility, and as-deposited properties will be discussed to guide process selection for a range of casting repair applications. EWI will also provide case studies for advanced digital manufacturing technology including robotic defect grinding and weld repair, scan-to-plan defect sizing and weld repair, reducing workforce requirements through cobotics and telemanufacturing, and how hybrid manufacturing and additive manufacturing can improve (but never replace) casting processes. EWI will wrap up the talk with a look ahead at promising casting repair technologies recently developed and how they may provide benefits for certain copper casting applications. 

Paul Clements, Sloan Valve Co., Augusta, AR

Ben Yates, American Foundry Society, Inc. Schaumburg, IL

Ben Yates will share a brief overview of data trends and economic indicators from the 2025 Mid-Year Forecast & Trends report published by AFS in July.