Research

Fostering innovation is one of the three pillars of the AFS mission. AFS has a long history of sponsoring metalcasting research and innovation. The goal of AFS research is to move the metalcasting industry forward, remove technical barriers and gaps, and improve the overall efficiency and quality of the metalcasting process.

AFS works with leading casting technical experts to discuss state of the industry, and ask leading questions such as: What would make our job better? What would we like to be able to do in 5 years, or 10 years that we cannot do now? AFS research projects help develop new technologies, improve our understanding of basic casting issues, and benchmark best practices. 

AFS involvement in metalcasting research has two facets: direct funding, and partnerships.

AFS-Funded Research

AFS directly sponsors research programs through a fund based on an allocation of a portion of AFS Corporate Member dues. The Research Board selects projects and provides oversight. Most research projects are developed by the AFS technical committees and their members serve as the steering committee to help monitor and direct the research toward project goals and objectives. The mix of projects varies each year, based on submissions from the divisions.

If you are interested in participating in an AFS research project or committee activity, contact the AFS Vice President of Metalcasting Technical Services Brian Began at bbegan@afsinc.org, or Assistant Technical Director of Metalcasting Services Bo Wallace at bwallace@afsinc.org.

To submit a research proposal, click here.

Chart updated April 2025

Back to Top

Research Partnerships

AFS is also involved in outside casting research programs. These partnerships and consortiums allow AFS to participate in additional funding and provide additional value to the industry. AFS is involved in two primary partnerships:

AMC: AFS maintains its collaboration with the American Metalcasting Consortium. The consortium is a research partnership including four metalcasting associations to promote cast metals research and infrastructure improvements to benefit U.S. military and defense needs. AMC is funded through the U.S. Department of Defense, Defense Logistics Agency, managed through the Advanced Technology Institute (ATI). Under the current (5 year) program commencing in March 2023, AFS will directly manage three projects.

AMC Emergent Metal Casting Solutions (EMCS) Program (2023-2028)

The first project focuses on investment casting and will entail three distinct objectives.  The first objective will be to assess new materials, processes, or automation technologies in hopes of achieving more rapid production.  The second objective will be to focus on processes and recommendations for improving the recycling of spent shell materials with associated ambition for lower cost and reduced environmental impact.  The third objective is to develop best-practice data-driven design tools for risering unique Ni-based alloys where current risering capabilities require more understanding.

A second project is developing interactive digital capabilities to more rapidly transfer metalcasting technology and best practice knowledge.  In this project, AFS electronic platforms such as the digital library, CADS, AFS Onlive and a new digital publications platform will be enhanced to be mobile-friendly and with enhanced navigation and improved content.

The thrust of the third project is to model the relationship between surface defects on cast metal components and casting process variables and parameters.  Success would enable corrective actions to improve casting surface quality and minimize casting surface defects.

In addition, AFS will be providing technical oversight and guidance for an additional project managed by an outside investigator.  This project is a continuation of a previous project that is to finalize guidelines for Nano-Reinforcing Aluminum alloys to cost-effectively increase strength without increasing weights.

Previous AMC Research

Aluminum Casting Performance Initiative (ACPI) Program (2025-2028)
The American Foundry Society has received funding as part of the Aluminum Casting Performance Initiative to pursue three projects relating to improving reliability and quality of aluminum casting methods.

The first project aims to develop a machine learning based image recognition tool to diagnose aluminum casting defects. This system aims to capture knowledge from the aluminum quality workforce and assist training of new teammates, while improving inspection speed and costs.

The second project seeks to develop datasets for alloys to be added to the Metallic Materials Properties Development and Standardization (MMPDS) handbook and the Casting Alloy Database Search (CADS). This information will provide pedigreed data for DoD end users to utilize C355-T6 alloy castings with no knockdown factor and with further optimizations in design.

The third project aims to develop a cutting-edge in-line tool for automated production of aluminum investment castings critical to the DoD. This data will be used to create a digital twin of the shell manufacturing processing and casting process.

Research was funded through the American Foundry Society, as part of the Aluminum Casting Performance Initiative, Emergent Metal Casting Solutions (EMCS) program, sponsored by the Defense Logistics Agency Information Operations, J68, Research & Development, Ft. Belvoir, VA and the DLA Troop Support, Philadelphia, PA.

ACRC: AFS is also a member of the Advanced Casting Research Center (ACRC), an industry-university research consortium focused on addressing the global foundry industry. As a member, AFS assists in oversight and selection of casting-related research programs. ACRC is located at the University of California, Irvine. ACRC is currently managing an AFS recommended program on innovative heat treating for aluminum alloys.

America Makes / National Center for Defense Manufacturing and Machining (NCDMM):
AFS is a partner in the America Makes Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis (IMPACT) program funded through the Office of the Under Secretary of Defense, Research and Engineering Manufacturing Technology Office (OSD/R&E) and the Air Force Research Laboratory (AFRL).  Under IMPACT, America Makes seeks to promote and accelerate the development and deployment of innovative, cost effective, energy-efficient AM and 3D printed technologies to meet defense and/or commercial needs.  

•    IMPACT 1.0:  Transitioning Best Practices and Technology Improvements for Printed Sand Molds/Cores (2023-2025):  AFS, along with Product Development & Analysis (PDA), LLC, will be part of a cross-functional team under the leadership of Honeywell Aerospace and will lead the efforts to support industry engagement, and the technology transfer of the technologies developed under this program as well as support efforts to characterize the baseline performance of the printed sand molds and their impact on resultant casting quality outcomes.

•    IMPACT 2.0:  Transitioning Best Practices and Technology Improvements for Advanced Technology Printed Sand Equipment (2024-2026):  AFS, along with PDA, LLC, will be part of a cross-functional team under the leadership of Honeywell Aerospace and will coordinate efforts to support industry participation and adoption of domestic equipment and best practices and the technology transfer of the technologies developed under this program as well as support efforts to reinforce the casting supply chain with US-made and supported printed sand molds for both government and private casting buyers.
 

Chart updated May 2025

Back to Top

AFS Research Board

The AFS Research Board nominates a slate of potential new candidates in the fall meeting. The current chair contacts the candidates regarding their interest in serving, and the current research board members select the incoming member at the winter meeting. The five-year term for the new member begins in the second calendar quarter.

If you are interested in getting consideration for joining the AFS Research Board, please send a one or two page biography to bbegan@afsinc.org or bwallace@afsinc.org.

Back to Top

Research Now Underway

Innovation is at the heart of the AFS mission – and at the heart of innovation is research. Multiple ongoing research projects are in various stages of development. Click here to view current AFS-Funded Research.

Back to Top

Research Success Stories

AFS-funded research serves the entire metalcasting industry. Click below to learn more about some of our most impactful recent projects.

 

Back to Top