2020 Sand Casting and Additive Manufacturing Conference

John Danko, Danko Arlington Inc. (Baltimore, MD)

Hear from an early adopter of 3D sand printing! Started just after the 1918-1919 Spanish Flu pandemic, Danko Arlington recently celebrated its 100th anniversary. John Danko, president of Danko Arlington, will discuss how additive manufacturing has transformed the foundry and the lessons learned while adapting to changing environments over the last century. Stressing innovation and out-of-the-box thinking, John will emphasize e-commerce, digital platforms, remote management, and 3D sand printing to best prepare metalcasters for the next generation.

Bryan Kluge, Imerys (Cincinnati, OH)
Pete Gravunder, Badger Mining Corp. (Berlin, WI)

Travis Hepfner, Cadillac Casting Inc. (Cadillac, MI)
Michelle Ring, Minerals Tech (Carmel, IN)

Are new sand additions important to sand system quality? Listen to one foundry's story. With a big influx of heavily cored jobs at the facility, it didn't make sense to keep adding new sand when they were constantly removing sand from the system to better maintain levels. Learn how this foundry overcame the challenges created by this system change.

Steve Neltner, REFCOTEC (Orrville, OH)

Hear from one of the leading sand system experts! This presentation discusses how green sand additives can greatly enhance the properties of prepared molding sand. Additionally, Neltner will discuss how foundries use specialty additives to create better sand property consistency, reduced casting cleaning time, and scrap.

Dave Silsby, Simpson Technologies (Aurora, IL)

Larry Kaiser, American Colloid Company (Hoffman Estates, IL)

Jerry Thiel, University of Northern Iowa (Cedar Falls, IA)
Jiten Shah, Product Development & Analysis LLC (Naperville, IL)

Dr. Yoya Fukuda, Kimura Foundry America Inc. (Shelbyville, IN)

Kelley Kerns, HA-International (Westmont, IL)

As the demands on printing technologies and capabilities advance, so do the performance expectations on the consumables. What you should expect from resin systems, cleaners, and coatings to optimize your operation? Hear a leading supplier discuss the latest technological advances.

Doug Imrie, Southern Cast Products Inc. (Jonesboro, AR)

Rick Lucas, ExOne (Irwin, PA)

Jiten Shah, Product Development & Analysis LLC (Naperville, IL)

 Dr. Scott Giese, University of Northern Iowa (Cedar Falls, IA)

Bill Johnston, Ellwood Engineered Castings (Hubbard, OH)

Learn from a foundry that has gone through the process of replacing silica sand with ceramic media. The presenter will walk through the full conversion process, from evaluating ceramic media for a possible foundry conversion, trials to evaluate the material, steps to make a complete conversion to a ceramic molding material, and lessons learned during and after the conversion.

Sairam Ravi, University of Northern Iowa (Cedar Falls, IA)
Brodie Biersner, HA-International (Westmont, IL)

Bring your problems and questions on everything you need to know about chemically bonded cores and molds and refractory coatings. A panel of experts will answer your questions and help solve your most pressing problems in this area.

Kelley Kerns, HA-International (Westmont, IL)
Joe Muniza, ASK Chemicals (Dublin, OH)

Dr. Sam Ramrattan, Western Michigan University (Kalamazoo, MI)
Jeff Cieplewski, Weaver Material Services, Inc.
Dr. Lee Wells, Western Michigan University (Kalamazoo, MI)
Andy Pike, Mueller Co.

Milan Raval, Altair Engineering, Inc. (Troy, MI)

Many foundries prefer chemically bonded sand mold over green sand when it comes to castings with thin-wall sections and complex internal dimensions, yet casting issues can result in costly defects. This presentation addresses chemically bonded sand erosion and surface finish issues for aluminum and cast iron castings. Erosion in chemically bonded sand can occur when molten alloy dislodges grains of sand, resulting in a rough as-cast finish.

Dan Coyle, Magma Foundry Technologies (Schaumburg, IL)

Sairam Ravi, University of Northern Iowa (Cedar Falls, IA)

Claude Krause, Carbo Industrial Technologies, Broussard, LA

Kirk Rogers, Case Western University (Cleveland, OH)
Kip Woods, Emerson Process Management (Nevada, IA)

Alan Franc, Techmer PM (Clinton, TN)

The production of foundry tooling has been adopting additive manufacturing (AM) as a fabrication method. Conventional fused filament fabrication is the most common AM production process but is typically limited in types of materials available. These materials (such as PLA and ABS) have relatively poor abrasion and chemical resistance. This presentation will discuss and compare several thermoplastics composites with improved performance for foundry tooling.

Clay Guillory, Titan Robotics Ltd. (Colorado Springs, CO)

Marshall Miller, Flowserve Corp. (Rock Springs, GA)

The current cost of molds is a barrier to access of customers to the lost foam casting process. By applying new additive processes and materials through the AFS project to develop lost foam tools in polymers and titanium, the cost of tools is reduced to a fraction of the cost of subtractive tools.

Marshall Miller, Flowserve Corp. (Rock Springs, GA)

Jeff Krause, HA International, Westmont, IL

Jarek Olszak, Laempe-Reich (Trussville, AL)

Jeff Krause, HA International (Westmont, IL)
Kip Woods, Emerson Process Management (Nevada, IA)

Jerry Thiel, University of Northern Iowa (Cedar Falls, IA)