2023 Copper Workshop Agenda
Session Chair:
Buddy Barnhill Jr.
Lee Brass Co., Anniston, AL
Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada
The basic metallurgy copper alloys is presented. Starting with an introduction to copper, followed with various major and minor alloying elements and their impact on properties. Copper alloy families are introduced with common applications.
Chris Greenfield
The Federal Metal Co., Bedford, OH
Zach Spellman
Imperial Group LLC, Chicago, IL
Matt Levine,
Leonard Levine Metals Corp., Chicago, IL
Michelle Ring
Norican Group, Carmel, IN
Kay Rowntree
Industrial Hygiene Sciences LLC, Waterford, WI
Ted Schorn
Enkei America Inc., Columbus, IN
There is a strong current of excitement over autonomous inspection using machine vision coupled with artificial intelligence. Before a foundry jumps into such a project, a few words of caution are in order. Ted will describe what characteristics make sense for inspections without humans and those that continue to need direct human involvement.
Ted Schorn
Enkei America Inc., Columbus, IN
Some authors in the safety field have offered the opinion that setting a “zero defect” goal for safety programs is not only not achievable, but harmful. Others insist that we must target zero injuries in our efforts to manage safety. Ted will review this controversy, offering an overview of the issues and why such a question matters practically as we try to reduce injury rates in our foundries.
Session Chair:
Gerald Richard
MAGMA Technologies, Schaumburg, IL
Gerald Richard
MAGMA Foundry Technologies, Schaumburg, IL
In this talk we will begin by reviewing traditional gating methods and how to calculate them. Then, we will move to more advanced gating design practices including pouring basin design, parabolic sprues and vortex surges. The goal is to understand which set of practices will help minimize defects such as misrun, sand inclusions, and leakers.
Paul Clements
Sloan Valve Co., Augusta, AR
This presentation will cover basic gating and risering principles for range of copper based alloys. Instruction will be supported with the aid of fluid flow and solidification modeling results to demonstrate root cause analysis of common filling and solidification defects. Emphasis will be put on understand molding and pour system constraints to maximize yield as it applies to casting quality.
Andy Shea
AY McDonald Mfg. Co., Dubuque, IA
Some casting designs become difficult for foundries to make. This presentation identifies some good designs for no lead brass castings with green sand molds and goes through gating changes that have reduced casting scrap.
All Presenters & Attendees
TopGolf
2050 Progress Pkwy
Schaumburg, IL
Session Chair:
Jeff Sorenson
Lee Brass, Anniston, AL
Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada
Principles and best practices of copper melting will be discussed. Topics include Charge materials, Oxidation, gas content, melt protection and processing (deoxidation, degassing, grain refinement). Presentation includes tests for melt and metal quality.
Tom Prucha
Metal Morphasis LLC, Rochester Hills, MI
Copper based alloys continue to be an important cast material offering unique engineering and performance properties. Over the past few years numerous papers of various topics that include alloy development, manufacturing, process modeling and optimization research, dissimilar melting joining and compound casting, and improvements in melt technology have been published in the International Journal of Metalcasting (IJMC). This talk will review some key findings from these papers and potential areas for further investigation to help advance copper-based metal castings. Finally, beneficial examples from research and findings outside of these copper specific papers, including topics like additive manufacturing and Industry 4.0, will be discussed.
Marshall Miller
3D Systems, Rock Spring, GA
Customers rarely, if ever, tell us the molding equipment arrived so quickly and was so inexpensive they were astounded. Today, the technology is here to deliver resilient molding equipment more quickly and less expensively than conventional purely subtractive methods.
This presentation will provide comparisons between additively manufactured molding equipment and traditional methods for green sand, no-bake, lost foam and investment casting tooling and how additive manufacturing drives down cost and delivery dramatically.
David Oppedahl,
Federal Reserve Bank of Chicago, Chicago, IL
This talk will provide an overview of key economic factors, such as output, employment, inflation and US monetary policy. An economic forecast for the US will be shared as well.
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.
Panelists:
Leigh Omer
H. Kramer & Co., Chicago, IL
Kumar Sadayappan
CanmetMATERIALS, Ontario, Canada
Jeff Sorenson
Lee Brass Co., Anniston, AL
Jim Valentine
Neptune Technology Group, Inc., Tallassee, AL
Have you ever had a scrap problem that you just cannot find a solution for? If so, we have a panel session that can help with that problem. Come join Industry Experts in this panel session that will focus on scrap issues and how to fix that problem casting that always seems to show up. You can bring that casting with you to the Copper Workshop on September 27th and 28th at AFS Headquarters in Schaumburg, IL. If you are worried about getting on the plane with your casting, you can send it to AFS attention Brian Began and we will make sure that it makes it to the session. Please include any specifics on molding process, alloy, sand properties, etc. - anything that can help the panel members and others in the session to help come up with a solution or solutions.