Metalcasting Industry Research - American Foundry Society

Metalcasting Industry Research Support of research is critical for North America to maintain a strong, vibrant, healthy and continually advancing metalcasting industry. Part of the AFS mission is to promote these activities for the betterment of our membership, our industry and our society. AFS directly funds research projects from allocation of a portion of the annual dues paid by AFS Corporate Membership. The current AFS Funded Research Projects are described below. The other projects are funded through research partnerships, government funding and industry contributions. AFS participates in these projects by securing industry partners

and providing technical management and oversight. Current research funding partnerships include: Achieving Lightweight Casting Solutions for Defense Applications (ALCS) funded via a Congressional Appropriation and conducted under a Cooperative Agreement with U.S. Army ARDEC Benet Labs, the U.S. Department of Energy (DOE) former Office of Industrial Technology [Advanced Manufacturing Office-(AMO)] funded through the Cast Metals Coalition (CMC) Program, and the U.S. Department of Defense (DOD) Defense Logistics Agency (DLA) Castings Solutions for Readiness (CSR) Program funded through the American Metalcasting Consortium (AMC).

AFS Funded & Monitored Research Seven active and eleven total projects are currently being funded through the allocation of a portion of the AFS Corporate Member Dues in FY2012-2013 /FY2013-2014.

Optimizing Mechanical Properties of Cast Aluminum Alloys—A319 & A356 (Phase I/Phase II)—CWRU (08-09#04/10-11#01) Coordinator: Case Western Reserve University and AFS Aluminum Division (2) The mechanical properties of cast aluminum products can exhibit wide variation even when the same alloy is used. Best practices to achieve maximum properties encompass: high molten metal quality (clean metal, degassing), metal treatments (modification, grain refining), good gating practices, filtration, directional solidification, fast cooling rates and adequate risering. The industry would benefit from a well-defined set of “potential” (i.e., maximized) properties that can be achieved for any given alloy when best practices are applied. This project assisted to establish a database with “potential” properties of cast aluminum alloys. In other words, if best practices in melting the aluminum and treating it are carefully followed, a high cooling rate is applied and shrinkage porosity is eliminated, what would the properties be? Two principal results emanated from the Phase II work. Firstly, the modified CWRU separately-cast test-bar mold continued to outperform the standard ‘Stahl’ test-bar mold which is covered by ASTM specification B108 with measurably higher average tensile properties. Secondly, the application of melt treatment---grain refinement and modification---in addition to ‘best practice’ melting and melt cleaning, demonstrated in A356 alloy an increase in Quality Index over and above the Phase I results. Results at the CWRU lab and also at a commercial foundry were very similar. Indeed, the desired threshold of 40 ksi tensile, 30 ksi

International Journal of Metalcasting/Summer 2013

yield, and 10 % elongation were greatly exceeded: (45-32-15), this despite a seemingly over-modified condition reflected in 0.022% strontium content. It is believed that improved feeding capability with the knife-ingate CWRU mold design is responsible for this improvement, better feeding overcoming some observed micro-porosity at this high strontium level, and which afflicts the standard Stahl mold design at normal strontium levels (0.0100-0.0150%). For 319 alloy, two commercial foundries provided the venues for pouring test-bars, using their standard ‘best’ melt practices including clean charge materials, degassing, modification and/or grain refining, and in-furnace filtration. Results were compatible with their own test-bar data and were commensurate with their customer’s product requirements. With the demonstrated improvement with the modified Case test-bar mold design, ASTM is being approached to consider incorporation/approval of this design within the standard. The clear conclusion to this work is that best practices during melting and melt treatment do yield best properties in a separately cast test bar for both A356 and 319 alloys, especially with the enhancements provided by the CWRU knife-ingate mold design. Properties in the casting can be expected to be similar to those measured in the test-bar, as long as the solidification rate is similar to the test-bar (approximately 15-20 micron SDAS), and provided that the area of the casting under evaluation is greatly free from defects. Status Update: This work is now complete. It focused on improvements resulting from metal treatment and heat treatment. The paper detailing the final report was at the 117th Casting Congress & CastExpo’13 in St. Louis. 57

Ductile & CG Iron Casting Skin— Evaluation, Effect on Fatigue Strength & Elimination Phase II (09-10#01) Coordinator: The Ohio State University and AFS Cast Iron Division (5) The elimination of the flake skin is one of the key elements of unlocking the full design potential of compacted graphite iron (CGI). Capitalizing on the results of a previous AFS sponsored effort, 04-05#02, “Study of the Effect of the Casting Skin on the Tensile Properties of Light Weight Ductile Iron Castings,” the Department of Materials Science and Engineering at The Ohio State University (OSU) proposes to conduct research with the goal of understanding the mechanism of formation of casting skin in CGI, evaluating its effect on selected mechanical properties, and developing the methodology for its complete elimination. The results of this research will be of immediate applicability to the industry without major capital investment. The research strategy is designed to develop the knowledge required to improve and ultimately eliminate the skin quality of CGI castings and to generate data on its impact on the static mechanical and fatigue properties of CGI, as well as on the efficiency of shot blasting in improving these properties. Additionally, the study may help in the definition of the minimum thickness of the layer that must be removed by machining to avoid negative skin quality effects. The research will capitalize on the experience in the characterization of casting skin accumulated in the Virtual Solidification and Casting Laboratory (VisionCast) at OSU. The success of this investigation will rely on the completion of extensive experimental work that will provide critical data required in the understanding of casting skin formation and elimination. The developed correlations between process variables, casting skin quality and mechanical properties will provide the impetus to further expand the applications of CGI. During Phase I, the mechanism for skin formation and test specimens design was validated. During Phase II, fatigue specimens will be cast and the influence of skin formation on fatigue will be determined. Also, potential actions to reduce or eliminate skin formation will be investigated. Status Update: The project is complete along with two papers reviewing the work were presented at the 117th Metalcasting Congress & CastExpo’13 in St. Louis and a paper published in the IJMC Vol. 7, Issue 2 Spring 2013.

Phase II—Development of Core Gas Venting Guidelines (11-12#02a/b) Coordinator: Andrei Starobin, Alchemcast, and AFS Engineering Division (1) Venting of chemically bonded sand cores and molds is necessary to prevent excessive binder gas blow into a poured casting. All major organic binders currently in use in foundry core making practice outgas significantly and the problem of core/mold venting remains an engineering foundry challenge. 58

Some of the venting techniques practiced today involve forming vent channels in molds drilled to core prints, forming vent channels in cores during core blowing, forming blind core vents in multi-core assemblies, coarsening sand for better permeability, reducing binder content and coating cores. In some cases re-gating, core re-orientation and slowing of metal pour also leads to better core performance. The available means of control of core gas pressure generate a large engineering design space where one would like to make quick and balanced choices. This project delivers to the foundry person a simple Core Venting Design Calculator that should indicate if a given core requires venting and, if so would report approximate impact of various venting techniques and process parameters on core gas pressure. Experimental Phase II work focused on the measurement of peak gas pressure at different core immersion rates. Faster core immersion in iron castings leads to higher peak gas pressure. The first full version of the Core Venting Design Calculator has been completed. PUNB, Shell and PUCB Isocure binders are covered in the calculation framework Status Update: The project is complete and the CVDC calculator was validated for a number of cored Al and Iron castings. It will be demonstrated at a webinar, date to be announced and targeted for the summer of 2013. Those wishing more information, please contact Andrei Starobin at starobin@ cybermesa.com.

Studies of a Quenched Cupola Part IV: Behavior of Coke (11-12#01) Coordinator: University of Antiqua, S. Katz Associates and AFS Melting Methods & Materials Division (8) The cupola furnace produces about 60% of liquid iron used for castings. Despite the age of the process, over 200 years, the cupola has maintained its position as the predominant melting furnace because it is able to melt a much wider variety of scrap than the more modern electric furnaces, hence providing iron at lower cost. Today’s cupolas are far different than the original furnaces which were carried on the back of a horse drawn platform to produce iron for itinerant pot-makers. The virtue of this furnace is its ability to transform itself to meet current needs. Today the cupola furnace must transform itself once more to insure its continued use. There are two major problems that need to be solved: (1) the cupola furnace burns coke which generates more carbon emissions than any other foundry process. As a result, future emissions legislation could impose severe penalties on cupola melting. Since the thermal efficiency of coke-combustion is only 50% - 65%, a significant reduction in emissions could be provided by improving the combustion efficiency. (2) The cupola furnace supplies a large fraction of the carbon for alloying, however the efficiency of coke dissolution is very low (5% - 10%). As a result the required amount of coke required for iron production increases significantly when there is a need for alloy-carbon.


The cupola furnace is among the most complex processes employed in the foundry. All the easy improvements have already been made. Further improvements will require a more sophisticated understanding of the complex internal processes. To this end, the Department of Energy and the American Foundry Society sponsored a project to water-quench a cupola furnace while in full operation and then to conduct an archeological examination of the contents. Three papers were published in 2009 covering the details of the quenching experiment, and tracing the changes in the iron, steel, silicon carbide and slag from the charge door to the tap-hole. The current and final paper covers the corresponding changes in coke, the material whose use must be reduced in order to reduce carbon emissions. It is anticipated that this study will generate ideas for the improvement of cupola performance which includes cost and energy savings and improved combustion efficiency. A recent research project, commissioned by Committee 8K, measured all of the properties used to describe both foundry and blast furnace coke. It included coke from all the current foundry coke producers. No available cupola studies have examined the importance of the additional properties used for testing blast furnace coke (petrographic analysis, reactivity, abrasion resistance, degree of graphitization, ash melting point and ash catalyst index). The proposed study proposal will be the first to examine the importance of these additional properties. Given below are a number of potential improvements in coke performance that are conceptually possible. The analyses of coke in this proposed study should identify which concepts could most profitably be pursued. 1. Reduce CO formation as it produces less energy and more emissions than CO2. 2. Reduce the abrasive loss of coke. 3. Reduce the melting point of coke ash to increase carbon dissolution in iron. 4. Produce alloys in-situ, e.g. SiC or Mn. Thermodynamics indicates it is possible. 5. Determine if coke properties, not currently measured, will provide new insight into coke’s performance. Status Update: The project is complete. An overview paper (Part V) reviewing all the findings of all (4) Phases is being prepared for the Fall 2013 issue of the IJMC. The Phase IV paper was given at the 117th Metalcasting Congress & CastExpo’13 in St. Louis. Those wishing more information should contact Sy Katz, at [email protected].

Magnesium Melt Cleanliness (11-12#04) Coordinator: Dr. C. (Ravi) Ravindran, Ryerson University, and AFS Magnesium Division (6) High-volume application of lightweight materials is key to increasing fuel efficiency and vehicle performance and decreasing exhaust emissions to address environmental concerns. Currently, Mg alloys, which are the lightest structural materials, repre-


sent only ~ 0.3% of the vehicle weight. The proposed research is part of an ongoing effort to increase the use of Mg alloys at a significant level in the automotive industry. One of the most important parameters in controlling the properties of Mg and its alloys for various applications is melt cleanliness with respect to inclusions. The presence of such inclusions will strongly influence the mechanical properties and corrosion resistance of structural parts. The project seeks a better understanding of the origin of defects and inclusions in order to improve melt cleanliness and effectively improve the mechanical properties of Mg alloys. The proposed project aims at carrying out an analysis of the inclusions in Mg castings currently produced, with the ultimate objective to reduce or eliminate/remove them. This project constitutes a first step for the improvement of Mg melt cleanliness. It will provide a clear picture of the current Mg melt quality in the industry. In the future, the project will have an important impact on the productivity through quality improvement and consequently reduction of defective castings. As a result, it will lead to cost reduction and enhancement of foundry competitiveness. Ultimately, the project will help improve the melt quality and lead to reduction of scrap, cost reduction and enhancement of foundry competitiveness. It will also lead to an increase of Mg competitiveness as compared to other materials. The consequent improved mechanical properties of Mg castings will lead to an increase of their structural applications in automobiles. It is the aim of the principal investigator and the Steering Committee to ensure broad diffusion of the project results. The project results will be presented in several scientific articles and presented in chapter meetings, casting congresses or in international peer-reviewed journals. Finally, a two-page foam board poster on current Mg melt cleanliness will be developed. Status Update: The project is ongoing with sampling being conducted at several Mg metalcasting facilities. The work is now being monitored by the AFS Aluminum Division (2) and the AFS Research Board. An update report was given at the 117th Metalcasting Congress & CastExpo’13 in St. Louis. Ryerson is actively seeking additional Mg metalcasting facilities to supply samples to analyze and those wishing more information about the project or participation should contact Dr. Ravi Ravindran, at [email protected].

Veining Reduction Project– Thermo-Mechanical Approach (12-13#01) Coordinator: Dr. Sam Ramrattan, Western Michigan University, and AFS Mold-Metal Interface Reactions Committee (4-F) The proposed research addresses a major technology barrier in manufacturing identified in the Department of Energy Metal Casting Industry Technology Roadmap. The research program addresses the identified manufacturing barrier of understanding the difficulties and expensive costs associated in achieving

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higher levels of dimensional accuracy. Today’s sand casting technology demands precision and the use of superior molding materials is a means to this end. In 1990, the 4-F Committee estimated that $60 million is spent on labor, energy, and scrap to correct metal penetration and veining defects in iron castings. Most of the problems occur in internal cores where it is difficult to remove and salvage the casting. Incidentally, coatings are applied to these areas to rectify the situation. The occurrence of surface defects on coated cores can be attributed to large variations in coating thickness and possible application methods. Demonstration of these variations on surface quality supports the need to better understand the mechanism for casting surface defects necessary to compete in the global market. The proposed research also complements completed and ongoing projects supported by the 4-F Committee and metal casting industry. Thin-wall gray iron technology is strongly dependent on the knowledge of veining and penetration. Other potential AFS-funded research areas where the proposed activities have direct and indirect importance in the development of improved casting technology are heat transfer in permanent molds, thermo-physical properties for solidification modeling, and dimensional accuracy for precision casting.

New Approaches to Clay Control in Green Sand-Phase 2 (12-13#02) Coordinator: Dr. Sam Ramrattan, Western Michigan University and AFS Green Sand Molding Committee (4-M) Measurement of live clay in molding sand is critical to control of foundry green sand. Live clay levels must be controlled to develop and maintain proper strength levels and mechanical properties of the molding sand. Control of the live clay level is also critical to control of moisture and compactability because clay is the primary moisture absorber in molding sand. If clay level could be better controlled, the moisture and compactability could be more closely controlled. Inadequate control of compactability is the leading cause of green sand casting defects, and the associated costs of scrap, rework, labor, and energy to individual foundries and the industry as whole warrant investigations into alternative methods of control.

The results of this study can help a foundry improve competitiveness by reducing defects, rework and scrap. It is critical for the project success to transfer the information to the foundry industry. Currently we are conducting tests for our industry sponsors that will benefit through this research by providing feedback and process improvements.

The foundry industry needs a faster, more accurate, and low cost alternative to properly measure active clay in green sand. The Methylene Blue Clay techniques employed by the foundry industry for measuring active clay suffer poor reproducibility and are thus incapable of maintaining accuracy. Casting defects are consistently attributed to variations in green sand systems and limitations of the clay control methods for green sand. A better clay measurement and control program is necessary to improve green sand systems. Western Michigan University has a new set of tests that can be used as process control tools to characterize and measure clays in green sand. This study explores the applicability of these tests to measure and control clay in green sand.

The 4-F Committee has used the AFS Chapter meetings as a technology transfer tool in discussing the on-going research project conducted by the committee. The presentations of the results will be aimed at the Casting Congress and at AFS Chapter Meetings. We will disseminate results from the casting trials at local AFS Chapter meetings to reach a broader range of users.

The AFS Green Sand Additives and Testing Committee (4-H) has been interested in finding a replacement for the Methylene Blue Clay Test as well as in studies of the heat damage to clays. The purpose of this study is to determine the effectiveness of using alternative in-process tests for measuring active clay in green sand while simultaneously studying the heat damage to clays.

Upon final completion of the research project, a paper will be written for AFS Transactions. This paper will document the scientific details of the research project and will be used for a Casting Congress Presentation. CMI has used facilities at WMU to conduct metal casting training programs. The findings of this study can be incorporated into a training program at WMU to enhance the learning experience through practical applications for the course attendees.

With research support from AFS during Phase 1, Western Michigan University (WMU) has developed a new methodology based on dye absorption for measuring clays in green sand. The new procedure provides a direct instrument read that requires minimal operator training. In addition, the consumables are environmentally friendly, of lower cost and with easier clean-up compared to the current AFS Methylene Blue Clay standard. The AFS Green Sand Additives and Testing Committee (4-H) has been interested in finding a replacement for the Methylene Blue Clay Test. The AFS 4H Committee had endorsed Phase I efforts at WMU and during Phase 2 the AFS Green Sand Molding Committee (4-M) has identified a Steering Committee that is willing to assist with plant trials and evaluation of the proposed test procedure. The purpose of this new phase of research is to further refine the dye absorption technique, and to develop a standard absorption curve for specific working foundry sand. This will take the efforts of Phase 1 from an experimental lab test to one that

Status Update: Project I is now complete and was monitored by the AFS Mold-Metal Interface Reactions Committee (4F). An update was given at the 117th Metalcasting Congress and CastExpo’13 in St. Louis, along with a presentation in the Metalcasting Technology Theater workshop on NonStandard Foundry Sand Testing. Those wishing more information about the project or participation should contact the Steering Committee chair Fritz Meyer at friedhelm.meyer@ ask-chemicals.com or Dr. Sam Ramrattan @ sam.ramrattan@ wmich.edu. 60


can replace the existing MB Clay test. Besides the support of AFS, the NewGen Sand Consortium has agreed to fund half the Phase 2 project costs and also assist with project monitoring. This is the first project sponsored by the NewGen Sand consortium and represents a unique collaborative effort. Status Update: The Phase II work is now complete. It included further refinement of the test and investigation of how it performs against various sand mixtures and foundry plant trials is being conducted at (5) foundries and WMU. The work is being monitored by the AFS Green Sand Molding Committee (4-M). An update was given Saturday at the 117th Metalcasting Congress & CastExpo’13 in St. Louis, along with a presentation in the Metalcasting Technology Theater Non-Standard Foundry Sand Testing Workshop. Continued training and verification of the test is being done by the working group, including 1-day workshops at WMU. A Phase III is proposed with the purpose to conduct more extensive industrial trials, look at the effects of secondary foundry green sand additives on the test-to-test variability and create a standardized and validated test approach to be included in the AFS Core and Molding Handbook. Those wishing more information about the project, or participation should contact the Steering Committee chair Mike Slaydon at [email protected] or Dr. Sam Ramrattan at sam. [email protected].

Identifying, Implementing and Sustaining Energy Savings (12-13#03) Coordinator: James Wiczer, PhD, Sensor Snyergy and AFS Energy Committee (1-G) In order to reduce operational costs associated with operating individual pieces of equipment and processes, it is necessary to understand all of the costs associated with these operations. One major cost category often neglected is the cost of the power required to operate equipment. This cost category can be very significant but it is often inconvenient to measure and identify these costs. In fact, currently in foundries and other manufacturing facilities, there is very limited use of power monitoring for individual pieces of equipment. Due to perceived difficulties in monitoring power used for individual melts or production batches, power costs are frequently lumped with other overhead costs as necessary expenses that cannot be associated with a specific piece of equipment, process, or product. These power costs are usually viewed as costs that must be incurred in order to operate a facility but cannot be reduced, modified, or audited in detail. Monitoring of power used by individual pieces of equipment is essential to control power costs and conserve energy. In order to reduce usage, management and staff must have access to realtime measured power-use information to be able to associate cause and effect for equipment and processes. Typically, costs of electricity, natural gas and other sources of power used in foundry operations are lumped into monthly or batch invoices. For the case of electricity costs, a monthly invoice from the local electric utility typically provides the costs for all electricity used by


the entire facility during a month-long period. From this monthly aggregate information, it is extremely difficult or impossible to determine the cost of operating a particular piece of equipment for a single batch, melt, production run, or time interval. This project will build on earlier, self-funded work to identify potential energy savings opportunities in foundry operations. This earlier effort was conducted by Sensor Synergy in collaboration with the American Foundry Society Energy Committee (1-G). In this study, Sensor Synergy and AFS corporate member Alu-Bra Foundry (Bensenville, IL), tested the use of realtime, power monitoring equipment to help identify electricity cost saving opportunities. The work proposed here will extend the work at Alu-Bra to better identify the type of measurements required to capture and exploit foundry-based energy saving opportunities. The Alu-Bra tests focused on monitoring electricity used by three of Alu-Bra’s induction furnaces. In addition to measuring and recording electricity use for each furnace every 2-seconds, the study also provided Alu-Bra’s management team with a remote, real-time display of electricity costs for continuous monitoring by key stake-holders at Alu-Bra. To make meaningful interpretations of these measurements, data summaries were correlated with observations of operator procedure and practices. Electricity savings of 10% were measured from implementations of initial suggestions. Throughput was increased by 3.5% after this first set of changes. If all suggested changes are implemented, it is estimated that Alu-Bra will achieve a 10% melting throughput increase and a 25% savings in electricity use for a total annual savings of $70,000 after an expenditure of about $1,000 on parts and labor to implement the project energy saving recommendations. The proposed project will expand this research by developing three additional foundry case studies. During these additional energy use monitoring projects, we will seek opportunities to extend the earlier work at Alu-Bra to include the following: • Confirm robustness and reliability of the sensors in the foundry environment. • Extend the testing beyond induction melting to other foundry equipment and energy consumption points within the foundry (such as air compressors). • Investigate use of sensors to define natural gas consumption. Status Update: Work has been completed on a V-Process, vacuum system for real-time energy-use data collection and remote access. Additional measurements are planned in the melt systems at that facility and also the melt, molding and finishing systems of a no-bale ductile iron foundry. The work is being monitored by the AFS Energy Committee (1-G). An update was at the 117th Metalcasting Congress & CastExpo’13 in St. Louis, along with a presentation in the Metalcasting Technology Theater on Energy Savings in the Foundry. Those wishing more information about the project or participation should contact the Steering Committee chair Brian Reinke at breinke@ tdi-consulting.com or the principal investigator James Wiczer at [email protected].

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Influence of Mn and S on the Properties of Cast Iron (12-13#04) Coordinator: Richard (Rick) B. Gundlach, Element Materials and AFS Ductile Iron, CG Iron & Gray Iron Research Committee (5-R) Sulfur is generally considered a tramp element in cast iron, and its level must be controlled. When manganese is not present at sufficient concentrations, sulfur reacts with iron to produce a low-melting phase that can produce hot-shortness in iron castings. Consequently, the industry has always added manganese to control sulfur in cast iron. Various formulae have been promulgated in the industry for balancing Mn and S in cast iron. Many employ a stoichiometric relationship between Mn and S, requiring an excess Mn content to avoid FeS formation. Some simply employ a Mn to S ratio (such as 5 – 7) to assure that no FeS forms. Others advocate that the sulfur content must simply be at or above 0.04%S to obtain adequate inoculation response. This study intends to define a new concept in the practice of balancing Mn and S in gray cast iron, by employing thermodynamic principles to determine the level of free sulfur in the molten iron during eutectic solidification. It also intends to show that the nucleation and solidification behaviors of cast iron vary depending on whether the composition is below or above the MnS solubility limit at the time (temperature) of eutectic solidification. To our knowledge, past research has not addressed the two regions in cast iron chemistry – the regions above and below the solubility limit of MnS. No work has purposely investigated the influence of S on strength at lower Mn concentrations where MnS precipitation occurs only after the beginning of eutectic solidification. This research will be conducted with a view to account for the thermodynamic relationship between Mn and S. Another primary objective is to learn how to produce gray cast iron with exceptional strength, without the use of expensive alloying elements. The primary objective of this study is to characterize the relationship between S, Mn and the strength of cast iron in a wide range of section sizes. The strength is expected to vary significantly as sulfur is increased and approaches the MnS solubility limit. Further changes in strength are expected as sulfur rises above the MnS solubility limit. The maximum attainable strength is also expected to correlate with Mn content. A second objective of this study is to further develop the correlation between Mn, S and the fineness of the graphite structure. A third objective of this study is to learn how to develop higher strengths in heavy section castings, through balancing the Mn and S contents. It is anticipated that the need for alloying to produce high-strength grades of cast iron will be significantly reduced. A fourth objective of this study is to develop a better understanding of the multiple roles of sulfur in the nucleation and eutectic solidification processes in cast iron. Status Update: The project is almost complete with all the test samples having been poured at one of the participating metalcasting facilities, mechanical testing complete and samples analyzed for chemistry, hardness and microstructure, including 62

evaluation for chill depth and analysis thermal analysis curves. Further work is being done on Eutectic Cell Size and having all the test data evaluated with the intent of finding correlations among the properties, microstructure and composition. The work is being monitored by the AFS Ductile Iron, CG Iron & Gray Iron Research Committee (5-R) plus a group of sponsoring companies. Those wishing more information about the project or how to participate as a sponsor should contact the Steering Committee chair Leonard Winardi at [email protected] or Rick Gundlach at rick.gundlach@ element.com.

Helium-Enhanced Semi-Permanent Mold Aluminum Casting (12-13#05) Coordinator: Prof. Paul Sanders, Michigan Tech University; Prof. Kyle Metzloff, UW-Platteville and AFS Aluminum Permanent Mold Committee (2-E) The effect of helium injection in aluminum permanent mold casting has been investigated by Doutre (2000), Wan and Pehlke (2004), and Metzloff (2009). Filling the air gap that forms between the solidifying metal and permanent mold with helium increases the heat transfer coefficient and casting cooling rate. Higher cooling rates decrease the time to ejection resulting in throughput improvements. Doutre measured the effect of helium on the cooling rate of several aluminum alloys using cylindrical and plate molds and found a 30-50% reduction in time to ejection temperature. Doutre found that helium-enhanced cooling improved commercial semi-permanent mold intake manifold casting productivity by 29%, but the details of the helium injection process (injection time, location related to cores, etc.) and the resulting microstructure and mechanical properties were not discussed. Wan and Pehlke performed both modeling and experiments on helium injection on permanent molds. They found that injection of helium (as compared to air) improved cooling times to 400°C by 37% with conductive mold coatings and 48% with insulating coatings. Metzloff examined the effects of heliumenhanced cooling in a production environment with conductive and insulating mold coatings and the effect of external mold cooling. The helium injection was most beneficial with a standard insulating coating and external cooling, yielding a 33% reduction in cycle time over the baseline production practice and a 10% reduction over an optimized cycle without helium injection. The die in this study had a large internal metal core through which helium was injected. The benefit of helium was likely minimized as the casting shrunk onto the metal core, decreasing the air gap in the core area. It was thought that the helium injection would have a greater effect if the air gap was larger, especially in semi-permanent mold castings that have poor thermal conductivity in the sand core regions. Saleem (2012) studied the effect of helium on the cooling rate and resulting properties of sand castings. This study found a 43-100% increase in cooling rate with a corresponding decrease in SDAS leading to a 34% increase in yield strength and a 22% increase in ultimate strength with no significant loss in ductility


or increase in cost. Argyropoulos (2008) found that helium injection into a refractory mold made the gap develop up to 34% faster compared to air injection, but the heat transfer rate was higher by up to 48%. The cost of helium would suggest that gas mixtures should be investigated. A 1992 U.S. Patent by Air Products (5,173,124) provides evidence that a 80%He-20%Ar gas mixture has a 12% higher convective heat transfer coefficient in turbulent flow. It was also noted that a 59%He-41%Ar mixture had the same convective heat transfer coefficient in turbulent flow. However, helium injection into the mold-casting shrinkage gap is not thought to provide turbulent flow (Wan and Pehlke). In this case, the more relevant parameter is likely thermal diffusivity. Sevast’yanov (1985) showed a quadratic decrease (decaying faster than a linear rate) in thermal diffusivity as argon was substituted for helium in the range of 20-80% at 27°C. Additionally, Purohit (1979) has shown a quadratic decrease in thermal conductivity with argon additions to helium at 727°C. The objective of the project is to develop and demonstrate a method for improved productivity and properties of semi-permanent mold aluminum castings using helium-assisted cooling. A semi-permanent mold will be designed to produce a pipe with three section thicknesses using a cylindrical sand core. This simple casting geometry will be used to evaluate the effect of helium injection through a core, and allow for the characterization of a sand core and permanent mold within the same casting. A proposed CAD model has been completed by Carley Foundry (see figure at end). Andrei Starobin at Mold Dynamics will model core outgassing due to binder loss and the pressure head required for helium gas delivery. MAGMA modeling of the mold design will be done as a cost-share in collaboration with MAGMA. MAGMA will be used to optimize the feeding system to produce a sound casting and provide an initial estimate of cooling rates based on literature heat transfer coefficients. The deliverable will be a CAD model and process gas flow (Starobin) and casting parameters (MAGMA). During mold design, consideration will be given to the requirements necessary for a proposed semi-permanent mold core dimensional study. This research mold is expected to be utilized in several AFS-sponsored projects. The experience gained during the 2009 Metzloff work for helium injection and temperature collection will be utilized. Co-PI Metzloff will lead the helium injection system and temperature data collection specifications. Thermocouples (1/16 in. diameter to improve response time) will be placed in the mold, core, and casting cavity. The mold thermocouples will be placed as near to the cavity surface as possible and spring loaded to maintain contact with the casting. The helium injection port will be placed in the core print to allow helium flow through the core and into the air gap between the solidifying metal and mold in the remainder of the casting. The mold will be fabricated in the Michigan Tech School of Technology Machine Shop and assembled for casting on a permanent mold machine at a participating member foundry. The temperature data collection and helium injection system will be assembled and tested prior to the casting trials. International Journal of Metalcasting/Summer 2013

A Six-Sigma approach will be used to optimize the process parameters for helium-enhanced semi-permanent mold casting. A full factorial designed experiment will be run to characterize the helium injection process. A center point (run 5) will be used to check for non-linearity in the parameter settings, and an extra run will assess the effect of argon gas mixtures on the cooling rate and properties. Replicates may be run depending on observed experimental variation. Microstructure evaluation to characterize the grain size, SDAS, and porosity and property evaluation of the castings will be conducted. Finally, the projected cost savings from reduced cycle time and reduced part volume (based on strength improvements) will be calculated. The additional costs associated with setup time and gas usage will be accounted for in the total cost analysis. The 2009 study showed a projected cost reduction of ~7% for permanent mold casting. Status Update: The project has just started. Updates will be given at quarterly AFS Div. 2 Aluminum 2E committee meetings. The final results will be published as an IJMC paper and presented at the AFS Casting Congress Those wishing more information about the project or how to participate as a sponsor should contact the Steering Committee chair Brian Began at [email protected] or Prof. Paul Sanders at [email protected].

High Strength Cast Iron Castings Produced by Engineered Cooling (12-13#06) Coordinator: Dr. Simon Lekakh and AFS Ductile Iron, CG Iron & Gray Iron Research Committee (5-R) The majority of industrially produced cast iron castings have a microstructure consisting of graphite phase in ferrite/pearlite metal matrix which were developed directly in metal casting processing (as-cast) without needing an additional heat treatment. The “as-cast” cast iron structure was formed during: (i) solidification (prime structure) and (ii) eutectoid reaction (final structure). The current state-of the art cast iron industrial processes mainly control the mechanical and thermo-physical properties through the prime solidification structure by: • carbon equivalent variation for controlling prime austenite/graphite eutectic ratio • inoculation treatment for graphite nucleation and decreasing chill tendency • magnesium treatment for controlling graphite shape (flake in GI, vermicular in CGI, and spherical in SGI) • melt refining from dissolved impurities (S, O, N), and • melt filtration for improving casting cleanliness. Practically speaking, only one method―an additional alloying by Cu, Mo, Ni and other elements, is used for direct control of the structure of metal matrix formed during eutectoid reaction. The all described above methods could be called as “chemical” methods because they control the microstructure through changes in the cast iron composition. However “chemical” methods have some serious limitations: (i) high cost of alloying additions, (ii) limited increase strength in as-cast condition, and (iii) need an additional austempering heat treatment for achievement a higher strength of cast iron castings. 63

Analysis of the performance of standard cast irons with different graphite shape and targeted properties according to this project are shown in Figure 1. The mechanical properties data are represented by, so called “Quality index”, which is a strength/hardness ratio. For example, standard SGI is significantly stronger than CGI; however SGI has lower thermal conductivity which is a limiting factor for application for cast components of intensively thermo/mechanically loaded heavyduty engines. The targeted properties for CGI produced by a novel process in “as-cast” are shown in Figure 1. The targeted strength of GI will be near the level of current CGI, and targeted strength of SGI in “as-cast” condition will be matched to the strength of heat treated castings. The objective of this project is to develop a novel metal casting process for production of high strength cast iron castings in “ascast” condition applying engineered cooling. The goals include: • increase “quality index” (UTS/HB ratio) • increase strength without sacrificing toughness • decrease casting cost by eliminating alloying elements • decrease energy consumption for heat treatment Status Update: The project is just being started. The work is being monitored by the AFS Ductile Iron, CG Iron & Gray

Iron Research Committee (5-R) plus a group of sponsoring companies. Those wishing more information about the project or how to participate as a sponsor should contact the Steering Committee chair Matt Meyer at [email protected] or the PI Simon Lekakh at [email protected].

Figure 1. Performance of standard cast irons with different graphite shape and targeted properties according this project.

Metalcasting Industry Funded & Monitored Research American Metalcasting Consortium/U.S. Dept. of Defense/ Defense Logistics Agency Funded Projects Castings Solutions for Readiness (CSR) Program AFS, as part of its efforts in the American Metalcasting Consortium (AMC), has recently secured contracts funded through the U.S. Department of Defense, Defense Logistics Agency, Defense Supply Center Philadelphia and the Defense Logistics Agency, Ft. Belvoir, VA. The group of projects is under an AMC program entitled Castings Solutions for Readiness (CSR). The two new projects are continuations of previous AFS AMC efforts, including one project called Cast High-Integrity Alloy Mechanical Property Standards (CHAMPS) and the other Casting Standards and Specifications.

CHAMPS Project―Additional Alloy Design Data The CHAMPS Statistical Properties Project goal is incorporation of material property design data for additional cast alloys, A206-T4 and T7 in the initial phase and then 17-4-PH or Ti6Al4V in second phase, into MMPDS (Metallic Materials Properties Development and Standardization) handbook, which replaced Mil-handbook 5, so that this material can be specified and used to design and manufacture flight critical components in military and civilian aircraft. This builds on the

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original just completed E357 effort of establishing a framework to design a series of test specimens that encompass the various section thicknesses used in these applications utilizing process simulation software, validate the approach metallographically, coordinate collection of required samples from a consortium of qualified foundries and submit the data for statistical analysis and approval by MMPDS board for incorporation into the MMPDS standards. The benefit to DLA is the development of statistical based property data will permit the use of castings across a broader range of applications and will provide the following benefits. The Engineering Support Activities at the DLA will be able to make cast alloy conversion / replacement decisions with assurance using statistical data on tensile, compressive, shear, and bearing properties from the FAA recognized source, MMPDS Handbook. Also reduced lead times with cast components competing on an equal basis with forging and assemblies from sheet, plate, and extruded mill products. As with the E-357 project, the intended outcome will be cast A&B design property allowables for the alloys selected for inclusion in the MMPDS (old Mil Spec Handbook 5) to meet FAA requirements. This will allow aerospace design engineers


to specify castings without using design safety factors. Various working groups will be actively looking at melt practices, test casting gating and filling, heat treatment parameters, testing protocol and weld repair standards. The initial casting trials will follow the approach taken for E357 and conducted for 1.5 x 2.5-in. plate cast in both horizontal and vertical gating approaches, and a heat treat study was conducted at various participating foundries. These plates will be tested for tensile properties and undergo microstructural evaluation. The project is now starting with the initial activity investigating modeling the gating and rigging used for a previous E357 project followed by some casting verification trials. Those wishing to participate or wanting more information should contact Steve Robison, AFS, at [email protected].

Casting Standards and Specifications Accessing state-of-the-market technical, specification and training materials for castings is challenging. AFS is working to provide current and qualified information in a network friendly form to users of castings via the Casting Standards and Specifications project. The effort includes both archival and recent technical information in searchable databases. Specifications and standards are summarized, and the user is guided in their application. Tutorials covering the fundamental design concerns are also presented. The development of an online material design property database will greatly enhance the ability for the next generation of component designer to create the

lightest weight and most efficient parts quicker and at lower cost. These tools facilitate more effective and efficient procurement to both DoD and industry in the support of weapon systems. Along with data from various AFS research projects, like the recently completed 08-09#01 & 08-09#03 projects for the Development of Fatigue Properties Database, AFS has also incorporated the USAMP Light Metals Materials Database properties and recently strain life fatigue data for CGI Grade 400 and a hi-alloy Class 40 Gray Iron into the AFS Casting Alloy Data Search (CADS) onto the AFS design website: www.metalcastingvirtuallibrary.com/cads/cads.aspx. This completes this phase of the project and AFS is working with ASM to create Cast Alloy Material Property Datasheets to be put on the ASM Material Selector and AFS websites. The work planned under this project will add design properties for 4-5 additional cast metal alloys per year, while continuing to upgrade the CADS online database. During the first year work was completed on Class 25E Gray Iron, Ductile Iron EN-GJS500-07 (lower hardness version of 80-55-06) for 1 and 3 inch section thickness and HiSiMo Ductile Iron. Work is ongoing for 1 and 2 inch section Aluminum E357, with specimens coming from the previously completed CHAMPS E357 project. The project would like to secure additional cast materials, including common grades of steel and copper-based alloy. For more information, contact Thomas Prucha, AFS, at [email protected] or AFS Technical and Information Services, Katie Matticks at [email protected].

Cast Metals Consortium/U. S. Department of Energy/ Advanced Manufacturing Office–AMO The Department of Energy program under its EERE ITP programs (now the Advanced Manufacturing Office –AMO), since the slate of projects were proposed back in 2003 and started in 2005, has funded under the CMC-SMARRT coordinated under the CMC (Cast Metals Coalition) various projects to promote energy efficiency and reduction. During this last year these following programs that were previously stopped have received funding for restarting and completion: ·

The Porosity Free Mg & Al Casting project at CWRU

The original proposal called for two structural magnesium alloys to be investigated. Recent work under an AFS sponsored project has brought to the forefront the critical impact of micro-shrinkage on the mechanical properties of permanent mold cast A356 aluminum alloy. In essence, casting any high integrity lightweight alloy, magnesium or aluminum, requires careful thermal design of the mold to eliminate shrinkage porosity. At the same time, skilled metal treatment is needed to prevent gas porosity.


Procedures for degassing, risering, chilling and pouring of aluminum and magnesium alloys that would eliminate or significantly reduce microporosity will therefore be evaluated. ASTM B108 no-bake sand mold test bars and permanent mold test bars will be cast. Two step molds, one in sand and another permanent mold will be used to determine the effect of cooling rate on mechanical properties and DAS. A combination of risers and chills will be utilized to establish directional solidification conditions. Computer simulation will be used to optimize the arrangement of risers and chills and to determine the pouring temperature for generating a temperature gradient. MAGMA Foundry Technology will be supporting this effort with computer software. The degree of microporosity in the castings will be determined by X-Ray, radiography, optical microcopy image analysis and density measurements.

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· Lost Foam Thin Wall in Aluminum and Magnesium at Canmet & UAB

A two-stage work is planned based on a study of some aspects of the above variables. CMAT will study small steel castings with lip-pour in Stage 1, and large castings with bottom-pour in Stage 2. Casting with various type of gating systems, including an innovative radial choke approach will be poured. The poured castings shall be analyzed at CMAT with respect to casting surface cleanliness that includes a measure of re-work required, hardness measurements and chemical composition. Certain castings shall be selected for microstructural characterization and mechanical testing. This work will be coupled with modeling the flow from ladle, the flow in mold and solidification. A better understanding and control of steel casting cleanliness can be provided based on the experimental and modeling results.

·

Light Metals Permanent Mold Casting at Canmet

The main objectives of this project are to: (a) establish the processing parameters for selected prototype components during gravity and/or low pressure permanent mold casting of at least one hot tearing susceptible aluminum alloy; (b) study the effects of mold temperature and grain refiner addition on hot tearing during solidification in metal molds; and (c) determine the mechanical properties in the as cast and heat-treated conditions.

The main objectives of the final phase of the project are to: (a) develop appropriate lost foam casting technology for near-net shape prototype engineering components from selected aluminum alloys (535, A206 and A319) and (b) investigate the effects of vacuum molding and pouring techniques and applied pressure on the quality of the prototype thin-wall components produced during lost foam casting.

· Clean Steel at Canmet

The following effort is the proposed completion of this project under the E-SMARRT program. Clean steel castings are a concern in steel foundries as well as continuous slab casters. This work is focused on the foundry castings. According to their poured weight, steel casting may be divided into three categories: small (less than 20 lb.), medium (in the range of 20 to 200 lb) and large (more than 200 lb.) castings. A number of variables can influence the steel casting cleanliness, as listed below for example: · · · · · · ·

Alloy types Use of raw materials and returns Charging sequence and melting process Melt treatment (de-oxidation, degassing, deslagging) Melt flow from ladle to mold: lip-pour ladle, teapot ladle, and bottom-pour ladle Melt flow within the mold Interfacial reactions between melt and mold.

AFS Information Services Casting Process and Alloy Assistance The AFS website offers assistance for casting design engineers in selecting the best casting process for a potential component, and also provides casting alloy design and property data on many commonly used alloys. The website provides casting users, design engineers and purchasers with relevant and accurate information on casting capabilities and properties, providing easily accessible and retrievable information from a single site. The alloy data can be quickly exported to a spreadsheet or FEA tools. The comprehensive site includes assistance for selection of alloys, casting process, alloy property data for many common alloys and a metalcaster directory to locate potential casting sources.

tests used in the metalcasting industry and various casting defects, including potential causes and solutions. AFS technical staff associates continue to support AFS members and casting users through telephone and email requests for technical help, casting problems and metalcasting information.

Library

Technical Resource

The AFS library online database serves the needs of the metalcasting industry for current and historic metalcasting information. AFS is continuing to electronically archive the full AFS Transactions series using non-destructive scanning technologies. The project will be complete in 2013, with all AFS Transactions fully electronically archived and web searchable, from the very first edition (published in 1896) to the present.

Technical department staff and technical committee members provide regular contributions to MODERN CASTING and Metal Casting Design & Purchasing magazines. The column, CastTIP, documents the best practices for various procedures and

The updated and advanced AFS library website with almost 40,000 papers and articles about metalcasting are available for purchase. Located at www.afslibrary.com, the website houses the world’s largest collection of metalcasting reference material.

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The online AFS library is powered by a Google search engine, providing state-of-the-art functionality to help users find articles quickly. A real time online help desk feature can assist users in refining their search or locating a specific article. The site then provides the option to purchase the AFS copyrighted papers and articles by automatic download or email.

For more information on the library website, contact AFS technical and information Services, Katie Matticks at 847/824-0181, ext. 294, [email protected].

AFS Technology Transfer CastExpo’13 and 117th Metalcasting Congress Sponsored by the American Foundry Society (AFS), CastExpo’13 and the 117th Metal casting Congress, April 6-9, 2013 in St. Louis provided metalcasters, suppliers, casting buyers and designers with the opportunity to connect and learn about the latest metalcasting innovations and procedures. CastExpo’13 featured more than 400 exhibitors displaying the latest in metalcasting technology, and technical education sessions, including more than 100 presentations, covering all metalcasting and die casting processes and all cast metals. CastExpo also provided a venue to learn and network with other foundry and die casting personnel. Cast Expo also hosted the annual World Foundry Organization (WFO) Technical Forum. The forum included presentations from international foundry experts and was scheduled as part of the CastExpo technical sessions and events.

Conferences, Workshops and Webinars The AFS Art Casting Conference was held May 29-30, 2013 at the Embassy Suites in Loveland, CO. This conference, targeting artists and foundries specializing in cast metal art, covered topics relating to art foundry operations and management, technology and processes, metallurgy and advanced metal quality, safety in the foundry, additive manufacturing technologies, digital technology, municipal bidding, mold creation, shell preparation, wax pulling, patinas, melting and casting. Participants benefited from multiple networking opportunities as well as open forum discussions. The conference included a tour of Art Castings of Colorado located in Loveland, CO. AFS workshop on Classification, Testing Procedures, and Characterization of Cast Irons (June 25-26, 2013) will be held at Element Materials Technology, Wixom, MI. The course will cover all issues related


to testing and characterization of cast iron, including chemical analysis, metallographic evaluation, tensile testing, hardness testing, impact testing and relevant industry standards, such as ASTM and SAE. Utilizing the laboratory facilities at Element, the workshop will feature demonstrations of the various tests. The metallographic demonstrations will include instructions on sample preparation, microstructural interpretation, and quantitative measurement of graphite types, size, count and nodularity. For more information, contact Jami Crouch, technical assistant, 800/534-7237 x246, [email protected]. The conference on Post Casting Processing of Aluminum Casting, scheduled for Sept. 23-25, 2013, will cover processes such as weld repair, heat treating processes and variants, cleaning room technologies, machining, defect recognition, hot isostatic pressing and other post casting processing issues. For more information, to participate as a speaker or exhibitor or to register, contact Steve Robison, AFS senior technical director, 800/537-4237 x227, [email protected] or Katie Matticks, AFS technical and information services, 800/537-4237 x294, [email protected]. Co-sponsored by American Foundry Society and the Ductile Iron Society, the 2013 Keith Millis Symposium on Ductile Iron will be held on October 15-17, 2013 in Nashville, Tennessee at the Loews Vanderbilt Hotel. Technical presentations will cover all areas of metallurgy and production of ductile iron, austempered ductile iron and compacted graphite iron, including applications, treatment and inoculation methods, special processing, and testing. For more information, contact Scott Lammers, AFS technical director, 800/537-4237 x228, [email protected] or Jami Crouch, AFS technical assistant, 800/537-4237 x246, [email protected].

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Metalcasting Industry Calendar of Events 2013 Aug 11-12

AFS Environmental 101 Seminar, The Marriott Pittsburgh City Center, Pittsburg, PA

Aug 13-15

AFS 25TH EHS Conference, The Marriott Pittsburgh City Center, Pittsburgh, PA

Aug 20-22

AFS/CMI Board of Directors Meeting, AFS Headquarters, Schaumburg, IL

Aug 22-23

AFS Chapter Officers Conference, Hilton Garden Inn, Des Plaines, IL

Sep 7-10

Steel Founders’ Society of America (SFSA), Annual Meeting, Half Moon Bay, CA

Sep 16-18

North American Die Casting Association (NADCA), Die Casting Congress & Tabletop, Kentucky International Convention Center, Louisville, KY

Sep 22-24

AFS Foundry Executive Conference, Silverado Resort and Spa, Napa, CA

Sep 30-Oct 3

Society of Manufacturing Engineers (SME), Canadian Manufacturing Technology Show (CMTS), International Centre, Mississauga, ON

Oct 6-9

Investment Casting Institute (ICI), 60th Annual Technical Conference and Expo, Wyndham Grand Pittsburgh Downtown, Pittsburgh, PA

Oct 13-16

Non-Ferrous Founders’ Society (NFFS) Annual Meeting, Talking Stick Resort, Scottsdale, AZ

Oct 14-17

AFS/Ductile Iron Society (DIS), 5th Keith Millis Symposium, Loews Vanderbilt Hotel, Nashville, TN

Oct 15-17

Society of Manufacturing Engineers (SME), WESTEC, Los Angeles Convention Center, Los Angeles, CA

Oct 22-23

AFS Advanced Foundry Waste Seminar, The Crowne Plaza Atlanta Airport Hotel, Atlanta, GA

Oct 23-25

AFS Conference on Post Casting Processing of Aluminum Castings, Indianapolis, IN

Oct 27-31

Materials Science & Technology Conference & Expo (MS&T) 2013, Montreal, Quebec, Canada

Nov 5-6

Casting Industry Suppliers Association (CISA), Annual Meeting & Business Outlook, The Westin O’Hare, Rosemont, IL

Nov 18-21

SME FABTECH, McCormick Place, Chicago, IL

Nov 21-22

FEF College Industry Conference, Westin Hotel, Chicago, IL

Dec 10-11

ACRC Winter Workshop, WPI, Worcester, MA

Dec 11-14

Steel Founders’ Society of America (SFSA), National T&O Conference, The Drake, Chicago, IL

2014 Jan 26-27

AFS/CMI Board of Directors Meetings, Rancho Las Palmas Resort & Spa, Rancho Mirage, CA

Feb 5-7

AFS Human Resources & Labor Relations Conference, Hyatt Regency, San Antonio, TX

Mar 18-20

SME FABTECH Canada, Toronto Congress Centre, Toronto, Ontario, Canada

Mar 26

AFS “Preparing for an EPA-OSHA Inspection (Before, During, After), AFS Headquarters, Schaumburg, IL

Apr 8-11

AFS 118Th Metalcasting Congress, Renaissance Hotel & Convention Center, Schaumburg, IL

May 12-14

SME- Montreal Manufacturing Technology Show (MMTS), Place Bonaventure, Montreal, Quebec

May 18-20

Casting Industry Suppliers Association (CISA), Annual Conference, Hyatt Regency, Ft. Meyers, FL

May 19-21

71st World Foundry Congress, The Euskalduna Conference Centre, Bilbao, Spain

Jun 4-6

Ductile Iron Society (DIS), Annual Spring Meeting, The Coast Lethbridge Hotel & Conference Centre, Lethbridge, Alberta, Canada (Host: Lethbridge Iron Works, Lethbridge, Alberta, Canada)

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Jun 9-12

SME The Big M, RAPID 2014 and Annual Conference, Cobo Center, Detroit, MI

Aug 19-21

AFS/CMI Board of Directors Meeting, AFS Headquarters, Schaumburg, IL

Sep 22-24

NADCA Die Casting Congress & Tabletop, Frontier Airlines Center, Milwaukee, WI

Oct

Ductile Iron Society (DIS), Meeting location to be determined, (Host: Decatur Foundry, Decatur, IL)

Oct 10-13

Non-ferrous Founders’ Society (NFFS) Annual Meetings, Sea Pines: The Inn at Harbour Town, Hilton Head, SC

Nov 4-5

Casting Industry Suppliers Association (CISA), Annual Meeting & Business Outlook, the Westin O’Hare, Rosemont, IL

Nov 4-6

Society of Manufacturing Engineers (SME), FABTECH, Georgia World Congress Center, Atlanta, GA

Nov 20-21


Dec 10-13

Steel Founders’ Society of America (SFSA), National T&O Conference, The Drake, Chicago, IL

2015

Feb 26-28

AFS Northwest Regional Conference, Red Lion Hotel, Seattle, WA

Apr 21-23

AFS 119TH Metalcasting Congress, Greater Columbus Convention Center, Columbus, OH

Jun 16-20

GIFA, Dusseldorf, Germany

Oct 5-7

North American Die Casting Association (NADCA), Die Casting Congress and Exposition, Indianapolis Convention Center, Indianapolis, IN

Nov 19-20


2016

Apr 16-19

CastExpo ’16, Minneapolis Convention Center, Minneapolis, MN

For further information on conferences and meetings, please contact the appropriate organization directly at the phone number or web address shown below. Information is updated frequently on the AFS website: www.afsinc.org. The Aluminum Association Inc. American Metalcasting Consortium American Society of Mechanical Engineers (ASME) ASM International Casting Industry Suppliers Association Ductile Iron Society FEF Industrial Minerals Association-North America Investment Casting Institute Iron Casting Research Institute Institute of Indian Foundrymen The Minerals, Metals & Materials Society (TMS) National Industrial Sand Association Non-Ferrous Founders’ Society North American Die Casting Association Steel Founders’ Society of America World Foundry Congress


703/358-2960 843/760-3219 212/705-7100 440/338-5151 623/547-0920 440/665-3686 847/490-9200 202/457-0200 291/573-9770 614/275-4201 www.indianfoundry.org, [email protected] 724/776-9000 202/457-0200 847/299-0950 847/279-0001 815/455-8240 www.71stwfc.com or [email protected]

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