Tuesday, April 17, 2012 07:15 AM AUTHOR/CHAIR BREAKFAST Room: Morrow AFS Author/Chair Breakfast .   This breakfast provides the opportunity for AFS authors, session chairs, student and staff to meet and coordinate details for the educational sessions of the day.     08:30 AM COPPER ALLOY Room: Delaware A Presiding: William Surman, I Schumann & Co., North Huntingdon, PA; Greg Svoboda, I Schumann & Co., Bedford, OH. Antimicrobial Copper: Clinical Performance Against Bacteria That Cause Infections and Impact on Hospital Patients (12-113) James Michel, Harold Michels, Wilton Moran, Adam Estelle, Kyle Sexton, Copper Development Association, New York, NY; Michael Schmidt, Medical University of South Carolina, Charleston, SC.   Cast and wrought copper alloys are intrinsically antimicrobial materials. An extensive body of laboratory research has proven their ability to kill more than 99.9% of wide range of pathogen within two hours. The contribution of bacterial touch surface contamination to Hospital-Acquired Infections (HAI) has not been well defined. Studies show that more than half of environmental surfaces are not adequately cleaned and may become re-contaminated within minutes. The inherent antimicrobial activity of copper surfaces offers an advantage over conventional cleaning alone, as EPA-approved antimicrobial copper surfaces kill bacteria continuously. A study was conducted to assess whether a lower environmental bio-burden on critical touch surfaces would result in a lower risk of contracting an infection while hospitalized. DESCRIPTION OF THE STUDY: Patients entering the ICU at 3 hospitals (Medical University of South Carolina, Ralph H. Johnson VA Medical Center and Memorial Sloan-Kettering Cancer Center) were followed for development of HAI. Six frequently touched objects were made out of copper alloys and placed in 8 total rooms. Bio-Burden associated with each object was compared to that of identical control objects found in another 8 ICU rooms. RESULTS: The relative risk of contracting an HAI for patients in rooms with copper objects was reduced by over 40% compared to patients in rooms with standard objects. Additionally, copper reduced the microbial burden on surfaces by 98%. These findings suggest that the environment plays a substantial role in the contraction of HAI’s. Through the introduction of continuously active antimicrobial surfaces in ICU rooms it was possible to lower the infection rate from 19 infections per 1000 patient days in control rooms to 4 infections per 1000 patient days in copper rooms. Based on these results, exciting opportunities for copper alloy castings are developing for products such     08:30 AM ENVIRONMENTAL, HEALTH AND SAFETY Room: Delaware B Presiding: Michael Lenahan, Resource Recovery Corp, Coopersville, MI. PANEL: EHS Hot Topics (12-155) Thomas Slavin, Navistar Inc., Chicago, IL; Jitendra Radia, McWane Inc., Birmingham, AL; Mark Remlinger, Matthews International Corp, Pittsburgh, PA; Jeff Hannapel, The Policy Group, Rockville, MD; Stephanie Salmon, AFS Washington Office, Washington, DC.   Update on activities in areas of air topics, water and waste topics along with safety and health topics that affect metalcasters.     08:30 AM MAGNESIUM Room: Delaware D Hot Tearing in Magnesium AZ91E Bell Housings Produced by the Low Pressure Permanent Mold Process (12-022) Franco Chiesa, Nicolas Giguère, Centre de Métallurgie du Québec, Trois-Rivières, Québec, Canada; Bernard Duchesne, Collège de Trois-Rivières, Trois-Rivières, Québec, Canada; Jocelyn Baril, Technologie du Magnésium et de l’Aluminium, Trois-Rivières, Québec, Canada.   Magnesium is very seldom poured in permanent molds (be it by gravity or low pressure) because of the hot tearing propensity of most magnesium casting alloys. This downside is much less acute in pressure die casting where the very high solidification rate associated with the process results in a fine grain structure much less prone to hot tearing; this explains why most magnesium castings are pressure die cast. Thick structural castings may be poured in sand because the mold constraint responsible for hot tearing is much less in a collapsible mold. In the present study, the influence of various operating factors on the hot tearing of magnesium AZ91E bell housings poured by the low pressure permanent mold (LPPM) process was determined by conducting four runs (of 15-16 castings each) carried out using different operating parameters; the objective was to find the conditions allowing to produce bell housings free from hot tears. Two grain refiners were tested, namely 0.5% C2Cl6 and 0,25% Al-5Ti-1B; one run was poured at 700°C instead of 740°C for the three other runs; finally, one run was carried out using a very conducting mold coating (Boron nitride) instead of a customary insulating coating. A lower pouring temperature was found to reduce the hot tearing tendency. Most importantly, bell housings free from hot tears could be produced only when the conducting boron nitride coating was used. Recycling and Degassing of AZ91E Magnesium Alloy Castings and its Effects on Mechanical Properties and Microstructure (12-032) Abdallah Elsayed, Sophie Lun Sin, Eli Vandersluis, Jordan Hill, Suleman Ahmad, Comondore Ravindran, Ryerson University, Toronto, ON, Canada.   The objective of this study was to examine the effects of filters and a hexachloroethane degasser on the microstructure and mechanical properties of recycled AZ91E magnesium alloy castings. This research is important as it will allow an increased use of recycled metal, thus reducing the costs of magnesium castings. The AZ91E castings were produced using a H13 tool steel mold machined to ASTM B108-06 standards. Casting conditions examined included no filter, filter, filter + 1 remelt, filter + 2 remelts and finally, filter + 2 remelts + 1wt.% Ashbury 751 degasser. The mold and pouring temperatures were 475 and 720 C (887 and 1328 F) respectively. Without a filter, the average yield strength, tensile strength and elongation of the AZ91E alloy casting were 93 MPa, 155 MPa and 2.26 %, respectively and with a filter increased to 97 MPa, 167 MPa and 3.18 % respectively. The highest average elongation was 4 % for the AZ91E + filter + 2 remelt + 1wt.% degasser casting. The remelting of castings caused increased scatter in mechanical properties and resulted in Mg-Al based oxides on the fracture surfaces which bonded poorly with the matrix causing premature fracture. The results emphasized the importance of investigating the recycling of magnesium castings to promote their use in aerospace and automobile applications. A better understanding of the formation, behavior and removal of inclusions in magnesium melts will improve the quality of magnesium castings. Microstructure Evolution of Cast Mg AZ31-B Alloy at Low Superheat (12-073) Laurentiu Nastac, Nagy El-Kaddah, The University of Alabama, Tuscaloosa, Al.   Magnesium is the lightest of all structural metals and offers significant weight savings compared to traditional automotive materials. One of the processing difficulties of such a reactive metal is contamination of the alloy with oxides during melting. This paper describes the microstructure evolution of cast Mg AZ31-B alloy using the Magnetic Suspension Melting (MSM) at a low superheat of 5ºC. Metallographic examination of the MSM cast alloy shows no evidence of oxide formation. It was found that casting at this low superheat produce fine globular grain structure compared to the dendritic structure in conventionally cast alloys. A stochastic mesoscopic model previously developed was applied to simulate the microstructure evolution of cast Mg AZ31-B alloy at low superheat. A comparison between predictions and experimental microstructures was performed.     08:30 AM MELTING METHODS & MATERIALS Room: Delaware C Presiding: Todd Lyles, Specialty Foundry Products Inc, Bessemer, AL; Russ Seider, Pryor Giggey Co., Littleton, CO. PANEL: Coreless Induction Failure Modes Part 2 (12-143) Mark Kohler, Ajax Lectrotherm, North Canton, OH; John Oneson, Kohler Co, Kohler, WI; Robert C. (Chuck) Cushing, EMSCO Inc., Rancocas, NJ.   An in-depth narrative and visual review of both common and uncommon failure modes and a discussion on many of the present day challenges with which coreless induction foundries must contend with as they attempt to extend the lives of their furnace coils. A wide range of failure modes will be covered, including but not limited to: mechanical, thermal, chemical/material deposition, poor maintenance, and crisis maintenance. Changes within the foundry environment that can influence coreless induction furnace service life will also be discussed. Examples will be included that demonstrate how some theoretically unrelated changes can contribute to a reduction in service life or can cause major equipment failure. Specific emphasis will be placed upon the role that both chemistry and refractory interactions have on the service life of coreless induction furnace coil. The perspective of both the foundry management and operations will be reviewed as it relates to the day-to-day experiences at a leading Midwest iron foundry that operates medium frequency coreless induction furnaces.     10:15 AM CAST DESIGN & PURCHASING Room: Union B & C What a Foundry Needs to Communicate with its Commercial Pattern Shop in Order to Obtain Best Value for the Pattern Tooling (12-149) Brad Goddard, Brad Goddard, LLC (former Lawton Pattern Mgr.), Little Suamico, WI; Torben Rasmussen, Niagara Pattern, Niagara Falls, ON, Canada; Bill Smith, Foundry Pattern Service, Chattanooga, TN; Mike Ballard, Cincinnati Pattern, Cincinnati, OH; Ed D'Angelo, D'Angelo Pattern, New Middletown, OH; Kevin Kiddle, Bestpro Pattern, Sterling Heights, MI.   There are vital and fundamental essentials that should be communicated to the commercial pattern shop in order to obtain the best value tooling. What exactly are they? Not too long ago, Pattern shops worked closely with foundries and knew exactly what was required. With some exceptions, those days are gone. Current practice - Today, those left to handle obtaining tooling send PDF files and brief cover letters asking for "Price & Delivery" on a particular pattern. As a result today, the Commercial Pattern Shop has to "Guess" what is needed by the foundry customer. The foundry, which this panel discussion is directed to does not want to lose the order because "their pattern price was too high". This panel discussion - is an enlightenment on the subject presented by each panel member and then queried by questions from the moderator and more so by the session attendees. All types of patterns will be discussed: wood, metal, plastic, foam, composites materials, large & small patterns, job shop to high volume production patterns and rapid prototyping.     10:15 AM CAST IRON Room: Delaware D Presiding: Mike Riabov, Neenah Foundry Co , Neenah, WI; Fred Linebarger, Miller and Company, Rosemont, IL. An Experimental Methodology Based on Solidification Curves for Controlling the Manufacture of Vermicular Graphite Irons (12-006) Aitor Loizaga, Peio Larrañaga, Iker Asenjo, Jon Sertucha, Ramón Suárez, Azterlan, Durango (Bizkaia), Spain.   Two models for the prediction of the nodularity level in compacted graphite (CG) cast irons have been developed. The experimental CG irons were produced with either FeSiMg alloy, or a combination of FeTi and FeSiMg. The models development was based on the data provided by the cooling curves recorded from standard inoculated samples and their associated microstructures. A first model included the definition of a nodularity index (NIst) that can be determined rapidly for a given metal batch. Inoculation was also shown to be essential in guaranteeing optimal formation of graphite particles. A second model considered the effect of the cooling conditions on the graphite particles. The cooling curves and the metallographic features of a number of test-castings with different cooling moduli (M) were studied so as to improve the predictive model previously developed. A nodularity index that includes the effect of the modulus, NIM, was defined for this goal. A good correlation between the experimental and the calculated NIM values was found in the range of 5-90% nodularity. Finally, validation experiments were performed using real castings in order to evaluate the application of both predictive models in industrial conditions. Sponsored Research: Intercritically Austenitized, Quenched and Tempered, Ductile Iron (12-062) Ricardo Aristizabal, Robin Foley, University of Alabama at Birmingham, Birmingham, AL; Alan Druschitz, Virginia Tech, Blacksburg, VA.   Ductile iron having a microstructure of graphite nodules in a matrix of ferrite plus martensite was produced using a ductile iron alloyed with ~0.7 wt% manganese and ~0.5 wt% nickel. The microstructure was obtained by austenitizing in the intercritical region (ferrite+austenite) followed by quenching in a polymeric solution at room temperature. The intercritical austenitizing temperatures were determined experimentally and samples were heat treated to obtain three different volume percents of martensite (16, 24, 37 vol%). Also, the material was evaluated under three different tempering conditions: untempered, tempered at 400°C for one hour and tempered at 500°C for one hour. This paper reports the relationship between volume percent of martensite, tempering conditions, microstructure and tensile properties. Sponsored Research: Standard Machinability Test for Cast Iron (12-075) Michael Finn, Finn Metalworking and Cutting Solutions, Loveland, OH.   A method for quantifying the machinability of cast iron was designed and validated using three different grades of gray cast iron, ASTM A48 Class 35B, A159 Class G1800, and A159 Class G3000. Cutting tool life tests were done while face turning cast machinability discs over a range of turning speeds. A thirty minute tool life, the V30 machinability value, was calculated from the regression line of the observed end-of-life criterion plotted with the cutting speeds. The flank wear of the cutting tool was measured while facing the machinability discs for thirty minutes at the calculated “V30 value” speed. The repeatability and reproducibility of the V30 machinability value for one of the grades, ASTM A48 Class 35B, was assessed using the testing procedure. Castings from ten heat-lots of the ASTM A48 Class 35B gray iron were shipped to three machining house facilities for testing. The “V30 value” speed of the first heat-lot of ASTM A48 Class 35B gray cast iron was used while facing discs from the ten heat-lots of ASTM A48 Class 35B gray cast iron for thirty minutes. The repeatability and reproducibility were calculated from the mean and ranges of the flank wear observed at each facility. The mean flank wear measurements observed at each facility were also compared to reveal the statistical relationship of the observed data and procedure. The properties of the machinability discs were characterized for determining relationships to the results.     10:15 AM COPPER ALLOY Room: Delaware A Presiding: Mike Jones, Ford Meter Box Co Inc, Wabash, IN; John Remakel, A Y McDonald Mfg Co, Dubuque, IA. PANEL: Update on No Lead Alloys For Potable Water Applications (12-157) Dave Purkiss, NSF International, Ann Arbor, MI; Jon Remakel, A Y McDonald Mfg Co, Dubuque, IA; Mark Biehl, Ford Meter Box Co Inc., Wabash, IN.   Panel Topics: Purkiss: NSF Update Remakel: No Lead Alloy Updates Biehl: No Lead Alloy Updates   The national and various state laws mandating no lead brass alloys for potable water applications and NSF 61 and annexes f and g as well as NSF 372 will be reviewed. Updates will also be provided on developments of no lead alloys that are under consideration for potential usage.     10:15 AM MELTING METHODS & MATERIALS Room: Delaware C Presiding: David Williams, ASI International Ltd., Cleveland, OH. PANEL: Refractory Repair Channel Induction Furnaces (12-133) Bob Riccardi, Ajax TOCCO Magnethermic, Warren, OH; Tim Hoyt, Allied Mineral Products Inc., Columbus, OH; Rick Falkowski, United Refractories Co., McMurray, PA.   Panel Topics: Riccardi: Channel Furnace Maintenance - a Refresher Course Hoyt: Maintenance and Repair of Channel Furnace Refractories Falkowski: Channel Furnace Refractory Maintenence   This panel will serve as a review of various repair methods and techniques that are implemented in repairing channel furnace refractories. Topic areas to include, casting, shotcreting, gunning and ramming of refractory materials to repair sidewalls, floors/throats and siphons.     10:15 AM MOLDING METHODS & MATERIALS Room: Delaware B Presiding: Scott Giese, University of Northern Iowa, Cedar Falls, IA; Jeffrey Krause, HA International LLC, Westmont, IL. Sponsored Research: Foam Pattern Aging and its Effect on Crack Formation in Investment Casting Ceramic Shells (12-025) Wesley Everhart, Simon Lekakh, Von Richards, Jeffrey Smith, Haifeng Li, K. Chandrashekhara, Missouri University of Science and Technology, Rolla, MO.   The application of rigid plastic foam for large investment casting patterns with complex geometries can improve the dimensional tolerances and the surface quality of the steel casting. However, these pattern materials promote crack formation in investment casting shells during pattern removal using standard firing procedures. In typical investment casting shell processing, drying stages provide an aging period which can change the compatibility strains of the shell/foam assembly. In order to accurately predict shell cracking occurrence during pattern removal, the aging strain of the pattern must be considered. ASTM standard tests and independently developed experimental methods were combined with finite element modeling to predict stress development in the shell. The model takes into consideration the thermal properties of the pattern and the shell materials to determine the heat transfer to determine a thermal gradient within the materials. This is combined with mechanical properties to determine the thermal expansion stresses developed in the shell during firing. An experimentally measured delay of the thermal expansion of the aged pattern was incorporated in a three-dimensional nonlinear finite element model and used to predict possible crack formation in the shells during pattern removal. The effect of pattern aging on crack formation in the shell was experimentally validated. Recommendations for pattern removal parameters to decrease stress and eliminate crack formation in the shell were formulated. The Evolution of High Performance Feeding Aids to Improve Casting Quality (12-039) Stefan Fischer, Udo Skerdi, ASK Chemicals Feeding Systems GmbH, Bendorf, Rhein, Germany; Lee Horvath, Ralph Showman, ASK Chemicals LP, Dublin, OH.   Metal casters are constantly looking for ways to increase productivity and to improve casting quality and integrity in order to compete in an increasingly competitive market. Feeding aids and especially riser sleeves have evolved over the years to keep pace with those demands. This paper reviews those improvements in sleeve design and materials and details the latest advancements with current mini-riser technology.     11:45 AM Special Events Room: Morrow Copper Division Luncheon .   Ted Schorn, Vice President of Strategic Planning & Development for Enkei America Inc., will discuss "An Executive's Responsibility for Plant Safety." Plant safety is often described as a responsibility of the floor supervision, with critical roles assigned to shop floor personnel and the professional safety manager/engineer. While top management support for safety is often cited as important, the practical details of an executive’s responsibility for safety have been far less described. What, in practical terms, ought foundry executives do to support and improve safety in their shops? Our speaker will identify some specific actions and attitudes that top executives can and should take to make a difference in the safety performance of their facilities. These actions and attitudes will be derived from the leadership principles fundamental to good stewardship of our people and the foundry operation.     2:00 PM CAST DESIGN & PURCHASING Room: Union B&C Presiding: Paul Jones, ThyssenKrupp Waupaca, Waupaca, WI. Bringing Casting Business Back to North America (12-160) Mike Russell, Linamar , Guelph, ON, Canada; Stephen Doyle, Meritor Inc, Troy, MI; Jim McKee, John Deere Foundry , Waterloo, IA.   There have been many discussions about the trend to procure metalcastings from off-shore sources. In recent years there has been a decrease in off-shore purchasing as an increasing number of metalcasting buyers are utilizing U.S. based foundries to produce their casting component needs. Global competition and the economic downturn have changed the procurement trends and increased the complexity in purchasing. This panel discussion will provide an opportunity to hear form leading casting buyers as they discuss the latest trends. The panel will cover the issues of supply chain management, supplier development, supplier quality and metallurgy responsibilities. Panelists will provide their perspectives regarding trends, dynamics and key factors for success within continent and across continent casting suppliers. A question and answer period will be included.     2:00 PM CAST IRON Room: Delaware D Presiding: Kevin McMahon, Elkem, Forest Jct, WI; Stephen Sauer, Carpenter Brothers Inc, Milwaukee, WI. PANEL: Safety Programs: They Work in All Size Shops (12-120) Tyler Hill, Grede, Reedsburg, WI; David Konieczny, John Deere Foundry , Waterloo, IA; Robert Peaslee, Manitowoc Grey Iron Foundry Inc, Manitowoc, WI; Nick Fox, Galesburg Castings Inc., Galesburg, IL; Tricia Endsley, Bremen Castings Inc, Bremen, IN.   This panel will show that safety programs work in all size shops. Presenters from shops in the tons/day range all the way up to 800 - 1000 tons/day will give examples of safety programs that are working in their facility. They will demonstrate that a safe operation is custom made by each shop for their own particular application. A unifying thread that runs through all sizes of organizations is that successful programs are driven by the people,not vice versa. Cost effective programs are doable no matter what size shop you have!     2:00 PM COPPER ALLOY Room: Delaware A Presiding: Michael Buyarski, The Federal Metal Co, Bedford, OH; J. Leigh Omer, Fresno Valves & Castings Inc, Selma, CA. PANEL: Safety in the Foundry (12-166) Jack McMillin, Ajax Tocco Magnethermic Corp, Warren, OH; Peter Satre, Allied Mineral Products Inc., Columbus, OH; Larry Bauer, Foseco Metallurgical Inc., Cleveland, OH.   Panel Topics: McMillin: General Melt Safety and Practice, Channel and Coreless Satre: Non-ferrous Safety for Refractories Bauer: Crucible Safety and Procedures   To come     2:00 PM MELTING METHODS & MATERIALS Room: Delaware C Presiding: Mark Bauer, General Motors , Saginaw, MI; David Kasun, Kuttner LLC, Port Washington, WI. PANEL: Tuyere Velocity - Case Studies (12-140) Richard Erickson, ThyssenKrupp Waupaca, Tell City, IN; Ron Stewart, Cadillac Casting Inc, Cadillac, MI; Daniel Weiskopf, Neenah Foundry Co., Neenah, WI; Ted Rundblad, East Jordan Iron Works Inc, East Jordan, MI.   The purpose of this discussion is further comparisons of the effects of tuyere velocity on the daily operations of a cupola. Different cupolas will be compared with varying rates of tuyere and stack velocities, in the hope that a distinct pattern may be found. Such a pattern would clearly show an improvement in efficiency in a particular range of tuyere velocity when all other variables are contained.     2:00 PM MOLDING METHODS & MATERIALS Room: Delaware B Presiding: John Serra, Carpenter Brothers Inc, Milwaukee, WI; David Jablonski, Badger Mining Corp, Berlin, WI. Replacement of Olivine with Silica Sand in Non-Ferrous Foundries (12-005) Victor LaFay, Steve Neltner, S&B Industrial Minerals North America Inc., Cincinnati, OH; Mark Ziegler, Unimin Corporation, Rockford, IL; Jerry Thiel, University of Northern Iowa, Cedar Falls, IA.   Olivine sand is no longer available to the non-ferrous foundry industry and silica sand has been used for many years as the aggregate for non-ferrous foundries. This paper addresses the replacement of silica sand in foundries that have historically utilized olivine sand. Application of Biasill Sand in Non-Ferrous Foundries (12-084) Victor LaFay, S&B Industrial Minerals North America Inc., Cincinnati, OH; Charlie Rowe, Jay Morrison, Carpenter Brothers Inc., Muskegon, MI.   Non-ferrous foundries are looking for alternative aggregates to be utilized in green sand operations. Biasill is an acceptable alternative to the currently employed aggregates.     3:45 PM CAST IRON Room: Delaware D Presiding: Kathy Hayrynen, Applied Process Inc., Livonia, MI; Eugene Muratore, Rio Tinto Iron & Titanium America, Chicago, IL. Microstructure, Composition and Impact Strength Variations Measured in a Heavy Section As-Cast Ferritic Ductile Iron Casting (12-011) Serge Grenier, Chantal Labrecque, Rio Tinto Iron and Titanium, Sorel-Tracy, QC, Canada.   For those heavy section ductile iron castings that are designed for critical applications (eg. Wind turbines), a series of validation tests, such as impact Charpy V-notch and tensile tests, are required by the end user to confirm the quality of the casting. It is well known that the properties of nodular irons are dependent upon characteristics such as nodule count, nodularity and pearlite content. In heavy section castings, the long solidification time results in significant local microstructural variations. One of the difficult requirements for wind turbines is to achieve specific impact strength at -40ºC. Because of the small volume of material in the vicinity of the V-notch and the fact that rupture occurs almost exclusively in that small volume, one would expect the local microstructure to have a significant effect on the impact test results obtained. This paper reviews the various impact strengths obtained at -40ºC vs the microstructures next to the V-notch in the volume of high quality as cast ferritic castings. Also discussed are the relationships between the various locations in the volume and the locally measured values of pearlite content, nodularity, nodule count, ferrite grain size, nodule size and nodule volume density. Results are presented as distributions mappings, compiled throughout a casting section. Effect of Si Segregation on Low Temperature Toughness of Ductile Iron (12-031) Simon Lekakh, Von Richards, Missouri University of Science and Technology, Rolla, MO; Nadezhda Medvedeva, Institute of Solid State Chemistry, Ekaterinburg, Ekaterinburg, Russian Federation.   Micro-structural features as graphite morphology and element segregation in ductile iron are originated during solidification. These phenomena significantly affect impact toughness and the ductile-to-brittle transition temperature (DBTT) of ductile iron, limiting low temperature applications. Room/low temperature tested Charpy specimens with a wide range of nodule count were taken from different locations in a 10” diameter continuously cast bar and the heavy section of no-bake sand castings. In the as-cast condition, regular composition ductile iron (2.5% Si) with finer graphite structure exhibits higher toughness when compared to ductile iron with large graphite. On the contrary, in silicon homogenized ductile iron, significant increase in impact toughness and decrease of DBTT were observed in specimens with larger graphite nodules and neighboring nodule distances. To mitigate the negative effect of Si segregation in a heavy section, ductile iron casting with 1.5% Si was produced and tested at different temperatures. The results showed the possibility of significantly decreasing the DBTT temperature below minus 400C and increasing impact toughness. Thermodynamic analysis and diffusion modeling solidification segregation together with first principle calculations of shear and cleavage of BCC Fe alloyed with Si were used to understand the brittleness phenomena and can be applied for alloy design. Microalloying in Austempered Ductile Iron (ADI) (12-019) Devinder Padan, Tata Motors Limited, Jamshedpur, Jharkhand, India.   Austempered Ductile Iron (ADI) is well known for its outstanding engineering properties eg tensile strength, elongation, wear resistance etc. which are comparable with those of steel. Normally ADIs are alloyed with elements eg Mo, Ni, Cu and Mn etc. Microalloy steel is another successful development where presence of elements like V and Nb, significantly improved its mechanical properties. Based on the experience gained in microalloy steel, it was expected that beneficial effects of micro alloying elements V and Nb may also be exploited in ADI as well. Accordingly experiments were carried out on microalloy ADI. The effect on mechanical properties, microstructure, austemperability were examined. The study confirmed that microalloying of ADI with 0.1 % V or 0.043 % Nb with 1.4 % Ni improved ultimate tensile strength significantly and it was superior to that of conventional ADI alloyed with 0.3 % Mo and 1.4 % Ni. The wear resistance of microalloy ADI improved remarkably. No significant change in austemperability observed. Improvements in mechanical properties were attributed to presence of precipitates of V and Nb carbides. The present paper deals with some of the findings of study on microalloying in ADI.     3:45 PM ENVIRONMENTAL, HEALTH AND SAFETY Room: Delaware A Presiding: Michael Lenahan, Resource Recovery Corp, Coopersville, MI. Low Emission Foundry (12-083) Mauro Favini, IMF S.r.l, Luino (VA), Italy.   Analysis of the environmental critical areas of a no bake foundry, with particular attention to molding, pouring, shake out and sand reclamation systems. New approach to the foundry project and applicable solutions for solid waste, air emissions, liquid waste and dissipated energy. GHG Emissions Update (12-156) James Schifo, Keramida Inc., Indianapolis, IN.   The US Environmental Protection Agency has passed regulations covering the emissions of greenhouse gases (GHG) during the past three years. GHG are now a regulated pollutant and subject to the same permitting requirements as other metalcasting emissions. This presentation will cover the latest developments in the GHG regulatory arena and provide guidance to metalcasting facilities on the requirements of the new "Tailoring Rule."     3:45 PM MELTING METHODS & MATERIALS Room: Delaware C Presiding: Twalla Smith, Pure Power Technologies, Indianapolis, IN; Harvey Ulfers, John Deere Foundry, Waterloo, IA. PANEL: High Alloy Content in Steel Scrap - Current & Future (12-148) Eugene Muratore, Rio Tinto Iron & Titanium America, Chicago, IL; Kurt Terandy, OmniSource Corp., Ft. Wayne, IN; Leonard Basaj, Metal Technologies Inc, Ravenna, MI; Ernest Timmons, John Deere Foundry, Waterloo, IA.   Panel Topics: Basaj: High Alloy Content in Steel Scrap - Current & Future   Scrap steel, one of the basic building blocks of cast iron production, is changing. High alloyed steel, used for it strength and lighter weight, is becoming a larger percentage of the steel industry output. Panel will discuss what is driving this change, what can be expected now and in the future, and how two foundries are reacting to this raw material change.     3:45 PM MOLDING METHODS & MATERIALS Room: Delaware B Presiding: Sara Joyce, Badger Mining Corp., Berlin, WI; Vic LaFay, S & B Industrial Minerals NA, Cincinnati, OH. Sponsored Research: Measurements and Confirmation of Thermal Properties of Investment Ceramic Shell by Multiple Methods (12-023) Mingzhi Xu, Simon Lekakh, Chirag Mahimkar, Von Richards, Missouri University of Science and Technology, Rolla, MO; Shelly Dutler, MAGMA Foundry Technologies, Inc., Schaumburg, IL.   Prediction of solidification shrinkage during investment casting requires applicable and realistic thermal properties of the ceramic shell. The thermal properties of ceramic shells are affected by the composition and fabrication technique. Depending on the ratio of wall thickness between the casting and shell, two different heat transfer scenarios are possible: i) most of the melt superheat and latent heat are accumulated by the shell and shell enthalpy plays a major role for thin-walled casting solidification and ii) most of latent heat transfers through the shell to environment and thermal conductivity of the shell controls solidification of a relatively thick-walled casting. Thermal properties of the industrial shell were investigated using traditional physical methods (DSC, Laser Flash method). A modified procedure to correct laser flash results for porous specimen is presented. In addition, to assess the properties determined by these physical methods, inverse modeling of experimental cooling curves was performed. A melt with known properties (pure Ni) was poured into the ceramic shell molds which had thermocouples located in the center of casting and outside the shell layer. Inverse modeling using proprietary casting process simulation software, MAGMASOFT® and its additional optimization tool were applied for calculation of temperature dependent heat capacity and thermal conductivity of the shell. The effects of the shell microstructure and porosity on its thermal properties are discussed. The experimental/modeling data were compared to theoretically predicted data. The results obtained will be used for improving the precision of investment casting process modeling. Effect of Binder Content on Heat Transfer (12-103) Scott Giese, Sairam Ravi, Kris Boss, Brodie Biersner, University of Northern Iowa, Cedar Falls, IA.   The goal of the research study was to observe the influence of total binder content and ratio on the solidification time in thin wall aluminum sections for the phenolic urethane no-bake binder system. A356 aluminum was poured in a multiple fin, thin wall casting inserted with thermocouples to measure the thermal profile developed in the mold and the solidification time in a thin wall fin. The solidification time decreased as the total binder phenolic urethane binder content increased. Increasing the Part 1 resin content showed a decrease in the solidification time with a corresponding decrease in the mold temperature profile. The research established the potential heat transfer effect on the solidification time for thin walled aluminum castings, demonstrating the feasibility of using a resin binder to control the solidification rate.     5:30 PM Special Events Room: Regency Ballroom Welcome Reception .   The American Foundry Society would like to welcome all attendees to this reception, which will provide the opportunity to meet with customers, vendors and other attendees. Cocktails and hors d’oeuvres will be served.     Wednesday, April 18, 2012 07:15 AM AUTHOR/CHAIR BREAKFAST Room: Morrow AFS Author/Chair Breakfast .   This breakfast provides the opportunity for AFS authors, session chairs, students and staff to meet and coordinate details for the educational sessions of the day.     08:30 AM CAST IRON Room: Delaware C Presiding: Brad Steinkamp, Wells Manufacturing Co, Woodstock, IL; Kathy Hayrynen, Applied Process Inc., Livonia, MI. Sponsored Research: Aging and Machinability Interactions in Cast Iron (12-026) Simon Lekakh, Von Richards, Missouri University of Science and Technology, Rolla, MO.   This article summarizes the study of the effect of cast iron natural aging on casting machinability. In the first part, cast iron natural aging kinetics was discussed with taking into consideration the effects of alloying elements which are nitride-forming (Ti), carbide-forming (Cr), and nitrogen mobility modifiers (Mn). The study quantitatively established the aging process as a function of temperature and cast iron chemistry. For practical application, an aging time diagram was developed. A second part of the review included measurement of machinability with respect to aging conditions using such parameters as a cutting force, tool wear, surface quality and tolerance. Relationships between cast iron aging and casting machinability were verified in multiple laboratory and industrial tests. Different possible scenarios for improving casting machinability were discussed and optimal operation windows were suggested. Finally, as a demonstration case, the optimal aging time for improving casting machinability was calculated based on one cast iron chemistry and experimentally verified. Sponsored Research: The Effect of Nodularity and Surface Condition on the Fatigue Properties of CG Iron (12-037) Sarum Boonmee, Doru Stefanescu, The Ohio State University, Columbus, OH.   Previous studies have demonstrated that the casting skin decreases considerably the fatigue limit of compacted graphite (CG) iron. The paper explores the effect of nodularity (15, 30 and 40%) and of the surface condition of the test casting (as-cast, machined, shot blasted) on the bending fatigue of CG iron. A fatigue skin factor was defined as a ratio between the fatigue limit of as-cast to machined samples. It was found that the fatigue skin factor increases from 0.68 to 0.85 when nodularity decreases from 40% to 15%. A set of samples with 15% nodularity was tested to quantify the effect of shot blasting. It was found that shot blasting is effective in improving the fatigue limit and in minimizing the effect of the casting skin. Sponsored Research: Investigation of Cast Iron Processing to Produce Controlled Dual Graphite Structure in Castings (12-024) Simon Lekakh, Jingjing Qing, Von Richards, Missouri University of Science and Technology, Rolla, MO.   The change in graphite shape from flake to spheroidal significantly increases the strength of cast iron while simultaneously decreasing thermal conductivity to about half the value in flake graphite iron. In many industrial applications, such as the cylinder head of diesel engine, a combination of high strength and thermal conductivity is essential. A compromise could be achieved by using compacted graphite iron while a more effective way would be to develop controlled distribution of the dual graphite structure in the casting that matches the function of specific regions of the casting design. In this study, the process of casting such functionally region-specific material was modeled and experimentally investigated. It was shown that four main conditions need to be satisfied for the achievement of a controlled dual graphite structure in the casting: - A distinct change in ductile/gray iron melt composition during mold pouring by melt treatment, - Sequential fill of the mold cavity by different melt compositions using special gating systems, - Minimum post filling melt momentum in the mold, - Avoidance of natural convection in the melt before casting solidification. Different approaches were tested using an experimental casting with flat internal cores. The experimental results achieved thus far were compared to modeling predictions and the different possible process routes are discussed.     08:30 AM ENVIRONMENTAL, HEALTH AND SAFETY Room: Delaware A Organic Coatings to Prevent Molten Metal Explosions (12-125) Alex Lowery, Wise Chem LLC, New Albany, OH; Joe Roberts, Pyrotec Inc., Spokane Valley, WA.   Over 60 years ago, the first reported molten metal explosion from a bleed-out during direct chill casting in an aluminium mill was reported. Soon thereafter testing was performed to determine the root cause of the explosion. Upon determination of the root cause, an investigation to determine if any preventive measures could be instituted to prevent the explosions was conducted. Results found that a specific organic coating (e.g., Wise Chem E-212-F) prevented molten metal explosions, whereas some specific organic coatings initiated the explosions. Fifteen years ago the U.S. Department of Energy in conjuncture with the Aluminum Association reinvestigated the root cause of the molten metal explosion to occur. Testing identified three additional coatings that could afford protection.     08:30 AM LOST FOAM CASTING Room: Delaware D PANEL: New Developments and Markets in Lost Foam - Part I (12-158) Ray Donahue, Mercury Marine, Fond Du Lac, WI; Charles Rau, Technologies Green Partners, Gig Harbor, WA; Franz-Joseph Woestmann, University of Paderborn , Paderborn , Germany; Renato Begnis, Massimo Santoro, Isotta Fraschini, Spoleto, Italy; Harry Littleton, University of Alabama/Birmingham, Birmingham, AL.   Efforts are ongoing to expand lost foam applications by improving the material properties of cast alloys. Topics in this panel will include pressurized aluminum in lost foam, rapid solidification for improved properties, and latest research efforts into the pairing of compacted graphite iron (CGI) with lost foam.     08:30 AM MOLDING METHODS & MATERIALS Room: Delaware B Presiding: Doug Trinowski, HA International LLC, Westmont, IL; Josh Werling, Prince Minerals Co, Quincy, IL. Thermomechanical and Chemical Properties of a Novel, Green Core Binder (12-058) John Fox, The Pennsylvania State University, University Park, PA.   Metalcasting within the United States aims to meet ever-more stringent environmental standards as new process technologies are developed. Conventional foundry core binders are responsible for up to 70% of a foundry’s volatile organic compound (VOC) emissions. New core binder technologies are essential for environmental sustainability within foundries. Herein, conventional and novel foundry core binders were appraised using thermal gravimetric analysis (TGA), dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), hot distortion testing (HDT) and (Pilot-scale) molten iron erosion tests. Inherently, these tests cannot replace full-scale casting trials to evaluate binder effectiveness, however, these tests were performed to more fully elucidate binder properties that might cause casting defects or other unwanted behaviors at high temperatures. During each of these lab protocols, the combination of collagen plus alkali silicate as binders exhibited properties that matched or exceeded those of conventional phenolic urethane. Also, in iron erosion testing, the collagen/alkali silicate binder exhibited the same low erosion as conventional phenolic urethane. In hot distortion testing, the collagen-alkali silicate binder exhibited longer resistance to thermal bending, and comparable thermal flexibility to conventional phenolic urethane. Herein, conventional and novel foundry core binders air emissions were appraised using thermal gravimetric analysis mass spectrometry (TGA - MS). Fourier transform infrared spectroscopy, and X-ray photoelectron spectroscopy (XPS) were utilized to characterize how collagen and silicate chemically interact. The analytical techniques indicate that cross-linking occurred between the carboxyl functional group innate to collagen and sodium silicate. Casting Trials Measuring Thermo-Mechanical Defects in Various Chemically Bonded Sand Systems (12-107) Sean Derrick, Andrew Oman, Sam Ramrattan, Western Michigan University, Kalamazoo, MI.   Chemically bonded sand cores and molds are an important part of metal casting technology and their interaction at the mold-metal interface is of great interest. With today’s emphasis on near-net-shape, thin wall castings, and with ever more stringent casting dimensional reproducibility requirements, there is a need for test methods and or casting trials that accurately measure the thermo-mechanical distortions of chemically bonded sand binder systems in real time. The thermal distortion test (TDT) has proven to be an efficient laboratory technique for identifying anomalies and measuring distortion in various chemically bonded sand binder systems. However, laboratory test are unable to address all the influences at the mold-metal interface. It is important to conduct casting trials that provide distortion measurements and evidence of the actual casting defects. Two new casting trials were developed for comparing TDT data. One model was used to compare laboratory distortion data to casting distortion. The second model related TDT anomalies to casting defects. There were thermo-mechanical relationships found between the TDT data and the cast trials.     08:30 AM WORKSHOPS & SEMINARS Room: Fairfield Workshop: Combustion System Basics (12-137) Jim Checkeye, Don Whipple, Bloom Engineering, Williamsville, NY.   Will describe the basic burner types and the components that control them. Also will discuss typical control and safety devices and how they function and field tips for set up and tuning.     10:15 AM ALUMINUM Room: Delaware B Control and Measurement of Hydrogen in Aluminum (12-002) Geoffrey Sigworth, Brian Began, Foseco, Cleveland, OH.   The control of dissolved gas in liquid metal is absolutely vital in the production of high quality castings, and for this reason numerous degassing processes and more than a dozen methods of gas analysis have been developed over the years. The most important of the existing techniques are reviewed briefly in this paper, and our present scientific understanding in both areas is summarized. The methods and equipment available now to degas metal appear to be well established and reliable. Moreover, competition among different suppliers, better materials, and improved lance designs have resulted in lower operating costs. Unfortunately, there has not been a corresponding improvement in techniques available to measure gas. A review of the existing methods show that each is seen to offer some inherent disadvantage. However, a recently developed electrochemical probe appears to be a simple way to obtain an accurate measurement. Since the majority of foundry defects are usually related to porosity and/or shrinkage formation, an improved real time measurement should have a significant commercial benefit. Behaviour of Bubbles under Directional Solidification Conditions (12-065) Yuefei Teng, Yuansheng Yang, Institute of Metal Research, Shengyang, Liaoning, China; Honglei Yu, Lilin Wang, Weidong Huang, Norhwestern Polytechnical University, Xi'an, Shanxi, China; Qingyou Han, Purdue University, West Lafayette, IN.   Behavior of bubbles under directional solidification conditions was studied using the transparent succinonitrile system. For each experiment, the growth rate of the solid and the temperature gradient ahead of the freezing front were kept constant in order to obtain a well aligned cellular/dendritic array. Our study indicates that bubbles are formed in the mushy zone and grow with the solid. New bubbles may form near an existing bubble if excess amount of dissolved gas is available. The growth of a bubble stops when the local concentration of the dissolved gas is low. At high growth rates of the solid, a buuble often jumps towards the liquid zone and sometimes escapes the mushy zone. Bubbles in the liquid ahead of the freezing front can also be engulfed by the growing solid, forming a teardrop-like morphology. Radical Motion of Bubbles in the Mushy Zone (12-066) Qingyou Han, Purdue University, West Lafayette, IN.   Bubbles usually form during solidification of alloys having a large solubility of gas in the liquid but a negligible solubility of gas in the solid. These bubbles become pores in a solidified casting, deteriorating the mechanical properties, notably the fatigue life of the alloys. In situ observation of pore formation in metallic alloys is difficult because of their opacity. Transparent organic materials are uniquely suitable for studying bubble formation during solidification. This article describes the patterns of bubble motion in the mushy zone of cyclohexane under directional solidification conditions. Worm-like or elongated bubbles are formed at low growth rates of the solid. At high growth rates, radical motions of bubbles in the mushy zone occur. Often, bubbles jump at great speeds from location to location towards higher temperature regions, or high liquid fraction regions in the mushy zone. If the growth rate of the solid is suddenly decreased or stopped, these radical motions of bubble, or even eruption of bubbles, usually occurs at the freezing front. It is believed that these types of radical motion of bubbles in the mushy zone strongly affect the final distribution and the size of pores in a solidifying casting.     10:15 AM CAST DESIGN & PURCHASING Room: Union B & C Iron Casting Defect Analysis and Correction (12-144) Michael Slaydon, Rochester Metal Products Corp. , Rochester, IN; Brad Harris, Bremen Castings Inc., Bremen, IN; Todd Jensen, ThyssenKrupp Waupaca, Etowah, TN; Jay Zins, Dotson Iron Castings, Mankato, MN; Godfrey Sergeant, Grede - New Castle, New Castle, IN.   Excellent quality and low scrap in green sand foundries have moved from a benchmark to a necessity to stay in business. Good controls of all processes and proper analysis of mistakes (scrap) are tools to help achieve this. To correct deficiencies in our systems, foundry quality personnel must first properly identify the defect and then put in place appropriate corrective actions. This panel will present case studies by iron foundries detailing their scrap analysis and quality improvement experiences. Participating foundries include matchplate and vertical green sand molding in both gray and ductile iron shops. Shrinkage, sand inclusions, explosive penetration, and core buoyancy will be discussed.     10:15 AM CAST IRON Room: Delaware C Presiding: George Kokos, Caterpillar Inc., Peoria, IL; John Grabel, Trivoli, IL. Honorary Lecture: Inoculation – Facts & Fiction (12-128) Torbjorn Skaland, Elkem Foundry Division, Kristiansand, Vest-Agder, Norway.   Inoculation is recognized as one of the most important metallurgical treatments of liquid cast iron. Different theories have been developed to explain interactions between inoculant and liquid metal in forming heterogeneous nucleation sites for graphite. Due to the complexity of the process and the small size of its reaction products, confirming theories of inoculation has proven very challenging. Factors such as thermodynamic stability, reaction kinetics, phase crystallography, and surface tension play important roles in successful graphite nucleation. The different sequences of grey and ductile iron nucleation reactions have been studied extensively, and new understanding of grey iron inoculation differentiating fundamentally from the ductile iron nucleation process will be elaborated on. Also reviewed the influence of the magnesium treatment, in ductile iron on the behavior of liquid metal transformation to solid and the important key elements in the nucleation process and effects of their non-metallic heterogeneous compounds on graphite formation.     10:15 AM ENGINEERING Industrial Engineering Room: Delaware A Presiding: Donald O'Connell, Neenah Foundry Co., Neenah, WI. PANEL: Case Studies in Casting Finishing (12-138) Julie DeWeese, Dalton Corp, Warsaw, IN; Ross Vass, Rice Industries, Lino Lakes, MN; Joe McGreal, Ervin Industries, Monticello, IA; Donald O'Connell, Neenah Foundry Company, Neenah, WI.   Panel Topics: DeWeese: Case Study No. 1 Vass: A Comparison Between Diamond Abrasives and Traditional Grinding Abrasives McGreal: Effective Shot Blast Operation O'Connell: Case Study Number 2   Effective casting finishing begins with an efficient and cost effective shot blast operation. This panel looks at typical shot blast operations and provides the tools required to implement proper shot blast practices and achieve optimal surface preparation at minimal cost. Additionally, recent trends in casting finish automation have shown an increased use of diamond abrasives. This panel explores the use and application of diamond abrasives and compares their performance to the performance of traditional grinding abrasives. Technical data on shot blast operation and diamond abrasives is presented by authors who are industry leading suppliers of both shot and diamond abrasives to the casting industry. The panel also includes several case studies in which this technology was applied in foudry operations. These case studies provide a review of the benefits obtained, lessons learned during implementation, keys to success and the controls needed to sustain the gains.     10:15 AM LOST FOAM CASTING Room: Delaware D PANEL: New Developments and Markets in Lost Foam - Part II (12-159) Ray Donahue, Mercury Marine, Fond Du Lac, Wi; Charles Rau, Technologies Green Partners, Gig Harbor, WA; Franz-Joseph Woestmann, University of Paderborn, Paderborn, Germany; Renato Begnis, Isotta Fraschini, Spoleto, Italy; Massimo Santoro, Isotta Fraschini, Spoleto, Italy; Harry Littleton, University of Alabama/Birmingham, Birmingham, AL.   Panel Topics: Littleton: New Developments and Markets in Lost Foam, Part 1.   Lost Foam continues to be successfully developed, marketed, and applied, both in the US and abroad. This panel of lost foam experts will look at specific domestic and European applications that support this trend.     11:45 AM Special Events Room: Franklin BCD AFS Recognition Luncheon .   This luncheon will feature the Best Paper and Division Awards and presentation of the Howard F. Taylor Award and Ray H. Witt Award.     2:00 PM ALUMINUM Room: Delaware B Modeling the Response of Aluminum Alloy Castings to Precipitation Hardening Heat Treatment (12-068) Chang Kai Wu, Makhlouf Makhlouf, WPI, Worcester, MA.   In this publication we report on the development of a computer model that enables predicting the physical and mechanical property changes that occur in aluminum alloy castings in response to precipitation-hardening heat treatment. The model accounts for all three stages of the typical precipitation hardening heat treatment; i.e., the solutionizing, quenching, and aging stages; and it allows predicting the local hardness and room temperature tensile properties as well as the magnitude of residual stress and dimensional changes that develop in the casting during each stage of the heat treatment process. The model uses the commercially available finite element software (ABAQUS) and an extensive database that was developed specifically for the aluminum alloy under consideration – namely, A356.2. The database includes the mechanical, physical, and thermal properties of the alloy all as functions of temperature; and it employs this database and Quench Factor Analysis to predict the properties of the casting. The model predictions were verified against measurements made on aluminum alloy casting that was heat treated according to a standard T6 heat treatment and the model predictions were found to be in good agreement with the measurements. Modelling of Microstructure and Mechanical Properties of Aluminum Alloys During the Casting Process and Heat Treatment (12-028) Marc Schneider, MAGMA Giessereitechnologie GmbH, Aachen, North Rhein Westphalia, Germany; Christof Heisser, MAGMA Foundry Technologies, Schaumburg, IL.   Alloy composition, metallurgy and local solidification conditions define the the microstructure and defect distribution within aluminum castings. The local microstructure and defects have a definite impact on the mechanical properties. This paper will provide an overview of a new methode to simulate the creation of local microstructure within the casting process and all the way through the heat treatment process. Influence of Solutionizing Time, Modification, and Cooling Rate on the Decomposition of Mg-Containing Pi-Iron Intermetallic Phase in 357 Alloys (12-009) Ehab Elsharkawi, Agnes Samuel, Fawzy Samuel, Université du Québec à Chicoutimi, Chicoutimi, QC, Canada; Eider Simielli, Alcoa , Alcoa Center, PA; Geoffrey Sigworth, GKS Engineering Services, Dunedin, FL.   The pi-AlFeMgSi iron intermetallic phase is known for its detrimental effect on the strength of Al-7Si-Mg alloys by reducing the amount of Mg in the matrix available for strengthening. During solution heat treatment, and at a Mg content of 0.55 wt% in the 357 alloys, the pi-phase showed partial decomposition into fine beta-phase needles. This type of decomposition was examined for the purposes of this study over extended periods of solution heat treatment time in non-modified and Sr-modified 357 alloy samples obtained at different cooling rates in order to evaluate the mechanism of pi- to beta-phase decomposition. The results obtained show that the volume fraction of pi-AlFeMgSi phase decreases significantly at prolonged solution treatment times. The highest amount of the newly-formed beta-phase was observed in the solution treatment time range of 60 to 80 hours. The pi-phase iron intermetallic particles appear to be segregated away from the modified Si in the Sr-modified alloys, particularly those solidified at a low cooling rate. An analysis of the chemical composition of the matrix using wavelength dispersive spectroscopy (WDS) at different stages of solution heat treatment revealed that the pi- to beta-phase decomposition during solution heat treatment results in a distinct increase in the Mg content of the matrix. Furthermore, no changes were observed in the calculated stoichiometries of the pi-phase or the beta-phase intermetallic during solution treatment in all the alloy samples studied.     2:00 PM CAST DESIGN & PURCHASING Room: Union B & C Optimization of Conversion to Castings from Fabrications and Weldments, Using Case Studies (12-142) David Laude, G & W Electric Co., Blue Island, IL; Dwight Barnhard, Superior Aluminum Castings Inc., Independence, MO; Chris Witt, Dotson Iron Castings, Mankato, MN.   Engineers designing castings face the uncertainty of foundry capabilities and experience frustration due to absence of industry techniques. Often, a product design causes severe problems at the casting stage, and the foundry may request the customer to either modify the design or pay a higher price to offset the costs of tooling modification, increased scrap and additional operations. As foundry engineers produce what product engineer’s design, revisions are expensive and time consuming. Yet, these are inevitable because product designers have limited knowledge about casting processes and have no means to evaluate the influence of design features on castability. This anatomy of great castings with ten things engineers should know when designing castings will provide engineers insight into foundry industry techniques and capabilities. The result of collaboration between foundry and original equipment manufacturer in the design phase will ensure successful casting conversions in shortened time frame.     2:00 PM CAST IRON Room: Delaware C Presiding: Matthew Meyer, Bremen Castings Inc, Bremen, IN; Andrew Adams, Foseco , Cleveland, OH. Evolving Foundry Strategies and Alloy Designs to Counter the Rare Earth Price Explosion (12-020) Gunnar Maltsev Hansen, Cathrine Hartung, Lena Magnusson Aberg, Elkem Foundry Products, Kristiansand, Norway; Douglas White, Elkem Materials Inc., Boca Raton, FL.   The prices of Rare Earth metals have increased dramatically over the last year, from a historically quite stable level below $10 per kg until second half of 2010 up to more than $160 per kg by the end of Q2 2011. The steep increase is caused by the combination of increased domestic consumption of Rare Earth metals in China, and a reduction in production output mainly due to environmental regulations. As a result Chinese authorities have drastically reduced export quotas of these metals. Since China produce more than 90% of the Rare Earth metals available on the international market this has caused a worldwide shortage of these important elements. This presentation will briefly summarize the historical and present market situations, including uses for Rare Earth Metals in other industries. The multiple effects of adding Rare Earths to iron will be discussed with special attention to the amount of RE required to manage tramp elements present, while avoiding deteriorated graphite in heavier sections. An overview of common Rare Earth containing products used in the foundry industry will be given. Alternative strategies on how to minimize the use of RE will be provided to counteract the reduced availability and the price increase, including some actual strategies that have been implemented by foundries in Europe and the USA. Testing alternate strategies with minimum risk to iron quality in full production will be discussed. Simultaneous Cooling and Contraction / Expansion Curve Analysis During Ductile Iron Solidification (12-071) Mihai Chisamera, Iulian Riposan, Stelian Stan, Politehnica University of Bucharest, Bucharest, Romania; Michael Barstow, Consultant Metallurgist, Fremont, CA.   An experimental device was developed with a technique to simultaneously evaluate cooling curves and expansion or contraction of cast metals during solidification. The recorded data are processed using specialized software, which conveniently displays both cooling and contraction/expansion curves and their specific parameter values. The first part of the paper summarizes the side by side performance using two molds testing different inoculants, different inoculant additions, different mold media, different iron chemistries, under otherwise constant conditions. Its application is illustrated with results on shrinkage tendency of ductile iron treated with FeSiMgRECa, as affected by mold rigidity (green sand and resin sand molds) and inoculant type (Ce,Ca,S,O-FeSi and Zr,Ca-FeSi alloys). The second part of the paper describes the possible role of this equipment in a foundry to monitor variations in cast iron quality using identical mold media solidification conditions (a specially designed ceramic cup, incorporating a thermocouple and contraction/expansion measuring device). The inoculation efficiency of two rare earth bearing FeSi alloys (RE-FeSi and La-FeSi) was compared, in FeSiMgCa treated irons (no RE), to reduce undercooling during solidification. As a consequence their role affected the contraction/expansion events, which were shown to control the presence of shrinkage in ductile irons. The Use of Combined Liquid Displacement and Cooling Curve Analysis in Understanding the Solidification of Cast Iron (12-045) Doru Stefanescu, Molly Moran, Sarum Boonmee, The Ohio State University, Columbus, OH; Wilson Guesser, Tupy and Universidade do Estado de Santa Catarina, Santa Catarina, Brazil.   Understanding and controlling the graphite expansion during the eutectic solidification of cast iron is of vital practical importance, as graphite expansion directly affects the shrinkage propensity. Numerous studies have been conducted to measure the amount of this expansion and the time of its occurrence. Unfortunately, most of these studies used a measuring device that could not separate metal displacement from mold displacement, which made it difficult if not impossible to correctly interpret the associated phenomena. In this paper we introduce a Liquid-to-Solid Dilatometer, which all but eliminates the mold displacement. In addition, the dilatometer records the cooling curves. This makes possible a combined interpretation, giving an unambiguous answer to questions such as the beginning and end of the eutectic solidification. Experimental results for gray, ductile and compacted graphite cast iron are presented and discussed. The effect of chemical composition on graphite expansion is analyzed.     2:00 PM ENGINEERING Process Design and Modeling Room: Delaware A Presiding: Theodore Schorn, Enkei America Inc, Columbus, IN. PANEL: Understanding, Exploring, and Strategizing Leadership in Todays Foundry (12-127) Nick Fox, Galesburg Castings Inc, Galesburg, IL; Kenley Hansen, ThyssenKrupp Waupaca, Waupaca, WI; David Hughes, DS&D Cast Solutions Inc, Pelham, AL.   This panel will focus on the impact of effective leadership within the foundry industry. Emphasis on the failures of todays leaders and how it impacts the workforce. A case study will be presented on bringing a shuttered foundry back online and how they utilized leadership. Finally discussions will be held on understanding leadership and how to modernize todays management.     2:00 PM MOLDING METHODS & MATERIALS Room: Delaware D Presiding: Michael Bartol, American Colloid Co, Hoffman Estates, IL; Jerry Thiel, University of Northern Iowa, Cedar Falls, IA. Silver Anniversary: High Efficiency Cold Box Processes - Technology Focused on Business Goals (12-001) James Archibald, Jörg Kroker, ASK Chemicals LP, Dublin, OH.   Twenty five years ago a senior planning manager at Caterpillar’s Mapleton foundry and I benchmarked the attributes of SO2 cured cold box binder systems. The paper benchmarked technical properties and attributes of the chemical binder systems. Looking back our business goal and our job was to take cost out by driving efficiency, reducing “work in progress” and improving the dimensional accuracy of the cast parts and the final products produced in the supply chain. Over the last 25 years chemists, engineers and metal casting experts have developed new Cold Box systems to improve productivity and environmental requirements. This silver anniversary paper briefly reviews the significant progress in binder chemistry, and the CB process and equipment improvements by highlighting key examples in certain casting market segments. New design capability for modeling complex core & mold tooling is reviewed. Practical, economical automation & core assembly deliver remarkable productivity and quality achievements are benchmarked. Precision sand casting and efficient metal feeding systems make near net shape castings a reality and clearly takes cost out of the casting process are reviewed. Future needs for improvements in the cold box process and chemistry are discuued. Further Evaluation of Anti-Veining Sand Additives (12-003) Ralph Showman, Sean Harmon, ASK Chemicals LP, Dublin, OH.   There are a number of types and formulations of anti-veining sand additives that are currently in use throughout the world. Three new types of mineral additives have recently been developed and introduced into foundry production. A series of tests were conducted to compare the performance of these new additives to those previously in use. Testing includes casting evaluations for veining, penetration, and surface finish and core testing for the impact on core strength, benchlife, humidity resistance, hot distortion, emissions, and odor. Data is presented from the tests using sands and coldbox binders from several geographic regions including Europe, China, North America, and Brazil.     2:00 PM WORKSHOPS & SEMINARS Room: Fairfield Workshop: Refractory Basics, Selecting the 'Right' Refractory, Refractory Lining Design, Product Application, Heating and Sintering Refractories (12-145) Timothy Hoyt, Allied Mineral Products Inc., Columbus, OH.   This workshop is meant to be a basic overview of refractory materials and how they are applied in different applications. It is meant to provide useful information to anyone who deals with using or specifying refractory materials.     3:45 PM ALUMINUM Room: Delaware B Prediction and Experimental Validation of Microstructure and Mechanical Properties in Aluminum Castings (12-041) Jianzheng Guo, ESI US R&D, Columbia, MD; Sam Scott, ESI Group NA, Farmington Hills, MI.   A comprehensive numerical model has been developed for the calculation of the microstructure and mechanical properties of aluminum casting alloys. After specifying the alloy chemical composition and solidification process parameters, the model predicts the microstructure and potential defects after solidification. The model takes into account the relationship between the different input parameters and the link to basic metallurgical features. In this paper an A357 alloy is chosen to study the microstructure and mechanical properties evolution through the process of casting. The effects of cooling history during casting processes on aluminum alloy castings are numerically and experimentally investigated. The microstructure and mechanical properties are predicted and compared with experimental measurements. Localized Strengthening of Cast Al Components via Friction Stir Processing (12-070) Ning Sun, Diran Apelian, Worcester Polytechnic Institute, Worcester, MA.   The casting process is a complex one in that three key transport processes take place simultaneously: heat flow, fluid flow and mass flow. This complexity gives rise to inhomogeneity within the microstructure, porosity, and to other defects. Ironically, successful castings are made not through control of the microstructure, but through the control (or management) of defects. In this vein, we have pursued a processing method by which one can locally manipulate the structure, as well as to locally strengthen it. Friction Stir Processing (FSP) has been studied and developed and applied to Al cast alloys for such applications. What is attractive about FSP is that it can be incorporated in the overall manufacturing cycle as a post-processing step during the machining operation. We have optimized FSP for processing of Al alloys; and have established the mechanism of microstructure evolution and evaluated the resultant mechanical properties. We have also explored and evaluated FSP as a means to locally fabricate composites. In this presentation, these will be presented and reviewed. Sponsored Research: Phase II – Optimization Mechanical Properties of Cast Aluminum Alloys (12-132) David Neff, Willoughby, OH; David Schwam, Case Western Reserve University, Cleveland, OH.   Phase I of this project addressed the benefits of best practices in melting and melt cleaning on achieving highest mechanical properties in as-cast and T6 conditions in A356, using separately cast testbars in a modified ASTM B108 mold as a criteria. The present work, Phase II, expands on that with both A356 and 319, employing microstructural enhancements (grain refining, modification, SDAS) in addition to best practices in melt treatment. This work reports on results to date utilizing molds poured at commercial foundries which attempt to employ ‘best practices’. Mechanical properties are reported for the T6 condition for A356, and for botrh the T6 and T7 conditions for 319 alloy. Fatigue results are also presented. In both Phase I and Phase II, best results are obtained not only by best melting, melt treatment, and microstructural refinement practices, but also by minimizing microporosity (achieved with the modified test bar mold) and keeping iron content as low as practical.     3:45 PM CAST IRON Room: Delaware C Presiding: Jerry Wilkinson, Kohler Co, Kohler, WI; Alex Gyarmaty, Coorstek Advanced Materials Hamilton ULC, Paris, ON, Canada. Sponsored Research: Comparison of Monotonic and Cyclic Properties of Ductile Irons in the AFS/DOE Strain-Life Fatigue Database for Cast Iron (12-082) John Tartaglia, Element Materials Technology, Wixom, MI.   A strain-life fatigue database for cast irons was developed utilizing AFS and the United States Department of Energy (DOE) funding. The database contains monotonic and cyclic property data, as well as the associated chemical analysis and microstructural data for a variety of cast irons, including gray, ductile, compacted graphite, and white cast irons. This paper first reviews the contents and format of the database. The database and its associated report contain no comparative analysis of any of the cast iron grades. The fresh approach of this paper is to analyze and compare the data across each section size and strength-ductility combination for four ductile iron grades, i.e., ferritic 60-40-18, ferritic-pearlitic 65-45-12, pearlitic 100-70-03 and martensitic 120-90-02. The ductile cast iron results in the database generally exhibited the expected trends. Modulus and Poisson’s ratio were the same for all the conditions. Monotonic strength always decreased with increasing elongation and ferrite content. The higher strength grades and conditions exhibited greater high cycle fatigue resistance and decreased low cycle fatigue resistance. Annealing decreased the monotonic strength of 60-40-18 whereas normalizing increased the strength and dramatically increased fatigue resistance of pearlitic 100-70-03. Monotonic ductility was only slightly affected by heat treatment. Gray Cast Iron with High Austenite-to-Eutectic Ratio Part I - Calculation and Experimental Evaluation of the Fraction of Primary Austenite in Cast Iron (12-033) Gorka Alonso, Pello Larrañaga, Jon Sertucha, Ramon Suarez, Azterlan, Durango, Biscay, Spain; Doru Stefanescu, The Ohio State University, Columbus, OH.   The amount of primary austenite at the end of solidification in the microstructure of cast iron has a direct impact on the mechanical properties. However, the large majority of papers discussing the mechanical properties of cast iron relate these properties only to graphite shape. The main reason is the difficulty in correctly assessing the amount of primary austenite in the microstructure. The paper describes two methods of measuring the fraction of primary austenite in cast iron: i) through the use of cooling curve analysis, and ii) through quantitative evaluation of color-etched micrographs. The first method also allows the evaluation of solid fraction evolution along the solidification process, which is validated with quenched (interrupted solidification) gray iron specimens. Gray Cast Iron with High Austenite-to-Eutectic Ratio Part II – Increasing the Austenite-to-Eutectic Ratio through Inoculation (12-034) Pello Larrañaga, Jon Sertucha, Aitor Loizaga, Ramon Suarez, Azterlan, Durango, Biscay, Spain; Doru Stefanescu, The Ohio State University, Columbus, OH.   A higher amount of primary austenite in the microstructure of gray iron typically results in higher strength, if the pearlite-to-ferrite ratio is constant. The most common method to increase the amount of austenite in the microstructure is by decreasing the carbon equivalent. However, a lower carbon equivalent produces higher hardness and increased propensity to shrinkage defects. The paper describes a method of increasing the austenite fraction through the manipulation of the chemical analysis of the iron. Iron powder, iron shots and ferrotitanium inoculation were explored. When using appropriate titanium additions the austenite fraction in a 4% carbon equivalent gray iron can be increased, for example, from 0.18 to 0.27. This was accompanied by the solidification of superfine interdendritic graphite. A detailed analysis of the graphite through optical and electronic microscopy is also provided. Gray Cast Iron with High Austenite-to-Eutectic Ratio Part III - High Strength, Low Hardness, High Carbon Equivalent Gray Iron with Superfine Graphite (12-035) Pello Larrañaga, Jon Sertucha, Aitor Loizaga, Ramon Suarez, Azterlan, Durango, Biscay, Spain; Doru Stefanescu, The Ohio State University, Columbus, OH.   The standard methods to increase the mechanical properties of gray cast iron include the use of a lower carbon equivalent and/or of alloying elements. However, these methods produce higher hardness and, in particular for the case of lower carbon equivalent, increased propensity to shrinkage defects. The paper describes a method of increasing the tensile properties of hypoeutectic gray iron of relatively high carbon equivalent through the manipulation of the chemical analysis of the iron and otherwise standard procedures. When using appropriate sulfur and titanium contents the primary austenite-to-eutectic ratio is highly augmented and superfine interdendritic graphite is produced. The tensile strength of gray iron of average 4% Carbon Equivalent can be increased to 300-350 MPa, without a significant increase in hardness, which remains in the range of 185-200HB.     3:45 PM ENGINEERING Process Design and Modeling Room: Delaware A Presiding: Jitendra Shah, Product Development & Analysis LLC, Naperville, IL. PANEL: Research Advances in Modeling (12-146) Andrei Starobin, Core & Mold Venting Solutions, Santa Fe, NM; Charles Monroe, Richard Huff, Caterpillar Inc, Champaign, IL.   During the design of a component, changes to geometry and rigging add time and cost to production. Optimization can be used to reduce the lead time to a finished product example by automating the exploration of casting design and rigging to reduce casting defects such as shrinkage porosity. Little work, however, has been done to discuss the optimization of a casting's geometric boundaries to improve its soundness and directional solidification. The benefit of such an optimization, is discussed and how the design of a part can be evaluated for castability. In another discussion a program is developed for the use by the foundry process engineer that estimates gas pressure during casting in a chemically bonded core and compares it with the available metallostatic head of the metal, to prevent gas defects. The program can be used to identify cores that require venting in Al and Iron castings and covers PUCB, PUNB and Epoxy Acrylic binder systems.     7:00 PM Special Events Room: Regency Ballroom Annual Banquet .   Highlights of the annual banquet include the presentation of the AFS Gold Medal followed by an evening of entertainment. Cash bar from 6:00-7:00 p.m.     Thursday, April 19, 2012 07:15 AM AUTHOR/CHAIR BREAKFAST Room: Morrow AFS Author/Chair Breakfast .   This breakfast provides the opportunity for AFS authors, session chairs, students and staff to meet and coordinate details for the educational sessions of the day.     08:30 AM ALUMINUM Room: Delaware B Hot Tearing in Cast Al Alloys: Mechanisms and Process Controls (12-069) Shimin Li, Diran Apelian, Worcester Polytechnic Institute, Worcester, MA; Kumar Sadayappan, CANMET - MTL, Hamilton, ON, Canada.   Hot tearing has been an issue for many casting alloys, and much work has been devoted over the years to understand the underlying mechanism, and to be able to mitigate it during casting. Unfortunately, the literature and thus our understanding to date has been a bit muddled, as there exists conflicting data and theories. In addition, many of the tests that have been developed to evaluate hot tearing have been qualitative in nature. Through the Light Metals Alliance, WPI’s Metal Processing Institute and CANMET joined forces in 2006 to clarify our understanding of hot tearing and to enable us to control it during casting. In this presentation, we will give an overview of our work, describe the quantitative test we have developed and discuss processing variables one needs to control to mitigate hot tearing. Effects of Intermetallics on the Fracture Behavior of Al-Si-Cu-Mg Base Alloys (12-010) Mohamed Ibrahim, Agnes Samuel, Fawzy Samuel, Université du Québec à Chicoutimi, Chicoutimi, QC, Canada; Abdulrahman Al-Ahmari, King Saud University, Riyadh, Saudi Arabia.   Fracture behavior, as well as impact toughness, is influenced by alloy composition, solidification rate, and the heat treatment conditions applied. This study was undertaken to investigate the effects of intermetallics on the fracture behaviour of non-modified and Sr-modified Al-Si-Cu-Mg base alloys. Castings were prepared from both experimental and industrial 319 alloy melts containing 0-0.6wt% Mg. Impact test bars were cast in two different molds, namely a star-like permanent mold and an L-shaped permanent mold, which provided cooling rates corresponding to secondary dendrite arm spacings (SDAS) values of 24 and 50 μm, respectively. The bars were tempered at 180ºC (T6 treatment) and 220ºC (T7 treatment) for 2-48 hours. Charpy impact tests were carried out on these unnotched bars to measure their impact energy values. It was observed that the addition of Mg resulted in the precipitation of the β-Mg2Si, Q-Al5Mg8Cu2Si6, π-Al8Mg3FeSi6, and the blocklike θ-Al2Cu phases. The fracture surfaces of non-modified alloys exhibited long Si particles with cracks in the interior, while those of the Sr-modified alloys displayed a dimpled structure throughout the matrix. Increasing the Mg content up to 0.6% resulted in the appearance of fractured particles of Q-Al5Mg8Cu2Si6 and π-Al8Mg3FeSi6 phases. Decreasing the cooling rate or increasing the aging temperature did not alter the fracture mechanism with respect to the alloy composition. It was also observed that the tendency of Sr to segregate the Al2Cu phase away from Al-Si eutectic regions causes sluggishness of the dissolution of Al2Cu during solution heat treatment. The presence of relatively large proportions of undissolved Al2Cu compromises the beneficial effects of a soft Al matrix, leading to lower toughness values. Assessment of the Effect of Mg Addition on the Solidification Behavior of Al-Si-Cu Cast Alloys (12-013) Adel Mohamed, Fawzy Samuel, Université du Québec à Chicoutimi, Chicoutimi, QC, Canada; Saleh Alkahtani, AlKharj University, AlKharj City, Eastern Province, Saudi Arabia.   The purpose of this study was to determine the influence of different amounts of Mg on the microstructures of experimental and industrial 319 alloys. Thermal analysis was carried out for the various alloy compositions to determine the reactions corresponding to the formation of various phases. These phases were identified by examining the corresponding microstructures of the as-cast alloys. The results indicated that the addition of Mg leads to the segregation of the copper phase, resulting in the formation of the block-like form of the CuAl2 phase rather than its finer eutectic-like form. This makes it more difficult to dissolve the CuAl2 phase during solution heat treatment. It was also observed that the degree of modification achieved in the microstructures of the 319 alloys, irrespective of the alloy source, is greatly enhanced at 0.6 wt% Mg content. Addition of Mg also leads to the precipitation of the Al5Mg8Cu2Si6 phase, which normally precipitates after the CuAl2 phase. However, when the Mg level exceeds 0.4 wt%, the precipitation of the Al5Mg8Cu2Si6 phase also takes place in another reaction, before the precipitation of the CuAl2 phase. The morphology of the Al5Mg8Cu2Si6 phase in this case is script-like rather than the irregular-shaped particles normally observed.     08:30 AM ENGINEERING Quality Systems Room: Delaware A Presiding: Richard Huff, Caterpillar Inc, Champaign, IL. Simulation of the Entire Core Production Process (12-029) Marc Schneider, MAGMA Giessereitechnologie GmbH, Aachen, North Rhein Westphalia, Germany; Roy Stevenson, MAGMA Foundry Technologies, Inc., Schaumburg, IL.   The core production process is still full of surprises and core related casting defects are a considerable cost factor of the casting production process. The increasing complexity of castings leads to higher demands on the cores. The core production process is also exposed to more demanding requirements in regard to work place safety and environmental impact. The design of complex cores needs to be considered during the casting development process to assure a technically and economically feasible production of cores and castings. The simulation of the entire core production process is therefore a valuable tool, in conjunction with the traditional casting process simulation, to fullfil these requirements. A thin-walled water jacket core is used to demonstrate the capabilities of this technology. Systematic Optimization of Aluminum Sand Casting Gating Systems (12-027) Joerg Sturm, MAGMA Giessereitechnologie GmbH, Aachen, North Rhein Westphalia, Germany; Georg Dieckhues, Ohm und Haener Metallwerk, Olpe Germany, North Rhein Westphalia, Germany; Steve Sikorski, MAGMA Foundry Technologies, Inc., Schaumburg, IL.   The process development in foundries is under constant pressure from market pressures. Foundries need to improve processes in an ever faster manner. This is especially true for foundries encountering large numbers of new parts per year. Traditionally, the development process for gating and riser systems, as well as process parameters, has been based on factors like "experience" and "trial and error". Within this process casting process simulation has established itself as reliable tool to methodogically develop the rigging and process parameters for castings, especially in combination with automatic optimization tools. Using a real-world aluminum casting as an example, the technology of automatic optimization is explained in a step-by-step approach. Continued Advancements in the Simulation of Thin Wall Ductile Iron Castings (12-057) James Van Wert, Kimon Symeonidis, Victaulic Company, Easton, PA; Sam Scott, Adi Sholapurwalla, ESI North America, Farmington Hills, MI; Jianzheng Guo, ESI US R&D, Columbia, MD.   The ductile iron casting industry faces unique challenges in the production of castings that foundries that cast other alloys do not encounter. As the metal solidifies, graphite formation may lead to a net expansion, reducing or even eliminating the need for feeders as seen in steel and other alloys. Interactions among the evolved metallurgy, alloy composition, inoculation, and mold strength must be understood and implemented in simulation to provide an accurate result. Once these complex algorithms are integrated into casting simulation, the ductile iron industry can use analysis with confidence to help drive the rigging design and casting process. Recently, Victaulic investigated a large industrial pipe elbow casting which required re-engineering due to carbide defects. Casting trials and iterations were performed in conjunction with simulation, to observe the correlation of carbides, porosity and other characteristics which would lead to potential defects during the casting process. ESI Group’s ProCAST Casting Simulation software was employed to identify these defects, enabling Victaulic engineers to come up with a better casting design, which eliminated these defects in the foundry. As-cast and simulation results through these various casting iterations will be presented.     08:30 AM MARKETING Room: Delaware C Presiding: Christo van Baalen, Castalloy Inc., Waukesha, WI. Castings as a Source of Competitive Advantage and/or "Castings Done Right" (12-044) Paul Jones, ThyssenKrupp Waupaca, Waupaca, WI.   Liquids flow better than solids. We also know how they flow and solidify better than ever. So why do we have such battles between casting producers and casting users. More importantly, why do casting users not experience the full benefits of the metal casting process? It is not because of technology limitations within the metal casting industry. It is not because of lack of knowledge of how to design castings amongst the casting producers. I believe it is about relationships and egos within casting users. Perhaps of greater impact may be the relationships, egos and attitudes of the casting producers. The ultimate goal is to perfect the relationships between casting users and producers. With proper relationships the full benefit of castings can be achieved. This paper explores the various relationships and proposes alternative actions to address the causes of ineffective casting applications. An alternative title could be "Castings Done Right". Large Austempered Parts- MONSTER Opportunities (12-080) John Keough, Vasko Popovski, Applied Process Inc., Livonia, MI.   Application of Austempered Ductile Iron (ADI) is rapidly increasing as the result of improved ductile iron quality, greater knowledge of the process and its properties and, advancing equipment technologies that have improved the consistency and capabilities of the process. Until recently, the process has been limited, generally, to parts under one ton. Today, a new system has been developed to allow designers to produce Austempered iron and steel parts up to 10 tons in mass and up to 261 cubic feet (7.5 cubic meters) in size. The potential now exists for designers to develop very large parts with thinner sections and then Austemper them to the strength level needed. This would allow the consolidation of parts and a reduction in mass, waste and cost. This paper will discuss this new heat treatment technology and opportunities for new, large casting applications previously only produced by forging, weldments and assemblies. Embedding Sustainability (12-134) Dana Cooper, Fairmount Minerals Ltd, Benton Harbor, MI.   Sustainable Development Pays: Financial Success Is Rooted in the Ability to Identify and Respond to Key Social and Environmental Issues Sustainable innovation can drive the success of a business. Sustainable development affords a social license to operate and helps to drive innovation and growth. As a business, profitability creates prosperity for our shareholders and employees while contributing to economic development in our communities. Enhancing the sustainable attributes of our products by utilizing sustainable materials, such as recycled content and ensure proper marketing of the products in a way that is in compliance with relevant regulations and codes. The stronger the bottom line, the more positive direct economic impact. From innovative waste elimination to energy efficiency to wellness initiatives and more, we find that sustainable development pays.     08:30 AM MOLDING METHODS & MATERIALS Room: Delaware D Presiding: Stephen Neltner, S & B Industrial Minerals NA, Cincinnati, OH; Mark Ziegler, Unimin Corp., Ottawa, IL. PANEL: Iron Casting Defect Analysis and Correction (12-094) Michael Slaydon, Rochester Metal Products Corp., Rochester, IN; Brad Harris, Bremen Castings Inc, Bremen, IN; Todd Jensen, ThyssenKrupp Waupaca, Etowah, TN; Jay Zins, Dotson Iron Castings, Mankato, MN; Godfrey Sergeant, Grede - New Castle, New Castle, IN.   Panel Topics: Sergeant: Shop Floor Sand Control   Excellent quality and low scrap in green sand foundries have moved from a benchmark to a necessity to stay in business. Good controls of all processes and proper analysis of mistakes (scrap) are tools to help achieve this. To correct deficiencies in our systems, foundry quality personnel must first properly identify the defect and then put in place appropriate corrective actions. This panel will present case studies by iron foundries detailing their scrap analysis and quality improvement experiences. Participating foundries include matchplate and vertical green sand molding in both gray and ductile iron shops. Shrinkage, sand inclusions, explosive penetration, and core buoyancy will be discussed.     08:30 AM WORKSHOPS & SEMINARS Room: Fairfield Workshop: Understanding and Conserving Energy in the Foundry (12-139) Brian Reinke, TDI Consulting Inc. / AFS Energy Solutions, Lemont, IL; Michael Whitfield, Lodge Mfg Co, South Pittsburg, TN; James Wiczer, Sensor Synergy, Barrington, IL; Doug Presny, Kinergetics, LLC , Madison, WI.   Effective energy management has a direct and positive impact on your profitability and the long-term health of your business. To assess your energy management program, ask yourself a few questions: 1) Do you know how much you are spending on energy for each ton of casting shipped? 2) Do you know where the energy is being used and can you identify what equipment or processes are the biggest energy consumers? 3) Does your foundry have a formal energy management program and targets for reducing energy consumption? Whatever you are facing presently with energy costs, you will likely see a major escalation in coming years, as energy eats up a greater percentage of your operating budget. Even though energy costs are relatively low today in some markets, a close look into the future reveals market forces and government policies that can lead to an explosion of energy costs. This workshop will address some of the major issues that foundries face as they move toward energy efficiency. Many foundries do not fully understand their electric bill. The workshop will help participants understand their bill, and the related issues of demand, power factor, voltage level, usage charges and taxes. This presentation will discuss new technology that provides real time electric use data for each piece of equipment in the foundry. A key mantra for energy reduction is that if you can measure it, you can control it and change it. An innovative, self-contained and portable sub-metering solution allows foundries to easily measure energy consumption in real time, identifying usage patterns. A recent case study of a recent foundry installation will be reviewed. The workshop will conclude with a very informative presentation on improving process heating and waste stream heat recovery that can provide dramatic savings every day.     10:15 AM Special Events Room: Franklin BCD President’s Session .   AFS President Tim McMillin and leaders of the AFS Technical Divisions have called this special session to discuss issues of critical importance to the U.S. metalcasting industry. Come hear their thoughts on the state of the industry. This session is open to all attendees.     12:45 PM Special Events Room: Battelle Hall Lunch with the Exhibitors .   All Metalcasting Congress attendees are invited to have complimentary lunch with the exhibitors from 12:45 until 2:00 p.m. All attendees will have the opportunity to visit the booths and meet representatives from the various suppliers to the metalcasting industry.     2:00 PM ALUMINUM Room: Delaware B Thermal Control of Die Cooling Using Inexpensive Standard Cameras (12-053) Davor Srsen, Xiang Chen, Henry Hu, University of Windsor, Windsor, ON, Canada.   In the die and permanent mold casting process, proper control of cooling is essential for producing high quality parts and yielding high production rates. In particular, defects can be caused by the uneven cooling of the part during solidification. In this paper, two standard silicon-based CCD cameras are used to localize the position of the die, and measure the temperature distribution of the die. Using the temperature distribution, the cooling of the dies is adjusted, to reduce the variance in temperature on the die. The first camera uses an infrared-pass filter to sense only the temperature dependent infrared thermal radiation, and measure temperature on the die. The second camera uses standard visible light imaging to localize the die. The validity of this approach is demonstrated experimentally. PANEL: Applications of Cores to Permanent Mold (12-096) David Weiss, Eck Industries Inc., Manitowoc, WI; Randy Oehrlein, Carley Foundry Inc., Blaine, MN; Bob Braun, Wisconsin Aluminum Foundry Co., Manitowoc, WI; Dennis Daniels, Alumalloy Metalcasting Co , Avon Lake, OH.   The use of cores in permanent mold casting is an important casting technology that is widely used in aluminum foundries. Important considerations include type of cores used, venting techniques and core removal methods. This panel explores those issues through a process overview and case studies.     2:00 PM CAST DESIGN & PURCHASING Room: Union B & C Cost-Effective Casting Design: A How to for Designers and Purchasers (12-141) Mike Gwyn, SCRA, North Charleston, SC.   World-Renowned casting design expert Mike Gwyn, who has spoken to designers and buyers from industries as diverse as the military, automotive, railroad and construction, will provide an innovative, conceptual approach to the design of metal castings. Designers and buyers will learn the importance of alloy selection and how it impacts the design boundaries of a casting. The session also examines a systems approach to casting design that can be applied with new designs or conversions to castings. This presentation also will review the corrlation between casting processes and the design of the casting.     2:00 PM MARKETING Room: Delaware C Presiding: Geary Smith, G & W Electric Co, Blue Island, IL. Capital Investment and Casting Demand (12-136) Raymond Monroe, Steel Founders' Society of America, Crystal Lake, IL.   While much of the tonnage of casting production goes to consumer durable goods, many casting producers service the capital goods market. Castings are essential for producing and maintaining the capital infrastructure critical to transportation, energy production and distribution, mining, and construction. The excess capacity installed in the 1970's has been largely eliminated and global growth is stimulating demand for reinvestment. This discussion will examine the current state of the market for capital investment and its likely impact on casting demand.     2:00 PM STEEL Room: Delaware A Effect of Ni on Fluidity of Cr-Mo Steels (12-030) Abhilash Dash, Simon Lekakh, Von Richards, David Van Aken, Missouri University of Science and Technology, Rolla, MO.   The effect of Ni on fluidity of Cr-Mo steels (0.18% C, 0.15% Si, 0.7% Mn, 0.5% Cr, 0.15% Mo) was studied using several experimental techniques and CFD Fluent and Magmasoft modeling. Computer assisted, single thermocouple, thermal analysis showed that Ni decreased the liquidus, solidus, and dendritic coherency (DC) temperatures while Ni little effect on the solid fraction at DC. Filling time was evaluated by measurement of electrical resistivity of a W-wire inserted into a spiral mold and experimental fill time data was used for modeling analysis of factors influencing spiral length fill. Measured fluidity lengths showed a monotonic increase with superheat for all steels and had a maximum value in steel alloyed with 5% Ni in comparison to un-alloyed, low alloyed by 3% Ni and high alloyed by 9% Ni steel. To understand the mechanism of fluidity increase in steel alloyed by Ni, the measured and calculated (FACTSAGE software) physical properties of liquid and solidified Ni-alloyed Cr-Mo steel were applied in Magmasoft simulations of spiral length and predicted results were compared to measured fluidity. Sponsored Research: Increasing Melting Energy Efficiency in Steel Foundries (12-040) Siddhartha Biswas, Kent Peaslee, Simon Lekakh, Missouri University of Science & Technology, Rolla, MO.   Steel foundries are one of the most energy intensive industries. The increasing concerns over volatile energy cost and carbon dioxide emission have pushed the foundries to improve melting efficiency and hence decrease electrical energy consumption. This paper summarizes the effort made at Missouri S&T in this regard. A combination of industrial statistics (STATGRAPHICS software) and measurements (thermocouple, infrared camera) with computational modeling (Factsage and Fluent software) were used to find out the opportunities to improve energy efficiency. Decreasing electrical energy consumption by the addition of chemical energy through SiC addition and oxyfuel burner installation in Electric Arc Furnace has been studied via industrial trials. The possibility of reduction of extensive heat losses in the ladle during melt holding was investigated. A dynamic model of heat losses from furnace tap to mold pouring was developed and used for optimization of industrial cases. The Effects of Silicon on Mechanical Properties and Inclusion Content of a 0.3wt-% Plain Carbon Steel. (12-090) Joshua Gittings, Robert Tuttle, Saginaw Valley State University, University Center, MI.   Foundries are always looking for ways to reduce cost for casting production. Silicon has long been known to reduce the liquidus temperature of steel thereby increasing the amount of superheat and fluidity for the same pouring temperature. This comes with no additional refractory requirements or refractory wear. However, little is known about how silicon affects the mechanical properties of plain carbon steel. A 1030 grade steel was alloyed at three different levels of silicon: 0.1wt.%; 0.5wt.%; and 1.0wt.%. This study found that strength increased with increasing silicon content at the expense of impact toughness. Also, total inclusion area was dramatically higher in the 1.0wt.% silicon alloy indicating that inclusion formation is more favorable with increasing silicon levels (>1wt.%).     2:00 PM WORKSHOPS & SEMINARS Room: Fairfield Presiding: Andrew Adams, Foseco , Cleveland, OH. Workshop: Would You Like To Get More Good Castings Shipped? (12-147) Christof Heisser, MAGMA Foundry Technologies, Inc., Schaumburg, IL; Andrew Adams, Foseco, Cleveland, OH; Brian Johnson, Hickman Williams & Co, Oak Brook, IL; James Barlow, George Kokos, Caterpillar, Inc., Peoria, IL; Henry Frear, Applied Process Inc, Livonia, MI.   The demand for shipping more castings per day comes from many sources; your customer to meet their production requirements, yourself to meet a personal goal you set, your management to meet financial commitments, or others. To address this challenge we must work with the equipment, consumables, processes and personnel that are available because we do not have infinite resources. The Workshop will present information on striving to obtain the maximum output with the available resources. Whether it is minimizing errors and defects or more fully utilizing a resource or personnel, each topic will cover an area that has assisted foundries in getting more good castings out the door.     3:45 PM ALUMINUM Room: Delaware B In-situ Manufacturing of Nano-Particle Reinforced Metal Matrix Composites (12-067) Cecilia Borgonovo, Makhlouf Makhlouf, Worcester Polytechnic Institute, Worcester, MA.   Aluminum matrix nano-particle composite materials exhibit promising mechanical and thermal properties such as high specific strength, hardness, stiffness, and resistance to creep and thermal degradation. Unfortunately, processing these materials is not easy and numerous attempts have been made to overcome the typical issues associated with their synthesis. These methods include mechanical alloying, powder metallurgy, powder infiltration and spray deposition. However, most of these methods are expensive and each one of them has its own limitations. Manufacturing methods that are based on mechanical agitation are cost-effective, but the particles tend to agglomerate because of the excessive Van der Waals forces associated with nano-sized particles. The agglomerated particles can be dispersed by ultrasonic vibrations, but the use of ultrasonic devices on the foundry floor is not practical and the method is not easily scalable. In-situ fabrication of the particles in the metal matrix is an answer to many of these challenges. In this method, the nano-sized particles are formed directly within the melt by means of a chemical reaction between a specially designed aluminum alloy and a gas. In this publication, we report on the synthesis of aluminum-aluminum nitride nano-composites by the reaction of a nitrogen-containing gas with molten aluminum-lithium alloy. Nano-Refinement of Eutectic and Primary Silicon Phases in Al-Si Cast Alloys for High Strength Structural Applications (12-101) Mohammad Shamsuzzoha, Laurentiu Nastac, The University of Alabama, Tuscaloosa, AL; John Berry, Mississippi State University, Mississippi State, MS.   Amongst the high strength lightweight materials, hyper-eutectic Al-Si cast alloys with constituent phases in the nanoscale size are highly desirable for aerospace and automobile applications. Recently, we have achieved via directional solidification technology ultra-high strength Al-Si alloys. In these directionally solidified alloys, both the eutectic and primary silicon phases are nano-sized fibrous morphologies. This paper describes the microstructure evolution and manufacturing of these advanced alloys and introduces ways of implementing these findings of directionally solidified casting into near net shaped castings. Effects of Alloying Elements and Cutting Tool Materials on the Machinability of Al-Si Cast Alloys (12-079) Guillermo Garza-Elizondo, Ehab Samuel, Adel Mohamed, Agnes Samuel, Fawzy Samuel, Université du Québec à Chicoutimi, Chicoutimi, QC, Canada; Saleh Alkahtani, AlKharj University, AlKharj City, Eastern Province, Saudi Arabia.   This article investigates the effects of alloying elements namely, Sn, Fe, and Mn, and drilling tool materials with a standard geometry on the machinability of heat-treated hypoeutectic B319.2 and near-eutectic 396 alloys. A specific T6 heat treatment was selected to establish the hardness levels for the alloys investigated within the range of 110±10 BHN, conforming to most of the required hardness levels in the commercial application of aluminum alloys. Attention is focused on the effect of workpiece microstructure on the performance of the cutting tools in terms of tool wear, surface roughness and chip formation. The results reveal that the 396 alloy displays the more rapid increase in the total drilling force and moment with an increase in the number of holes drilled. The differences in machining behavior of the 396 and B319.2 alloys may be attributed mainly to the variation in the silicon content, 10.8%Si and 7.5%Si, respectively. The addition of 0.15% Sn to the 396 and B319.2 alloys has a beneficial effect on the tool life of the different drills used. The presence of sludge in the 396 alloy resulting from the addition of 0.25%Fe and 0.25%Mn, leads to an extremely rapid increase in the total drilling force and moment, and has an unfavourable effect on tool life. A visual examination of the chips reveals that the fan shape is by far the predominant form during the drilling of the alloys studied and also, that the fan shape, due to its compact size and shape, is the ideal chip for most drilling applications.     3:45 PM ENGINEERING Plant Engineering Room: Delaware C Presiding: Donald Brink, Saginaw, MI. PANEL: Fluidized Bed Processing of Ferrous and Non-ferrous Castings, Including Metallurgical Considerations. (12-126) Herbert Doty, General Motors, Milford, NH; Robert Bend, Formed Light Alloys, Plymouth, MI; Donald Brink, Retired, Saginaw, MI; Gerald (Jerry) Reier, BHM Services, LLC, Fort Worth, TX.   Panel Topics: Doty: Fluidized Bed Heat Treatment Brink: The evolution of fluidized beds for use in the processing of ferrous and and non-ferrous castings, Reier: Fluid Bed Calciner (Furnace) for Reclaiming Excess Sand In Green Sand Foundry   This panel will present the evolution of the fluidized bed processing of castings, showing how the process emerged as a player in the casting industry. It will also show how fluidized beds have answered the needs of the casting industry as it has moved from iron to aluminum, and from green-sand molding to precision-sand molding. We will take a look at the future of the industry with regard to equipment and metallurgical capability.     3:45 PM Special Events Best of the International Journal of Metalcasting Room: Delaware D Leakage Defects via Bubble Trails in Grey Iron Castings John Campbell, University of Birmingham, Ledbury, Herefordshire, United Kingdom.   From the inaugural issue in Fall 2007, this paper details the study of leakage defects in a large grey iron diesel engine crankcase casting. The castings were opened by fracturing and the fracture surfaces were subjected to SEM study. The analysis revealed the leak paths that were determined to be vertical bubble trails resulting from the blowing of a core. There appeared to be two distinct types of leak structure. (A) Well-formed clusters of perhaps 10 or 20 bubble trails that appeared to consist of tubes formed from films of iron silicates, thought to originate from fairly modest core blow events. (B) Severe damage from more serious blow events more akin to volcanic eruptions, creating deep craters on the casting surface. The different bubble trail compositions are attributed to the different oxidizing and reducing gases evolved by the core during the progress of the decomposition of its organic binder. Thirty Years of Casting Process Simulation Dr.-Ing. Erwin Flender, Dr.-Ing. Joerg Sturm, Magma Gmbh, Aachen, Germany; Christof Heisser, Magma Foundry Technologies, Schaumburg, IL.   Few developments in recent decades have changed the understanding of the metalcasting process as fundamentally as casting process simulation. Published in the Spring 2010 IJMC, this presentation will provide an overview of the historical development, current state, and future of process simulation. Written from a European point of view, the authors discuss their involvement in the history and development of casting process simulation and their thoughts on how this technology will advance in coming years.     3:45 PM STEEL Room: Delaware A Dynamic Fracture Toughness of High Strength Cast Steels (12-054) Laura Bartlett, Abhilash Dash, David Van Aken, Von Richards, Kent Peaslee, Missouri University of Science and Technology, Rolla, MO.   The dynamic fracture toughness of Cr and Mo steels with nickel contents of 0, 1.56, and 5.5 wt.% was evaluated and compared to a lightweight steel of composition Fe-30.40%Mn-8.83%Al-1.07%Si-0.90%C-0.53%Mo. Each steel was heat treated to a Rockwell C-scale hardness range of 36 to 38. The 4130, 4325, and HY130 steels were quench-hardened and tempered. The lightweight steel was solution treated, water quenched, and age hardened. Of the alloys tested, the lightweight steel, the 4325 steel, and the Al-killed and Ca-treated HY130 steel had similar dynamic fracture toughness values of 153, 153, and 165 kJ/m2, respectively. The 4130 steel had a much lower toughness of 94 kJ/m2. The lightweight Fe-Mn-Al-C alloy performed better at Rockwell C32, producing the highest measured dynamic fracture toughness of 376 kJ/m2. Toughness of the Cr and Mo steels was strongly dependent on deoxidation practice. Alloys treated with ferro-titanium showed a reduction in toughness, which was attributed to TiN particles and in one case eutectic Type II sulfides. Addition of misch metal to an aluminum and ferro-titanium treated HY130 steel eliminated the Type II sulfides and increased the dynamic fracture toughness from 58 to 88 kJ/m2. HY130 obtained the highest toughness (165 kJ/m2) when aluminum deoxidation was followed by calcium treatment. Effect of Chemical Composition on the Carbide Re-precipitation Kinetics of Hadfield Austenitic Manganese Steel (12-110) Ricardo Fuoco, Davi Todorov, Metso Minerals Brazil, Sorocaba, São Paulo, Brazil; Alberto Cavalcanti, Institute for Technological Research, San Paulo, Brazil; Nelson Luiz dos Santos, Usiminas, Ipatinga, Minas Gerais, Brazil.   The solution heat treatment of Hadfield austenitic manganese steel is basically used to dissolve the eutectic carbides and the carbides precipitated in the grain boundaries during the cooling of the casting in the mold. So, after the solution soaking time the material presents only austenite grains, with very high toughness. At the end of the solution time, the parts must be cooled as fast as possible to avoid carbide re-precipitation in the grain boundaries. Since this final step is very critical in the production of large castings, with thicknesses larger than 150mm, large water tanks with strong stirring systems associated with water cooling equipments are normally used. However, the heat extraction capacity of the water tank is limited and for thick parts is normally necessary the selection of the steel chemical composition. In this article, isothermal heat treatments were used to study the kinetics of carbide re-precipitation of some Hadfield steels with different chemical compositions. The results show lower carbide re-precipitation kinetics with reductions in the carbon and chromium contents and with increase of the molybdenum content. The comparative results were presented as TTT carbide re-precipitation curves. On the Crystallography of Peritectic Austenite and the Role of Primary Ferrite in High Manganese and Aluminum Steels (12-052) Meghan McGrath, David Van Aken, Missouri University of Science and Technology, Rolla, MO.   Two high manganese and aluminum steels with duplex microstructures of δ-ferrite and austenite, having different volume fractions of primary δ-ferrite (0.35 vs. 0.66), were used to study the crystallography of austenite formed during the peritectic reaction. Electron backscattered diffraction (EBSD) was used to characterize the crystallographic growth directions and orientation relationships between the two phases. A scanning electron microscope (SEM) with energy dispersive x-ray spectrometer was used to analyze the composition profile across the δ-ferrite/austenite interface and show that the mechanism of the peritectic reaction remains the same for each alloy. For a primary δ-ferrite volume fraction of 0.66, the austenite formed by peritectic reaction was seven times more likely to have the Kurdjumov-Sachs (K-S) orientation relationship. In contrast, a lower volume fraction of δ-ferrite produced a peritectic reaction where both δ–ferrite and austenite grew with either a or parallel to the heat flux and the Kurdjumov-Sachs orientation was observed for only 5% of the peritectic interfaces. A tungsten inert gas (TIG) weld was performed on the alloy with 0.35 primary δ-ferrite for comparison to the texture developed in the casting since the majority of reported studies on the peritectic crystallography were performed in welds. In this study both δ-ferrite and austenite had the same crystallographic growth directions more often in the weld and a K-S orientation relationship was observed more frequently in the equiaxed zone of the weld than in the columnar zone of the casting.     Friday, April 20, 2012 08:30 AM ENGINEERING Quality Systems Room: Delaware C Presiding: Nick Fox, Galesburg Castings Inc, Galesburg, IL. Management Decision Making and the Cost/Benefit of Multiple 100% Inspections (12-049) Theodore Schorn, Enkei America, Inc., Columbus, IN.   This paper develops a model of the cost and quality effectiveness of single and multiple 100% inspections and applies that model to management decision making in the foundry. Four specific cost cases are evaluated against a series of potential scenarios of visual inspection error and the number of inspections performed. Conclusions are drawn about the general advisability of multiple 100% inspections. The work illustrates the relative value of improving incoming product quality and improving the effectiveness of the visual inspection operation, finding that overall cost can be reduced equally by either action to a degree. The work also concludes that repetitive sorting of rejected product to find inadvertently rejected good product is counterproductive in both quality and cost.     08:30 AM MAGNESIUM Room: Delaware B Magnesium Casting: Raw Material Considerations (12-164) Rob Bailey, BS Metallurgy, Manitowoc, WI.   This session will highlight several material issues relating to magnesium casting. Presentations will help foundries improve sampling of magnesium ingots, develop a protocol for ingot quality testing and reconcile in-house testing with automotive qualification testing.     08:30 AM STEEL Room: Delaware A Sponsored Research: Experiences in Casting FeMnAl (12-076) Robert Tuttle, Saginaw Valley State University, University Center, MI.   This paper covers the author’s experiences melting FeMnAl alloys in his laboratory. These results were observed while conducting a machinability study of these alloys. Carbon recoveries were found to be approximately 95% with the argon cover and charge practice used. Severe phosphorous pickup from a fiber refractory liner was also documented. Initially, furnace refractory life dropped dramatically during the first four heats of FeMnAl. However, changes in melting practice returned refractory life to a level equal to normal steels. Severe oxide films were found to form while pouring despite an argon cover during melting. These oxides formed while filling the mold and would not entirely be removed by filtration. It was also discovered that a zircon mold wash was not necessary to produce FeMnAl castings. The goal of this paper was to ensure foundries would be aware of some of these issues before attempting to melt this alloy. Sponsored Research: Preliminary Machinability Study of Fe-Mn-Al-C Steel (12-089) Robert Tuttle, Saginaw Valley State University, University Center, MI.   There is limited information available on the machining characteristics of Fe-Mn-Al-C alloys. A series of milling and drilling experiments were conducted to provide a baseline of data on the machining performance of these alloys. Plates of Fe-Mn-Al-C and ASTM A723 Grade 2 steels were milled and drilled with two different tool geometries at three different cutting speeds. All tools were TiAlN coated solid carbide. Flood cooling was used for both machining studies. The results of both experimental series found the Fe-Mn-Al-C alloy was harder to machine than the ASTM A723 Grade 2 steel. Endmills broke before finishing the Fe-Mn-Al-C plates at the highest cutting speed. All of the endmills used on the Fe-Mn-Al-C plates had significant wear at the depth of cut line. No drill successfully drilled the target of twenty holes. Most of the drills failed after two or three holes. One drill made seven holes before testing ceased. Examination of the drill point found severe wear. The low machinability observed in the Fe-Mn-Al-C alloy was attributed to the high rate of work hardening in these alloys. Columbia Steel Casting Co Inc. Molding Sand Binder Test Report (12-129) Brian Riley, Columbia Steel Casting, Portland, OR.   To come later     10:15 AM HOYT MEMORIAL LECTURE Room: Union BC Hoyt Memorial Lecture: “Stop Pouring; Start Casting” (12-093) John Campbell, University of Birmingham, Ledbury, Herefordshire, United Kingdom.   The necessity to stop the pouring of liquid metals is becoming urgent. Pouring is the main source of entrained bifilms. Bifilms are the mechanisms which initiate all our familiar casting problems including porosity, hot tears, low mechanical properties, corrosion initiation etc. As dislocations explain plasticity, bifilms explain pore initiation and fracture initiation. Only when pouring is eliminated (or, at second best, sufficiently controlled) will casting processes start to achieve their potential to deliver routinely sound and reliable castings (with the additional potential to make healthy profits!). Furthermore, with simplified foundry designs, including the elimination of pouring, the casting industry has the potential to produce products that are so much better than those currently available that engineering throughout the world would be revolutionized. Although not widely realized, evidence for massive benefits from bifilm-free metals already exists in the Al alloy and Ni alloy casting industries. The groundwork is in place for a historical revolution in the casting industry.     11:45 AM Special Events Room: Franklin BCD President's Luncheon & Annual Business Meeting .   The lunch features the presentation of special awards and election of AFS/CMI officers and directors. In addition, the AFS/CMI Director's Award Casting of the Year and the Millionaires Safety Awards will be presented.