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DIDION INTERNATIONAL INC. phone, 636.278.8700


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MODERN
CASTING.COM
ONLINE-ONLY COLUMN SOCIAL MEDIA
Building a Culture of
Employee Retention
I often hear about different organizations
and how they want to grow their culture.
I will hear about a culture of quality, a
high-performance work culture, a culture of
excellence, etc. I rarely hear anyone say we
want to build a culture of employee reten-
tion. Perhaps, that’s why they don’t have
excellent employee retention. Ironically, a
culture of employee retention is actually a
driver of productivity, quality, customer ser-
vice, and, most importantly, the bottom line.
For that reason, it’s a must to have a culture Webinar Looks at What the 2018 Elections Will
of employee retention. It takes a concerted Mean for Metalcasting
effort in environments like a foundry to build
a culture of employee retention because On Facebook, AFS posted a link to watch a webinar giving post-
it isn’t the easiest environment to work in. election analysis. AFS members who missed the live webinar can watch a
Here is how you can go about building a recording on Casting Connection at castingconnection.afsinc.org.
culture of retention:
• The first step in building a culture of
employee retention is to state that’s your Conference
objective. State it in your values state- Attendees
ment. Tell your employees that openly and Enjoy Tours
honestly. Acknowledge you have a problem AFS tweeted photos from
and that your employee retention isn’t November’s Aluminum Cast-
what you would like it to be. ing Conference held in Knox-
• Tell your employees you want to hear from ville, Tennessee. Attendees
them what you can do to change that. were given the opportunity
Who better to ask than the people you to tour Oak Ridge National
want to stay? Laboratory and Manufactur-
ing Demonstration Facility.
• Gather all of the input that you can and
then set some priorities about what you
are going to do to build that culture. Then,
start taking action. It’s amazing the impact
you can have in a short period of time CONNECT WITH US
when you start to act on a problem. After
all, if you had a quality deviation with
some castings, you would immediately
Follow: Like: American
jump into a corrective action mode. Do the
@AmerFoundrySoc Foundry Society
same with employee retention. Don’t go it
alone either. Ask your employees to help
you to work on the priorities you set. They
will gladly jump in and lend a hand if they
know you are serious about building that Follow: Join: Foundry and
culture.—Jeff Kortes americanfoundrysociety Diecaster Network
Visit www.moderncasting.com to read the
full column.

December 2018 MODERN CASTING | 3


DECEMBER 2018
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY VOLUME 108 | NUMBER 12

P. 17 COLUMNS
7 Editorial
Four Trends to
Watch in 2019
D. KURKUL

16 Washington Alert
AFS Submits
Comments on EPA’s
Affordable Clean
Energy Proposal
S. SALMON, J. HANNAPEL

P. 32
AND C. RICHTER

40 By The Law
Brush up on
Marijuana Laws
and Policy
D. RESSER

41 Safe Practice
OSHA Takes New
Approach to Safety
Incentives
D. HUNTER

P. 18 46 Marketing Mind
Something Old,
Something New
18 Faircast’s Fresh Start R. JEFFERSON
Bought out of foreclosure, three crucial months helped Faircast survive after its
future looked bleak. B. SANDALOW
DEPARTMENTS
23 Census of World Casting Production: Global Casting 3 From Online
Production Expands
Worldwide casting production grew by 5.3% during a busy 2017. 8 Industry News
A MODERN CASTING STAFF REPORT
17 In a World
28 Study Measures Potential Exposures From Sweepers Without Castings
Results of the research project demonstrate the use of well-maintained powered
industrial sweepers configured with HEPA filtration most likely do not contribute 42 Casting Innovations
to exposure. T. SLAVIN 43 Metalcasting Supplies
32 Excellence in Going Green 48 AFS News
Companies share how their sustainability projects led to environmental
improvements. The ideas that were implemented also helped businesses 49 College Connection
save costs. A MODERN CASTING STAFF REPORT
51 Classifieds
35 Designing Cores With Virtual Design of Experiments 55 Advertising Index
Virtual design of experiments and coremaking simulation can help establish
cost-effective production parameters that can be applied to other casting jobs 56 Shakeout
within a foundry. M. BLANDINO, I. WAGNER, J. STURM
moderncasting.com
Cover Design: Mike Berrafato

December 2018 MODERN CASTING | 5


1695 N. Penny Lane
Schaumburg, IL 60173-4555
847-824-0181 • 800-537-4237
Fax: 847-824-7848
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY www.moderncasting.com
Published monthly by the American Foundry Society, MODERN CASTING magazine presents the North American
metalcasting industry with technical and management information for operational and business decisionmaking. The
information and ideas presented in MODERN CASTING do not necessarily reflect the position of its staff, advisors
or advertisers, nor that of the American Foundry Society. Advertising is open to suppliers of metalcasting equipment,
technology, parts and services and others allied to the field.

STAFF

Managing Associate AFS VP, Marketing and


Editor Editor Communications
SHANNON WETZEL BRIAN SANDALOW RICHARD JEFFERSON
swetzel@afsinc.org bsandalow@afsinc.org rjefferson@afsinc.org

Advertising Sales Advertising Sales


Midwest, West, Western Northeast, Ohio, Southeast,
Canada, International Eastern Canada
Reach Thousands FABIO CAVALIERI JOE MURPHY
adsales25@aol.com
fabio@afsinc.org
of Casting Buyers
PRODUCTION
Instantly... Art Director Marketing/PR Specialist
MICHAEL J. BERRAFATO, mberrafato@afsinc.org JOE COSTIN, jcostin@afsinc.org
Deliver your foundry’s message
AFS VP, Business Development Manager of Customer Service
to thousands of casting BEN YATES, byates@afsinc.org BARBARA JACKOWSKI, bjackowski@afsinc.org
designers and buyers via Marketing and Communications Specialist IS Manager
advertising in MCDP magazine KATELYN STANEK, kstanek@afsinc.org RICH FETT, rfett@afsinc.org

and its website.


Ben Yates
CONSULTING EDITORS
byates@afsinc.org Management Federal Legislation & OSHA Regulations
DOUG KURKUL, dkurkul@afsinc.org STEPHANIE SALMON, ssalmon@afsinc.org
800-537-4237
Casting Technology/Research Environmental Regulations
STEPHEN T. ROBISON, str@afsinc.org CHRISTIAN RICHTER, crichter@thepolicygroup.co
FRANK HEADINGTON, fheadington@afsinc.org JEFF HANNAPEL, jhannapel@thepolicygroup.com
JULIETTE GARESCHE, jgaresche@afsinc.org

PRINTED IN USA

MODERN CASTING (ISSN-0026-7562) is published monthly by the American Foundry Society Inc. Editorial, executive and subscription offices: 1695 N.
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6 | MODERN CASTING December 2018


EDITORIAL

Four Trends to Watch in 2019


H
appy New Year to all Modern Casting controlling the House, but they
readers. At most foundries, 2018 was will be safe from reversal for at
a strong year and planning for 2019 least the next two years. The real
began months ago. Here are four trends for question in Washington will be
metalcasters to carefully watch as 2019 unfolds: whether the President and both
chambers can come together
Economic Strength on commonsense, bipartisan
The past year saw the strongest U.S. eco- initiatives such as infrastructure
nomic growth of the current expansion, as the investment, workforce readiness
2017 tax-cuts law spurred robust growth, strong programs, and policies conducive
job creation, and modestly higher business in- to continued capital investment.
vestment. Today, the economy still looks strong, With many new lawmakers and
though the recovery is perhaps a bit long in the staff arriving in the nation’s
tooth. Respected economists say that a combi- capital without backgrounds in
nation of skills shortages, tariffs, rising interest manufacturing, it’s important to introduce
rates, and concerns about a change in leader- them to our industry. AFS is advancing its
ship in the House of Representatives could policy agenda on Capitol Hill and encourages
slow the economy sharply in 2020. This threat all metalcasters to participate in the Govern-
warrants close attention. For metalcasters en- ment Affairs Fly-In on June 11-12.
gaged in long-term planning, the 2019 AFS an-
nual Metalcasting Forecast and Census which Workforce Demographics
is published in January provides invaluable Nearly 30 years ago, a blue-ribbon com-
information about casting sales and projections. mission chaired by William Brock predicted
It is a free benefit to AFS Corporate Members, the manufacturing skills shortage. Today,
and available for sale to others. You owe it to as a generation of reliable employees retire,
your business to pick up a copy. worker shortages are the new norm. Forward-
thinking foundries are watching demographic
Marketplace Trends trends while tapping into a variety of alterna-
The electrification of the auto industry is tive sources of employees, including appren-
advancing faster than many observers expected. tices, recently laid-off workers, returning
This is just one of the marketplace trends with veterans, immigrants, even recovering addicts.
enormous implications for many foundries. Meanwhile, to prepare our talent and culture
Light-weighting, additive manufacturing, for the future, consider attending the AFS
conversions from other forms of production Metalcasting Management and Development
to castings, exporting, and reshoring are other Summit in Charleston, South Carolina, on
marketplace trends that warrant the continued Feb. 7-8. Visit afsinc.org to register.
sharp attention of Modern Casting readers at All of us at Modern Casting look forward
this pivotal time. to seeing you at industry events in the coming
year. Let’s make it a great year!

Shifting Political Agendas


For months, the media highlighted a
perceived split between Trump backers and
traditional Republicans. Now, it’s the Demo-
crats whose divisions are about to appear in
the spotlight. Some newly elected members
of the House majority want to eliminate coal
and natural gas from the economy so recklessly
Doug Kurkul, AFS CEO
that even their party leaders are alarmed that
these policies would cripple the economy. The If you have any comments about this editorial or any
Administration’s regulatory reforms at EPA other item that appears in Modern Casting, email
will receive increased scrutiny with Democrats Shannon Wetzel at swetzel@afsinc.org.

December 2018 MODERN CASTING | 7


INDUSTRY NEWS

Eagle Alloy Honored as Michigan Manufacturer of the Year


The Michigan Manufacturers manufacturers make to their employ- ing at the forefront when it comes to
Association announced Eagle Alloy ees, customers and communities. The progressive ways to attract students to
(Muskegon, Michigan) has been Eagle Alloy team received the award the manufacturing community, utiliz-
selected as the 2018 recipient of the during the 2018 MFG Excellence ing career day events, internships and
John G. Thodis Michigan Manufac- Awards on November 8 at the Kellogg community engagement with over 40
turer of the Year Award. The award Center in East Lansing. charitable organizations.
honors the important, positive and Eagle Alloy was selected by an “The Eagle Alloy team, from its ex-
tangible contributions individual independent panel of judges for be- ecutives to its shop floor, represent the
very best of manufacturing and place a
high emphasis on integrity, teamwork,
respect, continuous improvement and
accountability,” said Chuck Hadden,
MMA president & CEO. “With a
tradition of social responsibility and
innovative products, the Eagle Alloy
name belongs among the 38-year lin-
eage of the John G. Thodis Michigan
Manufacturer of the Year award.”
“There are a lot of phrases or
buzzwords associated with a success-
ful business, whether it be continuous
improvement or lean manufacturing,”
said Mark Fazakerley, co-chairman,
Eagle Group. “We do all of those, but
I think when it comes right down to it,
Eagle Alloy is presented with the John G. Thodis Michigan Manufacturer of the Year Award. the business is built on trust.”  

Foundry Educational Foundation holds College Industry Conference


The next generation of metalcasters ing and Women in Metalcasting, and AFS and FEF also will be working
gathered at the Foundry Educational sell AFS metalcasting books. They also to continue growth in the number of
Foundation’s College Industry Con- briefed FEF Key Professors on timely students who attend CastExpo and
ference in Chicago Nov. 15-16. AFS programs. Metalcasting Congress.  
The annual event attracts promis-
ing students at FEF schools who are
looking for careers in metalcasting.
Prospective employers meet with the
students, many of whom come away
with internships or job offers.
FS board member Dr. Russ Ros-
mait (Pittsburg State University) was
awarded with the AFS-FEF Out-
standing Professor Award. Andrew
Rose of Penn State University was
presented with a scholarship from
Modern Casting magazine.
AFS staff members Katie Mat-
ticks, Katelyn Stanek, Bo Wallace,
Tyler Buchenot, Joe Costin and Doug
Kurkul were on hand to welcome
AFS student chapter members,
encourage students to use their free
first-year individual memberships
after they graduate, ensure they are
aware of Future Leaders of Metalcast- Modern Casting scholarship winner Andrew Rose poses with AFS CEO Doug Kurkul.

8 | MODERN CASTING December 2018


CONVEYOR DYNAMICS

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Having the ability to choose direction provides flexibility
when designing your material flow. Feed multiple furnaces,
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The flexibility and choice is available with the Dyna Sync
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INDUSTRY NEWS

Magellan gets Aeromet license


Magellan Aerospace announced it “Magellan is delighted to join the ance between strength and weight
has been licensed by Aeromet In- global network of A20X foundries when designing a component. The
ternational (Worcester, England) to and to be able to offer the unique higher strength characteristics of this
manufacture cast parts with Aeromet’s benefits of A20X castings to its alloy open up new opportunities for
A20X aluminum alloy at its Haley, customers,” said Haydn Martin, vice engineers to utilize the advantages of
Ontario, facility. A20X is used in aero- president, business development, cast components in critical aerospace
space, defense and space applications. marketing and contracts, Magellan. applications where, traditionally, light
“We are very pleased to welcome “The constant challenge for aerospace alloy castings have not been able to
Magellan Aerospace to the global engineers is to find an optimum bal- meet the requirements.”
A20X supply chain,” said Mike Bond,
director of A20X, Aeromet. “Demand
for A20X castings is growing signifi-
cantly as aerospace and defense cus- Siemens, Chromalloy open joint venture
tomers seek to unlock the weight and
Siemens (Munich) and Chro- “Advanced Airfoil Compo-
cost reduction potential offered by the
malloy opened joint venture nents is proud to exclusively
high-strength alloy. The global supply
Advanced Airfoil Components deliver innovative, high-tech
chain is key to supporting customers
in Hillsborough County, Florida. casting components for Siemens
around the world.”
According to a news release, the gas turbines at this new, state-of-
A20X is approved for aerospace
new venture will add 350 jobs and the-art site,” said Kevin Upde-
with MMPDS and AMS classifica-
the investment from the companies grove, CEO, Advanced Airfoil
tions and used in high strength, high
totals $139 million. Components.
temperature applications.

10 | MODERN CASTING December 2018


INDUSTRY FACES INDUSTRY NEWS
INTRODUCING
EJ celebrates new facility with AGILE CASTING SOLUTIONS
ceremony, open house
Agile Casting Solutions, a division of
Humtown Products, is 100% dedicated
to 3D printing.
With two printers and a brand new
facility (that houses up to 10 printers),
we’re prepared to accommodate the
industry’s growing demand!

EJ had a ceremony to celebrate the opening of its new facility.

AFS Corporate Member EJ hosted a private


open house for its new greenfield foundry in War-
ner Township, near Elmira, Michigan.
In a news release, the company said “the new
(facility) will allow EJ, previously known as East
Jordan Iron Works, Inc., to remain competitive,
grow the business, and retain 340 jobs in Northern Take the next step
Michigan.” toward innovation with
The 200-acre site in Warner Township has been Humtown Products’
under construction since February 2017 and was Agile Casting Solutions
slated to begin production in November. division!
The new foundry is 14 miles from the original
manufacturing facility in East Jordan.
“EJ is proud to continue to keep manufactur-
ing in Northern Michigan and to be able to retain
employment,” the company said. MARK’S THOUGHT OF THE MONTH:
“In just a few weeks, the foundry will be in
production, producing some of the highest qual- “People, even more than things, have to be
ity infrastructure access solutions in the world,” restored, renewed, revived, reclaimed, and
said Tracy Malpass, president, EJ. “This facility is redeemed. Never throw out anyone.”
the single largest investment undertaken by our - Audrey Hepburn
company.”
Attendees were provided a tour of the facil-
ity. Over the following weekend, over 1,200 EJ
retirees, employees and family members received a
first-hand look at the facility.
The ceremony was attended by fourth, fifth, and
sixth generation members of the Malpass family,
as well as many state and local dignitaries, which
included U.S. Congressman Jack Bergman, State
Representative Tristan Cole, State Senator Wayne
330.482.5555
Schmidt, and Brandon Fewins on behalf of U.S. www.humtown.com
Senator Debbie Stabenow.

December 2018 MODERN CASTING | 11


INDUSTRY NEWS

NEWSCAST
AFS Corporate Member Oil City customers, both new signings and and WDC Acquisitions LLC (Cres-
Iron Works (Corsicana, Texas) held customers now installed with Odys- ton, Iowa).
a blood drive in November. The event sey. During the July–September 2018 B&L has also brought five additional
was sponsored by Carter BloodCare. timeframe, three Midwest metalcast- customers online with Odyssey ERP
AFS Corporate Member B&L ers signed on to the browser-based software implementations: Ancast
Information Systems (Bridgman, Odyssey ERP software system: J&M Industries LTD (Winnipeg, Manitoba),
Michigan), announced the recent Precision Die Casting (Elyria, Ohio), Fisher Cast Steel (West Jefferson,
additions to the Odyssey group of New GLDC (Muskegon, Michigan), Ohio), Madison-Kipp Corporation
(Madison, Wisconsin), Quality Cast-
ings Company (Orrville, Ohio), and
Superior Brass & Aluminum Casting
Company (East Lansing, Michigan).
U.S. Rep. Dave Loebsack (D-Iowa)
visited Sivyer Steel (Bettendorf, Iowa).
During the visit, Loebsack met with
CEO Mike Baxley and president Keith
Kramer. According to local reports, Loe-
bsack learned about the facility’s progress
since being bought out of bankruptcy.
GH Tool & Mold, a Tooling Tech
Group (Macomb, Mich.) company
and a supplier of diecast tooling and
machining services, has received
DD2345 certification, which per-
mits access to unclassified military
technical data belonging to Canada’s
Department of National Defense
(DND) and to the U.S. Department
of Defense (DOD).
This certification enables G.H. Tool &
Mold to obtain unclassified export con-
trolled technical data, to request unclas-
sified visits directly with other certified
U.S. or Canadian defense contractors or
military facilities, and to attend gatherings
such as symposiums, program briefings,
meetings regarding advance requirements
or contracting agencies; and to pre-solic-
itation, pre-bid, pre-proposal, pre-award
conferences, workshops and tours.
Heimatec Inc. (Prospect Heights,
Illinois) announced that it will become
part of a new corporation, Platinum
Tooling Technologies Inc. Heimatec
provides live tooling for the North
American machine tool industry.
“I’d been pondering this move for
some time and, after considerable dis-
cussions with Heimatec GmbH, Tec-
nicrafts Industries, Henninger GmbH,
and other principals we represent, it
seemed time to make this decision and
move forward with the new company,”
said Heimatec president Preben Han-
sen, who will lead the new company as
its president and COO.

12 | MODERN CASTING December 2018


INDUSTRY NEWS

PERSONALS

AFS Corporate Member Busche further expand our R&D efforts and has assumed the role of CEO of KB
Performance Group (Southfield, drive innovation in our lightweight, Foundry Services. He is also currently
Michigan) announced the appoint- safety-critical casting and precision serving as 2nd Vice President of AFS,
ments of CFO Christopher Lilla, machining technology, we will also Chairman of the AFS Government
and Tamika Frimpong, Chief Hu- focus on strengthening our vertically Affairs Committee, and President of
man Resources Officer and Gen- integrated model to the benefit of our AFS/FIRST.
eral Counsel. These appointments customers, shareholders and partners.  Tracy Dougherty has been named
following the addition of Joseph This is an exciting time for BPG as we vice president of sales at AFC-Hol-
Perkins as CEO in August 2018. build on our success to date and take croft (Wixom, Michigan). Dougherty
The majority of BPG’s senior our organization to the next stage of has been with AFC-Holcroft since
management team will now be growth and operating excellence.” 2008, and served in several sales-
headquartered at the company’s AFS Corporate related roles, most recently as the
Southfield Technology Center/ Member Kurtz Bros. company’s sales manager.
Corporate Headquarters, a research Inc. (Independence, AFS Corporate Member Bad-
and testing facility just outside of Ohio) announced ger Mining Corporation (Berlin,
Detroit. the addition of Mike Wisconsin) announced sales associate
“Chris and Tamika complete Lenahan to its ex- Mike Rockney has retired. In a related
our senior management team and ecutive management move, Pete Gravunder joined the
represent outstanding additions to team. Lenahan, who foundry sales team as a technical sales
Mike Lenahan
our organization given their back- brings more than 30 representative. Gravunder has held a
grounds and experience levels in the years of operational variety of positions at Badger in opera-
auto industry,” Perkins said. “As we leadership in the metalcasting industry, tions and quality control.

December 2018 MODERN CASTING | 13


INDUSTRY NEWS

PERSONALS

Superior Tube, a unit of AM- manager, based at Superior Tube’s quality manager, Hassan Raid is now
ETEK Specialty Metal Prod- facility in Collegeville, Pennsylvania. EHS manager, Tamer Elbably was
ucts and a manufacturer of small Eric Lentz was tabbed as operations picked as planning supervisor, Brian
diameter tubing, announced several manager, Mark Heuberger is the Gorney joins as process engineer
appointments to its company staff. manufacturing engineering man- and metallurgist, and Superior Tube
William Scilingo was named plant ager, Scott Bussinger was chosen as has also appointed three additional
account representatives: Avery Cole-
man, Lauren Brunner, and Tyriq
Kershaw.
Pittsburg State University alum
Steve Sikorski, president of AFS
Corporate Member MAGMA
Foundry Technologies (Schaum-
burg, Illinois), was recently named
a winner of the university’s Dr.
Kenneth K. Bateman Outstanding
Alumni Award.

OBITUARIES

Richard Boyd
died November 10,
2018. He was 70. Boyd
had served as an AFS
National Director
from 1994-1997, and
was on the Board of
Directors of the AFS Richard Boyd
Keystone Chapter
for over 30 years. He also had been an
active member of the Steel Founders’
Society of America, serving in multiple
capacities. Boyd had a lengthy career in
metalcasting, working at Huntington

ON TIME
Ingalls Industries, Newport News
Shipbuilding, Nova Precision Casting
Corp., Pennsylvania Steel Foundry,

EVERY TIME
and Dodge Steel Co.
Stephen P. Ducha-
rme died October
24, 2018. He was 63.
Ducharme began his
foundry career as a
At REFCOTEC we realize that running out of product or having technical issues costs you money plant engineer with
by the hour. That’s why our production and technical team is always ready to respond when you
call upon us. With a 5-day standard lead-time and same day production and shipment possible Columbia Bronze
when necessary, you can rest assured product will be there when you need it. Stephen Ducharme Corporation. From
there, he moved to The
Federal Metal Co. in technical sales un-
REFCOTEC, INC. 330.683.8200 (fax) til 1995, and then began working at H.
330.683.2200 542 Collins Boulevard Kramer and Co. He had been a member
Orrville, OH 44667 of AFS since 1980 and was a member
sales@refcotec.com of the Copper Alloy Division of AFS
throughout his career.

14 | MODERN CASTING December 2018


APRIL 27-30, 2019 ATLANTA, GEORGIA

& METALCASTING CONGRESS


connecting SUPPLIERS | METALCASTERS | CASTING BUYERS

CastExpo 2019 is around the corner. You have been anticipating it for three years—the chance to meet at the
largest North American gathering of the metalcasting supply chain. When attendees think of CastExpo, they
think of full-scale exhibits, cutting-edge technology demos, packed aisles, exciting new equipment, innovative
sessions and a show floor full of energy. Representatives of the entire metalcasting industry supply chain will be
at CastExpo 2019 on April 27-30, 2019, in Atlanta. Register early for the best rates.

It’s been three years in the making.

CASTEXPO is ready for YOU.


CASTEXPO DELIVERS:
EXHIBITS CAST IN NORTH AMERICA (CINA)
More than 6,000 customers, peers, prospects, This unique exhibit opportunity is the capstone of
students, and others will be on hand, along with the supply chain, providing metalcasters the oppor-
full-scale displays from 400-plus exhibitors. tunity to showcase their capabilities and services to
buyers and design engineers. Complementing the
Cast in North America pavilion will be a dedicated
EDUCATION Casting Designer and Buyer track.
Metalcasting Congress at CastExpo 2019 delivers
thought-provoking sessions on how to improve
operations, efficiency and quality. It draws high-lev-
el decision-makers who benefit from educational
lectures and practical discussions with YOU in mind.

Register online at castexpo.com


or fill out the attached registration form inside this edition of Modern Casting.
WASHINGTON ALERT Stephanie Salmon, AFS Washington Office; Jeff Hannapel & Christian Richter, The Policy Group, Washington, D.C.

AFS Submits Comments on EPA’s


Affordable Clean Energy Proposal
THE SOCIETY EXPRESSED ITS SUPPORT FOR THE ACE PROPOSAL, STATING THE EPA HAS TAKEN A MORE REASONABLE
APPROACH TO ADDRESSING CARBON EMISSIONS WHILE SUPPORTING ENERGY-INTENSIVE MANUFACTURERS.
AFS recently submitted com- has taken a more reasonable ap-
ments to the Environmental Protec- proach to addressing carbon emissions
tion Agency (EPA) in support of while supporting energy-intensive
the agency’s proposed Affordable manufacturers, including foundries,
Clean Energy (ACE) rule that would and ensuring necessary and essential
establish emission guidelines for environmental protections in our com-
states to develop plans to limit carbon munities. 
dioxide (CO2) emissions from existing The ACE rule provides greater flex-
fossil-fired power plants. If final- ibility for states in addressing emis-
ized, the ACE rule would replace the sions from existing power plants, a list
Obama administration’s 2015 Clean of candidate technologies for states to
Power Plan (CPP) rule, which EPA evaluate, as well as promoting invest-
is proposing to repeal (in a separate ment to ensure cleaner, more efficient
rulemaking) on the grounds that the power plants. This approach is critical
CPP exceeded the agency’s authority to an effective, all-of-the-above energy
under the Clean Air Act.  policy that AFS supports. The CPP
AFS recently submitted comments to the EPA
AFS expressed its support for the in support of the agency’s proposed Affordable was stayed by the U.S. Supreme Court
ACE proposal, stating that the EPA Clean Energy rule. and has never been in effect.  

D.C. UPDATE
Updated China Report Shows Currently, additional tariffs of 25% are in Due to the large number of retirements
Continuation of Market Distortion place on two lists of Chinese imports with a and ousted incumbents in both chambers,
In November, the United States Trade combined annual trade value of $50 billion. we have one of the largest freshman
Representative (USTR) released a report Additional tariffs of 10% are also imposed on a class of lawmakers in recent years, with
updating information on its Section 301 third list of $200 billion in Chinese goods, with100 new members. There’s a significant
investigation of China’s policies and those tariffs set to increase to 25% on January amount of work to be done to introduce
practices related to technology transfer, 1, 2019, absent intervention by President Trump. the metalcasting industry. Engagement is
intellectual property (IP) and innovation. Moreover, the looming specter of additional key to educating lawmakers and advocat-
The original report from March 2018 tariffs on a fourth list, which could cover an ing for pro-growth policies, so be sure
found China was doing little to protect IP additional $260 billion in Chinese goods—ef- to mark your calendars for the 2019 AFS
and innovation, leading to the implemen- fectively all or nearly all remaining imports from
Washington Fly-In on June 11-12.
tation of tariffs on imports of specific China into the United States—is also under AFS is eager to work with the 116th
goods from China. This follow-up report consideration by the administration. Congress, which officially begins work
finds that “China has not fundamentally on January 3, 2019, to ensure its mem-
altered its unfair, unreasonable, and New Congress Has Opportunity to Work bers focus on enacting measures that
market-distorting practices” since the Together to Improve Infrastructure and will further contribute to pro-growth and
March 2018 report. Develop the Workforce pro-manufacturing policies. One of the
The updated report details China’s The midterm elections are completed, with top priorities will be helping both par-
use of various tools to intervene in U.S.’ control of Congress now split, the Democrats ties come together to enact the kind of
operations including ongoing direct winning back control of the House of Represen- significant new infrastructure measures
investment in, and acquisition of, U.S. tatives and Republicans adding to their majority the President has long promised. This
companies and assets by Chinese enti- in the U.S. Senate. is an issue that leaders in both parties
ties, thereby allowing China to obtain “We congratulate all the winners from the have expressed support for, and AFS
cutting-edge technologies and intellec- midterm election and look forward to having expects them to make infrastructure a
tual property and generate large-scale the opportunity to educate newly elected mem- top priority early in the new year.
technology transfer at a record pace bers about the metalcasting industry’s many
For additional information, contact
in 2018. These lists of goods contain a contributions to our nation’s broader economic Stephanie Salmon, AFS Washington Off ice,
number of metal castings. prosperity,” noted AFS CEO Doug Kurkul. 202/842-4864, ssalmon@afsinc.org.

16 | MODERN CASTING December 2018


IN A WORLD WITHOUT CASTINGS

Would Your Office Have Light?

Many light fixtures, like this one, feature diecast housings.

It’s hard to do your job without adequate lighting.


It also helps if the light fixtures are attractive and easy
to look at.
These lighting fixtures feature diecast aluminum
housings and connector boxes. They are sturdy,
cost-efficient and look modern.

December 2018 MODERN CASTING | 17


Faircast’s
Fresh Start
Bought out of foreclosure, three crucial months helped Faircast survive after its
future looked bleak. brian sandalow, associate editor

T he staff at AFS Corporate


Member Faircast (Fairfield,
Iowa) didn’t really have a
name for it, but it was a period that
defined the company.
For the first three months after the
facility was bought out of bankruptcy
in the summer of 2017, Faircast was
doing everything it could to get by.
Workers were being re-hired, relation-
ships with customers and suppliers
required mending, much-needed capi-
tal investments were being planned,
and just enough castings were being
produced to keep clients happy.
It was a hectic and pivotal time for
the company. If the effort had been
unsuccessful, the restarted foundry
likely wouldn’t have survived past the
first quarter of its new life.
It did.
“Everybody pulled together and
made it happen,” said board member
Roger Vorhies.
In June 2017, the foundry (then
known as Fairfield Castings LLC) had
stopped pouring, was in foreclosure The foundry can change jobs several times per day, bringing flexibility and versatility.

18 | MODERN CASTING December 2018


and the facility laid off the bulk of
its 220-person staff. A plant that
had roots going all the way back to
1892 was going to whither away
and disappear, tearing a chunk of
employment from its community
while inconveniencing its customers
in the agricultural, railroad, military,
construction and industrial sectors,
among others.
But a group of 13 local investors,
nine of whom had business dealings
with the foundry, came together to
buy the dormant plant that restarted
on July 6, 2017. If they hadn’t, it
would have negatively impacted The facility has roots that go back to 1892.
several local businesses.
But that wasn’t the only rea-
son the foundry was saved and
rebranded. The investors wanted to
keep jobs in Fairfield.
“There’s great people and great
ownership,” Vorhies said.
The first three months were
crucial to the long-term survival
of Faircast. That survival was
partly helped by built-in strengths
of the foundry, and the staff
already in place.

The First Three Months


When the plant was bought out
of foreclosure, the investors inher-
ited a lot of the issues left behind.
The sand system controls needed to
be updated. Unexpected scrap issues
cropped up, and the cupola baghouse
was overheating. Molding machines
are slightly aged and need updating.
But another issue was more
intangible: trust.
Customers didn’t know whether
they could believe in Faircast,
even after it was bought and
rebranded. Some had even taken
their patterns out of the foundry
and found new casting sources.
Following the restart, one major
customer had lengthy daily check-
ins on Faircast to see whether they
were casting their components.
Meanwhile, a few suppliers were
owed money and didn’t want to do
business with the new ownership
of a foundry that had $5 million
worth of unsecured credit. There
were suppliers who preferred only
to take cash from the plant. Faircast has a modern baghouse for clean air.

December 2018 MODERN CASTING | 19


“One phone call, one project at
a time,” said Wilson. were in a panic. I had to remain
calm.”
“Customers were in a Wilson and VanCamp and oth-
ers did things the old-fashioned
panic. I had to remain calm.” way. If they needed to get in touch
with a customer or supplier, they
were willing to fly to meet them.
One pitch was to give the com-
pany a chance, that if Faircast got
an opportunity it would deliver.
Even the local phone company Jennifer VanCamp and others. There were reassurances about the
was wary of Faircast, highlighting During the end of the previous new owners, that these were local
the challenge ahead for the staff. ownership, they weren’t able to people invested not just in the
Like many of her colleagues keep people truly informed of company, but the community.
who had been at the plant for what was going on. “All of the comfort had to come
years, production/operations man- So when they got the chance to from us, saying these guys are seri-
ager Jennifer Wilson was counted use their contacts, their relation- ous,” Wilson said. “They want to
on to sell the new Faircast to old ships helped. keep the foundry running.”
contacts. Customers knew her, like “One phone call, one project at “Once suppliers found out the
they knew scheduling supervisor a time,” said Wilson. “Customers owners were local, it opened it up,”

Faircast is not captive, and its biggest customer makes up only 8% of its business.

20 | MODERN CASTING December 2018


VanCamp said. “We built a level of trust by being open
and honest with them. For the biggest suppliers, that’s
what it took.”
That also helped with another group of important
people who needed reasons to trust: the employees.
The workers had been put through upheaval.
They saw their company go through bankruptcy
and questions about its future. And those questions
meant concerns about their own futures.
Makenzie Zeitler, the EHS/human resources man-
ager, said employees felt like they needed a voice. To
make sure it is heard, owners and management spend
time on the shop floor, hearing what workers have to
say. Incentive programs and monthly lunches reward
the staff for their efforts. An open-door policy assures
employees a chance to have input.
“The owners have tried to make sure employee
morale is much better than it was before,” Zeitler said.
“Morale is a huge component of this company. A place
that people want to come to work is a big deal.”
The investors were aware of that. They knew get-
ting as many workers back as possible was a “big deal,”
though a few employees were lost to other companies.
As of now, there are around 120 employees at Faircast.
That number isn’t what it used to be, but it could be
much worse.
“It was wonderful to have all of that experience
come back,” Wilson said.
The trust has come back, too. But it wasn’t easy and
didn’t happen overnight.
“Employees trusting us has been one of our big-
gest complications and hardest obstacles to overcome,”
Zeitler said. “Now they feel completely content we’re
going in the right direction.”

The foundry has an induction furnace and a cupola.

December 2018 MODERN CASTING | 21


Clearly, Faircast is on the right are two squeezers and two rota-lift into the cupola and into the iron
path. And it’s headed that way manual molding machines. solution. Faircast does it con-
thanks to some of the long-stand- That the facility has induc- tinuously, allowing for complete
ing strengths of the facility. tion melting and a cupola means control of the chemistry of the
it’s versatile. Faircast can change metal coming from the cupola.
Quick and Agile jobs several times per day and Right now, it looks like
Though it was clear plenty of because of that, the customer Faircast’s chemistry as a whole is
work needed to be done, Faircast base is diverse. The largest strong.
and its new owners had a strong customer makes up around 8% of They’ve added a modern
foundation to build on. business. baghouse to clean the air, and
The green-sand casting job Faircast also has a system on there are plans to invest in new
shop pours gray and ductile iron, its ductile inoculation that ensures molding machines over the next
melting around 90 tons per day. iron is treated to the prescribed 3-5 years. The customer base is
The ductile iron is melted with an specifications. If it’s not, the system stabilized, and the sales force is
induction furnace, and the cupola is shuts down and a supervisor sees selling the company’s merits, not
coke-fired. Faircast uses both shell whether the iron is actually good. just asking for trust.
core and isocure. On site are three If it’s not, the alloy is adjusted. The first three months are in
vertical molding machines that can Installed around 2012, the the past, which everybody relishes.
produce parts in both ductile and system prevents poor iron from Vorhies’ emotions bear that out.
gray iron, along with three B&P getting into castings. “It’s somewhere between relief
match plate molding machines. As for the master melt, that is and planning and looking to the
For low-volume applications, there where alloys are injected directly future,” he said. “Just exciting.”

PRODUCTION
CONTROL
SOFTWARE
DESKTOP | CLOUD | APP

www.synchroerp.com

22 | MODERN CASTING December 2018


CENSUS OF WORLD CASTING PRODUCTION

Global Casting
Production
Expands

Worldwide casting production grew by 5.3% during a busy 2017.


a modern casting staff report

I
n 2017, global production Of the 33 countries that pro- increase of 6.2%.
increased to more than vided data for the past two years, Total production of iron increased,
109.8 million metric tons, an 25 reported an expansion in annual with gray iron growing 6% and ductile
increase of 5.3% when com- volumes when comparing 2017 to iron expanding by 3.8%. Steel output
pared to the previous year, 2016. Among the top-10 countries grew by 6%, while aluminum produc-
according to this year’s Mod- in total output, Russia had the high- tion jumped by 6.7%.
ern Casting Census of World est growth in 2017 with an increase The data reported in the Census of
Casting Production. The nearly 110 of 8.3% in production. World Casting Production is supplied
million metric tons of metal cast- China increased its total produc- by each nation’s metalcasting associa-
ings produced in 2017 represent an tion by two million metric tons to a tion or similar representatives., as well
increase of 5.5 million tons. This total of 49.4 million. Meanwhile, the as the World Foundry Organization
rate of growth comes after two years U.S. saw its tonnage increase by 4%, and CAEF-The European Foundry
of less than a half percent growth. and the gray-iron heavy India saw an Association.

December 2018 MODERN CAST I NG | 23


2017 Casting Production (metric tons)

Gray Ductile Malleable Copper Other


Country Steel Aluminum Magnesium Zinc Total
Iron Iron Iron Base Nonferrous

Austria 42,900 102,900 A 10,800 - 148,287 - - - 304,887

Belarus - - - - - - - - - 258,900
Belgium 26,900 8,400 A 7,300 - 799 - - - 43,399
Bosnia &
17,500 9,100 - 1,350 - 10,500 - - - 38,450
Herzegovina*
Brazil 1,261,107 517,222 - 186,616 20,811 223,359 5,458 1,154 - 2,215,727

Bulgaria 30,300 9,200 A 10,400 292 5,540 - 42 - 55,774


Canada 330,841** - - 90,091** 14,237** 211,374B - - - 646,543

China 21,150,000 13,750,000 600,000 5,550,000 800,000 7,300,000C - - 250,000 49,400,000

Croatia* 31,100 11,800 - 50 221 25,174 - 25 15 68,385

Czech Republic 176,000 55,000 A 64,000 20,000 101,000 - 1,000 - 417,000

Denmark 27,500 56,100 A - 1,292 3,014 - - 100 88,006

Egypt 175,000 - - 10,000 8,000 7,000 - - - 200,000

Finland 19,500 36,300 A 6,200 3,247 2,548 - 101 - 67,896

France 574,100 696,300 A 60,400 17,877 346,899 - 24,719 2,501 1,722,796

Germany 2,421,400 1,587,700 A 175,800 79,192 1,137,096 18,190 62,188 4 5,481,570

Hungary 24,600 54,500 A 3,100 1,799 124,229 327 1,717 - 210,272


India 8,442,300 1,227,200 50,000 1,030,200 1,305,400 - - - 12,055,100
Italy 755,800 425,100 A 54,100 71,007 856,381 8,001 72,007 700 2,243,096
Japan 2,281,000 1,403,612 42,000 161,900 75,401 1,489,700D - - - 5,453,613
Korea (Republic of) 1,019,800 686,500 2,000 159,800 25,700 629,400 - - 13,000 2,536,200
Mexico 892,188 526,897 - 373,965 217,200 817,911 - 81,300 - 2,909,461
Norway 8,300 21,100 A - - 8,883 - - - 38,283
Pakistan 163,000 24,730 - 45,550 15,540 17,600 - - - 266,420
Poland 480,000 160,000 A 50,000 6,100 330,000 - 7,500 2,900 1,036,500
Portugal 41,500 97,200 A 5,900 16,800 35,000 - 2,250 - 198,650
Romania 20,000 3,500 - 7,000 4,500 70,000 7,000 500 250 112,750
Russia 2,637,500E - - 862,500 - 725,000F - - - 4,225,000
Serbia 26,300 3,100 - 18,150 3,100 10,120 1 30 - 60,801
Slovenia 75,100 38,600 A 30,200 842 51,209 - - - 195,951
South Africa 140,000 157,000 - 93,500 14,000 38,000 - 500 - 443,000
Spain 365,700 698,100 A 64,900 15,096 141,810 - 8,941 850 1,295,397
Sweden 159,400 55,600 A 21,750 8,312 46,138 1,138 9,274 - 301,612
Switzerland 36,500 22,800 A 1,100 2,021 13,373 - 1,209 - 77,003
Taiwan 605,081 208,293 - 66,193 30,826 368,286 - - - 1,278,679
Turkey 720,000 825,000 A 170,000 25,000 380,000 - 35,000 - 2,155,000
Ukraine** 400,000 120,000 30,000 580,000 60,000 280,000 15,000 25,000 50,000 1,560,000
U.K. 138,000 196,000 A 44,700 8,500 136,200 2,640 7,350 - 533,390
U.S. Metric 3,327,027 2,633,294 40,034 1,264,026 209,369 1,679,072 138,890 325,062 51,292 9,668,066

WORLD TOTAL 49,043,244 26,428,148 764,034 11,281,541 1,776,282 19,076,302 196,645 666,869 371,612 109,863,577

* 2016 Results ** 2015 Results A Includes Malleable Iron B Source: Aluminum Association C Includes Magnesium D Includes all diecasting
E All iron F All nonferrous

24 | MODERN CASTING December 2018


Metalcasting Plants by Nation & Trends
Country Iron Steel Nonferrous 2017 Total
Austria 20 3 33 56
Belarus - - - 135
Belgium - - 6 6
Bosnia & Herzegovina* 5 2 4 11
Brazil 452 153 565 1,170
Bulgaria 80 - 18 98
Canada** - - - 175
China* 14,000 4,000 8,000 26,000
*Croatia 26 5 - 31
Czech Republic - - 37 37
Denmark 8 - 7 15
Finland 11 7 14 32
France - - - 380
Germany 192 45 337 574
Hungary 27 7 86 120
India - - - 4,600
Italy 139 37 862 1,038
Japan** - - - 1,612
Korea 550 - 100 650
Mexico - - - 800
Norway 5 - 6 11
Pakistan 1,595 60 185 1,840
Poland 180 35 240 455
Portugal 23 8 57 88
Romania - - - 100
Russia* - - - 1,140
Serbia* 11 8 17 36
Slovenia - - 45 45
South Africa 38 43 86 167
Spain 46 29 52 127
Sweden 26 12 61 99
Switzerland 15 2 39 56
Taiwan - - - -
Turkey 441 105 386 932
Ukraine* 270 280 290 840
U.K.* 216 - 204 420
U.S. 617 341 977 1,935
TOTAL 18,697 5,182 12,510 45,331
*2016 data **2015 data

FIND MORE DATA AND TRENDS IN THE AFS FORECAST


2019 AFS Forecast & Trends is an indispensable resource for foundries as they make
business-planning decisions. The annual Forecast & Trends is included as a benefit for
AFS Corporate Members. The complete Forecast will be mailed and emailed to Corporate
Members. It will include foundry-sector growth projections as well as additional international
casting information beyond what is published in this edition of Modern Casting. The Forecast
is available to individual members for $750, and to non-members for $1,000 through the AFS
Bookstore at afsinc.org. To invest in a Corporate Membership and receive the Forecast &
Trends at no cost, contact Ben Yates @ BYates@afsinc.org or 847-803-5278.

26 | MODERN CAST ING December 2018


81 st ISCONSIN REGIONAL
Foundry Conference and Exposition
February 13-15, 2019 • Potawatomi Hotel & Casino • Milwaukee, WI

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Highlights:
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www.wisconsinafs.org
Study Measures Potential
Exposures From Sweepers
Results of the research project demonstrate the use of well-maintained
powered industrial sweepers configured with HEPA filtration most likely
do not contribute to exposure. tom slavin, slavin osh group llc (chicago)

F ollowing the publication


of the OSHA respirable
crystalline silica (RCS)
standard in March 2016,
whether powered industrial sweepers
would be allowed in foundries that use
silica sand was unclear. Although these
Study Conclusions
Several observations and conclu-
sions can be drawn from the study and
from committee discussion:
HEPA Filtered Sweepers
• OSHA has indicated acceptance of
from pollution control systems, can
help water bind to dust particles.

Dry Sweepers
• OSHA has indicated the use of
sweepers not equipped with HEPA
filters is considered an “other
HEPA filtered sweepers, consider-
are basically vacuums, they generally ing them in the same category as [housekeeping] method” and they
use brushes to lift particles and push HEPA filtered vacuums. are not prohibited by the standard’s
them into the path of the vacuum. • Overall, the study data show a housekeeping provisions, as long as
This raises the question of how the 17% reduction with HEPA filtered they are operated and maintained
housekeeping provision of the rule equipment. However, the data also properly.
would apply: demonstrate substantial variability. • Although results vary consider-
(h) Housekeeping: (1) The • Maintenance is a key to the suc- ably, data for the 4-hour periods
employer shall not allow dry sweeping cessful operation of HEPA filtered before and after dry sweeping for
or dry brushing where such activity sweepers. To protect the HEPA all sites show that RCS exposures
could contribute to employee exposure filter from quickly overloading, a are slightly lower (about 9%)
to respirable crystalline silica unless staged filter system is used, requir- after sweeping.
wet sweeping, HEPA filtered vacuum- ing frequent attention. • Poorly maintained sweepers may
ing or other methods that minimize • Cleaning the filter can be a dusty increase RCS concentrations.
the likelihood of exposure are not process. If compressed air is used, Sweepers have filters that are effec-
feasible. (29 CFR 1910.1053 (h)(1). the operation should be performed tive at trapping some respirable
In order to determine whether in conjunction with a ventilation dust particles, although not as
powered industrial sweepers could system to capture the dust. efficiently as a HEPA filter. How-
contribute to employee exposure, AFS ever, filters can become damaged,
sponsored a research project to mea- Wet Sweepers seals can become compromised, or
sure exposures associated with use of • Wet sweepers are allowed by the hoppers can fill up and release dust.
sweepers and the results were shared standard. This may be indicated by a visible
with OSHA staff. In early October, • Only one set of tests was performed dust cloud as the sweeper travels.
OSHA agreed to allow the use of with wet sweeping and the data are • Industrial hygienists experienced
industrial sweepers not equipped with not considered to be reflective of in foundry operations have found
HEPA filters, as long as the employer wet sweeper performance due to sweeper operator exposures to be
follows other applicable requirements background activities and measure- low compared to other foundry
in the standard (e.g., the hierarchy of ment questions. activities. We recommend that
controls to reduce and maintain expo- • Maintenance is important for the sweeper operator exposure levels
sures below the permissible exposure water supply and to direct the mist and visual review of dust generation
limit) and maintains the equipment to the proper area of the brush. be used as indicators of sweeper
in accordance with manufacturer Too much or too little water can be fitness. Foundries that use dry
recommendations. OSHA encour- problematic. Droplet or mist size sweepers should measure operator
ages employers to acquire industrial may also be important to maintain. exposure, adhere to manufacturer
sweepers equipped with HEPA filters Some users have found ionized recommended maintenance prac-
when their existing sweepers need to water, such as waste ozonated water tices, and observe sweepers for signs
be replaced. of visible dust generation.

28 | MODERN CASTING December 2018


Study Methodology
The project involved six foundries
with four measurement sites each.
Dry sweeping was performed at each
site. In addition to testing dry sweep-
ing at all sites, an extra day of wet
sweeping was tested at one site and
an extra day of HEPA sweeping was
tested at three sites. The three major
sweeper manufacturers were repre-
sented. Testing methods included
both traditional time averaged
samples and real time measurements. Fig 1. Site C real time respirable silica concentrations are shown.
The exposure of interest was the
non-sweeper employee exposure,
those employees in the work area for the 13-minute period of sweeping exposures are slightly lower (about
whose exposure would be increased or activity shows a decline in dust levels 9%) after sweeping.
decreased if sweepers were used. The from beginning to end of the sweeper In addition, some important
primary research question was whether period. Nevertheless, the overall quan- qualitative observations can be made.
sweeping, by removing dust loading titative average for that period (27.5 Poorly maintained sweepers may
from the floor, reduced the amount µg/m3) is slightly higher than average increase RCS concentrations. For
of RCS that would be generated by for the pre-sweeping period. As this example, the sweeper at Site F had
forklift and pedestrian traffic. example shows, it is difficult to extract some problems, not only as demon-
the contribution of the sweeper effects strated by the data, but also as appar-
Study Results from the overall exposure data. ent to the people on site who observed
Results were widely variable and Despite the difficulty in extracting a visible dust cloud as the sweeper
dependent on numerous process and sweeper related effects from general travelled. Sweepers have filters that
operational factors and confound- dust data, it is possible to make some are effective at trapping some respi-
ers. As demonstrated by the real time limited overall observations. rable dust particles, although not at
respirable dust exposure data from Site the 99-plus % level as a HEPA filter.
C, the foundry is a dynamic environ- Dry Sweeping With Powered Indeed, the dirtier the filter the more
ment with many potential dust sources Industrial Sweepers effective is the fine particle capture
in the background that can mask the Table 1 shows the data for the efficiency. However, filters can become
effect of sweeping. It is difficult to 4-hour periods before and after dry damaged, seals can become com-
tease out the contribution of fork lift sweeping for all sites. Although promised, or hoppers can fill up and
traffic traveling over a dirty/clean floor results vary considerably, the RCS release dust.
from the contribution of other dust
producing activities.
The difficulty of precisely identify-
ing the sweeper effect is demonstrated
in the chart in Figure 1, from Site C of
the study. It is possible process-related
dust-producing activities may account
for the slight increase in average dust
level in the four hours before and four
hours after sweeping (28.5 vs 26.9 µg/
m3). A qualitative review of the dust
data reveals upward trending of dust
levels throughout the shift except for
sharp reductions corresponding to the
8:30 a.m. break time for grinders and
the 11 a.m. lunch break. The slightly
higher concentration for the post-
sweeping period could be due to the
normal increase in levels throughout
the day rather than to the sweeper use. Fig 2. Real-time data for Site D is charted.
Similarly, a qualitative review of data

December 2018 MODERN CASTING | 29


Table 1. Summary of Area Samples From Multiple Foundry Sites Collected Before and After Sweeping Activities
Foundry Sample 4-hr TWA 4-hr TWA Reduction Reduction
(Sweeper) Location (Pre-Sweeping) (Post-Sweeping) (µg/m3) (%)
A 18 22 (4) -22%
Site A B 19 25 (6) -32%
(Standard) C 6 6 N/A N/A
D 6 6 N/A N/A
A 16 6 10 63%
Site B B 56 16 40 71%
(Standard) C 48 37 11 23%
D 16 6 10 63%
A 34 29 5 15%
Site C B 26 34 (8) -31%
(Standard) C 65 70 (5) -8%
D 46 51 (5) -11%
A 14 16 (2) -14%
Site D B 17 23 (6) -35%
(Standard) C 26 23 3 12%
D 19 25 (6) -32%
A 81 60 21 26%
Site E B 50 45 5 10%
(Standard) C 33 25 8 24%
D 47 25 22 47%
A 40 51 (11) -28%
Site F B 75 84 (9) -12%
(Standard) C 56 54 2 4%
D 53 53 N/A N/A

Average 36 33 3 9%
Median 34 25 9 26%
Definitions
TWA - Time-Weighted Average
µg/m3 - micrograms per cubic meter
mg/m3 - micrograms per cubic meter
(Standard) - A sweeper without additional attachments (curtaining) or features (misting or HEPA), representative of most commonly utilized sweepers in foundry environments
(HEPA) - Sweeper equipped with High Efficiency Particulate Air Filters
N/A - Not Applicable. Concentrations were non-detect, thus a reduction cannot be calculated

Notes
1. The limit of detection (LOD) for the respirable crystalline dilica samples was 12 µg/m3. Nondetect (ND) results are assigned 1/2 of LOD (6 µg/m3)
2. Samples analyzed under mod. NIOSH 0600, Gravimetric (Respirable Dust) and mod. NIOSH 7500/mod. OSHA ID-142; XRD (Respirable Crystalline Silica)

While not the focus of, nor round of testing. The results for HEPA during the day, and that level was still
measured in this research project, equipped sweepers are shown in Table below the Action Level.
industrial hygienists experienced 2. Overall, the data show a 17% reduc- By way of qualitative observation,
in foundry operations have found tion with HEPA filtered equipment. it is important to note that main-
sweeper operator exposures to be low However, the data also demonstrate tenance is also key to the successful
compared to other foundry activities. variability. Some of the factors that operation of HEPA filtered sweep-
We recommend that sweeper opera- may account for variability, in addi- ers. To protect the HEPA filter from
tor exposure and visual review of dust tion to the process issues discussed quickly overloading, a staged filter
generation be used as indicators of above, are the low background levels system is used, requiring frequent
sweeper fitness. Foundries who use at some of the sites. For example, the attention. Cleaning the filter can be
dry sweepers should measure opera- pre-sweeping level at site A location a dusty process. If compressed air is
tor exposure, adhere to manufacturer was below the detection limit, so a used, the operation should be per-
recommended maintenance practices, value of ½ the detection limit (i.e. 6 formed in conjunction with a ventila-
and observe sweepers for signs of vis- µg/m3) was used for calculations. The tion system to capture the dust.
ible dust generation. post sweeping measurement resulted
in a 287% increase over pre-sweeping. Wet Sweeping
HEPA Filtered Sweepers However, it is important to note that Only one set of tests was per-
Three test sites deployed HEPA the increase may have been due to formed with wet sweeping. The data in
filtered sweepers in an additional background process related build up Table 3 show a 13% increase in dust

30 | MODERN CASTING December 2018


Table 2. Summary of Area Samples From Foundry Sites Collected Before and After Sweeping Activities With HEPA Filtered Sweepers
Foundry Sample 4-hr TWA 4-hr TWA Reduction Reduction
(Sweeper) Location (Pre-Sweeping) (Post-Sweeping) (µg/m3) (%)
A 15 27 (12) -80%
Site A B 6 23 (17) -283%
(Standard) C 6 6 N/A N/A
D 6 6 N/A N/A
A 45 16 29 64%
Site B B 110 29 81 74%
(Standard) C 6 28 (22) -367%
D 16 6 10 63%
A 62 58 4 6%
Site E B 81 73 8 10%
(Standard) C 56 66 (10) -18%
D 73 68 5 7%

Average 44 36 7 17%
Median 56 29 27 48%

Definitions
TWA - Time-Weighted Average
µg/m3 - micrograms per cubic meter
mg/m3 - micrograms per cubic meter
(Standard) - A sweeper without additional attachments (curtaining) or features (misting or HEPA), representative of most commonly utilized sweepers in foundry environments
(HEPA) - Sweeper equipped with High Efficiency Particulate Air Filters
N/A - Not Applicable. Concentrations were non-detect, thus a reduction cannot be calculated

Notes
1. The limit of detection (LOD) for the respirable crystalline dilica samples was 12 µg/m3. Nondetect (ND) results are assigned 1/2 of LOD (6 µg/m3)
2. Samples analyzed under mod. NIOSH 0600, Gravimetric (Respirable Dust) and mod. NIOSH 7500/mod. OSHA ID-142; XRD (Respirable Crystalline Silica)

Table 3. Summary of Area Samples From Foundry Sites Collected Before and After Sweeping Activities With Wet Sweepers
Foundry Sample 4-hr TWA 4-hr TWA Reduction Reduction
(Sweeper) Location (Pre-Sweeping) (Post-Sweeping) (µg/m3) (%)
A 59 56 3 5%
Site D B 50 56 (6) -12%
(Wet) C 51 63 (12) -24%
D 54 66 (12) -22%

Average 54 60 (7) -13%


Median 51 63 (12) -24%

exposure after wet sweeping, but that maintain. Some users have found that controls to reduce and maintain each
result is not reflective of wet sweeper ionized water, such as waste ozonated employee’s exposure to or below the
performance. A review of the real time water from pollution control systems, PEL in accordance with paragraphs
data shows a cyclic pattern of back- can help water bind to dust particles. (c) and (f )(1) of the standard. Such
ground events with one event in the controls could include appropriate
pre-sweeping period and three other Additional Considerations modifications to the sweepers (e.g.,
events in the post-sweeping period, For all powered industrial sweepers installing a shroud around the bottom
likely accounting for the data results. (HEPA or non-HEPA), the employer of the equipment to limit escaping
In addition, the possibility should be using the sweeper must ensure compli- dust) or establishing new, appropri-
noted that the real time monitor read- ance with all applicable provisions of ate work practices (e.g., limiting the
ings may have been affected by fine the silica standard, including the PEL. speed of operation). If feasible engi-
water particles. Thus, the employer must assess the neering and work practice controls
As with dry and HEPA filtered exposures of employees operating or are not sufficient to reduce exposures
sweepers, some qualitative observa- working in the vicinity of the sweeper to or below the PEL, the employer
tions can be made about wet sweepers. in accordance with paragraph (d) of must use them to reduce employee
Maintenance is important to maintain the standard. And if any of those exposure to the lowest feasible level
the water supply and direct the mist to employees are exposed to silica levels and provide appropriate respira-
the proper area of the brush. Droplet above the PEL, the employer must use tory protection. See 29 C.F.R. §
or mist size may also be important to feasible engineering and work practice 1910.1053(f )(1).  

December 2018 MODERN CASTING | 31


Excellence in
Going Green
Companies share how their sustainability projects led to environmental
improvements. The ideas that were implemented also helped businesses
save costs. a modern casting staff report

B eing environmentally
responsible and improv-
ing the bottom line
aren’t mutually exclusive goals. Many
facilities achieve better growth and
cost savings, improve their brand and
for promoting environmental sustain-
ability within a facility. Foundries,
inherent recyclers, have even more
of a business case for environmental
sustainability than many other indus-
tries. From implementing manage-
sustainability of natural resources. 
The American Foundry Society’s
EHS Division presented its inau-
gural Green Foundry Case Study
Awards on Oct. 10.
The Green Foundry Case Study
reputation, strengthen stakeholder ment systems and metrics, to waste Awards recognize AFS Corpo-
relations, and boost their profitability. management and beneficial reuse, rate Members for achievements in
Often, a business case can be made metalcasters can play a key role in the sustainable industry, innovation and
environmental engagement. The
winners were:
• Kennedy Valve, a division of
McWane, (Elmira, New York),
first prize in sustainable industry.
• Waupaca Foundry Inc. (Waupaca,
Wisconsin), runner-up in sustain-
able industry.
• Amsted Rail Company (Grive-
port, Iowa), runner-up in sustain-
able industry.
• Clow Valve, a division of
McWane, (Oskaloosa, Iowa), first
prize in innovation.
• Waupaca Foundry Inc. (Waupaca,
Wisconsin), first prize in environ-
mental engagement.

Stormwater Improvement
McWane Inc. took first prize
for a significant stormwater
improvement project at its Kennedy
The inaugural Green Foundry Case Study Award winners at the 30th AFS EHS Conference are shown Valve division in Elmira, New York.
with their plaques. McWane diverted the normal flow

32 | MODERN CASTING December 2018


rather than spending $22,000 per
month in landfill fees.
• Supporting a local business, the
briquette maker.
With a constant outlet for this
material, the facility does not have
to search for outlets. The material
is sent to the briquette facility on a
regular basis with limited stockpil-
ing at the facility. Metal waste can
be briquetted fairly easily, so other
foundries may find they are a poten-
tial source for briquetting, as well.

Alloy Replacement
McWane Inc. took first prize for
innovation by replacing a leaded
brass alloy with a low-lead brass
alloy for manufacture of their valves
and hydrants at its Clow Valve
division in Oskaloosa, Iowa. The
Waupaca Foundry Inc. submitted several case studies from a number of plants throughout the U.S. transition to no-lead alloys was
related to creative uses for spent sand and slag.
required by the Safe Drinking Water
Act, but hydrants and valves were
exempt. McWane went beyond the
of water from the foundry operations energy dependence earned the com- legal requirements and voluntarily
yard to a grassy area, where it can pany the 2009 Wisconsin Governor’s eliminated brass from its operations.
infiltrate into the soil versus sending Award for Excellence in Environ- This switch required the revision and
this same stormwater to the river. The mental Performance. approval of specifications from the
company also installed a vortex style American Water Works Association
particulate separator by Aqua-Shield Making Briquettes (AWWA), Underwriters Labora-
in the sand laden west yard storm- Amsted Rail Company Inc. col- tories (UL), Factory Mutual (FM),
water drain leading to the outfall. lected and sent 100 tons of grind- the National Sanitation Foundation
This device reduces total suspended ing fines each month to a nearby (NSF) and its customers’ specifica-
solids by 70%. briquetting company. This kept 100 tions. The resulting benefits included:
The local stormwater coalition was tons of waste out of the landfill each • Reduced lead exposure to
so impressed it is using this project as month. The briquettes were returned workers.
a model, hoping other locations in the to Amsted Rail for use as a feed- • Reduced hazardous waste gen-
county adopt similar practices. stock in its electric arc furnaces. The eration leading to a reduction of
benefits of the project include: their generator status.
Heat Recovery System • No longer having to search for • Eliminated process steps and
Waupaca Foundry Inc. installed a interested buyers to take this equipment needed in the bag-
heat recovery system at Plant 1 to heat byproduct off its hands. house system.
its building with previously wasted • Recycle grinding waste on site • Reduced lead in the stormwater
heat during cool months. It removed
an old glycol heat rejection system and
replaced it with a waste heat recovery
loop system to recover heat from their
cupola. The closed-loop system deliv-
The new system provides 70% of the
ers a heated water/glycol solution to
coils installed in the make-up air units
heating requirements in a typical
that provide space heating to various
zones throughout the facility.
Wisconsin winter,
The new system provides 70% of providing a two-year return
the plant’s heating requirements in a
typical Wisconsin winter, providing on the investment.
a two-year return on the investment.
This allowed the plant to reduce its

December 2018 MODERN CASTING | 33


Amsted Rail Company Inc. collected
runoff (environment).
and sent 100 tons of grinding fines
• Cut costs for treatment chemi-
cals, equipment, maintenance, and
each month to a nearby briquetting
reduced disposal costs by $40,000 company. This kept 100 tons of waste
per year.

Creative Use of Spent Sand


out of the landfill each month.
and Slag
Waupaca Foundry Inc. submit-
ted several case studies from a
number of plants throughout the theater. Developers avoided for ease in later re-excavation.
U.S. related to creative uses for over $1.2 million in construc- • 35,000 cubic yards of spent
spent sand and slag that were not tion material costs. foundry sand with clay content
only acceptable to the community • 150 tons of foundry sand was were used as an imperme-
but enhanced the community in a used as herd bedding for Ten- able layer for construction in
variety of ways, in turn improving nessee cattle. When the bedding agriculture, landfill, and general
the reputation of the foundry indus- needed removal, it was tilled construction projects. A dem-
try. In some cases, this required into the soil as amendments to onstration project was devel-
testing of the materials for leachate, enhance grazing lands. Wau- oped to showcase the compact-
compactibility, impermeability and paca worked with the Tennessee ibility and minimal hydraulic
other characteristics, but the testing Department of Agriculture and conductance of the material to
allowed the public to find comfort environmental regulators to get prove its suitability for landfill
and confidence the materials were approval for this project. closure projects. The clay-laden
safe. Waupaca found a variety of • 600 tons of foundry slag was foundry sands have proven to
outlets for these byproducts: used to couch and backfill be useful serving as an imper-
• 85,000 tons of slag were used pipeline. The Tennessee utility meable barrier preventing con-
as a geotechnical fill to create a company found the properties of tamination of soil and ground-
baseball field, multi-use recre- the slag to be ideal to secure the water. This use also reduces the
ational field, and outdoor amphi- pipe, provide swift drainage, and need to mine additional clay
from the earth.
• 90,000 cubic yards of sand and
slag were used as undefined geo-
technical fill material for a mine
reclamation project in a sand and
gravel pit. Filling and restoring
the old mine site improves safety,
reduces erosion, and allows the
land to be used for agriculture,
recreation or wildlife habitat.
• 200,000 cubic yards of sand and
slag were used to create a com-
munity sledding hill, and ice rink,
amphitheater and parking lot.
The sand and slag were used as
unconfined geotechnical fill in
lieu of native mined construction
materials.
If your metalcasting facility has
advanced sustainability or management
initiatives, AFS wants to hear from
you. To enter your sustainability project
to be included in next year’s Green
Foundry Awards database, go to www.
afsinc.org/sustainability-metalcasting.
For more information, contact
Foundries, inherent recyclers, have even more of a business case for environmental sustainability Senior EHS Technical Director Juliette
than many other industries. Garesche (jgaresche@afsinc.org).

34 | MODERN CASTING December 2018


Designing Cores With
Virtual Design
of Experiments
Virtual design of experiments and coremaking simulation can help establish
cost-effective production parameters that can be applied to other casting jobs
within a foundry. mauricio velazquez blandino, magma foundry technologies, inc. (schaumburg illinois),
ingo wagner and joerg sturm, magma giessereitechnologie gmbh (aachen, germany)

I n metalcasting, using software


to simulate core production is
one of the most efficient ways
to design core boxes and solve
production problems. The applica-
tion of innovative methods for virtual
experimentation and computer-based
analyzed, and subsequent changes are
then derived and tested by the expert
(Fig. 1). This procedure is repeated
until the core box reaches the series
production stage. In the real world of
complex processes like core produc-
tion, it is easy to lose track of the
cates whether the result improves or
worsens from one change to the next.
Multiple core box changes, however,
also result in an increasing number of
possible combinations. This can result
in losing track of whether a different
combination than the one selected
design of experiments (DoE) offers quantitative assessment of decisions. may have led to the desired result
new potential for the largely auto- Due to the numerous interactions, faster or yielded a better result.
mated and first principle-based core the relationships between the applied In most cases, it is not possible
production process design. changes and the resulting effects are to retrace the history of core box
Today, simulation of core shooting not always clear. In many cases, only changes. This limits the assessment of
and curing for different binder sys- the final core density result indi- root causes and their effectivity. Most
tems, including the thermal control of
core boxes, comprehensively represents
the core making process. The appropri-
ate representation of the process-rel-
evant physics, which often take place
simultaneously, is a basic requirement
for the realistic prediction of the pro-
cesses. For core shooting, the coupled
flow of sand and air needs to be
calculated, with both materials able to
move independently. For the gassing
of PUCB cold box binder systems or
the dry hardening of inorganic binders
in thermally controlled core boxes, the
transport as well as the vaporization
and condensation of amine or binder
water in the porous core are calculated
based on the process-specific physical
conditions.
Virtual experimentation through
individual simulations is replacing Fig 1. The manual optimization of core boxes through step-by-step variation and testing (red) is
real-world experimenting. One or time-consuming and does not always lead to the desired result. The systematic documentation
of changes and the resulting effects supports the design of robust core boxes that make good
multiple parameters are modified, cores right from the start (blue).
the resulting effects are observed and

December 2018 MODERN CASTING | 35


tions, types and number of nozzles.
• Positions, types and number of core
box vents.
• Parting line venting.
These variables result in a great
number of possible combinations
that influence the core quality as
well as cost-effective production.
Virtual design of experiments using
autonomous engineering enable novel
methodologies for core box design and
process layout.

Reducing the Scrap Rate of a


Fig 2. By subsequently weighting the different core quality criteria, it is possible to evaluate the
analyzed local wear tendencies of the core box (mold erosion).
Turbocharger Core
In one example of virtual design of
experiments, the aim was to optimize
the core box used for series production
manual core box optimizations result as well as the methodological approach to minimize the high scrap rates. Dur-
in an economic output of good cores change towards process optimization. ing the manual optimization, adopted
and a low scrap rate. However, it is not Designing a robust core box is cru- measures combined with changing the
possible to evaluate the quality of the cial for achieving a good quality core sand binder mixture did not ade-
solution quantitatively. It can merely be that remains stable throughout series quately lead to the desired result. In
observed that the final core box design production. the virtual optimization, the vent posi-
is working. A consequent application Typical design variables in the core tions and the shooting pressure were
of simulation supports the documenta- box include: automatically varied. Quality criteria,
tion of the changes and the resulting • Number of cores in the core box in particular the filling degree of the
learning effects. This allows the creation (depending on the core size and the sand in the volute and the tendency
of core box design rules based on first machine size if applicable). for core box wear below the shoot
principles. The operational procedures • Core position and orientation; posi- nozzles, were evaluated (Fig. 2).
The proper filling of the volute had
a higher priority than the tool wear
below the analyzed shoot nozzles. This
allowed a quick identification of the best
compromise, in this case, the selection of
the nozzle configuration that produces
the best cores with minimum shooting
pressure for the smallest possible core
box wear (Fig. 3).
The interactions between the
variable parameters were determined
through statistical analysis. The core
quality was improved with the addi-
tion of vents to the volute bottom as
well as by eliminating the vents in the
volute neck. From the results, rules and
clear instructions were derived for the
core box design that could be applied
to future applications.
The assessment revealed a pressure
increase only moderately improved core
quality. In practice, the core box design
and the shooting pressure are uncoupled.
The core box design determines the
robustness of the production process,
Fig 3. Adding nozzles to the volute bottom as well as reducing the number of vents in the volute whereas the variation of the shoot-
neck supports the complete filling of the volute. A pressure increase comparatively only slightly
improves the result, but leads to an increased wear tendency. ing pressure constitutes a variable for
improving the quality in case of actual

36 | MODERN CASTING December 2018


production problems. If the core quality
is insufficient, the shooting pressure
is increased as a rule. In doing so, an
increased core box wear is tolerated.
This knowledge can serve to uncouple
core box design parameters and process
parameters subordinate in terms of
time from one another and simplify the
optimization process. If a core box has
a robust design, different solutions are
available for producing cores (Fig. 4).

Virtual Core Box and Process


Optimization of a Water Jacket Core
In another example, the optimiza-
Fig 4. Virtual optimization allows for a robust core box design that leads to a quality core, even in
tion of a production core box for a non-optimum process conditions. The designs to the left of the green lines show a high tolerance
thin-walled water jacket was analyzed. towards production variations thanks to the buffer zone (yellow area).
The objective of the optimization was
designing the core box and controlling
the process to enable the production
of good-quality cores under favorable various defects. This condition is the density was used as a quantitative
economic conditions. Deviating from initial situation for the systematic quality criterion.
the previous production conditions, optimization. The objective is to The different core defects at dif-
different shoot nozzle types were minimize the defect indications in the ferent positions of the sand are not
tested for the core box, all of which simulation. The degrees of freedom for related to each other due to the local
show little need for cleaning and were this core box are the shoot nozzle type fluid flow behavior. At the same
supposed to yield good results with and the change of nozzle properties, time, the root causes of defects at the
minimum shooting pressure. Under the variation of vents in critical areas different locations are comparable.
these conditions, the cores showed and the shooting pressure. The sand Therefore, the issue can be resolved
by analyzing a representative part of
the core. The number of variants to
be calculated can also be reduced by
subdividing the virtual optimization
into smaller subtasks.
The DoE results for the variation
of both the shoot nozzle and sand flow
properties show an established stepped
shoot nozzle used with normal core sand
yields usable results without requiring
improved sand flow properties. When
using a simpler nozzle, the cores show
considerable defects, so this approach is
not further adopted for the practical use.
For the second virtual design of
experiments, the nozzles and the sand
properties were set as fixed boundary
conditions. The aim of the parameter
study was to eliminate the core defects
both in the segments between the cyl-
inders and in the combustion chamber
roof. The degrees of freedom are the
vents in the respective defect areas as
well as the shooting pressure. The two
nozzle groups are each systematically
opened or closed, whereas the pressure
Fig 5. A core with a characteristic defect (a) is shown as a simulation model with highlighted is varied in four steps. This results in
evaluation areas to be automatically and quantitatively assessed (b), along with simulation
results for the four nozzle configuration variants for a specific pressure level (c). 16 completely calculated designs.
Even individual simulation results

December 2018 MODERN CASTING | 37


Fig 6. In the parallel coordinate plot, one line with one specified color summarizes the process
parameters and resulting sand densities for a virtual design of experiments. Closing the vents in
the combustion chamber area (blue) results in improved sand compaction, while the vents in the Fig 7. The core for a housing cover is
intermediary area (red) need to be open for good compaction (yellow lines). Open combustion shown before (a-not fully cured) and after
chamber vents often result in defects during the gassing process (bottom right). optimization (b).

provide valuable insights. The defect however, all vents are active, the a completely compacted core in this
causes become visible and help core defect occurs during the gas- area (Fig. 6).
derive specific corrective measures sing process when gas is actively
(Fig. 5). In the center thin-walled injected through the vents. In the Optimizing Gassing and Purging
section, all designs present a slightly combustion chamber roof, sand is for PUCB Cold Box Processes
reduced compaction. The design of displaced directly below the vent- In core production, measuring
experiments reveals that this minor ing nozzles. Therefore, by closing technology for quantitatively deter-
reduction of core compaction can be these vents, the core quality is con- mining the processes taking place
slightly improved by increasing the siderably improved. The cores are during gassing is available only to a
shooting pressure. By closing the completely filled in these areas, and limited extent. Even if it is not pos-
vents in the combustion chamber due to the closed vents, the gassing sible to measure the amine transport
roof, the local compaction remains defect can no longer occur. Like- throughout the core box, the simula-
constant in all areas. The core qual- wise, the results prove the vents at tion of the gassing process delivers
ity in these areas is still acceptable the spaces between the cylinders quantitative results that allow for
after the shooting process itself. If, are required in order to guarantee the evaluation and virtual optimiza-
tion of the process.
In vertically parted core boxes,
gassing typically takes place top down,
with possibly very long gas flow paths.
The degrees of freedom in the core box
particularly apply to the variation of
the vents, to ensure the effective amine
transport into the lower areas that are
critical for curing (Fig. 7).
The quantitative evaluation of a
single simulation calculation reveals
the problems arising during the
gassing process. For normal vent-
ing nozzle configurations viable for
core production, a large part of the
amine is purged prematurely out of
the core box (here 80% in the upper
third). Only a little amine reaches
the bottom area of the core. Achiev-
ing a complete curing of the core
Fig 8. This graph analyzes the amount of injected amine that flows out of the core box in the without making changes to the core
individual core segments, and thus are not available for gassing of the critical bottom section.
box is only possible by increasing

38 | MODERN CASTING December 2018


the amine amount, the gassing pres- changing the vent type. The objec- areas to ensure a reproducible curing
sure as well as the gassing time. tive is to better align the gas flow and process. The temperature distribution
Venting design is systematically improve the overall gassing process for in the core box needs to be constant
changed to achieve effective curing the core. A virtual test field also allows in cycle operation. Therefore, experts
without changing the core shooting for simultaneously examining gassing in thermal control design are often
result. In the example in Figure 8, parameters, such as the pressure of the faced with major challenges. On the
to ensure that the amine reaches all machine or the amine type, regarding one hand, the degrees of freedom for
areas of the core, the number of vents their effectivity. Thanks to the missing designing heating devices are limited
needs to be substantially reduced top variance, a statistically verified design by the restricted available space or
down. Virtual design of experiments of experiments with 12 designs is suffi- core box requirements. On the other
allows different variants to be analyzed cient for a process condition to achieve hand, core boxes are characterized by
through the automated quantitative the set objectives and define the mea- cross-sectional transitions and chang-
evaluation and comparison of the sures for practical implementation. ing wall-thicknesses.
individual variants. Simulation and virtual optimization
Gassing is a dynamic process Thermally Optimized Core Boxes are effective tools for designing the
where the injected amine first flows For Hot Curing Processes thermal control of core boxes. Based on
into the core box and then is purged Designing the thermal control the first design, an individual simula-
out of the core based on the nozzle for core boxes used in hot cur- tion provides a detailed insight into the
configuration and the applied process ing processes can be laborious. The temperature balance of the core box in
parameters. The simulation results geometry and local wall-thicknesses cycle operation. Based on this knowl-
allow for the tracking of the transient of the core require the definition of edge, variants for eliminating weak
behavior of the amine flow as well specific temperature levels in certain points are derived. Generally, the aim
as the assessment of the local amine is to achieve a uniform temperature on
amount within the core during the the core box surfaces relevant to the
entire process. These criteria thus allow core. Usually, the degrees of free-
for the quantitative comparison of dom are the geometry, positions and
the different variants as well as for a dimensions of the heating devices. The
corresponding evaluation of the gas- control via thermocouples is another
sing effectivity. Compared with the degree of freedom, since the position of
optimized solution, the initial variant control thermocouples strongly influ-
has an amine content 40% lower in the ences the uniformity of heating.
critical area. At the same time, reduc- In the example in Figure 9, the
ing the number of vents using the temperature in the critical thick-
same gassing conditions results in a walled core area is too low for a proper
four times higher back pressure in the drying of the inorganic core. The
core. This implies for the optimized provided meander heater path needs to
variant, the amine remains in the core be replaced by another configuration.
box much longer, acting as a more The objective of the virtual design of
effective catalyst for the curing process. experiments is to define a sufficiently
For horizontally-parted core boxes, high temperature that will vary only
both the gassing and the flow situa- slightly during cyclic operation. The
tion are fundamentally different. For degrees of freedom are the variation
extensive cores, questions arise particu- of the heating device itself, in this case
larly regarding the positioning of the of the electric heaters, and of their
cores below the hopper and the nozzle individual capacities. Other degrees
positions. The gas flow through the of freedom may be the changes to the
core strongly depends on the gassing thermocouple positions. A design of
nozzle positions related to the vents experiments comprising 16 designs
as well as on the variation of the core already provides clear information
wall-thickness. Therefore, the positions about the measures to be imple-
of individual gassing nozzles and vents mented. The new heater configura-
have a significant impact on the gas- tion reliably allows reaching the set
Fig 9. In the first design, a meander heater
sing effectivity. The evaluation of the path in the thick-walled chain case area (a), temperatures from 120C to 130C with
current state by means of an individual did not achieve the required temperature different heater capacities.  
simulation is a good starting point profile. An automated simulation includes the
process-specific degrees of freedom such as This article is based on the paper “Virtual Design of
for a systematic optimization. Then, Experiments and Optimization of Core Produc-
the replacement of the meander heater path
the expert defines degrees of freedom (b) and the heating capacities. tion (18-046) originally presented at the 122nd
for repositioning single nozzles or for Metalcasting Congress in Fort Worth, Texas.

December 2018 MODERN CASTING | 39


BY THE LAW

Brush up on Marijuana Laws and Policy


DAVE RESSER, COOPER LEGAL GROUP LLC, INDEPENDENCE, OHIO

F
oundry products cannot reach Arizona, Connecticut, Delaware, Illinois, an independently qualifying medical
their intended market without Maine, Minnesota, Nevada, New York condition. Therefore, employers may
the labor of humans. That can and Rhode Island provide some em- want to engage in an interactive process
often mean issues related to employ- ployee protections from discrimination even if it is not required by law.
ment and labor steal attention away primarily on the basis of being a medical Despite the relatively new state stat-
from the critical operational issues marijuana cardholder or for testing posi- utes permitting medical marijuana use,
of the foundry. While the issue of tive for marijuana during a drug test. law enforcement officials may prosecute
marijuana use may not always be at The Massachusetts Supreme Court medical marijuana patients, even if they
the front of our minds in relation to a also recently ruled that employers may grow their own medicine and even if they
foundry operation, it can certainly affect need to accommodate off-duty medical reside in a state where medical marijuana
operations safety, relations between federal marijuana use in certain situ- use is protected under state law. The
different sectors of the workforce, and ations; New York has a similar policy. United States Supreme Court indicated
many more operation factors. As in the ruling of Gonzales v. Raich
more states legalize marijuana
use for medical or recreational
An effective workplace drug (2005) that Congress and the
Food and Drug Administration
purposes, employers continue
to struggle with how to address
policy may, in order to be should work to resolve this issue.
The Raich decision does not
the issue in the workplace. Your most effective, address the say that the laws of any medical
foundry may find that writing marijuana state are unconsti-
and communicating a clear and current attitudes of the time tutional; nor does it invalidate
consistent marijuana policy to be them in any way. Also, it does
valuable prior to the actual need and not rely upon the same not say that federal officials must
for the policy. prosecute patients. Decisions
Despite medical marijuana old drug and alcohol policy. about prosecution are still left
(or cannabis) laws in 46 states (as to the discretion of the federal
of the writing of this column), government.
marijuana is still illegal under federal law. This can mean if an employee in one When developing your marijuana
The federal government regulates drugs of these states is using marijuana with and drug use policy, keep in mind many
through the Controlled Substances Act a medical marijuana card, employers employers regard recreational marijuana
(CSA) (21 U.S.C. § 811), which does not likely cannot terminate their job on that use just as they would recreational alco-
recognize the difference between medical basis. However, if an employee is using hol use, with the additional understand-
and recreational use of marijuana. How- marijuana recreationally, the employee’s ing that unlike alcohol, marijuana is
ever, these laws are generally applied only job would likely not be similarly pro- still illegal under federal law. Certainly,
against persons who possess, cultivate, or tected. Other state decisions indicate many foundries already apply a drug-
distribute large quantities of marijuana, that possession of a medical marijuana free workplace policy; however, if your
so you may not be surprised to read some card may not protect an employee’s job foundry does not, perhaps it is time to
people openly grow, sell, and consume while violating work drug policies, but consider it with the advice of your busi-
marijuana products. Because of this, em- it may protect their employee benefits. ness attorney.
ployers have to be prepared for the fact Again, these rulings vary from state-to- Employers do not have to tolerate
that it is now much easier to obtain mari- state, so you need to consult your busi- on-the-job intoxication even if a worker
juana—and in new forms such as oils, ness attorney who needs to be familiar is using marijuana for medical reasons,
creams, brownies, etc. How are employers with the current state of marijuana so accommodations might include ad-
supposed to know what products may be laws in the state(s) where the foundry ditional time off or a leave of absence for
laced with marijuana? This information is located and/or where the foundry the period the worker needs to use the
may be difficult to ascertain, but employ- employees are working. drug. Workplace policies should clearly
ers may want to start being more mindful In the majority of states, includ- state employees cannot be drunk, high,
of changes in employee performance and ing California, employers do not have or otherwise impaired while at work. Ev-
indicators of an employee’s influence of to make accommodations even for eryone needs to know they cannot have
marijuana and other drugs. off-duty medicinal use. The current an edible at lunch and come back to the
Despite the federal statutes banning case law in California makes that clear, office or go back to the foundry floor. An
the possession, cultivation, and distri- but the law could evolve as attitudes workplace drug policy may, in order to
bution of marijuana, many states have regarding marijuana use change over be most effective, address the current at-
enacted medical and recreational use time. The underlying issue is that a titudes of the time and not rely upon the
statutes. Furthermore, statutes at least in medical marijuana cardholder may have same old drug and alcohol policy.

40 | MODERN CASTING December 2018


SAFE PRACTICE

OSHA Takes New Approach to Safety Incentives


DARREN J. HUNTER, ROONEY RIPPIE AND RATNASWAMY LLP (CHICAGO)

T
he Occupational Safety and Improvements to the Voluntary Protec- OSHA explained safety incentive
Health Administration (OSHA) tion Programs (VPP Policy Memo). This programs that reward workers based
does not currently have regula- VPP Policy Memo sets forth specific on leading indicators is always permis-
tions related to safety incentive programs safety incentive program criteria for sible. OSHA clarified, however, that a
or post-incident drug testing policies. It OSHA’s VPP participants to address program that rewards workers based on
has nonetheless opined on the valid- OSHA’s concern that, “(w)hen an incen- lagging indicators is also permissible, so
ity of certain types of safety incentive tive discourages worker reporting or, in long as the program is not implemented
programs and post-incident drug testing particularly extreme cases, disciplines in a manner that discourages reporting.
policies in order to advance key policy workers for reporting injuries or hazards, OSHA acknowledged that a rate-based
initiatives, namely: to improve the accu- problems remain concealed, investi- incentive program may have an inadver-
racy of injury and illness recordkeeping gations do not take place, nothing is tent effect of deterring employees from
statistics; and to incentivize employers to learned or corrected, and workers remain properly reporting an injury because
rely on leading rather than lagging indi- exposed to harm.”    the employees may not want to lose an
cators to measure safety performance. On March 12, 2012, OSHA issued a opportunity to receive a reward. OSHA
Lagging and leading indicators are memorandum: Employer Safety Incen- stated that any inadvertent deterrent ef-
terms in the safety field to measure an tive and Disincentive Policies and Prac- fect of a rate-based program would like-
employer’s overall safety record. Lag- tices which expressed concern with safety ly be counterbalanced if the employer
ging indicators measure the outcome incentive programs that “unintentionally adopts positive elements, such as:
of undesirable events that have already or intentionally provide employees an • Rewarding employees for identifying
happened, such as work-related acci- incentive not to report injuries.”  unsafe conditions.
dents. Leading indicators, on the other On May 12, 2016, OSHA adopted • Training employees to reinforce report-
hand, are safety metrics that precede a new regulation: Improve Tracking ing rights and responsibilities and em-
undesirable events, such as reporting of Workplace Injuries and Illnesses, in phasizes the employer’s non-retaliation
hazards, so an incident may be avoided. which OSHA created a new provision policy.
Employers often implement safety under its recordkeeping standard, section • Implementing a mechanism for accu-
incentive programs based on leading 1904.35(b)(1)(iv), that expressly bars an rately evaluating employees’ willingness
and lagging indicators. For example, an employer from retaliating or discriminat- to report injuries and illnesses.
employer pay its employees a monetary ing against any employee for reporting OSHA further stated most workplace
bonus or may provide non-monetary a work-related injury or illness. While drug testing is permitted, including:
prize, such as a pizza party, if employ- the new regulation did not expressly • Random drug testing.
ees report hazards (i.e., issues identi- place any restrictions on safety incentive • Testing unrelated to the reporting of a
fied during a Gemba walk), or if the programs or post-incident drug test- work-related injury.
employees do not sustain any injuries ing policies, OSHA explained in the • Testing under workers’ compensation
during a reporting period (i.e., a rate- preamble to the final rule certain safety laws.
based incentive program). OSHA is incentive programs and post-incident • Testing under federal law, such as a
concerned employees will be discour- drug testing policies would likely deter Department of Transportation rule.
aged from reporting an incident if it reporting. In October 2016, OSHA is- • Testing to evaluate the root cause of a
will affect their incentive pay. sued several guidance documents, stating workplace incident, so long as the em-
During the Obama administration, that it would enforce section 1904.35(b) ployer tests all employees whose conduct
OSHA took several steps to address (1)(iv) consistent with the preamble. could have contributed to the incident,.
safety incentive programs and post- Under the new administration, While OSHA referred to this new
incident drug testing policies: OSHA is taking a different approach. In interpretation as a clarification, it is really
On Sept. 28, 2010, OSHA com- October, OSHA issued an interpretation an about-face of its previously articu-
menced a National Emphasis Program “clarifying” its position. To avoid any un- lated views on safety-incentive programs
(NEP), Directive on its Injury and Ill- certainty, OSHA expressly stated section and post-incident drug testing policies.
ness Recordkeeping National Emphasis 1904.35(b)(1)(iv) does not prohibit safety OSHA expressly stated this new inter-
Program, which remained in effect for incentive programs or post-incident drug pretation supersedes any inconsistent in-
two years. Under this NEP, OSHA testing. OSHA elaborated that safety terpretative documents OSHA previous-
investigated companies with policies that incentive programs or post-incident drug ly issued. In light of this interpretation,
may discourage accurate recordkeeping, tests would only violate the standard “if employers may feel more comfortable
including safety incentive policies based the employer took the action to penalize implementing safety incentive programs
exclusively on lagging indicators.  an employee for reporting a work-related and post-incident drug testing policies,
In June 2011, OSHA issued a policy injury or illness rather than for the but should still include the necessary
memorandum under its Voluntary legitimate purpose of promoting work- protections to ensure that employees are
Protection Program (VPP): Revised place safety and health.” In this case, the not deterred from reporting work-related
VPP Policy Memorandum #5: Further employer’s motive must be proven. injuries and illnesses.

December 2018 MODERN CASTING | 41


CASTING INNOVATIONS

New Molding Material Recipe Eliminates Veining


Even though furan is reliable for due to the addition of the addi- for example, extends linearly up to
the high production requirements of tive. This has completely avoided approximately 752F (400C) and
cores and molds as a binder system the typical rupture of the sand then shows a sudden increase in the
in 3D printing, some small weak- core surface in high temperature temperature range of the reversible-
nesses are present. So far, the vein- stressed places, such as the inner transformation and thus increases
ing on the surface and on the inner contours of the castings, when the stresses.
contours of castings with furan in casting the hot cast material. As a Instead of being able to compen-
combination with sand in complex result, the industrial test object, in sate for the pressure due to material
geometries in high-temperature this case a typical impeller from flexibility, the rigid property of the
casting is difficult to avoid. Follow- the pump industry, could be cast sand-binder mixture causes cracks
ing consistent development work, without any signs of veining. in the surface. The mixture of sand
ExOne (Gersthofen, Germany) has In principle, when casting with and furan binder, thus organically
counteracted the veining in furan steel, several factors responsible bonded moldings, gives way and
through the use of additives. for the expansion of the sand core forms surface cracks. The liquid
Veining is and remains annoying, surface meet. The expansion of the metal now flows into these very fine
not only because the reworking on silica sand results in the quartz in- surface cracks. The fact that silicon
the surface or on the inner contours version. High casting temperatures dioxide expands in the mold cavi-
of castings always requires a com- cause fast quartz conversion and ties causes the filling of the casting
plex post-processing and drives up thus lead to increased stresses in the metal in the resulting gap.
production costs. For many casters, molded part. But the grain size and Then, with the removal of the
it is also a personal disappoint- grain distribution of the silica sand casting from the sand mold, the im-
ment after all the preparations in also has an influence on the surface print of the previous cracks on the
the core manufacturing process and behavior, because a higher degree of surface will rise, forming a rib-like,
subsequent casting, to come across uniformity leads to higher stresses, vein-like crust, protruding from the
the annoying casting errors when since all silica grains pass through smooth surface.
unpacking the casting. the transformation temperature at In technical terms, one speaks of
ExOne has been intensely the same time. Thus, all the basic thin, irregular metallic protuberances,
involved with the task of combin- components of a typical sand mold which occur primarily on the inner
ing furan together with a classic have low ductility, and when the hot contours of a casting mold or in angles,
silica sand and a number of dif- metal is poured, there is a high pres- corners and edges of the castings.
ferent additives. sure on the surface of the sand mold. The aim of the ExOne test
Particularly convincing results The liquid, hot metal surround- series was to avoid these irregular
have been shown by the use of ing the core after casting causes a metallic protuberances. The devel-
furan resin in combination with temperature gradient between the opment department meticulously
sand and a mineral additive. In surface and the center of the core, tested all possible combinations
test experiments, silica sand in which is explained as a consequence of ExOne certified sands together
combination with furan binder of structural characteristics of the with the furan binder and various
has achieved a higher elasticity mold base material. Silica sand, additives. The “benchmark” was to
eliminate veining.
The refined FS003 sand with a
reduced packing density and thus
a smaller tension, in contrast to the
FS001 sand, was able to achieve a
50% reduction in veining (Fig. 1).
When blending furan with
synthetic sand, no veining could be
detected in the test series. With an
addition of 2% of the additive, only
about 10% of the usual veining ef-
fect, as it normally arises, remained.
If the addition of the additive is
increased from 2% to 4%, i.e. twice
the amount, then the end product,
which is free from veining, was reli-
Fig. 1. The refined FS003 sand with a reduced packing density and thus a smaller tension, in contrast ably reproducible, as in the furan-
to the FS001 sand, was able to achieve a 50% reduction in veining. sand mixture.

42 | MODERN CASTING December 2018


METALCASTING SUPPLIES

Data Collection Terminals Compact Spark Spectrometer


Hitachi High-Tech Analytical Science Corporation launched a
new optical emission spectrometer for metals analysis in found-
ries and metal production: the FM EXPERT. The FM EX-
PERT optical emission spectrometer combines analytical per-
formance with a compact size and optional floor stand module.
Its large wavelength range is ideal for the analysis of all relevant
elements in metals quality assurance and production process
control. The FM EXPERT also allows the analysis of nitrogen
at low levels thanks to its compact CCD optics system.
Visit www.hitachi-hightech.com/global/ for more information.

CMI Time Management (Enfield, Upgraded Range of Hanger-Type Blast Machines


Connecticut) announced the release Wheelabrator has re-engineered and up-
of the latest entry in its proprietary graded its HTS range of hanger-type blast
TouchTime line of data collec- machines. The range is now more tailored
tion terminals. Powered by an up- to the requirements of less-demanding
dated Windows operating system, light-to-medium applications, while
the TouchTime III time clock and maintaining reliability and durability. The
workforce management solution deliv- HTS range offers economical blasting of a
ers employee self-service capabilities variety of castings, forgings or heat-treated
designed to minimize time-consuming parts in highly flexible overhead mono-
manual data entry for human resource rail layouts (reversing Y-rail, closed-loop
and operations departments. through-feed).
Visit www.cmitime.com for more information. Visit www.wheelabratorgroup.com for more information.

Mold New Metalcasting


Talent ... Make a
Scholarship Gift

One School ...


One Scholarship
An FEF Support
Fund Tradition

Three easy ways to make your gift:


FEF website - www.fefinc.org/donate
Text - 847-979-4721
Phone - 847-490-9200
Build a lasting legacy by directing your
gift to your favorite FEF school

December 2018 MODERN CASTING | 43


ADVOCATE

METALCASTING MANAGEMENT
AND DEVELOPMENT SUMMIT
February 7-8, 2019 • The Mills House
Wyndham Grand • Charleston, South
Carolina • www.afsinc.org
This new, dynamic summit will advance
your leadership savvy and engage your
self-reflection. Anyone in the metalcast-
ing industry who currently leads or has
aspirations to lead the ever-changing
workforce should leverage this learn-
ing opportunity for motivating talent,
enhancing your culture, and identifying
your own leadership gaps. This is the
prime event for supervisors, HR pro-
fessionals and all leadership levels in
metalcasting.
Join us to take advantage of a personal
assessment, interactive workshops, and
roundtables giving immediate action-
able ideas to take back with you.
www.afsinc.org/conferences
ADVOCATE. EDUCATE. INNOVATE.

EDUCATE INNOVATE

GATING & RISER DESIGN 201 MOLD & CORE COATINGS


February 6-7 • AFS Headquarters • MANUAL, 3RD EDITION
Schaumburg, Illinois • www.afsinc.org www.afsinc.org
This course is a continuation of This edition of the popular book
Gating & Riser Design 101 with an updates information on coating se-
emphasis on application of sands, lection, process control of coatings,
chill, sleeves, other thermal control manufacturing and control testing,
properties, fluid flow principles and application and drying methods,
filtration, and your facility’s process test methods, and adds a chapter
parameter ranges to positively on coating related defects. The
change casting quality. Additionally, chapter on health considerations
the course will discuss methods to had been revised and updated with
translate quality requirements to the most current information.
cost implications for castings—pri- www.afsinc.org/store
marily through scrap reduction and
yield improvement to establish cost
and quality objectives in the tooling
design phase—and track the actual
information from this through the life
of the tools. This includes tracking
process parameter ranges and any
additional on-the-fly modifications
to the system.
www.afsinc.org/courses
MARKETING MIND

Something Old, Something New


RICH JEFFERSON, AFS VP OF MARKETING AND COMMUNICATIONS

O
ne of the big goals for AFS posters for AFS conferences.
is to constantly create more • Targeted marketing email.
value for Corporate Mem- • Social media.
bers. When the 2020 AFS Metalcast- • The Modern Casting Buyer’s
ing Forecast & Trends hits your inbox Guide.
at the first of the year, we hope you’ll • The Metal Casting Design & Pur-
take a few minutes to see what’s new. chasing Casting Source Directory.
We think you will find it an excep- We do all this, in house. We’re
tionally valuable resource. constantly talking to industry
After spending the year re- experts: suppliers, foundries, and
searching ways to make the Forecast buyers. We have the good fortune
more vital, we have an approach to interact regularly with them.
that could be called “something old, The Forecast, as you have known
something new.” it, offers you one kind of analyti-
Sometimes it’s good to try cal tool. We are adding to the tool
something new. On the other hand, box with analysis of other trends in Richard Jefferson
“if it ain’t broke, don’t fix it.” And metalcasting.
sometimes it’s not one or the other This year’s articles are a pilot (most everyone in Washington)
of those options, but both. project. Our plan is to expand and understands the full economic im-
For the old, the Forecast is not refine these analysis pieces each suc- portance of the entire metalcasting
changing, with the exception that cessive Forecast. Among the topics industry, not just one segment. This
we have been asked to ensure we in- we are going to cover are employ- is why we will continue reporting
clude a lesser-used alloy that we had ment and education in metalcasting, aggregate numbers along with the
stopped reporting on. The graphs supply chain, government affairs breakdown.
and the data will all be included. (USA), and energy. We hope to add Although not everyone appreci-
What’s new is the analysis of some other topics in coming years. ates the Forecast, there are those
issues vital to our members. Our We have absorbed various criti- who look forward to receiving it.
point is not to dig up “breaking cisms about the Forecast, which is One email I received stated, “We are
news,” but to delve into trends and normal. Thank you, one and all, looking at our 2019 budgets right
see if we can offer some helpful because you helped push us to make now and last year we used a projec-
information for the coming year, to these additions to the Forecast. One tion that AFS had published on how
provide a metalcasting context for of the criticisms is that aggregate they expected the foundry industry
our metalcasting readers. metalcasting numbers don’t help to perform in 2018. I was hoping to
Why are we going this direction? anyone. Aluminum foundries say get this projection for 2019 so I can
The AFS brand umbrella covers ar- they have little use for data about again use it in my own projections
eas of critical interest for metalcast- iron foundry output, and vice versa. for our company. Can you share this
ers: technical services (research, But wait. information with us?”
conferences, Metalcasting Congress, There is a most excellent reason Thank you for asking. Yes, we can
technical support, committees), to include aggregate numbers as a help you.
education (the Institute), member- key part of the Forecast. When the We are staying focused on our
ship services of a wide variety, AFS AFS goes about its important busi- goal of creating value for our mem-
Chapters, and media. ness on Capitol Hill and with exec- bers. For Corporate Members, your
Media is marketing and commu- utive branch agencies, it’s important Forecast will be delivered to your
nications on behalf of AFS Techni- that the non-metalcasting audience inbox in the new year.
cal Services, the AFS Institute, and
AFS Membership Services. We
produce a panoply of media:
• One AFS Metalcasting Forecast
GETTING THE FORECAST
and Trends.
For AFS Corporate Members the Forecast is a membership benefit. Individual
• Two magazines.
members may receive the Forecast for $750. The Forecast is available to anyone
• Seven newsletters.
for $1,000.
• Video.
• Promotional postcards, brochures,

46 | MODERN CASTING December 2018


AFS NEWS

CALENDAR
JANUARY 15-16 of iron melting and related processes.
Topics include charge materials selec-
ing industry who currently leads or has
aspirations to lead the every-changing
Introduction to Metalcasting tion; understanding of cost, value, and workforce should leverage this learning
SCHAUMBURG, ILLINOIS risk; information covering electric and opportunity for motivating talent, enhanc-
This course introduces the process of cupola melting procedures; refractory ing your culture, and identifying your own
metalcasting. It provides a broad picture lining and more. leadership gaps.
of what happens in a casting production
facility, while illustrating the technology,
variables and complexity involved in
FEBRUARY 6-7 FEBRUARY 19-20
producing a casting. Gating & Riser Design 201 AFS Advanced Foundry Waste and
SCHAUMBURG, ILLINOIS Byproducts Seminar 2019
AFS Headquarters
JANUARY 15 This course is a continuation of Gating &
Riser Design 101 with an emphasis on ap- SCHAUMBURG, ILLINOIS
WEBINAR: What Is an Inoculant and plication of sands, chills, sleeves, other ther-
What Does It Do?
WWW.AFSINC.ORG
mal control properties, fluid flow principles
and filtration.
FEBRUARY 26-27
Improving the Effectiveness of Visual
The concept of inoculation will be pre-
Inspection
sented, covering typical composition and
elements used along with an emphasis
FEBRUARY 6-8 SCHAUMBURG, ILLINOIS
on FeSi-based inoculants with controlled AFS Metalcasting Management and This course provides you with the informa-
chemistries. Development Summit tion needed to understand the factors
The Mills House—Wyndham Grand Hotel of influence on the human task of visual
CHARLESTON, SOUTH CAROLINA inspection, permitting true quality engineer-
JANUARY 29-30 ing of this critical operation.
Iron Melting 201 This new, dynamic summit will advance
SCHAUMBURG, ILLINOIS your leadership savvy and engage your
This course provides detailed coverage self-reflection. Anyone in the metalcast-

December 2018 MODERN CASTING | 47


AFS NEWS

Registration open for CastExpo 2019 in Atlanta


The metalcasting industry comes together every three Own Blueprint” program, where designers and buy-
years at CastExpo, the largest metalcasting trade show and ers can show their casting and machining drawings to
congress in North America, to meet new customers, to exhibiting foundries in order to explore casting options,
network with all the contacts they haven’t seen in three years, verify foundry capabilities, and learn about feasibility,
to see the best in new foundry equipment, and to discover costs, and material options.
new business opportunities. Metalcasting success starts with CastExpo 2019 includes a slate of impressive key-
CastExpo 2019, and registration is open today. note speakers, including Frank Abagnale, the inspira-
Produced by the American Foundry Society, CastExpo tion for the film Catch Me If You Can; Dr. Doru Stefa-
2019 is April 27-30 at the Georgia World Congress Center nescu, faculty emeritus at The Ohio State University
in Atlanta. Thousands will attend, making it the continent’s and University of Alabama; and Kaihan Krippendorff,
biggest gathering of the metalcasting supply chain in 2019. founder of Outthinker Roundtables.
CastExpo is known for its impressive show floor featuring Running concurrently with CastExpo 2019 is the
hundreds of industry suppliers, servicers, and related exhibitors. 123rd Metalcasting Congress, where many of the
Also on the show floor is Cast in North America, where met- industry’s leading thinkers share the latest research,
alcasters showcase their capabilities to designers and buyers. innovations and breakthroughs. Attendees can choose
This year marks the return of the popular “Bring Your sessions from multiple educational tracks covering all
areas of metalcasting, including a Designers and Buyers
Track offered on the show floor to complement Cast in
North America.
To register for CastExpo 2019, click here or visit
castexpo.com.

2019 Leadership Conference to be held Sept. 22-24 in Michigan


The AFS Foundry Leadership
Conference is coming to Michigan
next year.
Hosted annually by the American
Foundry Society, this popular event for
industry executives and other leaders
will be Sept. 22-24, 2019, at Grand
Traverse Resort and Spa in Traverse
City, Michigan.
The Foundry Leadership Confer-
ence features high-level speakers, in-
dustry roundtables, and presentations
about issues important to metalcasting
leaders, including industry innovation,
public policies and economic forecasts.
The 2018 Foundry Leadership
Conference in Florida saw attendance
increase for the third consecutive year
and attracted attendees from seven
The Grand Traverse Resort and Spa has three championship golf courses.
countries.

AFS announces new Board of Director nominees


AFS has announced its new Board of Director nomi- Foundry Inc. (Saint Marys, Ohio); and John Lancaster, plant
nees for the 2019-2023 class. They are Patrick Ameen, vice manager, General Motors (Pontiac, Michigan).
president industry relations, Amsted Rail (Granite City, Il- The final election of the new board members will occur in
linois); John Haas, president, Cadillac Casting Inc. (Cadillac, April, just before the start of the terms, which will run from
Michigan); Angela Schmeisser, president/CEO, St. Marys 2019-2023.

48 | MODERN CASTING December 2018


COLLEGE CONNECTION

Metalcasting journey for UWM student includes impactful internship

K
evin Slezak is a senior which had equipment and software CEO regarding potential technol-
attending the University that other spectrometers didn’t. He ogy applications.
of Wisconsin-Milwaukee, investigated and tested the new “Signicast helped me obtain a
majoring in physics and materials features to ultimately determine if scholarship at the end of my intern-
engineering. Throughout his stud- the machine was working as de- ship, leading to an invitation to
ies, he has had some exposure to signed. Completion of the project the Investment Casting Institute’s
investment casting, and the senior meant better quality control for the technical conference,” Slezak said.
capstone project he chose to work company’s alloys in the future. The “My university’s relationship with
on with MetalTek International’s second project focused on explor- FEF helped make my trip to the ICI
Investcast division gave him even ing applications of ultrasound to conference possible, allowing me
more experience. processing. This project was very to network with experts in the field
Slezak’s knowledge and inter- open ended, leading to extensive and learn more about the investment
est in investment casting greatly background research and culminat- casting industry.”
expanded during the summer of ing in a report and presentation
College Connection is a recurring feature that runs
2018. He spent several months as given to various department heads in Modern Casting highlighting the metalcasting
a process engineer intern at invest- within the company as well as the programs and students at FEF schools.
ment caster Signicast Corporation.
His time was split between the
headquarters in Hartford, Wiscon-
sin, and their former headquarters
in Brown Deer, Wisconsin.
Several process engineer interns
at were Signicast, and they spent the
first several weeks rotating through
all the processing positions in the
Hartford facility. This allowed them
to obtain a quick but detailed picture
of the beginning-to-end production
process. Through the remainder of
the summer, each intern was assigned
a project that was to be their primary
focus while the remaining time was
spent assisting the process engineers.
This work included metallurgical
testing as well as tests and data analy-
sis related to other processes.
Slezak was assigned two summer
projects. The first project involved
testing the company’s relatively
newer optical emission spectrometer Kevin Slezak spent several months as a process engineer intern at investment caster Signicast.

UNIVERSITY OF WISCONSIN-MILWAUKEE (MILWAUKEE)

Metalcasting-related degrees: Students can earn a BS in Materials Science & Engineering, but they can also earn an MS in
Mechanical Engineering and a PhD in Industrial Engineering.

Metalcasting course examples: The courses required to complete a Materials Science & Engineering degree are offered begin-
ning at the freshman level. Engineering Materials is where students start. Other required courses include Materials Processing
& Manufacturing, Physical Metallurgy, Thermodynamics of Materials, and Mechanical Engineering Experimentation. Engineering
Basis of Materials, Mechanical Behaviors of Materials, and Materials Laboratory are also required classes.

Professor notes: Pradeep Rohatgi has been the FEF Key Professor at UWM since 1993. He received both his MS in Materials Sci-
ence & Engineeering and his ScD in Materials Science from the Massachusetts Institute of Technology.

December 2018 MODERN CASTING | 49


HELP WANTED
MAGMA is growing and looking to bring on multiple
Your knowledge is people to join our team! We are currently looking
to hire a Project Engineer to focus on Non-Ferrous.
Technical Director
valuable. Let the AFS In- A Project Engineer to focus on High Pressure Die Purpose:
stitute help you share it. Casting. We are also looking for a Technical Train- The Technical Directors helps to position AFS as an
ing Specialist... If any of these positions interest indispensable technical resource to the metalcast-
You, an active member of the metalcasting you, please follow this link to our website for more ing industry; provides administrative and technical
industry, have the experience we need to drive details regarding the positions and how to apply. assistance to the Technical Council committees to
the direction of our growing skills training Bit.ly/MAGMAjobs assist them in achieving the Society’s goals and
program. There are opportunities for course objectives; and serves as a technical resource to
facilitation and curriculum development in PTC INDUSTRIES LTD—are looking to hire Inde- the AFS members.
both volunteer and paid capacities. pendent Sales Representatives on a 1099 basis. Key Accountabilities:
Course facilitation requires a minimum of semi- Base + Commission. – Our products are ISO9001,
• Serve as technical liaison to assigned techni-
annual travel and the ability to be comfortable ABS, Lloyd, TUV, DNV, Norsok, PED approved
cal committees, helping them to advance the
speaking with large groups. The Institute Stainless Steel, Titanium and High Alloy Castings
AFS mission and vision. Supervise adminis-
provides you with online training to hone your for High Integrity Engineered Product applications.
trative services for those committees.
skills of managing the delivery of professionally Investment Castings(Replicast) up to 10,000lbs.
developed curriculum and yearly evaluations for Looking for representation in all states. Contact • Administer annual Casting Congress and
personal facilitation development. PTC Industries Ltd, a.rowett@ptcil.com program/papers activity.
• Aggressively work to recruit individuals to
When you are involved in curriculum de- participate in assigned committees.
ROBERTS SINTO CORPORATION (RSC)—is the
velopment, you have a unique opportunity
North American group company of Sintokogio • Plan and administer specialty conferences,
to provide input about the skills the in-
Ltd., a worldwide family of companies with an in- ensuring detailed compliance with budgeted
dustry needs to grow. No travel is required.
ternational reputation for excellence in the metal revenue and expense targets.
Work with professional adult-learning
casting industry. Sintokogio has 42 companies • Provide superior technical services to member
experts who create course materials from
in 16 countries. The business segments include companies.
the knowledge and content you provide.
foundry, surface treatment, environmental
equipment, and material handling. RSC has an • Serve as technical resource for staff, AFS
For more information, contact Clarence magazines, and AFS Institute.
Trowbridge at ctrowbridge@afsinc.org immediate opening for a full time experienced
or complete a quick form at: Sales Managers for our Foundry Division.The • Promote involvement and membership in AFS.
Sales Manager position oversees the manage- • Support AFS chapters by serving as local
https://americanfoundrysociety.wufoo. ment of the equipment sales, parts, consumables chapter speaker on request.
com/forms/afs-institute-instructor- and service in a designated territory. Qualified • Perform other duties as assigned.
sme-application/ applicants must have a Bachelor’s degree (B. A.)
from four-year College or university; and five to Required Skills or Experience:
seven years capital equipment sales experience The incumbent will:
CONSULTANTS and/or training; or equivalent combination of
education and experience. Foundry experience
• Have significant knowledge of one or
more of the following areas: iron, steel,
preferred. Please contact Rachel Lunce at: non-ferrous, sand and molding methods,
K. Copi Technologies rachel.lunce@robertssinto.com if inter- additive manufacturing.
Metallurgical consultant for grey & ductile ested or refer to the company website: • A minimum of a Bachelor’s degree in an
iron foundries https://sintoamerica.com/ engineering, metallurgy, material sciences,
Specializing in: or related curriculum.
• Process improvements, especially in EQUIPMENT FOR SALE • Knowledge of the metalcasting industry and
ductile iron production manufacturing.
• Cost reductions FOR SALE: Palmer CM177-M coremaker/mixer, • Professional experience in industry,
• Reduced scrap levels less than 100 hours; ABB 600 kw furnace c/w 1,600 academia, research lab, and/or trade as-
and 2,200 lb tilters, 10T bottom pour ladle; Palmer sociations that is relevant to the position.
• Improved yields
20,000 lb vibe table. Call Roger at 905-327-1727 • Strong computer skills in Microsoft Office
• Improved metallurgical properties or rheise1946@gmail.com Suite and the ability to explain and work
44 years of hands-on practical with data.
experience with a proven record Of
continuous improvements EQUIPMENT WANTED • Because of a high level of interaction
with industry personnel, strong customer
Contact: Ken Copi Osborn 716 rjw molding machine wanted, must be in relations and communication skills are
Email: kwcee@aol.com working condition. Contact: Gerald@ambroco.com required.
Cell: 912-665-1801 or call: 216-341-7800. • Willingness to travel frequently, with oc-
casional evening and weekend work.
CONSULTANTS • Effective public speaking and writing skills.
• Must be able to read and write in English.
• Must be able to multitask.
• Must have valid driver's license.
A D V O C AT E
. E
D U
CA
TE
. IN
N O VAT E .

AND THE INSTITUTE

For more information, contact Cathy


Potts at cpotts@afsinc.org

December 2018 MODERN CASTING | 51


FOR SALE-USED EQUIPMENT

BAGHOUSE DUST COLLECTORS: Our Website is updated Daily, please visit:


SCIENTIFIC, 85,000 cfm, 8,670 ft² filter media, WWW.FOUNDRY-EQPT.COM for all our latest equipment inventory.
Pulse Clean, Walk-In, 250 HP Twin City Blower
DCE DALAMATIC, 75,000 cfm, 2 module, 10,333 Featured Machine
ft² media, envelope-style filters GUDGEON Brothers Thermal Sand Reclaim System
WHEELABRATOR #3317, 70,000 cfm, 10,974
Model TF-12000, 6 Tons Per Hour, New in Year 2008
ft² filter media, pulse clean, blower
BACT, 60,000 cfm Baghouse, 12,126 ft² Filter (2) Drycoolers, High Temperature Dust Collector
Media, Pulse Clean
FABRIC FILTERS 50,000 cfm baghouse, 8,591 ft • Foundry Liquidations, Consignments,
media, pulse clean, Walk-In, blower & controls Appraisals, & Auctions
CSL 46,000 cfm baghouse, 6,782 ft media, pulse • Friendly and Knowledgeable Staff On Hand,
clean, Walk-In, blower, ductwork and controls Warehouse Services
MIKROPUL, 45,000 cfm, 6,506 ft² media, 150 HP • Proud Member of Machinery Dealers National Association (MDNA)
blower, controls, walk-in plenum
DUSTEX, 40,000 cfm, 4,144 ft² media, blower,
explosion vents, top-access doors, controls WORLD EQUIPMENT & MACHINE SALES, CO.
IVI 30,000 cfm, New in 2011, 4,706 sq ft filter, 6111 Cochran Road, Solon, Ohio 44139, TEL: 440-519-1745 FAX: 440-519-1748
Pulse Jet, Walk in Plenum, blower mike@foundry-eqpt.com or marty@foundry-eqpt.com
ETA #1715, 25,000 cfm, 4,004 ft², 100 HP
Ground Mount, Belt Drive Blower
PANGBORN, 20,000 cfm, 2,751 ft² media, holds
(210) bag filters
CARTRIDGE DUST COLLECTORS:
FARR 144XL, 100,000 cfm, 40,608 ft² media,
screw conveyor discharge, blower Visit FLSales.com for the largest online equipment inventory
DUST HOG #FJH160-4, 85,000 cfm, 36,160 ft²
media, Blower & Ductwork, Controls • Our website is updated hourly for the best selection
TORIT #4DF128, 60,000 cfm, 28,928 ft² media, • Complete listing of upcoming liquidations and auctions
Reconditioned, Blower, Controls • Certified appraiser on staff
TORIT #DFT4-80, 45,000 cfm, 20,320 ft² media, • We offer cleaning and painting
reconditioned, blower • We offer reconditioning and rebuilding
WHEELABRATOR, 45,000 cfm, 22,050 ft² media
TORIT #DFT4-48, 30,000 cfm, 12,192 ft² media, We’re the one-stop resource for buying and selling foundry equipment
extended dirty air plenum, air management
module, blower, controls
AAF OPTIFLO #4RC32, 20,000 cfm, 8,800 ft² We have completed a facelift at our warehouse. Schedule a visit today,
media, pulse clean, blower, controls, ductwork over 900 items in stock.
AIREX #DCC30, 15,000 cfm, 6,780 ft² media, back-
draft damper, explosion vent, blower, ductwork WWW.FLSALES.COM 440-498-8484 JGREENE@FLSALES.COM
DONALDSON TORIT DFT3-24 cartridge, 12,000
cfm, 6,096 ft media, explosion vents, pulse
clean, blower FOR SALE—B & P Lab Mulbaro, Cincinnati 12” Lab Muller, Simpson 18” & 24”. Lab Mullers, Simpson #05
HIGH VAC SYSTEMS: Porto-Muller, Simpson #1F Mix-Muller. Rebuilt Falk. Reducers for Simpson #1F, #1.5F, #2F, #1.5G, #2G &
#2.5G. Muller wheels for Simpson. #1F, #1.5F, #2F, #1.5G, #2G, #2.5G & #3G. Many new, reconditioned
MULTI-VAC #SM11-SR, 11.5 HP Blower & used items available for all sizes of Simpson Mix-Muller and Multi-Mull. Additional information upon
DEMARCO MV20E, 20 HP, Hopper. request – Korco Mfg. Inc. 724-758-5020
DEMARCO #MV60LPG, Propane, Portable FOR SALE—No Bake Machinery – Mixers, Heaters Sand Reclaimers, Rollovers, Mold Handlers, Roller
/ Belt / Vibrating Conveyors, Transporters, Handlers, Shakeouts, Blast Machines, Dust Collectors, Also
SAND RECLAIMER: Green Sand Machinery, Mullers, Molding Machines, Core Room / More Call John @ 540-297-8884 or
Richards Model FX4000 Thermal Sand Reclaimer, fdrysand@yahoo.com
New 1999, 2 TPH, MAKE OFFER!
SPECTROMETERS—Most Base metals available. Late model CCD and Phototube. Warranty and training
MANY OTHER DUST COLLECTORS IN STOCK! included. Call for models and descriptions. I.A.S. LLC 256-287-1477 or sales@steelanalyzer.com
Check out our website!
www.amindustrialmachinery.com
MODERN
CLASSIFIED
CASTING
AM INDUSTRIAL
216-433-7171
curt@amindust.com

A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY ADVERTISING


Any good surplus foundry equipment
for sale-we offer free advertising Visit us at: Contact:
at www.aapfoundryequipment.com www.afsinc.org/MCclassifieds Fabio Cavalieri at 847/827-3622
A.A.P. Equipment inc. 450-266-0607 For full pricing details E-mail: fabio@afsinc.org

52 | MODERN CASTING December 2018


PROFESSIONAL SERVICES

Peter E. Macler PHOENIX INDUCTION CORPORATION


Associates, PLLC
Management and Engineering Consultants
2019 CastExpo - Atlanta - Booth 2702
• Foundry Design and Modernization
• Master Planning
• Business Assessments
• Q.C. and Productivity
• Safety & Environmental
“An Induction Supply Company”
• Expert Witness Services
• Coil Specialists: Design, Build & Repair
Peter E. Macler, BSME, MSIE, PE • Forging/Heating & Coreless Coils
1347 Grand Pass, Canyon Lake, TX 78133 • Heat Treating Coils
830-481-3193 • Machined Quality Coils
pm@maclerassociates.com • Workhead Transformers
www.maclerassociates.com • Open and/or Cast Block Design
• Skid Rails
AFS Corporate Member, Founded in 1987
248-486-8760
sales@phoenixinduction.com
www.phoenixinduction.com
*Registered trademarks of their respective companies

Fast • Accurate • Comprehensive


Our customized services are setting unprecedented standards in
thermal analysis of metals of any kind.
844-MELTLAB (844-635-8522)
www.meltlab.com • info@meltlab.com

HIT YOUR
TARGET with

AFS CAREER
OPPORTUNITY PACKAGES.

December 2018 MODERN CASTING | 53


EMPLOYMENT

Career
Opportunities
Packages Available Now!

54 | MODERN CASTING December 2018


ADVERTISING INDEX

AD INDEX
Company Page Email/Website Phone FAX Contact

AFS Wisconsin Chapter 27 afswi@teamwi.com 262-532-2440 262-532-2430 Customer Service

ASK Chemicals 2 info.usa@ask-chemicals.com 800-848-7485 614-790-3941 Customer Service

Clariant 25 www.clariant.com 704-331-7000 704-377-1063 Customer Service

Conveyor Dynamics 9 www.conveyordynamicscorp.com 636-279-1111 636-279-1121 Mike Didion

Didion International, Inc. inside front cover info@didion.com 636-278-8700 636-278-3155 Art Grillo

Exone Company 21 www.exone.com 877-773-9663 724-864-9663 Customer Service

FEF 43 www.fefoffice.org 847-490-9200 847-890-6270 Brian Lewis

General Kinematics Corporation inside back cover mail@generalkinematics.com 815-455-3222 815-455-2285 Customer Service

Gradient Lens Corporation 12 info@gradientlens.com 800-536-0790 585-235-6645 Customer Service

Greensand Controls LLC 10 www.greensandcontrols.com 920-446-2468 920-446-2469 Perry Thomas

I2r Power 6 www.powercablecompany.com 888-600-0900 Customer Service

Hoosier Pattern, Inc. 4 www.hoosierpattern.com 260-724-9430 260-724-9433 Customer Service

Humtown Products Company 11 www.humtown.com 330-482-5555 330-482-9307 Customer Service

Industrial Vacuum 13 www.industrialvacuum.com 800-331-4832 920-261-1136 Customer Service

Joest Inc 13 info@joest-us.com 630-469-0900 630-469-3800 Customer Service

LaempeReich outside back cover email@reichcompanies.com 205-655-2121 205-655-2123 Jarek Olszak

Magma Foundry Technologies, Inc. 1 sales@magmasoft.com 847-969-1001 847-969-1003 Customer Service

Nicholas Industries 22 www.nicholasindustries.com 262-635-2464 Customer Service

Refcotec, Inc. 14 sales@refcotec.com 330-683-2200 Customer Service

Synchro ERP Ltd. 22 sales@synchroerp.com 800-323-2808 800-323-2808 Customer Service

Thermtronix Corp Insert www.thermtronix.com 760-246-4500 760-246-4550 Joe Danega

BUSINESS STAFF/ADVERTISING SALES REPRESENTATIVE

MODERN MIDWEST, WEST & INTERNATIONAL NORTHEAST, OHIO & SOUTHWEST

CASTING
Fabio Cavalieri Joe Murphy
Schaumburg, IL 60173-4555 P.O. Box 1422, Fairfield, CT 06825
847-824-0181 800-537-4237 203-254-9595
Fax: 847-824-7848 Fax: 203-259-4447
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY fabio@afsinc.org AdSales25@aol.com

December 2018 MODERN CASTING | 55


SHAKEOUT Bronze Castings Add to
Accuracy of Restoration

To get a historic restoration just right, every tiny detail must be


managed. One thing wrong can ruin the accuracy of the project.
The group restoring the historic Henry and Eleanor Ford estate, Fair Lane,
in Dearborn, Michigan supplied a scanned solid model file of the house’s
18 thermostat covers to Aristo-Cast (Almont, Michigan). The century-old
mansion is being faithfully restored to reflect its years as the Ford family
residence. The restoration team felt it was important to have exact replicas of
the thermostat covers so anyone who touched them would feel the richness
of the castings. The same silicon bronze was used for the replicas.

56 | MODERN CASTING December 2018

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