American Foundry Society

Welcome to e-Connections, the weekly AFS email newsletter. In this December 4, 2007, edition:

IJMC Includes Study on Nanocomposites, Machining
The second issue of the International Journal of Metalcasting will be released in January 2008. This issue will feature 6 papers, including one on "Recent Developments on Ultrasonic Cavitation Based Solidification Processing of Bulk Magnesium Nanocomposites" by G. Cao, H. Konishi and X. Li, Univ. of Wisconsin-Madison, that will discuss the potential to double the strength of aluminum castings with only a 1-2% addition of nano-sized particles of Silicon and Carbon. A second paper titled "Age Strengthening of Gray IronKinetics Study" by V.L. Richards, T.V. Anish, S. Lekakh, D.C. Van Aken, Univ. of Missouri–Rolla, W. Nicola, Warsaw, Ind., will discuss improvements in machinability along with increases in strength that have been observed, and now documented for gray cast iron. 

Don't delay, subscribe now to receive the leading transfer of research and technology to the global metalcasting industry. For more information on the IJMC, and to download a subscription form, visit www.metalcastingjournal.com or contact AFS customer service at 800/537-4237.

Internet Course Survey Available
AFS and its Cast Metals Institute (CMI) are developing short format (1.5 to 2 hour) internet courses. In order to determine the subjects that are to be included, a short survey has been made available. Take a few moments to fill it out, and you will be entered into a drawing to receive a free CMI course.

To take the survey, click here. For more information on this survey, contact Jennifer Head, CMI special projects and course coordinator, at jhead@afsinc.org.

OSHA Revises Enhanced Enforcement Program
The Occupational Safety and Health Administration (OSHA) announced this week that it is revising its enhanced enforcement program (EEP) to focus more closely on recalcitrant employers, and their past history of safety and health violations. According to the new compliance directive describing the program, the modified EEP will take into account previous violations, especially previous willful, repeat, and failure-to-abate violations. The revised enforcement program will go into effect Jan. 1, 2008.

Employers in the EEP are subject to follow-up inspections, inspections of other company sites, notification of OSHA enforcement to the corporation, enhanced settlement provisions, and federal court enforcement under Section 11 (b) of the Occupational Safety and Health Act. According to an OSHA official, over the past four years, the agency has logged 2,129 EEP cases, averaging 524 cases each year. OSHA has found that 67 percent of the EEP employers had 100 or fewer employees.

According to the directive, a large percentage of inspections have involved employers with 25 or fewer employees.These small employers have had only one serious violation related to a fatality and no significant OSHA history within the previous three years, according to the directive.

An employer's history of OSHA violations will be based on the employer's nationwide inspection history, including violations in state plan states, as well as those under federal OSHA jurisdiction.The prior history must be based on a final order, not simply citations that were issued. Past violations include those that are "similar in kind" to the current violation. For example, if there are violations of OSHA's fall protection standards, a prior fall from a scaffold is considered similar in kind to a current fall through a floor opening or from a roof, the directive said.

OSHA has expanded the criteria for enhanced enforcement cases to include:

  • a fatality inspection in which OSHA finds one or more willful or repeated violations related to the death;
  • a fatality inspection in which OSHA finds one or more serious violations related to the death and the employer has either an OSHA history of violations similar in kind to the violation that led to the current fatality consisting of at least one serious, willful, or repeat violation within the last three years, or the occurrence of another fatality within the last three years regardless of whether any citation was issued;
  • an inspection that results in the citation of three or more serious violations that are also classified as willful or repeat and the employer has an OSHA history of violations similar in kind to one or more of the violations found in the current inspection consisting of at least one serious, willful, or repeat violation within the last three years;
  • an inspection that results in one or more failure-to-abate notices where the underlying violations were classified as serious;
  • any egregious case or a significant case consisting of one or more inspections in which the proposed penalties total more than $100,000;
  • grouped and combined violations that are counted as one violation;
  • an unclassified violation, depending upon what the citation classification was, or would have been, if the unclassified designation was not used.
Since there are significant differences between the original EEP and the revised program, the data from the two programs will not be comparable and will be maintained separately. The revised EEP also provides that if an establishment has entered into a settlement agreement in which an EEP-qualifying violation is deleted, or if the violation has been vacated by an administrative law judge, the Occupational Safety and Health Review Commission, or court decision, "the entry on the Log will be lined-out and the IMIS EEP2 code will be removed from the establishment's Internet Inspection Detail summary. States with their own safety and health programs are being strongly encouraged to participate in the EEP program. The compliance directive CPL 02-00-145 describing OSHA's enhanced enforcement program is available on the agency's website at http://www.osha.gov under directives.

For more information regarding OSHA's revised Enhanced Enforcement Program, contact Stephanie Salmon, AFS Washington office, at ssalmon@afsinc.org, or Fred Kohloff, AFS director environmental, health and safety, at fhk@afsinc.org,

Casting Cost Estimating Course Available
The Cast Metals Institute (CMI) will be offering a Casting Cost Estimating course Feb. 19-20 at AFS Headquarters, Schaumburg, Ill. This course uses a workshop approach to take students through the basics of predicting job costs using example jobs, as well as prints students bring to class. Estimates based on blueprints will be presented and discussed. Methods for determining cost centers also will be discussed, along with ideas for assigning standard costs. Students will review sample estimates using a form created during the lectures.

For more information, or to register for this course, click here or contact AFS customer service at 800/537-4237.