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Upcoming Educational Events
Aug. 16-19
21st Environmental, Health & Safety Conference
Indianapolis
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Aug. 16-19
Ergonomics in the Metalcasting Facility Seminar
Indianapolis
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Aug. 18-20
Analysis & Reduction of Casting Defects (05-10)
AFS Headquarters, Schaumburg, IL
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Aug. 18-20
Chemically Bonded Molding & Coremaking Methods & Materials (06-10)
Hampton Inn & Suites Charlotte Airport
Charlotte, NC
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Aug. 25-27
Metallurgy of Copper Base Casting Alloys (07-10)
Mohawk College, Hamilton, ON
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Sept. 8-Oct. 19
Interactive Six Sigma Green Belt
Certification (08-10), Internet
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Sept. 9-10
Midwest Industrial Efficiency Exchange, Detroit, MI
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Sept. 15-17
Analysis & Reduction of Investment
Casting Defects (09-10)
AFS Headquarters, Schaumburg, IL
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Sept. 20-22
Foundry Executive Conference
Loews Coronado Bay Resort, Coronado, CA
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Sept. 22-24
Metallurgy of Gray & Ductile Iron (11-10)
Genetti Hotel & Suites, Williamsport, PA
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Sept. 28-29
Best Practices for Aluminum Castings:
Maximizing Casting Quality and Strength
AFS Headquarters, Schaumburg, IL
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Oct. 20-21
Labor Relations & Human Resource Conference
Embassy Suites Indianapolis North, Indianapolis
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Nov. 12-13
Art Casting Conference
Four Points by Sheraton, Tempe, AZ
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Practical Tips for
Your Facility
Casting Cost Estimating
Developing production standards, such as yield rates, molds per hour, and grinding rates, is a critical and necessary step towards creating accurate estimates. Informal production standards based on historical information are better than nothing, but should be used with caution as they usually reflect averages and will understate or overstate either end of a broad product mix range.
Cost Effective Casting Design
Six parameters (based on physics) underlie cost-effective casting design: fluid life, solidification shrinkage, slag/dross formation tendency, pouring temperature, section modulus and modulus of elasticity. All six, applied as a system, drive the geometry of casting design. Geometry is not only the result of casting design but is also the most powerful weapon in creating successful casting design.
Designing junctions is the first step to finding castable geometry via the six-faceted system for casting design.
Cupola Melting
Before changing a significant component in the charge, to save a few cents per ton, make sure the risk factor is understood. Surprise elements that are due to contamination or nondeclaration can wipe out up front savings with huge casting scrap cost or rework costs. That does not suggest change is impossible but more research initially will avoid a lot of post-mortem investigation.
Inoculating Gray and Ductile Iron
There are minimums and maximums for both gray and ductile irons for minor elements, as well as major elements, and outside that range the inoculation effect may be unsatisfactory. Sulfur has to be controlled in both irons, at different levels.
Inoculation is the final key step to produce a saleable, machinable casting with satisfactory mechanical properties. Inoculation should be applied sparingly, as late as possible, with the “cleanest” inoculant available in a consistent practice.
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