2012 Issue 334

The Ductile Iron News

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To Promote the production and application of ductile iron castings Issue 3, 2012

FEATURES

2012 FALL MEETING HIGHLIGHTS

Speaker Bios - AM Session Speaker Bios - PM Session Melt Yard and Deck Basics - Larry Helm Iron Control in a Large Induction MeltFoundry - Brandon Reneau Optimizing Magnesium Recovery - BrianJohnson New Developments in Binders & Coatingsfor DI - Doug Trinowski Cast, Clean, and Make Money - GeneMuratore Blending Optimization in the DI Industry -Peter Moulder Observations for Management on IronFoundry Safety Statistics - Ted Schorn

Introduction to THORS - The OnlineLearning Resource - Al Alagarsamy &John Mirka

DEPARTMENTS

News Briefs Back Issues DIS Home Page

Ductile Iron News - Issue 3, 2012

The Fall Technical and Operating meeting of the Ductile Iron Society was held on October 24-26, 2012 at the Embassy Suites in East Peoria, Illinois. The Wednesday started off with theResearch Committee meeting and with a record of 46 members attending. More informationcan be found by visiting the Research Committee on the DIS website. In the afternoon all theother Operating Committee meetings were held including the Board of Directors meeting. The first day was concluded with our reception.

On the second day, the attendees were presented with 9 different speakers and a panel of 4speakers on, Back to Basic Melt Shop. You can find out more about each presentation andthe panel presentations by clicking on the topic/speaker on the menu on the left hand side ofthis page. At the banquet that evening, the proceedings were hosted by the Ductile IronSocietys President, Patricio Gil.

Patricio Gil, CEO of Blackhawk Foundry de Mexico

The attendance for the Fall meeting was 152. This was a record for the last 10 years.

Thanks to all members and guests for attending and making this a very successful meeting. Patricio then introduced our guests for this meeting. David Champagne, Steve Niekamp andJim Stubbs of Midwest Foundry (Minster Machine) of Ohio, Matt Sharifi, Dale Wells and JimOBrian of Ariel Corporation of Ohio, Kurt Larsen of ARG from Denmark, Stephen Kamykowski

Mark your calendars for the 5th Keith Millis Symposium Oct. 14-17, 2013

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and Kyle Rabine of Brillion Iron Works of Wisconsin, Sean Betty and Terry Oldfield from VAENortrak of Illinois, Martin Deters of Tenneco, Bill Weller of Ajax Tocco, and Jim Hauska ofFoundry Support Operations, Inc.

After the meeting concluded, Midwest Foundry joined as a Foundry member and ArielCorporation joined as a Research Patron.

Along with these guests we also had Ross Rosmait (FEF Key Professor) and Jacob Lehman(Asst. Professor) of Pittsburg State University and 6 students who were Brennon Holenda, JonMcPherson, Shawn Moody, Chad Morrell, Josh McLennan and Macon McNair attend ourmeeting as student guests. Along with these students we had 2 students from the Universityof Northern Iowa and they were Coleman Housman and Matthew Wason.

From l to r, Shawn Moody(Pittsburg State) BrennonHolenda(Pittsburg State) Matthew Wason(Northern Iowa)Coleman Housman(Northern Iowa) JonMcPherson(Pittsburg State) Macon McNair(PittsburgState) Chad Morrell(Pittsburg State) JoshMcLennan(Pittsburg State)

Patricio then introduced all the new members that joined the DIS since our last meeting inJune 2012 in Muskegon, MI. Re-joining the DIS was Cifunsa Del Bajio and representing themto receive their new membership certificate was Alberto Pinones along with Teo Quinteroand Daniel Gomez Ballesteros. Also joining the DIS as new members were Pacific AlloyCastings Company from California, Associate member Cobra Trading represented by KevinDykstra and Ryan Hoefler, Associate member Snam Alloys from India and Associate memberRex Heat Treat represented by Mel Ostrander.

Next Patricio asked Gene Muratore of Rio Tinto to come to the front and present eachspeaker with a token of appreciation for volunteering to speak to our group. Gene then askedeach speaker from the morning session to come to the front of the room to receive their gift.

Doug Trinowski of HA International spoke on, New Developments in Binders & Coatings forDuctile Iron.



Doug Trinowski of HA International & Gene

Guy-Roger Nauroy of FerroPem who spoke on, Long term Price Evolution on Silicon BasedAlloys.

Guy-Roger Nauroy of FerroPem

Ted Schorn of Enkei America, Inc. who spoke on, Observations for Management on IronFoundry Safety Statistics.

Ted Schorn of Enkei America, Inc. & Gene

Al Alagarsamy, DIS Consultant and John Mirka of Thors who spoke on, Thors The OnlineLearning Resource.

Al Alagarsamy DIS Consultant & Gene John Mirka of Thors & Gene

Brian Johnson of Hickman Williams & Company who spoke on, Optimizing MagnesiumRecovery.



Brian Johnson of Hickman Williams & Company & Gene

Then Patricio invited Kathy Hayrynen of Applied Process to present our DIS gift to theafternoon speakers. Thanks go out to both Kathy and Gene for volunteering to act as ourmorning and afternoon technical chair persons.

Gene Muratore of Rio Tinto who spoke on, Cast, Clean and Make Money.

Gene Muratore of Rio Tinto

Eli David of Globe Metallurgical Sales, Inc. who spoke on, Production and Use of Ferro SiliconAlloys.

Eli David of Globe Metallurgical Sales, Inc. and Kathy

Then the speakers who participated in the panel on Back to Basic Melt Shop.



Larry Helm of Seneca Foundry

Kyle Anderson of Waupaca Foundry & Kathy

Brandon Reneau of Caterpillar, Inc. & Kathy

Dan Webb of Progress Rail & Kathy



Peter Moulder of Management Sciences Associates, Inc. who spoke on Reduction in MaterialCosts in a Ductile Iron Melting/Foundry Environment: Promises & Observations.

Peter Moulder of Management Sciences Associates, Inc.

Patricio then finished off the proceedings of the banquet by asking the Plant Manager ofCaterpillars Foundry operation in Mapleton, IL to come to front of the group and give them abrief presentation on the history of the plant and safety guidelines for the tour that the groupwill go on the next morning.

Gary Bevilacqua of Caterpillar Inc.

The Ductile Iron Society wishes to extend our appreciation and gratitude for hosting the planttour on the final day. Thanks especially go out to Brandon Reneau for organizing thearrangements for the tour. We also would like to thank Gary and the many folks atCaterpillar who volunteered to host and act as tour guides.



Please mark your calendars for our next Ductile Iron Societys Annual meeting will be held onJune 5-7, 2013 at the Westin Indianapolis with a tour of Pure Power TechnologiesMetalcasting Group in Indianapolis, IN. Please check the DIS website at www.ductile.org formore details. Also the Ductile Iron Society will hold a Production Seminar in late March, 2013in Mexico and March 5-6, 2013 in Chicago, IL. Again, check the DIS website for more details.

The Ductile Iron Society would also like to acknowledge those folks who make the meetingsrun smoothly and volunteer their time to the operation of the DIS.

Pete Guidi of Hitachi Metals Automotive Comp USA DIS Treasurer

Susie Lambert & Jim Wood



Bruce Blatzer

THE FEF COLLEGE INDUSTRY CONFERENCE 2012

The FEF College Industry Conference was recently held at the Westin Michigan Avenuein Chicago. Over 280 industry executives (including nine FEF Past Presidents), studentdelegates, key professors and university administrators were in attendance this year. The conference began on Thursday, November 15, with the Career InformationSession which gave 81 student delegates the opportunity to interact withrepresentatives of 43 companies in the metal casting industry. The InformationSession and social time before and after the event is structured to facilitate thesharing of job opportunities and to connect students to potential employers in theindustry.

During the General Session on Friday, the following speakers shared their vastexperiences in the metal casting industry: Dwight Barnhard (Superior AluminumCastings), Mo Lynn (Fairmount Minerals), and John Keough (Applied Process).

The FEF/AFS Distinguished Professor Award was given to FEF Key Professor, ScottGiese, University of Northern Iowa, in recognition of his demonstrated personalinterest in his students, as well as his knowledge of the industry. As part of theluncheon this year, the Student Delegate scholarships were presented (see next pagefor complete list) - 20 students were awarded a total of $44,500.00. Additionally, the



Keith Millis and Ron Ruddle scholarship recipients were announced, as well as therecipient of the first William Allan Hunter Scholarship. At the Annual Reception on the evening of November 16, FEF's highest award, the E.J.Walsh Award, was presented to longtime FEF Board Member & Treasurer, Rob Steele.

Next year's conference will be help on November 21 & 22 at the Westin MichiganAvenue in Chicago. Plan now to attend this exciting event!

CIC Student Delegate Scholarships-November 16, 2012

AFS Detroit-Windsor-George Booth Schol. - Andrew Miko - Michigan TechAFS-Saginaw Valley Scholarship - Lawrence Hengesbach - Western MichiganAFS Southwestern Ohio Scholarship - Colin Galey - Case Western ReserveRon & Glenn Birtwistle Mem. Scholarship - Steven Brown - Pittsburg StateRon & Glenn Birtwistle Mem. Scholarship - Mary Seals - Virginia TechDonald Brunner Scholarship-ThyssenKrupp Waupaca - David Kalchbrenner - Wisconsin-MilwaukeePaul Carey Memorial Scholarship - Jeremiah Hardwick - Trine University Clifford Chier-Badger Mining Corp. - John Anderson-Wisconsin-PlattevilleWm. E. Conway Scholarship-Fairmount Minerals - Austin DePottey - Michigan TechTony & Elda Dorfmueller Scholarship - Jose Saucedo - Inst. Tecnologico de SaltilloJohn Deere Scholarship - Justyna Baginska - Penn StateRichard Frazier Scholarship - Foster Webb - Trine UniversityLoper Award - Shawn Moody - Pittsburg StateModern Casting Scholarship - Shawn McKinney - Virginia TechChester V. Nass Memorial Scholarship - Melissa Wright - Michigan TechRobert W. Reesman Mem. Scholarship - Laura Kraus - Missouri Univ. of Science & Tech.MAGMA Scholarship-John Svoboda - Alicia Steele - Michigan TechGary Thoe Scholarship-ThyssenKrupp Waupaca - Nicholas Dixon - Western MichiganRay Witt Memorial Scholarship - John Pischak - Missouri Univ. of Science & Tech.Robert V. Wolf Mem. Scholarship - Jennifer DeHaven - Missouri Univ.of Science & Tech.

Special Scholarships

Keith D. Millis Scholarship - Brennon Holenda - Pittsburg StateKeith D. Millis Scholarship - Eric Nixon - Trine UniversityKeith D. Millis Scholarship - Coleman Housman - Univ. of Northern IowaKeith D. Millis Scholarship - Christopher Slinger - Wisconsin-PlattevilleRon Ruddle Scholarship - Andrew Oman - Western MichiganWilliam Allan Hunter Mem. Scholarship - Brett Hunter - Univ. of Alabama



Patricio Gil (DIS President), Brennon Holenda (Pittsburg State University) & Jim Wood (DIS Executive Director)

Patricio Gil, Coleman Housman (University of Northern Iowa) & Jim Wood

We would also like to acknowledge Eric Nixon of Trine University and Christopher Slinger ofWisconsin-Platteville who were not in attendance to receive their scholarships.

Jim WoodDIS Executive Director

View Ductile Iron Related Publications

Located in Strongsville, Ohio, USA15400 Pearl Road, Suite 234; Strongsville,Ohio 44136 Billing Address: 2802 Fisher Road, Columbus, Ohio 43204 Phone (440) 665-3686; Fax (440) 878-0070email:[email protected]


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FEATURES


Speaker Bios - AM Session

Speaker Bios - PM Session

Melt Yard and Deck Basics - Larry Helm

Iron Control in a Large Induction MeltFoundry - Brandon Reneau Optimizing Magnesium Recovery - BrianJohnson New Developments in Binders & Coatingsfor DI - Doug Trinowski Cast, Clean, and Make Money - GeneMuratore Blending Optimization in the DI Industry -Peter Moulder Observations for Management on IronFoundry Safety Statistics - Ted Schorn


DEPARTMENTS

News Briefs

Back Issues

DIS Home Page

October 25, Morning Session Speaker Bios

Gene Muratore - Session Chair

DOUG TRINOWSKI

DOUG IS A DEGREED CHEMIST AND BRINGS OVER 30 YEARS OF FOUNDRY AND PHENOLICRESIN TECHNICAL EXPERTISE. DOUG IS CURRENTLY THE VP OF TECHNOLOGY FOR HAINTERNATIONAL. IN THIS ROLE, DOUG LEADS ALL RESEARCH AND PRODUCT DEVELOPMENTFOR FOUNDRY RESINS, REFRACTORY AND LOST FOAM COATINGS AND AUXILIARYMATERIALS. HIS CAREER STARTED AT QC CHEMICALS FORMERLY THE QUAKER OATSCOMPANY IN 1976. HE THEN JOINED DELTA-HA IN 1989 AS A TECHNICAL SALESREPRESENTATIVE. DOUG IS ACTIVE IN THE AFS AND IS CURRENTLY CHAIR OF DIVISIONCOUNCIL. IN ADDITION, HE IS A PAST CHAIR AND DIRECTOR OF THE CAST METALS INSTITUTE. HE IS ALSO A TWO TERM PAST CHAIR OF THE DETROIT-WINDSOR AFS CHAPTER. DOUG HASBEEN HONORED TO RECEIVE AN AFS SERVICE CITATION AND AWARD OF SCIENTIFIC MERIT. HEALSO SERVES ON THE ADVISORY BOARD OF DIRECTORS FOR THE METAL CASTING CENTER,DEPARTMENT OF TECHNOLOGY AT THE UNIVERSITY OF NORTHERN IOWA IN CEDAR FALLS,IOWA. DOUG HAS JUST ACCEPTED THE POSITION OF GLOBAL DIRECTOR OF RESEARCH &DEVELOPMENT FOR HUTTENES-ALBERTUS BASED IN DUSSELDORF, GERMANY.

GUY-ROGER NAUROY

GUY IS CURRENTLY FERROPEMS FOUNDRY SALES MANAGER OUT OF FRANCE. HE ISRESPONSIBLE FOR THE SALES OF INOCULANTS, NODULARISERS, FOUNDRY CORED WIREWORLDWIDE FROM 2 FRENCH PLANTS AND ONE SOUTH AFRICAN ONE. GUY HAS BEENWORKING FOR FERROPEM FORMERLY PECHINEY ELECTROMETALLURGIE FOR THE PAST 30YEARS. HE WAS INITIALLY THE PRODUCTION ENGINEER IN 4 DIFFERENT FERROSILICON,INOCULANTS AND SILICON PLANTS. HE THEN BECAME THE MANAGER OF A SILICON PLANT,THEN IT MANAGER DURING THE MERGER WITH FERROATLANTICA. GUY HAS HELD HISCURRENTLY POSITION SINCE 2007.

TED SCHORN

TED HAS RESPONSIBILITY FOR QUALITY FOR THE NORTH AMERICAN OPERATIONS OF ENKEICORPORATION, THE WORLDS LARGEST PRODUCER OF CAST ALUMINUM ROAD WHEELS. HEHAS WORKED IN VARIOUS QUALITY AND MANUFACTURING POSITIONS FOR NEARLY 30 YEARS,THE LAST 23 WITH ENKEI. TED IS ACTIVE WITHIN THE TECHNICAL COMMITTEE STRUCTURE OFAFS, HAVING SERVED AS DIVISION COUNCIL, ENGINEERING DIVISION AND QUALITY SYSTEMS

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TECHNICAL COMMITTEE CHAIR. HE HAS EARNED NUMEROUS AWARDS FROM AFS INCLUDINGTHE AWARD OF SCIENTIFIC MERIT, TWO RAY WITT AWARDS AND WAS THE 2005 HOYTMEMORIAL LECTURER. TED CURRENTLY SERVES ON THE BOARD OF DIRECTORS OF AFS. HEHAS WRITTEN SCORES OF TECHNICAL PAPERS AND IS A FREQUENT CONFERENCE SPEAKER.

1ST AL ALAGARSAMY

AL IS WELL KNOWN AMONG THE DIS PARTICIPANTS. HE HAS BEEN INVOLVED WITH IRONFOUNDRIES FOR MORE THAN 40 YEARS AND HAS WORKED WITH THREE MAJOR FOUNDRYGROUPS IN RESEARCH AND DEVELOPMENT FUNCTIONS. PRESENTLY, HE CONTINUES TOWORK AS A CONSULTANT TO FOUNDRIES AND CASTING USERS ALIKE. HE HAS SERVED ASRESEARCH COMMITTEE CHAIRMAN AT AFS AND DIS. HE HAS DEVELOPED TRAININGMATERIALS FOR THE IRON FOUNDRIES IN AREAS OF METALLURGY, SAND CONTROL, CASTINGDEFECTS, ETC. HE IS WELL-RECOGNIZED IN THE DUCTILE IRON INDUSTRY AND RESEARCHINSTITUTIONS. HIS EDUCATIONAL BACKGROUND INCLUDES BACHELORS OF ENGINEERING INMECHANICAL ENGINEERING AND A MASTERS IN FOUNDRY SCIENCE AND ENGINEERING.

2ND JOHN MIRKA

THE THORS WEBSITE WILL BE DEMONSTRATED BY JOHN. JOHN HAS BEEN WITH THE THORSTEAM SINCE FEBRUARY 2012 SELLING TO OEMS AND SUPPLIERS. JOHN ALSO HAS AN ACTIVEROLE IN TRAINING THORS USERS.

BRIAN JOHNSON

BRIAN RECEIVED A BACHELORS OF SCIENCE IN METALLURGICAL ENGINEERING FROM THEUNIVERSITY OF WISCONSIN-MADISON IN 1998. HE WORKED FOR GREDE FOUNDRIES INREEDSBURG, WI WHERE HE WAS PLANT METALLURGIST FOR 4 YEARS, ELECTRIC MELTSUPERINTENDENT FOR 4 YEARS AND TECHNICAL SERVICES MANAGER FOR 4 YEARS. HE HASSPECIFIC EXPERIENCE WITH COVERED TUNDISH LADLES, PURE MAG CONVERTERS, ELECTRICMELT, CUPOLA MELT, PRESSURE POUR FURNACES, HORIZONTAL MOLDING AND VERTICALMOLDING. TWO YEARS AGO HE JOINED HICKMAN WILLIAMS AND COMPANY AS TECHNICALSUPPORT FOR THEIR CUSTOMERS AND SALES PEOPLE.






FEATURES







DEPARTMENTS

News Briefs

Back Issues

DIS Home Page

October 25, Afternoon Session

Speaker Bios

Kathy Hayrynen - Session Chair

EUGENE MURATORE

GENE GRADUATED FROM CASE WESTERN UNIVERSITY IN 1970 WITH A BACHELOR OFSCIENCE IN METALLURGY. GENE SPENT THE NEXT 20 YEARS AS AN OPERATINGMETALLURGIST FOR THREE FOUNDRIES IN THE PRODUCTION OF GRAY AND DUCTILEIRON CASTINGS. GENE HAS BEEN THE SENIOR FOUNDRY METALLURGIST FOR RIO TINTOIRON & TITANIUM SINCE APRIL OF 1991. AS SUCH, GENE IS RESPONSIBLE FORTECHNICAL SERVICE TO THE US, CANADA, MEXICO AND PARTS OF ASIA. GENE IS ACTIVEON 6 AFS TECHNICAL COMMITTEES, A BOARD MEMBER OF THE CHICAGO CHAPTER OFTHE AFS, AND A MEMBER OF THE AFS RESEARCH BOARD. IN ADDITION, GENE IS ALSOACTIVE WITHIN THE TECHNICAL STRUCTURE OF THE DIS AND 2 TERM PAST BOARDMEMBER.

ELI DAVID

ELI GRADUATED FROM THE ISRAEL INSTITUTE OF TECHNOLOGY WITH HIS BACHELORSDEGREE IN MATERIALS ENGINEERING AND KENT STATE UNIVERSITY WITH HIS MASTERSOF BUSINESS IN FINANCE. ELI STARTED HIS FOUNDRY CAREER AT THE QUALITYCASTINGS COMPANY IN ORVILLE, OHIO AS CHIEF METALLURGIST AND TECHNICALDIRECTOR, WHERE HE WAS EMPLOYED FOR SLIGHTLY OVER 10 YEARS BETWEEN 1979AND 1989. THIS POSITION PROVIDED EXTENSIVE EXPOSURE TO MANUFACTURING,METALLURGICAL AND QUALITY ASPECTS OF PRODUCTION OF GRAY, DUCTILE ANDMAGNESIUM CASTINGS. ELI IS CURRENTLY AND FOR THE LAST 8 YEARS HAS BEENEMPLOYED BY GLOBE METALLURGICAL INC. AS GENERAL MANAGER FOR FOUNDRYPRODUCTS. PRIOR TO THIS POSITION ELI WAS TECHNICAL MANAGER FOR GLOBEBETWEEN 1989 AND 2003. HE HAS MADE NUMEROUS PRESENTATIONS AT AFS AND DISMEETINGS ON VARIOUS METALLURGICAL AND OTHER CAST IRON FOUNDRY RELATEDTOPICS. ELI HOLDS A PATENT AS CO-INVENTOR OF THE FLEXIPOR PROCESS (AN INMOLDTREATMENT METHOD FOR THE PRODUCTION OF DUCTILE IRON)

BACK TO BASIC MELT SHOP PANEL

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LARRY HELM

LARRY GRADUATED FROM THE OHIO STATE UNIVERSITY WITH HIS BACHELOR OFSCIENCE IN METALLURGICAL ENGINEERING. HE IS ALSO A FEF SCHOLARSHIP HOLDER. HE THEN RECEIVED HIS MASTERS DEGREE IN INDUSTRIAL MANAGEMENT FROMLYNCHBURG COLLEGE. HE HAS WORKED IN A VARIETY OF POSITIONS FOR ELYRIAFOUNDRY, LYNCHBURG/INTERMET CORPORATION, BLACKHAWK FOUNDRY AND ISCURRENTLY QUALITY MANAGER WITH SENECA FOUNDRY. HOLDS CERTIFICATIONS OFCERTIFIED QUALITY ENGINEER AND CERTIFIED QUALITY AUDITOR FROM ASQ. HE IS APAST CHAIRMAN OF THE AFS CAST IRON DIVISION #5 AND A RECIPIENT OF THE AFSSERVICE CITATION. LARRY HAS BEEN INVOLVED IN THE FOUNDRY INDUSTRY FOR THELAST 41 YEARS.

KYLE ANDERSON

KYLE GRADUATED FROM MICHIGAN TECH IN 2011 WITH A BACHELOR OF SCIENCEDEGREE IN MATERIALS SCIENCE. HE IS CURRENTLY WORKING AS A METALLURGIST ATWAUPACA FOUNDRYS PLANT 4 IN MARINETTE, WI.

BRANDON RENEAU

BRANDON GRADUATED FROM THE UNIVERSITY OF MISSOURI ROLLA WITH ABACHELOR OF SCIENCE IN METALLURGICAL ENGINEERING. HE HAS WORKED FORINTERMET FOUNDRY IN DECATUR, IL FOR 4 YEARS, AND THEN INTERMET FOUNDRY INHAVANA FOR 4 YEARS AND CURRENTLY THE PLANT METALLURGIST AND MELTINGGROUP MANAGER AT CATERPILLAR MAPLETON FOUNDRY FOR THE LAST 8 YEARS. BRANDON IS A MEMBER OF THE 5R & 5P COMMITTEES AT THE AFS AND DIS RESEARCHCOMMITTEE VICE CHAIRMAN. HE HAS BEEN A PROACTIVE SUPPORTER OF AFS AND DISRESEARCH BY CASTING SAMPLES AT CAT.

DAN WEBB

DAN GRADUATED FROM AURORA UNIVERSITY WITH HIS BACHELORS DEGREE INORGANIZATIONAL BUSINESS MANAGEMENT THEN HIS ASSOCIATES DEGREE INAGRICULTURE BUSINESS MANAGEMENT FROM ILLINOIS CENTRAL COLLEGE AND ANASSOCIATES DEGREE IN APPLIED SCIENCES FROM ILLINOIS CENTRAL COLLEGE. DAN ISCURRENTLY THE ACCOUNT MANAGER AT PROGRESS RAIL WHICH IS A WHOLLY OWNEDSUBSIDIARY OF CATERPILLAR.

PETER MOULDER

PETER HAS AN UNDERGRADUATE DEGREE FROM THE UNIVERSITY OF NOTRE DAME. HE



ALSO OBTAINED HIS MASTERS DEGREE FROM THE AMERICAN UNIVERSITY INWASHINGTON, DC. PETER IS CURRENTLY IS AN ACCOUNT MANAGER WITHMANAGEMENT SCIENCE ASSOCIATES IN PITTSBURGH, PA. PETERS ACTIVITIES INCLUDEDEFINING THE APPLICATION OF TECHNOLOGY FOR THE RESOLUTION OF OPERATIONAL,MATERIAL MANAGEMENT, AND ENERGY ISSUES FOR METALS COMPANIES THAT ARE INTHE PRIMARY OR MELTING SECTION OF THE INDUSTRY. SPECIFIC AREAS OF EXPERTISEINCLUDE MATERIAL OPTIMIZATION, PROCESS AUTOMATION AND INFORMATIONTECHNOLOGY. HIS PRIME FOCUS NOW IS ASSISTING FOUNDRIES ACHIEVE BETTER ANDOPTIMAL USE OF RAW MATERIALS AND RAW MATERIAL PURCHASING. PETER HASBEEN A PARTICIPANT IN THIS INDUSTRY FOR THE LAST THIRTY YEARS. POSITIONS HAVEINCLUDED SOFTWARE ENGINEERING, SOFTWARE DEVELOPMENT MANAGEMENT,CONSULTING, AND SALES AND MARKETING.




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FEATURES







DEPARTMENTS

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Back Issues

DIS Home Page

Link to Presentation: Melt Yard and Deck Basics (Training Moments)

LARRY HELM

LARRY GRADUATED FROM THE OHIO STATE UNIVERSITY WITH HIS BACHELOR OFSCIENCE IN METALLURGICAL ENGINEERING. HE IS ALSO A FEF SCHOLARSHIP HOLDER.

HE THEN RECEIVED HIS MASTERS DEGREE IN INDUSTRIAL MANAGEMENT FROMLYNCHBURG COLLEGE. HE HAS WORKED IN A VARIETY OF POSITIONS FOR ELYRIA

FOUNDRY, LYNCHBURG/INTERMET CORPORATION, BLACKHAWK FOUNDRY AND ISCURRENTLY QUALITY MANAGER WITH SENECA FOUNDRY. LARRY HOLDS

CERTIFICATIONS OF CERTIFIED QUALITY ENGINEER AND CERTIFIED QUALITY AUDITORFROM ASQ. HE IS A PAST CHAIRMAN OF THE AFS CAST IRON DIVISION #5 AND A

RECIPIENT OF THE AFS SERVICE CITATION. LARRY HAS BEEN INVOLVED IN THEFOUNDRY INDUSTRY FOR THE LAST 41 YEARS.



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Melt Yard and Deck Basics (Training Moments)

Larry Helm

Seneca Foundry We Bring Iron to Life

ABSTRACT This article is a written version of a presentation made at the Ductile Iron Society Meeting held in Peoria, IL on October 24-26, 2012. It contains basically three components: 1st a little about who is Seneca Foundry, 2nd some information about melting and alloying practices employed at Seneca; and 3rd some general observations gathered over the years on melting, alloying, and general foundry topics. WHO IS SENECA FOUNDRY We are a family owned foundry located in North Central Iowa; that can trace our heritage as a company back over 100 years. Metals poured include: Gray Iron grades G30, G35, and G40; Ductile Iron grades D60, D65, D80, D100, and D120; along with Austempered and High Silicon-Moly Ductile Irons. Molding entails: Green Sand a Hunter 10 to a turntable and a Hunter20 to pallet lines, weights 1-90#; No-Bake weights up to 250#; and Lost Foam weights up to 100#. Core making consists of Shell, Cold Box, and No-Bake. Heat treating in house is annealing and stress relieve, other is performed by outside sources. Melting is by 2-2 ton medium frequency furnaces. Also included is Top Notch Tooling, a full service pattern shop; and Gold Chip Machining, a casting machine shop.

IRON YARD Our iron yard is very simple, one grade of steel, from one source (a back-up source is available).Manganese content is a compromise for use in both Gray and Ductile iron. Many foundries are not able to accomplish this and as a result will have piles of several grades in their yards. For us it works well, and allows us to minimize our need for inventories and storage area. In pig iron again only one grade is used (also from only one supplier), and is used only in Ductile Iron to control Mn and other elements levels in our base iron. Our returns are stored in meal tubs by iron type. Each gating system and riser is marked with the corresponding iron grade ex: G30, D80, etc. and after blasting is placed into the metal tubs. Unlike in cupola melting returns segregation for S control is very important in electric melting, so we work hard in keeping materials properly separated. Which brings us to our first Universal Law.

MURPHYS LAW OF IRON YARDS

Beware, keep everything well marked and separated on the yard;

especially all grades of returns!

Nothing is worse than going looking for that special material that was put out onto the yard the other day, and finding it gone; mixed into who knows whatever pile or charges. As mentioned before all of our returns are blasted and then handled in tubs in the yard. We work to keep sand, dirt, trash, non-ferrous material, and junk out of the iron yard. This leads to our next law.

THE 1st LAW of ELECTRIC FURNACES

Metal is easier to melt than Slag.

Studies have been done showing that is takes several times the number of kilowatts of power to melt 100# of slag as 100# of metal, thus anything that can be done to minimize non-metallics in our melt yards, and thus our charges; improves the efficiency and cost effectiveness of our electric melting operations. Cupolas are a different animal; there more dirt/sand can be tolerated due to the slagging practice that is established in order to flux the surface of the pieces of coke for maximum carbon and heat transfer. But even in cupolas if too much in the way of this dirt and sand is added (especially going into mud in inclement weather) you can pay a real penalty in chemistry and temperature control, along with excess flux and coke usage. Bottom line, a cleaner charge is a better charge. MELTING OPERATION Our furnace linings are Silica with 1.0% Boron Oxide, thus on sintering in a lining with Ductile Iron we will experience the B ferritizing effect on pearlitic grades. We try as much as possible to sinter in on Gray Iron. As a bonus the higher Si content in the sinter also seems to start the lining out better, with less overall wear and patching over its life. We will take a lining out after 35 to 45 heats, we tend to be conservative on this, but we also have outstanding coil life. If we must sinter in on Ductile Iron, we definitely stay away from pouring D100 right after the sinter; and even D80 if possible. If we have to go D80 we will over alloy with Mn for a period of time (typically for 2 hours), to counteract the B effect. In our charge make-up all materials are weighed against a designated recipe, and are dried out (not preheated) before charging. The importance of precise material weights cannot be overstated. This gives us another law.

THE 2nd LAW of ELECTRIC FURNACES

What you put in, is what you get out!

Again cupolas are different. There in charge make-up you are looking at losses in certain elements, such as Mn, Si, etc. This effect, along with the fact that various materials melt at different levels in the stack, gives you a sine wave of chemistries. With a cupola you are always looking at the center of the sine wave as your desired chemistry. But in electric melting these losses dont occur. What you see is what you get. To me making charge make-up that much more important in electric melting. We use a heel melting practice, thus the drying of the charges mentioned earlier. Dont want wet metallics being submerged in the bath. Molten iron and water dont mix well. Our initial charge into the furnace is 3800# and we normally tap out 550# ladles. Thus we are only changing 1/7 of the furnace on each tap/charge. This allows us pretty consistent chemistry control. We will pour multiple metal grades in a day, utilizing change-over charges (one per furnace) to go from Ductile to Gray, or from Hi-Sil-Moly to Gray. This brings up the cast iron version of pour acid into water.

CAST IRON LAW of MIXING Ductile can go into Gray, but not the reverse!

Ductile returns can mix into Gray iron allowing for extra alloys to be used. The reverse raises the S content in the Ductile, undesirable. Ductile carbon raisers again OK, you will have to add some S. The reverse is a disaster, just ask someone who did it! Even in ferrosilicons it is true. What would happen if a Ti ferrosilicon, good in Gray Iron for certain conditions; got accidently added to some Ductile? As a result we always refer to the Law of Mixing. ALLOYING For furnace alloys we use two carbon raisers, one for Ductile and one for Gray; S content obviously being the difference. One common SiC, iron pyrite to flavor the Gray Iron, a low alloy 75% FeSi for silicon units as needed, Ferro Mn and Cu and Ferro Moly for trimming. Our Ductile is produced using a tundish treatment ladle, our own design; using a Balanced (1%) RE, 5% MgFeSi. The final inoculant for both metals is a Ca Bearing 75% FeSi. Ferro Mn, Cu, and Ferro Moly are used for ladle additions for various iron grades. Some Ti Bearing 50% FeSi is used for some special Gray Iron jobs. It is kept basically under lock and key. Which brings up the:

LAW of FERROSILICONS

All Ferrosilicons are not created equal!

How often have we heard in our shops But they looked the Same! In my career ferrosilicons have caused more probably issues than any other alloys, other than maybe Sn; or possibly FeCr in Ductile Iron. Our Ferrosilicons contain various levels of combinations of Al, Ca, Sr, Z, Ba, Ti, and who knows what else! Trying to explain to someone on the floor why some are meant to work better than others for certain applications, has always been a challenge. While talking about ferrosilicons two other items come to mind. Overall in our industry we have tended to use inoculants of too large of a size for a given application. For instance the sizing which would be good for a 5000# transfer ladle; is not what you would want to use in a 500# pour off ladle. Studies have shown that the smaller the amount of iron, the smaller the sizing should be on the inoculant. Also the uniformity of sizing, controlling a consistent % of fines is important. Our final inoculation is done upon the transfer of iron from the transfer/treatment ladle into the pour off ladle. On some certain jobs we add an additional inoculant into the mold. You can add an inoculant in the transfer ladle, in the pour off ladle, into the iron stream, into the mold; or into multiple locations. Any of which can be effective processes. CHEMISTRIES You will naturally end up choosing C and Si ranges that suit the type of castings which you pour. At the same time you will control residual element levels, and levels of Pearlite formers and stabilizers for the grades of metal which you pour. But eventually you will bump into:

HELMS LAW of CHEMISTRIES

There will always be one (or more) jobs that will not run in your established ranges. Accept it, and adjust as needed.

Or, get rid of the job(s)!

Over the years I have been able to keep many gating/rigging people very busy in trying to solve scrap issues that we eventually only solved by adjusting the chemistries, typically C and Si. If you cannot easily do these necessary adjustments on an individual job basis, then help out your head and tell sales to remove the brick wall. At Seneca we re-gated one Gray Iron job multiple times in order to prove what Taguchi experiments had showed; that only a higher carbon would solve the issue. Result back to the original gating, and scheduling of pour off to allow the higher carbons. This can also happen with certain parts in especially heavier (or thinner) section sizes, where sometimes creative alloying is required.

TESTING/SAMPLING We test the base iron always before starting to pour from a furnace, both thermal analysis and spectrometer samples. Any adjustments are made before starting of pouring. After we start pouring additional base furnace samples are poured every 4 ladles/charges. Final chemistries are poured with any test bars, with additional finals throughout the day on Gray Iron; and a final on every ladle of Ductile. We wont burn all of them, but we pour them to have available in case we see any possible issues. We use chills sometimes on Gray Iron when looking for data, and pour micros on all ladles of Ductile. We always burn all specto samples 3 times. Good testing is important to keep from falling into:

MURPHYS LAW of CHANGES

Never make a major process change on data from only one test!

Ever have someone make an alloy % change to the MgFeSi after making only one burn on a sample, only to find that the single burn was on a slag stringer? Or make big C and/or Si addition changes on what turned out to be a faulty T/A cup reading? Enough said. Refer to the above law when preparing to make changes to the operation. Besides routine testing; look at testing the metal under any/all conditions. This would include for instance out of a furnace that has sat for a while, at start-up, the first ladle of the day; and at pour-off, the last ladle. It may tell you some interesting information about the metal going into your castings. You may find yourself at the:

3rd LAW OF ELECTRIC FURNACES

Unlike professional wrestling, Monday Morning Iron is Real!

It can, and will exist, in any style of electric furnace: coreless melters, channel holders, or pressure pour units. Monday Morning Iron is basically metal which has suffered a loss (or destruction) of nucleation. It can happen faster than you think, especially in medium frequency melters. We can see it happening especially on holding the furnaces overnight; and on furnace pour-off on Gray Iron. We have worked on the issue by adjusting charge materials/alloys to increase nucleation, and by paying closer attention to furnace metal temperatures. Now the:

4th LAW of ELECTRIC FURNACES

DO NOT superheat the metal any more than necessary!

Increased and/or unnecessary superheating will only harm the metal, nothing good comes from it. It can contribute to more slag formation, it causes destruction of nucleation, it can cause carbon boil; it is bad for the furnace linings. And at the same time it raises your costs for the additional electricity. Just dont put any more power into the metal than you need for good operations and the types of castings you are pouring. OTHER FOUNDRY GOOD PRACTICES This discussion on metal superheating is a great lead-in to a good rule of thumb adhered to by my old foundry professor.

METAL CHARACTERISTICS

Pour any given part: As cold as you can. As fast as you can;

And, as quietly as you can! Dr. D.C. Williams, OSU

This statement doesnt mean to pour all iron at a temperature that is barely liquid. It means simply dont pour any hotter than is necessary for that given part. It doesnt mean to fill the mold so fast that it blows out at the parting line. It does mean not to dribble the iron in so slowly that bad things start to happen to the mold and the metal. And it does mean to try to design the gating to minimize iron velocity and turbulence during filing. All of these characteristics will help in producing good castings. For more on pouting times refer to this old rule of thumb for horizontally parted molds.

POURING TIMES

A reasonable aim point in seconds; is the Square Root of the Pour Weight of the Mold.

As an example this would mean a 10# mold in about 3 seconds, a 100# mold in 10 seconds, a 1000# mold in 31 seconds, and a 100,000# mold in about 5 minutes. Is this a hard and fast rule, no it is an approximation. Some people would say we cant pour that fast; others would say we would never pour that slow. But I would bet that if you go out and time a number of jobs you will be slower than these numbers/times. Again the point here is the same as Dr. Williams. The faster you can fill an individual part, the better off you will be. As examples obviously vertical machines are much faster than these times, with only say 5-6 seconds of time to fill a mold. And in Lost Foam you can see downsprues with designed fill rates as high as 30-50# per second. TRAINING MOMENTS At the beginning of this article under the title, I had in parenthesis the term Training Moments. At Seneca each morning the Plant Manger has a meeting where we review production results against plan, scrap rates, safety subjects, and also a segment we call Training Moments. In just a few minutes we will go over topics such as the ones in this article on melting. And others such as sand, molding, cores, heat treat, clays, etc, basically just about any topic concerning foundry operations. The idea is to present in bite sized chunks, little bits of knowledge/wisdom concerning foundries. We have been doing this for over a year and have had good feedback from employees as they better learn how and what they do affects the castings they are producing. To finish I will leave one more nugget of wisdom from a supervisor I once worked with who was tired of dealing with runouts on a particular part number. He stated:

PLOGS LAW

You generally get a much better looking casting if you keep all of the metal in the mold!

Thank you.


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Link to Presentation: Iron Control in a Large Induction Melt Foundry

BRANDON RENEAU

BRANDON GRADUATED FROM THE UNIVERSITY OF MISSOURI ROLLA WITH ABACHELOR OF SCIENCE IN METALLURGICAL ENGINEERING. HE HAS WORKED FOR

INTERMET FOUNDRY IN DECATUR, IL FOR 4 YEARS AND THEN INTERMET FOUNDRY INHAVANA FOR 4 YEARS AND CURRENTLY IS THE PLANT METALLURGIST AND MELTING

GROUP MANAGER AT CATERPILLAR MAPLETON FOUNDRY FOR THE LAST 8 YEARS. BRANDON IS A MEMBER OF THE 5R & 5P COMMITTEES AT THE AFS AND DIS

RESEARCH COMMITTEE VICE CHAIRMAN. HE HAS BEEN A PROACTIVE SUPPORTER OFAFS AND DIS RESEARCH BY CASTING SAMPLES AT CAT.

THE DIS WELCOMES BRANDON WHO IS HERE TO TALK ABOUT BASE IRON CONTROLIN A LARGE INDUCTION MELT FOUNDRY



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B k B i BBack to Basics Base Iron Control in a LargeIron Control in a Large

Induction Melt Foundry)y)Brandon Reneaua do e eau

Caterpillar

DIS DIS T&O T&O Meeting, Meeting, October 24 October 24 --26, 201226, 2012Peoria, IL Peoria, IL

Caterpillar, MapletonCaterpillar, Mapleton Foundry

60 000 hi t 60,000 ship tons per year Gray and ductile iron castings for

Engine components Multiple molding methodsp g 25 lbs to 20,000 lbs castings

DIS T&O Meeting, October 24 DIS T&O Meeting, October 24 --26, 201226, 2012Peoria, IL Peoria, IL

Incoming Raw Materials Pig Iron Sorel Steel scrap

3 ft plate 2 ft plate

Low Mn busheling Low Mn busheling Mid Mn busheling Low Mn punchings (cover)

Gray and Ductile Returns Borings


Incoming Raw Materials Pig Iron Supplier Certs and quarterly check


Incoming Raw Materials

Steel scrap Met Lab checks 1 load per week perMet Lab checks 1 load per week per

supplier by spectrometer


Incoming Raw Materials

Borings Met Lab checks 1 load per 2 weeks perMet Lab checks 1 load per 2 weeks per

supplier by xray diffraction


Incoming Alloy Materials

Graphite Coke (gray iron); check quarterlyCoke (gray iron); check quarterly Low Sulfur crystalline (ductile iron);

check each shipmentp SiC check quarterly FeSi (furnace) check quarterly FeSi (furnace) check quarterly


Incoming Alloy Materials FeMn FeCr FeMo Cu

All checked each shipment

Pyrite FeSi (inoculants)

M F Si ( i ) MgFeSi (wire) MgFeSi (ladle)


Melting Equipment Melting Furnacesg

(2) 60 ton line frequency induction (1) 30 ton med. Freq. Induction( ) q (1) 12 ton Arc


Melting Equipment Holding Furnaces

(7) 55 ton Holders Optimum chemistry and temperature Minimize melting downtime Minimize melting downtime

Odermath Treatment room Wire feed Treat 30,000 lbs

Projelta Treatment room Wire feed Treat 21,500 lbs


Controls Temperature / Chemistry

Fill charge car order is important Empty charge car into furnace Run counts into furnace to melt to bath Run counts into furnace to melt to bath Take temperature via probe (Heat to 2600 F) Take chemistry via chill mold (after 2600F) Spectrometer and Leco C/S Run final counts into furnace

Deslag furnace Deslag furnace Take temperature Tap iron to transfer ladle


p

Controls Chemistry SpecificationsChemistry Specifications

CAT 1E Engineering Specifications Set absolute minimum or maximum Set absolute minimum or maximum

Foundry target Specifications Set targets to achieve specific properties onSet targets to achieve specific properties on

each casting Tighter than Engineering Specifications


Controls Things we dont do g

Chill wedges from base iron Thermal Analysis

Rely on Chemistry

Good practice Good practice Load charge cars properly Follow consistent melt process (time and temp)

D t h ld i i lt Dont hold iron in melters Inoculate well


For additional information, l t tplease contact:

Brandon Reneau Brandon Reneau Caterpillar, Inc Mapleton Foundry (309)-633-8406(309) 633 8406 [email protected]



file:///C|/WEBSHARE/062013/magazine/2012_3/johnson.htm[7/3/2013 12:13:11 PM]


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Link to Presentation: Optimizing Magnesium Recovery

BRIAN JOHNSON

BRIAN RECEIVED A BACHELORS OF SCIENCE IN METALLURGICAL ENGINEERING FROMTHE UNIVERSITY OF WISCONCIN-MADISON IN 1998. HE WORKED FOR GREDE

FOUNDRIES IN REEDSBURG, WI WHERE HE WAS PLANT METALLURGIST FOR 4 YEARS,ELECTRIC MELT SUPERINTENDENT FOR 4 YEARS AND TECHNICAL SERVICES MANAGERFOR 4 YEARS. HE HAS SPECIFIC EXPERIENCE WITH COVERED TUNDISH LADLES, PURE

MAG CONVERTERS, ELECTRIC MELT, CUPOLA MELT, PRESSURE POUR FURNACES,HORIZONTAL MOLDING AND VERTICLE MOLDING. TWO YEARS AGO HE JOINED

HICKMAN WILLIAMS AND COMPANY AS TECHNICAL SUPPORT FOR THEIRCUSTOMERS AND SALES PEOPLE.

THE DIS WELCOMES BRIAN WHO IS HERE TO TALK ABOUT OPTIMIZING MAGNESIUMRECOVERY THIS TALK WILL RELY ON BRIANS EXPERIENCES IN THE FOUNDRY AND

ON A LITERATURE REVIEW OF WORD DONE AS RELATES TO MAGNESIUM RECOVERY.



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O ti i i M iOptimizing Magnesium RecoveryRecovery

Brian Johnson Hickman, Williams & Companyp y

OverviewOverview Introduction.

Cover Materials Cover Materials. Ladle Design and Maintenance.

Tundish Tundish. Timing and Iron Control.

Temperature.p Sulfur Control.

Alloy Decisions. Additi (C Al B d RE) Additions (Ca, Al, Ba, and RE).

Magnesium Content. Sizing.Sizing.

IntroductionIntroduction Optimizing Magnesium Recovery.

There are several ways to treat ductile iron and the scope of this presentation will focus on MgFeSi alloys.MgFeSi alloys.

The converter process and cored wire process are beyond the scope of this presentation.

MgFeSi alloys have low vapor pressures which makes the addition of these alloys challenging.y g g

They react violently which makes recovery of the Magnesium difficult.

Introduction Due to the low vapor pressure there is one

over riding theme in increasing Magnesium Recovery. Delay the reaction as long as possible to

maximize the amount of magnesium capturedmaximize the amount of magnesium captured by the iron.

Cover Materials Purpose is to delay the MgFeSi reaction as

long as possible allowing for more iron capture of magnesium.

Traditional materials. Steel should be clean and dry.Steel should be clean and dry. Ductile iron spill or turnings clean and dry. Alloys such as copper on pearlitic grades . FeSi dependent upon base silicon levels. Cast shape made from left over iron in ladle.

Cover Material (contd) Alternatives to traditional cover materials.

Filling the ladle faster (50-100 #/second). Get as much iron into the ladle as possible

increasing the recovery of magnesiumincreasing the recovery of magnesium.

This may require furnace / ladle modificationsThis may require furnace / ladle modifications to achieve and being able to do this safely is paramount.

Faster fill times may allow for lower tap temperaturestemperatures.

Alloy Addition vs. Ladle Design y g

Open Ladle = 1.8% Alloy Pocket = 1 6%Alloy Pocket 1.6% Sandwich = 1.5%

T di h 1 4% Tundish = 1.4%

Alloy Addition vs. Process Changes

Shows progression in a chart from previous slide[6]

Shows progression in a chart from previous slide.

Covered Tundish Ladle Design Tundish Ladle.

Iron tap hole diameter needs to control iron flow upon tapping (does not allow air to(does not allow air to be pulled into ladle).

Cover helps in pimproving recoveries.

Pocket maintenance i iti l ll fitis critical so alloy fits into pocket from 1sttreatment to last. t eat e t to ast

Tundish Ladle DesignTundish Ladle Design Ladle pocket modification p

to create a taller / deeper pocket.

O ti i i b Optimizes recoveries by delaying / prolonging the MgFeSi reaction. Versus

Cover material may be reduced or even eliminated.

Accuracy of alloy delivery to pocket is even more critical.critical.

Tundish Ladle Maintenance Tap hole and pocket maintenance are critical

to maintaining optimal magnesium recovery.to maintaining optimal magnesium recovery. Tap hole gauges can be used to ensure

consistent diameter / shape for ladles after reline d d iand during use.

Requiring some frequency of pocket maintenance during ladle use can help maintain recoveriesduring ladle use can help maintain recoveries through out the life of ladle.

Drain ladles. When not in use hang ladles over a slag bed.

Allowing for as much iron and slag to naturally fall out of ladle as possible makes operators job easier and helpsladle as possible makes operators job easier and helps to extend the life of the pocket.

Timing and Iron Controlg Add alloy just before tapping iron.

The heat in the ladle can initiate ignition ofThe heat in the ladle can initiate ignition of MgFeSi alloy.

Tap temperature will directly impact the t f M F Si d damount of MgFeSi needed.

Increasing the speed of tapping or improving the insulation on ladle will allow for lowering tap g ptemperature which directly reduces the amount of alloy needed.

Consistent Base Sulfur control is also Consistent Base Sulfur control is also necessary for consistent recovery. Operators tend to error on the safe side, so it is

always easier to increase Mg than to decrease Mg.

Timing and Iron Control g Avoid torching as long as possible.

The torching causes a sulfur reversion which will require additional MgFeSi upon start uprequire additional MgFeSi upon start-up.

Torch heat is only surface heat and does not penetrate the lining, try only using for known extended down times.

Ladle washing with iron is much more effective for heating g gup a ladle but is often not feasible in many operations.

Be aware of where chemistry results are coming from.g Some foundries are testing chemistry after treatment.

Information used to adjust alloy usage only not for ensuring quality.

S f d i t ti h i t f l t i Some foundries are testing chemistry from last iron poured.

This information is used for usage control and quality assurance.

Alloy Design Discussion The Magnesium Reaction.

Mg + O = MgO Mg + O = MgO Mg + S = MgS

Magnesium will deoxidize and desulfurize and this action contributes to the Magnesium Requirement.

Mg Recovery = .76 (Sbase Sfinal) + Mgresidual x 100 Mginitial [1]

Alloy Design DiscussionAlloy Design Discussion It can be assumed that less available

oxygen and sulfur would allow foroxygen and sulfur would allow for better utilization of the Magnesium.With thi i f ti l k t With this information we can look to the Ellingham Diagram for ideas to

dif th t t t llmodify the treatment alloy or treatment process to achieve the d i d ff t f i idesired effect of improving Magnesium recovery.

Close to Preferential

4/3Al+O2 = 2/3Al2O3 2Ba+O2 = 2BaO2 2Ca+S2 = 2CaS

2M +O

Preferential R ti

2Mg+O2 = 2MgO

Reactions 2Ca+O2 = 2CaO 2Ce+S2 = 2CeS

[2]

Alloy Design DiscussionAlloy Design Discussion Near treatment ranges of 1800 K or 2770 F

th t th t ff ti d f Swe see that the most effective reducers of S and O are Cerium and Calcium.

We also see that Barium and Aluminum are beginning to become a factor in the reactions.reactions.

Lets keep in mind these are equilibrium ti d i di ti t f threactions and give us direction to further

investigate.

Alloy Design DiscussionCalcium-The observation from the Ellingham diagram is confirmed. Notice the range of sulfurs over which tests were run.tests were run.

[3]

Alloy Design Discussion Calcium Depending on sulfur starting point there is Calcium Depending on sulfur starting point there is

an optimum level of calcium in the alloys to have.

[3][3]

Alloy Design Discussion Cerium.

The action of Cerium (RE) is well documented in the literature.

Impact on deleterious elements.

This benefit is also shown in the EllinghamThis benefit is also shown in the Ellingham diagram with its reaction with Sulfur.

Producing Spheroidal Graphite Cast Iron by Suspension of Gas Bubbles in Melts AFS T ti l 83 1975 [5]Transactions, vol 83, 1975. [5]

Produced Ductile iron with 1% Cerium addition.

Th i l h f d f d i The economics recently have forced foundries to try to minimize this in their alloys.

Alloy Design Discussion Aluminum.

From the Ellingham diagram we see Al will react more dil ith O th M t l t d t treadily with O than Mg at elevated temperatures.

Aluminum is recognized for contributing to pinhole formation in iron castings..Aluminum will also add to the slag formation resulting in poor furnaceto the slag formation, resulting in poor furnace performance, more ladle and holder maintenance and increased risk for slag inclusions in castings At higher aluminum levels, FeSi-based alloys will tend to i l bilit b t th i d l f tiimprove solubility, but the increased slag formation and tendency for pinholes should call for caution. [4]

The greatest benefits were achieved when Al was introduced in to the iron via the inoculant late in theintroduced in to the iron via the inoculant late in the process or as a pre-conditioner of the base iron early in the process. Al added via the MgFeSi provided the minimum benefit. [4]

Alloy Design Discussion Barium.

One of the objectives of a O e o t e object es o apreconditioning treatment with high level of barium containing ferrosilicon is to manage or control the oxygen and sulfur activity, promoting the formation of oxysulfphides of barium (BaO andof oxysulfphides of barium (BaO and BaS). The aim is to promote a consistent magnesium recovery and aconsistent magnesium recovery and a reduction of the addition of magnesium alloy. [1]

Alloy Design Discussion Barium 9% Ba FeSi as cover for 5% MgFeSi iron Barium 9% Ba FeSi as cover for 5% MgFeSi, iron

taken to a pressure pour furnace.

[1]

Alloy Design Discussion Barium 9% Ba FeSi as cover for 8% MgFeSi, iron

transferred into pouring ladles and poured into molds. Results from molds.molds. Results from molds.

c

o

v

e

r

y

P

e

r

c

e

n

t

R

e

c

P

[1]

Alloy Discussion Barium 9% Ba FeSi added as a pre-conditioner prior to pure a u 9% a eS added as a p e co d t o e p o to pu e

magnesium treatment. Amount of pure magnesium as required to achieve a specific final Magnesium residual from pressure pour furnace.

[1]

Alloy Design DiscussionM i C t t Magnesium Content. 3-4% Mg.

Less violence in the reaction.Less violence in the reaction. Less emissions (lower smoke). Improved recovery due to quieter reaction (65-80%) As a ratio to Mg the Ca Al and RE are higherAs a ratio to Mg, the Ca, Al and RE are higher.

5-6% Mg. Less alloy use = less slag generation.

M l til ti ith l i (50% More volatile reaction with lower recoveries (50%-60%)

Alloy Sizing. A finer and wider sizing will give a denser

alloy bulk packing in the sandwich and by that the reactivity will be reduced. [6]y [ ]

Alloy Summary Calcium (Ca) Calcium (Ca).

Ca helps to create a quieter reaction and has been shown to improve Magnesium recovery.

Rare Earths (RE).Rare Earths (RE). Will help in improving Magnesium recovery but recent

economics have made this a less desirable option. Aluminum (Al).

May provide desired reduction in oxygen activity as a pre-conditioner but may enhance sensitivity to H2 pinholes.

Barium (Ba).Has been sho n to positi el impro e Magnesi m reco er Has been shown to positively improve Magnesium recovery as a pre-conditioner or cover alloy.

Local environmental requirements should be understood. Magnesium (Mg).Magnesium (Mg).

Lower content improves recovery, this becomes a function of economics.

Lower content alloys tend to have higher levels other h l f l ll ti t M t thelpful alloys as a ratio to Mg content.

Summary The reaction between the MgFeSi alloy

and the iron must be delayed as long as possiblepossible. Cover materials. Tap speeds.

Ladle maintenance Ladle maintenance. Alloy pocket design.

Factors affecting the amount of alloy d d t b t ll d llneeded must be controlled as well.

Base sulfur control/consistency. Iron tap temperature.p p Alloy design considerations. Alloy addition and testing timing.

References [1] Preconditioning Effect of Barium in Ductile Iron Production,

Proceedings of the AFS Cast Iron Conference, September 29-30, 2005, J.Fourmann

[2]The Ellingham Diagram Web Tool, www.engrsjsu.edu/ellingham/ellingham_tool_p1/php

[3] Thermochemistry of Nodulization and Inoculation of Irons, P di f th AFS C t I I l ti C f S t 29 30Proceedings of the AFS Cast Iron Inoculation Confernece, Sept 29-30 2005, S. Lekakh, D. Robertson, C. Loper Jr.

[4] Aluminum Benefits in Ductile Iron Production, Proceedings of the Keith Millis Symposium on Ductile Cast Iron October 20 22 2008 I Riposan MMillis Symposium on Ductile Cast Iron, October 20-22, 2008, I.Riposan, M. Chisamera, S.Stan, P. Tobac, G. Grasmo, D. White, C. Ecob, C. Hartung

[5] Producing Spheroidal Graphite Cast Iron by Suspension of Gas Bubbles in Melts AFS Transactions vol 83 1975 S YamamotoBubbles in Melts AFS Transactions, vol. 83, 1975 S.Yamamoto, Y.Kawano, Y.Murakami, B.Chang and R.Ozaki

[6] Ductile Iron Production A comparison of Alternative Treatment Methods, T.Skaland,

For additional information, l t tplease contact:

Brian Johnson Technical Sales Brian Johnson Technical Sales 2015 Spring Road

P.O. Box 5225Oak Brook, IL 60522

(630) 418-3209 - Cell(630) 574 2376 Fax (630) 574-2376 - Fax

[email protected] www.hicwilco.com



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Link to Presentation: "New Developments in Binders & Coatings for DI"

DOUG TRINOWSKI

DOUG IS A DEGREED CHEMIST AND BRINGS OVER 30 YEARS OF FOUNDRY ANDPHENOLIC RESIN TECHNICAL EXPERTISE. DOUG IS CURRENTLY THE VP OF

TECHNOLOGY FOR HA INTERNATIONAL. IN THIS ROLE, DOUG LEADS ALL RESEARCHAND PRODUCT DEVELOPMENT FOR FOUNDRY RESINS, REFRACTORY AND LOST FOAM

COATINGS AND AUXILIARY MATERIALS. HIS CAREER STARTED AT QC CHEMICALSFORMERLY THE QUAKER OATS COMPANY IN 1976. HE THEN JOINED DELTA-HA IN

1989 AS A TECHNICAL SALES REPRESENTATIVE. DOUG IS ACTIVE IN THE AFS AND ISCURRENTLY CHAIR OF DIVISION COUNCIL. IN ADDITION, HE IS A PAST CHAIR AND

DIRECTOR OF THE CAST METALS INSTITUTE. HE IS ALSO A TWO TERM PAST CHAIR OFTHE DETROIT-WINDSOR AFS CHAPTER. DOUG HAS BEEN HONORED TO RECEIVE ANAFS SERVICE CITATION AND AWARD OF SCIENTIFIC MERIT. HE ALSO SERVES ON THEADVISORY BOARD OF DIRECTORS FOR THE METAL CASTING CENTER, DEPARTMENTOF TECHNOLOGY AT THE UNIVERSITY OF NORTHERN IOWA IN CEDAR FALLS, IOWA.

DOUG HAS JUST ACCEPTED THE POSITION OF GLOBAL DIRECTOR OF RESEARCH &DEVELOPMENT FOR HUTTENES-ALBERTUS BASED IN DUSSELDORF, GERMANY.

THE DIS WELCOMES DOUG WHO IS HERE TO TALK ABOUT NEW DEVELOPMENTS INBINDERS & COATINGS FOR DUCTILE IRON



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Novel Urethane No-Bake BinderNovel Urethane No-Bake Binder For Reduced Smoke and Odor

Doug TrinowskiHA International LLC


Evolutionary ImprovementsEvolutionary Improvements


Agenda Making the Case

g

Emissions Data Phenolic Urethane Background TEOS-based Urethane No-Bake Binders

Background

Data

EH&S

Customer Experience

Frequently Asked Questions

S


Summary

The Reality Foundries are subject to environmental pressures

from different perspecti es

y

from different perspectives. MACT Standard Only largest Involved Area Source Legislation A Few More InvolvedArea Source Legislation A Few More Involved Permit Issues All Involved Nuisance Odors All Involved Work Exposures All Involved

B tt Li E f d i i t t d i thBottom Line: Every foundry is interested in the environmental impact of their operation


Making The CaseMaking The Case

How do we improve the environmental impact pof Phenolic Urethane No-Bake binders? Permit Issues Permit Issues Nuisance odors

AFS/CERP Published EmissionAFS/CERP Published Emission Factors

E i i F

CERP No-Bake Baseline Pouring, Cooling & Shakeout Tests In Iron

Target a UNB system with 30% reduction in

ProcessEmission Factors

(lbs HAP/ton) CERP Test Reference

PUNB (high solvent) 2.00 1256-1211 DG

HAPs and VOCs at Pouring, Cooling & Shakeout

PUNB (low solvent) 1.521 1410-113 FPShakeout

THE PHENOLIC URETHANE PROCESSPROCESSCHEMISTRY

Phenolic Resin + Isocyanate Resin

CHEMISTRY

(Part 1) (Part 2)

Amine Hardener

Urethane Polymer

What is in a Phenolic Urethane R i ?Resin?

Part 1 Resin Phenolic Base Resin 40-60%

Solvents & Plasticizers 40-50% Solvents & Plasticizers 40-50% Additives 5-10%

Part 2 Resin Isocyanate 70-80% Solvents 20-30%Solvents 20 30% Additives 5-10%

P t 3 C t l tDIS T&O Meeting, October 24 DIS T&O Meeting, October 24 --26, 201226, 2012

Peoria, IL Peoria, IL

Part 3 Catalyst

Phenolic Urethane Hi t i l P Li it tiHistorical Process Limitations

Environmental Conventional PUNB systems are solvent-based

Aromatic hydrocarbons Source of VOCs & HAPs

Use of aromatic hydrocarbons as solvent has led to high VOC content

20 to 30% in the systemy

Product Development Strategy: Reduce emissions and odor profile of Phenolic Urethanes by

replacing traditional petrochemical solventsreplacing traditional petrochemical solvents. No compromise to productivity or performance


TEOS SolventTEOS Solvent The Latest Generation

Solvent for Urethane BindersBinders

TEOS (Tetraethyl Ortho Silicate)

Silicon-based solvent bi i i dcombining organic and

inorganic characteristics Primary environmental

advantage over Aromatic Hydrocarbon or BiodieselHydrocarbon or Biodiesel Solvents is reduction of smoke & odor

Potential to reduce gas defectsdefects

Reduces odors during pouring, cooling, shake out

Other performance advantages seenadvantages seen

TEOS Solvent Application In North America, TEOS has recently been

TEOS Solvent Application

introduced in no-bake applications Already in widespread use in Europe for nearly

ten (10) years 10-15% of all UCB systems sold in Germany

Its primary benefit and advantage is smoke & odor reduction at pouring cooling and shakeoutreduction at pouring, cooling and shakeout


TEOS-based UNBsTEOS based UNB s Key product characteristics: Conventional UNB

Replaces aromatic solvents in Part 1 & 2 with TEOS

Provides excellent strength development and reactivityp y

Uses existing Activators/Catalysts

Performs on a variety of different sands includingdifferent sands, including new and reclaimed

Very low smoke and odor at pouring

Lower HAP generation than Conventional UNB

Fully mechanical reclaimable

TEOS UNB

Sand Performance ExamplesSand Performance Examples Data displayed

Reactivity Tensile Strength Development Collapsibility


Work and Strip TimeConventional vs TEOS based UNBConventional vs. TEOS based UNB

New Silica, 1% Resin 55/45 Pt1:Pt24.0

3.1 3.23.5

33.5

4

22.5

3

i

n

u

t

e

s

0 51

1.5M

00.5

Work Time Strip Time

Conventional UNB TEOS based

Strength Performance - New SandConventional vs. TEOS based UNB

New Silica, 1% Resin 55/45 Pt1:Pt2285300

176195

249

213

200

250

p

s

i

149176

100

150

T

e

n

s

i

l

e

,

p

0

50

100

T

010 min 60 min 24 hr

Time After Strip


Work and Strip Time - Mechanically ReclaimedC ti l TEOS b d UNBConventional vs. TEOS based UNB Resin level - varies, 60/40 Pt1:Pt2

6 67

5.56.1

6.6

5

6

7

3.5 3.63.8

3

4

5

i

n

u

t

e

s

1

2

3

M

0Work Time Strip Time

Conventional UNB -1.1% TEOS based - 1.1% TEOS based -0.9%

Performance - Mechanically ReclaimedC ti l TEOS b d UNBConventional vs. TEOS based UNBResin level - varies, 60/40 Pt1:Pt2

200

111

166

126 134

174

148150

200

p

s

i

43

9787

111

50

100

e

n

s

i

l

e

,

43

0

50

T

10 i 60 i 24 h10 min 60 min 24 hrTime After Strip

Conventional -1.1% TEOS based - 1.1% TEOS based - 0.9%

Dilatometer Collapsibility1800F, 50 psi Load

Conventional vs.. TEOS based UNBNew Silica, 1% Resin 55/45 Pt1:Pt2

188 187

180

200

s

)

160

180

s

e

c

o

n

d

s

120

140

t

i

m

e

(

s

100binder type


The Nose KnowsThe Nose Knows


Overview of Odor MeasurementsOdor measurements (olfactometry) using a close-to-practice test sample

at the Institute for Foundry Technology (IFG)

Odor ComparisonC ti l TEOS UCB S t

8000075% reduction

Conventional vs.. TEOS UCB Systems

60000

70000

80000

72,000Conventional TEOS

60% reductionTEOS-based

40000

50000 48,500

O

U

/

m

3

TEOS based systems result in significant odor

reductions

20000

30000

18,90016,000

35% reduction

0

10000

5 minutes 30 minutes 60 minutes

8,8005,600

Sample Time

OCMA VOC ComparisonOCMA VOC Comparison

OCMA Results:

OCMA VOC EMISSIONS TESTConventional UNB System (low solvent)

Shimadzu UX6200H Electronic Balance1.00% (B.O.S.) - 55/45 Pt 1:Pt 2, 3% Catalyst (B.O.Pt 1)

New Sand

Conventional UNB 0.81 lbs/ton

OCMA Results: Low solvent UNB

0.81 lbs per ton sandTEOS H b id 0 400

0.500

0.600

0.700

0.800

0.900

1.000

(

l

b

s

V

O

C

/

t

o

n

s

a

n

d

)

TEOS Hybrid: 0.99 lbs per ton sand

Slightly higher than conventional low OCMA VOC EMISSIONS TEST

0.000

0.100

0.200

0.300

0.400

0 1 2 3 4 5 6 7 8 9 10 11 12

E

m

i

s

s

i

o

n

s

(

Time (hours)

conventional low solvent at equivalent binder level

Similar VOCs at 0.700

0.800

0.900

1.000

n

s

a

n

d

)

OCMA VOC EMISSIONS TESTTEOS UNB Pt 1/ Conv Pt 2

Shimadzu UX6200H Electronic Balance1.00% (B.O.S.) - 55/45 Pt 1:Pt 2, 3% Catalyst (B.O.Pt 1)

New Sand

TEOS UNB 0.99 lbs/ton

reduced binder level

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

E

m

i

s

s

i

o

n

s

(

l

b

s

V

O

C

/

t

o

n

0.0000 1 2 3 4 5 6 7 8 9 10 11 12

Time (hours)

Emissions TestingEmissions Testing

Emissions at PC&S Emissions at PC&S were measured at UNI Metal Casting Center

Used improved methodologyThree systems Three systems compared: Conventional UNB Hybrid TEOS Part 1 /

Conventional Part 2 Full TEOS UNB

Pouring Cooling & ShakeoutPouring, Cooling & Shakeout Real Time VOC

Measurement Hybrid TEOS Part 1 /

Conventional Part 2Conventional Part 2 27% reduction in

Total Hydrocarbons (THCs)( )

Full TEOS UNB 42% reduction in

THCs

450

TotalVOCs;Pouring,Cooling,ShakeOut

350

400

C ti l dj t d

Conventional UNB:Max423.5ppm

300

350 Conventionalzeroadjusted

HybridTHCzeroadjusted

FullTEOSTHCzeroadjustedHybridTEOS UNB:Max291.1ppm

200

250

p

p

m

100

150

FullTEOSUNB:Max119.1ppm

50

100

Gasfiredladlepreheater

00 20 40 60 80 100 120 140

Time,min(0=pouring)

Particulate Matter AnalysisParticulate Matter Analysis

PM emissions measured

Qualitative differences Qualitative differences confirm field experience

Conventional Hybrid

EU TEOS UNB SYSTEM

P1: 0,6 % on sandP2: 0,6 % on sandP3 : 4% on P1

90100

Benzene Toluene Xylene

mg / kg sand 5060708090

e

1

0

0

AROMATICg g

Aromatic 160 203 53

TEOS 128 147 31 10203040

B

a

s

e

TEOS

OS 8 30

B T X BTX

Customer ExperienceCustomer Experience

TEOS-based UNBs have been introduced at greyTEOS-based UNB s have been introduced at grey, ductile iron and steel foundries in the U.S. starting in late 2011

Recently introduced at a large Midwest steel foundry


Customer Experience Smoke and odor at pouring dramatically reduced

Customer ExperienceSmoke and odor at pouring dramatically reduced

Substituted for conventional UNBs with equal or better core & mold and casting quality.

Require lower binder levels to produce tensile Require lower binder levels to produce tensile strength comparable to conventional systems.

Hot strength as good as conventional, including applications for large steel castingsapplications for large steel castings.

Lower Part 1 viscosity provides better flowability and eliminates pumping issues in cold climates.

Less sticking sand on patterns Less sticking sand on patterns.


Frequently Asked QuestionsFrequently Asked Questions Expected variation in binder %

Reductions of 5% 10% in binder content seen in practice Reductions of 5% 10% in binder content seen in practice Hybrid produces highest strengths

Does the system smoke?D i d i i k Dramatic reduction in smoke

Small amount of white smoke observed after pouring; dissipates quickly Is the system odorless?

Dramatic reduction in odor at pouring Different, less persistent odor during coring and molding

Effect of lower flash point compared to conventional UNBs does it make a difference, if yes how? No issues in practice with flash point


SummarySummary Key product characteristics:

Very low smoke and odor at pouring Lower HAP generation than Conventional UNB Provides excellent strength development and reactivity

Resin level reduction Uses existing Activators/CatalystsUses existing Activators/Catalysts Fully mechanically reclaimable


For additional information, please contact:contact:

HA International LLC630 Oakmont Lane, Westmont, IL 60559Phone: 630-575-5700Website: www ha-international comWebsite: www.ha-international.com


Questions?Questions?



file:///C|/WEBSHARE/062013/magazine/2012_3/muratore.htm[7/3/2013 12:13:13 PM]


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Back Issues

DIS Home Page

Link to Presentation: Cast, Clean, and Make Money

EUGENE MURATORE

GENE GRADUATED FROM CASE WESTERN UNIVERSITY IN 1970 WITH A BACHELOR OFSCIENCE IN METALLURGY. GENE SPENT THE NEXT 20 YEARS AS AN OPERATING

METALLURGIST FOR THREE FOUNDRIES IN THE PRODUCTION OF GRAY AND DUCTILEIRON CASTINGS. GENE HAS BBEN THE SENIOR FOUNDRY METALLURGIST FOR RIO

TINTO IRON & TITANIUM SINCE APRIL OF 1991. AS SUCH, GENE IS RESPONSIBLE FORTECHNICAL SERVICE TO THE US, CANADA, MEXICO AND PARTS OF ASIA. GENE ISACTIVE ON 6 AFS TECHNICAL COMMITTEES, A BOARD MEMBER OF THE CHICAGO

CHAPTER OF THE AFS, AND A MEMBER OF THE AFS RESEARCH BOARD. IN ADDITION,GENE IS ALSO ACTIVE WITHIN THE TECHNICAL STRUCTURE OF THE DIS AND 2 TERM

PAST BOARD MEMBER.

THE DIS WELCOMES GENE WHO IS HERE TO TALK ABOUT CAST, CLEAN, AND MAKEMONEY



susanRectangle

susanRectangle

Cast, Clean, and Make , ,Money

Gene Muratore

Ri Ti t I d Tit i A iRio Tinto Iron and Titanium America

Ductile Iron Society T & O MeetingDuctile Iron Society T & O MeetingOctober 25October 25--26, 2012 Peoria, IL26, 2012 Peoria, IL

OutlineOutline

Thoughts Importance of KnowledgeImportance of Knowledge Reeling in Profit

V l Ch t Value Chart Conclusions


ThoughtsThoughts Foundries and Fisherman

Alliterative Aromatic Requires Specific Tools Require Long Hoursq g Requires Specific Knowledge-Training Might Require Casting (vs Trolling,Might Require Casting (vs Trolling,

Netting, Seining) Product must be cleaned in order to


be saleable.

Knowledge-WhereKnowledge-Where

Ductile Iron Society DIS T & O MeetingsDIS T & O Meetings Regional Conferences

N ti l C f National Conferences DIS Training Classes CMI Classes Suppliers


Suppliers

Regional ConferencesRegional Conferences

Attract National/Global Speakers Geared to Local IssuesGeared to Local Issues


National ConferencesNational Conferences

AFS Research Aging of Gray IronAging of Gray Iron Thin Wall Ductile Iron

Technical Committee Reports Technical Committee Reports Experiences with Channel Clogging


DIS Committees, Research, Marketing, et al

Peer to Peer Interaction NetworkingNetworking Ductile Iron Focused Research


DIS Training/Cast Metals Institute

Foundry Manager Surveys Want: Fewer ImportsFewer Imports Less Government Regulation Higher Selling PricesHigher Selling Prices Better Trained Workers


SuppliersSuppliers

Tend to Hire Veterans History of EngagementHistory of Engagement Vested Interest

N t k d N ti ll /I t ti ll Networked Nationally/Internationally


Knowledge-WhatPart 1

Engineering Properties Specifications/GradesSpecifications/Grades Weldability

U di th h H t T t t Upgrading th

Documents

2012 Issue 334