foundries and foundry customers have extensive experience with radiography ratings and casting performance. No corre- lation between radiography and ultrasonic ASTM ratings pres- ently exists. Therefore, no one is sure how ASTM UT ratings correlate with casting performance or radiography.


The goal of the project is to determine the repeatability of UT inspection on steel castings. Additionally, the project will correlate UT ratings to radiographic ratings. This will assist foundries in understanding UT and enable them to appropri- ately use the technology.


Status Update: Round-robin testing for UT (including phased array) and x-ray is now being conducted. Anyone in- terested in how they might participate in this project should contact Prof. Bob Tuttle, Saginaw Valley State University, at rtuttle@svsu.edu.


High Temperature Properties of Nanoparticle Strengthened Cast Aluminum and Magnesium Alloys (07-08#06)


Coordinator: University of Wisconsin–Madison and AFS Aluminum Division (2)


The need of cast Al and Mg alloys having elevated temperature (>250 C) capabilities is expected to increase as automotive in- dustries are forced to improve the fuel efficiency of their prod- ucts. High performance Al and Mg nanocomposites are ex- tremely valuable in that these lightweight materials are expected to offer both superior room temperature and high temperature performance. Lightweight metal matrix nano-composite mate- rials (MMNCs) will be of significance to automobile, aerospace and numerous other applications. A method that combines solidification processes with ultrasonic cavitation based disper- sion of nanoparticles in Al and Mg alloy melts was developed by Professor Xiaochun Li at University of Wisconsin-Madison through a funded project from American Foundry Society (AFS). Equipment was demonstrated in a laboratory setting to produce small samples, proving the approach was feasible and significant property improvements obtained.


This project is to demonstrate the effect of nanoparticle strengthening on elevated temperature mechanical properties of Cast Al and Mg alloys. High temperature tensile (up to 400 ºC) and creep testing will be conducted in a modified MTS ten- sile testing machine. The research will establish knowledge bas- es for the nanoparticle effect on high temperature properties of the nano-structured Mg and Al alloys (e.g. AM60 and A319). It is expected to achieve significantly improved high tempera- ture properties in the nano-structured Al and Mg alloys. Micro- structure study will focus on fracture surface and nanoparticle dispersion effects.


Status Update: High temperature testing on Mg AM60 and Alu- minum A319 is complete and the final report is being written. Those wishing further information on the project should contact Prof. Xiaochun Li, University of Wisconsin-Madison, at xcli@ engr.wisc.edu.


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Aging and Machinability Interactions in Ductile Iron (08-09#02)


Coordinator: Missouri University of Science and Technology (MS&T) and AFS Cast Iron Division (5)


The proposed overall program will complete the understand- ing of how age strengthening affects machinability so that foundries may be able to utilize the strength improvement with age strengthening to cast equivalent grades at higher CE, lower alloy or lower pearlite content without the re- quirement to hold castings before machining. The objective of the proposed work is to explain the mechanism by which age strengthening changes the machinability of graphitic cast irons to investigate ductile irons.


Little is known about age strengthening effects on machinabil- ity of ductile iron. It has been shown that age hardening of the free ferrite microstructure component of ductile iron ex- ceeds the tensile strength increase of the bulk material. Work with ductile iron would not only provide information specific to ductile iron but could shed light on the general mechanism for age-strengthening effects on machinability in graphitic cast irons due to the larger amount of free ferrite that can be ob- tained in as cast alloys such as 65-45-12.


Status Update: The project work is ongoing and progress was reported in papers given at 2009 Metalcasting Congress. Those interested in the work of this project or committee should con- tact Prof. Von Richards, Missouri University of Science and Technology, at vonlr@mst.edu.


Optimizing Mechanical Properties of Cast Aluminum Alloys by Molten Metal Treatment (Phase I A356)—CWRU (Agreement 08-09#04)


Coordinator: Case Western Reserve University and AFS Alu- minum Division (2)


Mechanical properties of cast aluminum products can exhibit wide variation even when the same alloy is used. Best practices to achieve maxi-mum properties encompass: high molten metal quality (clean metal, degassing), metal treatments (modification, grain refining), good gating practices, filtration, directional so- lidification, fast cooling rates and adequate risering. The indus- try would benefit from a well-defined set of “potential” (i.e. maximized) properties that can be achieved for any given alloy when best practices are applied.


This project proposes to establish a data base with “potential” properties of cast aluminum alloys, in other words, if Best Practices in melting the aluminum and treating it are carefully followed, a high cooling rate is applied and shrinkage porosity is eliminated, what would the properties be?


Status Update: Work is now underway. Those interested in the work of this committee should contact Steering Committee Chair David Neff, theneffers@sbcglobal.net, or David Schwam, Case Western Reserve University, at dxx11@cwru.edu.


International Journal of Metalcasting/Winter 10


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