Metalcasting Industry Research
Support of research is critical for North America to maintain a strong, vibrant, healthy and continually advancing metalcasting in- dustry. Part of the AFS mission is to promote these activities for the betterment of our membership, our industry and our society.
AFS directly funds research projects from allocation of a por- tion of the annual dues paid by AFS Corporate Membership. The current AFS Funded Research Projects are described be- low. The other projects are funded through research partner- ships, government funding and industry contributions. AFS participates in these projects by securing industry partners and providing technical management and oversight. Current
research funding partnerships include: Achieving Lightweight Casting Solutions for Defense Applications (ALCS) funded via a Congressional Appropriation and conducted under a Coop- erative Agreement with U.S. Army ARDEC Benet Labs, U.S. Department of Energy (DOE) Office of Industrial Technol- ogy funded through the Cast Metals Coalition (CMC) Program, U.S. Department of Defense (DOD) Defense Logistics Agency (DLA) Castings for Improved Readiness (CIR) Program fund- ed through the American Metalcasting Consortium (AMC) and Superior Weapons Thru Casting (SWC) Program, which is a Congressional Appropriation & Cooperative Agreement with Benet Labs on behalf of AMC.
AFS Funded & Monitored Research
Eight projects are currently being funded through the allocation of a portion of the AFS Corporate Member Dues in FY2011-2012.
Standard Test for Machinability of Cast Iron (06-07#03)
Coordinator: Finn Metalworking & Cutting Solutions and AFS Cast Iron Division (5)
of cast iron. The V30
The objective of this project is to develop an easy standard machinability comparative test that can compare material of the same grade from different lots made in the same found- ry, qualify material of the same grade to a benchmark mate- rial and qualify material of the same grade from different foundries. Members of the AFS Cast Iron Committee (5-J) suggested that the measurable observation of the test would be the V30
Value based on a tool life database for each grade Value is the maximum cutting speed
The cutting tool (insert) would be removed and measured for flank wear. The heat or lot of cast iron passed the ma- chinability test if the flank wear did not exceed the “end-of- test” criterion.
for a 30-minute cutting tool life. The members envisage that the in-house or contracted testing laboratory would run the machinability test on a representative disc for 30 minutes at the V30
Value (specified speed) for that grade of cast iron.
Status Update: The project’s final report is now complete along with a Testing Guidelines Manual. This will be presented at the 2012 Metalcasting Congress in Columbus, OH. Those interested in learning more should contact Mike Finn, Finn Metalworking, at
finnmwcs@aol.com or the Steering Com- mittee Chairman Brad Steinkamp, Dura Bar, at bsteinkamp@
dura-bar.com.
Optimizing Mechanical Properties of Cast Aluminum Alloys—A319 & A356 (Phase I/Phase II)—CWRU (08-09#04/10-11#01)
Coordinator: Case Western Reserve University and AFS Alu- minum Division (2)
The mechanical properties of cast aluminum products can exhibit wide variation even when the same alloy is used. Best practices to achieve maximum properties encompass: high molten metal quality (clean metal, degassing), metal treatments (modification, grain refining), good gating practices, filtration, directional solidification, fast cooling rates and adequate riser- ing. The industry would benefit from a well-defined set of “po- tential” (i.e. maximized) properties that can be achieved for any given alloy when best practices are applied.
This project proposes to establish a database with “potential” properties of cast aluminum alloys, in other words, if best prac- tices in melting the aluminum and treating it are carefully fol- lowed, a high cooling rate is applied and shrinkage porosity is eliminated, what would the properties be?
Status Update: The first phase is complete and a report was given at CastExpo’10. Work on Phase II is ongoing and will fo- cus on improvements resulting from metal treatment and heat treatment. Initial test bars have been produced, variations in heat treat is being investigated and fatigue testing to complement the mechanical property tests is now being conducted. Progress re- ports are given at AFS Aluminum Division (2) meetings. Those interested in the work of this committee should contact Steering Committee Chair David Neff,
theneffers@sbcglobal.net.
International Journal of Metalcasting/Fall 2011 71
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80