66th Annual Technical Conference & Exposition TUESDAY, CONTINUED

8:55 a.m. – 9:25 a.m.

Paper No. 7: Eliminating Shrinkage Porosity in a Complex Investment Cast Part, Evan Letorneau, MAGMA Foundry Technologies, Booth 131 Shrinkage porosity continues to plague investment casting foundries resulting in costly repairs and in many cases scrapped castings. Reproducing castings that have been scrapped or reworking parts that can be salvaged are not only costly in terms of additional labor and materials needed, but can also be costly in the damaging effects of poor on time delivery. The damaging effects are then compounded if shrinkage remains in the casting and is found during a machining operation or worse, a failure in service. Reducing the number of shrinkage defects can have an enormous impact on the profitability of a product line, and ultimately, on the profitability of the company. Therefore, it is imperative to the Foundry Engineer to develop tree designs that fulfill the quality requirements that the customer requires despite growing casting complexity and expectations. In this paper, a systematic way of identifying the conditions that lead to shrinkage porosity and the methodology employed to eliminating the porosity will be reviewed using a case study of a complex investment cast part.

9:25 a.m. – 10:10 a.m.

Paper No. 8: An Investment Casting Foundry Experience in Improving Degassing and Grain Refining in Molten Aluminum Alloys Robert Zebick, Atlantic Casting & Engineering; Brian Began, Foseco, Booth 108 The requirement to degas, flux and grain refine molten aluminum alloys for investment casting are well established.

The evolution of casting buyer

requirements; now requiring larger castings or more complicated geometries than the previous generation, continually require better and more consistent melt treatments for the molten aluminum. Fortunately, several recent technological advancements have allowed degassing, flux and grain refining to be higher performing and more environmentally–friendly than were historically achievable. This paper will report on the efforts of Atlantic Casting & Engineering in Clifton, NJ to implement an improved aluminum alloy treatment process to keep up with the demands of industry.

process of implementation, this paper will document the rationale and evaluation process for implementing the process improvements. Finally, the paper will discuss the economic, technical and environmental benefits achieved upon complete implementation of the new treatment process.

10:10 a.m. – 10:30 a.m.

COFFEE BREAK 28 ❘ October 2019 ®


10:30 a.m. – 11:15 a.m.

Paper No. 9: Massive Shells and Castings in Reactive Alloys from a Highly Customized Facility…… Finally, Will Jeffs, Castings Technology International, Booth 342 Following years of design/manufacture and installation with many a hurdle, the large scale shelling facility, capable of producing shells weighing in excess of 4,000 lbs has finally come to fruition. The initial research into shell selection was conducted by AMRC castings, whilst the practical application and manufacture of real shells and castings was conducted after this initial development by Castings Technology International to supply shells to Western Europe’s largest titanium melting and casting furnace. The equipment consists of a large scale flood coater for primary coating, two 11 foot diameter slurry tanks for intermediate and back-up layers, plus three 13 foot diameter sand rainers for the three distinct layers. Two 11 foot wide drying pods, each with separately controllable humidity and temperatures for optimum shell build, investigation and results from the detailed drying trials shall also be presented and discussed. The paper shall detail the initial back-up shell property selection, including detailed test results, control parameters for such massive tanks and footage of this coating process. Following on from the shell manufacture there will also be details of the structural strength requirements and simulation of the stresses placed on the shell during casting to ensure shell survival during the most arduous conditions when they are spun and can be subjected to forces of 35 G (35 times the force applied when casting statically).

In addition to the

Innovation Theater Schedule 3:30 p.m.

Monday, Oct. 28th VA Technology:

Comanche Technologies:

Tuesday, Oct. 29th Renaissance Services:

Inductotherm Corp: 4:30 p.m. ICI Member Healthcare Program: 5:30 p.m.

3:30 p.m. 4:30 p.m.

ICI Member Healthcare Program: 5:30 p.m.

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