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11:15 a.m. – 12:00 p.m.


Paper No. 10: Improving Thermal


Conditions and Reducing Process Costs for Core Setters in Aerospace and IGT Applications Phil Geers, Blasch Precision Ceramics, Booth 226


In the continuous improvement of investment cast blades for Aerospace and IGT applications, the associated ceramic core technology is also being pushed to new limits. With increased tolerances and intricate geometry, ceramic cores require accurate processing that is consistent and cost effective. In this paper, methods are shown for improving ceramics core setter design by managing thermal mass with optimized geometric configurations. For each set of geometry, thermal profiles are analyzed using Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) techniques. The layout of core setter kiln configurations will be developed and explored showing how this technology applies to foundry. Methods will be shown for: improving consistency of thermal heat transfer, cost savings through reduction in thermal mass, and additional cost savings by improved heat transfer in the core setter kiln using optimized part layouts.


12:00 p.m. – 1:00 p.m.


1:00 p.m. – 1:30 p.m.


LUNCH


Paper No. 11: Analysis of 17–4 AND 15–5 Alloy Data from Investment Casting Trials Victor Okhuysen, Cal Poly Pomona University Investment castings have a penalty in design parameters vis-à-vis wrought products for aerospace applications.


specimens from 14 investment casters in 17-4 PH and 15-5 PH was conducted.


compressive, fatigue, etc. properties were obtained. These are compared with current MMPDS design values to ascertain if process improvements in the last decade lead to superior values to reduce or eliminate the penalty.


will be evaluated vs. process parameters to explore the possibility of superior practices in producing castings with these alloys.


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conversation #ICIExpo2019


3:00 p.m. – 6:00 p.m.


6:30 p.m. – 8:00 p.m.


®


1:30 p.m. – 2:15 p.m.


Paper No. 12: Enhanced Investment Casting Quality Using 3D–Printed Ceramic Filters Dan Z. Sokol, Renaissance Services – PERFECT–3D Division, Booth 324 Casting suppliers started adopting the use of ceramic


filters in the 1970s when foundries discovered that filters could help improve quality by reducing contamination in the molten metal. The general purpose of filters is to capture non-metallic inclusions as well as other contaminants (typically referred to as dross or slag) present in the molten metal. Today, many investment casting foundries use filters in one form or another. The first generation of ceramic filters is based on a straight-through extruded honeycomb design, which operates on the basic principle of sieving-out the contaminants. The second generation is based on an amorphous reticulated foam, which introduces the concept of the torturous path to improve the capturing of undesirable particles.


During the last decade, foundries started discovering


some of the short-comings of the first and second generation filters, which includes the inability to capture enough of the undesirable constituents and – even worse – the introduction of inclusions from splintering filters. This has resulted in the introduction of the third, and latest generation of filters, which is based on ceramic 3D-printing. Ceramic 3D-printing enables the production of a very precise filtering structure that provides the ability for a much more deterministic method for capturing contaminants.


2:15 p.m. – 3:00 p.m.


An extensive study with over 1000 Tensile, shear, pin,


Paper No. 13: Innovation and the Race to Space Michael Kugelgen, MK Technology GmbH, Booth 321 Investment Casting is one of the oldest primary


Additionally, these properties


forming technologies, around 5000 years old. During the last 5 decades there have been a lot of improvements in respect of better materials and process. But is this enough to face the challenge of other technologies, which seems to be more fresh and sexy? To be competitive against modern production processes like 7-axis high speed milling or 3D-metal printing? Let’s talk straight: Investment Casting is an archaic process, quite complex with many intermediate steps and a high risk to fail. The only chance we have to survive and not to share the fate of other technologies, which are now nostalgic history, is to think out of the box. To be really innovative and optimise speed, output and quality. But what is the difference between development, improvement, innovation and real break throughs. And is there something like a golden rule for innovations?


EXPOSITION EVENING RECEPTION October 2019 ❘ 29


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