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Paper No. 5: Slurry Analysis & Shell Material Testing Methods
Dave Berta, Sam Duncan, Ransom & Randolph Investment casting slurries are complex mixtures of materials that need to be controlled in order to produce ceramic shells able to withstand the forces and temperatures required to yield desired castings. In order to control colloidal-based slurries, it is important to understand basic colloidal silica chemistry and properly utilize testing techniques and procedures to measure and control various ceramic shell properties. This presentation will review the keys to a good slurry control program, including testing frequency and adjustments. It will also study historical and newly developed testing procedures used to measure and control various ceramic shell properties. These tests can be used to benchmark shell properties within a shell system or to compare different shell systems to one another.
THURSDAY, OCTOBER 15, 2020
11:00 a.m. - 12:00 p.m.
Paper No. 6: The Smart Manufacturing Institute John Dyck, CESMII CESMII was created in 2017, funded by the
US Government - Department of Energy with $70 million dollars, as a non-profit Institute to drive Smart Manufacturing. We are branded as the Clean Energy, Smart Manufacturing, Innovation Institute. But you’ll know us as “CESMII - The Smart Manufacturing Institute,” because Smart Manufacturing is the ultimate solution for productivity, security, agility, delivering innovation, and the cleanest energy of all, the energy that was not used in production, wasted with scrap or during periods of inefficient operation. The Investment Casting Institute has recently become affiliated with CESMII. Mr. John Dyck, CESMII CEO, will introduce the organization to ICI Members, addressing his vision for how the investment casting industry can benefit from the relationship.
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3:00 p.m. - 4:00 p.m.
Preparing our Future Engineers and Technologists, A Panel Discussion Brian Lewis, Foundry Educational Foundation Industry sustainability, as it pertains to human resources, has been a long, growing concern for many of our foundries. For the past decade, foundries have expressed “Attracting, Training and Retaining Talent” as a top concern. Not only have today’s universities tailored their engineering and technical programs to address such concerns, but their contributions to the investment casting industry are not limited to the future. These institutions of learning are also centers of excellence for technological development and industrial collaboration. University panelists will review their overall metalcasting and materials science program and address why investment casting holds importance to the university.
September 2020 ❘ 29
Paper No. 7: Evaluation of a Low-Cost Material Extrusion Printer for Investment Casting Applications Tom Mueller, Mueller AMS 3D printed patterns have been used to create prototype investment castings for more than 25 years now and have become the preferred method of creating prototype castings. Not only do printed patterns save time and money in the development of investment castings, they reduce the risk of cost overruns and delays in market introduction of the product incorporating that casting. However, the AM systems currently used to print the vast majority of prototype patterns range in price from $70k to $800k. Considering that prototype castings average about 2% of most investment foundry revenues, it is hard for foundries to justify making that large a capital investment that only affects a small percentage of their revenues. Capital funds would be much better spent on robots, shelling systems, or information systems that will improve profitability on all their revenues. As a result, few investment foundries have purchased pattern printing capability.
Instead
foundries purchase patterns from outside suppliers and are subject to the backlogs of their suppliers. In 2019-20, a study was done in a leading US investment foundry to evaluate a low cost (relative to other pattern printing technologies) material extrusion printer running a filament specifically formulated for investment casting patterns. The printer was used to print patterns for prototype castings, low volume casting orders, and for some tooling applications such as setters and machining fixtures. In this paper, the printer and filament are evaluated relative to more common printed patterns in areas including accuracy, surface roughness, cost, speed, and ease of casting.
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