CONTINUED... chlorides, oxides, oils and cleaning solvent residue lie within the valleys left over from the manufacturing process.


The surface roughness measurement


approach that is typically used in the U.S. does not take into account the highest peaks and lowest valleys. However, it is typically these highest machining peaks that penetrate these thin coating systems providing a point for external coating deterioration. The chlorides, oxides and other remaining contaminants initiate their coating system attack from within for a potential two- pronged attack at reducing overall coating system durability. The Surface Treatment System (STS) three step process eliminates the limitations of the current coating systems. The first step of the three step STS process is the rapid and simultaneous removal of surface contaminants, including metal-oxides and corrosion products with a laser ablation system that does not affect the underlying material.


CONTINUED... Quality and yield improvement, and most critically,


defect prevention and elimination of trials, directly yield cost savings, apart from other benefits. However, they are not well served by manual systems alone. Computer-aided simulation and methoding systems are the need of the hour. By enabling correct understanding of the casting’s behaviour, by delivering accurate methoding, and by virtual confirmation of the given method design, all before actual production, physical trials are eliminated while optimizing yield and achieving the desired quality. We present a few Case Studies that illustrate the


This FAA approved, controlled surface prep process has been demonstrated on both metal and composite materials and used in production today. The second step is a surface treatment system that will significantly reduce the surface roughness while not re-contaminating the surface in the process, as most surface finishing processes do. The third and final step is the application of a thin film vapor deposited carbon coating, called Diamond-Like Carbon (DLC). Even if one of the three steps can’t be completed, the application of any of the three steps will still improve the product. The complete three step STS process results in an omniphobic (meaning that nothing will stick to it), extremely durable surface finish with 10x lower friction than Teflon which oils, machining chips, ceramic mixtures, etc. will not stick to, resulting in a nearly self-cleaning surface that provides significantly reduced friction, improved wear resistance and life/quality of numerous consumer products while increasing profit margins.


3:00 p.m. - 4:00 p.m.


Paper No. 10: Casting Simulation: An Aid To Address Industry’s COVID-19 Challenges Amarnath Bhat, SoftCAST Technologies Stephen Barnett, INCAST Consultancy In most parts of the world, the Foundry industry is cost-intensive; in many, it is also labor-intensive. Apart from the obvious manifest costs such as energy and material, the not-so-obvious latent costs of wastage are substantial. In today’s COVID-19 driven economic downturn, it has also become a reduced-demand industry. Scarcity of working capital due to the banker’s reticence to lend, coupled with supply chain disruptions, are adding to the foundryman’s misery. Hope does one cope? The answer lies in saving


costs; the foundryman needs to focus on factors wherein costs can be reduced or saved, without affecting the output.


September 2020 ❘ 31 ®


positive impact on cost savings resulting from defect prevention, quality and yield improvement, and elimination of shop trials, with the aid of a simulation and methoding system. The Foundry Collaborators for this Paper are: 1) Magyarmet Bt., Bicske, Hungary, 2) Micro Melt Pvt Ltd, Rajkot India, and 3) Rainbow Technocast, Rajkot India.


TUESDAY, OCTOBER 20, 2020


11:00 a.m. - 12:00 p.m.


Paper No. 11: COVID-19 - the Catalyst to Enhanced Performance


Julie Markee, ICI Director Key Process Innovations


This global pandemic has turned our worlds upside down. Everything from dining out, to educating our children to running our businesses has changed. In the investment casting industry, some businesses have been thriving while others have been struggling to stay afloat. But universally, we have been forced to change the way we run our businesses. In an effort to minimize spreading of this virus, social distancing has become the norm. And this works for some positions within an organization. However, from a manufacturing perspective, this has presented some challenges. These include training employees, safeguarding processes, ensuring consistent quality and confirming communication between operators and departments. In this paper, a number of best practices in addition to new tools will be shared in order to help engineers, supervisors and managers create an effective process to manage product quality and output remotely or with minimal interaction with the operators or between the management team as a whole.


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