AGENDA TUESDAY, OCTOBER 13, 2020
1:00 p.m. - 2:00 p.m.
Paper No. 1: Fundamental Analysis Into Properties Affecting Investment Casting Shell Strength Gavin Dooley, REMET UK, Ltd. This paper outlines the work carried out to understand the mechanisms which can affect the strength of a shell during drying within the foundry. As the Modulus of Rupture is the key parameter in question here, a Gauge R & R was carried out to understand the issues within the test method and optimize the method. Following this, the influence of inter coat dry time, final dry time and materials used were analyzed within this study. It was found the thickness was the highest source of variability within the testing of MOR. This was a manual measurement which could contribute most to the variability within the test. Following training and establishment of clear procedures within the test, the variability was reduced further. The analysis of drying indicated that polymer enhanced binder systems dramatically increased the strength developed at a shorter dry time. Furthermore, the green strength developed is also far higher for polymer enhanced systems, a key factor for reducing dewax related shell cracking.
3:00 p.m. - 4:00 p.m.
Paper No. 2: Hypoallegernic Surgical Cast Stainless Steel Sander Klemp, Davis Alloys
It has been known for many years that nickel and
alloys containing nickel can produce an adverse or allergic reaction in certain portions of the population.. The Center of Disease Control and Prevention (CDC) estimates that 10-20 percent of the population have varying degrees of nickel allergies. Due to nickels alloying effects, cost and availability there has been little desire or demand in the industry to discover a replacement or substitute for this element for austenitic stainless steel.
As greater awareness of nickel allergies and nickel ion toxicity permeates the minds of the population, a greater probability of liability lawsuits associated with adverse reactions to nickel bearing surgical implants could likely follow. Therefore, an alternative alloying element(s) may be necessary for the medical, surgical & jewelry industries. This paper will explore an alternative nickel free
variant of 316L/CF3M surgical stainless steel. This will be accomplished through the use of alloying elements that are both biocompatible and strong austenite formers. This alloy modification may enable a broader range of applications for this well known alloy. Comparative physical, mechanical and microstructure testing will be performed & results documented.
16 ❘ October 2020 ®
11:00 a.m. - 12:00 p.m.
WEDNESDAY, OCTOBER 14, 2020
Paper No. 3: Vacuum Induction Melting Process Optimization In Precision Investment Casting Furnaces Iñaki Vicario, Consarc Engineering Ltd. The alloy vacuum induction melting process is one of the most critical events in the Vacuum Precision Investment Casting (VPIC) furnace, and also in the Investment Casting Process. The induction melting process consists on how solid alloy is induction melted in preparation for pouring into a preheated shell mold. It is the first point for a successful and defect free casting process. It begins with the ingot and refractory one-shot liner loading stage into the induction coil, then continues with the power input from the VIP®
source into that coil, which
finally melts the solid ingot by means of induction. Once alloy is melted, process continues with the melt dross evaluation witnessing the cleanliness of the alloy, and it finishes with temperature regulation of the metal to have it ready to be poured into the shell mould. This work will summarize features and recommendations around the design of the VIP®
, induction coil, ingot/liner
charging system, melting recipe and final temperature regulation systems, as key parameters and their effective management and control.
1:00 p.m. - 2:00 p.m.
Paper No. 4: Rapid & Affordable Castings from 3D-Printed Ceramic Molds Dan Sokol, Renaissance Services PERFECT-3D and Shawn Franks, HTCI, Co. With the emerging challenge of 3D-printed metals, it is essential for the investment casting industry to become more agile and responsive for small quantity orders.
To remain competitive and further reduce
the lead time from concept to finished casting, one opportunity area for investment casters is the use of 3D-printed ceramic molds.
This approach enables
the foundry to bypass the efforts involved in the front- end patterns and dipping processes and go straight to pouring metal. In addition, 3D-printed ceramics also allows for the creation of more complex molds and customized metal flow & gating systems. This case study presentation from the Renaissance Services PERFECT-3D Division along with HTC Castings will provide an overview of the overall process used as well as the castings that resulted from the effort.
In addition to the advantages of additively manufactured tooling, this presentation will discuss some of the current limitations involved as well as casting features that offer the best opportunities to leverage 3D-printed ceramic molds.
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