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

Paper No. 13: 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.

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

Paper No. 15: Digital Twin Design Process for Development of Next Generation Lightweight Investment Casted Parts Dr. -Ing. Santhanu Jana, ALTAIR Engineering GmbH Industrial cast parts and processes are undergoing

major transformations due to lightweight designs to improve energy efficiency of major industries like automotive and aerospace. Hence, boundaries of castability are pushed, as these lightweight designs occasionally leads to thin walled and geometrically complex parts. Investment casting, with it’s ability to cast free form geometries, is one such process suited for production of such parts. However, here moldability and castability is also key issue and an early feasibility in the design phase is necessary to avoid costly reruns. This presentation demonstrates the application of Simulation-driven-design and manufacturing boundary conditions during the design phase to drive next generation lightweight designs through Investment Casting process. At first, an integrated workflow on simulation-driven-design and manufacturability to obtain lightweight part in a single environment is demonstrated. Next, this

digital twin approach is demonstrated for investment casting and sand-casting examples and hybrid manufacturing process. This simulation platform to design parts based on load analysis, manufacturability checks, material response and process optimization provides a powerful tool for concurrent engineering.

1:00 p.m. - 2:00 p.m.

Paper No. 14: Tool-less Digital Investment Casting Using 3D-printed “Ready To Pour” Ceramic Shells Dr. Suman Das, DDM Systems Additive manufacturing has had a significant impact on investment casting through 3D-printed patterns and cores. Recent developments in ceramic 3D printing have allowed the manufacture of both complete “ready to pour” shells and modular molds where individual shells are assembled onto ceramic sprue components. The use of printed shells eliminates multiple process steps in conventional investment casting including pattern molding, assembly,

shelling, and de-wax. The shell

printing process allows cores to be integrated and printed in place. The 3D printing process also allows shells to be created for casting geometries that cannot be molded and can include core geometries that cannot be molded monolithically such as multi-wall cooling passages for gas turbine blades. This paper reviews the results of casting trials by 4 foundries in a variety of alloys. Cast alloy chemistry, mechanical properties, casting accuracy and surface finish results will be presented.


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

Market Insights - A Panel Discussion Joseph E. Fritz, Investment Casting Institute, Carlos Olabe, European Investment Casters’ Federation Kenji Ito, Japan Foundry Society

This year has presented the investment casting industry with some of the greatest challenges with which it has been confronted. The market situation has also undergone some dramatic changes, and all manufacturers have been affected. Global industry now finds itself in a state of uncertainty. To be successful, it is imperative that foundry leadership be kept apprised of dynamically changing market trends to enable a fluid response. This panel discussion highlights the impact of the COVID-19 pandemic on the major markets served by the investment casting industry. Discussion will center around the impact on industry customers in North America, Europe and Japan, and how this impact has affected 2020 production schedules, as well as a look forward to recovery in the coming years.

20 ❘ October 2020 ®

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