Logistics Agency Information Operations, J68, Research & Development, Ft. Belvoir, Virginia. The 26-question survey was intended to take about 30 minutes and shed light on prevalent industry practices related to risering castings, shell and casting productivity, and the use/opportunity involved in recycling investment casting shells. The results largely confirmed the research team's


observations of the industry and provided metric references for the various opportunities involved in developing improved risering tools/technologies specific to investment castings, recycling shells, and improving productivity in shell (and casting) production. Keywords: Misc.


10:00 a.m. - 10:15 a.m. COFFEE BREAK


10:15 a.m. - 10:45 a.m. Paper No. 8 Superalloy Defect Characterization-In a Secure and Sustainable Economy Mark White, Impro Aerotek USA INC. In superalloy casting projects, a detailed familiarity


of defect origination is needed. Producing expensive in- demand aerospace castings requires an accurate knowledge of a defect’s underpinning. This study is important, because there are times accurate paths to defect solutions are not available. Aerospace casting engineers have the passed- along-ideas and sometimes decent theories, even if they do not consistently work. Especially when casting defects repeat themselves in an unpredictable aerospace casting supply chain. This work helps increase resiliency in supply while reducing labor which can improve human factors, physical resources and time resources which turns the situation into profitability without leaving an unsustainable mark. The type of situation we are trying to ease and


eliminate in this work occurs, for example, in reducing scrap; which is waste and not a sustainable feature. For example, in fluorescent penetrant inspection (FPI) where casting engineers may find themselves with a group of expensive castings unexpectedly needing FPI repair. The goal in characterizing superalloy casting defects is to improve casting yields, first-time through inspection results and to reduce repair. We replace and, in some cases, validate conference-room-to conference-room dogma in solving stubborn superalloy defect problems. Predictable, efficient and safe supply of superalloy investment castings addresses economy, human factors and safety in the new market situation. Design engineers and customers involved with


specifying and purchasing superalloy castings take heed to each process that you are specifying. Make certain you have a detailed and an applied understanding of each specification required. For example, it is necessary to have complete understandings of surface finish and mechanical properties as well as many other process areas. This


prevents waste in future testing and prevents production slow-downs from misunderstandings. Design engineers should apply the same design


protocols with additively manufactured components as is done with conventionally produced parts. (examples will be provided in the form of our additive case studies) Complexity in design is another consideration which


impacts predictability in a secure and sustainable supply chain. How complex do the parts really need to be? Using design software such as ANSYS is critically important to understand actual customer design need, for all aerospace and highly stressed industrial components. Investment casting process capabilities should be met and not exceeded, in design. Oftentimes in superalloys there are rare-earth and other


scarce elements involved in alloy development. Design engineers can now try using alloy combinations building on a strong movement in governments and in alloy design to diverge away from these elements. In most cases the casting engineer is happy to see them go as well, because they are also a source of reaction and defects. Areas of automation in cutoff and gate grinding


provide improved human factors as well as the possibility to reduce scrap. Case study of our company’s look into automated post-


cast equipment will be presented. This paper is offered to the ICI 2025 as a service


to casting engineers, design engineers and customers involved with producing and purchasing superalloy castings. This paper thoroughly discusses superalloys, applied casting metallurgy/technology, melting practice and precursors to inclusions in the superalloy casting process. Nickel-based IN-718 examples will be shared as well as work with MarM247LC and Cobalt-based MarM509. Other case-studies on alloys will be shared, as well. We provide detailed analysis which includes case studies, a metallurgical discussion, process data, an actual customer improvement summary, photos and a practical guide to managing this topic. We provide the reader with a literature review of superalloy casting research. Following the detail in our presentation will help on the


road to a secure and sustainable superalloy casting supply chain.


This paper represents a collaboration with and data


from our foundries where we successfully worked through these superalloy situations. Our hope in offering this work to the ICI 2025, is that the audience gains valuable information to go on and successfully handle this topic in their own companies where the situation is turned from “production stopping” to smooth production. Keywords: Quality Control and Defects


Agenda, Continued on pg 22 July 2025 ❘ 21 ®


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