Preliminary Agenda Abstracts


the possibility of printed wax pattern tooling. By printing the mold rather than the pattern, wax patterns could be molded, avoiding the need to use a different casting process. Compared to the traditional metal, 3D printed materials typically have a much lower coefficient of thermal conductivity resulting in slower cooling, longer cycle times and higher cost of molded patterns. To resolve the slow cooling issue, cooling lines and even conformal cooling lines can be incorporated into the mold design to increase production and lower the cost. Printed wax pattern molds could significantly lower the


cost of patterns when more than a few patterns are required as well as eliminate the difficulty in casting presented by printed patterns. This paper presents the results of a case study to evaluate the potential for printed wax pattern molds.


11:00 a.m. - 12:00 p.m. How It Is Made – Ceramic Shell Raw Materials Produced by The Fusion Process Michael Weissenbacher, IMERYS The investment casting technology is used to produce high quality parts for very demanding applications, like automotive, industrial gas turbines, medicine or aerospace. To fulfill the very demanding requirements of the final casting, all components need to be produced under the highest standards and strict quality controls. This paper describes the production of fused raw materials used for the ceramic shells, in particular fused alumina, silica, and stabilized zirconia. The paper will address the different routes through which these materials are produced, how they will further be processed and the characteristics of the final products. The paper will demonstrate how the arc furnace and tilting technology can be used to obtain a variety of products with very specific properties, and how this beneficially affects the quality and performance of investment casting shells and thus the quality of the finished casting part. Finally, the paper will discuss current efforts to reduce energy consumption and carbon dioxide emissions in the production of fused minerals that contribute to our company’s sustainability targets for the benefit of our customers and stakeholders.


12:00 p.m. – 12:40 p.m. LUNCH - Disneyland South Ballroom


12:40 p.m. – 1:20 p.m. Wireless Sensors for Investment Casting Shell Data Acquisition Nathaniel Bryant, University of Northern Iowa Current investment casting methods include a degree of


process variation that has been the source of casting defects and ultimately delays in product delivery. It is estimated that quality issues including casting defects resulting from process variation can cost manufacturers millions in rejected parts or delivery delays. Determining variations in the shelling and casting process can predict casting success and provide valuable information to improve the casting process. This


May 2022 ❘ 29 ®


2:00 p.m. – 6:00 p.m. EXPO – Disneyland Exhibit Hall & Disneyland North Ballroom


6:30 p.m. – 8:00 p.m. RECEPTION – Adventure Lawn


information can form the basis for foundries wishing to advance into manufacturing 4.0. Data from the shelling and casting process can aide metal casters in refining their processes to higher levels than ever before possible. Sensors within molds can collect process data which include temperature, pressure, moisture, gas chemistries, shift and rotation detection, and the magnetic field. The magnetic field, for instance, may provide insights into the flow of metal in mold cavities or even solidification. The University of Northern Iowa and Youngstown State University have developed a new low cost technology that has the ability to track the investment casting dipping and drying process along with casting data and transmit the results wirelessly for documentation. The technology uses low cost microcomputers and has the ability to sense and measure several critical characteristics simultaneously. The low cost of the technology utilized allows multiple trees to be tracked, individually recording their information.


1:20 p.m. – 2:00 p.m. An Investigation into Thermal & Mechanical Stresses on an Investment Cast Shell Gerald Richard, MAGMA Foundry Technologies, Inc., Booth No. 234 Investment Casters have a very challenging feat of engineering to create before pouring castings; creating the shell. The complex process of shell building requires time and experience to produce a vessel that can withstand high temperatures and handling during the remainder of the investment casting process. If this meticulous process isn’t carried out properly or if the shell thickness and characteristics aren’t calibrated properly for the castings being produced, shell cracking can be an issue which could result in lost time and money. In this paper, a focus specifically on the thermal load placed on the shell during pouring and the evolution of stresses and strains that develop, which if high enough, could result in shell cracking will be investigated. In addition, the mechanical load place on the shell due to the attachment of gates on trees along with how brackets, frames, or other supports’ from the pouring floor impact the shell will also be reviewed.


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