Preliminary Agenda Abstracts WEDNESDAY, AUGUST 24, 2022, con’t.
11:00 a.m. – 11:40 a.m. Advanced Core Removal for the Modern IC Foundry Howard Pickard, LBBC Technologies, Booth No. 409 As core systems become increasingly complex in terms of material and geometry, LBBC Technologies present recent advances to autoclave ceramic core removal systems. With foundries looking to be more efficient in every area of their operation, having the ability to make real time decisions is crucial to their overall success. This paper presents new advancements in how the
temperatures and respective pressures of operation can now be up to 500ºF and 500psi to enable the removal of silica and alumina/quartz content. How operating at these temperatures and pressures requires new advances in system design to ensure the balance between practical,
reliable operation
against a high level of safety system. Aligned to these operating developments, this paper will discuss the advancements of control systems and online connectivity capabilities for the modern autoclave equipment. The paper will present how using the latest cloud data management analysis techniques allows the foundry the ability to stay and be connect and analysis real time data of the pressure vessels. This has in turn helped the modern foundry by leveraging this connectivity to improve efficiency of operation and quality of output as well as improving the overall equipment performance.
11:40 a.m. – 12:15 p.m. A Scabbing Defect Investigation Andy Bomberger, Tech Cast LLC Chris Whitehouse, 3M Technical Ceramics Inc. Booth No. 320
A not uncommon shell condition causing casting defects is referred to as scabbing, where early dips loose adhesion with the backup shell. This condition was extensively studied at Tech Cast using ICI Process Control Seminar techniques and a full factorial four factor two level experimental design. Shell properties were semi-quantitatively inspected and measured for approximate surface area in order to determine their severity. Shell strength and permeability data was measured at 3M Midway to confirm shells built in the test cell were
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equivalent to shells built in the production cells. The results of this study should be helpful for any foundry seeking solutions to shell conditions and resulting cast metal defects.
12:15 p.m. – 12:50 p.m. LUNCH - Disneyland South Ballroom
12:50 p.m. – 1:30 p.m. Thermal Properties Evaluation of IC Shell by Hot Disk Transient Plane Source Method, Artem Trofimov,Orton Ceramic Foundation, Booth No. 523
Nip Singh, S&A Consulting Group LLP, Thermal properties of investment casting (IC) shells
have a strong influence on the cooling, solidification, thus, mechanical properties of casting. Simulation/modeling of IC process also requires thermal properties (thermal conductivity; specific heat, etc.) and its accuracy is highly dependent on the measurements of these properties. Traditional methods to measure thermal properties of the shells are a hot wire (only measures thermal conductivity) and a laser flash (only measures through-plane thermal diffusivity). The hot wire method requires very large and thick samples (ca. 1 inch thick), which often is too big for the shell system. The laser flash calls for (1) very small samples (0.5-inch diameter, 1-3 mm thick), which might not be representative of the shell due to pores, composition and microstructure variations, and (2) additional measurements of heat capacity and density to calculate thermal conductivity – therefore, resulting thermal conductivity combines errors of obtaining diffusivity, heat capacity, and density. In this work, Hot Disk Transient Plane Source technique
is proposed since it allows different size samples to be tested (from a few millimeters and larger) simulating actual shell used in the foundry, provides both thermal conductivity and thermal diffusivity from a single measurement (therefore, enabling the calculation of volumetric heat capacity), and capable of differentiating between through-plane and in-plane thermal properties (assuming known heat capacity of the samples). Different shell systems (materials and number of coats) for different desired properties of castings will be investigated and reported.
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32 ❘ May 2022 ®
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