61st Technical Conference & Equipment Expo Program
3:00 p.m. - 6:00 p.m. 6:00 p.m. - 7:30 p.m.
7:00 a.m. - 6:00 p.m. 8:00 a.m. - 8:10 a.m.
8:10 a.m. - 8:40 a.m.
SUNDAY, OCTOBER 5, 2014 REGISTRATION
WELCOME RECEPTION
MONDAY, OCTOBER 6, 2014 REGISTRATION
WELCOME INTRODUCTION Paper No. 1
“Automation,” The Why and How Bruce Phipps, MPI, Inc. Can automation be used in the investment casting foundry wax room? It is easy to answer this question with a firm yes, but the actual implementation of automation in a commercial wax room is much more problematic than may be apparent. There are many aspects of foundry operations that must be considered to successfully automate the wax room and achieve an acceptable ROI. With appropriate care and preparation, the automation of the wax room will exceed most expectations. The wax room is where many of the issues causing scrap begin. Incorrect die lubrication, manual pattern handling, poor assembly techniques and inadequate wax welds all contribute to metal scrap rates, yet often they are not addressed when attempting to improve casting yields. This paper will serve as a primer to better understand the items that must be considered when developing an automation plan. Key considerations to be addressed include; what should be automated, can a phased approach to automation be taken and what is required to automate either injection or assembly processes.
An overview of some of the successful automation
projects will be covered. 8:40 a.m. - 9:10 a.m.
Paper No. 2
Advanced Technology: Ceramic Shell Manufacturing Systems Eric Rodriguez, VA Technology, Ltd. Shell quality directly translates to casting quality, which in turn translates to business profitability and success. Today, advanced technologies are available to provide zero defect shells …. 100% of the time, with shell weights now extended to 2.5 tons. Shell Manufacturing Systems have been engineered to meet the required characteristics for aerospace, medical, and commercial casting companies. Innovative technologies have been developed to achieve maximum capacity output, and maximum dimensional integrity. Differing foundry requirements demand tailored solutions to satisfy quality and productivity goals. These ‘more ways than one’ solutions can all succeed providing they are underpinned with robust control to maintain Key Process Variables (KPV) and ensure the highest degree of process variability avoidance.
The paper will provide technical
details of the most advanced, productive, and largest sized Shell Manufacturing Systems for KPV control in operation throughout the international world of investment casting.
24 ❘ October 2014 ® 9:10 a.m. - 10:10 a.m. Panel Discussion
The Role of the Trade Association in Advancing the Industry Joseph E. Fritz, Investment Casting Institute Bill Sorensen, Foundry Educational Foundation Carlos Olabe, European Investment Casters’ Federation Thomas E. Prucha, American Foundry Society
10:10 a.m. - 10:30 a.m. 10:30 a.m. - 11:00 a.m.
Coffee Break sponsored by Paramelt
Paper No. 3
The Evolution of Pattern Wax Cleaners Sankar Bhattacharja / Ronald S. Doles Michael A. Romba, Nalco, an Ecolab Company In precision investment casting, the cleaning of wax patterns prior to investing in prime coat slurries is an important step in producing castings with a superior surface finish that is without defects. Solvents such as MEK, 1,1,1-trichlorethane and Freon® TF were widely used in the industry to remove surface contaminates from wax parts prior to shelling. Due to health, safety, and environmental factors, the industry was forced to move to relatively environmentally friendly cleaners such as citrus d-limonene. However, d-limonene still presents significant drawbacks, such as low flashpoints, the need to create and keep it in emulsion form, and shortages of raw materials that generate large cost fluctuations. This paper presents the work and methodology used to formulate a new cleaner that has low volatility and eliminates the drawbacks noted above. Included in the paper is detailed comparison data such as wetting and rinsing ability and prime coat adhesion.
Analytical microscopy is used to take a
closer look at the impact these products have on the wax surface. 11:00 a.m. - 11:30 a.m.
Paper No. 4
Vacuum Precision Investment Casting Furnace Design for Improved Productivity and Yield of Equiaxed, Directionally Solidified, and Single Crystal Castings
Andrew J. Elliott / Noel Guilliard / Allan Kay / Jai Narayan, Consarc Corporation Equiax and directional solidification investment casting furnace designs are discussed in the context of improved productivity and yield for the investment caster. Current design features, configurations, and options to address process needs, facility constraints, and productivity are reviewed.
This manuscript further highlights how
these furnace features and design choices can reduce casting defects and improve product yield. Finally, emerging technologies that may provide further enhancements for investment casting productivity and yield are considered.
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