61st Technical Conference & Equipment Expo Program
TUESDAY, OCTOBER 7, 2014, CONTINUED 9:10 a.m. - 9:40 a.m. Paper No. 8
New Methods to Manufacture Cores: 3D Printing and Room- Temperature Pourable Ceramic Jack Ziemba, Aristo Cast Eric Hellstrom, Florida State University Dan McGuire, University of Wisconsin-Whitewater Recent research conducted by Aristo Cast in Almont, MI and researchers from academia has produced the development of refractory powder recipes that permit the fabrication of highly detailed investment casting cores utilizing 3D powder printing technology. This invention will allow CAD programmers to design and transfer core files directly to commercially available 3D powder printers, creating usable refractory cores capable of withstanding temperatures up to a 3000ºF range. This new process offers the investment caster an additonal tool that will reduce manufacturing lead times as well as minimize tooling costs typically associated with the fabrication of investment casting cores.
9:40 a.m. - 10:15 a.m. Panel Discussion
Operator Training: Pitfalls and Best Practices Julie Markee, Key Process Innovations Mark Oles, Pine Tree Castings Connie Rudolph, Wisconsin Precision Castings Successful operation of an investment casting foundry requires the strict adherence to the process.
This includes ensuring that the
process is well-defined and controlled. Operators play a vital role in maintaining and controlling the process and while all foundries recognize the need to train their operators, most foundries don’t have a formalized process for conducting and verifying training. The purpose of this panel discussion would be to briefly discuss some of the common pitfalls around operator training and then have 2 to 3 foundries discuss how they approach operator training. each speak, discussion will open to the audience for questions.
After they 61st Technical Conference & Equipment Expo Sponsors:
Conference tote bags sponsored in partnership with Guardian Software Systems Conference lanyards sponsored in partnership with Remet®
Coffee break sponsors: Paramelt In’Tech Industries, Inc. Ceradyne, Inc., a 3M Company Nalco
26 ❘ October 2014 ® 10:15 a.m. - 10:30 a.m. 10:30 a.m. - 11:00 a.m.
Coffee Break sponsored by In'Tech Industries, Inc.
Paper No. 9
Evaluating Spalling Factors Through Measuring Intercoat Adhesion Conrad Holek / Zach Feffer, Ransom and Randolph The spalling defect caused from the delamination of shell layers in ceramic molds is a significant source of casting scrap and rework. Spalling occurs due to poor adhesion of one or more layers in a ceramic shell. The layer where delamination occurs has traditionally been difficult to isolate because no measurement technique has been widely utilized. Traditional efforts to solve this defect typically involve changes to the shell building process that cannot be evaluated until castings are completed. Process changes without evidence to indicate that the defect will be eliminated are risky. The foundry can lose time, material and potentially process control without seeing any impact on spalling defect reduction. Implementing a measurement technique earlier in the shell building process can reduce these risks. This paper focuses on a method to measure the weakest adhesion point of a ceramic shell sample. This test has been used to isolate ceramic shell construction variables that effect intercoat adhesion of ceramic shell layers. Utilizing this method, a foundry can optimize the slurry shell building process to reduce the potential for spalling defects on their castings. This test can be employed on a small scale without the need to jeopardize standard production.
11:00 a.m. - 11:30 a.m. Paper No. 10
Investigating the Behavior of Casting Wax During the Autoclave Process. Use of Controlled Stress Rheometry and FTIR Grant Bradley Ph.D. BSc, Remet UK Previously, Remet reported on the use of controlled stress rheometry (alongside DMA and DSC) as a method for investigating the behavior of casting waxes during the injection and subsequent cooling processes. This paper reports the use of temperature ramped controlled stress rheometry (yield measurement) and temperature controlled FTIR to investigate the behavior of wax during the autoclave process. Drawing on results obtained from Birmingham (UK) University’s FOCAST (Fundamentals Of investment CASTing) program, experiments have been carried out to investigate factors affecting the flow and absorption characteristics of wax at the shell/wax interface during the early stages of the autoclave process. Results are reported focusing on the variation in time and temperature response of various waxes, and the potential effects upon the dewax process.
I
N
E
V
E
S
I
T
M
S
E
N
T
C
A
T
S
T
A
I
N
G
I
N
S
M
T
I
S
T
U
T
E
N
I
V
E
T
E
N
T
C
S
I
N
G
I
N
T
T
U
T
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56
