59th Technical Conference & Expo Program
SUNDAY, OCT. 7 3 - 6 p.m.
...............................................REGISTRATION
6 - 7:30 p.m. ............................WELCOME RECEPTION
MONDAY, OCT. 8 7 a.m. - 6 p.m.
.......................................REGISTRATION 8 - 8:10 a.m. ..................... WELCOME INTRODUCTION
8:10 - 8:45 a.m. ............................................ Paper No. 1 Russ Gallagher, Bescast
The Influence to Thermal Conductivity of a High Emissivity Coating to a Fused Silica Shell System This study is a refinement of a previous presentation
(2010 ICI Conference) on the influence to thermal con- ductivity of a high emissivity coating applied to a fused silica shell system. Heat transfer modifying treatments are commonly used in the investment casting industry as an attempt to influence the progression of solidification in a direction that feeds the volumetric contraction in areas not easily gated. Complex parts with marginally designed gating systems often suffer from a “latent defect” of inter- nal shrinkage that may only be revealed after machining or failure in service. While the high emissivity coating aids in the selective cooling of a fused silica shell, a variety of insulating techniques are also used to improve casting quality. This presentation will describe the heat transfer test method used by Bescast, Inc. to report temperature loss as a function of time and the cooling rate difference as a function of time. The selective application of coating and insulating blankets provide the casting engineer more tools in the quest to provide the customer with castings that meet the internal soundness requirements.
8:45 - 9:20 a.m. ............................................ Paper No. 2 Joe Stanco, Remet Corporation A Robust Solvency Power Test for Determining End Life of Pattern Washes For many years, foundries relied on straight colloidal
binder slurry systems to meet their shellbuilding needs. Then in the 1970s polymer-enhanced slurry systems helped foundries produce a more robust shell. But even today, many foundries look at polymers as just another slurry additive like a wetting agent or antifoam. Many times, the thought is “a polymer is a polymer,” with one being no better than another. Actually, polymers comprise a large class of synthetic and natural materials with a wide range of properties. The selection of the right polymer, based on its enhanced properties and use in the proper application, can have a huge effect on shell properties like improved crack resistance, drying rate, and permeability. This paper will discuss basic polymer chemistry as well as the role of polymers in slurry and shell properties and
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performance. Polymer performance test results on both prime and backup shell systems will be presented.
9:20 - 9:55 a.m. ............................................ Paper No. 3 Bruce Phipps, MPI Digitization in the Wax Room- How Digitization is Used to Improve and Control the Process There is little question that we live in a digital world.
The question becomes how can we put the information to work? This paper serves to answer that question specifi- cally as digital data exists in the wax room of an invest- ment casting foundry. Meeting customer expectations has been a driving force for decades and many different qual- ity management systems have evolved to achieve this re- quirement. Business management dictates that any suc- cessful program provides a sound ROI. A common theme with these programs is data collection and analysis. Our digital world makes both the collection of key metrics and the analysis of those metrics more much more economi- cal. All this effort has lead toward more robust process control. The core of this paper deals with how to collect appropriate data and analyze that data for the highest lev- els of process control in the wax room. Using the latest model wax injection and assembly equipment allows this level of process control and data collection for both qualita- tive and quantitative analysis.
9:55 - 10:15 a.m. ................................................. BREAK
10:15 a.m. - 10:50 a.m. ................................ Paper No. 4 R.C. Oberst, Industrial Ceramic Products; Nicole Ilg, O’Fallon Casting Water Soluble Ceramic Cores in the Manufacture of Aluminum Investment Castings
Newly developed water soluble ceramic core materi- als have some advantages over soluble wax and tradi- tional ceramic cores. Continuing research and recent developments are outlined.
10:50 - 11:25 a.m. ......................................... Paper No. 5 Gavin Dooley, University of Birmingham Characterization of Rapid Shell Manufacturing System for Improved Lead Times in the Manufacture of Invesment Cast Parts This paper presents the results of research being car-
ried out within the EU-funded MedCast Project entitled “Development of Foundry Casting Methods for Cost- Effective Manufacture of Medical Implants” (MedCast, GA number 251269). The partnership is led by DePuy Johnson & Johnson and three university collaborators. Research into shell systems has focused on understand- ing the behaviour of a rapid drying shell. The strength, permeability, thermal expansion and microstructure of a rapid shell system are compared to a representative shell
September 2012
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