19-20#09 PVD Coatings to Aid Release for Permanent Mold Castings
Principal Investigators: Dr. Stephen Midson, Colorado School of Mines
Steering Committee Chair: Randy Oehrlein, Carley Foundry Inc.
Aluminum often strongly solders to uncoated steel dies when cast in permanent metal molds. To address this problem, metalcasters use lubricants, which often need to be applied to the die prior to the production of each casting. For high-pressure diecasting, organic lubricants are sprayed onto the die, while for permanent mold casting, ceramic coatings and graphite are used. Although the application is necessary, they cause various problems, such as reducing the quality of the castings and the creation of costly housekeeping issues. In addition, they are expensive and add to the cost of the casting.
The purpose of this project was to develop and utilize a laboratory test that can provide a quantitative measurement of the impact of different PVD coatings on the level of adhesion and force required to extract long cores from aluminum coatings.
Library Paper Number: Coming Fall 2024
Webinar Link: Click Here
20-21#03 Low CRI, High CSR Coke Cupola Trials
Principal Investigators: Steve Hay, Hay Melting Solutions; Bruce Blatzer
Steering Committee Chair: Alex Croll, Waupaca Foundry
Higher CSR (coke strength after reactivity) coke has higher hot strength--implying that coke with those properties will travel farther down the cupola shaft, which can enhance metal temperature and carbon pick up. Furthermore, the stronger coke in the presence of heat and CO2 will better support the burden in the cupola. Furthermore, lower ash fusion temperatures of blast furnace coke imply higher carbon pickup from such coke. Research is needed to determine if coke for cupola melting with a lower CRI (coke reactivity) and higher CSR can enhance performance and cost for cupola melting.
The purpose of this project is to reduce coke per ton of iron melted with no change in melted iron properties and no detrimental changes in the melting operation.
Library Paper Number: Coming Fall 2024
Webinar Link: TBD
17-18#07 Welding Alloy and Process for Al-Cu Sand Castings
Principal Investigators: David Weiss, Eck Industries; Gerald Gegel, Material Process Consultancy
Steering Committee Chair: John Grabel, CAT
Current practices to weld 200 series alloy castings, particularly for repair of wall defects or defects depths greater than 0.25” result in unsatisfactory welds. Both 206 and 2319 weld rods are typically used for repair welding of 206 castings.
The purpose of the project is to develop a new weld wire alloy and repair welding practices to assist with aluminum alloy casting defects. This project will also determine the effect of weld repair on tensile properties of A206 sand castings.
Library Paper Number: Coming Fall 2024
Webinar Coming October 8, 2024: Register Here
21-22#05 Digital Active Clay Measurement in Green Sand
Principal Investigators: Dr. James Springstead and Dr. Sam Ramrattan, Western Michigan University
Steering Committee Chair: Brian Rachwitz, EJ
Casting defects are consistently attributed to variations in green sand systems and limitations of the clay control methods for green sand. A better clay measurement technique is necessary to improve green sand systems.
The purpose of this project is to create a novel optimized method for the measurement of active clay in green sands that will be tested in multiple working foundries and is ready to be implemented as a standardized method.
Library Paper Number: Coming Fall 2024
Webinar Link: Click Here