19-20#02 Effect of Ceramic Sand on Cast Iron Mechanical Properties
Principal Investigators: Dr. Scott Giese, University of Northern Iowa
Steering Committee Chair: Brandon Reneau, Caterpillar
Due to the OSHA Silica Rule under enforcement in the foundry industry today, many foundries are considering changing from silica sand to a ceramic sand/media to alleviate the issue. Many questions are associated with this change, but one that is of primary importance is understanding the effect, if any, in microstructure and the associated mechanical properties that might accompany the use of the ceramic sand/media.
The purpose of this project was to evaluate the effect of ceramic sand/media on the mechanical properties for Class 30 iron and 80-55-06 ductile iron.
Library Paper Number: Coming Fall 2025
22-23#04 Biobased Polymer Foam Pattern for Lost Foam Casting
Principal Investigators: Jacob Belke, Mercury Marine
Steering Committee Chair: Marshall Miller, 3D Systems
Lost foam patterns are made of expanded polystyrene (EPS) which is derived from crude oil. The negative environmental impact of the oil and gas industry has been well documented and is not sustainable.
The purpose of this project was to identify an environmentally sustainable biopolymer(s) that can become an alternative to the current petroleum-derived polystyrene.
Library Paper Number: Coming Fall 2025
19-20#07 LFC Molds Produced Using Additive Manufacturing
Principal Investigator: Marshall Miller, Tesseract4D
Steering Committee Chair: Jeff Prickett, Metals Alloys & Refractories
Tooling constructed of T6061-T6 is considered expensive and requires special software and skilled programmers.
The purpose of this project was to determine the applicable metal additive manufacturing method and material for medium and high-volume production considering material durability, material costs, cycle time, equipment costs, and skill level required for production as compared to conventional methods.
Library Paper Number: 24-011
Webinar Link: Click Here
19-20#08 LFC Molds Produced Using Polymer FDM & SLA Additive Manufacturing
Principal Investigator: Marshall Miller, Tesseract4D
Steering Committee Chair: Jeff Prickett, Metals Alloys & Refractories
Tooling constructed of T6061-T6 is considered expensive and requires special programing software and skilled programmers.
The purpose of this project was to determine the applicable FDM (fused deposition modeling) polymer additive manufacturing and SLA (stereolithographic additive) method and material for low- and medium-volume production considering material durability, material costs, cycle time, equipment costs, and skill level required for production as compared to conventional methods.
Library Paper Number: 24-011
Webinar Link: Click Here
22-23#03 Effects of Si in High-Cr White Cast Irons
Principal Investigators: Richard Gundlach, Gundlach Consulting Services; "With help from John Tartaglia, Element Materials Technology"
Steering Committee Chair: Brian Bendig, Penticton Foundry
Silicon is a common alloying element that cannot be avoided in High-Cr white irons (HCWI). It has unique attributes that influence the microstructure and hardenability of heat-treated castings, and industry does not know how to adjust for variations in silicon.
The purpose of this project was to study the effects of different types of inoculants on the austenite grain size and mechanical properties of the differently inoculated cast irons. Heterogeneous nucleation to refine austenite in cast irons was also explored.
Library Paper Number: 24-088
Webinar Link: TBD