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Level 1 environmental assessment of cupola emissions at the Tioga Foundry

Description: Sampling and analysis was undertaken to characterize and quantify particulate, organic and inorganic chemical concentrations in gaseous effluents downstream of an afterburner (AFB) or stack air addition (SAA) system in a cupola at the Tioga Casting Company in Owego, New York. The US Environmental Protection Agency/Industrial Environmental Research Laboratory (EPA/IERL) Level 1 environmental assessment procedures were used to determine if the level of pollutants present differed when using the A… more
Date: January 1, 1984
Creator: Menzies, K. T.; Adams, J. W. & Thrun, K. E.
Partner: UNT Libraries Government Documents Department
open access

Foundry energy conservation workbook

Description: This report discusses methods for promoting energy conservation in foundries. Use of electric power, natural gas, and coke are evaluated. Waste heat recovery systems are considered. Energy consumption in the specific processes of electric melting, natural gas melting, heat treatments, ladle melting, and coke fuel melting is described. An example energy analysis is included. (GHH)
Date: unknown
Partner: UNT Libraries Government Documents Department
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Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase III

Description: Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, … more
Date: April 1, 2008
Creator: Sabau, Adrian S
Partner: UNT Libraries Government Documents Department
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Foundry energy conservation workbook

Description: The foundry industry is a significant user of energy, and therefore, a natural candidate for efforts to save energy and improve efficiency by both governmental agencies and technical/trade associations. These efforts are designed to both improve the national energy position and improve the industry's efficiency and profitability. Increased energy cost and the reduced availability of fossil fuels at certain times have provided the incentive to curb waste and to utilize purchased energy wisely. E… more
Date: January 1, 1990
Partner: UNT Libraries Government Documents Department
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Final report on Expendable Pattern Casting Technology

Description: The Expendable Pattern Casting (EPC) process is a potential casting process breakthrough which could dramatically improve the competitiveness of the US foundry industry. Cooperatively supported by US Industry and the Department of Energy and managed by the American Foundrymen's Society, a project was started in May 1989 to develop and optimize expendable pattern casting technology. Four major tasks were conducted in the first phase of the project. Those tasks involved: (1) reviewing published l… more
Date: July 1, 1990
Partner: UNT Libraries Government Documents Department
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Final report on process modeling of cupola furnaces

Description: This report describes the first phase of the AFS/DOE program on mathematical modeling of cupola behavior, covering the period May 19, 1989 to July 19, 1990. The objective of the program is to develop a comprehensive mathematical model of the cupola furnace for on-line and off-line process control and optimization. The work is being carried out by five organizations: Massachusetts Institute of Technology with responsibility for heat transfer and fluid flow modeling, and incorporation of the chem… more
Date: July 1, 1990
Partner: UNT Libraries Government Documents Department
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Impact evaluation of an induction furnace replacement under the Energy $avings Plan at Mackenzie Specialty Castings, Incorporated

Description: This impact evaluation of an induction furnace replacement that was recently installed at Mackenzie Specialty Castings, Incorporated (Mackenzie Castings) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy Savings Plan (ESP) Program. The project consists of replacing old power supplies and induction furnace with new, more efficient supplies and equipment. The objective of this impact evaluation was to assess how much electrical energy is bei… more
Date: April 1, 1994
Creator: Oens, M. A. & Spanner, G. E.
Partner: UNT Libraries Government Documents Department
open access

Foundry energy conservation workbook

Description: This report discusses methods for promoting energy conservation in foundries. Use of electric power, natural gas, and coke are evaluated. Waste heat recovery systems are considered. Energy consumption in the specific processes of electric melting, natural gas melting, heat treatments, ladle melting, and coke fuel melting is described. An example energy analysis is included. (GHH)
Date: December 31, 1990
Partner: UNT Libraries Government Documents Department
open access

Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase II

Description: The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The first part of the project involved preparation of reports on the state of the art at that time for all the areas under consideration (die-wax, wax-shell, and shell-alloy). The primary R&D focus during Phase … more
Date: September 30, 2005
Creator: Cannell, Nick & Sabau, Adrian S.
Partner: UNT Libraries Government Documents Department
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FINAL REPORT: Reduction in Energy Consumption and Variability in Steel Foundry Operations

Description: This project worked to improve the efficiency of the steel casting industry by reducing the variability that occurs because of process and product variation. The project focused on the post shakeout operations since roughly half of the production costs are in this area. These improvements will reduce the amount of variability, making it easier to manage the operation and improve the competitiveness. The reduction in variability will also reduce the need for many rework operations, which will re… more
Date: May 24, 2005
Creator: Peters, F.
Partner: UNT Libraries Government Documents Department
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Determination of Bulk Dimensional Variation in Castings

Description: The purpose of this work is to improve the efficiency of green sand foundries so that they may continue to compete as the most cost-effective method of fabrication while meeting tightening constraints on near-net shape manufacturing. In order to achieve this objective, the study is divided into two major components. The first component concentrated on identifying which processes control surface finish on the castings and which provide potential reductions in variations. The second component ide… more
Date: April 14, 2005
Creator: Morse, Dr. James F. Cuttino Dr. Edward P.
Partner: UNT Libraries Government Documents Department
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Prevention of Porosity Formation and Other Effects of Gaseous Elements in Iron Castings

Description: Iron foundries have observed porosity primarily as interdendritic porosity in large freezing range alloys such as Ni-Hard I and hypoeutectic high Cr alloys or pinholes and fissure defects in gray and ductile irons. For most iron foundries, porosity problems occur sporadically, but even occasional outbreaks can be costly since even a very small amount of porosity can significantly reduce the mechanical properties of the castings. As a result when porosity is detected, the castings are scrapped a… more
Date: April 1, 2005
Creator: Center, Albany Research
Partner: UNT Libraries Government Documents Department
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Gating of Permanent Molds for ALuminum Casting

Description: This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferre… more
Date: March 30, 2004
Creator: Schwam, David; Wallace, John F.; Engle, Tom & Chang, Qingming
Partner: UNT Libraries Government Documents Department
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Grain Refinement of Permanent Mold Cast Copper Base Alloys

Description: Grain refinement behavior of copper alloys cast in permanent molds was investigated. This is one of the least studied subjects in copper alloy castings. Grain refinement is not widely practiced for leaded copper alloys cast in sand molds. Aluminum bronzes and high strength yellow brasses, cast in sand and permanent molds, were usually fine grained due to the presence of more than 2% iron. Grain refinement of the most common permanent mold casting alloys, leaded yellow brass and its lead-free re… more
Date: April 29, 2004
Creator: Sadayappan, M.; Thomson, J. P.; Elboujdaini, M.; Ping Gu, G. & Sahoo, M.
Partner: UNT Libraries Government Documents Department
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Heat Treatment Procedure Qualification for Steel Castings

Description: Heat treatment practices used by steel foundries have been carefully studied as part of comprehensive heat treatment procedure qualification development trials. These studies highlight the relationships between critical heat treatment process control parameters and heat treatment success. Foundry heat treatment trials to develop heat treatment procedure qualifications have shed light on the relationship between heat treatment theory and current practices. Furnace load time-temperature profiles … more
Date: April 29, 2004
Creator: Charles, Mariol; Deskevich, Nicholas; Varkey, Vipin; Voigt, Robert & Wollenburg, Angela
Partner: UNT Libraries Government Documents Department
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Excess Foundry Sand Characterization and Experimental Investigation in Controlled Low-Strength Material and Hot-Mixing Asphalt

Description: This report provides technical data regarding the reuse of excess foundry sand. The report addresses three topics: (1) a statistically sound evaluation of the characterization of foundry sand, (2) a laboratory investigation to qualify excess foundry sand as a major component in controlled low-strength material (CLSM), and (3) the identification of the best methods for using foundry sand as a replacement for natural aggregates for construction purposes, specifically in asphalt paving materials. … more
Date: October 31, 2004
Creator: Tikalsky, Pauul J.
Partner: UNT Libraries Government Documents Department
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Development of Lead-Free Copper Alloy-Graphite Castings. Technical Report, January 1994--December 1994

Description: Water model experiments were conducted to develop a two-stage stirring method for obtaining higher yields and a more uniform distribution of graphite particles in copper alloys. This was followed by several melts for synthesis of copper-graphite alloys in which Ti was used as a wetting agent to improve the wettability of graphite in the copper melt. In the first stage, a vortex method was employed to facilitate the addition of graphite particles into the copper melt. In the second stage, a spec… more
Date: July 1, 1995
Creator: Rohatgi, P. K.
Partner: UNT Libraries Government Documents Department
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Development of a Cast Iron Fatigue Properties Database for use with Modern Design Methods

Description: A reliable and comprehensive database of design properties for cast iron is key to full and efficient utilization of this versatile family of high production-volume engineering materials. A database of strain-life fatigue properties and supporting data for a wide range of structural cast irons representing industry standard quality was developed in this program. The database primarily covers ASTM/SAE standard structural grades of ADI, CGI, ductile iron and gray iron as well as an austempered gr… more
Date: September 18, 2003
Creator: DeLa'O, James, D.; Gundlach, Richard, B. & Tartaglia, John, M.
Partner: UNT Libraries Government Documents Department
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Re-Engineering Casting Production Systems - Final Report - 03/02/1998 - 03/01/2001

Description: The goal of this three-year project was to improve the production systems in use by steel foundries in the United States. Improvements in the production systems result in less rework, less scrap, and less material handling, all of which would significantly reduce the energy demands of the process. Furthermore, these improvements would allow the companies to be more competitive, more responsive to customers' needs, deliver products with less lead time and require less capital. The ultimate resul… more
Date: June 25, 2001
Creator: Peters, Frank & Van Voorhis, Timothy
Partner: UNT Libraries Government Documents Department
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Ergonomic Improvements for Foundries

Description: The goal of this project was to make improvements to the production systems of the steel casting industry through ergonomic improvements. Because of the wide variety of products, the wide range of product sizes, and the relatively small quantities of any particular product, manual operations remain a vital part of the production systems of the steel casting companies. Ergonomic improvements will assist the operators to more efficiently and consistently produce quality products.
Date: June 18, 2002
Creator: Peters, Frank & Patterson, Patrick
Partner: UNT Libraries Government Documents Department
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Final Report, Volume 4, The Develpoment of Qualification Standards forCast Super Duplex Stainless Steel (2507 Wrought Equivalent)

Description: The objective of the program is to determine the suitability of ASTM A923 Standard Test methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic-Ferritic Stainless Steels for 25 Cr Cast Super Duplex Stainless Steels (ASTM A890-5A). Different tests were carried out on the materials procured from various steel foundries as stated in the ASTM A923. The foundries were designated as Foundry A, B, C and D. All the materials were foundry solution annealed. Materials from Foun… more
Date: September 30, 2005
Creator: Hariharan, Vasudevan & Lundin, Carl, D.
Partner: UNT Libraries Government Documents Department
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Clean Metal Casting

Description: The objective of this project is to develop a technology for clean metal processing that is capable of consistently providing a metal cleanliness level that is fit for a given application. The program has five tasks: Development of melt cleanliness assessment technology, development of melt contamination avoidance technology, development of high temperature phase separation technology, establishment of a correlation between the level of melt cleanliness and as cast mechanical properties, and tr… more
Date: February 5, 2002
Creator: Makhlouf, Makhlouf M. & Apelian, Diran
Partner: UNT Libraries Government Documents Department
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Cupola modeling research: Phase 2 (Year one), Final report

Description: Objective was to develop a mathematical model of the cupola furnace (cast iron production) in on-line and off-line process control and optimization. In Phase I, the general structure of the heat transfer, fluid flow, and chemical models were laid out, providing reasonable descriptions of cupola behavior with a one-dimensional representation. Work was also initiated on a two-dimensional model. Phase II was focused on perfecting the one-dimensional model. The contributions include these from MIT,… more
Date: November 20, 1991
Partner: UNT Libraries Government Documents Department
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Proposed industrial recovered materials utilization targets for the metals and metal products industry

Description: Set targets for increased utilization of energy-saving recovered materials in the metals and metal products industries (ferrous, aluminium, copper, zinc, and lead) are discussed. Data preparation and methodology development and analysis of the technological and economic factors in order to prepare draft targets for the use of recovered materials are covered. Chapter 2 provides an introductory discussion of the factors that affect the recovery and reuse of secondary materials and the competition… more
Date: May 1, 1979
Partner: UNT Libraries Government Documents Department
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