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[Automotive Foundry Workers]

Description: Photograph of an unidentified man smoking a cigarette while pouring molten metal into a cast. Another worker can be seen in the background behind the flying sparks. Identical picture of another photo in the collection with a slightly lighter saturation. Photo by: Joe Clark, HBSS.
Date: 19uu
Creator: Clark, Joe
Partner: UNT Libraries Special Collections

[Automotive Foundry Workers]

Description: Photograph of an unidentified man smoking a cigarette while pouring molten metal into a cast. Another worker can be seen in the background behind the flying sparks. Photo by: Joe Clark, HBSS.
Date: 19uu
Creator: Clark, Joe
Partner: UNT Libraries Special Collections

The restoration of an Argonne National Laboratory foundry

Description: The Environmental Management Operations` Waste Management Department (WMD) at Argonne National Laboratory-East (ANL-E) undertook the restoration of an unused foundry with the goal of restoring the area for general use. The foundry was used in the fabrication of reactor components for ANL`s research and development programs; many of the items fabricated in the facility were radioactive, thereby contaminating the foundry equipment. This paper very briefly describes the dismantling and decontamination of the facility. The major challenges associated with the safe removal of the foundry equipment included the sheer size of the equipment, a limited overhead crane capability (4.5 tonne), the minimization of radioactive and hazardous wastes, and the cost-effective completion of the project, the hazardous and radioactive wastes present, and limited process knowledge (the facility was unused for many years).
Date: September 1, 1997
Creator: Shearer, T.; Pancake, D. & Shelton, B.
Partner: UNT Libraries Government Documents Department

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

100% foundry compatible packaging and full wafer release and die separation technique for surface micromachined devices

Description: A completely foundry compatible chip-scale package for surface micromachines has been successfully demonstrated. A pyrex (Corning 7740) glass cover is placed over the released surface micromachined die and anodically bonded to a planarized polysilicon bonding ring. Electrical feedthroughs for the surface micromachine pass underneath the polysilicon sealing ring. The package has been found to be hermetic with a leak rate of less than 5 x 10{sup {minus}8} atm cm{sup {minus}3}/s. This technology has applications in the areas of hermetic encapsulation and wafer level release and die separation.
Date: April 6, 2000
Creator: Oliver, Andrew D. & Matzke, Carolyn M.
Partner: UNT Libraries Government Documents Department

Waste minimization assessment for a manufacturer of iron castings and fabricated sheet metal parts

Description: The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. Waste Minimization Assessment Centers (WMACs) were established at selected universities and procedures were adapted from the EPA Waste Minimization Opportunity Assessment Manual. That document has been superseded by the Facility Pollution Prevention Guide. The WMAC team at the University of Louisville performed an assessment at a plant that manufactures iron castings and fabricated sheet metal parts. Foundry operations include mixing and mold formation, core making, metal pouring, shakeout, finishing, and painting. Cutting, shaping, and welding are the principal metal fabrication operations. The team`s report, detailing findings and recommendations indicated that paint-related wastes are generated in large quantities, and that significant waste reduction and cost savings could be realized by installing a dry powder coating system or by replacing conventional air spray paint guns with high-volume low-pressure spray guns. This research brief was developed by the principal investigators and EPA`s National Risk Management Research Laboratory, Cincinnati, OH, to announce key findings of an ongoing research project that is fully documented in a separate report of the same title available from University City Science Center.
Date: August 1, 1995
Creator: Fleischman, M.; Harris, J.J.; Handmaker, A. & Looby, G.P.
Partner: UNT Libraries Government Documents Department

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. The survival analysis statistical technique was used to characterize foundry sand over a full spectrum of general chemical parameters, metallic elements, and organic compounds regarding bulk analysis and leachate characterization. Not limited to characterization and environmental impact, foundry sand was evaluated by factor analyses, which contributes to proper selection of factor and maximization of the reuse marketplace for foundry sand. Regarding the integration of foundry sand into CLSM, excavatable CLSM and structural CLSM containing different types of excess foundry sands were investigated through laboratory experiments. Foundry sand was approved to constitute a major component in CLSM. Regarding the integration of foundry sand into asphalt paving materials, the optimum asphalt content was determined for each mixture, as well as the bulk density, maximum density, asphalt absorption, and air voids at N{sub ini}, N{sub des}, and N{sub max}. It was found that foundry sands can be used as an aggregate in hot-mix asphalt production, but each sand should be evaluated individually. Foundry sands tend to lower the strength of mixtures and also may make them more susceptible to moisture damage. Finally, traditional anti-stripping additives may decrease the moisture sensitivity of a mixture containing foundry sand, but not to the level allowed by most highway agencies.
Date: October 31, 2004
Creator: Tikalsky, Pauul J.
Partner: UNT Libraries Government Documents Department

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 transfer of technology to the industrial sector. Within the context of the first task, WPI has developed a standardized Reduced Pressure Test that has been endorsed by AFS as a recommended practice. In addition, within the context of task1, WPI has developed a melt cleanliness sensor based on the principles of electromagnetic separation. An industrial partner is commercializing the sensor. Within the context of the second task, WPI has developed environmentally friendly fluxes that do not contain fluorine. Within the context of the third task, WPI modeled the process of rotary degassing and verified the model predictions with experimental data. This model may be used to optimize the performance of industrial rotary degassers. Within the context of the fourth task, WPI has correlated the level of melt cleanliness at various foundries, including a sand casting foundry, a permanent mold casting foundry, and a die casting foundry, to the casting process and the resultant mechanical properties. This is useful in tailoring the melt cleansing operations at foundries to the particular casting process and the desired properties of cast components.
Date: February 5, 2002
Creator: Makhlouf, Makhlouf M. & Apelian, Diran
Partner: UNT Libraries Government Documents Department

A vertically integrated pixel readout device for the Vertex Detector at the International Linear Collider

Description: 3D-Integrated Circuit technology enables higher densities of electronic circuitry per unit area without the use of nanoscale processes. It is advantageous for mixed mode design with precise analog circuitry because processes with conservative feature sizes typically present lower process dispersions and tolerate higher power supply voltages, resulting in larger separation of a signal from the noise floor. Heterogeneous wafers (different foundries or different process families) may be combined with some 3D integration methods, leading to the optimization of each tier in the 3D stack. Tracking and vertexing in future High-Energy Physics (HEP) experiments involves construction of detectors composed of up to a few billions of channels. Readout electronics must record the position and time of each measurement with the highest achievable precision. This paper reviews a prototype of the first 3D readout chip for HEP, designed for a vertex detector at the International Linear Collider. The prototype features 20 x 20 {micro}m{sup 2} pixels, laid out in an array of 64 x 64 elements and was fabricated in a 3-tier 0.18 {micro}m Fully Depleted SOI CMOS process at MIT-Lincoln Laboratory. The tests showed correct functional operation of the structure. The chip performs a zero-suppressed readout. Successive submissions are planned in a commercial 3D bulk 0.13 {micro}m CMOS process to overcome some of the disadvantages of an FDSOI process.
Date: December 1, 2008
Creator: Deptuch, Grzegorz; Christian, David; Hoff, James; Lipton, Ronald; Shenai, Alpana; Trimpl, Marcel et al.
Partner: UNT Libraries Government Documents Department

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for October 1 to December 1998, and January 31 to March 31, 1999]

Description: Some highlights are: (1) Material development, process development, and part validation are occurring simultaneously on a fast track schedule. (2) Prior project activity has resulted in a program emphasis on three components--manifolds, mounting brackets, and motor mounts; and three casting techniques--squeeze casting, pressure die casting, and sand casting. (3) With the project focus, it appears possible to offer manifolds and mounting brackets for automotive qualification testing on a schedule in line with the PNGV Year 2004 goal. (4) Through an iterative process of fly ash treatment, MMC ingot preparation, foundry process refinement, and parts production, both foundries (Eck Industries and Thompson Aluminum Casting Company) are addressing the pre-competitive issues of: (a) Optimum castability with fly ash shapes and sizes; (b) Best mechanical properties derived from fly ash shapes and sizes; (c) Effective fly ash classification processes; (d) Mechanical properties resulting from various casting processes and fly ash formulations. Eck and TAC continued experiments with batch ingot provided by both Eck and the University of Wisconsin at Milwaukee. Castings were run that contained varying amounts of fly ash and different size fractions. Components were cast using cenosphere material to ascertain the effects of squeeze casting and to determine whether the pressure would break the cenospheres. Test parts are currently being machined into substandard test bars for mechanical testing. Also, the affect of heat treatments on ashalloy are being studied through comparison to two lots, one heat treated and one in the ''as cast'' condition.
Date: April 21, 1999
Creator: Weiss, David; Purgert, Robert; Rhudy, Richard & Rohatgi, P.
Partner: UNT Libraries Government Documents Department

Clean cast steel technology. Final report

Description: This report documents the results obtained from the Clean Cast Steel Technology Program financially supported by the DOE Metal Casting Competitiveness Research Program and industry. The primary objective of this program is to develop technology for delivering steel free of oxide macroinclusions to mold cavities. The overall objective is to improve the quality of cast steel by developing and demonstrating the technology for substantially reducing surface and sub-surface oxide inclusions. Two approaches are discussed here. A total of 23 castings were produced by submerge pouring along with sixty conventionally poured castings. The submerged poured castings contained, on average, 96% fewer observable surface inclusions (11.9 vs 0.4) compared to the conventionally poured cast parts. The variation in the population of surface inclusions also decreased by 88% from 5.5 to 0.7. The machinability of the casting was also improved by submerged pouring. The submerge poured castings required fewer cutting tool changes and less operator intervention during machining. Subsequent to these trials, the foundry has decided to purchase more shrouds for continued experimentation on other problem castings where submerge pouring is possible. An examination of melting and pouring practices in four foundries has been carried out. Three of the four foundries showed significant improvement in casting quality by manipulating the melting practice. These melting practice variables can be grouped into two separate categories. The first category is the pouring and filling practice. The second category concerns the concentration of oxidizable elements contained in the steel. Silicon, manganese, and aluminum concentrations were important factors in all four foundries. Clean heats can consistently be produced through improved melting practice and reducing exposure of the steel to atmospheric oxygen during pouring and filling.
Date: June 1, 1998
Creator: Bates, C.E. & Griffin, J.A.
Partner: UNT Libraries Government Documents Department

Dimensional variability of production steel castings

Description: Work is ongoing to characterize the dimensional variability of steel casting features. Data are being collected from castings produced at representative Steel Founders` Society of America foundries. Initial results based on more than 12,500 production casting feature measurements are presented for carbon and low alloy steel castings produced in green sand, no-bake, and shell molds. A comprehensive database of casting, pattern, and feature variables has been developed so that the influence of the variables on dimensional variability can be determined. Measurement system analysis is conducted to insure that large measurement error is not reported as dimensional variability. Results indicate that the dimensional variability of production casting features is less than indicated in current US (SFSA) and international (ISO) standards. Feature length, casting weight, parting line and molding process all strongly influence dimensional variability. Corresponding pattern measurements indicate that the actual shrinkage amount for casting features varies considerably. This variation in shrinkage will strongly influence the ability of the foundry to satisfy customer dimensional requirements.
Date: December 31, 1994
Creator: Peters, F.E.; Risteu, J.W.; Vaupel, W.G.; DeMeter, E.C. & Voigt, R.C.
Partner: UNT Libraries Government Documents Department

The implications of tolerance system interpretation on past and present dimensional variability studies

Description: Dimensional variability studies and published dimensional variability standards have been used by the foundry industry for years as an indicator of the casting process` ability to produce uniform parts. These studies are an extremely useful tool in the continuous ``dimensional dialogue`` between foundries and customers. The nature of these studies, and of the current tolerancing systems used by casting designers, leaves room for some misinterpretation and misuse of these study results. This paper contains two important discussions. The first part explains exactly what these studies represent. Following this is a brief explanation on dimensional and geometric tolerances and how they communicate dimensional requirements.
Date: December 31, 1994
Creator: Vaupel, W.G.; DeMeter, E.C.; Peters, F.E. & Voigt, R.C.
Partner: UNT Libraries Government Documents Department

National Metal Casting Research Institute final report. Volume 1, Sand reclamation

Description: A mobile thermal foundry sand reclamation unit was designed and constructed. This unit consisted of thermal and mechanical sand reclamation equipment installed on the bed of a 50 foot low-boy trailer. It was transported to a number of Midwest foundries for on-site demonstration of the sand reclamation process. This allowed participating foundries to have their own refuse sand (10-100 tons) processed and then reused in production for evaluation. The purpose for building the unit was to demonstrate to foundries through ``hands on`` experience that refuse sands can be reclaimed and successfully reused particularly in regard to product quality. Most of the participating foundries indicated a high level of satisfaction with the reclaimed sand. Laboratory testing of samples of the used sand, before and after processing by the demonstration unit, verified the usability of the reclaimed sand. One of the foundries participating was a brass foundry, the sand from this foundry contained lead and is classified as a hazardous material. After reclamation the sand was no longer hazardous and could also be reused in the foundry.
Date: August 1995
Creator: Vondra, L. F. & Burningham, J. S.
Partner: UNT Libraries Government Documents Department

Assessing the capabilities of patternshop measurement systems

Description: Casting customers continue to demand tighter dimensional tolerances for casting features. The foundry then places demands on the patternshop to produce more accurate patterns. Control of all sources of dimensional variability, including measurement system variability in the foundry and patternshop, is important to insure casting accuracy. Sources of dimensional casting errors will be reviewed, focusing on the importance of accurate patterns. The foundry and patternshop together must work within the tolerance limits established by the customer. In light of contemporary pattern tolerances, the patternshop must review its current measurement methods. The measurement instrument must have sufficient resolution to detect part variability. In addition, the measurement equipment must be used consistently by all patternmakers to insure adequacy of the measurement system. Without these precautions, measurement error can significantly contribute to overall pattern variability. Simple robust methods to check the adequacy of pattern measurement systems are presented. These tests will determine the variability that is contributed by the measurement equipment and by the operators. Steps to control measurement variability once it has been identified are also provided. Measurement system errors for various types of measurement equipment are compared to the allowable pattern tolerances, that are established together by the foundry and patternshop.
Date: December 1, 1995
Creator: Peters, F.E. & Voigt, R.C.
Partner: UNT Libraries Government Documents Department

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 preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.
Date: March 30, 2004
Creator: Schwam, David; Wallace, John F.; Engle, Tom & Chang, Qingming
Partner: UNT Libraries Government Documents Department

Yield improvement and defect reduction in steel casting

Description: This research project investigated yield improvement and defect reduction techniques in steel casting. Research and technology development was performed in the following three specific areas: (1) Feeding rules for high alloy steel castings; (2) Unconventional yield improvement and defect reduction techniques--(a) Riser pressurization; and (b) Filling with a tilting mold; and (3) Modeling of reoxidation inclusions during filling of steel castings. During the preparation of the proposal for this project, these areas were identified by the High Alloy Committee and Carbon and Low Alloy Committee of the Steel Founders' Society of America (SFSA) as having the highest research priority to the steel foundry industry. The research in each of the areas involved a combination of foundry experiments, modeling and simulation. Numerous SFSA member steel foundries participated in the project through casting trials and meetings. The technology resulting from this project will result in decreased scrap and rework, casting yield improvement, and higher quality steel castings produced with less iteration. This will result in considerable business benefits to steel foundries, primarily due to reduced energy and labor costs, increased capacity and productivity, reduced lead-time, and wider use and application of steel castings. As estimated using energy data provided by the DOE, the technology produced as a result of this project will result in an energy savings of 2.6 x 10{sup 12} BTU/year. This excludes the savings that were anticipated from the mold tilting research. In addition to the energy savings, and corresponding financial savings this implies, there are substantial environmental benefits as well. The results from each of the research areas listed above are summarized.
Date: March 16, 2004
Creator: Carlson, Kent
Partner: UNT Libraries Government Documents Department

National Metal Casting Research Institute final report. Volume 4, Plan for technology transfer

Description: This project was developed because of growing concern over the decline of the US metal casting industry; it springs from the Public Law 101-425 ``Department of Energy Metal Casting Competitiveness Research Act of 1990.`` The project sought the opinion of two groups in the metal casting industry: the operating users (foundries, other producers), and information purveyors. They were asked what was working, what was not, and what were some promising, innovative programs that are taking place or should be tried. Results and recommendations are given.
Date: April 1, 1994
Creator: Griffee, W.B. & Davis, S.
Partner: UNT Libraries Government Documents Department

Reduction in Energy Consumption & 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 result in a direct reduction of energy usage, particularly by the reduction of repeated heat treatment operations. Further energy savings will be realized from the reduction of scrap and reduced handling. Field studies were conducted at ten steel foundries that represented the U.S. steel casting industry, for a total of over 100 weeks of production observation. These studies quantified the amount of variability, and looked toward determining the source. A focus of the data collected was the grinding operations since this is a major effort in the cleaning room, and it represents the overall casting quality. The grinding was divided into two categories, expected and unexpected. Expected grinding is that in which the location of the effort is known prior to making the casting, such as smoothing parting lines, gates, and riser contacts. Unexpected grinding, which was approximately 80% of the effort, was done to improve the surfaces at weld repair locations, to rectify burnt on sand, and other surface anomalies at random locations. Unexpected grinding represents about 80% of the grinding effort. By quantifying this effort, the project raised awareness within the industry and the industry is continuing to make improvements. The field studies showed that the amount of variation of grinding operations (normalized because of the diverse set of parts studied) was very consistent across the industry. The field studies identified ...
Date: May 4, 2005
Creator: Peters, Frank
Partner: UNT Libraries Government Documents Department

Heat Treatment Procedure Qualification for Steel Castings

Description: The science of heat treatment has been well studied and is the basis from which existing specifications and practices for the heat treatment of steel castings have been developed. Although these existing specifications address the general needs of steel castings to be heat-treated, they do not take into account the variability in the parameters that govern the processes. The need for a heat treatment qualification procedure that accounts for this variability during heat treatment is an important step toward heat treatment quality assurance. The variability in temperatures within a heat treatment furnace is one such variable that a foundry has to contend with in its day-to-day activity. Though specifications indicate the temperatures at which a particular heat treatment has to be conducted, heat treatment specifications do not adequately account for all aspects of heat treatment quality assurance. The heat treatment qualification procedure will comprise of a robust set of rules and guidelines that ensure that foundries will still be able to operate within the set of constraints imposed on them by non-deterministic elements within the processes.
Date: February 2, 2003
Creator: Voigt, Professor Robert C.
Partner: UNT Libraries Government Documents Department

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 being saved at Mackenzie Castings as a result of the ESP and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Mackenzie Castings`s proposal and completion report). Based on this impact evaluation, energy savings from this project are expected to be 425,257 kWh/yr at minimum annual production, 647,037 kWh/yr at typical annual production, and 1,294,074 kWh/yr at maximum annual production, or 0.05, 0.07, and 0.15 average megawatts, respectively. On a per-ton basis, this project will save 608 kWh/ton or 31% at minimum production and 431 kWh/ton or 39% at typical and maximum production. The project cost $277,110 to install, and Mackenzie Castings received payment of $102,551 (in 1993 dollars) from Bonneville for acquisition of the energy savings. The real levelized cost of these energy savings to Bonneville is 22.9 mills/kWh at minimum production, 15.1 mills/kWh typical production, and 7.5 mills/kWh at maximum production (in 1993 dollars) over the project`s assumed 15-year life. The real levelized cost to the region is 59.1 mills/kWh at minimum production, 38.8 mills/kWh at typical production, and 19.4 mills/kWh at maximum production in 1993 dollars, not including transmission and distribution effects.
Date: April 1, 1994
Creator: Oens, M. A. & Spanner, G. E.
Partner: UNT Libraries Government Documents Department

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, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The shell mold was considered to be a pure elastic material. The alloy dimensions were obtained from numerical simulations. For 17-4PH stainless steel parts, the alloy shrinkage factors ...
Date: April 1, 2008
Creator: Sabau, Adrian S
Partner: UNT Libraries Government Documents Department