FEATURES Ductile Iron News – Issue 2, June 2014

• 2014 Annual Mtg. Highlights The Ductile Iron Society held their spring 2014 Annual Meeting in Lethbridge, Controlling Slag Defects in GI & Alberta, Canada at the Coast Hotel & Conference Center from June 4 to 6, 2014. • DI – Alan Patrick, Matt th LaFramboise & Dave Williams On Wednesday June 4 , we started the 3 days with the DIS Research Committee 3D Printing for the DI Foundry meeting from 8am to 12 noon. There were 39 members and guests that attended • Industry – Steve Murray in person and 7 members and guests that attended by conference calling. The Is the Growth of the Ductile Iron • rest of the other 4 operating committees held their meetings from 1:00pm to Industry at Risk – George Kokos 3:00pm and the newly formed DIS MetalCasting Forum was held from 3:00pm to High Silicon Molybdenum Cast Iron With Mixed Graphite (MG) 5:00pm. At the same time the DIS Board of Directors held their meeting to • Shapes for Elevated Temper- review the past year’s financials along with approving the new budget for ature Applications – Delin Li 2014/15, and the elections of 4 new directors and 1 new Vice President. Preventing Rust and Corrosion on • Ductile Iron Using VCI Technology – Wayne Siefert The Research Committee approved and the Board of Directors gave their Machining Ductile Iron: Benefits, approval for the funds for a new research project #53 on “Reducing the Casting • Concerns and General Guidelines – Tim Heagney Skin in Ductile Iron Castings” for $18,700.00. The research will be performed by Virtual Tour of Penticton Foundry UAB in Alabama. Also we are just waiting for the final report on research project • – Chad Gentes #49 and as soon as it is complete you will find it on the DIS website. Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim • th Csonka, Joseph Keske,, Kyle On Thursday June 5 , the attendees were presented with 2 panels. One was on Rabine the continuing subject of, “back to the basics”, and this time it was on “Inoculation”. Also we had one smaller panel on “controlling Slag Defects in Gray DEPARTMENTS & Ductile Iron”. We had 5 other individual presentations and one virtual tour of • News Briefs Penticton Foundry by Chad Gentes. As we have done in the past, you can find these presentations attached to this news edition. If not available you can • Back Issues contact Jim Wood, the Executive Director at [email protected] . • DIS Home Page At the luncheon on Thursday, June 5th we held the Annual Meeting for the members who were in attendance.

Patricio Gil (DIS President) of Blackhawk de Mexico

Here are the notes from Patricio’s presentation;

At this time i will recap the society’s activities during this past year before proceeding with the annual business meeting and the election of new officers.

The Ductile Iron Marketting Group once again was out attending trade exhibitions throughout the year. They exhibited back in March at the 2014 Con/Ag show in

Las Vegas, Nevada where it was reported that over 150,000 people attended.

Thanks go out to the volunteers and their companies who made this a great success. They were;

Vasko Popovski of Applied Process

Henry Frear of Applied Process

Carlos De La Graza of Blackhawk De Mexico

Bob O’Rourke of Charter Dura Bar

Chris Witt of Dotson Foundry

Jim Wood of DIS

Greg Selip of Ellwood Engineered Castings

Brian Connell of Ellwood Engineered Castings

Dylan Bruins of Lethbridge Iron Works

Mark Mundell of Lethbridge Iron Works

Vadim Pikhovich of Magma Corporation

John Lewensky of Pure Power Technologies Dave Gilson of Sintercast

The group of volunteers felt it was a great success and we were able to connect with design engineers as well as help out some consumers of ductile iron castings.

In addition, the member services committee had our table top on display in April at the 2014 AFS CASTING CONGRESS in Schaumburg, Illinois. Our booth and the volunteers, who manned it, were very busy during the whole show. Thanks go out to Mark Beers of ASK, Jim Wood of DIS, Alan Patrick of Elyria Foundry, Patricio Gil of Blackhawk de Mexico, Alex Gyarmaty of Coorstek and other committee members and volunteers.

We are striving to make our library available to the members through the website. There is now a link to the Lyle Jenkins Library under the Members Only area. These books were a collection of Art Spangler, Lyle Jenkins, P. H. Mani And Keith Millis.

Also staying with the website, everyone should have now seen our new look. Thanks go to Susie for starting up the “Ask the Experts” program again and it too is under the Members Only area. Keep watch on the website periodically because you will stay in touch with up-to-date news and the calendar of events.

The board approved increasing our scholarships from $2000 to $3000 each for 4 very awarding students.

This past fiscal year we gained four new members.

GENERAL MOTORS DEFIANCE OHIO (RESEARCH PATRON) PRODUCTORA DE HIERRO MALEABLE S.A. (FOUNDRY MEMBER-MEXICO) DITEMSA (ASSOCIATE MEMBER-MEXICO) CDB PROJECTS SERVICES LLC (ASSOCIATE MEMBER)

During this past year we held two general meetings. The first one was our Annual Meeting held in Indianapolis, Indiana in conjunction with a tour of Pure Power Technologies plant (formerly Navistar) in Indianapolis with 143 attending including 20 guests. The second meeting held last fall, was the 5th Keith Millis Symposium in Nashville, TN. The attendance for that meeting was 218 including 26 guests. Thanks to the AFS for co-sponsoring this symposium. Also a special thanks go out to those corporate sponsors who donated $1000 each to help offset the costs of the reception & banquet.

The Ductile Iron Society did hold a Production Seminar on February 11 & 12, 2014 at the Hilton Garden Inn at O’hare Airport in Chicago. The attendance was 30 for this seminar. We were very delighted to see so many people register. Thanks go out to our very special instructors, Kathy Hayrynen of Applied Process, Gene Muratore, DIS consultant and Don Craig of Selee Corporation. Also in march 2014 we lost a very good friend of the DIS. Fred Linebarger was a past director of the society, long time member of the DIS Research Committee and also a long time instructor at the DIS production seminar. We will all miss his humor and wit during future seminars.

Also, I want to thank all of those that contributed to our “Hot Topics” publications and those who wrote articles for the “Ductile Iron News”.

Four Keith D. Millis Scholarships were awarded at the 2013 FEF College Industry Conference held on November 15 & 16, 2013 at the Westin Hotel in Chicago. I would like to thank John Keough of Applied Process and Gary Gigante of Waupaca Foundry for selecting this year’s students. They were Erica Hill of The University of Northern Iowa, Steve Miller of The University of Wisconsin – Milwaukee, Connor Montgomery of The University of Wisconsin – Platteville and Matthew Wason of The University Of Northern Iowa. Each student received $3000.

Once again this year’s CIC Conference is in November at the Westin Downtown Chicago and we will again hand out $12,000 in scholarships to 4 deserving students.

Your society continues to make a donation to the Keith Millis scholarship fund every year so it will continue to grow. This past year we made a one-time donation of $20,000 and reached another goal of Chromium in donations to the fund. This $20,000 came as a result of the proceeds from the Keith Millis Symposium. AFS also donated $20,000 to their fund from the same Keith Millis Symposium.

Jim Wood attended this past year’s conference. We also had a table top booth for the industry information session where we distributed the “Doing It Spheroidal” T-shirts. Thanks go out to Kathy Hayrynen & Chip Keough of Applied Process who donated their time to help out at the table top.

Also we would like to thank those members who sponsored these T-shirts. They are Ask Chemicals, Applied Process, Allied Mineral Products, Buck Company, Bremen Castings, Blackhawk De Mexico, Dotson Iron Castings, Dura-Bar, Foseco, Globe Metallurgical, Green Packaging, Hitachi Metals Automotive Components, Hickman Williams & Company, Lethbridge Iron Works, Magma Foundry Technologies, and Waupaca Foundry. Also I should mention the hard work by your University Relations Committee members. Thanks go out to Bill Sorensen and Pam Lechner for their invitation to attend this important conference.

The Research Committee met three times during the past year. We completed one project in January 2014. It was #48 and was “Evaluation Of Normalizing Heat Treatment To Develop Improved Properties In Heavy Section Pearlitic Iron” by Rick Gundlach of Element Materials Technology. Also we are just waiting on the final report from #49 and it was “Analysis of Pearlitic Ductile Iron With Enhanced Mechanical Properties”. The Research Committee awarded two new projects, #51 – “Fatigue Resistance Of Weld Repaired Ductile Iron Castings” to Edison Welding Institute in Columbus, Ohio and #52 – “Evaluation Of The Influence Of Barium, Silicon And Inoculation In Counteracting The Effects Of Increased Manganese Levels On Varying Section Thickness Of Ferritic Ductile Iron” to Joyworks in Ann Arbor, MI and Element Materials Technology in Wixom, MI. This was a total of $77,000 of new research work.

The Research Committee is looking for approval on 1 new project for the 2014/2015 budget year for $18,700 on “Reducing The Casting Skin In Ductile Iron Castings” by the University of Alabama.

Thanks go out to Anhua Yu of HMAC for volunteering to be our Chairman of the Research Committee for the last 3 years and we welcome Brandon Reneau of Caterpillar as the new Chairman. Vadim Pikhovich of Magma will replace Brandon as the new Vice Chairman for the next 3 years.

We will now proceed with the annual business meeting.

We have 1 Associate member retiring from the Board of Directors as of June 30th. He is Alex Gyarmaty of Coorstek, ULC. We would like to thank Alex for his participation and dedication to the society over the past 3 years. We also have 3 Foundry members retiring from the Board of Directors as of June 30th. They are Tim Brown of Benton Foundry, Andy Franks of Hitachi Metals Automotive group and Greg Selip of Ellwood Engineered Castings. Also we would like to thank these 3 gentleman for volunteering their time and dedication to the society for the last 3 years.

If there is anyone who would be interested in volunteering their time to join the DIS Board of Directors, please let Jim Wood know.

To replace those retiring board members, the Nominating Committee recommends the following slate to serve on the Board of Directors for a 3 year term effective July 1, 2014;

DAVE GILSON OF SINTERCAST - (ASSOCIATE MEMBER) MARK FIELDS OF GLIDEWELL SPECIALTY PRODUCTS – (FOUNDRY MEMBER) BRANDON RENEAU OF CATERPILLAR – (FOUNDRY MEMBER) JOHN LEWENSKY OF PURE POWER TECHNOLOGIES – (FOUNDRY MEMBER)

Also this is my last Annual Report to the members as your President. Our next President of the society is Bob O’Rourke of Dura-Bar and to replace him as Vice President the Nominating Committee recommends Mike Galvin of Buck Company as our new Vice President.

Ask the attendees to approve the slate. Those show their approval by saying yea, and those who disapprove signify by saying nay. The attendees voted unanimously to approve the slate.

I declare that this annual meeting is now adjourned.

Thanks, Patricio Gil June 5, 2014

At the banquet on Thursday evening, Patricio was the master of ceremonies for his last time. Patricio first introduced all the guests who came to attend this meeting. They were;

Randy Penner, Darren Henaire, Neal McCain and David Correia of Ancast Foundry in Winnipeg, Manitoba Richard Pyper and Jason Brooks of Karrich Industries in Selkirk, Manitoba Kris Klynstra of Wesmat in Leduc, Alberta Bart Frauenfeld of Inproheat in Edmonton, Alberta Ike Wall of Monarch Industries in Winnipeg, Manitoba Ike Dyck and Jorge Bernal of Integra Castings in Winkler, Manitoba Ray Tyers of OCL in Vancouver, British Columbia Warren Geraghty of Robar Industries in Vancouver, British Columbia Rick Bell of Urbanmine Inc. in Winnipeg, Manitoba

Patricio then presented membership certificates to the following new members of the DIS and the representative of that company in attendance.

Patricio (L) & Mark Murphy of CDB Projects Patricio (R) & Haydn Parkin of Ditemsa

Services LLC

Patricio (L) & Gabriel Trujillo of Prod- Patricio (L) & Walt Wan of Betz Ind. uctora De Hierro Maleable S.A. de C.V.

Betz Foundry has been a member of the DIS since March 2009 but never received their membership certificate so we presented one at this meeting to Walt who was representing Betz Foundry.

Patricio then introduced Kathy Hayrynen as the AM Technical Chair to assist in handing out our traditional speaker gift to each of the presenters.

Kathy & Wayne Siefert of Green Packaging Kathy & Tim Heagney of Charter Dura-Bar

Kathy & Chad Gentes of Penticton Fdy Kathy & Jim Csonka of Hickman Williams & Company

Kathy & Mike Galvin of Buck Company Kathy & Riley Kerestes of Caterpillar, Inc.

Joseph Keske of Waupaca Marinette Kathy & Kyle Rabine of Brillion Iron Works

Patricio then asked Jim Csonka of Hickman Williams & Company, the PM technical chair to assist in handing out the speaker gifts.

Jim & Alan Patrick of Elyria Foundry Jim & Matt LaFramboise of Auburn Labs

Jim & Dave Williams of ASI International Steve Murray of Hoosier Pattern

Jim & George Kokos of Caterpillar, Inc. Jim & Delin Li of Canmet Materials Canada

Patricio then called the retiring Directors to the front of the room to receive their certificates of appreciation. They were;

Patricio and Andy Franks of Hitachi Metals Patricio and Alex Gyarmaty of CoorsTek, Automotive Group ULC

Patricio and Greg Selip of Ellwood Engineered Castings

Also retiring is Tim Brown of Benton Foundry who was not in attendance. Thanks again to all these Board Members for volunteering their time to serve on the Board for the last 3 years.

Patricio then introduced the new directors who were voted on the Board officially at the annual meeting at lunch earlier in the day. They are Mark Fields (Foundry Director) of Glidewell Specialties Foundry Company, Dave Gilson (Associate Director) of SinterCast, John Lewensky (Foundry Director) of Pure Power Technologies and Brandon Reneau (Foundry Director) of Caterpillar, Inc. Also Mike Galvin of Buck Company was elected the Vice President for the next 2 years.

Congratulations to each gentleman and we look forward to their service to the

DIS.

Next Patricio handed out to Anhua Yu of Hitachi Metals Automotive Group, the certificate of appreciation for his retirement from the position of Research Committee Chairperson for the last three years.

From Left Bob O’Rourke (Incoming President) Anhua Yu and Patricio Gil

Also the society wishes to THANK Patricio for the last 2 years that he has been the President of the DIS.

From left are Bob O’Rourke, Patricio Gil and Jim Wood

th On Friday June 6 the group was given a tour of Lethbridge Iron in Lethbridge, Alberta, Canada. John Davies gave a small presentation on Thursday evening about the history of Lethbridge Iron. Today it is still a family owned company and is the third generation.

This concluded the Spring Annual Meeting in Lethbridge, Alberta, Canada. There were 120 in attendance and we wish to thank every one of them and their companies for allowing them the time to attend. We hope to see everyone at the fall T&O meeting to be held in Decatur, IL from October 29-31, 2014 at the Decatur Conference Center & Hotel with a tour of Decatur Foundry.

FEATURES DIMG/ DESIGN WITH DUCTILE IRON SEMINAR

The DIS will hold the first ever Design with Ductile Iron Seminar on Tuesday,

• 2014 Annual Mtg. Highlights October 28, 2014 at the Decatur Conference Center & Hotel from approximately Controlling Slag Defects in GI & 9:00am – 3:00pm for any of our DIS Members who would like to invite their • DI – Alan Patrick, Matt customers or any design engineers to attend. This is sponsored by the Ductile LaFramboise & Dave Williams 3D Printing for the DI Foundry Iron Society and will be organized by the Ductile Iron Marketing Group. Here is a • Industry – Steve Murray tentative schedule for this meeting Is the Growth of the Ductile Iron • Industry at Risk – George Kokos 9:45 – 10:00am Introduction/ Video High Silicon Molybdenum Cast Iron With Mixed Graphite (MG) 10:00 – 11:30am Basics of Ductile Iron – Properties, Micro-structures, • Shapes for Elevated Temper- Standards, Processing and Compacted Graphite Iron ature Applications – Delin Li Overview Preventing Rust and Corrosion on • Ductile Iron Using VCI 11:30 – 12:00 Ductile Iron Casting Design and Conversions

Technology – Wayne Siefert 12:00 – 12:45pm Lunch Machining Ductile Iron: Benefits, 12:45 – 1:45pm Ductile Iron Casting Design and Conversions • Concerns and General Guidelines (Cont.…) – Tim Heagney Virtual Tour of Penticton Foundry 1:45 – 2:00pm Ductile Iron Machining • – Chad Gentes 2:00 – 3:00pm Heat Treating of Ductile Iron Inoculation Method Panel – Mike 3:00pm Q&A, and Adjournment Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle

Rabine Keep an eye on the DIS website for more information and look for future notifications. There will likely be a limit to the number of attendees. Lunch and

DEPARTMENTS breaks will be supplied. This will be free to any attending.

• News Briefs FUNDIEXPO • Back Issues

• DIS Home Page Please mark your calendar for the 2014 FundiExpo being held in Monterrey, Mexico from September 24-26, 2014. Some of our members will be making presentations. Gene Muratore will be making a presentation on behalf of the DIS and Dave Williams of ASI will be making a presentation on fluxes. Also the DIS Member Services committee and Jim Wood will be taking our table top booth to this show and exhibiting. The exhibit days are September 24 & 25 from 11:00 to 19:00 and September 26 from 11:00 to 18:00.

Thanks go out to Fernando Morales of Fundicion Aguilas (a DIS foundry member) and Expo Chairman for giving the DIS this opportunity to exhibit. If any members speak English and Spanish and would like to volunteer to work the booth, please contact Jim Wood at the DIS office or [email protected] .

Jim Wood

DIS Executive Director

CONTROLLING SLAG DEFECTS IN GRAY & DUCTILE IRON FEATURES

ALAN PATRICK, MATT LaFRAMBOISE, DAVE WILLIAMS • 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & • DI – Alan Patrick, Matt ALAN PATRICK LaFramboise & Dave Williams 3D Printing for the DI Foundry • Industry – Steve Murray ALAN GRADUATED FROM THE UNIVERSITY OF PITTSBURGH IN 1973 Is the Growth of the Ductile Iron • WITH HIS BS IN METALLURGY AND MATERIALS ENGINEERING. HE Industry at Risk – George Kokos High Silicon Molybdenum Cast BEGAN HIS PROFESSIONAL CAREER WITH HAYES-ALBION Iron With Mixed Graphite (MG) • CORPORATION IN ALBION, MI FOLLOWED BY AUTO SPECIALITIES Shapes for Elevated Temper-

ature Applications – Delin Li CORPORATION, BUCK COMPANY, ROCKWELL AUTOMATION, GREDE Preventing Rust and Corrosion on – IRON MOUNTAIN, BRILLION IRON WORKS, AND IS PRESENTLY • Ductile Iron Using VCI

Technology – Wayne Siefert EMPLOYED AT ELYRIA AND HODGE FOUNDRIES AS THEIR Machining Ductile Iron: Benefits, CORPORATE METALLURGIST. HE HAS HELD MANY POSITIONS IN • Concerns and General Guidelines

– Tim Heagney METALLURGY AND QUALITY OVER HIS CAREER AND HAS BEEN A Virtual Tour of Penticton Foundry • MEMBER OF MALLEABLE RESEARCH & DEVELOPMENT – Chad Gentes Inoculation Method Panel – Mike FOUNDATION, AFS, DIS AND ICRI. HE SERVED ON THE AFS 5L Galvin, Riley Kerestes, Jim • MOLTEN METAL PROCESS COMMITTEE AND AUTHORED CHAPTER 15 Csonka, Joseph Keske,, Kyle

Rabine OF THE DUCTILE IRON HANDBOOK, “DUCTILE IRON PROCESS

CONTROL”. ALAN HAS BEEN IN THE FOUNDRY INDUSTRY FOR 41 DEPARTMENTS YEARS.

• News Briefs

• Back Issues MATT LaFRAMBOISE

• DIS Home Page MATT GRADUATED IN CHEMISTRY FROM THE UNIVERSITY OF MICHIGAN AND SAGINAW VALLEY STATE UNIVERSITY. HE STARTED HIS CAREER AT AUBURN ANALYTICAL LABS AS AN ASSOCIATE TECHNICIAN IN 1988 AND HAS SLOWLY WORKED HIS WAY TO TECHNICAL MANAGER/PRESIDENT IN 2009 AND PART OWNER OF AUBURN LABS IN 2012. HE IS ALSO PARTNERED IN B&K CONSULTANTS SINCE 2009 AS A SLAG CONSULTANT.

CONTROLLING SLAG DEFECTS IN GRAY & DUCTILE IRON, cont’d

DAVE WILLIAMS

DAVE GRADUATED FROM ILLINOIS INSTITUTE OF TECHNOLGY WITH HIS BS IN METALLURGICAL ENGINEERING IN 1978. HE STARTED HIS PROFESSIONAL CAREER WORKING AS PLANT METALLURGIST FOR 2 DIFFERENT FOUNDRIES. THEN HE WENT TO ALLIED MINERAL PRODUCTS FOR 21 YEARS BEFORE JOINING HIS CURRENT JOB AS VICE PRESIDENT OF TECHNOLOGY AT ASI INTERNATIONAL. DAVE HAS OVER 36 YEARS OF EXPERIENCE IN THE FOUNDRY INDUSTRY. HE HAS BEEN AN ACTIVE MEMBER OF THE DIS, SERVING ON THE DIS RESEARCH COMMITTEE AND CURRENTLY AS DIRECTOR OF THE DIS. HE HAS ALSO BEEN AN ACTIVE MEMBER OF AFS FOR 31 YEARS, SERVING ON THE DIVISION 8 MELTING METHODS AND INDUCTION MELTING AND POURING COMMITTEES. DAVE WAS THE KEY ORGANIZER OF THE RECENT FERROUS MELTING CONFERENCE AND ACTIVE INSTRUCTOR FOR THE AFS CAST METALS INSTITUTE. CONTROLLING SLAG DEFECTS IN GREY AND DUCTILE IRON

Alan Patrick, Rick Lewis, Hannah Lewis Elyria Foundry

MttMatt LFLaFram biboise , AbAuburn AltilAnalytical LbLabs David Williams, ASI International Ltd

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

CONTROLLING SLAG DEFECTS IN GREY AND DUCTILE IRON

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada “Next to doing the right thing, the most important thing is to let people know you are doing the right thing.”

John D. Rockefeller

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Monthly Slag Scrap for Grey and Ductile Castings

‐‐‐‐‐‐ % Ductile, ‐‐‐‐‐% Grey 0.90%

0.80%

0.70%

0.60%

0.50%

0.40% Percentage

Slag 0.30%

0.20%

0.10%

0.00% 12 12 12 12 13 13 13 13 13 13 13 13 13 13 13 14 12 13 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ Jul Jan Jan Jun Oct Oct Apr Sep Feb Sep Dec Dec Aug Aug Nov Nov Mar ‐0.10% May Employ Good Foundry Practices Review and evaluate the foundry for the application of good foundry practices. 1. Use good gating practices that allow slag to separate from the metal flow. 2. Pour with low in-gate velocities, minimizing turbulence. (< 0.5 m/sec.) 3. Properly use filters in gating systems. 4. Use good pouring techniques to keep basins and pouring cups full during complete pour. 5. Eliminate conditions that allow a vortex in pouring cups or pouring basins. 6. Use separate ladles for grey and ductile iron. 7. Use controlled Flux additions to cleanse molten metal. DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Pouring Video

DIS Annual Meeting, June 2, 2011 Dallas, Texas Start at the Beginning 1. Raw Materials should be free of excessive rust, oil, dirt, etc. Inspect and reject all loads as appropriate. 2. If preheating, do not over heat. Max. temp. should be <750oF to prevent excessive oxidation. Do not heat beyond time necessary to reach temperature. 3. Furnace spouts should be round and well maintained to minimize oxidation, temperature loss and slag formation. 4. Keep furnace lids in good condition and tightly closed – prevents oxidation and slag generation. Also saves energy. 5. Keep all molten metal containing vessels well covered. 6. Remove all slag from furnace prior to tap and remove all slag from ladles prior to pour.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Melt Cold - Pour Hot

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Melt Cold - Pour Hot

True ‐ Lies

Only ‐ Choice

Good ‐ Grief

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Melt Cold Do not over-heat the melt, do not over-preheat the charge materials – this minimizes oxide generation and maintains optimal metal quality (generates a high level of nucleation with a reduced carbide forming tendency).

USE CHARGE MATERIALS THAT PROMOTE A QUALITY METAL 1. Use Graphitic Carbon raiser not Petroleum Coke 2. Use Silicon Carbide in place of Ferro Silicon 3. Use low rust charge materials

Confirm: Check furnace chill levels to validate that you have achieved a presence of strong nucleation. Pour chill wedges (Grey and Ductile) With an ASTM W3 wedge shoot for a 5/32” chill average or less.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

5 Pour Hot • Tap metal as fast as possible with as little turbulence as possible. Minimizes oxidation (slag) and maintains metal quality (reduces nuclei loss and produces least carbide forming tendency) with minimal temperature loss.

1. Reduces oxidation (slag) 2. Reduces nuclei loss 3. Reduces temperature loss 4. Reduces carbide formation

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Furnace Spout Design

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Old Spout – temperature Square Spout Design drop 150 to 200+oF New Spout – temperature drop 75 to 150oF When square spouts are older they preferentially erode at the corners causing When square spouts are new increased atmospheric this design typically has an exposure and splashing effective increased surface area which can result in oxidation greater than that of a round rates and temperature spout, with a rate of oxidation drops that are as much as 3 and temperature drop that is times that of a round spout. about 1.5 times greater. DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Round Spout Design

Level of oxidation is minimal due to preferred Temperature drop is geometry creating typically 50 to75oF reduced exposure to depending on rate atmosphere. Metal POUR HOT of tapping. stream is compact and volume flow is maximized Spouts must be well allow ing rapid ttiapping maitiintaine d to allow with minimal splashing for a compact metal and the smallest amount flow and minimal of temperature drop. temperature drop.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

7 Furnace Spout 75 ‐200+oF temp. Design drop All spouts should be made with a round trough o to create a 50 ‐75 F compact temp. stream and drop miiinim ize exposure to oxidation.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Cover Molten Metal

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Heat Loss of Liquid Iron in Ladles

4 4 Types of Heat Loss or Heat Q = Ɛ * σ * (T1 ‐ T2 )

Transfer Ɛ is the emissivity of the radiating body –0.33 1. Conduction σ is the Stefan‐Boltzman constant – (5.67 * 10‐8 W/m2 * K4) T1 is the temperature of radiating body ‐ 2700 2. Convection T2 is the temperature of receiving body ‐ 120 or 2550

3. Radiation KW Heat Loss 200,000 180,000 177,302 160,000 140,000 120,000 100,000 KW 80,000 60,000 31,271 40,000 20,000 0 0 500 1000 1500 2000 2500 3000 ΔT oF

Experience has shown that immediately covering a ladle between fills with a good insulating material, the tapping temperature loss can be reduced to 50oF or less.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

One Excuse After Another

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Why Perlite Works

HEAT

Rapidly heating perlite ore to temperatures of Expanded perlite Perlite is a volcanic about 900oC glass that is mined, (1,700oF) softens the grows up to 20 volcanic glass sized and processed times its original causing entrapped volume and takes to produce a high water molecules in temperature the rock to turn to on a foam like steam and expand internal structure. insulating product. the particles like popcorn.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Perlite Structure

The expanded particles that These glass bubbles are result are actually clusters of extremely good insulators that minute, lightweight, insulating withstand very high glass bubbles. temperatures.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Perlite Properties

• Per lite iiis inorgani c and non-combtiblbustible. • Very light weight, avg. bulk density, 6 lbs./ft3. • Fusion point 2450oF. • Low thermal conductivity, 0.35 Btu.in/hr.ft2.oF. • 48% Oxygen, 34% Silicon, 7% Aluminum, 4% Potassium, 4% Sodium

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Use of Perlite

X

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Test Your Slag

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

FNC 1 Melt Points FNC 2 Melt Points 3200 3200 3000 3000 2800 2800 2600 Mon 2600 Mon 2400 Thurs 2400 Thurs Linear (Mon) Linear (Mon) 2200 2200 Linear (Thurs) Linear (Thurs) 2000 2000

FNC 3 Melt Points FNC 4 Melt Points 3400 3400 3200 3200 3000 3000 2800 Mon 2800 Mon 2600 2600 Thurs Thurs 2400 2400 Linear (Mon) Linear (Mon) 2200 2200 Linear (Thurs) Linear (Thurs) 2000 2000

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Representative Slag Samples

Slag from Monday Slag from Thursday

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Slag Sampling Preparation

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Preparation of Slag Samples

Crush Slag into 1/4” to 3/4” Visually remove foreign material

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Sample Preparation (Continued)

Separate Magnetic material ID and bag samples for lab

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Packaged and ID Slag Samples sent to Lab for Analysis

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Relating Slag Chemistry Control to Production Problems Three Important Physical Characteristics of Slag: • Melt Point –The temperature at which slag becomes a liquid. • Viscosity –Measurement of slag thickness or fluidity. • Wetting Ability –The slag/refractory interface energy is required to be high to prevent refractory penetration and erosion. Are we able to modify and control these characteristics through slag chemistry and reduce slag scrap?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Summary of Oxide Effects on Slag Melting Point

• MOMnO, FOFeO, BOBaO, COCaO, MOMgO and

Na2O reduce the melting point of slag

• SiO2 and Al 2O3 increase melting point

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Summary of Oxide Effects on Viscosity • MnO, FeO, BaO, CaO, MgO and

Na2OdO reduce vi scosit y

• SiO2 and Cr2O3 increase viscosity

• Al2O3 increase viscosity in neutral and acidic slag

• SiO2 reduce viscosity in basic slag

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Summary of Oxide Effects on “Wetting Ability”

• SiO2 and Al2O3 increase the interface energy and therefore increase wetting characteristics

• MgO, CaO reduce the interface energy and therefore reduce wetting characteristics

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

What is more important ?

• the fluidity, • the viscosity • or the wetting ability of the slag?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Slag Testing - Raw Data

Basicity w/ Approx. FN Report Sample Date Met Lab #NaOMgOAlO SiO P O SKOCaOTiOV O Cr O MnO FeO TC Al O Fe Melting C 2 2 3 2 2 5 2 2 2 5 2 3 2 3 Date Removed Point 12‐ 8/16/2012 1 D 0.00 1.88 13.64 52.71 0.08 0.03 0.25 3.28 0.44 0.01 0.21 3.03 20.31 4.12 3.45 8/28/2012 2610 1970 12‐ 8/23/2012 1 D 0.00 2.23 7.57 51.33 0.06 0.04 0.47 4.04 0.27 0.02 0.40 4.10 22.01 7.47 16.29 8/31/2012 2710 2029 12‐ 8/30/2012 1 D 0.00 3.01 9.02 53.52 0.08 0.03 0.46 8.96 0.36 0.00 0.38 3.22 17.29 3.65 8.9 9/7/2012 2700 2075 12‐ 9/5/2012 1 D 0.00 2.07 24.71 25.72 0.10 0.08 0.22 3.59 1.07 0.03 0.35 5.47 35.87 0.71 2.54 9/18/2012 2640 2101 12‐ 9/6/2012 1 D 0.00 2.54 8.79 42.58 0.06 0.08 0.43 4.33 0.40 0.03 1.38 4.64 19.50 15.24 18.27 9/18/2012 2610 2105 12‐ 9/20/2012 1 D 0.00 2.52 14.99 52.78 0.07 0.09 0.36 4.68 0.43 0.01 0.30 6.78 14.08 2.91 4.70 9/27/2012 2590 2194 12‐ 9/27/2012 1 D 0.00 3.35 10.22 64.70 0.06 0.04 0.63 3.49 0.38 0.02 0.51 4.20 11.30 1.10 3.03 10/5/2012 2730 2277 12‐ 10/4/2012 1 D 0.02 1.98 5.85 61.68 0.05 0.11 0.69 3.48 0.33 0.02 0.80 4.83 14.80 5.36 28.38 10/16/2012 2860 2330 12‐ 10/11/2012 1 D 0.00 2.43 18.95 40.78 0.06 0.02 0.34 3.52 0.77 0.02 0.32 9.15 22.92 0.71 1.09 10/19/2012 2190 2409 12‐ 10/18/2012 1 D 0.00 2.88 18.21 50.41 0.06 0.08 0.74 6.80 0.63 0.02 0.36 6.32 12.34 1.14 4.11 10/25/2012 2390 2445 12‐ 10/25/2012 1 D 0.00 2.96 18.96 54.33 0.06 0.03 0.41 6.55 0.69 0.03 0.51 7.06 8.07 0.34 1.15 10/31/2012 2530 2495 12‐ 11/1/2012 1 D 0.00 3.23 16.71 53.07 0.06 0.06 0.55 5.71 0.53 0.02 0.47 5.37 12.56 1.66 6.00 11/7/2012 2530 2553 12‐ 11/8/2012 1 D 0.00 3.28 25.85 45.97 0.06 0.11 0.39 6.38 0.58 0.01 0.18 5.08 11.44 0.67 6.62 11/14/2012 2710 2629 12‐ 11/15/2012 1 D 0.01 2.26 15.65 40.90 0.06 0.04 0.37 4.32 0.61 0.04 0.45 8.47 24.01 2.80 2.37 11/21/2012 2150 2664 12‐ 12/6/2012 1 D 0.00 2.67 11.64 56.32 0.05 0.11 0.55 4.45 0.33 0.01 0.36 4.33 10.60 8.60 8.19 12/17/2012 2700 2769 12‐ 12/13/2012 1 D 0.01 3.58 17.31 44.20 0.06 0.10 0.40 4.48 0.48 0.02 0.41 7.22 18.53 3.19 8.15 1/2/2013 2200 2835

Determine the Melting Temperature of Slag 1. Analyze the slag chemistry

2. Use the FeO‐Al2O3‐SiO2 ternary phase diagram 3. For FeO use MgO + CaO + MnO + FeO(Basic Oxides)

4. For Al2O3 use reported % from laboratory

5. For SiO2 use reported % from laboratory 6. Using these three oxide percentages, normalize each oxide % (divide each of them by the percentage that when they are added together they fall short of 100%) so that when added together they equal 100% 7. Plot the percentage line of each normalized oxide % on the phase diagram as illustrated DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Normalizing Example FeO+ (Basic Oxides) = 29.2%

Al2O3 = 29.3% SiO2 = 39.1% Where the Sum = 29.2+29.3+39.1 = 97.6% Then normalizing 29.2 / 97.6 = 30% 29.3 / 97.6 = 30% 39.1 / 97.6 = 40% The normalized values add to 100%

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Introduction of

Matt LaFramboise Auburn Analytical Labs

Slag Analysis for Various Melting Operations

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Where to take Slags

• Slags should initially be taken at every point where slag is generated.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Sampling Technique

• Samples should not be taken directly after an alloy addition is taken

• Samples should be retrieved in the same time period of the process, and with the same equipment

• The information gathered is only reliable if the sampling technique is correct

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Where slag analysis is useful

• Findinggg the “Normal” slag for your melt

• Optimizing and extending refractory lining life.

• Troubleshooting of casting defects.

• Solving operational issues.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Preparing the slag

• Preparing the slag to a fine enough mesh to ensure a homogeneous mixture

• Proper mixing of the slag

• Weighing the sample with an inert binding agent to form the pressed pellet.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Analysis for Slag X-Ray Fluorescence Spectrometry • Similar ppyrocess to analyzing a metal sample • Measures the amount of various elements present • Final results calculated with a computer program • Samples are either milled & pressed or fused into a disk

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada X-Ray Fluorescence Spectrometer

Samples

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Things we look for

Analyzing the slag and the importance of standards

• Alloy recovery issues • Tramp elements • Other operational issues

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Back to: Employ Good Foundry Practices

6. Use separate ladles for grey and ductile iron.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Changing the Slag Chemistry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Introduction of

Dave Williams ASI In terna tiona l Ltd

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Change in Interpretation of Slags

Why do fluxes improve the Metal Cleanliness?

How do fluxes actually clean the insolubles emulsified in the molten iron?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

What do Fluxes accomplish?

Fluxes will react with and modify the chemical composition of the complex compounds such as oxides, sulfides, phosphates, aluminates, etc, such that they will separate out, away from the metal matrix and be mechanically removed.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Common Slag Inclusion Components:

Manganese Silicates, 2MnO∙SiO2 tephroite Melting temp erature: 2453F ()( 1345C) Considering the stability energy of formation (Gibbs Free Energy) at 2642F ΔGform = ‐ 4010 Cal/mole 2 MnO + SiO2 → 2MnO∙SiO2

Iron Silicates, 2FeO∙SiO2 fayalite Melting temperature: 2223F ( 1217C) Considering the stability energy of formation (Gibbs Free Energy) at 2642F ΔGform = ‐ 3370 Cal /mole 2 FeO + SiO2 → 2FeO∙SiO2 DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

MORE common Slag Inclusion Components

Alumino Silicates, 3Al2O3∙2SiO2 Mullite melt temp 3380F(1860C), ΔGform @2700F = ‐3177 Cal/mole 3Al2O3 + 2SiO2 => 3 Al2O3∙2SiO2 Al2O3∙SiO2 Andalusite, kyanite, sillimanite

Magnesium Silicates, 2MgO∙SiO2 Forsterite Melt temp 3434F(1890C), ΔGform @2700F = ‐13017 Cal/mole 2MgO + SiO2 => 2 MgO∙SiO2

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 4Al + 3O2 => 2Al2O3 Stable 2Mg + O2 => 2 MgO Stable 2Ca + O2 => 2CaO Stable 2Ce + O2 => 2 CeO Very Stable DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ca + S => CaS Extreme Stability Ce + S => CeS Extreme Stability Mg + S => MgS Moderate Stability DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 2Ce + N2 = 2CeN Extreme Stability

2Al + N2 = 2AlN Extreme Stability

3Mg +N2 = Mg3N2 Not Stable DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Reactants in Fluxes

Strong Flux Reactants: +2 Ca ion included in CaF2 (Fluorspar) Na+1 ion included in Cryolite

Mild Flux Reactants: Na2O - Oxide compound COCaO - OidOxide compound

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Potential Reactions of Flux with Slag Components

Na2O + SiO2 -> Na2O•SiO2 Na2O + Al2O3 -> Na2O•Al2O3

CaO + Al2O3 -> CaO•Al2O3 CaO + SiO2 -> CaO•SiO2

CaO + Al2O3SiO2 + Na + S -> Na2S Ca 2+ + S -> CaS

©2014 ASI International Ltd. Potassium would behave similarly to Sodium.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

The Effect of CaO on Complex Compounds

Calcium Oxide on Mullite, 3Al2O3∙2SiO2 3CaO + 3Al2O3∙2SiO2 => 3(CaOAl2O3)∙2SiO2 @2700F Anorthite, melt temp 2835F(1557C) ΔGform = ‐33,564 Cal/mole

Calcium Oxide on Forsterite, 2MgO∙SiO2 2CaO∙SiO2 + 2MgO∙SiO2 => 2(CaOMgO)∙2SiO2 @2700F Diopside, melt temp 2536F(1391C) ΔGform = ‐33,922 Cal/mole

Calcium Oxide on Sulfur , CaO + 2S => CaS + O+2 Oldhamite, melt temp 4577F(2525C) Δ Gform = ‐86573 Cal/mole

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Effect of Na2O on Complex Compounds

Na2CO3 + SiO2 → Na2SiO3 + CO2

Sodium Oxide on Silica, SiO2 ΔGform = ‐59,967 Cl/Cal/mol e

Na2O + SiO2 ‐> Na2O∙SiO2 Melt Temp 1990F (1088C)

Sodium Oxide on Alumina, Al2O3 ΔGform = ‐41,559 Cal/mole

Na2O + Al2O3 ‐> NaAlO2 Melt temp 3002F(1650C) Na2O + Al2O3 ‐> Na2O∙Al2O3 Melt temp 2469F(1353C)

Sodium Oxide on Alumino Silicate, 2Al2O3∙SiO2 2Na2O + 2Al2O3∙SiO2 => 2 (Na2OAl2O3)∙2SiO2

©2014 ASI International Ltd.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

3,400 -8,045 **

** Educated Guess, need to verify by Calculation DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Challenge to any foundry struggling with Inclusions Carefully examine the defect after sectioning, polishing and etching under various magnification. Do X‐Ray Fluorescence on Slag and Inclusion for summary of OOidxides, and SSlfulfur, compare to previ ous hist ory Do X‐Ray Diffraction for detection of complex compounds present, decide if melt, molding or agitation related Possible SEM, i.e. electron probe microscopy to detect unique tramp elements. Evaluate potential source Devise a recovery action plan to begin to address potential causes from X‐Ray results and SEM. Investigate all Tramps and considered dissolved gases.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

What about Rare Earth Metals? For foundry applications, the metals involved are primarily Cerium (Ce) Lanthanum (La), Praseodymium(Pr), Neodymium (Nd). In most applications such as inoculation or magnesium treatment, Cerium and Lanthanum are the primary metals of choice. Lanthanum Atomic Weight 138.9 Cerium Atomic Weight 140.1 Praseodymium Atomic Weight 140.9 Neodymium Atomic Weight 144.2

Barium Atomic Weight 137.3 Iron Atomic Weight 55.85 The Molecular Weights of the Oxides and Sulfides of the REM’s will be heavy and eventually collect towards the lower portion of any holding /pouring vessel. (when compared the weight to iron compounds.)

Considering the melting points of these Oxides and Sulfides, these remain unmelted and insoluble at typical molten iron temperatures.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Elyria Foundry found that using a patented fluoride‐free, chloride‐free flux, at a continuous rate of 1 lb/ton of molten iron within a transfer ladle, the benefits assisted in a cleansing process of the iron and reduced the slag inclusion defect. Any flux addition , due to its cleansing nature, must require a slag removal step to fllfollow. Elyria’s results were shown on the opening chart.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

EXAMPLE: Treatment Ladle / Ductile Iron

Pictures illustrating the first and second addition of Flux crushed briquettes for two consecutive wash heats. Note the turbulence on top of the bath. DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Treatment Ladle / Ductile Iron

A Typical View of Ladle Slag after Treatment Process has been completed. Also pictured is the pouring spout of the ladle showing the build-up.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Treatment Ladle / Ductile Iron

Views of the Treatment Ladle being subjected to the third 1000Kg wash heat with 0.43 Kg Flux treatment.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Treatment Ladle / Ductile Iron

Views of the fourth wash heat treatment with 0.43Kg Treatment of Flux. Note the vigorous reaction with the slag. The Gas being released is carbon dioxide, NO Fluorine or Chlorine

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Treatment Ladle / Ductile Iron

After the fif th and final wash heat, the Ladle was drained to reveal significant improvement in cleanliness of the Ladle sidewalls, spout and treatment pocket.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Flux in Mag. Treatment Ladles Fluxing a 1 ton Treatment Ladle with 5 “Wash Heats” one Lb(0.4Kg) per Ladle

Initially, loss of pocket capacity due to Insoluble Build-Up.

After the 5 individual treatments, pocket capacity was restored as shown

Treatment Ladle / Ductile Iron Before Treatment After Treatment

AtA typ ica l vi ew of TtTreatment LdlLadle View of the ladle after the 5 w ash after 72 hrs of operation heats in a cold state. This was achieved with minimal scraping, strictly the addition of Flux to 5 different “wash heats.”

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada % Ductile % Gray 2.50% Gray & Ductile Slag as a Percentage of No Bake Production by Cast Date Jul 29 2012‐ Sept 8 2013

2.00%

0.50%

1.50%

0.06%

0.02% 0.05% Additions

0.87% Additions 0.83% 0.05% 0.17% 0.11% Additions 1.00% 0.19% 1.32% 0.25% 0.45% 1.22% Redux Flux 0.94% Redux Flux

reduced

of

0.11%

0.33% as edux Flux med ut w 0.29% 1.44% R 0.00%

o

0.21% 0.72% 1.33%

Resu 1.22%

Ran 0.36% 1.17% 1.10% 1.06% 0.50% 1.01% Started 0.06% 0.91% 0.03% 0.85% 0.51% 0.71% 0.35% 0.73% 0.74% 0.72% 0.03% 0.68% 0.08% 0.24% 0.19% 0.61% 0.20% 0.00% Redux addition 0.58% 0.58% 0.26% 0.54% 0.10% 0.19% 0.13%0.46% 0.46% 0.32% 0.44% 0.06% 0.39% 0.39% 0.00% 0.35% 0.28% 0.30% 0.30% 0.31% 0.20% 0.30% 0.09% 0.00% 0.22% 0.21% 0.20% 0.00% 0.00% 0.24% 0.24% 0.18% 0.18% 0.17% 0.15% 0.19% 0.18% 0.00%0.15% 0.13% 0.00% 0.12% 0.11% 0.10% 0.07% 0.05% 0.05% 0.07% 0.09% 0.03% 0.08%0.08% 0.00% 0.00% 0.00% 0.02% 0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00% 0.02% 0.00%

Melt Point vs Slag Defect

FNC 1 - Ductile FNC 3 - Gray 5 3200 5 3200 3000 4 3000 4 2800 2800 3 3 2600 2600 2 2 2400 2400 1 2200 1 2200 0 2000 0 2000

FNC 2 - Ductile FNC 4 - Gray 5 3200 5 3200 3000 4 4 3000 2800 2800 3 3 2600 2600 2 2 2400 2400 1 2200 1 2200 0 2000 0 2000

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Oxide graphs Furnace #1

CaO 8.00

7.00 UCL 6.197 6.00

5.00 CaO CL 4.415 4.00

3.00 LCL 2.633

2.00

Sample Date

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

MnO 15.55 13.55 UCL 13.076 11.55 9.55 7.55 CL 6.432 5.55 MnO 3.55 1.55 LCL -0.212 -0450.45 -2.45

14.00

12.00 UCL 11.852

10.00

8.00 nO CL 6.396 M 6.00

4.00

2.00 LCL 0.940 0.00

Date Gray & Ductile Slag as a Percentage of No Bake Production by Cast Date Feb 10 2013‐ Feb 5 2014 3.00%

2.50%

2.00% 1.24%

1.50% % 120‐544

0.06% % 53729 0.02% % Gray reduced 0.11% 0.18%2.14% 1.00% was

1.35% 1.22% 1.02% tion i 0.00% 1.10% 1.28% 1.33% 1.22% 0.50% 1.06% 1.01% 0.51% 0.13% Redux add 0.72% 0.03% 0.00% 0.24% 0.19% 0.26% 0.10% 0.54% 0.32% 0.15% 0.06% 0.00% 0.35% 0.41% 0.35% 0.38% 0.39% 0.30% 0.09% 0.00% 0.18% 0.00% 0.00% 0.00% 0.24% 0.24% 0.28% 0.20% 0.17% 0.15% 0.19% 0.18% 0.00%0.15% 0.14% 0.00% 0.20% 0.14% 0.05% 0.12% 0.07% 0.11% 0.10% 0.09% 0.03% 0.08%0.08% 0.08% 0.11% 0.00% 0.00% 0.02% 0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00% 0.02% 0.00% 0.01%0.03% 0.03%0.00%0.00%0.00% 0.05% 0.00%0.00%0.00% 0.00%0.00%0.00%0.00%0.00% 0.05%0.00% 0.00%

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Summary Objective: Minimize Oxidation and Remove Oxides • Employ Good Foundry Practices • MlMelt CldCold ‐ PHPour Hot • Confirm Nucleation with Chill Wedge Control • Use quality charge materials SiC, Graphitic Carbon, clean steel, minimal rust on pig iron. • Cover all MltMolten MtlMetal • Keep ladles free of slag build up, use proper fluxing agents.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Conclusions

1. The melt point of the slag fell as flux additions were made due to increases in MnO and CaO. [In the first 6 months MnO began to rise as flux additions were made causing a lower viscosity (higher fluidity) of our slag. In the next 6 months when we introduced Silicon Carbide, the amount of MnO began to fall.] Controlled additions of flux were found to be very beneficial.

2. The increase in CaO from our flux addition reduced the wetting ability of our slag preventing build up in the ladle between gray and ductile taps. [This contributed to a major improvement in slag reduction].

3. Other s ign ificant i mprovements i n sl ag red ucti on occurred as a result of initial employment of good foundry practices. Further improvements occurred as we identified problem jobs and then applied proper gating practices.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Questions?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES 3D PRINTING FOR THE DUCTILE IRON FOUNDRY INDUSTRY

• 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & • DI – Alan Patrick, Matt STEVE MURRAY LaFramboise & Dave Williams 3D Printing for the DI Foundry • Industry – Steve Murray STEVE GRADUATED FROM INDIANA UNIVERSITY IN MATH. HE Is the Growth of the Ductile Iron • FOUND HIS CALLING WHEN HE STEPPED INTO A PATTERN SHOP Industry at Risk – George Kokos High Silicon Molybdenum Cast AFTER GRADUATING AND IT WAS LOVE AT FIRST SPLINTER. Iron With Mixed Graphite (MG) • OVERCOMING THE CHALLENGE OF HOW TO PRODUCE OR Shapes for Elevated Temper- ature Applications – Delin Li MANUFACTURE A CASTING IS ONE OF THE THINGS THAT KEEPS HIM Preventing Rust and Corrosion on INVOLVED AND INTERESTED IN THE METAL CASTING INDUSTRY. • Ductile Iron Using VCI Technology – Wayne Siefert USING CIMATRON CAD SOFTWARE TO DESIGN WITH, ADDITIVE Machining Ductile Iron: Benefits, MANUFACTURING OF ALL SORTS TO CREATE WITH, AND 3D SAND • Concerns and General Guidelines – Tim Heagney PRINTING TO MAKE CASTINGS OF ANY ALLOY STIMULATES NEW Virtual Tour of Penticton Foundry • CASTING DESIGNS. HE NOW HAS THE OPPORTUNITY TO MAKE – Chad Gentes Inoculation Method Panel – Mike CASTINGS THAT WERE NOT EVEN MANUFACTURABLE JUST A FEW Galvin, Riley Kerestes, Jim • YEARS AGO. AT THE 2014 AM-UG CONFERENCE IN TUCSON HE TOOK Csonka, Joseph Keske,, Kyle Rabine AND PASSED THE SME ADDITIVE MANUFACTURING CERTIFICATE EXAM. DEPARTMENTS • News Briefs • Back Issues

• DIS Home Page 3-D Printing For The Ductile Foundry Industry

Steve Murray Hoosier Pattern

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

3-D Printing

Defined by the ASTM F42 Committee as the fabrication of objects through the deposition of material using a print head, nozzle or other printer technology.

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada 3-D Processes

Material Extrusion Material Jetting Binder Jetting Sheet Lamination Vat Photo Polymerization Power Bed Fusion Directed Energy Deposition

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada

Ductile Foundry

Investment Casting

Sand Casting

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Printed Investment Casting Patterns • Investment casting patterns built using an additive manufacturing process • No tooling required • Now used by m or e th an 95% of investment foundries

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada

Most Common Printed Patterns

Type Manufacturer Description

Hollow stereolithography models with an Qui c kCas t 3D Sys tems itinternal s truc ture– phthotopol ymer res in solidified with a UV laser

Projet Wax 3D Systems Inkjet printed wax patterns

Polystyrene models built using selective CtfCastform 3D Sys tems laser s in ter ing (SLS) an d in filtrat ed with wax

PMMA models built using finely ground Voxeljet Voxeljet powder bound with a binder applied with inkjet technology Four Uses for Printed Patterns Application Description

Prototype Create production quality castings without the cost or time required for tooling. Several desdesignign alternatives to be tested Castings at the same time. Avoids tool rework.

Process Optimizing gate location and pattern orientation, shrink confirmation, dip robot programming, straightening fixture Development development

Bridge Enables limited production while waiting for Production tooling to be delivered.

Low Volume Cost effective production of jobs whose Production volume is too low to justify the cost of tooling

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada

3-D Printed Sand

Cores Solid Shell Solid / Shell Hybrid

Molds Simulate Horizontal or Vertical Parting

Not An All Or Nothing Technology Mix And Match

DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Why Use 3-D Printed Sand

Prototype Sample Design Before Production Sample Changes Castings Till Production Comes On Line Legacy Parts

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 3-D Provider

Experience & Knowledge Are They SME Additive Manufacturing Certified

Vendor Capabilities Match Your Needs Process Material Timing Quality

Changes

Proactive

Response Time

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

For additional information, please contact:

• Steve Murray

• 906 North 10th Street • Decatur, IN 46733

• Cell 574-210-5934

• [email protected] • www.hoosierpattern.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES IS THE GROWTH OF THE DUCTILE IRON INDUSTRY AT RISK

• 2014 Annual Mtg. Highlights GEORGE KOKOS Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams GEORGE GRADUATED FROM IOWA STATE UNIVERSITY IN 1986 WITH 3D Printing for the DI Foundry • Industry – Steve Murray HIS BS IN METALLURGICAL ENGINEERING AND IN 1988 HIS MS IN Is the Growth of the Ductile Iron • METALLURGY. GEORGE IS CURRENTLY THE SR CASTING Industry at Risk – George Kokos High Silicon Molybdenum Cast TECHNOLOGY STEWARD AT CATERPILLAR INC. IN MOSSVILLE, Iron With Mixed Graphite (MG) • ILLINOIS. GEORGE HAS 25 YEARS OF EXPERIENCE IN THE CASTING Shapes for Elevated Temper- ature Applications – Delin Li INDUSTRY IN WHICH THE MAJORITY OF TIME WAS SPENT AT THE Preventing Rust and Corrosion on MAPLETON FOUNDRY THAT MANUFACTURES BLOCKS, HEADS AND • Ductile Iron Using VCI Technology – Wayne Siefert LINERS FOR CATERPILLAR ENGINES. HE HAS ALSO WORKED Machining Ductile Iron: Benefits, OVERSEAS IN THE ASIAN PACIFIC REGION PROMOTING CASTING • Concerns and General Guidelines – Tim Heagney EXPORTS TO THE USA AND MOST RECENTLY IN MEXICO WHERE HE Virtual Tour of Penticton Foundry • SERVED AS TECHNICAL DIRECTOR FOR TECHNOCAST. – Chad Gentes Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim • HE CURRENTLY SERVES AS THE CHAIR OF AFS 5B, THE CO-CHAIR OF Csonka, Joseph Keske,, Kyle Rabine 5A, AND ON THE EXECUTIVE COMMITTEE OF THE PEORIA CHAPTER OF THE AFS/ASM. DEPARTMENTS • News Briefs • Back Issues

• DIS Home Page Is the growth of ductile iron industry at risk?

George Kokos Caterpillar Inc.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Burning Platform DI components fail in the field • Reduced fatigue life initiates crack growth – Graphite skin reduces fatigue limit by 15%1 – Dross reduces fatigue limit 20% to 33%121,2 • Crack grows until critical crack length • Designers immediately change material to cast steel or forging

1=1983 BCIRA paper by K Palmer 2=1982 International Journal of fatigue by M Starkey DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Outline • DI castings have dross and GI skin defects that effect performance • Variables that cause graphite skin and dross • Foundry controls • Strategies to reduce DI failures

GI Skin can promote failures

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Defect Type & Size / Location

Cast Surface m Graphite Float 5 mm Dross 3-5 mm Skin Flake m 0.5-1.5 Chunky 10 mm-Core Ferrite Whole Section

Section Centerline (Core)

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Graphite skin – why does it form?

1.2 mm skin

50X

Gray cast iron layer is present on as cast surface Mg/RE from melt is tied up by oxygen and or sulfur from mold “Fading” is accelerated at the mold/metal interface

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Performance Issues with Graphite Skin • GI skin acts as a pre-existing crack promoting fatigue failures • Mechanical properties are reduced • Other Issues – Machined surface have a patchy appearance

Part Spec

Hardness 4.5 mm 4.1-4.4mm Yield (Mpa) 205 275 min Ultimate (Mpa) 350 415 min Elongation (%) 6 10 min

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Graphite Skin Variables • Mg/RE level in iron • Sulfur and Oxygen in mold coatings • Long turbulent runner system • Build up of S in furan (catalyst with high sulfuric acid) • Build up of S in green sand (seacoal with high sulfur) • Cooling rate

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Validating Process Improvements (On Actual Castings) • Low S catalyst in Furan mix

• Higher % of new sand in mix ((y)initially 100%) – Reduced new sand with low S catalyst to 10% • Goal of .05% max S in sand mix • New Mg Silicate alcohol paint flow coated Old Process New Process

Process Improvements 1.5mm skin 0.05mm skin

50X 100X DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Foundry controls to assure consistent results • % new sand to furan mix • % low S seacoal to green sand • Measurement control of catalyst to furan • Sulfur % in sand mix • Correlate S% with GI skin depth in parts

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Communicate engineering requirements to supplier

• Add a skin requirement to specifications • Allow more skin for bigger castings • Show example micros

Casting Casting Casting Size Size Size 123 GI/CGI to DI

Allowed GI X mm X+ mm X++ mm Skin Depth

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Dross Inclusions • Occurs inside the mold as a product of magnesium-treated iron • Identified by the shape of the oxide- film stringers and magnesium content present . Normally found on cope surface.

Element Weight% Atomic%

C K 14.02 21.86 O K 41.56 48.68 Mg K 24.88 19.18 Al K 2.96 2.05 Si K 8.37 5.58 PKP K 0310.31 0190.19 Ca K 0.34 0.16 Fe K 6.40 2.15 Ce L 1.17 0.16

Totals 100.00

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Dross Defects Cast Surface • Dross occurs in 100% of ductile castings • Dross volume increases with casting size • Orientation (angle) of defect is random • Dross location and volume (()psize) impacted by gating – High stress area in drag reduces risk Dross 3-5 mm ~95% of Dross In These Areas Gate Section Centerline (Core)

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Summary of variables effecting dross • Location and amount of dross defects is process dependent. We have proven influence of the following: • In-gate velocity - stay below 1 m/s (turbulence) • Usage of filters • Consistency and speed of pouring times • Cannot put in gates at the parting line (fountaining) • Riser size and position effects dross location but not quantity • # of in-gates and their position effects sloshing of iron - needs to be smooth / even entry • Extra stock and or flow offs also effects position of dross • Quality of de-slag process prior to pouring • Defect location is cope side

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Filling Velocity

Sloshing can be seen in the casting

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Future or Ongoing Efforts to Apply to Future Product

• Updated specifications to place limitations on dross and skin in DI & CGI • Updating defect criteria for critical locations to callout on print • Develop training program (focus on castings for designers/analysts) • Review and update casting design guide • Review fatigue de-rating factors for as-cast DI • Document and deploy fracture mechanics tool and flaw tolerant design guide for use by product groups • PFMEA and control plan review on critical parts

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Strategies to minimize effects of surface defects • Work with supplier to assure high stress region is not in the cope surface or near a riser • Run oxidation models to minimize oxidation and locate in low stress region • Add machine stock and remove defect layer (5 mm) • Mag particle all PPAP parts to assess risk – Minimum defect size that can be detectable = 2mm • Note tensile test location on print in high stress region

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Defect Location Matters

Same casting is used in 2 orientations •LHS defect area in tension •RHS defect area in compression

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Special Inspection •Surface Requirements •Defined by SCRATA plates •Plastic replicas of several different severities for different defects (surface texture, gas) •Dross •3mm linear surface defect on machined surface

•Internal Requirements 2.93 mm •Several defects (gas, sand, shrink) •Can saw cut and use liquid penetrant to identify the presence of defects •Radiography is required for acceptance

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Special Inspection •Use in critical areas of a Ductile Iron Casting which require greater foundry inspection to ensure adequate reliability •Applies only to sections of a casting •Used in this case due to potential safety issue High Stress

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Verification of Strength in Casting

• Best to have Y block cast attached to part or check the actual casting – Assure connection does not promote shrink • Can get skin measurements and tensile results from this sample (assure same cooling rate)

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Questions All castings have defects that must be taken into consideration for design and analysis. True or False

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Questions Dross defects (or any non-metallic inclusion—sand, slag, etc) are generally located where:

A) Cope B) Drag C) Under a core D) Location cannot be predicted

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Questions High stress regions of the casting should not be shared with the foundry due to IP concerns. True or False

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Questions The preferred method to reduce stress in castings is to simply increase the section thickness. True or False

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada For Additional Information, Please Contact: • George Kokos • Caterpillar Inc – Advanced Materials Technology – Tech Center Bldg K - Room 185 – PO Box 1875 – Peoria, IL 61656-1875 • 309-578-6453 • [email protected] • www. caterpillar.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES HIGH SILICON MOLYBDENUM CAST IRON WITH MIXED GRAPHITE (MG) SHAPES FOR ELEVATED TEMPERATURE • 2014 Annual Mtg. Highlights APPLICATIONS Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams 3D Printing for the DI Foundry • Industry – Steve Murray DELIN LI Is the Growth of the Ductile Iron • Industry at Risk – George Kokos High Silicon Molybdenum Cast DELIN IS A CASTING RESEARCH SCIENTIST FOR CANMET MATERIALS, Iron With Mixed Graphite (MG) • Shapes for Elevated Temper- A PART OF THE FEDERAL GOVERNMENT NATURAL RESOURCES ature Applications – Delin Li CANADA IN HAMILTON ONTARIO SINCE 2012. FROM 2000 TO 2012, Preventing Rust and Corrosion on • Ductile Iron Using VCI HE WORKED AT WESCAST INDUSTRIES INC. IN THE AREAS OF Technology – Wayne Siefert FERROUS ALLOY DEVELOPMENT AND FOUNDRY PROCESS Machining Ductile Iron: Benefits, • Concerns and General Guidelines IMPROVEMENT. HE WORKED AT WESCAST GLOBAL FACILITIES IN – Tim Heagney CANADA, USA, EUROPE, AND CHINA. HE IS ALSO AN ASQ SIX SIGMA Virtual Tour of Penticton Foundry • – Chad Gentes BLACK BELT AND ASQ QUALITY ENGINEER. Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle DR. LI ALSO WORKED AT THE SPACE FLIGHT CENTER IN HUNTSVILLE, Rabine ALABAMA, GERMAN AEROSPACE RESEARCH CENTER AND QUEEN’S UNIVERSITY. DEPARTMENTS • News Briefs • Back Issues

• DIS Home Page Medium Graphite-nodularity High-Silicon Molybdenum (MG SiMo) Cast Iron for Elevated Temperature Applications

Delin Li CanmetMaterials, Natural Resources Canada

Clayton Sloss Wescast Industries Inc.

Presented at DIS Annual Meeting, June 4-6, 2014, Lethbridge, Alberta, Canada

ABSTRACT RESULTS AND DISCUSSION

Both spheroidal graphite (SG) iron and compacted The main results of high-Si cast irons from this work graphite (CG) iron castings are currently produced for include microstructures, solidification curves, tensile automotive applications. The graphite morphology testing data, thermophysical properties, hot oxidation nodularity is typically specified lower than 30% for CG and engine exhaust simulator (EES) testing. and higher than 80% for SG. The so-called medium- nodularity graphite or mixed graphite (MG) cast iron has MICROSTRUCTURES been proposed and developed, in which the nodularity was defined from 40 to 70%. A series of material and Different amounts of nodulizers were added into SiMo casting evaluations were conducted for the high-silicon iron to achieve a variety of graphite nodularity. The moly (SiMo) iron with different graphite shapes, target chemistry was 4.0% Si, and the target carbon including SG, MG, and CG. equivalent was from 4.40% to 4.70% dependent on the critical thickness of castings and the required graphite INTRODUCTION nodularity. Figure 2 displays the graphite morphology development from CG to MG and to SG by increasing Compositions, microstructures, material properties, and the addition of Fe-Si-Mg nodulizer from 0.50% to 1.50%. foundry practice of SiMo iron castings are well The SG etched micrograph shows the moly-rich documented. As both SG SiMo and CG SiMo iron precipitates at the grain boundaries. castings are applied to elevated temperature conditions, can SiMo cast iron with moderate or medium graphite- COOLING CURVES nodularity (MG) integrate advantages of both SG and CG microstructures? Thus, in this work, SiMo iron with The representative cooling curves are shown in Figure 3 MG microstructure was initiated and investigated. for high-Si CG, MG, and SG irons respectively. Some parameters are listed in Table 1. The liquidus EXPERIMENTAL PROCEDURES temperatures TL are approximately the same, which indicates the same carbon equivalent used among the There are four major melting casting facilities in three curves. The recalescence R, an indicator of CanmetMaterials as shown in Figure 1, including high undercooling, appeared to increase with increasing the pressure die caster, vacuum induction melting, air residual magnesium. S1 stands for the primary induction melting of up to 500 kg iron capacity, and twin solidification. The large S1 for CG sample was probably roll caster. due to high carbon equivalent and less magnesium additions. Although the MG and SG samples had the All SiMo-related melting-casting trials and materials same hypereutectic CE as the CG sample, a higher testing were performed at the Technical Development residual magnesium altered the CE effectively, Centre of Wescast Industries Inc. promoted undercooling, and caused the MG and SG samples to solidify in a eutectic mode, as shown in Figures 4 (b) and (c) in which little primary solidification was detected. Table 1 – Solidification parameters of CG, MG, and SG SiMo samples with different graphite nodularity were SiMo samples determined from cooling curves. sent to external laboratories for measurements of thermal conductivity, emissivity, and heat capacity, as a Nodularity TL R function of temperature. Graphite morphology does S1 GRF1 influence the thermal conductivity, as implied in Table 3. (%) (°C) (°C) However, when the temperature is at 400 °C, the CG ~ 30 1142 0.8 80 80 difference in thermal conductivity was decreased. The thermal conductivity of CG SiMo appears to decrease MG ~ 60 1140 1.0 1 101 with temperature. But the thermal conductivity of SG SG ~ 90 1142 4.8 1 79 SiMo increases or flattens with temperature. The CTE (coefficient of thermal expansion) and Ac1 (the critical phase transformation) temperature of CG, MG, and SG samples were also measured. No significant impact TENSILE TESTING was detected of the graphite nodularity on CTE and Ac1.

Table 2 presents some tensile testing results. As Table 3 – Thermal conductivity (W/K.m) of SiMo iron. expected, the elongation at room temperature (RT E) and 0.2% offset yield strength (RT YS) were increased Graphite Shape 100 °C 400 °C 700 °C with increasing the graphite nodularity. The YS at 425 °C also slightly increased with nodularity. In contrast to CG 36 33 30 RT elongation, lower ductility was observed for the SG samples, while higher ductility was obtained for the MG Intermediate lower nodularity samples, tested at 425 °C. This may be SG 26 29 30 explained as follows.

Table 2 - Tensile testing results at RT and 425 °C of SiMo iron samples with different graphite nodularity. OXIDATION AND CORROSION RESISTANCE A series of high temperature oxidation testing were Nodularit 425 °C RT 425 °C RT YS conducted including static oxidation and thermal cyclic y YS E (%) E (%) (MPa) oxidation testing as shown in Figure 5. Table 4 briefly (%) (MPa) characterizes the hot oxidation behaviors of CG, MG, 30 5.0 5.0 450 360 and SG SiMo samples, based on the testing results. More weight changes were observed for CG samples 50 8.0 8.0 480 380 than SG samples. There was severe internal oxidation for CG samples because of the interconnected graphite 70 10.0 6.0 500 390 structure, but less external oxide scales. For the SG 90 14.0 2.0 510 395 samples, the opposite trend was observed. The MG samples exhibited hot oxidation behavior intermediate between that of CG and SG irons.

The brittleness at medium temperature (BMT) has long Table 4 – Brief summary of hot oxidation behaviors of been known as deleterious phenomena in ferritic ductile SiMo irons with different graphite shapes. irons. One mechanism was suggested: the BMT is caused by the grain boundary segregation of impurities, Weight External Internal Scale which could be the magnesium assisted sulfur segregation. From Table 2, the BMT occurred for SG Change Scale Oxidation Adherence samples. CG samples exhibit low elongation at both RT CG More Thinner More Stronger and 425 °C. However, for MG samples, moderate elongation was achieved at both room temperature and SG Less Thicker Less Weaker ° ° 425 C. The tensile elongation ranges at RT and 425 C MG Combined CG and SG are schematically depicted in Figure 4 for CG, MG, and SG samples. Heat treating trials were also conducted. Little or no changes in BMT were found before and after heat treating, though the elongation at RT went up ENGINE EXHAUST SIMULATOR (EES) TESTING evidently after annealing heat treatment. Wescast has developed EES facilities for product THERMOPHYSICAL PROPERTIES testing, as shown in Figure 6. The thermal cycling profiles in EES testing include heating/cooling rates, peak/valley temperatures, and holding time. The cycles to failure determined from EES testing were expressed as the thermal durability, and were in turn influenced by Table 6 – Production of MG iron castings in some a variety of factors such as product design, test companies. parameters, chemistry, and microstructures. Company Terminology Used From the testing results of manifold types 1, 2, and 3 (Table 5), the MG SiMo has shown equal or better EES MG SiMo: W (Canada) performance than CG and SG SiMo parts. It also 30% to 70% CG should be pointed out that CG, MG, and SG irons may have a different application scope in terms of product FCV35 and FCV42 K (Japan) geometries and engine requirements. 40% to 75% CG Table 5 – Cycles to failure of different exhaust Aim at manifolds and materials evaluated by EES testing under S (Shanghai, China) 50/50 CG/SG different exhaust gas temperatures (EGT) and thermal profiles. Medium Vermicularity X (Henan, China) 30% to 50% CG Outle SG CG MG Product t SiM SiM SiM Type EGT o o o CONCLUSIONS 1 190 150 270 T1 SiMo cast iron has been intensively evaluated including 2 265 250 330 SG, CG, and MG microstructures.

3 1140 1575 MG SiMo has shown appreciable improvements in T2 materials properties and foundry process, as compared 4 945 1335 to SG SiMo and especially to CG SiMo. 5 1800 2017 T3 MG SiMo iron castings are produced in some 6 2287 2900 companies. A new ASTM standard specification for SiMo with SG, MG, and CG microstructures was initiated. PRODUCTION OF MG IRON CASTINGS ACKNOWLEDGMENTS MG can stand for moderate graphite-nodularity, medium graphite-nodularity or mixed graphite. Due to a SiMo related work in this paper was conducted in moderate amount of nodulizers and inoculant added Wescast Industries Inc. under the skillful contributions of during the melt treatment, MG iron castings obviously N. Heap, D. Aitchison, R. Milord, F. Yu, and B. have much lower tendency for formation of flake Makarski. The company permission is greatly graphite, chunk graphite, and other degenerated acknowledged. graphite, shrinkage, inclusions, and other casting defects, as compared to CG and SG. In addition, the This paper was partially based on 2007 SAE paper machinability, thermal fatigue life and brittleness at 2007-01-1227 (selected for SAE’s 2007 Transactions) medium temperature of MG iron castings were about MG SiMo. improved as compared to SG and CG iron castings. Because of the benefits offered by MG iron, there has Delin acknowledges the financial support by Natural been production of MG iron castings in some companies Resources Canada and Mark Kozdras of as listed in Table 6, for example. CanmetMaterials program manager for the review. Figure 1: Four major mleting casting facilities in CanmetMaterials. HPDC – high pressure die casting, AIM – air induction melting, VIM – vacuum induction melting, and TRC – twin roll caster.

Figure 2: Micrographs of SiMo iron with different graphite morphologies. The SG etched micrograph shows the moly-rich precipitates at the grain boundary. (a) (b)

(a) (b)

(c)

(c) Figure 3: Selective cooling curves measured from high-Si cast iron trials: (a) CG, (b) MG, and (c) SG.

CG SG MG 24 20 16 12 8 4 Elongation(%) 0 0 RT 425 C 7

Figure 4: Tensile elongation ranges at RT and 425 °C (~ 800 °F) for SiMo irons with different graphite shapes, SG, MG, and CG. The SG samples show low ductility at 425 °C. The CG samples show low ductility at both room temperature and 425 °C. For the MG samples, moderate ductility was achieved at both room temperature and 425 °C (~ 800 °F). Figure 5: High-temperature oxidation testing of SiMo samples, a- mufffle furnace used for static oxidation tests, b- thermal cyclic oxidation tests developed in Wescast, c- SiMo samples after static oxidation testing, d- samples used for dimesnsion stability tests at high temperature, and e –tensile samples used for oxidation tests to study the mechnaical properties before and after oxidation tests.

Figure 6: Engine exhaust simulator (EES) facility developed in Wescast. FEATURES PREVENTING RUST AND CORROSION ON DUCTILE IRON USING VCI TECHNOLOGY • 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & WAYNE SIEFERT • DI – Alan Patrick, Matt LaFramboise & Dave Williams 3D Printing for the DI Foundry • Industry – Steve Murray WAYNE STARTED HIS CAREER AS DIRECTOR OF SALES AND Is the Growth of the Ductile Iron MARKETING FOR DIFFERENT DISTRIBUTORS OF VCI PRODUCTS. HE • Industry at Risk – George Kokos THEN MOVED ON FOR ANOTHER 4 YEARS AS THE NORTHEAST High Silicon Molybdenum Cast Iron With Mixed Graphite (MG) REGIONAL MANAGER FOR DAUBERT VCI, A LEADING • Shapes for Elevated Temper- ature Applications – Delin Li MANUFACTURER OF VCI PRODUCTS. WAYNE HAS A TOTAL OF 25 Preventing Rust and Corrosion on YEARS OF EXPERIENCE IN THE PACKAGING INDUSTRY, SPECIALIZING • Ductile Iron Using VCI Technology – Wayne Siefert IN RUST PREVENTATIVE PACKAGING. SINCE 2007, WAYNE HAS BEEN Machining Ductile Iron: Benefits, THE PRESIDENT OF HIS OWN COMPANY, GREEN PACKAGING, INC. IN • Concerns and General Guidelines – Tim Heagney HARLEYSVILLE, PA., STOPMYRUST.COM, AND GREEN-VCI PRODUCTS. Virtual Tour of Penticton Foundry HE IS ALSO AN AUTHOR OF A BOOK, “A COMPLETE GUIDE TO RUST • – Chad Gentes PREVENTION USING VCI”. Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle Rabine WAYNE IS RECOGNISED AS AN AWARD WINNING LEADER IN THE FIELD OF ANTI-CORROSION PACKAGING, ROUTINELY SOLVES

DEPARTMENTS CORROSION AND RUST ISSUES FOR HUNDREDS OF THE COUNTRY’S • News Briefs LEADING METAL PARTS MANUFACTURERS, INCLUDING FOUNDRIES, • Back Issues METAL STAMPING, HEAVY EQUIPMENT MANUFACTURERS, SPRING

• DIS Home Page MANUFACTURERS, POWDERED METAL PARTS PRODUCERS AND MANY OTHERS WITH VCI PRODUCTS. Preventing Rust and Corrosion on Ductile Iron Using VCI Technology

Wayne Siefert Green Packaging, Inc.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

What We Will Cover Today

• What is Rust? • How Does Rust Form? • Different Types of Rust • Condensation and its Affects • Seasonal Climate and How it Affects Metal • VCI ((pVapor Corrosion Inhibitors) • “The Dirty Dozen-The 12 Most Common Mistakes That Can Lead to Rust and Corrosion”

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Question?

• How much does rust and corrosion cost American industry on a yearly basis?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Why Should You Care About Rust? According to the National Association of Corrosion Engineers, last year, rust and corrosion cost American Industry $360 Billion Dollars! Of that amount, nearly $30 Billion Dollars was lost by American Metal Parts Manufacturers.

Tod ay, we will sh ow you 12 ways t o prevent this tremendous loss of money in your company and increase your company’s profits.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada How Much Does Corrosion Cost Your Company? • The Average Ductile Iron Foundry Loses $76,350 in costs related to Rust and Corrosion • Re-Working Parts • Transportation • Labor in Sorting • Scrapping

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

How Can You Benefit From NO RUST? • What’s In It For ME? • No More Angry Customers Calling to Complain About Rust • No More Lost Money and Labor in Re-Working Rusty Parts • No More Moneyyp Lost in Scrappping Rusty Parts • More Time to Deal With More Important and Productive Activities

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada What Is Rust?

We should take a look at exactlyyg what corrosion is. According to Wikipedia, “Corrosion means the breaking down of essential properties in a material due to chemical reactions with its surroundings.

In the most common use of the word, this means a loss of electrons of metals reacting with water and oxygen. Weakening of iron due to oxidation of the iron atoms is a well-known example of electrochemical corrosion. This is commonly known as rusting.”

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Corrosion Basics

Metal + H2O + O2 = Corrosion

65% Relative humidity is sufficient to cause corrosion

Objective is to:

• Eliminate O2 OR H2O • Create a Barrier Between Metal and H2O and O2 • Inhibit the Electron Flow • VCI Creates a Barrier AND Inhibits the Electron Flow

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Corrosion Basics: Types of Corrosion Color of Rust Can Determine Cause

Red rust hydrated oxides - high oxygen & water exposure Yellow rust oxide-hydroxide - very soluble iron oxide Brown rust ferric oxide - high oxygen lower moisture Black rust from limited oxygen - Iron (II)oxide

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Corrosion Basics

Higggh & low energyy areas create electric potential

• Metals which have higher electric potential are more susceptible to corrosion. i.e. Highly Machined parts, parts subjected to high heat, excessive forming, stamping, etc.

• Metal grains and micro structure are a major influence.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Corrosion Basics

What Causes RUST and CORROSION?

Corrosion is influenced by PART & PROCESS factors: • Type and nature of the metal • Ductile Iron is very porous

Metal and part processing

AdAnd many envi ronment tlfal fact ors: Relative humidity Contaminants Temperature

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Corrosion Basics

Process Corrosion Factors

Machining Exposes grain boundaries and creates microscopic peaks and valleys.

Heat Treating Creates differences in electrical potential and can be a source for contaminates.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Corrosion Basics

Process Corrosion Factors

Cleaning Poorly maintained cleaning solutions are a source of corrosion and may cause “flash rust”.

Handling & Packaging Contamination from human handling or contact with untreated packaging materials.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Condensation

Wikipedia: Condensation is the change of the physical state of matter from gas phase into liquid phase, and is the reverse of evaporation. It can also be defined as the change in the state of water vapor to water when in contact with any surface.

• Water that collects as droplets on a cold surface when humid air is in contact with it.

• The process by which a gas cools and becomes a liquid

• Small drops of water that form on a cold surface

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Condensation

• Warm air has the capability of holding more moisture than cool air.

• As the air (or your metal part) cools, condensation forms

• Condensation can form when parts go from warm to cold OR cold to warm

• Condensation becomes an electrolyte

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Common Forms of Condensation

• Morning Dew – Air gets colder at night • Glass of Iced Tea or Bottle of Beer from the refrigerator • On the Windows in your Home • On your Car on a Cool Morning • Moisture on Your Metal Parts

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Spring •Warm Days • Cool Nights • Can Have High Humidity • Condensation can form on all metal surfaces in plants that are not climate-controlled • Condensation can form on metal parts being shipped due to temperature fluctuations in the truck during shipping

• Condensation can form on metal parts going from warm plant to cool truck or cool truck to warm plant

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Summer • Hot Days and High Humidity • Cooler Nights • Condensation can form on all metal surfaces in plants that are not climate-controlled

• Condensation can form on metal parts being shipped due to lower night time temperatures in the truck during shipping • Condensation can form on metal parts going from warm truck to cooler customer plant if A/C

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Fall

• Warm or Cool Days • Cool or Cold Nights • Condensation can form on all metal surfaces in plants that are not climate-controlled • Condensation can form on metal parts being shipped due to lower night time temperatures in the truck during shipping • CdCondensa tion can form on me tltal parts going from cool truck to warmer customer plant

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Winter • Cool or Cold Days and Nights • Condensation can form on all metal surffiltthttlitaces in plants that are not climate- controlled • Condensation can form on metal parts being shipped due to lower night time temperatures in the truck during shipping • Condensation can form on metal parts going from warm plant to cold truck • Condensation can form on metal parts going from cold truck to warmer customer plant

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada How to Combat the Effects of Condensation • Acclimate Parts to Ambient Temperatures Slowly • Protect Parts From Corrosion as Soon as Possible • If Using a VCI Bag, Keep the Bag Open Until Parts Reach Room Temperature BEFORE Sealing the Bag • Add a Sheet of VCI Paper to Your Package for Additional Protection

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Prevention

• Traditionally, the following products have been used in an attempt to prevent rust and corrosion:

• Rust Inhibiting Oils • Rust Inhibiting Greases • Tectyl • Cosmoline • Motor Oil • WD-40 • Desiccants • NEWER TECHNOLOGY: • VCI Paper and VCI Bags

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada OK, So What Is VCI?

• VCI is an abbreviation for Vapor Corrosion Inhibitor or Volatile Corrosion Inhibitor . These corrosion inhibiting compounds are coated on paper or polyethylene bags, and have sufficient vapor pressure to release molecules into the air.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

OK, So What Is VCI?

• Due to their polarity, the VCI molecules are attracted to the surface of metal, just like a magnet. VCI molecules move from the paper or film directly to the surface of metals. When these compounds come in contact with metal surfaces they form a very thin molecular layer. This thin layer effectively inhibits corrosion on the metal surface by preventing air and moisture from coming in contact with the surface of the metal.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Rust Prevention Methods Using VCI • VCI Bags

• VCI Paper

• Combination of Both is Best • Increase the Amount of VCI molecules in Package • VCI Poly Bag creates a Moisture Barrier • VCI Paper formulation is Water-Soluable • Our VCI Paper is Coated on Both Sides, so a Sheet in the Middle of the Package will do a Great Job

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Rust Prevention Methods (Including VCI) Work Best When… • They are Performed Consistently Throughout the Plant (Standardized Procedures) • They are Performed Consistently Throughout the Year – When Are Your Parts Produced? – When Are They Actually Shipped? – When Are Theyyy Actually Used by Your Customer?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada OK, So What Is VCI?

• Our VCI packaging products include VCI papers, VCI poly bags, VCI poly sheeting , VCI stretch film, VCI foam, VCI Emitters, VCI Wire, VCI chipboard, and many others.

• VCI products are environmentally-friendly, cost-effective, and simple to use. These advantages, along with many others make VCI products an excellent choice for corrosion inhibition, eliminating the need for messy grease, oils, protective coatings, and other ineffective methods.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Benefits Of VCI

• Our VCI packaging products include VCI papers, VCI poly bags, VCI poly sheeting , VCI stretch film, VCI foam, VCI Emitters, VCI Wire, VCI chipboard, and many others.

• VCI products are environmentally-friendly, cost-effective, and simple to use. These advantages, along with many others make VCI products an excellent choice for corrosion inhibition, eliminating the need for messy grease, oils, protective coatings, and other ineffective methods.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Top Twelve Reasons For Rust and the Answers 1. Gloves, Gloves, Gloves!! 2. Wood is NOT Good! 3. Cover Up!! 4. If You Can’t Stand the Heat, Stay Out of the Heat Treat Area!! 5. “Dry Up!” 6. Keep it Clean!! 7. Water is Water is Water….Right? No! 8. It Doesn’ t Take a PhD to Adjust the pH! 9. Keep Your Cool!! 10. Oil is SO 1990’s!! 11. The Right Stuff 12. Finally! Use Enough VCI!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

1 Gloves, Gloves, Gloves!

The #1 mistake is employees touching metal parts with their bare hands.

Acids, oils, and contaminants on human hands can cause and accelerate corrosion.

SOLUTION: All employees who handle metal parts including production workers, inspectors, and packaging personnel should wear gloves when handling metal parts. Simple solution: wear gloves…..every time!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 2 Wood is not good The 2nd biggest mistake is having metal parts in direct contact with any of the following: Corrugated cardboard cartons Wooden Pallets Wooden Crates Wooden Boxes Untreated Paper or Plastic

All forestry products (wood, paper, corrugated) contain moisture, acids, and chlorides that can cause corrosion. Most commonly, this mistake causes “contact corrosion” where parts that are in contact with the wood, cardboard, or paper will have rust or corrosion on the spots that were in direct contact. This often causes sporadic rust, where some parts in a particular shipment are rusty and some are not rusty. SOLUTION: Create a barrier between your metal parts and any wood or corrugated boxes and/or line boxes, crates etc. with a VCI poly bag, or VCI paper. This creates an effective barrier between your metal parts and the wood products that cause rust.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

3 Cover up The 3rd most common mistake is leaving metal parts uncovered in the plant. Leaving metal parts uncovered, unprotected while they are in your plant, waiting for secondary operations, or in queue for additional machining, drilling, tapping, or other operations, or while those parts are waiting to be packaged or shipped, leaves those parts susceptible to rust and corrosion.

Leaving metal parts uncovered and unprotected in the plant and making those parts susceptible to corrosion from forklift exhaust. Chlorides, Sulfides, and oxides from fork truck exhaust all contribute to corrosion of metal parts.

SOLUTION: Cover all metal parts with VCI paper or VCI poly bags to protect them from oxygen and contaminants that are in the plant atmosphere.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 4 If You Can’t Stand the Heat… Stay Out of the Heat Treat Area!! NNumberumber 4 is storing metal parts near youryour manufacturingmanufacturing areas, especially heat-treat processing areas. The heat treating process causes by-products that can cause corrosion on metal parts.

SOLUTION: Move stored metal parts away from the heat treat area, and cover all of your metal parts with VCI paper or VCI poly bags to protect them from heat treat by-products.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

5 Dry Up! The 5th most common mistake is not allowing metal parts to dry after taking them out of cleaning solution. Stacking metal parts on top of each or ppgacking them in boxes after takingthem out of the cleaning solution without thorough drying is a recipe for rust. If you are washing parts, make sure that you do not stack metal parts on top of each other or pack them into boxes until the parts are completely dry. Wet parts can rust when stacked on top of each other because the fluid will act as an electrolyte and form a galvanic cell between the two parts. SOLUTION: Make sure your metal parts are thoroughly dry before stacking them or packing them in boxes. Place metal parts in a wire basket to allow the parts to air dry. Vibratory action, forced air, and htheat can d dthtry the parts more qui iklWhckly. When pac kikaging dry par ts, ma ke sure to package the parts quickly into VCI paper or VCI bags.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 6 Keep it clean! The 6th most common mistake is dirty metalworking fluids and dirty cleaning solutions. Small metal particles, also called “swarf” in the solution can end uppp on metal parts and if not ppyyproperly washed away can form a galvanic corrosion cell, and corrosion will occur underneath the swarf. SOLUTION: Keep your metalworking fluids and cleaning solutions clean and free of dirt and swarf. Fluids and solutions should be checked on a regular basis, and kept free of contaminants that can cause corrosion.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

7 Water is water… right? No! The 7th most common mistake is using public water sources for cleaning fluids and for water-based rust inhibitors. Public water can contain higg,h chlorine levels, and can contain other chemicals that can cause corrosion. The pH of public water can also vary greatly. As we will see in the next most common mistake, proper pH plays an important part in preventing rust and corrosion on metal parts. SOLUTION: Switch from public water to distilled or deionized water. For water-based rust inhibitors, consider a ready-to-use product, like our Dry Coat Rust Preventative.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 8 It doesn’t take a PhD to change the ph The 8th most common mistake is improper pH of cleaning solutions. Failure to maintain ppproper pH levels in your cleanin gsolutions can quickly lead to corrosion. Proper pH levels depend on the type of metal parts you are producing. For ferrous parts, you should maintain a pH level of at least 9.0. For non-ferrous metal parts such as copper, and alloys like brass and bronze, a pH level of 7.0 – 7.5 should be maintained. SOLUTION: Regularly check and correct pH levels of all your cleaning solutions. Adjust according to manufacturer’s instructions.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

9 Keep your cool! The 9th most common mistake is failure to maintain proper temperature in manufacturing and shipping areas. For every 10 deggpree Celsius increase in temperature, corrosion rates can double. Fluctuations in temperature can cause metal pores to open, and also can cause condensation to form on your parts. Condensation becomes an electrolyte, allowing corrosion to occur. High humidity can cause electrolytes to form on the surface of metal parts, enabling the corrosion cell to form, and allowing corrosion to propagate. When you package your parts in high humidity, you lock that atmosphere into your packaging. SOLUTION: Maintain lower temperatures and lower humidity levels by installing climate controls, air conditioning and/or dehumidifiers. Also, be sure to p lace me ta l par ts in to VCI bags or VCI paper as quickly as possible.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 10 oils is so 90’s!! The 10th biggest mistake is using Rust Preventative Oils or R.P Oils instead of VCI packaging. R.P. Oils are the traditional method of ppgreventing rust and corrosion. However,R.P. Oils are messy, labor intensive, and bad for the environment. R.P. Oils are also less effective than VCI products when it comes to preventing rust.

• Lower labor costs: Simply place your parts in a VCI Bag or wrap them in a sheet of VCI Paper. No coating, spraying, dipping or brushing necessary • No need for messy oils and greases • VCI molecules reach all recessed areas of your parts for complete corrosion protection • Your customer receives your product in a clean dry state • VCI protected parts can be used immediately with no need for removal of oils and greases . VCI molecules evaporate into the air when parts are removed from VCI packaging • More environmentally-Friendly • No employee health and safety issues as with oils: No slip and fall accidents • No disposal fees (VCI is completely repulpable and recyclable) • Lower insurance costs (due to no flammable liquids)

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

11 the right stuff! The 11th most common mistake is using VCI products improperly, such as using a VCI pppaper desi gned for non-ferrous metals on ferrous metal parts. Some VCI manufacturers incorrectly state that one VCI formulation will work for every application. This is simply not true. Other mistakes include facing the wrong side of the VCI paper toward the metal, although our VCI papers are coated on BOTH sides to eliminate the possibility of making this mistake. SOLUTION: Al ways f oll ow manuf act urer’ s instructions when using VCI products. Consult with a VCI expert like Green Packaging, Inc. to design a VCI system for your specific application, and help you implement the usage of VCI products properly.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada VCI For Ductile Iron Ductile Iron is very porous and rusts very quickly

So dium Nitrit e i s t ypi call y used in ferrous VCI formulations Sodium Nitrite is not very effective as a vapor phase inhibitor

Nitrites have been classified as carcinogens

Always choose a NITRITE-FREE VCI formulation for complete protection of Ductile Iron parts NaNO2 Contact a VCI specialist to determine the best VCI formulation for your specific needs.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

12 Finally, use enough VCI The final mistake is not using enough VCI paper. The formula is to use at least 1 square foot of VCI paper or VCI poly for every 1-3 sqqquare feet of metal surface. Or use at least one square foot of VCI for every cubic foot of void space.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Summary As we have seen, there are many factors that can contribute to the formation and acceleration of corrosion and rust. Some of these factors such as temperature, humidity, manufacturing by-products, and even the types of metals you are processing are beyond your control. But there are procedures that you can put into place to lessen the possibility of corrosion. Using VCI poly bags, and VCI paper are a great way to reduce or eliminate corrosion and rust on your metal parts. VCI chemistry mitfigrates from th e paper or pol y and dditdeposits on all of the metal surfaces of your parts, including hard-to-reach recessed areas, holes, etc., leaving your metal parts clean, dry, and corrosion-free for years.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Questions

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Thank you! Thank you for your time and participation!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

For additional information, please contact:

• Name: Wayne Siefert • Address: 1527 Ge hman Rd. Harleysville, PA 19438 • Phone: Toll Free 1-855-4-NO-RUST (1-855-466-7878) • Fax: 215-368-7269 • Email: [email protected] • www.green-vci.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES MACHINING DUCTILE IRON: BENEFITS, CONCERNS AND GENERAL GUIDELINES • 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams TIM HEAGNEY 3D Printing for the DI Foundry • Industry – Steve Murray Is the Growth of the Ductile Iron • TIM HAS OVER 35 YEARS OF EXPERIENCE IN PRECISION MACHINING Industry at Risk – George Kokos High Silicon Molybdenum Cast AND MANUFACTURING OPERATIONS WORKING WITH MANY Iron With Mixed Graphite (MG) • FERROUS AND NON-FERROUS MATERIALS. HE BEGAN HIS CAREER Shapes for Elevated Temper- ature Applications – Delin Li AS A MACHINE SETUP/OPERATOR, PROGRESSED THROUGH PROCESS Preventing Rust and Corrosion on AND MANUFACTURING ENGINEERING, AND ON THROUGH GENERAL • Ductile Iron Using VCI Technology – Wayne Siefert PLANT MANAGEMENT. Machining Ductile Iron: Benefits, • Concerns and General Guidelines – Tim Heagney HE IS CURRENTLY IN THE POSITION OF “PROCESS OPTIMIZATION Virtual Tour of Penticton Foundry • – Chad Gentes MANAGER” WITH DURA-BAR, SERVING AS TECHNICAL SUPPORT TO Inoculation Method Panel – Mike THE SALES FUNCTION WORKING WITH CUSTOMERS TO IMPROVE Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle MACHINING PROCESSES WITH EMPHASIS ON IMPROVED Rabine PRODUCTIVITY AND REDUCED OPERATING COSTS.

DEPARTMENTS THE DIS WELCOMES TIM WHO IS HERE TO TALK ABOUT “ • News Briefs • Back Issues

• DIS Home Page Machining Ductile Iron: Benefits, Concerns and General Guidelines

Tim Heagney Dura-Bar

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Benefits – Machining Castings vs. Steel

1. Reduced weight of component 2. Intricate profiles and shapes 3. Free machining characteristics of Ductile Iron 4. Superior chip management 5. Improved productivity resulting in lower overall cost

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Cost of Productivity

Typical Manufacturing Facility

Manufacturing Cost includes: Labor, Machining, plus Building & Administration Costs

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Typical Concerns – Machining Ductile Iron

Hard to machine

Dirty and causes damage to my machine Requires too much horsepower

Burns througggh tooling Can’t achieve surface finish

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Machining Speed

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Machinability Ratings (speed)

• 1212 Steel - 100% • 12L14 Steel - 170% • 1050 Steel - 54% • 4140 Steel - 66%

• 60-40-18 Ductile - 61% • 65-45-12 Ductile - 61% • 80-55-06 Duct ile - 40% • 100-70-03 Ductile - 30%

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Machining Feed / revolution

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Machining Feeds

The specific cutting force is the force (Ft) needed to shear off a specific chip cross-section, under Ft certain conditions.

•Steel – 217,000 to 450,000 lbs./inch2 •Ductile Iron – 114,550 to 195,750 lbs./inch2 •Aluminum – 50,000 to 100,000 lbs./inch2

Based on the lower cutting force required, Ductile Iron can be machined at higher feed-rates than steel.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Guidelines for Successful Machining

• Design the casting with machining in mind • Use tooling designed specifically for machining cast iron • Rigidity, (machine, fixture, and tooling) is critical • Use proper machining approach (speed, feed, depth of cut) • Proper filtration, chip evacuation, and machine maintenance

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Any Questions?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada For additional information, please contact:

• Tim Heagney • Dura-Bar – 1800 West Lake Shore Drive – Woodstock, Illinois 60098 • Phone: 815-206-6770 • Fax: 815-338-1549 • [email protected] • www.dura-bar.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES VIRTUAL TOUR OF PENTICTON FOUNDRY • 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams CHAD GENTES 3D Printing for the DI Foundry • Industry – Steve Murray Is the Growth of the Ductile Iron • CHAD OBTAINED HIS MATERIALS ENGINEERING DEGREE FROM THE Industry at Risk – George Kokos High Silicon Molybdenum Cast UNIVERSITY OF ALBERTA IN EDMONTON, ALBERTA. HE HAS BEEN Iron With Mixed Graphite (MG) • WORKING AS THE QUALITY ASSURANCE MANAGER AND Shapes for Elevated Temper- ature Applications – Delin Li METALLURGIST AT PENTICTON FOUNDRY IN PENTICTON, BRITISH Preventing Rust and Corrosion on COLUMBIA SINCE NOVEMBER 2006. • Ductile Iron Using VCI Technology – Wayne Siefert Machining Ductile Iron: Benefits, SINCE SOME OF OUR FOUNDRY MEMBERS ARE HARD TO GET TO, • Concerns and General Guidelines – Tim Heagney WE HAVE DONE THIS IN THE PAST A FEW TIMES WITH GREAT Virtual Tour of Penticton Foundry • SUCCESS. – Chad Gentes Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle Rabine

DEPARTMENTS • News Briefs • Back Issues

• DIS Home Page Penticton Foundry Virtual Tour

Chad Gentes Penticton Foundry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton, British Columbia Canada

DIS Annual Meeting, June 4, 2014 Lethbridge, Alberta, Canada Penticton, British Columbia Canada

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

History of Penticton Foundry • 1935 Wilkins Machine shop and Foundry started producing castings in downtown Penticton near City Hall. Melted with a cupola furnace and moulded with green sand .

• 1951 Ray O’neal and Harry Hughes purchased the foundry and renamed it to Peach City Foundry.

• 1976 Peach City Foundry moved to a new location in the new industrial area of Penticton on Commercial way, switched to Induction melting and added in no bake moulding .

• 1984 Name change to Penticton Foundry and moved to the current location.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada L.L. Wilkins Machine Shop and Foundry • First Foundry was owned and run by Mr. Cliff Wilkins on Westminster ave downtown Penticton • Foundry was located right behind this building DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Mr. Wilkins

DIS Annual Meeting, June 4-4-66, 2014 Lethbridge, Alberta, Canada Original Location

• First location was positioned close to the rail line • Coking coal railed in from St. Louis,dropped at the back door

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton in 1950’s • Rail line going through town. • Packing houses on the water. Shipping via lake or Rail line

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Peach City Foundry

• Municipal casting foundry. • Green sand and Cupola melting, all Grey Iron. Manhole covers and tree grates • 5-7 employees

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Original Foundry in the 1970’s and in May 2014

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada June 22, 1976 removal of the Cupola, May 2014

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Cupola Melting Peach City Foundry • Mr. OONeil’Neil tapping out the Cupola Furnace

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Peach City Foundry

• Green Sand Floor Moulding

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

1976 Peach City Foundry

• 2. 5 ton Induction melting • Nobake Moulding • Muucpanicipal Castings

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 1976 Peach City Foundry

• Jim OONeil’Neil had taken over for his father • Written up in the paper for the new foundry expansion

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

1976 Peach City Foundry

• Very first pour at new Peach City facility.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada 1976 Peach City Foundry

• Jim O‘Neill and Rusty Pettinger • Early pour at Peach City Foundry.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Current Location of Penticton Foundry • 568 Dawson Ave Penticton BC • Location since 1984.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry 568 Dawson Location 568 Dawson Location May 1950’s 2014

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry

• Canadian,,y Privately Owned • 80 Full time employees • Long time employer • Employees 10-15 years = 12 • Employees 15-20 years = 10 • Employees 20+ years = 12 • Pouring 50% Ductile and 50% HCWI

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry Pattern Shop- Randy and Pattern Shop- Colin Jim

DIS Annual Meeting, June 4-4-66 2014 Lethbrige, Alberta, Canada Penticton Foundry

• 3- 5000 lb Induction furnaces. • Currently 55000 lbs per day avg.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry New Core Room 2012- New Palmer mixer and Old Core Room- - Palmer Table mixer

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry

• Gaylord Core blow mould.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry

AMC- Mixer Wulf AMC Closing- Glen & Dale

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry New 1000 lb Jobbing 1000 lb Jobbing Mixer Mixer 2013

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry Pouring lines, floor jobbing moulding in back Pouring Lines, breakout, ground Grinding in background

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry

Heat Treat Oven 1 Heat Treat Oven 2

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton Foundry

• New Pattern Storage Facility 2014

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Penticton Foundry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Worked at all 3 Facilities

Jim O‘Neill Wulf Reinert

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Worked at all 3 Facilities

Rusty Pettinger

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Penticton from up high Apex ski hill in the background/Penticton Penticton and Okanagan down low lake from up high

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Other Reasons People Live in Penticton

Brian Rock Climbing Skaha Bluff’s

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Other Reason’s to live in Penticton • Cycling

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Canadian Wines

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Thank you to the following

Penticton Museum & Archives Jim O‘Neill Penticton Foundry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada For additional information, please contact:

• Chad Gentes • 568 Dawson Ave. • 250 492 7043 • 250 492 6933 • [email protected] • www.pentictonfoundry.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada FEATURES INOCULATION METHODS PANEL

• 2014 Annual Mtg. Highlights MIKE GALVIN – LADLE INOCULATION Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams MIKE GRADUATED FROM MONTANA TECH IN 1986 WITH HIS B.S. IN 3D Printing for the DI Foundry METALLURGICAL ENGINEERING. HE GREW UP IN PHILLIPSBURG, NJ. • Industry – Steve Murray HE STARTED HIS CAREER WITH VICTAULIC IN EASTON, PA FROM Is the Growth of the Ductile Iron • Industry at Risk – George Kokos 1988 TO 1998 AS A METALLURGIST THEN MOVED ON TO ALLIED High Silicon Molybdenum Cast MINERAL PRODUCTS IN FORT WASHINGTON, PA FROM 1998 TO Iron With Mixed Graphite (MG) • Shapes for Elevated Temper- 2000 IN REFRACTORY SALES. HIS NEXT STOP WAS WITH ELECTRO- ature Applications – Delin Li NITE IN PHILADELPHIA, PA FROM 2000-2001 AS FOUNDRY PRODUCT Preventing Rust and Corrosion on • Ductile Iron Using VCI MANAGER AND THEN BUCK COMPANY IN QUARRYVILLE, PA FROM Technology – Wayne Siefert 2002 TO PRESENT AS TECHNICAL DIRECTOR. MIKE WAS ON THE DIS Machining Ductile Iron: Benefits, • Concerns and General Guidelines BOARD OF DIRECTORS FROM 2005 – 2008, CHAIRMAN OF THE – Tim Heagney PROCESS SUBCOMMITTEE FROM 2009 TO 2011 AND IS CURRENTLY A Virtual Tour of Penticton Foundry • – Chad Gentes VOTING MEMBER OF THE RESEARCH COMMITTEE. MIKE WAS THE Inoculation Method Panel – Mike AFS KEYSTONE CHAPTER CHAIRMAN FROM 2007-2008 AND THE AFS Galvin, Riley Kerestes, Jim • Csonka, Joseph Keske,, Kyle 2008 EAST COAST REGIONAL TECHNICAL CHAIR. Rabine RILEY KERESTES – IN-BASIN INOCULATION DEPARTMENTS • News Briefs RILEY GRADUATED FROM THE UNIVERSITY OF ILLINOIS IN 2004 WITH • Back Issues A DEGREE IN MATERIALS SCIENCE ENGINEERING. RILEY STARTED HIS • DIS Home Page FOUNDRY CAREER WITH GREDE ST. CLOUD AS A METALLURGIST. RILEY IS CURRENTLY THE METALLURGIST FOR CATERPILLAR IN MAPLETON, IL. HE IS ALSO THE SECTRETARY FOR THE AFS 5P COMMITTEE AND IS A 6 SIGMA BLACK BELT. RILEY IS CURRENTLY ATTENDING THE UNIVERSITY OF ILLINOIS TO OBTAIN HIS MBA. JIM CSONKA – INOCULATION ALLOYS

JIM GRADUATED FROM CASE WESTERN RESERVE UNIVERSITY WITH A DEGREE IN METALLURGY AND MATERIAL SCIENCE ENGINEERING. HE HAS WORKED AS THE PLANT METALLURGIST AT EMI COMPANY AND WARD MANUFACTURING BEFORE TAKING A JOB WITH AMERICAN ALLOYS AS THEIR TECHNICAL SERVICE ENGINEER. IN 1993, JIM JOINED HICKMAN WILLIAMS & COMPANY AS A TECHNICAL SALES ENGINEER AND IS CURRENTLY LOCATED IN PITTSBURGH. JIM IS A MEMBER OF HICKMAN, WILLIAMS & COMPANIES TECHNICAL SUPPORT GROUP AND ALONG WITH CUSTOMER SERVICE; HE IS ALSO RESPONSIBLE FOR SOURCING THE MgFeSi, INOCULANTS AND CERAMIC FILTERS FOR THE COMPANY. JIM IS CURRENTLY THE CHAIRMAN OF THE DIS COLLEGE AND UNIVERSITY RELATIONS COMMITTEE AND AN ACTIVE MEMBER OF THE RESEARCH COMMITTEE. JIM WAS A MEMBER OF THE DIS BOARD OF DIRECTORS AND A PAST CHAIRMAN OF THE PROCESS SUB COMMITTEE OF THE DIS RESEARCH COMMITTEE.

JOSEPH KESKE – IN STREAM INOCULATION

JOE GRADUATED FROM MIGHIGAN TECH WITH HIS B.S. IN METALLURGY AND MATERIALS ENGINEERING IN 1997. IN 1999, HE WENT TO THE COLORADO SCHOOL OF MINES AND RECEIVED HIS M.S. IN METALLURGY AND MATERIALS ENGINEERING.

JOE STARTED HIS CAREER WITH BETHLEHEM STEEL CORPORATION IN SOUTHFIELD, MI AS AN APPLICATION ENGINEER IN THE STAMPING DEPARTMENT. HE THEN MOVED ON TO POWERLASERS CORPORATION IN PIONEER, OH IN SALES, AND AS APPLICATION ENGINEERING & PRODUCTION MANAGER FOR 5 YEARS. THE NEXT STOP WAS KS KOLBENSCHMIDT PISTONS IN MARINETTE, WI AS SENIOR METALLURGICAL ENGINEER AND FINELY TO HIS CURRENT POSITION AS PLANT METALLURGIST AT WAUPACA FOUNDRY IN MARINETTE, WI.

KYLE RABINE – WIRE INOCULATION

KYLE GRADUATED FROM SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY WITH A METALLURGICAL DEGREE. KYLE STARTED WITH BRILLION IRON WORKS AFTER HIS GRADUATION IN 2012. CURRENTLY KYLE IS A METALLURGIST WITH BRILLION IRON WORKS IN BRILLION, WI. Ladle Inoculation of Ductile Iron

Mike Galvin Buck Company Quarryville, PA

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Buck Company Quarryville, PA • Non Ferrous Foundry • Ferrous Foundry • Heat Treat • Pattern Shop CNC • 220,000 ft² • 345 employees

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Went from this …

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

… to this!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Non Ferrous Foundry

• Aluminum • Brass and Bronze • 3 Automatic Molding Machines • 7 Aluminum Resistance Furnaces • 9 Coreless Induction Furnaces • T6 Heat Treat Capability

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ferrous Foundry

• Malleable, Gray and Ductile Iron • 60-40-18, 65-45-12, 80-55-06 100-70-03 & ADI • 9 Automatic Molding Machines • 2 C&D • 2 Sand systems

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Melt

• 5 Coreless Induction Furnaces • Each with 6 ton capacity • 2400 lb tap & charge

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Melt

• 2700º FFtaptemp tap temp • 1000 lbs. steel, 1400 lbs. sprue • Alloys and Carbon • Tap, charge, melt, verify chemistry

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Melt

• 2700º FFtaptemp tap temp • 1000 lbs. steel, 1400 lbs. sprue • Alloys and Carbon • Tap, charge, melt, verify chemistry • Melt Deck Theory of Spectroscopy • The accuracy of a spectrometer is directly linked to whether it is in spec or not in spec.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

MgFeSi Treatment

• Covered Tundish • 4.5% MgFeSi • 50% FeSi • Cover (spill iron) • Trim FeSi

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada MgFeSi Treatment

• Covered Tundish • 4.5% MgFeSi • 50% FeSi • Cover (spill iron) • Trim FeSi • 2600ºF • Slag & Wedge check

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ladle Inoculation

• Transfer iron from Bull ladle to pouring ladle • Add other alloys as needed • Full pouring ladle • Slag ladle

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Pouring

• Iron distributed to several pouring ladles • Automatic mold handling • Fade Timer • Nodularity check

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ductile Iron

• 65-45-12

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Alloy Additions

• 65-45-12 • Copper - 80-55-06, 100-70-03

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Alloy Additions

• 65-45-12 • Copper - 80-55-06, 100-70-03 • Monel

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Ladle Inoculation

• 300, 400, 600, 900, 1500 lb pouring ladles • Scoops sized per ladle • 1 lb per 300 lb Fe • 50% FeSi w/ Ba • .5 x 10mm sizing

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ladle Inoculation Procedure

• Do not add FeSi too early • Add to stream, not bull ladle • Add evenly to stream • Add grade alloys at the same ti me • Fill ladle completely

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Pros and Cons

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Pros - Versatility of Ladle Inoculation • Start with 65 -45-12 • Produce several grades at one time • Add grade changing alloys easily • Add Ba, Bi, La, RE … on a need basis • Add 20 x 70 FeSi in the down sprue for carbides • A395

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Cons – how to combat them

• Cup size – heaping • FeSi sizing • Poor addition • Slag build up in ladle • Under filled pouring ladle

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade, add alloys, add different types of FeSi

DIS Annual Meeting, June 2, 2011 Dallas, Texas Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade, add alloys, add different types of FeSi • Simple addition that can be done manually

DIS Annual Meeting, June 2, 2011 Dallas, Texas

Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade, add alloys, add different types of FeSi • Simple addition that can be done manually • Need a set procedure to do it correctly

DIS Annual Meeting, June 2, 2011 Dallas, Texas Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade, add alloys, add different types of FeSi • Simple addition that can be done manually • Need a set procedure to do it correctly • Don’t over fill, under fill the cup or the ladle • Don’t add FeSi too early, too late • Don’t add FeSi too quick, too slow

DIS Annual Meeting, June 2, 2011 Dallas, Texas

Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade, add alloys, add different types of FeSi • Simple addition that can be done manually • Need a set procedure to do it correctly • Don’t over fill, under fill the cup or the ladle • Don’t add FeSi too early, too late • Don’t add FeSi too quick, too slow • Produces good Ductile Iron!

DIS Annual Meeting, June 2, 2011 Dallas, Texas Acknowledgements

• Dick McMinn • Dave Sharkus • Every Alloy guy I ever met

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

In-Basin Inoculation Best Practices

Riley Kerestes Caterpillar, Inc. Foundry Mapleton, IL

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Caterpillar Mapleton Foundry • 600 employees • Produce engine components (Blocks, Heads, Liners, Flywheels) • Pour Gray, Ductile, CG iron • Molding with Green Sand , Cold box , Air set, Furan

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada In-Basin Inoculation Chemistry • In-Mold Inoculants can be used for any type of iron

• Ductile Iron – High Al & Ca

• Grey Iron – High Ca and Mn (helps inoculant go into solution due to lower pour temp)

• CGI – Low Al

• Specialty Additions – Bi, La & Ce for certain applications and casting issues

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

In-Basin Inoculation Delivery Method • Anchored into pouring basin or into drag mold sand

• Can be placed loosely in sprue well

• Proper sizing can be calculated with charts available from suppliers

• Variety of sizes is important for initial iron poured and to provide inoculation during the entire duration of casting pour time.

• Pouring basin capable of holding 20-30% of mold weight to encourage good stirring and mixing DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada In-Mold Inoculation Advantages • Uniform inoculation throughout the pour

• Addition rate is easilyyj adjusted to var ygpying pour weig hts and times

• Inoculant goes into solution in the absence of an atmosphere

– Reduces Atmosphere generates oxides and potentially slag

• Latest stage inoculation – minimizing fade effect – use less inoculant

• Pouring more than one mold in ladle – inoculation effect varies though out ladle with ladle inoculation

• Pouring Flexibility – floor molding or basins in different locations

• Higher nodule counts - very important for riserless ductile iron castings

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

In-Mold Inoculation Options • Powdered in-mold – first iron inoculated very well – duration of pour can be suspects – less expensive method

• Pressed Inserts – go into solution very quickly – more inoculation effect in the beginning – dissipates much faster than the cast inserts - can generate some slag (binder is needed)

• Cast Inserts – more consistent delivery through the pour – small and large inserts needed to achachieveieve uniform inoculation – more expensive

• 15g-50kg sizes available

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada In-Mold Inoculation Best Practices • Pour Time, Pour Weight, Pour Temp are critical variables to figure proper sizing

• Typical pour temp 2450°F-2575°F – key for first inoculant in mold – too cold no reaction – too hot use up inoculant before pour is over

• Usually a 0.1% addition rate 8-25mm – Heavy section (50-200mm) 0.15%

• Do not want to over inoculate – the iron only has so much energy to absorb the inoculant – additional concerns at lower temperatures

• Can greatly improve final microstructure if there is a long time between furnace tap into ladle and actual pour into mold – long fade times

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

In-Mold Inoculation Best Practices • Using this method filters are highly recommended – especially if added in the well or drag – pouring basin iron travels further for both mixing and avoiding any undissolved silicon

• Smaller inserts are more important when not using a stopper rod , plate or some dela y method – if you delay fill until basin is full then smaller inoculant tabs can be avoided

• Ideally inserts are placed on pattern and anchor and secure it into the sand (~1/3 in sand or 2/3 exposed to metal) or placed loosely into a chamber in the drag

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada In-Basin Examples – C175 Engine Block & Liner

12,500 lbs.

50 lbs.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

In-Basin Examples – 3600 Engine Block

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Real Life Cost Savings– C175 Flywheels • C175 Ductile Flywheel housings were the largest scrap hitter for 2012 on Line 6 by dollars.

• A majority of this scrap (68%) was due to improper microstructure and chemistry and failing to meet the customer specified mechanical property requirements.

• The goal of the project is to reduce the overall varitiiation i n th e mi crost ruct ure and ph ysi cal propert y performance of these castings that is causing us to reject the parts as scrap and reduce the scrap rate for this defect to 0% without significantly increasing the cost of the casting. DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Real Life Cost Savings •Improved Inoculation by adding in-basin inoculation to maximize late stage property enhancement and minimize inoculant fade Old Inoculation Process Map Add 0. 3% Ladle inoculant at transfer Cost per Treatment = $14.13

New Inoculation Process Map Add 0.1% SO Add 0.1% Ca Add 0.1% In-Basin Coated ladle FeSi bearing ladle FeSi Inoculation at transfer at transfer

Cost per Treatment = $13.88 DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Real Life Cost Savings

•Quality Improvement – Castings are displaying improved physical properties and microstructure due to the late stage inoculation method and more versatile inoculation process. Fade time is irrelevant now.

Histogram of 7687 Ultimate Strength, psi Histogram of 7687 Yield Strength, psi Histogram of 7687 Elongation, % Normal Normal Normal

60190 44960 5 0.00009 Me t hod 0.00025 Method 0.35 Me t hod N N N 0.00008 O O 0.30 O Me an St De v N 0.00020 0.00007 Mean StDev N Me an St Dev N 79655 4512 56 48499 1833 56 0.25 12.85 1.206 56 0.00006 73974 6966 198 47105 2618 198 12.27 2.493 198 0.00015 0.00005 0.20

0.00004 Density

Density 0.15 0.00010 Density 0.00003 0.10 0.00002 0.00005 0.00001 0.05

0.00000 0.00000 54000 60000 66000 72000 78000 84000 90000 0.00 39000 42000 45000 48000 51000 54000 86 1816141210 Ultimate Strength, psi YieldStrength, psi Elongation, % Tensile Strength Yield Strength Elongation •Increased by 8% •Increased by 3% •Increased by 5% •St Dev decreased 35% •St Dev decreased 30% •St Dev decreased 52%

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Real Life Cost Savings– C175 Flywheels

Process Capability of 7687 Yield Strength, psi - Old Method Process Capability of 7687 Yield Strength, psi - New Method

LSL LSL Process Data Wi t h in Process Data Wi t h in LSL 44960 Overall LSL 44960 Overall Target * Target * USL * Potential (Within) Capability USL * Potential (Within) Capability Cp * Cp * Sample Mean 47177.3 Sample Mean 48241.4 Sample N 190 CPL 0.35 Sample N 63 CPL 0.84 StDev(Within) 2124.21 CPU * StDev(Within) 1296.1 CPU * StDev(Overall) 2605.78 Cpk 0.35 StDev(Overall) 1901.36 Cpk 0.84 Overall Capability Overall Capability Pp * Pp * PPL 0.28 PPL 0.58 PPU * PPU * Ppk 0.28 Ppk 0.58 Cpm * Cpm *

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9 2 5 8 1 4 4 6 8 0 2 3 4 4 4 5 5 4 4 4 5 5

Observed Performance Exp. Wit hin Performance Exp. Overall Performance Observed Performance Exp. Wit hin Performance Exp. Overall Performance PPM < LSL 157894.74 PPM < LSL 148278.67 PPM < LSL 197403.27 PPM < LSL 15873.02 PPM < LSL 5675.07 PPM < LSL 42191.04 PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM Total 157894.74 PPM Total 148278.67 PPM Total 197403.27 PPM Total 15873.02 PPM Total 5675.07 PPM Total 42191.04

Yield Strength CpK increased 2.4x!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Real Life Cost Savings– C175 Flywheels Process Capability of 7687 Ultimate Strength, psi - Old Method Process Capability of 7687 Ultimate Strength, psi - New Method

LSL LSL Process Data Wi t hin Process Data Wi t h in LSL 60190 Overall LSL 60190 Overallll Target * Target * USL * Potential (Within) Capability USL * Potential (Within) Capability Sample Mean 74102.2 Cp * Sample Mean 78909.1 Cp * Sample N 190 CPL 0.83 Sample N 63 CPL 2.07 StDev(Within) 5606.21 CPU * StDev(Within) 3021.11 CPU * StDev(Overall) 6989.12 Cpk 0.83 StDev(Overall) 4792.42 Cpk 2.07 Overall Capabilit y Overall Capability Pp * Pp * PPL 0.66 PPL 1.30 PPU * PPU * Ppk 0.66 Ppk 1.30 Cpm * Cpm *

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 6 2 8 4 0 0 4 8 2 6 0 4 8 5 6 6 7 7 8 9 6 6 6 7 7 8 8 8

Observed Performance Exp. Wit hin Performance Exp. Overall Performance Observed Perf ormance Exp. Within Performance Exp. Overall Performance PPM < LSL 42105.26 PPM < LSL 6540.35 PPM < LSL 23265.43 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 46.92 PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM > USL * PPM Total 42105.26 PPM Total 6540.35 PPM Total 23265.43 PPM Total 0.00 PPM Total 0.00 PPM Total 46.92

Tensile Strength CpK increased 2.5x!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Real Life Cost Savings– C175 Flywheels • What did we achieve? – Continuous Process Improvements • Process Robustness – The castings are now less susceptible to being scrap for Magnesium and ladle inoculant fade due to the late stage in-basin inoculant addition. • Three castings have been poured with lower than desired Magnesium levels of 0.030-0.035%. In the past this chemistry has lead to castings being scrap for failing to meet physical properties due to poor microstructure. • However these castings all met physical property and microstructure requirements and were useable castings using the new inoculation method. • We have achieved 0% Scrap since the new inoculation method was implemented in March 2013 (vs. ~3 per month previous)

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Real Life Cost Savings– C175 Flywheels • What did we achieve? – Cost Reduction & Avoidance • Quality Improvement – Our castings are more robust due to the late stage inoculation . This quality improvement was done without increasing the inoculation costs by adding in late stage in-mold inoculation in addition to the ladle inoculation. • Cost avoidance Internal – Reducing scrap to zero for this kind of defect represents an annual savings of $111,000 for the two Flywheels. The more robust process makes this possible! • Cost avoidance External – Reducing salvage repair work at the machine shop represents an additional annual savings of for the two Flywheels. • Total Project Annual Savings = $111,000 • Savings per Casting = $74.00 : Savings per pound=$0.05

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

For additional information, please contact:

• Riley Kerestes • Caterpillar, Mapleton Foundry • 309-633-8507 • [email protected]

Thank you for your attention.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Choosing an Inoculant, what options to consider.

Jim Csonka Hickman, Williams & Company

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Where do Inoculants come from? • Are they mined in the desert or some mountainous region? • Do they come from the bottom of the ocean? • Produced in a Subm er ged Ar c Furnace, what is that?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Ferrosilicon Ingredients

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Furnace layout, typical FeSi plant.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

5 ton ladles used to pour into 8 foot pig molds.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Cooling of 4 inch thick, 8 foot diameter molds.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Taken to Crushing and Screening system.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

How do you pick an inoculant that is right for you? • Is the silicon in the inoculant the key factor? • Does the silicon percentage play a role? • Endothe rmic v s. Ex oth ermi c? • Melting Temperature vs. Dissolution rate?

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Melting points, Thermal values. • Si level Liquidis Thermal effect Temperature (1#/ton steel 2,902F)

• 75% FeSi 2,430 F + 0.4 F

• 65% FeSi 2,320 F - 0.1 F

• 49% FeSi 2,240 F - 0.8 F

• 15% FeSi 2,280 F - 1.6 F

• Ferroalloys & Alloying Additives Handbook, P.D. Deeley, 1981, page 121,

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Dissolution study based upon Silicon percentage. • 1983 studyyy by C. Dremann of Foote Mineral. • Part of a study to improve In-Mold MgFeSi. • Alloys were sized to 10 x 30 mesh. • 110 cm3 of alloy varying in Si % was added to a chamber. • 23 to 25 second pour time at 2550 +/- 10 F. • Filmed using quartz glass window as side of chamber. • Used a point grid to determine volume percentage dissolved. • Calculated dissolution rate by counting frames of Super 8 film at 2.36 frames per cm and 18 frames per second. • Wide angle lens recorded pouring and clock.

• AFS Transactions, 83-108, pages 263 to 268 DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Dissolution study based upon Silicon percentage. • Silicon Grams Pour Volume % Dissolution • percent time dissolved time rate • 36 315 24 2% 0.1 cm3/s • 46.9 277 25 23 1.0 • 59.9 201 23 78 2.6 • 75.6 169 23 100 21.3 5.4 • 88.3 135 23 100 14.6 7.3 • 99.1 138 23 28 1.3

• Alloys had 0.3% Ca, 0.7% Al unless noted below. • 36% Si alloy had 13.4% TRE. • 59.9% Si alloy had 3.4% Ca, 4% Ba, 12% Mn. • 75.6% Si alloy had 1% Ca, 1.5% Al. • 99.1% Si alloy had 0.1% Ca, 0.2% Al.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

What role do Ca, Al, Ba, Sr, TRE etc. play? • Does FeSi inoculate , or just bring the inoculating elements to the party? • Widely believed that at the center of a nodule is an oxide or sulfide particle. • Not all oxide or sulfide particles are the same. • Oxide or sulfide particles form at varying rates, and stay suspended for different lengths of time.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada What role do Ca, Al, Ba, Sr, TRE etc. play? • Gibbs Free Energy of Formation.

• Ellingham Diagrams.

• More negative the number, the greater chance of formation.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson, 1979 AFS Casting Congress DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson, 1979 AFS Casting Congress DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Free Energy of Formation

• Oxides • Sulfides

• Al2O3 -730 • CaS -723 • BaO -737 • CeS -815 • CaO -903 • MgS -389

• CeO2 -693

• Values in kJ/mole at 1800K • Ellingham Diagram Web Tool, San Jose State • = 1527 C = 2780 F University • K = C + 273.16

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Oxide or Sulfide Density

• Oxides or Sulfides with higher densities, in theory, will stay in solution longer thus will be available for nucleation. • Reduce inoculant fade. • Extend inoculant life.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Sulfide Densities

• Aluminum Al2S3 2.02 • Barium BaS 4.25 • Calcium CaS 2.18

• Cerium Ce2O2S6.00

• Cerium Ce2S3 5.19

• Lanthanum La2O2S5.87

• Lanthanum La2S3 4.99 • Magnesium MgS 2.85 • Strontium SrS 3.20

• The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson. DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Inoculating Potential

• Look at each inoculant by the potential of creating oxides or sulfides per pound of material. • Add up the percent of each oxide or sulfide former per individual inoculant. • Take into account , the FeSi percentage may change the amount of oxides/sulfides available.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Inoculating Potential

• Examples, considering a constant % FeSi.

• FeSi with 1% Ca, 0.7% Al = 1.7%

• FeSi with 1% Ca, 0.7% Al, 2% Ba (or TRE) = 3.7%

• FeSi with 1% Ca, 3.5% Al = 4.5%

• FeSi with 1.25% Ca, 0.925% Al, 4% Zr = 6.17%

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada Inoculant Choices

• Many things to consider: • Silicon percentage of inoculant. • Oxide/Sulfide formation potentials. • Oxide/Sulfide densities. • Potential based upon percentage of nucleating elements.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Thank you!

• Jim Csonka • Hickman, Williams & Company

• [email protected] • Mobile: 216-233-3143 • Office: 724-772-3334

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Evolution of In-Stream Inoculation Practice Joseph S. Keske Waupaca Foundry – Plant 4

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Overview

• Cause & Effect (6M approach) • Method • Machine(s) • Measurement • Material – General Comments • Pros and Cons • Conclusions

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

174 Cause & Effect

Material Man Mother Nature In-Stream Inoculation MhiMachine Measurement Method

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Method • Minimize Impact of Operator – Only metallurgggists can make changes • Centralized location for raw material – services all molding machines • Low-level sensors • Integrate equipment • Treat every job as safety critical and stop pouring when operating parameters are not within range

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

175 Cause & Effect

Material Man Mother Nature In-Stream Inoculation MhiMachine Measurement Method

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Machine(s) & Integration • Vertical Molding Machine (VMM) & mold mapping • Pressure Pour Furnace • Hot-Metal Carrier • Inoculant Feeder

Feeder must run under any circumstance where iron could be released into molds

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

176 Machine (Feeder) • KISS Philosophy (Keep It Simple…) • Motor, Auger, Air Pressure • Feed Rate set by Motor RPM (voltage) • Inoculant is hopper-fed into auger chamber • Inoculant exits auger and is blown through a pipe, directed at iron stream

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Measurement • Condition of tube and position of inoculant stream must be monitored • Inoculant needs to be added in inverse proportion to section sizes • Chill/carbide-prone parts require higher additions – insurance! Complete integration to VMM allows feeder to operate at settings dictated by part number

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

177 Measurement – Stopping Pouring • Low inoculant situations must be identifi ed with measurabl e vari abl es. • Motor Voltage (low V = low RPM) • Incoming Pressure (low P = low inoc.) • Back Pressure (low P/high P) – Pipe Mi ssi ng, i nocul ant not fl owi ng – Pipe blockage VMM MUST STOP POURING!

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Measurement – Testing Controls

• Conditions that trigger the VMM to stop pouring must be tested • During scheduled down time, the system integration is checked by intentionally creating feeding scenarios that should trigger alarms • Feed rate to motor voltage calibration

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

178 Method • Time Stamp and Store Data • Identification of Suspect Product is paramount to success • Every piece of data pertaining to pressures and motor rpms is in a database. • Every time a delivery tube is replaced, the metallurgist is notified and tube alignment verified

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Material • Waupaca Foundry has not changed inoculant material since about 1998 • Inoculant has performed consistently – Bi/Ba and RE blend • Other materials have been tested • Current methodology makes trials of new inoculants almost impossible

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

179 Pros/Cons • Highly automated • System integration • Feed rates done by is complex and part number! problems can be • PLCs and alarms tough to diagnose provide protection • New material trials • Resulting iron is are almost consistent, few impossible and issues with pose risk (entire nodularity or plant would run eutectic carbides trial) • No visual - YET

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

Method

• Even with all of the alarms, conclilusive evid ence of fi inocul ltant hitting the iron stream, 100% of the time, does not exist • Waupaca Foundry’s most recent inoculant project is looking at the various camera technologies to be added to our list of checks.

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

180 Summary – Success at Waupaca • Take a 6M approach • Focus on Methodology & Measurement • Machine integration so pouring stops automatically • Store data - tracking suspect product is simplified

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

For additional information, please contact:

• JKkJoe Keske • 805 Ogden St. Marinette, WI 54143 • 715-735-4986 • [email protected] • waupacafoundry.com

DIS Annual Meeting, June 4-4-6,6, 2014 Lethbridge, Alberta, Canada

181 182 Wire Inoculation Brillion Iron Works

• Foundry operations since 1900 • Complex, highly-cored ductile and Kyle Rabine gray iron foundry Brillion Iron Works • In-house pattern shop • Complex core assembly in-house

DIS Annual Meeting, June 44--6,6, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Brillion Iron Works Brillion Iron Works

Customer Direct HWY 10 Access Warehouse Brillion Campus=138acres/ 56 Hectares • 2 plants Peters – Peters and Gabler Office Gabler • Induction melting

• Wire Mg treatment Larsen • TS16949 & QS9001 Certified • ISO-14001 Certified

DIS Annual Meeting, June 44--6,6, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Types of Inoculation What is Wire Inoculation?

• Ladle inoculation • Cored steel wire containing a • Wire inoculation powdered inoculant • In-mold inoculation – Same concept as Mg wire treatment • In-stream inoculation • Can use any kind of inoculant in the cored wire

DIS Annual Meeting, June 44--6, 20146, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

183 Wire Inoculation Items Wire Inoculation Uses

Wire feeder Cored wire coil • In treatment ladle • In pouring ladle

DIS Annual Meeting, June 44--6,6, 2014 DIS Annual Meeting, June 44--6, 20146, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Wire Inoculation Uses Wire Inoculation Uses

• In pouring launders • In mold

DIS Annual Meeting, June 44--6,6, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Wire Inoculation Pros Wire Inoculation Pros Cont.

• Inoculant goes into solution under • Adapts well to automation the surface • Reduces need to transfer ladles to • Less chance for inoculant to dissolve inoculate iron in an atmosphere – Treating, alloying, inoculating all-in-one • Able to add any inoculant to wire ladle

DIS Annual Meeting, June 44--6, 20146, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

184 Wire Inoculation Cons Questions?

• Cost of equipment – Wire feeder machines • Maintaining machine • Calibration • Extra cost to add inoculant in wire – Have to pay for the wire sheath

DIS Annual Meeting, June 44--6, 20146, 2014 DIS Annual Meeting, June 44--6,6, 2014 Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

For additional information, please contact:

• Kyle Rabine • 200 Park Ave, Brillion, WI 54110 • 920-756-6439 • [email protected] • www.brillionironworks.com

DIS Annual Meeting, June 44--6, 20146, 2014 Lethbridge, Alberta, Canada

185 FEATURES NEWS BRIEF

• 2014 Annual Mtg. Highlights Controlling Slag Defects in GI & • DI – Alan Patrick, Matt LaFramboise & Dave Williams 3D Printing for the DI Foundry • Industry – Steve Murray Is the Growth of the Ductile Iron • Industry at Risk – George Kokos High Silicon Molybdenum Cast News Release Iron With Mixed Graphite (MG) • Shapes for Elevated Temper- 24 June 2014 ature Applications – Delin Li Preventing Rust and Corrosion on • Ductile Iron Using VCI Technology – Wayne Siefert Global molybdenum production and use at new Machining Ductile Iron: Benefits, • Concerns and General Guidelines high – Tim Heagney Virtual Tour of Penticton Foundry • – Chad Gentes Global production of molybdenum in 2013 reached a new high of 539.2 million Inoculation Method Panel – Mike lbs, up from the previous year’s record of 535.2 million lbs. Full year figures from Galvin, Riley Kerestes, Jim • the International Molybdenum Association (IMOA) also show global molybdenum Csonka, Joseph Keske,, Kyle Rabine use at 537.7 million lbs, breaking the previous year’s record high of 522.5 million lbs.

DEPARTMENTS The greatest usage of molybdenum in 2013 was in China, where use increased • News Briefs from 188.4 million lbs in 2012 to 196.2 million lbs in 2013. Europe recorded the second biggest share with 140.4 million lbs, up from 135.9 million lbs in 2012. • Back Issues Japan and USA were the third and fourth largest users of molybdenum by region, • DIS Home Page recording 57.4 and 56.1million lbs respectively. Usage in the CIS was 23 million lbs, with other countries together totalling 64.6 million lbs. China was also the biggest molybdenum producing area in 2013, although output fell slightly to 194.9 million lbs, compared to the previous year’s record high of 207 million lbs. Production in North America rose from 176.5 million lbs in 2012 to 180.5 million lbs in 2013. South America was the third largest producing region, accounting for 128 million lbs in 2013, up from 118.7 in 2012. Production in other countries increased slightly from 33 to 35.7 million lbs in 2013. New figures for the fourth quarter of 2013, also released, saw total molybdenum production rise from 134.9 million lbs in Q3 to 141.4 in Q4. China’s molybdenum production increased slightly from 49.7 in the third quarter of 2013 to 51.2 million lbs in Q4. North American production fell slightly, from 44.5 million lbs in Q3 to 43.2 in Q4. Production in South America increased from 31.7 million lbs in Q3 to 38.1 in Q4. Global usage increased from 137.5 million lbs in Q3 to 138.2 in Q4. Usage in China decreased slightly from 52.9 million lbs in Q3 to 51.6 in Q4. Usage in Europe increased 34 million lbs in Q3 to 35.1 in Q4. Japan and USA used 14.4 and 14.2 million lbs respectively in Q4. Tim Outteridge, IMOA’s Secretary-General, commented: “These figures indicate that molybdenum use remained buoyant throughout 2013, with production keeping pace or slightly exceeding demand. Figures for both production and use reached new highs once again in 2013.”

For more information contact:

Alan Hughes T: +44 (0)1606 852011 M: +44 (0)7759 243969 E: [email protected] NEWS BRIEFS NEWS BRIEF

For more information, contact: Charlotte Zang 410-810-8862 [email protected] For immediate release …

Michigan Manufacturing International (MMI) Completes New Plant in Hosur, India

MMI adds Worldwide Quality Control Manager in India and Supply Mgr in China.

Stevensville, Md., June 17, 2014 - Jacob Prak, CEO of Michigan Manufacturing International (MMI) recently returned from Hosur, India where the new MMI plant has been completed. This stop was part of Prak’s annual visit to MMI locations in Mumbai, Coimbatore, and Bangalore, India, and Shanghai, Fuyang, Ningbo, Jinan, Shenzhen, Dongguan, and Hong Kong, China.

The MMI Hosur facility is primarily an assembly plant that receives its inputs from a highly qualified local supply base. “We estimate that approximately 65% of our sales in India come from the Hosur location, making this plant very important for us. It is vital to our ability to offer the best and most cost-effective supply options to our customers,” Prak said.

Prak estimates that MMI purchases 10% of the company’s total volume from South Korea, 10% from the Pearl River delta region in China, 50% from the Yangtze delta region in China and 30% from India. During the trip to Asia, MMI filled two key positions. Prabhu Rajendran was chosen as the new Worldwide Quality Control Manager. His primary focus will be implementing and managing quality assurance processes. Jarbo Lu was named as the new Supply Manager for Shandong province in China.

“These new MMI team members will be instrumental in ensuring that MMI products meet the highest quality control standards,” Prak said. “I am very pleased to have them join our growing company.”

Founded in 1991, Michigan Manufacturing International (MMI) specializes in supplying manufactured to print assemblies and components to original equipment manufacturers (OEM). Products include assemblies, castings, stampings, machined parts, gears, bearings and more. Services include product engineering, manufacturing, inventory management and stocking programs — all designed to streamline client operations and increase profitability. MMI designs the most effective, highest quality solutions from anywhere in the world.

For more information about MMI, visit www.michmfg.com or call 800-677-0504. NEWS BRIEFS

1695 N. Penny Lane, Schaumburg, Illinois 60173

FOR IMMEDIATE RELEASE Contact: Shannon Wetzel, [email protected] June 2, 2014 847/824-0181 ext. 266 AFS Issues Call for Papers for 119th Metalcasting Congress

Schaumburg, Ill. The American Foundry Society (AFS) has issued a call for papers for its 119th Metalcasting Congress to be held April 21-23, 2015, at the Greater Columbus Convention Center, Columbus, Ohio.

AFS is seeking papers covering all issues relating to metalcasting, diecasting and foundry management and operations, including unique in-plant procedures, new technologies, equipment, products and other innovations that have contributed to enhanced metalcasting productivity and quality.

Technical paper abstracts are due Aug. 15 and complete papers are due Sept. 15. Paper number assignment, offer and abstract form and authors guide will be available July 1, 2014 on the Metalcasting Congress website (www.metalcastingcongress.org).

For more information, contact Pam Lassila, Metalcasting Congress administrative assistant, at 800/537-4237 Ext. 240 or [email protected] or visit www.metalcastingcongress.org.

Headquartered in Schaumburg, Ill., AFS is a not-for-profit technical and management society that has existed since 1896 to provide and promote knowledge and services that strengthen the metalcasting industry for the ultimate benefit of its customers and society. NEWS BRIEFS NEWS BRIEFS

Family-Owned Bremen Castings Welcomes Fifth Generation to Company Bremen Castings Has a Lot to Celebrate in Its 75th Year

Not only did Indiana-based Bremen Castings just celebrate its 75th milestone, the family owned and operated machine shop and foundry is welcoming another one of its own to the team. Jordan Brown, a 5th generation member of the Brown family, will join Bremen Castings as Inside Sales Manager.

Daughter of President James (JB) Brown and granddaughter of Chairman and CEO James E. Brown, Jordan graduated from Indiana University Bloomington with a Bachelors degree in Management and a Minor in Business and Human Resources. Jordan interned at BCI the past three summers, working in various roles within BCI and BCI Defense to learn about all aspects of the business.

“Bremen Castings is a family business and Jordan needs to learn how it operates from the ground up. My grandfather, James L. Brown, my father, and I, all started this way,” adds JB Brown. “We are excited to see Jordan grow and bring her ideas into BCI. The metal casting industry has been male dominated for years and its time for a change; we look forward to seeing this within BCI and the foundry industry as a whole in the years to come.”

Please contact me if you would like to speak with James (JB) Brown about Bremen Castings Inc.

Carolyn Blackman | Vice President Empower Public Relations 625 N. Michigan Avenue- Suite 2500 Chicago, IL 60611 O: 312.854.8830 C: 312.375.4106 [email protected] www.empowerpr.com NEWS BRIEFS

Aarrowcast Wins AFS/Metalcasting Design & Purchasing Casting Competition Schaumburg, Ill. Aarrowcast Inc., Shawano, Wis., has won the 2014 American Foundry Society (AFS)/Metal Casting Design & Purchasing Magazine Casting of the Year award for its ductile iron oil pan produced for a John Deere 9-liter engine. The 842-lb. casting is the result of collaborative effort between supplier and customer to achieve weight reduction while meeting the application’s strength requirements. The agriculture component combined a frame casting, two fabricated brackets and a stamped steel oil pan. Through a combination of finite element analysis and solidification simulation, the design team achieved a 77-lb. weight reduction while still accommodating a 60-horsepower increase in the engine. Because of the compact design of the oil pan casting, the package allowed for a lower engine position in the tractor chassis and eliminated a 2-degree angle. The volume of oil accommodated by the oil pan was increased over the original steel stamping. Aarrowcast used 11 interlocking cores to establish dimensional repeatability and designed a gating strategy that provided low velocity and turbulence during feeding of molten metal into the casting to achieve quality requirements. The casting illustrates an increased use of castings that are structural and functional into one piece,” said one of the casting competition judges. “It combines parts from several processes into one casting with complex coring.” The AFS/Metal Casting Design & Purchasing Magazine Casting Competition is held every year to give North American metalcasting facilities the chance to show the engineering and purchasing community what a cast metal part can accomplish. Aarrowcast was recognized for its winning casting during the President’s Brunch April 10 at the 118th AFS Metalcasting Congress in Schaumburg, Ill. Six other castings were honored as Best in Class or Honorable Mention winners. Best in Class:

• Aristo-Cast Inc., Almont, Mich., for a magnesium investment cast electronics mount for the aerospace industry. • Pier Foundry & Pattern Shop, St. Paul, Minn., for a ductile iron green sand cast hub used in the mining industry. • Signicast Investment Castings, Hartford, Wis., for a steel investment cast knife blade holder for a thresher used in farming. • Tooling & Equipment International, Livonia, Mich., for an aluminum water passage cast via low pressure permanent mold casting that integrates cooling system parts for an automotive application. Honorable Mention:

• O’Fallon Casting, O’Fallon, Mo., for a aluminum fan housing used on a commercial helicopter. • Meritor Design, Troy, Michigan, for a ductile iron green sand cast subframe used in a military application. The American Foundry Society is a not-for-profit organization formed in 1896. With its headquarters in Schaumburg, Ill., AFS provides members and consumers with information and services to promote and strengthen the metalcasting industry.

Shannon Wetzel MODERN CASTING Metal Casting Design and Purchasing 800/537-4237 ext. 266 [email protected] www.moderncasting.com www.metalcastingdesign.com