the ductile iron news issue 3.pdf · at the banquet that evening, the proceedings were hosted by...

The Ductile Iron News

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To Promote the production and application of ductile iron castings Issue 3, 2012

FEATURES

2012 FALL MEETING HIGHLIGHTS

• Speaker Bios - AM Session

• Speaker Bios - PM Session

• Melt Yard and Deck Basics - Larry Helm

• Iron Control in a Large Induction MeltFoundry - Brandon Reneau

• Optimizing Magnesium Recovery - BrianJohnson

• New Developments in Binders & Coatingsfor DI - Doug Trinowski

• Cast, Clean, and Make Money - GeneMuratore

• Blending Optimization in the DI Industry -Peter Moulder

• Observations for Management on IronFoundry Safety Statistics - Ted Schorn

•Introduction to THORS - The OnlineLearning Resource - Al Alagarsamy &John Mirka

DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

Ductile Iron News - Issue 3, 2012

The Fall Technical and Operating meeting of the Ductile Iron Society was held on October 24-26, 2012 at the Embassy Suites in East Peoria, Illinois. The Wednesday started off with theResearch Committee meeting and with a record of 46 members attending. More informationcan be found by visiting the Research Committee on the DIS website. In the afternoon all theother Operating Committee meetings were held including the Board of Directors meeting. The first day was concluded with our reception.

On the second day, the attendees were presented with 9 different speakers and a panel of 4speakers on, “Back to Basic Melt Shop”. You can find out more about each presentation andthe panel presentations by clicking on the topic/speaker on the menu on the left hand side ofthis page. At the banquet that evening, the proceedings were hosted by the Ductile IronSociety’s President, Patricio Gil.

Patricio Gil, CEO of Blackhawk Foundry de Mexico

The attendance for the Fall meeting was 152. This was a record for the last 10 years.

Thanks to all members and guests for attending and making this a very successful meeting. Patricio then introduced our guests for this meeting. David Champagne, Steve Niekamp andJim Stubbs of Midwest Foundry (Minster Machine) of Ohio, Matt Sharifi, Dale Wells and JimO’Brian of Ariel Corporation of Ohio, Kurt Larsen of ARG from Denmark, Stephen Kamykowski

Mark your calendars for the 5th Keith Millis Symposium Oct. 14-17, 2013

http://www.ductile.org/

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and Kyle Rabine of Brillion Iron Works of Wisconsin, Sean Betty and Terry Oldfield from VAENortrak of Illinois, Martin Deters of Tenneco, Bill Weller of Ajax Tocco, and Jim Hauska ofFoundry Support Operations, Inc.

After the meeting concluded, Midwest Foundry joined as a Foundry member and ArielCorporation joined as a Research Patron.

Along with these guests we also had Ross Rosmait (FEF Key Professor) and Jacob Lehman(Asst. Professor) of Pittsburg State University and 6 students who were Brennon Holenda, JonMcPherson, Shawn Moody, Chad Morrell, Josh McLennan and Macon McNair attend ourmeeting as student guests. Along with these students we had 2 students from the Universityof Northern Iowa and they were Coleman Housman and Matthew Wason.

From l to r, Shawn Moody(Pittsburg State) BrennonHolenda(Pittsburg State) Matthew Wason(Northern Iowa)Coleman Housman(Northern Iowa) JonMcPherson(Pittsburg State) Macon McNair(PittsburgState) Chad Morrell(Pittsburg State) JoshMcLennan(Pittsburg State)

Patricio then introduced all the new members that joined the DIS since our last meeting inJune 2012 in Muskegon, MI. Re-joining the DIS was Cifunsa Del Bajio and representing themto receive their new membership certificate was Alberto Pinones along with Teo Quinteroand Daniel Gomez Ballesteros. Also joining the DIS as new members were Pacific AlloyCastings Company from California, Associate member Cobra Trading represented by KevinDykstra and Ryan Hoefler, Associate member Snam Alloys from India and Associate memberRex Heat Treat represented by Mel Ostrander.

Next Patricio asked Gene Muratore of Rio Tinto to come to the front and present eachspeaker with a token of appreciation for volunteering to speak to our group. Gene then askedeach speaker from the morning session to come to the front of the room to receive their gift.

Doug Trinowski of HA International spoke on, “New Developments in Binders & Coatings forDuctile Iron”.



Doug Trinowski of HA International & Gene

Guy-Roger Nauroy of FerroPem who spoke on, “Long term Price Evolution on Silicon BasedAlloys”.

Guy-Roger Nauroy of FerroPem

Ted Schorn of Enkei America, Inc. who spoke on, “Observations for Management on IronFoundry Safety Statistics”.

Ted Schorn of Enkei America, Inc. & Gene

Al Alagarsamy, DIS Consultant and John Mirka of Thors who spoke on, “Thors – The OnlineLearning Resource”.

Al Alagarsamy – DIS Consultant & Gene John Mirka of Thors & Gene

Brian Johnson of Hickman Williams & Company who spoke on, “Optimizing MagnesiumRecovery”.



Brian Johnson of Hickman Williams & Company & Gene

Then Patricio invited Kathy Hayrynen of Applied Process to present our DIS gift to theafternoon speakers. Thanks go out to both Kathy and Gene for volunteering to act as ourmorning and afternoon technical chair persons.

Gene Muratore of Rio Tinto who spoke on, “Cast, Clean and Make Money”.

Gene Muratore of Rio Tinto

Eli David of Globe Metallurgical Sales, Inc. who spoke on, “Production and Use of Ferro SiliconAlloys”.

Eli David of Globe Metallurgical Sales, Inc. and Kathy

Then the speakers who participated in the panel on “Back to Basic Melt Shop”.



Larry Helm of Seneca Foundry

Kyle Anderson of Waupaca Foundry & Kathy

Brandon Reneau of Caterpillar, Inc. & Kathy

Dan Webb of Progress Rail & Kathy



Peter Moulder of Management Sciences Associates, Inc. who spoke on “Reduction in MaterialCosts in a Ductile Iron Melting/Foundry Environment: Promises & Observations”.

Peter Moulder of Management Sciences Associates, Inc.

Patricio then finished off the proceedings of the banquet by asking the Plant Manager ofCaterpillar’s Foundry operation in Mapleton, IL to come to front of the group and give them abrief presentation on the history of the plant and safety guidelines for the tour that the groupwill go on the next morning.

Gary Bevilacqua of Caterpillar Inc.

The Ductile Iron Society wishes to extend our appreciation and gratitude for hosting the planttour on the final day. Thanks especially go out to Brandon Reneau for organizing thearrangements for the tour. We also would like to thank Gary and the many folks atCaterpillar who volunteered to host and act as tour guides.



Please mark your calendars for our next Ductile Iron Society’s Annual meeting will be held onJune 5-7, 2013 at the Westin Indianapolis with a tour of Pure Power TechnologiesMetalcasting Group in Indianapolis, IN. Please check the DIS website at www.ductile.org formore details. Also the Ductile Iron Society will hold a Production Seminar in late March, 2013in Mexico and March 5-6, 2013 in Chicago, IL. Again, check the DIS website for more details.

The Ductile Iron Society would also like to acknowledge those folks who make the meetingsrun smoothly and volunteer their time to the operation of the DIS.

Pete Guidi of Hitachi Metals Automotive Comp USA – DIS Treasurer

Susie Lambert & Jim Wood




Bruce Blatzer

THE FEF COLLEGE INDUSTRY CONFERENCE 2012

The FEF College Industry Conference was recently held at the Westin Michigan Avenuein Chicago. Over 280 industry executives (including nine FEF Past Presidents), studentdelegates, key professors and university administrators were in attendance this year. The conference began on Thursday, November 15, with the Career InformationSession which gave 81 student delegates the opportunity to interact withrepresentatives of 43 companies in the metal casting industry. The InformationSession and social time before and after the event is structured to facilitate thesharing of job opportunities and to connect students to potential employers in theindustry.

During the General Session on Friday, the following speakers shared their vastexperiences in the metal casting industry: Dwight Barnhard (Superior AluminumCastings), Mo Lynn (Fairmount Minerals), and John Keough (Applied Process).

The FEF/AFS Distinguished Professor Award was given to FEF Key Professor, ScottGiese, University of Northern Iowa, in recognition of his demonstrated personalinterest in his students, as well as his knowledge of the industry. As part of theluncheon this year, the Student Delegate scholarships were presented (see next pagefor complete list) - 20 students were awarded a total of $44,500.00. Additionally, the



Keith Millis and Ron Ruddle scholarship recipients were announced, as well as therecipient of the first William Allan Hunter Scholarship. At the Annual Reception on the evening of November 16, FEF's highest award, the E.J.Walsh Award, was presented to longtime FEF Board Member & Treasurer, Rob Steele.

Next year's conference will be help on November 21 & 22 at the Westin MichiganAvenue in Chicago. Plan now to attend this exciting event!

CIC Student Delegate Scholarships-November 16, 2012

AFS Detroit-Windsor-George Booth Schol. - Andrew Miko - Michigan TechAFS-Saginaw Valley Scholarship - Lawrence Hengesbach - Western MichiganAFS Southwestern Ohio Scholarship - Colin Galey - Case Western ReserveRon & Glenn Birtwistle Mem. Scholarship - Steven Brown - Pittsburg StateRon & Glenn Birtwistle Mem. Scholarship - Mary Seals - Virginia TechDonald Brunner Scholarship-ThyssenKrupp Waupaca - David Kalchbrenner - Wisconsin-MilwaukeePaul Carey Memorial Scholarship - Jeremiah Hardwick - Trine University Clifford Chier-Badger Mining Corp. - John Anderson-Wisconsin-PlattevilleWm. E. Conway Scholarship-Fairmount Minerals - Austin DePottey - Michigan TechTony & Elda Dorfmueller Scholarship - Jose Saucedo - Inst. Tecnologico de SaltilloJohn Deere Scholarship - Justyna Baginska - Penn StateRichard Frazier Scholarship - Foster Webb - Trine UniversityLoper Award - Shawn Moody - Pittsburg StateModern Casting Scholarship - Shawn McKinney - Virginia TechChester V. Nass Memorial Scholarship - Melissa Wright - Michigan TechRobert W. Reesman Mem. Scholarship - Laura Kraus - Missouri Univ. of Science & Tech.MAGMA Scholarship-John Svoboda - Alicia Steele - Michigan TechGary Thoe Scholarship-ThyssenKrupp Waupaca - Nicholas Dixon - Western MichiganRay Witt Memorial Scholarship - John Pischak - Missouri Univ. of Science & Tech.Robert V. Wolf Mem. Scholarship - Jennifer DeHaven - Missouri Univ.of Science & Tech.

Special Scholarships

Keith D. Millis Scholarship - Brennon Holenda - Pittsburg StateKeith D. Millis Scholarship - Eric Nixon - Trine UniversityKeith D. Millis Scholarship - Coleman Housman - Univ. of Northern IowaKeith D. Millis Scholarship - Christopher Slinger - Wisconsin-PlattevilleRon Ruddle Scholarship - Andrew Oman - Western MichiganWilliam Allan Hunter Mem. Scholarship - Brett Hunter - Univ. of Alabama



Patricio Gil (DIS President), Brennon Holenda (Pittsburg State University) & Jim Wood (DIS Executive Director)

Patricio Gil, Coleman Housman (University of Northern Iowa) & Jim Wood

We would also like to acknowledge Eric Nixon of Trine University and Christopher Slinger ofWisconsin-Platteville who were not in attendance to receive their scholarships.

Jim WoodDIS Executive Director

View Ductile Iron Related Publications

Located in Strongsville, Ohio, USA15400 Pearl Road, Suite 234; Strongsville,Ohio 44136 Billing Address: 2802 Fisher Road, Columbus, Ohio 43204 Phone (440) 665-3686; Fax (440) 878-0070email:[email protected]

mailto:[email protected]


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FEATURES












DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

October 25, Morning Session Speaker Bios

Gene Muratore - Session Chair

DOUG TRINOWSKI

DOUG IS A DEGREED CHEMIST AND BRINGS OVER 30 YEARS OF FOUNDRY AND PHENOLICRESIN TECHNICAL EXPERTISE. DOUG IS CURRENTLY THE VP OF TECHNOLOGY FOR HAINTERNATIONAL. IN THIS ROLE, DOUG LEADS ALL RESEARCH AND PRODUCT DEVELOPMENTFOR FOUNDRY RESINS, REFRACTORY AND LOST FOAM COATINGS AND AUXILIARYMATERIALS. HIS CAREER STARTED AT QC CHEMICALS FORMERLY THE QUAKER OATSCOMPANY IN 1976. HE THEN JOINED DELTA-HA IN 1989 AS A TECHNICAL SALESREPRESENTATIVE. DOUG IS ACTIVE IN THE AFS AND IS CURRENTLY CHAIR OF DIVISIONCOUNCIL. IN ADDITION, HE IS A PAST CHAIR AND DIRECTOR OF THE CAST METALS INSTITUTE. HE IS ALSO A TWO TERM PAST CHAIR OF THE DETROIT-WINDSOR AFS CHAPTER. DOUG HASBEEN HONORED TO RECEIVE AN AFS SERVICE CITATION AND AWARD OF SCIENTIFIC MERIT. HEALSO SERVES ON THE ADVISORY BOARD OF DIRECTORS FOR THE METAL CASTING CENTER,DEPARTMENT OF TECHNOLOGY AT THE UNIVERSITY OF NORTHERN IOWA IN CEDAR FALLS,IOWA. DOUG HAS JUST ACCEPTED THE POSITION OF GLOBAL DIRECTOR OF RESEARCH &DEVELOPMENT FOR HUTTENES-ALBERTUS BASED IN DUSSELDORF, GERMANY.

GUY-ROGER NAUROY

GUY IS CURRENTLY FERROPEM’S FOUNDRY SALES MANAGER OUT OF FRANCE. HE ISRESPONSIBLE FOR THE SALES OF INOCULANTS, NODULARISERS, FOUNDRY CORED WIREWORLDWIDE FROM 2 FRENCH PLANTS AND ONE SOUTH AFRICAN ONE. GUY HAS BEENWORKING FOR FERROPEM FORMERLY PECHINEY ELECTROMETALLURGIE FOR THE PAST 30YEARS. HE WAS INITIALLY THE PRODUCTION ENGINEER IN 4 DIFFERENT FERROSILICON,INOCULANTS AND SILICON PLANTS. HE THEN BECAME THE MANAGER OF A SILICON PLANT,THEN IT MANAGER DURING THE MERGER WITH FERROATLANTICA. GUY HAS HELD HISCURRENTLY POSITION SINCE 2007.

TED SCHORN

TED HAS RESPONSIBILITY FOR QUALITY FOR THE NORTH AMERICAN OPERATIONS OF ENKEICORPORATION, THE WORLD’S LARGEST PRODUCER OF CAST ALUMINUM ROAD WHEELS. HEHAS WORKED IN VARIOUS QUALITY AND MANUFACTURING POSITIONS FOR NEARLY 30 YEARS,THE LAST 23 WITH ENKEI. TED IS ACTIVE WITHIN THE TECHNICAL COMMITTEE STRUCTURE OFAFS, HAVING SERVED AS DIVISION COUNCIL, ENGINEERING DIVISION AND QUALITY SYSTEMS


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TECHNICAL COMMITTEE CHAIR. HE HAS EARNED NUMEROUS AWARDS FROM AFS INCLUDINGTHE AWARD OF SCIENTIFIC MERIT, TWO RAY WITT AWARDS AND WAS THE 2005 HOYTMEMORIAL LECTURER. TED CURRENTLY SERVES ON THE BOARD OF DIRECTORS OF AFS. HEHAS WRITTEN SCORES OF TECHNICAL PAPERS AND IS A FREQUENT CONFERENCE SPEAKER.

1ST AL ALAGARSAMY

AL IS WELL KNOWN AMONG THE DIS PARTICIPANTS. HE HAS BEEN INVOLVED WITH IRONFOUNDRIES FOR MORE THAN 40 YEARS AND HAS WORKED WITH THREE MAJOR FOUNDRYGROUPS IN RESEARCH AND DEVELOPMENT FUNCTIONS. PRESENTLY, HE CONTINUES TOWORK AS A CONSULTANT TO FOUNDRIES AND CASTING USERS ALIKE. HE HAS SERVED ASRESEARCH COMMITTEE CHAIRMAN AT AFS AND DIS. HE HAS DEVELOPED TRAININGMATERIALS FOR THE IRON FOUNDRIES IN AREAS OF METALLURGY, SAND CONTROL, CASTINGDEFECTS, ETC. HE IS WELL-RECOGNIZED IN THE DUCTILE IRON INDUSTRY AND RESEARCHINSTITUTIONS. HIS EDUCATIONAL BACKGROUND INCLUDES BACHELORS OF ENGINEERING INMECHANICAL ENGINEERING AND A MASTERS IN FOUNDRY SCIENCE AND ENGINEERING.

2ND JOHN MIRKA

THE THORS WEBSITE WILL BE DEMONSTRATED BY JOHN. JOHN HAS BEEN WITH THE THORSTEAM SINCE FEBRUARY 2012 SELLING TO OEM’S AND SUPPLIERS. JOHN ALSO HAS AN ACTIVEROLE IN TRAINING THORS USERS.

BRIAN JOHNSON

BRIAN RECEIVED A BACHELORS OF SCIENCE IN METALLURGICAL ENGINEERING FROM THEUNIVERSITY OF WISCONSIN-MADISON IN 1998. HE WORKED FOR GREDE FOUNDRIES INREEDSBURG, WI WHERE HE WAS PLANT METALLURGIST FOR 4 YEARS, ELECTRIC MELTSUPERINTENDENT FOR 4 YEARS AND TECHNICAL SERVICES MANAGER FOR 4 YEARS. HE HASSPECIFIC EXPERIENCE WITH COVERED TUNDISH LADLES, PURE MAG CONVERTERS, ELECTRICMELT, CUPOLA MELT, PRESSURE POUR FURNACES, HORIZONTAL MOLDING AND VERTICALMOLDING. TWO YEARS AGO HE JOINED HICKMAN WILLIAMS AND COMPANY AS TECHNICALSUPPORT FOR THEIR CUSTOMERS AND SALES PEOPLE.







FEATURES












DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

October 25, Afternoon Session

Speaker Bios

Kathy Hayrynen - Session Chair

EUGENE MURATORE

GENE GRADUATED FROM CASE WESTERN UNIVERSITY IN 1970 WITH A BACHELOR OFSCIENCE IN METALLURGY. GENE SPENT THE NEXT 20 YEARS AS AN OPERATINGMETALLURGIST FOR THREE FOUNDRIES IN THE PRODUCTION OF GRAY AND DUCTILEIRON CASTINGS. GENE HAS BEEN THE SENIOR FOUNDRY METALLURGIST FOR RIO TINTOIRON & TITANIUM SINCE APRIL OF 1991. AS SUCH, GENE IS RESPONSIBLE FORTECHNICAL SERVICE TO THE US, CANADA, MEXICO AND PARTS OF ASIA. GENE IS ACTIVEON 6 AFS TECHNICAL COMMITTEES, A BOARD MEMBER OF THE CHICAGO CHAPTER OFTHE AFS, AND A MEMBER OF THE AFS RESEARCH BOARD. IN ADDITION, GENE IS ALSOACTIVE WITHIN THE TECHNICAL STRUCTURE OF THE DIS AND 2 TERM PAST BOARDMEMBER.

ELI DAVID

ELI GRADUATED FROM THE ISRAEL INSTITUTE OF TECHNOLOGY WITH HIS BACHELORSDEGREE IN MATERIALS ENGINEERING AND KENT STATE UNIVERSITY WITH HIS MASTERSOF BUSINESS IN FINANCE. ELI STARTED HIS FOUNDRY CAREER AT THE QUALITYCASTINGS COMPANY IN ORVILLE, OHIO AS CHIEF METALLURGIST AND TECHNICALDIRECTOR, WHERE HE WAS EMPLOYED FOR SLIGHTLY OVER 10 YEARS BETWEEN 1979AND 1989. THIS POSITION PROVIDED EXTENSIVE EXPOSURE TO MANUFACTURING,METALLURGICAL AND QUALITY ASPECTS OF PRODUCTION OF GRAY, DUCTILE ANDMAGNESIUM CASTINGS. ELI IS CURRENTLY AND FOR THE LAST 8 YEARS HAS BEENEMPLOYED BY GLOBE METALLURGICAL INC. AS GENERAL MANAGER FOR FOUNDRYPRODUCTS. PRIOR TO THIS POSITION ELI WAS TECHNICAL MANAGER FOR GLOBEBETWEEN 1989 AND 2003. HE HAS MADE NUMEROUS PRESENTATIONS AT AFS AND DISMEETINGS ON VARIOUS METALLURGICAL AND OTHER CAST IRON FOUNDRY RELATEDTOPICS. ELI HOLDS A PATENT AS CO-INVENTOR OF THE FLEXIPOR PROCESS (AN INMOLDTREATMENT METHOD FOR THE PRODUCTION OF DUCTILE IRON)

BACK TO BASIC MELT SHOP PANEL


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LARRY HELM

LARRY GRADUATED FROM THE OHIO STATE UNIVERSITY WITH HIS BACHELOR OFSCIENCE IN METALLURGICAL ENGINEERING. HE IS ALSO A FEF SCHOLARSHIP HOLDER. HE THEN RECEIVED HIS MASTERS DEGREE IN INDUSTRIAL MANAGEMENT FROMLYNCHBURG COLLEGE. HE HAS WORKED IN A VARIETY OF POSITIONS FOR ELYRIAFOUNDRY, LYNCHBURG/INTERMET CORPORATION, BLACKHAWK FOUNDRY AND ISCURRENTLY QUALITY MANAGER WITH SENECA FOUNDRY. HOLDS CERTIFICATIONS OFCERTIFIED QUALITY ENGINEER AND CERTIFIED QUALITY AUDITOR FROM ASQ. HE IS APAST CHAIRMAN OF THE AFS CAST IRON DIVISION #5 AND A RECIPIENT OF THE AFSSERVICE CITATION. LARRY HAS BEEN INVOLVED IN THE FOUNDRY INDUSTRY FOR THELAST 41 YEARS.

KYLE ANDERSON

KYLE GRADUATED FROM MICHIGAN TECH IN 2011 WITH A BACHELOR OF SCIENCEDEGREE IN MATERIALS SCIENCE. HE IS CURRENTLY WORKING AS A METALLURGIST ATWAUPACA FOUNDRY’S PLANT 4 IN MARINETTE, WI.

BRANDON RENEAU

BRANDON GRADUATED FROM THE UNIVERSITY OF MISSOURI – ROLLA WITH ABACHELOR OF SCIENCE IN METALLURGICAL ENGINEERING. HE HAS WORKED FORINTERMET FOUNDRY IN DECATUR, IL FOR 4 YEARS, AND THEN INTERMET FOUNDRY INHAVANA FOR 4 YEARS AND CURRENTLY THE PLANT METALLURGIST AND MELTINGGROUP MANAGER AT CATERPILLAR MAPLETON FOUNDRY FOR THE LAST 8 YEARS. BRANDON IS A MEMBER OF THE 5R & 5P COMMITTEES AT THE AFS AND DIS RESEARCHCOMMITTEE VICE CHAIRMAN. HE HAS BEEN A PROACTIVE SUPPORTER OF AFS AND DISRESEARCH BY CASTING SAMPLES AT CAT.

DAN WEBB

DAN GRADUATED FROM AURORA UNIVERSITY WITH HIS BACHELORS DEGREE INORGANIZATIONAL BUSINESS MANAGEMENT THEN HIS ASSOCIATES DEGREE INAGRICULTURE BUSINESS MANAGEMENT FROM ILLINOIS CENTRAL COLLEGE AND ANASSOCIATES DEGREE IN APPLIED SCIENCES FROM ILLINOIS CENTRAL COLLEGE. DAN ISCURRENTLY THE ACCOUNT MANAGER AT PROGRESS RAIL WHICH IS A WHOLLY OWNEDSUBSIDIARY OF CATERPILLAR.

PETER MOULDER

PETER HAS AN UNDERGRADUATE DEGREE FROM THE UNIVERSITY OF NOTRE DAME. HE



ALSO OBTAINED HIS MASTERS DEGREE FROM THE AMERICAN UNIVERSITY INWASHINGTON, DC. PETER IS CURRENTLY IS AN ACCOUNT MANAGER WITHMANAGEMENT SCIENCE ASSOCIATES IN PITTSBURGH, PA. PETER’S ACTIVITIES INCLUDEDEFINING THE APPLICATION OF TECHNOLOGY FOR THE RESOLUTION OF OPERATIONAL,MATERIAL MANAGEMENT, AND ENERGY ISSUES FOR METALS COMPANIES THAT ARE INTHE PRIMARY OR MELTING SECTION OF THE INDUSTRY. SPECIFIC AREAS OF EXPERTISEINCLUDE MATERIAL OPTIMIZATION, PROCESS AUTOMATION AND INFORMATIONTECHNOLOGY. HIS PRIME FOCUS NOW IS ASSISTING FOUNDRIES ACHIEVE BETTER ANDOPTIMAL USE OF RAW MATERIALS AND RAW MATERIAL PURCHASING. PETER HASBEEN A PARTICIPANT IN THIS INDUSTRY FOR THE LAST THIRTY YEARS. POSITIONS HAVEINCLUDED SOFTWARE ENGINEERING, SOFTWARE DEVELOPMENT MANAGEMENT,CONSULTING, AND SALES AND MARKETING.





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FEATURES












DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

Link to Presentation: “Melt Yard and Deck Basics” (Training Moments)

LARRY HELM

LARRY GRADUATED FROM THE OHIO STATE UNIVERSITY WITH HIS BACHELOR OFSCIENCE IN METALLURGICAL ENGINEERING. HE IS ALSO A FEF SCHOLARSHIP HOLDER.

HE THEN RECEIVED HIS MASTERS DEGREE IN INDUSTRIAL MANAGEMENT FROMLYNCHBURG COLLEGE. HE HAS WORKED IN A VARIETY OF POSITIONS FOR ELYRIA

FOUNDRY, LYNCHBURG/INTERMET CORPORATION, BLACKHAWK FOUNDRY AND ISCURRENTLY QUALITY MANAGER WITH SENECA FOUNDRY. LARRY HOLDS

CERTIFICATIONS OF CERTIFIED QUALITY ENGINEER AND CERTIFIED QUALITY AUDITORFROM ASQ. HE IS A PAST CHAIRMAN OF THE AFS CAST IRON DIVISION #5 AND A

RECIPIENT OF THE AFS SERVICE CITATION. LARRY HAS BEEN INVOLVED IN THEFOUNDRY INDUSTRY FOR THE LAST 41 YEARS.





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“Melt Yard and Deck Basics” (Training Moments)

Larry Helm

Seneca Foundry “We Bring Iron to Life”

ABSTRACT This article is a written version of a presentation made at the Ductile Iron Society Meeting held in Peoria, IL on October 24-26, 2012. It contains basically three components: 1st a little about who is Seneca Foundry, 2nd some information about melting and alloying practices employed at Seneca; and 3rd some general observations gathered over the years on melting, alloying, and general foundry topics. WHO IS SENECA FOUNDRY We are a family owned foundry located in North Central Iowa; that can trace our heritage as a company back over 100 years. Metals poured include: Gray Iron grades G30, G35, and G40; Ductile Iron grades D60, D65, D80, D100, and D120; along with Austempered and High Silicon-Moly Ductile Irons. Molding entails: Green Sand a Hunter 10 to a turntable and a Hunter20 to pallet lines, weights 1-90#; No-Bake weights up to 250#; and Lost Foam weights up to 100#. Core making consists of Shell, Cold Box, and No-Bake. Heat treating in house is annealing and stress relieve, other is performed by outside sources. Melting is by 2-2 ton medium frequency furnaces. Also included is Top Notch Tooling, a full service pattern shop; and Gold Chip Machining, a casting machine shop.

IRON YARD Our iron yard is very simple, one grade of steel, from one source (a back-up source is available).Manganese content is a compromise for use in both Gray and Ductile iron. Many foundries are not able to accomplish this and as a result will have piles of several grades in their yards. For us it works well, and allows us to minimize our need for inventories and storage area. In pig iron again only one grade is used (also from only one supplier), and is used only in Ductile Iron to control Mn and other elements levels in our base iron. Our returns are stored in meal tubs by iron type. Each gating system and riser is marked with the corresponding iron grade ex: G30, D80, etc. and after blasting is placed into the metal tubs. Unlike in cupola melting returns segregation for S control is very important in electric melting, so we work hard in keeping materials properly separated. Which brings us to our first Universal Law.

MURPHY’S LAW OF IRON YARDS

“Beware, keep everything well marked and separated on the yard;

especially all grades of returns!”

Nothing is worse than going looking for that “special” material that was put out onto the yard the other day, and finding it “gone”; mixed into who knows whatever pile or charges. As mentioned before all of our returns are blasted and then handled in tubs in the yard. We work to keep sand, dirt, trash, non-ferrous material, and junk out of the iron yard. This leads to our next law.

THE 1st LAW of ELECTRIC FURNACES

“Metal is easier to melt than Slag.”

Studies have been done showing that is takes several times the number of kilowatts of power to melt 100# of slag as 100# of metal, thus anything that can be done to minimize non-metallics in our melt yards, and thus our charges; improves the efficiency and cost effectiveness of our electric melting operations. Cupolas are a different animal; there more “dirt/sand” can be tolerated due to the slagging practice that is established in order to flux the surface of the pieces of coke for maximum carbon and heat transfer. But even in cupolas if too much in the way of this dirt and sand is added (especially going into mud in inclement weather) you can pay a real penalty in chemistry and temperature control, along with excess flux and coke usage. Bottom line, a “cleaner” charge is a better charge. MELTING OPERATION Our furnace linings are Silica with 1.0% Boron Oxide, thus on sintering in a lining with Ductile Iron we will experience the B ferritizing effect on pearlitic grades. We try as much as possible to sinter in on Gray Iron. As a bonus the higher Si content in the sinter also seems to start the lining out better, with less overall wear and patching over its life. We will take a lining out after 35 to 45 heats, we tend to be conservative on this, but we also have outstanding coil life. If we must sinter in on Ductile Iron, we definitely stay away from pouring D100 right after the sinter; and even D80 if possible. If we have to go D80 we will over alloy with Mn for a period of time (typically for 2 hours), to counteract the B effect. In our charge make-up all materials are weighed against a designated recipe, and are dried out (not preheated) before charging. The importance of precise material weights cannot be overstated. This gives us another law.

THE 2nd LAW of ELECTRIC FURNACES

“What you put in, is what you get out!”

Again cupolas are different. There in charge make-up you are looking at losses in certain elements, such as Mn, Si, etc. This effect, along with the fact that various materials melt at different levels in the stack, gives you a sine wave of chemistries. With a cupola you are always looking at the center of the sine wave as your desired chemistry. But in electric melting these losses don’t occur. What you see is what you get. To me making charge make-up that much more important in electric melting. We use a heel melting practice, thus the drying of the charges mentioned earlier. Don’t want wet metallics being submerged in the bath. Molten iron and water don’t mix well. Our initial charge into the furnace is 3800# and we normally tap out 550# ladles. Thus we are only changing 1/7 of the furnace on each tap/charge. This allows us pretty consistent chemistry control. We will pour multiple metal grades in a day, utilizing change-over charges (one per furnace) to go from Ductile to Gray, or from Hi-Sil-Moly to Gray. This brings up the cast iron version of “pour acid into water”.

CAST IRON LAW of MIXING “Ductile can go into Gray, but not the reverse!”

Ductile returns can mix into Gray iron allowing for extra alloys to be used. The reverse raises the S content in the Ductile, undesirable. Ductile carbon raisers again OK, you will have to add some S. The reverse is a disaster, just ask someone who did it! Even in ferrosilicons it is true. What would happen if a Ti ferrosilicon, good in Gray Iron for certain conditions; got accidently added to some Ductile? As a result we always refer to the Law of Mixing. ALLOYING For furnace alloys we use two carbon raisers, one for Ductile and one for Gray; S content obviously being the difference. One common SiC, iron pyrite to flavor the Gray Iron, a low alloy 75% FeSi for silicon units as needed, Ferro Mn and Cu and Ferro Moly for trimming. Our Ductile is produced using a tundish treatment ladle, our own design; using a Balanced (1%) RE, 5% MgFeSi. The final inoculant for both metals is a Ca Bearing 75% FeSi. Ferro Mn, Cu, and Ferro Moly are used for ladle additions for various iron grades. Some Ti Bearing 50% FeSi is used for some special Gray Iron jobs. It is kept basically under lock and key. Which brings up the:

LAW of FERROSILICONS

“All Ferrosilicons are not created equal!”

How often have we heard in our shops “But they looked the Same!” In my career ferrosilicons have caused more probably issues than any other alloys, other than maybe Sn; or possibly FeCr in Ductile Iron. Our Ferrosilicons contain various levels of combinations of Al, Ca, Sr, Z, Ba, Ti, and who knows what else! Trying to explain to someone on the floor why some are meant to work better than others for certain applications, has always been a challenge. While talking about ferrosilicons two other items come to mind. Overall in our industry we have tended to use inoculants of too large of a size for a given application. For instance the sizing which would be good for a 5000# transfer ladle; is not what you would want to use in a 500# pour off ladle. Studies have shown that the smaller the amount of iron, the smaller the sizing should be on the inoculant. Also the uniformity of sizing, controlling a consistent % of fines is important. Our final inoculation is done upon the transfer of iron from the transfer/treatment ladle into the pour off ladle. On some certain jobs we add an additional inoculant into the mold. You can add an inoculant in the transfer ladle, in the pour off ladle, into the iron stream, into the mold; or into multiple locations. Any of which can be effective processes. CHEMISTRIES You will naturally end up choosing C and Si ranges that suit the type of castings which you pour. At the same time you will control residual element levels, and levels of Pearlite formers and stabilizers for the grades of metal which you pour. But eventually you will bump into:

HELM’S LAW of CHEMISTRIES

“There will always be one (or more) jobs that will not run in your established ranges. Accept it, and adjust as needed.

Or, get rid of the job(s)!”

Over the years I have been able to keep many gating/rigging people very busy in trying to solve scrap issues that we eventually only solved by adjusting the chemistries, typically C and Si. If you cannot easily do these necessary adjustments on an individual job basis, then help out your head and tell sales to remove the brick wall. At Seneca we re-gated one Gray Iron job multiple times in order to prove what Taguchi experiments had showed; that only a higher carbon would solve the issue. Result back to the original gating, and scheduling of pour off to allow the higher carbons. This can also happen with certain parts in especially heavier (or thinner) section sizes, where sometimes “creative alloying” is required.

TESTING/SAMPLING We test the base iron always before starting to pour from a furnace, both thermal analysis and spectrometer samples. Any adjustments are made before starting of pouring. After we start pouring additional base furnace samples are poured every 4 ladles/charges. Final chemistries are poured with any test bars, with additional finals throughout the day on Gray Iron; and a final on every ladle of Ductile. We won’t burn all of them, but we pour them to have available in case we see any possible issues. We use chills sometimes on Gray Iron when looking for data, and pour micros on all ladles of Ductile. We always burn all specto samples 3 times. Good testing is important to keep from falling into:

MURPHY’S LAW of CHANGES

“Never make a major process change on data from only one test!”

Ever have someone make an alloy % change to the MgFeSi after making only one burn on a sample, only to find that the single burn was on a slag stringer? Or make big C and/or Si addition changes on what turned out to be a faulty T/A cup reading? Enough said. Refer to the above law when preparing to make changes to the operation. Besides routine testing; look at testing the metal under any/all conditions. This would include for instance out of a furnace that has sat for a “while”, at start-up, the first ladle of the day; and at pour-off, the last ladle. It may tell you some interesting information about the metal going into your castings. You may find yourself at the:

3rd LAW OF ELECTRIC FURNACES

“Unlike professional wrestling, Monday Morning Iron is Real!”

It can, and will exist, in any style of electric furnace: coreless melters, channel holders, or pressure pour units. Monday Morning Iron is basically metal which has suffered a loss (or destruction) of nucleation. It can happen faster than you think, especially in medium frequency melters. We can see it happening especially on holding the furnaces overnight; and on furnace pour-off on Gray Iron. We have worked on the issue by adjusting charge materials/alloys to increase nucleation, and by paying closer attention to furnace metal temperatures. Now the:

4th LAW of ELECTRIC FURNACES

“DO NOT superheat the metal any more than necessary!”

Increased and/or unnecessary superheating will only harm the metal, nothing good comes from it. It can contribute to more slag formation, it causes destruction of nucleation, it can cause carbon boil; it is bad for the furnace linings. And at the same time it raises your costs for the additional electricity. Just don’t put any more power into the metal than you need for good operations and the types of castings you are pouring. OTHER FOUNDRY GOOD PRACTICES This discussion on metal superheating is a great lead-in to a good rule of thumb adhered to by my old foundry professor.

METAL CHARACTERISTICS

“Pour any given part: As cold as you can. As fast as you can;

And, as quietly as you can! Dr. D.C. Williams, OSU

This statement doesn’t mean to pour all iron at a temperature that is barely liquid. It means simply don’t pour any hotter than is necessary for that given part. It doesn’t mean to fill the mold so fast that it blows out at the parting line. It does mean not to dribble the iron in so slowly that bad things start to happen to the mold and the metal. And it does mean to try to design the gating to minimize iron velocity and turbulence during filing. All of these characteristics will help in producing good castings. For more on pouting times refer to this old rule of thumb for horizontally parted molds.

POURING TIMES

“A reasonable aim point in seconds; is the Square Root of the Pour Weight of the Mold.”

As an example this would mean a 10# mold in about 3 seconds, a 100# mold in 10 seconds, a 1000# mold in 31 seconds, and a 100,000# mold in about 5 minutes. Is this a hard and fast rule, no it is an approximation. Some people would say we can’t pour that fast; others would say we would never pour that slow. But I would bet that if you go out and time a number of jobs you will be slower than these numbers/times. Again the point here is the same as Dr. Williams’. The faster you can fill an individual part, the better off you will be. As examples obviously vertical machines are much faster than these times, with only say 5-6 seconds of time to fill a mold. And in Lost Foam you can see downsprues with designed fill rates as high as 30-50# per second. TRAINING MOMENTS At the beginning of this article under the title, I had in parenthesis the term “Training Moments”. At Seneca each morning the Plant Manger has a meeting where we review production results against plan, scrap rates, safety subjects, and also a segment we call “Training Moments”. In just a few minutes we will go over topics such as the ones in this article on melting. And others such as sand, molding, cores, heat treat, clays, etc, basically just about any topic concerning foundry operations. The idea is to present in bite sized chunks, little bits of knowledge/wisdom concerning foundries. We have been doing this for over a year and have had good feedback from employees as they better learn how and what they do affects the castings they are producing. To finish I will leave one more nugget of wisdom from a supervisor I once worked with who was tired of dealing with runouts on a particular part number. He stated:

PLOG’S LAW

“You generally get a much better looking casting if you keep all of the metal in the mold!”

Thank you.


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Link to Presentation: Iron Control in a Large Induction Melt Foundry

BRANDON RENEAU

BRANDON GRADUATED FROM THE UNIVERSITY OF MISSOURI – ROLLA WITH ABACHELOR OF SCIENCE IN METALLURGICAL ENGINEERING. HE HAS WORKED FOR

INTERMET FOUNDRY IN DECATUR, IL FOR 4 YEARS AND THEN INTERMET FOUNDRY INHAVANA FOR 4 YEARS AND CURRENTLY IS THE PLANT METALLURGIST AND MELTING

GROUP MANAGER AT CATERPILLAR MAPLETON FOUNDRY FOR THE LAST 8 YEARS. BRANDON IS A MEMBER OF THE 5R & 5P COMMITTEES AT THE AFS AND DIS

RESEARCH COMMITTEE VICE CHAIRMAN. HE HAS BEEN A PROACTIVE SUPPORTER OFAFS AND DIS RESEARCH BY CASTING SAMPLES AT CAT.

THE DIS WELCOMES BRANDON WHO IS HERE TO TALK ABOUT “BASE IRON CONTROLIN A LARGE INDUCTION MELT FOUNDRY”





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B k B i BBack to Basics – Base Iron Control in a LargeIron Control in a Large

Induction Melt Foundry)y)Brandon Reneaua do e eau

Caterpillar

DIS DIS T&O T&O Meeting, Meeting, October 24 October 24 --26, 201226, 2012Peoria, IL Peoria, IL

Caterpillar, MapletonCaterpillar, Mapleton Foundry

60 000 hi t• 60,000 ship tons per year• Gray and ductile iron castings for

Engine components• Multiple molding methodsp g• 25 lbs to 20,000 lbs castings

DIS T&O Meeting, October 24 DIS T&O Meeting, October 24 --26, 201226, 2012Peoria, IL Peoria, IL

Incoming Raw Materials• Pig Iron – Sorel• Steel scrap

– 3 ft plate– 2 ft plate

Low Mn busheling– Low Mn busheling– Mid Mn busheling– Low Mn punchings (cover)

• Gray and Ductile Returns• Borings


Incoming Raw Materials• Pig Iron – Supplier Certs and quarterly check


Incoming Raw Materials

• Steel scrap – Met Lab checks 1 load per week perMet Lab checks 1 load per week per

supplier by spectrometer



Steel scrap – Met Lab checks 1 load per week perMet Lab checks 1 load per week per

supplier by spectrometer



• Borings– Met Lab checks 1 load per 2 weeks perMet Lab checks 1 load per 2 weeks per

supplier by xray diffraction


Incoming Alloy Materials

• Graphite – Coke (gray iron); check quarterlyCoke (gray iron); check quarterly– Low Sulfur crystalline (ductile iron);

check each shipmentp• SiC – check quarterly• FeSi (furnace) check quarterly• FeSi (furnace) – check quarterly


Incoming Alloy Materials• FeMn• FeCr• FeMo• Cu

All checked each shipment

• Pyrite• FeSi (inoculants)

M F Si ( i )• MgFeSi (wire)• MgFeSi (ladle)


Melting Equipment• Melting Furnacesg

– (2) 60 ton line frequency induction– (1) 30 ton med. Freq. Induction( ) q– (1) 12 ton Arc


Melting Equipment• Holding Furnaces

– (7) 55 ton Holders– Optimum chemistry and temperature– Minimize melting downtime– Minimize melting downtime

• Odermath Treatment room– Wire feed– Treat 30,000 lbs

• Projelta Treatment room– Wire feed– Treat 21,500 lbs


Controls• Temperature / Chemistry

– Fill charge car – order is important– Empty charge car into furnace– Run counts into furnace to melt to bath– Run counts into furnace to melt to bath– Take temperature via probe (Heat to 2600 F)– Take chemistry via chill mold (after 2600F)– Spectrometer and Leco C/S– Run final counts into furnace

Deslag furnace– Deslag furnace– Take temperature– Tap iron to transfer ladle


p

Controls• Chemistry SpecificationsChemistry Specifications

– CAT 1E Engineering Specifications• Set absolute minimum or maximum• Set absolute minimum or maximum

– Foundry target Specifications• Set targets to achieve specific properties onSet targets to achieve specific properties on

each casting • Tighter than Engineering Specifications


Controls• Things we don’t do g

– Chill wedges from base iron– Thermal Analysis

• Rely on– Chemistry

Good practice– Good practice• Load charge cars properly• Follow consistent melt process (time and temp)

D ’t h ld i i lt• Don’t hold iron in melters• Inoculate well


For additional information, l t tplease contact:

• Brandon Reneau• Brandon Reneau• Caterpillar, Inc – Mapleton Foundry• (309)-633-8406(309) 633 8406• [email protected]



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Link to Presentation: Optimizing Magnesium Recovery

BRIAN JOHNSON

BRIAN RECEIVED A BACHELORS OF SCIENCE IN METALLURGICAL ENGINEERING FROMTHE UNIVERSITY OF WISCONCIN-MADISON IN 1998. HE WORKED FOR GREDE

FOUNDRIES IN REEDSBURG, WI WHERE HE WAS PLANT METALLURGIST FOR 4 YEARS,ELECTRIC MELT SUPERINTENDENT FOR 4 YEARS AND TECHNICAL SERVICES MANAGERFOR 4 YEARS. HE HAS SPECIFIC EXPERIENCE WITH COVERED TUNDISH LADLES, PURE

MAG CONVERTERS, ELECTRIC MELT, CUPOLA MELT, PRESSURE POUR FURNACES,HORIZONTAL MOLDING AND VERTICLE MOLDING. TWO YEARS AGO HE JOINED

HICKMAN WILLIAMS AND COMPANY AS TECHNICAL SUPPORT FOR THEIRCUSTOMERS AND SALES PEOPLE.

THE DIS WELCOMES BRIAN WHO IS HERE TO TALK ABOUT “OPTIMIZING MAGNESIUMRECOVERY” THIS TALK WILL RELY ON BRIAN’S EXPERIENCES IN THE FOUNDRY AND

ON A LITERATURE REVIEW OF WORD DONE AS RELATES TO MAGNESIUM RECOVERY.





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O ti i i M iOptimizing Magnesium RecoveryRecovery

Brian Johnson Hickman, Williams & Companyp y

OverviewOverview• Introduction.

Cover Materials• Cover Materials.• Ladle Design and Maintenance.

– Tundish– Tundish.• Timing and Iron Control.

– Temperature.p– Sulfur Control.

• Alloy Decisions. Additi (C Al B d RE)– Additions (Ca, Al, Ba, and RE).

– Magnesium Content.– Sizing.Sizing.

IntroductionIntroduction• Optimizing Magnesium Recovery.

– There are several ways to treat ductile iron and the scope of this presentation will focus on MgFeSi alloys.MgFeSi alloys.

• The converter process and cored wire process are beyond the scope of this presentation.

– MgFeSi alloys have low vapor pressures which makes the addition of these alloys challenging.y g g

• They react violently which makes recovery of the Magnesium difficult.

Introduction• Due to the low vapor pressure there is one

over riding theme in increasing Magnesium Recovery.– Delay the reaction as long as possible to

maximize the amount of magnesium capturedmaximize the amount of magnesium captured by the iron.

Cover Materials• Purpose is to delay the MgFeSi reaction as

long as possible allowing for more iron capture of magnesium.

• Traditional materials.– Steel – should be clean and dry.Steel should be clean and dry.– Ductile iron spill or turnings – clean and dry.– Alloys such as copper on pearlitic grades .– FeSi – dependent upon base silicon levels.– Cast shape made from left over iron in ladle.

Cover Material (cont’d)• Alternatives to traditional cover materials.

– Filling the ladle faster (50-100 #/second).• Get as much iron into the ladle as possible

increasing the recovery of magnesiumincreasing the recovery of magnesium.

• This may require furnace / ladle modificationsThis may require furnace / ladle modifications to achieve and being able to do this safely is paramount.

• Faster fill times may allow for lower tap temperaturestemperatures.

Alloy Addition vs. Ladle Design y g

• Open Ladle = 1.8%• Alloy Pocket = 1 6%Alloy Pocket 1.6%• Sandwich = 1.5%

T di h 1 4%• Tundish = 1.4%

Alloy Addition vs. Process Changes

• Shows progression in a chart from previous slide[6]

• Shows progression in a chart from previous slide.

Covered Tundish Ladle Design• Tundish Ladle.

– Iron tap hole diameter needs to control iron flow upon tapping (does not allow air to(does not allow air to be pulled into ladle).

– Cover helps in pimproving recoveries.

– Pocket maintenance i iti l ll fitis critical so alloy fits into pocket from 1st

treatment to last. t eat e t to ast

Tundish Ladle DesignTundish Ladle Design– Ladle pocket modification p

to create a taller / deeper pocket.

O ti i i b• Optimizes recoveries by delaying / prolonging the MgFeSi reaction. Versus

• Cover material may be reduced or even eliminated.

• Accuracy of alloy delivery to pocket is even more critical.critical.

Tundish Ladle Maintenance• Tap hole and pocket maintenance are critical

to maintaining optimal magnesium recovery.to maintaining optimal magnesium recovery.– Tap hole gauges can be used to ensure

consistent diameter / shape for ladles after reline d d iand during use.

– Requiring some frequency of pocket maintenance during ladle use can help maintain recoveriesduring ladle use can help maintain recoveries through out the life of ladle.

• Drain ladles.– When not in use hang ladles over a slag bed.

• Allowing for as much iron and slag to naturally fall out of ladle as possible makes operators job easier and helpsladle as possible makes operators job easier and helps to extend the life of the pocket.

Timing and Iron Controlg• Add alloy just before tapping iron.

– The heat in the ladle can initiate ignition ofThe heat in the ladle can initiate ignition of MgFeSi alloy.

• Tap temperature will directly impact the t f M F Si d damount of MgFeSi needed.

– Increasing the speed of tapping or improving the insulation on ladle will allow for lowering tap g ptemperature which directly reduces the amount of alloy needed.

• Consistent Base Sulfur control is also• Consistent Base Sulfur control is also necessary for consistent recovery. – Operators tend to error on the safe side, so it is

always easier to increase Mg than to decrease Mg.

Timing and Iron Control g• Avoid torching as long as possible.

– The torching causes a sulfur reversion which will require additional MgFeSi upon start uprequire additional MgFeSi upon start-up.

• Torch heat is only surface heat and does not penetrate the lining, try only using for known extended down times.

• Ladle washing with iron is much more effective for heating g gup a ladle but is often not feasible in many operations.

• Be aware of where chemistry results are coming from.g– Some foundries are testing chemistry after treatment.

• Information used to adjust alloy usage only not for ensuring quality.

S f d i t ti h i t f l t i– Some foundries are testing chemistry from last iron poured.

• This information is used for usage control and quality assurance.

Alloy Design Discussion• The Magnesium Reaction.

– Mg + O = MgO– Mg + O = MgO– Mg + S = MgS

• Magnesium will deoxidize and desulfurize and this action contributes to the Magnesium Requirement.

Mg Recovery = .76 (Sbase – Sfinal) + Mgresidual x 100 Mginitial [1]

Alloy Design DiscussionAlloy Design Discussion• It can be assumed that less available

oxygen and sulfur would allow foroxygen and sulfur would allow for better utilization of the Magnesium.With thi i f ti l k t• With this information we can look to the Ellingham Diagram for ideas to

dif th t t t llmodify the treatment alloy or treatment process to achieve the d i d ff t f i idesired effect of improving Magnesium recovery.

Close to Preferential

• 4/3Al+O2 = 2/3Al2O3

• 2Ba+O2 = 2BaO2• 2Ca+S2 = 2CaS

2M +O

Preferential R ti

2Mg+O2 = 2MgO

Reactions• 2Ca+O2 = 2CaO• 2Ce+S2 = 2CeS

[2]

Alloy Design DiscussionAlloy Design Discussion• Near treatment ranges of 1800 K or 2770 F

th t th t ff ti d f Swe see that the most effective reducers of S and O are Cerium and Calcium.

• We also see that Barium and Aluminum are beginning to become a factor in the reactions.reactions.

• Lets keep in mind these are equilibrium ti d i di ti t f threactions and give us direction to further

investigate.

Alloy Design Discussion•Calcium-The observation from the Ellingham diagram is confirmed. Notice the range of sulfurs over which tests were run.tests were run.

[3]

Alloy Design Discussion• Calcium Depending on sulfur starting point there is• Calcium – Depending on sulfur starting point there is

an optimum level of calcium in the alloys to have.

[3][3]

Alloy Design Discussion• Cerium.

– The action of Cerium (RE) is well documented in the literature.

• Impact on deleterious elements.

– This benefit is also shown in the EllinghamThis benefit is also shown in the Ellingham diagram with its reaction with Sulfur.

• “Producing Spheroidal Graphite Cast Iron by Suspension of Gas Bubbles in Melts” AFS T ti l 83 1975 [5]Transactions, vol 83, 1975. [5]

• Produced Ductile iron with 1% Cerium addition.

Th i l h f d f d i– The economics recently have forced foundries to try to minimize this in their alloys.

Alloy Design Discussion• Aluminum.

– From the Ellingham diagram we see Al will react more dil ith O th M t l t d t treadily with O than Mg at elevated temperatures.

– “Aluminum is recognized for contributing to pinhole formation in iron castings…..Aluminum will also add to the slag formation resulting in poor furnaceto the slag formation, resulting in poor furnace performance, more ladle and holder maintenance and increased risk for slag inclusions in castings…… At higher aluminum levels, FeSi-based alloys will tend to i l bilit b t th i d l f tiimprove solubility, but the increased slag formation and tendency for pinholes should call for caution. “ [4]

– “The greatest benefits were achieved when Al was introduced in to the iron via the inoculant late in theintroduced in to the iron via the inoculant late in the process or as a pre-conditioner of the base iron early in the process. Al added via the MgFeSi provided the minimum benefit.” [4]

Alloy Design Discussion• Barium.

– “One of the objectives of a O e o t e object es o apreconditioning treatment with high level of barium containing ferrosilicon is to manage or control the oxygen and sulfur activity, promoting the formation of oxysulfphides of barium (BaO andof oxysulfphides of barium (BaO and BaS). The aim is to promote a consistent magnesium recovery and aconsistent magnesium recovery and a reduction of the addition of magnesium alloy. “ [1]

Alloy Design Discussion• Barium 9% Ba FeSi as cover for 5% MgFeSi iron• Barium – 9% Ba FeSi as cover for 5% MgFeSi, iron

taken to a pressure pour furnace.

[1]

Alloy Design Discussion• Barium – 9% Ba FeSi as cover for 8% MgFeSi, iron

transferred into pouring ladles and poured into molds. Results from molds.molds. Results from molds.

cove

ryPe

rcen

t Rec

P

[1]

Alloy Discussion• Barium – 9% Ba – FeSi added as a pre-conditioner prior to pure a u 9% a eS added as a p e co d t o e p o to pu e

magnesium treatment. Amount of pure magnesium as required to achieve a specific final Magnesium residual from pressure pour furnace.

[1]

Alloy Design DiscussionM i C t t• Magnesium Content.– 3-4% Mg.

• Less violence in the reaction.Less violence in the reaction.• Less emissions (lower smoke).• Improved recovery due to quieter reaction (65-80%)• As a ratio to Mg the Ca Al and RE are higherAs a ratio to Mg, the Ca, Al and RE are higher.

– 5-6% Mg.• Less alloy use = less slag generation.

M l til ti ith l i (50%• More volatile reaction with lower recoveries (50%-60%)

• Alloy Sizing.– “A finer and wider sizing will give a denser

alloy bulk packing in the sandwich and by that the reactivity will be reduced. “ [6]y [ ]

Alloy Summary• Calcium (Ca)• Calcium (Ca).

– Ca helps to create a quieter reaction and has been shown to improve Magnesium recovery.

• Rare Earths (RE).Rare Earths (RE).– Will help in improving Magnesium recovery but recent

economics have made this a less desirable option.• Aluminum (Al).

– May provide desired reduction in oxygen activity as a pre-conditioner but may enhance sensitivity to H2 pinholes.

• Barium (Ba).Has been sho n to positi el impro e Magnesi m reco er– Has been shown to positively improve Magnesium recovery as a pre-conditioner or cover alloy.

– Local environmental requirements should be understood.• Magnesium (Mg).Magnesium (Mg).

– Lower content improves recovery, this becomes a function of economics.

– Lower content alloys tend to have higher levels other h l f l ll ti t M t thelpful alloys as a ratio to Mg content.

Summary• The reaction between the MgFeSi alloy

and the iron must be delayed as long as possiblepossible. – Cover materials.– Tap speeds.

Ladle maintenance– Ladle maintenance.– Alloy pocket design.

• Factors affecting the amount of alloy d d t b t ll d llneeded must be controlled as well.

– Base sulfur control/consistency.– Iron tap temperature.p p– Alloy design considerations.– Alloy addition and testing timing.

References• [1] “Preconditioning Effect of Barium in Ductile Iron Production”,

Proceedings of the AFS Cast Iron Conference, September 29-30, 2005, J.Fourmann

• [2]The Ellingham Diagram Web Tool, www.engrsjsu.edu/ellingham/ellingham_tool_p1/php

• [3] “Thermochemistry of Nodulization and Inoculation of Irons”, P di f th AFS C t I I l ti C f S t 29 30Proceedings of the AFS Cast Iron Inoculation Confernece, Sept 29-30 2005, S. Lekakh, D. Robertson, C. Loper Jr.

• [4] Aluminum Benefits in Ductile Iron Production, Proceedings of the Keith Millis Symposium on Ductile Cast Iron October 20 22 2008 I Riposan MMillis Symposium on Ductile Cast Iron, October 20-22, 2008, I.Riposan, M. Chisamera, S.Stan, P. Tobac, G. Grasmo, D. White, C. Ecob, C. Hartung

• [5] “Producing Spheroidal Graphite Cast Iron by Suspension of Gas Bubbles in Melts” AFS Transactions vol 83 1975 S YamamotoBubbles in Melts AFS Transactions, vol. 83, 1975 S.Yamamoto, Y.Kawano, Y.Murakami, B.Chang and R.Ozaki

• [6] “Ductile Iron Production – A comparison of Alternative Treatment Methods”, T.Skaland,


• Brian Johnson Technical Sales• Brian Johnson – Technical Sales• 2015 Spring Road

P.O. Box 5225Oak Brook, IL 60522

• (630) 418-3209 - Cell(630) 574 2376 Fax• (630) 574-2376 - Fax

• [email protected]• www.hicwilco.com



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Link to Presentation: "New Developments in Binders & Coatings for DI"

DOUG TRINOWSKI

DOUG IS A DEGREED CHEMIST AND BRINGS OVER 30 YEARS OF FOUNDRY ANDPHENOLIC RESIN TECHNICAL EXPERTISE. DOUG IS CURRENTLY THE VP OF

TECHNOLOGY FOR HA INTERNATIONAL. IN THIS ROLE, DOUG LEADS ALL RESEARCHAND PRODUCT DEVELOPMENT FOR FOUNDRY RESINS, REFRACTORY AND LOST FOAM

COATINGS AND AUXILIARY MATERIALS. HIS CAREER STARTED AT QC CHEMICALSFORMERLY THE QUAKER OATS COMPANY IN 1976. HE THEN JOINED DELTA-HA IN

1989 AS A TECHNICAL SALES REPRESENTATIVE. DOUG IS ACTIVE IN THE AFS AND ISCURRENTLY CHAIR OF DIVISION COUNCIL. IN ADDITION, HE IS A PAST CHAIR AND

DIRECTOR OF THE CAST METALS INSTITUTE. HE IS ALSO A TWO TERM PAST CHAIR OFTHE DETROIT-WINDSOR AFS CHAPTER. DOUG HAS BEEN HONORED TO RECEIVE ANAFS SERVICE CITATION AND AWARD OF SCIENTIFIC MERIT. HE ALSO SERVES ON THEADVISORY BOARD OF DIRECTORS FOR THE METAL CASTING CENTER, DEPARTMENTOF TECHNOLOGY AT THE UNIVERSITY OF NORTHERN IOWA IN CEDAR FALLS, IOWA.

DOUG HAS JUST ACCEPTED THE POSITION OF GLOBAL DIRECTOR OF RESEARCH &DEVELOPMENT FOR HUTTENES-ALBERTUS BASED IN DUSSELDORF, GERMANY.

THE DIS WELCOMES DOUG WHO IS HERE TO TALK ABOUT “NEW DEVELOPMENTS INBINDERS & COATINGS FOR DUCTILE IRON”





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Novel Urethane No-Bake BinderNovel Urethane No-Bake Binder For Reduced Smoke and Odor

Doug TrinowskiHA International LLC


Evolutionary ImprovementsEvolutionary Improvements


Agenda• Making the Case

g

• Emissions Data• Phenolic Urethane Background• TEOS-based Urethane No-Bake Binders

– Background

– Data

– EH&S

– Customer Experience

– Frequently Asked Questions

S


– Summary

The Reality• Foundries are subject to environmental pressures

from different perspecti es

y

from different perspectives.– MACT Standard – Only largest Involved– Area Source Legislation – A Few More InvolvedArea Source Legislation A Few More Involved– Permit Issues – All Involved– Nuisance Odors – All Involved– Work Exposures – All Involved

B tt Li E f d i i t t d i thBottom Line: Every foundry is interested in the environmental impact of their operation


Making The CaseMaking The Case

• How do we improve the environmental impact pof Phenolic Urethane No-Bake binders?– Permit Issues– Permit Issues– Nuisance odors

AFS/CERP Published EmissionAFS/CERP Published Emission Factors

E i i F

CERP No-Bake Baseline Pouring, Cooling & Shakeout Tests In Iron

• Target a UNB system with 30% reduction in

ProcessEmission Factors

(lbs HAP/ton) CERP Test Reference

PUNB (high solvent) 2.00 1256-1211 DG

HAP’s and VOC’s at Pouring, Cooling & Shakeout

PUNB (low solvent) 1.521 1410-113 FPShakeout

THE PHENOLIC URETHANE PROCESSPROCESSCHEMISTRY

Phenolic Resin + Isocyanate Resin

CHEMISTRY

(Part 1) (Part 2)

Amine Hardener

Urethane Polymer

What is in a Phenolic Urethane R i ?Resin?

• Part 1 Resin– Phenolic Base Resin 40-60%

Solvents & Plasticizers 40-50%– Solvents & Plasticizers 40-50%– Additives 5-10%

• Part 2 Resin– Isocyanate 70-80%– Solvents 20-30%Solvents 20 30%– Additives 5-10%

P t 3 C t l tDIS T&O Meeting, October 24 DIS T&O Meeting, October 24 --26, 201226, 2012

Peoria, IL Peoria, IL

• Part 3 Catalyst

Phenolic Urethane Hi t i l P Li it tiHistorical Process Limitations

• Environmental– Conventional PUNB systems are solvent-based

• Aromatic hydrocarbons– Source of VOC’s & HAP’s

– Use of aromatic hydrocarbons as solvent has led to high VOC content

• 20 to 30% in the systemy

• Product Development Strategy:– Reduce emissions and odor profile of Phenolic Urethanes by

replacing traditional petrochemical solventsreplacing traditional petrochemical solvents.– No compromise to productivity or performance


TEOS SolventTEOS Solvent• The Latest Generation

Solvent for Urethane BindersBinders

– TEOS (Tetraethyl Ortho Silicate)

– Silicon-based solvent bi i i dcombining organic and

inorganic characteristics – Primary environmental

advantage over Aromatic Hydrocarbon or BiodieselHydrocarbon or Biodiesel Solvents is reduction of smoke & odor

– Potential to reduce gas defectsdefects

– Reduces odors during pouring, cooling, shake out

– Other performance advantages seenadvantages seen

TEOS Solvent Application• In North America, TEOS has recently been

TEOS Solvent Application

introduced in no-bake applications • Already in widespread use in Europe for nearly

ten (10) years– 10-15% of all UCB systems sold in Germany

Its primary benefit and advantage is smoke & odor reduction at pouring cooling and shakeoutreduction at pouring, cooling and shakeout


TEOS-based UNB’sTEOS based UNB s• Key product characteristics: Conventional UNB

– Replaces aromatic solvents in Part 1 & 2 with TEOS

– Provides excellent strength development and reactivityp y

– Uses existing Activators/Catalysts

– Performs on a variety of different sands includingdifferent sands, including new and reclaimed

– Very low smoke and odor at pouring

– Lower HAP generation than Conventional UNB

– Fully mechanical reclaimable

TEOS UNB

Sand Performance ExamplesSand Performance Examples• Data displayed

– Reactivity – Tensile Strength Development– Collapsibility


Work and Strip TimeConventional vs TEOS based UNBConventional vs. TEOS based UNB

New Silica, 1% Resin – 55/45 Pt1:Pt24.0

3.1 3.23.5

33.5

4

22.5

3

inut

es

0 51

1.5M

00.5

Work Time Strip Time

Conventional UNB TEOS based

Strength Performance - New SandConventional vs. TEOS based UNB

New Silica, 1% Resin – 55/45 Pt1:Pt2285300

176195

249

213

200

250

psi

149176

100

150

Tens

ile, p

0

50

100T

010 min 60 min 24 hr

Time After Strip


Work and Strip Time - Mechanically ReclaimedC ti l TEOS b d UNBConventional vs. TEOS based UNB Resin level - varies, 60/40 Pt1:Pt2

6 67

5.56.1

6.6

5

6

7

3.5 3.6 3.8

3

4

5

inut

es

1

2

3M

0Work Time Strip Time

Conventional UNB -1.1% TEOS based - 1.1% TEOS based -0.9%

Performance - Mechanically ReclaimedC ti l TEOS b d UNBConventional vs. TEOS based UNBResin level - varies, 60/40 Pt1:Pt2

200

111

166

126 134

174

148150

200

psi

43

9787

111

50

100

ensi

le,

43

0

50T

10 i 60 i 24 h10 min 60 min 24 hrTime After Strip

Conventional -1.1% TEOS based - 1.1% TEOS based - 0.9%

Dilatometer Collapsibility1800°F, 50 psi Load

Conventional vs.. TEOS based UNBNew Silica, 1% Resin – 55/45 Pt1:Pt2

188 187

180

200

s)

160

180

seco

nds

120

140

time

(s

100binder type


The Nose KnowsThe Nose Knows


Overview of Odor MeasurementsOdor measurements (olfactometry) using a close-to-practice test sample

at the Institute for Foundry Technology (IFG)

Odor ComparisonC ti l TEOS UCB S t

8000075% reduction

Conventional vs.. TEOS UCB Systems

60000

70000

80000

72,000Conventional TEOS

60% reductionTEOS-based

40000

50000 48,500

OU

/m3

TEOS based systems result in significant odor

reductions

20000

30000

18,90016,000

35% reduction

0

10000

5 minutes 30 minutes 60 minutes

8,8005,600

Sample Time

OCMA VOC ComparisonOCMA VOC Comparison

• OCMA Results:

OCMA VOC EMISSIONS TESTConventional UNB System (low solvent)

Shimadzu UX6200H Electronic Balance1.00% (B.O.S.) - 55/45 Pt 1:Pt 2, 3% Catalyst (B.O.Pt 1)

New Sand

Conventional UNB – 0.81 lbs/ton

• OCMA Results:– Low solvent UNB

• 0.81 lbs per ton sandTEOS H b id 0 400

0.500

0.600

0.700

0.800

0.900

1.000

(lbs V

OC

/ to

n sa

nd)

– TEOS Hybrid:• 0.99 lbs per ton sand

– Slightly higher than conventional low OCMA VOC EMISSIONS TEST

0.000

0.100

0.200

0.300

0.400

0 1 2 3 4 5 6 7 8 9 10 11 12

Em

issi

ons (

Time (hours)

conventional low solvent at equivalent binder level

– Similar VOCs at 0.700

0.800

0.900

1.000

n sa

nd)

OCMA VOC EMISSIONS TESTTEOS UNB Pt 1/ Conv Pt 2

Shimadzu UX6200H Electronic Balance1.00% (B.O.S.) - 55/45 Pt 1:Pt 2, 3% Catalyst (B.O.Pt 1)

New Sand

TEOS UNB – 0.99 lbs/ton

reduced binder level

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

Em

issi

ons (

lbs V

OC

/ to

n

0.0000 1 2 3 4 5 6 7 8 9 10 11 12

Time (hours)

Emissions TestingEmissions Testing

• Emissions at PC&S• Emissions at PC&S were measured at UNI Metal Casting Center

• Used improved methodologyThree systems• Three systems compared:– Conventional UNB– Hybrid TEOS Part 1 /

Conventional Part 2– Full TEOS UNB

Pouring Cooling & ShakeoutPouring, Cooling & Shakeout• Real Time VOC

Measurement– Hybrid TEOS Part 1 /

Conventional Part 2Conventional Part 2• 27% reduction in

Total Hydrocarbons (THCs)( )

– Full TEOS UNB• 42% reduction in

THCs

450

Total VOCs; Pouring, Cooling, Shake Out

350

400

C ti l dj t d

Conventional UNB: Max 423.5 ppm

300

350 Conventional zero adjusted

Hybrid THC zero adjusted

Full TEOS THC zero adjustedHybrid TEOS UNB: Max 291.1 ppm

200

250

ppm

100

150

Full TEOS UNB: Max 119.1 ppm

50

100

Gas fired ladle preheater

00 20 40 60 80 100 120 140

Time, min (0 = pouring)

Particulate Matter AnalysisParticulate Matter Analysis

• PM emissions measured

Qualitative differences– Qualitative differences confirm field experience

Conventional Hybrid

EU TEOS UNB SYSTEM

P1: 0,6 % on sandP2: 0,6 % on sandP3 : 4% on P1

90100

Benzene Toluene Xylene

mg / kg sand 5060708090

e 10

0AROMATICg g

Aromatic 160 203 53

TEOS 128 147 31 10203040

Base TEOS

OS 8 30

B T X BTX

Customer ExperienceCustomer Experience

• TEOS-based UNB’s have been introduced at greyTEOS-based UNB s have been introduced at grey, ductile iron and steel foundries in the U.S. starting in late 2011

• Recently introduced at a large Midwest steel foundry


Customer Experience• Smoke and odor at pouring dramatically reduced

Customer ExperienceSmoke and odor at pouring dramatically reduced

• Substituted for conventional UNB’s with equal or better core & mold and casting quality.

• Require lower binder levels to produce tensile• Require lower binder levels to produce tensile strength comparable to conventional systems.

• Hot strength as good as conventional, including applications for large steel castingsapplications for large steel castings.

• Lower Part 1 viscosity provides better flowability and eliminates pumping issues in cold climates.

• Less sticking sand on patterns• Less sticking sand on patterns.


Frequently Asked QuestionsFrequently Asked Questions• Expected variation in binder %

Reductions of 5% 10% in binder content seen in practice– Reductions of 5% – 10% in binder content seen in practice– Hybrid produces highest strengths

• Does the system smoke?D i d i i k– Dramatic reduction in smoke

– Small amount of white smoke observed after pouring; dissipates quickly• Is the system odorless?

– Dramatic reduction in odor at pouring– Different, less persistent odor during coring and molding

• Effect of lower flash point compared to conventional UNB‘s – does it make a difference, if yes how?– No issues in practice with flash point


SummarySummary• Key product characteristics:

– Very low smoke and odor at pouring– Lower HAP generation than Conventional UNB– Provides excellent strength development and reactivity

• Resin level reduction

– Uses existing Activators/CatalystsUses existing Activators/Catalysts– Fully mechanically reclaimable


For additional information, please contact:contact:

HA International LLC630 Oakmont Lane, Westmont, IL 60559Phone: 630-575-5700Website: www ha-international comWebsite: www.ha-international.com


Questions?Questions?



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Link to Presentation: Cast, Clean, and Make Money

EUGENE MURATORE

GENE GRADUATED FROM CASE WESTERN UNIVERSITY IN 1970 WITH A BACHELOR OFSCIENCE IN METALLURGY. GENE SPENT THE NEXT 20 YEARS AS AN OPERATING

METALLURGIST FOR THREE FOUNDRIES IN THE PRODUCTION OF GRAY AND DUCTILEIRON CASTINGS. GENE HAS BBEN THE SENIOR FOUNDRY METALLURGIST FOR RIO

TINTO IRON & TITANIUM SINCE APRIL OF 1991. AS SUCH, GENE IS RESPONSIBLE FORTECHNICAL SERVICE TO THE US, CANADA, MEXICO AND PARTS OF ASIA. GENE ISACTIVE ON 6 AFS TECHNICAL COMMITTEES, A BOARD MEMBER OF THE CHICAGO

CHAPTER OF THE AFS, AND A MEMBER OF THE AFS RESEARCH BOARD. IN ADDITION,GENE IS ALSO ACTIVE WITHIN THE TECHNICAL STRUCTURE OF THE DIS AND 2 TERM

PAST BOARD MEMBER.

THE DIS WELCOMES GENE WHO IS HERE TO TALK ABOUT “CAST, CLEAN, AND MAKEMONEY”





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Cast, Clean, and Make , ,Money

Gene Muratore

Ri Ti t I d Tit i A iRio Tinto Iron and Titanium America

Ductile Iron Society T & O MeetingDuctile Iron Society T & O MeetingOctober 25October 25--26, 2012 Peoria, IL26, 2012 Peoria, IL

OutlineOutline

• Thoughts• Importance of KnowledgeImportance of Knowledge• Reeling in Profit

V l Ch t• Value Chart• Conclusions


ThoughtsThoughts• Foundries and Fisherman

– Alliterative– Aromatic– Requires Specific Tools– Require Long Hoursq g– Requires Specific Knowledge-Training– Might Require Casting (vs Trolling,Might Require Casting (vs Trolling,

Netting, Seining)– “Product” must be cleaned in order to


be saleable.

Knowledge-WhereKnowledge-Where

• Ductile Iron Society• DIS T & O MeetingsDIS T & O Meetings• Regional Conferences

N ti l C f• National Conferences• DIS Training Classes• CMI Classes• Suppliers


Suppliers

Regional ConferencesRegional Conferences

• Attract National/Global Speakers• Geared to Local IssuesGeared to Local Issues


National ConferencesNational Conferences

• AFS Research– Aging of Gray IronAging of Gray Iron– Thin Wall Ductile Iron

• Technical Committee Reports• Technical Committee Reports– Experiences with Channel Clogging


DIS Committees, Research, Marketing, et al

• Peer to Peer Interaction• NetworkingNetworking• Ductile Iron Focused Research


DIS Training/Cast Metals Institute

• Foundry Manager Surveys Want:– Fewer ImportsFewer Imports– Less Government Regulation– Higher Selling PricesHigher Selling Prices– Better Trained Workers


SuppliersSuppliers

• Tend to Hire Veterans• History of EngagementHistory of Engagement• Vested Interest

N t k d N ti ll /I t ti ll• Networked Nationally/Internationally


Knowledge-WhatPart 1

• Engineering Properties• Specifications/GradesSpecifications/Grades• Weldability

U di th h H t T t t• Upgrading through Heat Treatment• Improvements Possible via Filtering


Engineering PropertiesEngineering Properties

• Difficult to Sell That Which You Don’t Know!


Specifications/GradesSpecifications/Grades

• Does It “Fit” Your Operation.• What Are the Potential Margins?What Are the Potential Margins?• Competitive Material(s)?


WeldingWelding

• Historically Considered Impractical• Has Limited Some Designs in DuctileHas Limited Some Designs in Ductile

Iron• Successful Applications Have Not• Successful Applications Have Not

Been Widely AdvertisedC tl Vi bl• Currently Viable


Impact Properties @ +20CImpact Properties @ +20C

• Weld Metal 50-90 joules• Fusion Zone 12-20 joulesFusion Zone 12 20 joules• HAZ 14-16 joules

D til I 12 16 j l• Ductile Iron 12-16 joules• Steel 40-50 joules


Upgrading Through Heat Treatment

• Potential New Markets• Conversions• ADI

– 2008 Shipments = 200,000 NT2008 Shipments 200,000 NT– 2011 Shipments = 220,000 NT– 2012 Shipments = 280,000 (est)p , ( )


– (Source-AP)

Improvements Possible With Filtering

• Improved Mechanical Properties• Improved MachinabilityImproved Machinability


Benefits of FiltrationBenefits of Filtration


Knowledge-WhatPart 2

• Improvements Through Late p gInoculation

• Use of a Quality Index (Tartaglia,Use of a Quality Index (Tartaglia, Gundlach, Goodrich )

• Solidification Modeling• Solidification Modeling


Late InoculationLate Inoculation

• Beneficial in All Moduli• Particularly Beneficial in ThinParticularly Beneficial in Thin

Sections and Heavy Sections


BenefitsBenefits

• Higher Nodule Count• Improved NodularityImproved Nodularity• Fewer carbides

L ti• Less segregation• Higher Mechanical Properties• Improved Machinability


Quality IndexQuality Index

• DIS Research Project #46 “Ductile Iron Structure/Property Optimization p y p& Enhancement”

• An Index “Q” Was Utilized to SelectAn Index Q Was Utilized to Select Significant Producers


Solidification ModelingSolidification Modeling

• GOAL- Make It Correct the First Time


Reeling In ProfitReeling In Profit

• US Still World #1 in Design• Embrace TechnologyEmbrace Technology• Build a Sales/Marketing Approach

A id C dit P i i• Avoid Commodity Pricing• Discover your Niche• Find Discrete Market Opportunities• Will Fish Jump Into the Boat?


Will Fish Jump Into the Boat?

Value ChartValue Chart* Exchange Rate Sensitive

Region Quality Price* Logistics Investment Technology Total

NA 10 7 10 7 10 44

EU 10 6 6 8 10 40EU 10 6 6 8 10 40

JKT 9 8 6 8 9 40JKT 9 8 6 8 9 40

China 8 10 5 10 7 40Ductile Iron Society T & O MeetingDuctile Iron Society T & O Meeting

October 25October 25--26, 2012 Peoria, IL26, 2012 Peoria, IL

8 10 5 10 7 40

ConclusionsConclusions

• The Casting Industry is Dynamic• Opportunities AboundOpportunities Abound• The Doors of Wisdom Are Never

ClosedClosed


Thank YouThank You

Questions?



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Link to Presentation: Blending Optimization in the DI Industry

PETER MOULDER

PETER HAS AN UNDERGRADUATE DEGREE FROM THE UNIVERSITY OF NOTRE DAME. HE ALSO OBTAINED HIS MASTERS DEGREE FROM THE AMERICAN UNIVERSITY IN

WASHINGTON, DC. PETER IS CURRENTLY IS AN ACCOUNT MANAGER WITHMANAGEMENT SCIENCE ASSOCIATES IN PITTSBURGH, PA. PETER’S ACTIVITIES

INCLUDE DEFINING THE APPLICATION OF TECHNOLOGY FOR THE RESOLUTION OFOPERATIONAL, MATERIAL MAMAGEMENT, AND ENERGY ISSUES FOR METALS

COMPANIES THAT ARE IN THE PRIMARY OR MELTING SECTION OF THE INDUSTRY. SPECIFIC AREAS OF EXPERTISE INCLUDE MATERIAL OPTIMIZATION, PROCESS

AUTOMATION AND INFORMATION TECHNOLOGY. HIS PRIME FOCUS NOW ISASSISTING FOUNDRIES ACHIEVE BETTER AND OPTIMAL USE OF RAW MATERIALS AND

RAW MATERIAL PURCHASING. PETER HAS BEEN A PARTICIPANT IN THIS INDUSTRYFOR THE LAST THIRTY YEARS. POSITIONS HAVE INCLUDED SOFTWARE ENGINEERING,

SOFTWARE DEVELOPMENT MAMAGEMENT, CONSULTING, AND SALES ANDMARKETING.

THE DIS WELCOMES PETER WHO IS HERE TO TALK ABOUT “REDUCTION IN MATERIALCOSTS IN A DUCTILE IRON MELTING/FOUNDRY ENVIRONMENT: PROMISES AND

OBSTRUCTIONS”





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Blending Optimization inBlending Optimization in the Ductile Iron Industry

Peter Moulder Management Science Associates (MSA)

Pittsburgh Pa


Presentation Agendag• Types of Optimization

• A Brief History of Mathematical/Linear Programming

• Advantages of and Technical Improvements in Optimization

• Typical Metals Industry Related Optimization Applications

• Cost Savings ExamplesCost Savings Examples

• The Power of Post-Optimality Analysis

• Ductile Iron Application– Uses– Objections

Why Optimization?Why Optimization?• What percentage of your costs areWhat percentage of your costs are

raw materials?• Significant chemistry variation in• Significant chemistry variation in

melting?Significant Inventory build up?• Significant Inventory build up?

• Not effectively using revert?• Effectively using ERP system in the

melting area?

Blending OptimizationThere are two basic types of optimization solvers available commercially today ─ Heuristics Approaches and Mathematical Programming FormulationsFormulations.

Heuristics Approaches include Genetic Algorithms, Neural Nets, Fuzzy Logic and others. Heuristic Approaches lead to a solution that is usually reasonably close to the best answer. They do not by their very nature guarantee optimal solutions. These “close is good enough” type solutions also forfeit a tremendous amount of “sensitivity” information that can be extremely valuable in real world settingsthat can be extremely valuable in real world settings.

Mathematical Programming Formulations include the techniques of linear programming, integer programming, and goal programming, as

ll ti l h t h i Th lt f thwell as many operational research techniques. The results from these techniques can be proven optimal, and are demonstrably superior to others in the blending problem domain.

Optimization and Foundry Automationp y

ERP / Business Software

Process Automation SoftwareOptimization

Furnaces CastingScrap Y dYard

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

History of Linear Programming George Dantzig is known as the Father of Linear Programming for his development of the simplex method, first published in 1947. The first applications were developed for the Army during the second world war to plan expenditures and returns in order to reduce costs to the Army and increase losses to the enemy.

D D t i th i i ti f th i G d Will H tiDr. Dantzig was the inspiration for the movie Good Will Hunting.

Many of the central concepts of optimization theory are derived or inspired from linear programming To this dayor inspired from linear programming. To this day, improvements to this class of solution techniques are continually being made.

Problems solved with these techniques include microeconomic, food blending, inventory management, HR resource allocation, airline ticketing/scheduling, transportation/delivery routing, g g, p y g,petrochemical plant optimization and many other applications.

Least Cost Optimization History

Technology

p y

Late 1970’s – Timeshare Systems

Early 80’s to late 80’s Mini Computer Systems (DEC IBM)Early 80 s to late 80 s – Mini Computer Systems (DEC,IBM)

Mid 90’s – Client Server, Interfaces to other systemsEthernet, PC’sEthernet, PC s

2000’s – SAAS / ASP- Integration with ERPg

7

Least Cost Optimization Forms• Spread Sheet EXCEL with Solver• Spread Sheet – EXCEL with Solver

Self Contained Calculators • Fully Functional Systems

Optimization with material parameters– Optimization with material parameters– Commercial LP (unlimited parameters, mixed integer,

support)– Integration with ERP , Business, Transaction systems

I t l ti d d t• Inventory – real time, reserved updates• Purchasing• Melting (i.e. Heat Planning, Spectrometers, Alloy

systems)• Scrap Yard Systems• E-Commerce , Metal Exchange

– State-Of –Art Technology– Multi heat Multi gradeMulti heat, Multi grade– What If– Scenario Building– Simple , effective, flexible , adaptable Human Machine

Interface8

Interface

Mathematical Programming Advantages

In the metals industry, the basic blending problem is to find the least cost combination of materials to meet chemical, size and other constraints for a given grade of steel.

A mixed-integer linear program (MILP) is an excellent approach to solving this type of cost minimization problem. The MILP technology provides the ability to solve situations the other methods cannot handle, or handle through non-optimal workarounds. These include:

– Limiting the number of materials in a solution– Using materials in discrete quantities (e.g., butts, slugs, etc.)– Minimum usage amounts (i e use no increments of materials < 50 lbs )– Minimum usage amounts (i.e., use no increments of materials < 50 lbs.)– Polynomial and/or Non-linear fractional case constraints – Grouping Materials– Other custom formulated constraints i.e. Filters– Provides a wide range of sensitivity analysis on costs and constraints– Provides assistance in diagnosing infeasible results

Metals Industry Scrap Optimization Models

• Single Heat Charge – determine least cost combination of materials to produce a given grade

• Multi-Heat Campaign Optimization – determine the optimal allocation of materials over an entire schedule

• Alloy Additions Calculations – determine the additions required to a molten bath to produce a given steel grade

• Purchasing Planning – determine the necessary materials needed to produce a production schedule, considering on hand inventory, an anticipated revert stream and market materialsUnder Crane Loading Optimization determine the best replacement• Under Crane Loading Optimization – determine the best replacement material to use as an operator is loading a scrap bucket

• Marshalling Yard Planning – determine what materials should be loaded into rail cars for a specific time/frame schedule, and anloaded into rail cars for a specific time/frame schedule, and an indication of when switching should occur

Post Optimality Analysisp y yOne frequently overlooked but extremely powerful feature of mathematical programming driven blending optimization is Sensitivity Analysis As a result of the optimization process costs are derived forAnalysis. As a result of the optimization process, costs are derived for various alternative solutions on the way to finding the optimal. These costs can be used to determine the impact of materials and constraints submitted to the model. Two important aspects of the sensitivity analysis are Reduced Costs and Dual Prices.

The Reduced Cost indicates how changing the cost of a material not chosen by the LP will affect the optimal solution or in other words thechosen by the LP will affect the optimal solution, or in other words, the amount by which that material’s cost must improve before the LP will have an optimal solution in which that material is part of the solution.

Th D l P i i di t h iti th ti l l ti i ithThe Dual Price indicates how sensitive the optimal solution is with respect to the costs associated with binding constraints. The dual price for a constraint is the amount by which the optimal solution total cost changes if the right hand side (RHS) of the constraint were increased bychanges if the right hand side (RHS) of the constraint were increased by one (1) pound, provided that this change does not change the solution.

Cost Savings Examples Th i it d b l f t l t i l d t diThe savings cited below come from actual trials and studies conducted for clients. Possible savings that could be achieved by any one company in particular, are heavily contingent on current practices accuracy of chemical and other informationcurrent practices, accuracy of chemical and other information, inventory availability and product mix. Some previous results are:

– A 10% savings on heat charge costs was demonstrated by analyzing data from a three-month time span. This comparison was between an existing optimization model and a newer MILP optimization model.

– Multi-heat optimization continually shows a 2-5% savings over solving individual heats.

S i f 5 8% d t t d f i t t d ill b– Savings of 5–8% were demonstrated for an integrated mill by modifying their standard charge mix and expanding the types of scrap to consider.

– A Foundry operation reported a 15% decrease in raw material costs when a purchase planning function was implemented.

Uses in Ductile Iron Foundries• Refine Standard Charges in a fluctuating scrap

purchasing marketC id diff t t i l t i Ch• Consider different materials to use in a Charge– Updates to Standard Charges (number of, and

number of materials)number of materials)– Consider Market material offerings

• Convert Gross Material weight to Chemistry driven melt in … connect desired physical and mechanical properties to chemistry

• Extend metallurgical requirements to material• Extend metallurgical requirements to material melting– Nodulization– Cleavage

Uses in Ductile Iron Foundries• Optimize Revert flow

– Minimum, maximum, fixed, percentage– Manage replacement valuationsManage replacement valuations

• Assist in ‘hitting’ chemistry (chemistry control) and added ladle weight

• Reduce variability of elemental melt in chemistry• Reduce variability of elemental melt in chemistry• See effects of market prices on raw material costs and

usageObt i ti i d f t i l i lti d• Obtain optimized us of material in a multi grade environment

• Reduce excess inventory• Provide a least picture of raw material purchases• Business Analytical Tool

Uses in Ductile IronUses in Ductile Iron Foundries

• Reduce Variance in ‘Melting’ and Final chemistry• Provide connectivity to a ERP ITEM based software

– Actual costing– Actual costing– Material tracking– BOM interface– Least Cost MRP interface– MRP– Purchasing

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

Objections in Ductile Iron Environment• Don’t believe in technology• Cultural

– Many years of doing things the same– Resistance to change

• Minimal number of Grades being meltedMinimal number of Grades being melted• Minimum number of Standard Charges• Minimal number of Materials

L i diff ti l t i l• Low price differential among materials• Limited Purchasing Horizon• Look at purchase of software cost rather than results• IT objections• Unsuccessful in the past

Objections in Ductile Iron Environment

Li it d b f li• Limited number of scrap suppliers• Limited staff• Already using optimization• Already using optimization

– Satisfied with performance– No resultsNo results

Conclusions & QuestionsM th ti l P i M d l h b ff ti l• Mathematical Programming Models have been effectively solving blending optimization problems for many years in a wide variety of industries

• There are many metals industry blending problems that can benefit from optimization and provide a very fast ROI

• Improvements in the underlying solver technology have• Improvements in the underlying solver technology have increased the speed of solutions, provided the ability to impose practical considerations on the mathematical problem (e g limiting number of materials etc ) and provide effective(e.g., limiting number of materials, etc.), and provide effective feedback to operators making the models easier to use and understand

S• Sensitivity Analysis provides additional value to savvy users and can determine the cost impact of following certain practices and constraints for review and evaluation

• Conduct a Trial


• Peter Moulder• MSA, Pittsburgh PA• 724 265 6442• 412 302 7481 (cell)• pmoulder@msa com• [email protected]• www.msa.com/metals



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Link to Presentation: Observations for Management on Iron Foundry Safety

Statistics

TED SCHORN

TED HAS RESPONSIBILITY FOR QUALITY FOR THE NORTH AMERICAN OPERATIONS OFENKEI CORPORATION, THE WORLD’S LARGEST PRODUCER OF CAST ALUMINUM ROADWHEELS. HE HAS WORKED IN VARIOUS QUALITY AND MANUFACTURING POSITIONS

FOR NEARLY 30 YEARS, THE LAST 23 WITH ENKEI. TED IS ACTIVE WITHIN THETECHNICAL COMMITTEE STRUCTURE OF AFS, HAVING SERVED AS DIVISION COUNCIL,ENGINEERING DIVISION AND QUALITY SYSTEMS TECHNICAL COMMITTEE CHAIR. HE

HAS EARNED NUMEROUS AWARDS FROM AFS INCLUDING THE AWARD OF SCIENTIFICMERIT, TWO RAY WITT AWARDS AND WAS THE 2005 HOYT MEMORIAL LECTURER. TED CURRENTLY SERVES ON THE BOARD OF DIRECTORS OF AFS. HE HAS WRITTEN

SCORES OF TECHNICAL PAPERS AND IS A FREQUENT CONFERENCE SPEAKER.

THE DIS WELCOMES TED WHO IS HERE TO TALK ABOUT “OBSERVATIONS FORMANAGEMENT ON IRON FOUNDRY SAFETY STATISTICS”





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Observations for M IManagement on Iron

Foundry Safety StatisticsFoundry Safety Statistics

Ted J. SchornEnkei America, Inc.,


Outline

• Overview of historical performance on safetyy

• Safety performance topography• Observations and recommended• Observations and recommended

focus


Historical Trend, TCIR

16

18

,

10

12

14

iden

t Rate

6

8

10

tal Case Inci

0

2

4Tot

02003 2004 2005 2006 2007 2008 2009 2010

Iron Foundries All Foundry Private Manufacturing

Drawn from Table 1, Nonfatal Injury and illness, Bureau of Labor Statistics


Historical Trend DART Rate

89

Historical Trend, DART Rate

567

Rate

2345

DAR

T R

012

2003 2004 2005 2006 2007 2008 2009 20102003 2004 2005 2006 2007 2008 2009 2010




Historical Trend, LCIR

3

3.5

2

2.5

T Ra

te

0 5

1

1.5

DAR

T

0

0.5

2003 2004 2005 2006 2007 2008 2009 2010


D f T bl 1 N f t l I j d ill B f L b St ti tiDrawn from Table 1, Nonfatal Injury and illness, Bureau of Labor Statistics


Employment Trend, Foundry & Manufacturing

14000

16000

140

160

180

00's

10000

12000

100

120

140

loym

ent, 10

0

men

t, 10

00's

6000

8000

60

80

acturin

g em

pl

ndry Employm

2000

4000

20

40

Manufa

Foun

002003 2004 2005 2006 2007 2008 2009 2010




BLS Data Collection StrategyI j d Ill T lInjury and Illness Topology

Nature of disabling condition

Part of the body affectedA foundry worker

sprains

Event or ExposureSource directly

his back from twisting while

movingEvent or Exposure

producing disability partsfrom a conveyor into a bin


Nature of Illness or Injury leading to days I F d i 2010

708090

away, Iron Foundries, 2010

3040506070

Case Rate

0102030C

(1) Incidence rates represent the number of injuries and illnesses per 10000 full‐time workers and were calculated as: (N / EH) X 20000000 whereN = number of injuries and illnessesEH = total hours worked by all employees during the calendar year20000000 = base for 10000 full‐time equivalent workers (working 40 hours per week 50 weeks per year).


Part of the Body Affected leading to

90

Part of the Body Affected leading to days away, Iron Foundries, 2010

51 8% Back

60708090

e

51.8% Back23.2% Shoulder 38.3% Finger

22.2% Wrist11.7% Hand

33 6% Foot/Toe

304050

Case Rate 33.6% Foot/Toe

32.4% Knee

70.6% Eye

01020

Trunk Upper Extremities

Lower Extremities

Head Multiple Body Systems


Source of injury or illness leading to

70

days away, Iron Foundries, 2010

30405060

e Ra

te

0102030

Cas


Event or Exposure leading to days away, Iron F d i 2010

100

120

Foundries, 2010

45.4% Struck by21% Caught in

40

60

80

Case Rate

21% Caught in19.1% Struck against

31% Lifting

0

20

40C


Number of days away from work for injuries and illnesses, Iron foundries,

2010

50

60

70

30

40

50

ase Ra

te

10

20

30

Ca

01 2 3‐5 6‐10 11‐20 21‐30 31+

Cases involving X days away


Age of individuals suffering nonfatal occupational injuries and illnesses involving days away fromwork

30.0%

injuries and illnesses involving days away from work, ferrous foundries

20.0%

25.0%

ses

15.0%

%

ent o

f Total Ca

2006

2007

2008

5.0%

10.0%

Perce

2009

2010

0.0%Under 14 14 to 15 16 to 19 20 to 24 25 to 34 35 to 44 45 to 54 55 to 64 65 and

over


Seniority of individuals suffering nonfatal occupational injuries and illnesses involving days away fromwork

60.0%


40.0%

50.0%

ses

2006

30.0%

cent of Total Ca 2006

2007

2008

2009

10.0%

20.0%

Perc

2010

0.0%Less than 3 months 3 months to 11 months 1 year to 5 years More than 5 years


Hours worked at the time of nonfatal occupational injuries and illnesses involving days away fromwork

25.0%


15 0%

20.0%

Cases

2006

10.0%

15.0%

ercent of Total 2006

2007

2008

2009

0 0%

5.0%

Pe 2010

0.0%Less than 1

hour1 ‐ 2 hours 2 ‐ 4 hours 4 ‐ 6 hours 6 ‐ 8 hours 8 ‐ 10 hours 10 ‐ 12

hours12 ‐ 16 hours


Time of day of nonfatal occupational injuries and illnesses involving days away fromwork ferrous

30.0%

illnesses involving days away from work, ferrous foundries

20.0%

25.0%

ases

10 0%

15.0%

cent of Total Ca

2006

2007

2008

2009

5.0%

10.0%

Perc 2009

2010

0.0%12:01 AM ‐4:00 AM

4:01 AM ‐8:00 AM

8:01 AM ‐12:00 PM

12:01 PM ‐4:00 PM

4:01 PM ‐8:00 PM

8:01 PM ‐12:00 AM

Not reported


Day of the week of nonfatal occupational injuries and illnesses involving days away fromwork ferrous

30.0%

illnesses involving days away from work, ferrous foundries

20.0%

25.0%

Cases

2006

10 0%

15.0%

rcen

t of Total C

2007

2008

2009

5.0%

10.0%

Per

2010

0.0%Sunday Monday Tuesday Wednesday Thursday Friday Saturday


3%

Recordable Cases By Foundry Type

45%15%

3% 13%Iron

Steel, investment

Steel, not investment

Aluminum diecasting

Iron Foundries have 45% of the

recordable cases

6%15%

15%Non‐ferrous diecasting

Aluminum not diecast

Non‐ferrous not diecast

recordable cases but

only 36% of the l

Employment By Foundry Type

employment within the foundry

industry

36%5%

14%

6% Iron

Steel, investment

Steel, not investment

Al i di i

y

10%15%

14%

5% Aluminum diecasting

Non‐ferrous diecasting

Aluminum not diecast

Non‐ferrous not diecast2010 Data Source: BLS2010 Data, Source: BLS


OBSERVATIONS ON THEWhat do we do now?

OBSERVATIONS ON THE DATA FOR IRON FOUNDRIES


A game planA game planBenchmark

DataData

InterpretationInternal Action

ComparisonInternal Analysis


General observations

• Foundries have a significantly higher recordable injury rate than private j y pmanufacturing – over twice the averageg

• Iron foundries have consistently had higher recordable injury rates thanhigher recordable injury rates than the foundry industry average



• The foundry industry, and iron foundries in particular, have made p ,significant strides in safety performance in the period of 2006 –p p2008

• Since 2008 performance hasSince 2008, performance has reached a plateau for foundry and all manufacturingmanufacturing



• Safety data does not support the myth that:y– The young guys get hurt more often– The less experienced guys get hurtThe less experienced guys get hurt

more often– Late in the shift or OT work causes

injury



• Our workforce is aging and the experienced older workers need to p– Follow safety rules; no exemptions!– Work within their limitsWork within their limits– Be methodical about set ups,

procedures and checksp


Key Focus

• The key area to work in improvement is ergonomics and work place layout g p yand handling– Sprains/Strains #1Sprains/Strains #1– Lifting, overexertion injury– Very high back and shoulder injuryVery high back and shoulder injury– Managing parts


Key Focus

• Ergonomics and handling is also a training issue that has to be treated gas seriously as using proper PPE– Proper lifting practiceProper lifting practice– Reaches and extensions– Knowing when to stop; fatigue heatKnowing when to stop; fatigue, heat

issues


Summary

• The foundry industry has come a long way but has much farther to gog y g

• Iron foundries are the largest segment of the industry and lead thesegment of the industry and lead the indicators – we must set the pace and the direction of our industry’sand the direction of our industry s image


Summary

• The industry statistics need to be used in YOUR FOUNDRY to generate gimprovement where you work

• Don’t worry about the industry careDon t worry about the industry, care about YOUR PEOPLE



• Ted J Schorn• Ted J. Schorn• 2900 W. Inwood Drive, Columbus, IN 47201• Office: 812-373-7000• Fax: 812-373-7020• [email protected]



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Link to Presentation: Introduction to THORS - The Online Learning Resource

1ST AL ALAGARSAMY

AL IS WELL KNOWN AMONG THE DIS PARTICIPANTS. HE HAS BEEN INVOLVED WITHIRON FOUNDRIES FOR MORE THAN 40 YEARS AND HAS WORKED WITH THREE MAJOR

FOUNDRY GROUPS IN RESEARCH AND DEVELOPMENT FUNCTIONS. PRESENTLY, HECONTINUES TO WORK AS A CONSULTANT TO FOUNDRIES AND CASTING USERS

ALIKE. HE HAS SERVED AS RESEARCH COMMITTEE CHAIRMAN AT AFS AND DIS. HEHAS DEVELOPED TRAINING MATERIALS FOR THE IRON FOUNDRIES IN AREAS OF

METALLURGY, SAND CONTROL, CASTING DEFECTS, ETC. HE IS WELL-RECOGNIZED INTHE DUCTILE IRON INDUSTRY AND RESEARCH INSTITUTIONS. HIS EDUCATIONAL

BACKGROUND INCLUDES A BACHELORS OF ENGINEERING IN MECHANICALENGINEERING AND A MASTERS IN FOUNDRY SCIENCE AND ENGINEERING.

2ND JOHN MIRKA

THE THORS WEBSITE WILL BE DEMONSTRATED BY JOHN. JOHN HAS BEEN WITH THETHORS TEAM SINCE FEBRUARY 2012 SELLING TO OEM’S AND SUPPLIERS. JOHN ALSO

HAS AN ACTIVE ROLE IN TRAINING THORS USERS.

THE DIS WELCOMES AL & JOHN HOW ARE HERE TO TALK ABOUT “THORS – THEONLINE LEARNING RESOURCE”





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Introduction to THORS - The Helpful Online Resource Site

Foundries and other manufacturing industries face many challenges. One of these challenges is how to impart effective training to employees. Foundry operations are becoming more automated which reduces the tediousness of the work resulting in less employee boredom and minimizes their exposure to harsh, repetitive motion. As the processes are automated, a higher level skilled workforce is required. Foundries are finding it increasingly difficult to recruit and retain skilled workers. It is becoming a necessity to train and educate workers in many areas of the foundry since there are no technical schools to train them. In addition, as the work force gets older and retire, skill sets are lost.

Learning needs to be job specific as well as general. Replacement workers need to be adequately trained to prevent quality and productivity concerns. When workers are trained, the effectiveness of training needs to be evaluated and the training needs of everyone should be tracked for reinforced training on a periodic basis. The challenge is to structure the learning by job category and by employee and to track the progress of each employee from trainee to journeyman.

A well-trained workforce and continually monitored and updated training will result in a knowledgeable workforce. This knowledge can then be institutionalized and will not be lost when someone leaves the company. Once this knowledge is easily accessible and transportable across the division and company, continual training becomes easier and structured and will keep the company from becoming obsolete.

Current training methods involve different settings:

Off-site training - One or two employees are sent outside the plant for several days to be trained in one area such as melting or sand control, etc. This type of training is expensive and results in lost work time at the plant. Training is generic in nature and other employees in the department will not be exposed to the same training. Knowledge gained by a few individuals is not easily transferable to others.

On-site training -To train the whole group at a time will disrupt production. Worker turnover requires continued training. Obtaining the best trainer is also difficult. The training content needs to be developed and updated to keep up with changes and new technology. Training methods and the delivery methodology rarely change resulting in loss of effectiveness.

To overcome these challenges and to enable foundries and other manufacturing companies to train, evaluate and track the progress of employee learning, a new format has been developed. This new format includes training that is on demand and tailored to the needs of each individual and enables management to streamline the training process. Also, the technical content is updated with multiple sensory learning to make it very effective and retainable for a longer period of time. The following article explains in detail this new learning process along with its advantages.

THORS is a useful site for both casting producers and users alike.

2 of 7

THORS - The Helpful Online Resource Site

THORS (The Helpful Online Resource Site) is an online educational program that presents complex manufacturing processes like castings, machining, gears, forgings, polymers (rubber and plastics) and numerous other processes in clear, easy-to-understand language for the layman to understand.

THORS stands out among other products of its kind by its innovative format. It makes learning easy and interesting with unique animations containing live demonstrations of various manufacturing processes, images of real equipment, flowcharts showing the flow of processes from beginning to end and numerous other visual effects. THORS uses quizzes to test the ability of people to retain what they have learned, and to further reinforce that learning. The learning content in THORS has relevance to both Original Equipment Manufacturers who build products using castings, machining, gears, and so on, and to their suppliers who manufacture these same products.

THORS is unique in its philosophy, that helping people apply what they learn is the greatest benefit to an organization. We believe that knowledge is important to developing an individual, but helping that individual apply that knowledge in making the right value decisions is what provides an excellent return to the OEM and their suppliers. THORS accomplishes this using a set of unique tools like the Supplier Manager, the Parts Manager, the RFQ (Request for Quotation) Manager, the Tooling Manager and The Dashboard.

The knowledge in THORS was acquired by collaboration with subject matter experts, including industry veterans who want to give back to the industry, well-respected manufacturers and original equipment manufacturers, all of whom contributed to and verified the accuracy of the content. THORS stores all of this valuable, difficult-to-find information in one place, saving companies numerous hours of research and eliminating time spent confirming reliability of information sources. The content in THORS keeps companies informed on the cutting edge of technology in the manufacturing industry, enabling them to out learn and outperform the competition. True learning is boundaryless. For example, castings are machined and gears need to be machined before gear cutting. THORS is unique in its ability to transport the learner seamlessly between casting, machining and gear modules. THORS is a dynamic entity, where content is added regularly to make it deeper and broader, based on feedback from our customers and input from our domain experts.

THORS Solves Several Key Problems That Companies Face

By solving several key problems companies face, THORS immensely improves OEM and supplier performance and profitability. These problems are, employees making poor value decisions, companies failing to preserve institutional knowledge when employees leave, and companies not effectively and efficiently onboarding new employees with domain and institutional knowledge.

Making the Right Value Decisions

Leaders of an OEM or their suppliers agree that the success of their company depends on the ability of its people to make the right value decision. Poor value decisions that employees make result in the

3 of 7

largest losses in company productivity and profits. Leaders are keen to foster the ability of their employees to make right value decisions. There are many factors that influence the ability of an individual to make right value decisions such as inadequate depth of knowledge, lack of access to previously gained experience, or missing previous history.

THORS provides a solution for a person starting in the organization, a solid foundation of knowledge, and for experienced employees, the ability to drill deep and improve their depth of knowledge. It presents information and learning material in a unique and interesting flowchart format that gives the reader a 20,000 foot view and the ability to drill down to the layer that interests them. The information is provided in a layperson friendly format, where all the person needs is the ability to read English and operate a mouse. The information is presented in such a manner that people understand the whole process or picture, and what role they play in the success or failure of their company. Giving people this view of the big picture and the ability to drill into the details is critical to enabling their decision-making ability. THORS provides quizzes, which can be used to constantly test knowledge retention. Finally, the true benefit of learning comes from applying what is learned; THORS shortens the distance between learning and applying and enables employees to make good value decisions, resulting in increased productivity and profits for the organization.

Challenges in Preserving Institutional Knowledge and Effective Onboarding of New Employees

Today people move more frequently from company to company; employee turnover is much higher than it was several decades ago. This poses two new problems to both OEM’s as well as manufacturers. The first is how to retain knowledge within the company when a person leaves, which we call institutionalizing knowledge. Second is how do you quickly onboard a new comer with specific domain knowledge so he is productive very quickly.

THORS has the functionality to capture knowledge that has been generated by many years of experience and trial and error, and institutionalize it. While this knowledge is stored in many companies as a series of documents usually in folders, THORS provides a unique way to store this information contextually. The ability to weave in company-specific knowledge on top of process-specific domain knowledge is a critical element in the ease and speed of orienting and onboarding new employees in a consistent manner. Knowledge and experiences grow every day, and THORS provides a vibrant platform that can continue to grow as your organization grows. Employees can start learning from the basics and keep progressing deeper and deeper as their ability and confidence improves.

Applying Knowledge with Interactive Tools

The Supplier Manager

The Supplier Manager tool provides Original Equipment Manufacturers and their suppliers a common platform. There are several inefficiencies in the typical engagement process between an OEM trying to source product from a supplier, and a manufacturer trying to sell product to an OEM. OEM’s do not have a robust platform to effectively capture supplier capability so that they can keep current with the constant improvements and investments by the supplier. The supplier in turn struggles to effectively

4 of 7

portray his unique abilities to the OEM, especially getting the OEM to remember his unique capabilities when the OEM is going out to source product. This lack of understanding of the suppliers capabilities results in many request for bids being sent erroneously which frustrates the supplier, makes him less efficient, and causes loss of productivity to the OEM.

THORS Supplier Manager effectively solves this problem, by providing a secure space where both the manufacturers can effectively display their capabilities, and the OEM’s can effectively identify the right supplier by their capabilities. It also provides a level of collaboration between people in an organization across continents and cultures, driving efficiency and productivity.

The RFQ Manager

Building on the Supplier Manager is the RFQ Manager, which streamlines and makes efficient the entire quoting process. The Intelligence behind the THORS RFQ Manager matches OEM requirements to the supplier capability, and ensures that the supplier receives request for quotes for parts that are completely within his capability. It also provides cutting edge tools that make the entire supplier selection and bid evaluation process very efficient for the OEM.

The Tooling Manager

The Tooling Manager tracks and manages tooling inventory. Companies spend millions of dollars on patterns, dies, fixtures, gauges, etc., yet few have a truly robust system that tracks and manages these assets. The Tooling Manager has a collaborative and structured framework for suppliers to store the information pertaining to OEM owned tooling at a location that is accessible to both. It also has a depth of functionality in storing all pertinent information related to tooling in one location.

The Parts Manager

The Parts Manager provides a centralized platform to store all information pertaining to the parts that the OEM procures. This solves the problem of storing the information that exists at multiple locations within an organization and streamlining the storage and access to this information. This is a focal access point for storing institutional knowledge and subsequently making it easy for onboarding.

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It is important to note that all of the tools above have a THORS thread feature that facilitates communication between the OEM and the manufacturer. All relevant communication is stored in one location and is not lost in one person’s mailbox.

The Dashboard

This is a THORS tool that will enable companies to structure and manage learning within an organization all the way down to an individual. This tool gives the company the ability to customize learning based on the job function, prior experience and specific needs of the individual. The THORS Dashboard can track the progress of an individual and facilitate data-based decision making within an organization.

The THORS Structure and Learning Philosophy

THORS is a cloud-based solution that is accessible any time and any place. Subscribers can log into THORS from anywhere in the world, as long as they have the right browser version and an Internet connection. It saves time and money, because people do not have to take time off from work and travel to a specific work location. THORS has a unique built-in search functionality; it is meant to be a real-time reference tool for the user.

THORS’ learning philosophy is based on a multi-sensory learning method that includes written material, audio, video, interactive tools, quizzes, etc., that have been proven to improve knowledge retention. The chart below shows how the multi-sensory method improves what people remember after two weeks.

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While THORS provides a good breadth and depth of knowledge, we can also develop custom content, and tailor the content to a specific location, plant or department. The program has the capacity to upload entire in-house training modules for companies, including specific machines, processes, safety and quality information, customer concerns, etc. All proprietary information is uploaded to a secure, protected site.

THORS believes that there is no end to knowledge or learning, and have created a learning environment that is constantly living and growing. Unlike printed training material that becomes obsolete the second it is printed, THORS online training content is constantly updated, based on input from the user community and domain experts.

THORS – Building an Ecosystem

THORS is really a thriving ecosystem, where original equipment manufacturers and their suppliers come to learn, collaborate and transact business. It is a hub that strives to make all its stakeholders more knowledgeable, efficient and always striving to find a better way to do things.

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THORS Widely and Enthusiastically Received by Original Equipment Manufacturers and Their Suppliers

THORS has been widely and enthusiastically received, the quotes below describe how customers feel about THORS:

“I think of THORS as an interactive, well-organized, encylopedia and wikipedia for "how things are made". They are building the tool on a category-by-category basis utilizing global experts.”

“I think the tool as shown would be helpful to the new engineer regarding the explanation of an overall process.”

“Very impressive! I would suggest that this is an extremely powerful tool that could incorporate a number of functions outside of just education, (i.e., engineering, purchasing, quality, etc.) I think we ought to move very quickly to incorporate this tool into Caterpillar, especially while the cost is still nominal.”

“I was very excited about this program. Not only will it help me, it will also help our younger employees who have never run any machines or have been in foundries to help teach them the basics so they know what people are talking about.”

“It will also help me learn more about processes I have had limited exposure to even though I have been in manufacturing for over 30 years. It also would be updated to newer technology as it is developed.”

Future THORS Modules

Modules have been released for Castings, Machining and Gears. Modules that are currently in various stages of development include Engineering Drawing for non-engineers, Polymer Processing (Rubber and Plastics) Forgings, Steel Manufacturing, Heat Treatment, and Metal Forming (including stamping and fine blanking). Future potential modules include Oil Seals, Motors, Powder Metallurgy, and Fasteners.

THORS provides a vibrant fast growing source of knowledge on the manufacturing universe for both original equipment manufacturers and their suppliers. For more information on THORS, visit the THORS Web site at: www.thors.com.


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Link to Presentation: Base Iron Melt Control

KYLE ANDERSON

KYLE GRADUATED FROM MICHIGAN TECH IN 2011 WITH A BACHELOR OF SCIENCEDEGREE IN MATERIALS SCIENCE. HE IS CURRENTLY WORKING AS A METALLURGIST

AT WAUPACA FOUNDRY’S PLANT 4 IN MARINETTE, WI.

THE DIS WELCOMES KYLE WHO IS HERE TO TALK ABOUT “BASE IRON MELTCONTROL”





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Back to BasicsBack to BasicsBase Iron Melt Control

Kyle AndersonyWaupaca Foundry


Melt Department


Raw Material• Premium Pig• Regular Pig• Steel

– SlitterPl t– Plate

• Returns– High and LowHigh and Low

Copper• No Obsolescence


Testing

• Steel analyzed every truck loady

• Pig iron delivered bydelivered by boat; analyzed every shipmentevery shipment


Furnace Chemistry

0 03

0.035

0.04

0.02

0.025

0.03PSCR

MO

0.01

0.015

SN

TIALV

0

0.005

1 3 5 7 9 11131517192123252729313335373941434547495153555759616365676971737577798183858789



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News Briefs

MEETINGS - BUSINESS - PEOPLE

MEETINGS

BUSINESS

Cintas Launches Flame Resistant Clothing Webpage

New online resource provides educational tools and product information

CINCINNATI – October 10, 2012. Every year, thousands of workers are involved in electrical arcaccidents, molten metal splashes, flash fires and combustible dust explosions on the job. To educatecompanies about these risks, as well as what they can do to comply with new industry standards,Cintas has launched a new website dedicated to its Flame Resistant Clothing line.

Cintas is the largest provider of professionally managed flame resistant clothing programs in NorthAmerica. Not only does Cintas provide personal protective apparel, but it also now provides employerswith an online resource to stay updated regarding standards and guidelines for safety compliance inthe workplace.

“We developed this website to enhance our safety message and to be a resource for safety managersacross North America when it comes to protective apparel. We care about the safety of our customerswho rely on our uniforms to do their work, and we want to be seen as more of a resource that just auniform provider,” says Jeff Koehne, protective apparel marketing manager at Cintas. “With thiswebsite, which will be updated continually with educational videos, regulation updates and otherindustry and hazard information, we can be their main resource for safety information and productdevelopments as well.”

Over 500 hundred Fortune 1000 companies and hundreds of thousands of individuals rely on Cintaspersonal protective apparel, making Cintas the most trusted source for flame resistant clothing. Twoseparate lines of flame resistant clothing are offered, one for everyday tasks and one for working ingreater risk environments, and their protective apparel specialists can help companies design andimplement customized programs to meet every need.

To learn more, visit the new Cintas Flame Resistant Clothing websiteat: http://www.cintas.com/FlameResistantClothing/.

Rachael KeshishianAccount Associate and Social Media Coordinator Rubin Communications Group4542 Bonney Rd. Suite BVirginia Beach, VA [email protected]: (757) 456-5212Cell: (757) 818-4625Fax: (757) 456-5224

POSTED 01-08-2013

Indiana Foundry Hits Record on Days Without Lost Time

Bremen Castings Celebrates 495 Days

Foundries and machine shops are notoriously known for being dangerous places, but one Indianafoundry is changing the tides of the industry. Bremen Castings Inc. (BCI) in Bremen, Indiana has gonealmost 500 days without lost time. Lost time injury is defined as an occurrence that resulted in afatality, permanent disability or lost time from work of one day or shift and possibly more.

President JB Brown notes, “We have an incredible staff that come to work and every single day, butwe’ve implanted strategies and procedures to make sure that everyone is accountable for everyone’ssafety while at work. One example is that require all employees to file “near miss” reports. So ifthere is a cable in the way or a slippery step, the employee is responsible for moving it and filing areport to inform upper management of the issue. This example is then looked at by our executive


http://www.cintas.com/FlameResistantClothing/

http://www.cintas.com/FlameResistantClothing/


tel:(757)%20456-5212

tel:(757)%20818-4625

tel:(757)%20456-5224

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team to determine how we can possibly change things in the future to prevent a possible situationfrom happening.” BCI’s last lost time occurred over a year ago and required their employee to missone full shift of work. Since then the foundry and machine shop have gone incident free.

In the future BCI would like to establish a zero incident culture, 1,000,000 man hours without a lostwork time and two years without lost work time. JB Brown is available to speaking about thismilestone and their safety initiatives within Bremen Castings. Please contact me to schedule aninterview.

Carolyn Blackman | PublicistEmpower Public Relations625 N. Michigan Avenue- Suite 2500Chicago, IL 60611O: 312.854.8830C: 312.375.4106

POSTED 01-08-2013

NEWS RELEASE

Monterrey, Mexico, 23 October 2012 – Metallic surface preparation experts, Wheelabrator Group, celebratedthe opening of a brand new 34,000 sq ft manufacturing & aftermarket parts and service facility in Mexicounder the name WG Plus de Mexico. “Our investment plans are to continue to expand our company globallyto meet the growing demands and needs of our customers.” (Robert E. Joyce Jr., President and CEO,Norican Group). Local Mayor, Ing. Jaime H. Rodriguez Calderón also pledged support for the localcommunity.

WG Plus de Mexico S. De R.L. de C.V. facility

With a doubling of existing capacity, the Monterrey, Mexico facility supports regional (OEM) OriginalEquipment Manufacturing and aftermarket sales as well as equipment manufacturing operations for ourglobal customer base. This facility is the culmination of investment in local operations since opening asmall sales office in 2006. Following a rapid increase in sales, Wheelabrator Group made the decision tomove to a larger facility in 2008 to provide expanded services to our customers. The requirement ofadditional space to meet local customer service, inventory requirements and the creation of a supply chainoperation facility for the assembly of standard OEM equipment demanded the transition to a still largerfacility in 2011. The 2012 expansion provides heavy duty manufacturing, secondary light assemblyoperations and aftermarket support to service the increased demand for all of the Americas.

See how the opening was broadcast on Info7 News: http://info7.mx/a/noticia/357142

Unique after sales capability

The organization offers complete equipment support services on a global level, which is unique in the

industry. Wheelabrator Plus provides the necessary support to keep equipment running at optimum capacity.

Replacement parts, services, maintenance, modernization of equipment, and training provide customers

support to help them reduce operating costs, maximize customer productivity and leverage technology to

support manufacturing improvements: "We stand ready to serve our customers wherever and whenever

they require our support. Ask any of our team members how we can help you increase your profitability."

(Robert E. Joyce Jr., President and CEO, Norican Group).

Wheelabrator currently employs 25 people in Monterrey, and this number is expected to increase.

Further information

Publisher and press contact:

Wheelabrator Group

Pamela Akin

Marketing Manager, Americas

http://info7.mx/a/noticia/357142



Tel.: 706 884 6884 Ext 2295

Email: [email protected]

www.wheelabratorgroup.com

POSTED 01-08-2013

2011 Overall Steel Recycling Rate Hits All-Time High

Record levels of steel scrap consumption announced on America Recycles Day

November 15, 2012, Pittsburgh, PA -- In celebration of America Recycles Day, the SteelRecycling Institute (SRI) announced today that the recycling rate for the world’s most recycledmaterial – steel – is at an all-time high of 92 percent. More than 85 million tons of steel scrapwas consumed by steelmaking furnaces 2011—an increase of nearly 10 million net tons versus2010.

Jim WoodsSr. Director, CommunicationsSteel Recycling Institutep: 412.922.2772 x215f: 412.922.3213c: 412.974.2586e: [email protected]

POSTED 01-08-2013

N E W S R E L E A S E

Agency Contact: Rosemarie Ascherl ▪ 440.234.1812 x126 [email protected]

Corporate Contact: Jeff Naymik ▪ 216.361.1900 x510 [email protected]

Osborn Offers Complete Line of Metal Finishing Solutions

CLEVELAND – November 2012 – Osborn offers a complete line of metal finishing products.

Popular go-to metal finishing products available from Osborn include:

· ATB™ Wheel Brushes. The complete line of advanced technology brushing wheel brushes includesnarrow- and wide-face models, small ring locks and specialty treated configurations. The brushesfeature abrasive nylon filaments that eliminate the need to clean finished surfaces on metallic and non-metallic surfaces.

· ATB Disc Brushes. Available in three standard stock configurations, max density, turbo and standard,the disc brushes are reliable, high-performance tools with consistent quality. These flexible brusheseasily integrate into automated machinery, CNC machining centers, transfer lines and robotic cells.

· NovoFlex Flexible Honing Tools. These self-centering tools will conform to the bore surface andprovide a consistent, even surface finish. They feature round, abrasive beads at the end of flexiblefilaments with either silicon carbide or aluminum oxide grit.

All Osborn abrasive products are designed for superior performance and long life, using durablematerials.

“At Osborn we’re proud to offer our customers an extensive metal finishing line and a large arrayof standard products,” said Jeff Naymik, marketing manager at Osborn. “We also pride ourselveson engineering custom finishing solutions for every application.”

Osborn is the world’s leading supplier of surface treatment solutions and high-quality finishingtools for hundreds of industrial and commercial applications such as metal finishing, honing andsurface polishing. Celebrating its 125th anniversary in 2012, Osborn now includes operations in


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15 countries and serves customers in more than 100 countries. A unit of Jason Inc., Osborncarries more than 10,000 standard products and more than 100,000 customized solutions toserve a diverse of group customers and industries. For more information, visitwelding.osborn.com.

POSTED 01-08-2013

Heartland Institute, 13 Others Sign LetterUrging Congress to Oppose Carbon Taxes

Fourteen conservative think tanks and advocacy groups have joined forces to urge Congress to oppose carbontaxes. The open letter, written by The Heartland Institute, was released and delivered to members of Congress todayand appears below.

The letter was signed by representatives of the following organizations:

The Heartland Institute The American Conservative UnionAmericans for Limited Government Caesar Rodney InstituteJohn Locke Foundation Cascade Policy InstituteTennessee Tax Revolt Nashville Tea PartyMaryland Taxpayers Association American Tradition PartnershipCompetitive Enterprise Institute Freedom ActionThe Liberty 21 Institute The Cherokee Tea Party Patriots

The following statement from John Nothdurft, director of government relations at The Heartland Institute, may beused for attribution.

“Creating a new tax on carbon will do nothing to fix the debt crisis we are facing. Don’t be fooled. The brunt of acarbon tax will hit the pocketbooks of consumers and workers by driving up the cost of energy and other necessarygoods as well as pushing manufacturing jobs overseas.

“These 14 think tanks and advocacy groups want Congress to know that a carbon tax will not save us from the fiscalcliff. The focus in Washington should not be what new taxes we can come up with, but rather how can we grow theeconomy and curb long-term entitlement spending.”

To speak with Mr. Nothdurft or other carbon tax experts at The Heartland Institute, please contact Tammy Nash [email protected] and 312/377-4000. After regular business hours, contact Jim Lakely at [email protected] 312/731-9364.

Dear United States Senators and Representatives:

Recently, several current and former elected officials have called for adoption of a “revenue neutral carbon tax” or a“carbon tax swap.” Under this proposal, a new tax on the carbon content of fossil fuels would be imposed,presumably to reduce carbon dioxide emissions and protect the world’s climate. The revenue raised by the new taxwould be offset by reductions in other taxes or simply returned to taxpayers and consumers.

On behalf of the members represented by our organizations, we urge you to oppose efforts to impose a carbon tax,whether “revenue neutral” or otherwise. Enacting a carbon tax, with or without promises to offset the tax burden byreducing other taxes, is a bad idea for the following reasons:

Carbon taxes are job killers. Energy cost is tightly correlated with economic growth, and any increase in the priceof energy has negative impacts on job creation, per-capita income, and growth in GDP. Since 80 percent of energyconsumed in America comes from fossil fuels, a carbon tax would raise energy costs across the board, hurting everyindustry and every consumer.

Promises of revenue neutrality will be broken. Reductions in other taxes or programs to rebate to consumers therevenue generated by a carbon tax will almost certainly be temporary, while the new tax rate will rise over time.Promises to cut taxes are rarely kept and are never binding on future legislatures. Accordingly, a newly imposedcarbon tax will be revenue neutral only for a short time, and then become a source of rapidly rising tax revenues.

Carbon is already taxed high enough. Americans in every state except Alaska already pay a combined federal andstate gasoline tax that is higher than a carbon tax would need to be set at to pay for the negative effects of carbondioxide produced by their cars and trucks. Opinion polls show the American public are adamantly opposed to payinghigher taxes in the name of battling “global warming.” (Diesel and gasoline account for about 29% of total U.S.greenhouse gas emissions.)

Higher carbon taxes cause environmental harm. Carbon taxes force the substitution of wind and solar power forfossil fuels, but these alternative energy sources cause real and substantial environmental damage. Wind turbines,while providing merely 2 percent of U.S. electricity, kill at least 440,000 birds each year, including many endangeredspecies, according to the U.S. Fish and Wildlife Service. Wind power kills a similar number of bats and requires thedevelopment of vast areas of pristine land. Solar thermal power is similarly land-intensive and utilizes substantiallymore water than coal and natural gas power.

Reducing carbon dioxide concentrations in the air causes environmental harm. Plant growth is limited by theamount of carbon dioxide in the air, and the modest increase in atmospheric carbon dioxide during the past centuryhelped make possible record crop production and the expansion of plant life throughout the planet. Reductions inatmospheric carbon dioxide would cause a reduction in crop production, plant growth, and biosphere richness.

Reducing carbon dioxide emissions is unnecessary for three reasons:

http://www.welding.osborn.com/

http://heartland.org/policy-documents/14-think-tanks-and-advocacy-groups-urge-congress-oppose-carbon-taxes

http://www.heartland.org/





U.S. carbon dioxide emissions already are declining. U.S. carbon dioxide emissions are lower than they were atthe turn of the century. This decline is accelerating as low-cost natural gas, made possible by the shale gasrevolution, induces utilities to replace high-carbon coal power with lower-carbon natural gas power. Other marketfactors also are inducing a long-term decline in carbon intensity, and no new taxes are necessary to continue thistrend.

Reducing U.S. emissions won’t stop or delay climate change. While U.S. carbon dioxide emissions already arefalling, emissions in India, China, and other developing countries are rising rapidly, causing global emissions to riseregardless of what we do in the U.S. In fact, increasing energy costs in the U.S. would simply drive manufacturing(and jobs) to India and China, where energy costs are lower and carbon dioxide emissions per-unit of output arehigher.

Global warming fears are overstated. Real-world temperatures continue to rise much more slowly than predictedby global warming advocates, and real-world weather and climate data reflect few if any of the predicted negativeconsequences of global warming.

For these reasons, we the undersigned urge you to oppose efforts to impose so-called “revenue neutral carbontaxes” on American consumers.

Sincerely,

Joseph BastPresidentThe Heartland Institute

Al CardenasChairmanThe American Conservative Union

William WilsonPresidentAmericans for Limited Government

Barrett E. KidnerChairman & CEOCaesar Rodney Institute

Roy Cordato, Ph.D.VP for Research and Resident ScholarJohn Locke Foundation

Tina M. PisentiExecutive Vice President & COOCascade Policy Institute

Ben CunninghamTennessee Tax RevoltNashville Tea Party

Dee HodgesPresidentMaryland Taxpayers Association

Donald FergusonExecutive DirectorAmerican Tradition Partnership

Myron EbellDirectorFreedom ActionCompetitive Enterprise Institute

Larry KaufmannExecutive DirectorThe Liberty21 Institute

Jim RustThe Cherokee Tea Party Patriots

POSTED 01-08-2013

CHARTER MANUFACTURING COMPANY PURCHASES WELLS MANUFACTURING COMPANY, INCLUDINGDURA-BAR AND DURA-BAR METAL SERVICES

Acquisition Adds New Iron Bar Division to Charter Family of Companies

MEQUON, Wis. – Charter Manufacturing Company today announced it has acquired Dura-Bar and Dura-Bar Metal



Services as part of its stock purchase of Illinois-based Wells Manufacturing Company. As a result of the acquisition,

Charter adds a fourth division focusing on specialty iron bar to its family of companies, which also includes Charter

Steel, Charter Wire and Charter Automotive.

Dura-Bar is a world leader in the production, technology and application of continuous cast iron bar stock, and Dura-

Bar Metal Services is a distributor of Dura-Bar products and bronze alloys. Charter Steel is a leading American supplier

of carbon and alloy steel bar, rod and wire products, and Charter Wire is a leading supplier of precision cold finish

bar, cold-rolled steel custom profiles, flat wire and other wire coil products. Charter Automotive is a Tier 1/Tier 2

supplier of engineered components and assemblies for the automotive industry.

“Dura-Bar and Wells Manufacturing Company make an excellent match for Charter Manufacturing,” said John A.

Mellowes, Chairman and CEO of Charter Manufacturing, a family-owned company now led by the third and fourth

generations of the Mellowes family. “Both are family-owned companies that are respected leaders in their particular

industries. For Charter, the acquisition of Dura-Bar and Dura-Bar Metal Services allows our organization to diversify

and extend our reach into new markets. The acquisition complements our continuing, strong focus on the automotive

sector, and while that will always be important to Charter, this acquisition extends our reach into the capital goods

market.”

Thomas W. Wells, Chairman, President and CEO of Wells Manufacturing Company and the third generation of his

family to lead the privately-held company, said the acquisition strengthens Dura-Bar’s position as an international

leader in providing continuous cast iron bar stock. Wells will play an active role on the transition team.

“This acquisition strengthens Dura-Bar’s future and enhances its ability to grow nationally and internationally for the

long term,” he said. “Both Charter and Wells share similar value structures and a work culture that will allow the

organization to be the most competitive cast iron bar enterprise in the world.

“Charter shares our commitment to people and a focus on being an invaluable resource to customers,” Wells added.

“The two companies are extremely compatible, and both have strong track records as high-quality, committed family-

owned businesses. We anticipate a long and successful future.”

Wells Manufacturing Company has approximately 360 employees at its Dura-Bar facilities in Woodstock, Ill.; York,

Penn.; Salisbury, N.C.; and Changzhou, China. Charter has operations in Milwaukee; Cuyahoga Heights and Fostoria,

Ohio; Lichfield, U.K.; and Wuhu, China. Charter employs about 1,500 people.

Mellowes said that there will be no employment or staffing changes for the foreseeable future, and he praised Dura-

Bar’s solid management team and highly skilled workforce. “One of the most attractive parts of this acquisition is that

Dura-Bar has high quality people on its team,” he said. “Their commitment to continuous improvement, high

standards and customer satisfaction fit well with our mission.”

Mellowes added that the timing of the acquisition was ideal for Charter because of positive economic developments

worldwide and the fact that Charter has a strong balance sheet.

“This is a great move at the right time, and Charter’s acquisition of Wells and Dura-Bar will allow us to continue to

strengthen our existing businesses and reach into new markets,” Mellowes said. “We feel very positive about the

future of our company and our industry, and this acquisition demonstrates our optimism.”

The sale was approved by federal regulators and is effective immediately. Terms of the transaction were notdisclosed.

POSTED 01-08-2013

Press Release

Commitment in the Indian foundry market

ASK Chemicals invests in new manufacturing facility in IndiaHilden (Germany), November 13, 2012 –

With a celebratory groundbreaking ceremony, ASK Chemicals laid the foundation for the



construction of a new plant in Kurkumbh (near Pune), India. The company is thus opening afurther chapter of its Indian-German cooperation. The first step is to build a 12,000 sqmmanufacturing and storage facility on an area of 80,000 sqm, where binders, coatings,auxiliary materials and risers will be produced for the Indian foundry industry. The newmain plant of ASK Chemicals will enable vital new jobs to be created in Kurkumbh. Thecompletion of the production site is planned for 2014.

With this commitment, ASK Chemicals, the world’s leading supplier of foundry chemicals, iscreating the basis for continuing the successful expansion of its business activities on a keytarget market in Asia.

On the company’s strategic planning, Stefan Sommer, CEO of ASK Chemicals, says: “Ourintention is to grow faster than the total Indian market.” India’s economic power plays afundamental role for the investment by ASK Chemicals. “We are firmly convinced that theIndian foundry industry will profit from our many years of experience and our profoundexpertise in this important key industry,” says Mr. Sommer on the occasion of theceremony, looking ahead.

Dr. Jochen Landes, Managing Director of ASK Chemicals India, sees great opportunities fordevelopment for the company in India. “I am delighted that our company chose Kurkumbhfor this investment and can hardly wait to see the new facility grow.”

As a member of the global network, ASK Chemicals India has access to the entire foundryexpertise of the Germany-based global player and is thus able to provide customers in thewhole of India with its innovative products and services.

Figure 1: The ASK Chemicals team releases doves

NEWS RELEASE 11 December 2012

MOLYBDENUM’S CONTRIBUTION TO SUSTAINABLE DEVELOPMENT

IMOA’s Secretary General, Tim Outteridge, gave a presentation to the China InternationalTungsten Molybdenum & Vanadium Forum 2012 in Changsha, China, on 12 November,entitled ‘Molybdenum’s Contribution to Sustainable Development’.

Attended by some 200 delegates including producers and converters, the conference wasa further opportunity to raise awareness of molybdenum’s contribution to sustainabledevelopment.

Mr Outteridge described the key properties of molybdenum before outlining thechallenges to sustainable development arising from global energy demand,industrialisation and urbanisation. Taking each of these in turn, he demonstrated how theunique attributes of molybdenum were being put to use in the development of sustainablepractices and technologies.

Molybdenum is an important enabler of many sustainable technologies through its use asan alloy and occasionally as a primary component. In different alloys, molybdenumenhances strength, even at high temperatures, maintains toughness, increases durabilityand provides exceptional resistance to corrosion. Chemically, it is serves many uses as acatalyst.

“Molybdenum already makes a substantial contribution to sustainable development inmany technologies and applications which I outlined in the presentation,” said MrOutteridge. “It plays a key role in many renewable energy applications such as



hydroelectric, wind and solar and helps to protect the environment through its use incatalysts for the production of ultra-low sulfur diesel, and in alloys for flue gasdesulfurization installations at power stations.

“Vehicle engines and power stations run more efficiently at the higher temperaturesenabled by moly-containing alloys, and in high strength steels molybdenum contributestowards ‘lightweighting’ of cars and trucks and to reducing raw material and energy usein construction projects.”

“The challenges of sustainable development must be addressed and molybdenum has arole to play in many technologies and applications which are in use today, activelycontributing to a more sustainable future,” he added.

For more information contact: Alan Hughes T: +44 (0)1606 852011 M: +44 (0)7759 243969E: [email protected]

POSTED 01-08-2013

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