DIS advances ductile iron research and services through the years.

The Ductile Iron Society has been at the forefront of the ductile iron industry for 40 years, helping producers find answers and working to improve production methods.

From its inception in 1958, the Ductile Iron Society (DIS), North Olmsted, Ohio, has helped foundrymen find much-needed answers about ductile iron production. The group was born from a relatively small group of ductile iron licensees who were bound by their desire for open discussion on the new material. Through the years, members have benefited from DIS' push for research and advocacy efforts. Today, the Society continues to offer a forum on ductile iron, while leading the charge for ductile iron uses, specifications and marketshare.

This year, the Society's 40th anniversary, offers members and other interested foundrymen the opportunity to reflect on the group's humble beginnings and fruitful past.

A Thirst for Information

After International Nickel Co. (INCO) first started licensing foundries in 1948 for production of the new material, it arranged for the licensees to gather and discuss their production experience three times each year. During those early meetings, INCO would present its latest information on ductile iron, including production improvements, expected properties, advertising efforts and product specifications, and licensees would share their experiences with the metal.

Even though laboratory production of ductile iron was an accomplished fact, mass production on the foundry floor involved its own challenges. There was no question as to the properties obtainable with good ductile iron, but assuring present and potential customers that every casting would have these properties was sometimes difficult. Beings of varying sizes and shapes, individual problems varied, and, as the questions piled up, the need for a group focused specifically on ductile iron production was apparent.

"People really didn't know how to handle the metal," said Bill Beatty, a signer of the group's original articles of incorporation. Beatty, who was with Morris Bean & Co. at the time, said that because most of the original licensees were gray iron foundrymen, it took some time to discover the best production methods for ductile iron.

Shortly after INCO started licensing its ductile iron process in 1949, Professor Howard Taylor of the Massachusetts Institute of Technology realized that there was a "somewhat confused, indecisive situation existing among ferrous foundrymen because of limited knowledge about the product and its manufacturers," past DIS Executive Director Keith Millis said in a welcoming speech to the 1975 AFS-DIS joint conference.

Taylor organized a meeting on ductile iron at Swampscott, Massachusetts, and invited a number of prominent foundrymen in the U.S., Canada and Europe. "I remember that there was a rather large number of people present, most of them at a caliber that filled me with awe," Millis said. "A number of knowledgeable people spoke of their experiences and experiments with the new material and of their thoughts as to the future." This was the first ductile iron conference, and it showed that there was definitely a thirst for knowledge about the new metal and a desire for an organization that could lead the quest for knowledge. The forum provided INCO could not keep pace with the explosive interest in the relatively new metal, and foundrymen began to look at representation from existing trade groups.

Building Pressure

Even though there was great interest in the continuing INCO meetings, there was some concern as to what would happen when INCO's patent ran out, said Ken Guise, who also signed the original articles of incorporation. Under patent laws, INCO's exclusive right to the magnesium process was scheduled to terminate after 17 years. There was concern as to whether INCO, would be a factor in the ductile iron scene after its patent expired. Foundrymen worried about who would coordinate the promotion, monitor the quality of the product, provide a medium for the exchange of ideas and disseminate information concerning ductile iron when INCO was no longer serving as a licenser.

In addition to concern about the future of ductile iron, producers were anxious about their present licensing agreement because INCO filed a patent infringement suit against Ford Motor Co. "When Ford Motor Co. contested the patent, there was concern that it might win the case and the licensees would be left high and dry," Beatty said. The court eventually determined that the INCO patents were valid, but this early difficulty spurred greater communication between the producers of the metal and helped bond them together.

The Need for Representation

There was a question among various trade groups as to where the ductile iron movement should be placed. "Man 'of the early ductile iron producers felt ductile iron should stand on its own and not become a step-child to an existing trade organization," Guise said.

Because many new ductile iron producers were gray iron foundrymen, they began to rely on their own Society, the Gray Iron Founders' Society (GIFS), for information and production innovations. However, many became dissatisfied with the small amount of attention being paid to the metal, according to Beatty. "It didn't occur to licensees that the Gray Iron Society was servicing ductile iron as a separate material at all," he said.

Following an INCO licensee meeting in Ann Arbor, Michigan, in 1956, Millis announced that several members were interested in forming a trade organization devoted solely to ductile iron. He asked anyone who was interested to meet after the licensee meeting, and approximately 20 people attended. That early group included Art Avedisian, Taylor & Fenn; Bert Baptist, Beloit Iron Works; Beatty; Sam Carter, ACIPCO; C.W. Gilchrist, Cooper-Bessemer Co.; Guise, Kuhns Brothers Co.; Chet Mally, Stuart Foundry; Neil Mingledorff, Savannah Foundry & Machine Co.; Bert Parker, Youngstown Foundry and Machine Co.; Glenn Phelps, Otaco Foundry; Jack South, American Brake Shoe Co.; and Bob Thompson, H.P. Deuscher Foundry. After several meetings, Thompson, Beatty and Guise were appointed to a committee to report progress to the remaining members of the group.

"Still it wasn't easy to get a new society started because you must have money, and you must be able to offer something for that money," Beatty said about the group's efforts to stand on its own. To make matters even more difficult, there was resistance from the GIFS. Because GIFS had been gaining business from new ductile iron producers, as foundrymen began to discuss the formation of a new group, GIS officers actually stormed one of the first gatherings. "During a meeting in Columbus, Ohio - there were about 20 foundrymen there - they came in and let us know they weren't going to let us organize," Beatty said.

"Some argued against DIS and said there were already enough trade associations," said Sam Carter, Jr., retired vice president and works manager, ACIPCO. "We saw that it would be a weak situation if a new group was a division of GIFS. Gray iron people hated to see ductile iron take over. We needed a separate organization to stand on its own feet. It was a new material, not a souped-up gray iron. Engineers had to reevaluate their materials based on the unusual properties of ductile iron. That's why some of the producers were firm that we needed a DIS."

The foundrymen remained undaunted, and with Thompson as their "ringleader" and Beatty writing a set of by-laws, the DIS was incorporated into the State of Ohio on July 2, 1958. With a registration fee of $25, the Society was off and running.

The purpose of the Society, as outlined in the original articles of incorporation, was "to promote the interests of the ductile iron foundry industry by advertising and education by the collection and dissemination of information relative to the ductile iron foundry industry for the benefit of the public and individual members of such society; for the development of new markets and uses for ductile iron; the establishment of standards and of research into the uses and processes of manufacture of ductile iron."

At the Outset

Initially, all members were producers. Meetings were held along the format established by INCO with quality, advertising, production problems and new ideas being discussed. DIS members were involved with the writing of new specifications for various grades of ductile iron, working with various code bodies to include ductile iron as an approved material, encourage and sponsor research where information was either scarce or did not exist and publish a newsletter promoting ductile iron. "In the beginning we were just interested in continuing what INCO had been doing - holding three meetings per year to discuss production problems," Beatty said.

"We were like sponges, so we wanted to absorb everything we could about ductile iron," Guise said.

"We had little political struggles in the early years," said Carter, "But as the Society became successful, more solid companies recognized the need to get in, and membership grew and got well established."

Many of the associate members, which were foundry suppliers, contributed a great deal to advancements in ductile iron, according to Carter. Even though some trade organizations didn't allow suppliers, DIS welcomed the research and developments foundry suppliers were keen on providing. However, suppliers interested in ductile iron programs couldn't "take over" because they couldn't hold office. "They were always inventing something - alloys, fluxes and test systems to help ductile iron," Carter said. "And they were very interested in it and telling us about it. These associate members were glad to participate, and they did a lot to contribute to the DIS."

Beatty, who served as president of the Society from 1969-71, said one of the biggest problems during those early days was to raise money for ductile iron research and projects. "There was a period when it was nip and tuck and we worked to keep the Society together and keep people interested," he said.

Moving Toward Autonomy

As INCO was reaching the end of the patent age, it also wanted DIS to take over meetings and assume responsibility for all research and marketing, Carter said. Even after DIS was incorporated, INCO had continued to hold meetings, but now that the company was leaving the ductile iron arena, it was apparent that DIS would be on its own. "INCO recommended we form a society like had been formed in Germany and Japan," he said. "I was the representative from our company. Keith was very supportive and a technical advisor of INCO. He encouraged the formation of the DIS, and he supported it all the way."

DIS didn't have an executive director at the beginning, but, about the time that INCO's patent ran out, it hired Jim Lansing, who had been working with the Malleable Iron Founders' Society, to work out membership kinks and keep the Society healthy and growing. He used his previous association experience to DIS' advantage, organizing and arranging meetings and contacting foundrymen across the country. "He started part time, but he put a lot of time in, and we got a lot for our money,' Beatty said. Later, Jim Vanick was hired from INCO as technical director.

Research Activities

Following the initial surge to work on production problems, the Society worked with other trade groups, such as AFS and the Society for Manufacturing Engineers (SME), to develop standards and enforce them. "The first few years we spent a tremendous amount of time and money on coming up with workable codes, procedures and specifications," said Guise. "We focused on the practical part of production. At the time, there were people making 'ductile iron' who didn't know what they were doing. There was no one around to enforce specifications. DIS worked to guard the integrity of the metal. Ductile iron is one of the most wonderful metals, but if you don't produce it right, you end up with one of the poorest grades of gray iron going." The DIS began to serve as a vehicle to ensure foundries were following the proper procedures, and became one of the driving forces behind ductile iron certification.

"I was already involved in Steer Founders', Iron Founders' Society, and the Non Ferrous Founders' groups," said Carter, "and I felt we needed to get a research program together. As soon as we could scrape up the money, we needed to start some research. After I retired, they put me in as chairman of the research committee - I held the post for 10 years."

During this time, DIS accomplished 18-20 research reports. "Then I was particularly interested in quality and quality training," Carter said. "We set up a certification program that is still carried on to an extent today. Vanick would go in and visit different facilities. He spelled out certain requirements - personnel training for controlled procedures - and the company was to pledge that they would uphold quality standards of DIS and its principles."

Companies paid a fee to be certified, and as quality improved, people became convinced ductile iron was an essentially controlled material. Research into guidelines and better production methods as well as the subsequent enforcement of those standards began to pay off.

In total, DIS has completed 27 research projects. Lyle Jenkins, DIS vice president of technology, described some of the projects indicative of the quality of all DIS-funded research:

* Project 23, "Heavy Section Ductile Iron Technology," which proved the size of the chill necessary to control the graphite structure in heavy section ductile iron castings;

* Project 20, "Machinability of Ductile Iron," which aimed to help foundries better understand machinability, allowing them to better serve customers and expand use of the metal;

* Project 18, "Impact Properties of Ductile Iron by Dynamic Tear Testing," which provided a means to look up and correlate microstructure and chemistry to determine the iron's resistance to fracture with results from 14 different foundries;

* Project 15, "An Investigation of the Effects of Graphite Parameters on the Fracture Toughness of Ductile Iron," which tells what occurs when fatigue cracks start so that they can be avoided.

Today

Jack Hall, executive director since 1990 when he replaced Millis, said that the group still follows its original mission statement today. "We aren't trying to change as a Society - we want to continue to work in the educational and research field of ductile iron," Hall said. The group boasts 90 foundry members and 37 associate members. According to the bylaws, DIS is only permitted to accept one associate member for every two foundry members. "We don't want to become a social group,' he said. "We're not a showy society."

DIS still prides itself on service, offering members a number of benefits including:

* Research - Research projects are funded and directed by DIS on a continuing basis. Projects are specifically aimed at improving production technology, solving long-standing production problems and providing better manufacturing economies;

* Instant News Service - Developments of special significance or timeliness are mailed to members throughout the year. In addition, members can be updated on the most recent research projects at the DIS website, www.ductile.org;

* T&O Meeting - Two meetings each year provide forums for the dissemination of technical and operating information by qualified speakers and for the exchange of information among members, both informally and in workshop sessions;

* Plant Visits - Visits are scheduled in conjunction with the two annual meetings to reinforce theory with practical information;

* Technical Bulletins - Technical and operating papers presented at DIS meetings are distributed to members exclusively for the first two years following publication. These papers are meant to serve as a permanent reference source for members;

* Individual and Foundry Consultations - The executive director and the technical and research directors are available to provide technical information or to refer members to other sources;

* Education - Training programs for members' operating personnel are presented periodically. DIS also offers a Keith Millis Scholarship Fund to students interested in pursuing a career in ductile iron. This year, the Society plans to award approximately $6000 in scholarships. To supplement the fund, the group plans to donate its proceeds from this month's Keith Millis Symposium, which is co-sponsored by AFS/modern casting;

* Quality Guidance and Certification - To ensure the metallurgical integrity and properties expected of ductile iron, the DIS Quality Assurance Committee has published a manual of recommended quality controls including minimum standards for procedures, personnel and facilities;

* Quality Reputation - Upon application, the DIS Certified Producer Policy * Committee will award certification to ductile iron producers that are in compliance with the standards of control. This certification is meant to assure consumers of ductile iron quality.

Marketing Efforts

DIS also participates as a member of the Ductile Iran Marketing Group (DIMG), which is dedicated to promoting ductile iron. The nonprofit organization disseminates technical information to design and materials engineers and purchasers of castings and mechanical components.

The group was founded in 1986 by the members of DIS, QIT (now known as Rio Tinto Iran &Titanium America) and Miller & Co. "Walter Gruver (of QIT) knew that the best way to grow the raw materials market was to grow the market for ductile iron castings and to do that we needed to better educate the design community," said Paul Gerhardt, general manager, Rio Tinto Iran & Titanium America. Gruver stood up at a DIS meeting and outlined the initial idea behind a group dedicated specifically to marketing it and promoting ductile iron through whatever means necessary. He said that QIT would match dollar for dollar the contribution of anyone else who wished to join. Today, the three members of the group each contribute $10,000 annually to marketing efforts.

When it formed, the DIMG began to hold education seminars with groups of engineers in various parts of the North American continent to acquaint them with all the information necessary to start designing for the metal. It was hoped that the seminars would encourage producers to become involved in an all-out effort to expand the total markets for ductile iron.

"(The DIMG has) recognized the lack of effort in education and promotion and has come to understand that the design engineers of today know little about ductile iron, its properties, broad fields of application and economics," said Millis in a speech given in Britain in the late 1980s. "This initial effort took the form of advertising in leading metals and engineering magazines. The ads offered technical information on ductile iron. The response was an excess of 4000 requests from all industries. This evidence of a gross lack of knowledge about the material by engineers responsible for selecting materials for application substantiated their beliefs about the need for education."

DIMG has promoted the metal through trade shows, including the Design Engineering Show. Today, the group continues to purchase print advertisements in publications geared toward designers and purchasers of castings. "The measure of our success is the written requests for literature and materials, and over the last 12 years we've had 80,000 such requests," Gerhardt said.

In addition, DIMG provides a number of books, research materials and videos and has even sponsored an early casting design contest. The purpose of the contest was to encourage the design of new applications in ductile iron or the conversion to ductile iron from other materials and was open to producers and consumers alike.

The DIMG's website, located at www.ductile.org/dimg/index.html, offers the "Ductile Iron Design Engineers Digest," a 48-page summary of ductile iron properties, applications and design ideas. Also online is the group's two-page "Why Convert to Ductile Iron," "Cost Saving Design Ideas in Ductile Iron" and "Ductile Iron Data," which gives complete property and specifications information. Hard copies also are available.

Other free publications include:

* Ductile Iron Design Engineers Digest, a 48-page summary of ductile iron properties, applications and design ideas. This also is downloadable;

* Why Convert to Ductile Iron, a booklet which covers physical properties of ductile iron, alternate materials and austempered ductile iron;

* Cost Saving Design Ideas in Ductile Iron, a 28-page booklet describing conversions from other materials and processes to ductile iron castings. This also is downloadable.

Looking Ahead

In the future, the Society plans to offer its Ductile Iron News Magazine on the internet, expand its T&O sessions and offer a "Hot Topics" monthly mailing to workers on the shop floor.

According to William Phelps, Francis & Nygren Foundry Co., current DIS president, staff will continually look at the group's mission statement, redefining its meaning for the times. However, the founders of the Society really knew what was needed, because that initial mission statement drafted in 1959 still applies. "We've read it and read it and read it, and we just can't do any better," Phelps said. "That's really what we do. Those words still fit today."

DIS Presidents

1958-62 Robert S. Thompson, The H.P. Deuscher Co. 1962-64 Chester F. Mally, Stuart Foundry Co. 1964-66 Sam F. Carter, American Cast Iron Pipe Co. 1966-67 H.J. South, Abex Corp. 1967-68 Neil H. Mingledorff, Savannah Machine & Foundry Co. 1968-69 Bertram S. Parker, Youngstown Foundry & Machine Co. 1969-71 William Beatty, Morris Bean & Co. 1971-73 J.W. Bryant, Newbury Manufacturing Co. 1973-75 H. Milt Bacon, Beloit Foundry Co. 1975-77 William C. Butterfield, The Sandy Hill Corp. 1977-79 Charles W. Mooney, Jr., Buck Co., Inc. 1979-81 Lane M. Currie, H.C. Macaulay Foundry Co. 1983-85 James D. Voss, Hamilton Allied Corp. 1985-87 Ray H. Witt, CMI International, Inc. 1987-89 Richard L. Caister, Lynchburg Foundry Co. 1989-91 Richard A. Nicholas, The Quality Castings Co. 1991-93 William F. Lange, Teledyne Casting Service 1993-95 Richard L. McMinn, Buck Co., Inc. 1995-97 Doyne Chartrau, Ward Manufacturing 1997-99 William E. Phelps, Francis & Nygren Foundry Co.

DIS Executive Directors

1959-1975 Jim Lansing 1975-1990 Keith Millis 1990-present Jack Hall