Iron foundries: wage a counterattack! (Cast Iron Honorary Lecture).

Ductile Iron: At a Crossroads," was the theme of the Cast Iron Honorary Lecture by P. Gerhardt, Rio Tinto Iron & Titanium America. Gerhardt traced ductile iron's rapid rise over the last three decades, including a 6% compounded growth rate from 1987-2000. Now reaching maturation levels, ductile iron still is growing, but has slowed, a point resonated through recent headlines "proclaiming" the triumph of forged steel, powdered metals and light metals.

While the threat of material shifts remain, Gerhardt offered thoughts on the more immediate concern to domestic iron foundries--China. Detailing both China's pros and cons (poor infrastructure and long deliveries), he described what he hopes will he a counterattack waged by the domestic industry. According to Gerhardt, a five-pronged approach is needed that consists of improvements in technology, process efficiency, research, design knowledge and marketing.

Technology--Among Gerhardt's examples were process simulation software, computerized cooling curve analysis and filtration. He also cited the "new" irons, including austempered ductile iron (ADI), compacted graphite iron, low-carbon ductile and carbidic ADI.

Process Efficiency--He noted significant results in cost and speed can be found via operational improvements. Among the areas to consider, he said, are rapid prototyping techniques, nearnet shape castings, more efficient furnaces, robotics and automated casting cleaning systems.

Research--Gerhardt believes research must be supported and utilized. Among his examples are thin-wall iron, heavy-section ADI, Monday-morning iron, nondestructive testing and the development of a fatigue properties database.

Machinability--Because machining usually exceeds the cost of the casting itself, he noted there's ample ground to gain by improving surface finish, reducing draft angles, reducing grinding, and eliminating internal slag and other inclusions.

Design Knowledge--In addition to the problem of specifications that short-change iron castings, Gerhardt also cited the current language problem between foundries and designers that must be addressed. 'Foundries speak of tensile and yield strength, elongation and hardness,' he said. "Meanwhile, the design engineer cares about Young's modulus, fracture toughness, fatigue, and cyclic stress and strain." Moreover, he added that many of today's engineering students do not even know that cast irons exist.

Marketing-Gerhardt is a strong believer in seeking out replacement work and higher margin business. Specifically, he noted the need to better sell cast iron's properties, provide design data, demonstrate metalcasting's uniqueness and educate engineering students and professors. "Our sights should be set on forgings, weldments, fabrications, stampings and assemblies," he said.

Gerhardt summarized the lecture by saying that the status quo must be replaced with a proactive sense of urgency. "We need to produce castings in a smarter way and the industry must work together more cooperatively to expand the market for cast products."