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Wisconsin group examines new techniques, basic methods.

"Embracing proven truths and considering the new" might be an appropriate theme of the 59th AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System.

AFS - Andrew File System
 Wisconsin Chapter Annual Foundry Conference and Mini-Expo, which was held February 8-9 in Milwaukee. With 39 technical presentations covering a wide range of topics in education, cast iron, nonferrous, steel, and engineering, energy and environmental, a total of 873 gathered to revisit solid foundry practices, as well as to hear about nontraditional ones.

The meeting, a cooperative effort that also involved the Stateline, Northeast Wisconsin and Univ. of Wisconsin Chapters of AFS, drew 78 exhibitors, who showcased their products and capabilities for the second largest foundry region in the U.S.

New CMMC CMMC Central Manchester and Manchester Children's University Hospitals
CMMC Chase Manhattan Mortgage Corporation
CMMC Corps Materiel Management Center
CMMC CONUS MILNET Monitoring Center
CMMC COMSEC Materiel Management Center

A glimpse of cutting edge technology emerged from a presentation by Bill Powell, Waupaca Foundry, on the markets, opportunities and challenges of cast metals matrix composites (CMMCs).

In addition to describing the low pressure permanent mold method Waupaca uses for producing CMMC disc brakes, Powell discussed a new alternative for CMMC production, Lanxide's Primex pressureless molten metal infiltration process. In effect, Powell said the method is "a casting process without a mold."

With infiltration, a blown alumina alumina (əl`mĭnə) or aluminum oxide, Al2O3, chemical compound with m.p. about 2,000°C; and sp. gr. about 4.0.  oxide ceramic preform pre·form  
tr.v. pre·formed, pre·form·ing, pre·forms
1. To shape or form beforehand.

2. To determine the shape or form of beforehand.

 (similar to a core) is placed upon either molten or solid aluminum and processed through a heat treat oven. During heating, the preform spontaneously absorbs the aluminum, filling voids through a capillary action. Cycles are typically 30 min to 1 hr.

He said the result is a near-net shape casting without evidence of metal entry. Quality-wise, Powell said the process produces 100% sound castings without material defects, since the preform effectively serves as a filter. In addition, only a muller for levitating alumina oxide, a modified coreblower and a heat treat furnace are required.

Waupaca has experimented with solid (the preform can be placed directly on beer cans, wire, or aluminum stock) and molten aluminum. It is currently producing preproduction pre·pro·duc·tion  
1. Taking place or existing before production: preproduction planning.

 prototypes for caliper caliper

Instrument that consists of two adjustable legs or jaws for measuring the dimensions of material parts. Spring calipers have an adjusting screw and nut; firm-joint calipers use friction at the joint to hold the legs unmoving.
 pistons, and has sent parts to customers for testing.

The process is revolutionary, said Powell, since it doesn't necessitate molding, sand systems, finishing chores, traditional melting or material landfilling. He also added that it is highly productive and requires only 40% of the energy required by green sand molding.

Iron Permanent Molding

Another potential paradigm shift A dramatic change in methodology or practice. It often refers to a major change in thinking and planning, which ultimately changes the way projects are implemented. For example, accessing applications and data from the Web instead of from local servers is a paradigm shift. See paradigm.  was explored by Yury Lerner, Univ. of Northern Iowa, in his presentation on developments in cast iron permanent molding. While the process has been embraced for nonferrous metals, only a few U.S. foundries employ the method for cast iron (namely Grede Perm Cast, Cynthiana, Kentucky Cynthiana is a city in Harrison County, Kentucky, United States. The population was 6,258 at the 2000 census. It is the county seat of Harrison CountyGR6. Geography
Cynthiana is located at  (38.
, and Honda, Anna, Ohio Anna is a village in Shelby County, Ohio, United States. The population was 1,319 at the 2000 census.

Anna is the location of a Honda Motor Co., Ltd plant that builds the GM L66 engine and Honda J engine.
), compared to 15 throughout Europe.

He said recent R&D has led to significant improvements in permanent mold design and material, optimized chemical composition of base irons and practical use of ultrasonic nondestructive non·de·struc·tive  
Of, relating to, or being a process that does not result in damage to the material under investigation or testing.


Due to the absence of sand and chilled corners, Lerner said the process can provide better machinability. Also, defects are more easily identified, and close dimensional tolerances may be achieved. "Despite controversial opinion, cast iron permanent molding is cost-effective for some high-production jobs," said Lerner, "and has a great future."

Niche Marketing

Among the conference's management-oriented topics, which included employee recruitment, equipment leasing Equipment Leasing is a financing option to lease equipment for a certain amount of time. Leasing Benefits
  • Control secondary market, offer the ability to up-grade and trade-in.
  • Converts cash buyers of small machines to larger, more expensive purchases.
 and quality atmosphere, was "Marketing for Results" by Grede Foundries' Merrill York. Defining niche marketing as knowing what you do best and capitalizing on opportunities, he pointed out the elements critical to planning. They are: defining your foundry, marketplace, customers and parts; organizing your plan; and implementing it.

He shared the popular saying at Grede, "Nothing happens until somebody sells something." York said: "It's a correct statement, but tells only half the story. The other half now says 'Without a focused marketing plan, no one sells the right things.'"
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No portion of this article can be reproduced without the express written permission from the copyright holder.
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Title Annotation:American Foundrymen's Society Wisconsin Chapter
Author:Lessiter, Michael J.
Publication:Modern Casting
Date:Apr 1, 1996
Previous Article:Achieving unity of purpose.
Next Article:S.E. foundrymen position themselves for the future.

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