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AFS research reports.

AFS Brass & Bronze Research

"Lead-Free and Low-Lead Cast Copper Alloys for Plumbing Fittings" (90-192), was addressed by D. Peters, Copper Development Assn, and K. Kundig, International Copper Assn. Peters reported that Phase I had been completed and two alloys warrant further analysis for their economic" acceptability as substitutes for traditional lead plumbing fittings. Also, a study at the Univ of Florida on treating the surface of leaded alloys to reduce the pickup potential has been completed. The economic ramifications will be studied in Phase 11, as will the physical property characteristics and machinability of the two most promising alloys.

"Lead in brass and Bronze Waste Sand Streams" (90-040), authored by P. Trojan and T. Ostrom, Univ of Michigan/Dearborn, involves the study of high volume brass and bronze alloys containing lead that builds up as entrapped metal and mold/metal interface reaction product in system sands. Several years of research to identify the forms of lead, the toxicity with respect to foundry practice and the methods available to minimize the environmental impact were summarized.

AFS Engineering Research

A panel discussion on the "Practical Experience of Using Modeling on the Foundry Floor" (90-141) was presented by the Heat Transfer Committee 1-F. Panel members were: M. Robinson, PCC Airfoils, Inc; C. Kim, GMTechnical Center;J. Grabel, Caterpillar, Inc; and J. Berry, Univ of Alabama/Tuscaloosa. Each panelist discussed the application of process modeling in foundry situations. The panel emphasis was a status report on an AFS sponsored research project entitled "Predictive Criteria for Shrinkage Avoidance." The program goal is to determine the critical factors in predicting shrink in aluminum castings and how this research will be applied to foundry model predictions.

AFS Molding Methods & Materials This panel presented a historical perspective as well as current results of the "Penetration Project" (90-162). The panelists were: J.M. Svoboda, Process Metallurgy Intl; S. Storer, American Colloid Co; and D.M. Stefanescu, Univ of Alabama. Project work is being conducted at UA and is summarized in AFS Research Report #2. Initial experiments are designed to develop a baseline contact angle for each of the various materials and systems. industry funding is currently being sought for Phase 11 of the project. AFS will provide a 2:1 match in funding, up to $50,000, toward this effort.

AFS Aluminum Research

Two presentations addressed aluminum research projects. Solidification Characteristics of Aluminum Alloys" (90182)was presented by S. Backerud, Univ of Stockholm, and included an update of research into the solidification characteristics of aluminum foundry alloys, as well as a report on progress in the development of a textbook.

The second aluminum presentation, given by A. Maloit, consultant, and K. Oswalt, Northrop, covered Phase 11 of "A Study of the Relationship of Notch Yield Ratio and Fracture Toughness of Structural Aircraft Quality D357 Aluminum Casting Alloy" (90-171). The D" version of alloy 357 was evaluated using material supplied by three foundries that produce aerospace castings.

AFS Cast Iron Research

Research work on the "Effects of Chemical Composition, Graphite Size & Solidification Conditionson Tensile Properties of Gray Cast Irons" (90-062) was presented by C.E. Bates, Southern Research Institute. Bates focused on results from four foundry trials. The dominant factor in predicting the strength of gray iron was found to be the maximum graphite flake length. He also discussed the strength prediction equation which was derived from his research.

The following three papers describe various aspects of an AFS funded research project on heavy section Austempered Ductile Iron (ADI). They were all authored by several Michigan Tech Univ staff members and presented by K.B. Rundman. The first, "Fatigue Properties of Heavy Section ADI Castings" (90-166), explained that section size plays an important role in fatigue properties and demonstrated the variation in fatigue properties with Mn content.

The goal of the second work, "Tensile Properties of Heavy Section ADI Castings" (90-167), was to document the change in graphite size, shape and distribution between high and low UTS bars. It was observed that the high bars had consistently higher values for all three parameters. It also was apparent that nodule count exhibited the greatest difference for the three measured categories.

"Isothermal Transformation Diagrams in a Heavy Section High Alloy Ductile Cast Iron" dealt with the I-T diagrams for heavy section high alloy ductile cast iron (90-126). It was reported that austenitizing temperature significantly affects the relative position of the I-T diagram and alloying elements delay the austenite decomposition reaction. Also, a probainite nose exists around 475C and provides an obstacle to obtaining lower temperature pro-bainite products on continuous cooling of heavy section castings. Finally, segregation of alloying elements dictates that the rate of isothermal transformation of austenite will decrease with time.

AFS investment Casting Research

C.V. White, GMI Engineering & Management Institute, reported on "A Study of Investment Cast Ductile Pouring Parameters on Mechanical Property" (90-168). This work is a jointly sponsored AFS/ICI research project investigating the effects of shell temperature and section size on the property and microstructure of a cast iron.

AFS Melting Methods & Materials

This panel reviewed the present status of the AFS/DOE Cupola Modeling Project (90-196). In individual presentations, panel members, D.L. Twarog, AFS, S. Katz, GM Research Labs, R.D. Pehlke, Univ of Michigan/Ann Arbor and J. Szekely, M IT, dealt with the model's predictability of heat transfer, chemical reactions and fluid flow in the cupola's various zones.

A session on the "Recent Advances in the AFS Channel Induction Furnace Clogging Project" was presented by D.C. Williams, Allied Mineral Products. A brief discussion of this 8-D Committee project revealed that progress has been made in evaluating the causes of ceramic clogging in channel furnaces.
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Title Annotation:American Foundrymen's Society
Publication:Modern Casting
Date:Jun 1, 1990
Previous Article:Aluminum division silver anniversary.
Next Article:Quality and computer modeling for the next decade.

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