OUR NEXT MEETING WILL BE OCTOBER 17, 2013
AT CANMET, 183 Longwood Road South, Hamilton L8P 0A5
2:30 PM – Tour of foundry to view a non-ferrous melting and casting.
3:30 PM – Seminars
James Lively – HOW TO ELIMINATE THE GENERATION OF HAZARDOUS FURNACE EMISSIONS AND SPENT FOUNDRY SAND BY PROCESS MODIFICATIONS
Dr. Yemi Fasoyinu – FACTORS THAT INFLUENCE HOT TEARING OF ALUMINUM ALLOY 206 POURED IN METAL MOLDS
Dr. frank Czerwinski – MICROSTRUCTURE GENERATION OF MAGNESIUM ALLOYS DURING SEMISOLID PROCESSING
5:00 PM – Meeting end
5:30 PM– Dinner in Kelsey’s
How to eliminate the generation of hazardous furnace emissions and spent foundry sand by process modification
James Lively
James Lively has worked the past 19 years for The TDJ Group in various positions including customer service, quality control and sales & marketing. TDJ provides specialty chemicals to various industries to eliminate the generation of hazardous by-products, such as furnace emissions and spent foundry sand. In 2004, James made partner in the firm and is currently serving as TDJ’s Operations Manager . Before coming to TDJ, he graduated in 1993 with a B.S. in Environmental Sciences from Southern Illinois University in Carbondale, IL (SIU-C). James continued his educational pursuits at SIU by earning an assistantship, allowing him to graduate with a Master’s Degree in 1995.
James currently serves on the American Foundry Society’s 10-F Waste committee where he has contributed to various reference documents such as Guidance on Hazardous Waste Compliance Manual. He also serves on the 10-E Air compliance committee.
Factors that Influence Hot Tearing of Aluminum Alloy 206 Poured in Metal Molds
Yemi Fasoyinu, Research Scientist
ABSTRACT
The commercial success of casting of Al-Si family alloys (e.g. 356) and Al-Si-Cu family alloys (e.g. 319) in metal molds for automotive and other applications have been demonstrated by many production foundries. This is not the case for Al-Cu family alloys (e.g. 206) because they are usually susceptible to hot tearing during solidification in metal molds. To address this issue, CanmetMATERIALS (CMAT) and other industry partners started a research project that is focused on developing a viable permanent mold casting technology for hot tear susceptible aluminum alloys 206 (Al-Cu alloy family) and 535(Al-Mg family). Alloy 206 is used in structural castings for automotive, aerospace, and other applications where its higher tensile and yield strengths than possible with alloys 356 and 319 are required. Selected engineering components were cast by gravity tilt-pour and low pressure permanent mold casting processes at CMAT and at partner foundries. It was shown that a combination of grain refinement and thermal management of the mold temperature is necessary for the elimination of hot tears in alloy 206. The results of the processing techniques that improved the hot tearing resistance and issues encountered during the casting of selected components poured in metal molds at CMAT and partner foundries will be presented.
Biography
Dr. Yemi Fasoyinu is a Research Scientist at CanmetMATERIALS (CMAT), Natural Resources Canada. He graduated with B.S and M.S degrees, Metallurgical Engineering, University of Wisconsin-Madison, USA, and Ph.D., Metallurgical Engineering, University of British Columbia, Vancouver, Canada. He has over 20 years of experience in research and development work related to solidification processing of metals and alloys, and development of metal casting technology for aluminium-, magnesium-, and copper-base alloys. He has developed research and development partnerships with many Canadian foundries, universities, and international organizations. He has authored/co-authored over one hundred publications in scientific journals, conference proceedings, and client and departmental reports. He is a member of AFS Aluminum Division 2 and Lost Foam Division 11 Committees.
Microstructure generation of magnesium alloys during semisolid processing
Frank Czerwinski, CanmetMATERIALS, Natural Resources Canada, Hamilton, Ontario, Canada
ABSTRACT
There is a continuous quest for a net-shape manufacturing technology that would allow reducing cost and at the same time improving properties. In this search, the ultimate goal is the single-step manufacture of components with intricate shapes, sound structural integrity and properties comparable to the wrought state at a low cost similar to casting. It is believed that semisolid processing, offering a replacement of multi-step energy-intensive manufacturing with a single-step process, exhibits features that may satisfy some of these requirements.
Although the semisolid processing concept was invented in 1970’s it is currently under intensive development and a critical breakthrough is still expected. Recent advances in both the fundamental and applied solidification research revealed the important role of the alloy nucleation step leading to novel research direction referred to as liquid metal engineering. This new approach allows for better understanding and control of microstructural and morphological transformations during semisolid processing.
The key difference of semisolid processing is the reduced temperature when compared to the casting of superheated melts. When considering the component manufactured, the reduced processing temperature positively affects the flow behaviour and solidification shrinkage. At the same time, however, the reduced temperature affects the alloy microstructure in terms of phases present, their content and morphology. The microstructural changes are not obviously clear and should be assessed for each particular alloy system. The presentation will provide an analysis of overall transformations experienced by thixotropic slurries and comparisons with conventional casting. General findings are supported by quantitative data extracted from semisolid processing of several magnesium alloys.
