2003 Issue 3.pdf

The Ductile Iron News

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To Promote the production and application of ductile iron castings Issue 3, 2003

FEATURES

• Cover Story - DIS Members VisitScandinavian Foundries

• Millis Scholarship Winner

• PQ-DIT Process

• Direct Flow Simulations in PressedFoundry Filters

• SAE Fellow Award

•Thermodynamic Evaluation ofBoron Removal from Ductile IronMelts

• U.S. EPA MACT Standards

• Ten Steps to Improving CastingYield in Ductile Iron Foundries

•Cost Reductions through DirectPouring on Automatic HorizontalMolding Machines

• Influence of Section Size on theMachinability of Ductile Irons

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DIS Members Visit Scandinavian Foundries

See Photos From the Scandinavian Tour

See Photos From the Millis Symposium - June 2003

View Ductile Iron Related Publications

Located in Strongsville, Ohio, USA15400 Pearl Road, Suite 234; Strongsville,Ohio 44136 Billing Address: 2802 Fisher Road, Columbus, Ohio 43204 Phone (440) 665-3686; Fax (440) 878-0070email:[email protected]

http://www.ductile.org/

mailto:[email protected]

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DIS Members Visit Scandinavian Foundries

We're happy to share photos from this memorable visitto Scandinavian Foundries.

DaniaFerryVald BirdElkemOystese

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View Ductile Iron Related

Located in Strongsville, Ohio, USA15400 Pearl Road, Suite 234; Strongsville,Ohio 44136


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Millis Scholarship WinnerDear Ductile Iron Society:

Last year I received the Keith D. Millis scholarship atthe CIC in Chicago. I wanted to attend a Chicagomeeting in the spring to thank and meet somerepresentatives, but Uncle Sam had other plans forme. I left with the U.S. Marines out of Peoria, IL toKuwait and Iraq for Operation Iraqi Freedom. Mysquad made it to Baghdad and back with the 6thEngineer Support Battalion. We even had reportersembedded with us. I have attached some pictures from the deployment. Ifigured the Society might like to know what or where one of their recipientswas doing last spring. At this time, I am finishing up with mechanicalengineering at Bradley University in Peoria, IL.

Thanks again and support your troops.

Semper FiAndrew SzostakPresident AFS Bradley Chapter

Convoy ReadyVillage Patrol Talk






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Millis SymposiumClick on any photo to see a larger picture.

Al AlagarsamyCitation Corporation

Werner BauerAustrian Foundry Institute

Lars-Erik BjorkegrenSwedish Foundry Association

Pat Demarino

Tim Dorn, John Keough, TonyThoma Tim Dorn

Alan Druschitz Jerome FourmannPechiney

Doug GambleSaint-Gobain Adv. Ceramics

P.R. GangasaniWells Dura-Bar

Dr. Robin GriffinUniversity of Alabama

Kathy HayrynenApplied Process, Inc.


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Kathy HayrynenApplied Process, Inc.

Head Table

Head Table Head Table

Sudesh KannanSelee

|John Keough

Applied Process, Inc.

Chantal LabrecqueRio Tinto Iron & Titanium

R. LeitermannMTI

Dan MaytonUrick Foundry

D. ReimerFarrar Corporation

Iulian RiposanUniversity of Bucharest

Hans RoedterRio Tinto Iron & Titanium

Karl RundmanMichigan Tech

Dr. Preston ScarberUniversity of Alabama

Torborn Skaland Bill Sorensen



Elkem Metals

Speakers Trevor TackaberryFoseco Metallurgical, Inc.

Ken TaylorFoseco Metallurgical, Inc.

Technical Chairmen

Bill Thomas Tony Thoma

Dr. Robert VoigtPenn State University





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The PQ-DIT Process. Improving Ductile IronProduction Using Situation-Based Additions of

MagnesiumRudolf V. SillénTechnical Director, NovaCast AB

Introduction:Almost every foundry that uses batch type treatments to produce ductileiron adds a constant amount of magnesium to each ladle. The amount ofthe addition, usually consisting of a ferro-silicon-magnesium alloy, hasbeen found by trial and error to suit the specific type of production thatexists in the foundry. A typical addition is 1.5%. If the amount of residualmagnesium is above a certain minimum level and other critical elementsare within acceptable limits then the dissolved carbon will precipitate asspheroidal shaped graphite. A foundry with heavy castings with largemodulus might aim at a minimum magnesium level of 0.055%. For anotherfoundry, with thin-walled castings and short times between treatment andpouring, a minimum level of 0.035 might be sufficient. These levels have tobe high enough to take care of "worst case" metallurgical variations in thebase iron (oxygen, sulphur, nitrogen, nucleation, etc.) and in Mg-yield.Although these levels do produce acceptable ductile iron, most of the timethey are too high and on average too much magnesium is used. The resultis unnecessarily high costs, problems with dross-inclusions, microshrinkages and reduced machinability.

Ideally, the magnesium addition should be varied depending on themetallurgical status of the base iron, i.e. total oxygen and sulphur, activecarbon equivalent, nucleation potential, treatment temperature, etc.However, this has not been possible until now, as the foundries havelacked practical and adequate measurement systems. Chemical analysiswith a spectrometer is simply not sufficient. It only quantifies the amount ofeach element but does not tell us anything about in what form theelements are present (e.g. oxides, sulphides, silicates) and even lessabout how the melt does nucleate during solidification. A magnesiumcontent of 0.045% might consist of 0.015% dissolved magnesium, 0.01%as MgO, 0.020% as MgS and Mg-silicates and nitrates and give a 95%nodularity. However, on another occasion the same total magnesium levelof 0.045% might result in only 50% nodularity due to a lower amount ofdissolved magnesium. The reason might be higher levels than usual in thebase iron of elements that tie up the magnesium such as oxygen, sulphuror nitrogen. This happens every now and then, but as it can not bedetected by spectrometer analysis, the foundry is forced to always use ahigh magnesium content sufficient for the worst case, e.g. 0.055% in orderto be able to produce ductile iron with 95% nodularity. The purpose of thePQ-DIT process control system developed by NovaCast AB is to solve thisproblem and allow the foundry to use the minimum amount at all times.

Fluctuations in the base iron:The metallurgical status of the base iron can fluctuate considerably. The


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total oxygen level might vary from 50 - 100 ppm, nitrogen from 40 - 120ppm, sulphur from 0.008 - 0.015 etc. The nucleation ability of the baseiron, which can be measured by thermal analysis, will influence the finalnodularity and the variation can be high. The illustration below shows twocases, which are realistic to happen in a foundry. Case 1 represents asituation where a magnesium level of only 0.025% would give a perfectductile iron. In Case 2 a magnesium level of 0.05% is required in order toobtain the same nodularity.

Mg-yield % 70 65Sulphur % 0.010 0.015

Oxygen ppm 60 80Nitrogen ppm 50 90

Nucleation High Low

If the foundry can not measure the status of the base iron they mustalways add enough magnesium to reach the 0.05% level. In reality eachmelt is an individual and the required magnesium level varies betweenthese two extremes. The conclusion is that every foundry producing ductileiron with traditional methods are using too much magnesium.

Prime Quality Ductile Iron Technology:PQ-DIT, is an abbreviation for Prime Quality Ductile Iron Technology. It isa new concept, developed by NovaCast, in order to produce high qualityductile iron with situation based magnesium additions. The technology isbased on advanced thermal analysis of the base iron combined withchemical analysis. The system estimates total oxygen as well as oxygenactivity in the melt, the active carbon equivalent, the nucleation status andseveral other important metallurgical parameters. Based on these data andthe chemical composition, PQ-DIT evaluates the melt and if neededrecommends additions of special conditioners to adjust the base ironbefore treatment.

When the base iron is within the acceptable process "window", PQ-DITcalculates the ideal amounts of magnesium and other additives to be usedwhen treating the iron. The "recipe" produced is specific for each alloy andtype of casting category. The PQ-DIT concept also includes consultancy



assistance in selecting optimal alloys and in improving melting andtreatment technology.

The starting point is a good base iron. In order to produce a high qualityductile iron the major requirements on the base iron are:

The active carbon equivalent (ACEL) must be selected to suit the castingto be made and the mould. The active carbon equivalent and the siliconcontent determine how much eutectic carbon can be used for reducing thecontraction during solidification. The active carbon equivalent is measuredwith the PQ-DIT system.

The nucleation properties of the melt must be within acceptable limits. Thiscan be ensured by controlling parameters such as the low eutectictemperature, the recalescence and specific graphite precipitation factors.By controlling these factors with PQ-DIT it is possible to optimize theamount and precipitation pattern for graphite and thereby reduce or eveneliminate the use of feeders.

The total oxygen level must be within a specific range. Note that ameasurement of the active oxygen only shows a small part of the oxygenin the melt. The important factor is the amount of total oxygen, becausealso oxides are reduced by magnesium. PQ-DIT estimates total oxygenand also oxygen activity.

The metallurgical "fingerprint", i.e. important thermal parameters,measured by PQ-DIT, must be within accepted control limits. This is doneby using an alloy profile diagram and a comparison with predeterminedsuccessful limits.

The chemical composition must of course also be within acceptable limits.It is especially important that the sulphur content is known with a highaccuracy. Acceptable sulphur levels for the base iron are 0.008 to 0.018%.

Testing and adjusting the base iron with PQ-DIT 1:When the base iron is melted and at the normal final holding temperature,a sample is poured using standard Quik-Cups. Two cups are used foreach test - one standard cup with tellurium and one without.

The PQ-DIT system evaluates the iron by using the parameters mentionedabove and suggests any adjustments needed for the base iron before themagnesium treatment. That includes additions of alloying elements as wellas correction of the oxygen content.

When the base iron is "conditioned", the PQ-DIT system suggests theideal additions of FeSiMg, cover material and Ce-MM or RE-silicide to beadded to the treatment ladle. This recipe can then be used for severalladles without the need to pour a new sample. The variations in "active"magnesium mainly depend on:

The FeSiMg-alloy, its composition and grain sizeThe design of the alloy chamberThe design of the treatment vesselType and amount of cover materialTreatment temperatureDwell time for the alloy in the alloy chamber (if hot) beforetreatmentThe total oxygen level in the base iron (See picture below)The sulphur level in the base ironThe nitrogen level in the base ironThe nucleation level in the base iron

The screen shows the result after testing a base iron. The OK sign tellsthe operator that the melt is ready for treatment. The profile diagramrepresents the "metallurgical fingerprint".



The Mg-yield often varies between 55 and 70% from ladle to ladle due tovariations in one or several of the mentioned factors unless specialprecautions are taken. The PQ-DIT technology includes know-how toreduce such variations.

Variations in oxygen and sulphur also make a big difference. A base ironwith a sulphur content of 0.01% and an oxygen content of 40 ppm mightrequire a total addition of about 1.1% of an FeSiMg alloy. If sulphur andoxygen increase to 0.015% and 80 ppm, then an addition of about 1.35%would be needed in order to achieve the same nodularity. If there were avariation in other factors that influence the Mg-yield, causing the yield todrop 15%, then the need for FeSiMg alloy would increase from 1.35 to1.60%.

The PQ-DIT process control system allows the foundry to control oxygen,sulphur and nucleation properties and by adjusting the additions of FeSiMgdynamically we can reduce the additions considerably as the exampleabove demonstrates. If the other factors are also considered to increasethe yield and the repetition accuracy then further reductions are possible.The PQ-DIT concept also includes technical advice about how to improvethe yield factors, selecting alloys and inoculants, etc. The picture showsthe screen with the recommended additions for the current melt.

Verification of the final iron with PQ-DIT 2:The final treated iron can be verified by pouring two Quik-Cups andanalyzing the cooling curves with the PQ-DIT 2 system. One of the cupscontains tellurium. The effect is that Te combines with the dissolved Mg inthe iron forming magnesium telluride (MgTe). The iron in that cup solidifiestherefore almost like a normal gray iron. By comparing thermal databetween the two cooling curves it is possible to estimate the percentageof dissolved magnesium as well as the nodularity in the iron (see screenshot). Acceptable limits can be set in the alloy database for different alloysand/or specific castings. The PQ-DIT 2 system needs to be calibrated foreach installation, as it is dependent on the alloys and treatment method



used.

The data from PQ-DIT are also used to fine-tune the whole treatmentprocess. When installing the system the target for final Mg should begradually reduced in order to find an optimal operating level.

Benefits:The PQ-DIT system offers a reproducible way of producing ductile ironwith very low levels of magnesium. The main benefits are:

Less tendency for micro shrinkage defectsPossibility to increase casting yield by reducing the need for feedmetalLess tendency for dross and other inclusionsBetter machinabilityIncreased process stabilityReduced costs - the Pay-Off time is often less than 6 month.

The micros below shows an improved nodularity with the PQ-DIT treatediron although the magnesium level is reduced by 38%!

Traditional treatmentMg=0.042%

With PQ-DITand special Elkem alloyMg=0.026%

Availability:



The PQ-DIT system consists of two parts. PQ-DIT 1, which is used tocontrol and adjust the base iron and to recommended ideal additions forthe magnesium treatment. This system should be installed at the meltingdeck or where the holding furnaces are.

PQ-DIT 2 is the verification system. It should be installed close to thepouring area as it is used to test and verify the final, treated iron.

The Prime Quality Ductile Iron Technology systems are supported byworld-class specialists in foundry technology and metallurgy fromNovaCast and Elkem.

The PQ-DIT process flow can be illustrated as follows:

References:

T. Skaland. A model for the graphite formation in ductile cast iron.Avhandling 1992:33. Metallurgisk institutt, Trondheim

R. Elliot. Cast Iron Technology. ISBN 0.408-01512-8

H. Fredriksson, M. Hillert. The Physical Metallurgy of Cast Iron. ISSN0272-9172

PQ-DIT_Description.doc





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Direct Flow Simulations inPressed Foundry Filters

(Due to the size of graphics in this article, the index has been omitted. Return to the cover page of this issue)

Ian Andrewsa, Jean-Marc Dumailleta and Attila Diószegib

a Saint-Gobain Advanced Ceramics Hamilton Ltd -45 Curtis Avenue, Paris, Ontario, N3L 3T6, CANADAb Department of Mechanical Engineering -Component Technology, Jönköping University Box 1026, S-551 11 Jönköping, Sweden

AbstractFluid flow simulation has been used as a tool to understand and optimise gating systems in foundrypractice. Gating systems frequently contain filters because of their favourable effect on the flow propertiesof molten metal. Consequently, filters can have a positive effect on the final quality of cast metals. Thepresent study uses direct flow simulation in the areas around real shape modelled filters. This directmethod, rather than the more traditional pressure drop method, gives new insight into the micro flowphenomena of molten metal passing through a filter. The simulations of flow patterns through the filterchannel support the theory of cake filtration and thereby promote the fundamental idea of metal filtration.

Keywords: Flow simulation, cake filtration, pressed filters.

1. IntroductionSolid liquid separation technology is widely used in different industrial processes. The phenomena involvedare very complex and significant efforts have been made to establish fundamental filtration theories. [1]Generally the principal separation modes are filtration, sedimentation and flotation. Filtering of liquid metalshas become standard practice in many foundries as the quality requirements of cast components haveincreased. A large variety of filters are used and the users generally report the beneficial effect of improvedquality. Casting defects related to inclusions are generally reduced and the machinability of casting isnormally improved.

However the actual filtration mechanisms are not clearly understood. Various work has which beenundertaken, to understand the effect of mould filling on the final properties of a casting, has shown theimportance of low fluid velocities contributing to low surface turbulence and less entrapment of surfacereaction products into the metallic bulk. [2] Since these effects have been known, the reported qualityimprovement of filtration was largely attributed to the low fluid flow rate through the filter and the filters rolein reducing the turbulence. Reports on microstructure investigation in connection to filters have shownseparation and segregation of non-metallic inclusions at the entrance side of filter. [3] This observationindicates the existence of separation phenomena at the filter interface, which are probably a result ofcomplex filtration mechanisms.

Development of fluid flow computation has given us new opportunities to study fluid flow in foundryprocesses and also the influence of filters on the flow. To fully incorporate a filter into a computer flowsimulation, a large amount of extra computing power is necessary. This is because of the intricate structureof a filter. To minimize the amount of extra computer power needed, a special method has been developedto incorporate filters in flow simulation [4]. The filter is considered as a permeable material and a pressuredrop is allocated for the fluid through the filter. Both parallel and transverse flow is considered to take intoaccount the anisotropy of the filter media. Filter producers and independent researchers have doneconsiderable work to develop filter data necessary to consider filters in simulations. [5] Validation workreports good accuracy when using a pressure drop to simulate flow through filters [6], however the flowphenomena in close connection to filters is not discussed.

Recent improvements in computational power give us the opportunity to consider the real shape of filters insimulation. Different ceramic filters have been modeled and simulated in their real shape [7] to study metalsolidification in a filter and its influence on the flow through the filter. The purpose of this paper is to studythe metal flow by simulation in the areas around real shape modeled filters and to compare this to realseparation phenomenon observed in filters.

2. Cake filtrationFiltration mechanisms, as they apply to foundry practice, are described by Rushton [1] and a schematic is



shown in Figure 1. This mechanism is known as cake filtration. The filtration process starts with solidparticles floating in the fluid being trapped on the entrance surface of the filter (Figure 1A). This entrapmentis assisted by the presence of low pressure and low velocity areas. At the beginning of the pour, thesuspended particles do not affect the flow through the filter (Figure 1B). The separated particlesprogressively build up a layer known as the "cake" (Figure 1C).

Figure 1. Cake filtration principles

A further increase of the fraction of particles that are suspended will eventually lead to a threshold whenthe retained particles will start to have an impact on the flow through the filter. As more particles areseparated a further, critical threshold will be passed as the cake start to influence the permeability of thefilter. The growth of the cake finally leads to the blockage of the flow. A mathematical description of thevelocity in a filter involving cake filtration is:

V = DP/m(Rm + RC) (1)V – velocityDP – pressure dropm – viscosityRm – resistance of the filterRC – resistance of the filter cake

Investigation of the metallic-ceramic interface at the entrance face of a filter is presented in Figure 2. Thepicture is a micrograph from a part of a gating system including a filter in ductile iron. The filter shown is apressed ceramic, with a hole of 2.3 mm diameter. On this micrograph, we can observe the entrance part ofone filter cell.

In the metallic matrix in contact with the entrance surface of the filter, it is possible to observe a bridge ofmicroscopic inclusions. These are mainly composed of MgO and MgS. The distribution of the inclusionsreveals a complex variety of separation processes. The inclusion cake gradually covers the filter channel,which eventually becomes completely blocked. The flow in contact with the entrance surface of the filterwill be investigated in the next chapter to determine whether there are suitable conditions for cakeformation.

Figure 2. Micrograph of an inclusion bridge

3. Simulation procedure



The simulation has been carried out using the MAGMAsoft simulation software on a gating system,commonly used in foundry practice, which incorporates a filter. Figure 3 shows the gating systemconsidering a horizontally parted casting and a filter in a vertical position. The mould material is consideredto be permeable green sand and the metal is considered to be a nodular cast iron. The filling conditionwas set as a time dependent volumetric function. The size of the gating system components is alsocommonly used in systems including filters, with an expanding channel area before the filter and a taperingarea after the filter.

Figure 3. Simulated gating system Figure 4. Pressed ceramic filter used in thesimulation

Three different simulations were performed. One simulation considers that there is no filter in the geometry,a second simulation assumes that the filter as a permeable material causing a pressure drop through it,and the third simulation considers a real, pressed ceramic filter (Figure 4.) The simulation parameters aregiven in the appendix. The calculated filling time is equal in all the cases ( tfilling = 18.7 sec.), which isobviously due to the commonly imposed filling conditions. The fact that there are no differences in fillingtime between the cases with and without filters reveals the neutral contribution of the filter to the total filingtime.

Figure 5 shows sequences from the simulated flow for the different filtering conditions.

Fraction filled No filter Filter as a permeable solid Real shaped filter

2.39%

3%

5%

30%



Figure 5. Simulated flow sequences for different filtering conditions.

Comparing the case with the filter as a permeable solid and the case of a real shaped filter, it is evidentthat the flow at a macroscopic level is very similar; the flow velocities at different filled fractions arecomparable. This observation underlines the correctness of modeling the filter as a permeable solid whenonly the thermal interaction between the metal and gating system is of interest.

Observing the flow at a higher magnitude, it is possible to see clear differences, especially in areas thatare in contact with the filter element. In the case of the solid permeable filter (Figure 6), there is ahomogenous flow distribution in the filter and the velocity decreases from the entrance surface of the filterto the exit surface, proportionally to the imposed pressure drop characteristics for this calculation method.

Figure 6. Velocity distribution in a permeablesolid filter at 30 % fraction filled

Figure 7. Velocity distribution in real shaped filterat 30% fraction filled

In the case of a real shaped filter (Figure 7), the simulation predicts a distribution of the flow velocityaccording to the shape and size of the filter channels.



A perpendicular view of the same area (Figure 8) shows the specific velocity distribution in connection withthe vertically placed filter. Light colours represent high velocities while dark colours represent low velocities.A low velocity area exists at the entrance side of the filter between the streams of higher velocity, indicatedby arrows.

Figure 9 shows the distribution of low velocity areas up to a half millimeter from the entrance face of thefilter, where the low velocity areas are interconnected in a complex way. Considering the fundamentaltheories of cake filtration, the presence of these low velocity areas helps to promote particle suspension.According to this simulation, pressed filters exhibit conditions that promote particle suspension and which



can then initiate cake filtration.

To underline the complexity of the phenomena exhibited at the entrance side of the filter, the distribution oflow velocity areas, up to a half millimeter from the entrance surface of the filter, are presented at differentfractions filled in Figure 10.

Figure 10a. Fraction filled 8% Figure 10b. Fraction filled 25%

Figure 10c. Fraction filled 50% Figure 10d. Fraction filled 75%

The results seen at different fractions filled close to the filter surface show a transition between interactinghigh velocity and low velocity areas. The low velocity area is expanding but also the high velocity areasare also changing. At this time there is no known method for calculating metal flow in combination withsolid particles in suspension. However, the frames of Figure 10 indicate that a consideration of the particlesin suspension, and thereby the influence of the cake on the flow in connection with the filters, would give adifferent flow pattern and promote the understanding of filtration mechanisms.

The flow with maximum velocity at the exit face of the filter is seen in an area where the streams areinteracting and sudden changes between high and low velocity areas coexist. Suitable conditions forseparation and cake formation exist at this filter exit and further studies will be performed on this specificpoint.

4. ConclusionsA real shape simulation on pressed foundry filters has been provided. While the traditional pressure dropmethod is adequate for investigating macroscopic flow phenomena in the molten metal within a runnersystem, this new method is able to show information on the fluid flow close to the filter itself. A gatingsystem commonly used in foundry practice was simulated. Complex flow patterns were observed at theentrance and exit surfaces of the filter. High velocity areas adjacent to low velocity areas create sharpvelocity gradients. The results are discussed in relation to general filtration mechanisms, where a cakefiltration mechanism is the most credible mechanism appearing in foundry filtration. The simulation resultsclearly show the possibilities for particle separation due to the presence of low velocity areas in the vicinityof the entrance surface of the filter. The physical properties of real inclusions existing in foundry practiceare not included in the calculation, although it is expected that these would change the flow characteristicsof the metal adjacent to the filter.

5. Acknowledgements

The simulation work has been carried out in collaboration with Foundrysoft AB in Sweden.

6. References



1. A. Rushton, A. S. Ward, R. G. Holdich: Solid-Liquid Filtration and Separation Technology, 2ndCompletely Revised Edition, 2001.

2. J.Campbell : Casting, 1991

3. Saint-Gobain Advanced Ceramics Hamilton, Molten Metal Filtration - An Engineered Balance -Internal report.

4. MAGMAsoftÒ 4.2, User manual, Part 2.

5. J.Bäckman, I.L.Svensson: Evaluation of Filter Parameters from Direct Observation of Metal Flow inAluminium Casting, 1st Intl. Conf. Gating, Filling and Feeding of Aluminium Castings, Memphis,USA, 1999.

6. J.M.Dumaillet, G.M.Wilson: A Comparison of Flow Modification through Cellular Foundry Filtersusing both Water Modelling and Simulation Software, Part 1, 2002, Transactions of the AmericanFoundry Society V 110 Paper No 02-106 P 187-198, 2002

7. J-C.Gebelin and M.Jolly: Numerical Modelling of Metal Flow Through Filters, Modelling of Casting,Welding and Advanced Solidification Processes X, 2003, Destin, USA, pp. 431-438.

Appendix I

Colour scale for the simulation results presented in Figures 5 to 10.

The mould material considered for thesimulation is permeable green sand.

Pb = 250 cm3 min-1. (Pb - permeability).

The cast material considered for thesimulation is a Ductile iron, Tpouring = 1400oC.

The mould filling condition is set up accordingto the following table:

Time(s) 0 0.29 0.31 0.78 2.00 3.00 3.10 6.00 8.00 10.00 15.00 40.00Pouring

rate(cm3/s)

860 820 530 430 380 350 280 260 250 240 190 170

The real shaped filter introduced in the gating system is a pressed ceramic filter with nominaldimension of 50x50x10 mm and cell diameter of f2.3 mm.

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SAE Fellow AwardDr. Alan P. Druschitz1042 Mistwood PlaceForest, VA 24551

Dear Mr. Druschitz,

On behalf of the SAE Fellow Committee, I am pleased and delighted toinform you of your elections to the FELLOW grade of SAE membership. The SAE Fellow Committee made their selection based on youroutstanding contribution in automotive cast products.

The Fellow grade of SAE membership was established in 1976 for thepurpose of honoring our member's professional contributions. This specialgrade was developed to recognize important technical achievements andto enhance the status of SAE's contributions to the profession and public-at-large. Election is awarded based on exceptional professional distinctionby reason of outstanding and extraordinary qualifications, experience, andsustained accomplishment in mobility technology.

The SAE Board of Directors established and maintains high standards forselection of members to the Fellow grade. They protect the dignity andenhance the prestige of the Fellow grade by electing only up to 20members each year. This year the Fellow Committee chose to elect 20members of which you are one.

As a new SAE Fellow, you along with the nineteen other newly electedFellows will be honored at a dinner by your peers. This dinner is to beheld at the Marriott Renaissance Center Hotel on Monday evening, March8, 2004 in Detroit during the 2004 World Congress and Exposition. Alsoduring the week of SAE's World Congress, you will be recognized at theHonors Convocation. You will receive invitations to both of these events.

In addition to being honored at SAE's World Congress, we will berecognizing your achievement in SAE UP date. Please forward a blackand white glossy photo of yourself or email it (as a tif file, 300 dpi) toJaniece Lang at SAE Int'l prior to December 5, 2003. Janiece's contactinformation will be listed at the bottom of this letter.

Congratulations on your election to SAE Fellow. I sincerely hope you willbe able to join us in March in Detroit to be recognized by your peers.

Sincerely,

Nicholas Gallopoulos, Chair2003-04 SAE Fellow Committee





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Thermodynamic Evaluation of Boron Removalfrom Ductile Iron Melts

See the Article which follows this link..





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“DUE TO THE CONFIDENTIAL NATURE OF THIS INVESTIGATION, COPIES OF THIS REPORT ARE AVAILABLE ONLY TO THE CUSTOMER.”

SORELMETAL

TECHNOLOGY DEPARTMENT

TECHNICAL SERVICE REPORT NO. SM-03-22

Thermodynamic Evaluation of Boron Removal from Ductile Iron Melts

INVESTIGATOR: DATE: August 13 th, 2003 Éric Planque, M.Sc.A. Foundry Metallurgist Martin Gagné Distribution F. Dubé E.C. Muratore R. Thibau

RIO TINTO IRON & TITANIUM INC.

-1-

S:\Produits_Ferreux\Public\20 MEMOS-RAPPORTS\SORELMETAL-300-310-320-330\320 Services Techniques\2003\SM-03-22.doc

1.0 INTRODUCTION The contamination of Ductile Iron melts by boron has been reported more and more frequently in the last few years. Boron was reported to offset the pearlite promoting effect of copper and, as a result, the manufacture of fully pearlitic castings was made more difficult in presence of boron. As little as 0.002% boron was reported to be detrimental. It was recently proposed by Dr R. Naro that sodium could be a good candidate for removing boron from Ductile Iron melts, and an experimental program was proposed to DIS. Prior to perform the tests, Rio Tinto offered to carry out thermodynamic simulations to verify if the reaction of sodium compounds with boron is theoretically possible. The results are presented below.

2.0 TETS PARAMETERS The thermodynamic calculations were run using the FACTSAGE data base of École Polytechnique de Montréal. Note that this simulation is purely thermodynamic and does not include kinetics factors that may influence the reactions under production conditions. The chemical composition of the iron is listed in Table 1; a boron concentration of 0.002% was taken as the reference level. The different mixtures injected in the liquid iron are listed in Table 2. Simulations were run at 1400 and 1550 oC.

Table 1 Chemical Composition of the Liquid Iron Elements Weight %

Fe 94.07 C 3.70 Si 2.00

Mn 0.20 P 0.02 S 0.01 B 0.002

Table 2 Mixtures Injected

Test # CaO SiO2 Na2O Na2CO3 kg/t 1 50 % 50 % 0 0 20 2 40 % min 40 % min Up to 20 % 0 Up to 40 3 0 0 0 100 % Up to 100

-2-


3.0 RESULTS 3.1 Injection of SiO2 + CaO At the selected test temperatures, this mixture forms pseudo-wollastonite and remains solid; no reaction with boron is predicted by the model. 3.2 Injection of SiO2+CaO+Na2O Adding Na2O reduces the melting point of SiO2+ CaO and the resulting slag can then absorb B2O3. The effect of injecting up to 20% Na2O in the CaO-SiO2 mix is shown in Figure 1. Boron removal is significantly more efficient at 1400 oC and a minimum concentration of about 0.0011% B is reached with a mix containing 5% Na2O. Increasing the Na2O content above 5% does not improve boron removal. When injected at 1550 oC, sodium tends to vaporize as elemental sodium or as NaO.BO. It creates a deficit in sodium that reduces the amount of liquid slag at equilibrium and its ability to absorb boron.

Figure 1 Boron Removal by Injection of SiO2-CaO-Na2O (20 kg/t)

The effect of slag basicity (%CaO/%SiO2) was verified for a mix containing 20% Na2O. Increasing the basicity (increasing the amount of CaO) decreases the boron removal efficiency by reducing the solubility of boron in the slag. The effect is seen at both test temperatures.

0.0000

0.0005

0.0010

0.0015

0.0020

0.0025

0 5 10 15 20 25

Na2O in the mixture (%)

B in

the

Iron

(%)

1550 C

1400 C

-3-


Figure 2: Effect of Injection Mixture Basicity on Boron Removal (20 kg/t, mix containing 20% Na2O)

The effect of the amount of injected material for a mix containing 5% Na2O (optimum as seen in Figure 1) with a basicity of 1 was also verified. Very little effect is seen at 1550 oC; however, increasing the injected amount of material up to 40 kg/t at 1400 oC reduces the boron content to 0.0008%.

Figure 3. Effect of the Amount of Injected Mix (5% Na2O) on Boron removal.

3.3 Injection of Na2CO3

Figure 4 presents the effect of Na2CO3injection on boron removal at 1400 and 1550 oC. It shows that Na2CO3, when injected at a rate of 20 kg/t at 1400 oC, reduces the

0.0005

0.0008

0.0011

0.0014

0.0017

0.0020

0.50 0.75 1.00 1.25 1.50 1.75

Basicity (%CaO / %SiO2)

B In

the

Iron

(%)

1550 C

1400 C

0.0005

0.0008

0.0011

0.0014

0.0017

0.0020

0 10 20 30 40 50

Mix 5% Na2O (kg/ton)

B in

the

Iron

(%)

1550 C

1400 C

-4-


boron concentration to 0.0004%; injecting 100 kg/t reduces it to 0. As the temperature is increased, the efficiency decreases. At 1550 oC, injecting about 60 kg/t is needed to reach 0.0004% B.

Figure 4. Effect of Na2CO3 Injection.

When injected, Na2CO3 decomposes to Na2O and CO2 and results in the formation of a Na2O – SiO2 slag (silicon in liquid iron is oxidized by CO2). At high temperature, the efficiency is reduced due to the vaporization of sodium and other compounds.

4.0 CONCLUSIONS AND RECOMMENDATIONS Based on thermodynamic calculations for boron removal in Ductile Iron melts, the following conclusions can be drawn:

Ø Sodium compounds are efficient to remove boron from liquid iron. Ø A mixture of CaO-SiO2-5% Na2O injected at a rate of 20 kg/t at 1400 oC

allows to reduce the boron content from 0.002% to 0.0011%; increasing the amount injected to 40 kg/t allows to reach 0.0008%.

Ø Na2CO3 is very efficient to remove boron; when injected at a rate of 20 kg/t at 1400 oC, the boron content decreases from 0.002% to 0.0004%.

Ø In both cases, increasing the liquid metal temperature decreases the efficiency of the boron removal process.

0.0000

0.0004

0.0008

0.0012

0.0016

0.0020

0 20 40 60 80 100 120

Na2CO3 (kg/ton)

B in

the

Iron

(%)

1550 C

1400 C


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AFS Plays Key Role in Helping to ShapeFinalized U.S. EPA MACT Standards

Des Plaines, Illinois…The American Foundry Society (AFS) 10E MACTAd-hoc Committee was successful in its efforts to work with the U.S.Environmental Protection Agency (EPA) on a rule to regulate theemissions of hazardous air pollutants (HAPs) from iron and steel foundries[commonly known as the Maximum Achievable Control Technology(MACT) standards].

The U.S. EPA’s Active Administrator Marianne Horinko signed the finalrule in August, establishing the National Emissions Standards for HAPsfrom iron and steel foundries. The AFS 10E MACT Ad-hoc Committeeworked extensively with U.S. EPA to modify many of the requirements ofthe proposed rule issued in December 2002. Most notably, a controversialprovision requiring a 200 ft/min capture velocity on all local exhaust hoodswas eliminated. Thanks in part to AFS efforts, foundries now are directedto follow good engineering practices in their design of the system.

Table 1 summarizes the requirements of the MACT standards with a copyof the final rule posted on the AFS website at www.afsinc.org.

“These standards will have a great impact on our industry, more so thanwhen the original Clean Air Act was implemented in the early 1970s,” saidCommittee Chairman Gary Thoe, ThyssenKrupp Waupaca Foundry, Inc.

The efforts of the AFS MACT Ad-hoc Committee included a directpresentation to U.S. EPA, weekly conference calls with high-level EPAstaff, extensive written comments and the hosting of metalcasting facilitytours for EPA officials.

For more information on the Iron and Steel MACT Standards, contact GaryMosher, AFS vice president of environmental services, at 800/537-4237ext. 228 or [email protected], or Dwight Barnhard, AFS executive vicepresident, at 800/537-4237 ext. 222 or [email protected].

Headquartered in Des Plaines, Illinois, AFS is a not-for-profit technicaland management society that has existed since 1896 to provide andpromote knowledge and services that strengthen the metalcasting industryfor the ultimate benefit of its customers and society.

Table 1. This chart summarizes the finalized MACT Standards.




http://www.afsinc.org/




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MODERN CASTING / October 2003 13

INDUSTRY NEWSVisit MODERN CASTING’s Late-Breaking Metalcasting News at www.moderncasting.com

Compiled by Jim White, Grede Foundries, Inc. Reviewed by AFS MAHC Steering Committee.

Iron and Steel MACT Rule Synopsis (download a larger version at www.moderncasting.com)Final rule signed August 29, 2003

Emission Emission Limit or Comment Monitoring Compliance ComplianceSource Work Practice Standard Requirements Demonstration DateCupolas Existing PM limit of 0.006 gr/dscf or Broken bag detectors, Initial compliance stack test 3 yr fromCupolas total metal HAP of 0.0005 gr/dscf P, etc. (Note 1) (Note 2) repeated at least every 5 yr rule publicationNew Cupolas PM limit of 0.002 gr/dscf or Broken bag detectors, Initial compliance stack At start-up

total metal HAP of 0.0002 gr/dscf P, etc. (Note 1) test (Note 2) repeated at of new cupolaleast every 5 yr

All new & VOHAP limit of 20 ppmv Afterburners at ∞ 1300F Afterburner Initial compliance stack 3 yr for existingexisting Cupolas (corrected to 10% O2) (15 min. avg.) (Accommodations temperature test (Note 3) repeated cupolas, at start-up

for start-up and off blast time) (continuous) at least every 5 yr for new cupolasElectric Melting FurnacesExisting Induction PM limit of 0.005 gr/dscf or total Broken bag detectors, Initial compliance stack 3 yr from& Electric Arc metal HAP of 0.0004 gr/dscf P, etc. (Note 1) test (Note 2) repeated rule publicationFurnaces at least every 5 yrNew Induction PM limit of 0.001 gr/dscf or total Broken bag detectors, Initial compliance stack At start-up forFurnaces metal HAP of 0.00008 gr/dscf P, etc. (Note 1) test (Note 2) repeated at new furnaces

least every 5 yrNew Electric PM limit of 0.002 gr/dscf or total Broken bag detectors, Initial compliance stackArc Furnaces metal HAP of 0.0002 gr/dscf P, etc. (Note 1) test (Note 2) repeated

at least every 5 yrAll Melting Furnaces

Scrap Certification or Supplier Certification: No post-consumer 1 yr from ruleautomotive scrap, oily turnings, plastics, publicationmercury switches, lead or organic liquids.

Scrap Selection and Supplier certifies no Hg switches or Pb components Written plan with Certify that plan has 1 yr from ruleInspection Program and foundry inspects all incoming scrap heavy on-going been prepared publication

according to written program and procedures. documentationAlso restrictions on oil and free liquids.

Scrap PreheaterExisting Scrap PM limit of 0.005 gr/dscf or total Broken bag detectors, Initial compliance stack 3 yr from rulePreheaters metal HAP of 0.0004 gr/dscf P, etc. (Note 1) test (Note 2) repeated at publication

least every 5 yra) VOHAP limit of 20 ppmv (good Implies afterburner if not b) of c), Initial compliance stack 3 yr from rule publicationengineering capture system or test (Note 3) Certify direct 3 yr from rule publicationb) Direct contact gas-fired preheater or if not direct contact = afterburner flame contact type 1 yr from rule publicationc) Scrap Certification

New Scrap PM limit of 0.001 gr/dscf or total Broken bag detectors, Start-up performance At start-up ofPreheaters metal HAP of 0.0008 gr/dscf P, etc. (Note 1) testing (Note 2) repeated new preheaters

at least every 5 yrVOHAP limit of 20 ppmv (good engineering Possible afterburner, if not heavy Initial compliance stack test 1 yr from rule publicationcapture system) or scrap certification flame penetration or scrap certification (Note 3) Certify that plan has

been preparedPouringExisting Pouring PM limit of 0.010 gr/dscf or total If existing emissions discharged to the Broken bag detectors, Initial compliance stack 3 yr from ruleStations metal HAP of 0.0008 gr/dscf atmosphere through a “conveyance) P, etc. (Note 1) test (Note 2) repeated publication

at least every 5 yrNew Pouring PM limit of 0.002 gr/dscf or total metal If emissions discharged to the atmosphere Broken bag detectors, Start-up performance testing At start-up forStations or pouring areas HAP of 0.0002 gr/dscf through a “conveyance” P, etc. (Note 1) (Note 2) repeated at least new lines

every 5 yrMold Vent Light-Off Mold vents spontaneously ignite or they Contains procedures for igniting mold vents Documentation required. Certify that plan has 3 yr from rule publication

are manually ignited at pouring stations and areas if it is determined been preparedthat they do not spontaneously ignite.

Fugitive Emissions Building opacity 20% opacity, except Applies to all building openings (desired to Formal opacity readings Initial opacity reading 3 yr from rule publicationfrom a building for one 6-min period per hour that does monitor uncollected pouring, (Note 4) repeated everyor structure not exceed 27% opacity. cooling & shakeout) 6 months thereafterCooling and Shakeout Emissions must be captured.New Cooling and VOHAP limit of 20 ppmv For automated conveyor and pallet lines Continuous Emissions Start-up performance At start-upShakeout lines (flow weighted average) that use sand mold systems or automated Monitoring stack test

shakeout lines that use sand mold systems (CEMS) requiredWritten PlansOperation & Describes capture and control systems, lists system Also must contain many details of Routine documented Certify that plan has been 3 yr from rule publicationMaintenance Plan parameters appropriate to evaluate performance system, including damper settings, inspections. prepared and that the

and establishes operating limits for those parameters. gauge settings, test points, etc. foundry will operateThe plan also must include requirements for system equipment according toinspections, PM procedures (with schedules), and the plan. Semiannualprocedures for corrective actions. Bag leak detectors deviation reports.required on all collection devices with PM limits.Mold Vent Light Off Contains procedures for igniting mold vents Documentation required. Certify that plan has been 3 yr from rule publication(Part of O & M Plan) at pouring stations and pouring areas if it is prepared. Semiannual compliance

determined that they do not spontaneously ignite. certification stating that theprocedures have been followed.

Start-up, Shutdown Must meet requirements of § 63.6 (e) of 3 yr from rule publication& Malfunction Plan NESHAP General Provisions (68 FR 32586,

May 30, 2003)Scrap Selection & See above, under Certify that plan has been 1 yr from rule publicationInspection Plan “All Melting Furnaces” prepared (if plan is required).Furan warm box mold No methanol, as listed in the MSDSof core making (applies to catalyst portion only)Triethylamine (TEA) Control discharge of scrubber to 1 Scrubber parameters, Initial compliance stack 3 yr from rule publicationcoldbox mold or core ppmv TEA or demonstrate a 99% including pH and liquid test repeated atproduction (new or control efficiency (as determined with flow. PH <4.5 measured least every 5 yrexisting facilities) fresh acid solution) at end of shift.

Note 1: Continuous Parametric Monitoring System (CPMS) required. Implies continuous readings available, but does not mandate continuous record. Recording frequency to be described in O & M Plan.Note 2: To determine compliance with the metal HAP emissions limits, EPA Method 1 through 4, and either Method 5, 5B, 5D, 5F or 5I, as applicable (to measure PM) or Method 29 (to measure total metal HAP) are required.Note 3: To determine compliance with the organic HAP limits, use EPA Method 18 to measure VOHAP, Method 25 to measure total gaseous non-methane organics (TBNMO) as hexane, or Method 25A to measure total organic compounds (TOC) as hexane.Note 4: To measure opacity, use EPA Method 9.


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Ten Steps to Improving Casting Yield in DuctileIron Foundries

Norberto T. Rizzo DownesDana de Venezuela S.H. Foundry DivisionValencia, Venezuela

Ramon D. Duque, Sudesh Kannan; SELEE Corporation.Hendersonville, NC, USA

ABSTRACTTen principles or rules for increasing yield in ductile iron castings areproposed. These include use of ceramic foam, shorter gating systems,non-turbulent gating system design, thinner runners and ingates, andproper and efficient use of risers. Many of these techniques have beenreported in the literature. It is suggested that cost-savings achieved byapplication of these principles can be significantly higher than thoseachieved by conventional scrap reduction procedures. Two case studiesoutlining the use of these principles with yield improvements are shown.

INTRODUCTIONSeveral gray iron foundries are slowly adding ductile iron castings in theirrepertoire. Shrinkage and proper micro-structure problems are often theirkey challenges. There is also a misconception that ductile iron castings areoften associated with large risers. It is common to see the bulky gatingdesign of gray foundries combined with large risers contributing tosignificant decrease in casting yield in many ductile iron castings. On theother hand, the primary customer for these foundries (the automotiveindustry) continues to make increased demand for cost reductions andquality improvements. Globalization brings additional factors into play inthese areas. The production engineer in a foundry has now becomeinvolved significantly in the commercial and economic aspects of running afoundry. The foundry process has significant variables and oftenoptimization of competing factors is essential to meet the goals ofproductivity and quality. These efforts, in turn, lead to improved profitabilityof the foundry business unit. This paper outlines ten principles of gatingand riser design that could help the foundry man to show dramaticimprovements in casting yield.

YIELD IMPROVEMENTS VERSUS SCRAP RATE REDUCTIONConventional attempts at reducing costs are often focused on scrapreduction. Yield is often indicated as the ratio of the casting weight to thetotal pour weight. In a hypothetical case, let us consider a casting that hasyield of 48%. If the current scrap level associated with the casting isaround 5%, the effective yield is around 45.6 % (48% *(100-5/100)=45.6%). Let us assume that the yield of that specific casting is increased(by the principles outlined in this paper) to 73% and there is an associatedscrap equal to 10%. The resultant effective yield (considering loss due toscrap) is around 65.7% (73% *(100-10/100)= 65.7%). Thus, the overalleffect of yield improvement can be a more significant cost reduction tool inspite of an increase in scrap levels. The authors do not minimize theimportance of quality improvements and scrap reductions. Scrap reductionthrough process control and continuous improvement is essential for thesurvival for most foundries. It is merely suggested that yield improvementshould also be given due consideration.

Metal weight to mold ratio is often considered important since it indicatesthe volume utilization of the mold for a given casting. The increasedvolumes of cores used in a mold also lead to increased costs. All yieldimprovement efforts should include ways to get additional castings per


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mold and minimize the volume of cores used in each mold.

TEN PRINCIPLES TO ACHIEVE HIGH YIELDThe following ten rules or ideas assist in reducing the gating systemdimensions and volume and result in higher yields without compromisingcasting quality. Two case studies at the end of the paper illustrateapplications of these principles.

1) Use of Ceramic Foam FiltersConventional application of filters is based on reducing the incidence ofscrap related to inclusions. However, the proper use of ceramic foam filtersin the runner system can help reduce the length of the runner and gates[1]. Flow modification can help reduce turbulence in the gating system andconsequently the formation of reoxidation slag. Long runners and ingatesare not needed to act as slag traps. Significant yield increases can, thus,be achieved by shorter runners and ingates.

2) Use of Stable Raw MaterialsOptimum performance is obtained from use of raw materials that minimizevariations in the process. For example, use of carburisers that have acrystalline structure, homogeneous, pure or preferably of natural origin andfree of any major impurities leads to good control of carbon content in theiron [2]. Good control over carbon content, in turn, leads to better controlof shrinkage volume. Figure 1 shows typical ranges of carbon and siliconfor sound castings [7].

Figure 1: Carbon and silicon ranges for sound ductile iron castings [7].

3) Use of Trapezoidal Gate Cross-Sections to Minimize Turbulent FlowAs mentioned above, the use of a ceramic foam filter minimizes the needto use runner and ingate sections as slag traps. Table I compares thegating elements of rectangular, trapezoidal (base= a height =3a, top= a/3to a/5) and triangular cross-section along with corresponding modulus,Reynold's numbers and weight of these cross-sections. The top row hascross-sections that have constant weight per unit length. It can be seenthat the classic rectangular cross-section has the maximum turbulence (asshown by a high Reynold's number)[3]. The lower row consists of gatingcross-sections with the same Reynold's numbers (same associated levelof turbulence). The weight of the triangular cross-section ingate is thelowest. However, the triangular cross-section is not preferred by mostfoundry men since there is a risk of mold erosion in the corners. The verylow modulus of the corners can also negatively affect the solidificationcharacteristics of the triangular ingate. Therefore, these analyses suggestthat a trapezoidal cross-section shown above can give a balance betweengood flow characteristics and lower weight.

Table 1: Comparison among the different types of runners.(Flow = 2.5 Kg/sec.)



Classic Trapezoidal Extended Triangle

Area (mm2) 450 450 450Perimeter (mm) 64.89 110.55 122.68Module (cm) 0.53 0.41 0.37Reynold "Re" 29450.9 22613.4 20378.1Weight(g/25.4mm) 81 81 81

(A): Weight - Const.

Classic Trapezoidal Extended Triangle

Area (mm2) 942 544 450Perimeter(mm) 123 123 123

Module (cm) 0.77 0.44 0.37Reynold "Re" 20353 20395 20378Weight(g/25.4mm) 170 98 61

(B): Re-const.

4) Optimizing Pour Times and Pouring SequenceConventional gating designs often focus on simultaneous filling of allcavities in a mold. This results in large sprues and runner systems neededto deliver the required flow rates. It is suggested that designs that permitsequential filling of cavities can reduce the need for high flow rates,consequently, the gating system can be leaner in size [4].

5) Optimum Gating/Runner Modulus to Control Temperature LossIt is generally known that shrinkage will increase as pouring temperaturesdecrease. The modulii of the gating channels must be kept in mind, sincehigh values (thicker and heavier runners and ingates) decrease the yield.However, too low values (very thin runners and ingates) will cause gatingelements to solidify rapidly and cause localized shrinkage in the castings.Care must be taken to ensure that significant metal temperature loss doesnot take place in the gating system.

6) The Use of Risers to Compensate ExpansionRisers must be considered as compensators (for shrinkage volume). Thesupply of molten metal needed for filling the casting comes from theingates. The objective is to avoid the over pressurization that generatesthe expansion during the solidification producing the formation ofsecondary shrinkage. The application of this concept allows the use ofsmall risers improving the casting yield [5,6]. Periodic sectioning andexamination of the risers is essential to verify that the risers are workingas designed. The volume of metal fed by each riser should be determined.

7) Placing Risers at Optimal LocationsIt is important to analyze the critical sections of a casting to ensure thatsolidification progresses in a logical fashion. The use of risers at keylocations to ensure a sound casting cross-section is essential. Figure 2shows sectional views of a carrier housing casting and the basis forlocating risers. The modulii of various sections are grouped together for



feeding by two risers. Feeding distance of each riser should be consideredwhen deciding on the location and position of the risers.

Figure 2: Positioning of risers based on modulii of important castingcross-sections.

8) Use of a Riser for More than One Casting (Whenever Possible)When a system allows, a design factor that allows for improvement of theyield, is sharing a riser with several castings, since its function is based onits modulus; and only the size needs to be adjusted to achieve therequired feeding volume to the castings.

9) The Use of Top RisersIn vertical molding systems, it is relatively simple to locate the top risers,but in a horizontal molding system, the situation is more complicated. Theapplication of these kinds of risers in both cases, allows the handling ofappropriate feeding volume (based on the difference between the riserheight and the cope height) with smaller size riser contributing toincreased yield.

10) The Use of Hot RisersHot risers are very efficient. The volume of metal that can be delivered tothe casting is significantly larger than the volume supplied by a cold riser.Consequently, the riser volume tends to be smaller. As mentioned earlier,periodic examination of riser sections is necessary to determine theefficiency and effectiveness of the risers.

CASE STUDIESWhile these case studies are specific to vertically parted molds, theprinciples can be used in horizontally parted molds also.

Example A Carrier Housing CastingFigure 3 shows the initial and final gating designs for a carrier housingcasting. Initial yield was 64% with three cavities per mold. The tenprinciples outlined above were applied to this mold. The main changesinclude placing a ceramic foam filter under the sprue, thinner ingates andreduced cores. The use of smaller top risers also helped in yieldimprovements. A final yield of 80% with four castings per mold wasachieved.



Figure 3: Illustration of a carrier housing casting.

Example B Differential Case CastingFigure 4 shows the initial and final gating designs for a differential casecasting. Initial yield was 58% with only eight castings per mold. The runnerand in-gate cross-sections were calculated based on Reynold's numbers(as outlined in Table I). In addition to placing a ceramic foam filter,extensive redesign of the hot risers were performed. The hot risers at themiddle level were 10% smaller as compared to the hot risers at the toplevel and 10% larger than the bottom level. The design, thus, used theadvantages of metallostatic pressure at the lower levels. The averageweight of the riser reduced from 1.2 Kg to 0.8 Kg. The final yield was 71%with 12 castings per mold.

Figure 4: Illustration of differential case casting.

CONCLUSIONSTen principles to improve yield in ductile iron castings have been outlined.Process improvements for scrap reduction are important. Process controlis essential for consistent quality. The focus of this paper has been tosuggest the possible benefits of cost reduction that can be achieved byyield improvements.

ACKNOWLEDGMENTS

The authors would like to thank their respective companies for theresources provided and permission given to publish this work. Specialthanks are due to Ms. Annie Demps of SELEE Corporation for her



assistance in preparation of this manuscript. We also wish to thank Mr.Luis Labrador, Mr. Gustavo Tirado, and Ms. Gabriela Toro of C.A.Danaven, Div. S.H.

REFERENCES

1. Aubrey L.S., Brockmeyer J.W..Wieser P.F., "Removal from Ductile Ironwith Ceramic Foam Filters" Transation 85-21 pp71-76. (1985)

2.Lloyd Thomas " Economic and Operational Considerations in the Use ofCarbon Charging Materials in Ferrous Metal Casting" .BCIRA BroadsheetNo.132, 1986

3. F.J. Bradley, J.A. Hoopes, S. Kannan, J.V. Balakrishna, S.Heinemann, "A Hdyraulics-based model of fluid flow in horizontal gating systems", AFSTransactions 92-101, p 917-923

4. C.R. Loper. Jr. AFS Transactions "Sequential Filling off Mold Cavities".1981 (81-07) AFS Gating and Risering of Cast Iron Vol. 1 Pg, 1-4

5. S.I. Karsay Ductile Iron III, Gating and Risering, Qit-Fer Titane.inc(1981).

6. S. I. Karsay, Encyclopaedia of Design Logic, Qit-Fer Titane.inc (1981).

7. Ductile Iron Handbook, American Foundrymen's Society Inc., (1999).

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Cost Reductions through Direct Pouring onAutomatic Horizontal Molding Machines

R. SmarsGrede Foundries, Inc., Liberty Division, Milwaukee, Wisconsin

T. TackaberryFoseco Metallurgical Inc., Cleveland, Ohio

ABSTRACTThe yield improvements and cost reduction advantages of direct pouringcombined with the quality and scrap reduction benefits of ceramic foamfiltration are widely recognized and accepted by ductile iron foundries.However, mold accessibility and space limitations on some automaticmolding equipment can complicate and limit the application of direct pourunits.

This paper describes a direct pouring system for iron that brings thequality improvements of reticulated ceramic foam filtration and the cost-reduction benefits of direct pouring to users of automatic horizontalmolding lines. Application of this system is illustrated in examples ofductile iron castings produced at Grede Foundries, Inc., Liberty Division,Milwaukee, WI.

Each of the castings was originally produced using a conventional gating,risering and in-line filtration system. After redesigning the patterns toincorporate direct pouring, castings were subjected to destructive and non-destructive testing and found to be 100% sound. Substantial casting yieldimprovements, scrap reductions, reduced shakeout and despruing times,as well as metal utilization improvements were noted.

INTRODUCTIONThe effectiveness of conventional gating systems, designed to allowinclusions to float out of the molten metal stream and attach to runnerwalls, can be improved by the addition of in-line ceramic foam filters.However, these traditional gating, risering and filtration systems consumevaluable space on the production pattern plate that might otherwise bedevoted to producing additional castings.

Direct pouring utilizing a specially designed feeder sleeve containing aceramic foam filter can eliminate conventional gating system components,leading to yield improvements, increased productivity and cost reduction.Direct pour units designed for use with horizontal automatic moldingequipment can overcome pattern plate accessibility limitations that have, inthe past, restricted the use of direct pouring on automatic moldingequipment.

DIRECT POURINGIn direct pouring, the mold cavity is filled with molten metal without the useof a conventional sprue, runner or ingate system. Liquid metal is poureddirectly though a riser at the top or side of the casting cavity. In fact, thedirect pouring unit replaces the pouring cup, down sprue, runner, ingate,contact and riser. As a result, substantial yield improvements can beattainable, as well as improved directional solidification characteristics.

KALPUR direct pouring units have been developed that consist of aspecially designed insulating sleeve containing a reticulated ceramic foamfilter.

Filtration Effectiveness


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The reticulated foam filter presents a tortuous path through which themetal must pass. Oxides and other suspended non-metallics are trappedon the surface of the filter or become entrained within the filter bodypores. The fluid flow pattern developed in each pore results in theentrained particles becoming trapped within these circulating currents.Should a random particle find its way out of one pore, it travels intoanother pore and so on, thus preventing the particle from escaping thefilter. As a result, the reticulated foam filter is capable of trapping oxideparticles significantly smaller than the open area of the pores.

The second predominate characteristic of the ceramic foam filter is that itefficiently reduces metal turbulence, thus eliminating the reoxidation of themetal stream. As water models and metal radiographs demonstrate, whenliquid iron passes through a Pressed or Extruded Filter, considerable metalsplash is generated, resulting in reoxidation of the metal stream. Incontrast, the ceramic foam filter (Figure #3) encourages smooth laminarmetal flow on exiting the filter, without generating excessive splash or airentrainment.

Pressed Filter Extruded Filter Ceramic

Fig. 3 Water modeling shows thedegree to which various iron

filtration media reduce turbulencein aerated water.

Foam Filter

Insulating SleeveThe insulating sleeve allows the metal contained in the riser to remain in amolten state longer, thus increasing the modulus and volumetric feedcharacteristics of the riser. Moreover, the direct pouring unit becomes thepouring cup, down sprue, riser, and filter support.

Two basic types of direct pouring unitsThe conventional direct pouring unit (Figure 1) istapered from top to bottom and is designed foruse in casting operations where there is accessto the top of the cope. The direct pouring unit canbe inserted in a molded cavity after the mold is



Fig. 1 Direct pour unitfor molds where top ofcope is accessible.

Fig. 2 Direct pour unit for horizontalautomatic molding.

Fig. 4 A special riser bob creates a cavityfor insertion of the reverse-taper unit.

formed or may it be rammed up in position whenreinforced with a removable plug.

The second type (Figure 2) is a reverse-taperunit designed for use in automatic horizontalmolding applications, where normally no copeaccess is allowed. The reverse-taper (RT) unitcan be inserted into the cope mold; or, withmolding machinery where the cope mold is notaccessible, the direct pour unit can be placed on

the drag mold half, or on a cover core package, and is closed over like acore.

REVERSE-TAPER APPLICATIONMETHODSThe reverse-taper direct pouringunit contains a ceramic foam filterthat is located in the top of the risersleeve and held in place by heat-shrink tape. This eliminates theneed to handle loose filters, and thetape volatilizes upon contact withthe molten metal. The riser sleeveis made of a highly insulatingmaterial. This allows the metalcontained in the sleeve to remain ina molten state longer, thusincreasing the modulus andvolumetric feed characteristics ofthe riser.

Reverse-taper units may be positioned at the base of the downsprue asside risers or positioned directly above the casting as top risers. Reverse-taper units can be easily inserted into rotated cope molds, inserted intocope molds using an insertion tool, or placed on the drag half of the moldand closed over.

Insert TechniqueIf the cope is accessible (asis the case with certainmolding machines that rotatethe cope 90 degrees aftersqueezing), the unit can bemanually inserted into aspecial riser bob cavity.

The riser bob (Figure 4) iscombined with a sprue toproduce the mold cavityneeded for insert applicationof the reverse-taper directpour unit into the cope mold.Crush strips, molded into thecavity formed by the riserbob, may be used to retainthe unit while the mold isrotated and closed. (Figure5).

Close-over TechniqueIn close-over applications,



Fig. 5 The reverse-taper unit may bemanually inserted into a rotated copefor top feeder applications.

multiple positions for the pouringbasin/cup are available acrossthe squeeze plate (head board)to accommodate various patternplate layout configurations.During molding, the cope frameis filled with green sand and thesqueeze cycle compresses thegreen sand, forming the pouringcup, sprue and reverse-taperdirect pour unit cavity. After themold is made, the direct pourunit can be set into a slightrecess print that is created inthe drag pattern. The cope canthen be closed over the unit (Figure 6).

Fig. 6 For close-over, side-feeder applications, the reverse-taper unitis positioned in a molded recess in the drag prior to closing themold.

FEEDING AND MODULUSThe "geometric modulus" or feeding capacity of the reverse-taper unitsleeve is equal to the feeding capacity of an exothermic/insulating feederof the same size. The ceramic filter does not affect the unit's feedingefficiency.

However, the "system modulus" or feeding capacity of the reverse-taper-sleeve/sprue/basin combination is increased since the sprue and pouringbasin metal function as part of the feeding system (See Figure 4). Duringsolidification, the metal in the pouring basin and sprue freeze off first, andthe balance of the feeding is done by molten metal contained in theinsulating sleeve.

If the filtration capacity and flow rate of the unit are suitable for theapplication, the system modulus will normally be more than adequate tofeed the casting. The only possible exception being heavy-section, cube-like shapes.

For side-gated applications that may be used to pour/feed single ormultiple castings, the unit should be mounted on a suitable riser base,close to the casting cavity or cavities. (See Figure 7)



Fig. 7 In this side-gated application, the reverse-taper unit ismounted on a riser base close to the casting.

Connecting feeder necks/gates should be sized to promote efficientfeeding. Proper sizing of the feeder neck/gate is a function of the castingor section modulus and is unaffected by the application of the reverse-taper direct pour system. As the foundry gains experience in theapplication of reverse-taper units, the advantage of a "live" neck/gatecondition can reduce neck contacts.

In a correctly sized runner system, the sprue itself functions as the choke,thus producing an unpressurized system that prevents the metal fromspraying into the casting cavity. This also allows for faster pouring sincethe foam filter controls head pressure and dampens the metal velocitycausing it to enter the casting with minimal turbulence.

UNIT SIZE SELECTIONIn most applications, the size of the reverse-taper unit selected isdetermined by the filtration capacity (total weight of metal that can passthrough the filter before blockage occurs) and flow rate (weight of metal itwill pass per second) of the filter attached to the sleeve. Considerationmust also be given to the feed volume requirements of the casting -keeping in mind that the pouring cup/sprue will be part of the feeder forthe early stages of feeding.

Filtration capacity and flow rate of the ceramic foam filter are affected bythe porosity of the filter, metal temperature, metal cleanliness, melting andinoculation practices, alloy composition and pouring method. Reverse-taper units with 10 ppi (pores per linear inch) filters are recommended forductile iron applications and units with 20 ppi filters, for gray ironapplications.

As mentioned above (See FEEDING AND MODULUS), if the filtrationcapability of the unit is satisfactory for the casting, the "system"modulus/feeding capability will normally be large enough to support thecasting solidification requirements.

GREDE FOUNDRIES, INC. LIBERTY DIVISION

FOUNDRY HISTORY:



Grede Foundries, Inc., Liberty Division is located at 6432 West StateStreet, Wauwatosa Wisconsin. It was purchased by Grede Foundries in1920 and specializes in producing ductile iron castings that have complexinternal shapes, and require close dimensional tolerances. The foundryproduces approximately 3000 tons of ductile iron and high-silicon moly ironcastings per month. The iron is melted in three 5-ton Brown-Boveri electricfurnaces and transferred into a 1600-lb. capacity tundish ladle where anaddition of 5% magnesium ferrosilicon with a 75% silicon covernodularizes the iron. The iron is manually poured using 700-lb. teapotpouring ladles, equipped with ladle harnesses and gearboxes.

Grede Liberty produces castings on two molding lines. A 20" x 24" 8" over8" flaskless Robert Sinto automatic molding machine produces castingswith pour weights to 115 lbs. and a production rate up to 125 molds perhour. The second molding line is a 20" x 20" to 36" x 36" pin-lift, cope-and-drag flask molding machine and produces castings with pour weightsup to 160 lbs. with a production rate up to 20 molds per hour. Isocyanatecold-box cores and shell cores are used. The sand system for bothmolding lines targets a green sand compactability of 40, permeability of90, moisture of 3.5% and a methylene blue of 8.5-9.5. Internal castingcores are produced from Isocyanate cold-box using various core blowersand from shell sand.

Grede Liberty has employed conventional runner systems with in-linefiltration for many years. While casting quality has been satisfactory, thedesire to increase casting yield, reduce shakeout and cleaning room time,as well as metal utilization led to the consideration to experiment withdirect pouring units. However, because of the configuration of the RobertSinto Molding Machine, it was difficult to employ conventional directpouring units, thus the reverse-taper direct pouring units were selected fortrial.

CASE STUDY #1This planetary gear carrier is produced in 65-45-12 ductile iron and has acast weighing 9.88 lbs. The production pattern contains four castingimpressions and is produced on the Robert Sinto Molding Machine. Thetarget pouring temperature is 2550ºF and the target pouring time is 6.0seconds. This casting was originally produced using a conventional, non-pressurized gating and filtration system. The filter was located horizontallyat the base of the sprue and the short drag runner connected the gatingsystem to a greensand riser. Ingates contained in the core packageconnect the castings to the common green sand riser.

The pour weight of the original system was 79 lbs., producing a yield of50%. The pouring time for this system averaged 7.5 seconds. Using the700-lb. teapot ladles, it was possible to pour eight castings per ladle,leaving a 68-lb. heel.

Original Cope



Original Drag

To achieve the desired yield improvement, the pattern was re-engineeredto replace the conventional filtered runner system with a 5/8 L10 reverse-taper direct pour unit. The modified pattern plate layout centrally locatedthe reverse-tapered direct pour unit as a side riser between the corepackages. The drag pattern was modified to create a riser basin and aprint into which the reverse-taper direct pour unit could be set. Attached tothe cope pattern was the riser bob required to form the cavity for closingover the direct pouring unit. The pouring basin / pouring cup waspositioned on the plate to match the location of the sprue. Ingatescontained in the core packages connect the four castings to the directpouring unit.

The original feeder was eliminated, along with the sprue, sprue basin, filterand runner bar. The reverse taper direct pour unit was sized to provideadequate modulus and volumetric feed capacity for all four castingcavities.

New Direct Pour Cope

New Direct Pour Drag

The reverse-tapered pouring unit reduced the pouring weight from theoriginal system of 79 lbs. to 55 lbs. and increased the yield from 50% to71.8%. The pouring time was also decreased from an average of 7.5seconds to 6.0 seconds. With the original system the 700 lb. teapot ladleswere only able to pour eight molds (32 castings) per ladle, leaving a 68 lb.heel. However, with the reverse direct pouring system it is now possible topour twelve molds (48 castings) from each 700-lb ladle, leaving a 40 lb.



heel. X-ray examination of the direct poured castings indicated no internaldefect, confirmed by quarter-sectioning and visual examination of the pilotrun.

Four carrier castings from the direct pour pilot run were sectionedand found to be 100 percent sound.

CASE STUDY #2This gear blank casting is produced in 70-50-03 ductile iron and has acast weight of 27.24 lbs. The production pattern contains two castingimpressions and is produced on the Robert Sinto Molding Machine. Thetarget pouring temperature is 2550ºF and the target pouring time is 8.0seconds. This casting was originally produced using a conventional non-pressurized gating and filtration system. The filter was positionedhorizontally in the runner bar between the sprue basin and the castingingates. The short curved runner connected the gating system to the to agreen sand riser. Ingates contained in the core package connect thecastings to the common green sand riser. The original pour weight was 84lbs., for a yield of 65.8%.

Original Cope

Original Drag

To increase the yield on this casting, the pattern was re-engineered toreplace the conventional filtered gating system with a 6/9 L10 reverse-taper direct pour unit. The reverse-tapered direct pour unit was positionedas a side riser adjoining both casting cavities. The riser bob used to createthe close-over mold cavity for the direct pouring unit was positioned ontothe cope pattern. The pouring basin was positioned on the plate to match



the sprue/riser bob pattern. The drag pattern was modified to create ariser basin and a print into which the reverse-taper direct pour unit couldbe set at the same time the cores were being set.

The original feeder was eliminated, along with the sprue, the two-sectionrunner bar, the filter and the filter print. The direct pour unit was sized toprovide adequate feeding capacity for both casting cavities.

New Direct Pour Cope

New Direct Pour Drag

The reverse direct pour system reduced the pour weight from 84 lbs. to 70lbs., for a new yield of 79 %. Also, the average pouring time was reducedfrom 8.0 seconds to 6.5 seconds. In addition to increasing the yield of the2-on configuration, the new direct pour system reduced the amount ofpattern plate area consumed, to the point that a third casting cavity could,and in several cases has been added.

The overall productivity of the foundry's casting operation was alsoincreased without any modification to melting or molding capacity. Themelt shop is limited to tapping 1600 lbs. of metal every eight minutes, or12,800 lbs. per hour. With the new reduced pour weight of 70 lbs. andrunning at 120 molds per hour, this leaves 4,400 lbs. of metal for the other(flask) molding line. At the original pour weight of 84 lbs., this would onlyleave 2,270 lbs. for the flask line, often not enough to run the flask line atfull capacity (20 molds/hr. x 160 lb./mold = 3,200 lb./hr.).

SUMMARY AND FOUNDRY EVALUATIONThe reverse-taper direct pouring system which contains a ceramic foamfilter, allows users of automatic horizontal molding lines to experience theproduction savings of high-volume molding, yield improvements, increasedpattern productivity and reduced cleaning expenses of direct pouring. Thus,the result is an overall increase in productivity, and improved foundryprofitability.

ACKNOWLEDGEMENTSThe authors wish to thank Grede Foundries Inc., Liberty Division, andFoseco Metallurgical Inc. for their cooperation in the development, testingand application of the reverse-taper direct pouring system and for theirsupport in the preparation of this paper.



REFERENCESAdam, A., "KALPUR direct pouring systems," Foundry Practice, Issue 227, (April 1996)Jeffs, P., "Aluminum casting productivity increases with predictive techniques," Foundry Practice, Issue 226, (July 1995)Midea, A.C., "Pressure Drop Characteristics of Iron Filters," AFS Transactions, 01-042 (2001)Moffat, G.L.; Ecob, C.M.; "Stelpur--A Novel Concept in Direct Pouring Feeding and Filtration of Steel Castings," Presented at the 35th SCRATA Conference, Sheffield, England, (May 1992)Moffat, G.L.; Loperfido, B.C.; "Reverse-Taper Direct Pouring System for Iron," Presented at the 2003 AFS Casting Congress, Milwaukee, Wisconsin, USA, (May 2003)Outten, J., "KALPUR for steel Direct Pouring System Improves Yield, Productivity, and Quality," Foundry Practice, Issue 227, (April 1996)Sandford, P., "Advances in the production of high yield aluminum castings using DYPUR technology," Foundry Practice, Issue 224, (March 1993)

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Influence of Section Sizeon the Machinability of Ductile Irons(Observations on the Machinability of Ductile Irons)

P. Cohen and R. VoigtThe Pennsylvania State UniversityUniversity Park PA 16802 USA

The link below opens an Acrobat file of the above article. Embedded inthe article are movies that show the machining in action.

Influence of Section Size on the Machinability of Ductile Irons

The Adobe Acrobat reader is a free program that you can download fromthis website: www.adobeacrobat.com.

You can use the Windows Media Player to view the movies. The Player isa free program that you can download from this website:

www.windowsmediaplayer.com.




http://www.adobeacrobat.com/

http://www.windowsmediaplayer.com/


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Survey of Ductile Iron Practices American Foundrymen’s Society

Committee 5-L, Molten Metal Processing Please take a few minutes to complete the following AFS survey, or route the survey to the appropriate person in your organization. All data will be treated as confidential for AFA committee use only. Check or fill-in those items that pertain to your operation: ( ) Tons of metal treated per week:

( ) 1.2 Greater than 200 tons treated/week ( ) 1.2 Less that 200 tons treated/week

Principle Type Castings Produced:

( ) Automotive ( ) Farm Machinery & Equipment ( ) Truck ( ) Pole Line Hardware

( ) Pressure pipe ( ) Valves & Fittings ( ) Other, describe _________________________

Melting Unit(s):

( ) 3.1 Cupola: How Many?_______ 1) Melt zone diameter___ inches 2) Melt zone diameter____ inches

( ) 3.1.1 Liningless/water wall ( ) 3.1.5 Slag separator

( ) 3.1.2 Refractory lined ( ) 3.1.6 Acid Slag, B < 0.9

( ) 3.1.3 Front Slagger ( ) 3.1.7 Basic Slag, B > 1.1

( ) 3.1.4 Rear Slagger ( ) 3.1.8 Neutral Slag, B 0.9 – 1.1

( ) 3.2 Coreless Induction: How many?____ Size:_______tons, Power_______Kw

( ) 3.3 Channel Induction: Vert ( ) Horiz ( ) How many?____ Size:_______tons, Power_______Kw

( ) 3.4 Direct Arc: How many?____ Size:_______tons, Power_______Kw

( ) 3.5 _______________________________ How many?____ Size:_______tons, Power_______Kw

Holding Unit(s):

( ) 4.1 Channel Induction: Vert ( ) Horiz ( ) How many?____ Size:_______tons, Power_______Kw

( ) 4.2 Coreless Induction: How many?____ Size:_______tons, Power_______Kw

( ) 4.3 Direct Arc: How many?____ Size:_______tons, Power_______Kw

( ) 4.4 Forehearth: How many?____ Size:_______tons, Power_______Kw

( ) 4.5 _______________________________ How many?____ Size:_______tons, Power_______Kw

Desulfurization:

( ) 5.1 None

( ) 5.2 Name the method used? _______________________________________ ( ) Batch ( ) Continuous

( ) 5.3 Amount of iron desulfurized? Batch_____lbx. Mins/batch______ Continuous_____________T/hr.

( ) 5.4 Type(s) of desulfurizer used? 1)______________________2)_____________________________

( ) 5.5 Typical percent of desulferizer used? 1)_________________% 2)_________________________%

( ) 5.6 If gas stirring, type gas ____________________ Rate of usage ________________ft3/ton iron.

( ) Typical iron temperature at desulfurization? ___________________%F

4/16/98 SURVEY.DOC

Iron Chemistry (typical):

Location % TC % Si %S %Mg %Cu %Cr %Mn At melter tap – Pearlitic NA At melter tap – Ferritic NA After Desulferization NA NA NA NA At Holder – Before Mg Treatment NA NA NA NA After Mg treatment In last casting/pipe poured in batch

6.1 Any Special Charge Material Selection? Describe_________________________________________

____________________________________________________________________________________

6.2 Time after Mg treatment that %Final Mg sample taken? ___________ minutes

6.3 Name the grade(s) of iron poured: ____________________________

Alloys added between the melter and the holder: (Enter “NONE” if none used)

( ) 7.1 Alloys added for chemistry trim

( ) 7.1.1 FeSi Typical amount added?________________ lbs./ton

( ) 7.1.3 Graphite Typical amount added?________________ lbs./ton

( ) 7.1.4 Typical amount added?________________ lbs./ton

( ) 7.2 Alloys added for preconditioning (if preconditioning is practiced):

( ) 7.2.1 FeSi Amount added?______________ lbs/ton

( ) 7.2.2 SiC Amount added?______________ lbs/ton

( ) 7.2.3 Graphite Amount added?______________ lbs/ton

( ) 7.2.4 ___________________ Amount added?______________ lbs/ton

Mg Treatment: (Enter “NA” if not applicable)

8.1 Method used?___________________________ Treatment Vessel type?___________________

Typical fill time:___________________ Do you use a cover/lid on the ladle?________________

8.2 Size of treatment batch?_______________lbs. No. of treatment/hr?______________

8.3 If MgFeSi used: Type_____________________ Size_________________% Mg in alloy__________

8.4 Additives in MgFeSi?__________%Ce____________%TRE(________%Ce in TRE)_____%Ca

_____________%Al_________________________________________________________other(s)

8.5 Is cover material used? ( ) yes ( ) no. Addition rate__________%

Type of cover material?___________________________________________________________

8.6 If Pure Mg used: ASTM Spec.__________Size Spec______________(grams/piece or dimensions)

TRE/Ce source: ________________, and typical addition rate:________%________lbs./treatment

8.7 If Wire used: Size Wire_____mm dia. Wire Content_____________________________________

TRE/Ce source: ____________________, and typical addition rate: ______%_______lbs./treatment

8.8 Nickel Mag Supplement ( ) yes, ( ) no. Analysis: Ni_____%, Si______%. lbs./treatment

8.9 Typical % Magnesium addition_______________________Typical %Mg recovery______________

8.10 Typical treatment temperature?________________________degrees F

8.11 Typical pouring temperatures? First pour_________________o F. Last pour __________ o F.

4/16/98 SURVEY.DOC


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News BriefsMEETINGS - BUSINESS - PEOPLE

MEETINGS

Ductile Iron Production Seminar. Rescheduled for March 16-17, 2004. Itwill be held at the Holiday Inn in Rolling Meadows, IL (3405 AlgonquinRoad, Nine miles NW of O'Hare Airport.) The seminar is organized toinstruct operations people on the basics of producing quality ductile ironcastings. It is also recommended as a refresher course for peopleexperienced in ductile production, who may have become a bit rusty onthe latest practices. Subjects involved in the production of quality ductileiron will be covered. The DIS Technical Director, James D. Mullins is thechairman of the seminar and the lecturers are tops in the field.

Ductile Iron Society 2004 Annual Meeting. June 23-25, 2004 at the DeltaMontreal Hotel in Montreal Quebec Canada. Events include a tour of theQIT Sorel Plant of Rio Tinto.

BUSINESS

INTERMET Announces Plans for New Foundry in MexicoTROY, Mich., September 15, 2003 – In an effort to better serve its globalcustomer base, INTERMET Corporation (Nasdaq: INMT), one of theworld’s leading manufacturers of castmetal automotive components, todayannounced that it plans to build and operate a ductile iron foundry inMexico. This new plant will be located in the Monterrey area and will bededicated to the production of automotive structural and safetycomponents such as steering knuckles, control arms, and brake calipersand brackets, as well as other highly engineered ductile-iron parts.

Construction of the 100,000-square-foot greenfield plant is expected tobegin before the end of the year and be operational by mid-2004. Planscall for two casting lines featuring vertical, flaskless molding, along withmedium-frequency induction furnace melting, a complete coldboxcoremaking operation, and highly automated casting finishing andvalidation. At full production, annual revenue for the plant is expected toreach approximately $40 million, with the potential for expansion in eitherductile iron or INTERMET’s Blue Sand™ aluminum casting process, whichalso is focused on structural components.

“The location of a casting operation in Mexico represents a critical step inINTERMET’s global expansion plan,” said Gary F. Ruff, INTERMET’sPresident and CEO. “This state-of-the-science facility also fits well into ourLASIK Vision strategy since it will utilize existing assets to minimize thecost and time for production startup. In addition, we believe the newfoundry will fill a demand in the Mexican cast-metal industry for safety-critical components supported by the full-service capabilities of INTERMETin research, development, engineering and design.”

INTERMET currently manufactures components for most of the world’sleading automotive OEMs and Tier 1 suppliers, and this new Mexicanfoundry should benefit its increasingly international customer base. Theplant, which is expected to have a significant book of business at startup,has been designed to be highly efficient using lean-manufacturingconcepts and a high level of automation to minimize variability — criticalfactors in the production of highly engineered safety and structuralcastings.


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INTERMET Vice President Jesus M. Bonilla added, “Mexico is a majorplayer in the global automotive industry. A number of automotive OEMsand system/module suppliers have assembly facilities there, but currentlymust import cast components to support their operations. With our newfacility, INTERMET will be positioned to effectively serve our customerbase. The site location in Monterrey, Nuevo Leon, places the plant in aregion close to our major customers, near transportation routes, andprovides a workforce skilled in the manufacturing and technical abilitiesneeded for our industry.”

With headquarters in Troy, Michigan, INTERMET Corporation is amanufacturer of powertrain, chassis/suspension and structural componentsfor the automotive industry. INTERMET’s strategy is to be the world’sleading supplier of cast-metal automotive components. The company hasapproximately 6,000 employees at facilities located in North America andEurope. More information is available on the Internet at www.intermet.com.

This news release includes forecasts and forward-looking statementsabout INTERMET, its industry and the markets in which it operates.Forward-looking statements and the achievement of any forecasts orprojections are subject to risks, uncertainties and other factors that couldcause actual results to differ materially from those expressed. Some ofthese risks and uncertainties are detailed as a preface to theManagement’s Discussion and Analysis of Financial Condition in thecompany’s 2002 Annual Report for the year ended December 31, 2002.Other risk factors include fluctuations in demand for our products in theMexican market, our ability to secure customers for full utilization of theplanned Mexico facility, and construction delays, cost increases or otherproblems that could affect our ability to begin production at the Mexicofacility within the planned timeframes.

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INTERMET Wins New Business in EuropeWill supply new high-volume Citroen vehicle platform with chassiscomponents.

TROY, Mich., September 11, 2003 - INTERMET Corporation, one of theworld's leading manufacturers of cast-metal automotive components,announced today that it will provide front suspension control arms for PSAPeugeot-Citroën's new Berlingo and Xsara Picasso mini-MPVs to be builtin France and Spain. Production of the ductile iron components isscheduled to begin in September 2004 at INTERMET's PortCast Foundryin Porto, Portugal.

"This contract is a reaffirmation of INTERMET's strategy of delivering itsindustry-leading manufacturing and engineering capabilities to a globalcustomer base," said Laurence Vine-Chatterton, president of INTERMET'sEuropean operations. "INTERMET technical personnel from both the U.S.and Europe worked with Citroën to find the right solutions for their uniquesuspension component needs."

INTERMET will supply Citroën with right- and left-hand lower control armsfor the life of the vehicle programs. The contract is valued at over $14million per year.

Jorge Fesch, general manager of INTERMET's PostCast Foundry, said,"Winning this new business reflects Citroën's complete confidence in ourability to manufacture quality safety-critical castings for such an importantvehicle platform. Over the years, our relationship with Citroën and PSA'sPeugeot division has resulted in many programs for INTERMET."

Currently, INTERMET supplies chassis and power train components forthe Citroën C3, C5 and C8 models as well as for Peugeot's 26, 307, 406,and 807 models, among others. More than half of all light vehicles on the



road in Europe use INTERMET-produced castings.

With headquarters in Troy, Michigan, INTERMET Corporation is amanufacturer of power train, chassis/suspension and structuralcomponents for the automotive industry. INTERMET's strategy is to bethe leading supplier of cast-metal automotive components in the world. The company has more than 6,000 employees at facilities located in NorthAmerica and Europe. More information is available on the Internet atwww.intermet.com.

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INTERMET TO OPEN SECOND PCPC™ MANUFACTURING PLANTNew business necessitates additional production capacity

TROY, Mich., November 10, 2003 - INTERMET Corporation (Nasdaq:INMT), one of the world's leading manufacturers of cast-metal automotivecomponents, today announced that it will open a second casting plantdedicated to the company's new PCPC™ (Pressure-Counter-PressureCasting) process. The plant is located in Jackson, Tennessee, adjacent toone of INTERMET's existing aluminum casting facilities, and initially willsupport a new steering knuckle program for the Dodge Durango beginningin June of next year.

The company's first PCPC plant in Stevensville, Michigan, which beganaluminum steering knuckle production in 2001 for a large General Motorslight-vehicle platform, is continuing at full capacity.

"The expansion of our PCPC process to Jackson is further confirmation ofINTERMET's leadership in providing innovative casting solutions thatdeliver competitive advantages for a growing base of customers," saidGary F. Ruff, President and CEO of INTERMET. "Our strength continuesto be in our ability to ensure that we have the ideal manufacturingcapability at the right place and at the right time."

When completed, the plant will feature PCPC cells designed toaccommodate larger aluminum structural components such as suspensioncontrol arms and light-truck steering knuckles. It is being designed withthe latest developments in lean manufacturing and one-piece workflow.The plant will have the capacity for up to 20 casting cells and heat-treatment systems. Fully equipped metallurgical laboratories and real-timeX-ray systems with automatic inspection also will be in place to helpsupport the manufacturing programs. Initial castings from the firstmachines installed in the 75,000 square-foot plant were made last week.

"We believe this plant is another example of INTERMET's ability toimplement our LASIK vision for the company," said Thomas Prucha,INTERMET's Vice President of Technical Services. "We took an existingbuilding that was constructed in 1999 and had aluminum melt and othersupport equipment already in place, and strategically redirected it toward anew INTERMET advanced process. It demonstrates the flexibility of ourteam, and that we can embrace new technologies while delivering resultsin a short timeframe."

With headquarters in Troy, Michigan, INTERMET Corporation is amanufacturer of powertrain, chassis/suspension and structural componentsfor the automotive industry. INTERMET's strategy is to be the world'sleading supplier of cast-metal automotive components. The company hasapproximately 6,000 employees at facilities located in North America andEurope. More information is available on the Internet at www.intermet.com.

Asia Pacific Investments a Priority for AshlandCasting SolutionsSang Lin (Calvin) Choi named Commercial Manager -China



DUBLIN, Ohio (USA) - To support its burgeoning coldbox business and promote additional growth in the AsiaPacific region, Ashland Casting Solutions has namedSang Lin (Calvin) Choi as commercial manager, China.

"Ashland Casting Solutions is committed to providing local customerservice and production capabilities to its customers worldwide," said RayYates, Ashland Casting Solutions' commercial director, Asia. "Sang Lin(Calvin) is a great asset and his appointment is part of our ongoing capitaland personnel investments in Asia, where we've been operating for nearly20 years."

Prior to his promotion to commercial manager, Choi served as a marketdevelopment specialist at Ashland Casting Solutions' headquarters inDublin, OH. Additionally, Choi has considerable sales experience workingwith various business units of Ashland Specialty Chemical Company inTaiwan and Korea.

Choi has a master's degree in business administration from Fu JenCatholic University (Taiwan) and a bachelor's degree in humanities fromSoonchenhyang University (Korea).

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Ashland Casting Solutions Introduces First New Cold Box Catalyst

DUBLIN, Ohio (USA) - Ashland Casting Solutions has introduced the firstnew catalyst for the ISOCURE™ phenolic-urethane forming cold boxbinder system. ISOFAST® catalyst features an alternative formulation,which provides significant productivity and environmental benefits to thecore-making process over the existing TEA and DMEA catalysts.

The new ISOFAST catalyst is not a hazardous air pollutant (HAP) andtherefore non-regulated under the new MACT standards. ISOFASTcatalyst is more efficient than TEA and results in a catalyst consumptionreduction of 25-50% by weight, while curing cycle times are shortened by35-45%. Additionally, the catalyst provides a more complete initial cure,which reduces the need for core box cleaning. The ISOFAST catalystproduces less odor than other catalysts, improving the core-roomenvironment, and the lower catalyst consumption reduces the volume ofscrubber solution that must be managed. Ashland's establishedISOCYCLE® catalyst recycling program is available for handling spentscrubber solution.

"We are continually learning about our customers' metal castingrequirements and developing solutions that help them achieve success intoday's demanding manufacturing market," said Mike Swartzlander, vicepresident, Ashland Specialty Chemical, and general manager, AshlandCasting Solutions. He added, "Casting Solutions introduced the ISOFASTcatalyst after working closely with our global customers to address specificenvironmental and productivity-related cold box process issues, andseveral major foundries very quickly made the switch."

Ashland Casting Solutions Introduces First New Cold Box Catalyst

DUBLIN, Ohio (USA) - Ashland Casting Solutions has introduced thefirst new catalyst for the ISOCURE™ phenolic-urethane forming cold boxbinder system. ISOFAST® catalyst features an alternative formulation,which provides significant productivity and environmental benefits to thecore-making process over the existing TEA and DMEA catalysts.



The new ISOFAST catalyst is not a hazardous air pollutant (HAP) andtherefore non-regulated under the new MACT standards. ISOFASTcatalyst is more efficient than TEA and results in a catalyst consumptionreduction of 25-50% by weight, while curing cycle times are shortened by35-45%. Additionally, the catalyst provides a more complete initial cure,which reduces the need for core box cleaning. The ISOFAST catalystproduces less odor than other catalysts, improving the core-roomenvironment, and the lower catalyst consumption reduces the volume ofscrubber solution that must be managed. Ashland's establishedISOCYCLE® catalyst recycling program is available for handling spentscrubber solution.

"We are continually learning about our customers' metal castingrequirements and developing solutions that help them achieve success intoday's demanding manufacturing market," said Mike Swartzlander, vicepresident, Ashland Specialty Chemical, and general manager, AshlandCasting Solutions. He added, "Casting Solutions introduced the ISOFASTcatalyst after working closely with our global customers to address specificenvironmental and productivity-related cold box process issues, andseveral major foundries very quickly made the switch."

PEOPLE

Milwaukee, Wisconsin - Grede Foundries, Inc., has named Dan Rhoadsas Vice President of Operations of its Wichita foundry in Wichita,Wisconsin.

Rhoads received a B.S. in Mechanical Engineering Technology fromPurdue University. He has held a variety of positions in engineering,operations, and foundry management. Since 1994, he has served asPlant Manager for Steere Enterprises in Canton, Ohio.

Grede Foundries’ facilities include 9 foundries in the United States and ajoint-venture operation in Mexico called ProezaGrede. The Companyspecializes in ferrous metals: gray iron, ductile iron, stainless steel, andspecialty metal castings. Grede Foundries works with customers in avariety of industries, providing castings for many products, fromautomobiles and construction machinery to farm machinery and equipment,and pumps and compressors. For more information, refer to Grede’s Website on the Internet at www.grede.com.

Kroker Named Global Technology Director for Ashland CastingSolutions

DUBLIN, Ohio (USA) - Ashland Casting Solutions announced today thatDr. Jörg Kroker has been promoted to global technology director. In hisnew role, Kroker will be responsible for global research & development(R&D) for all Ashland Casting Solutions' product lines, including sandbinders, refractory coatings, sleeves and filters. All Ashland CastingSolutions' worldwide lab facilities, including Asia, the Americas andEurope, will now report to Kroker. Additionally, he will manage thetechnical interface with Casting Solutions' joint venture and licenseeoperations.

"Ashland Casting Solutions' technology services continually providesolutions that help a global customer base achieve success in today'sdemanding manufacturing market," said Mike Swartzlander, vice president,Ashland Specialty Chemical, and general manager, Ashland CastingSolutions. "With Jörg at the helm of Casting Solutions' R&D function, wewill continue to launch industry leading solutions that drive futuresuccesses for our customers and integrate into their operations fromdesign to pour."

Luca Fontana, vice president, Global Technology for Ashland Specialty

http://www.grede.com/



Chemical, commented, "Jörg's position will ensure closer alignment of ourtechnology organization with the business groups, enabling us to betterprioritize key research initiatives. To be successful, it is critical that ourtechnology and business teams share a common line of sight to the needsof our customers."

Prior to his new role, Kroker served as global manager of Cold Box R&Dwhere he successfully led Casting Solutions' efforts to commercializeimprovements in the ISOCURE®, ISOMAX® and ISOSET® Cold Boxbinder systems.

Past professional experiences include several international leadershippositions with BASF in the U.S. and Germany. Kroker graduated cumlaude from Phillips University in Marburg, Germany, where he receivedboth his doctorate and Master of Science in organometallic chemistry.

Kroker will report to Swartzlander and Fontana.

About AshlandAshland Casting Solutions, a business group of Ashland SpecialtyChemical Company, is a leader in supplying products, processes andtechnologies to the global metal casting marketplace. The group hasoperations (including licensees and joint ventures) in 21 countries.

Ashland Specialty Chemical Company, a division of Ashland Inc., is aleading, worldwide supplier of specialty chemicals serving industriesincluding adhesives, automotive, composites, metal casting, merchantmarine, paint, paper, plastics, watercraft and water treatment. Visitwww.ashspec.com to learn more about these operations.

Ashland Inc. (NYSE:ASH) is a Fortune 500 company providing products,services and customer solutions throughout the world. Our businessesinclude road construction, specialty chemicals, lubricants, car-careproducts, chemical and plastics distribution and transportation fuels.Through the dedication of our employees, we are "The Who In HowThings Work™". Find us at www.ashland.com.

BLOSSBURG, PA - ACP Manufacturing, Co. LLC, with corporateheadquarters in Blossburg, a manufacturing plant in Lawrence Township,PA and a Sales Department in Novi, Michigan, announced managementpromotions effective immediately affecting local employees.

Doyne Chartrau, Cogan Station, PA, is promoted to Chairman of theBoard of Directors and Chief Executive Officer replacing Stephen Rhodes,Detroit, Michigan, who has retired. Mr. Chartrau will maintain the office ofhis new position in Blossburg, PA.

Replacing Mr. Chartrau as President and Chief Operating Officer of ACPManufacturing Co. LLC is Yasu Kumada, Painted Post, New York, whopreviously was Executive Vice President of ACP. Mr. Kumada will continueas a member of the Board of Directors of ACP. In addition to Mr.Kumada's responsibilities at ACP, Mr. Kumada is also named by HitachiMetals America, Ltd., President and Chief Operating Officer and memberof the Board of Directors of their subsidiary company, HNAI, Inc. (formerlyNukabe, Inc.) of Wellsboro, PA. In this capacity Mr. Kumada replacesToshi Suzuki of Novi, Michigan who has been assigned to be President ofthe Cast Products Division of Hitachi Metals America, Ltd.

Mr. Arthur P. (Pete) Guidi, Jr., Montoursville, PA, has been promotedfrom Vice President of Manufacturing to Executive Vice President of ACPManufacturing Co. LLC reporting to Mr. Kumada. Mr. Guidi will also serveas a member of the Board of Directors of ACP.

ACP Manufacturing Co. LLC, with 311 employees, originally wasconstructed in 1997 as a division of Ward Manufacturing to produce ductileiron critical safety automobile suspension parts. Customers now include



nearly all North America automobile producers or Tier 1 suppliers andFord of Australia.

HNAI, Inc. was originally established in 1998 as Nukabe, Inc. to providefinished machining on the parts produced at ACP. HNAI, Inc. employs 73at the Wellsboro facility and another 79 in Effingham, Ill, in their machiningplant and corporate headquarters.

BLOSSBURG, PA - Ward Manufacturing, Inc. announced managementpromotions effective immediately affecting local employees.

Doyne Chartrau, Cogan Station, PA, is promoted to Chairman of theBoard of Directors and Chief Executive Officer. Mr. Chartrau replacesStephen Rhodes, Novi, Michigan, who has retired. Mr. Chartrau hasserved as President and Chief Operating Officer since April, 1991 and willmaintain the office of his new position in Blossburg, PA.

Replacing Mr. Chartrau as President and Chief Operating Officer is ArthurP. (Pete) Guidi, Jr., Montoursville, PA, who has served as Vice Presidentof Manufacturing of Ward since 1995. In addition to his new responsibilitiesMr. Guidi has been appointed to be a member of the Board of Directors.

Mr. Guidi has been very active in the Pennsylvania FoundrymensAssociation and now serves as President. Additionally, Mr. Guidi has heldvarious positions and is active in the Ductile Iron Society and the AmericanFoundrymens Society.

Ward Manufacturing, with 754 employees, corporate headquarters, andfour manufacturing plants, is one of the largest employers in Tioga Countyand produces malleable iron and cast iron piping components andcorrugated stainless steel tubing. Natural gas distribution and fireprotection are the principal markets served and are predominantly in NorthAmerica. Ward was founded by Joseph P. Ward in 1924 and will sooncelebrate its 80th year of business.

In 1989 Ward Manufacturing was acquired from local owners by HitachiMetals America, Ltd. of Purchase, New York.

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Metal Casting Veteran Yates to Spearhead Ashland's Pan-AsianCommercial Development

DUBLIN, Ohio (USA) - Ashland Casting Solutions has promoted RayYates to commercial director, Asia. In this new role, Yates is charged withimplementing an aggressive pan-Asian growth strategy to expandAshland's business across Japan, Korea, China, Southeast Asia andAustralia.

"Ray's strong leadership skills are a key component to the start-up phaseof our pan-Asian growth strategy," said Mike Swartzlander, vice president,Ashland Specialty Chemical, and general manager, Casting Solutions. "Inaddition to having nearly 20 years of operating experience in China,Casting Solutions now has local customer support and manufacturingcapabilities, and we can assist our Asian customers in realizing significantbottom line results."

Yates is a metal casting industry veteran of nearly 20 years and hasserved in various international roles for Ashland Casting Solutions inRussia, Brazil, and China. Prior to joining Ashland, Yates worked atFOSECO as an international product group manager for the company'sfoundry binders, coatings and ancillaries businesses.

As an active leader in the metal casting industry, Yates holdsmemberships in the Institute of Cast Metals Engineers, American Foundry



Society, Institute of Patentees & Inventors, and The Diecasting Society.

Pallone Promoted to Regional Sales Manager

DUBLIN, Ohio (USA) - Ashland Casting Solutionsannounced today that Roman Pallone has beenpromoted to regional sales manager, with responsibilitiesfor the Eastern and Southern regions of the UnitedStates.

"Roman's experience will provide the sales leadership weneed to ensure we add value to our customers throughout the metalcasting process. His strong sales, engineering and finance skillscomplement our global manufacturing and support capabilities andtechnically sophisticated product offering," said Phil Lepianka, salesdirector, Americas.

Previously, Pallone worked for Ashland in Planning and Analysis where heassumed lead roles in strategic planning and acquisition analysis,including serving as project leader for the acquisition of Finland-basedNeste Polyester. He has prior specialty chemical sales experience withCytec Industries, which serves the paper and water treatment markets, aswell as financial analysis experience with Ford Motor Company.

Pallone received a master's degree in business administration from TheOhio State University and a bachelor's degree in chemical engineeringfrom Cornell University.

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2003 Issue 3.pdf

Documents

Transcript of 2003 Issue 3.pdf