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 DECEMBER 2021
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY VOLUME 111 | NUMBER 12

P. 22 COLUMNS
9 Editorial
“Customer Assistance
Is Needed in the Shoe
Department “
S. WETZEL

21 Washington Alert
New Buy American
Provisions Built Into
Infrastructure Law

P. 34
S. SALMON

P. 26
44 For the CEO
Succession
Planning—Have
You Started?
B. SILHACEK AND M. WISE

47 College Connection
When Moving
Backwards Is a
Good Thing
P. LECHNER

22 Underground Hero DEPARTMENTS

A young, entrepreneurial manufacturing team collaborated with a U.S. foundry
to design a skinny, coreless and versatile casting that easily morphs into mul-
tiple iterations that safeguard precious electrical cables—hundreds of feet into 3 From Online
the earth. K. PHELAN
11 Industry News
26 Census of World Casting Production: Fewer Castings Made in 2020
The COVID-19 pandemic had a significant impact on production as nearly all 20 Member Q&A
major countries—except China—reported fewer shipments in 2020.
A MODERN CASTING STAFF REPORT 40 Casting Innovations
30 A New Measure for Active Clay in Green Sand 46 AFS News
An alternative approach to measure active clay in green sand allows direct CEC
measurement by adsorption of highly selective Cu(II)-Triethylenetetramine dye 48 Metalcasting Supplies
and subsequent quantification in a spectrophotometer.
A. DECHER AND S. RAMRATTAN 49 Classifieds
34 Metalcasting Industry Year in Review 55 Advertisers Index
Modern Casting reviews the major foundry industry news from the last 12
months. A MODERN CASTING STAFF REPORT 56 Shakeout

moderncasting.com
Cover Design: Mike Berrafato

December 2021 MODERN CASTING | 5

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A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY www.moderncasting.com
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STAFF

Managing Director, Marketing Contributing AFS VP,

Editor & Communications Editor Marketing & Business
SHANNON WETZEL KATELYN STANEK KIM PHELAN Development
swetzel@afsinc.org kstanek@afsinc.org kphelan@afsinc.org BEN YATES
byates@afsinc.org

Advertising Sales Advertising Sales

Midwest, West, Western Northeast, Ohio, Southeast,
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FABIO CAVALIERI
Eastern Canada
JOE MURPHY CASTING SOURCE
fabio@afsinc.org adsales25@aol.com
THE LEADING
PRODUCTION RESOURCE
Art Director Manager of Customer Service FOR THE
MICHAEL J. BERRAFATO, mberrafato@afsinc.org BARBARA JACKOWSKI, bjackowski@afsinc.org

Director of Marketing and Communications IS Manager

METALCASTING
KATELYN STANEK, kstanek@afsinc.org RICH FETT, rfett@afsinc.org
SUPPLY CHAIN

CONSULTING EDITORS
Management Federal Legislation & OSHA Regulations
DOUG KURKUL, dkurkul@afsinc.org STEPHANIE SALMON, ssalmon@afsinc.org

Casting Technology/Research Environmental Regulations

STEPHEN T. ROBISON, str@afsinc.org CHRISTIAN RICHTER, crichter@thepolicygroup.co
TOM DORE, tdore@afsinc.org JEFF HANNAPEL, jhannapel@thepolicygroup.com
BRIAN BEGAN, bbegan@afsinc.org

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December 2021 MODERN CASTING | 7

 EDITORIAL

Customer Assistance Is Needed

in the Shoe Department
O
ver the weekend I was shopping in a longer you take to
department store. For the 30 minutes that even acknowledge
I shopped and the five minutes I waited a customer’s needs,
in line, I heard the robotic store intercom voice an- the wedge in your
nounce on loudspeaker that “Customer assistance is customer-supplier
needed in the shoe department,” repeatedly—every relationship is
30 seconds or so. driven deeper. What
At first, I didn’t totally register the announce- could have been
ment. But 10 minutes in, I could start to see the collaborative is now
smirks on other shoppers’ faces as once again we adversarial.
heard, “Customer assistance is needed in the shoe Like my store
department.” example, sometimes
I began to imagine the person in the casual helping one cus-
sneaker aisle: hoping to find out the store has more tomer may inconve-
sizes in the back and then becoming increasingly nience another. But
agitated the longer they had to wait. At some point, not helping them
it turns into a matter of principle. They are not leav- can have others doubting your capabilities. As I left
ing until they get their assistance! The robotic voice the store, I heard the loudspeaker again chime out,
began to sound more ominous the longer it went “Customer assistance is needed in the shoe depart-
on. I thought to myself, “whoever finally helps that ment.” I’m in no rush to return.
customer is going to get an earful.” What strategies do you use in your business to
The store was juggle your custom-
busy—associates ers’ needs? How
were working hard, What strategies do you use in quickly are you re-
and there were lines plying to requests—
at the checkout. your business to juggle your even if the response
So, it was under- is “We’re working on
standable that the customers’ needs? it but don’t have an
customer in the answer yet.”
shoe department The flipside
had to wait some to bad customer
time for help. And obviously the store was short- service is good customer service can win you new
handed—large signs at the front doors advertised work. As the founder of J.C. Penney Stores said,
job openings. “Courteous treatment will make a customer a
As the store manager, what would you do? Pull walking advertisement.”
a cashier from checkout to help the one customer, As we flip the calendar to a new year, I hope
causing the eight in line to wait longer? Hope the 2022 becomes a year of strong sales, safe employees,
waiting customer in Shoes gives up and leaves? The and happy customers.
longer it went on, not only was the one customer Thank you for reading.
becoming upset (I imagine), but my attitude of my
shopping experience began to shift as well. I was an-
noyed to be in line. I began rethinking my purchase.
Do you have someone waiting in your shoe
department? A customer who is asking for some
assistance—politely at first but now a bit more insis-
tently? Even during busy times, customer service is
a critical piece to your business. When you let down
Shannon Wetzel, Managing Editor
a customer, not only do you risk the loss of the sale,
but you could be losing credibility from other wit- If you have any comments about this editorial or any other
nesses, particularly when a company is not shy about item that appears in Modern Casting, email
letting the word out about a bad experience. And the swetzel@afsinc.org.

December 2021 MODERN CASTING | 9


Lodge expands 125-year-old Tennessee facility
AFS Corporate Member Lodge
Manufacturing Company has an-
nounced it will invest $56 million to
expand its South Pittsburg, Tennes-
see, facility, where it has operated
for 125 years. In order to meet in-
creased demand, Lodge will expand
Multi-industry components-maker Impro opens Mexico foundry
Impro, Wanchai, Hong Kong—
a global components manufacturer
serving auto, engine, construction and
agriculture equipment, medical and
energy markets—will soon open a new
sand casting foundry located on almost
68 acres in San Louis Potosi, Mexico.
Two distinct sand casting produc-
tion lines are to be housed in the
596,837 sq.ft.-facility, one for Shinto
automatic green sand molding for
castings up to 88 lbs. with an annual
and reconfigure its existing facility
and add additional manufacturing
equipment to enhance production
capabilities. Lodge will create 239
new jobs as a result of the expansion.
Founded in 1896, Lodge is a
fifth-generation, family-owned
capacity of 5,000 tons, and another for
KW static pressure green sand mold-
ing for castings up to 880 lbs. with
an annual capacity of 40,000 tons. In
addition to sand casting, the plant will
offer heat treatment, painting, second-
ary machining, and cleaning.
Production lines have been in-
stalled, and core technologies include
both cold and hot boxes. Equipment
brands include ABP induction furnace,
a KW automatic pouring machine,
December 2021 MODERN CASTING
INDUSTRY NEWS
company that manufactures the
largest selection of American-made
cast iron cookware. Lodge operates
two foundries in South Pittsburg,
the second of which opened in 2017
and increased the company’s manu-
facturing capacity by 75%.
and SinterCast technology.
The foundry’s laboratory offers
solutions for molding sand inspection,
chemical analysis, and casting inspection.
It’s equipped with mechanical property
inspection and X-ray capabilities.
The company stated its mission is to
offer better and more holistic solutions
to customers as part of an objective to
build a one-stop sand casting solution
in North America that includes several
value-added services.
| 11
INDUSTRY NEWS

Inductotherm founder’s legacy fuels numerous scholarships

through FEF
AFS Corporate Member Induc- scholarships like this one has made education. The support of the HMR
totherm continued its annual sup- me want to give back to future stu- Family Foundation allowed FEF to
port in 2021 of the Foundry Edu- dents just like you have for me.” continue its mission to support the
cational Foundation (FEF) through This year’s annual FEF funding next generation of leaders in the met-
the Henry M. Rowan (HMR) report noted: “The HMR Family alcasting industry.”
Family Foundation to further his Foundation scholarships in many cases Inductotherm, headquartered in
desire to give “where it would helped those students who did not Rancocas, New Jersey, is a global manu-
do the most good for the most receive, or who lost, an internship in facturer of melting, thermal processing,
people.” Thanks to the unwaver- the summer of 2020 because of the and production systems for the metals
ing support from the HMR Family pandemic, to be able to continue their and materials industry.
Foundation since the endowment
was created in 2013, FEF was able
once again to sustain this com-
mitment to provide uninterrupted
scholarships of over $200,000 to
169 students from this fund.
FEF worked closely with its Key
Professors and Executive Board dur-
ing the 2020/2021 academic year to
guarantee programs for students to
receive the funding needed to con-
tinue their academic activities. The
funding is also used to help students
participate in casting competitions
and national conferences, and to
promote metalcasting through open
foundry events.
One student recipient wrote,
“This money will be useful to help
pay for tuition and books for this
semester. It is great to be a part of
an industry that cares so much about
recruiting young people to join this Pictured: Henry M. Rowan, center, surrounded by his family, left, is joined by then FEF administrator
wonderful field. Being awarded Bill Sorensen at a 2013 event where Rowan was recognized for his FEF endowment.

Students celebrate Manufacturing Day at Batesville Products

AFS Corporate Member
Batesville Products Inc. (BPI,
Lawrenceburg, Indiana) recently
hosted students from two local
high schools and a middle school
for tours of its facility to learn
about engineering, casting, ma-
chining, inspection, and polishing.
They were shown new tech-
nologies in the manufacturing
industry, such as finite element
analysis and BPI’s sawing and
polishing robots. All the young
visitors took home hands-on
casting activities to simulate
the permanent mold aluminum
casting process.
These field trips were part
of BPI’s many celebrations for
Manufacturing Day, a national,
annual event to showcase modern
manufacturing and gener-
ate interest in manufacturing
careers. Batesville Products also
celebrated Manufacturing Day
with an employee lunch and
t-shirts. This year’s Manufactur-
ing Day was extra special for
BPI, as it coincided with the
company’s 75th anniversary as a
Students watch a demo at Batesville Products Inc. in Indiana family-owned aluminum casting
for Manufacturing Day. foundry.

12 | MODERN CASTING December 2021

 INDUSTRY NEWS

New revision of ASTM E1444 contains important changes

A revision of ASTM E1444 was change to E3024 as your standard. lamps. New requirements call for
published in October, replacing the 4. Changes to process controls and checking the intensity of battery-pow-
2016 version. This revision is a part calibrations. Table 1 in E1444 spells ered lights before and after each use.
of a standard review cycle to address out all of the required process controls This ensures that a drop in battery out-
changes in the aerospace industry. and calibrations and the frequency put has not caused the UV intensity
More than 70 changes and updates go at which each must occur. All of the to fall below the minimum required
into effect in this specification. Following changes in this revision involve UV-A continued on page 15
are some of the significant changes.
1. E1444 will become an aero-
space-only standard.There are sig-
nificant differences in how magnetic
particle inspection is conducted in
aerospace compared to other indus-
tries. Beyond just the process checks,
there are restrictions on the allowable
types of materials and equipment.
Rather than trying to accommodate
all possible applications with a single
standard, the scope of E1444 is chang-
ing to focus only on the aerospace
industry. Non-aerospace users will
have to switch over to E3024 Standard
Practice for Magnetic Particle Testing
for General Industry.
2. No visible or dry particles. One
effect of the aerospace-only scope
change is the removal of all references
to visible magnetic particle materi-
als—only wet fluorescent magnetic
particles are included in the latest
revision. If your application uses vis-
ible color-contrast materials or dry
magnetic powders, you will need to
change to E3024 as your standard.
3. Removal of industrial magne-
tizing techniques and accessories.
With the transition to the aerospace-
only scope, the following accessories
and techniques are not in E1444:
Laminated flux strips.
Pie gauges.
Battery-powered yokes.
Permanent magnet yokes.
Magnetic leeches.
Prods.
Particle sensitivity devices (mag-
netic cards, MTU blocks, etc.).
Handheld yokes, in general, will
only be permitted with prior authori-
zation by the Cognizant Engineering
Organization or Level III. Specialized
techniques like magnetic slurries for un-
derwater use, magnetic polymers, tapes,
and films are also not included in E1444.
If your application uses any of these
materials or techniques, you will need to

December 2021 MODERN CASTING | 13

 INDUSTRY NEWS
ASTM continued from page 13
levels. The integrity of all UV-A lamps sometimes add a bluish fluorescence E1444 now requires that the liquid
must now be completed daily instead to the bath. portion is evaluated for clarity under
of weekly. It is not specified in Table 1 A cloudy bath could also be a sign visible and UV light after the particle con-
(instead refer to section 7.4.5), but this of the particles starting to break down. centration test. If the graduation marks on
revision also requires checking LED Bright yellow-green fluorescence the pear-shaped centrifuge tube (between
UV-A lamps daily to ensure all diodes observed in the liquid bath after the the 5 and 25 ml marks) are not visible,
are functioning. particles have been allowed to settle then the bath must be discarded.
5. No more Ketos rings. It has been is the most common sign of particle Source: Magnaflux article by Shawn Kilty and David Geis
over 20 years since the publication of breakdown. at www.magnaflux.com.
AS-5282 standardizing the Tool Steel
Ring for system performance. Since
then, AS-5282 rings have had better
magnetic performance than the original
Ketos rings due to stricter alloy and
heat treatment control. To accommo-
date existing systems and older equip-
ment, the specs for old Ketos rings were
maintained in E1444. Starting with the
new revision, the Ketos ring will not
be carried forward, and only AS-5282
rings will be acceptable.
5. Removal of formulas for deter-
mining proper current. Formulas used
to calculate magnetizing current have
been around for ages. They are used in
MT training programs and for devel-
oping a technique on a new part. But
real-world part geometry is not always
straightforward, and formulas are just
a starting point at best. For aerospace
applications, the Level III is respon-
sible for determining the current
necessary for adequate magnetization.
That is normally done with sample
parts and QQIs, not with calculations.
While the formulas are no longer in
E1444, they will remain in E3024 and
E709 Standard Guide for Magnetic
Particle Testing for reference and
training purposes.
6. Requiring inspection before
demagnetization. Inspection of
parts before demagnetization is
now explicitly required by ASTM
E1444. Inspecting parts after demag
increases the likelihood of particles
migrating away from an indication,
potentially leading to missed flaws.
Although this is likely self-evident
to most MPI practitioners, it was
never explicitly called out in prior
revisions of E1444.
7. Discard murky magnetic
particle baths. Magnetic particle
baths can become cloudy over time
for several reasons. Contamination
from lubricants or other machining
fluids can turn the bath hazy and will

December 2021 MODERN CASTING | 15


NEWSCAST
Prince International Corp., the
second-largest producer of porce-
lain enamel globally and a major
player in glass coatings, says it is
exploring a sale of its porcelain
enamel and glass coatings business
in the U.S. and Europe. The an-
nouncement is in connection with
the company’s efforts to obtain
regulatory clearance required to
complete the acquisition of Ferro
Corp., which is expected to close
in the first quarter of 2022. With
over 110 years of expertise in frit
production and glass technology—
a key ingredient for porcelain
enamel and glass coatings—Prince’s
porcelain enamel and glass coatings
business serves niche, differentiated
end uses such as home appliances,
cookware, and automotive.
Kolene Corporation, a global
maker of custom-designed and
engineered molten salt bath
equipment and specialty chemical
formulations, has acquired Upton
Industries in Roseville, Michigan.
Founded in 1937, Upton Industries
designs and manufactures thermal
processing systems in the metal
heat treating industry. Using its
Engineered Thermal Solutions
methodology, Upton produces
heat treat equipment including
box type, car bottom, lift-off and
specialty furnaces utilizing ei-
ther electric heating or gas-fired
systems. Kolene will maintain both
the Detroit headquarters location
and the Roseville location, which
will be home to all Kolene’s manu-
facturing and fabrication.
December 2021 MODERN CASTING
INDUSTRY NEWS
Neenah acquires
U.S. Foundry facility
in Florida
AFS Corporate Member
Neenah Enterprises, the holding
company of Neenah Foundry, has
acquired an 18.7- acre manufac-
turing facility from Corporate
Member U.S. Foundry & Manu-
facturing Corp. in Medley, Flori-
da, for $17.43 million, according
to media reports. It represents
the first Florida facility for the
150-year-old company.
The 139,592 sq.ft. property
comprises six buildings but does
not include U.S. Foundry & Man-
ufacturing’s adjacent headquarters
where it produces cast iron and
steel municipal and industrial
castings.
| 17
INDUSTRY NEWS
BOLD FACES
After 39 years of distinguished consult-
ing service to AFS, Modern Casting and the
foundry industry, Joe Murphy is retiring as of
December 31. Murphy has been a significant
part of Modern Casting’s success over the years.
He worked closely with staff on regular issues
and special supplements, helping suppliers
get the maximum value and visibility for their
advertising dollar. His professionalism and
thoughtful input will be missed by all who work
on Modern Casting.
“As those of us who have been fortunate enough to Joe Murphy
By Q1 2024, Century Aluminum to produce 150,000 tons of billet in Iceland
Century Aluminum Co.’s subsidiary, Nordural Grundar-
tangi ehf, has started the construction of a new low-carbon
billet casthouse at its Grundartangi, Iceland smelter.
The casthouse will have a capacity of 150,000 tons of
billet production and is projected to begin production in the
first quarter of 2024. The expansion project will also enhance
Grundartangi’s annual capacity to manufacture primary
foundry alloys from its current 60,000 tons of capacity to
18 | MODERN CASTING December 2021
work with him know, he was passionate about helping
companies reach new customers and grow their influ-
ence,” said Ben Yates, vice president of Business De-
velopment at AFS and publisher of Modern Casting.
“We at AFS will miss Joe’s unmatched institutional
knowledge and perpetual enthusiasm, but we wish
him well as he pursues new endeavors.”
Going forward, effective January 1, Fabio
Cavalieri and Dave Kathe will have joint re-
sponsibility for selling Modern Casting, Casting
Source, and AFS digital products, with assigned
territories.
120,000 tons, according to Zacks Equity Research.
Century Aluminum reportedly stated the casthouse
would enable Grundartangi to produce over 80% of its
production as value-added products. Utilizing renewable
electricity to further process its aluminum into billets in
Iceland will strengthen the Natur-Al brand and lower
the carbon footprint of aluminum production through-
out Europe.
 INDUSTRY NEWS

OBITUARIES BOLD FACES

Darryl W. Hill passed away at the age of 62, on
November 5, 2021, shortly after contracting the COVID
virus. Hill began his 44-year career with Manitowoc
Grey Iron Foundry (MGIF) in 1977 right out of high
school and followed in his father’s footsteps, who also
worked for MGIF for 35 years until his death in 1997.
Hill spent his entire career in the molding department,
first as a molder and then as molding foreman. He was
also in charge of the sand lab and helped manage the ad-
vanced oxidation sand system. He loved
working in the foundry industry and will
be missed.
Michael “Mickey” Patrick Callaghan
died October 31. He was 71. Callaghan
had a long engineering career in the
automotive industry. Over the years, he
worked at Ford Motor Co. in Dearborn,
Michigan, Eagle-Picher in Fort Wayne,
Indiana, and retired from his career at
Michael “Mickey”
Continental Structural Plastics. He was Patrick Callaghan
also a member of the American Foundry
Society.
Thomas Charles Cousineau died
November 4 at Hospice of Heartwood
Lodge. He was 79. Cousineau’s career
with Carpenter Brothers spanned over
40 years, where he was in technical
sales of consumables/equipment to the
foundry industry. He was also a member
of the American Foundry Society.
Thomas Charles
Cousineau
The Aluminum Association announced that Charles
“Chuck” Johnson will join as the group’s new president &
CEO effective January 3, 2022. Johnson previously spent
more than four years as president and CEO of the Inter-
national Safety Equipment Association (ISEA), a trade
organization representing the personal protective equipment
and technologies industry. Prior to that, he served for 19
years at the Aluminum Association in roles of increasing
responsibility. The Aluminum Association also announced
Virginia Gum Hamisevicz as its new
vice president of Government Affairs &
International Programs. Hamisevicz has
almost 20 years of experience advocating
on energy, natural resources and trade
policy before Congress and the Executive
Branch. She spent more than a decade
with the National Mining Association as
vice president for Government Affairs. Virginia Gum
Lockton Companies has hired Hamisevicz
Andrew Creary as business and risk
consultant in Minneapolis. Creary will
work with clients to create comprehensive property and
casualty plans.

Let Us
Hear It
Whether you agree or disagree with what you see
in MODERN CASTING, we welcome
your comments.
To submit a letter, send an email to
Shannon Wetzel, Managing
Editor, at swetzel@afsinc.org.

December 2021 MODERN CASTING | 19

MEMBER Q&A

Career-Long Impact—Learning and

Leading With AFS
No stranger to the metalcasting industry, Mike Lenahan has held several key
leadership and business development positions over his career, including vice pres-
ident—industrial sales at Covia, CEO for KB Foundry Services, and now leading
industrial sales at Badger Mining Corp. He also has served in a variety of roles for
AFS on the local and national level, including several years on the Government
Affairs Committee, among others, and as the current AFS President.
Modern Casting reached out to Lenahan to learn more about his AFS involve-
ment and its impact on his career. This is the first in a series of industry profiles
the magazine will be running regularly.

Q: What’s your background in ing to give back, it also helped me

the foundry industry?
Lenahan: I started my career
with Sand Products Corporation
working in a sand lab and calling
on customers. My career has mostly
revolved around sand, both new sand
and “pre-owned” sand, and even
“pre-owned” dust. The beneficial
use/recycling bug has always been
something I have been passionate
about. I believe this is one of the
areas where domestic foundries can
obtain an edge.
Q: How and when did you first
become involved with AFS?
Lenahan: I went to my first
AFS Chapter meeting in Septem-
ber of 1987 and never looked back.
I was a steady attendee at three
local chapters and found this was
a great way to get an inexpensive
education specific to the foundry
industry. I have served as a board
member for several chapters and
also was chapter chairman of two
AFS chapters. I also have been
serving on both the government
affairs committee and EHS com-
mittees since the mid 1990s.
Q: What has kept you active in
the Society?
Lenahan: For me, AFS became
two things. First, it’s a great place to
learn, and I do that by participating
in technical committees and serving
on the AFS Government Affairs
Committee. Second, AFS is a place
where I can give back. I have par-
ticipated in teaching opportunities
through various course offerings and
seminars. While it has been reward-
with my presentation skills, some-
thing that actually did not come
naturally to me at all. Lastly, I have
made many lifetime friends in the
industry. There is great satisfaction
when you work with friends and
support their businesses through
involvement with AFS.
Q: Throughout your career, you
have worked for companies that are
AFS Corporate Members. How have
you seen these companies utilize
Mike Lenahan
their membership benefits?
Lenahan: The interesting thing
here is that each of the Corporate
Badger Mining Corp.
Members I have worked for viewed
being a Corporate Member as a
Current AFS Role: AFS President
source of pride. While we were
able to gain additional benefits,
First AFS Involvement: 1987
we viewed it as an opportunity to
support AFS and the mission of
Advocate, Innovate, and Educate.
Q: You started your term as AFS strength or expertise to collectively
president before the pandemic, and enhance problem-solving opportu-
then extended the term as the Soci- nities. That being said, there were
ety and industry dealt with COVID. unique problems during my service
How did your goals for AFS change on the executive committee and as
during this time? What role did AFS President. Instead of focusing
AFS play for the industry during on promoting AFS outwardly by
the pandemic? speaking to chapters and at con-
Lenahan: Ironically, my goals ferences, the vast majority of our
really did not change all that much. time was spent collaborating on
I view being AFS president from how to retain our talented staff and
40,000 feet. As such, my overarch- renegotiate some of the contracts
ing goal and mission was to support that threatened our financial posi-
the mission of AFS and support tion. Through open collaboration
our members and AFS leadership and teamwork, and through Doug
and AFS staff. My hope was that Kurkul’s leadership, we were able to
the leadership and staff at AFS avoid several significant additional
would ask for advice from me and expenses, thereby minimizing the
from the board in various areas of impact on our core.

20 | MODERN CASTING December 2021

Stephanie Salmon, AFS Washington Office, Washington, D.C.
New Buy American Provisions Built Into
Infrastructure Law
THE TERMS ARE INCLUDED TO BOOST U.S. MANUFACTURED GOODS
The bipartisan infrastructure law,
the Infrastructure Investment and Jobs
Act, which was signed into law by
President Joe Biden on Nov. 15, con-
tains several Buy America provisions
of interest to U.S. metalcasters that
supply castings to the federal govern-
ment and to public works projects.
The following key new Buy Ameri-
ca provisions are contained in the act:
• Every federal agency is required
to apply Buy America rules to all
taxpayer-funded public works and
infrastructure projects, within 180
days of the law’s enactment. Agen-
cies cannot provide federal finan-
cial assistance for a project “unless
all of the iron, steel, manufac-
tured products, and construction
materials used in the project are
produced in the United States.”
Currently, Buy America rules have
not been fully implemented with
respect to all federal programs that
provide grants for the construction
of infrastructure. This represents
an expansion of domestic prefer-
ences for infrastructure projects.
• The Office of Management and
Budget (OMB) must issue guide-
lines “to standardize and simplify
how federal agencies comply with,
D.C. UPDATE
DOL Initiates Rulemaking on Heat
Stress Standard for Indoor and
Outdoor Workplaces
As the U.S. Department of La-
bor’s Occupational Safety and Health
Administration (OSHA) continues to
shift its enforcement focus to heat,
it has begun the process to issue a
heat-specific workplace rule. On Oct.
27, OSHA issued an advance notice of
proposed rulemaking for the proposed
standard. For decades, federal OSHA
has enforced occupational heat illness
WASHINGTON ALERT
report on, and enforce the Buy
American Act.”
• It provides for waivers of the
domestic preference when: (A)
application of the preference
would be inconsistent with the
public interest; (B) the products
are not produced in the U.S. in
sufficient and reasonably avail-
able quantities or of a satisfac-
tory quality; or (C) inclusion of
American-made products would
increase the cost of the overall
project by more than 25%.
• Before issuing a waiver, an agency
must publish the proposed waiver
on both its own website and one
designated by OMB and provide
15 days for public comments on it.
• Federal agencies, before granting
a waiver, are required to assess
whether a significant portion of
the cost advantage of a foreign
product is the result of the use of
dumped steel, iron, or manufac-
tured goods or the use of injuri-
ously subsidized steel, iron or
manufactured goods.
• It directs the establishment of
the BuyAmerican.gov website, a
publicly available website contain-
ing information on all waivers
hazards through the Occupational Safety
and Health Act’s General Duty Clause.
OSHA has recently updated its Heat
Illness Prevention Campaign materials
to recognize both indoor and outdoor
heat hazards, as well as the importance
of protecting new and returning workers
from hazardous heat.
OSHA is soliciting feedback on a vari-
ety of issues, including but not limited to:
(1) potential underreporting of heat-re-
lated illness in the workplace; (2) which
industries or occupations are most at risk
December 2021 MODERN CASTING
and exceptions to the various Buy
American laws.
For iron or steel products, includ-
ing ferrous castings, all manufacturing
processes—from the initial melt-
ing stage through the application of
coatings—must take place in the U.S.
For manufactured products, includ-
ing nonferrous casting, the product
must be manufactured in the U.S. and
the cost of the components of the
manufactured product that are mined,
produced, or manufactured in the U.S.
is greater than 55% of the total cost
of all components (unless another
standard applies).
The infrastructure bill’s Buy Ameri-
can requirements will not apply to
infrastructure projects covered under
the WTO Government Procurement
Agreement or free trade agreements.
This means foreign firms can partici-
pate in infrastructure projects without
complying with the Buy American
preference, provided the project is
covered under an agreement.
It is critical for metalcasters sup-
plying to federal infrastructure projects
and for federally-aided public works
infrastructure projects at the state and
local levels to assess these new Buy
American directives.
for such illness; (3) best practices to
help protect workers from heat illness;
and (4) how should climate change
be factored into an OSHA heat illness
and injury prevention standard? AFS’
Safety Committee is in the process of
drafting comments in response to the
dozens of questions that OSHA has put
forth. Comments are due by December
27, 2021.
For additional information, contact
Stephanie Salmon, AFS Washington Off ice,
202-842-4864, ssalmon@afsinc.org.
| 21
 Underground
Hero
A young, entrepreneurial manufacturing team collaborated with a U.S.
foundry to design a skinny, coreless and versatile casting that
easily morphs into multiple iterations that safeguard precious
electrical cables—hundreds of feet into the earth.
I n 2012, the indestructible super-
hero, Hulk, endeared himself to
Marvel movie fans with his sim-
ple mantra: Smash. Six years later, a
trio of young entrepreneurs introduced
a Hulk with a slightly modified mis-
sion: Endure Smash. Their Hulk cross
coupling cable protector for the oil
and gas industry is an annealed ductile
iron casting used to securely grip and
preserve expensive electrical submers-
ible pump (ESP) cables and capil-
lary tubes that face up to 45,000 lbs.
of pounding force at the tube collar
deep inside a wellbore. With 425,000
clamps sold since 2018, it’s safe to say
they’ve been a smash success.
But in 2019, Oil & Tool Solu-
tions (OTS) Director of Product
Chandler England, together with his
co-founders—childhood friend, Matt
Smart, and engineer Mark Robin-
22 | MODERN CASTING December 2021
kim phelan, contributing editor
son—recognized a major void in the
ESP marketplace and decided to go
after the opportunity with gusto. Their
original Hulk product is a 7-in. clamp
produced at a foundry in China, and
while it represented breakthrough
innovation for securing long cables
and pipes in wells, narrower lines were
grossly underserved; with no success-
ful 5-in. device in the market, field
workers were more or less left to jerry
rigging their own unreliable solutions.
The need for a small-diameter clamp
was almost desperate.
Leading a team of engineers into
technically arduous territory, Robinson
was driven to develop a solution and
quickly before competitors could beat
them to it—a device that would be
both narrower and longer to protect
valuable cables. On the other hand, the
owners agreed their venture to design
a completely new clamp with thinner
walls and tighter tolerances presented
a unique occasion for rethinking
everything they’d been doing to manu-
facture the Hulk.
It was still pre-Covid and tariffs
had already gone into effect when
OTS stepped back to consider new
options, including U.S. production. A
resident of Charlotte, North Carolina,
England turned to an acquaintance
at Charlotte Pipe, who referred him
to Waupaca Foundry, both AFS
Corporate Members. For the next 12
months, which included the pandemic,
a new band of trailblazers—com-
prising OTS, the Waupaca team,
and a machining partner Waupaca
selected—designed, refined, tested,
and perfected the Hulk Slimcast 5-in.
clamp, which OTS took to market in
the fall of 2020. They’ve since installed
 Since machining was already required to create drill and tap
holes, the design team eliminated a core and leveraged machining
to enable multiple versions of the clamp with just one casting.

at 20 wells and sold 6,000 units this

October alone, and the clamp has
opened up a whole new playing field
in West Texas.
“We were maturing as businessmen
who began to understand the advan-
tages of manufacturing something in
the U.S. and utilizing the technologies
and robotics that have gotten better
and better,” said England. “We can
manage cash flow better, because we’re
not having to ship things across the
world and then they sit on the water;
we could eliminate this whole specula-
tive build-up of inventory. And there’s
a huge time gap before you are actually
selling product. So we thought, ‘How
do we get around that?’
“Plus, we are Americans, and we
personally feel that if we can get
things done stateside, that would be
our preference because we’re selling to
this market,” he added. “And we want
to be good stewards to the planet,
which means not shipping product
halfway around the world. If you can
shorten your supply chain, and manu-
facture things in the market you’re
selling to, that’s huge ... We want to
be profitable, we want to run a good
business, and we want to do things the
right way ... Just because everyone says
it’s cheaper to manufacture in India or
China and these other foreign coun-
tries because labor is cheaper, well, is
that really true?”
It wasn’t, when all costs were
evaluated, including the less-mone-
tary but equally potent price of lan-
guage, culture, and logistics barriers Prior to HULK Slimcast’s arrival in the fall of 2020, no successful device existed in the oil and gas
while embarking on a new product industry for securing cables and pipes, said OTS co-owner Chandler England.

December 2021 MODERN CASTING | 23

development awash in constraints
and complications.
“We knew that by going into these
tighter wellbores,” England said, “we
wanted to work with an American com-
pany so that if there are issues, we can
work together to resolve them quicker
and with less uncertainty.”
Many Solutions, One Casting
The collaboration produced numer-
ous favorable outcomes OTS had not
expected, and it started with their
choice of metalcaster.
Cast in ASTM 536 grade 60-40-18 ferritic ductile iron, Slimcast delivers strength to withstand up to
45,000 lbs of smashing force and achieves 18% elongation.
24 | MODERN CASTING December 2021
“We immediately formed a great
relationship,” said Mike Behring,
Waupaca director of off highway and
industrial sales, recalling the first
meeting. “I initially shared with them
that too many customers approach us
with initial designs and want to focus
solely on cost. I said, ‘Let’s not go
through this as a cost exercise alone;
let’s go through this as a partnering
exercise, and through that, we will
develop a cost competitive optimal
design and a foundry- and machining-
friendly casting ... In the end, they saw
we were able to accomplish all of the
goals partnering as a team.”
When England first met with
Waupaca, he said three things stood
out that won his trust: (1) they clearly
excelled in metallurgy and educated
the manufacturer on the best alloy to
employ for the application—ASTM
536 grade 60-40-18 ferritic ductile
iron; (2) when Waupaca engineers
inspected the existing Hulk clamp, they
didn’t trash-talk the Chinese workman-
ship—they praised what was good but
identified where it could be improved;
(3) the Waupaca team didn’t hoard all
the work—instead, they did what was
right for the project and introduced an
excellent machine shop into the mix,
a company that eventually became the
tier-1 supplier that is now Waupaca’s
customer for Slimcast.
Machining was, in fact, the lynch-
pin that ultimately enabled multiple
Slimcast SKUs to be derived from a
single casting, as opposed to pro-
ducing multiple castings, each with
separate tooling.
“If you think about it, we’re clamp-
ing onto different cables,” said Eng-
land. “Some cables are thicker than
others, some are wider. So we needed
to leave some extra metal in this cast-
ing and then have it machined out to
different levels so it could combine
with different SKUs of cable. And so
that allowed us get the cost down—
we can take one casting and machine
it into six different SKUs. And that is
a big deal.”
The achievement was a beneficiary
of a Waupaca revelation: The large,
high-cost sand core from the origi-
nal Hulk clamp could be completely
eliminated on the new casting. Instead,
the tooling engineers added several
strategically-located drafts in the
mold, which not only removed redun-
dancy but ended up maximizing the
machining time for the clamps.
How? The first generation Hulk used
both a core and machining to drill and
tap holes required for hinge pins and
latching swinging bolts operators use to
assemble and secure the clamp around
pipes and cables in the field. Behring
explained that machining alone could
take care of the pin holes on Slimcast,
but as long as machining was required

for that, why not leverage machining
to also handle several variations of the
clamp—a clever dodge around the far
more costly route of building tools for
half a dozen individual castings.
Getting those multiple iterations
just right took several weeks, and
England’s agile team came a-running
to the Southern Wisconsin area to
personally test samples whenever the
machine shop called them.
“It was a lot of back and forth,”
said England. “We basically just got
on airplanes and set up shop alongside
the machining team. We brought up
all our customers’ cables, the capil-
lary tubes; we shipped up a pull test
bench—we have to be able to grip
this cable, so we had this mechanism
to yank cables. We brought up pipe
and other presses to kind of crush it
and see how strong this thing was,
because everything is thinner now. So
we’d spend three or four days together,
they’d say ‘Here are the revisions we’re
going to make,’ and we’d say, ‘See you
in a couple weeks and we’ll retest it.’”
Versatile in the extreme, the per-
fected Slimcast family of clamps are
stocked at OTS’s Denver plant, and
the machine shop controls fulfillment
of the various machined versions of
the casting. Customer orders at OTS
sometimes have to be out the door
in as little six hours, so the quick-
changeovers enabled by automated
machining have paid off compared to
the lead times of casting.
“We don’t know which SKU is
going to be the most popular at any
given time,” said England, “because
one month, one cable may be super
popular, and then the next quarter,
another cable may be popular. This
would have been impossible if we had
done this internationally—we would
have had to more speculatively invest
in enough inventory of everything,
not knowing what’s going to be in
demand. But when there are shifts in
the cable markets or a big company
like Halliburton decides to switch to
a new contract and they tell us, ‘Oh,
by the way, run this cable,’ we can
adjust quickly enough.”
Value in the Pipeline
Before a drop of molten ductile
“We wanted to work with an American
company so that if there are issues,
we can work together to resolve them
quicker and with less uncertainty.”
iron hit the mold, Waupaca had
ensured the strength, wear, sound-
ness, and sizing requirements would
all hit the mark of their customer’s
specifications.
Using Magma simulations, Behring
said, the foundry could confidently
thin walls and change geometry of the
part, as well optimize pocket sizes in
the housing of the clamp.
“We also focused on casting
length and adhered to specified
lengths that were acceptable to us,
OTS, and the machine shop and
to assure that we were able to then
optimize the number of cavities in
the mold, which is another direct
contributor to reducing cost.”
The foundry’s metals expertise
proved critical, too.
“The yield strength of this mate-
rial, which can withstand the corro-
sive environment it’s in during the life
of the product, as well as the lower
cost of ductile iron versus steel, are
what make this particular grade opti-
mal for this application, Behring said.
“And the mechanical, ferritic
properties really allow something
comparable to a low alloy steel. Oil
Tool Solutions required a material
that could withstand high impact as
the drilling pipe enters the well and
many times collides with the well-
head blowback protector. In order to
accomplish that, you need this grade
of ductile iron with 18% elongation.
This is comparable to a lower control
arm on your vehicle—if your front
tire hits the curb, it’s going to push
that material. But at 18%, it will come
back to its original form.
“Once the coupling is entering
the wellhead protector, that smaller-
diameter Slimcast design smashes
into the concrete protector—it has to
have the impact qualities and elonga-
tion qualities to come back to form
without breaking.”
December 2021 MODERN CASTING
A full anneal is required to achieve
the elongation requirements, Behring
added, and has the added effect of
breaking down carbides in the cast-
ing’s microstructure that can interfere
with the metal’s desired attributes.
With a year of hard knocks under
its belt, Hulk Slimcast has an esti-
mated lifespan of three years or four
installation cycles, whichever comes
first, according to England. OTS adds
value to their customers by offering a
refurbishment service that will extend
each clamp’s working life even further.
Challenge Yourself
Slimcast’s successful debut as
a wholly American-made casting
for oil and gas wasn’t necessarily
the catalyst behind OTS’ deci-
sion to eventually reshore—as well
as redesign—the original, wider
Hulk product, but it certainly has
reinforced the idea. The company’s
Chinese casting partner has worked
out well for the last three-and-a-
half years, but it was never the end
game, said England. On the other
hand, he’s not in a hurry to execute
on reshoring just yet—there’s plenty
to capitalize on for the present as
Slimcast sales pick up steam.
Meanwhile, he stands by his own
mantra these days: Challenge your-
self. By rejecting hearsay and doing
their own homework, England and
his fellow OTS owners discovered
they could manufacture their inven-
tion better, stronger and at low cost
by working with high-caliber domes-
tic partners.
“We challenged ourselves, and
what we try to challenge others now
is, look under the hood, get some
pricing, talk to experts in your mar-
ket,” he said. “Maybe certain products
are not going to make sense to get
done here, but challenge yourself and
go through the process.”
| 25
CENSUS OF WORLD CASTING PRODUCTION

Fewer Castings
Made in 2020
The COVID-19 pandemic had a significant impact on production as nearly all
countries—except China—reported fewer shipments in 2020.
a modern casting staff report

I
n 2020, countries around
the world felt the effect of
government-mandated work
stoppages and restrictions due
to the COVID-19 pandemic.
Nearly every country surveyed
reported a significant drop in
production in 2020 compared to 2019.
One of the few exceptions was China,
which felt the effects of COVID ear-
lier than most, but then rebounded to
show a 6% growth overall. This comes
after two straight years of production
retraction for China. Korea’s casting
shipments were even with no decline
or growth.
New to the census this year is an
entry from Indonesia. According to the
Indonesian Foundry Industries Associa-
tion (APLINDO), the country produced
589,779 metric tons of castings, with
aluminum as the main metal poured.
The top 10 casting-producing
nations are listed on page 30. Once
again, China, India, and the U.S. hold
the top three spots.
The data reported in the Census
of World Casting Production is sup-
plied by each nation’s metalcasting
association or similar representa-
tives, as well as the World Foundry
Organization and CAEF—The
European Foundry Association.

26 | MODERN CASTING December 2021

 2020 Casting Production (metric tons)

Gray Ductile Malleable Copper Other

Country Steel Aluminum Magnesium Zinc Total
Iron Iron Iron Base Nonferrous

Austria 33,400 91,700A 9,600 106,798 4,504 246,002

A
Belgium 43,000 3,900 - 5,500 - - - - - 52,400

Brazil 1,148,123 468,952 - 269,512 20,524 160,464 4,534 1,064 - 2,073,173

CanadaB 330,841 - - 90,091 14,237 211,374 - - 646,543

China 21,750,000 15,300,000 630,000 6,350,000 870,000 6,800,000 - - 250,000 51,950,000

Croatia 19,465 6,161 - 120 202 65,606 - - 131 91,685

Czech Republic 117,000 34,500A - 41,000 16,000 77,400 300 800 - 287,000

DenmarkC 28,900 58,100A - - 1,188 2,224 - - 112 90,524

Finland 17,300 23,100A - 6,700 2,415 1,730 - - - 51,245

France 431,900 593,600A - 41,900 16,118 293,529 - 18,880 2,180 1,398,107

A
Germany 1,618,700 957,100 - 138,000 46,076 652,738 20,489 49,761 19 3,482,883
A
Hungary 16,500 58,000 - 2,000 729 118,900 250 1,662 99 198,140
India 7,911,763 1,095,522 50,000 912,893 - 1,344,182 - - - 11,314,360
Indonesia 77,783 42,060 86,940 128,724 46,086 182,586 - - 25,600 589,779
Italy 534,400 300,600A - 58,000 38,168 540,296 3,676 75,834 1,235 1,552,209
Japan 1,598,113 1,169,743 29,439 153,000 57,019 343,651 - 13,792 82,146G 3,446,903
D
Korea (Republic of) 881,400 670,700 - 150,000 24,100 642,200 12,000 - - 2,380,400
MexicoE 816,160 560,270 - 336,250 215,500 832,770 - 79,500 15,200 2,855,650
C A
Norway 8,800 22,300 - - - 6,526 - - 37,626
C
Pakistan 181,000 24,540 - 48,750 14,200 21,200 - - 2,730 292,420
Poland 360,000 124,000A - 40,000 4,800 272,000 - 6,000 2,400 809,200
A
Portugal 26,100 76,100 - 4,100 16,203 31,966 - 2,165 - 156,634
C
Romania 15,000 1,500 - 3,500 3,000 60,000 2000 250 90 85,340
RussiaC 2,184,000E - - 1,134,000 117,600 588,000 75,600 - 100,800 4,200,000
Slovenia 59,300 39,800A - 17,600 990 44,618 - 7,477 - 169,785
C
South Africa - - - - - - - - - 443,000
Spain 283,100 582,800A - 65,300 15,279 101,317 - 7,304 683 1,055,783
Sweden 126,000 51,000A - 20,200 - 56,400 - - - 253,600
Switzerland 8,400 11,900A - 2,500 2,023 10,815 - 762 - 36,400
Taiwan (ROC) 543,617 179,697 - 55,007 27,368 481,593 6,237 - - 1,293,519
Turkey 617,300 854,700A - 192,000 24,851 449,503 761 31,644 - 2,170,759
B
Ukraine - - - - - - - - - 1,560,000
U.K. 128,400 195,600A - 41,600 8,300 102,522 2,000 7,300 - 485,722
U.S. 7,616,824 304,279 1,425,120 47,786 354,802 9,748,811

WORLD TOTAL 49,532,589 23,597,945 796,379 10,317,847 1,907,255 16,028,028 132,351 352,773 838,227 105,505,602

A) Includes malleable iron B) 2015 data C) 2019 data D) Includes magnesium E) 2017 data F) Includes all ferrous G) Includes aluminum diecasting

December 2021 MODERN CASTING | 27

 Metalcasting Plants by Nation
Country Iron Steel Nonferrous 2018 Total
Austria 12 3 22 37
Belgium 5 8 6 19
Brazil 329 130 400 859
CanadaA - - - 175
ChinaB 14,000 4,000 8,000 26,000
CroatiaB 26 5 - 31
Czech Republic 55 27 37 119
DenmarkC 8 - 7 15
Finland 11 7 13 31
FranceC 86 34 - 120
Germany 140 39 327 506
HungaryC 27 12 33 72
India - - - 4,500
Italy 134 38 864 1,036
JapanD 913 - 1,647 2,560
Korea (Republic of) 513 134 230 877
MexicoE - - - 800
NorwayC 5 - 3 8
PakistanC - - - 1,880
Poland 180 36 240 456
Portugal 23 8 57 88
RomaniaC 25 15 40 80
RussiaB - - - 1,140
SerbiaB - - - 36
Slovenia 8 3 47 58
South AfricaE - - - 135
Spain 43 31 52 126
SwedenC 25 11 60 96
Switzerland 13 2 31 46
Taiwan (ROC) 386 199 309 894
Turkey 447 109 396 952
UkraineC - - - 840
U.K.B - - - 420,671
U.S. - - - 1,661
A) 2015 data B) 2016 data C) 2019 data D) Includes diecasting facilities E) 2017 data

TOP 10 CASTING PRODUCERS

1. China 51,950,000 metric tons 5. Germany 3,482,883 metric tons 8. Korea 2,380,200 metric tons
Percent change: 6% Percent change: -29.6% Percent change: 0%

2. India 11,314,360 metric tons 6. Japan 3,446,903 metric tons 9. Turkey 2,170,759 metric tons
Percent change: -1.5% Percent change: -34.7% Percent change: -6%

3. U.S. 9,748,811 metric tons 7. Mexico 2,855,650 metric tons 10. Brazil 2,073,173 metric tons
Percent change: -13.7% No new data. Percent change: -9.4%

4. Russia 4,200,000 metric tons

No new data.

28 | MODERN CASTING December 2021

Showcase Your Company’s Casting Successes
Participate in the Annual AFS Casting Competition
The AFS/ 
2022 Casting Competition is your chance to show the
engineering and purchasing community what a metal casting can accomplish. Beyond the com-
pany recognition and industry public relations gained through the “honored” castings, entries can
appear in  
magazine departments. Also, this year’s winners will be showcased at the
2022 CastExpo.

"!   !  Participation is open to all North American metalcasters and designers/users of metal castings. Previous entries may be
resubmitted. Castings are sought in all metals, casting processes, end-use applications and sizes/weights.
 The competition is free for AFS Corporate Member companies. For non-Corporate Member firms, a $75 fee is required, per entry.
(Make checks payable to: AFS 2022 Casting Competition.)

   !!       !!      !! 
   !!
1. Newcomer (Rookie of the Year)
This award will go to a company that has not submitted a casting in the last 10 years. Don’t be intimidated to enter the contest and
show your stuff.
2. Best Example of a Casting Conversion
This award will recognize companies that used metalcasting’s strengths to convert a product from a non-casting process.
3. Achievement in a Small Foundry Business
Not every foundry has armies of staff. Smaller facilities are doing great work, and they are a key part of the industry.
This will reward companies that are doing more with fewer workers.
4. Best Innovation/Prototype
The metalcasting industry continues to evolve and stride into the future. That’s partly because metalcasters are always stretching
capabilities and looking for newer and better. This category is for castings that might not be ready for full production but could be the
precursor to the next big thing.
 !  


 Please complete the form below (with any supplemental information) and send it, along with the casting, to:
Casting Competition’22, 1695 N. Penny Ln., Schaumburg, IL 60173-4555. Sending photos is strongly encouraged.
Castings may be used for trade show exhibits and permanent displays at AFS, and their images may be used in future AFS publications.
Castings can be returned at the entrant’s expense.
For information on the competition, contact  
Shannon Wetzel at 800/537-4237 or
swetzel@afsinc.org. Information also is available online at www.castingsource.com.

AFS Casting Competition Entry Form (Deadline: January 31, 2022)

Metalcasting Facility: _________________________________________________________________________
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A New Measure for
Active Clay in Green Sand
An alternative approach to measure active clay in green sand allows direct CEC
measurement by adsorption of highly selective Cu(II)-Triethylenetetramine dye
and subsequent quantification in a spectrophotometer. andreas decher, andreas decher
minerals services (wenden, germany); sam ramrattan, western michigan university (kalamazoo)

T he AFS 2210-00-S
Methylene Blue Clay Test
has been used as a part of
foundry control programs
to determine the active clay percent
in green sand since 1967. Active clay
content is an approach to quantify the
number of smectite clay minerals in
a bentonite or molding sand. These
minerals control bentonite properties
and act as green sand binder.
A new test procedure for estima-
tion of the active clay or smectite
clay content has been introduced for
foundry applications, which is based
on the determination of the Cation
Exchange Capacity (CEC) of the
molding sand. Using the highly stable
Cu(II)-Triethylenetetramine dye,
which shows a high affinity to the
clay mineral adsorption sites, a fast
and reliable CEC determination is
possible. In this study, superior accu-
racy and repeatability of the results
compared to methylene blue adsorp-
tion were demonstrated in laboratory
mixtures using sand with 6% - 12%
bentonite content. This range covers
most molding sand formulations in
modern foundry environments. By
adjusting sample weight, sand mixes
with bentonite content below 1% as
well as pure bentonites providing high
CEC can be analyzed.
within the interlayer of stacked smec-
tite platelets. If Na+-ions dominate,
they are hydrated to the extent that
individual platelets exfoliate, and
cohesive electrostatic forces develop a
bonding film to bind sand particles.
Due to the weak surface charge
of smectite clay minerals, adsorbed
cations can be replaced by other cation
species. This cation exchange reac-
tion is controlled by concentration,
charge, ion-radius, weight, and specific
interactions of cations or cationic
molecules with the constituents of the
clay mineral lattice.
Active clay determination by
methylene blue adsorption is a cation
exchange reaction where all available
anionic sites at the mineral surfaces
will be occupied by methylene blue
molecules (Figure 1). Methylene blue
adsorption does not quantify the
number of smectite clay minerals (aka
active clay) in the molding sand or
bentonite, but the number of available
anionic adsorption sites (CEC) of the
clay. However, using methylene blue
for active clay determination, intro-
duces some fundamental problems:
Knowledge of CEC does not
provide smectitie clay content. A
reference material is required where
smectite content has been quanti-
fied by alternative analytical methods
(X-ray diffraction) and where layer
charge and layer charge distribution
of the reference and the tested sample
must be the same. Differences in CEC
of individual smectites from differ-
ent bentonite sources can lead to an
error in active clay calculation of more
than 20%. Even within one bentonite
deposit, variations in CEC up to 10%
have been observed.

Background
Smectite clay minerals can be char-
acterized as silicate platelets providing
weak negative surface charges. These
charges are balanced by counterions
Fig. 1. Exchange of cations adsorbed to clay mineral surfaces by methylene blue.
(Na+, Ca2+, Mg2+) that can hydrate

30 | MODERN CASTING December 2021

 a) Weighing the sample directly into a centri- b) Mechanical dis- c) The sample is centrifuged for particle d) Spectrophotometry
fuge cup. Sample weight can vary – but needs persing of sample separation. After centrifugation, the at 578 nm.
to be noted precisely. Subsequently, 30 ml of into exchange clear solution is transferred into a cu-
solution are added from a bottle dispenser. solution. vette for spectrophotometer analysis.

Fig. 2. Testing procedure for molding sand CEC determination using Cu(II)-trithylenetetramine solution.

Methylene blue molecules in high
concentration can orientate them-
selves in dimers and trimers. Conse-
quently, two molecules may occupy
one adsorption site at the clay mineral
surface, which leads to a systematic
active clay overestimation.
Selectivity of methylene blue
against divalent cations such as Ca2+
and Mg2+ is not very high. Therefore,
a dispersant (Tetra-Na-Pyrophos-
phate) is required to replace divalent
cations by Na+-ions.
For characterization of soils and
bentonites, CEC is one of the key
parameters to be tested. Therefore,
different procedures in CEC measure-
ments have been established in various
industries and fields of research. Early
and still applied CEC determination
methods use multiple washing steps
with different index cations requiring
significant time and skilled lab techni-
cians for analysis. The advantage of
the methylene blue test introduced in
the 1960s to the foundry industry was
much faster results with less require-
ments for operator skills.
However, in clay and soil sci-
ence, an improved methodology was
required providing higher accuracy
and results in absolute numbers (with-
out using reference clays). Heavy-
metal-amine dyes are adsorbed very
selectively even at low concentrations
to clay mineral surfaces, replacing
quantitatively other adsorbed cations
in one step. The dyes can be analyzed
without dilution by UV-ViS spectro-
photometry with high accuracy. The
high selectivity as well as the direct use
in the spectrophotometer allows fast

Fig. 3. CEC analysis of bentonite/sand mixes obtained by MB and the new method. Actual data vs. predicted.

December 2021 MODERN CASTING | 31

and accurate analysis.
The advantages of using
spectrophotometry with an
organic dye for active clay
determination in the foundry
industry were presented at the
AFS Metalcasting Congress
2013. The absorbency of the
solution could be measured
accurately over a detectable
range with a spectrophotom-
eter. The shortcoming was
the inability to discriminate
over a tight active clay range.
For example, the test can
detect the difference between
6% and 8% active clay but
cannot discriminate 8%
from 9%. That research has
continued at Western Michi-
gan University (WMU) by
selecting suitable dye and
test procedures.
Fig. 4. CEC of sand mixes using Southern bentonite compared to calculated
For molding sand CEC CEC values.
determination, Cu(II)-Trieth-
ylenetetramine was selected,
a blue colored complex with
high affinity to clay mineral surfaces and
high photometrical extinction.
Tests were also out using Co(III)-
hexaamine dye, which, according to the
trivalent charge, allows higher sample
weight. But stability of the dye during
analysis and in presence of organics may
influence accuracy and affect usability.
Experiment and Results
CEC determination by Cu(II)-
Triethylenetetramine is based on the
reduction of dye concentration after
reacting to the clay minerals in the
molding sand. For evaluation of the
newly proposed method and required
steps of the testing procedure, four
different sand bentonite mixes were
prepared with bentonite addition of 6%,
8%, 10% and 12%. The bentonite used
for preparation of the blends was West-
ern bentonite with a CEC of 73 cmolc/
kg. Consequently, the 10% mix should
show a CEC of 7,3 cmolc/kg. CEC of
the remaining mixing ratios are calcu-
lated accordingly.
Mixing, centrifuging, and measuring
the absorbency are three major steps
of the new procedure. The procedural
steps are listed below and summarized
in Figure 2.
Accuracy and repeatability of
32 | MODERN CASTING December 2021
methylene blue and Cu(II)-Triethyl-
enetetramine method are demonstrated
in Figure 3. Test results obtained from
the four different blends are compared
to theoretical values calculated from
available CEC of the bentonite used for
preparing the blends and the bentonite/
sand mixing ratio. For CEC determi-
nation by methylene blue adsorption,
a reference Western bentonite with a
CEC of 92 cmolc/kg was used.
Each bentonite blend was tested
three times with both methods. Results
obtained by Cu(II)-Triethylenetetramine
showed a high reproducibility with low
variation between individual test results
(Table 1). The CEC expected for each
of the blends was found in good agree-
ment indicating high accuracy of the
test method.
On the other side, methylene blue
adsorption could provide results with
good reproducibility as well—but
higher variation compared to the
use of Cu(II)-Triethylenetetramine
was detected. A systematic deviation
from the expected “theoretical” result
was observed at higher bentonite/
sand ratios. Compromised accuracy
of the methylene blue method can be
explained by dimer and trimer for-
mation of methylene blue molecules
providing an overestimation
of CEC.
Occasionally, foundries
use blends of Ca- and
Na-bentonite for bind-
ing molding sand if dry
strength needs to be
reduced for shakeout
improvement. Ca-bentonite
contributes to the active
clay content of the molding
sand, but high concentra-
tion of adsorbed divalent
cations may negatively
influence methylene blue
adsorption. Figure 4 shows
that CEC determined from
blends of sand and Ca-ben-
tonite (Southern bentonite)
is in good agreement with
predicted values. Slope of
the straight line is almost 1,
as expected.
Working Molding Sand
and Active Clay
Calculation
CEC determination by Cu(II)-Tri-
ethylenetetramine adsorption provides
accurate and repeatable results in blends
of bentonite and quartz prepared
in laboratory. However, in an active
foundry environment, several compo-
nents in molding sand may influence
adsorption of Cu(II)-Triethylenetetra-
mine dye to clay mineral surfaces. Coal
and organic additives such as ground
corn knobs, starch, hydrocarbon resins,
etc. are frequently added for molding
sand optimization. Since molding sand
is operated in a recirculation system,
residues and condensates from burned
coal and organic binders are present
with difficult-to-predict influence on
CEC measurements.
Two molding sand samples have
been collected in a European foundry
during two subsequent shifts (Table
2). Bentonite content was perfectly
adjusted and did not change in both
shifts according to methylene blue
adsorption data. CEC determination
using Cu(II)-Triethylenetetramine also
confirmed that both samples have the
same bentonite content.
The result indicates no fundamental
problems by using Cu(II)-Triethylene-
tetramine for active clay determination
of a working foundry’s sand. Given the
 Table 1. Calculated and analyzed CEC data from sand bentonite blends using
Cu(II)-Triethylenetetramine and methylene blue adsorption
Bentonite Theor. CEC
[%] cmolc/kg
6 4,4
8 5,8
10 7,3
12 8,8
variety of molding sand formulations in
many foundries, more systematic testing
needs to be done. However, if com-
petitive adsorption does occur between
molding sand components and the dye,
the problem is expected to be worse
using methylene blue due to lower selec-
tivity toward clay mineral adsorption.
For active clay determination
based on methylene blue adsorption,
a reference clay with known smectite
content is required. After analyzing
the adsorbed methylene blue of the
reference clay, the active clay content of
the tested sample can be calculated. If
required, this procedure may be applied
using CEC values instead.
Table 3 provides an example of how
to calculate active clay of a molding
sand sample (here: from foundry sand
in Table 2) using CEC literature data
of Western bentonite from Wyo-
ming and Cheto type bentonite from
Arizona. Depending on the type of the
bentonite selected, active clay of the
respective molding sand sample may be
calculated to 7.8% or 9.1%, respectively.
Compared to active clay determi-
nation by methylene blue adsorption,
several advantages are found:
Compared to the AFS boiling
procedure, the new procedure gives
faster results, in particular, when several
samples can be analyzed in parallel.
Accuracy is increased by more reli-
able analytical procedures (spectropho-
tometry) and eliminating fundamental
flaws of the methylene blue method,
such as the formation of dimers and
trimers, which may depend on the
manufacturer of the dye and the type
of clay minerals tested.
A reference clay is no longer required.
Results obtained with the new method
are noted in absolute numbers in SI-
CEC Meth.-Blue CEC CuTrien hygroscopic and requirements for storage
cmolc/kg cmolc/kg and handling need to be followed. How-
4,5 4,5 ever, suppliers of foundry consumables
4,5 4,4 may offer the solution ready to use as a
4,6 4,5 service. Stability of the dye is very high
5,9 6,1 which allows long-term storage.
6,2 6,1 CEC determination of molding
6,2 6,0 sand using the newly proposed method
5,9 7,4 gives the opportunity for an automated
6,2 7,4
procedure. Human errors and test vari-
6,2 7,5
ability will be reduced, and active clay
9,5 8,8
9,3 8,8 determination may become part of an
9,5 8,8 inline sand control system.
While cost for consumables for
units. They could be used to calculate CEC determination using the new
active clay content based on literature method are below consumables cost for
data or supplier information, if desired. methylene blue adsorption, investments
But CEC value alone could be used for are required for equipment. Major
molding sand control as well. expenditures would be a spectropho-
Use of complexing agents like tometer and a centrifuge.
Tetra-Na-Pyrophosphat for removal Future work is required for testing
of divalent cations from the exchange and adapting the new method in work-
solution is no longer necessary. ing green sand foundries. Since clay min-
Compared to the use of methy- eral surface charges vary with pH, this
lene blue, less effort for laboratory effect needs to be monitored on molding
housekeeping and cleaning of equip- sand, as well as temperature and other
ment is required. process variables. Additives such as caus-
To avoid errors during CEC ticized lignite, different types of sea coal,
determination, accuracy and precision cereals and dextrin may affect adsorption
is required during all procedural steps. behavior of the dye and therefore need to
But requirements of the new method be investigated further.
are not exceeding requirements during Major emphasis of future work will
active clay determination by methylene be laid upon development of automated
blue. Spectrophotometry for determina- systems to reduce test-to-test variabil-
tion of the dye concentration is more ity, increase the number of daily active
sophisticated compared to the halo clay analysis, and have real-time active
method, but instruments can be pre- clay data available for sand prediction
configured to allow operation by staff and simulation systems.
without laboratory education. Probability The AFS Molding Methods &
of errors may be high during prepara- Materials Committee is looking at the
tion of the Cu(II)-triethylenetetramine new test as an alternate standard. Con-
solution from triethylenetetramine and tinued research will look at ways to
Cu-sulfate. Triethylenetetramine is automate the testing technology.
Table 2. CEC analysis of two of molding sand samples collected in two
consequent shifts
Sample LOI <25µm Active Clay CEC
[%] [%] [%] cmolc/kg
Shift 1 4,88 13,1 8,7 9,2
Shift 2 4,93 13,0 8,7 9,2
Table 3. Active clay calculation of molding sand sample (Tab. 4) from CEC by using
different reference clays
Reference Bentonite CEC @ 100% Active Clay Active Clay Molding Sand
cmolc/kg [%]
US Arizona (Cheto) 121 7,8
US Western 101 9,1
December 2021 MODERN CASTING | 33
 Metalcasting Industry

YEAR
IN REVIEW Modern Casting reviews the major casting
supplier news from the last 12 months.
modern casting staff report

is expected to create 30 jobs, with the potential for more

December 2020 as the plant expands. The facility will produce automotive
products, focusing on ones for electric vehicles.
Pratt & Whitney plans multi-million investment in
Craft Pattern & Mold adds 3 large machining centers
facility for turbine airfoil production, castings
Holding to its mantra of continuous reinvestment in the
Pratt & Whitney (East Hartford, Connecticut) a divi-
business despite the uncertainties of 2020, AFS Corporate
sion of Raytheon Technologies Corp., said it plans to invest
Member Craft Pattern & Mold (Montrose, Minnesota) took
at least $650 million through 2027 in a world-class turbine
delivery of three new Haas machines that expanded its ability
airfoil production facility in Asheville, North Carolina. The
to handle large tooling and secondary machining of castings.
1-million-sq.-ft. facility will house an advanced casting
The company manufactures prototypes for plastic and
foundry for the production of turbine airfoils; the company
metal parts as well as production tooling for a wide range of
will also conduct machining, coating and finishing of airfoils
commercial and industrial applications.
at the new location.

Rio Tinto launches new aluminum alloys to

support recycling
AFS Corporate Member Rio Tinto introduced a new
family of unique aluminum alloys designed to allow North
American diecasters to increase their use of recycled content
in the production of automotive parts.
The new alloy series has been developed for high pressure
vacuum diecasters to mix with their own scrap and recycled
cleaned crushed wheels. As an alternative to buying lower grade
secondary remelt ingots, the final blend will cost less, have a
lower carbon footprint, and meet stringent industry standards.

January 2021
Mitsui Kinzoku Die-Casting Technology America to
open Georgia plant
Mitsui Kinzoku Die-Casting Technology America is
building a $20 million facility in Griffin, Georgia. The project Craft Pattern & Mold

34 | MODERN CASTING December 2021

Naval Foundry and Propeller Center
Naval Foundry and Propeller Center makes
200,000-lb. casting for submarine
The Naval Foundry and Propeller Center (NFPC) in
Philadelphia, a detachment of Norfolk Naval Shipyard
and an AFS Corporate Member, made the first casting for
a Columbia-Class submarine late this summer, weighing
200,000 lbs.
NFPC is a Department of Defense manufacturing facil-
ity that specializes in advanced engineering, castings and
precision machining that supports the mission of the U.S.
Navy. Work done at the foundry supports the Columbia
Class submarine program, a class of submarines that will
replace the aging Ohio Class submarines and ensure sustain-
ment of the most survivable leg of the U.S. nuclear triad,
according to an NGPC press statement.
Kent Foundry set for $3.5 million project
Kent Foundry (Greenville, Michigan) was set to begin
work on a $3.5 million expansion project that would bring
30 new employees to the metalcaster. Kent is a manufacturer
of gray and ductile iron castings, and its parent company
Canerector Inc. (Toronto) announced the plans in July of
last year.
Brinco Planning Indiana steel foundry
According to local reports, Brinco (Wilmington, Dela-
ware) was planning to open a steel casting plant in Bristol,
Indiana. The “Elkhart Truth” reported Brinco will invest
almost $35 million and is planning to hire 250 workers. The
plant would produce rail parts.
In 2019, Brinco purchased the facility for $10 million.
The company intends to invest $4.5 million to improve
the space, and also spend $15 million on equipment at the
430,000 sq.-ft. facility.
February 2021
Construction of copper casting building to begin
IBC Advanced Alloys in Franklin, Indiana, was plan-
ning to invest more than $5 million to build a 32,000-sq.-ft.
copper casting facility on its current property, according to
a “Daily Journal” report by Leeann Doerflein. Also known
as Non Ferrous Products Inc., IBC manufactures beryllium
and copper advanced alloys parts for the defense, aerospace,
automotive, telecommunications and precision manufactur-
ing industries.
Dotson expansion in the works
AFS Corporate Member Dotson Iron Castings, which sup-
plies precision parts for farm machinery, heavy trucks, industrial
equipment and the construction industry and more, revealed a
major expansion in the works at its Mankato, Minnesota, plant,
including the addition of new meeting rooms, break areas, locker
rooms, and a rooftop patio.
Missouri foundry seeks to build, grow,
create more jobs
Lakeside Casting in Monroe City, Missouri, announced
plans to buy out the remaining $600,000 of its real estate
lease with the city and expand this year, according to area’s
local “The Herald-Whig” newspaper.
Founded by four partners with over 150 years of com-
bined experience in the diecasting business, Lakeside
markets itself as “Your Global Link to Zinc,” and makes
component parts such as ignition assemblies for trucks,
natural gas meters, key casting for the automotive industry
and many other OEM parts.
December 2021 MODERN CASTING | 35
Appalachian Cast Products poised for growth
with new investment
Premier Engineered Products (PEP; Grand Rap-
ids, Michigan), which owns Appalachian Cast Products
(Abingdon, Virginia), has a new investor—Charter
Growth Capital Fund (CGCF), which has provided mez-
zanine debt in support of PEP’s recapitalization. Birming-
ham, Michigan-based Colfax Creek is the lead investor in
the transaction.
Colfax Creek and foundry veteran Mike Ryan, formed
PEP in January 2019 to recapitalize Appalachian Cast
Products (ACP) and integrate Premier Die Casting’s
production into its Abingdon facility. Managed by princi-
pals of Charter Capital Partners, CGCF invests up to $5
million of mezzanine debt and/or equity capital into lower
middle-market companies.
Wisconsin Aluminum Foundry creates $100,000
engineering scholarship
Manitowoc County high school graduates planning to
attend the University of Wisconsin–Green Bay (UWGB)
may have an opportunity for financial support through a
new scholarship fund created by AFS Corporate Member
Wisconsin Aluminum Foundry (WAF), with support of the
Schwartz family, which has owned and operated the com-
pany since its founding in 1909. WAF donated $100,000
to create the Wisconsin Aluminum Foundry Engineering
Scholarship fund through the University of Wisconsin–
Green Bay Foundation.
March 2021
Lawton welcomes Penn-Mar to iron foundry group
AFS Corporate Member The C.A. Lawton Co.
(DePere, Wisconsin) acquired Penn-Mar, a gray and duc-
tile iron foundry in Hanover, Pennsylvania. Penn-Mar
manufactures multi-cored, gray and ductile iron castings
ranging from 150 to 5,000 lbs. Using an air-set, nobake
molding process, it serves the refrigeration/air condition-
ing, pump/compressor, and motor/ generator industries.
Kimura installs 4th furnace—with 1-ton capacity
A new Pillar Induction furnace with 1-ton melting
capacity was installed at AFS Corporate Member Kimura
Foundry America Inc. (Shelbyville, Indiana). The addi-
tion enables Kimura to meet customer demand for heavier
casting parts, particularly in the construction, agricultural
machinery, power generation, oil and gas, pump and com-
pressor industries.
The foundry also expects to improve pouring efficiency
and casting turnaround thanks to the high-capacity furnace’s
ability to pour multiple parts simultaneously. The company
began operating in November 2018 with three furnaces: two
with 300-lbs. melting capacity and one with 500 lbs. All its
furnaces are connected to a furnace monitoring system for
safety and stabilized operation.
36 | MODERN CASTING December 2021
Victaulic acquires Waupaca facility in Pennsylvania
Victaulic (Easton, Pennsylvania), a global manufacturer
of mechanical pipe joining, fire protection and flow control
solutions, purchased a 220,000-sq.-ft. Waupaca manufactur-
ing plant in Lawrenceville, Pennsylvania.
When operating at full capacity, the facility will increase
Victaulic’s foundry production capacity by 70% in the U.S.
and allow for future growth as Victaulic’s business demands
increase. The facility, including two foundry molding lines,
will also enable Victaulic to produce larger scale products.
TRM Equity acquires all assets of Elyria Foundry and
Hodge Foundry
TRM Equity acquired Elyria Foundry and Hodge
Foundry (Elyria, Ohio), a company specializing in ductile
iron castings up to 200,000 lbs. and serving many markets
including defense, oil and gas, construction equipment and
mining. Elyria Foundry has operated since the early 1900s
and has developed a strong technical and metallurgical team
that drives its success.
April 2021
Three-part renovation in progress at
Progressive Foundry
AFS Corporate Member Progressive Foundry, a ductile and
gray iron matchplate job shop about 40 miles northwest of Des
Moines, completed two-thirds of a three-phase, $6.8 million
renovation of its Perry, Iowa, facilities.
Phase 1, 15,000 sq.ft. of new construction completed in
November 2020, nearly doubled the size of the foundry’s
core room; it also included remodeling of a 25,000-sq.ft.
purchased building that now houses maintenance and stor-
age. Phase 2 in Spring 2021 comprised a new state-of-the-
art employee center with men’s and women’s locker rooms
and large indoor and outdoor patio break areas with a fully-
equipped kitchen. A new metallurgical lab, as well as offices
for the quality manager and all Progressive’s foremen, are in
the same building, which, in emergencies, is also becoming
the company’s storm shelter.
The foundry’s full upgrade is projected to conclude early
in 2022 with Phase 3’s newly constructed office building for
management and administrative personnel.
Progressive Foundry
ACTION acquisition complements Webster Industries’
equipment, castings lines
Northeastern-Ohio based Webster Industries, Inc.,
an AFS Corporate Member that makes conveyor chains,
sprockets, vibrating conveyors and specialty castings,
acquired Action Equipment Company (ACTION), a
manufacturer of vibratory conveying and process equipment.
The combination will allow Webster to expand high-quality
custom design offerings and vertically integrated produc-
tion capacity, while fulfilling innovative product and service
needs for the combined global customer base.
Ermak Foundry & Machining acquires Patriot Foundry
& Castings, RDS Dock Hardware
AFS Corporate Member Ermak Foundry & Machining
(Chaska, Minnesota) acquired Patriot Foundry & Castings
and RDS Dock Hardware of Franklin, New Hampshire.
With new capabilities brought online by Patriot and its
extensive partner network, Ermak plans to grow its regional
and national network and expand into new markets. Patriot
will have additional capacity, including rapid prototyping
and part development through Ermak’s proprietary product
development process, plus access to in-house heat treat,
machining, and permanent mold/gravity-fed die cast—pro-
viding customers with a broader, more cost- competitive
one-stop-shop for nonferrous castings.
May 2021
Metal Technologies acquires former customer in Mexico
AFS Corporate Member Metal Technologies
Gränges
(Auburn, Indiana) acquired AAASE’s Mexico machin-
ing operations in San Luis Potosi, Mexico, which will
do business as Metal Technologies Maquinados de SLP
(MTMS)—the existing management team remains in
place going forward.
“MTMS was one of our first and largest customers in
Mexico,” said MTI President and CEO Matthew Fet-
ter. “We knew the management team very well for many
years and the MTMS team was the critical part of the
acquisition. In addition, MTMS’ ability to machine a wide
size range of parts with complex operations and tight
tolerances was complementary with our existing machining
experience.”
Madison-Kipp expands footprint with
Indiana diecaster
Madison-Kipp Corp. (MKC; Madison, Wisconsin)
acquired the assets of a Richmond, Indiana, diecasting facil-
ity, which the company said expands its geographic footprint
and allows it to better serve its customers.
The transaction was part of a program to enhance
MKC’s manufacturing capabilities; combined with the
recent addition of seasoned leaders in engineering and
manufacturing, MKC said it has the capacity to remain
a highly reliable and technically sophisticated supplier of
complex parts to new and current customers. The addition
also opens the opportunity for supply chain optimization
for certain customers.
Wisconsin Aluminum Foundry buys Wabash Castings
AFS Corporate Member Wisconsin Aluminum Foundry
(WAF) (Manitowoc, Wisconsin) purchased Wabash Cast-
ings in Wabash, Indiana.
December 2021 MODERN CASTING | 37
 “We are excited to grow our operations and expand
on the success of Wisconsin Aluminum Foundry,” WAF
CEO Sachin Shivaram said in a news release. “Wabash
Castings is renowned for their ability to produce high
volume, complex castings. Their facility forms a perfect
complement to our existing breadth of production lines.
This acquisition will accelerate our growth in the electric
vehicle and consumer goods markets, among other excit-
ing opportunities.”
WAF makes aluminum- and copper-based alloy cast-
ings. It has more than 400 employees. Wabash Castings has
nearly 100 employees.
Gränges invests $33 million to increase aluminum
casting capacity in Tennessee
Gränges, a Swedish aluminum supplier of rolled alu-
minum products for heat exchanger applications, specialty
packaging and niche markets, said it will invest $33 million
to expand its aluminum continuous casting operations in
Huntingdon, Tennessee, to meet growing demand from
North American customers. The expansion includes invest-
ment in buildings and a new casting line.
When completed, the casting capacity in Huntingdon
will increase by about 25,000 tons per year and will enable
higher capacity utilization in the downstream rolling and
slitting operations.
Stainless Foundry & Engineering helps develop
antimicrobial stainless steel
Performance Compounds Inside (PCI) made historic
advancements in metallurgy with its 3PRE Technology, a
novel and proprietary process of activating antimicrobial
properties.
PCI’s first use of its 3PRE Technology is with
molybdenum, an essential element. When activated
through 3PRE Technology, molybdenum takes on
antimicrobial properties and can be added to stainless
steel during the foundry process to render it capable of
destroying and inhibiting bacteria and other disease-
causing microorganisms.
“Our foundry is pleased to have been involved in the
manufacture of the first antimicrobial stainless steel. We
are impressed with the homogeneity and consistency
of the end product and can anticipate multiple uses
across any number of industries,” said Jim Stachowiak,
president & CEO of Stainless Foundry & Engineering
(Milwaukee, Wisconsin).
June 2021
Rolls-Royce to design, manufacture propellers for U.S.
Navy’s Constellation (FFG-62) frigates
Rolls-Royce reached an agreement with Fincantieri
Marinette Marine to design and manufacture up to 40
fixed-pitch propellers for the U.S. Navy’s Constellation-class
(FFG-62) guided missile frigate program.
38 | MODERN CASTING December 2021
The first set of propellers (two per ship) is scheduled to
be delivered to Fincantieri in 2023. The propellers will be
manufactured in Rolls-Royce’s recently upgraded Pasca-
goula, Mississippi, foundry and will be some of the first
work to utilize the newly installed state-of-the-art equip-
ment and renovated facility funded through investments
from the DoD, Rolls-Royce, Jackson County (MS) and the
state of Mississippi.
July 2021
CaneKast, Inc. acquires Superior Aluminum Castings
AFS Corporate Member CaneKast (Chaska, Minne-
sota) and its privately-held companies Ermak Foundry &
Machining, Patriot Foundry & Castings and RDS Dock
Hardware acquired Superior Aluminum Castings in Inde-
pendence, Missouri.
“Four years ago, we started acquiring nonferrous foundries
because we believe in local manufacturing,” said Reg Zeller,
CEO and owner. “We are building a network of facilities that
will provide the benefits of a small business yet have state-of-
the-art technology typically only found in large conglomer-
ates. Superior is a great fit to help us achieve this vision.”
Pace Industries takes headquarters to Michigan
Diecaster Pace Industries relocated its Arkansas headquarters
to Novi, Michigan. The move was expected to create more than
60 new jobs in Novi initially while generating a total private
investment of $1.9 million with the support of a $250,000 Michi-
gan Business Development Program performance-based grant
approved by the Michigan Strategic Fund.
August 2021
Decatur Foundry Inc. completes new molding building
In August, AFS Corporate Member Decatur Foundry
Inc. (DFI) in Decatur, Illinois, went live with its new mold-
ing building, which replaced a molding facility lost to fire in
May 2019. Most of the job shop’s molding is floor molding,
and formerly, coremakers shared mixers with the molders,
said CEO Rex Ragsdale.
The $4.5 million upgrade accounts for over 60% of DFI’s
molding capacity; the balance is provided by its other onsite
molding buildings. The destroyed building provided 42% of
all capacity.
Tyler Pipe plans $35 million facility enhancements
Tyler Pipe, a subsidiary of AFS Corporate Member
McWane, will use approximately $35 million from an 80%,
five-year tax abatement approved by a Texas county commis-
sioners court to modernize its production capabilities and
expand production capacity.
Founded in the mid-1930s in Tyler, Texas, the company
produces a wide variety of plumbing products including
cast iron pipe and fittings. Its products are noted for their
Ford Meter Box
corrosion resistance, and longevity in water and sewage
systems. Improvements are scheduled to be fully opera-
tional by the second quarter of 2022. Tyler Pipe currently
has 368 full-time employees and plans to both retain and
expand its workforce.
September 2021
Ford Meter Box upgrades molding equipment for
complex brass castings
Waterworks product specialists and foundry Ford Meter
Box, an AFS Corporate Member in Wabash, Indiana,
upgraded its existing matchplate molding machine to a
DISA MATCH 14/19 with Automatic Core Setter, the first
MATCH in the new 14/19 size to be delivered to a customer.
Grede buys Neenah’s Advanced Cast Products division
AFS Corporate Member Grede, Southfield, Michigan,
acquired AFS Corporate Member Neenah Enterprises Inc.’s
commercial vehicle business and the supporting capital
assets, select portions of its industrial casting business and the
Advanced Cast Products business in Meadville, Pennsylvania.
October 2021
Doubled demand at Lodge Cast Iron triggers
capital investments
Demand for products made by cookware specialist
Lodge Cast Iron has doubled in the last two years, prompt-
ing the foundry to expand its molding capacity by 30%
with new equipment that will push its yearly output at two
South Pittsburgh, Tennessee, facilities from 70 million lbs.
to 100 million. The foundry bought the first DISAMATIC
D5 molding machine in the U.S and will install DISA’s
full Monitizer digital solution, including the Artificial
Intelligence-driven Monitizer | PRESCRIBE—the latter
is scheduled to be running by next spring.
Donsco, Inc. maximizes auto grinding production
AFS Corporate Member Donsco Inc. rearranged the
layout of one of its two plants for a more efficient working
environment, which includes four Sinto Barinder high-speed,
automated grinders. Donsco installed the machines to reduce
grinding time and create an all-in-one grinding solution.
JD Castings expands in Michigan
JD Castings, based in Niagara, Wisconsin, is expanding six
miles to the northwest in Iron Mountain, Michigan, which
is just over the Wisconsin state line about 100 miles north
of Green Bay. The foundry’s new facility is expected to cre-
ate up to 24 new jobs and generate a total private investment
of $770,000 with the support of a $200,000 Michigan Business
Development Program performance-based grant approved by
the Michigan Strategic Fund.
The company elected to expand in Michigan instead of at
its existing facility in Wisconsin.
November 2021
Stellantis casting facility gets environmental grant
The Kokomo Casting plant owned by Stellantis has received
a $10,000 pollution prevention grant from The Indiana Depart-
ment of Environmental Management in partnership with the
Environmental Protection Agency and the Purdue Manufactur-
ing Extension Partnership (MEP). The funding will go toward
retrofitting its current cooling process, which will result in the
reduction of 305,000 gallons of water per year.
Neenah acquires portions of U.S. Foundry
AFS Corporate Member Neenah Enterprises, the hold-
ing company of Neenah Foundry, has acquired an 18.7- acre
manufacturing facility from Corporate Member U.S. Foundry
& Manufacturing Corp. in Medley, Florida for $17.43 mil-
lion, according to media reports. It represents the first Florida
facility for the 150-year-old company.
December 2021 MODERN CASTING | 39
CASTING INNOVATIONS
Century Foundry Applies Automation for Future Success
Century Foundry, a third gen-
eration, family owned, aluminum-
casting supplier has been excelling
in metalcasting since 1976. Located
in Muskegon Heights, Michigan,
the company offers a single-source
responsibility for aluminum casting,
machining, heat treat, painting and
other selective out-sourcing options to
provide small, medium and large-sized
castings serving over 100 customers of
many markets across North America.
In September 1997, Century
purchased an FBO Sinto automated
flaskless molding machine and an
automated sand system. As business
continued to grow, Century expanded
its production floor to 38,000 sq.
ft. By the time 2014 came around,
Century acquired a third facility,
making the total production area
77,000 sq.ft., with 65+ employees.
The new facility holds a permanent
mold operation, heat treat oven, and
machining operations.
“Working in family business cer-
tainly has its ups and downs, but there
is a deep pride I have coming to work
every day knowing we’re all working
together to keep a business moving
that my family has built,” said Shane
LeRoux, vice president of operations,
Century Foundry. “That pride is what
drives me everyday to work hard, build
relationships with employees and
ensure everyone is working in the best
possible environment.”
Century Foundry produces castings
via green sand molds using both Sinto
automated machinery and manual
Roto-lifts as well as with nobake and
Century Foundry installed an automatic Barinder grinder to reduce cycle time. Century Foundry also operates an automated flaskless molding machine from
Sinto to produce aluminum castings.
40 | MODERN CASTING December 2021
permanent mold processes.
In March 2021, Sinto America
completed the installation of the
X7i-CDH22R-455MR-C Barinder
Grinder for Century Foundry. With
this project, Century was looking to
achieve more consistency on the fin-
ishing end of the casting product.
“Along with the consistency of this
machine, we really enjoy how easy the
machine is to use. We are also im-
pressed with the Barinder providing
a lifetime of sound performance and
quality products,” LeRoux said.
The first casting application that
Century used the Barinder had an
original manual processing time that
was 10:18 minutes on average. This
included the belt grind and a bench
operation for intricate details. With
the Barinder, the cycle time on the
same application, with minimal touch
up was 1:08 minutes, cutting the cycle
time by more than eight minutes,
creating a shortened ROI for the
foudry’s purchase.
“This machine was a large invest-
ment for Century, but after just two
months in production we’re already see-
ing an increase in throughput and con-
sistency,” LeRoux said. “We’re building
multiple fixtures currently to continue
the increase in production numbers.”
The X7i-CDH22R-455MR-C
Barinder Grinder is an automatic
cutting machine for gate and parting
line flash removal on small to medium
aluminum castings. It is suitable for
finishing inside and outside of complex
castings. With this machine, operators
can quickly change out the fixtures,
programs, and tools in less than five
minutes. Simple programming and
operations result in maximum uptime,
while long-lasting tools save operating
costs and reduce dust generation. There
is a two- or four-position servo pallet
changer and a rotating main chip saw
with pivoting end mill tool. Sinto also
offers a chip conveyor, mist lubricator
for the main cutting wheel, and a floor
chute air blow off. This high-speed and
efficient processing enables productiv-
ity and a high finish quality.
Along with the Barinder Grinder,
Century’s operation includes a Sinto
FBO-III Flaskless Molding Machine.
One of the first automated pieces of
equipment that Century purchased,
the Sinto has been running success-
fully for 24 years.
“This machine was brought in to
dramatically increase production and
bring our foundry to the next level,”
LeRoux said. “We went from produc-
ing 10 molds per hour on a roto lift to
producing 60+ molds an hour. This is a
high-quality machine that has proven
longevity. As of May 1, we have 5.1
million molds made off this machine.”
The FBO Flaskless Molding
Machine offers a wide variety of mold
dimensions to the foundry industry. The
robust design provides the confidence
and longevity that a foundry expects.
The design of the FBO molding
machine has safeguards against shifting
of molds. It also has the ability to vary
the molding height, which effectively
adapts the mold size to the various pat-
tern profiles and allows for the most ef-
ficient use of sand. Sinto offers multiple

options with this machine, including:
• Aeration.
• Chaplet.
• Set safety light curtain.
• Pattern heater and vibrator.
• Central lube.
• Sinto Industry 4.0 Analytics (re-
mote service option).
• Ewan remote connectivity.
Ceramic Abrasives Make Finishing Less Grinding on Operators
High temperatures, heavy physical
demands, and the need for constant
attention to safety—such is the work
environment for the foundry’s grind-
ing/finishing operators. One tool
that can help reduce their fatigue and
improve the productivity of a foundry’s
valuable labor is portable ceramic abra-
sives, such as those available at Weiler
Abrasives.
Portable abrasives, used for remov-
ing gates, risers, flash, parting, and other
excess material, are necessary to bring
the cast part into tolerance and make
it suitable for its end use. Traditionally,
zirconia-alumina (ZA) abrasive grain has
CASTING INNOVATIONS
• Air-cooled hydraulics.
• Non-standard pattern heights.
• Plate adapters.
With the automated molding
and automated grinding technol-
ogy Century has invested in over the
years, paired with a highly experi-
enced production team, the company
can prepare customer designs for
been used for finishing work on castings.
When combined with the right bond-
ing system for the application, the high
durability of ZA grain provides fast stock
removal and long life.
In recent years, however, ceramic
grain technology has replaced con-
ventional grains, like ZA, in industrial
applications such as roll grinding and
gear generation. Until recently, ceramic
grain hasn’t been available in a bond-
ing system appropriate for portable
foundry jobs––but new technology is
bringing the benefits of ceramic grains
to the foundry environment.
For example, because of their very
December 2021 MODERN CASTING
production and market with agility
and speed.
“When the molding machine was
brought in, we were able to cut lead
times in half,” LeRoux said. “With
lead times cut in half and the quality
of product the FBO produces, we im-
mediately became more of a player for
higher volume work.”
fine microstructure, ceramic grains
keep a sharp edge and maintain the
ability to make a big chip as they break
down, getting the work done faster.
Additionally, in common abrasive
product geometries, like cups, ce-
ramic offers similar life as ZA-based
products while generating a 20%–40%
faster cut rate. Faster material removal
translates to better productivity and
less operator fatigue.
In other ceramic abrasive prod-
ucts, like Type 27 discs, the bond
system can be manipulated to reduce
edge chipping. An anti-chipping bond
system locks the grain rigidly in place
| 41
CASTING INNOVATIONS
and takes advantage of the grain’s low,
specific cutting energy. This produces
excellent grinding efficiency and uni-
form product wear, allowing operators
to concentrate on the task at hand and
not worry about constantly adjusting
the angle of approach to maintain a
good working edge.
Besides ceramic’s benefits, Weiler’s
abrasives design incorporates an an-
chored hexagon nut design, which se-
cures the abrasive to the tool to increase
safety and prevent product breakage.
A Range of Casting Abrasives
Many different abrasive product
geometries are available for finish-
ing cast parts. These geometries are
designated by type: Type 11 products
are cup shaped; Type 27 products are
disc shaped; Type 1 products are wheel
shaped; and Type 16, Type 17 and Type
18 products are conic/plug shaped.
The physical size of Type 11 prod-
ucts makes them ideal for use on large
castings or forgings that have signifi-
cant amounts of excess material. Al-
though cups are the most efficient way
to remove material, they are not appro-
priate for many applications. In some
Although Type 11 cups are the most efficient way to remove material, they are not appropriate for many applications. Each product type is suitable for
different jobs inside a foundry, and product selection is often based on part geometry.
42 | MODERN CASTING December 2021
instances, it is necessary to perform
cutting operations while also grinding.
In these applications, a Type 27 product
is often the best choice for the work. In
other applications, the operator needs
access to part features that are too small
to reach with larger products. When
this occurs, cone- or plug-shaped abra-
sives are usually selected.
Each abrasive product type is suit-
able for specific foundry finishing ap-
plications, and selection is often based
on part geometry. For example, if a
parting line must be removed from a
This image shows two Type 27 grinding wheels.
The wheel on the left shows chipping, while the
wheel on the right shows even wear.
part’s ID, an angle grinder with a 6-in.
cup or a 9-in. Type 27 wheel won’t fit
inside the part. But a die grinder with
a cone that is 2 or 3 in. in diameter
will fit into the space.
Grinding Reminders
Operator fatigue can lead to short-
cuts, and shortcuts lead to accidents.
One thing operators should always
be mindful of is that the tool and
grinding media must be correctly
matched, and the orientation of the
grinding product to the casting must
eliminate the possibility of impinge-
ment, which can cause wheel breakage.
Portable grinding with large tools
and media in harsh environments is
physically exhausting. Finishing tools
can weigh 5 lbs. or more, with a few
extra pounds of consumables on the
end. Choosing abrasives that allow
operators to grind faster while using
less pressure helps reduce fatigue.
Weiler’s faster-cutting ceramic abra-
sives result in shorter grinding cycles,
which in turn, increase the output per
hour of the foundry with a reduced
risk of fatigue-induced mistakes and
accidents.
FOR THE CEO
Succession Planning—Have You Started?
BOB SILHACEK AND MICHAEL WISE, TURNING POINT MANAGEMENT ADVISORS LLC (MINNEAPOLIS)
Y
ou have spent your entire
professional life owning and
leading your family business.
You are the founder or next-gener-
ation family member running the
business and you are now approach-
ing retirement age. To retire you
will need to transfer your leadership
responsibilities to a next genera-
tion family member and potentially
some, or all, of your ownership. Have
you prepared a plan to transfer the
leadership responsibilities and own-
ership to the next generation? Many
family business owners have no
succession plan in place when they
approach their retirement date.
Several articles have been
written about “The Great Wealth
Transfer” that is expected to hap-
pen over the coming years as Baby
Boomers pass their wealth to next
generations. Much of the wealth
transfer involves family businesses.
Many estimates place the value to
be transferred between $50 trillion
and $70 trillion over the next 25
years! Nearly $9 trillion, or almost
half of U.S. GDP, will be trans-
ferred in the next seven years alone.
A few more interesting data
points about family businesses: Ac-
cording to a recent Deloitte Family
Business Survey, just over one-third
of families agree that business objec-
tives align with family goals, less
than a third fully agree about the
future development of the business,
and exactly one-third would already
be willing to give up control of the
family business. This survey points
to the criticality of a succession plan
that clearly addresses the family’s
and business’ goals and objectives.
Have you created your succes-
sion plan? Many business owners we
work with are so consumed by their
daily work they have never taken the
time to create a succession plan that
will allow them to retire when they
want to. Not having a succession
plan in place introduces many risks
and unknowns when that retire-
ment day approaches, which can be
44 | MODERN CASTING December 2021
avoided with proper planning well
in advance.
What is a succession plan? A suc-
cession plan outlines how you will
transfer leadership and ownership
to a family member(s) (next genera-
tion), non-family member(s) on your
management team or a third-party
acquiring entity. This is a quite simple
succession plan definition. Succes-
sion plans can be incredibly detailed
and complicated given ownership
and wealth transfer issues that have
tax consequences. We suggest you
consider using outside experts to help
you, your family and the organiza-
tion complete the plan. If you have an
Succession plans can
be incredibly detailed
and complicated given
ownership and wealth
transfer issues that
have tax consequences.
advisory board or board of directors
with nonfamily members, they can be
extremely helpful in this process.
Let’s start with the leadership
portion of the plan. You have been
the president and CEO of your
family business for a long time. You
have a strong management team that
may consists of family and non-
family members. Have you laid out
the transition plan for someone on
that team to assume your role? Has
that individual been trained to assume
your role? When it comes to family
members, many times owners just as-
sume that a child will take on the top
leadership role when they retire. How-
ever, without adequate training, both
outside and inside the organization,
that child may not be successful in the
new role. For next generation leader-
ship to be successful they need the
appropriate higher education, manage-
ment experience at another company
and experience at your company in
appropriate disciplines (operations,
sales, finance, etc.) and management.
If a family member is not in the plan
to assume your role, have you identi-
fied a current nonfamily manager to
transition into your role? A non-family
member transition to the leadership
role can many times be much easier
given family dynamics (multiple
siblings, ownership structure, wealth
transfer, etc.). However, there can be
situations where family members and
non-family managers are not ready
for the leadership role when you are
ready to retire. In some cases, a sale
of the company to a third party may
be the right solution.
Regarding your ownership, what
are your plans? Do you plan to retain
your ownership level, reduce it by
passing some on to family members
or management team employees, or
completely sell it to fund your retire-
ment? As mentioned earlier, owner-
ship changes within a family-owned
business can be complicated depend-
ing upon the structure. Many wealth
transfer and tax related issues must be
considered as part of your succession
plan. It is a crucial part of your succes-
sion plan, and you should be seeking
advice from outside advisors.
Let’s look at some options you may
want to consider in your succession
plan relative to ownership and your
family’s goals.
1. Retain full business owner-
ship with next generation leadership.
This is the hardest option, as the new
next generation leadership will have
to overcome “the old ways” of doing
business. There are many examples of
family businesses where leadership
was passed on to the next genera-
tion only to be reclaimed by the older
generation when they saw changes in
the business they didn’t like or were
not in agreement with. If you pass
leadership on to the next generation,

you need to trust their judgment; too
many times the “older generation”
takes the business back over.
2. Retain minority ownership,
with next generation or manage-
ment member leadership. This is less
difficult as the older generation has
given up ownership control which
allows the next generation or a man-
agement member to drive business
results without pressure to follow
“the old ways” of doing business.
This allows new leadership to ex-
plore new ways of doing business to
facilitate growth. The fact that the
older generation has no control can
also lead to conflict when they want
to exert some level of influence.
3. Retain minority ownership but
bring in new outside leadership. If
the next generation or the manage-
ment team are not ready to assume
the leadership role, then bringing in
outside management with the skills
and experience to drive short- and
long-term growth objectives will
benefit all stakeholders. It sends a
clear message of change and moving
in a new direction, especially if the
new manager invests capital as part of
your ownership transfer. This may be
a great option, but you really have to
perform strong due diligence on can-
didates to get a leader who can adapt
to the culture (though not totally)
and yet make changes they know are
important for the future success and
growth of the business.
4. Sell the business entirely and
realize the value of your ownership for
retirement. If the next generation has
no intention of leading or owning the
business going forward, a sale of the
business may be your best option. This
option eliminates the family dynam-
ics from the economic transaction and
allows you to freely pursue potential
financial and strategic buyers. This
will require a significantly different
approach as buyer due diligence and
outside valuations come into play.
Seeking outside advisors is critical
December 2021 MODERN CASTING
FOR THE CEO
when conducting a sale of a business.
As we mentioned earlier, the historic
transfer of wealth will be comple-
mented by an equally historic number
of family businesses that will invite
outside owners and managers to help
move the business forward when the
next generation is unable to do so.
There are no cookie-cutter solu-
tions to family business transitions
of leadership and ownership. Family
businesses have many stakehold-
ers, including suppliers, customers,
employees, family members, and local
communities. The decisions on leader-
ship and ownership transfers incor-
porated into your succession plan will
affect all your stakeholders. Starting
a succession plan years in advance of
your retirement will give you the time
to address all the issues.
Bob Silhacek and Michael Wise co-founded Turning Point
Management Advisors, LLC (www.turningpointmgmt.com),
a Minneapolis-based management consulting firm providing
turnarounds/business recovery solutions, interim executive
management, ownership transitions and sale and acquisition
advisory services to companies and their stakeholders that
have reached a critical juncture.
| 45
AFS NEWS
CastExpo 2022 returns, registration open
Thousands of people from across
the worldwide metalcasting supply
chain will network, learn, and do
business at North America’s largest
foundry event when it returns for
the first time since 2019.
CastExpo 2022 is coming to
the Greater Columbus Conven-
tion Center on April 23-26, 2022,
and registration is now open.
Hosted by the American Foundry
Society, this trade show and
congress features exhibits from
industry suppliers and metalcast-
ers, full-scale equipment demon-
strations, educational sessions on
technical and management topics,
keynotes, metalcasting classes
from the AFS Institute, and more.
Exhibits, presentations, and
featured events at CastExpo
incorporate every major alloy,
process, and related foundry and
46 | MODERN CASTING December 2021
manufacturing topic. The event
attracts people at all stages of their
careers, ranging from executives and
managers to technicians, engineers,
sales staff, researchers, and educa-
tors. In addition to content for met-
alcasters, a unique series of training
sessions just for casting designers
and buyers is offered on the exhibit
floor, so OEM representatives are
encouraged to attend, as well.
To take part in everything Cast-
Expo has to offer, including every
technical and management session,
all Institute courses, keynotes, the
Hoyt Memorial Lecture, and the
exhibit floor, opt for the all-inclusive
Education Pass. To view exhibits
plus keynotes and the Hoyt Memo-
rial Lecture only, the Exhibits Pass
is right for you. For more informa-
tion and to register, visit
www.castexpo.com.
AFS urges President
to take action on
supply chain
Solving the truck driver shortage
would help ease the nation’s supply chain
challenges, so AFS joined with more
than 100 organizations calling on the
Biden Administration to act.
In an open letter shared with the
White House and Congressional staffers,
the coalition suggested five actions that
would reduce strain on supply chains by
increasing the number of truckers on the
road: implementing the Younger Driver
Pilot Program, promoting transporta-
tion and supply chain careers, allowing
flexibility in vaccine mandates, hours of
service relief, and working to minimize
bottlenecks in ports.
The signatories, which include
trade associations covering dozens of
industries, said they stand ready to
help deploy these programs.
 COLLEGE CONNECTION

When Moving Backwards Is a Good Thing

PAM LECHNER, DIRECTOR OF ALUMNI & ACADEMIC RELATIONS, FEF (SCHAUMBURG, ILLINOIS)

T
o the joy and relief of FEF volved with open foundry days when liquid metal very interesting. I then
students and professors, con- I was in college. The two big reasons began taking as many courses as I
ditions are such that regular it’s important for me to attend this could on metal casting,” Stasko said.
outreach activities are now able to event is to give back and to hopefully Wolf added, “While attending
be scheduled and hosted on many recruit young minds with interest in college I was fascinated with design-
campuses. Tours of local foundries are the foundry industry for our co-op ing a part and physically making it.”
also now being enjoyed by students program at Metal Technologies.” Activities and experiences, in ad-
and professors. Both Stasko and Wolf mentioned dition to book-learning and lectures,
One such campus that has been that one of the reasons they con- are important opportunities offered
able to schedule some of these ac- tinued in the industry was because at FEF’s network of colleges and
tivities is Trine University in Angola, of their exposure to designing and universities. And encouragement
Indiana. In October, the Mechanical pouring castings. from FEF alumni has an immeasur-
Engineering students participated in a “I found the process of pouring able impact.
tour of Metal Technologies as well as
hosted an open foundry day.
Trine alum, Kramer Pursell
(Metal Technologies metallurgist),
met with the students to give them
a little background on the company
and prepare them for the processes
they would be seeing during the
tour. One of the important outcomes
of a facility tour is that students are
able to visualize how the things they
are learning are actually put into
practice in a real-world application.
Open foundry days are another
highlight for current, past, and
future students. Current students Trine University students visit Metal Technologies.
use their knowledge of the cast-
ing process to help future students
cast their own mementos. Future
students are exposed to the excit-
ing and important field of manu-
facturing. Past students have the
opportunity to encourage the next
generation to continue their pursuit
of metalcasting.
At one of the open foundry days,
former Trine students Dylan Stasko
and Devin Wolf spent the afternoon
in the Trine foundry. Wolf is cur-
rently employed as a process engi-
neer at Metal Technologies; Stasko
is currently employed at GM, also as
a process engineer.
“I think it is important to stay
connected with the university and
students to continue to grow the in-
dustry. It was my first time returning
to campus since graduating,” Stasko
said. “I enjoyed looking at some of
the work that students were doing.” From left, Michael Nunez, Luke McClung, Schuyler McNaughton, and Matthew Clark display their
Wolf added, “I was actively in- PPE at the Trine University foundry.

December 2021 MODERN CASTING | 47

METALCASTING
AFS NEWS SUPPLIES
Datalogger for Demanding Heat Treat
Applications
Datapaq Furnace Tracker
System from Fluke
Process comes com-
plete with the TP6 data
logger, thermal barriers,
and intuitive software.
Designed to be used
repeatedly, in-process in
the most hostile manu-
facturing environments, it provides accurate and reliable
through-process temperature surveys and helps users improve
process performance, decrease downtime, reduce temperature
uniformity survey (TUS) reporting times, and more. The
Datapaq TP6 Data Logger can withstand the longest, most-
demanding operating conditions and features a 316-grade,
stainless-steel case with a IP67 rating, making it water resis-
tant. The datalogger is available with either 10 or 20 thermo-
couple inputs and can be specified for use with base or noble
metal thermocouples. The latest thermal barrier models are
ideal for high-temperature heat treat processes and have been
designed to provide maximum thermal protection—including
applications such as vacuum and controlled atmosphere, slab
reheat and solution aging, among others.
Visit www.flukeprocessinstruments.com for more information.
48 | MODERN CASTING December 2021
Emission-Free Feeder Sleeve
FOSECO’s new
FEEDEX FEF is a highly
exothermic, high-strength
feeder sleeve ideal for
high-pressure casting,
to support green sand
foundries that want to
reduce environmental impact and costs while meeting their
increased demand for high-performance spot feeders. It of-
fers the identical industry-valued easy application, consisten-
cy, and high strength of conventional low fluoride FEEDEX
HD products, which makes the new feeder sleeves particu-
larly suitable for the challenges of high-pressure automatic
molding lines. The new sleeve material is the latest addition
to FOSECO’s fluoride-free portfolio, which also includes
KALMINEX 2000 and KALMINEX SD insert sleeves for
tougher conditions. To further benefit foundry sustainabil-
ity-related targets, FEEDEX FEF is manufactured with a
novel, renewable binder system that avoids the use of non-
renewable conventional PUCB binder systems. Beyond their
environmental advantages, ram-up sleeves meet the mechan-
ical and productivity demands of complex high-precision
casting. Applying the feeding solutions avoids shrinkage
defects and improves casting yields.
Visit www.vesuvius.com for more information.
HELP WANTED

A prominent Equipment company

is searching for:
A MANUFACTURING SALES REPRESENTATIVE Industrial Engineer
Job Summary Charlotte Pipe & Foundry Company has ex-
Candidate is required to sell goods to businesses, government agencies, and other organization. Contact cellent opportunity for an Industrial Engineer.
customers, explain the features of the products, negotiate process, and answer any questions that the
Job Summary: Position will work closely
customers may have about the products. Will visit with current clients and prospective buyers.
with Operations to lead process improve-
Essential Functions: ments and improve efficiency through
• Be a self-starter. production operation. Drive improve-
• Excellent presentation skills. ments through production process with
• Excellent communications, both written and verbal. improvements to layout and equipment
• Able to build and maintain customer partnerships. utilization. Organize and lead production
• Able to conduct research using internet and other resources to compile reports and analysis as required. improvement programs assigned by
• A team player, and able to interact with all level of management. management team. Establish methods for
• Able to work independently and exercise good judgment. maximum utilization of personnel.
• Able to read Technical Prints and Electrical Schematics. Minimum Requirements:
• Able to work hands-on with Installation Department.
Bachelor’s Degree in Industrial
• Computer literate and have good math skills. Engineering or related
• Will handle miscellaneous duties as required.
Good communication skills
Essential Physical Requirements:
• Communicate information and ideas, both written and verbally so others will understand. Please send resumes to:
• Read and understand information and ideas presented in writing. tcostello@charlottepipe.com
• Have a valid driver's license and able to drive an automobile.
• Able to travel on short notice by public transportation including (i.e.: aircrafts, trains, bus,
cars) domestically and internationally. FOUNDRY FOR SALE
• Must disclose any surgical implants, pins, braces or other devices that could be affected by
magnetic and induction fields. ALUMINUM PROTOTYPE CASTING FOUNDRY spe-
Condition of Employment: cializing in quick turnaround. Due to an unexpected
• Must be able to satisfactorily complete the hiring process requirements which includes a occurrence, this highly profitable company is for
comprehensive assessment, drug testing, and a background check. sale. A small family owned business with dedicated
workers located in Temperance, MI. Twenty year
Please send Resumes to: fabio@afsinc.org and reference Box number 2407 veteran who started the foundry. It has a strong
EOE customer base and is turn key. 734-621-1092
Mrsmartin2158@gmail.com

CASTING SOURCE Your knowledge is valuable. Let the AFS

THE LEADING Institute help you share it.
RESOURCE You, an active member of the metalcasting industry, have the experience we
need to drive the direction of our growing skills training program. There are
FOR THE opportunities for course facilitation and curriculum development in both vol-
unteer and paid capacities.
METALCASTING Course facilitation requires a minimum of semi-annual travel and the ability
SUPPLY CHAIN to be comfortable speaking with large groups. The Institute provides you with
online training to hone your skills of managing the delivery of professionally
developed curriculum and yearly evaluations for personal facilitation develop-
develop-
ment.
When you are involved in curriculum development, you have a unique oppor-
tunity to provide input about the skills the industry needs to grow. No travel
is required. Work with professional adult-learning experts who create course
materials from the knowledge and content you provide.
For more information, contact
Jen Christian at
jchristian@afsinc.org A D V O C AT E
. E
D U
or complete a quick form at:
CA
TE

https://americanfoundrysociety.wufoo.com/
. IN

forms/afs-institute-instructor-sme-application/
N O VAT E .

AND THE INSTITUTE

CASTINGSOURCE.COM

December 2021 MODERN CASTING | 49

HELP WANTED

A D V O C AT E

AMERICAN FOUNDRY SOCIETY AMERICAN FOUNDRY SOCIETY . E

D U

CA
Education and Member Engagement Manager

TE
. IN
JOB DESCRIPTION

Marketing and Communications Specialist
Position Reports To:
Director of Marketing and Communications
Purpose:
This position ensures the effective delivery of AFS messaging via Internet,
email, social media, print media, media relations and other channels.
Duties include project management, strategic communications planning,
writing, marketing, web posting, event staffing, media relations, basic
document layout, and other public relations outreach.
Key Accountabilities:
• Coordinate AFS-wide actions needed to ensure that AFS and Institute
conferences, trade shows, programs, messages, and courses are
promoted on time, according to the Comprehensive Marketing Calendar
via multiple media channels.
• Exercise primary responsibility for ensuring that main AFS website
– afsinc.org – is current, accurate and optimally communicates AFS
messaging at all times.
• Monitor web usage rates and report back results on a monthly basis.
• Exercise primary responsibility for advancing AFS messaging through
social media. Monitor statistics and report back conclusions.
• Serve as Marketing Division liaison to the AFS Institute and manage commu-
nications efforts on behalf of the Institute. Advise the Institute on best ways
to segment audiences and achieve Institute communications goals.
• Prepare parallel social media posts to promote coming magazines.
• Handle promotional e-mails for all of AFS, pulling lists from the database,
formatting HTML, etc.
• Complete daily writing assignments with excellent diction, spelling, and
punctuation.
• Post items to website and monitor site constantly for documents that are
obsolete or in need of updating.
• Track website visitors and identify what stories are most popular with the audi-
ence, tracking and reporting on audience overview, user acquisition, users by
time of day, pageviews, active users, and more.
• Assist in survey development, collection, and analysis of results.
• Committee liaison duties may be assigned.
• Ability to manage multiple tasks and projects simultaneously in a fast-
paced communications environment.
• Ability to learn internal AFS programs required.
• Prepare congratulatory letters for CEO’s review and signature, drawing from
articles in foundry magazines.
• Perform other duties as assigned.
Required Skills or Experience:
• Bachelor’s Degree in Public Relations, Communications, Journalism,
Digital Media or Marketing (with great writing samples).
• 2-4 years of experience in a fast-paced public relations, communica-
tions, copy-writing or marketing setting.
• Excellent writing, speaking, listening, and project-organization skills.
• Must be fluent in English, written and spoken.
• Proficiency with MS Office and social
media are mandatory. A D V O C AT E
. E
DU
• Knowledge of Photoshop highly desired.
CA
TE
N O VAT E .
Position Reports To:
Director of Training Solutions AND THE INSTITUTE
Purpose:
This position delivers on the business objectives of the
Institute by providing high-quality customer service, performing sales out-
out-
reach, fostering customer retention, and coordinating instructor activity. The
Institute is the education and training arm of the American Foundry Society.
Key Accountabilities:
• This position requires a well-organized, outgoing, and proactive individual
who thrives on engaging with customers and prospects (in person, Zoom,
phone and email) and helping them make the most of the programs
offered by the Institute. Comfort in presenting, asking for business and
securing new-business or renewal commitments is required. Excellent
communication skills are needed.
Customer Relationships:
• Make direct sales calls on current and potential customers, assess
business needs and identify appropriate Institute products, services
or packaged solutions to meet the needs.
• Develop ongoing customer relationships (through presentations, phone,
email, direct mail) that result in increased sales and customer retention for
the Institute’s live, electronic, and virtual training programs.
• Monitor and analyze sales and retention trends.
Course Scheduling and Instructor Relations:
• Collaborate in developing the course schedule, lining up instructors
and cost-effective venues, and administering post-course evaluations.
• Monitor students’ class evaluations for trends and coach instructors on ar-
eas for improvement, in consultation with the Director of Training Solutions.
• Travel to course sites as program manager, when needed.
E-Learning Program Growth and Administration:
• Foster the growth of the e-learning program by administering a comprehensive
year-around Foundry E-Learning subscriber retention program with contacts at
the 1-month, 6-month, 11-month and 12- month time frames.
• Monitor each subscribing company’s usage continuously to proac-
tively identify “drop risks” and and develop strategies for retention
. Ensure subscribers have access to all information and support
needed to derive the greatest possible benefit from Foundry E-
Learning. Serve as LMS subject matter expert and train customers on
how to use the product as needed.
• Perform Foundry E-Learning demonstrations and follow up with recipi-
ents to close sales.
• Train new and assigned internal staff on how to use the LMS.
• Foundry E-Learning Marketing: Write a monthly e-newsletter and other
materials, as needed.
Administrative and Marketing Duties:
• Maintain and interpret statistical information and student records, material
preparation,executingNorthAmericanMailings,classroomandlabmaterialsetup,
workbookpreparation,placingfoodorders,catalogupdates,andlogisticalsupport
toinstructors.CollaboratewithMarketingDivisionasneededonmarketingsupport.
• CEO and Business Development Projects: As a secondary responsibility, sup-
port the CEO and AFS Business Development VP through posting information
to Salesforce, assisting with BD initiatives, and similar projects.
• Perform other duties for AFS and the Institute as assigned.
Required Skills or Experience:
• Bachelor’s degree in Business, Communications, Marketing, or similar field.
• 3-5years’associationorcontinuingeducationprogramexperienceorsimilar.
• History of successful inside sales experience.
• Well-developed project management skills; excellent oral and written
communication skills; ability to prioritize and manage multiple ongoing

• Familiarity with CRM and e-blast tools projects in a fast-paced environment.

. IN

preferred, but not required. • The ideal candidate will be computer proficient with a background in Salesforce
NO

(or similar CRM), learning management systems, and Microsoft Word, Excel,
VAT E .

• Excellent project-management skills.

• Familiarity with manufacturing and
business-government relations is a plus.
• Occasional Travel required
• Must have valid driver's license.
For more information, contact Cathy Potts at cpotts@afsinc.org
PowerPoint, and Outlook, including being able to navigate Office 365.
AND THE INSTITUTE
• Ability to work as part of a team.
• Must be able to read and write in English.
• Must be self-motivated and possess the ability to work independently and use
sound, independent judgment.
• Ability to travel and work flexible hours when assigned for events and
virtual courses.
For more information, contact Cathy Potts at cpotts@afsinc.org

50 | MODERN CASTING December 2021

HELP WANTED

MELT SUPERINTENDENT
Must have prior Electric Arc Steel melting experi-
ence but will consider similar iron or induction
furnace background. Prior supervisory experience
EXCITING CAREER
required. Must have critical decision-making abil-
ity regarding equipment, materials, operations, OPPORTUNITY
personnel, quality etc. Conducting tests and
inspections of products, services to evaluate
quality or performance. Interested candidates
please contact: jobs@maynardsteel.com
Technical Director
AFS seeks a Technical Director to join our Metalcasting Technical Service Division. The ideal
candidate will have experience in environmental health and safety (EHS), ferrous metalcasting

HIT
and/or additive manufacturing. The position may be based in the Chicagoland area or remotely,
elsewhere in the United States.
Key Accountabilities:
• Staff AFS technical committees as assigned.
• Help plan and execute AFS conferences and workshops as assigned.
• Stay informed about current issues and be a primary technical resource to the metalcasting
industry and internal colleagues.
• Convey technical information and AFS policy positions orally and in writing.
• Write columns for magazines and deliver content for other AFS media.
• Serve as a speaker to AFS chapter meetings and other audiences.

YOUR
• Position requires travel, occasional weekend and evening work.
• Perform other duties as assigned.
Required Skills or Experience:
• A minimum of a bachelor’s degree in engineering, materials science, or other relevant field.

TARGET
• A minimum of 5 to 7 years of relevant manufacturing or related experience with
insight into metalcasting.
• Knowledge of ferrous metalcasting, environment, safety
and health or additive manufacturing is preferred. A D V O C AT E
. E
DU
• Ability to think on one’s feet and convey information
with

CA
persuasively orally and in writing.

TE
• Deep commitment to superior customer service, internally

. IN
and externally.

NO
AFS CAREER

VAT E .
• Must be able to multitask and effectively manage multiple
projects simultaneously.
OPPORTUNITY • Strong team leader and team player.
AND THE INSTITUTE

• Ability and willingness to travel.

PACKAGES. • Must have valid driver's license.

To apply for this exceptional career opportunity with AFS,

contact Cathy Potts at cpotts@afsinc.org

Career
Opportunities

Packages
Available Now!
MODERN
CLASSIFIED
CASTING
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY ADVERTISING
Visit us at: Contact:
www.afsinc.org www.moderncasting.com/classifieds
For full pricing details
Fabio Cavalieri at 847/827-3622
E-mail: fabio@afsinc.org

December 2021 MODERN CASTING | 51

FOR SALE-USED EQUIPMENT
BAGHOUSE DUST COLLECTORS:
ETA 2 MODULE (2) 7515x120, 220,000 cfm, 35,326
ft² filter media, pulse clean, (2) 400hp blowers
ETA 2 MODULE (2) 4515-120, 130,000 cfm, 21,204
ft² filter media, pulse clean, (2) 250hp blowers
SCHENCK PROCESS 144RPT812 pulse-jet
baghouse dust collection system, 100,000 cfm.
Blower and controls.
AEROPULSE 912-10, 85,000 cfm Pulse Jet Bag-
house, 14,320 sq ft filter area, blower & controls
BACT 630, 80,000 cfm Baghouse, 12,126 ft²
Filter Media, Pulse Clean
DONALDSON TORIT 484RF 12, 70,000 cfm Round
Baghouse, 7,555 ft² filter media, blower, controls
DONALDSON TORIT 376RF12, 50,000 cfm Round
Baghouse, 5,869 sq ft filter media, blower & controls.
DONALDSON DALAMATIC, 35,000 cfm Pulse Jet
Baghouse, 5,653 sq ft filter, envelope-style filters,
pulse clean (2) systems available
STEELCRAFT MP-10-256-3161, 25,000 cfm pulse jet
baghouse with blower, connecting ductwork, controls
CARTRIDGE DUST COLLECTORS:
WHEELABRATOR #822 WCC 36 cartridge,
120,000 cfm, 55,440 ft² filter media, caged ac-
cess ladder, rotary airlock discharge
UAS DUST HOG SBD 160-4, 110,000 cfm,
49,600 ft² filter media, A/R inlets, pulse, blower,
(4) systems available
FARR 144XL, 100,000 cfm, 40,608 ft² media,
screw conveyor discharge, blower
DONALDSON TORIT DFO4-144, 80,000 cfm, 27,360 ft
media, pulse clean, screw conveyor, blower & controls.
TORIT #4DF128, 60,000 cfm, 28,928 ft² media,
Reconditioned, Blower, Controls
MAC PROCESS 3MTF84, 57,000 cfm, 24,780 ft me-
dia, pulse clean, screw conveyor, blower & controls
TORIT #DFT4-80, 45,000 cfm, 20,320 ft² media,
reconditioned, blower
WHEELABRATOR, 45,000 cfm, 22,050 ft² media,
Model 514 WCC 36 (70) cont., pulse clean
CAMFIL FARR, #GS-48, Gold series, 45,000 cfm,
15,600 ft² filter media, pulse clean, blower, controls
CAMFIL FARR #GS-36 “Gold Series” cartridge,
40,000 cfm, 11,700 ft² filter media, automatic
pulse clean system, 100HP top mount blower
TORIT #DFT4-48, 30,000 cfm, 12,192 ft² media, extended
dirty air plenum, air management module, blower, controls
DONALDSON TORIT #DFE4-32, 25,000 CFM,
8,128 sq. ft. filter media, MaxPulse filter cleaning
system with venturi assisted pulse clean system,
IEP inlet isolation valve & rotary airlock
CAMFIL FARR #GS-24 “Gold Series” cartridge,
20,000 cfm, 7,800 ft² filter media, automatic
pulse clean system, 60 HP top mount blower
CAMFIL FARR GS-16, 14,000 CFM, 5,200 sq. ft. filter
media, automatic pulse clean system, (2) hopper
DONALDSON TORIT DFT3-24 cartridge, 12,000 cfm,
6,096 ft media, explosion vents, pulse clean, blower
DONALDSON TORIT DFE2-4 Evolution, 3,000
cfm, 1,016 ft media, blower, controls (2) available.
HIGH VAC SYSTEMS:
ULTRAVAC #201SP, 485 cfm, reverse pulse self
cleaning filtration system
AM16236 HI-VAC MODEL: 220 portable indus-
trial vacuum system – 20 HP blower, dumping
hopper for collected material.
MANY OTHER DUST COLLECTORS IN STOCK!
Check out our website!
www.amindustrialmachinery.com
AM INDUSTRIAL
216-433-7171
charles@amindust.com
52 | MODERN CASTING December 2021
Visit FLSales.com for the largest online equipment inventory
• Our website is updated hourly for the best selection
• Complete listing of upcoming liquidations and auctions
• Certified appraiser on staff
• We offer cleaning and painting
• We offer reconditioning and rebuilding
We’re the one-stop resource for buying and selling foundry equipment
We have completed a facelift at our warehouse. Schedule a visit today,
over 900 items in stock.
WWW.FLSALES.COM 440-498-8484 JGREENE@FLSALES.COM
World Equipment & Machine Sales Co.,
Any good surplus foundry equipment 4550 Darrow Rd, Stow, OH 44224
for sale-we offer free advertising
Shipments & Warehouse:
at www.aapfoundryequipment.com 1700 Commerce Dr, Stow, 44224
A.A.P. Equipment inc. 450-266-0607
Tel: (440) 519-1745
Fax: (440) 519-1748,
Direct (440) 287-7205
FOR SALE—B & P Lab Mulbaro, Cincinnati 12” email: mike@foundry-eqpt.com
Lab Muller, Simpson 18” & 24”. Lab Mullers,
Simpson #05 Porto-Muller, Simpson #1F Mix-
Muller. Rebuilt Falk. Reducers for Simpson #1F, USED AND REBUILT FOUNDRY
#1.5F, #2F, #1.5G, #2G & #2.5G. Muller wheels EQUIPMENT FOR SALE
for Simpson. #1F, #1.5F, #2F, #1.5G, #2G, #2.5G
& #3G. Many new, reconditioned & used items Our Website Is updated Daily
available for all sizes of Simpson Mix-Muller and WWW.FOUNDRY-EQPT.COM
Multi-Mull. Additional information upon request
– Korco Mfg. Inc. 724-758-5020 Come visit us at our
NEW LOCATION in Stow, OH
EQUIPMENT FOR SALE
COKELESS MELTING FURNACE for melting ferrous
metals. Sweating capabilities to separate non-
ferrous from comingled scrap - Natural Gas fired -
Includes Heat Recuperator for pre-heating combus-
tion air - rated at 2 Tons per hour - Manufactured
in USA - New 2017 - Contact Splitvane Engineers
Inc, sales@splitvane.com; ph +1 360 988 6058
410 West 3rd St - Sumas WA 98228 USA
MODERN PROFESSIONAL SERVICES
CASTING
Peter E. Macler
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY Associates, PLLC
CLASSIFIED Foundry Design and Engineering Since 1987
pm@maclerassociates.com
ADVERTISING www.maclerassociates.com
830-481-3193
Visit us at: 1347 Grand Pass, Canyon Lake, TX 78133
www.afsinc.org/MCclassifieds
For full pricing details
Contact: Career Opportunities
Fabio Cavalieri at 847/827-3622
E-mail: fabio@afsinc.org Packages Available Now!
FOR SALE-USED EQUIPMENT PROFESSIONAL SERVICES

PHOENIX INDUCTION CORPORATION

GreenSand Controls Inc. is the leading
supplier of process control equipment for
controlling the production and quality of
green sand used in the metal casting industry.
GSC not only sells a complete line of foundry
equipment from green sand preparation to
molding and metal handling systems, but
also refurbishes old Hartley Controls sand
testing equipment and has spare parts to boot. “An Induction Supply Company”

P.O. Box 247 W740 HWY 110 • Provide professional, qualified service for
Fremont, WI 54940 AJAX*, AIH*, IEH*, PPS*, Robotron* and
Ph: 920-446-2468 Fax: 920-446-2469 Bone Frontier* power systems
email: greensandcontrols@hotmail.com • Board repair, capacitors, SCRs, IGBTs,
transformers and spare parts for
OEM equipment
• We sell used, rebuilt and new power supplies
HELP WANTED
248-486-8760
sales@phoenixinduction.com
www.phoenixinduction.com
Your knowledge is *Registered trademarks of their respective companies

valuable. Let the

AFS Institute help
you share it.
You, an active member of the met-
alcasting industry, have the experi-
ence we need to drive the direction
of our growing skills training
program. There are opportunities
for course facilitation and curricu-
lum development in both volunteer
and paid capacities.
Course facilitation requires a mini-
mum of semi-annual travel and the
ability to be comfortable speaking
with large groups. The Institute
provides you with online training
to hone your skills of manag-
manag-
ing the delivery of professionally
developed curriculum and yearly
evaluations for personal facilitation
development.
When you are involved in cur-
riculum development, you have
a unique opportunity to provide
input about the skills the indus-
try needs to grow. No travel is
required. Work with professional
adult-learning
experts who A D V O C AT E
. E
D
create course U
CA
TE

materials from
. IN
NO

the knowledge
VAT E .

and content you AND THE INSTITUTE

provide.
For more infor-
mation, contact FOUNDRY FOR SALE
Jen Christian at
FOR SALE in MAINE: Modern solid mold foundry, specializing in Brass & Bronze investment castings since
jchristian@afsinc.org 2001. Well known for custom architectural hardware, antique auto & boat components plus much more.
or complete a quick form at: This is a wonderful opportunity so leave the RAT RACE and enjoy owning your own business! Michael
https://americanfoundrysociety. Hall The Jordie Lee Company 207-773-1111
wufoo.com/forms/afs-institute- MIDWEST ALUMINUM FOUNDRY with automatic sand, permanent mold, and air set sand. In-house heat
instructor-sme-application/ treating, machine shop. Serving automotive, industrial lighting, pipeline tools and marine industries.
In business since 1952 many long-term customers, owner retiring. Contact: thunsinger@usa.net

December 2021 MODERN CASTING | 53

EMPLOYMENT

40+ Years Experience

Management / Executive
Search and Recruiting
for Metalcasters

All Functions / Metals

Professional / Confidential
Nationwide / Worldwide HELP WANTED
Customer Focused

Gregory Borchert
President
greg@glborchert.com 720-336-5818

Colin Borchert
colin@glborchert.com 512-795-4310

www.glborchert.com

Career
Opportunities
Packages Available Now!

54 | MODERN CASTING December 2021

 ADVERTISING INDEX

AD INDEX
Company Page Email/Website Phone FAX Contact

Anderson Global 19 SalesTeam@andersonglobal.com 231-733-2164 Customer Service

ASK Chemicals inside front info.usa@ask-chemicals.com 800-848-7485 614-790-3941 Customer Service

Conveyor Dynamics 8 www.conveyordynamicscorp.com 636-279-1111 636-279-1121 Mike Didion

Didion International, Inc. 1 info@didion.com 636-278-8700 636-278-3155 Art Grillo

FEF 48 www.fefinc.org 847-490-9200 847-890-6270 Brian Lewis

General Kinematics Corporation inside back mail@generalkinematics.com 815-455-3222 815-455-2285 Customer Service

Georgia Pacific 15 GPChemical@gapac.com 866-447-2436 Customer Service

Hoosier Pattern, Inc. 6 www.hoosierpattern.com 260-724-9430 260-724-9433 Customer Service

Industrial Vacuum 7 www.industrialvacuum.com 800-331-4832 920-261-1136 Customer Service

LAEMPE REICH back cover contactus@laempereich.com 205-655-2121 205-655-2123 Jarek Olszak

Magaldi Technologies, 2 SalesNA@Magaldi.com 678-705-9219 Brandon Kruse

Magma Foundry Technologies, Inc. 10 sales@magmasoft.com 847-969-1001 847-969-1003 Customer Service

Refcotec, Inc. 13 sales@refcotec.com 330-683-2200 Customer Service

Simpson Technologies Corp. 17 www.simpsongroup.com 630-978-0044 630-978-0068 Customer Service

Sinto America insert www.sintoamerica.com 517-371-2460 517-371-4930 Customer Service

Summit Foundry Systems, Inc. 4 sales@summitfoundrysystems.com 260-749-7740 260-749-7228 Customer Service

Thermtronix Corp insert www.thermtronix.com 760-246-4500 760-246-4550 Joe Danega

Weiler Abrasives 14 www.weilerabrasives.com 800-835-9999 Customer Service

BUSINESS STAFF/ADVERTISING SALES REPRESENTATIVE

MODERN MIDWEST, WEST & INTERNATIONAL NORTHEAST, OHIO & SOUTHWEST

CASTING
Fabio Cavalieri Joe Murphy
Schaumburg, IL 60173-4555 P.O. Box 1422, Fairfield, CT 06825
847-824-0181 800-537-4237 203-254-9595
Fax: 847-824-7848 Fax: 203-259-4447
A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY fabio@afsinc.org AdSales25@aol.com

December 2021 MODERN CASTING | 55

 Up In The Air
SHAKEOUT

An open loft added more square footage to a new weekend cabin for a three-generation
family, but a ladder to access it would obstruct the open floorplan on the main floor.
With one brother a casting expert and the other an engineer and woodworker, the
solution sailed in as a “floating” ship’s ladder that demanded the skills of both young men,
and the help of their two other brothers.
Inspired by “Tree House Masters” television program as well as movies with escape
ladders, engineer Claydon Pearson––whose brother, Cole Pearson, oversees their family’s
foundry, Washburn Iron Works in Washburn, Wisconsin––devised a design whereby two
100-lb. iron casting counterweights would be fixed as hand-holds onto the loft-end
of the ladder, which he had crafted himself out of fir.
The perfectly balanced ladder is stored in the air when not in use but is easily
lowered from either level when needed.
Using all the mathematical and physics principles he could muster, Claydon conquered a
major hurdle of finding the center of mass on each side of the fulcrum, which is essential
for determining the size of the casting. “The next challenge was finding a hinge that could
function under the extreme loads of the ladder––easier said than done!” Pearson said.
“So, I designed my own hinge, and a talented metal worker at the foundry fabricated it.”
Claydon built the pattern box and pattern, accounting for shrinkage and draft to release
the nobake sand mold from the pattern. Cole and brother Taylor helped prepare the
mold, and Cole had the iron poured. Eldest brother Tavis and Cole painted the castings
black to match the ladder design, then mounted them on the ladder.

56 | MODERN CASTING December 2021