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The Hill and Griffith Company
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The Hill and Griffith Company's News Blog

AFC News - Courses Announced for 119th Metalcasting Congress

Posted by Hill and Griffith Company on Thu, Apr 02, 2015 @ 02:01 PM

American_Foundry_Society

From 119th Metalcasting Congress program announcement, April 2, 2015

The annual Metalcasting Congress features the latest advancements in metalcasting technology and services across the supply chain. The 119th Metalcasting Congress will be held in Columbus, Ohio, April 21 - 23, 2015, at the Greater Columbus Convention Center.

Register Now for the 119th Metalcasting Congresss

Casting Design & Purchasing Courses

Wednesday, April 22, 2015

8:00 AM-9:30 AM
Casting Design & Purchasing
Total Cost of Doing Business Overseas (Panel 15-063)
Rex Harrison, Oshkosh Corp., Oshkosh, WI
Harry Moser, Reshoring Initiative, Kildeer, IL
Matt Petersen, A Stucki Co, Moon Township, PA

1:30 PM-3:00 PM
Casting Design & Purchasing 
Design Analysis - Past Winners of Casting of the Year (Panel 15-136) 
Randy Brull, Aarrowcast Inc., Shawano, WI 
Adam Curtis, Signicast Investment Castings, Hartford, WI 
Tom Browning, Stahl Specialty Co, Kingsville, MO 

3:15 PM-4:45 PM
Casting Design & Purchasing 
The Ten-Step Program for Casting Defect Analysis (15-159) 
Kevin Fleischmann, The Institute, Schaumburg, IL

Rapid Prototyping…”How Fast is Fast and Why do I Need Tooling” (15-172)
Dave Rittmeyer, Hoosier Pattern Inc., Decatur, IN

Thursday, April 23, 2015

8:00 AM-9:30 AM
Casting Design & Purchasing 
Intro to Casting Processes (Panel 15-153) 
Randy Brull, Aarrowcast Inc., Shawano, WI 
Adam Curtis, Signicast Investment Castings, Hartford, WI 
Scott Frens, Fort Recovery Industries Inc, Fort Recovery, OH 
Michael Johnston, Lost Foam Group International, Alexander City, AL 

9:45 AM-10:45 AM
Casting Design & Purchasing 
How Casting Design Affects Casting Prices (15-157) 
Tom Kayser, Osco Industries Inc, Portsmouth, OH

Intro to the Cast Aluminum Family - What the Buyer Should Know (15-161)
Nicole Tedrow, Fairfield Aluminum Castings Co., Fairfield, IA

 

Tags: American Foundry Society

AFC Casting Defect Analysis #26-15 Course Announced

Posted by Hill and Griffith Company on Thu, Mar 26, 2015 @ 04:21 PM

American_Foundry_Society

From AFC Newsletter, March 26, 2015

Register Now for the course April 29 – 30, 2015 in Schaumburg, IL 

In order to determine the true root cause of a casting defect and select the proper corrective action, a systematic evaluation method must be applied. The intention of this course is for participants to become proficient in applying a ten step procedure that will enable them to analyze and reduce metalcasting defects by correctly identifying defects and their root causes, and determining appropriate corrective actions. This course is applicable to sand molding processes (green, nobake, coldbox, shell).

Course Instructors: Kevin Fleischmann, AFS Institute Scott Lammers, AFS

 

Course Introduction

The intention of this course is for participants to become proficient in applying a ten step procedure that will enable them to analyze and reduce metalcasting defects by correctly identifying defects and their root causes, and determining appropriate corrective actions. This course is applicable to sand molding processes (green, nobake, coldbox, shell).

Benefits to Taking the Course: In order to determine the true root cause of a casting defect and select the proper corrective action, a systematic evaluation method must be applied. Implementing the wrong solution can cost the foundry in terms of runtime, cost, waste, safety, reduced return on investment or profit, sales and expertise. Learning a systematic procedure for root cause identification supports the business goal of designing, producing and selling quality castings that are made in a timely manner and in a safe environment for a profit.

Learning Outcomes:

After completing this course, participants should be able to:

  1. Name the 4 most common casting defects, and identify the causes and potential solutions for

    each.

  2. Given defect samples, apply a ten-step procedure in order to correctly identify the casting

    defects and their root causes, and determine appropriate corrective actions and solutions using the AFS-CIATF International Atlas of Casting Defects and the three AFS Casting Defects handbooks in order to minimize or eliminate the defects.

Lesson Outline

Introduction
o Course purpose and goals

o 10 Step Root Cause Analysis Tool

o Business goals related to defect identification Casting Defects Overview

o Why a 10 Step Procedure? o Setting scrap rates
o Defect categories

  •   Demonstration of Root Cause Analysis

  •   Sand-Related Defects

  •   Oxide-Related Defects

  •   Group Problem Solving

  •   Gas-Related Defects

  •   Shrink-Related Defects

  •   Group Problem Solving

  •   Wrap-up

o Review & assessment of learning outcomes o Course Evaluation

Tags: American Foundry Society

AFS Green Sand Casting Defect Analysis Course #01B-15

Posted by Hill and Griffith Company on Tue, Jun 24, 2014 @ 11:16 AM

Green Sand Casting Defect Course

Offered by the American Foundry Society - July 30 – 31, 2014, Schaumburg, IL 

Register Now

In order to determine the true root cause of a casting defect and select the proper corrective action, a systematic evaluation method must be applied. Implementing the wrong solution can cost the foundry in terms of runtime, cost, waste, safety, reduced return on investment or profit, sales and expertise. The intention of this course is for participants to become proficient in applying a ten step procedure that will enable them to analyze and reduce metalcasting defects by correctly identifying defects and their root causes, and determining appropriate corrective actions. This course is applicable to sand molding processes (green, nobake, coldbox, shell).

Course Syllabus and Pricing


The Hill and Griffith Company is known for our hands on approach with green sand casting release agents and supplies. Let us visit your plant and recommend products that suit your needs.

Bulletins and Technical Papers for Metal Casting Products

Tags: American Foundry Society, AFS, Green Sand Casting Products

Hill and Griffith Congratulates Casting of the Year Recipients

Posted by Lauren Campbell on Fri, May 23, 2014 @ 03:01 PM

The Hill and Griffith Company would like to congratulate all the winners in this year’s Casting of the Year Award presented by Modern Casting, an American Foundry Society Publication.Casting of the Year: Oil Pan

This year’s 2014 winner goes to Arrowcast, from Shawano, Wisconsin. Arrowcast casted an extremely complex oil pan for the John Deere tractor company. The casting facility said it was the biggest job the ductile iron casting facility has ever done and at a weight of 842 lbs., it is surprising that it provided a weight reduction of 77lbs from the previous oil pan. The design team used a combination of finite element analysis and solidification simulation to achieve the desired outputs; using the green sand casting process to metalcast this beast. Its application is for the John Deere 9 liter engine and the casting design allowed the team to combine a frame casting, two fabricated brackets and a stamped steel oil pan into one ductile iron casting. At a size of 26 x 56 inches, the compact design of the oil pant casting allowed for a lower engine position in the tractor chassis and eliminated a 2-degree angle of the engine. The volume of oil was also increased over the steel stamping.

Best-In-Class

Aerospace electronics mountBest-In-Class this year was quite an interesting group. Beginning with Aristo-Cast Inc. located in Almont, Michigan who casted a hand-held electronics mount used in aerospace and is one of a kind. Made from AZ91E-T6 magnesium, investment casting was their process of choice and provided the ability to combine many parts into one and additionally lowered part cost and weight. The device acts as a bracket to mount processing electronics and in the process is used as a heat sink to manage the thermal load from all of the electronics.Hub Casting

Pier Foundry & Pattern Shop Inc., located in St. Paul, Minnesota created a hub casting made of ductile iron for a mining application. The part, casted with green sand, weighs 90lbs and was built to replace a 34-piece weldment to improve the ease of manufacturing while holding up to the rigors of continuous mine operation. The hub rotates at 3,600 rpms and the cast design saved the customer $76,000.00 in the first year!

Casted Knife holderSignicast Investment Castings, located in Harford, Wisconsin, offered up a new knife holder casting. Made of 4140 steel and casted by the investment casting process, the new 1.9 lbs. weighted knife holder casting exhibits improved dimensional stability, eliminating the need for a secondary straightening process. It also saved the customer additional time and reduced cost by 25% due to the elimination of post-fabrication machining activities.Automotive Casting

Tooling & Equipment International, located in Livonia, Michigan presented a water passage made of aluminum used to integrate cooling system parts for an automotive application. At a weight of 4 lbs., low pressure permanent mold was the process of choice and was produced through advanced prototyping technology for Honda. This part achieved design freedom through the use of intricate cores.

Honorable Mention

Military Cast SubframeMeritor Design, from Troy Michigan and Willman Industries, from Cedar Grove, Wisconsin worked together to create a Protec Series 30 Cast Subframe. Casted using the green sand process, this subframe is made of ductile iron and was converted from the military, reducing weight by 28% and the number of components from 79 to 1; eliminating 136 fasteners in the process.

O’Fallon Casting from O’Fallon, Missouri submitted a fan-housing unit converted from a commercial helicopter. Using investment casting, the fan-housing unit provides aerodynamics to produce a laminar fluid flow and also acts as a heat sink. Made of F357-T6 aluminum, the investment casting process enabled the unit to be cast as a single piece. Fan Housing Casting


The Hill and Griffith Company is known for our hands on approach. Let us visit your plant and recommend products that suit your needs.

Bulletins and Technical Papers for Metal Casting Products

Tags: Awards, Metal Casting, American Foundry Society

AFS Announces Recipients of 2013 Safe Year Award

Posted by Hill and Griffith Company on Tue, Mar 18, 2014 @ 11:20 AM

American Foundry Society , March 14, 2014

American Foundry Society

Thirteen metalcasting facilities qualified as recipients of the 2013 AFS Metalcasting Safe Year Award. This award recognizes AFS Corporate Member facilities that achieved one year (365 consecutive calendar days) without a lost time accident. To qualify for the award, the one-year milestone must have been reached on any day in 2013. The count begins on the day following the last lost time accident or the date the previous one year milestone was reached.

The awards will be presented at AFS’s 26th Environmental, Health & Safety Conference on August 12 in Atlanta.

Recipients are:

•    Bremen Castings, Inc., Bremen, Ind. (05-30-12 to 05-29-13)

•    John Deere Foundry, Waterloo, Iowa (10-15-12 to 10-14-13)

•    Grede II LLC-Bessemer, Bessemer, Ala. (08-06-12 to 08-05-13)

•    Grede LLC- Reedsburg, Reedsburg, Wis. (10-29-12 to 10-28-13)

•    Grede II LLC-Selma, Selma, Ala. (10-05-12 to 10-04-13)

•    Griffin Pipe Products Co., Lynchburg, Va. (08-23-12 to 08-22-13)

•    ME Global, Inc. Tempe, Ariz. (11-07-12 to 11-06-13)

•    MetalTek International-Wisconsin Centrifugal Division, Waukesha, Wis. (08-12-12 to 08-11-13)

•    MetalTek International-Wisconsin Investcast Division, Watertown, Wis. (04-25-12 to 04-24-13)

•    NEMAK USA, Dickson, Tenn. (12-20-12 to 12-19-13)

•    Neenah Foundry, Neenah, Wis. (06-10-12 to 06-09-13)

•    Neenah Foundry-Deeter Operations, Lincoln, Neb. (07-24-12 to 07-23-13

•    The Schaefer Group, Inc., Dayton, Ohio (01-01-13 to 12-31-13)


If you like this article, learn more about Hill and Griffith's attendance at the Die Casting Congress Trade Show.


learn more about Grifcote products

 

The Hill and Griffith Company is known for our hands on approach. Let us visit your plant and recommend products that suit your needs.

Bulletins and Technical Papers for Metal Casting Products

Tags: Die Casting, American Foundry Society, AFS

Kawasaki Names Waupaca Foundry Supplier of the Year

Posted by Hill and Griffith Company on Tue, Aug 20, 2013 @ 01:50 PM

July 19, 2013, MODERN CASTING

Kawasaki Motors Manufacturing Corp., U.S.A. (KMM), Maryville, Mo., named Waupaca Foundry Inc., Waupaca, Wis., its 2012 Supplier of the Year.

Waupaca Foundry

“This award recognizes the company that is the best at what they do.  KMM sets their expectations high for suppliers. Waupaca was able to meet this challenge,” said Paul Walter, purchasing assistant manager, KMM. He said many factors go into the selection of supplier awards, but the company with the best total value is awarded the highest honor. Waupaca Foundry was the top performer from 100+ global suppliers last year.

Waupaca Foundry’s plants in Waupaca and Marinette, Wis., were recognized for timely response to KMM needs and overall ease of doing business. The Waupaca plant makes flywheels for Kawasaki engines; the Marinette plant makes crankshafts. Both plants were cited for 100% on-time delivery. Suppliers are reviewed monthly by KMM, with a focus on customer service, product quality, cost and productivity.

“Our production processes and technology have been developed to ensure overall quality for our customers,” said Gary Gigante, president and CEO, Waupaca Foundry. “But our greatest asset is the skill and knowledge of our team members. We’re thrilled our focus on customer service has been rewarded with this recognition.”

Previously, Waupaca Foundry received the 2010 Cost Savings Award for all KMM suppliers.

Waupaca Foundry Inc. produces gray and ductile iron castings for the automotive, commercial vehicle, agriculture, construction and industrial markets. Waupaca employs approximately 3,700 people


Hill and Griffith is proud to be a supplier partner with Waupaca Foundry, Congratulations on your award. The Hill and Griffith Company is known for our hands on approach. Let us visit your plant and recommend products that suit your needs.

Bulletins and Technical Papers for Metal Casting Products

Tags: Awards, Metal Casting, American Foundry Society

CASTEXPO 2013 Predicts Bright Future for Casting Solutions

Posted by Samantha Farris on Tue, May 07, 2013 @ 09:26 AM

Reports from around the web: 


Metalcasting Industry Comes Alive at CastExpo’13, American Foundry Society

Hill and Griffith Casting Solutions booth2

The American Foundry Society (AFS) hosted CastExpo’13 at the America’s Center in St. Louis, April 6-9. The event featured more than 450 exhibitors on a sold-out show floor and various technical presentations as part of its Metalcasting Congress and a Metalcasting Technology Theatre on. A total of 7,192 metalcasters attended CastExpo’13.

“So much was happening on the show floor and a positive vibe filled the air,” said Jerry Call, AFS executive vice president. “It’s great to see all of the positive feedback we have already received from CastExpo’13 attendees and exhibitors.” In addition to the exhibitors, top industry award winners were honored at the show.

The 118th Metalcasting Congress will be held April 8-11, 2014, at the Renaissance Hotel & Convention Center, Schaumburg, Ill., and the 119th Metalcasting Congress will be April 21-23, 2015, at the Greater Columbus Convention Center in Columbus, Ohio.

Read more.


Check out the latest videos, interviews, and impressions of the show, Foundry-Planet Ltd.

CASTEXPO 2013 Casting Solutions resized 600

CastExpo 2013 in St. Louis, Mo., Video, Watch Video.

The U.S. metal casting industry is on an upward rise and evidence of this excitement was displayed at the CastExpo'13. The exceptionally well-organized event was hosted by the AFS and held at the America's Center in St. Louis April 6 – 9. A record 7,192 metal casters attended the show, according to the AFS, and 450 exhibitors displayed their latest technology and equipment at the show. More than 170-featured presentations were held parallel to the event as well as the World Technical Forum. “So much was happening on the show floor and a positive vibe filled the air,” said Jerry Call, AFS executive vice president. “It’s great to see all of the positive feedback we have already received from CastExpo’13 attendees and exhibitors.”

Headquartered in Schaumburg, Ill., AFS is a not-for-profit technical and management society that has existed since 1896 to provide and promote knowledge and services that strengthen the Metalcasting industry for the ultimate benefit of its customers and society.

The web site has a collection of all the company videos posted on YouTube.

Read more.


LinkedIn: Foundry and Diecaster Network

"Pre-Registration numbers look great, over 6000 and counting," Thomas Prucha, AFS V. P. Techncial Services, Greater Detroit Area.

"What was your favorite moment/moments from CastExpo13? It's a tough call, but I think mine is Gene Muratore's rousing Hoyt Lecture. As he declared, metalcasting IS a technical industry. Coming a close second are all the discussions with exhibitors who made a deal over the course of the four day show. It's wonderful to hear about metalcasters investing in their future," Shannon Wetzel, Experienced editor, Greater Chicago Area.

Read more.


O’Fallon Casting Wins AFS/Metalcasting Design & Purchasing Casting Competition, American Foundry Society

The American Foundry Society (AFS) and its publication Metal Casting Design & Purchasing magazine announced O’Fallon Casting, O’Fallon, Mo., as the winner of the 2013 Casting Competition. The metalcaster won with its electronics housing produced for the defense industry. The component’s elegant design and incredible detail exemplifies the capabilities of the investment casting process.

Read more.

Hill and Griffith Casting Solutions booth3 resized 600

Carley Foundry, Blaine, Minn., was a Best in Class winner for its 750-lb. aluminum radar casting produced via the nobake sand casting process. Converted from machined plates welded together, the design resulted in a 67% reduction in part cost and enabled the end user to realize a substantial tooling cost savings.


Green Marketing - How to make your plant LEED Platinum Certified, Lohre & Associates

vw chattanooga plant resized 600 resized 600

A recent visit to CASTEXPO 2013 in St. Louis encouraged us to investigate what it would take to make a foundry LEED Platinum. A VW ad on 60 Minutes gave us the inspiration.

From the VW press release, "Volkswagen’s Chattanooga manufacturing plant has received a Platinum Certification from the U.S. Green Building Council’s (USGBC) Leadership in Energy and Environmental Design (LEED®) green building certification program. The facility is the first and only automotive manufacturing plant in the world to receive the Platinum certification."

With planning and a corporate education plan, high levels of Leadership in Energy and Environmental Design (LEED) can be achieved. LEED was created by the U.S. Green Building Council (USGBC) in 1993 to encourage sustainable building practices. The USGBC is a non-governmental organization. It has become accepted as the sustainable building certification standard by the U.S. Government. All government buildings are required to be LEED Certified. LEED is based on a 100-credit system and broken up into five categories: Sustainable Sites, Water Efficiency, Energy and Atmosphere, Materials and Resources, and Indoor Environment Quality.

We'll review each of these and provide examples we learned at CASTEXPO 2013 and other significant corporations. We're using as our example a typical manufacturing plant's features and characteristics. To follow along, download the LEED Checklist we used as our guide to achieve LEED Platinum writing this blog. With careful planning, patience, learning and follow through companies can achieve this high level of sustainability with a very low investment and significant savings over the life of the facility. We achieved LEED Platinum Certified at our office for $12 per square foot including the USGBC fees. And it's been the best Green Marketing investment we could ever make.

Read more.



Die Casting Congress 2013The Die Casting Congress & Tabletop will be September 16-18, 2013, at the Kentucky International Convention Center in Louisville, KY. During the three days of Congress sessions, technical and management presentations will be given by experts from around the world. These presentations will expose metalcasters to the latest technology, ongoing research and successful management tools that will assist companies in enhancing their competitiveness.

Read more.

Hill and Griffith Casting Solutions booth resized 600

We encourage you to put the knowledge and experience of Hill and Griffith's highly trained technical personnel to work for you, please stop by booth 315.

Tags: Hill and Griffith, Metal Casting, Casting Solutions, Die Casting Congress, American Foundry Society, CASTEXPO, Foundry Planet