Fostering innovation is one of the key pillars of the American Foundry Society’s 2023-2027 Strategic Plan. Research is an essential part of that pillar, which is why I’d like to talk to you about this important topic and how the research projects of AFS will deliver benefits for foundries.

Aluminum Casting Performance Initiative (ACPI)

More than ever, the federal government understands the importance of castings to national defense and the manufacturing economy. Congress recognized the importance of castings by directing $4 million to AFS for aluminum casting research, which is just getting underway. 

The first ACPI project aims to develop a machine-learning-based image recognition tool to diagnose aluminum casting defects. This system is intended to capture knowledge and assist training of new team members, while improving inspection speed and costs.

The second project seeks to develop datasets for alloys to be added to the Metallic Materials Properties Development and Standardization (MMPDS) handbook and the AFS Casting Alloy Database Search (CADS). This information will provide pedigreed data for customers to utilize C355-T6 alloy castings with no knockdown factor and with further optimizations in design.

The third ACPI project aims to develop a cutting-edge, in-line tool for automated production of aluminum investment castings critical to the DoD. This data will be used to create a digital twin of shell manufacturing processing and the casting process.

DLA-Funded Research

AFS is also coordinating $3.9 million in research and related projects funded by the Defense Logistics Agency through the American Metalcasting Consortium. Under the 2023-2028 AMC Emergent Metal Casting Solutions Program, the first project focuses on investment casting and will comprise three distinct objectives. The first objective is to assess new materials, processes, or automation technologies with the goal of achieving more rapid production. The second goal is to focus on ways to improve the recycling of spent shell materials with lower cost and reduced environmental impact.  A third goal is to develop best-practice data-driven design tools to address risering challenges. 

Today, most foundries have AFS technical books on a desk or a bookshelf. Under a second exciting AMC project, soon many of these resources will be digitized and accessible from mobile devices, with video, photos and web links. Imagine the impact when foundry employees can access the best technical information right from the foundry floor!   

A third DLA-funded project is to model the relationship between surface defects on cast metal components and casting process variables and parameters.  Success would enable corrective actions to improve surface quality and minimize surface defects. Fourth, AFS will be providing technical oversight for a project managed by an outside investigator to finalize guidelines for Nano-Reinforcing Aluminum alloys to cost-effectively increase strength without increasing weight.

AFS-Funded Research

The AFS Research Board, chaired by Kathy Hayrynen, has directed AFS funding to 11 projects, beyond those that are recently completed. AFS is partnering with private-sector investigators as well as major universities.  

In total, this AFS research funding—exceeding $8 million—is focused on lost foam, additive manufacturing, investment casting, other molding methods, as well as melting and the major metals. In addition, AFS is working with America Makes and the Advanced Casting Research Center (ACRC) on research initiatives. Spearheaded by the AFS Technical Services Department and Senior Vice President Brian Began, this research will benefit foundries for many years to come.