1. Ingeniería

Program Booklet
The 77th Annual Wisconsin Regional Foundry
Conference and Exposition
In cooperation with
AFS - Northeastern Wisconsin Chapter and
AFS - Stateline Chapter
“Made in Wisconsin”
February 11-13, 2015
Crowne Plaza Hotel - Milwaukee Airport
6401 South 13th Street
Milwaukee, WI 53221
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Our Mission:
“The American Foundry Society - Wisconsin Chapter is dedicated to serving its membership through
educational, professional, and social activities designed to strengthen and promote the local metalcasting
industry today and for the future.”
REGIONAL CONFERENCE AGENDA
CONFERENCE AGENDA
Wednesday, February 11, 2015
Registration: 2:30 p.m.
Exposition Hours: 3:00-6:00 p.m.
Reception with Vendors: 5:00-6:00 p.m.
Conference Banquet: 6:15 p.m.
Thursday, February 12, 2015
Registration: 7:30 a.m.
Technical Sessions: 8:30 a.m.-4:45 p.m.
Exposition Hours: 8:00 a.m.-5:15 p.m.
Lunch with Vendors: 11:45 a.m.-1:30 p.m.
Networking with Vendors: 4:45-5:15 p.m.
Awards Banquet: 5:30 p.m.
Friday, February 13, 2015
Registration: 8:00 a.m.
Technical Sessions: 8:30-11:30 a.m.
NO EXPOSITION HOURS
REGIONAL CONFERENCE PROGRAM
WEDNESDAY - FEBRUARY 11, 2015
Time
Session | Location
3:00 p.m.
Exposition Kick-Off | CONCORDE BALLROOM
6:15 p.m.
Featured Wednesday Night Speaker: Mr. Rich Meeusen, CEO and President, Badger Meter
Chair: Mr. George Forish, Jr., Precision Pattern, Inc.
Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
THANK YOU TO OUR WEDNESDAY NIGHT DINNER SUPPORTER:
THURSDAY - FEBRUARY 12, 2015
Time
Session | Location
8:30-9:45 a.m.
General Kick-Off Keynote Speaker | AVIATION THEATRE
Topic: TBD
Speaker: Chris Norch, President, Denison Industries, AFS President
Description: TBD
Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
Co-Chair: TBD
10:00-11:15 a.m. Education | AVIATION THEATRE
Topic: Cast Metals Roundtable
Speaker: Steve Lawallen, Cast Metals Association
Description: TBD
Chair: Mr. Rick Yrigoyen, Foundry Products, Inc.
Co-Chair: TBD
10:00-11:15 a.m. Engineering | CONCOURSE 1
Topic: Sand, Clay and Mulling Technology - Update
Speaker: Mr. Jim Furness, President, Furness Newburge, Inc.
Jim will provide an update on the recently development of mull to energy concept, and share how it relates to
clay/sand reclamation to benefit foundries.
Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
Co-Chair: TBD
10:00-11:15 a.m. Ferrous | CONCOURSE 2
Topic: Operation of a Rear-Slagging Cupola
Speaker: Mr. Jeremy Mowry, Melting Engineer, American Cast Iron Pipe
While front-slagging cupolas are the mainstay in North American iron melting, a few rear-slagging cupolas have
endured the test of time. In this talk, the advantages and disadvantages of separating iron and slag inside the cupola will be discussed. This includes well design, refractory, tapping, operation, draining, and maintenance.
Chair: Mr. Adel Rahman, Kuttner, NA
Co-Chair: Mr. Doug Dearey, Maynard Steel
10:00-11:15 a.m. Non-Ferrous | CONCOURSE 3
Topic: Developments in Aluminum Binder Applications
Speaker: Matthew Hartman, ASK Chemicals
Description: TBD
Chair: Mr. David Jablonski, Badger Mining Corporation
Co-Chair: TBD
THURSDAY - FEBRUARY 12, 2015
Time
Session | Location
11:45 a.m. 1:30 p.m.
LUNCH
2:00-3:15 p.m.
Value Added Services | AVIATION
Topic: Value Added Roundtable Part I
Speakers: Professionals from A&E, AAASE, ThermTech
Description: TBD
Chair: Mr. John Lewensky, Pure Power Technologies, Inc.
Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
2:00-3:15 p.m.
Education | CONCOURSE 1
Topic : The Future Leaders of Metalcasting
Speakers: Al Spada, AFS National and Steve Lane, Metallurgical Engineer, Southland Metals
Al Spada and Steve Lane will give an overview of the “Future leaders of Metalcasting” Executive Development
Program. FLM is sponsored by AFS to support and strengthen the network of metalcastings next generation of
leadership through outreach and professional development. The program focuses on strategic planning, human
resource, finance, marketing, sales, technology, and personal development.
Chair: Mr. Wayne Carr, Olson Aluminum
Co-Chair: Mr. Tom Gaeding, Carpenter Brothers, Inc.
2:00-3:15 p.m.
General | CONOURSE 2
Topic: Sand Cores and Molds-Costs and Possibilities
Speaker: Don Covert, Solution Provider/Technical Sales, Humtown Products, Inc.
Don will be providing an overview of what sand cores really cost, insight into todays technology, and provide us
an understanding in prototype with reduced capitol expenditure.
Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
Co-Chair: TBD
2:00-3:15 p.m.
Non-Ferrous | CONCOURSE 3
Topic: Increasing Efficacy of Aluminum Operations Through Proper Flux Selection
Speaker: David Youngblood, President & CEO, Basic Resources, Inc.
By combining proper methodology on the front end with advantageous product choices, flux can significantly
improve aluminum operations through improved efficiency, flexibility, and cost savings.
Chair: Mr. Paul Schumacher, Refractory & Insulation Supply, Inc.
Co-Chair: TBD
3:30-4:45 p.m.
Value Added Services | AVIATION
Topic: Value Added Roundtable Part II
Speakers: Professionals from A&E, AAASE, ThermTech
Description: TBD
Chair: Mr. John Lewensky, Pure Power Technologies, Inc.
Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
THURSDAY - FEBRUARY 12, 2015
Time
Session | Location
3:30-4:45 p.m.
Marketing | CONCOURSE 1
Topic: Your Foundry: Safer Than An Aircraft Carrier?
Speaker: Mark Mehling, Management Advisor, The Foundry Marketer
The same methods that revolutionized safety in air travel can be applied in a foundry. This proven system has no
inspections or fines. And embraces the most dangerous (and often overlooked) part off the plant- the people! In
this presentation, learn how you can save workdays, lives, and money with a pro-active, predictive, easily implemented approach. Whether you are the CEO worried about your people, the Safety person with day-to-day accountability, or even CFO looking to reduce medical costs, you will get answers in this fast moving and informative presentation by an experienced safety expert. If you are looking for a better answer than just gloves, glasses,
and OSHA, you MUST attend this presentation.
Chair: Mr. Adel Rahman, Kuttner, N.A.
Co-Chair: TBD
3:30-4:45 p.m.
Ferrous | CONCOURSE 2
Topic: TBD
Speaker: Greg Miskinis, Waupaca Foundry
Description: TBD
Chair: Mr. Adel Rahman, Kuttner, N.A.
Co-Chair: TBD
3:30-4:45 p.m.
Non-Ferrous | CONCOURSE 3
Topic: Combustible Dust and Explosion Protection
Speaker: Jim Axt, Engineered Systems Support, Summit Filtration Technology, LLC.
We will cover combustible dust standards, National Emphasis Program, OSHA, NFPA and Chemical Safety
Board Reviews along with Process Hazard Analysis (PHA) guidance. We will also look at applicability, feasibility, identification of risks and mitigation strategies and options, and how to avoid becoming a statistic.
Chair: Mr. Nic Gerrits, Carpenter Brothers, Inc.
Co-Chair: TBD
5:30 p.m.
AWARDS BANQUET
Casting Competition and Scholarship Awards Ceremony
Featured Thursday Night Speaker: Mr. Gary Gigante, President and CEO, Waupaca Foundry, Inc.
Chair: Mr. Adel Rahman, Kuttner, N.A.
Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
THANK YOU TO OUR THURSDAY NIGHT DINNER SUPPORTER:
FRIDAY- FEBRUARY 13, 2015
Time
Session | Location
8:30-9:45 a.m.
General | AVIATION
Topic: Making manufacturing more environmentally sustainable: Good for the planet, good for your bottom line
Speakers: John Jozwowski, Cast Iron Manufacturing, Kohler Company
Nathan Nissen, Sr. Environmental Health & Safety Program Manager-Sustainability Kohler Company
Kohler Co. manufactures plumbing products and industrial castings at its cast iron foundry in Kohler, Wis. The
company produces grey, enamel and ductile iron products. Kohler has a long history of environmental stewardship and has implemented significant changes to make its manufacturing processes and overall operations more
environmentally friendly. This discussion will focus on recent changes to make the company’s cast iron operations more sustainable and decrease its environmental footprint by reducing greenhouse gas emissions, conserving water and increasing waste recycling.
Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.
Co-Chair: Mr. Doug Sawyer, Universal Welding & Engineering, Inc.
8:30-9:45 a.m.
Non-Ferrous | CONCOURSE 1
Topic: Tips for Successful Application of Casting Simulation to Nonferrous Castings
Speaker: David Schmidt, Vice President, Finite Solutions, Inc.
Dave will provide several case studies of simulations of various nonferrous castings to illustrate how to get the
most accurate results possible. Discussion will include model and process setups, analysis of simulation results
and techniques for creating efficient gating and riser designs.
Chair: Mr. David Jablonski, Badger Mining Corporation
Co-Chair: TBD
8:30-9:45 a.m.
Engineering | CONCOURSE 2
Topic: “Sand Reclamation Overview” - Reclaimed sand that performs well as - or better than - new sand.
Speaker: David Silsby, Director of Sales, Simpson Technologies Corporation
This presentation will review the basic reclamation process flow and the different reclamation options available
to today’s foundries.
Chair: Mr. Tom Gaeding, Carpenter Brothers, Inc.
Co-Chair: Mr. Steve Carr, Olson Aluminum
8:30-9:45 a.m.
Safety | CONCOURSE 3
Topic: Foundry Insurance and Risk Management Issues
Speaker: John Mares, Foundry Risk Consultant, Marsh & McLennan Agency
Foundry Insurance and Risk Management issues including: Workers Compensation, Property, and Liability Cover ages. What is the total impact of an injury to an employee? What is the effect on your Workers coverage?
What is the effect on your Workers’ Compensation Experience Mod: What does the claim end up costing the
foundry client.? What other Risk exposures are unique to foundries and how can they be addressed.
Chair: TBD
Co-Chair: TBD
FRIDAY- FEBRUARY 13, 2015
Time
Session | Location
10:00-11:15 a.m. Ferrous | AVIATION
Topic: Use of Lower Magnesium Alloys for Ductile Treatment
Speaker: Ken Kopi, Field Account Manager, Elkem Materials, Inc.
A discussion of why lower Mg treatment alloys provide higher and more consistent Mg recovery, reduced slag
and ladle buildups, and several other benefits. Several case studies are included
Chair: TBD
Co-Chair: TBD
10:00-11:15 a.m. Safety | CONCOURSE 1
Topic: Foundries Are Going Broke...Could Yours Be Next?
Speaker: Mark Mehling, Management Advisor, The Foundry Marketer
This presentation, delivered to at the 117th Metalcasting Congress, is an overview of the study of 23 closed
foundries. 7 Myths and 7 Numbers were identified as key elements in the bankruptcies. You will learn how the
same methods used for defect analysis on the plant floor can be applied to the biggest threat to a businessrevenue and sales defects. If you are troubled by cheap foreign competition, only have ‘buy on price’ customers,
and believe that lowering prices is the only way to get more business, this presentation is a MUST ATTEND to
begin the journey to long term higher profits and stability.
Chair: Mr. Adel Rahman, Kuttner, N.A.
Co-Chair: TBD
10:00-11:15 a.m. Non-Ferrous | CONCOURSE 2
Topic: 3D Technology and 3D Printing of Sand Molds
Speaker: Steve Murray, SME Additive Manufacturing Certified, Hoosier Pattern
What is 3-D Printing? Why use 3-D printing in your foundry: What you need to know about 3-D Sand Printing
before you start, additive manufacturing ( 3-D sand printing ) can add to a foundries bottom line.
Chair: Mr. Nic Gerrits, Carpenter Brothers, Inc.
Co-Chair: TBD
10:00-11:15 a.m. Engineering | CONOURSE 3
Topic: Measuring Shrink by Thermal Analysis
Speaker: David Sparkman, President, MetLab Systems, Inc.
New research in thermal analysis is showing subtle differences in iron that reveal micro and macro shrinkage, as
well as cracking and gas holes. This goes well beyond the traditional thermal analysis or the usual intelligent
systems approach and can actually see void formation as a reduction in the normal stresses that form mostly in
ductile iron and in many aluminum alloys.
Chair: Mr. Eric Lovejoy
Co-Chair: TBD