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The Making Steel Castings webinar series brings forward past concepts from Wlodawer’s “Directional Solidification of Steel Castings” (for eBook purchase: https://shop.elsevier.com/books/directional-solidification-of-steel-castings/wlodawer/978-0-08-010536-9) while linking to today’s simulation technology to provide a core understanding of the trade-offs that can be made in making steel castings.9

Introduction

Introduction to the topic and panelists.

16 minutes 58 seconds recorded on February 6 2024

Simulation Limitations

Limitations of simulation and why it is important to look at a casting as a whole as all of the steel that goes into a mold (part cavity and rigging) will be affected by the directional solidification of the steel. This topic also stressed three other key items: the effects of variation, reality v. modeling (get out to the shop floor and get data), and “making steel castings” is much more beyond just rigging with many factors playing into the total cost of a casting.

40 minutes 8 seconds recorded on February 9 2024

Rigging Basics

Rigging basics – what is rigging, its history and terminology with focus on sand casting. This topic also discusses how rigging and mold features (vents, draft, risers) apply to and affect making good steel castings along with some founders’ tricks for doing things such as promoting feeding from a riser.

35 minutes 39 seconds recorded on March 4 2024

Casting Engineering

Casting engineering - who is it, what this is and what you need to know. This topic also reinforces the benefits of being out on the shop floor.

18 minutes 09 seconds recorded on March 4 2024

Wlodawer Introduction

29 minutes 45 seconds recorded on March 18 2024

Solidification Shape and Dimension Effect

25 minutes 08 seconds recorded on March 18 2024

Modulus Hand Calculations

13 minutes 08 seconds recorded on April 17 2024

Modulus Example

14 minutes 50 seconds recorded on March 18 2024

Modulus Simulation

17 minutes 12 seconds recorded on April 5 2024

True Modulus Ratio

12 minutes 49 seconds recorded on April 5 2024

Riser Calculations

20 minutes 57 seconds recorded on April 5 2024

Thermal Gradient

Considerations for holistic casting modulus, what is a thermal gradient in a steel casting and how it affects solidification, feeding range and what influences the range, tricks of the trade to manage thermal gradient, benefit to rough machining and formation of porosity.

40 minutes 58 seconds recorded on May 3 2024

Riser Neck

How the riser neck affects the feeding from the riser head, considerations for neck design and foundry engineering factors to consider beyond casting yield.

22 minutes 45 seconds recorded on May 17 2024

Riser Heads

Open v. blind risers, feeding volume v. distance, important of atmospheric pressure on feeding, venting, and tricks of the trade for risers on large castings.

55 minutes 03 seconds recorded on May 31 2024

Ring Risers

Description, applications and practice for utilizing ring risers

9 minutes 16 seconds recorded on June 14 2024

Riser Sleeves and Hot Topping

Benefits of sleeves, times to not use sleeves, percent feeding from riser, concerns of extensive riser piping, lower feed demand, and why insulating sleeves are not in Wlodawer

30 minutes 42 seconds recorded on June 14 2024

Thermal Gradient and End Effect

56 minutes 44 seconds recorded on June 28 2024

Necked-down Risers and Thin Sand Sections

Variety of terms for necked-down risers, function, benefits, application of thin sand sections to increase modulus without increasing metal thickness, heating pads and why they are not common, need for superheat and challenges with thin sand sections, and considerations for different feeding options

32 minutes 4 seconds recorded on July 26 2024

Core Penetration and Sand Compaction

9 minutes 27 seconds recorded on July 26 2024

Riser Terms

Riser terminology and practical comment on gating

4 minutes 33 seconds recorded on July 26 2024

Chills, Fins, Specialty Sands and Venting

52 minutes 21 seconds recorded on August 2 2024

Venting and Modeling

55 minutes 18 seconds

Internal Chills

42 minutes 2 seconds

Miscellaneous

Basics of Export Compliance - ITAR and EAR

54 minutes 5 seconds recorded on April 25 2018

Webinars sample

SFSA Webinars

Contents

What is Steel?

What Makes Steel Strong?

Heat Treating Steel

What Makes Steel Stainless?

Introduction to Steel Melting Practices

Pouring and Gating Steel

Induction Melting Steel

Design of Experiments - Part 1 - Measurements

Design of Experiments - Part 2 - Experiments

Design of Experiments - Part 3 - Analysis

Clean Steel - Part 1

Clean Steel - Part 2

Clean Steel - Part 3

Clean Steel - Part 4

Clean Steel - Part 5 - Gating 1

Clean Steel - Part 6 - Gating 2 - Lip Pour

Clean Steel - Part 7 - Gating 3 - Bottom Pour

Clean Steel - Part 8 - Innovative Pouring and Gating

Porosity - Holes in Steel Castings

Porosity - Air Entrainment and Blowholes

Porosity - Pinholes

Porosity - Inclusions and Porosity

Porosity - Shrinkage and Porosity

Cracks in Steel Castings 1

Cracks in Steel Castings 2 - Solidification

Cracks in Steel Castings 3 - Craze Cracks and Hot Cracks

Cracks in Steel Castings 4 - Stress and Riser Cracks

Cracks in Steel Castings 5 - Aluminum Nitride Rock Candy

Cracks in Steel Castings 6 - Heat Treat and Quench Cracks

Cracks in Steel Castings 7 - Hydrogen and Delayed Cracking

Test Uncertainty in Mechanical Testing of Steel Castings

Steel Casting Performance

Mold Metal Challenges

Mold Metal Challenges 2 - Sand Expansion

Mold Metal Challenges 3 - Interface Chemistry

Mold Metal Challenges 4 - Specialty Sands

Mold Metal Challenges 5 - Iron Oxide

Mold Metal Challenges 6 - Dimensions

Mold Metal Challenges 7 - Erosion

Mold Metal Challenges 8 - Penetration

Mold Metal Challenges 9 - Burn-in or Burn-on

Mold Metal Challenges 10 - Veining and Hot Tearing

Mold Metal Challenges 11 - Porosity

Mechanical Testing Introduction

Mechanical Testing - Test Blocks

Steel Casting Mechanical Testing Keel and Test Blocks Part 2

Steel Casting Mechanical Testing Keel and Test Blocks Part 3 - Temperature Gradients and Solidification

Steel Casting Mechanical Testing Keel and Test Blocks Part 4 - Non Keel-Block Test Blocks

Steel Casting Mechanical Testing Keel and Test Blocks Part 5 - Tensile Testing

Steel Casting Mechanical Testing Keel and Test Blocks Part 6 - Charpy V-Notch Testing

Steel Casting Mechanical Testing Keel and Test Blocks Part 7 - Fatigue and Creep

Steel Casting Mechanical Testing Part 8 - NDT and Performance

Segregation and Steel Castings

Segregation and Flow

Micro-segregation and Homogenization

Macro-Segregation Solidification and Flow

Segregation under Risers

Segregation and Convection

High Alloy Segregation

Corrosion

Corrosion 1 - Uniform and Galvanic

Corrosion 2 - Pitting, Crevice, and Intergranular

Corrosion 3 - Leaching, Erosion Corrosion, Stress Corrosion (Cracking), and Passivation

Corrosion 4 - Corrosion Testing A262 Practice A and E

Corrosion 5 - Corrosion Testing Part 2

Making Steel Castings