FMT2021 04

APRIL 2021 foundrymag.
com
THE NEW
COMPETITORS
Powdered materials, binder-
jet printing, and sintering are
being deployed to challenge for
PHWDOFDVWHUV·PRVWYDOXHGPDUNHWV
IN THIS ISSUE
Controlling Conditions
for Cupola Melting
Patternmaker Builds
Brand on Accuracy
Moldmaking According
to Industry 4.0
The Expectations
Gap and the Push for
Digitization
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^ CONTENTS
Volume 149 Number 4
14 MANAGEMENT & TECHNOLOGY

2 SUMMIT PARK DRIVE, SUITE 300
ADDITIVE MANUFACTURING CLEVELAND, OH 44131
13 Metallurgy Breakthroughs Show a New PH 234/466-0200
WWW.FOUNDRYMAG.COM
Phase of Competition
Powdered materials, binder-jet printing, and sintering EDITORIAL STAFF
are advancing to a point that developers say will be EDITOR ROBERT BROOKS
“disruptive” to metalcasting. rbrooks@endeavorb2b.com
METALLURGY GRAPHICS EDITOR BILL SZILAGYI

14 Controlling Conditions for Cupola Melting bszilagyi@endeavorb2b.com
There are several steps to maximizing cupola operating
performance, but the first and most important is to manage
the detrimental influences of iron oxide.
18 QUALITY CONTROL
18 Patternmaker Builds its Brand on Accuracy
A range of advanced metrology systems and capabilities
are helping Accurate Pattern Inc. improve and expand its
resources for product quality and customer service.
MOLDS/CORES
20 To Industry 4.0 …and Beyond
Dotson Iron Castings adopted Sinto America’s enVision
Process Visibility System for its molding lines, resulting in
improved production, less downtime, faster cycle time,
better maintenance scheduling, and more.
MANAGEMENT ON THE COVER: Design by Bill

22 Communication Creates Expectations Szilagyi, graphics editor.
24 Building and shaping customers’ impressions is part of what
your brand must do, and every message you deliver will
influence their expectations.
INFORMATION TECHNOLOGY
28 Industry 4.0 Pushes Manufacturers
to Digitize Operations
A widening “expectations gap” between suppliers and
buyers means that manufacturers’ investments must
create a seamless digital experience and quick-response
capabilities.
23
Editor’s Note...................................................2
Metalcasting News ................................. 6
Newsmakers .................................................12
Visit the Foundry Management & Technology
Technical Development ........................ 23
website www.foundrymag.com for the online
Success Story....................................... 20
suppliers directory.
Message Received ................................ 22
New Products ...................................... 23
Advertiser Index ..........................................24
Product Express ...........................................25
Business Staff...............................................27
Closing Comment ........................................32
FOUNDRY MANAGEMENT & TECHNOLOGY (ISSN 0360-8999) is published monthly by Endeavor Business Media, 1233 Janesville Ave, Fort Atkinson, WI, 53538. Periodicals
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A P R I L 2 0 2 1 | FO U N D RY M AG . CO M | FO U N D RY | M A N AG E M E N T & T E C H N O LO G Y 1
^ EDITOR’S NOTE Robert Brooks
Editor
Is This a Private Game?
T
here is a growing sense of optimism about U.S. Private equity is not a new phenomenon. Investment
economic recovery, with various data points funds have long been part of the free market economy,
available to argue that the year-long whammy ef- only more so in recent decades as other sources of capital
fected by a global pandemic is over – or will be soon. investment have become restricted by disclosure require-
In recent weeks analysts have offered the monthly ments, and as investors seek higher and faster returns
Purchasing Managers’ Index, durable goods ship- than listed holdings can ensure. They’ll take risks, but
ments, and various metrics of consumer spending to they want some cover.
argue that the pre-pandemic levels of low inflation Then, too, many manufacturing businesses have often
and high employment, plus renewed strong industrial been cast as high-risk investments, meaning a high-risk
demand are just about to resume. investor may be the only type offering capital when it’s
To believe evidence like this requires a lot of tumblers needed. Private equity has done a lot of good for metal-
to fall into place, a lot of prior economic assumptions casters and other U.S. businesses, and those who rely on
to be fulfilled. I have become less confident that prob- those businesses for their own livelihoods. The secrecy
lems of such consequence will work out so neatly. My they keep about their plans and goals is part of the fee for
confidence in economic recovery is based on a simpler their services.
observation: metalcasting operations are drawing inves- It was not always true that privacy came at a cost. The
tors’ capital. quaint image of a family-owned business supporting
Since the start of 2021 we have reported a half dozen dozens of employees and the community where they
acquisitions of U.S. casting plants, along with a steady all thrive is an idealized notion of commercial life that
log of expansions and new equipment programs. I don’t barely exists any longer – some metalcasting exceptions
have to see my fiscal principles fulfilled for my con- notwithstanding. And such images do not exist out of
fidence to be boosted; I merely have to note that these context: they fit within a broader idealism involving
investors cannot all be wrong. I am drawing assurance responsible government, a trustworthy legal system, reli-
from their confidence. able commercial institutions, effective academic bodies,
It’s hard to come up with better arguments to explain and so forth. It’s a mythic nostalgia we maintain based on
these investors’ confidence because every one of them the shortcomings of reality.
lacks the details that justify the investors’ risk-taking. We It’s an impression that is highly personal too, set in an
don’t know how much they’ve paid or other basic terms alternate universe where our own feelings and motives
of their investments. We cannot compare their transac- are not questioned, and we feel no suspicions about those
tions to other comparable moves. They are private deals, we encounter there. Our own assumptions about what is
not quite secret but carried out by corporate entities. The good and bad are the standard that everyone shares. The
personal motives and stakes are not clear. outcomes we want are all agreed to be the best ones.
To the extent that the investors explain their actions In reality, we live in a world that is almost entirely
they cite goals to improve performance or product qual- impersonal. It is wholly commercial: relationships are
ity, or customer service. We cannot predict their re- transactional and values are negotiable. Surrendering
wards or measure their successes. We must assume that your thoughts and records is the price of admission. We
there is a commercial strategy for recouping the capital are governed by pragmatism, not principle. Personal ex-
invested but revealing that would give away too much pression is sanctioned so long as it conforms to shifting
of the plan, apparently. social “truths.” Integrity, meaning a unity of principles
Surely the metalcasting sector needs the capital infu- and responsibility that ensures an individual’s autonomy,
sion. It’s an expensive business that makes its profits in affords one very little.
margins, not multiples. Metalcasters need to update their Privacy is an expensive commodity in this world, and
machinery and technologies and meet evolving stan- if we cannot afford it then the best that we can expect is
dards. They need to adapt their ways of doing business that those who can pay for it have invested wisely.
to match the current accelerated pace of designing and
manufacturing, and delivering, finished parts. All this
requires capital, now.
2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | A P R I L 2 0 2 1
ADVERTORIAL
Can Coating Alone Prevent Penetration?

Today’s foundry operations insist on high-quality castings that are defect-free as-cast,
with little to no rework time, and high dimensional tolerances.
Q: Is it possible to prevent persistent veining and

penetration defects using only a premium
refractory coating, without the aid of a sand additive??
A: ASK Chemicals has premium refractory coat-

ings that will enhance the iron casting process
without the additional expense and production pro-
cess requirements of sand additives. These coatings
been formulated to provide consistent microstructure
and metallurgical properties to gray iron, ductile iron, At top, the results with a thin coating (1-2 mils) of MIRATEC MB 508; above, a
good coating layer (12 mils.)
and compacted graphite iron (CGI) casting.
These coatings also provide an insulating barrier Depending on the casting and dimensional tol-
between the molten iron and the sand core or mold, erances you may need to make allowances for the
having a direct effect on cooling rates of the metal, heavier coating layer within the tooling.
promoting good nodularity. One such coating is MIRATEC MB 508, specifi-
cally designed to penetrate the sand core in order to
provide greater protection than just a proud layer of
coating can provide.
If extreme veining defects are occurring with the
current casting program, and using a premium coat-
ing is not possible based on the selected process it
may be likely that a sand additive like VEINO ULTRA
RS 4 will still be required to provide 100% defect-free
Casting samples showing penetration effects with the use of a standard
refractory coating. castings.
Casting samples showing penetration results using a premium ASK Chemicals

refractory coating.
Using these types of premium coatings promotes

excellent peel, providing a clean casting with little to MIRATEC MB 508 is designed to penetrate the sand core, to provide greater
protection than a surface coating.
no residual sand or coating in the casting.
In order for a coating to provide sufficient protec- Seek metalcasting solutions … discuss ideas
tion against veining and penetration defects, the op- and new technologies with ASK Chemicals
erators must apply an adequate sand coating layer of Join the Conversation …
approximately 10-12 mils, or greater, depending on Sumbit your questions
at www.foundrymag.com
casting section.
CASTING TECHNOLOGY
BEYOND TOMORROW
Are you
READY
for tailor-made
services?
Ideally positioned thanks to perfectly tailored

technical services
In the future, anyone who wants to be more than just well positioned requires reliable partners and tailor-
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ASK Chemicals experts look forward to hearing from you:

Phone: +1 800-848-7485
E-mail: info@ask-chemicals.com
www.ask-chemicals.com/beyondtomorrow
^
METALCASTING NEWS
…READ MORE detailed reporting on foundry operations and technology at foundrymag.com/news
Ermak Foundry
Adds Two Aluminum
Casting Businesses
M innesota-based Ermak Foundry
and Machining has acquired Pa-
triot Foundry & Castings in Franklin,
NH, a specialty producer of nonferrous
sand castings; and RDS Dock Hard-
ware, also in Franklin, NH, which casts
aluminum docks, decks, and bridge
hardware.
The value of the transactions, com-
pleted in early February, was not an-
nounced. For Ermak Foundry, the ac-
Elyria Foundry photo

quisitions follow its 2019 purchase of
The new ownership claimed that the iron foundry operation “has range to produce very large
castings and the depth of technical talent to solve problems for its customers.”
Investment Group Buys Elyria Foundry,

Hodge Foundry
rivate investment group TRM Equity acquired Elyria Foundry, Elyria,
P OH, recently for an undisclosed price. The seller was not identified.
Elyria Foundry is a gray and ductile iron foundry that produces parts
Ermak Foundry photo

ranging in size from 20 to 200,000 lbs., for defense projects, oil-and-gas
equipment, wind energy systems, mining and mineral processing machin-
ery, construction equipment, and similar applications.
The foundry has an affiliated operation in Greenville, PA. Hodge Foundry
produces large-scale, engineered gray and ductile iron castings for critical
applications in the power generation segment. This includes parts for wind The Minnesota group acquired Patriot
turbines and coal pulverizers, along with other parts for mining and mineral Foundry and RDS Dock Hardware, both in New
Hampshire, adding more nonferrous alloy
processing machinery. Its specialties are large, heavy-section iron castings capabilities as it installs automated molding and
weighing from 3,000 to 200,000 lbs. sand testing.
“The foundry industry has been under considerable pressure over the last
few decades, and we have focused on the companies with unique positions Northwest Casting Inc., St. Paul, MN,
and capabilities in their space,” stated Jeffrey Stone, managing director for and ongoing improvements to its cast-
TRM Equity. “Elyria Foundry has range to produce very large castings and ing capabilities.
the depth of technical talent to solve problems for its customers. We look Patriot Foundry’s sellers were Chris
forward to partnering with the Elyria Foundry team to navigate through a and Debbi Leuteritz, and the transac-
challenging environment and continue to be a valued resource to its cus- tion was coordinated by Generational
tomers far into the future.” … READ MORE Equity, a private investor group. “The
new ownership of Patriot is a great fit,”
CONGRATULATIONS TO
BOCAR
U.S
ON THEIR INVESTMENT IN
AMERICAN MANUFACTURING
AT THEIR PLANT IN
HUNTSVILLE, AL
Foundry Solutions & Design
Engineering & Project Management

316 Maxwell Rd, Suite 500, Alpharetta, GA 30009, USA Phone: 770.667.4545 Fax: 770.667.4544
e-mail: engineering@foundrysd.com, www.foundrysd.com
^ METALCASTING NEWS
the broker stated. “Ermak has the management and opera- Northwest Casting’s permanent mold/gravity-fed diecast and
tional expertise to take this company to the next level. It was in-house heat-treat capabilities last year. Our emphasis has
a pleasure to lead this M&A transaction.” expanded to other nonferrous alloys in tandem with the in-
Ermak Foundry and Machining general manager Eric stallation of our automated molding and sand testing systems.
Sloan said the group’s “access to capital and experience “Patriot expands our aluminum capability geographi-
adding automation across the enterprise allows for future cally, as well as expertise in brass, bronze, zinc, and other
expansion of Patriot and RDS Dock Hardware. With this copper-based alloys,” he continued, “plus the capability for
acquisition, we will have nearly quadrupled the size of the assembly of complete parts.” … READ MORE
company in four years. We’ve been focused on automating
both the shop floor and back office, so we have a strong Precision Castparts Loses
foundation from which to scale the companies.”
Ermak Foundry, Chaska, MN, offers no-bake and green- Unionization Appeal
sand-cast and permanent-mold aluminum castings for var-
ious markets (general industrial, recreational, construction,
utility, and agricultural manufacturers.) It also offers ma-
P recision Castparts Corp. lost a U.S. Court of Appeals
ruling in a challenge it had brought to a National Labor
Relations Board conclusion concerning employees’ efforts
chining and heat-treating services. to organize a union in 2017. The NLRB found that PCC
Patriot Foundry’s customers are concentrated in the committed an unfair labor practice when it refused to engage
Northeast U.S., and include defense programs, packaging, in bargaining with about 100 welders working for its PCC
communications, aerospace, automobile, and multiple other Structurals subsidiary in Portland, OR, and challenged their
market segments. effort to affiliate with the International Association of Ma-
Seth Cutler, president of Ermak, commented: “The acqui- chinists and Aerospace Workers union.
sition of Patriot was a logical next step after the integration of Now, reportedly, the union plans to send a “demand let-
ter” to Precision Castparts to force it to begin negotiating a
contract.
Precision Castparts has three business units: Investment
Cast Products, including PCC Structurals and PCC Airfoils;
Forged Products, including Wyman-Gordon, PCC Energy
Group, Titanium Metals Corp. (TIMET), and Special Metals
Corp. (SMC); and Airframe Products, including PCC Fas-
teners and PCC Aerostructures. While it is heavily focused
on aerospace manufacturing, it also supplies energy and
industrial markets.
The 2017 vote by the welders was the start of an attempt
by the IAM union to organize PCC workers, which at that
time totaled about 30,000. About 20% of the workers at
that time were subject to collective-bargaining agreements.
Ninety-two welders participated in the 2017 vote, of whom
54 endorsed the organizing effort.
Last year PCC implemented an extensive downsizing
program, reducing its total workforce by about 30% amid
a severe downturn in commercial aerospace demand. Also
last year, Warren Buffet’s Berkshire Hathaway Inc. took
a $9.8-billion writedown on Precision Castparts, which it
bought for $32.1 billion in 2016. … READ MORE
AB&I Foundry to End Molding

Operations
D uctile-iron pipe producer AB&I Foundry will cease
moldmaking in Oakland, CA, in 2022, and shift those
processes to another McWane Inc. holding, Tyler Pipe in
Tyler, TX. “The company will be per-

manently shutting down molding oper-
ations in 2022 to satisfy ever-increas-
ing regulatory standards as quickly as
possible and well in advance of regula-
tory deadlines,” according to an AB&I
Wisconsin Aluminum Foundry photo

Foundry statement, referring to Cali-
fornia air-quality regulations.
About 100 positions will be elim-
inated, according to an estimate by
AB&I in its statement.
“AB&I has an excellent compli-
ance record with applicable regulatory
standards,” stated Michael Lowe, the
foundry’s general manager. “Changing
standards create business uncertainties Wisconsin Aluminum The private transaction adds more aluminum
green-sand casting capability, in what the CEO
that make it difficult to continue our Foundry Buys said, “will accelerate our growth in the electric
vehicle and consumer goods markets.”
operations in California.” Wabash Castings
Other foundry operations will con- in a private transaction. The green-sand
tinue in Oakland with enhanced engi-
neering controls, according to the com-
pany. … READ MORE
W isconsin Aluminum Foundry re-
ported it has purchased the assets
of Wabash Castings Inc., Wabash, IN,
foundry is seen as “a perfect comple-
ment to our existing breadth of produc-
tion lines.” According to a statement by
A P R I L 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 9
^ METALCASTING NEWS
Wisconsin Aluminum Foundry CEO construction, commercial vehicles, The terms of the acquisition were
Sachin Shivaram. defense, medical, and railroad manu- not announced.
“This acquisition will accelerate our facturing, among others. Its holdings The machining operation is close
growth in the electric vehicle and con- also include Manitowoc Pattern & Ma- to a General Motors crossover vehi-
sumer goods markets, among other ex- chining, MP&M a precision machining cle assembly plant, noted Nicholas
citing opportunities,” he added. and foundry tooling producer with en- D. Heiny, general counsel for MTI.
The Wabash Castings brand will be gineering capabilities for prototyping “Growth of existing U.S. business lines
maintained. through assembly, NDT, and other ser- is substantially strengthened by hav-
Wabash Castings produces com- vices. … READ MORE ing a presence in Mexico. We view this
plex-cored parts like pumps, man- as definitely a way to strengthen our
ifolds, and turbo chargers, among Metal Technologies U.S. presence by growing in Mexico,”
others, for automotive manufacturers Heiny stated.
(including EVs), heavy-duty truck Inc. Buys Machine “MTMS was one of our first and
builders, off-highway and construction Shop in Mexico largest customers in Mexico,” MTI
equipment producers, and other gen-
eral manufacturing operations.
Wisconsin Aluminum Foundry,
F oundry group Metal Technologies
Inc. has purchased a specialty ma-
chining operation in Mexico from AAA
president and CEO Matthew Fetter
commented about the purchase. “We
knew the management team very well
Manitowoc, WI, uses green-sand, air Sales & Engineering, nearby MTI’s gray for many years, and the MTMS team
set, and permanent-mold casting and and ductile iron foundry in San Luis Po- was the critical part of the acquisition.
low-pressure molding to pour a range tosi. The plant’s management team will In addition, MTMS’ ability to machine
of aluminum and copper-based al- remain, operating the facility as Metal a wide size range of parts with complex
loys for automotive, agriculture and Technologies Maquinados de SLP. operations and tight tolerances was
1 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | A P R I L 2 0 2 1
METALCASTING BRIEFS
complementary with our existing ma- Eck Industries, Manitowoc, WI, recently certified its quality system to
the AS9100D standard, for aviation and aerospace market suppliers. The
chining experience. air-cooled cylinder head shown here is cast in 200 Series aluminum for
“We believe customers benefit from small aircraft. Eck produces air-set, permanent mold, and low-pressure
permanent mold castings in various alloys, and offers in-house heat
casting and machining solutions close treatment, dye penetrant inspection and radiography services.
to their operations,” Fetter added.
“MTI is the only company that can do Guardian Software Systems will supply its ERP platform to investment caster
this in Mexico as well as the U.S.A.” Dameron Alloy Foundries, with plants in California, Kentucky, and Mexico,
MTI, headquartered in Auburn, IN, Dameron Alloy Foundries excels as an industry leader with over 70 years of
metal casting experience. Wisconsin-based Guardian also recently added Trum-
produces gray iron, ductile iron, and aus-
bull Foundry/Jarvie Performance Castings, a no-bake foundry in Niles, OH, as
tempered ductile iron castings, as well as an ERP/MES software client.
aluminum diecastings, at six locations in
Indiana, Michigan, Minnesota, and Ten- General Kinematics recently acquired Foundry Equipment Co., Stanwood,
nessee, in addition to the Mexican iron IA, expanding its portfolio for foundry system integration. “FECo has the same
foundry. The group also has a specialty commitment to quality and customer satisfaction that General Kinematics pro-
machining operation in Michigan. vides and will be a great addition to our existing group of experienced foundry
Each plant is set up to produce cast- experts,” commented Tom Musschoot, GK president.
ings for particular markets, including
Franklin Bronze Precision Components, an investment caster in Franklin,
automotive, heavy trucks, hydraulic
PA, has adopted laser-based SLA additive manufacturing to produce rapid
systems, compressors, appliances, prototypes and short-run castings. “The addition of this 3D printer to our
small engines, railroad, trailer axle, and facility allows us to quickly prove out design changes without needing to alter
general industrial customers. the tooling each time. For instance, making a gating change can be proved
… READ MORE before cutting into the tool,” said senior IC process engineer Neil Kruse.
A P R I L 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 1
^ NEWS MAKERS
Leadership Change management posi- burn stated. “I look forward to using my

at Vesuvius GmbH tions at Dow Chem- over-25 years of foundry-sand prepara-
R afael Carbonell has replaced Heinz

Nelissen as managing director of
Vesuvius GmbH’s foundry division.
ical in Europe, and
recently served as
Division CFO at
tion knowledge to support our custom-
ers’ needs, now and into the future.”
Nelissen will remain with the com- Trinseo Europe, a Carpenter Bros.
pany as area director, manufacturer of plas- Adds Environmental
Northern Europe, Windegger tics, latex binders,
until June 30, 2021, and synthetic rubber.
Sales Rep
at which time he will
retire.
Carbonell holds
“Hubert is a seasoned manager who,
alongside traditional CFO responsibili-
ties, will set new emphases in the digi-
C arpenter Brothers Inc. and its af-
filiate J. Carpenter Environmen-
tal announced the hiring of Matthew
a master ’s degree talization strategy of ASK Chemicals,” Ednie as the Northeast regional direc-
Carbonell in Mathematics and stated Frank Coenen, ASK Chemicals tor for environmental technical sales.
Theoretical Phys- CEO. “I am very pleased that we were He is Carpenter Brothers’ first sales
ics from Cambridge able to win Hubert Windegger for our representative solely
University and an company.” assigned to environ-
MBA from London mental products and
Business School. New Regional Mgr. at services.
Carbonell spent Simpson Technologies Ednie brings over
10 years holding 24 years’ experience
Nelissen
various management
positions in alumi-
num manufacturing,
C ory Ashburn has joined Simpson
Technologies as its regional ac-
count manager, Midwest, responsible
Ednie
in environmental re-
mediation projects
and compliance issue
and for the past two for the sales of all Simpson products resolution to the staff of J. Carpenter
years he has been the and services in Iowa, Environmental, which provides envi-
Vesuvius Group’s Illinois, Indiana, ronmental products and equipment to
European Vice Presi- Michigan, Minne- foundries and other manufacturers.
dent EMEA Foundry. sota, Missouri, Ne-
He will continue in braska, North Da- Global Marketing
that role in his role as kota, South Dakota, Manager Named for
Erger
managing director. and Wisconsin.
Hannes Erger, the Vesuvius business Previously, Ash-
Superior Die Set
Ashburn
unit manager for iron and steel found-
ries, has been added to the group’s
management team.
burn spent six years
with the Foseco / Vesuvius organiza-
tion as an account executive, and before
W isconsin-based Superior Die
Set Corp. appointed Maria Van-
Haverbeck as its global marketing
then he was a product and sales manager head, a new position for the custom
New CFO for ASK during 11 years with American Colloid supplier to stamping, plastic injec-
Chemicals Group Co. He also worked as a regional sales tion molding, and forging businesses.
manager for the Hill & Griffith Co. VanHaverbeck will be responsible for
H ubert Windegger has joined ASK

Chemicals as the group’s chief
financial officer as of March 1, it an-
Ashburn has served two terms on
the board of directors of the Wiscon-
sin Chapter of the American Foundry
building the marketing department and
synchronizing strategies for Superior
Die Set and its brands, Greendale Pre-
nounced, calling him “an experienced Society and is a four-time recipient of cision Services and ProPlastica.
financial expert” and making him re- the American Foundry Society (AFS) “Maria will position us in the mar-
sponsible for finance, controlling, dig- Technical Presentation award. He was ketplace as a global leader; her edu-
italization, and IT. Windegger replaced five times presented the AFS Service cation, background and experience in
Anders Wester, who had served as CFO Appreciation Award. manufacturing make her a perfect fit
of ASK Chemicals Group since 2018. “It is my true pleasure to be a part of for Superior Die Set,” stated vice presi-
Windegger previously held various the Simpson Technologies team,” Ash- dent Rodney Yeomans.
^ TECHNICAL DEVELOPMENT
Metallurgy Breakthroughs Show a New Phase of Competition
Powdered materials, binder-jet printing, and sintering are advancing to a point that developers
say will be “disruptive” to metalcasting.
well-designed, well-produced casting is proof of its own value, “High-speed aluminum 3D-printing paves the way for other
A but buyers’ demands go beyond design and production. That’s an opportunities that we’re just now starting to take a look at because
opening for proponents of 3D-printing, who lately are making their of the ability to do complex parts with aluminum that previously
intentions known – not with new design or production capabilities but weren’t possible,” according to Harold Sears, Ford technical leader
with metallurgy, long assumed to be the real advantage foundries and for additive manufacturing. “It’s really opening doors for other
diecasters held in this competition. opportunities.”
Desktop Metal Inc. CEO Ric Fulop called his group’s co-devel- ExOne noted that new process could increase Ford’s effi-
opment of an aluminum 6061 powder for ciency by allowing it to affordably produce
binder-jet additive manufacturing a “break- complex parts uniquely designed for ad-
through … one of the most sought-after ditive manufacturing, which could mean
materials for use in automotive, aerospace, “size and weight reductions, part consoli-
and consumer electronics.” according to Ric dation, and performance improvements.”
Fulop, Desktop Metals CEO and co-founder. “Developing a fast, affordable, and easy
Desktop Metal and partner Uniformity Labs way to 3D-print aluminum with traditional
claim the alloy offers greater than 10% elon- material properties is a critical step toward
gation plus improved yield strength and ul- light-weighting more products and delivering
timate tensile strength compared to wrought An aluminum 6061 engine block model a more sustainable future,” stated John Hart-
demonstrates the high resolution and geometric
aluminum 6061. control available in the ExOne/Ford binder jet 3D ner, ExOne CEO.
The alloy, Uniformity 6061, is proceeding printing and sintering process. [Business Wire] Another frontier in this competition sees
toward qualification and a commercial release. AM specialist 3D Systems collaborating
Adam Hopkins, Uniformity Labs founder and with Huntington Ingalls Industries’ Newport
CEO said the new alloy “opens the door to a News Shipbuilding division to develop cop-
wide variety of thermal and structural applica- per-nickel (CuNi) and nickel-copper (NiCu)
tions across industries.” alloys for powder-bed fusion (a/k/a “binder
Binder-jet additive manufacturing is the jet”) production – potentially allowing NNS to
process in which a printer-head device selec- replace castings with additively manufactured
tively deposits a liquid binder onto a layer of parts, and to cut lead times by up to 75%.
powdered metal according to a pattern defined CuNi and NiCu are corrosion-resistant al-
Fully dense, sinterable 6061 aluminum with
from a CAD file of the finished part. Each better than wrought strength will be available loys with high strength and durability across
completed layer is bonded to a successive for binder jetting technology, according to co- a wide range of temperatures. However, com-
developers Desktop Metals Inc. and Uniformity
layer, according to the design, and the formed Labs. [Business Wire] ponents produced in these alloys require long
part is later sintered with a combination of heat lead times (sometimes more than one year,
and atmospheric pressure to densify the part structure. according to 3DS) and multiple suppliers. A successful powder-metal
The developers said the new powder makes it possible to sinter un- formulation that could be available for metal 3D printing could shorten
adulterated 6061 aluminum, meaning it is not necessary to coat pow- the supply chain considerably, it is proposed.
der particles prior to printing, nor to mix sintering aids into the powder, Newport News Shipbuilding is the sole designer, builder, and re-
nor to use binders containing expensive nanoparticles or metals. fueler of U.S. Navy aircraft carriers and one of two providers of U.S.
At nearly the same time another “breakthrough” for binder-jet Navy submarines. It would be able to use the new materials with its
printing of aluminum 6061 was announced by AM developer ExOne current metal AM capabilities to produce replacement parts for cast-
Co. and Ford Motor Co., who have been collaborating on the devel- ings as well as valves, housings, and brackets.
opment since 2019. They are seeking to patent a 3D-printing and Once the CuNi and NiCu materials have been demonstrated suc-
sintering process which they claim, “delivers properties comparable cessful, 3D Systems anticipates they will be added to its materials
to diecasting.” portfolio and would be available for corrosion-resistant applications
Aluminum 6061 contains magnesium and silicon elements, and it in other industries, like oil-and-gas production and refining, and utility
feature good mechanical properties and good weldability. It is com- energy production.
monly extruded, forged, and sometimes diecast. Ford and ExOne The metallurgy of powdered materials may be the emerging venue
contend their process for binder-jet printing and sintering aluminum for the ongoing competition between metalcasting and other manufac-
6061 results in parts with densities greater than 99%. turing processes – a contest that buyers will settle.
Metallurgy
Controlling Conditions
for Cupola Melting
There are several steps to maximizing cupola operating performance, but the first and most
important is to manage the detrimental influences of iron oxide.
Ron Beyerstedt
produced by blast air contact with the molten metal. (See this
effect illustrated in Fig. 1, p. 16.)
Iron oxide present in the tuyere raceways produces carbon-ox-
idation loss. There have no meaningful measurements of the car-
bon loss in the raceway due to the ever-changing dynamic nature
of the cupola melt zone.
Mastermelt DeOX counters iron-oxide formation in the race-
ways: The elusive carbon loss does not need to be determined.
DeOX injection simply eliminates the loss, making further inves-
tigation moot.
DeOX is the only material available that eliminates iron oxide
in the tuyere raceways. As stated previously, iron oxide formation
cannot be stopped but DeOX instantly chemically reduces it to
inert by-products. With iron oxide and its effects neutralized,
free-oxygen atom levels in the molten iron bath decrease near
to oxygen’s inert level of activity, effectively de-oxidizing the
cupola melting operation
First contact
I
ron oxide threatens all iron-melting processes. In cupola
melting, much greater amounts of iron oxide are produced The mechanism of the oxidation loss reactions is iron oxide
during the normal melt cycle than are produced in electric contacting the molten iron droplet’s surface, immediately adding
furnace melting. This makes iron oxide’s effect much more free-oxygen atoms to the molten iron. Those oxygen atoms seek
pronounced in cupola melting. In EF melting, 20%-30% oxida- out other elemental atoms within the iron’s matrix and combine
tion loss is the extreme of losses encountered. In cupola melting, (oxidation process) in accordance with the Laws of Thermody-
in the worst-case scenario, the oxidation losses approach 65%. namics. High temperature (as in the tuyere raceways) favors car-
Carbon oxidation losses remain unknown to this day. bon loss, and low temperature (as in the upper melt zone) favors
When a cupola is first started, blast air “burns-in” the coke bed. silicon loss.
During this phase, no iron oxide is produced because no iron is The amount of iron oxide formed controls the amount of the
melted. The blast air simply preheats the coke, preparing for the loss. Once free-oxygen atoms enter molten iron, there is nothing
upcoming melting campaign. available to iron melting personnel to stop the oxidation reaction.
Once metallic charging and melting commences, blast air The only option available to them is to somehow cut off the oxy-
contacts the molten metal droplets as they descend through the gen atom supply.
oxygen-rich layer immediately in front and above the cupola In steel melting, operators add aluminum (0.03% Al) to quickly
tuyeres. This oxygen-rich high-temperature zone (5,000°F) in the combine with free-oxygen atoms but this option is not available
cupola causes iron-oxide formation on the droplet’s surface and to iron melting personnel due to pin-holing sensitivity in cast iron,
vaporization of a portion of the iron oxide formed. The FeO gas promoted by elevated levels of aluminum.
spreads throughout the cupola, leading to FeO contamination of The volume of iron oxide produced in the tuyere raceways is
the entire cupola. controlled in part but, significantly, this is a consequence of the
Iron oxide causes significant chemistry losses, both carbon and blast air’s humidity. High humidity makes cupola melting very
silicon. The graph below shows silicon loss as melting progresses difficult.
in a 35-tph cupola. Silicon loss finally reaches steady-state when Most coke suppliers will comment on how cupola-melting per-
FeO exiting the cupola contained in slag equals the FeO being sonnel always claim coke quality deteriorates during the hot-sum-
mer months. Obviously, coke quality has not deteriorated. be done about it, so no concern was assigned to it.
The fact is more iron oxide is produced during melting and the The common practice used to increase molten iron’s carbon
increased iron-oxide level causes increased carbon and silicon content was to raise coke rates – the famous “coke bump”.
losses. A typical scenario in the high-humidity periods: increase Carbon increase occurs from coke that has transitioned through
coke rate; add or increase pig iron; reduce steel in the metallic the 5,000°F temperature range directly above tuyere level. This
charge; enter complaint with coke suppliers. high temperature causes the amorphous coke to
Up until now, nothing was available to reduce convert to graphitic-carbon atom structural ar-
iron-oxide formation in the tuyere raceways.
The common rangements. Once the coke has been graphitized
Mastermelt’s DeOX is available now to counter – practice used to and descends below the oxygen-rich blast air re-
not stop – iron-oxide formation. increase molten gion, carbon dissolution into the descending iron
droplets readily occurs.
Natural course iron’s carbon Carbon pick-up can vary significantly, but it
Iron oxide forms naturally – by the Laws of content was to raise is highly dependent on the metal temperature.
Thermodynamics. Mastermelt’s DeOX, however The volume of coke below tuyere level remains
counters iron-oxide formation by catalytically
coke rates – the constant so addition of “coke bumps” or other
reducing it into inert by-products as it forms. famous temperature control means to produce increased
Cupola melting encounters carbon oxidation carbon appears to occur simply due to metal tem-
“coke bump”.
losses in the tuyere raceways, and encounters car- perature increases. Carbon’s dissolution rate into
bon pick-up directly below the raceways from the molten iron is significantly affected by metal
incandescent, graphitized coke. Carbon is lost and then gained, temperature.
and the overall effect is a net increase in carbon. Cupola operators Cupola operating temperature is a critical operating parameter
refer to the overall carbon pickup as “carbon from the coke bed.” that requires much investigation and review. Temperature of
In the past, the carbon loss occurring in the tuyere raceways molten iron exiting the cupola becomes the main focus for melt
has gone un-treated. Two schools of thought existed with cupola performance improvement once iron oxide’s presence within the
operators: either the carbon loss was unknown, or nothing could cupola is countered.
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Metallurgy
2
Consider the following cupola operating parameters, which
affect a cupola’s molten iron temperature:
1.75
1. Uniform blast-air distribution between tuyeres;
% Silicon
2. Proper blast-air penetration away from the cupola’s shell;
1.5
3. Streamline blast-air flow;
4. Minimize retained slag level – proper metal dam height;
1.25
5. Proper-size coke;
6. Proper-size metallic charge materials;
1
7. Reduced cement bonded charge materials; 2:00 AM 2:15AM 2:30AM 2:45AM 3:00AM
8. Proper amount of limestone;
9. Inject oxygen uniformly in tuyeres; use special injection 1:45 AM 2.02 The cupola charge consisted of steel,
nozzles. 2:00 AM 1.70
sprue and 50# SC bricks
Numerous benefits result when cupola operating improve- 2:16 AM 160

Full silicon recovery=1.96% Si
ments are instituted: 2:30 Am 1.60

Silicon recovery near tap-out
time=1.88% Si indicating Minimum
1. Improved refractory service life throughout the cupola; 2:45 AM 1.44
FeO present at start up.
Silicon recovery after FeO built for
2. Straight-line metal chemistry control – with no oxidation 3:00 AM 1.26 one hour=65%
losses;
3. Eliminate pig iron and other special metallic charge Figure 1. Silicon loss continues as melting progresses in a 35-tph cupola,
finally reaching a steady state when FeO exiting the cupola in the slag
materials; equals the FeO being produced by blast air contact with the molten metal.
4. Eliminate chemistry declines over hold periods;
5. Provide instant chemistry recovery after cupola down on coke weight. Nothing different happens from one cupola to the
periods; next, although each melt department superintendent insists, “the
6. Reduced coke rates; limestone used is the limestone needed.”
7. Reduced slag volume produced in melting cycle; This is a falsehood that must be discussed. Limestone adds
8. Substantial cost savings; nothing to metal quality, and it is added to counter coke ash’s sil-
9. Improved metal quality; ica content. Ten-percent limestone works at one cupola, it should
10. Precise management of metal quality. work at all cupolas.
Melt operators must consider the effect of coke size on com-
Take control bustion energy produced. The coke salesman promoting 10%,
The first and foremost step to improving cupola operation tiny-sized coke substitution for normal-sized coke is misleading:
is to gain control of iron oxide formation throughout the melt Coke combusting to form CO2 liberates nearly four times the heat
process. Once iron oxide contamination of the cupola is re- released by coke combusted to form CO.
solved, coke rates can be reduced to the 6-7% level. CO formation is favored by the large carbon-surface area
The reduced coke rates produce dramatic energy efficiency found with small coke. Large coke burns hotter: Adding 10% tiny
improvement and corresponding reductions in greenhouse gas coke substitution should be stopped. Anyone considering small-
emissions. Slag volume produced is cut in half. Monetary sav- size coke should consider reducing the overall coke rate by the
ings are significant – millions of dollars saved annually. amount of the proposed tiny coke addition rate.
Controlling iron oxide completely changes cupola oper- No minimum coke-rate is required to produce a certain melt-
ations: No slag buildup occurs in the front box. No tap hole ing result. Coke rate determines metal temperature only after the
erosion occurs. No wide variations in metal chemistry occur. cupola is de-oxidized with Mastermelt DeOX Metal Treatment.
Each of the points listed above will be discussed further in Seven-percent coke rate is being used now in operating cupolas in
coming articles, and these and many more operating points the U.S., indicating that all cupolas can operate at that level.
will be discussed in our upcoming cupola operating workshop. Cupolas operating at low coke rates today do so due to no
A simple change like a two-inch reduction in metal dam significant carbon level increase being required during the melt
height can increase metal temperature by 60°F. a four-inch re- cycle. DeOX Metal Treatment removes this restriction, providing
duction in tuyere height increases metal temp 75°F. Obtaining increased carbon levels without requiring increased coke rates –
uniform blast air distribution eliminates isolated wear areas maximizing cupola operating performance.
within the cupola, reduces coke rates, reduces chemistry varia- This is the second in a series of reports examining cupola
tions, and increases metal temperature. design, cupola melting practice, and cupola technology
Then consider this: limestone additions vary dramatically solutions. Also see “Maximizing Cupola Performance,” FM&T
from cupola to cupola. Reducing limestone increases metal March 2021.
temperature, decreases chemistry loss, increases metal tem-
perature, and enables easier slag handling in the front box. Ron Beyerstedt is the president of Mastermelt LLC. Contact him
Cupolas today operate at 10 to 45% limestone additions based at ron@mastermelt.com
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Quality Control
Patternmaker Builds its Brand on Accuracy

A range of advanced metrology systems and could perform only time-consuming spot checks using hand tools.
capabilities are helping Accurate Pattern Inc. Now, the wide reach of the model (~13 ft. diameter) allows
improve and expand its resources for product them to check patterns like truck hoods, wind turbine blades, and
boat hulls in a single set-up. If necessary, the operators can shift
quality and customer service.
the scanner on its portable stand and the software stitches the scan
aking “accuracy” part of your brand may be a risk, but a fairly data together. “The Romer arm’s 0.003-in. accuracy confirms the
M unavoidable one if the business is patternmaking. Accurate quality our customers need,” he said.
Pattern Inc., Butler, WI, specializes in wood, metal, and plastic Switching from Elm to Wenzel CNC CMM increased checking
patterns, tools, fixtures, gauges, prototypes, and models for man- accuracy and efficiency by 10X, according to Accurate Pattern. Pre-
ufacturers. Its capabilities include CAD design, manual and CNC viously, they were able to guarantee to +/- 004 in. (0.1 mm), but now
machining, woodworking and metalworking, painting and weld- measurement accuracy is better than 0.0003 in. (0.006 mm). Upgrading
ing and other services for design, to the PolyWorks|Inspector™ soft-
engineering, and production job ware means that the Wenzel DCC
shops. CMM machine can inspect quality
Accurate and reliable quality fixtures in half the time.
control is also a customer-ser- Daniel Jones, the model shop
vice issue, and for that Accurate manager, further credits the tech-
Pattern co-founder and president nical assistance available from Ex-
Bruce Williams acknowledges act Metrology, including projects
the tools and systems supplied involving first-article inspections,
by Exact Metrology – a provider quick changes on a car model and
of 3D and CT scanning, reverse modified a cast aluminum tool.
engineering, quality inspection, The Hexagon Romer Absolute
product development and 2D Arm was used for FAI on fiber-
drawings, as well as metrology Using the Romer Absolute Arm to verify changes to the mold glass and vacuum formed parts,
pattern for a model car pattern at Accurate Pattern Inc.
equipment sales. and to verify changes to a model
“We only entered the quality car pattern. The scanner was used
fixture market because of the inspection capabilities Dean helped us to align on a five-axis router and recut within 0.005 in. Then, laser
obtain,” he explained, recalling Exact Metrology co-president Dean inspection helped to verify how much hand-sanding was necessary
Solberg’s recommendation of an Elm CMM/ layout machine with before painting the finished model.
PC-DMIS software, more than a decade ago. Recently, a cast aluminum tool needed to be modified. In order
In 2014, Solberg suggested Accurate Pattern should install a to know wall thickness and the position of water lines, the tool was
Wenzel CNC CMM with Open DMIS software machine, for coor- laser-scanned to compare the results to CAD data, and to machine
dinate measuring with CNC machining. Later, following an Exact within the wall without damaging the water lines.
demonstration, the shop implemented a Hexagon Absolute Arm “We have been able to greatly reduce our customer non-confor-
seven-axis device, its second CMM system. Over the past year, Ac- mances by inspecting our patterns in-house,” Jones said. “We have
curate Pattern Inc. has worked with Exact Metrology to update the also been able to re-machine jobs with more precision thanks to the
open DMIS software on the Wenzel CMM to PolyWorks|Inspector™, capabilities of scanning the job in position on the machine.”
a 3D dimensional analysis and quality control program developed by Reverse-engineering is another capability now available. Ac-
Innovmetric Software. curate Pattern Inc. digitizes existing shapes to CAD format for
The Elm CMM layout machine with PC-DMIS software sig- redesign and reproduction, allowing rapid design changes, scaling,
nificantly enhanced the shop’s capabilities for pattern and fixture or mirror imaging.
measurement. Previously, it had been able to use only height gages Accurate Pattern is set to receive ISO 9001:2015 certification
and calipers, and they were not able to certify their work. The Elm this year, and Bruce Williams is looking forward to building on
allowed Accurate Pattern Inc. to start quality fixture-building and “accuracy” for further improvements and capabilities – including
greatly improved accuracy in all their work. large-format metrology scanning. “I want to do verification on the
“The Romer Arm with PolyWorks|Inspector™ was a game- machine, have handheld scanning for on-site digitizing and have
changer for inspecting patterns and molds 100% to reference CAD cloud-based CAD, inspection, and reverse engineering software,”
data,” Williams said, noting that previously the shop’s technicians he explained.
^ SUCCESS STORY
To Industry 4.0 …and Beyond

Dotson Iron Castings adopted Sinto America’s enVision Process Visibility System for its molding
lines, resulting in improved production, less downtime, faster cycle time, better maintenance
scheduling, and more.
feasible, shortening process or equipment launch

cycles, and improving yields, and enhancing com-
munication across the organization.
“At Dotson, we continue to reinvest, redevelop,
and recreate what a foundry can be so that we can
deliver the best value and quality to our customers,”
according to president Eric Nelson. “Sinto’s ePVS,
allows us to be the most efficient foundry we can be,
by taking our focus off maintenance and putting it on
the customer.”
As Nelson recalled, Dotson’s introduction of the
system two years ago came with some uncertainty.
“Rolling out the ePVS system at Dotson started as
a ‘nice-to-have’, … not sure exactly what benefits
we would see. What we are really trying to improve
on is our ability to not overwork on equipment, from
a maintenance standpoint, but really address the
equipment and work on it at the right time.
“The first mechanical issue that was highlighted by
I
ndustry 4.0 is a vast subject involving technological sys- the system has turned it into a ‘must-have’,” Nelson continued.
tems and functions integrated with practical manufacturing “We have been able to address concerns well before they create
applications, but it’s worth noting that some metalcasting compounding issues in the remainder of the system. It doesn’t
operations are well beyond the concept stage. Dotson Iron replace our maintenance team, but it makes them much more
Castings, the Mankato, MN, producer of ductile iron and aus- efficient.”
tempered ductile iron components is one example. Sinto America’s enVision Process Visibility System (ePVS)
In simple terms, Industry 4.0 describes a network of ma- is a data acquisition and process visualization platform designed
chines and processes sharing critical operating data, and at the to make it easy to see what’s happening at any moment, what
same time contributing to an expanding volume of data that will happen soon, and what should be done to maximize the
grows an organization’s control over its activities and opportu- potential of a specific production process. It provides real-time
nities. Dotson has been operating its molding machines, transfer data, allowing operators to see and address problems before a
stations and turn tables with Sinto America’s enVision Process failure occurs, for a significant reduction in unplanned down-
Visibility System (ePVS) since 2019. time. Envision also makes it easy to correlate data and identify
Dotson and Sinto have a long working history, involving patterns over longer periods of time, so that it can predict when
various systems installed for molding, automatic pouring, au- recurring maintenance will be necessary, and to replace a default
tomatic grinding, and blast-cleaning machines. The integrated maintenance schedule with one based on real, reliable data.
data analytics of the ePVS installation allows Dotson operators “I think ePVS is great,” offered Dotson’s maintenance man-
to visualize the operating conditions in such a way that perfor- ager, Kenny Elliott. “It gives us advance notice of things that
mances can be evaluated in real time, and potential failures can may be wearing out. ePVS is giving our maintenance techni-
be recognized and avoided. cians opportunities to fix things before they break. It is giving us
The ePVS system makes available real-time analysis of oper- the ability to plan out our maintenance better.
ations on any device, at any time, and at any place. It also allows “The analytics program shows me a bright future on what we
the operators to adopt predictive maintenance practices, locating can do and what the future holds for being able to be a proactive
hidden liabilities and promoting higher system productivity. maintenance team rather than a reactive maintenance team,”
At the organizational level, it makes long-term planning more Elliott added.
One situation Dotson faced began with a warning indication we can incorporate, the data is there. Being able to grab that data
for a “Sand Gate Close” process. After investigating the history of and see it immediately is a great benefit.”
sand-gate closing and several related operations, it was suggested Another improvement Dotson has identified concerns pro-
that sand was clogging the sand gate. With this discovery, the oper- duction and line-side monitors. The foundry wanted to improve
ation was able to be fixed before any downtime was incurred, and line-side pace awareness for all three of its molding lines. Using
the process cycle time decreased from 3.9 to 0.49 seconds. ePVS, live production counts and targets are displayed at opera-
One of ePVS’s most appreciated features
is its ability to reveal the “hidden” potential
capacity of individual machines or production
processes. The enVision’s detailed visual data
helps the users gain better visibility quickly,
and bring to light lag times, production gaps
and unused assets, revealing inefficiencies
and opportunities for meaningful optimiza-
tion – which otherwise would have remained
hidden. The ePVS portrays clearly how, when,
and where throughput can be increased, and
how maximum production can be achieved.
“What we have found with Sinto is that the The ePVS system displays each motion and event in a molding line’s operation, and gives
ability to understand the equipment is criti- actionable information to operators, which they can apply to keep the line running. [Sinto America]
cal and really helps us leverage that data we
have,” Nelson explained. “We have seen a
10% improvement in our mold production. We
have reduced our preventative maintenance
time by 18%, which is huge for us, as it is
making our techs more efficient. We have also
decreased our downtime in that area by 15%.”
He continued: “It takes a lot of money to
run a foundry on an hourly basis so any addi-
tional capacity we can gain, without adding
hours, goes right to the bottom line.”
Dotson set many goals to be achieved with
ePVS, including raising production volume
without increasing production hours. The
Dotson president Eric Nelson said ePVS system data on mold production has helped to improve
foundry needed its cycle time to be at 120 molds/ the foundry’s maintenance practices. “We have been able to address concerns well before they
hour to meet demand, and by applying Sinto’s create compounding issues in the remainder of the system,” he noted. “It doesn’t replace our
maintenance team, but it makes them much more efficient.”
Analytics program Dotson was able to work
with a Sinto service technician and data analyst to identify areas for tor stations, which led to improved mold output per shift by 5-6.
cycle time reductions. The team was able to reduce cycle time by 5 Working with Sinto’s data analysts Dotson was able to share
seconds (over 14%) remotely. the workload for root-cause analysis. During one study, Dotson
By decreasing maintenance and machine issues, product qual- was experiencing intermittently slow mold push-out. A Sinto
ity improves too. Dotson was able to be more productive in a data analyst reviewed time history and compared that infor-
shorter period of time. Shayne Pribyl, a Dotson maintenance tech- mation to interrelated operations. It was found that a cylinder
nician working directly with the equipment and ePVS, reported switch needed adjusting to accommodate an interlock with the
that since the system was adopted he has seen a direct improve- mold-handling system, which reduced group cycle by 20% and
ment in product quality as a consequence of the machinery oper- reduced maintenance hours required.
ating more consistently. “Sand quality, molding quality, pattern Sinto maintains that Industry 4.0 is paving the way to future
quality – ePVS helps all of it,” Pribyl said, “in the sense that we successes for metalcasting plants, and points to Dotson Iron
can monitor, on a daily basis, the consistency of the machines. Castings’ improvements in production, downtime, cycle time,
“Producing high-quality, consistent molds while hitting the visual targets, maintenance scheduling, and communication as
required number of molds daily, is great,” according to Pribyl. proof. Sinto’s “long-term technicians have been able to help us
“ePVS can only continue improving everything we are working quickly see the trends that we might not have seen otherwise,”
on. From molding machines to the core room, everything that according to Dotson president Eric Nelson.
^ MESSAGE RECEIVED
Communication Creates Expectations

Building and shaping customers’ impressions is part of what your brand must do, and every message you de-
liver will influence their expectations.
Alexandria Trusov
hen you deliver a business communication, what is formation can be couched as an ad or social media (short form
W your goal? To clarify? To educate? To sell products or

services? To set expectations?
When you deliver a business communication, what is your
content), or a blog or on your website (long-form content.) Clar-
ifying content might compare and contrast your product against
a competitor or common standard. It may expound on additional
goal? To clarify? To educate? To sell products or services? To set service options.
expectations? Good communication starts with a plan. Planned commu-
What if I told you that every communication sets expec- nications begin with thinking about what you want readers to
tations? Especially in busi- do or how you want them to
ness. Communication style, feel. Regardless of channel,
tone, and transparency all approach the content from that
contribute to telling a story angle. Include a call to action,
to potential customers, and and you’ll have the recipe for
Tascha Rassadornyindee | Dreamstime

current customers, about communication success.
what they should expect Do you want your customer
from your business, your or prospect to feel educated,
brand, and/or you. How you intrigued, empowered, moti-
will perform as their trusted vated? Are you solving their
business partner. problem (offering relief)? Are
What if I told you every you making their job easier
communication educates the (offering support)? How will
reader about your business, your brand, and/or you? It also may your message support that emotional connection?
educate customers and potential customers about your business’ Next, focus on whether that communication will be singular
processes, products, or services. or part of a series? Are you building to an information crescendo
Communications frame consumer expectations, whether you or reinforcing a brand value, or is the communication part of an
are a business-to-business (B2B) or business-to-consumer (B2C) outreach campaign? Where is the best place to share the commu-
enterprise, because businesses are comprised of humans having nication? Is it visual or written, or some combination of the two?
human experiences. What you say – your communication – can Each of these communication choices builds into your cus-
help set you up for success. Likewise, a lack of focus and intent tomers’ expectations of your business and their experience of
in your communications can be a barrier to your best sales efforts. your business. Whether customer expectations are met, ex-
Planning communication messages results in both a higher goal ceeded, or failed also becomes part of the brand experience for
and a stronger bottom line. other potential customers. People tend to tell three people about
As tempting as it might be, not every communication is about a positive experience and up to 10 people about a negative ex-
making a sale. Some communication builds relationships and perience. Those statistics pre-date the viral appeal of our current
trust. The variety of offering information and asking for the sale digital reality. In our modern world of testimonials, social media,
also creates more of the feeling of a conversation and less of a and reviews, your customer’s experience easily becomes a part of
sales pitch. your brand story that is outside of your control.
When you put out information just for the sake of putting out But your brand story is not outside the influence of your mar-
information – it’s a bit like people at a cocktail party who will keting. Marketing is about communications, and communica-
not stop talking about themselves. It’s less a conversation than tions can set customer expectations. Your communication plan
a monologue. It doesn’t build a relationship. (And if you think influences how potential and current customers experience your
business transactions are not relationships, you have forgotten brand and the expectations they have about you.
that purchasing is emotional as well as transactional.) Alexandria Trusov is the Global Marketing Manager at Alpha Resources
Educational communications build trust which can lead to a and a B2B marketing consultant to manufacturers and other B2B com-
sale, and more important to the bottom line, a long-term customer panies. Contact her at atrusov@truinsightsconsulting.com or visit www.
relationship (aka lifetime customer value). The educational in- truinsightsconsulting.com.
^ NEW PRODUCTS
… READ MORE is your tip to visit FoundryMag.com/new-products for up-to-date, extensive, informative reporting on new metalcasting technology.
Ceramic-Alumina,
Micro-Fracturing Grain
Grinding Discs
SAINT-GOBAIN ABRASIVES introduced
the Norton BlazeX F980 fiber discs with a
premium ceramic-alumina, micro-fracturing
grain for grinding in stainless steel and hard-
er-to-grind materials. New, proprietary Cool
Friction technology dissipates heat during
grinding, reducing rework and extending
the performance life of Norton BlazeX F980
fiber discs.
An offline programming suite offers a virtual function to calculate robot stopping distances, to
optimize operator safety and reduce robotic cell footprint by up to 25%. [ABB Robotics]
Braking Distance Simulator for Robotic Cells

ABB ROBOTICS’ RobotStudio® offline programming and simulation software
has been upgraded with a new, virtual robot braking-distance function designed
to create an exact simulation of the real-world stopping distance of a robot.
It makes it possible to calculate accurately the robot’s braking distance, and
thereby to overcome the need to add safety margins into cell designs. As a result, Norton BlazeX F980 fiber discs incorporate a
plants and workshops may save up to 25% of required operating space. proprietary heat-dissipating technology that
increases cut rate and performance life in
Predicting exactly where a robot will stop depends on a range of variables, stainless steel and harder-to-grind materials.
including speed, payload and the robot’s own inertia. These factors, individually [Saint-Gobain Abrasives]
or combined, can result in the robot coming to a halt outside of its safety zone,
sometimes by several meters. To compensate for the variability in stopping dis- Norton BlazeX F980 fiber discs are suit-
tances, engineers designing robot cells traditionally oversize them to allow for able for stock removal, deburring, beveling,
additional movement as the robot comes to a stop, which uses unnecessary space blending, cleaning/detailing, and finishing
on the factory floor. in metalcasting operations. Other industrial
The new RobotStudio function uses ABB’s motion-control technology to applications include MRO, metal fabrica-
predict the robot’s movements with millimetric precision. This allows the exact tion, welding, oil-and-gas, energy, and ship-
movement of the robot to be simulated in RobotStudio, so the user can determine building.
the correct size of the safety zone required, and the ideal location of features In addition, a self-lubricating grinding aid
including light curtains, safety fencing and controllers. treatment and active filler contribute to pro-
For applications using ABB’s SafeMove software, the data on the robot’s ducing cool cuts. Its micro-fracturing grain
final position can be used to determine the size of the ‘green,’ ‘amber’ and ‘red’ consistently exposes sharper grain edges to
zones where the robot either will continue working, slow down, or come to a deliver a better cut rate and longer disc life
halt, depending on the location of the operator. This is especially beneficial in when compared to blended ceramic alumina
collaborative applications where operators need to be confident that a robot has discs.
stopped before approaching it. “Due to improved ceramic grain together
“Our new robot braking-distance function for RobotStudio equips the user with our new Cool Friction technology,
with information about a robot’s real-world movements with an unprecedented self-lubricating grinding aid and active filler,
level of accuracy,” according to Antti Matinlauri, head of product management there is a 50% increase in cut rate and disc
for ABB Robotics. “Predicting the braking behavior of a robot with its payload life when using Norton BlazeX F980 fiber
will help system integrators and end users save time and costs, with up to 25% discs compared with Norton Blaze F980 fi-
reduction in the footprint when it comes to designing and building a robot cell or ber discs and other leading discs,” said Pat-
setting up a safety zone. This will help our customers optimize their processes rick Carroll, Norton | Saint-Gobain Abra-
and get the most out of their automation solutions.” … READ MORE sives senior product manager. “Prioritizing
the operator experience is first and foremost,
^
NEW PRODUCTS
… READ MORE is your tip to visit FoundryMag.com/new-products for up-to-date, extensive, informative reporting on new metalcasting technology.
so Norton BlazeX F980 fiber discs deliver

a smooth cut requiring less pressure, result-
ing in less fatigue and longer times between
change-overs.”
BlazeX F980 fiber discs are offered in 36
grit and are available in a standard 7/8-in.
hole pattern fitting most angle grinders, and
in the most popular sizes for any application.
Rugged design promotes reliable level
The Speed-Change BlazeX F980 fiber measurement for dry materials, including sand,
disc version features the Norton quick, in hostile work environments, with no moving
parts and no calibration required.
tool-free, twist-on/off speed-change fas- A dual-helix design combines fast, high-volume
tener. Discs lock to standard back-up pads level measurement for applications that filling with accurate dribble flow at the end of
the cycle.
with a unique nut design and are easily re- include sand, gravel, and rock, crushed
moved, increasing productivity with more stone, ore, talc mine, crushed dolomite, It features a dual-helix design that com-
time to grind. and recycled crushed concrete, as well bines fast, high-volume filling with accu-
Previously available BlazeX discs as lightweight aggregates: clay, pumice, rate dribble flow at the end of the cycle.
include BlazeX F970 fiber and quick- perlite, vermiculite, etc. Its compact design is ideal when limited
change discs for carbon steel and soft-to- DJT level indicators also work well space prohibits multiple individual screw
grind materials.. … READ MORE in dusty environments and in vessels units.
equipped with vibrators. Two helixes — 1½ and 4-in. in diam-
High-Temp, Point-Level The U.S.-made units are factory-cali- eter — are mounted on an 18 × 22-in.
brated — no field calibration is required hopper. They are rated at 17 cu ft and 283
Detection — and approved for Class I, Group C & cu ft per hour, respectively, at maximum
DYNATROL division of Automation D; Class II, Groups E, F & G; and Class RPM with 100%-efficient conveyable
Products Inc. offers level indicators that III Services. … READ MORE product and no slippage.
provide high, intermediate, or low point- TSF is ideal for batching to weigh-hop-
level detection in hostile, high-tempera- Twin-Screw Feeder for pers; low loss-in-weight scale-monitored
ture environments. Dynatrol® Bulk Sol- flow; low loss-of-weight batch applica-
ids DJT level indicators have no moving
Precise Batch Sizes tions with scales; drum and pail packout
parts and require no adjustments, result- BEST PROCESS SOLUTIONS designed lines; and recipe-type batching by multi-
ing in low operating costs. the Model TSF twin-screw feeder for pre- ple computer-controlled units with many
The rugged design promotes reliable cise batching and weighing applications. options available. … READ MORE
^ AD INDEX
Advertise Website Page
ASK Chemicals ..................................................................www.ask-chemicals.com........................................................................................4-5
Conveyor Dynamics Corp. ......................................www.conveyordynamicscorp.com .............................................................................. IBC
Didion International, Inc. ....................................................... www.didion.com ................................................................................................ 17
Foundry Educational Foundation .......................................... www.fefinc.org.................................................................................................. 10
Foundry Solutions & Design, LLC ......................................www.foundrysd.com .............................................................................................. 7
General Kinematics Corp. ........................................... www.generalkinematics.com ....................................................................................IFC
Heraeus Electro-Nite Co. .......................................................www.heraeus.com ................................................................................................ 9
Hoosier Pattern, Inc. ....................................................... www.hoosierpattern.com ....................................................................................... BC
LGT Manufacturing Co. ................................................. www.lgtmanufacturing.com........................................................................................ 8
OTP Industries...............................................................www.omegatractorparts.com .................................................................................... 15
Summit Foundry Systems, Inc. ............................. www.summitfoundrysystems.com .................................................................................. 3
Tinker Omega Sinto, LLC .................................................. www.tinkeromega.com .......................................................................................... 19
Webb-Stiles Co.....................................................................www.webb-stiles.com ........................................................................................... 11
ADVERTISE IN THE
PRODUCT EXPRESS
CONTACT:
JOE
DINARDO
brought to you by
Phone:
440.487.8001
jdinardo@endeavorb2b.com
A U TO MATED FOUNDRY SYST E M S MAT E RIA L H A ND L ING E Q U IPME NT

Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . 260-749-7740 Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
MO LD H A ND LING E Q U IPME NT
States Engineering, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
CO N VEY OR S, BELT
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740 SA ND H A ND LING E Q U IPME NT
CO N VEY OR S, P NEUMAT I C
Dynamic Air Inc., St. Paul, MN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651-484-2900 States Engineering, Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
CO N VEY OR S, V IBR ATIN G
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . .636-279-1111 SA ND RE CL A MAT IO N E Q U IPME NT
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222 Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
CO REMAK ING General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
SH A KE O U T S, RO TA RY
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
SH A KE O U T S, VIB RAT ING

D RO SS R EC LAMATION
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . .636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222
EL EVATOR BUCK ETS, S E L F CL E ANI NG VA CU U M CL E A NING E Q U IPME NT & RE NTA L
States Engineering Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . .260-747-6195 DeMarco Industrial Vacuum Corp., Crystal Lake, IL. . . . . . . . . . . . . . . 815-344-2222
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740 Visit our website: DeMarcoVacuums.com • Email: Sales@DeMarcoVacuums.com
F O UN D RY S YS T E M S VA LVE S, B U T T E RFLY
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740 Posi-flate, St. Paul, MN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651-484-5800
^
BUSINESS STAFF ^
CLOSING COMMENT
continued from p. 28
industrial buyers and the growing expectation gap that is starting to
be filled by sourcing networks and more modern plants.
MANAGEMENT & TECHNOLOGY The report found that 67% of industrial buyers expect a quote
2 Summit Park, Suite 300 • Independence, OH 44131 in less than 24 hours from the time they submit a request for quote
Telephone: 234-466-0200 (RFQ), and only four percent are willing to wait up to a week for a
response. The findings also show that to fill this expectations gap
BUSINESS STAFF
and meet new demands, 48% of both prototype and production
John DiPaola • VP and Group Publisher
jdipaola@endeavorb2b.com (440) 331-6099 buyers always or often send RFQs to sourcing networks; and 18%
are sending to those networks first when they have an urgent need.
Joe DiNardo • Associate Publisher
jdinardo@endeavorb2b.com (440) 487-8001 These findings alone point to why manufacturers need to
Brenda Wiley • Production Manager modernize the front office to support a more streamlined sales and
bwiley@endeavorb2b.com (714) 406-2661 quoting process. As buyers regularly work with manufacturing
Frank Chloupek • Director, User Marketing networks, they expect a seamless digital experience and quick
fchloupek@endeavorb2b.com (909) 736-0826 service. Manufacturers need to invest in modern digital solutions
Robin Slanie • Sales Support Specialist that enable them to deliver the same capabilities and services in
rslanie@endeavorb2b.com
order to compete with the networks rather than becoming depen-
Steven Porter • Group Digital Advertising Manager
dent on them.
sporter@endeavorb2b.com
By digitizing the front-office in the manufacturing facility,
REPRINTS, CUSTOMER SERVICE, AND CONTENT REUSE manufacturers improve collaboration and reduce risks that cause
Reprints/Permissions • Reprints@endeavorb2b.com issues downstream from the quoting process. By leveraging tools
National Archives (NAPC) • Microfilm Copies that reduce silos of information and consolidate it into a single,
Tel.: 1-800-420-6272, ext. 657 secure location – sometimes known as a Digital Thread – manu-
SALES OFFICES facturers can gain a competitive edge and meet buyers’ changing
Joe DiNardo • U.S. and Canada expectations. As manufacturers assess solutions, there are several
jdinardo@endeavorb2b.com, Tel.: (440) 487-8001 capabilities they should prioritize in their search:
Julian Maddocks-Born, • U.K., Europe • Secure, cloud-based file sharing. With one central tool that
julian@itsluk.com, Tel.: 44-1442-288299
stores all the files and tribal knowledge, manufacturers can quote
Yoshinori Ikeda • Japan
Tel.: 81-3-3661-6138, Fax: 381-3-3661-6139 faster and more consistently.
Cesare Casiraghi • Italy • Immediate searchability. Build a library of historic data and
c.casiraghi@tin.it • Tel.: 39-031-261407 • Fax: 39-031-261380 ensure no time is wasted re-quoting parts by being able to search
Adonis Mak • China, Hong Kong and reference past quotes for similar RFQs in seconds.
adonism@actintl.com.hk • Tel.: +85-2-2838-6298
• In-context collaboration tools. Communicate securely and ef-
Charles Yang • Taiwan
medianet@ms13.hinet.net • Tel.: +886-4-2322-3633 • Fax: +886-4-3233-3646
fectively in real time without needing additional software. Users
can quickly and easily annotate PDFs to better communicate with
ENDEAVOR BUSINESS MEDIA other team members around specific content. Imagine being able
Chris Ferrell • CEO to make time stamped notes for the future, mark specific areas of
Scott Bieda • CRO prints, and assign tasks in the context of a drawing.
Patrick Rain • COO • Analytics. Every plant generates terabytes of data every year,
June Griffin • CMO
Angela Mitchell • VP, Accounting
so manufacturers should look for software with an analytics en-
Jessica Klug • VP, Finance gine to help prioritize quotes for optimal win-rates, and to drive
Mike Christian • EVP, Industrial insights using data gathered from past jobs to evaluate current
Monique Leija • VP, Digital Business Development RFQs and decide the best way to quote them.
Kristine Russell • EVP, Special Projects Ease of use also should be a top priority as manufacturers
Curt Pordes • VP, Production Operations
Glenn Scheithauer • VP, Technology
compare solutions, ensuring less-experienced sales reps and
Tracy Kane • Chief Administrative and Legal Officer estimators can participate in the quoting process. The right soft-
ware partner will listen to manufacturers’ needs, understand the
challenges they are up against, and constantly tailor the solution
to help the organization be successful and competitive in the new
reality shaped by Industry 4.0.
Endeavor Business Media, 331 54th Ave N., Nashville, TN 37209, U.S.
www.endeavorbusinessmedia.com. Jason Ray is the CEO of Paperless Parts, an online market-
Printed in U.S.A. • Copyright © 2021 Endeavor Business Media, LLC
All Rights Reserved
place for custom parts, with proprietary technology to elim-
FOUNDRY MANAGEMENT & TECHNOLOGY is indexed in the Applied Sciences and Technology Index and with inate costs associated with sourcing and quoting. Contact
the Engineering Index generally available in libraries. Copying: Permission is registered with the Copyright
Clearance Center Inc. to photocopy any article, with the exception of those for which separate ownership is Ray at paperlessparts@v2comms.com
indicated on the first page of the article, for a base fee of $1.25 per CCC. (Code No. 0360-8999/97 $1.25 + $.60)
^ CLOSING COMMENT
Industry 4.0 Pushes

Manufacturers to Digitize
portions of the market with technology to
improve the buyer experience. Investments
like these continue to drive the change in
what buyers expect and demand from their
manufacturing partners, further widening the
disparity between buyers’ expectations and
what the average manufacturer can provide.
It is also evident that the evolving role of
the industrial buyer is playing a part in wid-
ening the gap, as OEMs look to reduce their
spending on procurement and supply-chain
management. At one time it was standard
for buyers and manufacturers to maintain
working relationships over long periods, but
as buyers are forced to manage more line
BiancoBlue | Dreamstime
items each year and must increase their ef-

ficiency through the use of software, those
relationships have become more – or entirely
– transactional.
The way buyers are measured is evolving
A widening “expectations gap” between too, as a focus on speed and risk mitigation have become a critical
suppliers and buyers means that aspect of their role.
All of these forces are creating an opportunity for those who
manufacturers’ investments must create
are willing to invest early in Industry 4.0 technology. While this
a seamless digital experience and quick- may seem daunting, the onus is on the manufacturer to continually
response capabilities. improve its processes and adopt new technologies, to gain a compet-
itive advantage over plants that are slower to modernize.
T
he effects of Industry 4.0 may feel like a double-edged Most manufacturers focus the bulk of their technology invest-
sword for many manufacturers. On one hand, Industry ment on the plant floor to drive efficiency, but opportunity created
4.0 has enacted positive progress throughout the man- by this gap in expectations can only be filled through changes in
ufacturing sector. Plants are more focused than ever on the front office. Activities like sales, estimating, quoting, and pro-
leveraging data and automation to make their operations more curement are all at the tip of the spear when it comes to filling the
efficient as emerging technologies become available to them. At expectation gap, and often are fraught with inefficiency in the av-
the same time, however, the mismatch between the opportunity for erage manufacturer. These activities require a lot of collaboration,
improvement and the pace that manufacturers adapt to the changes and benefit from a secure cloud platform that can streamline efforts
is creating an expectations gap that some companies are starting to and protect against cyber security breaches, now one of the greatest
take advantage of. threats to the manufacturing sector. Simple investments in these
A good example of this is the recent Protolabs acquisition of areas will dramatically improve a manufacturer’s ability to compete
3DHubs for $280 million to access the front-end buyer experience as the market evolves and the expectations gap grows.
and customer base that they have built. Similarly, companies like To help manufacturers improve their business strategies and tech-
Fictiv, Xometry, and Mfg.com have invested hundreds of millions nology investments for Industry 4.0, Paperless Parts surveyed more
of dollars into their digital-sourcing platforms for buyers. These are than 400 part buyers for its 2020 Part Buyer Expectations Survey
just a few individual cases that highlight how digital-first companies Report. The findings of the survey highlighted the changing role of
are investing to fill the expanding expectations gap and capture large continued on p. 27
Jason Ray | CEO, Paperless Parts

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APRIL 2021 foundrymag.

NEITHER Endeavor Business Media NOR ANY THIRD PARTY CONTENT

14 MANAGEMENT & TECHNOLOGY

METALLURGY GRAPHICS EDITOR BILL SZILAGYI

MANAGEMENT ON THE COVER: Design by Bill

Is This a Private Game?

Can Coating Alone Prevent Penetration?

Q: Is it possible to prevent persistent veining and

A: ASK Chemicals has premium refractory coat-

Casting samples showing penetration results using a premium ASK Chemicals

Using these types of premium coatings promotes

Ideally positioned thanks to perfectly tailored

ASK Chemicals experts look forward to hearing from you:

Elyria Foundry photo

Investment Group Buys Elyria Foundry,

Ermak Foundry photo

Foundry Solutions & Design

Engineering & Project Management

AB&I Foundry to End Molding

Tyler, TX. “The company will be per-

Wisconsin Aluminum Foundry photo

Leadership Change management posi- burn stated. “I look forward to using my

R afael Carbonell has replaced Heinz

H ubert Windegger has joined ASK

What is an ALPHA TRACK PAD?

The Alpha Track Pad [patent pending] is ideal for excavators/track

Numerous benefits result when cupola operating improve- 2:16 AM 160

ments are instituted: 2:30 Am 1.60

Equipment & Capital outlay

Capabilities for Faster Payback

Other systems achieve 50% of the

By combining Lump Reduction,

DIDION INTERNATIONAL INC. phone, 636.278.8700

Patternmaker Builds its Brand on Accuracy

To Industry 4.0 …and Beyond

feasible, shortening process or equipment launch

Communication Creates Expectations

W your goal? To clarify? To educate? To sell products or

Tascha Rassadornyindee | Dreamstime

Braking Distance Simulator for Robotic Cells

so Norton BlazeX F980 fiber discs deliver

A U TO MATED FOUNDRY SYST E M S MAT E RIA L H A ND L ING E Q U IPME NT

CO REMAK ING General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222

SH A KE O U T S, VIB RAT ING

Industry 4.0 Pushes

items each year and must increase their ef-

Jason Ray | CEO, Paperless Parts

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