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Program Announced for WFO Technical Forum at GIFA 2011

April 5, 2011
Four-day conference, open to all, will address technical advances, process developments, and design trends
The WFO Technical Forum, incorporating presentations relating to the GIFA and NEWCAST trade events, will have open access to all visitors.

For metallurgists and metalcasters with an academic bent, the attraction in Düsseldorf this summer won’t be just the acres of products and equipment displayed at GIFA 2011, the 12th International Foundry Trade Fair. They will be concentrating also on the World Foundry Organization’s Technical Forum, a four-day series of presentations by researchers and technicians documenting recent progress in metallurgy and metalcasting processes.

GIFA and the WFO Technical Forum take place June 28 through July 2, at Messe Düsseldorf.

The WFO is a global consortium of more than 30 national foundry trade associations, which coordinates and documents information as a resource for metalcasting research and activity.

The WFO Technical Forum is a traditional companion to the GIFA event. The 2011 Forum will follow the template set with the 2007 program, involving a regularly schedule presentations in an auditorium on the fairground, adjacent to the exhibits so registrants to the expo can visit the conference at no cost.

The preliminary program lists over 40 30-minute presentations on topics ranging from metallurgy to molding methods, as well as casting processes, diecasting techniques, heating, and finishing.

The program (listed below) includes numerous presentations chosen for attendees of NEWCAST, the 3rd International Trade Fair for Precision Castings, an exhibition that highlights casting designs and applications. In line with that area of interest, the WFO forum will feature presentations on casting process simulation, metal solidification, metal-matrix composite technology, and numerous other specialties.

June 28 – July 1, 2011 in Düsseldorf

Tuesday, June 28, 2011
WFO Technical Forum

10:00 Opening
A. Turner, World Foundrymen Organization Ltd., West Midlands/UK

10:30 — Modern engine concepts require new binder and refractory coating solutions
A. Serghini*, Dr. K. Seeger, Hüttenes-Albertus Chemische Werke GmbH, Düsseldorf, Germany

11:00 — Technology for gravity and low-pressure pouring of iron metals
Dr.-Ing. M. Rische*, S. Andorf, Dr.-Ing. E. Dötsch, ABP Induction Systems GmbH, Dortmund, Germany

11:30 — Reclamation of water glass ester old sands in a medium size aluminum foundry
Dr. H. Polzin*, P. Jaruszewski, J. Müller-Späth, TU Bergakademie Freiberg, Freiberg, Germany

12:00 — Inorganic binder system in the sandwich between “technology push“ and “market pull“ - The basis for continuous success?
Dr. J. Müller*, Dr. C. Wallenhorst, ASK Chemicals GmbH, Hilden, Germany

12:30 — Foundrybench - Energy saving options in foundries
M. Tapola, AX-LVI Consulting Ltd, Tampere, Finland

13:00 Break

13:15 — Development of aeration molding method and practical use of a small-size flaskless molding machine
S. Tsuzuki*, Y. Hadano, T. Komiyama, S. Takasu, Sintokogio Ltd., Toyokawa, Japan

13:45 — Quick dry no-cement castables: A novel non-cementitious mineral bond permitting extreme rapid dry out &heating up of monolithic refractory linings
J. Soudier*, Calderys, Saint Quentin Fallavier, France; P. Malkmus, Calderys, Neuwied, Germany

14:15 — Evaluation of the influence of different carbide forming elements on the microstructure and the properties of ferritic ductile iron
U. Petzschmann*, Dr. G. Wolf, Dr. W. Stets, IfG Institut für Giessereitechnik gGmbH, Düsseldorf, Germany

14:45 — A new process for the ductile iron foundry melt shop
B. Simmons, Foseco International Limited, Tamworth/UK

15:15 — Improvement in die coating performance with parameter design of quality engineering
A. Ogasawara*, Honda Motor Co., Ltd,, Japan; K. Ishikawa, S. Takechi, Direct Sen Bou Co., Ltd., Japan; H. Kosugi, Moto Honda da Amazonia Ltda., Brazil

15:45 — Prediction of the microstructure of austempered ductile iron casting parts after heat treatment
U. Getzla, ACTech GmbH, Freiberg, Germany; O. Köser*, A. Jacot, Calcom ESI, Lausanne, Switzerland

16:15 — Autonomous optimization of casting processes and designs
I. Hahn, Dr-Ing. J. C. Sturm*, MAGMA Giessereitechnologie GmbH, Aachen, Germany

16:45 — Cored, stable aluminum tube inlays for high-pressure diecasting, magnesium casting, and other casting processes
F. Heppes*, Dr. S. Rupp, Drahtzug Stein combicore GmbH & Co. KG, Grünstadt, Germany

17:15 End
* Speaker subject to change

Wednesday, June 29, 2011

10:00 — Simulation of distortion and residual stress in high-pressure diecasting – a comparison between simulation and experiment
P. Hofer, Österreichisches Giesserei-Institut, Leoben, Austria

10:30 — Nodular ductile cast iron – Influences of microstructure on structural durability
A. Heinrietz*, J. Eunger, Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF, Darmstadt, Germany; A. Sobota, Institut für Giessereitechnik gGmbH, Düsseldorf, Germany

11:00 — Influence of microstructural defects of austempered ductile iron on mechanical properties
A. Sobota*, IfG Institut für Giessereitechnik gGmbH, Düsseldorf, Germany; A. Nissen, Frankenberg, Germany; Dr.-Ing. P. Trubitz, Institut für Werksto technik, TU Bergakademie Freiberg, Germany

11:30 — Energy and material efficient production of hybrid metal plastic components
T. Zucker*, K. Morgenstern, Dr. W. Nendel, TU Chemnitz, Chemnitz, Germany; B. Zimmer, Goepfert Werkzeug & Formenbau GmbH & Co. Teilefertigung KG, Weimar, Germany; Dr.-Ing. N. Erhard, H. Dannenmann, J. Kurz, Oskar Frech GmbH + Co. KG, Schorndorf-Weiler, Germany

12:00 — Fast and economically to more material and energy efficient cast parts
Dr.-Ing. T. Schmidt, Heidenreich & Harbeck AG, Mölln, Germany

12:30 — Simulation-aided optimization of runner systems for aluminum sand castings
Dr.-Ing. G. Dieckhues, Ohm & Häner Metallwerk GmbH & Co. KG, Olpe, Germany

13:00 Break

13:15 — Paradigm shift in revised EN 1563 enables improved properties and production economy (GJS) in both as-cast and austempered states
Dr. R. Larker, Indexator AB, Vindeln/Sweden

13:45 — Use of casting technologies for production of in wheel motors
F. J. Wöstmann*, A. Kock, D. Schmidt, F. Horsch, H. Pleteit, M. Gröninger, Fraunhofer Institut für Fertigungstechnik und Angewandte Materialforschung - IFAM, Bremen, Germany

14:15 — Mold and core future has started today - conditions for future mold- and core production are developed
C. Grefhorst*, Dr. O. Podobed, S&B Industrial Minerals, Marl, Germany; V. Lafay, S&B Industrial Minerals, Cincinnati, OH, U.S.A.; N. Rickardson, S&B Industrial Minerals, Montoir, France

14:45 End

Thursday, June 30, 2011
WFO Technical Forum

10:00 — Knowledge-based control of molding processes in foundries by real-time analysis of product and process data
M. Dittrich*, Heinrich Wagner Sinto Maschinenfabrik GmbH & Co. KG, Bad Laasphe, Germany, D. Metz, Prof. Dr.-Ing. M. Grauer, S. Karadgi, Universität Siegen; Prof. Dr.-Ing. J. Bast, TU Bergakademie Freiberg, Freiberg; Dr.-Ing. G. Dieckhues, Ohm & Häner Metallwerk GmbH & Co. KG, Olpe, Germany

10:30 — High-volume production with inorganic core technology at Volkswagen Foundry Hanover
K. Gehring, Dr.-Ing. F. Hansen*, G. Jäger, S. Uhde, Volkswagen, Hanover Foundry, Hanover, Germany; K. Löchte, Dr. rer. nat. U. Pohlmann, Hüttenes-Albertus Chemische Werke GmbH, Düsseldorf, Germany

11:00 — Technology and configuration of porous burners made by Promeos
Dr.-Ing. J. Volkert, promeos GmbH, Erlangen, Germany

11:30 — Modulated machine design for core production with inorganic binder
R. Wintgens, Laempe & Mössner GmbH, Schopfheim, Germany

12:00 — Cleantech: The new core making process for aluminum casting
M. Vargas*, S. Sarrazin, Tung-Fai Lo, Hüttenes Albertus, France

12:30 — The path to an economical and emission-free foundry
B. Münker*, Daimler AG, Stuttgart, Germany; R. Böhm, Hüttenes-Albertus Chemische Werke GmbH, Düsseldorf, Germany; M. C. Schneider, MAGMA GmbH, Aachen, Germany

13:00 Break

13:15 — Higher productivity by enhanced coatings for the gravity and low pressure gravity diecasting process
Dr. R. Stötzel, ASK Chemicals GmbH, Hilden, Germany

13:45 — Simulation as a tool to reduce the time to market HPDC first shot meet the tolerances
K. Weiss*, C. Honsel, R. Vomhof; RWP GmbH, Roetgen, Germany; H. Zeilmaker, C. van den Broek, Brabant Alucast Products BV, AN Oss/The Netherlands; R. Krack, Schaufler Tooling GmbH & Co.KG, Laichingen, Germany

14:15 FGS – High-pressure diecasting without gating?
Dr.-Ing. N. Erhard*, D. Gerwig, Oskar Frech GmbH + Co. KG, Schorndorf-Weiler, Germany

14:45 — Lower your cost per casting by precise molding with the DISA MATCH machine
B. Haugbølle*, DISA Industries A/S, Herlev/Denmark; V. N. Satyanarayana, DISA India, Bangalore, India

15:15 — Some remarks on the reclaiming technology for inorganic core sands
Prof. Dr.-Ing. T. Steinhäuser*, B. Wehren, Universität Duisburg-Essen, Germany

15:45 Force Control – Robot based machining
M. Kohlmaier*, M. Kremer, ABB AG, Wr. Neudorf, Austria

16:15 — Water-free electrostatic spray technology for high pressure diecasting
K. Togawa*, H. Ohira, H. Komatsubara, M. Kobayashi, Aoki Science Institute/Lubrolene, Tokyo, Japan; R. Aoki, T. Hattori, Asahi Sunac, Owariasahi, Japan; T. Butler, Ultraseal International, Coventry/UK

16:45 — Energy-efficient decentralized dust separation technology using the example of fettling shop
B. Müller, Keller Lufttechnik GmbH + Co. KG, Kirchheim unter Teck, Germany

17:15 End

Friday, July 1, 2011

10:00 — Reliable prediction of residual stresses and distortions for large iron castings
Dr.-Ing. A. Egner-Walter, MAGMA Giessereitechnologie GmbH, Aachen, Germany

10:30 Rapid manufacturing by V-process
Dr.-Ing. J. Schädlich-Stubenrauch*, SpaceCast Präzisionsguss GmbH & Co. KG, Eschweiler, Germany; Dr.-Ing. A. Kessler, IfG Institut für Giessereitechnik gGmbH, Düsseldorf, Germany

11:00 — Structural parts – a challenging growth opportunity
M. Fabbroni, Bühler Druckguss AG, Uzwil, Switzerland

11:30 — Net-shape casting of an inside thread in zinc diecasting
U. Schwab, Adolf Föhl Gmbh & Co. KG, Rudersberg, Germany

12:00 — Lead free bronze castings with sulfide dispersion for water supply products
Prof. Dr. T. Maruyama*, Dr. Eng. T. Kobayashi; Kansai University, Suita, Japan; R. Matsubayashi, K. Shimizu, Shiga Valve Cooperative, Hikone, Japan; H. Abe, North Eastern Industrial Research Center of Shiga Prefecture, Hikone, Japan

12:30 Break

Friday, July 1, 2011
WFO Technical Forum

12:45 — Project for energy and resource conservation during diecasting
U. Jordi, Bühler Druckguss AG, Uzwil, Switzerland

13:15 — Experiments and modeling of rotary degassing for aluminum foundries
Dr. P. V. Evans*, Technology Strategy Consultants, Blackwell/UK; R. Simon, A. Froescher, Foseco Foundry Division, Vesuvius GmbH, Borken, Germany; R. Kendrick, Foseco UK, Tamworth, England

13:45 — Simulation makes core manufacturing in the foundry transparent
M. Schneider*, I. Wagner, MAGMA Giessereitechnologie GmbH Aachen, Germany

14:15 — Wedge Theory - New approach to explain the formation of “Chunky Graphite” in ductile cast iron
A. Udroiu, Satef Hüttenes Albertus Spa, Italy

14:45 — Detection and evaluation of defined quality criteria in the casting production
R. Radecker*, Microvista GmbH, Blankenburg, Germany; H. Meishner, Nemak Wernigerode GmbH, Wernigerode, Germany

15:15 — Effects of various parameters on the nodules distribution in heavy section casting
S. Grenier*, C. Labrecque, Rio Tinto Iron & Titanium, Sorel, Quebec, Canada

15:45 — Additive manufacturing processes for the production of sand molds and shells: Modern trends and possibilities for the South African foundry industry
D. Nyembwe, Department of Engineering Metallurgy, University of Johannesburg, South Africa

16:15 Closing remarks
Dr.-Ing. Gotthard Wolf, VDG Verein Deutscher Giessereifachleute e. V. Düsseldorf, Germany

16:30 End

Newcast Forum/WFO Technical Forum
Jume 28-July 1, in Düsseldorf
Promoter: VDG Verein Deutscher Giessereifachleute e.V.
Sohnstrasse 70, D-40237 Düsseldorf
Phone: +49 (0) 211 / 6871 – 332
Fax: +49 (0) 211 / 6871 – 109
E-Mail: [email protected]

Organization: BDG Bundesverband der Deutschen Giesserei-Industrie
Sohnstrasse 70, D-40237 Düsseldorf
Phone: +49 (0) 211 / 6871 – 338
Fax: +49 (0) 211 / 6871 – 364
E-Mail: [email protected]

Messe Düsseldorf GmbH

Postfach 10 10 06, D-40001 Düsseldorf Messeplatz, Stockumer Kirchstrasse 61, D-40474 Düsseldorf Phone: +49 (0) 211 / 4560 – 01 Fax: +49 (0) 211 / 4560 – 668 E-Mail: [email protected]

General information
Messe Düsseldorf GmbH
Hall/Halle 13C30
Registration: Not required
Participation: Open to all
Participation fee: Free of charge
Lectures: The proceedings with the abstracts of the lectures will be available at the counter
Language: German – English (simultaneous translation)