Simple Solutions That Work! Issue 11

team members is the solution. They understand that to fix aluminum casting issues and implement effective process controls, the foundry team must thoroughly understand the critical processes and controls of producing an aluminum casting. They also understand that with a high turnover rate, you can’t invest in training employees that may not be around next week. They will strategically choose a few loyal supervisors, managers, or operators to invest in and challenge these key employees to share their knowledge with the rest of the team. Once an aluminum foundry has committed to a training strategy, they must then determine how to train their key people. A few of the larger foundries are lucky enough to have an in-house expert to provide the training. However, most must go outside for help. But where? An overlooked resource is retired foundry engineers and 19 Contact: DAVE MOORE dave@foundryway.com metallurgists. These retired foundrymen are a wealth of knowledge and most maintain a deep connection to the industry where they spent their life. Although not likely to take a full- time position, many are willing to share their knowledge on a consulting basis. It’s worth a quick call to a few area foundries and the local chapter of the AFS to find a potential retiree willing to help. For a more structured approach, there are associations that can help. Both the American Foundry Society and North American Die Casting Association do a good job of presenting at aluminum conferences and offer some classes as well. However, in our opinion we find that a comprehensive training program which combines classroom learning with hands-on training is the best approach. With a full working metallurgical and testing laboratory along with non-destructive test equipment, attendees are able to move directly from the class book to the lab or foundry floor to fully understand critical processes and controls. Comprehensive training should include all aspects of an aluminum foundry from alloys to final inspection and analysis but with deep dives into critical areas such as defect identification, causes, and controls. Anyone with more than a few days in the foundry has heard the terms grain size, cell size, modification, and refinement. But most don’t know what they are, how to control them, and what effect they have on the casting. When an instructor is able to take you directly from a book to a furnace, to a microscope, and to a tensile tester, you only then gain a lasting understanding. The quality demands on foundries will continue to increase with the critical requirements of the industries they serve. Minimizing casting defects such as inclusions and porosity while maximizing the strength of casting alloys will become important to all industries and something that can only be understood through experience or comprehensive training. As our experienced work force retires, our newer operators will need to rely on comprehensive training to fit this tall order. MAKING YOUR INSTALLATION ASUCCESS