Simple Solutions That Work! Issue 18

22 coolers. This involved catching samples at various access points at different intervals across an 8-hour shift. Those samples were tested for LOI. The raw sand samples were also tested at the mixer along with mixed sand at various intervals for LOI, screen analysis, work time, strip time, tensile, temperature, catalyst level, and sand bin level. This gave the foundry a complete look at how the sand system variation could affect the mold quality and casting results. By utilizing and partnering with the Field Service Team’s associates, they got the answers they needed to optimize system control and productivity levels. This is just one example of how partnering will work as it did for this foundry to bring value to its operation. Sand Lab Analysis provides the value of knowing the process is in control. How well is the quality / sand lab functioning? What test should I be running? Do I need to have a full-time person do these tests? Those are all questions that foundry management considers at some point or another. A qualified Field Technical Service partner can help bring clarity to that area. For starters, in an audit, the department can look at the current test results (or lack thereof), recommend the proper tests for the system you are using, and help train the technicians. A good supplier/Field Technical Service partner will also have a fully functioning lab that can corroborate results and fill in gaps until you can establish internal procedures. The value of a process under control goes straight to the bottom line. Since it all starts in the mold/core area, how can you not afford to have this area under control? Casting Evaluation and Defect Analysis – It goes without saying, “Foundries are not in the business of selling molds and cores; they are in the business of selling castings.” How to address casting issues and defects will always be a part of the foundry. They are universally known and can offer value in the following areas: Casting Evaluations • Process Variables • On-site Inspection • Metallurgical Assistance • Solidification Modeling • Defect Determination • Consultation and Recommendations Utilizing your supplier’s Field Technical Service Team as another set of eyes can be a great way to help address those issues. A Field Technical Service Team member sees numerous different foundries and results. In addition, partnerships with universities and outside labs can give insight and solutions. Evaluating other resin/ coating/additive technologies/ feeders can bring value by eliminating defects. Don’t let casting issues bring your foundry operation down; use whatever resources available to bring value to the process.