Handout for Workshop Participants

Reducing Casting Defects: Improving Quality and Collaboration

Gain practical skills to identify and address common casting defects effectively.
Learn strategies for fostering collaborative relationships with foundries to enhance casting performance.
Discover how AFS resources can support casting buyers in improving quality outcomes.

Focus on Describing Defects: Use detailed descriptions for effective identification (e.g., "Irregular cavity in top boss area" vs. "shrinkage defect").
Collect Process Data: Compare good and bad batches to identify key variables across melting, molding and pouring processes.
Avoid Single Variable Assumptions: Defect one result from multiple factors - be open-minded during root cause analysis.
Use Experimental Design: Leverage quality teams to run statistically significant trials for corrective actions.
Document Everything: Maintain detailed records to track changes in processes, materials, and team dynamics over time.

Stay informed with the latest trends, case studies, and best practices in casting design and sourcing.

Explore the most comprehensive library of metalcasting technology, featuring technical literature, reports, and studies.

Learn about creating, growing, and maintaining buyer-supplier relationships through targeted online modules.

A globally recognized resource for identifying and classifying casting defects based on physical descriptions (shape, appearance, location).

Attend workshops tailored to casting buyers, including defect analysis and quality improvement techniques.

Network with peers and discuss defect challenges or sourcing strategies through AFS's online forum.

Dr. Sudesh Kannan ("Dr K") – Cybersecurity & Foundry Consultant

Chicago-Based | Phone: +1-847-497-0380 | Email: DrSudeshK@yahoo.com

Key articles available in Modern Casting / Casting Source Magazines

5 Steps to Identify Casting Defects Dr Sudesh Kannan, Abhishek Pathak, Tom Cobett, July, 2018

The Value of Scrap, Rework, and Yield at Steel Foundries R. Stevenson, D. Coyle and G. Richard, September 7, 2021

I Have Inclusions: Identifying the Source, R. Gallo, September 10, 2017

Testing 1-2-3: Eliminating Veining Defects, July 1, 2014

Simulation software and lab testing methods were used to pinpoint why the defect occurs and how to avoid it.

Sudesh Kannan, CISSP, PhD

Cyber Security Professional | Metal Casting Consultant

+1-630-267-0678

Text: 847-497-0380