For more detailed course information or to register, visit www.afsinc.org/education-calendar.

Tel: 800/537-4237

Casting Defect Analysis #07-15

October 7-8 / Chattanooga, TN / Member: $835 / Non-member: $985

In order to determine the true root cause of a casting defect and select the proper corrective action,
a systematic evaluation method must be applied. The intention of this course is for participants to
become proficient in applying a 10-step procedure to analyze and reduce metalcasting defects by
correctly identifying defects and their root causes and determining appropriate corrective actions.
This course is applicable to sand molding processes (green, nobake, coldbox, shell).

Who Should Attend

The target audience for this course consists of individuals responsible
for managing and overseeing the production management staff;
managing and supervising production staff; purchasing, sales,
marketing or office operations; auditing/inspecting/quality control;
production or engineering or design.

View the detailed course syllabus, including lesson plan, through the
Education Calendar at www.afsinc.org/education-calendar.

Instructors
Kevin Fleischmann,
AFS Institute
Scott Lammers,
AFS Institute

Two Complimentary Books

With Course Registration

Casting Defects Handbook

of Your Choice

Choose From Iron & Steel, CopperBase Alloys or Aluminum Alloys

Course Information: The course will begin at 8:15 a.m. on the first day, and end by 3:30 p.m. on the second
day. Detailed travel information, including available hotel room blocks, will be provided in a confirmation
letter e-mailed within one business day of registration.

Education Solutions

Course Syllabus for:

Casting Defect Analysis
Course Code
1-200

CEUs
1.1 CEUs

Course Introduction
The intention of this course is for participants to become proficient in applying a ten step procedure that
will enable them to analyze and reduce metalcasting defects by correctly identifying defects and their
root causes, and determining appropriate corrective actions. This course is applicable to sand molding
processes (green, nobake, coldbox, shell).
Benefits to Taking the Course: In order to determine the true root cause of a casting defect and select
the proper corrective action, a systematic evaluation method must be applied. Implementing the wrong
solution can cost the foundry in terms of runtime, cost, waste, safety, reduced return on investment or
profit, sales and expertise. Learning a systematic procedure for root cause identification supports the
business goal of designing, producing and selling quality castings that are made in a timely manner and
in a safe environment for a profit.
Learning Outcomes:
After completing this course, participants should be able to:
1. Name the 4 most common casting defects, and identify the causes and potential solutions for
each.
2. Given defect samples, apply a ten-step procedure in order to correctly identify the casting
defects and their root causes, and determine appropriate corrective actions and solutions using
the AFS-CIATF International Atlas of Casting Defects and the three AFS Casting Defects
handbooks in order to minimize or eliminate the defects.
Lesson Outline
Introduction
o Course purpose and goals
o 10 Step Root Cause Analysis Tool
o Business goals related to defect identification
Casting Defects Overview
o Why a 10 Step Procedure?
o Setting scrap rates
o Defect categories
Demonstration of Root Cause Analysis
Sand-Related Defects
Oxide-Related Defects
Group Problem Solving
Gas-Related Defects
Shrink-Related Defects
Group Problem Solving
Wrap-up
o Review & assessment of learning outcomes
o Course Evaluation

Instructional Methods:
Demonstration
Guided problem solving practice
Group activities
Class discussion
Information research
Q&A
Assessment Methods:
No formal assessment will take place in this course; however, attendees will participate in informal
activities such as knowledge check and Q&A sessions with the facilitator to verify that learning outcomes
are being met. Assessment of successful achievement of learning outcomes must be included
throughout the course in order to meet the ANSI/IACET 1-2013 standard for continuing education
programs and for CEUs to be awarded.
Course Prerequisites:
Prior to taking this course, participants should be able to:
explain the basic process and principles of metalcasting using appropriate terminology.
Or
have taken the Introduction to Metalcasting Institute course.
Texts, Books or other Resources Included in the Registration Fee:
AFS-CIATF International Atlas of Casting Defects
and choice of 1 of the 3 handbooks below
AFS Casting Defects Handbook: Iron and Steel
AFS Casting Defects Handbook: Aluminum & Aluminum Alloys
AFS Casting Defects Handbook: Copper & Copper-Base Alloys
Attendee Requirements to Earn CEUs:
1. Present at least 10 hrs of the total 11 hrs of instructional time (90%), which does not include
lunch or breaks.
2. Active participation (can include asking questions, communicating with other attendees during
and taking part in group activities, providing responses during whole class or group discussions).
3. Successful achievement of learning outcomes.
Who Should Attend?
The target audience for this course consists of individuals responsible for:
Managing and overseeing the production management staff
Managing and supervising production staff
Purchasing, sales, marketing or office operations
Auditing/inspecting/quality control
Production or engineering

Casting Defect Analysis