SFSA CASTEEL REPORTER
Steel Founders' Society Of America
AUGUST - 2014

Casteel Commentary

This month’s Casteel Commentary argues that we need to make steel casting design and use accessible to the next generation of designers and purchasers. This suggests that we will need to take some responsibility for the performance of the part and deliver a finished component to eliminate the challenges that our current customers face when using castings. We will likely need to machine and finish the casting to deliver a compliant component that is cast. We will also need the NDE and design tools to develop and deliver reliable performance that we can guarantee.

Spring Management Meeting

The SFSA Spring Management Meeting in Tulsa included a number of presentations that are available to you at http://www.sfsa.org/folio/downloads.

Western Division Meeting and Heavy Section Product Group

The SFSA Western Division Meeting and Heavy Section Product Group meeting is August 21-22 at Bradken Tacoma. The Heavy Section Group will be discussing specialty sands for large castings. The Western Division meeting has a number of interesting topics. Details for the meeting are here.

SFSA Annual Meeting

The SFSA Annual Meeting is not to be missed. We are meeting in Montreal September 6-9, 2014. Meeting topics will include: US EPA ENERGY STAR in steel foundries, design liability management, DoD Impact on Manufacturing, steel capacity study, the SFSA market forecast, and steel drivers. Registration and additional information can be found here.

Technical & Operating Conference

The 68th SFSA Technical & Operating Conference will be held December 11-13 at the Drake Hotel in Chicago, with a Workshop session on the afternoon of Wednesday December 10. A preliminary program is attached to this newsletter and available here. More information will be sent to SFSA members as it becomes available.

SFSA Trend Cards

 

AISI Weekly Steel Production

 

SFSA Trend Cards-Backlog

Future Leaders Group

The Future Leaders meeting is scheduled for October 7-8 in Milwaukee, WI and will include tours of Mercury Marine and Maynard Steel Casting. The meeting will include a roundtable for networking and technology advancement, along with a mini-seminar for continued learning. The group will also discuss on-going support for activities such as the steel casting wiki.

Upcoming Meetings

2014
Nov. 4--5 , San Juan Del Rio, Queretaro, Mexico
Dec. 10 , Chicago, IL
Dec. 10--13 , Chicago, IL
2015
Jan. 13 , Rosemont, IL
Jan. 24--25 , Florida
Sep. 12--15 , Washington, DC

Southern Division Meeting

The Southern Division meeting will be October 15-16 at MetalTek - Carondelet near St. Louis. The focus of the meeting will be discussions on protecting liquid metal during the induction melting process (SPAL/EGAL technology). Terry LaSorda from Air Liquide will provide a presentation along with three foundries who have noted benefits from adopting the process.

Market News

Markets have continued to show slow and small improvements for most of 2014. SFSA Trend cards have yet to show any improvement in shipments but bookings for steel and stainless steel castings are improving. The slow shipments are evident not only in the trend cards but the continued reduction of the backlog.

Improvements in steel mill products can be seen both in the monthly and weekly data. The weekly data from AISI is posted each week on the website and in the past few weeks, production is back to the levels in early 2012. Steel casting demand normally follows the same trend as steel production with some delay. Steel mill production has stabilized and is trending up. This would suggest the steel castings should see some modest growth in demand for the balance of 2014.

Steel Mill shipments reported by the DOC Census also shows the trend for improved sales of steel mill products. The shipments of iron and steel castings reported by Census are up slightly from the low in mid 2013. This index also tends to lead the trend in steel casting shipments.

Capital Goods orders and shipments continue to increase since late 2012. Even though the prime rate has not increased to winding down of QE indicates a strengthening market. All of these indicators suggest that steel casting demand should improve for the balance of 2014 and continue to show ongoing modest growth in 2015.

Casteel Commentary

New markets, new customers, new employees, new challenges; all require that we develop new approaches. Our industry has existed by taking casting designs that are legacies of old business or innovations from new designers. Our current approaches to casting design and market development are not well suited to our new and changing environment. We expect new customers and a new generation of designers to adopt and learn antiquated methods of design and specifying steel castings.

When a new customer designs a casting, he assumes that the steel has uniform properties. He expects that he will get the minimum properties of the specified material anywhere in the casting. He expects that the quality of the casting to allow him to depend on sound and inclusion free material everywhere.

When he finds out that it is customary on important castings to use NDE like RT (radiographic testing) or MT (magnetic particle testing) to verify casting quality, it is disconcerting. His expectation is that he can order the highest standards of soundness and inspection as a given.

In our efforts to “educate” this new potential customer, we assure him that while the casting may have a range of properties in the casting with some below the material standard requirements and the casting will have significant indications in RT and MT, the casting will meet his required service performance. We try to convince the new customer that he can accept normal “commercial” practices for RT and MT requirements and the casting will perform. The fact that the specification material properties are only required in the test bars and not in the casting will be okay. And we will provide not guarantee, he has to take the liability of designing a casting in our traditional system with no determinate engineering rationale to provide assurance of performance.

We are working with a number of member companies to try to develop castings for the building construction industry. As we try to design and qualify parts, it becomes painfully obvious that we need new approaches to design that provide commercially cost effective casting designs while also providing assurance that the design and casting quality will give the requires safe and reliable service.

At SFSA we are trying to develop an approach using modeling and performance based NDE to allow engineers to design reliable castings that are elegant in performance and suited to foundry production. Our hope is that this approach will allow designers to create unique and creative castings that will expand our marketplace. To do this completely though we will need to shift some of our business practices.

We need to figure out a way to participate or otherwise engage in the design process to take some responsibility and even liability for performance. We need to develop the capacity to machine or otherwise finish the castings so we deliver not a raw casting but a finished component with predictable assembly and performance at our customer’s and the user’s site. We need to become capable of meeting our customer’s expectations by finishing the casting and supplying a quality component ready to assemble and use.

The next generation of designers and purchasers will become increasingly reluctant to take the quality and performance risk of using a casting. We need to find a way to provide a casting that meets their expectations with the guarantee of reliable performance.

We are not there yet and we are not yet capable of this transition but we must find a way to do this or our customers will find alternative products to meet their needs.

Contact Raymond Monroe

 

 
august14.pdf
(419kB)
The August 2014 Casteel Reporter
may14.pdf
(251kB)
The May 2014 Casteel Reporter
february14.pdf
(375kB)
The February 2014 Casteel Reporter
december13.pdf
(297kB)
The December 2013 Casteel Reporter
october13.pdf
(244kB)
The October 2013 Casteel Reporter
august13.pdf
(302kB)
The August 2013 Casteel Reporter
may13.pdf
(321kB)
The May 2013 Casteel Reporter
april13.pdf
(295kB)
The April 2013 Casteel Reporter
february13.pdf
(233kB)
The February 2013 Casteel Reporter
january13.pdf
(326kB)
The January 2013 Casteel Reporter
Forecast2013.pdf
(881kB)
The 2013 SFSA Market Forecast
december12.pdf
(275kB)
The December 2012 Casteel Reporter
october12.pdf
(158kB)
The October 2012 Casteel Reporter
july12.pdf
(256kB)
The July 2012 Casteel Reporter
may12.pdf
(420kB)
The May 2012 Casteel Reporter
march12.pdf
(482kB)
The March 2012 Casteel Reporter
nffsseminar.pdf
(247kB)
NFFS Foundry Noise Exposure Seminar information
february12.pdf
(301kB)
The February 2012 Casteel Reporter
december11.pdf
(243kB)
The December 2011 Casteel Reporter
forecast2012.pdf
(1.3MB)
The 2012 SFSA Market Forecast as presented at the 2011 Technical & Operating Conference
october11.pdf
(530kB)
The October 2011 Casteel Reporter
september11.pdf
(1.1MB)
The September 2011 Casteel Reporter
july11.pdf
(475kB)
The July 2011 Casteel Reporter
june11.pdf
(295kB)
The June 2011 Casteel Reporter
april11.pdf
(438kB)
The April 2011 Casteel Reporter
march11.pdf
(1.3MB)
The March 2011 Casteel Reporter
january11.pdf
(442kB)
The January 2011 Casteel Reporter
november10.pdf
(475kB)
The November 2010 Casteel Reporter
october10.pdf
(770kB)
The October 2010 Casteel Reporter
august10.pdf
(483kB)
The August 2010 Casteel Reporter
201008eqp.pdf
(37kB)
Equipment available
july10.pdf
(688kB)
The July 2010 Casteel Reporter
SFSA Directory Information Form.pdf
(180kB)
The form used to update foundry listings in the Directory of Steel Foundries
june10.pdf
(770kB)
The June 2010 Casteel Reporter
may10.pdf
(545kB)
The May 2010 Casteel Reporter
march10.pdf
(651kB)
The March 2010 Casteel Reporter
february10.pdf
(451kB)
The February 2010 Casteel Reporter
january10.pdf
(410kB)
The January 2010 Casteel Reporter
FR74-209 CO2.pdf
(573kB)
CO2 Emissions reporting rule
Combustible Dust FR ANPR 10-21-09.pdf
(319kB)
Federal Register notice seeking input on development of a standard for combustible dust
december09.pdf
(352kB)
The December 2009 Casteel Reporter including graphs and attachments
toptenoshaviolations09.pdf
(29kB)
Top Ten OSHA Violations
october09.pdf
(1.3MB)
The October 2009 Casteel Reporter
steelbus1009.pdf
(236kB)
Business report and market trend graphs
september09.pdf
(464kB)
The September 2009 Casteel Reporter
MagmaSoft Tax Credit.pdf
(112kB)
MAGMATIMES article on Federal Research & Experimentation tax credit.
august09.pdf
(1,008kB)
The August 2009 Casteel Reporter
MIEEE.pdf
(644kB)
Midwest Industrial Energy Efficiency Exchange information
july09.pdf
(896kB)
The July 2009 Casteel Reporter
FEF CIC Ad 2009.pdf
(532kB)
Foundry Educational Foundation College Industry Conference
april09.pdf
(868kB)
The April 2009 Casteel Reporter
march09.pdf
(924kB)
The March 2009 Casteel Reporter
february09.pdf
(1.2MB)
The February 2009 Casteel Reporter including business trend information, graphs and attachments.
steelgurujan2009.pdf
(744kB)
Steel market condition information.
yrc0209.pdf
(756kB)
SFSA's Yellow Freight and Roadway discount program.
january09.pdf
(1.3MB)
The January 2009 Casteel Reporter including business trend information, graphs and attachments.
Company FMLA policy (federal).pdf
(304kB)
Federal FMLA Policy.
employee under fmla.pdf
(104kB)
U.S. Department of Labor poster on Employee Rights and Responsibilities under FMLA.
Certification of Illness or Injury to a Covered Service Memb.pdf
(188kB)
FMLA Leave Certification of Serious Illness or Injury for a Covered Service Member.
october08.pdf
(140kB)
The September 2008 Casteel Reporter including business trend information and graphs and attachments.
steelguruoct2008.pdf
(636kB)
Steel market condition information.
september08.pdf
(272kB)
The September 2008 Casteel Reporter.
steelbus0908.pdf
(180kB)
Business trend numbers and graphs only.
steelgurusep2008.pdf
(76kB)
Steel market condition information.
august08.pdf
(644kB)
The August 2008 Casteel Reporter
steelbus0808.pdf
(396kB)
Business trend numbers and graphs only.
steelguruaug2008.pdf
(376kB)
Steel market condition information.
july08.pdf
(408kB)
The July 2008 Casteel Reporter
steelgurujul2008.pdf
(244kB)
Steel market condition information.
ITAR-Info.pdf
(268kB)
Part 121 - The United States Munitions List
ITAR-Info-Violation.pdf
(92kB)
Part 127 - Violations and Penalties
DEEDGrantApp053006.pdf
(108kB)
Demonstation of Energy-Efficient Developments grant application. To be submitted by the utility company.
DEED-Members.pdf
(80kB)
Utility companies participating in the DEED program.
june08.pdf
(64kB)
The June 2008 Casteel Reporter
steelgurujune2008.pdf
(80kB)
Steel market condition information.
may08.pdf
(64kB)
The May 2008 Casteel Reporter
steelgurumay2008.pdf
(92kB)
Steel market condition information.
april08.pdf
(200kB)
The April 2008 Casteel Reporter including business trend information, graphs and attachments.
steelbus0408.pdf
(28kB)
Business trend numbers and graphs only.
steelguruapr2008.pdf
(84kB)
Steel market condition information.
march08.pdf
(124kB)
The March 2008 Casteel Reporter including business trend information, graphs and attachments.
steelgurumar2008.pdf
(96kB)
Steel market condition information.
MoldThickness2.pdf
(56kB)
Calculation of Minimum Mold Thickness in Steel Casting - Jacob Thole, Dr. Christoph Beckermann, University of Iowa.
february08.pdf
(736kB)
The February 2008 Casteel Reporter
steelgurufeb2008.pdf
(88kB)
Steel market condition information.
january08.pdf
(880kB)
The January 2008 Casteel Reporter
steelgurujan2008.pdf
(208kB)
Steel market condition information.
AFSAreaSourceSummary.pdf
(128kB)
AFS Summary of the EPA Area Source Rule.
FR-AreaSourceFinal.pdf
(524kB)
40 CFR Part 63 - EPA National Emission Standards for Hazardous Air Pollutants for Iron and Steel Foundries Area Sources; Final Rule
  Due to the Technical & Operating Conference, no newsletter was published for December 2007.
november07.pdf
(448kB)
The November 2007 Casteel Reporter
futureleaders1107.pdf
(96kB)
Future steel foundry industry leaders meeting notice.
eqp-auction1207.pdf
(96kB)
Equipment available - auction ends Dec. 6 2007
october07.pdf
(240kB)
The October 2007 Casteel Reporter
steelguruoct2007.pdf
(188kB)
Steel market condition information.
ofr2007-1257.pdf
(4.7MB)
Cr, Cu, Mn, Mo, Ni, and steel price drivers. US Geological Survey
september07.pdf
(64kB)
The September 2007 Casteel Reporter
steelgurusep2007.pdf
(72kB)
Steel market condition information.
Docket2007N-0330.pdf
(12kB)
Docket 2007N-0330 Presidential Interagency Working Group on Public Safety (Import Safety)
fr17se07P.pdf
(224kB)
Proposed EPA Area Source Rule for Iron and Steel Foundries
august07.pdf
(36kB)
The August 2007 Casteel Reporter
steelguruaug2007.pdf
(112kB)
Steel market condition information.
IEEE Workshop1007.pdf
(28kB)
IEEE Industrial Energy Efficiency Workshop information
july07.pdf
(55kB)
The July 2007 Casteel Reporter
steelgurujul2007.pdf
(96kB)
Steel market condition information
june07.pdf
(64kB)
The June 2007 Casteel Reporter
steelgurujune2007.pdf
(44kB)
Steel market condition information
may07.pdf
(92kB)
The May 2007 Casteel Reporter
steelgurumay2007.pdf
(88kB)
Steel market condition information
finemanbio.pdf
(44kB)
Biography of Howard Fineman, speaker at the 2007 SFSA Annual Meeting
SBB Steel Markets.pdf
(304kB)
Steel - Global Impacts to North American Minimill Competitiveness, by Thomas A. Danjczek, President, Steel Manufacturers Association - speaker at the 2007 SFSA Annual Meeting
april07.pdf
(152kB)
The April 2007 Casteel Reporter
steelguruapr2007.pdf
(380kB)
Steel market condition information
march07.pdf
(1.5MB)
The March 2007 Casteel Reporter
steelgurumar2007.pdf
(240kB)
Steel market condition information
hexcr-fiore.pdf
(112kB)
Information on Hexavalent Chromium
february07.pdf
(52kB)
The February 2007 Casteel Reporter
steelgurufeb2007.pdf
(192kB)
Steel market condition information
january07.pdf
(56kB)
The January 2007 Casteel Reporter
steelgurujan2007.pdf
(260kB)
Steel market condition information
december06.pdf
(544kB)
The December 2006 Casteel Reporter
internapp.pdf
(56kB)
SFSA Internship sponsorship information and form
steelgurudec2006.pdf
(220kB)
Steel market condition information
november06.pdf
(136kB)
The November 2006 Casteel Reporter
steelgurunov2006.pdf
(352kB)
Steel market condition information
october06.pdf
(48kB)
The October 2006 Casteel Reporter
september06.pdf
(331kB)
The September 2006 Casteel Reporter
august06.pdf
(420kB)
The August 2006 Casteel Reporter
steelbus0806.pdf
(28kB)
Industry business numbers and graphs only
july06.pdf
(660kB)
The July 2006 Casteel Reporter
steelbus0706.pdf
(124kB)
Industry business numbers and graphs only
China6-22-2006.pdf
(296kB)
Evaluation of Chinese Economy and Trading Practices
Chinese Steel Subsidies Paper.pdf
(396kB)
The China Syndrome: How Subsidies and Government Intervention Created the World's Largest Steel Industry
RL32333.pdf
(184kB)
CRS Report for Congress - Steel: Price and Policy Issues. Update June 26, 2006
june06.pdf
(132kB)
The June 2006 Casteel Reporter
China tour tentative list-0606.pdf
(16kB)
Tentative list of plants to be visited on the tour of China
may06.pdf
(540kB)
The May 2006 Casteel Reporter
steelbus0506.pdf
(28kB)
Industry business numbers and graphs only
HexCr monitoring.pdf
(76kB)
Exposure Monitoring Guidance for Compliance with the new OSHA Standard fro Hexavalent Chromium
KFTA comments.pdf
(400kB)
U.S.-Republic of Korea Free Trade Agreement: Written Comments Concerning the Probable Economic Effect of Providing Duty-Free Treatment for Imports
AMMEX EERE-ITP.pdf
(28kB)
EERE's Industrial Technologies Program: Proven Returns on Federal and Industrial Investments
april06.pdf
(80kB)
The April 2006 Casteel Reporter
emsguide.pdf
(1MB)
Environmental Management Systems Implementation Guide for the foundry sector, USA EPA
AreaSourceUpdate.pdf
(168kB)
Iron & Steel Area Source rule
march06.pdf
(124kB)
The March 2006 Casteel Reporter
monroe-outlookSpring2006.pdf
(756kB)
Economic outlook presentation given by Raymond Monroe at the SFSA Spring Management Meeting on March 9, 2006
lashinsky-outlook2006.pdf
(36kB)
Economic outlook presentation given by Bernard Lashinsky at the SFSA Spring Management Meeting on March 9, 2006
keramida-annual compliance calendar.pdf
(148kB)
Regulatory Compliance Calendar for Steel Foundries by Keramida
keramida-Env Audits.pdf
(48kB)
Environmental Audits in the Primary Metals Sector - Jim Schifo, Keramida
keramida-Regulatory Calendar - 2006.pdf
(1.1MB)
Common Environmental Compliance Deadlines - Keramida
February06.pdf
(496kB)
The February 2006 Casteel Reporter
china exports surge.pdf
(20kB)
China steel exports surge due to domestic overcapacity
2005CHINASD_0106.pdf
(68kB)
Chinese Steel Industry - Record Steel Output with Big Decline in Net Imports in 2005
Measurement Error - ISU.pdf
(388kB)
Measurement Error of Visual Casting Surface Inspection - Iowa State University
january06.pdf
(51kB)
The January 2006 Casteel Reporter
december05.pdf
(495kB)
The December 2005 Casteel Reporter
USCCCHINAexec_summ_05.pdf
(82kB)
USCC Executive Summary on China Trade
november05.pdf
(83kB)
The November 2005 Casteel Reporter
hexcr-nov05.pdf
(1,041kB)
Congressional letters on Hexavalent Chromium
october05.pdf
(79kB)
The October 2005 Casteel Reporter
rdtaxcredit.pdf
(77kB)
Presentation on the R&D Tax Credit given at the 2004 SFSA Annual Meeting
september05special.pdf
(15kB)
Special September 2005 Casteel Reporter about the possible impact of a natural disaster on the steel casting industry
september05.pdf
(81kB)
The september 2005 Casteel Reporter
testbars.pdf
(1,043kB)
"Test Coupons and Casting Quality" and "Mechanical Properties of Test Bars Compared to Castings"
august05.pdf
(455kB)
The August 2005 Casteel Reporter
MoriciSteelPrices.pdf
(62kB)
Manufacturing and Steel Prices, by Peter Morici, February 2005
China prices 7-2005.pdf
(385kB)
Prices of Castings, Foundry Raw and Auxiliary Materials in Some Regions of China
pub3771.pdf
(3,110kB)
US ITC Publication 3771, Foundry Products: Competitive Conditions in the U.S. Market
july05.pdf
(70kB)
The July 2005 Casteel Reporter
WFO2005 Paper.pdf
(305kB)
World Foundry Organization paper on the last 20 years of steel casting research
june05.pdf
(54kB)
The June 2005 Casteel Reporter
SFIC Washington Forum OSHA.ppt
(164kB)
Presentation on OSHA Proposed PEL for Hexavalent Chrome, in PowerPoint format
SFIC Washington Forum OSHA.pdf
(453kB)
Presentation on OSHA Proposed PEL for Hexavalent Chrome, in PDF format
may05.pdf
(197kB)
The May 2005 Casteel Reporter
MACT-Scrap.pdf
(159kB)
Amendments to the Scrap metal and Inspection provisions of the Iron and Steel Foundry MACT
april05.pdf
(115kB)
The April 2005 Casteel Reporter
IntlTradeEvents.pdf
(38kB)
International Trade Events
equipment0405.pdf
(49kB)
Equipment Available
march05.pdf
(590kB)
The March 2005 Casteel Reporter
february05.pdf
(624kB)
The February 2005 Casteel Reporter
january05.pdf
(483kB)
The January 2005 Casteel Reporter
afs-gac.pdf
(568kB)
AFS Government Affairs Conference Information
december04.pdf
(292kB)
The December 2004 Casteel Reporter
november04.pdf
(445kB)
The November 2004 Casteel Reporter
october04.pdf
(223kB)
The October 2004 Casteel Reporter
september04.pdf
(489kB)
The September 2004 Casteel Reporter
august04.pdf
(414kB)
The August 2004 Casteel Reporter
antitrust.pdf
(59kB)
General Rules of Antitrust Compliance & Antitrust Policy Statement of Steel Founders' Society of America
july04.pdf
(278kB)
The July 2004 Casteel Reporter
june04.pdf
(242kB)
The June 2004 Casteel Reporter
may04.pdf
(840kB)
The May 2004 Casteel Reporter
Nolan_Dollars.pdf
(6,013kB)
Dollars and "Sense" presentation by John Nolan, Vice President, Steel Dynamics, Inc.
Nolan_Dollars_Sequel.pdf
(3,103kB)
Dollars and "Sense" "The Sequel" presentation by John Nolan, Vice President, Steel Dynamics, Inc.
april04.pdf
(333kB)
The April 2004 Casteel Reporter
march04.pdf
(428kB)
The March 2004 Casteel Reporter
  Due to our office move, the February 2004 Casteel Reporter was not produced.
january04.pdf
(211kB)
The January 2004 Casteel Reporter
december03.pdf
(522kB)
The December 2003 Casteel Reporter
november03.pdf
(253kB)
The November 2003 Casteel Reporter
october03.pdf
(232kB)
The October 2003 Casteel Reporter
september03.pdf
(322kB)
The September 2003 Casteel Reporter
august03.pdf
(219kB)
The August 2003 Casteel Reporter
july03.pdf
(550kB)
The July 2003 Casteel Reporter
june03.pdf
(175kB)
The June 2003 Casteel Reporter
may03.pdf
(175kB)
The May 2003 Casteel Reporter
april03.pdf
(277kB)
The April 2003 Casteel Reporter
march03.pdf
(377kB)
The March 2003 Casteel Reporter
february03.pdf
(256kB)
The February 2003 Casteel Reporter
january03.pdf
(266kB)
The January 2003 Casteel Reporter
december02.pdf
(500kB)
The December 2002 Casteel Reporter
  Due to circumstances beyond our control, the November 2002 Casteel Reporter is not available online.
october02.pdf
(204kB)
The October 2002 Casteel Reporter
september02.pdf
(251kB)
The September 2002 Casteel Reporter
august02.pdf
(159kB)
The August 2002 Casteel Reporter
june02.pdf
(324kB)
The June 2002 Casteel Reporter
may02.pdf
(497kB)
The May 2002 Casteel Reporter
april02.pdf
(518kB)
The April 2002 Casteel Reporter
march02.pdf
(255kB)
The March 2002 Casteel Reporter