Foundry Work Research Articles

Analysis of the Possibility of Making a Digital Twin for Devices Operating in Foundries

This work aims to conduct an analysis to find opportunities for the implementation of software incorporating the concept of digital twins for foundry work. Examples of implementations and their impact on the work of enterprises are presented, as is a definition and history of the concept of a digital twin. The outcome of this work is the implementation of software that involves a digital copy of the author’s device, created by the “Łukasiewicz” Research Network at the Krakow Institute of Technology. The research problem of this scientific work is to reduce the number of necessary physical tests on real objects in order to find a solution that saves time and energy when testing the thermal expansion of known and new metal alloys. This will be achieved by predicting the behavior of the sample in a digital environment and avoiding causing it to break in reality. Until now, after an interruption, the device often continued to operate and collect data even though no current was flowing through the material, which could be described as inefficient testing. The expected result will be based on the information and decisions obtained by predicting values with the help of a recurrent neural network. Ultimately, it is intended to predict the condition of the sample after a set period of time. Thanks to this, a decision will be made, based on which the twin will know whether it should automatically end its work, disconnect the power or call the operator for the necessary interaction with the device. The described software will help the operator of a real machine, for example, to operate a larger number of workstations at the same time, without devoting all their attention to a process that may last even for hours. Additionally, it will be possible to start work on selecting the chemical composition of the next material sample and plan its testing in advance. The machine learning handles model learning and value prediction with the help of artificial neural networks that were created in Python. The application uses historical test data, additionally retrieves current information, presents it to the user in a clear modern form and runs the provided scripts. Based on these, it decides on the further operation of the actual device.

Analyzing musculoskeletal risk-severity among small scale casting workers using ergonomic assessment tools: A statistical approach

Work-related musculoskeletal disorders (WMSDs) are leading cause of injuries among economically backward workers employed under small scale metal casting units especially in developing countries. In India, most casting unit's falls under small and medium enterprises having inadequacy of advanced technological equipment's due to several economic constraints and rely intensively on manual labour. Foundry work is very much prone to WMSDs involving much physical interaction of workers with their jobs which includes several risk factors. The study objectives were to analyse the musculoskeletal risk prevalence among small scale casting workers using ergonomic assessment tools and statistical approach. In present study, WMSDs risk prevalence has been examined using Rapid Entire Body Assessment (REBA) and virtual ergonomics. Further, risk evaluations were analysed using Mann-Whitney U test and Taguchi L25 orthogonal array. Results revealed manual handling task as being most vulnerable followed by the fettling section. Statistically significant differences were observed (p-value < 0.05) among all the work-sections except lift-lower task and molding section (p = 0.361; p > 0.05) for left side region; and lift-lower task and fettling section (p = 0.230; p > 0.05) for the right side region, where differences were not statistically significant. ANOVA results indicated that workstation height followed by population percentile and object weight were dominant factors significantly affecting the response parameter i.e. L4-L5 spine compression (p-value < 0.01); however workstation width (p-value > 0.05) had no significant effect. The present study may guide foundry industrialists in analysing the mismatch between the workers' job profile and redesigning existing workstation layouts in small scale foundries based on minimizing the WMSDs risk severity associated with the work tasks.

RISK ASSESSMENT IN 13-STORY BUILDING PROJECTS WITH THE FAILURE MODE AND EFFECT ANALYSIS (FMEA) METHOD AND THE DOMINO EFFECT

The building construction project is one of the activities that can pose a safety risk. Work safety risk assessment can be done using the Failure Mode and Effect Analysis (FMEA) method and looking at the Risk Priority Number (RPN) value. The purpose of this research is to take a case study of the building Office in determining the highest RPN and provide recommendations on its management. This project consists of 13 earthworks, passenger hoist, tower crane, scaffolding jobs, ironworks, formwork work, foundry work, mechanical, electrical plumbing (MEP) work, welding work, and floor wall doing works, and ceramic installation work. The highest RPN from the observations occurred in Iron Fabrication which can cause fingers hit by a bar cutter and bender. In this case, personal protective equipment (PPE) is significant in preventing these impacts from occurring in the project work area.

ANALYSIS METHOD OF GRADUAL CAST INSITU PROJECT COMPLETION OVERPASS PT. TALENTA BUMI MARABAHAN

Overpass project development Marabahan is a CSR (Corporate Social Responsibility) from PT. Talenta Bumi, namely making public care facilities for the security and facilitate road transport and to improve the welfare of society .This project Overpass consists of main bridge prestressed concrete girders with spans of 30 m and bridges using slab pile construction with a total length of 200 m. This study aims to determine the calculation method of the analysis of in situ casts gradually and to determine the method of implementation of the phased-situ cast on Marabahan Overpass project.Analysis of cast insitu method stages in the project completion Overpass PT. Marabahan Earth's talents will be obtained security calculations on the structure of the Overpass. Foundry work first is casting with cast in situ on the crown, after it's done casting method cast in situ stages at the slab to be divided into two stages, namely the first layer 20 cm (half slab) and the second layer 15 cm (top slab) using scaffolding as a scaffold and job formwork with main reinforcement ɸut 22-150 which gradually cast directly on the ground with the popularity chart Fc validation test cylinder '30 MPa and graphs coefficient of concrete strength PBI age 71. For loading on board, the work scaffolding (scaffolding) at the time of cast insitu gradually in the field wearing a scaffold with a heavy load capacity (heavy duty) has a maximum load of 675 kg/bay or 0.675 tons/m2, and using strong wooden scaffolding with wood class III based voltage PKKI 1961 timber permit.Based on the analysis results of calculations using the method of cast insitu gradually, by doing a test trial error with conditional on calculation of security moment of the plan should be greater than the moment of ultimate, then casting the first layer half slab in getting workable with the concrete less than one day the Fc '5 MPa and to stage a second layer using a comparison chart coefficient PBI age compressive strength, obtained Fc' 9.57 MPa to 1.5 days workmanship of the concrete casting. With the trial based on the test results of the concrete age, can accelerate and cut time jobs and can save the cost of the work, such as the cost of the use of formwork and scaffolding usage. suggestednecessary to test the concrete test cylinders for 1 day, 2 days, 3 days, etc,so that getting the maximum test.

High alveolar nitric oxide is associated with steeper lung function decline in foundry workers

Occupational dust exposure induces inflammatory responses that often precede the onset of clinical disease. Inflammation in the peripheral part of the lung can be demonstrated by measuring the alveolar NO concentration (CANO) in exhaled breath. The aim of the study was to assess whether cumulative dust exposure affects the change in CANO during follow-up and whether baseline CANO can predict an impairment in lung function during follow-up in foundry workers. We examined 74 dust-exposed and 42 nonexposed foundry workers and measured CANO and lung function at baseline and after 7 years of follow-up. An increase in CANO during the follow-up period was positively associated with cumulative dust exposure in foundry work (p = 0.035). Furthermore, a higher baseline CANO was associated with an accelerated decline in the forced vital capacity (FVC) during the follow-up period (absolute decrease in FVC p = 0.021, relative decrease in FVC p = 0.017). Higher cumulative dust exposure in foundry work is associated with a greater increase in CANO during follow-up, suggesting ongoing pulmonary inflammation in these subjects. Importantly, a high baseline CANO is associated with an accelerated decline in lung function, suggesting that CANO measurements might serve as a screening tool for high-risk workers.

Obituary

Obituary

Quantitative health risk assessment of inhalation exposure to automobile foundry dust

With a growing awareness of environmental protection, the dust pollution caused by automobile foundry work has become a serious and urgent problem. This study aimed to explore contamination levels and health effects of automobile foundry dust. A total of 276 dust samples from six types of work in an automobile foundry factory were collected and analysed using the filter membrane method. Probabilistic risk assessment model was developed for evaluating the health risk of foundry dust on workers. The health risk and its influencing factors among workers were then assessed by applying the Monte Carlo method to identify the most significant parameters. Health damage assessment was conducted to translate health risk into disability-adjusted life year (DALY). The results revealed that the mean concentration of dust on six types of work ranged from 1.67 to 5.40mg/m3. The highest health risks to be come from melting, cast shakeout and finishing, followed by pouring, sand preparation, moulding and core-making. The probability of the risk exceeding 10-6 was approximately 85%, 90%, 90%, 75%, 70% and 45%, respectively. The sensitivity analysis indicated that average time, exposure duration, inhalation rate and dust concentration (C) made great contribution to dust health risk. Workers exposed to cast shakeout and finishing had the largest DALY of 48.64a. These results can further help managers to fully understand the dust risks on various types of work in the automobile foundry factories and provide scientific basis for the management and decision-making related to health damage assessment.

Occupational Exposure to Fine Particles and Ultrafine Particles in a Steelmaking Foundry

Several studies have shown an increased mortality rate for different types of tumors, respiratory disease and cardiovascular morbidity associated with foundry work. Airborne particles were investigated in a steelmaking foundry using an electric low-pressure impactor (ELPI+™), a Philips Aerasense Nanotracer and traditional sampling equipment. Determination of metallic elements in the collected particles was carried out by inductively coupled plasma mass spectrometry. The median of ultrafine particle (UFP) concentration was between 4.91 × 103 and 2.33 × 105 part/cm3 (max. 9.48 × 106 part/cm3). Background levels ranged from 1.97 × 104 to 3.83 × 104 part/cm3. Alveolar and deposited tracheobronchial surface area doses ranged from 1.3 × 102 to 8.7 × 103 mm2, and 2.6 × 101 to 1.3 × 103 mm2, respectively. Resulting inhalable and respirable fraction and metallic elements were below limit values set by Italian legislation. A variable concentration of metallic elements was detected in the different fractions of UFPs in relation to the sampling site, the emission source and the size range. This data could be useful in order to increase the knowledge about occupational exposure to fine and ultrafine particles and to design studies aimed to investigate early biological effects associated with the exposure to particulate matter in the foundry industries.

Wisdom from the Hoyt Lecture

Each year since 1943 the American Foundry Society has featured a “foundation lecture” delivered by an individual chosen to share their wisdom and experience at the Society’s annual assembly. These lectures, named in 1947 after Charles Edgar Hoyt, reflect the thinking and passion of the best and brightest spokesmen of the metalcasting industry. Seldom however has this repository of wisdom been examined in aggregate and seldom have any engaged in an effort to observe themes in these lectures for the benefit of a contemporary audience. The author, the Hoyt Memorial Lecturer in 2005, presents his understanding of the wisdom of the Lecture around common themes in these presentations, including the nature and importance of research, our responsibility to people engaged in foundry work, the importance of education, the nature of the relationship between foundry and government, quality and the art of management. The author includes reading suggestions from the Hoyt corpus for those interested in going further into the Lecture’s wisdom.

Comparative analysis of physical and chemical characteristics of selected clays deposits found in Kebbi State, Nigeria

The intent of this paper was to explore the physical and chemical characteristics of clays in Kebbi State, Nigeria, and the clays were compared with standard clay which is considered with highest quality standard in casting. Clay’s deposits from Dukku River along River Rima, Jega River which is the tail end of River Niger and Yauri were investigated for their potentials as raw materials used for casting and ceramic industries. Samples were collected from three local governments’ areas at the bank of the Rivers. Chemical analyses of individual clay were determined by employing four different techniques as follows; Complexiometric Titration, Atomic Absorption Spectrophotometer (AAS), X-Ray Diffraction (XRD), and X-Ray Fluorescence (XRF). The data collected from the analyses revealed that the structures of clay minerals were mainly kaolinite, Smectite (bentonite), and illite, and non-clay minerals for the three places were mainly quartz, feldspars and gibbsite. The results obtained revealed high silicate clays and moderate alumina content with trace elements of oxides (Fe2O3, CaO, K2O, TiO2, MgO, MnO, Na2O) also present within acceptable limits. Physical tests results at 900°C and 1300°C were used to determine firing shrinkage, colour, and modulus of rupture, bulk modulus, apparent density, crack formation, apparent porosity, water absorption, and bulk densities. The modulus of rupture, bulk densities, and fired linear shrinkage of all the samples increase with increasing firing temperature. The findings of this work revealed that the clays minerals from Dukku and Yauri had the necessary properties for the foundry work and refractory applications, but clays from Jega, can be exploited for commercial purposes after beneficiation by reducing the level of iron, quartz and other impurities. Key words: Clay minerals, chemical analysis, firing characteristics, oxides.

THE FATE OF THE ENGINEER DERECHINSKY

This paper present's data on the repression of scientists in the USSR. From this study, it can be concluded that repression of scientists has the effect on the development of science and technology in the USSR. Some conclusions are made of falsification of court cases. Finally different problems are reported concerning various books on the subject of metallurgy primarily that of foundry work, written by Derechinsky. Data on rehabilitation of the outstanding scientist and teacher are given. Archival data indicate the complete innocence of engineer Derechinsky. The absurdity of arrest not only of the scientist, but also of his wife – the doctor of the therapist is proved. The troubles of the scientist's wife in his rehabilitation are shown. The article describes the complete absence of evidence in the indictment of the scientist and teacher.

Pneumothorax in the cases of silicosis in southern part of Rajasthan

Background: Silicosis is an occupational lung disease caused by inhalation of dust containing crystalline silica particles of size 0.5-5 microns in diameter. It commonly occurs in workers involved in quarrying, mining, sandblasting, tunneling, foundry work and ceramics. Pneumothorax is one of the complications of silicosis. The occurrence of pneumothorax in a patient with silicosis is a rare event, but it may be fatal. The incidence of secondary spontaneous pneumothorax (SSP) in silicosis as such is not known. This study aims to report the cases of secondary spontaneous pneumothorax in patients of silicosis in Southern part of Rajasthan.Methods: 50 patients of silicosis established by historical, clinical evaluation and radiological evidence with increased dyspnoea were included in the study. In all patients Chest X ray was done immediately.Results: Among 50 patients of silicosis with increased dyspnoea, Chest X ray showed pneumothorax in 20 patients of which 4 had bilateral pneumothorax, 7 had right pneumothorax and 9 had left pneumothorax. The mean duration of exposure to silica particles was 10 years (5 to 15 years). All the patients had various degrees of dyspnoea and chest pain. Tube thoracostomy was performed in 15 patients while 5 patients were managed conservatively with oxygen and bronchodilators.Conclusions: Our study showed an increased incidence of secondary pneumothorax in silicosis patients. The occurrence of pneumothorax, though rare in silicosis is a potentially life-threatening complication and may cause serious morbidity and mortality. The patients of silicosis who develop sudden onset of dyspnoea should be promptly investigated for this complication.

Chapter 16 Natural resources

Abstract The natural resources of the Andaman–Nicobar Islands and surrounding seas are discussed. Rocks and minerals found on the Andaman Islands include magnetite, pyrite-chalcopyrite, chromite, gold, nickel, sulphur, coal and limestone, but in most cases their concentrations are sub-economic. Lensoid bodies of algal-biohermal limestones of Palaeogene age on Middle Andaman Island are abundant, accessible and of good grade for cement or foundry work. The Neogene limestones are also suitable for this purpose. Basalts and strongly indurated sedimentary rocks, without any overburden, are quarried for construction work. Limited offshore exploration for oil and natural gas shows great promise, but has yet to be developed.

Lung cancer risk in welders and foundry workers with a history of heavy smoking in the USA: The National Lung Screening Trial

ObjectivesFoundry work is a risk factor for lung cancer; however, the association with welding is unclear, as smoking is common among metalworkers and may mask the relationship. We evaluated whether...

Pulmonary inflammation in foundry workers.

To assess whether cumulative dust exposure in foundry work is associated with airway inflammation measured by the analysis of fractionated exhaled nitric oxide (NO) concentration, or by inflammatory markers in exhaled breath condensate or serum. We examined 476 dust-exposed and nonexposed foundry workers, and assessed the individual cumulative exposure to dusts and respirable quartz. Bronchial and alveolar NO production and inflammatory markers in exhaled breath condensate and in serum samples were also analyzed. After adjusting for pack-years of smoking, increased levels of alveolar NO, serum C-reactive protein, and interleukin-8 were associated with a higher level of cumulative exposure to dust. The referents had higher serum myeloperoxidase levels, bronchial NO output, and 8-isoprostane levels in exhaled breath condensate than in the dust-exposed groups. Dust exposure in foundry work may induce both systemic and alveolar inflammation.

Cause-specific mortality due to malignant and non-malignant disease in Korean foundry workers.

BackgroundFoundry work is associated with serious occupational hazards. Although several studies have investigated the health risks associated with foundry work, the results of these studies have been inconsistent with the exception of an increased lung cancer risk. The current study evaluated the mortality of Korean foundry workers due to malignant and non-malignant diseases.MethodsThis study is part of an ongoing investigation of Korean foundry workers. To date, we have observed more than 150,000 person-years in male foundry production workers. In the current study, we stratified mortality ratios by the following job categories: melting-pouring, molding-coremaking, fettling, and uncategorized production work. We calculated standard mortality ratios (SMR) of foundry workers compare to general Korean men and relative risk (RR) of mortality of foundry production workers reference to non-production worker, respectively.ResultsKorean foundry production workers had a significantly higher risk of mortality due to malignant disease, including stomach (RR: 3.96; 95% CI: 1.41–11.06) and lung cancer (RR: 2.08; 95% CI: 1.01–4.30), compared with non-production workers. High mortality ratios were also observed for non-malignant diseases, including diseases of the circulatory (RR: 1.92; 95% CI: 1.18–3.14), respiratory (RR: 1.71; 95% CI: 1.52–21.42 for uncategorized production worker), and digestive (RR: 2.27; 95% CI: 1.22–4.24) systems, as well as for injuries (RR: 2.36; 95% CI: 1.52–3.66) including suicide (RR: 3.64; 95% CI: 1.32–10.01).ConclusionThis study suggests that foundry production work significantly increases the risk of mortality due to some kinds of malignant and non-malignant diseases compared with non-production work.

Epidemiologic characteristics of compensated occupational lung cancers among Korean workers.

An understanding of the characteristics of occupational lung cancer is important to establish policies that prevent carcinogen exposure and to compensate workers exposed to lung carcinogens. This study analyzed the characteristics of occupational lung cancers in workers who were compensated under the Industrial Accident Compensation Insurance Law between 1994 and 2011. A total of 179 occupational lung cancers were compensated. The main carcinogenic exposure was asbestos, followed by crystalline silica and hexavalent chromium. The mean exposure duration and latency were 19.8 and 23.2 yr. The most common industry was manufacturing, followed by construction and transportation. The most common occupation was maintenance and repair, followed by foundry work, welding, painting, and spinning or weaving. Although asbestos was predominant carcinogen, the proportion of these cases was relatively low compared to other developed countries. Proper surveillance system is needed to monitor occupational lung cancer and improve prevention measures.

Effect of Occupational Manganese Exposure on Uric Acid Levels in Human Urine

Objective To investigate the effect of long-term and low-level occupational Mn exposure on the level of uric acid (UA) in human urine. Methods In this study, 65 volunteers were recruited, who were working on welding and foundry work in an plant in Gansu province, China. Additionally, 29 control samples were collected from individuals who did not have any history of excessive Mn exposure. An improved high performance liquid chromatography system equipped with a diode-array detector (HPLC-DAD) method was developed to determine the UA level in human urine. A Spectra AA 220 Atomic Absorption Spectrophotometer (AAS) was used to measure the Mn level in the urine. Results The analytical method was validated for concentrations ranging from 3.82–45.84 μg/mL with acceptable accuracy, precision, and recovery. Overall, the UA levels of Mn exposure samples were significantly lower than that of control samples ( P<0.05). Conclusion The practical method developed here is suitable for both routine monitoring of UA level in human urine and metabolism research. Long-term and low-level occupational Mn exposure may lead to a lower UA level in urine, and UA might be an indicator of the early stage of manganism.

Topical Anesthetic Abuse Keratopathy: A Commonly Overlooked Health Care Problem

To evaluate the clinical course, treatment modality, factors affecting the epithelization period, and visual outcome in patients with topical anesthetic abuse keratopathy. The medical records of 19 patients with a confirmed diagnosis of topical anesthetic abuse keratopathy were retrospectively examined; occupation, initiating event, biomicroscopic findings, treatment modality, epithelization period, and best-corrected visual acuity (BCVA) were noted. The Wilcoxon signed rank test was used to compare BCVA before and after treatment; P values <0.05 were considered statistically significant. In all, 26 eyes in 19 men aged 21-44 (mean age: 31 ± 6) years were included. Initiating events included exposure to arc welding flash (8 patients), metallic foreign body injury (8 patients), and chemical injury (3 patients). On admission to hospital, 10 patients (52.6%) reported that they were using topical anesthetics. Upon admission to the hospital, 10 patients (52.6%) self reported that they were using topical anesthetics. The remaining 9 subjects were discovered to be using topical anaesthetic drops during hospitalization. Twelve patients (63.2%) were found to continue using these agents during their hospitalization. Oval corneal epithelial defect, stromal infiltrate, ring-shaped keratitis, and hypopyon were noted in 100%, 46.2%, 57.7%, and 42.3% of the eyes, respectively. Topical antibiotics (fluoroquinolones or combined fortified cephalosporins and aminoglycosides), preservative-free lubricants/autologous serum, and bandage contact lens/eye patches were used for treatment. Mean epithelization period was 19.96 ± 11.16 days (range: 6-50 days). Mean pretreatment and posttreatment BCVA was 0.12 ± 0.16 (range: 0.001-0.7) and 0.66 ± 0.30 (range: 0.0-1.0), respectively (P < 0.001). Ophthalmologists should be suspicious of topical anesthetic abuse keratopathy in young male manual laborers specialized in welding business and foundry work presenting with persistent epithelial defects, ring-shaped keratitis, and accompanying severe ocular pain.

Cancer morbidity of foundry workers in Korea.

Foundry workers are potentially exposed to a number of carcinogens. This study was conducted to describe the cancer incidence associated with employment in small-sized Korean iron foundries and to compare those findings to the Korean population. Cancer morbidity in 208 Korean foundries was analyzed using the Standardized Incidence Ratio (SIR) and Standardized Rate Ratio (SRR). Overall cancer morbidity in foundry workers (SIR=1.11, 95% confidence interval [CI]=1.01-1.21) was significantly higher than that of Korean general population. Lung cancer (SIR=1.45, 95%CI=1.11-1.87) and lymphohematopoietcic cancer (SIR=1.58, 95%CI=1.00-2.37) in production workers were significantly high compared to Korean general population. Stomach cancer in fettling (SRR=2.10, 95%CI=1.10-4.01) and lung cancer in molding (SRR=3.06, 95%CI=1.22-7.64) and in fettling (SRR=2.63, 95%CI=1.01-6.84) were there significant elevations compared to office workers. In this study, statistically significant excess lung cancer was observed in production workers comparing to Korean general population and office workers. Also, cancer morbidity of overall cancer, lung cancer and stomach cancer was significantly increased with duration of employment at ten and more years comparing to Korean general population. These findings suggest in causal association between exposure to carcinogens during foundry work and cancer morbidity.