Author: callahan

A Note to Our Students

Dean Janet Callahan stands in front of the summer gardens on campus at Michigan Tech
Janet Callahan, Dean of the College of Engineering, Michigan Technological University

Your journey is unique: Each person here comes from a different background, and has had different experiences across their life.

The lived experiences of each of us are different; they are not equal, and they are certainly not equitable. My experience, as the daughter of an engineer and a nurse (guess which one was my mother!) is an example—I was exposed to the best of school districts, played with toys as a child that taught me 3d spatial skills, and I was indulged by my parents when I showed an interest in photography. And then found myself one of about four women in a class size around 40, as I studied engineering in the 1980s—and truly—at my alma mater there were only male-gendered bathrooms on every floor, and one I could use on one floor only. Things have changed now, but my point is, this was my journey, and it was my unique journey.

I have heard from many students, especially in this new year, who have reached out to me directly, to share experiences, concerns, and frankly their outrage as well. Please do not hesitate to contact me if you have ideas about how we can improve your experience as a student and as a member of our community. And, I would love to hear your story—your journey to Michigan Tech, your experiences here, and your dreams. Just send me an email and we’ll have a zoom meeting: Callahan@mtu.edu And if you are in a student club or organization and would like me to stop in during a meeting, to listen, I would be honored to do so.

I would love to hear your story—your journey to Michigan Tech, your experiences here, and your dreams.

Dean Janet Callahan

This is a true statement: diversity in an equitable and inclusive environment is essential for the development of creative solutions to address the world’s challenges. Across your educational experiences you have probably learned that when we design solutions, we must have a diverse team with multiple perspectives in order to develop the best solutions. Without a winning team, we can’t win. Our own perspective is not enough — we don’t know what we don’t know.

Finally, I assure you that we are fully committed to diversity, equity, and inclusiveness

Janet Callahan, Dean
College of Engineering
Michigan Tech


We Reject Racism.

Michigan Tech stands together as a community to reject any actions steeped in racism, hatred and fear. These actions are repugnant to the College of Engineering. They have no place in our classrooms, labs or offices, nor in our society.

The College of Engineering believes that diversity in an inclusive environment is essential for the development of creative solutions to address the world’s challenges. 

Our faculty, staff and students are fully committed to diversity and inclusiveness. There is much work to be done and we all have a part to play in order for meaningful change to occur.

  • Janet Callahan, Dean, College of Engineering
  • Leonard Bohmann, Associate Dean, College of Engineering
  • Larry Sutter, Assistant Dean, College of Engineering
  • Sean Kirkpatrick, Chair, Dept. of Biomedical Engineering
  • Pradeep Agrawal, Chair, Dept. of Chemical Engineering
  • Audra Morse, Chair, Dept. of Civil and Environmental Engineering
  • Glen Archer, Chair, Dept. of Electrical and Computer Engineering
  • Jon Sticklen, Chair, Dept. of Engineering Fundamentals
  • John Gierke, Chair, Dept. of Geological and Mining Engineering and Science
  • Steve Kampe, Chair, Dept. of Materials Science and Engineering
  • Bill Predebon, Chair, Dept. of Mechanical Engineering – Engineering Mechanics
  • Walt Milligan, Interim Chair, Dept. of Manufacturing and Mechanical Engineering Technology

Read More:

My Mother’s Hands

Author's hand outstreched over a jigsaw puzzle on a card table, with Husky dog far in the background,  to show her knuckly fingers and her mother's ring

Okay, so I have my mother’s hands. May she rest in peace. For her fiftieth birthday, many years ago, us four daughters decided to get her a nice piece of jewelry. We shopped, and together we tried out a bunch of rings. 

My other sisters’ hands are more delicate than mine. My hands call to mind a worker, or farmer, or crafter, hands with knuckles and calluses. While shopping, we decided my hands were the best model for the ring for our mother, and so I was the odd model on this shopping expedition, with the jewelry merchants looking at me with eyebrow askance. With their beautifully groomed hands they examined mine, seeking different shapes and kinds of rings to try on, to find something that would balance my knuckly fingers.

One day, many years later, I was inside watching some commotion in the driveway. My stepson needed to add water to his radiator. The cap was stuck. He, his dad, and a friend were standing around the car, hood up, scratching their heads.

Watching this from inside the house, I figured it wouldn’t hurt to have a go. Grabbing a kitchen towel, I wandered outside. Approaching the car, I asked about the problem, then casually swooped in with my towel and my mother’s hands. 

I doubled up the kitchen towel over the four-pronged, blunt radiator knob, grasped it with my dominant hand, then added my other hand over top, all fingers locking in to seal the strength. I locked wrists, forearms, elbows to my shoulders and slowly rotated my torso. Of course the cap gave way. I straightened up, pulled off the towel, brushed off the thanks, and walked back into the house.

From my dad, I got the engineer’s outlook, and from my mom these strong, wise hands. From both of them, I was given ample opportunity to try anything, fail, and try again. 

Where did I learn to do this, I wonder? To not use my wrist and hand alone? The feeling wasn’t pride exactly, but closer to gratitude—for my parents who taught me to roof and landscape, and to use my head to solve problems. From my dad, I got the engineer’s outlook, and from my mom these strong, wise hands. From both of them, I was given ample opportunity to try anything, fail, and try again. 

I am now an engineering professor and have been given tremendous responsibility as a dean. Problem solving is what we teach engineering students, mingled with theory and design. We also give them ample opportunity to learn by doing. Yet, the largest part of their problem-solving “knack,” will come from the projects they already did, well before arriving in college.

All the tasks given to a child, the forced labor assigned to teens, and the challenges you take on as an adult, add up. I remember Dad giving instructions with no more detail than, “Take down this wall,” and I could not have wished for a better engineering teacher. We lost him too soon, when he was just 48, to cancer.

I wear her ring now and it fits me well. I could never fill her shoes, but I can fill her gloves. Around the blister earned from raking this weekend and the snagged skin from a thorn, I look at my mother’s hands and imagine them still shuffling and playing cards, the way she did when our work was through. 

My mother passed ten years ago this month. Miss you Mom! Still feel your strong—and gentle—touch.

Do you have your own stories about your mom, or dad, to share? Please email me. I would love to hear them, callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech


Did You Sign Your Name on This Door?

Now, I live close to campus, in a stately banker’s home on Houghton Avenue.

We bought Mrs. Frim’s house (Mrs. Frimodig) in 2018. At one point, the home had been famously rented out to Michigan Tech alumni, many who signed their names on the attic door. Widowed after Mr. Frim unexpectedly passed at an early age, Mrs. Frim earned a living in this way.

Roger Smith, an engineering alumnus who grew up in Houghton, weeded for Mrs. Frim as a young man. I met him at Reunion 2018; he relayed to me that “She had a nice side garden in the south-east backyard – with lots of gladiolas. I spent a lot of hours toiling there…at 15-25 cents an hour!”

Sadly, that poor side garden has turned into goutweed heaven—an invasive species. I started attacking it yesterday. I read that I can “exhaust it,” or dig it up! So I exhausted myself digging it up and only made a small start; it will take the next two years to recover that patch of garden. Ha-ha, says the goutweed…. 

Did any of you happen to carve your name on the attic door? If so, please let me know! Take a look at all five panels, for a closer look. Maybe you’ll see someone you know!

If you find your name, or know more about this door, please email me. I would love to hear the stories; callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech



Hello from Michigan Tech, and Parasailing on a Snowboard?

Are you, or someone you know, thinking about where you will choose to attend college? If so, I want to share my perspective, as I’m still fairly “new” to Michigan Tech (this is my second year here). I also have the perspective of having spent time at three different universities. Maybe it will help you make your decision.

First, the East Coast, where I attended the University of Connecticut (and the mascot there is also a Husky). My parents were only willing to pay for in-state tuition—that narrowed the choice pretty quickly for me! So I went to “UConn” and had a great education, majoring in chemical engineering, and then metallurgy/materials science for my master’s and PhD degrees (I didn’t set out to get those other degrees, but that is another story). UConn is in Storrs, Connecticut, about a 40 minute drive from the capital city of Hartford. So I would call it a rural campus. Because it wasn’t “too far” to get home, many students went home on weekends—so it didn’t have a strong sense of community. You can drive from one end of CT to the other in 2 hours or so.

After UConn, my first job was as a professor at Georgia Tech, which is in downtown Atlanta, Georgia—an urban campus in the deep South. The Atlanta metropolitan area has 5.6 million people, a vastly different experience from UConn. A great education, but, in a very big city—which comes with traffic, smog, high-priced housing, crime and safety concerns. What I really liked about Georgia Tech: it is a technologically-focused university, like Michigan Tech. I stayed 12 years at Georgia Tech, and then headed West!

Following that, I spent 14 years at Boise State University, in Idaho in various leadership roles at the university. BSU is located in downtown Boise, but the population of Boise is only about a quarter million. So a very safe campus, where the College of Engineering enrolls about 15% of BSU students. A good education for students, but nowhere near the reputation in engineering of Georgia Tech or Michigan Tech.

Now here in Midwest, in the UP, at Michigan Tech, where I serve as dean of engineering, I offer you these perspectives: It’s a strength to attend a university that is technologically focused, if your focus is engineering or related fields. This university has a very strong sense of community and belongingness. Maybe that’s because of the technological focus. And maybe it’s because it’s a long drive “home” for many. It’s beautiful here. It’s safe. And it’s fun—we’re still enjoying the snow statues, broomball, and more from our Winter Carnival. Just yesterday, in fact, I enjoyed an interesting view across the waterway, of a student and their dog, attempting to harness the wind to snowboard horizontally, pulled by the wind. Alas, the coefficient of friction was too high, or the wind was not blowing strongly enough, but they did give it a good try! And the dog was very excited about the whole operation. As was I.

I have never seen anything like this anywhere else across my years. Michigan Tech is full of interesting, engaged, curious, fun, and adventurous people.

Now, if you, or someone you know, want to know more, be sure to email me, callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech

I Was Asked to Be a Judge for Winter Carnival

Riley Simpson wears formal attire, a silver crown, and holds flowers and an award on stage at Michigan Tech Rozsa Center.
Asked to be a judge for Carnival Queen this year, I accepted with alacrity. And probably became the first judge ever to ask all the candidates a metallurgical question involving the lever rule—a question I knew no-one would know the answer to (none were materials science and engineering majors, who would have the best shot at knowing the answer). The object of the question was focused on critical thinking.

The Saturday morning before Carnival Week was day one of my judging. In my training, I was told I could ask any questions I wanted, and was given a set of standard questions to choose from. 

“Any questions?” I repeated?”

“Yes, anything you want—just ask everyone the same questions.” 

I warmed them up with a few standard questions: “Why do you want to be Carnival Queen,” and “Why did you choose to come to Michigan Tech,” and then stepped right into it, by going to the board and drawing a banana-shaped phase diagram, labeling the axes, temperature versus component (we used a gold/silver phase diagram).

I warmed them up to it by talking about how a pure component below its melting point was solid, and then after it was heated past its melting point, it was liquid. And then I explained how with a binary alloy with soluble components, the extra component adds a degree of freedom to the system. And that in turn gives such alloys a range of temperatures over which both liquid and solid are present. Then, I identified a state point in this two-phase region, just below the liquidus for a 50/50 alloy, and asked: “At this temperature and composition, we see there is both liquid and solid present. My question is: Do you think the mixture will be mostly liquid, or mostly solid?”

A few candidates asked clarifying questions, a few reasoned out loud. And, as I had hoped, given how we really stress critical thinking across all majors, all got the answer right. When I followed up and asked them why they thought it would be mostly liquid, the reasoning was sound—they tied it in with proximity to the liquidus or to the point being at a higher temperature. Very proud of all the Queen’s Finalists!  
Riley Simpson is shown smiling in her AFROTC uniform.
Congrats to Riley Simpson ⁠— 4th year mechanical engineering student, future commissioned second lieutenant (pending) in the United States Air Force, pilot/aviation enthusiast ⁠— and now, 2020 Winter Carnival Queen at Michigan Tech
Riley Simpson: Impeccable and inspirational at the Michigan Tech Winter Carnival Queen Coronation.

The second judging event took place the following Saturday night, during the Coronation. That evening, I enjoyed seeing all the candidates again, this time formal attire. They answered questions up on stage with last year’s Queen—a much higher pressure situation than I think I put them under! All of the finalists did a great job, and I am pleased to report that this year’s Carnival Queen is a Guardian of the North, Riley Simpson, whose passion is for flying, and whose musical talent was evidenced by an elegant and lively performance on the xylophone.

Riley is a fourth-year Mechanical Engineering student and member of the Advanced Metalworks Enterprise who will be commissioned as an Air Force officer when she graduates, and I’m confident she will go far in her career.

It was my great honor to meet all these confident, intelligent, talented, and service-oriented Winter Carnival Queen’s finalists. My last interview question, back on that first Saturday, was, “Do you have any questions for me?” It was immediately evident that they had not anticipated being asked to ask a question (I was mimicking a job interview). And, they all rallied, and with a variety of questions, such as, “Why did you come to Michigan Tech,” and “What does a dean do?” My favorite question came from one candidate who asked me, “Did you ever do anything like this (meaning, run to be Carnival Queen)? “Oh my goodness no!” I exclaimed. “It took me many years to get the confidence to be in the public eye.” It took me about an additional two decades!

Now, if you’re interested in learning the answer to the question I asked the Winter Carnival Queen contestants, “mostly liquid or mostly solid”—or want to hazard a guess, feel free to contact me, callahan@mtu.edu.
Janet Callahan, Dean
College of Engineering
Michigan Tech

Some Attributes of Huskies

Here is a picture of Echo, after recovering from her poisoning, at the cabin.

At Michigan Tech, our mascot is the Husky. I have a lot of fun with this, because Echo, one of our two family dogs, is a Husky. So I have learned a lot about this breed of dog from our Echo.

I want to call out five basic attributes that I associate with Huskies.

First of all, Huskies are very clever dogs. For example, Echo knows the name of many of her toys. Her favorite toys make noises—right now, the special favorite is a stuffed Woody Woodpecker—who makes the most ridiculous noise. So I can ask Echo, “Where’s, ‘whoo-hoo-hoo-ha-ha,’ and she knows exactly what toy to bring me.

Also, Huskies are very careful dogs—most of the time. Echo is really careful to sniff each treat I offer her, before eating it. Even though she knows it’s the same dog biscuit that she had yesterday, well—she has to sniff it every time. Which is why I was so surprised when one night earlier this year, as I was staying one night at what was soon to become our family cabin (out near Point Abbaye, Michigan), I heard her crunching on something. I went to investigate—and I couldn’t believe it. She was eating rat poison which I didn’t realize was there. It had been left in a hidden corner on the kitchen floor! Luckily, it was the kind of rat poison that has an antidote (massive doses of vitamin K).

And—Huskies are VERY VOCAL and musical dogs. I believe Echo speaks entire sentences. She can clearly communicate when she is hungry, when she wants to go out, if she is bored, if something is wrong, and more. And if we begin to howl (as much as any human can), she gets downright musical, joining in and sometimes harmonizing.

Finally, Huskies are incredibly playful dogs. Echo can play catch with herself. She tosses her toys up in the air, and then pounces on them as they come down. She plays dueling stick with our other dog, they run in tandem, each with their mouths on the stick as they bound down the trail, like a harnessed team of horses with a bit in their mouth. And more. Not really a fetching dog, Echo tends to set up more elaborate play-games.

Our mascot, Blizzard, with the Michigan Tech Husky Pep Band.

That brings me to Husky Nation, Michigan Technological University—a place where you can be clever, careful, vocal, musical and playful!

Now, if you’re interested in becoming a Michigan Tech Husky, or know someone who might be interested, and you want to know more, please let me know—Callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech

Echo’s hairy paws

Echo is very clever. She “nose” a lot!

Echo runs with a big smile on her face!

Last but not least, our very own Husky statue here on campus at Michigan Tech.

Integrity Matters.

Five on a Treasure Island, by English author Enid Blyton, the first book in The Famous Five series.

Integrity matters. 

I learned about integrity from my parents, and from my teachers. I do remember a young-age incident, around first or second grade. My older sister and I broke into a locked room in our rented house (Olinbury House in Sussex, England) which held a treasure of books that we wanted to read. We knew we should not enter that room. However, we could see through the keyhole more books, in the very same enchanting series we loved. This was around 1968. Books still ruled the day—and we were already spending 100 percent of our allowance on books to read. So that was the temptation, more books. 

In the scullery, we noticed a set of keys that we tried against this locked room. In the bathtub, while reading this book, as my mother could not tear me away from it, somehow the truth came out.  Later that evening, I was punished a multiple factor more than I would have been, because of not being truthful about where I had “found” the book. My poor older sister was punished even more than me, “as she should have known better.” She was 9, and I was 7. 

I strongly remember another incident, in sixth grade. We were a set of students at different levels, all “learning” math (without actual instruction). I had fallen behind, and so I faked my homework, copying the answers from the back of the book. Mercifully, I was caught by the teacher, checking my work. I found this incident profoundly disturbing, and I remember feeling ashamed of myself. It was then, about age 11, that I fully realized it was my own decision what sort of integrity I would possess, across my life. In that moment, I believe, my character was set.

Fast forward. Throughout this past year, I’ve been in frequent correspondence with one of our engineering alumni. He lives in California and regularly sends me clippings from the LA Times concerning the admissions scandals at USC. While I do understand parents being concerned about their child’s education, I do not understand how a parent would compromise not only their own, but also their child’s integrity, out of a desire to have them be admitted to a university on a basis other than their own merit.

At Michigan Tech—of course, as you know—no one can earn a degree except through their own work. With this comes character. Along with character comes  confidence, courage, and conviction in the knowledge that with enough time and resourcesyou can do pretty much anything.

The picture below is from our Department of Mechanical Engineering’s senior dinner, where soon-to-be-graduates make an obligation to themselves to uphold the standards of the engineering profession, known as The Order of The Engineer.

Order of the Engineer ceremony, Department of Mechanical Engineering-Engineering Mechanics at Michigan Technological University.

That evening, in my first year as Dean of Engineering at Michigan Tech, I participated as well:

“As an Engineer, I, Janet Callahan, pledge to practice integrity and fair dealing, tolerance and respect; and to uphold devotion to the standards and the dignity of my profession, conscious always that my skill carries with it the obligation to serve humanity by making the best use of the Earth’s precious wealth. As an Engineer, I shall participate in none but honest enterprises. When needed, my skill and knowledge shall be given without reservation for the public good. In the performance of duty and in fidelity to my profession, I shall give my utmost.”

Now, if you’re interested in taking this oath (if you haven’t already) and you want to know more, please let me know—Callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech

Lift Bridge Wins Award, Snags Trailer⁠—Built to Last 

Portage Lake Lift Bridge is a double-deck, vertical lift bridge, the only one of its type in Michigan. Here shown with a blue sky and summer day in the background.
The monumental Portage Lake Lift Bridge—a double-deck, vertical lift bridge—is the only one of its type in Michigan.

The Portage Lake Bridge, or more commonly known as the Lift Bridge, was designated in May, 2019 as an American Society of Civil Engineers (ASCE) Michigan State Historic Civil Engineering Landmark of the Year. Built in 1959, the bridge provides a key role in connecting the Keweenaw’s local industries to the nation, and uses a first-of-its-kind intermediate lift span position. It also was an early example of accelerated bridge construction. 

The Lift Bridge is a double-deck vertical lift bridge⁠—the only one of its type in Michigan and uncommon nationwide. While the lower deck was originally used by trains; these days, snowmobiles roar through the lower deck in winter. This riveted steel bridge was built to support the Keweenaw’s copper mining and logging industries and to serve the nation’s need for copper and timber. So you might say, it’s built to carry heavy loads!

the Caterpillar motor in the boat Janet was in
One of two Caterpillar engines on Don’s boat.

I was invited one recent Friday to meet one of our civil engineering alumni from the class of ‘66, Donald R. Anderson. He was docked in Hancock, just east of the Lift Bridge, traveling with his son, up from Grand Haven. They were in town waiting for the extended family, to arrive and spend a few weeks together on the boat as they worked their way through the Apostle Islands area. We were chatting, taking a look at the engines, and enjoying some local cider when BAM! A very loud boom sounded from the Lift Bridge. We all turned to watch as a tandem trailer loaded with trailers pulled to a halt. Over the next hour, inspections of the rig, and bridge seemed to happen while we looked up from below with high-tech binoculars and speculated about the impact. We figured that being in tandem, one of the trailers rocked up just as the truck pulled through and snagged that edge a bit. The truck eventually pulled down and around and took time to do a safety check just behind the marina.

A section of the lift bridge is shown with a tandem trailer loaded with trailers inside
A tandem trailer loaded with trailers comes to a halt on the Lift Bridge

On my way home, pedaling across the bridge I stopped and took a few images. You can see how there is a bit of battered metal at the leading edge on the Houghton side. No easy way to tell what marks are new or old from down on the ground (and I am a metallurgist). My assessment⁠—that bridge was built to last. I bet it will still be in use for its 100th anniversary. They build things to last up here in the Keweenaw. And remember your metallurgy: steel can plastically deform and even strengthen as a result of the increased number of dislocations.

underside of Portage Lake Lift Bridge
Lift Bridge wear and tear 

Dr. Tess Ahlborn, professor of Civil and Environmental Engineering at Michigan Technological University, working with two recent civil engineering masters of science graduates Emma Beachy and Michael Prast, submitted the application of Lift Bridge for Historic Civil Engineering Landmark Award at both the state and national levels. While Lift Bridge has now won the state ASCE Landmark of the Year award, the jury’s still out on the national level award. You can read more about the Lift Bridge here.

Thank you Tess, Emma and Michael, and the Department of Civil and Environmental Engineering, for the 300 pages of historical content that supported the nomination.

Dr. Tess Ahlborn, Professor of Civil and Environmental Engineering and Director of the Center for Structural Durability at Michigan Tech

Keys to a Unique Nameplate

I’ve just received an amazing gift. A unique, foundry-casting of my name in brass. The Michigan Technological University foundry is one of the few remaining operational university metallurgical facilities where students can work to create 3D positive prints, stamp them into sand, and then pour (with eye protection, fireproof aprons and face shields, tongs, and gloves) orange-hot molten metal into the sand to create metal castings.

I’m near the end of my first year as Dean of Engineering at Michigan Technological University. As background, it’s relevant to note that Michigan Tech was founded in 1885 to support the emerging copper and iron mining activities Michigan’s western Upper Peninsula. Founded to train the future mining and metallurgical engineers, Michigan Tech through the years has established an incredibly strong reputation for training “can-do” engineers—many who know a bit about metallurgy! But even I was surprised when presented with a personalized nameplate for my office—cast in the MSE foundry using brass recovered from a cache of old university office keys!

My new nameplate.

The university had accumulated a large number of brass keys from locks that were long-ago decommissioned. Looking for an ultimate way to securely dispose of the keys, the university public safety department approached the foundry team to ask if they could be melted and destroyed using the foundry. “Of course,” they replied. Timing is always important. At about that same time, Materials Science and Engineering Chair Steve Kampe had asked the foundry team to make a nameplate for me. I was just starting my new job as Dean, and happened to have my own credentials as a metallurgical engineer. Over the next several weeks, a pattern was 3D printed and the key brass was compositionally modified to facilitate its use as a casting alloy—and the nameplate came to be.

Sam Dlugoss holds a version of the finished nameplate
Sam Dlugoss

The “Dean nameplate project” was led by Sam Dlugoss, a chemical engineering student hired as a co-op employee in the foundry. I am humbled each time I see it as I unlock my office door with my own brass key. I think about the hands of the graduate students, staff, and faculty that are represented in the keys that ultimately were melted into my nameplate—and how these dedicated and aspiring engineers and scientists carried their keys and opened their labs and offices each day for many years, to do the work that has established the reputation we now carry on at Michigan Tech.

Last week, students in the foundry created more nameplates, this time for our College of Engineering Advisory Board Members. In the photos below, the students are working with iron.

A dip type thermocouple probe is used to measure the temperature of the liquid iron before tapping the furnace.
A dip type thermocouple probe is used to measure the temperature of the liquid iron before tapping the furnace.

As the iron is tapped into the ladle, ferrosilicon inoculant is added to the liquid stream. The inoculant provides nucleation sites for creating the proper iron-graphite microstructure in the solidified gray cast iron metal.
As the metal is tapped into the ladle, ferrosilicon inoculant is added to the liquid stream. The inoculant provides nucleation sites for creating the proper iron-graphite microstructure in the solidified gray cast iron metal.

After tapping into the ladle is complete, some sparks fly as the inoculant reacts with the liquid iron.
After tapping into the ladle is complete, some sparks fly as the inoculant reacts with the liquid iron.

The pouring team fills the molds.
The pouring team fills the molds.

 The pouring basin is kept full so that the molten metal quickly fills the mold cavity.
The pouring basin is kept full so that the molten metal quickly fills the mold cavity.

As the pouring team fills the 3rd mold [middle ground], an MSE staff member [foreground] lifts the mold jacket from the 2nd mold, and will transfer it to the waiting 4th mold [background] prior to it being poured. The jacket supports the green sand mold against the hydraulic pressure of the liquid metal entering the mold.
As the pouring team fills the 3rd mold [middle ground], an MSE staff member [foreground] lifts the mold jacket from the 2nd mold, and will transfer it to the waiting 4th mold [background] prior to it being poured. The jacket supports the green sand mold against the hydraulic pressure of the liquid metal entering the mold.

The metal has solidified but the molds are left to cool for a few minutes before the castings are shaken out.
The metal has solidified but the molds are left to cool for a few minutes before the castings are shaken out.

A mold with a casting inside is transported to the shake-out bin.
A mold with a casting inside is transported to the shake-out bin.

The molds are dumped into the shake-out bin where they disintegrate. Because sand is a good insulator the castings are still very hot after shake-out, as evidenced by the still glowing runner section. A few taps with a hammer loosens the sand. This green sand will be reused to make more molds after it is conditioned and remixed with water.
The molds are dumped into the shake-out bin where they disintegrate. Because sand is a good insulator the castings are still very hot after shake-out, as evidenced by the still glowing runner section. A few taps with a hammer loosens the sand. This green sand will be reused to make more molds after it is conditioned and remixed with water.

Once cool, the nameplates will be separated, then buffed and polished.

Now, if you’re interested in metallurgy, and you want to know more, please let me know—Callahan@mtu.edu.

Janet Callahan, Dean
College of Engineering
Michigan Tech