Carl Loper Brings Metal Casting Expertise to Engineering Faculty

Milwaukee's place at the center of Wisconsin's foundry industry helped attract Loper, Jr., an internationally known expert in foundry science and metal casting, to UWM this fall. Carl R. Loper joined the University of Wisconsin-Milwaukee's College of Engineering and Applied Science as an adjunct professor.

Loper, a Milwaukee native, retired from the University of Wisconsin-Madison earlier this year after more than 40 years as a professor in the material sciences and engineering department. He joined the UWM faculty, he says, because he wants to continue his research work with the foundry industry.

"Wisconsin has one of the largest concentrations of foundries in the United States, and Milwaukee is at the center of Wisconsin's industry," says Loper of his decision.

Loper is the author of several books, including a standard textbook in the field of metal casting, holds nine patents, has prepared more than 100 technical and scientific publications, and consults with foundries around the world. Metal casting is the art and science of making the molds used to manufacture metal parts for everything from Harley-Davidson's motorcycles to Kohler Company's bathroom sinks. Nobody has yet invented a better way to manufacture large or small hollow or complex components, says Pradeep Rohatgi, director of UWM's Center for Composite Materials and Wisconsin Distinguished Professor. This is why the foundry industry's history stretches back more than 11,000 years, he says.

Loper is considered a top international expert in ductile iron, a type of cast iron that is strong, cost-effective to produce, and versatile. Ductile iron is characterized by the spherical shape of the graphite in the steel/graphite mixture that makes up cast iron.

"Dean William Gregory was very enthusiastic about having Loper as an adjunct professor because his work fits in well with the Milwaukee Idea," says Rohatgi. "He will strengthen our ability to improve the foundry industry, which is an important part of the local economy." The local foundry industry was also very enthused about having Loper at UWM, he adds. Loper's work also ties in with the Milwaukee Idea's environmental efforts, Rohatgi adds.

"The foundry industry has had to make rather significant changes to conform to environmental regulations," says Loper. When he first began teaching and researching, metal casting involved much more trial and error and produced a large amount of byproducts. "Now, there is significantly more science involved," says Loper. "We are able to make castings that have better mechanical properties, are more consistent and have fewer defects, and can be produced at a lower cost." And a majority of the materials used in the production of metal castings are recycled materials, says Loper.

Loper has melded practical applications with academic research throughout his career. He enrolled at the UW Extension Center in Milwaukee (now UWM) when he was 19 and bored with the manual labor he was doing after high school. In a metallurgy course, he met a number of local foundry workers, and became interested in the field. After working for a summer at a local steel foundry, he decided to go to UW-Madison and pursue his interest in metal casting. After graduating with his bachelor's degree in metallurgical engineering, he went to work at the local foundry where he'd spent his summers. An economic downturn took him back to school for additional courses, and professors and colleagues encouraged him to use his talents in the academic world.

Students Loper taught and mentored in his 40 years in the academic world now work at foundries all over the world or as professors and researchers in the fields of metallurgy, materials science and cast metals technology.

In addition to continuing his other research, Loper will be involved with Rohatgi and the Center for Composite Materials. The Center works in partnership with local industry, researching ways to develop products from recycled materials, and make lightweight but strong composites for everything from motorcycles to small engines. These materials are in demand in the space program and airline and automotive industries as well as for the military. For example, says Rohatgi, developing materials for lighter weight tanks makes it easier to quickly airlift the equipment where it's needed.

One of Loper and Rohtagi's goals is to encourage more young people to look into careers in metal casting and foundry work. UWM is active in the Foundry Education Foundation, which supports research, development and education in the field. With the average age of foundry workers increasing, it's important to interest educated young people in the field, and let them know about job opportunities, says Loper.

"There are numerous small, medium and large foundries in this area. It is one of the primary industries in Wisconsin." He is particularly supportive of the Founder Education Foundation program because of the role it played in helping him get started in the field, he says. Several years ago, the Foundry Education Foundation named him a distinguished key scholar.

While Wisconsin is looking to biotechnology, information technology and service industries to diversify its economy, the state needs to also pay attention to areas where it is already a leader, says Rohatgi. "Along with agriculture and mining, manufacturing is one of the few areas where you are actually building wealth," says Loper. "We need to maintain the tremendous lead we have in metal casting."

(Loper will be interviewed on WUWM's At Ten program on Thursday, Dec. 5.)