castings cover 11.4 dec 10 - foundry-planet ltd. › fileadmin › redakteur › ... · the abp...

castings sa vol 11 no 4 December 2010 1

castings saA specialised journal covering the technology,

processors and materials field for castings

vo lume 11 number 4December 2010

cover storyABP Induction

industry newsJohn Davies reports back after visitingthe 69th World Foundry Congress;China 2010; 2011 Automechanika;Green Scorpions;SAIF 2010 Annual Golf Day;KEW Foundries;GIFA - METEC - THERMPROCESS - NEWCAST ’11;Export tariff on scrap metal; Travel Package; RC Systems; NFTN; Knights Foundry; John Winter & Co. Ltd.; Adrie; SAIF training courses for 2011

international newsFord foundry;Mercedes small car revolution; The Turkish foundry industry; Germany - Car exportsremain buoyant

product reviewGraded coal; ABB; Oxford Instruments;MAGMA5, the new generationof casting process simulation software;Nikon releasesShuttlePix P-400R Digital Microscope

44

38

8

4Castings SAvol 11 no 4ISSN 1605-7589

Publishing EditorBruce Crawford

Editorial BoardMarc Hindle

Technical ArticlesReprinted with permission fromInstitute of Cast Metals Engineersjournal – Foundryman and FoundryTrade Journal published by dmgBusiness Media Ltd, UK.

Production ManagerWendy Crawford

ReproductionJericho Graphic Design

Printed ByMasterpack

Advertising Bruce Crawford/Wendy CrawfordTel: +27 11 463 0489Cell: + 27 83 628 7654E-mail: [email protected]

castings sa is published by BA Crawford SpecialisedPublications (Pty) Ltd. PO Box 69 299, Bryanston,South Africa, 202141 Arklow Road, Bryanston, South Africa, 2021Tel: + 27 11 463 0489E-mail: [email protected]

SubscriptionsAnnual – Local: R120.00 (incl. VAT)International: On application

CopyrightAll rights reserved. No editorial matterpublished in Castings SA may be reproduced in any form or languagewithout written permission of the publishers. While every effort is madeto ensure accurate reproduction theeditor, authors, publishers and theiremployees or agents shall not beresponsible or in any way liable for anyerrors, omissions or inaccuracies in thepublication whether arising from negligence or otherwise or for any consequences arising therefrom. Theinclusion or exclusion of any productdoes not mean that the publisher oreditorial board advocates or rejects itsuse either generally or in any particularfield or fields.

castings sa is the official journal of the South African Instituteof Foundrymen (SAIF)

Printed on:

2 castings sa vol 11 no 4 December 2010

EDITOR’S COMMENT

Looking forward to 2011

Despite what the pessimiststhink 2010 has been a relatively positive year

for our industry. I know that weare not up to the levels of 2007and 2008 but at least there istalk of investment and growthbeing shown. On the downsidethere have been a coupleof closures and buyouts, however in the main all of us are still in business, hopefullywith plans in place to show

growth in the coming years.There are notable exceptions that really buck the trend

and these companies are already implementing their plans.Firstly I refer to the delightful story on Knights Foundry further on in the magazine. Here is a company that hasshown tremendous growth over the last two years and whichis planning to invest more in capital equipment and staff.

Then there is the Western Cape foundry that will beembarking on major expansion growth over the next threeyears. Details will follow as they come into the public domain.

Not to be left behind, Springs based Zealous Automotivehave recently signed an agreement whereby the joint customer investment in two fully automated diecasting cellswill be in excess of R 60 million. The state-of-the-art diecasting and machining facility will be the first of its kind inSouth Africa and should be producing castings by mid 2011.

Already in progress is a multi million Rand upgrade offacilities at the SOE foundry in Koedoespoort, Tshwane. Thisupgrade follows the Transwerk Foundries R 8 million investment in furnaces and other equipment that were commissioned in late 2009.

The beginning of a new era for the SAIF with theappointment of a General Manager, John Davies, has beensuccessfully implemented and is already starting to showpositive results on the training side.

Furthermore the SAIF has been very instrumental insecuring the confirmation of a National Pavilion for South African companies - foundries and manufacturers - to exhibit their products and innovative components infront of an international audience at the forthcomingGIFA / NEWCAST 2011 in Düsseldorf, Germany. Organisedin conjunction with Trade & Investment South Africa (TISA),a division of the Department of Trade & Industry, there arein the region of 15 South African companies that havetaken up this offer.

When looking at some of these highlights I am certainlypositive about the prospects for our industry in 2011.

Lastly, I would like to welcome aboard Adrie ElMohamadi, who has been appointed the new project leaderof the National Foundry Technology Network (NFTN), as fromthe beginning of November 2010. Adrie has built up a reputation as someone who gets the job done and I wouldlike to wish her all the best in the new position.

On that note I would like to wish all my readers and clients well over the forthcoming summer break and all the best for 2011.

The aim of the SAIF is to promote and develop withinSouthern Africa the science, technology and application offounding for individuals and involved industries.

Individual Member (local) – R550.00 Individual Membership (country) – R330.00 Junior Member – R100.00 – must be enrolled as a fullschedule student, in an accredited educational institutionin the Metals Industry as a trainee, and who has notreached his 23rd birthday.Retired Member – R250.00 Company Member (local) – 1 to 150 foundry relatedemployees – R2 275.00 Company Member (local) – more than 150 foundry relatedemployees – R4 600.00Company Membership (country) 1 to 150 foundry relatedemployees – R1 350.00 Company Membership (country) more than 150 foundryrelated employees – R2 750.00 Overseas Membership – R1 000.00 per annumAll of the above fees exclude VAT and are per annum

President – Luis DiasVice President – Enno Krueger

Immediate Past President – Mark PotgieterPrevious Immediate Past President – Richard Seymore-WrightTreasurer – Wessel Watt

Bruce Crawford Nigel PardoePeter van Wyk John Davies Blennah Ramushweu Takalani MadzivhandilaMpho Mabotja Wouter Retief Grant Estman

President - Willy PolisTraining Coordinator – Anthony O’ BrienFinancial & Technical Speakers – Dean Horne & Sean StadlerAdministration – Kevin MissenheimerSocial Co-ordinator & Technical Speakers –Mike Killain

University of JohannesburgMetal Casting Technology Station - MetallurgyRoom G101, John Orr Building, Corner Siemert and Beit Street, Doornfontein, Johannesburg, Gauteng.Postal Address: P.O. Box 14863, Wadeville, 1422.John Davies - Tel: 011 559 6468; Cell: 083 630 2809;Email: [email protected] Kleynhans - Tel: 011 559 6455, Cell: 083 598 7840;Fax: 011 559 6526: Email: [email protected]

Website: www.foundries.org.za

Contact details for Western Cape: Tel: 021 573 7311; Fax: 021 573 7296; Cell: 072 313 8375

Address Details

Western Cape

Elected Members

Constitutional Members

Council Appointments for 2010/2011

Fees

south african institute of foundrymen

cover story

- a fusion ofexperience, passion

and future

In 1903 the company's predecessors atASEA in Sweden built the first inductionchannel furnace for foundry operations.

The principle is ingeniously simple: the energyrequired for the melting process is induceddirectly into the charge by electromagneticcoils. Not only is this technology faster, it isfundamentally more efficient and precise.Since this breakthrough the company hasbeen passionately working to improve induction technology.

Intensive research and development workhas always been and remains the foundationfor ABP's innovative, top-quality product linethat meets the ever-increasing demands ofcustomers throughout the world.

In the course of the company's historythey have continuously expanded their know-how and consolidated their market position by means of strategic partnerships.In 1988 ASEA merged with Brown Boveri toform ABB. Over time they added sophisticated

control, automation and information technology to ABP's products, and supplemented them with consulting, planning,start-up and training services. Today ABP components and systems are used in nearly every foundry throughout the world.

In 2005, with the backing of a group of experiencedfoundry industry investors, the Foundry Systems group wasacquired from ABB and ABP Induction was born. With headquarters in Dortmund, Germany and operations in theSweden, Russia, USA, Mexico, Brazil, China, India, Thailand andJapan, the company is re-dedicating themselves with new energy to their long established core skill: developing and integrating induction related equipment and services for foundries and forges in order to make customers even more successful.

Mankind has been melting and processing metals for 7,000 years.Historically, this consumed a great deal of energy, chiefly in the formof burning coal, until 100 years ago when the company introduced a

new technology to melt metals: electric induction.

An ABP Medium frequency induction melting furnace,Type IFM 6 and IFM 8, 6 MW

An ABP Medium frequency induction melting furnace,Type FS 40, 3 MW


In 2008 ABP Induction LLC merged with the Pillar Induction Group - another expert in inductionmelting and heating - thereby adding further sites inthe USA and China. This merger has turned the ABP Induction Group into one of the global leaders inthe industry and will successfully continue the tradition of its predecessors.

The ABP Induction Group today focuses on salesand service in all major industrial regions, employs170 people in Germany and 470 people worldwide.

The production range includes induction systemsfor melting, pouring and holding ferrous and non-ferrous metals, heated and unheated pouring furnaces, inductive heating equipment for forming,heat treatment and hardening as well as modern control technology.

MeltingEngineering advances in the coreless medium

frequency furnace have boosted induction meltingrates in recent years. The development of static frequency converters has led to higher efficiency,improved reliability, minimum maintenance costs and lowercapital investment. ABP Induction offers induction furnace systems which are designed to guarantee the highest efficiency and economy required in today's modern foundry.

ABP coreless induction furnaces cover capacities of 1,000 kg to 60 tons with power supplies up to 18,000 kW. Innon-ferrous foundries, both the medium frequency corelessand channel-type induction furnace have proved to be aninvaluable melting tool. ABP offer systems for melting aluminium as well as for melting copper or zinc up to capacities of 105 tons and nominal inductor power ratings of2,450 kW.

Each of the company's products and services is based onproven ABP Induction systems enhanced by reliable, innovativefeatures. This is why the team, made up of process engineers,metallurgists and designers - in close cooperation with theircustomers - develop customized products and solutions to satisfy each unique application.

Pouring systemsFor the last link in the molten metal processing chain

- the pouring process - ABP Induction offers induction-heatedpouring furnaces and non-heated pouring systems which canbe linked perfectly into the operation chain of the molding line.

Having manufactured the first pouring system, ABP remains

the technology leader with innovative products and automationsolutions. For example the LaserPour® and OPTIPOUR®

systems and recently the newly designed electro-mechanicalstopper system.

ABP's pouring systems have helped to increase productivity,reduce returns, increase the quality of castings and improvethe working conditions in the foundry. ABP can supply pouringsystems with useful capacities of 1.7 to 25 tons and nominalinductor power ratings between 70 kW and 500 kW.

Induction-heated holding furnacesStoring and holding molten metals is one of the chief

issues in the entire molten metal logistics of a foundry. To meetthe customers' demands with regard to economy and flexibility,the ABP Induction range includes coreless and channel holdingfurnaces with furnace capacities to 155 tons.

EngineeringWhether it concerns the planning of a new plant or the

optimization of existing systems, ABP accompanies customersfrom concept creation through commissioning to after salesservice. The customer's individual solution is the center-point inevery phase of the project and will be optimally realised at thehighest technical level. The know-how gained over decades andthe use of efficient tools provides customers with the security ofknowing that the projected target values will also be achievedin the daily operation. ABP's scope of performance includes,amongst other things, concept preparation, process simulation,investment and benefit estimation, implementation and commissioning, factory planning, layout planning, and stafftraining and service. The company offers customers the appropriate products and solutions in every area of engineering.

Automation solutionsABP Induction's automation solutions effectively increase

the customer's capacity to compete. As a partner in all questions concerning the optimization of the customer's wholebusiness process in automation areas ABP Induction provideclients with industry-specific solutions for foundries as well asforming plants.

For more information ABP Induction Systems GMBH or visit www.abpinduction.com, TEL: +49 (0) 231 997-0 or contact Induction Furnaces on TEL: 011 623-1814/17An ABP channel type induction furnace, Type IRT 110

An ABP Pouring system, Type OCC 200


John Davies reports back after visitingthe 69th World Foundry Congress

16 to 20 October 2010, Hangzhou, China

The 69th World Foundry Congress (WFC), sponsored bythe World Foundrymen Organisation (WFO) and organised by the Foundry Institution of Chinese

Mechanical Engineering (FICMES), was held in October2010 in Hangzhou, China. The bi-annual WFC is the mostinfluential international event in the foundry industry worldwide. During the Congress, a broad and in-depthexchange and communication on science and technologywas carried out to supply a platform for foundry enterprisesto present their technology and products. The InternationalFoundry Photograph Exhibition was held concurrently andthe Excellent Photographs Evaluation was organized beforethe exhibition.

The theme for the 2010 Congress was Green Foundry.With the world facing the pressures of energy, resourcesand environment it was therefore appropriate for delegatesto explore new casting technologies and methods for energy conservation and environmental protection. It isindeed a crucial problem that needs to be solved for thesake of harmonious and sustainable development betweenhuman society and nature.

Hangzhou is a dynamic city as well as an internationaltourist city. It has earned a reputation originally created byrenowned Italian traveler Marko Polo, as 'the most beautiful and magnificent city in the world'. Hangzhou is a2200-year old famous cultural and historic city. It was oneof the seven ancient capitals of China.

One of the main functions of the WFO is to unite theindustry and disseminate appropriate information in a standardised and systemised manner at an annual event.To this end the World Foundry Congress is held bi-annuallyfor the presentation of technical papers and providing anadequate networking opportunity for those wishing to havea thorough understanding of the latest research and developments in the cast metals industry.

All Member countries are invited to be involved in eachcongress via the presentation of official exchange papers.In addition each Member country generally encourages alarge number of delegates from their country to participatein the event.

The forthcoming congresses will be held in the following countries:

2012 Monterrey, Mexico 25th - 27th April2014 Bilbao, Spain2016 TBA, Poland2018 TBA Japan

The WFO will hold its Technical Forum during the GIFA show in Dusseldorf, Germany. GIFA is the world'slargest foundry show and combines 4 shows into one.

The Technical forum will follow the same highly successfultemplate as in 2007 being in the main hall theatre andallowing visitors to the show to register for free and drop into any of the highly topical and technically relevant papersbeing presented.

The Technical Forum, also held bi-annually is scheduled to take place in the following countries:

2013 - USA2015 - Dusseldorf, Germany2017 - South Africa

John Davies, CEO of the South African Institute ofFoundrymen, attended the congress in China along withLucky Juganan, the senior lecturer from the EngineeringMetallurgy Department of the University of Johannesburg.Both were sponsored by the NFTN.

Report back"Accompanied by Mr Lucky Juganan, the senior lecturer

from the Engineering Metallurgy Department of theUniversity of Johannesburg, I was privileged to attend the69th World Foundry Congress, held this year in Hangzhou,China, representing the SAIF and the NFTN, which kindlysponsored the trip" said John Davies.

"Following a trouble free registration we visited theChina Foundry 2010 exhibition, at which 74 exhibitors werepresent, including well known foundry consumable and

The theme for the 2010 Congress was Green Foundry.


industry news

Lucky Juganan, John Daviesand Luis Baranano Zenekazelaia (delegate from Spain),

with Li Rongde, Chairman of the WFC 2010 Organising Committee(on the left of John Davies) and two other members

of the committee at the closing ceremony

capital plant suppliers and many Chinese based foundriesand foundry auxiliary supply companies.

"Familiar brands, such as Foseco, Elkem, Huttenes-Albertus, Spectro, Selee, ESI, ASK-SUD Chemie,Magma and Kunkel Wagner were present along with theChina Foundry Association and many others (full list ofexhibitors is available).

"The afternoon bus tour of the City of Hangzhou was avery pleasant introduction to the city with a lake situated inthe centre, surrounded by parks and gardens and dottedwith ancient temples and other historic buildings - mostenjoyable. (In Hangzhou there are6.6 million people, with27 trees to each resident.)

"We attended theofficial delegate's banquet along with representatives fromthe approximately 26 member countriespresent. The welcomefrom the various dignitaries was warmand very friendly.

"The Congress proper was openedwith about 2000 delegates from 33 different countries,but dominated by theChinese delegation representing theapproximate 26 000 foundries intheir country.

"The WFO President,Don Huizenga from theUSA officially openedthe proceedings, alongwith appropriatespeeches by variousindustry and localoffice bearers. Therewas also an introduction of thelocal arts and culturewith singing, dancingand acrobatics.

"The first plenarysession covered topicsof general interest withnine different presentations.

"The opening presentation set thetheme of 'reduce, recycle and re-use' forthe rest of theCongress, with a critical look at energyconservation and emission reductionstrategies for a sustainable foundryindustry. It was followed by a

SWOT analysis on the low cost nations competing withdeveloped countries. Particularly noting that China produces 35 million tons, or a third of the world's castingproduction and growing. The USA is next with nearly 11 million tons, followed by India with 8 m tons.

"A paper on ancient Chinese casting technologiesrelieved the tension and was very fascinating.

"The following two days allowed delegates to select from four different session venues providing choices of 108 diverse presentations, covering iron and steel metallurgy, foundry practices and processes,



aluminium and its alloys, die and precision castings,numerical simulation and modeling and computer applications. All the presentations that I attended followedthe green theme, using less, reducing emissions or recycling and improving precision in the process variables.An example of this was the presentation (no.86) on the useof high power thermal plasma heating in automatic castingunits, used to stabilize the metal temperature under aNitrogen cover at low costs. Papers not selected for presentation were available in poster format and the list ofall the titles will be available for distribution, and fullcopies can be provided from the transactions for all interested members.

"The closing session was preceded by a meeting of allmember countries present (26 out of 29), at which the RSAdelegates re-confirmed the bid to host the 2017 Technical

Forum in South Africa. Itis proposed that a workinggroup be established toprovide the planning andimplementation resource ifthe bid is acceptable tothe NFTN and its funders.

"The World FoundryCongress is a formidablegathering of cast metalspecialists from many (33)different countries. Thefocus is on research intomaterial, processes andpractices, carried out attertiary institutions, technical institutes as wellas foundry auxiliary materials suppliers. Thescope of research is asbroad as the industry andin the main very specialised. Collaborativeresearch is also carried outacross many borders. Norsurprisingly, research inChina is bounding ahead inquantity terms and as theindustry ascends theCasting complexity ladder,is certain to improve rapidly in quality.

"The foundry visits tothe Yeong-Guan Energy Technology Group and the NationalTruor Engine Plant were amazing showing both jobbing andseries production foundries using new state-of-the-artequipment, in safe and environmentally friendly plants,making high-tech castings for the wind energy and automotive truck markets respectively.

"The jobbing foundry made castings in grey and ductileiron from 500 to 80,000 kilograms! It had sand mixingcapacity or 140 tons per hour, and casting 200 000 tonsper annum.

"The automotive foundry was fitted with a high pressureK-W moulding and sand system, integrated with a key-coneautomatic core making and transfer system. All inductionmelting and pouring was via a pouring car with exchangeable ladles producing 85 000 blocks per annum(say 40 000 tons).

“The foundry visits to the Yeong-Guan EnergyTechnology Group and the National Truor Engine Plant were

amazing showing both jobbing and series production foundriesusing new state-of-the-art equipment, in safe and

environmentally friendly plants, making high-tech castings forthe wind energy and automotive truck markets respectively.’’

A few of the heavy section ductile iron castingsmade at the Yeong-Guan Foundry, in Jiangsu Province

in China

Ladles ready for use at the Yeong-GuanFoundry, where grey and ductile iron castings

from 500kg to 80 000kg are produced

Brendan Homann and Dudley de Beer, both of Insimbi Alloy Supplies, have recently returned from a two week visit to China.

China 2010- A first visit impression

The purpose of the visit was to attend the 69th WorldFoundry Congress which was held in Hang Zhou, and inaddition to this, the opportunity was taken to meet with

some of our existing suppliers as well as potential new suppliers.

"As an observation, the Congress was extremely wellorganized and the papers presented offered the attendees awide variety of choice, depending naturally on the interest ofthe delegates. Unfortunately, even though all the papers werepresented in English, the majority of the presenters wereChinese. Given that some of presentations were of a highlytechnical nature, this made it very difficult to grasp preciselywhat was being said.

"In general, the theme of the Congress was "green", whichseems to be the international trend in today's foundry industry.

"Contrary to expectation, Hang Zhou, as is the case withmost of the other cities visited, is a modern, well laid out citywith good infrastructure. Certainly there are still the oddthree-wheel delivery vehicles to be seen, and electrically powered scooters abound, but there is also an abundance ofMerc's, BM's and the like as well as many models of the locally produced Buick.

"Part of the Congress itinerary included a works visit onthe last day. There were six options to choose from, and wedecided on a trip that took us to a large ferrous jobbingfoundry called Zhejiang Jiali Wind Power Technology Co.Ltd.,and an aluminium wheel facility called Zhejiang WanfengTechnology Development Co. Ltd.

"The former produces primarily ductile iron castings forwind power generation. The plant still utilizes cupolas to meltthe base iron, and duplexes into induction furnaces for trimming and pouring.

"Moulding is in steel boxes, using furane resin. The castings observed range in mass between 5 and 10 tons net.All the pattern equipment seen was made from wood. Thescrap rate indicated by the production personnel spoken to isaround 3% and no weld rectification is permitted.

The company has staff accommodation on site and presumably this benefit is included in the cost to company figure mentioned of USD 600 per month. The workforce complement is around 350."

"The group was also shown the company's new foundrywhich is currently under construction a few kilometers away.Again at this site, the first building completed is staff accommodation.

The new plant will be equipped with four induction furnaces, two of 7 ton capacity, and two 12 tonners.

"The other plant visited produces 10 million low pressuredie cast, car and motorcycle rims per annum, mainly for thelocal market. The plant that the group was taken through,albeit quite rapidly, is apparently the old one, and is not dissimilar to the local wheel plants in South Africa. Ironicallythe new one is apparently highly automated and equippedwith state of the art robotics. One would think that with a population of about 1, 4 billion people, job creation would be encouraged, but evidently the mighty RMB takes preference.

"

Brendan Homan and Dudley de Beer of Insimbi Alloy Suppliesstanding in front of a wind turbine casting

Brendan and Dudley with the reception committeeat a ferro alloy plant



"The second part of the trip involved a great deal of traveling, commencing with a car journey, firstly south fromHang Zhou to Shaoxing and then northwards to Shanghai via the Hang Zhou bay bridge. This 36 kilometre, six lane,bridge is the world's longest ocean spanning structure, and shortens the trip to Shanghai by approximately 120 kilometres. The engineering is really mind boggling.

"From Shanghai, the next leg was a flight to Jinzhou in theLiaoning province, which borders on North Korea. Severalsuppliers are situated in this area with plants manufacturinga diverse range of ferro-alloys.

"These northern cities are somewhat less glitzy than their southern counterparts, but there are plenty of signs ofurban renewal, with vast tracts of ground having been clearedof older buildings and the construction of high rise buildingsbeing built at a furious rate.

"In keeping with the "green" theme, evidence of this wasalso seen at a carbon product producer, where the bakingplant was shut until certain environmental requirements aremet. Granted, this plant is situated adjacent to a residentialsuburb.

"A few comments need to be made with regards to doing business with the Chinese. Every employee seems to be proud of the company they work for. Theexchange of business cards, or as the Chinese say "name cards" is not just a simple paper swap, but a presentation of one's self, and is done with reverence.

"In conclusion, an impression of a trip to China withoutmentioning food would be incomplete.

The Chinese are very hospitable people, and almost every meeting is accompanied by a meal. It is considered"bad form" not to partake, but in many cases eating the food is a very trying experience. It would appear to the outsider that they eat everything and anything. As it was explained however, eating together creates a relationship, and unless there is a relationship, there is no trust. Simply put, no trust means no business, so you eat!"

A cast iron pot for water to dowse fireat the Forbidden City in Beijing


Many new initiatives to bepart of 2011 Automechanika

SA programme

Importantly a lot of attention is being paid to upskillingand training as the shortage of skilled workers is a majorchallenge in the automotive industry.

These activities will involve a skills competition organised by the Merseta in conjunction with the Retail Motor Industry organisation (RMI), which is one ofthe major supporters of this bi-annual event inJohannesburg. Midas will be promoting its e-learning andlearnerships programmes, while Bosch will be offering anumber of job opportunities in conjunction with Merseta aswell as hosting a technology demonstration centre with its associated brands.

The organisers of AutomechanikaSA are sponsoring a number of otherachievement awards besides theexisting competition for innovations.These include an AftermarketMarketer of the Year, an AftermarketEntrepreneur of the Year, Trade andTechnical Writer of the Year, MotoringPhotographer of the Year and awardsfor environmental ("Green") achievements.

The Proudly South African showcase, which proved very popularat the 2009 show, will be expandedsubstantially to include componentmanufacturers as well as local makers of specialist cars.

There will be a number of important conferences and workshopsduring the four days of the show.

The major conference will be thatof the RMI, where topics will include the new Consumer Protection and Companies Acts, franchising,skills development and compulsory vehicle and emissions testing. It will be held on the Thursday. There will be a joint convention for members of the Motor IndustryWorkshop association (MIWA), Engine RemanufacturingAssociation (ERA) and the SA Diesel Fuel InjectionAssociation (SADFIA) as well as a separate meeting for ACD franchisees, which is a network of independent workshops.

The SA Motor and Body Repairers' Association

(SAMBRA) is having a conference over a day and a half onthe Wednesday and Thursday, while the Tyre Dealers andFitment Centre Association (TDAFA) will have an executivecommittee meeting on the Thursday afternoon as well as aroad show event the following day.

Members of the SA Petroleum Retailers' Association(SAPRA) will be given feedback on the latest dealer satisfaction survey on the Friday. This is similar to the National Automobile Dealers' Association (NADA) survey where motor dealers rate their vehicle

suppliers.Meanwhile the organisers of

Automechanika South Africa haveannounced aggressive plans to make this second staging of the world famous brand name even moresuccessful than the inaugural eventin 2009.

Major effort is aimed at makingthe event more attractive to visitors - both from South Africa itselfand to those from the target marketon the African continent. Thisincludes the compilation of a detaileddatabase of potential visitors fromAfrica as these people are seen as avery important market into the future.

The South Africa Department ofTrade and Industry is providing financial support to assist the organisers in bringing Africa trade visitors from Africa to the event.

The interest from exhibitors at thisstage is also very gratifying with more than 20 countriesshowing interest in arranging national pavilions and severalof them have booked space already.

Interest from major companies in displaying their waresat the Johannesburg show is also encouraging. Among theexhibitors that have signed contracts already are RobertBosch, Diesel Electric, Mercedes-Benz and LiquiMoly.

"We are feeling very bullish about next year's trade fairas the South African economy continues to improve, withthe rand particularly strong," said Show Director Philip Otto.

Next year's Automechanika South Africa, to be held at theMTN Expo Centre, Nasrec, from March 9-12, will introduce many new initiatives

as well as continuing with proven projects such as the Innovation Awards thatproved very popular at the inaugural trade fair at this venue in 2009.

Major effort is aimedat making the event

more attractive to visitors- both from South Africa

itself and to those from thetarget market on the

African continent. This includes thecompilation of a

detailed database ofpotential visitors fromAfrica as these people

are seen as a very importantmarket into the future


Green Scorpions start environmentalcompliance inspections

The Department of Environmental Affairs has embarkedon a six-month long campaign to inspect complianceto environmental legislation throughout the country.

The Environmental Management Inspectorate (EMI),dubbed the Green Scorpions, will carry out the complianceassessments.

During the campaign, 40 environmental authorisations,and 20 waste licences will be inspected.

The main objectives of the campaign are to monitoradherence to conditions stipulated in environmental management plans, waste licences, and to improve thegeneral status of compliance within the regulated community by taking proper enforcement actions in theevents of non compliance.

The EMI has prioritised and clustered specific environmental assessments in each province and will dedicate one week for inspections in each province.

The first environmental compliance inspections tookplace in the Western Cape from September 27, to October 1.

Based on the risk prioritisation process, the GreenScorpions inspected the following facilities in the province:the construction of the new Eskom Safari substation inPaarl, the upgrade of the East Fort water scheme by theKnysna municipality, the development of a reverse osmosisproject in the Port of Saldanha by Transnet, the construction of a substation and relocation of power linesin Kwa-Nokuthula (Plettenberg Bay) by the Bitou municipality, and the Section 31L compliance notice issuedby the department to the Department of Public Works forillegal construction of facilities for the storage of materialsand maintenance of vessels in the sea or within 100 minland of the high-water mark of the sea, as well as the illegal construction of facilities for the aboveground storageof dangerous goods.

Following the inspections in the Western Cape, provincial inspections will take place in KwaZulu-Natal, the Free State and the Eastern Cape. Further inspectionswere envisaged in December, January and March.

SAIF2010 Annual Golf Day

The SAIF Council would like to thank the followingcompanies for sponsorship of prizes, tee boxes andgreens: ABB, Ceramic & Alloy Specialists,

Crawford Publications, Delf Sands, Endeco, Extratech,Foseco South Africa, GFE-MIR Alloys and Minerals, Independent Mineral Distributors, Insimbi Alloy Supplies, JC Impellers, Lil Sales, Mineral-Loy cc, Nimag Group, QTE Training, SAIF, Sasol Synfuels, SI Group HA, Saveway,Spectro Analytical Instruments, Thos Begbie,Vestcast andYellow Star Manufacturing.

The competition on the day was fourball alliance with two scores to count and four scores to count on the par 3s.

There were three closest to the pin prizesand the winners were:

5th hole - Sponsored by SI Group HA (HA Falchem SA) - Phil Walker

7th hole - Sponsored by Foseco South Africa - Tyrone Tarr

11th hole - Sponsored by Insimbi Alloy Supplies - Philip Ingham

There were two longest drive prizes andthe winners were:

8th hole - Sponsored by Yellow Star Manufacturing - Naas Grobler

18th hole - Sponsored by LIL Sales - Petrus Coetzee

Special thanks must go to Insimbi Alloy Supplies for collecting R 740.00 from the players for charity on the 11th hole. This year's recipient is the Avril Elizabeth Home.

The winners on the day on a score of 113 points were Kevin Keeling, Russel Symons, Clive Hill and David Osborne.

The longest day prize winners were Nico Botha, Johan Banadie and Martin Volschenk on a score of 29.

The South African Institute of Foundrymens' Annual Golf Daytook place on Thursday 11th November 2010.

The event was held at the Reading Country Club.


Second on the day on a score of 107 points were Tinus Pentz,Shaun Treadwell, Gawie Pretorious and Steve Ellis

Third on the day on 101 points were Joseph Matthysen, Henry Swanepoel, Victor Havenga and Vic Conning

The winners on the day on a score of 113 points wereKevin Keeling, Russel Symons, Clive Hill and David Osborne.Luis Dias, the SAIF President, handed out the prize to Clive,

Kevin and David


Closest to the pin winner on the 5th hole, sponsored bySI Group HA (HA Falchem SA) was Phil Walker. Phil is seen with

Gordon McNeiledge (left) of SI Group HA (HA Falchem SA)

Closest to the pin winner on the 7th hole, sponsored byFoseco South Africa was Tyrone Tarr. Tyrone (left) is seen with

Mark Wynn of Foseco South Africa

Closest to the pin winner on the 11th hole, sponsored byInsimbi Alloy Supplies was Philip Ingham. Philip (left) is seen

with Brendan Homan of Insimbi Alloy Supplies

The longest drive winner on the 8th hole, sponsored byYellow Star Manufacturing was Naas Grobler. Naas (left) is seen

with Joseph Matthysen of Yellow Star Manufacturing

The longest drive winner on the 18th hole, sponsored byLIL Sales was Petrus Coetzee. John Davies (left), CEO of the SAIF,

handed the prize to Petrus

The hackers of the day were Johan Banadie, Martin Volschenk and Nico Botha

Special thanks must go to Insimbi Alloy Supplies for collecting R 740.00 from theplayers for charity on the 11th hole. This year's recipient is the Avril Elizabeth Home.

In the most recent project, KEW Foundries won the contract to supply sheave wheels to Konkola CopperMines PLC, to be used on the Konkola No. 4 shaft.

The contract involves the design, manufacture and supplyof five sheave wheels for the deepest new shaft sinkingproject being conducted in Zambia. The contract forms part of an intensive capital upgrade of the mine, known as the Konkola Deep Mining Project(KDMP).

"The sheave wheels will be installed in No. 4 shaft'seighty one metre high headgear and will service the minesBlair Multi-rope winder," says Jaime Goncalves, Technical Director, KEW Foundries. The sheave wheels,each with a diameter of 4877 millimetres, will be used tohoist materials from depths of 1430 metres. The suppliedsheave wheels will facilitate hoisting speeds of eighteen metres per second, with a payload of twenty sixtons.

KEW Foundries received operational parameters fromthe KDMP project managers for the required sheave wheelsdetailed in specifications drafted by the team at TWP."Once we had received the parameters, our design teamwas able to design a solution which is not only cost-effective, but will also withstand the harsh operatingconditions present on the mine. Our sheave wheel solutions feature a cast iron construction method and abolted assembly technique. We have found that thisprocess of manufacture increases mine uptime, as thesheave wheels require far less maintenance than sheavewheels constructed using a welded assembly technique,"explains Goncalves.

KEW Foundries has built up a professional relationshipwith TWP and Konkola Copper Mines PLC, based on qualityworkmanship, cost-effective solutions and proficient service delivery. Goncalves extrapolates, "We have beensupplying sheave wheel solutions to Konkola Copper Mineseven before Vedanta Resources acquired the company in 1998. KEW Foundries has supplied solutions to both the Nchanga shaft, and the Konkola No. 1 shaft. To date our solutions have performed outstandingly."

KEW Foundries was established in 1891 and is Africa's sole manufacturer of cast headgear sheave wheels. The company also offers an extensive range ofhand moulded castings in Grey and SG Iron up to 7 tons in weight, pressings, and general machining.Supported by comprehensive design and drafting facilities, including a dedicated pattern shop, machineshop, and laboratory, KEW Foundries serves a host ofSouth African and international mining and industrial markets.

For more information contact Jaime Goncalves,Technical Director KEW Foundries TEL: 053 841 0474

KEW Foundriessupplies sheave wheelsto various TWP projects

KEW Foundries has supplied sheave wheels for a number of TWP Mining projects,including the Konkola No. 4 shaft project in Zambia, and the

Impala Platinum No. 20 shaft project where the multi-disciplinary consultingengineering firm was the EPCM contractor.



Invitation to attend theGIFA - METEC - THERMPROCESS - NEWCAST

(GMTN) 2011 presentation in Johannesburg

Mr. Joachim Schäfer, the Managing Director of Messe Düsseldorf and The Southern African-GermanChamber of Commerce and Industry

extend an invite to all prospective visitors toGMTN 2011 to attend a presentation onGMTN 2011. The presentation will be followed by a breakfast.

Come and update yourself on GMTN2011 and also get to be briefed about theSouth African National Pavilion for GIFA / NEWCAST, already planned and confirmed by the dti (the Department ofTrade and Industry). You will also beinformed on the different travel packagesarranged.

The four leading international tradefairs, GIFA, METEC, THERMPROCESS, NEWCAST, are being held in Düsseldorf,Germany from 28 June to 2 July 2011. More than 72,000 tradevisitors from all over the world are expected to gather

information on trends and innovations in these industries.The presentation will be taking place on Thursday the 10th

of February 2011, at Emperors Palace,Johannesburg in Assembly 3 and 4 and willbe hosted by Mr. Joachim Schäfer, theManaging Director of Messe Düsseldorf,and the Southern African - GermanChamber of Commerce and Industry. Thisfree of charge breakfast function will start7.30 am for 8:00 am. To register, pleasecontact Ms. Lisa Kuntze on Tel: 011 486 2775 or email [email protected].

Mr. Schäfer will be in Johannesburgfrom the 9th to the 12th of February 2011.If you would like to meet Mr. Schäfer during his stay in Johannesburg please contact Ms. Lisa Kuntze on the same

details as above. We look forward to welcoming you to theGMTN Presentation!

One year after beingappointed MD ofsecondary aluminium

producer Zimalco WillieWillemse and the company arestill fighting to have an exporttariff on scrap metals imposed,as reported in Engineering News.

"The secondary aluminiumindustry is calling for SouthAfrica's Department of Tradeand Industry (DTI) to impose anexport tariff on scrap metals, asthe current high cost of buyingthe metals by local aluminiumcompanies is shrinking theindustry" said Willie

"South Africa's scrap metalmerchants are exporting their scrap metals and, over the pastten years, aluminium die casting companies that use scrapmetals in their production process have steadily decreased innumber by more than 40%. The secondary aluminium industrydoes not have sufficient access to scrap metals, owing to thehigh cost of the raw material" Willie continued.

"Local aluminium producers are, in effect, paying the highestprice in the world for their scrap aluminium from South Africa'sraw material suppliers, as the various scrap metal merchantscurrently controlling the market export the in-demand scrapmetals to more lucrative overseas markets," he says. "This istantamount to exporting energy as secondary aluminiumrequires less than 10% of the energy required to produceprimary aluminium. This has resulted in secondary aluminiumproducers buying the scrap at unaffordable rates and theircustomers importing finished components into South Africa."

"The base price of the local foundry ingot is similar tooverseas companies' finished product selling price, forcingcompanies to increase their prices. This results in a lack ofcompetition in the industry and stunts finished product exportgrowth" said Willie.

"Scrap metals are being exported and the finished components are imported. We are creating jobs for other countries and not our own," he says.

"Even if the raw material is converted locally, after beingacquired at such a high price, and exported, duties in manycases will apply to the completed product on arrival at the overseas destination."

Taking strain Although South Africa's aluminium scrap metal accounts

for less than 1% of the world market, it is critical to the localsecondary aluminium industry.

"During the past ten years, five secondary smelters haveshut down, with a loss of melting capacity of over 2 000 tonsper month. Piston manufacturers and wheel producers havealso closed down and this decline has been increasingly common over the past five years" said Zimalco sales and marketing director Bob Stone.

"About 40% of companiesin the die-casting sector havealso shut down, resulting in48% job losses. Die-castingproduction decreased from1 670 tons per month in 2000,to 780 tons per month in 2010,a decline of 53,3%, he says.

"Since 2003, the export ofaluminium scrap has grown,reaching a total of 35 992 tonsfor 2009 and 14 940 tons forthe first half of this year, whilethe exports of beneficiatedscrap have declined from13 803 tons in 2003, to3908 tons in 2009, and arecurrently at only 2095 tons for

the first half of 2010.""South Africa has also lost investments from America and

Europe, particularly by automotive components manufacturers.Investment opportunities arrive only once in an eight- to ten-year life cycle of vehicle models within the automotiveindustry" said Willie.

"A potential investment in the production of 800 tons permonth of commercial die-casting components, which was afavourable investment for job creation, was lost because therewas no guarantee of the availability of the raw materials atcompetitive prices owing to South Africa's government exportpolicies at the time" said Bob Stone.

"While the local automotive industry is also showing signsof growth, it appears to be ?'imported growth'. It is, in manycases, cheaper for the automotive industry to import components and forgo its Motor Industry Development Planbenefits. As a result, local production and supply of aluminiumcomponents to the motor industry have declined" continuedBob Stone.

Zimalco, which has d a production capacity for 1 500 tonsper month of commercial export alloy, has produced very fewexport products in the past few months" said Willie.

"Zimalco has a busy plant, but it is not operating at fullcapacity. If we receive more support from the government,Zimalco can create about 20% more jobs at its plant, and manyother companies will be able to do so as well," he added.

Meanwhile, the industry, which has a melting capacity inthe region of 5 250 tons per month, is trying to level the playing field for South Africa in the world market by restrictingthe export of scrap metals. The lobbying for imposing an exporttariff on scrap metals has been carrying on for over elevenyears.

"South Africa has an excess of scrap for its current needsand has the capacity to absorb all the excess aluminium scrapcurrently being exported, just not at the current export price"said Willie.

"The South African secondary aluminium industry is morethan capable of converting that scrap, keeping the scrap in thecountry and exporting the finished products and components


Call to impose an export tariffon scrap metal

Willie Willemse and Bob Stone

by adding value to the raw material while creating more jobs.Sustainable competitiveness; secure full time job creation andsocioeconomic upliftment must be a priority," says Bob Stone.

"Further, mining giant BHP Billiton's Bayside smelteroperations ceasing the manufacture of beneficiated aluminiumproducts, such as rod, wheel rim alloy and extrusion billet hascreated further challenges for the secondary aluminium industry."

Stone adds, for example, that the non production ofextrusion billets has left extruders with the options of eitherproducing their own billets or importing the billets.

"Between 700 and 800 tons per month of extrusion billetsis now being imported and some extruders have started toincrease the manufacture of their own billets, which, tomaintain lower costs, requires old extrusion scrap. This scrap,which is currently in high demand, has created a shortage andincreased the price in the market" says Bob Stone.

Future possibilities "The availability of local raw material that is competitively

priced will enable the industry to grow. During the early 2000s,a number of studies were undertaken by the University of theWitwatersrand and funded by the DTI and the Metals RecyclersAssociation, to determine whether it would be beneficial forSouth Africa to make scrap metal competitively accessiblelocally. Several further independent studies have beencommissioned by the DTI over the last eight years" saidBob Stone.

"The outcome of these reports, including studies done byZimalco and other independent parties, were positive in terms

of the local beneficiation of South Africa's resource of scrap,creating jobs, encouraging investments and leading tosocioeconomic upliftment."

"The latest report, which was commissioned and funded by the DTI, was completed at the end of 2009. Its recommendations were approved by the Trade and IndustryMinister Rob Davies and it is currently in the possession ofMinister of Finance Pravin Gordhan for approval and, hopefully,implementation" said Bob Stone.

"Although the DTI has shown its support for the SouthAfrican foundry industry through its commitment to the SouthAfrican trade policy and strategy framework, which hasidentified key programmes, such as competitive raw materialpricing of scrap metals as crucial in developing the metalsector, the department is still discussing measures with theNational Treasury to increase the local beneficiation of scrapmetal and no decision has been made to date" says Bob Stone.

"The DTI is working with the National Treasury and theDepartment of Customs and Excise in this regard. Zimalco hasbeen led to believe that an export tax of 20% would be implemented on scrap metals. The company is staying positive,but we have no way of knowing what the final decision will be,"said Bob Stone.

Zimalco says that the metal merchants can sell the scrapmetal to whomever they please; however, the company wouldlike to see the implementation of a tax on scrap exports,enabling more local beneficiation, leading to more competitively priced products and enabling business growthand the creation of jobs.


Foundry professionals from all over the world will meet from28 June 2011 to 2 July 2011 for the world's number oneexhibition for the foundry/castings industry. The event is

set to feature manufacturers of major foundry machinery andplant, professionals from the supply industry, providers of engineering services and for the first time, foundries exhibitingtheir castings and capabilities. The exhibition affords all South Africans involved in the industry the chance to view thelatest technology available.

Trade Fair Travel in conjunction with Castings SA and theSouthern African - German Chamber of Commerce and Industryhave organised two tours for visitors to visit the exhibition.

Tour 1Sunday 26 June 2011: Depart Johannesburg InternationalAirport (Swiss Air) LX 289 19:30Monday 27 June 2011: Arrive Zurich 06:10Depart Zurich LX 1016 07:25Arrive Düsseldorf 08:45

On arrival a coach driver will transport you to the 4 starLindner Hotel Rheinresidenz (www.lindner.de). This delightful,126 roomed hotel is located a short walk to the River Rhineand a 15 minute walk to the Konigsallee and Alstadt. The "U"Bahn station, Nordstrasse is located only 350 metres awayfrom the hotel, and then 7 minutes directly into MesseDüsseldorf. The fairground entrance ticket is included in thetour cost and allows the holder free travel on all Düsseldorftransport systems. Accommodation is reserved in twin bed orsingle rooms, with buffet breakfast.

Under own arrangements to visit Trade Fair until:Friday 01 July 2011: Make our own way toDüsseldorf Airport

Depart Düsseldorf LX 1027 19:55Arrive Zurich 21:00Depart Zurich LX 288 22:45Saturday 02 July 2011: Arrive Johannesburg 09:10

Tour priceR15 570.00 per person sharing a twin room orR18 560.00 with a single room

Tour 2Monday 27 June 2011 Depart Johannesburg InternationalAirport (Swiss Air) LX 289 19:30 Tuesday 28 June 2011 Arrive Zurich 06:10 Depart Zurich LX 1016 07:25 Arrive Düsseldorf 08:45

On arrival a coach driver will transport you to the 2 star,tourist class Ibis Hotel Hauptbahnhof www.ibishotel.com. As thename implies, the hotel is adjacent to the main rail station,where the journey time to Messe Düsseldorf is only 15 minutes. The famous Old Town (Altstadt) and Konigsalleeare a short walk away. The fairground entrance ticket is included in the tour cost and allows the holder free travel on all Düsseldorf transport systems. Accommodation isreserved in twin bed or single rooms, with buffet breakfast.

Under own arrangements to visit Trade Fair until:Saturday 02 July 2011: Make our own way to Düsseldorf Airport Depart Düsseldorf LX 1027 19:55 Arrive Zurich 21:00 Depart Zurich LX 288 22:45 Sunday 03 July 2011 Arrive Johannesburg 09:10

28 June - 2 July 2011, Düsseldorf, Germany


AIRBUS S.A.S. 2009COMPUTER RENDERING BY FIXION- GWLNSD


Tour priceR13 590.00 per person sharing a twin room orR16 190.00 with a single room

Information about both toursDue to the constant fluctuation of airport departure taxes

and fuel surcharges these have been excluded from the tourcost. At the time of preparing this tour taxes and surchargeswere approximately R3 100.00 per ticket. The exact amountwill be added to the final invoice when the tour balance is due,usually 6 weeks before departure.

Bookings close on the 13th April 2011. Due to severedemand for hotel accommodation, all unsold rooms will bereleased back to the agent. Reservations after this date will be requested on an adhoc basis, and will incur a late booking fee of R250 per reservation whether confirmed or not, and must be paid in advance. No reservationwill be confirmed until a completed booking form and a nonrefundable deposit of R2,000.00 is received by Trade FairTravel.

Tour costs are based on exchange rates prevailing at 1 October 2010. Final tour costs will be recalculated when thebalance is due.

Prices include• Return airfare Johannesburg/Düsseldorf• Airport/Hotel transfer• Accommodation for 4 nights• Full buffet breakfast daily

• Entrance ticket to Fairgrounds• Medical/travel insurance• Düsseldorf City Guide

Optional extras• Special reduced domestic add on fares available• Passengers wishing to extend their stay may do so at

an additional R500.00• Passengers wishing to travel to London or other cities,

may do so on payment of the additional fare

N.B. No refunds given to passengers not utilizing airporttransfers and Trade Fair Travel regret they are unable to acceptpayment by credit card.

SAIF foundry visits in GermanyThe SAIF is negotiating with the German Foundry

Association to visit foundries in the area during your stay.

If you are interested in taking part in a one day tour please contact John Davies on Tel: 011 559 6455 or on 083 630 2809. Transport will be provided and a cost will beadvised depending on the numbers.

Travel package contact detailsPlease return your completed booking form which can be

downloaded off the website www.tradefairtours.com to Trade Fair Travel, Tel 031 916 1414, Fax 031 916 5674, email [email protected]


Today the company has grownconsiderably employing 15 staff and besides still

offering the electrical engineeringservices now also manufacturesequipment for the electrical, foundryand electroplating industries.

"I started the company, with mywife Claire, having served myapprenticeship as a power electrician with the South AfricanRailways. I then educated myself inthe evenings to achieve a HigherNational Diploma in Heavy CurrentEngineering in the late seventies"explained Rob.

"I then joined the now liquidatedDavcor Engineering in 1984, specializing installing PLC controlsin the foundry equipment manufactured. As far back as 1985,this was quite innovative technologyat the time.

"Once I started my own companyI still contracted back to Davcor forthe next fifteen years, and worked very closely with the lateCourtney Jane, who was married to my sister. We developedsome amazing machines and he really was the most innovative thinker, always applying sound engineering principles. Courtney taught me an immeasurable amount of valuable lessons in my life, both on the engineering and personal side."

Manufacture, servicing and repairs of foundry equipment"It was during this period that I built up my experience in

manufacturing foundry equipment with the focus on coremaking machinery. However we do not only offer newmachines in this area, we also offer repairs and servicing."

"But I am not limited to only manufacturing core makingmachinery. Other equipment manufactured for the foundry industry includes:

• Compaction tables• Pneumatic conveying systems• Dust collection units• Reclamation plants• Classifier units • Continuous mixers.

Likewise we also offer repairs and servicingfor this equipment as well."

"Sadly once Courtney died in 2002 the Davcor business dried up and the companywas subsequently liquidated."

"I had in the mean time become moreinvolved in primarily doing industrial electricalcontrol systems on hydraulic equipment for alarge German based company and had very little involvement in the foundry industry for awhile. We ended up losing our intellectual property to this company, and have learnt thatthere is not much a small company can do toprotect itself from this happening in South Africa."

"Fortunately we have also been involved in

RC Systems' origins date back to 1987 when Rob van Niekerk started his businessproviding electrical engineering services to manufacturing companies in the

Gauteng area.

RC Systems - 23 years on

Byron and Rob van Niekerk

A 5 ton an hour continuous mixer that RC Systems manufactures


the electroplating industry offering heating and cooling applications for plating tanks and level control, as well asmaterials handling systems."

"Other business includes numerous projects for dust control applications using PLC's for air flow control on largeducting systems and filtercleaning applications."

"In addition we haveextended our experiencein the steel industry withthe installation of controls for tapholeequipment. Here ourclients include HighveldSteel, ArcelorMittal andmany of the Samancorplants."

"On the electrical system side the companyis involved from thebeginning and we offer atotal turnkey solution ofsystem design, softwareprogramming, MCC panelmanufacture and installation. We use various PLC equipment inour installations includingMitsubishi, Modicon,Siemens, Allen Bradleyand Omron."

Energy saving foundryequipment

"Lately we haveapplied my foundryexpertise to manufacturing equipmentwith the focus being onenergy savings wherepossible. We also specialize in power factorcorrection equipmentwhich can be a large saving if installed correctly. The input costsof energy are becomingone of the biggest challenges facing thefoundry industry at themoment."

"One of the more successful installations inthis area has been themanufacture and installation of equipmentat the Germiston foundryKnight Sales."

"My son Byron joinedthe company in 2008 andis currently doing his

apprenticeship. In total we have 10 technical staff memberswith some of them having been with us for as long as 18 years."

For further details contact RC Systems on TEL: 011 425-4273

“We also specialize in power factor correction equipment which can be alarge saving if installed correctly. The input costs of energy are becoming one of the

biggest challenges facing the foundry industry at the moment.”


The NFTN would like to extend its list of serviceproviders. If you have expertise in the following areasand are able to do freelance consulting please submit

your company profile, track record, and CV.

Areas of support:• Process control and monitoring• Energy efficiency improvements• Benchmarking• Technical training• Cost savings in the foundry• Cycle time improvements• Die designs• Trouble shooting• Reject reductions• Productivity improvements & foundry layout• Casting simulation• Assessors• Moderators• Foundry technical subject matter experts,

particularly in moulding, melting and patternmaking

NFTN mobilisation support programmeNFTN would like to announce its mobilisation support

programme. This programme is intended to support non-routine, competitive, improvement or development projects within individual foundries through a partial financial contribution by the NFTN. Note that the programme is NOT applicable to routine tests or analysisbut for matters such as:

• Problem solving• New product development• Casting simulation• Productivity improvement

For further details contact Adrie El Mohamadi at theNational Foundry Technology Network: Email: [email protected], 082 902 4083 (Mobile)and 012 841 2127 (Office)

NFTNlooks for service providers

Although the Van der Waltfamily has been associated with the

foundry industry since the1960s it was only five yearsago that the company pouredits first casting and this wasdone in a way that was not normal.

First generation brothersKoos, Johann and Jan van derWalt have always been a closeknit union when it came to business and this strong bondhas now continued through toJohann's sons Vincent andCobus and son-in-law LouisMiller.

At the age of 64 Johann isstill a very integral part of the business turning out new handcrafted patterns on a dailybasis. Koos passed away in1999 and Jan retired in 2008leaving Johann and the second

generation to run the company.The brothers got together in business in 1985 when

EJ van der Walt Patternmakers, a company that still exists,was formed. Koos had always been the 'salesman' of thefamily while Johann and Jan were the craftsmen. Bothtrained as patternmakers, completing their apprenticeshipsat Ace Patternmakers and Scaw Metals respectively, whileKoos ran a brokerage business buying and selling castings.

The name Knight Sales, which was the brokerage sideof the business, does not readily associate itself with thefoundry business. It was derived from its location inKnights Industrial area in Germiston, Gauteng. Howeverbecause of the long association with the foundry industrythe family has kept the name but now trades as KnightsFoundry.

"I joined the company in 1999 when Uncle Koos passed away and continued with what was the core of the Knight Sales side, namely buying and selling

Knights Sales(T/A as Knights Foundry)

expands in tough timesThis relatively new family run foundry has increased its order intake

by 80 % during the recession.

Standing, Cobus and Vincent van der Walt with brother-in-law Louis Miller

Johann Van der Walt


castings" said elder brother Vincent (31)."We always placed an emphasis on

service and delivering castings on timeto clients and not trying to bargain withthe foundries for rock bottom prices"continued Vincent.

"When you are reliant on outside supply you eventually run into problemsso the thought of manufacturing our owncastings was always top of mind. We took the plunge in 2005 but we didnot start off pouring our own metal fromthe beginning. We moved to our currentlocation in Wadeville, Gauteng and purchased a pugmill for mixing CO2 sandfor moulds. Our source of metal was supplied by Steve Thomas who had hisfoundry located next to us, until recently.The building was only 540 m² but it wasadequate for us at the time. The type ofcastings we concentrated on were crusher and pump spares and these castings still form alarge part of our mix today" said Vincent.

"We did the fettling of the castings and my dad's business EJ van der Walt Patternmakers would make thepatterns.

"In 2006 we decided it was time that we moved towardsbecoming a fully fledged foundry. This was when weinstalled our first furnace, a 350 Kg induction furnacealong with all the necessary equipment needed to run whatwe thought would be a relatively small foundry. At the sametime we increased our floor space by another 600 m²."

Since then Knights Foundry has been on fairy talegrowth expansion.

Factory space was increased by 1 500 m² in 2007, 560m² in 2009 and a further 2000 m² this year.

"There are a few reasons this has happened" said brother Cobus (25) who joined the company in 2003 on ahalf day basis while studying at TUKS University RugbyInstitute.

"Business was buoyant at that point and in a relativelyshort space of time we had built up a reputation of supplying quality castings. Both my brother and I have noformal training in foundry practice but we have always been hands on characters and at the same time we studied the Foseco Hand Books and other literature.Steven, from Quantus Foundry, who was located next door at that time, was also very helpful in giving us the

practical experience" explained Cobus.Besides increasing the size of the factory floor space

during this period, the foundry has also invested in moreequipment to cope with the extra workload.

"After the first furnace the next significant capitalexpenditure we made was on the finishing and fettling side.A shot blasting machine was purchased in 2007 and thiswas done because of the nature of the product we werecasting. They are not safety critical castings but need to bedelivered as burr free as possible" said Vincent.

"With the extra floor space that we now have, we havebeen able to re arrange the whole flow of the foundry andthe finishing side of the business has been moved into itsown dedicated factory, completely away from the foundry.The benefits of not having dust and filings in the foundryarea are enormous."

Shortly thereafter a one ton induction furnace was purchased and this year a new 300 Kg induction furnacewas installed. Included in this investment drive, finding itsway onto the floor was a 3 ton capacity top hat heat treatment facility with two bases.

2010 - A big year for investmentIncluding the furnace, Knights Foundry has spent nearly

R 2 million on new equipment this year with most of thisamount going into a no-bake closed loop moulding systemdesigned, manufactured and installed by Benoni based RC Systems.


A general view of the revamped casting area

The new 5 ton an hour continuous mixer manufactured andinstalled by RC Systems in October this year

RC Sytems also installed an eight ton hopper


The system consists of a 5 ton an hour continuousmixer with a 100 CFM screw compressor, 5 ton an hourreclamation plant, a 8 ton hopper, a classifier and dust collection unit, a fully automated pneumatic conveyor and58 metres of roller track. A 25 ton sand silo and a 15 tonmixing silo have also been installed.

"Up until now we have always operated on the CO2 system but now with us investing in the alkaline sand

system it has put us in another league" enthusedCobus. "We have increasedour stainless steel side of thebusiness and this was a mustthat we went this route. Herewe must thank Foseco andRob van Niekerk from RCSystems for guiding usthrough the teething period."

"We would never havetaken this leap into theexpansion project if we didnot invest in the fifth generation, theSPECTROMAXx benchtop unit.All of the important elementsrequired in the metal industrycan be determined with thisanalyzer, including traces ofcarbon, phosphorous and

sulfur. The installation of this instrument gave us the confidence that we can supply castings to spec and withcomplete traceability" said Vincent.

Materials and castingsKnights Foundry has up until now concentrated mainly

on high chrome and low carbon steel castings for the wearpart and spares sector but increased requests has seen

The new 25 ton sand silo A new CO2 unit has also been installed

has seen a significant increase on the low carbon steelalloys and stainless steels side. This now accounts fornearly 40 % of the mix.

The castings mix has branched out into impellers, pumpcasings, mill liners, expellers and other general engineeringcastings. The company has not dabbled in manganese castings yet but if requested by clients will cast non ferrouscastings.

Castings range from 1 kilogram up to 920 kilogramsand are supplied to OEMS and other manufacturers thatare assembling. Machining of the castings is also offeredbut this is shopped out at this stage.

From 10 ton a month net weight in castings KnightsFoundry is now casting in the region of 180 ton a monthnet weight in castings. This is a significant increase in tonnage and quite remarkable considering the economicclimate over the last two years.

"The customers that we deal with have started to showgrowth in the last year but our customer base has alsoincreased. This is why we have increased our order intakeby 80 % during the recession" said Vincent very proudly.

"We do not supply to an end user but we know that ourcastings are exported in some way or other. The impellersthat we cast we know are used on one of the biggest copper mines in Zambia, for example."

Patternshop and patternmakingDad Johann has been working with his hands and wood

all his life and when you visit the pattern shop you can seethe expertise and experience oozing from the man. It is toolate for Johann to convert to CNC but in this case it is notnecessary. Johann is a craftsman and is very proud of thefact. The patterns he has made in his life time are toonumerous to count but the attention to detail that he takesover every new pattern is evident.

Brother-in-law Louis MillerThe tremendous growth in the company has also seen

the required storage space for the number of increasedpatterns that the company holds, escalate. Today the company has in the region of 1 200 patterns on theirbooks and brother-in-law Louis Miller has become the master of this department.

"When I joined the company just less than 18 monthsago there were patterns all over the place. The time it wastaking to locate a pattern was horrendous. My backgroundis logistics and materials handling and I was tasked to sortthis department out. As you can now see every single pattern is catalogued, bin allocated and stored in multistory racks. Everything is computerized and it now takesless than a minute to find a pattern" explained Louis.


Castings in the heat treatment bay Castings in the dedicated 450 m² fettling and finishing facility

“The customers that we deal with have started to show growthin the last year but our customer base has also increased. This is why we have

increased our order intake by 80 % during the recession.”

"Another advantage is that an area that used to houseour 1 200 patterns has been reduced to the extent that wenow have room for another 1 200 patterns."

But Louis is not limited to just looking after the patternstorage area. Just like his brother-in-laws Vincent andCobus he has had to get his hands dirty and work in theother areas in the foundry. At this stage the pouring of thestainless steel castings is handled by one of the three. Thisputs a tremendous burden on them especially when theyare working a double shift five days a week and half dayson the weekend.

"It means that one of us has to around all the time butwe prefer it this way because we can control the quality."

Belinda MillerBelinda (sister of Vincent and Cobus and wife of Louis)

has been with the company since 2003 once she completed a three year Diploma in Business Administrationat Technikon Pretoria. Belinda implemented a fully computerised Pastel accounting system which enabled thecompany to build a data history on the customer base. The system has also allowed the company to take thetraceability further and all products are now labeled withcommodity code, weight and a description. Future production planning has been made easier and it also facilitated Louis to work out a system for the storage ofcustomer patterns.

A pour taking place

Knight Sales have purchased a number of stacking framesor stillages. This allows faster and smoother handling of mouldsor castings while cooling. The stillages can be stacked four high,allowing better space utilisation and are easily moved around

by a forklift. Casting into the moulds while on the stillagecan also take place

All patterns have been catalogued on the computer,binned and stored. The company has halved the amount

of storage space taken up by the patterns since theyemployed this system



Future expansionNot happy to sit still for long the family

has seen the potential to increase theirshare of the stainless steel market andcurrently a dedicated 1 400m² foundry isbeing constructed alongside their existingfacility.

"We are looking to cast about 45 tons a month of stainless steel castingsbut we realized that we had to separatethis side of the foundry business from therest. When the new foundry starts producing next year in March we will then be able to increase our high chrome and carbon steels side" explained Cobus.

"Fortunately the electricity supply is in place on site. Once the structure isfinished all we have to do is install the twohalf ton furnaces and another no-bakemoulding system. We will also be purchasing another shot blasting machine"continued Cobus.

Family businessThe family involvement in Knights

Foundry does not stop with Johann, Vincent, Cobus, Louis and Belinda. Johann's wife Letitia has been involved with the admin side of EJ van der Walt

Pattermakers from the beginning..The company currently has 58 staff.For further details contact Knights Foundry on

TEL: 011 827 2517

"We would never have taken this leap into the expansion project if we did not invest in the fifth generation, the SPECTROMAXx benchtop unit."

MSP Trading is headed up by Ray Primrose who hasbeen in the foundry and patternmaking businessmost of his life, both on the manufacturing and

supply side.John Winter & Co Ltd has been supplying foundry

consumables for over 50 years, with the original businessbased on the sand binder at that time of core oils. Sincethen, changes in foundry manufacturing techniques hasbrought about changes to the products now required inmodern foundry processes, giving rise to a very large rangeof foundry consumables. Sand binders are still the basisfor the business, whether resins, sodium silicates, greensand and even the original oil sand products as used 50 years ago and are still used in specific applications.

In recent times, the development of new products suchas core and greensand additives, have allowed the business to expand into some of the largest global foundrysectors. John Winter & Co Ltd is also constantly developingnew products for changes in processes and current issuesof environmental legislation.

With its Head Office and manufacturing facility locatedon the original site in Washer Lane in Halifax, WestYorkshire the core business of John Winter & Co Ltd is concerned with supplying foundries with their consumableand material requirements.

In early 2000 the company established a network of agents and distribution channels to service the Asia Pacific and North American foundrymarkets and this has seen rapid growth as the

decade has progressed. In 2006 the company added pattern shop requisites to

their range of specialist products targeting foundries andmodel makers as the customer base.

As a show of the commitment to service and maintenance of quality levels the company formalised itsexisting quality system in 1991 and now operate the

Lloyds Register Quality Assurance to meet ISO 9001:2008 throughout the

company.MSP Trading (Pty) Ltd started

trading in October 2010 as a supplycompany to the foundry and patternmaking industries, supplyingboth international and locally madeproducts.

"I started off my career in the industry as a patternmaker with O Conolly & Co in Bulawayo, Zimbabwebefore moving to South Africa in 1973. I held various positions with differentfoundries, including Vecor, Chamdor Iron & Brass, Xmeco and Salcastbefore joining what was then known asGenkem and ended up as the nationalexport manager and sales manager for theresin division" explained Ray Primrose.

UK based foundry consumable manufacturer and distributorJohn Winter & Co. Ltd. has recently appointed MSP Trading as their sales agent

for the Southern African region.

John Winter & Co. Ltd.appoints MSP Trading as

their sales agent

Ray Primrose



"I was with them for 15 years before the company was taken over by Zeta Chemicals. I then spent six years in my own business manufacturing table tops and tombstones before I decided to get backinto the foundry industry" continued Ray.

"After working for acouple of foundry suppliers I got theopportunity to open upMSP Trading, which isan acronym for Metal,Sand & Powder Trading.

"With my 43 yearsof experience I am ableto carry out comprehensive trialsand provide full writtenreports along with technical assistancewhere required.

"The company hasaccess to and will beable to supply sandbinders, core oils,sands, sand additives,release agents, adhesives, core putty & moldseel,& filters, refractoryproducts, melt treatproducts for aluminium, copperbased and ferrousalloys, hot topping compounds, die coatings and primary/secondary aluminium smelting.

"Now that I am onmy own and my company is the agreed supplier inSouthern Africa to John Winter & Co. Ltd I can dedicate my timeand give John Winter & Co. Ltdproducts my full attention and offerthe industry qualityproducts with committedbackup and service."

For further details

contact Ray Primrose on TEL: 011 425 1153, Cell 074 104 6766 or email [email protected]

As a show of the commitment to service and maintenanceof quality levels the company formalised its existing quality system in 1991

and now operate the Lloyds Register Quality Assuranceto meet ISO 9001:2008 throughout the company

Adrie El Mohamadi has been appointed the new projectleader of the National Foundry Technology Network (NFTN),as from the beginning of November 2010. Adrie takes over

from Letlotlo Phohole.Adrie has been involved in the development space for more

than 15 years, of which close to 10 has been with GTZ. Her professional background is in Management especially in areas ofInnovation Systems and Technology Transfer. Her employmenthistory with GTZ South Africa stretches from 2001, working fordifferent projects. In June 2006, she joined the Employment andSkills Development Service Programme (ESDS), as the TechnicalCoordinator for the Technology Station Programme (TSP).

The major support to Tshumisano (which has now been integrated into the Technology Innovation Agency (TIA)) and itsTechnology Stations was the facilitator of organisational andinstitutional development, skills development, technology transfer, innovation systems and capacity building. Adrie hasbeen responsible for coordinating the Rapid Appraisal of LocalInnovation Systems (RALIS) within six different sectors of theSouth African economy and is also coordinating the Career Path Framework for the foundry industry (which was an

outcome of the foundry RALIS in February 2008). She has sat ona number of Advisory Boards of Technology Stations situated atvarious Universities of Technology.

"I saw the position at NFTN as an opportunity and challengeto concentrate on only one sector. I have been closely involvedwith the foundry industry since 2008. I believe that understanding the innovative capacity of a sector does notdepend (only) on the use of certain technologies, managementprocesses or the performance capability of research institutions.Importantly it also depends on collaboration between actors ofthe private sector, the state, educational and research institutions as well as linkages with international innovation networks" said Adrie.

"I believe that my track record of successfully coordinatingmulti stakeholder projects on both national and internationallevel in various sectors of the South African economy will enableme to contribute to moving the foundry industry into a differentglobal competitive field. My ability to not only to think strategically but also drive a process to implementation is one ofmy strengths, which I believe could be what is needed to ensurethat current policy and strategy framework and existing activities


Adrie takes over theproject leader position at the NFTN

from various role-players within the sector be connected."

"Taking the above into account I would like to concentrate on the following:

1. Coordinate a process that will put the foundry sector as a whole (one sector plan) on the radar of government and other stakeholders.

2. Explore ways of making thefoundry industry more globally competitive.

3. Assist to improve the communication channels on support,standards and tools available for theindustry.

4. Assist to increase the absorptionof new, relevant technologies and lastly

5. Continued and intensified support in up-skilling the industry workforce on all levels."

We wish Adrie all the best in thenew position.

For further details contact Adrie at the National Foundry Technology Network: Email: [email protected],TEL: 082 902 4083 (Mobile) and 012 841 2127 (Office)


The following courses will be offeredby the SAIF for 2011. As the year progresses

more courses will be announced.

SAIF training courses for 2011

Moulding: Commencing on the22nd January 2011 through tothe 5th March 2011.

Melting, metallurgy, coresand coremaking courses arealso scheduled to take place inthe first quarter next year,followed by a fettling course.There is also a course on GravityDie Casting scheduled for February2011.

The SAIF are busy preparing tocommence with training courses inthe KwaZulu Natal area. These are scheduled to take place in the firstquarter of 2011.

The WCIF Foundry OperatorsCourse will be available in 2011 for

presentation on an in-house basis atfoundries.

SAIF foundry visits in GermanyThe SAIF is negotiating with the

German Foundry Association to visitfoundries in the area during your stayat GIFA/NEWCAST. The scheduling of aone day tour, which will include transport, will depend on the numbersand will be done on a first come firstserved basis.

If you are interested in taking part in the training courses or going on the one day tour pleasecontact John Davies on Tel: 011 559 6455 or 083 630 2809 (Mobile).


By now, the forges at the Cleveland Casting Plant willhave gone cold. The demand for cast iron engines is nearly over. The Ford plant that once employed more than 10,000

people will shed its final 300 workers. "We took raw materials, we took scrap iron and sand,

and made it into something," said Danny Wade, a plantworker and a committeeman for United Auto Workers Local1250. "We're losing that. It's a sad thing."

There's still a future for Ford's complex in Brook Parkwith more work and jobs rushing in to one of the twoengine plants next to the casting plant. But the closing ofthe iron foundry after 58 years marks the end of an eraand the end of a way of life for many workers.

Satan's bakeryThe casting plant was a miserable place to work -- hot

and dirty, it was a place where mistakes got people killed. "You didn't distinguish between the old and the young.

It was like a big family," plant worker Curtis Brown said."You had to look out for each other. You have molten hotiron coming at you, you have to depend on each other."

David Day worked at the casting plant from 1976 until1983 while going to Baldwin-Wallace College and later theUniversity of Akron. Day, now a psychology professor inCrawley, Australia, said it's hard to overstate how miserableit was to come to work on a hot day.

"In the summer months it was absolutely brutal," hesaid in an e-mail from the University of Western Australia."Some wise guy got to wearing a thermometer around hisneck and would point gleefully as the temps rose above110, 115 and higher."

Day said Ben Hamper, a retired autoworker, came upwith the best description of a foundry he's ever seen in hisbook "Rivethead," calling a similar plant "Satan's private little bakery."

Early days at Brook ParkIn the 1950s, Ford was struggling to meet demand for

cars and pickups. It had built an engine plant in Brook Parka few years earlier and needed to continue expanding itscapabilities. Ford decided to build a modern foundry tomake engine blocks for the engine plant.

The concept was simple: forge the engine blocks at thecasting plant, then truck them over to Cleveland EnginePlant No. 1 for assembly into 215-cubic-inch (3.5-liter)inline six-cylinder engines. Putting casting and engineassembly on the same site saved money by avoiding having

to pack the engines up for shipment across the country. A year after the casting plant opened, Ford started

building Cleveland Engine Plant No. 2 on the south side ofthe property. In 1957, it opened an engine plant in Lima,Ohio, and it expanded the casting plant to send engineblocks there as well.

For more than 40 years, engine blocks went straightfrom the casting plant to the adjacent facilities. But technology started to change. In 1994, ClevelandEngine Plant No. 2 started assembling engines with aluminium blocks sent down from a Ford plant in Canada.

Ford later converted the other engine plant to aluminium blocks. Instead of sending its castings nextdoor, the casting plant started sending cast-iron engineblocks up to plants in Michigan. The transportation costsavings disappeared, and all three plants suffered fromoccasional shutdowns as demand rose and fell.

Mike Gammella, president of UAW Local 1250, saidworkers had been worried for years that Ford would retirethe cast-iron engine blocks used in its trucks and biggervehicles in favour of aluminium ones.

Trouble starts In 2007, Ford announced it would close the casting

plant, saying it could get what few iron engine blocks itneeds from suppliers. "We've done everything we can to getthem to reconsider" closing the plant, Gammella said.

The union offered work-rule concessions meant to lowercosts at the plant, tested new technologies that would havelet Ford make diesel truck engine blocks at the plant andmet with executives to try to figure out what the companyneeded.

But union leaders couldn't overcome the fact that Fordsimply isn't using iron in most of its vehicles. The companyhas repeatedly said it decided that making engine blockswas not a core technology, making it something it couldhappily outsource to suppliers.

Recently, Mexico-based automotive supplier CifunsaDiesel announced it had won a Ford contract to make theV-8 diesel blocks that had been produced in Brook Park.Cifunsa already makes the V-8 engine block that Ford usesin its commercial trucks.

After years of using cast-iron engines for most of itsmodels only the Avon Lake-built E-Series van, commercialtrucks and Ford's Expedition sport utility vehicle and itsLincoln Navigator corporate twin will have them in 2011model years. A very small number of special-edition F-150 pickups will also offer a cast-iron V-8. Most F-150

international news

For nearly six decades, thousands of workers in Brook Park, Ohio toiled through intense heat to turn sand and iron into engines that powered Ford cars and trucks.

Written by Robert Schoenberger, The Plain Dealer

Ford foundry in Brook Parkto close after 58 years of service


pickups and all Mustang muscle cars, will use aluminium. Spokesman Richard Truett said aluminium engines

allow Ford to cut weight from big vehicles without sacrificing power. Weight cuts translate into fuel economygains.

"It's taken a lot oftime, trial and error tomake an aluminium blockthat's as durable as aniron block," Truett said."We're finally there."

That trend has beengood for Engine Plant No.1 in Brook Park. It's making the V-6 enginesused in the Mustang andF-150, and that plantexpects to add a shift thisyear. Many workers will gostraight from the castingplant into training forwork at the engine plant.

Still, the loss of thecasting plant will benoticed.

When Ford's employment in Brook Parkhit 15,000 in the 1960s,about 10,000 of thoseworkers were in the casting plant. As recentlyas 2004, more than4,000 people worked atthe Brook Park plants. ByJanuary, Gammellaexpects that number tobe 1,100.

Curtis Brown expectsto be one of those people,working at an engineplant instead of packingsand for castings. He hasabout five more years toput in before he canretire.

He's looking forwardto cooler, more comfortable conditions,but Brown said he'll missthe togetherness thatcame from working in theharsh heat of the foundry.

Between the safetygoggles, soot in the airand the heat, Brown saidyou often couldn't tellwho was working next toyou, but you always trusted him.

"It's different. You can

see the other person," Brown said. In the engine plants,workers "gravitate to different little groups. But in thefoundry, it was a family. We stuck together. We were united."

There's still a future for Ford's complex in Brook Park with more work and jobsrushing in to one of the two engine plants next to the casting plant.

But the closing of the iron foundry after 58 years marks the end of an eraand the end of a way of life for many workers

The new car is based on ground-breaking new technology, according to senior Mercedessources.

Many in the industry had expected the line-up of newsmall Mercedes to be a family of conventional, Golf-classroad cars. However, the head of development for the A andB-class and Smart families, Jorg Prigl, says the new MFAMercedes Front-drive Architecture platform is so radicalthat it will be the subject of a patent.

"We will start with the B-class and the MFA platform willcontain an IP [Intellectual Property] solution that will allowus to produce both a direct, high-roof, high seating positionreplacement for the B-class as well as a new range in theAudi A3 class," Prigl told Autocar at the recent Paris motorshow.

The structural innovation was apparently cooked up bythe heads of 'body in white design and safety' at Mercedes."The MFA also gives us the package room to fit a batterypack, fuel cell stack, hydrogen tanks and CNG tanks," saidPrigl. "It will allow us to build an internal combustion or

electrically driven vehicle, as well as a number of body styles." Some Mercedes insiders say the MFA patent could be

revealed on 29 January next year, exactly 125 years afterKarl Benz was awarded a patent for his Motorwagen, whichwas described as an "automobile fuelled by gas". Theupshot is that the MFA patent is likely to centre around anautomobile that can be "powered by petrol, diesel, naturalgas, hydrogen and electricity."

Mercedes is also poised to bill the new A-class and B-class family as "the first car of the next chapter" in thehistory of the automobile.

Gorden Wagener, global automotive design chief forDaimler, said the new B-class is aimed at "loyal clients"who want the high driving position. "The A-class is completely different, a revolution, a benchmark in compactcars. It really defines the Mercedes brand," he said.

A number of other body styles will emerge from the MFAproject, including a small saloon previewed by the F800concept. Most of the MFA models will be built at a newMercedes factory situated in Hungary.

Mercedes small car revolutionMercedes is to shake up the premium small car segment next year

when it launches an all-new B-class.


Metallurgy and castings are not something new forthe Turkish foundrymen. The very first metal wassmelted in Anatolia nearly 9000 years ago to make

raw copper beads, later to alloy it with arsenic, tin or zincto produce warfare, household or personalgoods. This later progressed into the makingof the first wrought iron.

This heritage was lateron passed over to thefuture citizens of theselands, namely Romans,Byzantians, Selcukians andthe Ottomans.

Starting from the1950's, private capital was invested in foundries establishing modern facilities enabling the Turkish foundryindustry to compete worldwide today.

Towards the end of the last century, Turkey became amajor supplier of foundry products for Europe.

With a population of 71,500,000 and GNP at PPP terms(569 billion US $ in 2005) Turkey ranks at number 19 in

the world scala and number5 in Europe for GNP at PPP terms.

As for the Turkishfoundry industry, eventhough there is a long andpowerful history in thebackground, the growth wasslow until the 1990's, butfrom there on, the growthwas in double digits.

Major growth areas arein the ductile iron and aluminium castings, all triggered bythe automotive, farm tractor and earth moving equipmentmanufacturing growth both domestic and in Europe.

The Turkishfoundry industry


The Turkish foundry industry,even though there is a long

and powerful history in the background,showed slow growth until the 1990's,

but from there on,the growth was in double digits


In September 2010 exports of passenger cars fromGerman OEMs rose once again. In comparison to thesame month last year they were up by more than

5 per cent, which means that since the beginning of thisyear over 3.1 million cars have been supplied to foreigncustomers.

Incoming orders from abroad have expanded by 6 per cent, so their growth is somewhat slower than at the beginning of the year. Matthias Wissmann, President of the German Association of the AutomotiveIndustry (VDA) stressed, "Since August 2009 the German manufacturers have again recorded growth on theforeign markets. The figure is already settling down at ahigh level."

On the recovering US market, the German carmakerspushed up their September sales by 18 per cent. Year-to-date sales of light vehicles bearing a German badgein the USA already come to nearly 650,000. This corresponds to an increase of 15 per cent, while the

market as a whole expanded by 10 per cent over the sameperiod.

The domestic market has recorded 260,000 new registrations and is therefore, as expected, 18 per centbelow the previous year's figure. Wissmann said, "We already achieved a turnaround in orders from ourdomestic customers in September; orders from Germanyhave risen by over 10 per cent. By the end of the year wewill also be seeing climbing registration figures on ourhome market again."

Production at plants in Germany fell slightly inSeptember. Nearly 535,000 passenger cars rolled off theassembly lines, yet production shows a clear year-to-daterise of 14 per cent (to 4.1 million). Wissmann underscored, "This means that the production figures fromthe first three quarters are now only 5 per cent below therecord set in 2008. The German passenger car industryhas returned to pre-crisis levels much faster than expected."

Germany - Car exportsremain buoyant

Foundrymen have often regarded coal and carbonaceous additives to greensand systems for the production of iron castings as a "necessary

evil". It is perfectly possible to produce castings with littleor no carbonaceous products but experience has shownthis is limited to the smaller casting weights and such systems are generally characterised by poorer surface finish and lack of casting definition.

Fundamentally a greensand system is silicasand, bentonite and water. To improve the surface finish,improve casting dimensionalstability and to have less sand carryover and cleanercastings at knockout, carbonaceous additives areused to good effect. Surface defects, gas relatedproblems often associatedwith a poor choice of carbonaceous additive, normally results in reducingor removing this carbon additive as the "lesser of two evils" and to spend moretime at shot blast to clean the castings.

Looking across the foundry industry, coal is still widelyused and is the most cost effective carbonaceous additiveand even many "so called" coal substitutes or replacementscontain a large percentage of coal. Coal has not only stoodthe test of time but its set of unique properties actuallymakes it ideal for iron casting production in greensand systems. It is accepted theory that coal not only provides a lustrous carbon barrier to metal penetration but its ability to produce coke helps create a filler

between sand voids, resulting in good surface finish, with excellent knockout conditions.

With the correct choice of coal, the combination of lowash, high volatile and swell index properties coupled withthe key element of grading size, ensures castings are produced free from metal penetration and surface relatedproblems.

Coal, like bentonite has two moistures, which need consideration. Surface moisture and chemically combined moisture (inherent),which need to be treated withgreat respect in storage and processing. This particularproperty has often given coala "bad press" and firescaused by spontaneous combustion have in the pastled many foundrymen to seekalternatives.

By careful selection, safe handling and processing coal continues tooffer a good simple cost effective solution. Coal is subject to regulationsin storage, processing and

transportation and then further subjected to safe handlingand use by the foundry. Despite these handicaps, it is stilleconomical to the end user and modern processing andgrading methods ensure it is used in the optimum condition.

This is an extract from a paper given by AlexanderBrown, Product Manager (Coal/Bentonite),James Durrans & Sons Ltd. If you would like a copy of the fill transcript please contact Peter Bird of Durrans RMS on TEL: 011 917 0702

Graded coalIts role in iron casting production from greensand systems


product review

ABB's newest robot - the IRB 6640

The IRB 6640 is ABB's newest robot for heavy liftingneeds. It was built to replace its forerunner, the IRB 6600 robot. With six axes of motion, a protection

rating of IP67, and a maximum payload of 235kg, it isready to tackle the tough challenges. Its strong design isideal for material handling, machine tending, or spot welding applications.

The standard IRB 6640 version has a 2.55m horizontalreach. It is a floor mount model with the ability to bendbehind itself for extra accessibility.

Maintenance Ease:ABB created the IRB 6640 to be simple to move and

maintain. The robot foot is slightly larger and forklift pockets allows for easy relocation. The robot is 400kglower than the IRB 6600 model.

Diversity:The IRB 6640 is available in multiple variations.

Highly versatile, this model can transform for foundry or clean room settings. A variety of payload and reach differences allow companies to closely fit their application. These versions range from 130kg, 180kg,185kg, and 205kg. Two internal dressing models

are available: the IRB ABB 6640ID-200 and 6640ID-170.

For further details contact Johan Helberg of ABB South Africa on TEL: 082 773 2029

Oxford InstrumentsFOUNDRY-MASTER-PRO stationary

CCD-array vacuum OES analyzer

The FOUNDRY-MASTER-PRO is thefirst class laboratory optical emission spectrometer for complete

metal analysis. Engineered for high performance and

reliability, the new FOUNDRY-MASTER-PROwith its innovative optical system andextended wavelength range assures precise identification and trace analysisof important elements, such as N in steeland P in aluminium.

Proprietary detector and read-outtechnology, developed specifically forspectroscopy applications, out performconventional photomultiplier tube basedsystems.

The wavelength range is 130nm - 800 nm covering all elements,precise analysis including grade determination, uncompromising analysis

with high long-term stability and lowestlimits of detection.

Additional features include a unique spark stand; proven jet-streamtechnology and a superior plasma oscillator ensure straight forward andprecise analysis. Sample geometries,from large semi-finished products to tinywires present few challenges. Ease of use and simplicity differentiatethe FOUNDRY-MASTER-PRO.

The intuitive user interface andnumerous customer-driven features conspire to make life simple. Compact,robust and reliable, the high-precisionFOUNDRY-MASTER-PRO can be used inany location.

For further details contact Horst Klever of Rand Analytics cc on TEL: 011 678 1654

The ABB-robot IRB 6640 is applied to assemble different typesof modules in robotised assembly cell at ABB's Pudong roboticsfactory, Shanghai. This is the perfect robot for high production

capacity applications in environments from foundries to clean rooms



MAGMA5 continues the series of MAGMASOFT®

solutions used by foundries world-wide in order tooptimize their cast component production. The

software is based on more than 20 years of development,during which the Aachen based company has continued toinnovate on and establish casting process simulation as astandard.

"First understand, then optimize", following this standard,MAGMA5 delivers a profound understanding of castingprocesses that allows optimization along the completeprocess chain of the cast component. Within the software,this is made possible through different perspectives whichcan be used simultaneously by the user.

Integrated information and tools for simulation projectsIn MAGMA5, all steps that are necessary for casting

process simulation can be specified and performed from aprocess perspective. This allows the complete productionprocess from geometry input, through the design of gating,risering and tooling, on to solidification and finishing processessuch as heat treatment, to be described and simulated.

In the process perspective, all information about the used materials, metallurgy and melting practice, production conditions and finishing processes such as heat treatmentcome together. This allows the user to get a completeoverview of the entire manufacturing process he wants tosimulate.

Altogether, the process orientation of MAGMA5 sets the basis for a profitable manufacture of cast components - through improved casting layouts, achieving the requiredcasting quality, and saving costs.

New simulation capabilitiesMAGMA5 provides important new casting process

simulation capabilities. New advanced turbulence models aswell as the consideration of surface tension improve the moldfilling prediction for gravity castings. And, tracer particles canbe modeled with mass and size to evaluate slag inclusions.Burn-on and penetration criteria help identify sand relatedsurface defects. Moreover, a new module for the simulationof as-cast local microstructures and properties of aluminiumalloys is available with MAGMAnonferrous. The stress moduleMAGMAstress has also been completely reworked and for thefirst time offers the option to simulate thermally inducedcasting stresses for the complete manufacturing route. A newand comprehensive plasticity model provides improved accuracy, because it considers temperature-dependent aswell as time-dependent effects on stresses and strains.

Clearly presented resultsSimulation results such as 3D graphics, diagrams, and

tables can be shown in multiple views and can be displayedin selectable levels of detail. This means that results can beevaluated reliably in order to allow an optimization of cast

components and casting processes.

New software architecture securesfuture developments

The new methodology thatMAGMA5 provides is mirrored in thesoftware architecture. Technically, thesoftware is built on a completely newplatform and, as it is also modularlyextendable and scalable, it offersdevelopment potential for the comingyears. Due to standard interfaces thatallow the free import and export ofdata, MAGMA5 can be completely integrated into the user's work environment.

With MAGMA5, new hardware andoperating systems offer new opportunities. MAGMA5 is fully nativeWindows compliant and runs on 64-bitWindows operating systems, offering

MAGMA5,the new generation of castingprocess simulation software

MAGMA GmbH introduces MAGMA5, a new generationof casting process simulation.

the advantage of greatly increased memory access. For Linuxusers, MAGMA5 is available for the current SUSE and RedHatLinux Enterprise distributions. MAGMA5 supports multi-corearchitectures effectively. The combination of MAGMA5 andthe latest hardware (Core i7/Neharlem CPU) results in areduction of simulation times by up to a factor of 5.

With the currently released MAGMA5 Version 5.0 all important sand casting processes are supported. The simulationof permanent mold and die casting processes including gravity die casting is available with MAGMA5 Version 5.1.

MAGMA5 in a compact overview:• Comprehensive project management• Solid modeling with a CAD kernel as well as import

and export of CAD data (STL, STEP, CATIA, Pro/E)• Automatic mesh generation of the geometry within

seconds• Comprehensive process description with direct access

to all process steps and the related simulation definitions• Completely new capabilities for the prediction of: mold

filling, burn-on and penetration, local microstructures andproperties of aluminium alloys, thermal stresses of the castcomponent for all production steps

• Interactive and automatic result evaluation• Comprehensive database for all required data and

properties of casting processes and materials • Available for 64-Bit Windows XP, 64-Bit Windows 7,

64-Bit RedHat Enterprise Linux 5, 64-Bit SUSE LinuxEnterprise 11

About software for casting process simulationCasting process simulation software predicts the

complete casting process including mold filling, solidification and cooling, and allows the quantitative prediction of mechanical properties, thermally induced casting stresses and distortion of cast components.Simulation accurately describes a cast component's quality up-front before production starts and the casting methoding can be designed with respect to therequired component properties. This not only results in a reduction in pre-production sampling as the precise layout of the complete casting system leads to energy, material, and tooling savings.

The range of application of MAGMA solutions comprisesall cast alloys, from cast iron to aluminium sand casting, permanent mold and die casting up to large steel castings.The software supports the user in the modeling of the component, the determination of melting practice and casting methoding through to mold making, heat treatment,and finishing. This saves costs consequently along the entiremanufacturing route.

During the last 10 years, the use of casting process simulation has become obligatory for many foundries.MAGMA5 now expands the capabilities of casting processsimulation. This will further accelerate the acceptance of thesoftware.

For more information contact Andrew Mc Farlane, AMETEX (Pty) Ltd TEL: 011 914 2540 or email: [email protected]


Nikon Metrology hasreleased its ShuttlePix P-400R Digital Microscope,

made for inspection, observation,simple measurement and recording of high-resolutionimages. For on-site analysis ofsamples, it serves as a handheld microscope that shoots high-resolution images as quickly and easily as taking pictures with a digital camera.For stationary use, the ShuttlePixmicroscope interfaces seamlesslywith a motorized stand. With the equipped 17-inch touchscreen monitor, the user can easily control, display,measure or print images. The microscope also connects to astandard PC or laptop running dedicated 3D image reconstruction software.

The ShuttlePix addresses the market need for an easy-to-use device that magnifies samples and can recordand save images as digital files. Nikon combined its technological excellence in optical technology with its expertise in digital image processing technology to enablethe creation of the ShuttlePix.

The motorized stand isequipped with a motorized Z,which does not require a PC forcontrol. Operation of the stand is

simple, allowing extended depth offocus (EDF) imagecapture with thetouch of a button.

ShuttlePixoffers a 20x zoomwith a magnificationrange of 20x- 400x on a17-inch monitor,which is doublethat of competitors'

models. For optimal lighting, thezoom head has built-in 4 sectionLED ring illumination.

Benefits:1.Shuttle styleThe ShuttlePix P-400R allows

the removal from the MotorizedFocusing Stand Controller providing the possibility to capture images under different

conditions with cordless operation. By adapting theShuttlePix P-400R on to the Motorized Focusing StandController and in combination with the 17" touch panel monitor, image capturing can be easily completed.

2. Easy operationThe ShuttlePix P-400R allows for simple operation, just

like a compact digital camera. For this reason, even withoutexperience or knowledge on how to use a microscope, the

observer can easily capture fineimages of the sample.

3. 20x Optical zoom coveringfrom low to high magnification.

An LED illuminator is integrated with the ShuttlePix P-400R in a compact body with20x optical zoom lens. It iscapable of observing a widerange of magnifications between20x-400x (*) without the needto change a lens.

4. Observation of all-in-focus image, 3D image

By attaching the ShuttlePix P-400R on to the MotorizedFocusing Stand Controller, all-in-focus images can be createdeasily using the control buttons. Then, by using a dedicatedApplication Software, the creation of reports and 3D imageobservation, measurement is possible.

* Magnification on dedicated 17" Monitor: Source: www.automation.com

For more information, contact your nearest IMP branch,Gauteng: 011 916 5000, Kwazulu Natal: 031 764 2821, Western Cape: 021 852 6133, Eastern Cape: 041 364 0159, Free State: 018 293 3333 or Email: [email protected];Website: www.imp.co.za


Nikon releasesShuttlePix P-400RDigital Microscope

castings cover 11.4 dec 10 - foundry-planet ltd. › fileadmin › redakteur › ... · the abp...

Documents