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Conference Programme

World Cast in Africa – Innovate for Sustainability

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South AfricanInstitute of Foundrymen




Monday – 13 March 2017Time Topic09:00 – 17:00 Exhibition Build-up 09:00 – 17:00 Registration of BRICS and WFO international delegates BRICS Site Visits 15:00 – 17:00 WFO Executive Meeting19:00 BRICS and WFO Informal Dinner

PresentationsAll presentations will be made available for download from the Metal Casting Conference website.

http://www.metalcastingconference.co.za/

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Tuesday – 14 March 201708:00 – 17:00 Exhibition Build-up 08:00 – 09:00 Registration of BRICS and WFO international delegates (late arrivals)09:00 – 16:00 7th BRICS Foundry Forum: Human Capital Development for the foundry industry10:00 – 12:30 WFO General Assembly 12:30 – 14:00 Lunch14:00 – 16:00 BRICS/WFO Workshop on Human Capital Development 19:00 7th BRICS Foundry Forum & WFO Dinner: Sponsored by Silver Sponsor (Foseco)

Wednesday – 15 March 2017Markets, Strategy and Leaders for the future07:00 – 08:30 Registration08:30 Official Opening of Exhibition & Conference: Partners (SAIF, UJ MCTS, NFTN, WFO)09:00 Government//Policy//South Africa: Setting the Scene09:20 A new movement in the foundry industry: Professor Myungho Kim, President, World Foundry

Organization10:00 NFTN Presentation (Topic to be confirmed): Mr Ashley Bhugwandin, Manager, Technology

Localisation, CSIR10:20 Refreshments in exhibition venueSession 1: Plenary10:45 The Impact of the Foundry Industry on Manufacturing in South Africa: Henk Langenhoven, Chief

Economist, Steel and Engineering Industries Federation of Southern Africa (SEIFSA)11:15 Leadership for Innovation: Dr Willie Visser, Director of the Centre for Positive People @ Work at

USB-ED (University of Stellenbosch Business School – Executive Development)11:45 Aluminium Casting Supply to the Automotive Sector: Mark Krieg, Executive Director, Aluminium

Federation of South Africa (AFSA)12:15 Recent Zinc Casting Alloy Developments: Technology and Markets: Dr Frank Goodwin, Director of

Technology and Market Development, International Zinc Association12:45 Lunch in exhibition venueSession 2: Plenary 14:00 The present situation and the development trends of the worldwide foundry industry: Prof Gotthard

Wolf, Institute Director, Gießerei-Institut, der TU Bergakademie, Freiberg14:30 The 5-year strategic plan for China’s foundry industry: Speaker to be confirmed15:00 From fabricated to casting: Per Rolf Roland, Owner, P R Roland Foundry Consultant AS, Norway15:30 Refreshments in exhibition venueSession 3: Plenary 16:00 Design and implementation of a strategy to modernise a jobbing foundry: Clayton

Anderson, Chief Executive Officer, Thomas Foundry16:30 Indian Foundry Industry: Clusters – The way forward: Speaker to be confirmed17:00 Environmental Management – A driver for business growth and efficiency, Phil Rawnson

FICME, Managing Director, MRT Castings Ltd



Thursday – 16 March 2017Technology and Processes07:00 Registration (Day delegates)Session 4: Plenary 08:00 Metallurgical aspects of the production of High Chromium Irons: Professor Adel Nofal, Professor of

Foundry Technology, CMRDI, Egypt08:45 Energy savings, safety for operators and the digital foundry world, (Industry 4.0) – State-of-the-

art induction furnace technology: Hermann-Josef Kroes, Director of Global Sales, New Systems, Foundries, ABP Induction Systems GmbH

09:15 Eco Form a concept for hand moulded no bake castings: Dipl.-Ing. Jens Mueller-Spaeth, Managing Director, G U T

09:45 Chances and limits of High silicon ductile iron: Dr.-Ing. Claudia Dommaschk, Foundry Department, TU Bergakademie Freiberg, Germany

10:15 Refreshments in exhibition venue

Parallel Sessions: Thursday – 16 March 2017Session 5: Parallel Session 6: Parallel Session 7 : Parallel

10:45 Cast iron inoculation enhancing by oxy - sulphides forming elements contribution: Prof Iulian Riposan, Professor Materials Science and Engineering, POLITEHNICA University of Bucharest /Romanian Foundry Technical Association

Technical Requirements for Profitability in Die Casting: Dr Ioannis Ioannidis, President and CEO, Oskar Frech GmbH

Machinability of Austempered Ductile Iron (ADI) as related to microstructure and strain hardening behaviour: Mostafa Ahmed Othman, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt

11:15 Application of immersion colour etching to austempered ductile iron (ADI) microstructure and their correlation with modern techniques of imaging the scanning electron microscopy: Łukasz Boroń, Laboratory of Structure Analysis and Mechalnical Testing, Foundry Research Institute, Cracow, Poland

Study on Metal-Die Interface Heat Transfer in Squeeze Casting Process: Dr Zhiqiang Han, Key Laboratory for Advanced Materials Processing Technology (MOE), China

The effect of heat treatment on the mechanical properties and machinability of AAR Grade E Steel: Abdul Esakjee Business and Product Development, Transnet Engineering, South Africa

17:30 Close18:30 Welcome Function: Galleria: Sponsored by Platinum sponsor



11:45 Macrosegregation simulation analyis for a large rotor steel casting: Dr Nawaz Mahomed, Associate Professor: Mechanics Department of Mechanical and Mechatronic Engineering, Stellenbosch University Centre for Renewable and Sustainable Energy Studies, Stellenbosch University Metals Technology Laboratory (METL), Cape Peninsula University of Technology

Advanced coating systems for cleaner engine blocks and heads: Simon Turley, Huettenes Albertus Group

Casting technology and development of magnesium alloys for industrial applications: Dr Mohamed Eissa Moussa, Department of Manufacturing Technology, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt

12:15 Optimal Feeding System Design of steel casting by IPOPT based on Casting Simulation Technology: Xu Shen, State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science & Technology, Wuhan, China

Investigation of Microstructural Features of AlMg9 alloy: Zdenka Zovko Brodarac, Vice Dean Science and Finance, Faculty of Metallurgy, University of Zagreb, Croatia

Effect of feeder size on the quality and yield of austenitic stainless steel pump impeller produced by sand casting: Hudivhamudzimu Mugeri, Vaal University of Technology, Faculty of Engineering and Technology, Department of Metallurgical Engineering

12:45 Clean Steel Castings: Exploring the dynamics of producing clean steel castings with modern technology: Nick Child, International Marketing Manager Clean Steel, Foseco

Comparison of the Effectiveness of Primecast and PMMA Additive Manufacturing Processes to produce patterns for Investment Casting of Ti6Al4V and Al 206: Nthateng Nkhasi, Centre for Rapid Prototyping and Manufacturing, Central University of Technology, Free State

Weldability of austempered ductile iron (ADI) and the applied NDT Methods: Mohamed Sayed, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt

13:15 Lunch in exhibition venueSession 8: Parallel Session 9: Parallel Session 10: Parallel

14:00 Material and Energy efficiency in Melting Systems: Dr Ralf Jennes, Team Manager, Shaft furnaces for iron production in foundry and steel industry, KüttnerGmbH & Co. KG

How to improve performance and delivery time, in an environmentally way, by using PENTEX binder system: Manuel Vargas, International Product Manager, Huettenes Albertus Group

Viability of casting a bearing bronze using a permanent mould for a small foundry: Chozi Lungu, School of Chemical and Metallurgical Engineering, University of Witswatersrand



14:30 Creative decision support system for cast metal industry with integration of inference: Dr Dorota Wilk-Kolodziejczyk, Assistant Professor, AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science and project manager LIDER, Poland

Thermal Distortion Test for Chemically Bonded Sands: Prof Sam Ramrattan, Western Michigan University, Kalamazoo

Study on the post-solidification intensive riser cooling for heavy steel castings: Dr Jinwu Kang, Associate Professor, School of Materials Science and Engineering, Tsinghua University

15:00 True precision since 1993: Markus Weck, Technical Director, ZPF GmbH

Inorganic binders: Benefits, state of the art, actual use: Thomas Steinhäuser, Professor for foundry technology, University of Duisburg-Essen

Payback period for the acquisition of a Three Dimensional Printer in the South African foundry Industry: Elvis Gonya, Department of Metallurgy, University of Johannesburg

15:30 Energy monitoring and control in melting operation in SA foundries: Farouk Varachia, Station Manager, Metal Casting Technology Station, University of Johannesburg (MCTS)

Specialized cold-box binder systems and additives for complex foundry applications: Peter Gröning, Huettenes Albertus Group

Design of a sand control system for a no-bake aluminium foundry : Farai Banganayi, Metal Casting Technology Station, University of Johannesburg (MCTS)

16:00 The foundry industry - energy conservation imperatives: Prof Tony Paterson, University of the Witwatersrand

Innovative latest technology and measurement system on refractory coatings: Chandan Panda, Vice President, Technical Services, Forace Polymers

Comparison of South African Bentonites for Greensand Casting Application: Justin de Beer, Department of Metallurgy, School of Mining, Metallurgy and Chemical Engineering, Faculty of Engineering and the Built Environment, University of Johannesburg

16:30 Research and Application of the Triangular Collaborative Management Model among the Casting Quality, Process, and Producing: Ji Xiaoyuan, State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science & Technology

The latest development in coatings for heavy iron and steel castings : Tim Birch, International Marketing Manager, Mold & Core, Foseco Netherlands

Design principles applicable to three dimensional printing of sand mould for metal casting: Case of a cast iron valve housing component: Mashila Motadi, Metal Casting Technology Station, University of Johannesburg (MCTS)



Friday – 17 March 2017Technology and Processes continuedSession 11: Plenary08:00 ExOne - Patternless and Digital Production of Molds and Cores For Sand Casting Applications using

Three-Dimensional Printing: Helmut Magg, Senior Sales Manager, ExOne Digital Part Materialization08:30 A new simulation system with the inclusion of metallurgical quality in the production line:

R. Suarez, Engineering and Foundry Department, IK4 AZTERLAN, Durango, Bizkaia, Spain09:00 Perfection in Every Single Mould: Frank Höhn, Area Sales Manager, Heinrich Wagner Sinto

Maschinenfabrik GmbH09:30 Lessons from the Metal Casting Technology Station (MCTS) and the National Foundry Technology

Network (NFTN)’s technical assistance programme to South African sand: Dr Kasango Nyembwe, Head of Department, Metallurgy, University of Johannesburg

10:00 Refreshments in exhibition venueSession 12: Plenary10:30 A framework for Concept Design for Efficient Manufacturing: Merging Topology Optimization,

Additive Manufacturing with Traditional Casting: Ravi Kunju, Vice President, Manufacturing Solutions, SolidThinking (A division of Altair)

11:00 Waste to Energy - Renewable Energy Solution for Foundries: Garth Sinclair, Managing Director, Met-Link, representing Ecorevert

11:30 Recent developments in mould and core making: Dr Harmut Polzin, TU Bergakademie Freiberg, Gießerei-Institut

12:00 Foundry Binders - 3R to improve workplace environment: Dipak Ghosh, Head Techical Operations, Forace Polymers Pvt. Ltd

12:30 Mechanical Characterization of Austempered Ductile Iron Obtained by Two Step Austempering Process: Ajay Likhite, Associate Professor, Department of Metallurgical and Materials Engineering VNIT, India

13:00 Informal Farewell Lunch (At Swimming Pool)Exhibition Breakdown

17:00 Furan-Phenol Hybrid Resins, a choice for high-quality castings: Christian Fourberg, Product Manager No-Bake Systems, Huettenes Albertus Group

Total low cost innovative greensand solutions for small and medium sized foundries: Bo Wolff Haugbølle, General Product Manager, DISA Industries AS

Thermal reclamation of used sand from a Voxeljet VX 1000: Oyombo Dady, Metal Casting Technology Station, University of Johannesburg (MCTS)

17:30 Close19:00 Gala Dinner: Senate 1 & 2: Sponsored by Gold Sponsor (Huettenes Albertus Group)

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