vol 16 no 4 - castings sa sa... · induction furnace technology and energy efficiency a bp...

castings sa vol 16 no 4 December 2015 1

Castings SAvol 16 no 4ISSN 1605-7589

Publishing EditorBruce Crawford

Online EditorDamon Crawford

Editorial BoardMarc Hindle

Production ManagerWendy Crawford

ReproductionJericho Graphic Design

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Advertising Bruce Crawford/Wendy CrawfordTel: +27 11 463 0489Cell: + 27 83 628 7654E-mail: [email protected] Website: www.castingssa.co.za

castings sa is published by BA Crawford Specialised Publications (Pty) Ltd. PO Box 69 299, Bryanston, South Africa, 2021

41 Arklow Road, Bryanston, South Africa, 2021

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CopyrightAll rights reserved. No editorial matter published in Castings SA may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

castings sa, published every second month, is the official journal of the South African Institute of Foundrymen (SAIF). The information and ideas presented in castings sa do not necessarily reflect the position of the SAIF staff, executive, advisors, sponsors or members.

4 cover storyInduction furnace technology and energy efficiency

6 industry newsInsimbi; Southway Refractories on the move; DTI - depleted budget; Lauds; Morgan Molten Metal Systems; Vulcan Engineering and Acetarc Engineering; Car industry boost; Steel Lobby launched; SAIF signs up - BRICS Foundry Association; Draft carbon tax bill; Spectrum Technical; Gibela; Problem with theft

24 international newsAlcoa; EUROGUSS; 14th World Conference on Investment Casting; Metal recyclers; China's market economy; ASK Chemicals; World steel output; Spectro; Power Division; Exova; 72nd World Foundry Congress; CastExpo and 120th Metalcasting Congress 2016; High Tech Die Casting 2016; New energy-efficient technique; ExOne; Goliath’s humongous gate; Metallurgy training

40 product review Oxford Instruments; IMF; Spectro; Filtration technology; New Struers LaboSystem; Combicore cores; Mould cleaning standards; New data manager; StrikoWestofen

castings saA specialised journal covering the technology,

processors and materials field for castings

volume 16 number 4December 2015

2 castings sa vol 16 no 4 December 2015

EditOR’S COMMEntThe new buzz phrase - ‘Water Shedding’

As 2015 races to an end we, in South Africa, have been hit with another buzz

phrase – “Water Shedding”, as if we do not have enough to contend with. Corruption, labour unrest and lack of productivity, Chinese imports, crime, dictatorship politics, load shedding or electricity blackouts, increasing wage and salary demands, entitlement, self enrichment, power hungry, degeneration, vandalism,

B-BBEE, bad driving and lack of manners – I could go on and on – all stressful situations that we have to deal with in our daily lives. And now we have to contend with the drought affecting large parts of South Africa.

The implications of drought are too horrible to contemplate because the consequences will affect every one of us minnows. Granted we are experiencing unusual weather conditions this summer. But can the drought and “Water Shedding” that is scheduled to take place be blamed entirely on the lack of rainfall that has occurred in most regions of South Africa this year? No it certainly cannot be, in my opinion. It is more a case of bad management and a lack of maintenance to an ageing infrastructure, something that is the norm these days rather than the exception.

In the suburb where I live just last week (first week of November) we had three full days without water. This is not the first time this year that we in our suburb have been without water for at least 12 hours. It probably has been close to 20 occasions and all as a result of the same pipes malfunctioning. Time and again the pipes are repaired and before long the water is streaming into the road. Imagine the cost to the taxpayers, and I am only talking about my incident. This to me is systematic of the badly run and mismanaged councils and municipalities all over South Africa. The exception is the Western Cape and we all know why the area is a pleasure to visit. Worse still it is a case of an ‘I don’t care’ attitude that is prevalent, and a lack of accountability.

You might think I am generalizing, but when so many of us are talking about these subjects, more and more often, they surely must be fact. Some areas are affected more than others and yes, we should not complain because we are relatively unaffected compared to those that have less than us, but the fact still remains that there is definite degeneration of basic services taking place in our country. How long must we put up with the robot (traffic light) that has not worked for a week or the leaking sewerage pipe that is flowing directly into our water system?

I would like to know how far we must fall before it is too late? We have a beautiful country with plenty of valuable resources, mineral and human, wonderful landscapes and natural environments that need to be cherished and promoted. If we as a country do not look after them we will not be able to enjoy them in the future.

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

Membership Fees for 2015Junior MemberR100.00 per annum

Individual MemberR700.00 per annum

Company Member - less than 150 employees R3 000.00 per annum

Company Member - more than 150 employeesR6 000.00 per annum

Retired Member R330.00 per annum

International Member R2 000.00 per annum

All prices include VAT

Council Appointments for 2014/2015President - Takalani Madzivhandila Vice President - Janley Kotze Treasurer - Justin de Beer Constitutional Members

Immediate Past President - Enno Krueger

Elected MembersAndrew McFarlane Adrie El Mohamadi David Mertens Colin Smit Bruce Crawford Cyprian KyaluJohn Davies Dalmari McQueenKevin van Niekerk Joshua van FlymanNigel Pardoe

Western CapePresident - Mike KillainFinancial & Technical Speakers - Dean Horne & Sean StadlerAdministration - Kevin MissenheimerSocial Co-ordinator & Technical Speakers - Mike Killain

Address detailsUniversity of Johannesburg Metal Casting Technology Station - Metallurgy Room G101, John Orr Building, Corner Siemert and Beit Street, Doornfontein, Johannesburg, Gauteng. Postal Address: P.O. Box 14863, Wadeville, 1422.

John Davies - Tel: +27 (11) 559 6468; Cell: 083 630 2809; email: [email protected]

Executive Secretary - Tel: +27 (11) 559 6455; Fax: +27 (11) 559 6526; email: [email protected]

Website: www.foundries.org.za

Contact details for Western Cape: Mike Killian - Cell: 082 442 3785

south african institute of foundrymen


cover story

Induction furnace technology and energy efficiency

ABP Induction Systems GmbH, headquartered in Dortmund, Germany develops and

manufactures induction melting furnaces and induction heating equipment for the foundry, steel and forging industries including suitable automation solutions. These induction systems are used for melting, holding, pouring and heating metals and are used in the manufacture of components for the automotive industry, mechanical engineering, energy industry (particularly wind power) or the construction industry (e.g. pipes, valves or pumps).

In the field of high-performance induction systems, ABP Induction sees itself as a technology leader. In Germany, the company is also the market leader and the world‘s second largest manufacturer. The equipment is manufactured in Dortmund, in Vadodara in India and in Shanghai, China. 65% of the equipment made in Dortmund is exported. Worldwide sales and service are handled by a total of eleven branches of ABP in all major markets.

ABP Induction has its roots in two companies: the Swedish company ASEA and BBC from Switzerland. The Dortmund site was founded by BBC in 1922 and the first industrial furnaces were built there from 1923. In 1988 the two companies merged to form ABB. The induction division was hived off from ABB in 2005 and ABP Induction Systems GmbH was established. Today the company is owned by the US financial investor CM Acquisition.

In 2008 ABP Induction merged with the Pillar Induction Group — another expert in induction melting and heating — thereby adding further sites in the USA and China. This merger has turned the ABP Induction Group into one of the global leaders in the industry.

Since the invention of the first functional channel-type induction furnace by the former company ASEA in the Swedish town of Gysinge in 2003, the company has continued to advance induction technology. A total of 30 patents have been filed. The most important ones include the Twin Power technology in which two furnaces operate with a single power supply, a crucible push-out device and transverse-field heating.

As a manufacturer of equipment for particularly energy-intensive industries, ABP Induction is also involved in the EU project NIWE, exploring efficient processes associated with induction technology. ABP invests approximately 1% of its annual turnover in research and development, which is carried out exclusively in Dortmund.

The engineering work required in developing new or planning restructured facilities is constantly increasing in scope and complexity. This is especially the case of small and medium size steel melt shops.

Highlights presented at the GIFA 2015 exhibition included the Optipour® camera version automatic pouring control system and the Presspour® type OCC pouring used for holding and the automated pouring of ferrous and copper alloys.

Optipour® - Camera versionThe automatic pouring control system Optipour® camera

version is an automatic pouring control system which requires a minimum of monitoring and provides constantly high quality castings. Two different measurement techniques for measurement of the bath level in the pour cup are available for the various requirements.

By measuring a specific area within an exactly adjusted measuring field you can reach an almost proportional measurement of the fill level of the cup. This signal is used to control the stopper actuator.

The camera module is built as a closed system and is connected via a standardised signal with the regulating system. This means a high long-term reliability as it is possible to change it later on against nearly every available system.

Optipour® uses real-time level measurements in order to monitor and control the level of iron in the pour cup. As the level increases, a system actuator throttles the stopper rod to reduce the pouring rate, preventing overpouring of the mould.

ABP Twin-Power® design, hydraulic station and pump stands in two climate controlled containers for reduced installation times


The automatic positioning of Optipour® makes it possible to use smaller pour siphons. At the end of a pouring operation, Optipour® is capable of bringing the pour cup level to a level set by the operator, thus reducing the total quantity of iron poured and increasing the yield. Less iron needs to be remelted and as a result power, alloy and material handling costs are reduced.

Using a high speed, fast response actuator, the Optipour® reacts exactly to level changes in the pour cup. If the level drops to a selected set point, the system instantly increases the iron flow, thereby maintaining the desired iron level in the cup.

Since a high and accurate iron level in the pour cup is maintained throughout the entire pour, Optipour® ensures that the slag is not pulled into the mould but stays floating on top of the iron. The result is higher quality castings thanks to less slag inclusions.

Presspour® type OCC The pouring furnace Presspour® type OCC is used for

holding and the automated pouring of ferrous and copper alloys. As far as cast iron is concerned, available are models with a total capacity of 2 900 kg to 25 000 kg and an inductor power of 130 kW to 500 kW.

The pouring furnace with its pressure-tight cover has a cylindrical shape. The feed and discharge channels end in the bottom of the vessel (siphon principle). This configuration ensures practically slag-free pouring.

An electro mechanic drive with a variable adjustment unit moves the stopper after the selected pouring program. This can be done by either using the teach-in method or the closed-loop mould level control called Optipour®.

In order to adapt to varying pouring positions, the furnace can be moved lengthwise and perpendicularly to the casting system.

Power supplyThe inductor is connected to the power supply system via a

furnace transformer, which permits selection of the various furnace voltages for holding and superheating.

The inductor of the Presspour® furnace is a quick-change unit lined with a corundum or magnesite-based spinell-forming dry mass responsible for keeping the melted metal warm. The inductors are supplied optionally as channel-type (air or water-cooled) or crucible-type (water-cooled) inductors.

Continued automatic monitoring of the furnace system guarantees safe operation at any time. All along, the control of the entire pouring procedure is possible.

At the designing stage, the main emphasis was placed on a simple operation and maintenance of the system. With the help of

detailed instructions, an efficient and quick training of technical personnel is enabled to ensure, for instance, assembly, operation and troubleshooting.

Power supplies ABP offers for the power supply of their induction furnace

systems converters using different technologies: thyristorized converters and IGBT converters.

The basic function of a converter system is to convert line frequency, three phase power from the utility network to a variable, load governed frequency that is appropriate for a particular induction melting or heating load.

6, 12 or 24 pulse rectifiers are used in these converters. The pulse count refers to the number of current pulses drawn from the three phase utility network per cycle of line voltages. The greater the number of pulses per cycle, the smoother the current will be. Smoother current helps to avoid harmonic distortion of the utility line voltage. Low distortion of the line voltage is necessary to avoid problems with other equipment connected to the utility lines.

In over 100 years of serving the metal casting and forging industries, ABP Induction Systems enthusiasm for molten metal has always been strong.

For further details contact ABP Induction Furnaces on TEL: 011 623 1814/17 or cell number 072 158 1117 or email [email protected]. You can also visit www.abpinduction.com

ABP MF Induction furnace, type FS 30 (3 t) for continuous batch melting

ABP Ecotop® hoods for fume extraction in all positions

The ABP pouring furnace Presspour® type OCC


industry news

Diversification and optimised efficiencies realise strong results for Insimbi

JSE listed Insimbi Refractory and Alloy Supplies has released a stellar set of

results for the six month period ending 31 August 2015. The results were better than expected given the difficult trading conditions that have affected the steel industry in South Africa.

Insimbi is principally a supplier of ferrous and non-ferrous products and commodities. However, the company has over time diversified into a number of different fields with product lines now including ceramic bricks/linings, aluminium alloys, chemicals, technical textiles, kiln realignment and mechanical preventative services, and more recently the plastics converting segment with the purchase of Polydrum (Pty) Ltd.

Insimbi, a South African based company, is engaged in supplying the steel, aluminium, cement and foundry industries with resource-based commodities like ferrous and non-ferrous alloys, as well as refractory materials, sourced locally and from abroad, by integrating the supply, logistics and technical support function. The steel segment focuses on the supply of a range of alloys, including non-ferrous alloys, to the steel and stainless steel industry. The foundry segment focuses on the supply of a range of alloys and ancillary raw materials, including foundry sand, ceramic ducting, to ferrous and non-ferrous foundries, including heavy-duty foundries, automotive foundries, and electroplating specialists. The refractory segment is engaged in the supply of ceramic refractory linings to the cement, paper and pulp, steel and platinum industries.

The company, which listed on the AltX in 2008, moved to the main board in January 2012. At the time of the move Insimbi said the move would expand its options for raising capital and the listing would open up “exciting opportunities”.

“In challenging global markets, Insimbi has been pragmatic in positioning itself, notably in the foundry and refractory segments, to achieve increasing profit and return for shareholders, seen in our increase in revenue of 7.5% for the period. Our reliance on the beleaguered steel sector has reduced considerably and we have effectively reached a level of

sustainability,” said CEO Pieter Schutte.

“Furthermore, we have continued to optimise efficiency in all of our divisions, especially at our secondary aluminium smelters as we seek to define new markets for our aluminium products. Before year end, we will have commissioned an upgraded smelting facility at our Johannesburg operation.”

“The Company also looks to expand on not only our core segments but also in our Nano Milling paint based products, with the appointment of an experienced quality technician, as well as the plastics segment with the acquisition of Polydrum (Pty) Ltd, which has provided additional cash flow to our increasing revenues.”

“As our focus moving forward remains on the businesses fundamental resilience by reducing working capital and operational costs as well as strengthening our relationship with current suppliers, management will also be looking at ways to expand on current incremental profit and I look forward to updating the market on further opportunities in the future.”

Operational overview “The foundry segment has performed well generally and

despite continued competition both locally and from abroad, it achieved revenue of R366.8 million, a 4.5% or R15.7 million increase on the previous period under review. This segment is traditionally a “barometer” of how well the economy is doing and it appears to have reached a comfortable level of sustainability. A change in product mix coupled with a weaker currency, has helped lift margins.”

Upgrade at Benoni secondary aluminium smelter“The two secondary aluminium smelters, which form part of

this segment, have been operating much more efficiently although they have been faced with a lower order book as a result of the challenges facing the steel industry. We are actively looking for other markets for our range of aluminium

Foundry division performs well despite the naysayers in the industry and continued competition both locally and from abroad.

Insimbi have commissioned a more modern and efficient smelting facility at their Benoni operation. The current

primary melting furnace, which is a reverbratory furnace, is being converted into a holding furnace. In its place Insimbi have imported a gas fired tilting rotary furnace with a five

ton capacity. Besides the efficiencies that Insimbi will obtain, production capacity will be ramped up to 30 tons a day, which is

a 20% increase on the current situation. It also gives Insimbi the opportunity to process their own dross


products and with a weaker currency, there are opportunities in the export market but raw material, energy and logistic costs remain a challenge when competing with overseas producers.”

“Nonetheless we are in the process of commissioning a more modern and efficient smelting facility at our Benoni operation, and we are confident that this will improve our operational efficiencies and recoveries to the degree necessary to enable us to export competitively.”

“The current primary melting furnace, which is a reverbratory furnace, is being converted into a holding furnace. In its place we have imported a gas fired tilting rotary furnace with a five ton capacity. Besides the efficiencies that we will obtain production capacity will be ramped up to 30 tons a day, which is a 20% increase on our current situation. It also gives us the opportunity to process our own dross.”

“Additionally we have upgraded the baghouse at the facility. This upgraded facility should be operational by no later than the end of November 2015.”

Prospects “It seems that every year we make mention of the

challenging economic conditions facing businesses in South Africa, and yet Insimbi continues to not only survive but flourish, and we continue to seek and find opportunities that help us grow. This year is proving to be no different and while businesses are still faced with significant challenges, the board and management of Insimbi are optimistic that as in previous years, opportunities will continue to present themselves, and that we will be able to take advantage of them for the benefit of all our stakeholders.”

“We remain confident that our government will react positively and promptly to ensure that our strategic South African assets, particularly in the steel and resource sectors, are given the opportunity to stabilise in the short term and return to operational and economic viability in the medium term. This confidence is supported by the recent implementation on import duties on certain grades of steel being imported into South Africa. A similar request for import tariffs on certain aluminium products has recently been made by Hulamin Limited. We hope that these initiatives bring the stimulus these industries require as it will benefit not only those industries directly, but all their suppliers and other stakeholders. Insimbi is one of them.”

Foundry sector“Despite all the naysayers the foundry segment has shown

tremendous resilience over the past few years and while foundries have closed, those that have not have grown stronger, more efficient and are becoming even more resilient.

The foundry segment is very much part of our core business and we will continue to service this segment with the recognition it deserves.”

“The refractory segment is another core segment and, like the foundry segment, has proven it’s resilience over the past decade. Recently, the cement players in this segment have been successful in getting ITAC to implement import tariffs on cheap cement, which has, for a long time, been imported into South Africa at the cost of our local industry. The impact has not filtered through yet but we are optimistic that when it does, Insimbi will be ready to meet the increased demands made on us by the cement industry.”

“As mentioned earlier, the secondary aluminium smelters are running optimally and our investment in new furnace technology will hopefully improve our recoveries. The commissioning of this upgraded plant is imminent. Scrap supplies have become much more consistent with respect to both quality and price. This can in part be attributed to the ITAC regulation implemented in 2013/4 which monitors and regulates the issuing of export permits to the waste metals industry.”

“In July, we acquired a 75% stake in Polydrum, a manufacturer of durable plastic products, for R9.4 million. The acquisition of Polydrum has been an interesting one and we see the potential for this low mass high volume operation. Capital expenditure has already been approved for the installation of two extra manufacturing lines and we will be expanding our reach into the rest of South Africa. Polydrum earned revenue of R2.9 million and gross profit of R1.1 million in the first month of inclusion in the interim results.”

“Currently about 85% of our business is generated from within South Africa. Going forward more attention will be given to our bordering countries and the North and West African countries to increase our presence in these countries.”

“The strategy of management to diversify our product offerings and services over the years has certainly put us in a positive position, and as said previously we will continue to look for opportunities.”

Changes to the Board of Directors Daniel O Connor retired as chairman and non executive

director of Insimbi at the Annual General Meeting (“AGM”) which was held on 25 June 2015. Mrs Lerato Okeyo was appointed as independent chairman of the Board effective the same day. Mrs Cleopatra Shiceka was appointed as non executive director to the board on 7 July 2015, as well as chairman of the Audit and Risk Committee.

For more information contact Insimbi Group of Companies on TEL: 011 902 6930 or visit the website www.insimbi-alloys.co.za

Insimbi’s secondary smelter manufactures and supplies aluminium alloy ingots

Insimbi’s secondary smelter manufactures and supplies aluminium alloy pellets


The Department of Trade and Industry (DTI) has temporarily suspended new applications for its Manufacturing Competitiveness Enhancement Programme (MCEP), as the

large number of applications far exceeded the funds set aside for the programme. Initially, R5 billion had been set aside for the programme, which was designed as an incentive to support enterprises in the production sectors of the economy, but these funds had now been fully committed.

The MCEP sought to secure higher levels of investment, raise competitiveness and retain employment in the country s waning manufacturing sector. To date, the MCEP had supported 1 153 entities acquire capital equipment and reengineer business processes to improve their competitiveness. All assisted enterprises also retained jobs and were committed to black economic empowerment.

The DTI had highlighted the high number of applications it had received under the MCEP in May this year, when it limited the programme incentives to projects requiring investments of less than R50 million. A new application window would be opened in April 2016, pending the availability of funds. All other incentives of the department would continue as normal. The DTI

also emphasised that it would continue to honour all approved applications under the MCEP.

According to the DA: “A large percentage of manufacturing companies rely on this programme to continue operations and contribute to the economy of the country. Suspending the MCEP will consequently force a number of companies to either close down operations or lay-off a number of employees.

“The programme is vital to ensuring that our manufacturing sector remains competitive, retains jobs and has the necessary space to create more jobs. Our current manufacturing sector is already in turmoil due to the ongoing electricity crisis, failing commodity prices and labour unrests. Effectively suspending intake into this crucial programme until April next year will cause a number of companies to shut their doors. Our economy cannot survive further business closures.”

“In addition to the suspension of the MCEP, the DTI reports in its latest annual report that it under-achieved dramatically with regards to the projected number of jobs to be retained from approved enterprises through the MCEP. The planned target of 99 600 jobs will under-achieve by 61 703 jobs, a staggering 62% less than expected.”

DTI temporarily suspends manufacturing incentive owing to depleted budget

Southway Refractories, which was established in 1999, has recently moved into a new factory and office accommodation purchased by the company in Alrode,

South Gauteng. For several years the company was located in Elandsfontein,

Gauteng in a rented facility consisting of 1 900m² under roof. Through consistent growth Southway eventually had to rent an extra 600m² factory a few kilometres away, which finally persuaded management to look for a new facility.

“We were bursting at the seams and operating in a situation which was not ideal. The Hilltop Industrial Park factory suited our needs when we first moved there. But growth and the subsequent need to accommodate the extra stock that was required, in a safe and secure environment, pushed us to breaking point,” said Southway Refractories Sales Director John Rogers.

“The big move to the Potgieter Street factory took place in August 2015. We now have 4 000m² under roof storage space and another 800m² for office accommodation. The buildings have been in existence for some time and were previously occupied by a pharmaceutical company so we had some reorganising and alterations to do, but nothing major.”

“Besides the extra space, the advantage of our new location is that we have closer and quicker access to the highways, and the flow of stock coming in and leaving is more organized with better access for the larger trucks. This will allow us to improve our service and delivery of products to clients.”

Southway Refractories is an importer and distributor of refractory products to the Sub-Saharan African Market. The product range comprises a variety of refractory bricks, monolithics, ceramic fibre products, silicon carbide products,

graphite/carbon electrodes and blocks, acid resistant bricks, precast shapes, rock wool, porous plugs, nozzles and sliding gates.

Most of the company’s products are imported from reputable manufacturers in China and the company has an office in Beijing, China whose personnel carry out regular quality checks at source.

“We have very few suppliers and most of them are located in the one area of China, where the raw materials used in manufacturing our products are prevalent. To give you an example of the size and how these manufacturers/suppliers have embraced modern and efficient production practices, one of them has 24 tunnel kilns, presses up to 3 600 tons and all product is robotically handled,” explained Rogers.

Southway Refractories services the iron and steel, non-ferrous, ferroalloys, petrochemical, foundry, cement, heavy mineral and glass industries. Turnkey projects are carried out by Southway Refractories and clients include Anglo Platinum, ArcelorMittal South Africa, Impala Platinum, PPC Cement and Samancor Ltd.

The company was established by David Chang, who is still the majority shareholder. However, Southway Refractories is BBBEE compliant with 26% black ownership. Siyanda Resources, which has a 14% effective shareholding, is a resources consulting company with many interests in the mining arena including coal, manganese and chrome.

A big plus for the company has been the fact that they have kept the same contact numbers. The total staff compliment is now 20, an increase of four as a result of the relocation.

For further details contact Southway Refractories on TEL: 011 822 9838 or visit www.southway.co.za

Southway Refractories on the moveRefractory product supplier has more than doubled its factory size.


Local foundry equipment manufacturer Lauds Foundry Equipment has formed a strategic

partnership with US vibratory and rotary equipment manufacturer General Kinematics Corporation.

General Kinematics (GK) was established in 1960 by Albert Musschoot to market, design and custom fabricate vibratory handling and processing equipment for the processing of bulk materials. Currently headquartered in Crystal Lake, Illinois, USA, GK operates from a 220,000 square foot facility and is one of the world’s largest suppliers of vibratory processing equipment from vibratory feeders to entire process systems.

Today GK holds more than 200 worldwide patents, and is acknowledged as a major contributor to the technical advancement of vibrating and rotary equipment design and application. Over 50,000 General Kinematics units have been installed in virtually all of the world’s industrialised countries.

The company also has locations in Germany, the UK, China and India. GKC provides a full range of custom engineered vibrating material handling and processing equipment including feeders, conveyors, screeners, fluid bed heat transfer units, vibrating drums, high frequency shakeouts and specialised recycling equipment.

The company’s equipment is found in foundries, metal casting operations, recycling companies, the mining and bulk processing industries and general industry. The systems and equipment provide solutions for the cleaning room, the melt deck, lost foam, sand systems (reclamation), casting cooling, slag and dross reclamation, activating, separating, drying, processing, grinding, screening, dewatering, elevating and more.

In short GK specialises in vibrating equipment and solutions for bulk processing of material in the foundry, recycling, scrap, mining, minerals, food, chemical, and wood industries.

Each piece of GK equipment is custom engineered to client specifications to meet the client’s process objectives.

“We have signed an agreement with General Kinematics to market their equipment and solutions to companies in all these industries in Africa. Our sister company Lauds Foundry Equipment GmbH will be marketing their equipment in certain parts of Europe and the surrounding countries, basically where GK is not yet represented or has a presence,” said Kevin van Niekerk MD of Lauds Foundry Equipment.

“The type of equipment that GK manufactures will compliment the range of equipment that we manufacture in South Africa, or in Germany at Lauds Foundry Equipment GmbH.”

“These days manufacturers such as foundries or processing companies such as recyclers are looking for a turnkey solution to their capex improvements and investments. We can now offer a large portion of their requirements, and the complete solution in most cases.”

Lauds Foundry Equipment GmbH’s partnership with Foseco India

Meanwhile the German operation of Lauds Foundry Equipment, LFE GmbH, which was established early in 2014 to access the European market directly and easily, has signed an agreement with Foseco India, effective October 2015.

Foseco India will in future market LFE’s foundry equipment in India, South East Asia, the Philippines and Vietnam.

“Incorporating a manufacturing division in Germany, who are able to manufacture exactly what

we do in RSA, has doubled our capacity, enabling us to manufacture on both continents on the same project if so

Lauds forms strategic partnership with General Kinematics Corporation and Foseco India

A two-mass vibrating feeder from General Kinematics

A ducta-clean rotary media drum from General Kinematics

required. We have a 3 000m² state of the art facility, which includes a machine shop, a design team and fabrication.”

“Even though LFE GmbH has a relatively short history, the company has been making inroads and we have supplied equipment nto Russia, Slovenia and Turkey.”

UK market“Currently we are

exploring the options to have a presence in the UK. We believe that there are many opportunities in that region, and foundries would welcome equipment manufactured to European quality standards, but at a fraction of the cost compared to what is currently available. Our exchange rate is very favourable and we need to take advantage of that.”

“Our strategy is to explore all these markets even though we are still very active in South Africa. We want to grow the company both locally and internationally, while at the same time improving the design and efficiencies of equipment. You will only acquire this expertise if you are exposed to the international markets.”

South Africa and global partners

“Additionally, we continue our mutually beneficial arrangements with our global partners whereby we import, sell and service their equipment and systems locally. These include Pourtech AB of Germany who provide automated pouring solutions, Siapro of Slovenia, a company that manufactures shotblast equipment, Indemak of Turkey who supply us with furnaces, and Polish company Adjatech.”

“We have also developed a patented secondary reclamation unit for the

sand foundries. The unit, which is 100% locally designed and manufactured, only requires 15kW power consumption (5 ton per hour) and can be added to any primary reclamation system. Our tests on a pilot setup at a local university are showing that you can achieve up to 30% reduction in L.O.I.”

“We have also just recently won an order to manufacture and supply primary and secondary reclamation units to Thos Begbie.”

For further details contact Lauds Foundry Equipment on TEL: 011 824 1238 or email [email protected] or visit www.laudsfe.com

Vibrating screens


Morgan Molten Metal Systems, a division of Morgan Advanced Materials, has announced the appointment of Keegor Meltech (Pty) Ltd to distribute its complete

range of crucibles and accessories for the melting, holding and treatment applications used in the casting of ferrous and non-ferrous metals and metal alloys in South Africa.

Keegor Meltech (Pty) Ltd is part of the Keegor Group, which includes Leonard Light Industries and Keegor South Africa.

Keegor™ is a brand name that is a registered trademark to Leonard Light Industries (Pty) Ltd, which has been designing and manufacturing a range of Keegor™ brand products since the company’s inception in 1959 for the precious metals assaying and refining industry.

The company products and related accessories include furnaces, smelt-house hardware, sample preparation equipment, cupels, fire-clay crucibles and various items of fire assay hardware including tongs, trays, trolleys, bins, rollers, mixers, plates, cups, slag moulds, laboratory crushers and pulverisers.

With more than 150 years experience, Molten Metal Systems is a recognised leader worldwide in the supply of crucibles to non-ferrous metals industries.

Morgan’s crucibles and foundry products provide melting solutions to foundries, die-casters and metal melting facilities covering melting applications that include zinc, precious metals, aluminium, copper/brass/bronze and other non-ferrous metals.

Morgan’s crucibles are constructed from a wide range of high quality technical materials using advanced manufacturing techniques, and crucibles are available in a comprehensive range of sizes and shapes, for optimum performance in individual applications.

Some of the brand names associated with the Morgan range of crucibles include Salamander Super, Excel, Excel E, Hi-Melt, Grafit, ISO-Alustar, Indux, Stabil, Starrbide, Syncarb, Syncarb Z2, Syncarb Z2 e2 and Ultramelt.

Morgan’s crucibles are manufactured in various forms in fused silica and fireclay, magnesite, clay-graphite, carbon-bonded silicon carbide, tar-bonded silicon carbide and a ceramic bonded clay graphite with a high silicon carbide

and graphite content.

The crucibles are used in metal casting operations with temperatures ranging between 400°C and 1600°C, depending on the application.

Morgan Molten Metal Systems also offers a complete range of high performance foundry products and accessories including ladle bowl, launders, sheaths, plungers, tools, degassing tubes and refractory cements.

Morgan Advanced Materials is a manufacturer of ceramic and composite materials which are used in industries ranging from medical and electronics to oil, gas and mining.

“Worldwide, Morgan Advanced Materials has adopted a policy to appoint recognised distributors in the particular fields of industry. In this case we have appointed the Keegor Group who are very active in the precious metals, assaying, foundry and other metal melting industries to service and support these targeted industries,” said Cayan Bagatur, MD of Morgan Advanced Materials for the EMEA region.

“Eddie Short, who has been with Morgan Molten Metal Systems for the last 17 years as Product Manager has been appointed as Sales Director of Keegor Meltech and will remain the primary customer contact,” continued Bagatur.

“This is an exciting development for Morgan Molten Metal Systems’ products and the individual brands. The products are well established within the melting industries and have been growing tremendously in recent years. Morgan Molten Metal Systems has five manufacturing sites around the world — Brazil, China, Germany and two in India — which we source our crucibles from,” enthused Short.

“However, we will still have access to the local manufacturing facility at Morgan Advanced Materials for custom built crucibles. This division of Morgan Advanced Materials in Tulisa Park, Gauteng has just completed an upgrade in equipment for machined graphite products that are used to support specialist processes in demanding high temperature environments where their purity and structural characteristics are critical to achieving the required process quality,” continued Short.

“Additionally, we will be looking to add to the Keegor Meltech portfolio from established Morgan Molten Metal Systems partners. These include fluxes, die coats, degassing machines and epoxy metal fillers. We want to be able to offer a comprehensive range of products to our customers so that they have a one-stop commitment.”

“This arrangement with Morgan is highly complementary to our product portfolio, and we are pleased to expand our already established relationship with Morgan Advanced Materials. We can now provide our customers in South Africa with an extensive portfolio of high-quality products,” said Bruce Hansmeyer, MD of the Keegor Group of Companies.

The agreement comes into effect 1 December 2015.For further details contact Keegor Meltech on

TEL: 011 421 0711 or Eddie Short on 082 460 1593.

Morgan Molten Metal Systems appoints South African distributor Keegor Meltech


Vulcan Engineering Co., one of the largest in-house engineering, manufacturing, and installation groups in North America, dedicated to the metalcasting and heavy

industrial markets, has partnered with local new startup kid on the block company Globen Engineering Services and Supplies (Pty) Ltd.

“Although Globen has only been in existence since the beginning of September 2015 my experience in the foundry industry goes back to 1965,” said Globen founder Eric Benvenuti.

“After completing my Engineering studies at Wits Technikon, I started off in the foundry industry at Central Engineering, a family owned business. The company, at the time, ran three foundries — one in Vereeniging, one in Johannesburg and the other one in Alrode, Gauteng,” explained Benvenuti.

“Following a number of mergers and buyouts, I eventually ended up at MIS Engineering.

I stayed with the company for the rest of my career until I retired earlier this year, the majority of this time spent as Director in charge of Operations and Engineering. One of my biggest projects was the commissioning of the new greenfield foundry at MIS Engineering in 2013.”

“I am not one to sit around trying to keep myself occupied, so when I was approached by Vulcan Engineering Co. to represent them in Southern Africa, it presented an opportunity not to be missed, especially as I have had experience with the Company and their equipment in the past.”

“Vulcan has grown by holding to a simple philosophy of serving customers to help them succeed. This basic principle, implemented by Vulcan’s expert team, creates the impetus behind Vulcan’s continuing growth and success over the years.”

“Vulcan is a foundry engineering, equipment manufacturer and installation supplier. Developing specific equipment or systems for your application, or to provide equipment from their vast array of foundry-designed standard equipment and whatever your process, green sand, no-bake or lost foam, they offer solutions from ‘expertise backed by experience’.”

“The equipment includes the latest in lost foam casting lines featuring

the latest advancement in compaction technology, investment casting coating systems featuring the latest advancements in control technology, robotic automation for material handling, and casting cleaning applications and manipulators featuring the latest in digital controls.”

“Some of the well-known brands that the company has manufactured and installed in foundries worldwide includes the VTS™ machine featuring a tele-operated robot for large casting cut off and grinding, the Fox® grinder line of manual and

semi-automatic grinding equipment, the Donovan™ no-bake and

flask rollover equipment, Action® robots and

manipulators, Mid-West Machine™ metal conditioning equipment, Truflo® mould handling lines, sand cooling systems and riser removal

Impactors™.”“Vulcan Engineering

Co. was established in 1970 and dedicated itself to the metalcasting and heavy

industrial world markets. The company was started by, and

is still managed and staffed by, foundry people who came from operations, engineering and maintenance. As a foundry engineering, equipment and installation supplier, they offer solutions from the knowledge of your processes and daily challenges, whether your need is a single piece of equipment, or a complete turn-key concept-to-completion project.”

“Vulcan is one of the largest in-house design, manufacturing and installation companies in North America. The manufacturing facility, based near Birmingham, Alabama, includes design, fabrication, machining and assembly in a 46 500 square metre under roof facility.”

Vulcan Engineering and Acetarc Engineering partner with Globen Engineering Services and Supplies (Pty) Ltd

for lean manufacturing

Eric Benvenuti

Vulcan Engineering’s Fox swing frame cut-off machines

Vulcan Engineering’s all new VTS (Vulcan Tactile System)

is a leading edge robotic/

manipulator that allows you to grind and cut at virtually any angle with use of tactile and force

feedback. The VTS™can be used as a robot or as a

manipulator


New high capacity rollovers

“Launched earlier this year by Vulcan was the Donovan™ Mold Handling equipment, which is designed to handle, roll over and close cope, drag or complete moulds or flasks. This equipment can hold different moulds level, regardless of centre of gravity. Vulcan Engineering has built capable hydraulic systems that can run continuously without overheating. Self-contained hydraulics ensure a low maintenance, trouble-free operation.”

“The machine securely holds moulds for core setting, venting, cleaning and closing, without loss of position and eliminates the use of belts and chains by employing the long-wearing gear drive. The systems and equipment are available for use on moulds with flasks as well as flaskless (no-bake) moulds.”

“This particular gantry style rollover is designed to move over a conveyor to draw the flask package, lift and move the flask to a coating area. Once there, the rollover will rotate the flask 70 degrees to allow for manual coating of the mould.

After coating, the rollover will move the flask to another conveyor and set the flask on a bottom board to transfer to curing. As with any Vulcan product, they can customize this equipment to fit your foundry’s needs.”

Complementary equipment - Acetarc Engineering foundry ladles, molten metal pouring systems and associated handling

equipmentGloben has also secured the agency to represent Acetarc

Engineering Co. Ltd, manufacturers of foundry ladles, molten metal pouring systems and associated handling equipment.

Acetarc is a family owned and run company, located in the north of England. The company was established in 1967 and their equipment can be found in many foundries around the world. Some of the users include MIS Engineering, Pentair, ME Elecmetal, Rolls Royce Naval Marine Inc., Magotteaux, amongst others.

For further details contact Eric Benvenuti of Globen Engineering Services and Supplies (Pty) Ltd on TEL: 082 450 8232 or email [email protected]

Acetarc Engineering foundry ladles


The trade and industry department (DTI) is to implement a number of steps in an effort to sustain and

grow the automotive industry while steering it towards the Automotive Production and Development Programme (APDP) vision of high volume vehicle production.

The APDP was fully implemented by January 2013 with a view to steer the automotive industry towards producing about 1.2 million vehicles by 2020 with attendant expansion of the domestic supplier base, Trade and Industry Minister Dr Rob Davies said in a statement.

However, the APDP review stated that the 2020 target of producing 1.2 million vehicles per year was unlikely to be achieved due to a variety of reasons, such as the fact that the global economy was still recovering from the effects of the 2008/9 financial crisis.

“Secondly, it will also be extremely difficult to achieve significant expansion and deepening of the local supplier base under the prevailing economic conditions,” said Davies.

Since the original APDP framework was developed in 2008 the global and domestic economy changed dramatically, raising a concern that there could be limitations in the program that may lead to failure to achieve set objectives for the industry. Davies said government remained committed to further development of the automotive industry in line with the National Industrial Policy Framework (NIPF) and the Industrial Policy Action Plan (IPAP). The long-term development of the sector would be achieved through high vehicle production volumes and associated local value addition.

Therefore, in an effort to sustain and grow the automotive industry while steering it towards the APDP vision of high volume vehicle production, a number of proposals would be implemented:

• A post-APDP support framework would be developed during the course of 2016 to provide certainty in the policy environment for automotive manufacturing in South Africa after 2020;

• The volume threshold for vehicle production would be reduced from 50 000 units to 10 000 units a year to allow new entrants into the local industry from 2016;

• The Volume Assembly Allowance (VAA) would be offered on a sliding scale based on volume commencing at 10%

for 10 000 units to 18% at 50 000 units from January 2016; • A suitable capital incentive (AIS) level would be provided for new entrants at the less than 50 000 a year threshold (details would be captured in guidelines that should be finalised by April 2016); • The production incentive for catalytic converters would be frozen at the 2017 level of 65% rather than continue the phase down; • The qualification for component

suppliers to earn APDP benefits would be tightened to avoid these benefits being earned on non-core automotive products and therefore preference would be afforded to those products that added value in the value chain; and

• The DTI would engage the National Treasury in an effort to secure improved investment support for tooling as a

means of encouraging further component localisation. Overall national budget constraints were noted in this context.

Davies said the DTI would also engage the industry in efforts that sought to promote meaningful transformation.

“As we develop a post-APDP automotive master plan we will also actively engage the industry in efforts that seek to promote meaningful transformation of the industry through the inclusion of previously excluded groups along the entire automotive value chain. The current situation is characterised by extremely low participation of blacks in the automotive industry. This is prevalent through all parts of the sector’s value chain including distribution, retail, and after-sales/service. The levels of support afforded to the industry in SA need to be reflected through an appropriately transformed sector,” Davies said.

Details of the APDP were announced late in 2008, to replace the then autos sector specific programme, the Motor Industry Development Programme. In February 2014 the DTI engaged the services of specialist advisor Roger Pitot to co-ordinate a review of the APDP, with a mandate to make recommendations to secure optimal outcomes to the sector and economy while retaining long-term certainty for investment. The review was aimed at ensuring the APDP was working as intended, and fine-tuning where necessary.

Review of the APDP — Policy shift gives car industry boostDTI to implement measures to sustain automotive industry growth.

Move to lower barriers to attract more global manufacturers welcomed as positive step with gateway potential for rest of Africa.


Industry body, the National Employers Association of South Africa (NEASA) has launched a South African Steel Lobby that will advocate for the shelving of the antidumping

application by primary steel producers, and will look to negotiate an improved model for downstream manufacturers.

“The duties already introduced, as well as the looming introduction of anti-dumping measures (intended to benefit only the primary steel producers without considering the interests of more than 10 000 downstream manufacturers in South Africa), will serve only to accelerate the demise of this sector. These measures are ill-considered, shortsighted and self-serving. The Steel Industry, employers and employees - in fact, the whole of South Africa - are the losers.”

“The Steel Lobby (supported by employers even beyond NEASA membership) undertakes to see to it that, in dealings with the International Trade Administration Commission (ITAC) and the Department of Trade and Industry (DTI), the interests of downstream manufacturers are sufficiently represented,” NEASA said in a statement.

The International Trade Administration Commission of South Africa (ITAC) had imposed 10% duties on zinc-coated, aluminium- zinc-coated and colour-coated steel and was fast-tracking applications for other steel grades. Steel producer ArcelorMittal South Africa CEO Paul O’Flaherty has said it expected ITAC to approve protection across all domestically produced steel grades by the end of November.

Work was also under way on various antidumping and safeguard applications, in a bid to raise protection on certain products by upwards of 40%. NEASA further undertook that the Steel Lobby, would, in dealings with the ITAC and the Department of Trade and Industry, ensure that

the interests of downstream manufacturers were sufficiently represented.

“We shall keep you informed as matters unfold and constantly canvas your views,” the association said in an email to members.

For further details contact NEASA on TEL: 012 622 8971 or email [email protected]

Neasa concerned about ‘unequal’ antidumping duties — Steel Lobby launched

Representatives of the South African Institute of Foundrymen recently travelled to Russia to attend the International Congress of Russian Foundrymen and

Exhibition "Lityo-2015" in Nizhny Novgorod. At the same time the 5th BRICS Foundry Forum took place. The main subject of the Forum was "Production of steel castings", which gave delegates a perfect opportunity to explore the current economic situation in Russia and gain an impression of the huge potential they have there.

The hosts from the Russian Association of Foundrymen, with president Prof. Ivan Dibrov, provided an interesting program that included highlights of the Volga Region of Nizhny Novgorod, work visits to leading plants of the region and an intense exchange of information among the BRICS Foundry Forum members, suppliers and exhibitors.

Nizhny Novgorod, a leading region for the production of railway components, wheels, special steel parts, and automotive and aerospace products, was the right place for Russian metalcasters and the delegates from the BRICS Foundry Forum to meet.

The BRICS countries, which cover almost 60% of the world production of castings, held the 5th conference to support its member countries in becoming more competitive and strengthening their position in the global economy.

BRICS Foundry AssociationDuring the forum, delegates signed the constitution for

establishment of the interregional BRICS Foundry Association. The governor of the Nizhny Novgorod Region, Valery Shantsev, and representatives of the Ministry of Economic Development and the Ministry of Industry of Niizhny Novgorod participated at the signing ceremony.

The establishment of the BRICS Foundry Association was initiated by the national foundry associations: the Brazilian Foundry Association (ABIFA), the Russian Association of Foundrymen (RAF), The Institute of Indian Foundrymen (IIF), the China Foundry Association (CFA), and the South African

Institute of Foundrymen (SAIF), which have cooperated on annual Foundry Forums since 2011.

The BRICS Foundry Association is the project of multilateral, interregional, industrial cooperation and the first industrial association of BRICS countries.

The aim of the association is the consolidation of national foundry enterprises and organisations of BRICS countries for international industrial cooperation development, and assisting in the implementation of national development plans to provide BRICS economies sustainability as an integral part of the global economy.

Foundry production is a basic pillar of machine building and the machine tool industry. 30 to 50% of tools, machines, equipment, etc. consist of foundry products. At the same time, foundry enterprises are closely connected with metallurgy production and technology by providing foundries with metal raw materials.

Thus, the foundry industry is a vital technology link in the production cluster “Metallurgy–Foundry–Machine building” which is considered as one of the key factors of a national sustainable economy.

SAIF signs up as founding member of BRICS Foundry Association


This follows the announcement made by the Minister of Finance in the 2015 Budget. Cabinet approved the publication of the Bill, and noted that the carbon

tax forms an integral part of the system for implementing government policy on climate change as outlined in the 2011 National Climate Change Response Policy (NCCRP) and the National Development Plan.

South Africa has committed to reduce greenhouse gas (GHG) emissions below business as usual by 34% by 2020 and 42% by 2025‚ as well as adaptation measures‚ as outlined in the country’s Intended Nationally Determined Contributions (INDCs) recently submitted to the United Nations for the upcoming Conference of Parties (COP) 21 of the United Nations Framework Convention on Climate Change (UNFCCC) in Paris.

According to a statement issued by the Treasury‚ the carbon tax seeks to price carbon by obliging the polluter to internalise the external costs of emitting carbon‚ and contribute towards addressing the harm caused by such pollution.

“The Draft Carbon Tax Bill marks the next step in the consultation process conducted over the past 5 years‚ starting with the 2010 discussion paper on carbon tax‚ the 2013 Carbon Tax Policy Paper and the 2014 Carbon Offsets Paper. It takes into account comments received in writing‚ and from

meetings and workshops‚ from a wide range of stakeholders including business‚ NGOs‚ academia‚ civil society and labour.”

“The publication of the Draft Carbon Tax Bill provides an opportunity for further comments on the design and technical details of the carbon tax policy and administration. It should be noted that the final tax rate‚ exemptions‚ and the actual date of implementation will be determined by the Minister of Finance through the annual Budget process. The carbon tax will be implemented together with complementary measures like a reduction in the electricity levy and other measures to recycle revenue.”

“Stakeholders are invited to provide comments on the environmental and socio-economic impact of the carbon tax (taking into account revenue recycling measures)‚ as well as the design and legal wording of the Bill‚” the statement said.

A revised Bill incorporating comments received will be submitted to Cabinet for approval for tabling in Parliament‚ it added.

The Draft Tax Bill is published for public comments and is available on the National Treasury website: www.treasury.gov.za. Written comments should be submitted to Dr. Memory Machingambi, email: [email protected] by the close of business on 15 December 2015.

National Treasury publishes draft carbon tax bill for public comment


A feasibility study into the construction of the greenfield industrial complex and rail factory in Dunnottar, Ekurhuleni, which will house the Gibela Rail

Transportation rolling stock manufacturing plant, has been approved. The factory would produce 580 coaches and was expected to generate about 33 000 direct and indirect jobs.

During an Economic Sectors, Employment and Infrastructure Development Cluster (ESEID) media briefing recently, Transport Minister Dipuo Peters outlined that, at present, the Passenger Rail Agency of South Africa (PRASA) had received about 13 locomotives as part of the R51 billion contract for 600 new trains over ten years. PRASA expected another locomotive, currently being manufactured in Brazil, to be delivered by end-November.

South Africa’s 40-odd year gap when it comes to

train-building technology is about to close as the Gibela Rail Transport Consortium (Gibela) gears up to start the construction of its R1 billion, 85 000m² factory complex at Dunnottar in Ekurhuleni, Gauteng.

When the factory is completed and comes into production, building trains at a hitherto unheard of peak rate of 62 trains a year, South Africa will have taken a very visible and significant leap into the world of high-tech train manufacturing.

The ramifications of what the Gibela-PRASA nexus means for South Africa are extensive as this project will, in keeping with PRASA’s mandate, help restore the viability of South Africa’s commuter rail system.

When it is up and running, the Dunnottar facility will provide employment for at least 1 500 people, the majority of whom will be skilled artisans.

Gibela feasibility study approved

Greenfield industrial complex and rail factory to be built in Dunnottar, Ekurhuleni.

During the US Institute of Scrap Recycling Industries' Convention and Expo, held recently in the Canadian city of Vancouver, Recycling International met up with

David Loewenthal of URC, a Johannesburg-based scrap metal recycling company which processes and trades both ferrous and non-ferrous scrap. Recycling International asked him what had led the South African government to put a restriction on scrap metal exports in the first place.

Loewenthal: 'A sector of the consuming industry lobbied the Department of Trade and Industry (DTI) through the International Trade Administration Commission of South Africa (ITAC) that restricting scrap exports via a price preference system would result in greater metal consumption, and ultimately an increase in jobs which the ANC is presently lobbying for. When it was realised that restrictions would be placed, many of the other local consumers joined in and today we have this onerous minimum 20% scrap export restriction.'

And he adds: 'This new restrictive trade practice has now been in place for nearly two years, and not only have we seen no increase in the labour force of the consuming industry but possibly even a slight decrease. One must also bear in mind that, coupled with the current market

conditions, both ferrous and non-ferrous scrap collections have decreased - which is putting a lot of pressure on the entire scrap industry. Initially, the Metal Recyclers Association (MRA) took legal action against the DTI. The MRA lost the case as the matter was not regarded as urgent. It has

subsequently approached both the DTI and ITAC to try to clarify and simplify procedures, but on many occasions does not even get a response.’

According to Loewenthal, export restrictions are not the only problem for the South African recycling industry. 'We have a huge problem with theft in our country and I believe that we should abolish VAT as well as cash payments for scrap, which will make stolen material more difficult to dispose of. South Africa also has an energy crisis which is not only affecting our consumers but even the scrap processors. It has resulted in a huge impact on all our operating costs.'

And he concludes: 'In short, the South African scrap situation is very problematic, and until the DTI applies its mind in a manner which will promote both the scrap metal and scrap-consuming industries, the situation will only get worse.'

'We have a huge problem with theft'

David Lowenthal


The SAIF Council would like to thank the following companies for sponsorship of prizes, tee boxes and greens: Ametex, B&K Castings, Ceramic & Alloy Specialists,

Cerefco, Chemsystems, Cobra ISCA, Crawford Publications, Endeco Omega, Foseco South Africa, FP Specialities, Guestro Castings, IMP Scientific, Insimbi Alloy Supplies, JC Impellers CC, Lauds Foundry Equipment, LIL Sales, MCTS, Metal Connection, Mineral Zone, Nicast Foundry, Pentagon Resources, Procor, Rely Intracast, SAIF, SI Group HA, Thos Begbie and VIP Metals.

The competition on the day was fourball alliance with two scores to count on all holes. The closest to the pin prizes on the 5th, 7th, 11th and 15th holes respectively were sponsored by SI Group HA, Chemsystems, Insimbi Alloy Supplies and Cobra ISCA. The longest drive prizes on the 4th and 18th holes respectively, were sponsored by VIP Metals and Pentagon Resources.

Procor Foundry Supplies sponsored the 15th hole and unfortunately nobody won the hole in one competition. However, Procor did raise R5000.00 for the SAIF on the day via a challenge they gave to the participating golfers on the hole they sponsored. Well done to them.

Thos Begbie sponsored the 3rd hole and players had to enter a lucky draw competition by donating R10.00 and a golf ball. R750.00 was raised, and seen drawing the lucky winner was Eugene Rossouw of Thos Begbie, and Janley Kotze the SAIF Vice President. The prize was later auctioned for R1000.00 and thanks to Rudi Pienaar of High Duty Castings for the successful bid.

Another R200.00 was donated in the form of a fine for playing off the ladies tee-box on the 14th hole, and there were no ladies in the team. You know who you are. The SAIF thanks you for the donation.

There were four closest to the pin prizes and the winners were:

5th hole - Sponsored by SI Group HA — Dijon Brink7th hole - Sponsored by Chemsystems —

Twayne Stewart11th hole - Sponsored by Insimbi Alloy Supplies —

Rudi Pienaar15th hole - Sponsored by Cobra ISCA — Louis Miller

There were two longest drive prizes and the winners were:

4th hole - Sponsored by VIP Metals — Dwayne Barnes18th hole - Sponsored by Pentagon Resources —

Dwayne Barnes

The winners on the day on a score of 99 points were Mark Sims, Arthur Spires, Heinrich Engelbrecht and Louis Dique. Great score for players with handicaps of 17, 19, 27 and 27 respectively. Three of this fourball came in first in 2012.

Coming in second on a score of 98 points were Twayne Steward, Andrew Mc Farlane, Allan Atkinson and Dave Raper. In third place, also on a score of 98 points, were Charles McGeer, Shaun Tredwell, Riaan van Tonder and Louis Miller and in fourth place, also on a score of 98 points, were Alistair Rodgers, Nigel Brain, Matthew Cockcroft and Kevin Grieves.

The longest day prize winners were Justin de Beer, Marius Zwemstra, Erik Zimmermann and Charl Coetzer on a score of 34 points

SAIF 2015 Annual Golf Day

The longest day prize winners were Justin de Beer, Marius Zwemstra, Erik Zimmermann and Charl Coetzer

on a score of 34 points

Closest to the pin winner on the 7th hole, sponsored by

Chemsystems, was Twayne Stewart. He is seen collecting his prize

from Deon Smit (right), of Chemsysems


Insimbi Alloy Supplies, was Rudi Pienaar. He is seen collecting his prize from Dudley de Beer (right),

of Insimbi Alloy Supplies

The South African Institute of Foundrymens' Annual Golf Day took place on Thursday 12th November 2015. The event was held

at the Reading Country Club.



Cobra ISCA, was Louis Miller. He is seen collecting his prize

from John Davies (right), CEO of the SAIF

The longest drive winner of the day was Dwayne Barnes. Dwayne had the longest

drive on the 4th hole, sponsored by VIP Metals, and on the 18th hole, sponsored by Pentagon Resources.

Dwayne is seen collecting his prizes from Naas Grobler (left), of VIP Metals

The winners on the day on a score of 99 points were Louis Dique, Arthur Spires, Mark Sims and Heinrich Engelbreght (absent).

They are seen with Rui Dias, third right, who was representing the Dias family, the sponsors of the new SAIF Golf Day trophy,

which is known as the Luis Dias Trophy

Coming in second on a score of 98 points were Twayne Steward, Andrew Mc Farlane and Allan Atkinson (absent Dave Raper)

In third place, also on a score of 98 points, were Charles McGeer, Shaun Tredwell, Riaan van Tonder and Louis Miller

In fourth place, also on a score of 98 points, were Alistair Rodgers, Nigel Brain, Matthew Cockcroft and Kevin Grieves

In fifth place on a score of 96 points were Rob van Niekerk, Tulio Coehlo and Neville Sanders (absent Len Sanders)

Thos Begbie sponsored the 3rd hole and players had to enter a lucky draw competition

by donating R10.00 and a golf ball. R750.00 was raised, and seen drawing the lucky winner

was Eugene Rossouw of Thos Begbie, and Janley Kotze the SAIF Vice President. The prize was later auctioned for R1000.00 and thanks

to Rudi Pienaar of High Duty Castings for the successful bid


Lightweight, high-performance metals leader Alcoa has announced plans to further

expand its global aerospace business through a definitive agreement to acquire privately held Tital. The acquisition will strengthen Alcoa’s global position to capture increasing demand for advanced jet engine components made of titanium.

Germany-based Tital is a leader in titanium and aluminium structural castings for aircraft engines and airframes. Its revenues from titanium are expected to increase by 70 percent over the next five years as manufacturers of next-generation jet engines look to titanium solutions for engine structural components. Titanium can withstand extreme high heat and pressure, and is a lighter weight alternative to steel, providing increased energy efficiency and improved performance. These engines are used on large commercial aircraft, including wide- and narrow-body airplanes. Engines for narrow-body aircraft are among the top selling jet engines in the world.

Transaction benefitsThis transaction will further position Alcoa to capitalise

on strong growth in the commercial aerospace sector. Alcoa projects a compounded annual commercial jet growth rate of 7 percent through 2019 and sees a current 9-year production order book at 2013 delivery rates. Almost 70 percent of Tital’s revenues are expected to come from commercial aerospace sales in 2019. In 2013, the company generated revenues of approximately €71 million (US$96 million), more than half of which came from titanium products.

The acquisition will establish titanium casting capabilities in Europe for Alcoa, while expanding its aluminium casting capacity. Tital’s strong connections to European engine and aircraft manufacturers such as Airbus, Snecma, and Rolls-Royce, will enhance Alcoa’s customer relationships in the region, and beyond.

Alcoa splitting ‘downstream’ metal from ‘upstream’ value-added products

Directors of Alcoa approved a plan to separate the organization into two independent, publicly traded companies, one that comprises the primary aluminum production activities (bauxite, alumina, aluminum, casting, and energy), retaining the Alcoa name; and one that incorporates its “innovation and technology-driven” lines of business, including the Global Rolled

Products, Engineered Products and Solutions, and Transportation and Construction Solutions divisions.

Alcoa’s investment casting and forging operations would be included in the new company, which as yet is unnamed. In July, having completed its acquisitions of Firth Rixson Ltd., Tital, and RTI International Metals, Alcoa reorganized Engineered Products and Solutions (EPS) segment

around its activities I the critical aerospace market. EPS — which now becomes one of three components of the spin-off company, includes a) Alcoa Titanium & Engineered Products, b) Alcoa Fastening Systems & Rings and Alcoa Forgings & Extrusions, and c) Alcoa Power & Propulsion.

At that time, too, it formed the Transportation and Construction Solutions segment, which includes the former Alcoa Wheel & Transportation Products, and Alcoa Building & Construction Systems.

The new “upstream business” will be particularly focused on the aerospace industry (with products like jet engine and

industrial gas turbine airfoils, and aerospace fasteners) and the aluminum-intensive automotive market, via rolled products and aluminum commercial truck wheels.

Alcoa emphasized that both new companies will attract investors “best suited to their unique value proposition and operational and financial characteristics.”

“In the last few years, we have successfully transformed Alcoa to create two strong value engines that are now ready to pursue their own distinctive strategic directions,” stated chairman and CEO Klaus Kleinfeld. “After steering the company through the deep downturn of 2008, we immediately went to work reshaping the portfolio. We have repositioned the upstream business; we have an enviable bauxite position and are unrivalled in alumina, we have optimized Aluminum, flexed our energy assets, and turned our (primary aluminum) casthouses into a commercial success story. The upstream business is now built to win throughout the cycle.”

He continued: “Our multi-material value-add business is a leader in attractive growth markets. We have intensified innovation, made successful acquisitions, shed businesses without product differentiation, invested in smart organic growth, expanded our multi-materials profile and brought key technologies to market; all while significantly increasing profitability.”

The separation will be carried out in the second half of 2016.

Alcoa acquires titanium casting company

international news

Transaction enhances product suite in high-growth jet engine segment.

“In the last few years, we have successfully transformed Alcoa to create two strong value engines that are now ready to pursue their own distinctive strategic

directions,” stated chairman and CEO Klaus Kleinfeld


The international die casting industry meets at Europe’s biggest trade fair for die casting for the 11th time. The product spectrum shows innovative solutions for die

casting processes like aluminium die casting, magnesium die casting or zinc die casting. The event also focuses on topics like rapid prototyping, CNC machines, metal alloys, die casting moulds, peripheral devices, joining processes, process optimisation, energy efficiency, material testing, die casting machinery and 3D printing.

Focus on die casting processesEuroguss, which takes place every two years, started in

Sindelfingen in 1996 with 93 exhibitors, and today it is Europe’s biggest and most important trade fair for the die casting industry. The event set new records in 2014 with 470 exhibitors

and 11 187 trade visitors.Around half the Euroguss exhibitors are international.

After Germany with a big gap, the list of the most important exhibiting countries from Europe is headed by Italy followed by Turkey, Austria, Switzerland, Spain, France and Slovenia. The

exhibitors are die-cast foundries along with their suppliers, equipment suppliers and service-providers. At the fair they will be showing die-cast

products, technology along with machinery, peripheral appliances, furnaces, moulds, prototyping, metals and alloys as well as release agents and operating materials. Apart from this there is also a range of products covering the post-treatment of die-cast parts, quality assurance, control and drive technology along with software.

For further details visit www.euroguss

EUROGUSS - International trade fair for die casting

Technology, processes and products exhibition for the die casting industry takes place 12-14 January 2016 in Nuremberg, Germany.

14th World Conference on investment casting

The EICF (European Investment Casters’ Federation) and the ICI (Investment Casting Institute) from North America, and the JFS (Japan Foundry

Society) invites the global community of investment casting, foundries, suppliers, research and technology organisations and customers to attend the 14th World Conference on Investment Casting, to be held at “Le Palais des Congrès de Paris” in Paris, France, from April 17-20, 2016.

A host of presentations will be given on the following topics of interest and others:

• New advances in investment casting technology• Innovations in equipment and processes• Materials (advance materials & new

material solutions)• Quality & continuous improvement• Building value propositions for the

customers

For further details visit www.ecif.org

Paris, France, April 17-20, 2016.


2015 has been 'a very tough year' in which the 'bad economic climate' has led to adverse effects on companies' budgets and employment plans, according to

the BIR non-ferrous metals division's president David Chiao of the Uni-All Group in the USA, in a report in Recycling International.

Addressing the divisional meeting in Prague recently, Nick Rose of UK-based Tandom Metallurgical Group echoed these same sentiments in his world market summary. 'It was never going to be the year of plenty but the most pessimistic of bears couldn't have foreseen the constant downward spiral of 2015,' he lamented.

Billet exports from China 'at ever-decreasing prices' had been 'truly the cause of the present condition of ferrous scrap values', stressed BIR ferrous division president William Schmiedel of Sims Metal Management in the USA. 'The good news,' he added in Prague, 'is that the lower prices we are experiencing today should enable our customer base to again start to look at ferrous scrap as a reasonable, viable and economic option.'

At the BIR stainless steel and special alloys committee meeting, its chairman Joost van Kleef of Oryx Stainless described 2015 'as one of the most challenging years to date for the stainless steel recycling industry'.

China's continued exportation of its excess steel production in the form of semi and finished product has forced down ferrous scrap prices to levels ‘not seen in 11 years’, laments

William Schmiedel, president of the BIR ferrous division. “Our industry needs to find new ways to compete. We cannot

look to the market to help us but should rather concentrate on the things we can control, like our costs and streamlining our production wherever we can.”

China's finished steel exports in July and August combined for over 19m tons but even this figure was eclipsed by the record-breaking 11.3m tons shipped out in September alone, he points out. Among those countries feeling the impact, a number of steel mills in Taiwan are said to be in trouble 'and might have to close'.

And in the USA, scrap inventories have exceeded mill demand for the last quarter and thus provided domestic steel mills with an opportunity to 'continually reduce scrap prices month over month'. When consumers looked to lop US$ 50 off scrap prices in October, 'most scrap sellers capitulated and took any orders they could find'. This weakness appears set to persist into November as many mills’ order books remain weak and scrap 'continues to overhang the domestic market'.

The summary of the EU market puts Chinese billet at around US$ 260 per ton - or a reduction of approximately US$ 80 since July. HMS into Turkey has duly dropped to US$ 165-170 per ton, which is equivalent to a US$ 100 slump since the middle of 2015. These low scrap prices 'have adversely affected businesses across the entire EU', with some operators suggesting volumes are down as much as 40%.

Metal recyclers struggling through 'a very tough year'

Ferrous scrap prices at lowest point in 11 years.


ASK Chemicals, the global foundry chemicals supplier, has purchased the European foundry business of Hexion Inc. (Ohio, USA). With this acquisition ASK

Chemicals has broadened its portfolio of foundry chemicals in the field of Alphaset phenolic resins, Betaset phenolic resins and furan resins.

ASK Chemicals and Hexion have agreed on an intangible asset purchase of Hexion’s European business book and a long-term toll manufacturing agreement, whereby Hexion will continue to manufacture the products for ASK Chemicals.

Amongst other products, Hexion supplies binders and ancillaries to the international cast metals industry. These foundry products include binders for producing sand cores and moulds as well as refractory coatings, resin coated sands (RCS), adhesives and other associated consumables.

Both Hexion and ASK Chemicals are committed to ensuring that the transition of the business will be seamless. Customers can trust that there will be no changes in product, production or contractual terms.

“This acquisition is an important step in our growth strategy. With these new products ASK Chemicals is able to offer our customers an even broader portfolio of no-bake and furan resin,” states Frank Coenen, Chief Executive Officer of ASK Chemicals.

“We will introduce the world-leading products of the Alphaset family to a wider foundry market.”

Alphaset products are especially known for their superior technical and environmental performance in the field of no-bake binders.

For further details contact Applied Casting Solutions on TEL: 011 922 1824 or visit www.chemsystems.co.za

ASK Chemicals acquires Hexion’s European foundry business

Nine leading steel producer bodies from Europe and the Americas have issued a joint statement in which

they dismiss claims from China that it should be automatically accorded treatment as a market economy, after the fifteenth anniversary of its accession to the World Trade Organisation (WTO) in December 2016. The Chinese steel industry is 'the predominant global contributor' to the overcapacity 'crisis' afflicting the world steel industry, they insist.

China's 'overwhelmingly state-owned and state-supported' steel industry has an overcapacity of 336 to 425 million tons which is expected to grow in the coming years and is already resulting in exports that are on track to exceed 100 million tons this year.

“Provisions allow WTO members to treat China as a non-market economy country, unless the government of China or Chinese producers can show that they operate under market economy conditions,” the statement reads.

“Given the continuing significant role of the Chinese government in many key aspects of the Chinese economy, and especially in its state-owned and controlled steel sector, there can be no question that China remains very much a non-market economy today.”

At the BIR convention in Prague, China's billet exports at

'ever-decreasing prices' were said to be the main factor behind the recent slump in ferrous scrap values.

The statement is endorsed by: the American Iron and Steel Institute; the Steel Manufacturers Association; the Canadian Steel Producers Association; Mexican steel association Canacero; Latin American steel association Alacero; European steel association Eurofer; Instituto AcoBrasil; the Specialty Steel Industry of North America; and the Committee on Pipe and Tube Imports.

Steel producers question China's market economy ambitions

As emphasised at the BIR's late-October world recycling convention in Prague, external pressure is mounting on China over its low-priced steel exports.


Capacity utilisation in the global crude steelmaking sector was short of 70% in September - the

third consecutive month spent below this threshold. The utilisation rate of 69.3% was four percentage points below that of the same month last year but 1.3 percentage points ahead of that for August 2015.

Meanwhile, world crude steel output across the first nine months of 2015 was more than 30 million tons or 2.4% lower than in the same period last year at 1.212 billion tons. Latest statistics from the World Steel Association (WSA) confirm that, among the main producing countries and regions, year-on-year growth was restricted to India (+3.1% to 67.575 million tons), the Middle East (+1% to 20.908 million tons) and Oceania (+5.5% to 4.342 million tons).

Apart from conflict-hit Ukraine (-20.5% to 17.106 million tons), the steepest year-on-year crude steel output falls were recorded by Turkey, with a drop of 7.8% to 23.78 million tons and the USA, where production slid 8.6% in January-September this year to 60.629 million tons.

Japan's total was 5.2% lower at 78.81 million tons while China recorded a decline of 2.1% to 608.94 million tons. Far smaller reductions in output were registered by the EU-28 (-0.3% to 127.473 million tons),

South America (-1.4% to 33.35 million tons), Russia (-0.5% to 53.304 million tons) and Africa (-0.1% to 10.685 million tons), according to the WSA statistics.

30 million tons wiped off world steel output

Spectro Analytical Instruments Inc., with U.S. headquarters in Mahwah, New Jersey, has opened a new application and demonstration laboratory in Irvine,

California.The company developed the laboratory “due to the

remarkable growth in demand for application development support and strong interest in our next generation instrument lines,” says Mark Grey, vice president and general manager, Spectro Analytical Instruments.

The laboratory features the latest in the company’s instrumentation and technology for elemental analysis, including inductively coupled plasma optical emission spectrometry (ICP-OES), X-ray fluorescence (XRF) spectroscopy,

inductively coupled plasma mass spectrometry (ICP-MS) and optical emission spectroscopy using arc and spark excitation (arc spark OES).

Grey encourages laboratory managers, scientists, technicians and other professionals to use the laboratory’s state-of-the-art Spectro analysers and staff of lab technicians to assist in their application research, development and trouble-shooting projects.

The laboratory will also host technical events, training sessions and instrument and application demonstrations, Grey says.

For more information, contact Spectro Analytical Instruments on TEL: 011 979 4241

Spectro opens application and demonstration laboratory

The Yorkshire Man of Steel is a 30 metre high sculpture and visitor centre located in Rotherham England, forming a landmark gateway to Yorkshire and the Sheffield City Region.

The inspiration for the Yorkshire Man of Steel sculpture came from local sculptor Steve Mehdi’s own experiences in the steel industry and the region’s rich industrial history across the

steel and coal industries. The sculpture was originally intended as a memory to generations of people who worked in numerous factories and coal mines, unsung individuals who forged

the region's reputation of steel and coal in the process. It will also signpost the advances in the new technology sector and specialised steel manufacturing, which has led to

a transformation in the region in the 21st Century

Exova advances new aerospace material

Exova, a global testing group, has undertaken a test programme on a new corrosion-resistant

stainless steel alloy (CRES) for a consortium of leading aerospace organisations. The new material is being developed for use in landing gear components and is unique in its strength, lightness and affordability. Exova provided the consortium with a comprehensive range of tests to determine strength, fracture toughness and stress corrosion cracking resistance.

The new CRES steel offers enhanced corrosion resistance and is an example of innovation within the sector. The development of the material for aerospace applications

was undertaken by Airbus in partnership with Messier Bugatti Dowty, Carpenter Technology and the Advanced Manufacturing Research Centre at the University of Sheffield.

Speaking about the project, Stuart Abbs European director of aerospace for Exova, said: “Our laboratories in Toulouse and Dudley developed a bespoke testing programme to help the consortium accurately determine material

performance. Our work throughout the development phase underlines the mission-critical role that testing plays in advancing aerospace materials and aircraft performance.”

GE acquires France's Alstom, forms Power Division

A $10.6 billion price tag will net General Electric a tremendous asset to offer a go-to source for power plant management.

General Electric wrapped up a deal worth almost $11 billion to acquire the energy assets of French company Alstom recently and, in turn, formed the newly branded GE Power.

With the acquisition, GE aims to partner its own power generation technologies, services and expertise with the technology and geography of Alston to provide “total power plant and life cycle solutions that can support equipment from multiple suppliers.” GE paid a reported 9.7 billion euros, a little more than $10.6 billion.

“The completion of the Alstom power and grid acquisition is another significant step in GE’s transformation,” chairman and CEO Jeff Immelt said in a statement. “The complementary technology, global capability, installed base, and talent of Alstom will further our core industrial growth.”

The deal received approval from almost two dozen countries and regions, with anti-trust regulators in the United States and Europe forcing GE to sell off some of its maintenance assets

to keep it from dominating the gas turbine market.

GE Power will encompass more than 65,000 employees in more than 150 countries, with an estimated revenue of $30 billion, according to a company statement.

“We now offer utility and industrial power plant operators even more complete, customised ‘one-stop shop’ solutions — not just for developing new stations, but also optimised life cycle support for existing facilities to support local energy security,” said Steve Bolze, who will serve as the president and CEO of GE Power.

GE originally reached an agreement to purchase Alstom’s power and grid businesses back in April 2014 after a bidding war with Siemens.

GE also announced it had sold a rail signaling business to Alstom for $800 million — part of the company’s efforts to focus more directly on its energy portfolio.



The World Foundry Congress (WFC2016) will be held at Portmesse Nagoya located in Nagoya for the five days starting from May 21 to May 25, 2016.

It has been 26 years since the congress was last held in Japan.

The exhibition portion of the congress will be held on a large scale for the three days of May 22 to May 24, with an expected number of exhibitors exceeding 100 companies from Japan and abroad. The exhibition will be a venue to introduce foundry products made of steel, aluminium and copper alloy, as well as equipment, moulds, secondary materials and cutting-edge technology, such as the latest analysis software and 3D printers.

In addition, the exhibition will provide opportunities for interactions, products will be displayed and demonstrations held on large machinery such as large moulding machines, will take place. There will also be a PR booth to introduce products and technology.

Visitors can attend the exhibition free of charge, and it is expected more than 10 000 visitors will attend including those from the foundry industry and organisations, other

industries and students from over 30 countries around the world.

For further details visit www.wfc2016.jp

72nd World Foundry CongressMay 21 - 25, 2016 - Nagoya, Japan

One of the historic sites that visitors and exhibitors will be able to see in Nagoya is the Nagoya Castle

CastExpo and Metalcasting Congress 2016 brings together casting suppliers, metalcasters, and casting buyers for four packed days of

demonstrations, discussions, meetings, workshops and displays.

The event, sponsored by the American Foundry Society (AFS) will take place from 16-19 April 2016 in Minneapolis in the state of Minnesota, USA. CastExpo is the single largest trade show and exposition for metalcasting in the Americas.

The Metalcasting Congress is held every year in the spring and consists of technical sessions, awards banquets, a table-top exhibition show and Cast in North America (an exhibit opportunity for metalcasters to showcase their capabilities to casting buyers). Every three years, The Metalcasting Congress is held in conjunction with CastExpo and also features full equipment displays from international manufacturers.

For further details visit www.afsinc.org

CastExpo and 120th Metalcasting

Congress 201614 – 16 April 2016, Minneapolis, USA.

Held for the first time in Vicenza, Italy in 2002, the HTDC Conference has become a key-event for the international industrial and academic community

involved in the casting processes of aluminium, magnesium and other non-ferrous alloys.

Today, die casting production is facing new challenges from eco-sustainability and efficient energy usage to optimisation of product properties, from alloys’ properties improvement to design of lightweight components. Only an "open minded" approach, resulting in a high capability of being innovation-driven, integration-oriented and implementation-ready, will make die casting foundries successful in an international arena dominated by competition.

To sustain the development of this capability, i.e. the competitiveness in die casting production, HTDC 2016 will review:

• Innovations, from alloys to processes, from design to applications, which are available to foundries, suppliers, end-users

• Multi-disciplinary integration of concepts, methods and processes

• Implementation, into the industrial context, of new and modern solutions for quality, efficiency,

high performance

For further details visit www.aimnet.it/htdc2016

High Tech Die Casting 2016: Venice, Italy22-23 June 2016.


As manufacturers, particularly in the automobile industry, continue to work toward

incorporating lighter metals like aluminium with heavier steel, the ongoing problem has been how to successfully weld them together. The problem is that the high heat created in the welding process actually weakens these lighter metals, creating a less than optimum weld. After 10 years of research, engineers at The Ohio State University have developed a new welding technique that may prove to solve this problem while also using 80 percent less energy and creating bonds that are 50 percent stronger.

"With our method, materials are shaped and bonded together at the same time, and they actually get stronger," says Glenn Daehn, professor of materials science and engineering at Ohio State, who helped develop the new technique.

The traditional technique, called spot resistant welding, works by passing an electrical current through pieces of metal

using the natural electrical resistance within those metals. This generates heat that melts them together to form a weld. This process consumes a lot of energy, and the melted metals are left in a weaker state than they were before.

What Daehn and his team have done is create a new welding method called vaporised foil actuator (VFA) using short high voltage electrical pulses (lasting millionths of a second) passed through an aluminium foil, and a burst of hot gas traveling

at speeds approaching thousands of miles per hour, to bond the atoms of one metal to atoms on the other. Since the two different bonded metals don’t melt, neither metal is weakened and the resulting seam is stronger.

The energy savings comes from the fact that the electrical pulse is so short, and the required energy to vaporise the foil is less than is necessary to melt the parts together in a traditional process.

Daehn and his team have already used the process to successfully bond different combinations of copper, aluminium, magnesium, iron, nickel and titanium. They have created strong bonds between commercial steel and aluminium alloys — a feat which is impossible normally. VFA is evidently also able to shape metal parts during the welding process, which could save manufacturers an additional step.

In 2012, Honda announced it had created a similar result, welding aluminium to steel

using a variation of a process called friction stir welding (FSW). Rather than the high heat and gas applied to a third element like the aluminium foil used in the VFA process, FSW uses heat, friction and pressure with a third element to meld two metals together.

Like VFA, it uses less energy and creates a bond that has been proven to be stronger than that created by a traditional welding process. Variations of FSW have since been used by Lincoln, Mazda and Audi.

Researchers develop new energy-efficient technique to weld steel and aluminium

Microscope view of copper (top) welded to titanium (bottom) using a new technique

developed at The Ohio State University

Microscope view of steel (top) welded to aluminium alloy (bottom) using a new technique

invented at The Ohio State University

A diagram showing vaporisedfoil actuator welding, a technique

developed at The Ohio State University

"With our method, materials are shaped and bonded together at the same time, and they actually get stronger," says Glenn Daehn,

professor of materials science and engineering at Ohio State


• New binder increases 3D printing process speed and allows polymerization at room temperature, reducing post-processing

• CHP provides better surface finish and strength in complex 3D printed cores and molds ideally suited for automotive, aviation, hydraulic/heavy equipment and pump industries

The ExOne Company, a global provider of three-dimensional ("3D") printing machines and 3D printed and other products to industrial customers, has announced

the expansion of its suite of 3D printing binder offerings to add a new class of phenolic, referred to as cold hardening phenolic ("CHP"). ExOne's binder jetting technology uses a liquid binding agent selectively deposited to join powder particles and 3D print complex parts in industrial-grade materials.

The company initially introduced the availability of phenolic in July 2013, which binder is used with ceramic sand in the 3D printing of molds and cores, offering customers three primary benefits as compared with other binders:

• Casting higher heat alloys,• Creating a higher strength mold or core, and• Improving the quality of the casting due to

reduced expansion of the mold or core.

In addition to these benefits, the newly introduced

CHP binder accelerates the 3D printing process due to elimination of an infrared heating lamp that is utilised in the printing process with traditional phenolics. Using CHP, the polymerization of 3D printed molds and cores may occur at room temperature, further reducing both printing and curing time and eliminating the need for additional equipment such as a microwave. Alternatively, if additional drying is desired this may be achieved in a conventional air oven, equipment which is already maintained by most customers.

Rainer Hoechsmann, Chief Development Officer of The ExOne Company, commented, "With our focus on accelerating the adoption rate of our technology particularly in the foundry markets, we are excited to offer this new binder solution. Our customers are pleased with the strength, surface finish and high temperature resistance of our cores and mold packages printed with CHP, particularly for aluminium castings. We view this as an important offering in our technology and expect a shift in demand toward our machine platforms that allow this production."

ExOne is currently offering benchmark and production parts in certain material sets and expects to continue to expand its material offerings through 2015 and beyond. ExOne is also optimising its machine platforms and expects that its S-Print®, S-Max™ and Exerial™ platforms will each be available for purchase using CHP over the next nine months

For more information regarding ExOne's operations, visit the company's website at www.exone.com

ExOne expands suite of binders to include ExOne cold hardening phenolic (‘CHP')


This on-demand course teaches the basic microscopic structures present inside of metals, how these structures and metal composition influence metal strength,

and how these structures can be modified using common manufacturing processes to obtain specific mechanical properties. Several examples are presented to demonstrate how common alloying and manufacturing methods are used to modify the microscopic structures and properties of metals. This course takes four hours to complete. 0.4 CEUs will be awarded upon successful completion of the course.

Upon completion of this course students will be able to do the following:

• Explain the relationship between a metal’s properties and its composition, microscopic structure, and the manufacturing processes used to fabricate the metal

• Describe three types of microscopic structures present in metals

• Explain how cold working, alloying, and heat treating are used to strengthen a metal

• Explain the microstructure and property changes that occur in cold worked metals during annealing, in steels during through hardening, and during precipitation strengthening heat treatments

• Relate the heat treatment time and temperature to the microscopic structures and properties of through hardened steels, cold-worked metals, and precipitation strengthened alloys

Course outlineThe course consists of 12 modules and a final exam, and

will take 4 hours to complete. Modules are 5 to 25 minutes long and cover the following subjects:

• Composition• Microscopic structures• Crystal defects• Diffusion• Cold Working• Annealing• Solid Solution Strengthening• Precipitation Strengthening Heat Treatment• Steel and Steel Heat Treating• Target Audience

This course is targeted towards design, manufacturing, and quality engineers, and sales people and purchasing agents with technical backgrounds.

More information can be found at www.imetllc.com/metallurgy-courses

Metallurgy training: Principles of Metallurgy

Goliath’s humongous gate found

An expedition from the Bar Ilan University has discovered the fortifications and giant-sized entrance gate of the biblical city of Gath of the Philistines, home of Goliath.

The extraordinary size of the gate was surely enough to make way for the famed giant, though he never did return from meeting David.

Gath was the largest city in Israel during the 10th-9th century BCE, about the time of the "United Kingdom" of Israel. The city is located in the Judean foothills about halfway between Jerusalem and Ashkelon in central Israel.

Prof. Meir Ettinger of the Department of Land of Israel Studies and Archaeology says that the city gate is among the largest ever found in Israel and is evidence of the status and influence of the city of Gath during this period.

Among the various building discovered in the city is an iron production facility large enough to produce the kind of weapons used by Goliath as mentioned in the Bible. The city was eventually conquered and destroyed by Hazael, king of

Damascus, around 830 BCE.The gate of the Philistine city Gath was so impressive that it

received mention in I Samuel 21 in the story of David's escape from King Saul to Achish, king of Gath.

Gath is one of the largest tells or ancient ruin mounds in Israel and was settled almost continuously from the 5th millennium BCE until modern times.

Among other significant findings at the site is evidence of an earthquake in the 8th century BCE connected to the earthquake mentioned in the Book of Amos 1:1. Also found was the earliest Philistine inscription ever to be discovered which contains two names similar to the name

Goliath. In addition, a large assortment of weapons used by the Philistines were uncovered along with extensive evidence of the capture and destruction of the city by Hazael, as mentioned in 2 Kings 12:18. There is also evidence of the first Philistine settlement in Canaan around 1200 BCE.

An iron production facility found at the site.


Oxford Instruments has introduced a new model to its range of metal alloy sorters. mPulse, the handheld laser induced breakdown spectroscopy (LIBS) metals analyser

is now available as two options. mPulse and mPulse+

enable users to identify a wide variety of metal alloys at the press of the trigger, and measure light and heavy elements up to 10 times faster than any handheld XRF instrument on the market, says the company. With no costly detector or limited-lifetime X-ray tube to replace, maintenance and repair costs are low.

mPulse for fast scrap sorting

The mPulse analyser has been designed for the rapid identification and

sorting of heavier alloys such as stainless steels, Ni, Cu, Co, Ti alloys and many more.

The mPulse makes measurements in just one second regardless of the alloy type.

mPulse+ for aluminium sorting

The mPulse+ is able to separate even the close grades such as aluminium 6061 and 6063 in just one second. mPulse+ is designed for ultra-fast sorting of a wide range of metal alloys including magnesium and aluminium alloys, stainless steels, Ni, Cu, Co, Ti alloys and many more.

No X-raysmPulse and mPulse+ are

powered by LIBS technology which is 100% free from the regulatory constraints usually

associated with X-ray analysers. This means that costly and time consuming radiation safety training classes and user certifications are not required.

Rugged for low cost of ownershipDesigned with low cost of ownership in mind, both models

feature a strong sapphire window in the analyser’s nose, protecting the analysis head, safeguarding against the need for costly repairs and preventing contamination of the optics. The mPulse analysers are ready to use: with no set up required, skilled or unskilled staff can be up and running in minutes. Minimal training is required for optimal use and maximum throughput.

Mikko Järvikivi, Product Manager LIBS, Oxford Instruments, said “It has been exciting to witness the recent mPulse development. Based on feedback from our customers, our continuous development programme has allowed us to make enhancements to further improve our calibrations resulting in rapid yet accurate analysis for virtually any alloy sorting need.”

For further details contact Jaco Le Roux of United Scientific on TEL: 011 795 1900 or visit www.unitedscientific.co.za or www.oxford-instruments.com

product review

Oxford Instruments continues to develop metal alloy sorters - mPulse, the handheld laser induced breakdown spectroscopy (LIBS) metals analyser is now available


A new white paper explains why overcoming matrix effects associated with X-ray fluorescence (XRF) analysis is critical to achieving consistent high-accuracy results.

The paper, titled “Mitigating Matrix Effects with Advanced Spectra-Handling Functionality When Using XRF for High-Accuracy Elemental Analysis,” is available to download at http://goo.gl/5tIKb9 from Spectro Analytical Instruments, a leading manufacturer of advanced instruments.

A great advantage of energy dispersive X-ray fluorescence (ED-XRF) analysis for rapid screening analysis is its ability to measure samples directly with a minimum of preparation. Realising this benefit, however, requires eliminating potential errors that can result when atoms in the sample matrix influence the fluorescence of others, and thus the intensities measured by the spectrometer are influenced. Such effects,

which include absorption and enhancement, when taken collectively, are referred to generally as matrix effects. For quality control applications, when the sample matrix is known or can be matched, a variety of standards-based XRF calculation procedures are available to compensate for undesirable matrix effects.

However, creating the right basis for consistently high-accuracy results requires additional spectra handling functionality to determine the correct net intensities of the measured spectra. The new white paper explains why this additional functionality is a critical aspect of overcoming matrix effects and ensuring those consistently high-accuracy results. Download the new white paper from http://goo.gl/5tIKb9.

For more information, contact Spectro Analytical Instruments on TEL: 011 979 4241

New White Paper from Spectro: Why overcoming matrix effects with XRF analysis

is critical for high-accuracy results

At the recent GIFA 2015 the IMF Group took the opportunity to launch three new machines,

one each in the field of moulding, core-shooting and shot-blasting applications in the foundry industry.

MouldingAn intelligent mixer model

T36/60SL for No-Bake process with automatic and robotized filling controlled by a vision system which allows the continuous adaptation of the pattern filling position according to the real need of sand. The production management software and the very precise axles movements allow respectively the recognition of the pattern and the continuous adjustment of the filling position. The mixer features a production capacity of 60 tph with a total reach of 5 800mm.

Core shootingNew core shooting machine model SPH50-I, a hybrid

machine for inorganic and cold box processes using horizontally and vertically parted core boxes, for high rate production, suitable for the automotive sector. The mechanical cycle is 24 seconds. The maximum size of horizontally parted core box accepted is 1300 x 1100 x 600mm, while the maximum size of vertically parted core boxes is 1100 x 600 x 500mm. The maximum core box weight accepted is 2500 kilograms.

Shot blastingA shot-blasting machine SCM type, for continuous sand

removal and shot blasting of castings with ranging weights and shapes, specially designed for heavy-duty applications and high production demands. Shot is projected at high speed on the pieces by special blast wheels while hangers are rotated at two blasting stations. The result is a smooth and high quality surface finish. Castings are hung in bunch-like formation onto hangers connected via an overhead carousel conveyor.

For further details about the IMF Group contact Ceramic & Alloy Specialists on TEL: 011 894 3039 or visit www.ceramicalloy.co.za

IMF Group launches three new machines


Designed for reliability and speed for manual and semi-automatic grinding and polishing in the lab or next to the production line, the LaboSystem is ready for

your inspection. A choice between seven robust combinations gives you adaptability for your changing needs in demanding production environments. Struers’ LaboSystem also has the

endurance and speed you need to keep up with 24/7 throughput, enabling faster and more reliable preparation of specimens.

ReliableThe LaboPol is made from overall corrosion resistant and

impact proof materials. All the new LaboSystem products have been subject to 40 000 cycles of durability testing, and three months of field tests in four different countries.

FastLaboSystem is easy to learn, letting operators with no

previous experience come up to full preparation speed within minutes. The 300mm diameter disc size option means 44% larger preparation area (compared to 250mm diameter), shorter processing time and less time standing at the polisher.

AdaptableThe modular design of the LaboSystem lets you design your

sampling equipment to suit your individual needs. You can even upgrade along the way to accommodate new requirements.

Visit the website www.newlabosystem.com for more details.For more information, contact your nearest IMP Branch,

Gauteng TEL: 011 916 5000, KwaZulu Natal TEL: 031 764 2821, Western Cape TEL: 021 852 6133, Eastern Cape TEL: 041 364 2544, Free State TEL: 018 293 3333 or email: [email protected] website: www.imp.co.za

New Struers LaboSystem manual/semi-automatic polishing machines

Filtration technology for iron and steel foundries - Foseco

Since the introduction of Sedex iron filters more than 25 years ago, there have been many advances in terms of product performance and application technology.

Today iron filtration is regarded by most foundries as standard practice — the value and benefits of effective ceramic foam filtration are well documented and understood. Foseco has continued to work with customers to develop Sedex application technology to meet the increasing demands of casting end users. Gating system design can now be accurately modelled using Magmasoft casting process simulation software, and greater consideration is now given to the fluid flow characteristics of the melt.

Sedex filters today provide the most consistent metal flow rates and capacities for the customer, delivering the highest levels of filtration efficiency and inclusion removal.

Steel filtration technology has also advanced significantly in the last few years and foundries are now applying filters to castings of over 50 tons cast weight using the Hollotex CFU7 system.

Foseco have introduced new technology associated with their Stelex filter offering. This will provide improved consistency of performance and allow the application of finer

porosity filters where not previously possible. The steel foundry using the Stelex filters will enjoy the benefits of enhanced filtration efficiency and flow control resulting in their ability to produce higher quality and cleaner castings.

For more information contact Foseco on TEL: 011 903 9500 or visit www.foseco.com


Combicore cores for lightweight construction in die casting and other casting processes

New technologies and lightweight construction require new cooling concepts. In high pressure die

casting channels for cooling or oil are traditionally achieved by sliders or drilling afterwards. However, such cavities are bound to straight axes in the casting process.

With the innovative and highly stable Combicore solution, casting cores can now be applied in high pressure die casting for the first time, and the method allows for undercuts while retaining their shape, even with a high casting pressure level above 1000 bar.

The channels are no longer bound to straight axes. They can now follow the curved shape of the wall with single bends. This method results in a near net shape casting with a significant saving in material, and components are significantly lighter as compared to traditionally manufactured cast parts.

With the Combicore solution, engineers can design and develop new modern components. Combicore has proved to be successful in numerous applications, especially in the automotive sector where the cores are used for oil and cooling channels.

The Combicore cores can also be used in all other casting processes, like sand and chill-mould, as well as heavy metal casting.

Combicore casting cores consist of a metal tube filled with a moulding material. In light thin-walled aluminium castings

tubes of different alloys (e.g. AlMn1, AlMgSi0,5) and pure table salt are used. The filled tube is drawn through drawing dies and reduced in diameter. In the process the moulding material is compressed and solidified. The final shaping of the cores takes place on bending machines and if necessary by pressing.

Combicore cores allow for complex shapes to be cast, be several metres long and castings under 10mm in diameter. Due to the production processes used Combicore cores do not need any binder material or other additives. As a result there are no gases during the casting process.

Additionally, single cores can be connected to channel systems, which are easily inserted into the casting mould. The mounting of fixing bolts can simplify and accelerate the insertion process. After the casting process, the ecological

filler material is removed from the tube and can be recycled or used for other purposes.

The Combicore solution is about lost cores as the metal cover remains in the casting component as a protective channel wall. In doing so, cast defects or blowholes in the component play a minor part.

For further details contact Dr. Susanne Rupp of Drahtzug Stein on TEL: +49 (0)6356 966-225, email [email protected] or visit www.combicore.com

Highly stable cores used by foundries to implement oil and cooling channels in castings. For the first time, this method enables undercuts even in high-pressure die casting.

Stable cores for HPDC with casting pressures >1000 bar Combicores in different shapes

A cooling element for hybrid technology, a high pressure die casting cast with a

Combicore channel. The casting has gained special recognition at the International

High Pressure Die Casting Contest

In cooperation with Hüttenes-Albertus, a leading manufacturer of chemical products, Asco Carbon Dioxide’s dry ice blasting technology is setting new standards for the

removal of coatings on moulds.Mould and tool cleaning has great importance in foundry

operations. This is especially true when it comes to requiring optimal cleaning results of moulds and core boxes since an efficient cleaning process does not only increase quality but also boosts productivity while optimising costs.

In open dialogues with foundries, both companies figured out that there is still no efficient overall solution for partial or complete removal of the coating of moulds. Currently, heavy metal casting foundries need to remove the mould´s finishing coating several times a day. In addition, a regular removal of the base coating and an occasional roughening of moulds are required. This is an important criterion for the adhesion of the coating.

The removal of the finishing coating is mostly unproblematic and can be done efficiently with pure dry ice blasting which is a common practice in the foundry industry. However, when it comes to the removal of the base coating or the roughening process, pure dry ice blasting is of limited suitability, as the procedure takes too long or the desired effect cannot be reached due to physical reasons.

Pure abrasive blasting with sand or glass beads is too aggressive and would damage the surface of the moulds.

In addition, pure abrasive blasting causes high secondary pollution and/or clean up requirements.

This reason was enough for both companies to pool their joint expertise to offer an optimal overall solution to the end user. Hüttenes-Albertus is working on a special coating composition for smoothing porous moulding surfaces. For this purpose, finely to highly grounded base material is used. The coating isolates the mould´s ground and protects against thermal stress.

The common aim is to provide foundries not only with a high quality coating but also with the perfect complementary cleaning method. This is where Asco steps in because the recently launched Ascojet Combi blaster 1708 can close this application gap in the cleaning process.

The new Ascojet blasting unit is the perfect combination of gentle cleaning with dry ice pellets and the additional, abrasive effect of a specially selected additive.

The application can be used directly on the moulds without disassembling them, which is why the production can be continued immediately after the cleaning process, and the method can be integrated into the working process easily. This eliminates costly production downtimes and quality losses, and increases process safety with little effort.

For further details contact SI Group SA on TEL: 011 389 8200 or visit www.siigroup.com or www.huettenes-albertus.com

New standards set for mould cleaning using Asco technology


The device, with its new enhanced features, is a step from a data manager to a centralised monitoring and maintenance system for small solutions. The update of

the Advanced Data Manager Memograph M platform completes the Endress+Hauser portfolio update. Two years ago, the launch of Ecograph T as a universal data manager was the first step in that direction.

HART input cards as a true USPBesides the already existing universal inputs, Memograph

M RSG45 offers up to 20 inputs for HART signals. The HART protocol is supported by most sensors in the field. With HART inputs, the Memograph M can use the 4…20 mA signal as well as all four HART signals of a connected field device. Thus, the RSG45 allows the user to get more information from the field, which clearly improves the process insight and increases the process safety. Since there is no analog to digital conversion with the HART protocol, the calculations done by Memograph M RSG45 utilising HART are more accurate than the ones solely utilising analog signals. This results in cost savings, which is an added advantage in energy monitoring applications.

In addition, Memograph M RSG45 offers a HART gateway function. Therefore, the data manager allows direct access from the PC configuration software, FieldCare for example, to the field devices without the need for an additional HART modem or a loop interrupt. Thus, parameterisation of the field

devices can be done easily and quickly from the control room. With the help of this feature, the detailed instrument health status is available as well. This helps simplify maintenance and troubleshooting. This kind of HART functionality is unique in the market for data managers.

Stainless steel front and ATEX Ex xp approvalAnother highlight of Memograph M RSG45 is an optional

resistant stainless steel front made of 316L. This robust stainless steel front can be used in critical environmental conditions. As it does not have any interfaces on the device front, the Memograph M RSG45 can be operated on-site via a capacitive touch screen when this stainless steel front is selected. The stainless steel front, along with mounting the unit in a pressurised enclosure system makes the device appropriate for use in potentially explosive atmospheres. Due to this, safe data storage with Memograph M RSG45 becomes possible in ATEX Ex applications too.

Communication and integration flexibilityAnother new feature of Memograph M is the availability of

the industrial Ethernet based communication protocols EtherNet/IP and PROFINET. Both protocols are becoming more important in the process industry and help to increase

application flexibility of the device. All other fieldbuses that were already integrated in the previous device, like Modbus RTU, Modbus TCP, and PROFIBUS DP, will still be available as well on the Memograph M RSG45. This communication flexibility allows easy and cost-effective integration from the field level into the Ethernet based control levels and also minimises the commissioning time.

Also, WebDAV was implemented into the advanced data manager. WebDAV is an open standard to provide files on the internet as an extension of the Hypertext Transfer Protocol (HTTP). By WebDAV, the stored data of the SD card can be quickly, and due to encryption also safely, transferred to a PC without the need of additional software. As an additional advantage of WebDAV, Port 80 is used, which is generally not blocked by firewalls.

User friendliness and retention of well-known featuresOperation of the Memograph M is very user friendly. In the

standard version it can be done with the help of the navigator at the front of the device, and in the stainless steel version via touch screen. USB keyboard and mouse can be connected directly to the device. Furthermore, the device can easily be set up with the help of the completely new and improved web server. Indication of instantaneous values, instrument health status, remote access, and control of the device are also enabled by the web server.

Besides the described new functions, all important features that are already well known from the previous device are kept in Memograph M RSG45. The process values are indicated on the 7 inch high resolution display, in up to 10 signal groups, with various display options. All the values have tamper-proof recording on the internal memory. This is also optional on the SD card. The security requirements of FDA 21 CFR part 11 are fulfilled. There are several software packages available, including mathematic, tele-alarm, waste water and storm overflows, batches, and energy. Due to the different software packages and the modular design of the hardware, Memograph M RSG45 can be perfectly adapted to the particular application. You will only pay for what you need.

With the launch of the new Memograph M RSG45, Endress+Hauser is able to offer a state–of-the-art data manager portfolio: The Ecograph T RSG35 as the cost-effective solution for simple applications, and the Memograph M RSG45 with cutting edge technology at an excellent price-performance ratio for sophisticated applications. Data managers by Endress+Hauser are the right choice for every application.

For further details contact Benjamin Mlangeni, Product Manager Temperature System Components & Registration, Endress+Hauser on TEL: 011 262 8012 or visit www.za.endress.com

Focus on communication - New data manager

Advanced Data Manager Memograph M RSG45 features secure centralised monitoring and maintenance system.

Besides the described new functions, all important features that are already well known from the previous device are kept in Memograph M RSG45


With the new Schnorkle, liquid aluminium is transported from the melting furnace to the melting or holding furnaces in

a closed container, and introduced there using a transfer pipe without the need for tipping. With no contact to the atmosphere, the system ensures optimum safety and constant quality of the melt as the process chain between central melting aggregate and die-casting system is now closed.

High process reliability and occupational safety are two important pillars of optimum day-to-day foundry work. This is why StrikoWestofen (Gummersbach) has developed a new transport system with which hot liquid metal can be safely transported from the melting furnace to the dosing or holding furnace. “The idea behind this innovation was to consistently eliminate potential dangers like those which can occur in each phase of the process due to the handling of liquid aluminium,” explains Rudi Riedel, Managing Director of StrikoWestofen. “This is the only way to reliably prevent errors.” It could also allow the insurance premium for foundries to be reduced.

Schnorkle: closed systemThe new completely closed Schnorkle transport system

is the solution for achieving more process reliability and occupational safety. Schnorkle is filled directly at the melting furnace — either by hydraulic tilting of the furnace, from the

tapping valve or from a pump pocket using a pump. The pressure-tight cover is closed using one hand wheel only, and is transported to the dosing or holding furnace using a transport system such as a fork-lift truck. Pressure is applied to safely fill the melt into the dosing and holding furnace via a riser tube with no danger of spilling. The compressed air supply necessary for this is either connected on-site using a quick connect coupling, or is provided by a compressor on the fork-lift truck. A ready-to-install compressor is also available for Schnorkle as an optional accessory. With this option, the melt can be transferred to the dosing and holding furnace and the operator does not need to leave the fork-lift truck. Thanks to Schnorkle, it is no longer necessary to tip casting ladles at a great height using a lift truck.

Better metal quality and constant temperatureTreatment of the melt using impellers can also be

performed directly in Schnorkle without the need for transferring it to another container. The new system then ensures that the metal quality is preserved until the die-casting process begins. The flow rate of the melt coming from Schnorkle can be adjusted to allow low-turbulence transferal and minimize oxide formation. As a result of the closed system, Schnorkle has only low heat loss, and keeps the melt at a constant temperature. As it is no longer necessary to overheat the melt, the energy consumption of the foundry can be further reduced. The Schnorkle system is completed by a special preheating unit which requires considerably less gas than conventional ladle preheating systems.

For further details about Striko contact Ceramic & Alloy Specialists on TEL: 011 894 3039 or visit www.ceramicalloy.co.za

StrikoWestofen’s closed transport system for aluminium melt protects employees and equipment

Safety for people and equipment: this is a hot topic, especially in aluminium foundries where liquid metal is handled.

Closed transport system: With the so-called Schnorkle, hot liquid metal can be safely transported directly from the melting furnace to the dosing or holding furnace

Danger of accidents reduced considerably: Schnorkle from StrikoWestofen increases occupational safety in everyday foundry operation. Also, the quality of the melt profits from the minimal

contact with the atmosphere

vol 16 no 4 - castings sa sa... · induction furnace technology and energy efficiency a bp...

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