casting technologies

Transcription

knowledge can unlock the full potential of your foundry operations.
As a reliable and trusted supplier, Foseco can help you to improve
mechanical properties, increase casting integrity, lower fume emissions,
reduce waste or perhaps improve process control.
Whatever your foundry requirements are, talk to us.
A s i a Pa c i f i c
Vol 58, No 3 September 2012
Your foundry and Foseco. The power of two.
China • india • taiwan • Singapore
Indonesia • THAILAND • Philippines
Malaysia • Hong Kong • Japan • Europe
USA • Australia • Korea • New Zealand
l Treatment_NF_au_September_2012.indd 1
CASTING TECHNOLOGIES
COMMITTED TO FOUNDRIES
Phone: + (61) 2 9914 5500
Fax: + (61) 2 9914 5547
www.foseco.com.au
* COVERAL and ALSPEK are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
9/13/2012 9:15:58 AM
CM SERIES MIXERS
Sand Reclamation
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Moulds can be fed directly from casting line
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Gammavator
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Idea for small foundries
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Combined shakeout & sand elevation
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KNOCK OUT DECK
SAND
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design has been proven to provide
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Standard sizes from 1TPH to 100TPH.
Dual start spiral mixing blade
arrangement with over-lapping blades to
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Individually replaceable tungsten carbide
tipped blades held captive in slotted shaft
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Both sides of mixing chamber swing
away to provide easy access to the blades
and shaft for periodic
cleaning and maintenance
procedures.
Safety interlock on both
access doors.
Low sand level proving
probes in inlet hoppers to
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Pneumatically controlled
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320° rotation available on standard
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Slewing Ring on Multiple
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Multiple Pump Programs.
Fault diagnostic and
indication facility.
System Status Display.
High
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Standard type mixer with
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displaying full accessibility
to mixing shaft and blades
for periodic cleaning and
maintenance procedures.
A new Joint Venture to Benefit the Foundry Industry
Warill Engineering Sales (Aust) Pty Ltd, (WES) as of August 1st, 2012 has formed a joint
venture company with Omega Foundry Machinery Ltd based in the UK.
The new company will be known as WES Omega Foundry Machinery Pty Ltd, which will be based at the
existing WES premises located in Dandenong. The company will be headed by Les Craig (Managing Director)
and Peter Dimopoulos (Technical Director).
WES Omega will be in a position to manufacture the Omega product range along with the continuation
of the existing WES equipment. WES Omega will seek to see the improvement and extension of the
pre-existing equipment range servicing the foundry industry in Australia, New Zealand and parts
of South-East Asia.
Tungsten carbide tip mixing blades held captive in slotted
shaft to prevent rotation and provide efficient mixing action
and lowest possible resin addition rates.
Compliant Safety Interlock on barrel
doors interlocked with Mixer Isolating
Switch to provide safety for cleaning
and maintenance.
Sand inlet hoppers showing low level proving probes
and sand rating and isolation gates.
WES OMEGA FOUNDRY MACHINERY PTY LTD
WES OMEGA FOUNDRY MACHINERY PTY LTD
PH: +613 9794 8400 Fax: +613 9794 7232 Email: info@wesomega.com.au
Address: 16 Lanyon St, Dandenong Vic 3175, Australia
PH: +613 9794 8400 Fax: +613 9794 7232 Email: info@wesomega.com.au
Address: 16 Lanyon St, Dandenong Vic 3175, Australia
The technology of batch degassing for
hydrogen removal from aluminium
melts utilising different rotor designs
Background
Rotary degassing of liquid aluminium alloys is a widely used
commercial process to control levels of hydrogen, alkali metals
and inclusions in the melt prior to casting. However the time
taken to reach the required quality standard can vary considerable
depending on rotor design. A selection of different Foseco
degassing rotors has been characterised in a comprehensive
experimental program. The study has resulted in an Internet based
simulation software for the degassing process in foundries with
significantly improved degassing efficiency.
A comprehensive theoretical understanding of the kinetics of
aluminium degassing has been established in the past twenty
years. Whilst there have been some published experimental tests
of degassing theory in molten aluminium, in many cases key pieces
of information are not reported or determined, such that a critical
assessment of the underlying theory is compromised. Similarly,
practical implementation of such understanding in usable shopfloor process models has met with difficulties owing to lack of
knowledge concerning some key parameters. These include the
stirring intensity dissipated in the melt, and its relationship to the
average gas bubble size, and the mass transfer coefficient at the
free surface of the melt.
Gas porosity and inclusions
In foundries today we recognise two major issues of molten
metal quality; gas content and inclusions. The presence of porosity
became even more problematic when age hardening alloys were
developed, because near surface porosity invariably blistered on
the surface. Additionally, a significant loss of mechanical properties,
such as tensile strength was found with increasing porosity levels.
to the lance outlet or to the bottom of the furnace, create typically
finer bubbles of 10 to 20 mm in diameter; but even with them, the
homogenising and bubble distribution is not optimal. Initially, the
development of spinning injection systems with rotors attached
solved the problem of insufficient gas distribution and delivered
bubble sizes in the range of 3 to 10 mm in diameter.
Hydrogen solubility
Hydrogen comes from the water vapour in the atmosphere, which
readily reacts with liquid aluminium to produce two problematic
reaction products, i.e. alumina (inclusions) and hydrogen (gas).
2 Al (l) + 3 H2O (gas) = Al2O3 (s) + 3 H2 (gas).
Aluminium has problems with hydrogen, not because it
is particularly soluble in liquid aluminium, but because it is
particularly insoluble in solid aluminium and so it comes out
of solution during solidification. Solubility mainly depends on
the temperature of the aluminium. Alloying elements such as
magnesium also affect the hydrogen solubility.
Theory and principals of hydrogen removal
Hydrogen needs to be removed from the melt prior to casting
with inert gases, such as argon or nitrogen being used to purge
the melt. A given inert gas flow rate will have a greater interface
area for smaller bubbles. Additionally, each bubble stays longer
in the melt as the bubble gets smaller, since the terminal velocity
is reduced and allows longer time for hydrogen transport. A
deeper reaction zone in a ladle or crucible allows more time for
equilibrium because the bubble stays in the melt longer before
reaching the surface.
Therefore, the design for a practical degasser needs to create
the smallest bubbles low down in the treatment vessel, at a high
velocity; mixing the melt at the same time to get a homogenous
hydrogen distribution.
Lance treatment was the beginning of industrial degassing, but
lances tend to produce rather coarse bubbles between 10 and
50 mm in diameter without a wide bubble size distribution and
offered limited melt homogenising. Porous blocks, either attached
Figure 7. Comparison of inert gas bubble size generated by different
systems [2]
Power analysis of degasser rotors
Figure 8.
XSR Rotor
The recently developed FDR and XSR rotors
generate higher power than the traditional
rotors. Therefore, these rotors create finer
bubbles. The GBF XHT, predominantly used in
the Asian foundry market, performs similarly
to the best-in-class European designs.
Mixing capabilities of degasser rotors
A well designed degassing system will have two key attributes.
Firstly, the melt will be rapidly mixed to achieve and maintain
chemical and thermal homogeneity throughout the process. It
is important that the time required to achieve good mixing is
substantially less than the metal treatment time. Secondly, the
turbulence generated by the rotor will result in small average
size of inert gas bubbles, which the well mixed flow patterns will
ensure are well distributed throughout the melt.
At lower speeds of around 200 rpm, the FDR rotor needs about
40 seconds for effective mixing whilst other types need up to 3
times more. With increasing speed the differences between the
rotor types becomes smaller. These observations are almost inline
with experiences from foundry trials; FDR rotors start at a lower
speed and have a good degassing performance.
The FDR rotor is seen to perform well across the board at all
diameters. It generally had a significantly shorter mixing time than
the XSR rotor of equivalent diameter, primarily because the FDR
rotor delivers more power into the liquid at a given speed.
Batch degassing software
Figure 1. Surface porosity visible
on a casting
Figure 2. Internal porosity visible
on a machined face
Figure 3. Tensile strength vs. porosity level [1]
2 www.metals.rala.com.au
Figure 4. Hydrogen solubility in aluminium
Figure 5. Effect of increased water vapour pressure on hydrogen
solubility [2]
Foseco’s non-ferrous Marketing and Technology team have worked
with Technology Strategy Consultants to develop a web-based batchdegassing model. It has been designed as a tool to quickly analyse
Figure 10. Mixing time comparison for 190 mm rotors
foundries’ operations, and make suggestions for their improvement.
The mathematical model behind this software is based on the
best available published information, concerning the kinetics of
hydrogen degassing (e.g. hydrogen solubility, diffusivity, mass
transfer rates and stable bubble sizes). An extensive program was
undertaken to provide specific information about individual rotors.
The starting screen provides sub-menus for input of
• alloy composition
• ambient conditions
• operating parameters
• geometry of the treatment vessels
• hydrogen initial level
The operator can choose alloy compositions and crucible
resp. ladle geometries from a list or input own values. Ambient
conditions and operating parameters are foundry specific values,
which are known or needed to optimise the degassing process.
The initial hydrogen level is often unknown, but 0,3ml/100gAl
is a common value and changes in this influence the curves
insignificantly.
The rotor menu includes different types of rotors at various
diameters. By clicking one or more rotors the degassing curves are
drawn in a diagram showing hydrogen level vs. time. The model
calculates the degassing performance for each chosen rotor in
percentage of hydrogen
removed and the average
treatment gas consumption.
The input screen offers
the option to use a
The world is full of great
treatment gas containing
hydrogen. So there is a
instance, to make premiu
way to simulate upgassing
of engineers who
Figure 11. Screenshothands
of batch
processes as well.
degassing software
Our locally based teams
A plotting menu enables
the user to put in hydrogen levels measured with ALSPEK*
developHinnovative soluti
electrochemical hydrogen sensor; this data can then be plotted
Our with
products,
in the diagram to compare predicted degassing curves
real services an
knowledge
can unlock th
foundry trial results.
THE POWE
As a reliable and trusted
mechanical properties, in
The research work undertaken is proving to be an important
reduce
waste or perhaps
contributor to the understanding of hydrogen control
in aluminium
Conclusions
melts and this will improve the ability to optimise this important
Whatever your foundry re
part of metal treatment practice.
Foseco is finding the predictions of the degassing model to reflect
the reality in production foundries. The degassing model is proving
to be an effective tool for analysing and optimisingYour
the degassing
foundry and Foseco
process.
Each particular metal treatment station requires a particular set
of parameters – rotor design, diameter and rotor speed.
The model enables foundries to better understand the degassing
process. They can easily compare different strategies:
• shortest degassing time
• increase consumables life
COM
• avoidance of overgassing
By developing the scientific tests described
earlier, Foseco has developed more efficient
rotor designs which will achieve improved
performance for the FDU and MTS degassing
machines.
* COVER
METAL Casting
Technologies September 2012 3
Metal Treatment_NF_au_September_2012.indd 1
Ajax Tocco Magnethermic ......................................................BG66
Huettenes-Albertus Australia . ............................................. BG73
Arun Technology ..................................................................... BG67
IMF ................................................................................................. 35
Beckwith Macbro Sands . .............................................. 60 / BG67
Inductotherm . ................................................................................ 5
Bruker Quantron GmbH.......................................................... BG67
Linn High Therm ............................................................. 60 / BG79
CAST CRC ......................................................................................... 57
Metal Casting Technologies Magazine ................ BG69 / BG79
Cast Metal Services ................................................... 14-15 / BG68
Magma Engineering Asia Pacific....................... 16-17 / 25 / BG74
Casting Solutions .................................................................... BG69
Pacific Rim Foundry Services ..................................................... 55
CMC Cometals........................................................................... BG69
Powerhammer Company . ............................................... BG76-77
Didion International ..................................................... 8-9 / BG70
Sibelco . ...................................................................... 27 / 29 / BG75
Fein Power Tools ..................................................................... BG73
Spectro Analytical ............................................................ 23 / BG78
Finite Solutions ........................................................... 10-11 / BG71
Synchro ERP ...................................................................... 33 / BG79
Foseco ......................................................... OFC/ 2-3 / OBC / BG72
WES Omega Foundry Machinery . ........................... IFC-1 / BG80
G&C instrument Services ..................................................... 41 / 43
World Equipment Machine Sales ........................................ BG80
Hayes Metals ........................................................................... BG73
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CONTENTS
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President Thai Foundry Association
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ASIAN FOUNDRY OVERVIEW
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Pacificador Directo, National President,
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65 Buyer’s Guide
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Japanese Association of Casting Technology
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The Publisher reserves the right to alter or omit any
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against damages or liabilities that may arise from
material published.
Vol 58 No 3 September 2012
Philippine Metalcasting Association Inc.
(PMAI), 1135 EDSA, Balintawak,
Quezon City Metro Manila, Philippines
Tel: +632 352 287, Fax: +632 351 7590
Institute of Indian Foundrymen
IIF Center, 335 Rajdanga Main Road,
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Fax: +91 33 2442 4491
Metal Casting Technologies is a technically
based publication specifically for the Asia
Pacific Region.
The circulation reaches:
• Foundries
• Diecasters
• Iron and steel mills
• Testing labs
• Planners & Designers – CIM-CAD-CAM
Contents
30 New Zealand
By Gordon Muldrew
31
Front Cover - Foseco MTS1500 Automated Metal
Treatment Station. Also see pages 2-3, BG72, OBC.
Pakistan
By Abdul Rashid
32 Philippines
By Prof John HD Bautista
34 Thailand
By John Pearce
40
45CASTvacTM – an efficient vacuum technology for HPDC with low maintenance cost
By Laihua Wang & Gary Savage
49
China Foundry
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Iron & Steel
Institute
Use of PoDFA technique for rapid melt cleanliness assessment: a practical shop-floor tool for production of aluminum casting
By Thawatchai Kantisitthiporn and
Julathep Kajornchaiyakul
53
BACK TO BASICS
56
EVENTS
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BACK TO THE FLOOR
61
WEBSITE SHOWCASE
65
BUYER’S GUIDE
Australian Foundry
Association
TECHNICAL FEATURES
40Ferritic ductile irons: a revisit
By John Pearce
Balancing flow in vertically parted moulds
By J. F. Meredith
Melting metal for the virtual bronze foundry
By Prof John HD Bautista
Website showcase directory
Company showcase directory
METAL Casting Technologies September 2012
7
AUSTIN FOUNDRY
RECLAIMS BURIED TREASURE
ADVANTAGES AND FEATURES
4 Patented multi-chamber design combines
lump crushing, sand scrubbing, sand
conditioning, dual sand screening, and metal
separation for the fastest payback.
4 The time-tested design has the best
performance/highest yield (up to 97%)
in the industry.
Intake end
4 Significant savings from reduced binder
consumption, lower new sand purchases,
and minimal disposal costs.
4 Additional savings from conditioned and
higher quality reclaimed sand (which is more
uniform/consistent) lowers finishing costs
and reduces casting scrap.
High quality reclaimed sand
4 The patented design has the lowest operating
cost per ton in the industry worldwide,
with system sizes from 1-100 TPH
4 Highly efficient air-wash separation removes
binder, dust, debris, and excess fines.
4 Continuous improvement and development
have made us the world leader in sand
reclamation.
Sean GirdaukaS, V. P., auSTin FOundrY COrP.
AUSTIN FOUNDRY CORP., of Sheboygan WI, is
a gray and ductile iron jobbing shop that has been
producing quality castings ranging in size from
one pound to 5,000 pounds for a wide variety of
industries since 1946. Their molds are chemically
bonded with Furan and some Pepset binders.
“We first considered a sand reclamation system
a few years back, but with the recent downturn
in the economy and our ever-increasing costs,
becoming even more cost efficient became
a priority. The cost savings potential of a
DIDION® Sand Reclamation System became
obvious”, says Sean Girdaukas, Vice President
of AUSTIN FOUNDRY CORP.
“We sent sand samples to DIDION for testing, using their Rotary Lump Crusher/Sand
Reclaimer System. DIDION’S patented design
crushed the hard lumps, scrubbed the binder
off the sand grains, screened the sand twice,
recirculated the screen overs, and separated
tramp metal. After evaluating the test results
and their proposal, we purchased and
installed a DIDION® Sand Reclamation System.
Installation was fast and easy. We are very
pleased with the quality of the reclaimed sand
and the system is extremely reliable.”
“In the first eight months of use, we reclaimed
over four million pounds of spent sand which
would previously have been sent to a landfill.
We were able to dramatically reduce our new
sand purchases and disposal costs. In addition,
we have been able to cut back on binder
and catalyst usage with no ill effect. We
anticipate saving a quarter million dollars
annually. Helping the environment is saving
us money”, concludes Girdaukas.
Sean GirdaukaS, V. P., auSTin FOundrY COrP.
Reclaimed clean tramp metal
The team at Austin Foundry was excited to reclaim
a buried treasure. Turn a waste stream into a revenue
stream and keep the EPA and DNR inspectors happy.
Contact DIDION to help you become more efficient
and more profitable.
DIDION INTERNATIONAL INC.
Riverside lndustrial Centre
7000 West Geneva Drive
St. Peters, MO 63376
phone, 636.278.8700
fax, 636.278.3155
email, info@ didion.com
web, www.didion.com
Reclaim
your burie
treasure d
–
contact
DIDION.
Concise clean system
DIDION INTERNATIONAL INC.
Riverside lndustrial Centre
7000 West Geneva Drive
St. Peters, MO 63376
phone, 636.278.8700
fax, 636.278.3155
email, info@ didion.com
web, www.didion.com
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the foundry engineer might specify a minimum
acceptable yield percentage, or a maximum
acceptable level of macroporosity.
The Objective Function: States what the
foundry engineer is trying to achieve. Examples
might be to maximize the yield, minimize
shrinkage or minimize solidification time.
Once these elements are identified, the
user then launches an Optimization Run.
This consists of a series of simulations in
which the design conditions are varied under
the control of HyperOpt, model changes are
made and simulation results are evaluated,
all completely automatically, until the desired
result is achieved.
Using OPTICast, the foundry engineer can
start with an initial design and allow the
computer to do the work of modifying the
design and running simulations to achieve an
optimum result.
Now the technology of automated design
is brought to the foundry in the form of a
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Feeding Zone Analysis for Riser Design
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Casting simulation for the working foundry
11
contributors
EDITORIAL
DANIEL ALLEN
Based in London and Beijing, awardwinning writer and photographer
Daniel Allen has journeyed widely
across Europe, Asia, Africa and the
Americas. His work has featured in
numerous publications, including
the Guardian, National Geographic,
Discovery Channel magazine,
Geographical, Esquire and CNN Traveller.
Wiboolyos Amatyakul
President, Thai Foundry Association
commenced production of its first ever Chinese-designed car for
by inadequate infrastructure, skilled workers, scale, and domestic
the Indian market. This is a major step for the US automaker as
supply networks, as well as by political and intellectual-property
it tries to scale up in a market where foreign companies have
risks. Low worker productivity, corruption, and the risk to personal
struggled. India’s love for the small car and its highly competitive
safety are added concerns in some countries.
and price-sensitive market have confounded many of the world’s
john hermes d. bautista
PMAI Technical Consultant
phases. It will vary dramatically depending on labor content,
India-specific cars.
transportation costs, China’s competitive strengths, and the
The world economic infrastructure is very uncertain and
Barbara Cail
Dr. P. C. Maity
Metal Casting and
Materials Engineer
jeff f. meredith
Casting Solutions Pty Ltd
Gordon Muldrew
Gordon holds an Advanced Trade
Certificate in Moulding and a
Certificate from the AFS in Gating &
Riser Design. He has been involved
in the metal casting industry for over
25 years specialising in methoding
and computer simulation. Gordon is
Sales Manager for MetCast Services
Ltd and is currently the Chairman of
Casting Technology New Zealand Inc.
Neville A Murray
Has given numerous technical papers at
local and international foundry conferences.
Previously Meehanite metallurgist. Past
secretary of the Australian Ductile Iron
Producers Association. Currently President
of the Australian Master Patternmakers
Association.
john pearce
Metals Specialist, MTEC National
Metals and Materials Technology
Centre, Thailand
Manufacturing
renaissance is
inevitable
O
nce again we have great pleasure in bringing you the Asian
Foundry Overview for the metal casting industry in the
Asian market.
In the year which has passed, the strength and weaknesses
in the global economy have caused enormous change, particularly in
Europe and this change will continue. The world of certainty is no more.
Metals magazine, as you all know is distributed throughout Asia Pacific,
specifically through the membership of the China Foundry Association,
Thai Foundry Association, Pakistan Foundry Association and the Institute
of Indian Foundrymen. We also have subscribers in Malaysia, Japan, South
Korea, Italy, Spain and the US. So in this Annual edition we try to filter what
are the trends and expected impacts for global manufacturing which has a
flow-on affect for metal castings - the enabling industry.
Since last year’s Metals Annual, when we reported that China was then
the biggest global manufacturer of automobiles – requiring metal castings
components, it still retains this position. However, signals are now loud
and clear that there is a downward sales trend for autos in China as a
result of its, and the world’s economic slowdown. In China, as well as their
global clients, this has been caused by reduced demand brought about by
Abdul Rashid
Secretary,
Pakistan Foundry Association
high savings rates and fluctuations and uncertainty with unemployment.
However, there is a strong prediction that Chinese consumers are expected
to buy 25.5 million vehicles in 2015. And while the world’s auto economy is
in a painful state it’s interesting to note that in China, General Motors have
This reallocation of global manufacturing is in its very early
major automakers who try to compete with brands selling small,
strategic needs of individual companies. However, over the recent
there is no doubt that by the time I write next year’s editorial
past the shift of manufacturing to China was due largely to lack
column it will be profoundly different. The difference, amongst
of sufficient progress in automation of manufacturing processes.
other economic elements, will be revealed through a probable
Until automation is optimised, labor costs will remain the great
manufacturing renaissance. This will be brought about by the
dictator.
forced changes in manufacturing costs, environmental issues and
the deep deficits in skilled labor for the foundries.
For more than a decade now, deciding where to build a
While we normally focus heavily on car auto components
when we publish our Metals Annual Asian Foundry Overview it is
worth stating that there is a vast amount of research being done
manufacturing plant to supply the world was simple for many
in the US on lightweight metals, such as aluminum, magnesium
companies. With its seemingly limitless supply of low-cost labor
and titanium; also advanced high strength ferrous casting alloys
and an enormous, rapidly developing domestic market, an
like austempered ductile iron, compacted graphite iron and high
artificially low currency, and significant government incentives
strength steels. The research is investigating casting methods to
to attract foreign investment, China was the clear choice. Now,
produce various vital defense and commercial components for
however, a combination of economic forces is fast eroding
the US market in the shortest possible time. The research will
China’s cost advantage. And it is evident that Detroit has gone
help new production technologies, advancements in the metal
through a tough repositioning of its auto infrastructure and is
alloys to enhance properties and performance and extending
beginning to see the light for increased auto production driven
the state of the science in net shape manufacturing and rapid
by a new formula of quality and cost. It has an increasingly
prototype/production technology. However, the overall trend in
flexible workforce and a resilient corporate sector, and is
the global automotive parts market is pointing to a revamped
becoming more attractive as a place to manufacture. Indeed the
manufacturing approach. New materials, new designs and
Boston Consulting Group believes that sometime around 2015,
the move into new technologies are completely changing the
manufacturing in some parts of the US will be just as economical
traditional auto parts industry. This will directly affect jobs and
as manufacturing in China. They point out that wage and benefit
while it creates demand for new skills, it will relegate old skills
increases of 15 to 20 percent per year at the average Chinese
to history. The primary need in this area will be retraining and
factory will slash China’s labor-cost advantage over low-cost
ongoing study.
states in the US. And the added costs of transportation, duties,
supply chain risks, industrial real estate, and other costs when
Please enjoy what we offer as great reading on the
following pages.
fully accounted for; the cost savings of manufacturing in China
rather than in some US states will become minimal within the
next five years.
It seems evident that we could be looking at an economic
renaissance as some manufacturing will shift from China to
nations with lower labor costs, such as Vietnam, Indonesia,
and Mexico. But these nations’ ability to absorb the higher-end
Barbara Cail
manufacturing that would otherwise go to China will be limited
Managing Editor
METAL Casting Technologies September 2012 13
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COMPANY PROFILE
COMPANY PROFILE
17
CHINA
By Daniel Allen
Clean, Green & Lean, the Chinese foundry
industry looks to a sophisticated and
sustainable future
T
o meet the demands of a rampant national economy,
to boost exports, to remain competitive and profitable,
and to lessen its huge environmental burden - these
are the challenging tasks facing the Chinese foundry
industry today. It is no longer enough to focus solely on
quantity. Chinese foundries have to think smart, operate smart
and produce smart. Only by doing this can they move up the
value chain and establish China as a true foundry superpower.
Over the last decade the development of the Chinese
foundry industry has mirrored the breakneck development
of the Chinese economy. From 16.26 million tons in 2002,
industrial output had jumped to nearly 40 million tons by 2010,
accounting for 40% of world casting production. As casting
quality and production process sophistication have risen
over this period, more of the country’s domestic needs have
been met and the import of complex castings from overseas
has dropped.
Today, China is rightly viewed as the world’s preeminent
foundry nation. Yet for all the impressive statistics, the country’s
foundry industry now faces an array of serious challenges, many
of which will drive radical change over the next decade. These
problems include underinvestment in modern technology and
equipment, inefficient use of energy and raw materials, rising
labour costs and a scarcity of skilled labour, and a pressing need
to reduce environmental contamination and degradation.
“Despite recent growth, the foundry industry in China still
lags way behind the industries of advanced economies such as
America and Japan,” says Galen Wang, Marketing Manager of
the Dandong Ruiding Founding Co., Ltd. “In a way, the demands
of a surging Chinese economy, coupled with rising domestic
consumption and foreign investment, mean the Chinese
foundry industry has no alternative but to drag itself into the
21st century.”
There are currently around 30,000 foundries operating
in China, and installed capacity far exceeds actual demand.
These foundries vary hugely in term of scale, technology,
management expertise and casting quality, and this wideranging disparity is one of the major reasons for the industry’s
operational inefficiency, high energy use and levels of pollution.
More than 90% of China’s foundries have a poor environmental
record, poor working conditions, and employ outdated
equipment.
According to targets set out in China’s 12th Five Year Plan,
the number of Chinese foundries will drop from 30,000 to
approximately 20,000 by 2015, with a further reduction to
10,000 by 2020. Despite this drastic decrease, the aim is to ramp
up total castings production to 50 million tons by 2015, with a
total sales value of RMB 750 billion (US$120 billion). To meet
this target, the average production volume of each remaining
Chinese foundry will rise from around 1,200 tons today, to 2,500
tons by 2015, and 5,000 tons by 2020.
According to the China Foundry Association, growth in
castings production will be far from uniform over the next
decade. “Every sector will exhibit a different growth rate,” says
Thomas Gao, Director of the International Communications
Department at the China Foundry Association (CFA). “We expect
the production of automotive castings to rise 10%, machine
tools by 3%, heavy steel-power by 5% and infrastructure-related
castings by 6%. Steel mill castings will actually drop by 2%.”
Stricter environmental controls have already caused the
closure of many small and medium-sized Chinese foundries,
which generally employ open, cupola-style furnaces that cause
the greatest levels of pollution. Remaining foundries are having
to invest significantly in pollution control equipment, which is
a having a knock-on effect on prices, reducing competitiveness
domestically and on the global market.
“Over the next five to 10 years the total number of Chinese
foundries will decrease sharply, principally because of growing
competition and stricter pollution control legislation,” says
Galen Wang. “However, actual output will also be affected by
pollution control and to provide much-needed employment in
rural areas.
“The clustering of Chinese foundries has already significantly
helped the industry develop,” says Thomas Gao. “When done
properly clustering can help to reduce energy use, cut emissions
and lower production costs, he continues. “It also creates more
opportunities for co-operation in areas such as training, finance,
marketing and exports.”
In China, every ton of ductile cast iron produced consumes
an average of 550 to 700 kg coal - it only takes the equivalent
of 300 to 400 kg in developed countries. For every one ton of
steel castings produced, coal consumption is around 800 kg,
compared to 500 kg overseas. There is clearly plenty of scope for
boosting energy efficiency.
Until now, with the exception of a few large enterprises such
“Over the next five to 10 years the total number of Chinese
foundries will decrease sharply, principally because of
growing competition and stricter pollution control legislation”
the condition of the global economy, as well as the strategy of
foundry bosses. Despite the targets, it’s difficult to estimate how
output will develop with all the variables involved.”
“As the Chinese foundry industry restructures, the overarching
business model will change from captive type castings
consumption to independent, profit driven enterprises with
a greater emphasis on environmental protection and natural
resource conservation,” adds Gopal Padki, ex-CEO of Foseco
China and Group Vice President of China’s Shengquan Group.
“This will inevitably lead to mergers and joint management
of key strategic groups under government bodies for the
automotive, energy turbine, diesel, railway, tractor, mining and
pipe industries.”
At present the Chinese foundry industry is aggregated in six
main geographical clusters, and this trend is likely to continue.
A growing number of foundries and foundry complexes are
now situated away from large urban centres, to help with
as the China FAW Group, which already employs sophisticated
production and pollution reduction technology, most Chinese
foundries have paid little heed to the environmental damage
they may be causing. This is about to change.
According to the 12th Five Year Plan, 30% of China’s foundries
are tasked with achieving the standard of industrialised and
developed countries in terms of energy savings and emissions
reductions by 2015, while waste disposal and emissions will
reach national or local standards. Energy consumption will be
reduced by 10 % and waste discharge by 15%.
Investment in environmental protection currently accounts for
only 5% of the total investment by Chinese foundries – to meet
targets this figure will have to rise sharply. The development of
environmentally-friendly raw materials and end products needs
to be given greater consideration, while the “3 R” principle of
reducing, reusing and recycling should become the industry
code of practice.
19
Investment in sulphur dioxide and carbon capture technology,
and emphasis on cleaner, renewable energies, is vital. This will
increase future costs for capital investment, and also increase
the cost of operations for both existing and newer business
enterprises. In the longer term, however, reduced energy use
will benefit foundries, especially in light of uncertainty over oil
prices and power costs.
Despite targets and good intentions, environmental protection
and economic profit are not often comfortable bedfellows. Even
in well-governed cities there are invariably some foundries
that ought to be fined, and some that need to be closed for
severely polluting local air and water. Unfortunately, while these
enterprises contribute hefty tax revenue and are a good source
of employment, the inclination to act against them may be low.
“I think most Chinese foundries have the desire to be green
and efficient, but it all comes down to money,” says Galen
Wang. “Still, compared with developed countries, environmental
investment in China is far from enough. To achieve green
casting we have heavy responsibilities and also great potential.
With the right mindset, strategy and investment, I believe
we can change China from a big casting country into a green
casting power in the near future.”
In a nation where the lion’s share of rainfall and snowmelt
occur in the south, China is no stranger to regional water
scarcity and issues around hydro-engineering. Today, however,
surging economic growth has exacerbated the problem to
choking point.
China’s expanding industrial sector, which already consumes
70 percent of the nation’s energy, sucks up more energy
every year. In turn, rising energy demands mean that China’s
enormous reserves of coal – mostly located in the desiccated
north – are having to be exploited. Production and consumption
of coal has already tripled since 2000, and government analysts
project China’s energy companies will need to increase coal
production by a further 30 percent by 2020.
The knock-on problem here is that Chinese coal production
uses a lot of water. In fact, the water needed for mining,
processing and consuming Chinese coal accounts for the
largest share of the country’s industrial water use - a fifth of all
the water consumed nationally. With climate change already
impacting on water resource levels across China, the western
and northern regions – where many of China’s foundries are
located – will face severe water shortages.
With this in mind, Chinese foundries must look at measures
to reduce their water consumption, based around new
Bright minds are essential
for the development of
Chinese foundry technology.
technology and production processes, and efforts to ramp up
recycling and water efficiency on both a micro and macro level.
China’s hourly manufacturing labour rates are currently
way below rates in Japan (US$27.80) and Taiwan (US$8.68),
but roughly level with nations like the Philippines ($1.68), and
slightly higher than those in India. Still, pay hikes within the
foundry industry have been fairly significant over the last few
years, and cheap labour can no longer be relied upon to give
Chinese foundries a cutting edge.
While the Chinese foundry industry currently employs 1.5 to
1.6 million people, many foundries are finding it increasingly
difficult to attract and retain workers, partly because foundry work
is considered dirty and unrewarding. To change this perception,
working conditions and pay need to be improved, and skills
training improved. As of June 2010, 16 training bases had been
established by the CFA across China, allowing more than 10,000
technicians and skilled workers to be trained annually.
Bright minds are essential for the development of Chinese
foundry technology. Within the industry, basic and applied
research has to be enhanced for developing new technologies,
materials and equipment. Computer simulations need to be
introduced to improve production processes and the quality of
commonly-used metallic materials - this is particularly crucial
for the acceleration of high-end equipment manufacturing.
Software jointly developed by Tsinghua University and Huzhong
University of Science and Technology has already been put into
widespread use to improve casting quality and reduce waste.
“When it comes to technological progress, the trick is to be
innovative and profitable,” says Gopal Padki. “In these times of
immense uncertainty, global slowdown and domestic pressures,
the Chinese foundry industry needs to innovate not only in
technology, but in business, training and management too.”
Until now China has been regarded as an unstoppable force
in the global castings arena. The recent upward trend in foreign
investment in the Chinese foundry industry is a reflection
of its inherent strength, resilience, and huge potential for
growth. While moves up the value chain within the industry
have so far been tentative, and growing pains are inevitable,
widespread benchmarking with western standards is an
indication of Beijing’s determination to make China a true
foundry superpower. The next few years should certainly prove
interesting.
AUSTRALIA
W
By Nev Murray
e are very good at what we do!
The Australian foundry industry is adequately
capable with technical excellence, expertise and
capacity to service our own requirements for
castings, although hampered by costs.
Australia has foundries in all the main cities. Modern up to date
equipment is predominant in line with ‘world best practice’ with
high pressure touch screen high volume greensand machines,
loop line chemically bonded systems using, Furan, Alkaline
phenolic, Phenolic urethane, Sodium silicate, Shell, Cold box, high
pressure and gravity die casting and extensive Heat treatment
facilities. Foundry manufacturing plant and equipment is designed
and made in Australia to suit local conditions.
Established metal casting categories include; Iron, Steel,
Ductile and ADI, non-ferrous, high pressure and Gravity Die
casting, Investment, Art and sculpture, Ingot manufacture,
centrifugally spun ductile pipe. Although not strictly ‘foundry’
there are also a number of large ‘con cast’ steel billet plants in
Australia. Foundries range from small well run family owned
to large ‘multi-national’ owned operations. Some have been
successfully in business since the 1950’s. In recent years a few
large Australian foundries have ventured into establishing
foundries in China and India, with mixed results.
Quality control – environment and computers
Predominately Australian foundries incorporate integrated quality
procedures to ISO9001 and ISO9002 or other suitable and appropriate
controls to maintain casting integrity and customer requirements.
The ‘full bag’ of computerised 3D simulation methoding systems
is well established in Australia, as are internationally, with all their
technically competitive superiority claims.
Australian foundries employ qualified Patternmakers,
Metallurgists, Accountants, Sales and marketing personnel and
usually have modern laboratory facilities to back up the skills.
Multi axis computerised Cad-Cam and Rapid prototyping is used
in well-equiped pattern shops..
Most foundries have a formal Workplace Health and Safety
Policy and Environmental Management Policy in accordance with
enforced state legislations.
Foundry owners and managers travel extensively overseas to
international conferences and keep a close eye on economic and
technical developments.
Survival of the fittest
Currently our industry manufacturing sector, except mining, is
under pressure from rising costs and a sluggish economy due
to the international financial crisis, not unlike other economies
in the developed countries. Our worldwide competitiveness in
manufactured goods is suffering with our dollar high against the
US greenback, pulsing up and down between 0.90 and1.031 from
our more usual comfortable position of .60 and .80.
SOURCE: DELOITTE ACCESS ECONOMICS
1.10
1.00
0.90
0.80
0.70
0.60
2004
2008
2012
2016
$us per $A exchange rate
Australia however, with a stable government, strong regulated
banking system and doggedly persistent and determined
attitude to recover will pull out of this and, unassisted, recover
to a brighter future. The American and European economic
experiences still bleeding tears of money will not substantially
undermine our basic sound economy because Australia does not
depend on them for exported castings - they like our coal and
iron ore. Our exports of iron ore and coal are stronger than ever
with projected increased world market share at good prices. Coal
exports are expected to increase 100% in the next 2 years. Our
ability to supply may stretch our current resources.
Raw materials and consumables
This is the stuff we apply heat to, and then turn it into castings.
Apart from our own returns, bought scrap, sand and non-ferrous
ingot, most of it is imported. Many years ago Pig iron was made
in Australia by BHP and sold for $78.00 a tonne in about 1970.
A special high grade of Pig was made by ‘Wundowie’ in
Western Australia using charcoal instead of coke specifically
21
On-site, at-line and in the
laboratory - from SPECTRO
and its metal analyzers you
can expect:
for making SG ( Ductile iron ), and everybody used it. BHP cut
costs and stoped local production in 1972 and imported Pig
from China and Brazil. Wundowie soon closed, the imported
poor quality pig iron eventually improved and it is now all
imported. For good ductile iron production we import Sorrell
metal (Swedish Pig iron) or a ductile grade from South Africa.
No locally made Pig iron is available to our foundries. All other
ferrous alloys (lots of them) are imported, particularly from
China. Most of the other consumables, previously made here,
are imported as the supply companies find it more attractive to
buy cheaper from overseas.
Foundries have no alternative but to shoulder the extra costs.
What we have to put up with!
Australian Foundries operate in an environment created by
themselves, Government and international pressure. Our
unemployment CPI is currently running at 5.1% (average of all
states) and inflation running at 1.2%. (July) being the lowest in
13 years. The RBA has three times this year reduced the official
cash rate currently at 3.5%. The banks have followed the RBA
lead, to encourage the building sector and manufacturing
business for investment in new equipment, expansion and
employment, with banks currently at around 6%.
In Australia we enjoy a reasonably high standard of living
and a clean environment. This reflects in a requirement for
foundries, legislated by Government ‘Work Cover’ regulations,
to create safe working conditions and a clean pollution free
environment legislated by the National Environment Protection
Authority. Australia also has a generous compulsory ‘workers
compensation’ system which financially compensates workers
injured at work.
These strongly enforced industry regulations cover, noise,
heat, hazardous areas, emissions, disposal of waste, transport
and protective clothing. These add considerable extra costs
to making a casting. The Australian federal government has
recently imposed a ‘profit tax’ on the ‘cashed up’ mining
industry, and more recently, this year, a ‘carbon tax’ on the big
carbon dioxide generators specifically aimed at the coal fired
power generators. These measures to claw out cash from these
sectors, although they can afford it, will obviously kick in as
higher costs to foundries when they jack up electricity prices
and services to try and offset their new tax liabilities.
Where do our castings go?
Just about the only thing we don’t do a lot of is export. In the
past, Australia enjoyed a healthier export market than it now
has e.g. to the US.
All aspects of industry use castings in some form although
major consumers are mining, crushing and processing,
automotive, agriculture, water supply and reticulation, building,
rail, road construction and transport. Our shipbuilding has
protracted. We make world class castings in manganese steel,
hi chrome and Ni Cr irons for; mining, wear applications,
ground engaging and crushing industries as well as large
rubber lined slurry pumps and anything you can’t afford to
have worn out in a hurry. A huge range of castings are made
for general engineering applications and other manufacturing
industries from bottle moulds for glass works to manhole
covers, grating, automotive components, valves and fittings
for water reticulation and sewer lines and thousands of die
castings. Before the current dollar crisis Australian made
aluminium nickel bronze marine propellers enjoyed a good
export market.
Imported castings and survival at any cost
Talk with SPECTRO and find out why
SPECTRO‘s metal analyzers are an
investment in better efficiency and
higher profitability.
Tel. +852.2976.9162
Fax +852.2976.9542
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www.spectro.com
Considerable quantities of castings are imported due to
competitive pricing from overseas, and this is a situation
which has existed for many years, much to the grumblings
from the locals. Many castings are imported by ‘sales outlet’
establishments who resell although some of our long
established local foundries are importing castings made for
them at low cost in Asia. Imported castings come from China,
India, Malaysia, Vietnam, Germany and New Zealand. Past
experience has seen lobby groups and industry associations
All aspects of industry use castings in some form although
major consumers are mining, crushing and processing,
automotive, agriculture, water supply and reticulation,
building, rail, road construction and transport.
Metal
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Please visit us at:
JAIMA/JASIS 2012, 5 - 7 September, Tokyo, Japan
Guangzhou Mould Exhibition 2012,
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NDT 2012, 31 October - 2 November,
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THE FULL PICTURE !
pressuring their politicians to load import tariffs on imported
castings and give favourable consideration to local manufacturers
tendering on Government contracts. The pressure worked and
in the 1980’s the Federal Government introduced a plan to help
the foundries invest in new equipment and efficiency measures
by significantly raising import Tariffs to 40% for a trial time. In
1996 The Federal Industry Commission reported that due to lack
of effect the tariff be reduced (40%) to 5% in line with an overall
reduction of tariffs on imports.
How we got where we are!
The iron foundry industry in Australia started in early colonial
days although very little is recorded. Ship building did foster the
building of some large foundries from the mid 1800’s.
A number of large privately owned steel foundries had
been established in Sydney, Australia in the 1930’s producing
manganese steel castings for mining, earth moving and ship
building, including heavy cast steel chain. A government ship
building complex was built in 1900 including an iron foundry,
steel foundry and a bronze foundry. During the Second World
War these foundries were ‘protected industries’ and prospered
when Sydney became a ‘safe’ maintenance location for allied
ship repairs. Hadfields Steel Works Ltd. became very successful
and profitable, casting large ships anchors and chain for aircraft
carriers, battle ships and cruisers.
Ingots and automotive
In 1915 Australia’s largest company BHP was formed as a steel
maker and later in 1935 merged with A.I.S. (Australian Iron and
Steel) with blast furnaces to become a world leader in steel
making, and also with large foundries producing 30 tonne cast iron
ingot moulds and iron, steel and non-ferrous castings necessary
in the processes of blast furnace operation and associated
maintenance programmes. Eventually BHP was operating about 9
foundries around Australia. Not many are left today.
The Australian automotive manufacturing industry
started with General Motors building a foundry here in
1947. Subsequently the Ford Motor Company and then Chrysler
motors (later to become Mitsubishi Australia) built foundries here.
The disappearing act
There are not as many foundries in Australia today as
there were 40/50 years ago.
This is common with other Western developed countries
particularly when iron foundries were using cupolas,
but new larger modern foundries have been built which
make more castings with fewer people, less noise and
are environmentally improved. Mergers, take overs and
foundry upgrades have offset to some extent the closures.
In the last 12 months there have been 2 mergers and 2
closures. A sad note is that General Motors and Mitsubishi
Australia have closed their foundries (2010), leaving Ford
Australia the only vehicle manufacturing company still
operating a foundry in Australia today.
With falling engine block production Ford invested
20 million dollars and geared up in 2010, under an
agreement with global components supplier Bosch, for
the upgraded plant to be a centre of excellence for brake
rotor castings to fill the foundry capacity.
Current reports, at the time of going to press, are that
Ford Australia’s foundry is under a cloud of uncertain
existence due to falling car sales. In 2012 Ford received
34 million dollars from the Australian Government under
the Automotive Competitiveness and Investment Scheme
program Industry Assistance grants to assist its survival
in Australia. Ford said thanks but it can’t guarantee
producing in Australia after 2016, and in July this year
announced it will be putting off 440 jobs. Currently
Industry information indicates that Ford Detroit US (the
boss), is unhappy with the prospects of manufacturing in
Australia so the current Falcon will be only cosmetically
tweaked for next years and a totally new model is not
expected to be made in Australia in the future. Ford is
important to us and we hope we don’t lose them.
References:
3. Australian Financial Review.
1. RBA Reserve Bank of Australia.
4. Mr. John Adlard. AFI, MPA
historical archives.
2. ABS Australian Bureau of Statistics.
The Australian automotive manufacturing industry started
with General Motors building a foundry here in 1947.
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INDIA
A
By Dr. P. C. Maity
bout 4600 foundry industries in India are producing
9.05 million metric tons of castings according to
the latest data of 45th census of castings. 70% of
the castings are grey cast iron, 9% ductile iron, 12%
steel and other nonferrous is 9%. 80% of the foundries are
small scale category and are labour intensive. Medium scale
and large scale industries are of 10% each and are either semimechanised or mechanised. Indian foundry industry provide
jobs to about 0.5 million people directly and 1.5 million
people indirectly. The industry is making a contribution of INR
7000 per ton to the national exchequer in the form of excise
and other duties. The export of castings in 2010/11 touched
US$ 215 million.
It appears that India would continue to hold 2nd position
in the world in terms of tonnage of casting produced. China
produced largest volume of castings at 39.6 million metric tons.
United States produced total 8.238 million metric tons holding
third position in the world. Other countries in this series are
Germany, Japan, Russia and Brazil producing 4.794, 4,757, 4.2
and 3.24 million metric tons respectively.
Declined car market
Recently, the car sales in India has declined due to high interest
rates, high fuel prices and slow pace of economic growth. Most
of the customers buy a car financed by banks. As the interest
rate has increased in recent times, it has affected the sale of
cars. Similarly increase in fuel price has been enormous in
last few years. These factors have reduced the sale of cars. In
May, 2012, car sales in India grew only by 2.78% at 163,229 units
compared to 158,809 units in May 2011, which is the slowest
growth since October 2011 when car sales declined by 23.77%.
In the first two months of 2012-13, almost all the passenger car
makers were forced to rationalise production at their plants
since the decline of growth rate in car sales. GM India has
initiated suspension of production for one day per week in
order to avoid piling up of inventories. Tata Motors had to close
their Jamshedpur plant for three days at the end of June 2012
for the same reason.
Vision plan 2020
The large gap in production in castings between India and
China along with the fact that the foundry industry is not able
to keep up with the local demand both in terms of quantity
and quality have motivated The Institute of Indian Foundrymen
(IIF) to draw a Vision Plan 2020 for the foundry industry and
recommend the needed initiatives to materialise the vision.
To prepare the vision plan a detailed survey of 325 foundry
units from different regions with varying size and products was
carried out and 100 CEOs and decision makers were consulted
for their views. The collected data was analysed to draw the
vision plan through identifying the key issues and the steps to
be taken to overcome various constraints. Twenty interventions
were suggested on the basis of various findings of the analysis:
l To make the Indian foundry an attractive entity for all the
stakeholders
l To make foundry a viable investment option ranking equally
among other available alternatives
l Employees enjoy staying there
l The industry becomes a clean and environmentally friendly
l To realise a natural growth with the above and emerge as
a leading supplier of quality castings to the global market
covering all sectors by 2020.
Some of the important interventions suggested in the vision
plan are creation of Technology Upgradation Fund (TUF),
capacity consolidation by moving all similar units to a common
location and the facilities housed there, creation of new
capacity via “Green channel clearance” for giving approvals and
allocation of suitable land in the foundry park / cluster through
Indian or Foreign Direct Investment(FDI), common testing and
It appears that India would continue to hold 2nd position
in the world in terms of tonnage of casting produced.
processing facilities, low cost mechanisation, developing
training facilities and R&D centers, health care of workers
etc. The vision plan is to be implemented in two phases
of five years each. The total investment proposed under
the project is INR 21.34 billion to help the foundry industry
to move towards a production level of 11 million tons. The
survey revealed the readiness of the units to accept the
proposed interventions.
Foundry Park inaugurated in Howrah
Under the initiative of Indian Foundry Association
(IFA), Foundry Cluster Development Association and
the Government of West Bengal, a Foundry Park was
inaugurated by the chief minister of West Bengal Ms.
Mamata Banerjee on Feb. 4, 2012. At the initial phase,
60 foundry units, an Industrial Training Institute,
environmental laboratory, tool room would be set up by
investing INR 8 billion that would employ 40,000 people
directly or indirectly.
Shortage of skilled manpower in foundry industries –
tackling the issue.
Shortage of skilled manpower in foundries is a common
issue for all countries producing castings including
India. As discussed in last overview, initiative has been
taken by IIF to set up “Sector Skill Council – Foundry” to
upgrade the skill of foundry workforce. Two centres at
Coimbatore and Belgaum foundry clusters have already
been inaugurated recently under this scheme. It is a long
term program and the benefits of it are expected over the
years. In the meantime, various efforts by the stakeholders
are on the way to provide skilled manpower to the metal
casting industries. The Centre for Foundry Education and
Research (CFER) at Ahmedabad set up by Bhagwati groups
and friends with support from Government of Gujarat has
initiated six months’ training programme to train workers
for foundry industry. The training consists of two months
theory classes followed by four months’ on-the-job
training in different foundries. Two batches of 30 students
have already completed the training and all of them are
employed. CFER has also initiated Supervisor’s re-training
programmes. At the initiative of Dr. P. N. Bhagwati and
support from Government of Gujarat, Bhagwati-ITI
Kubernagar Foundry Training Centre was inaugurated
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on 15 December, 2011 at ITI Kubernagar, Ahmedabad premises
under “Skill Development” initiative of Industries and Mines
Department of Government of Gujarat. ITI Kubernagar in
collaboration with CFER has started Foundry Trade Apprentice
course of one year duration for the first time that covers both
classroom as well as practical training.
Another training center has been inaugurated on 17
December, 2011 at IIF, southern region premises in Chennai
by Mr. Gaurav Kapur, Director, Gargi HA. It is named as “Gargi
HA Training Center” and has facility for training 55 persons. It
is equipped with high tech facilities for conducting training
programmes and seminars for workers, supervisors and
managers of foundry industries.
Recently, the Western Region of IIF has taken initiative to
train shop floor workers on various topics such as moulding
practices, core shooting practices, aluminium foundry practices,
steel foundry practices etc. through local languages. These
training programmes are to be conducted at different chapters
of IIF, for which trainers are being arranged. Energy Efficiency
improvement is another area of the training schedule. These
training programmes are expected to start shortly.
To attract students of engineering institutes towards foundry
industries, a new initiative was taken for the first time during
the 60th Indian Foundry Congress held on March 2-4, 2012
at Bengaluru. During the programme “Students Meet Young
Foundry Leaders”, a few new generation foundry leaders
shared their experiences and views on the burning issue of
acute dearth of skilled manpower in the foundry sector. A
distinguished panel of young foundry leaders deliberated
on showcasing the modern Indian foundry, unconventional
employment opportunities in the modern Indian foundry,
knowledge and skill gap between industry expectation and
educational institution and role of modern Indian foundry
in enhancing student skills. Students showed keen interest to
the presentations by young foundry leaders.
Another recent development in this direction is the
establishment of the National Knowledge Network (NKN):
E-Foundry. The NKN is a state-of-the-art multi-gigabit
pan-India network for providing a high speed backbone for
knowledge related institutions in India, with the objective of
creating highly trained professionals. Using this facility, the
NKN:E-Foundry was launched for academic institutes on the
National Education Day, 11th November 2011 and was formally
opened to the foundry industry on the eve of the 60th Indian
Foundry Congress held on March 2-4 2012 at Bengaluru. The
NKN core committee commissioned the E-Foundry project, since
a readily usable knowledge base on foundry was available. It is
a free online resource of knowledge and technology in casting
design and simulation having high quality content developed by
experts that works under interactive and collaborative learning
environment. The major resources available at the E-Foundry
are lesson movies in casting design and simulation, online
simulation lab and other learning resources containing technical
papers and abstracts related to foundry. It is expected that the
E-Foundry project would act as a catalyst to attract and retain
young engineers to the metal casting industry.
Indian Foundry Congress 2012
The 60th Indian Foundry Congress was held at Bengaluru
during 2-4 March, 2012. About 1700 delegates attended the
congress. It was accompanied by IFEX-2012 (8th Exhibition on
Foundry Technology, Equipments and suppliers) and 2nd Asia
Foundry Forum. The exhibition was inaugurated on 2nd March
2012 by IIF’s past president Mr. S. Thiagharajan. About 280
exhibitors (including 79 exhibitors from abroad) had displayed
their products and services covering an area of approx. 15,000
sq. Meters. Four countries, namely, Japan, Italy, Germany and
China had group participation. The Congress was inaugurated
on the first day at 4-30 PM. By Mr. C. R. Swaminathan,
Chairman, Organizing Committee of the Congress. Minister for
large and medium scale industries of Karnataka state Mr M. R.
Nirani announced during the inauguration that the government
will set up a foundry cluster at Dobbaspet in next six months.
It was also announced to set up Foundry Innovation Center at
To attract students of engineering institutes towards
foundry industries, a new initiative was taken for the
first time during the 60th Indian Foundry Congress...
It is expected that the
E-Foundry project
would act as a catalyst
to attract and retain
young engineers to the
metal casting industry.
Bengaluru to conduct R&D work related to metal casting.
Technical sessions were held over the next two days.
About 60 technical papers were presented by authors
from India and overseas. The first technical paper was
presented by Prof M. C. Flemings, MIT, USA on the topic
“Metal casting Innovations, 1952-2012 and Beyond”. After
informing the delegates that his own career in metal
casting ranges from 1952 to 2012, Prof. Flemings initially
pointed out the meaning of the words “Innovation” and
“Invention”. Thereafter he discussed various important
innovations / inventions during 1952 to 2012. These
were Ductile Iron, Ceramic shell investment casting,
lost foam casting, single casting, Hitchiner Process, use
of computers for simulation, molten metal filtration
etc. He pointed out that ductile iron and ceramic shell
investment casting were the two most important
inventions that impacted on the global foundry business
heavily. Prof. Flemings also mentioned a few inventions
which may influence the future of the foundry industry.
These are SLIC process (combination of investment
casting and lost foam casting), ablation casting, 3D
printing of sand moulds, rapid prototyping, metal matrix
composites, further development in modelling and
simulation, magnesium alloy castings etc.
The Tech-Mart session focussed on “Automation
in Fettling and Casting Finishing” where three
companies made presentation about their products and
technologies related to this operation. Energy Forum was
another event during the Congress where dignitaries
participated in the event various issues related to energy
conservation. Valedictory session was the last event
during which best paper awards and awards for best
stalls in the exhibition were distributed.
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NEW ZEALAND
I
By Gordon Muldrew
n researching this article I looked back on some previous
versions. All of them start out how tough the last year
has been and that the economic outlook is grim etc. But
yet here we still are (well most of us) making castings
and hopefully a dollar or two.
Henry Ford once quoted “Business is never so healthy
as when, like a chicken, it must do a certain amount of
scratching around for what it gets”.
New Zealand’s GDP increased in the March quarter by 1.1%
with manufacturing up by 1.8% being the largest contributor.
So there are some signs of life but the general feeling is that
it is a tough environment for New Zealand foundries.
Earthquake-related rebuilding is expected to provide
substantial impetus to economic activity in coming years,
even though recent aftershocks are likely to delay some
rebuilding by 1 to 2 quarters. However we don’t expect this to
have a big impact on the foundry industry.
There have been a couple of closures of smaller foundries
with their work being absorbed by other existing foundries.
One foundry has recently changed ownership and another
larger foundry is currently up for sale. It is an uncertain time
for the staff at this particular foundry. We hope that it will be
sold and that the new owners can take the foundry forward
into the future.
Investment in plant and equipment has typically been
low but some of the larger foundries are investing in new
equipment this year which is good to see.
Foundries associated with the extractive/mining industry
seem to have better workloads at present than most others.
This will of course depend on China and its continued growth.
Our export market has continued to be challenging due to
the high exchange rate of the New Zealand dollar.
CTNZ hosted the annual AFI conference in Queenstown
last October/November. Attendance was good with
many Australian companies making the effort to visit
the conference and one of our top tourist attractions.
Feedback from the participants was excellent and all
had a good time. We would like to thank all those that
attended. We have just held a smaller conference in
Taupo with speakers from Australia and local experts
presenting papers on a range of topics. Attendance was
good with a couple of Australians making it over once
again. We encourage CTNZ members to return the favour
and attend the upcoming AFI conference in Sydney. The
annual AFI conferences always have excellent technical
content and it is a good opportunity to network and catch
up with old friends.
There is no foundry training school in this country and
the current level of those involved in formal training is
low. For many years we have relied on skilled migrants to
top up the trades and tertiary trained technical positions.
We have even let some Australians in! The size of our
industry makes it difficult to develop training to a higher
standard and this isn’t likely to improve.
In spite of the difficulties faced by our industry some
companies are leveraging their competitive advantage,
and they are prospering. In many cases the successful
business is high value, niche focused and operating where
design and services are bundled in with the castings.
We are extraordinarily good at problem solving and
devising innovative solutions. Our successful operations
are the ones that offer small run, highly technical, high
value castings or are foundries owned by business that
manufacture their own high value niche product that
incorporate castings and hold onto the foundry for
strategic reasons.
“Success is going from failure to failure without loss of
enthusiasm” – Winston Churchill
Investment in plant and equipment has typically been
low but some of the larger foundries are investing in
new equipment this year which is good to see.
PAKISTAN
P
By Abdul Rashid
akistan is a country of 180 million people with 1800
foundries operating with an installed capacity of
350,000 tons per year of grey, SG iron, steel and nonferrous castings. This does not include aluminium
die casting industry which is still working as small scale
jobbing foundries. Most of these foundries are engaged in the
production of automotive parts, tractors, sugar mills machinery
parts, cement factories consumables, chemical factories
consumables, agriculture implements, heavy industrial castings,
agriculture implements, pumps, valves, electric motors, textile
and cement machinery, processing industries and others.
The inception of tractor and automotive assemblers
introduced product quality awareness among the foundry
industry. The interchange-ability and quality consistency of cast
components required process mechanization and proper control
of input materials.
Developed countries have started shifting their casting
requirements to developing Asian countries including Pakistan.
We export foundry products to many countries in the world
like USA, Germany, UK, Brazil, Netherlands etc. Our export
during the year 2008-09 was US$60 million, 2009-10 it was
US$57 million and in the year 2010-2011 it was US$67 million.
Pakistan has tremendous growth potential and the world
foundries can benefit from:
l Low labour cost
l Large population with a strong domestic demand
l Construction cost for new casting facilities and completion
time is low
l Health & Safety compliances for molding binders are not
stringent as the developed world
l Tooling cost and local development of auxiliary foundry
equipment is low
Despite current economic situation, Pakistan is set to become
a market for 500,000 cars and 2.5 million motor cycles in
addition to bus, truck and farm machinery sectors.
To fulfil the future demands of casting in Pakistan as well as
for export destinations the Japanese/ Chinese auto giants and
all, interested to invest with their strong foot print in Pakistan,
Chief Guest and the President of PFA visiting 3rd International
Foundry Congress & Exhibition – held every two years
or their overseas vendors may invest in the foundry sector in
Pakistan in order to reap the profits of the rising demand in
Pakistan.
The balance sheets of multinationals which are already
operating in Pakistan for five to six decades by now bear
testimony to the fact that there is large potential for profits to
be made in Pakistan and virtually every multinational operating
in Pakistan is a blue chip company.
Agricultural machinery sector will also be the engine of
growth here and abroad as more and more Pakistani farm
machinery begins to be exported. The big growth in this sector
will create an ever increasing demand on vendor industries and
particularly on foundries.
Major challenges being faced by Pakistani foundries
l Even though the tooling cost is low, the quality needs
tremendous improvement through technology guidance
l Assistance in development of sufficient infrastructure
l Guidance in Indigenous development of foundry
consumables
l Guidance in development of training programs.
In order to get a share from the world market, Pakistan needs
properly trained manpower, equipment, allied tools and a
consistent quality of raw material in order to meet the global
requirements of finished castings at competitive price.
Such an initiative from developed countries will guide
developing countries like Pakistan so that the technology growth
in foundry industry may make this world a better place to live.
PFA warmly invites all readers of Metal Casting Technologies
Magazine to participate in 4th International Foundry Congress &
Exhibitions to be held on Dec 5 & 06 – 2012 at Lahore Pakistan.
For detail please visit www.pfa.org.pk
PHILIPPINES
T
By Prof. John H.D. Bautista
he Philippine Metalcasting industry is beset by many
problems calling for attention, but not getting the
attention that is required. At best, attention is halfhearted, meaning there is lack of sincerity and political
will. For sometime now, low-priced castings from China are
exerting a lot of pressure on our Metalcasting Industry in order
to preserve its domestic market. If we cannot compete in our
own domestic market with imported castings from China, the
more we cannot compete in the world market. Indications are
that, if the present situation persists, the Philippine domestic
market may be lost to China. This is a grave problem that we
have to address quickly and adequately. In the face of this
problem, we have the other related and relevant problems.
Listed below are the problems that need immediate attention.
1. Scrap metals are being exported and, because of the present
dollar exchange, the domestic foundries cannot compete with
the foreign buyers. This is slowly killing the foundry industry
in the Philippines. Since the Philippine government is cashstrapped, would it not be nice to slap an export levy on scrap
metal exports so that the playing field may be leveled? PMAI
would suggest an export levy of two pesos per kilo of scrap
exported or one that is graduated depending on the metal
being exported.
2. The present electric power cost is unreasonably high, and
still getting higher. We wish that MERALCO, our electric utility
company, would give a lower rate for off-peak operations to serve
as an incentive for factories to operate at night when the electrical
load of MERALCO is lighter. The last known demand charge was
P575.00 per kilowatt maximum demand in 2011, just last year.
There is a continually increasing cost of electric power. The
charges of the electric utility company for energy (KWH) and
demand (KW) are tabulated below showing the historical increases
as gathered from the Manila Electric Company (MERALCO – the
electric utility company of the region) Billing Department.
We are still suffering from this situation today as the demand
charge has gone from P12.60 per Kw. maximum demand in 1985
to P575.00 per Kw. maximum demand in 2011; an increase of
4,563 percent in 26 years! Today, a foundry that operates a 1,000
Kw. induction furnace would pay PHP575,000.00 per month
regardless of whether the furnace was operated only one day in
the month or 25 days at 24 hours/day in the month.
On the other hand, energy charge has gone from P1.79 per
Kwh in 1985 to P6.82 per Kwh. in 2011; an in-crease of only
381 percent in 26 years! It would be expected that the rate of
increase in both charges should be almost equal as the cost
elements would be susceptible to both inflation and price-level
changes. But when the rates of increase differ very much (when
the change in demand charge is almost ten times that of the
change in energy charge), something must be very, very wrong!
If this cannot be “moderated,” the alternative solution is
for the industry to generate its own electric power and this
could be done only through the clustering of the companies
in the Metal Engineering Industry. By operating its own power
plant, demand charge could be eliminated as this is merely
a penalty for companies in a grid or network that reach peak
load at about the same time, making it difficult for the utility
companies to cope with the irregularity. Electrical load could
more easily be determined and supervised in a cluster. An
additional advantage for a cluster would be the possible
“synergy” among the companies in the cluster with each doing
what it does best!
3. Productivity in foundries is very low. This can be solved by
more mechanization, but this cannot be done because of the
high cost of money. We are not financial experts; but, if we
were, we could recommend ways of lowering effective interest
rates. We feel that our financial experts are not looking this
way. They seem to be interested only in stock-market-like
financial operations.
4. The importation of second-hand machinery is preventing
Item
1985
1995
2005
2007
2011
Energy Charge per KWH used
P1.79
P2.94
P6.89
P6.43
P6.82
P12.60
P25.001
P382.00 2
P542.00 3
P575.00
Demand Charge per KW max. demand
Note: 1. By April 1997, this was increased to P220.00 per KW maximum demand.
2. This is an average figure (P366.32 to P406.12) as the demand charge was now based on the input voltage.
3. The average demand charge for the year 2006 was P429.39 per KW maximum demand.
the industry from embarking on an honest-to-goodness
machine-building program. This country needs a good
Machine-building Industry if it wants to align itself
with the more progressive, more advanced countries.
This can be done. Just ask those from the Metalworking
Sector, aside from those in the Metalcasting Sector. We
need the government to listen, because we have been
telling government what to do, but it refuses to listen
to us; instead it listens to the “traders.” More shopping
malls are being put up and less factories. No wonder
we have a high GNP, but a very low GDP. Result: the
Philippine peso deteriorates vis-à-vis the US dollar.
Is the government asking for more foreign investors
in the manufacturing sector? This will never happen
while the business climate is more conducive to trading
than manufacturing. The sad fact here is that trading
uses only a small fraction of the personnel used by
manufacturing, besides contributing only a small fraction
of the value-added that is possible with manufacturing;
hence our growing unemployment rate in the face of a
rising GNP. A paradox?
5. Technical smuggling is another problem that needs to
be controlled. The government should be swift in dealing
with such smugglers. From where we stand it seems that
there is an unholy alliance somewhere; as Hamlet said,
“Something is rotten in the State of Denmark.”
6. Finally, can the government agencies, especially the
DENR (Department of Energy and Natural Resources),
LLDA (Laguna Lake Development Authority), and MMDA
(Metro Manila Development Authority), lower the level
of their harassment of our Metalcasting Industry to
the tolerance level that is being given to the trucks,
trailers, busses, and jeepneys, all of which are actually
those responsible for the greater percentage of our air
pollution? Our foundries do not generate that much
amount of pollution (less than 5%); besides foundries
take the necessary steps to minimize both air and water
pollution. Then, again, there is probably an unholy
alliance that we do not know about. Just wondering,
because, in this country, whenever there is a possibility
of an unholy alliance, the probability is extremely high
that it will happen — maybe 99.9%?
THAILAND
GDP Growth %
Thailand
Brunei
Philippines
D
By John Pearce
uring 2011 manufacturing industry in Thailand,
especially the automotive and electronic sectors,
suffered severe disruption from the effects on parts
supplies of the tsunami disaster in Japan and then
from the catastrophic floods in central Thailand that lasted from
October through into the early part of 2012. The Thai Automobile
Industry Association (TAIA) estimated that these unforeseen
events resulted in production losses of at least 300,000 vehicles
during 2011 causing a fall in annual vehicle output to 1.49 million.
During the previous ten years or so, Thailand had shown steady
economic growth averaging 4% from 2000 to 2007 with the
industrial sector accounting for around 40% of GDP. During
the global economic crisis between 2008 and 2009, Thailand’s
economy contracted by about 2.3%, similar to other countries in
Extent of flooding in a Thai foundry melting shop
1.5
2.8
3.7
Singapore
Malaysia
Myanmar
Vietnam
Indonesia
Cambodia
4.9
5.2
5.5
5.8
6.4
6.7
Laos
8.3
ASEAN GDP Growth by Country in 2011
the region but bounced back in 2010 with expansion
at 7.8%, the highest rate since 1995. The 2011 floods,
the worst in 70 years, caused widespread damage
to many industrial estates and production plants in
the central region of Thailand reducing economic
growth to the lowest of all the ASEAN countries.
Around 900 companies including several foundries
and die-casting shops on seven industrial estates
suffered from damage and production losses due to
flooding. However, in spite of the disruption, Thailand
still managed to export industrial products to the
value of USD 167.9 billion, accounting for 73.4% of
total exports. To prevent future damage from flooding
the Thai Government has initiated a number of new
water resource management schemes. Plans are also
underway to develop new industrial estates in NE
Thailand and to develop cluster arrangements between
companies to enable switching of production between
plants in the event of any future problems.
During the global economic crisis between 2008 and 2009,
Thailand’s economy contracted by about 2.3%, similar to
other countries in the region but bounced back in 2010 with
expansion at 7.8%, the highest rate since 1995.
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and by publishing regular newsletters and a quarterly technical
Metal Castings Journal in Thai. During and after the flood crisis
the TFA provided advice and practical assistance to affected
foundries and related businesses with information on recovery
and refurbishment funding, etc. to restore plant and facilities.
Advancing aluminium technology
The TFA Board for 2011-2012
The 2012 situation is now looking much brighter with most
manufacturing plants having been renovated. Production
has restarted and is gradually returning back to normal
levels such that the TAIA has recently revised its production
forecast for 2012 up to 2.2 million vehicles. This means that
the Metal casters supplying auto- and motor-cycle parts,
and those supplying the electrical goods and electronics
sectors are operating at full speed. During the year the Thai
Foundry Association (TFA) has continued to help develop
metal casting capability by organizing seminars and plant
visits, by supporting conferences in metallurgy and materials
Dr. P. Dulyapraphant of MTEC explains the advantages of squeeze
casting
The month of June saw three major metal related meetings
held in Bangkok, beginning with a seminar on “Advances
and Technologies in Aluminium Casting”. The event,
attended by 120 delegates, was held on 5th June 2012 at the
Bureau of Supporting Industries Development (BSID) Centre
which also houses the offices the TFA and the Iron & Steel
Institute of Thailand (ISIT). BSID, which is under the Dept.
of Industrial Promotion, Ministry of Industry, organized
the seminar together with the TFA, the National Metals
and Materials Technology Centre (MTEC) and the Office of
Higher Education Admission.
The first of two keynote talks was given by Prof. Merton C
Flemings from Massachusetts Institute of Technology (MIT)
on “Sixty Years of Casting Innovations. What Next?” with
a special focus on developments in Al casting processes
including semi-solid and lost foam. In the second keynote
Mr. Sei Maeda, who is based in Thailand as the Chief
of the Technical Centre and Executive Vice-President of
Toyota Motor Asia Pacific Engineering & Manufacturing,
Staff from the Iron & Steel Institute of Thailand (ISIT). ISIT provides
technical, training, public relations and marketing services to the
Thai metals industry. ISIT has a well equipped technical & testing
centre situated in the BSID complex.
Left to right. Mr. Prakob Janma (BSID host) with Prof. Flemings,
Mr. Maeda & Dr. Jessada Wannasin
gave an overview of “Trends of Utilizing Aluminium for
Automotive”. His talk focused on how the application
of Al cast parts to replace steel and cast iron in engine
& drive train and body & chassis applications has saved
weight and contributed to improved fuel efficiency and
reduced emissions. He announced that a new Toyota plant
to produce Al cylinder blocks was under construction in
Thailand with production due to start in January 2014.
He said that all Al foundries must strive to reduce casting
defects, improve their use and accuracy of CAE and
develop in line inspection technology.
The current status, progress and future of Al castings
production in Thailand was then covered in the following
papers:
l “Progress in Al Castings R&D and Production in
Thailand” Dr. J. Pearce (MTEC)
l “Advancement in Melt Treatment of Al Alloys” Dr.
C. Limmaneevichitr (King Mongkut’s University of
Technology Thonburi)
Speakers Dr. T. Babul, Dr. J. Pearce & Mr. Funitani with Thanaporn
Korad, the conference organizer from MTEC.
“Squeeze Casting: New Opportunity for Thai Automotive Parts
Suppliers” Dr. P Dulyapraphant (MTEC)
l “Semi-Solid Metal Technology: Research, Development and
Applications in Thailand” Dr. J. Wannasin (Prince of Songkla
University)
l “Towards Enhanced Competitiveness in Production of Al
Castings” Dr. J. Kajornchaiyakul (MTEC)
As outlined in June 2012 MCT [1] Thai Al casting producers have
very little involvement in R&D as such but like the ferrous sector
they are increasingly interacting with Thai universities and MTEC
to solve technical problems. The conclusion from the seminar
discussion was that such interaction was having a positive effect
in improving overall capability of the industry. Towards further
development in Thai die-casting know how
Dr. Dulyapraphant of MTEC announced that a new HPDC
facility would soon be available in the MTEC Pilot Plant at the
Thailand Science Park. This will support improvements in die
design, optimization of process variables and development of
squeeze casting.
l
He announced that a new Toyota plant to produce Al
cylinder blocks was under construction in Thailand
with production due to start in January 2014.
Innovation in Materials Science and Technology
The aluminium event was immediately followed by the 7th
International Conference on Materials Science and Technology
organized by MTEC and held from 7-8th June at Swissotel
Le Concorde, Bangkok. Looking back over his many years of
experience at MIT, Prof. Flemings also gave a plenary talk at
this event, this time on “Innovations in Materials Science and
Engineering: From Research to Market”. The other plenary lecture
related to metals was given by Prof. Teruo Kishi, Advisor to and a
Former President of the National Institute for Materials Science
(NIMS) in Japan. Prof. Kishi focused on the environment and
future supplies of raw materials in his presentation on “Materials
research for Green Innovation and Critical Materials”. MSAT-7 was
attended by over 400 people with six separate sessions held on
each of the two days. A number of presentations covered metal
casting during the sessions on Metals, Alloys & Intermetallic
Compounds, Materials for Energy & Environment, and Simulation,
Design & Manufacturing. The casting topics, providing examples
of some of the current research in Thailand, included casting of
sterling silver jewelry alloys, surface layers in HPDC components,
indirect squeeze casting of auto-parts, runner design in HPDC, and
defects & microstructure in thixo-cast Al alloys.
Heat treatment – energy and the future
At the end of June the hot topic was Heat Treatment and Surface
Engineering, particularly the use of energy aspects. MTEC
together with the International Federation of Heat Treatment
& Surface Engineering (IFHTSE) organized the 1st International
Conference on Energy and the Future of Heat Treatment and
Delegates with staff and guides at the new Tohken Thermo
Training Centre in Chonburi
Surface Engineering – “EFhtse 2012”, which was held at the
Emerald Hotel Bangkok during 25-27th June.
Heat treatment & surface engineering (HTSE) together with
foundry, forming & fabricating, and machining are recognized
by government organizations in Thailand as key supporting
industries for manufacturing. However, probably because HTSE
processes are widely spread across many companies, there is no
real focus for HTSE in Thailand [2]. There is no heat treatment
society as such in Thailand but the TFA, the Thai Machinery
Association (TMA), the Thai Tool and Die Industry Association
(TDIA) and the Thai Corrosion of Metals and Materials
Association (TCMMA) are all involved with HTSE and, recognizing
the need to increase heat treatment know how, were active
supporters of the Bangkok conference. Sponsorship for the event
was provided by Thai Parkerizing Co. Ltd. and by Thai Tohken
Thermo Co. Ltd who are the two major providers of contract
HTSE services to Thai industries; both companies have Japanese
based parent organizations.
The conference technical programme began with a plenary
talk by Dr. Stan Lynch of the Defence Science and Technology
Organization, Australia, who reviewed the potential of FrictionStir Processing in surface engineering notably to improve the
fatigue and corrosion resistance of cast propellers for ships, to
eliminate porosity and increase ductility in cast Al alloy, and,
using portable equipment, to eliminate cracks in structures
which have occurred in service. Other plenary talks covered
energy conservation and renewable energy, global HTSE research
trends, thermal spraying, new trends in carburizing, plasma
nitriding and Thai government policy on energy efficiency.
Warm welcome for EFhtse delegates at the new Thai Parkerizing
plant in Rayong
Heat treatment & surface engineering (HTSE) together
with foundry, forming & fabricating, and machining are
recognized by government organizations in Thailand as
key supporting industries for manufacturing
Following the technical sessions a day tour was arranged for
delegates to visit the Thai Tohken Thermo plant in Chonburi
and a new Thai Parkerizing plant on the Hemaraj Eastern
Seaboard Industrial Estate in Rayong. In education and training
for Thai industry both companies lead by example. In 2011 Thai
Tohken opened a new purpose built training and technical
centre for both operator and supervisor training running
courses with co-operation from Suranaree University. Around
120 workers have also spent time at the Thai Tohken plants
in Japan for on-the-job training. Thai Parkerizing provides
scholarships to secondary and high school students and to
university students at 9 public universities. The company also
supports Thai R&D via research funding as the Thai Parkerizing
Chair Professor Award and via Best Paper Awards at Thai
conferences.
Following on from EFhtse 2012, on 28th June some 160 Thai
delegates attended a one-day seminar for industry on “Heat
Treatment and Surface Engineering – Practical Improvements
for Thai Industries” at the Chaophya Park Hotel in Bangkok. This
was supported by the Ministry of Science and Technology and
organized by MTEC, TMA, TFA, and the Thai-German Institute
(TGI). Improved use of HTSE processes is a key part of a TGI
based project on the Enhancement of Mould and Die Industry
Competitiveness.
With an emphasis on practical aspects the seminar covered
the following topics which were considered to be relevant to
the further development of Thai heat treatment:
l “Residual Stress: Advantages, Disadvantages and Measurement
Methods” Dr. P. Juijerm (Kasetsart University, Bangkok).
l “Metallurgy in the Heat Treatment of Superalloys” Dr. P.
Wangyao (Chulalongkorn University, Bangkok).
l “Japan Quality Control and Manufacturing Technology in Heat
Treatment” Dr. K. Funatani (IMST Institute, Japan).
l “Quenching and Tempering of Steels – Methods, Applications
and Practical Problems” Dr. T. Babul (Institute of Precision
Mechanics, Poland).
l “Heat Treatment in the Foundry Industry” Dr. J. Pearce (MTEC).
Future development
Over recent years the Thai cast metals industry has expanded
with the rapid growth of the automotive and electronic/electrical
sectors to concentrate on production of grey and ductile irons
and Al alloy parts. Capacity is estimated at around one million
tonnes per year of iron castings and some 100,000 tonnes of
Al alloy, mainly as high pressure die-castings. There are also a
number of well established jobbing ferrous foundries producing
a range of steel castings including High Manganese and
Stainless grades and alloy cast irons such as Ni-Hards, Ni-Resists
and High Cr irons. Cu base alloys are also produced for water,
architectural and lighting fittings.
In general in the Thai SME foundries further progress is needed
to improve process controls, to reduce energy waste and to pay
more attention to environmental aspects particularly in the use
chemical binders and coatings, fume and dust control, noise
reduction and in the handling and disposal of slag and dross.
The Ministry of Science & Technology is now operating under
a new five year plan for 2012-2016 with the target of increasing
the amount of R&D spending from the present 0.2% of GPD up
to 2% by the end of this period, with the number of research
workers rising from the present 8 per 10,000 of population to 15.
The cast metals industry and engineering in general must find
ways to tap into this extra funding.
Potential areas for the future development in the Thai cast
metals sector include:
l The introduction of compacted graphite irons and austempered
ductile iron into the automotive and general engineering sectors
l Magnesium based castings for auto-parts and electronics
l Improved production of corrosion and heat resisting steels
l Special alloys for use in power generation such as Ni-base
l Ti alloy castings. n
References
1.J. Pearce: “Recent aluminium castings
research in Thailand”. Metal Casting
Technologies (2012) Vol.58 No.2 June
pp.16-19.
2.J.T.H. Pearce et Al: “Global 21 part
17: Heat treatment and surface
engineering in the metals industry
in Thailand”. International Journal of
Heat Treatment & Surface Engineering
(2011) Vol.5 No.4 pp.140-144.
te c hn i c al f eature
Ferritic ductile irons: a revisit
By John Pearce
Introduction
T
he mechanical properties of correctly treated Ductile
Irons are directly related to the nature of their
matrix structures. Depending on composition and
casting variables these irons can be produced as-cast or in the
heat treated condition with ferritic, ferrite + pearlite, pearlitic,
acicular or austenitic matrix structures to give a wide range
of strength and ductility values or to provide additional heat,
corrosion or wear resistance. Irons with predominantly ferritic
matrix structures normally provide tensile strength levels of
at least 350-400 MPa with ductility of 15-22% combined with
excellent machinability. A typical microstructure is shown in
Figure 1. Factors influencing the production and structure &
properties of ferritic ductile irons were determined via detailed
research by Gilbert [1] and Barton [2] at BCIRA and by Cox [3, 4]
at International Nickel over 40 years ago. Over the last 15 years
research interest in ferritic ductile irons has been renewed
particularly with respect to the following applications:
l Replacing conventional Grade 500/7, which has a mixed
ferrite + pearlite matrix, by a fully ferritic iron giving
equivalent mechanical performance but with improved, more
consistent machinability [5, 6]
l Producing castings for turbines to generate energy by wind
power [7, 8]
l Improving the performance of exhaust manifolds and turbocharger housings for vehicles using Si-Mo irons [9, 10]
l Production of weight saving thin walled castings for vehicle
components [11, 12]
This short review revisits ferritic ductile irons to outline some
of these developments.
Producing ferritic matrix structures
Most Ductile Iron (DI) castings used to be heat treated to
achieve the required matrix structures [13]. The use of pure
charge materials (pure pig irons and Sorelmetal) together with
improvements in nodularisation and inoculation treatments
Fig 1. Microstructure of ferritic ductile iron produced by annealing [13].
now allows most ferritic grades to be produced as-cast
without the need for annealing. Impure pig irons and steel
scrap contain pearlite forming elements (e.g. Sb, As, Sn, V,
Mo, Mo, Mn, Cu, and Ni) such that their use must be limited.
Inoculation must encourage high nodule numbers which
firstly reduce the severity of any cell boundary segregation of
P and carbide forming elements, and secondly decrease the
diffusion distances for C to deposit onto the nodules during
solid state cooling. The lower the nodule number the greater is
the tendency for intercellular pearlite to form especially if the
Mn content is above 0.2% or impurity elements are not limited
[2]. In as-cast ferritic DI the Mn level must be below 0.2% but
can be up to 0.5% if castings are to be annealed. Intercellular
segregation effects become more severe as casting section size
increases so control of impurity levels and especially Mn, Cr and
P contents become even more important when larger castings
are to be produced [14, 15].
Depending on charge materials to produce a ferritic matrix
as cast the Si level may need to be increased from 2.22.4% to 2.7-2.8%. Si promotes ferrite formation as austenite
decomposes during cooling through the critical temperature
Intercellular segregation effects become more severe as
casting section size increases so control of impurity levels
and especially Mn, Cr and P contents become even more
important when larger castings are to be produced.
Fig 2. The effect of %Si content on Charpy V notch impact properties
of ferrite ductile irons [1].
range. Unfortunately Si also reduces toughness raising the ductile
to brittle fracture transition temperature (Figure 2) hence the %Si
level must be carefully controlled if the low temperature impact
property specifications at -20 and -40oC in ISO 1083:2004 and
ASTM A874-98(2009) etc. are to be satisfied [1, 16-19]. To achieve
the required low temperature toughness the final Si content is
normally limited to 2.25% together with Mn (<0.2%), Cr (<0.5%)
and P (<0.02%) and the castings must normally be annealed [18,
19]. Annealing involves heating the castings to 850-920oC and
holding for 2-10 hours followed by controlled furnace cooling
between 800 and 650oC or furnace cooling to 680-720oC and
then holding for 4-20 hours. Sub-critical annealing is not suitable
since it gives insufficient homogenization and also produces a
sub-grain structure in the ferrite matrix which is detrimental to
toughness [17, 18].
With regard to impact properties inoculation should
give sufficiently high nodule numbers needed to minimise
intercellular carbides but it should not be excessive since the
graphite nodules assist fracture lowering impact strength in the
ductile range [19].
The addition of Ni increases the proof and tensile strengths
of annealed ferritic DI reducing elongation, but it can provide a
better combination of strength and ductility than that obtainable
with as-cast ferrite & annealed ferrite-pearlite matrix irons
(Figure 3). The addition of up to 1%Ni is recommended to meet
proof and tensile strength requirements in the reduced Si level
grades designed for low temperature toughness [3, 4, 18-20].
Recent work [21] has confirmed the beneficial effect of Ni on
strength and on toughness in the low temperature range.
Fig 3. Beneficial effect of Ni on 0.1% proof stress-%elongation
relationship in annealed ductile irons [3, 20].
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turbines are up to 120m in height and weigh 450 tonnes. From
European experience it is reported by Roedter [7, 24] that the
average weight of DI cast components needed to generate 1MW
is around 13.5 tonnes. The parts include rotor hubs, shafts, and
nacelle frames etc. The targets already set for renewable power
in Europe and China suggest that wind power generation
will continue to increase by 25% from 2010 to 2020, and then
by another 25% between 2020 and 2030 – a large market for
large ferritic DI castings. This has stimulated renewed interest
in developing improved understanding of the production and
metallurgy of these irons and on their service performance [2527]. Experience and problems encountered in producing large
section DI and the avoidance of structural and other defects are
well reported in papers published in the 60s and 70s [e.g. 2, 15,
28]. Together with more recent reports [e.g. 18, 29] these can
provide invaluable information for foundries wishing to satisfy
the high technical demands of this market.
Heat resistant ferritic ductile irons
Fig 4. Charpy V notch impact properties for higher Si ferritic ductile
irons compared with conventional grades 400/15 (ferritic) and
500/7 (ferrite +pearlite) [6, 22].
Substitution for ferrite-pearlite Grade
ISO 1083/500-7
In the 500/7 (FCD 50) intermediate grade the matrix structure
can vary from near fully ferritic to near fully pearlite in different
sections of the same casting, and there is also similar variation
between castings situated at different positions in multi-cavity
moulds. This variation not only gives rise to variations in
mechanical properties within and between castings but also
causes considerable difficulties in machining. Detailed studies
in Sweden have shown that conventional 500/7 can be safely
replaced by an as-cast fully ferritic iron with %Si levels of 3.63.85% for components such as front axle housings for load
dumpers and front wheel hubs for trucks [5, 6]. Mechanical
testing [22] has revealed that the Si strengthened fully ferritic
material is slightly tougher that ferritic-pearlitic iron having the
Fig 5. Form of “chunky” graphite in heavy section ductile iron [2]
same tensile strength (Figure 4) and that fatigue properties are
equivalent. The 3.7%Si grade is now standardized as ISO 1083/
JS/500/10; one example of its use is in hydraulic rotators where
it has given 75% reduction in hardness variation within castings
resulting in a 30% increase in cutting tool life [23].
Heavy castings for wind power
The demand for alternative green sources of energy has
lead to the rapid development of the wind power industry,
notably in Europe, together with a demand for reliable and
safe performance from cast components in Grade 400/18LT
ferritic DI [7, 8, 24-26]. The LT denotes the requirement for
the iron to satisfy an average V-notched Charpy value of 12J
when tested at -20oC. Low temperature toughness is critical
in wind turbines located in N. Europe, China, N. America, etc
and offshore to cope with exposure to severe weather. Large
The demand for alternative green sources of energy
has lead to the rapid development of the wind power
industry, notably in Europe, together with a demand for
reliable and safe performance from cast components in
Grade 400/18LT ferritic DI.
Si-Mo ferritic DI can withstand maximum service temperatures
of up to 950oC. Increasing the Si content in ductile irons to
between 4-6% Si raises the ferrite to austenite transformation
temperature producing a stable ferritic matrix which is
resistant to growth and oxidation. Although Mo is a strong
carbide former it is added to these irons in amounts up to 2%
to improve high temperature strength and thermal fatigue
properties and to provide sufficient creep resistance over long
periods of service in castings used in furnaces and for vehicle
parts subject to thermal cycling such as exhaust manifolds
and turbo-charger bodies [9, 10]. The C content is reduced to
around 3% to improve mechanical properties and to minimise
problems with fluidity during filling thin sections. Some recent
work [30] has focused on the prevention of “chunky” graphite
in castings (Figure 5) since these irons, as well as austenitic
DI, appear to be more sensitive to the presence of rare earth
elements in smaller sections than unalloyed irons. In normal
ferritic DI grades chunky graphite can be a problem in heavy
sections and must be avoided in the wind power castings
mentioned above.
The high Si level in Si-Mo iron reduces ductility and
toughness but this does not normally cause problems in
assembly, maintenance or service. The irons can be used
as-cast but heat treatment may be required to decompose
or spherodise intercellular carbides especially if up to 2%Cr is
included in the composition. The chemical compositions and
microstructures of Si-Mo DI intended for high temperature
service automobiles are covered by the US SAE standard
J2582:2004. These irons are not as heat resistant as the
austenitic 35%Ni-5%Si-2%Cr DI grade or austenitic stainless
steel but they offer a more economic option for manufacturers.
problems encountered in
producing large section
DI and the avoidance of
structural and other
defects are well reported
in papers published in the
60s and 70s.
Thin wall ductile iron castings
Progressive improvements in pre-conditioning of melts and
in subsequent nodularisation and inoculation treatments
can enable the production of ductile irons free from eutectic
carbides in section sizes down to 2.5mm thus providing the
opportunity for weight saving in vehicle parts [31]. Progress in
this area has followed on from the US Dept. of Energy initiative
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Stand 12
43
which began in 1998 to develop capability for the manufacture
of lightweight iron castings [11]. Since then considerable data
has been obtained on how microstructures and mechanical
properties of thin wall castings can compare favorably with
thicker sections [e.g. 11, 12, 32].
Machined thin wall (2.5-6mm) plates have shown equivalent
or higher properties compared to usual (12.7mm) sections
but without machining the thin plates can show inferior
and variable properties if the surface finish is rougher than
a threshold level [11, 12]. To produce thin section castings
moulds with greater dimensional accuracy are needed and
the mould surface and pouring & filling conditions have to be
more closely controlled with extra attention to the design of
the gating system [33]. To produce ferritic matrix thin sections
a high degree of nucleation is needed to ensure a high
nodule number and to avoid inverse chill at the later stages of
solidification [34, 35].
Ductile Iron is now 64 years old but engineers still need it
and thanks to continued feeding by R&D efforts it seems to be
getting younger all the time. n
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1
References:
G.N.J. Gilbert: “Review of recent work on the mechanical properties of
nodular cast iron”. Foundry Trade Journal, 1966, Vol.120, May 19, pp.667672; May 26, pp.713-724.
R. Barton: “Factors influencing the production of as-cast ferritic nodular
(SG) iron”. BCIRA Journal, 1970, Vol.18, pp.534-541.
G.J. Cox & J.D. O’Loughlin: Foundry Trade Journal, 1971, Vol. 131, p.833.
G.J. Cox: “The impact properties of different types of ferritic spheroidal
graphite cast iron”. British Foundryman, 1973, Vol.66, pp.
L.E. Bjorkegren & K. Hamberg: “Ductile iron with better machinability
compared to conventional grades”. Foundryman, 1998, Vol. 91, pp.386-391.
L.E. Bjorkegren & K. Hamberg: “Silicon alloyed ductile iron with excellent
ductility and machinability”. Foundryman, 2001, Vol. 94, pp.42-48.
H. Roedter & M. Gagne: “Ductile Iron for Heavy Section Wind Mill Castings:
A European Experience”. Proceedings of 2003 Keith Mills Symposium on
Ductile Cast Iron, October 2003, South California, USA, 7pp.
I. Riposan et Al: “Performance of heavy ductile iron castings for windmills”
China Foundry, 2010, May, Vol.7, pp.163-170.
H. Roedter: “4-6% Silicon Ductile Irons for High Temperature Service”.
Suggestions for Ductile Iron Production No. 102, RTIT publication, 2006,
March, 2pp.
D. Li et Al: “Solidification Behaviour, Microstructure, Mechanical Properties,
Hot Oxidation and Thermal Fatigue resistance of High Silicon SiMo
Nodular Cast Irons”. Paper 2004-01-0792, SAE 2004 World Congress, 2004,
March, Detroit, US.
L.P. Dix et Al: “Static Mechanical Properties of Ferritic and Pearlitic
Lightweight Ductile Iron Castings”. AFS Transactions, 2003, Vol.111, pp.11491164.
D.M. Stefanescu et Al: “Study of the Effect of Some Process Variables on
the Surface Roughness and the Tensile Properties of Thin Wall Ductile iron
Castings”. AFS Transactions, 2007, Vol.115, pp.637-646.
J. Pearce: “Heat Treatment of Ductile Irons”. Metal Casting Technologies,
2003, Vol.49, March, pp.22-26.
G. Jolly & G.N.J. Gilbert: “Segregation in nodular iron and its influence on
mechanical properties”. British Foundryman, 1967, Vol.60, pp.79-92.
R. Barton: “Control of microstructure and mechanical properties in large
section as-cast nodular iron castings”. BCIRA Journal, 1976, Vol.20, pp.176186.
“Effects of silicon in nodular (SG) iron”. BCIRA Broadsheet 211-1, BCIRA 1982,
4pp.
“Factors influencing the ductile or brittle behaviour of nodular irons”. BCIRA
Broadsheet 212, BCIRA 1982, 4pp.
M.J. Fallon: “Experiences in the Manufacture of Ductile Irons”. The
Foundryman, 1995, vol.88, pp.308-318.
R.D. Forrest; “Meeting low temperature property specifications in ductile
iron”. Suggestions for Ductile iron Production No. 82, RTIT publication, 2006,
March, 2pp.
G.J. Cox: “The effect of composition on the microstructures and mechanical
properties of as-cast and heat treated SG iron”. Giesserei 1983, Vol.50, pp.9398.
J. Lacaze et Al: “Influence of 1% addition of Ni on structural and mechanical
properties of ferritic ductile irons” Materials Science & Technology, 2012,
Vol.28, 603-608.
L.E. Bjorkegren & K. Hamberg: “Silicon Alloyed Ductile Iron with Excellent
Ductility and Machinability”. Proceedings of 2003 Keith Mills Symposium on
Ductile Cast Iron, October 2003, South California, USA, pp.70-80.
R. Larker. “Solution strengthened ferritic ductile iron ISO 1083/JS/500-10
provides superior consistent properties in hydraulic rotators”. China Foundry,
2009, Vol. 6, November, pp.343-351.
H. Roedter: “Powerful Ductile Iron Castings for Wind Energy Applications”.
Suggestions for Ductile iron Production No. 110, RTIT publication, 2006,
March, 3pp.
I. Riposan et Al. “Influencing factors on as-cast and heat treated 400-18
ductile iron grade characteristics”. China Foundry 2007 Vol.4 pp300-303.
C. Labrecque & P.M. Cabanne. “Low temperature impact strength of
heavy section ductile iron castings: effects of microstructure and chemical
composition”. China Foundry 2011 Vol.8 February pp. 66-73.
J. Sertucha et Al: “Effect of alloying on mechanical properties of as cast
ferritic nodular cast irons”. Materials Science & Technology 2012 Vol.28
pp.184-191.
R. Barton: “Experience in the prevention of defects in nodular iron castings”.
BCIRA Journal, 1968, Vol.16, pp.554-567.
P.M. Cabanne et Al: “Production of Heavy and Thick Ductile Iron Castings
(Process Review and Potential Defects)”. Indian Foundry Journal, 2010,
Vol.56, pp.33-42.
R. Logan et Al: “An investigation of chunky graphite defects in SiMo iron
used for high temperature applications”. Indian Foundry Journal, 2011,
Vol.57, pp.41-48.
F.R. Juretzko et Al: “Precondition of ductile Iron Melts for Light Weight
Castings- Effect on Mechanical Properties and Microstructure”. AFS
Transactions, 2004, Vol.112, pp. 773-785.
A. Javaid et Al: “Effect of microstructure on the Mechanical Properties of
Thin-Wall Ductile Iron Castings”. AFS Transactions, 2001, Vol.109, pp. 10971114.
P. David et Al: “Gating system design to cast thin wall ductile iron plates”.
Foundry Trade Journal, 2009, Vol. 182, pp.119-126.
A. Javaid et Al: “Critical conditions for obtaining carbide-free microstructure
in thin- wall ductile irons”. AFS Transactions, 2002, Vol. 110, pp. 889-898.
K.M. Pederson & N.S. Tiedje: “Undercooling, nodule count and carbides in
thin walled ductile cast iron”. Foundry trade Journal, 2009, Vol. 182, pp.
54-57.
Abstract
V
acuum technology is considered to be the effective
method to remove air from the die cavity in the
high pressure die casting (HPDC) process. The key
component of the technology is the vacuum valve. It opens
to apply vacuum to the cavity, and closes to prevent metal
entering the vacuum system. The most popular method
currently used in the industry is the mechanical valve. Its major
shortcoming is its reliability, which causes machine downtime
due to metal blockage when the valve fails to shut off.
A new type of vacuum valve, called CASTvacTM, has been
developed in Australia under the CAST CRC program with a
research team from CSIRO. The technology is now licensed
to Wanda Technology. The nature of CASTvacTM is a threedimensional chill block which consists of no moving parts. It
is therefore as robust as a conventional two-dimensional chill
block, and never fails to terminate the liquid metal. It has a
large venting area which provides a high evacuating efficiency
compatible to the mechanical valve. It fits in the same die
pocket as the popular mechanical valve and requires a low
projected area.
CASTvacTM has been implemented in an industrial plant for
six years. The benefit by reducing the machine downtime
has been demonstrated. A cost model has been developed
and is presented in this paper. This model indicates machine
downtime and valve service were the major cost sources.
Introduction
Vacuum technology has existed in the die casting industry for
more than half a century. The technology has evolved from a
shut-off valve with the assistance of a simple PLC control, to
advanced mechanical valves with sophisticated logical controls,
which are currently in wide use. The benefit of using vacuum
to improve the casting quality is straightforward and has been
proven in the industry for some time. However, its adoption
is still limited. The barrier may be due to a number of factors
including ease of use, cost, and willingness of customers to
accept castings with limited porosity.
The early vacuum system consisted of a shut-off valve with a
simple PLC control actuated by the plunger position. To prevent
metal ingress into the vacuum line, the valve was normally
shut off before the change-over from the first stage to the
second stage of plunger speed. When the vacuum source was
cut off, air would quickly be drawn back through the gaps into
the cavity. Badal et al reported the leak rate could be as high as
230mbar/sec for the tested die1. This leak reduced the level of
vacuum previously generated in the cavity; a further limitation
was the gas would have no chance to be expelled as the valve
was closed.
Since the early 1980s, more advanced vacuum valves have
been developed and are commercially available, such as gasfree (GF)2, 3. These types of valves are shut off mechanically
by the metal impact or by sensing the metal front during the
The technology has evolved from a shut-off valve with
the assistance of a simple PLC control, to advanced
mechanical valves with sophisticated logical controls,
which are currently in wide use.
45
Fig. 1: The CASTvacTM fixed and moving half valves.
Fig. 2: CASTvacTM in semi-closed position.
Fig. 3: Comparison of the evacuation efficiency of CASTvacTM
with the popular mechanical valve and the conventional chill
vent using the same pocket width as CASTvacTM.
very last stages of cavity filling. The mechanical type of valve
is highly efficient since it extracts air until the end of the cavity
fill, but its weakness is in the complexity of the mechanical
shut off mechanism, which can be prone to blockage in the
harsh die casting environment.
Conventional chill vents are also commonly used with
vacuum, but their weakness is the small evacuation area which
restricts the rate of air evacuation. Typically the gap in the
washboard area is less than 1mm in depth and about 100mm in
width. To increase its evacuation area, the chill vent has to be
made wider. This will increase the die projected area, and as a
consequence increase the risk of die flash.
The simple vacuum system and the conventional chill
vent used with vacuum offer low evacuation efficiency.
Considering the additional cost and maintenance, die casters
have limited incentive to adopt these vacuum systems. The
mechanical valves offer lower reliability and productivity due to
unpredictable machine stoppages.
remain small in order to terminate the flowing molten metal.
In addition, to avoid die modification, our industry partners
specified the new valve would need to be compatible with the
existing die pocket dimensions for the mechanical valve they
were already using.
An innovative concept was developed by constructing a
folded washboard with its major chill faces at a right angle to
the die parting face, instead of parallel to the parting face of the
conventional chill vent. This would allow the new valve to have
nearly four times the venting area of the conventional chill
vent using the same die footprint. Such an increased venting
area enables vacuum performance to meet that achieved by
mechanical valves.
This innovation has been patent protected. The product from
this innovation was named CASTvac™, as it was developed by
CAST CRC Limited.
A CASTvac™ valve is illustrated in Fig. 1 (the two halves
side-by-side) and Figure 2 (two halves semi-closed). It can be
imagined that a continuous venting pathway will be formed
when the two halves are engaged.
An additional benefit of CASTvacTM is that the venting area is
increased without sacrificing the die projected area which is an
important resource for the die designer. This is a result of the
forces generated from the metal pressure acting on the major
faces of the washboard, which are directed at right angles to
the die parting face, counteracting each other. For instance, the
machine clamping force required to hold the same venting area
will be reduced from 360 tonnes for a conventional chill vent to
87 tonnes for a typical size of CASTvacTM valve (calculated from a
metal pressure 80MPa and the available venting area).
The valve has been implemented in production for six years
and made over one million shots on 800-tonne to 2500-tonne
HPDC machines in a die casting plant. After six years’ service
the first valve is still operating in good working condition.
There have been no blockages reported on this, or the other
valves, since put into operation.
CASTvac™ is produced in three sizes—small, medium, and
large—to match the equivalent sizes of the most popular
mechanical valve currently on the market. Figures 1 and 2
above show a medium-sized CASTvac™ with TiN surface
coating. Its evacuation performance, which was an important
aspect of the design goal, was measured with a bench test
and is illustrated in Figure 3. It compares CASTvac™ with the
equivalent-sized mechanical valve and a conventional chill
vent. As can be seen, the evacuation efficiency of CASTvacTM
is compatible with the mechanical valve, and is much better
than the conventional chill vent using the same pocket width
as CASTvacTM.
CASTvacTM valve contains a built-in ejection mechanism,
which eliminates the requirement for die modification for
ejector pins, and facilitates the valve change. It also contains
internal cooling, and a built-in air blast for self-cleaning.
CASTvacTM
The development of a new vacuum valve was an outcome of
a challenge posed by industry to have a vacuum valve that
was immune from the blockages they experienced with their
mechanical shut-off valves. The aim of the development was
therefore to design and construct a valve which was reliable and
whose evacuation efficiency could match the mechanical valve.
To achieve this reliability, an ideal design would be
for a valve with no moving parts. The mechanism of the
conventional chill vent was naturally considered (a so-called
‘valveless’ approach). However, increasing the venting area for
a conventional chill vent can only be achieved by extending
the width of the zigzag washboard since the gap size has to
The cost model of using vacuum-assisted
die casting
As suggested by Robbins4, “to calculate the approximate true
cost of downtime, simply subtract the actual cost of the alloy
used per hour from the selling price of the castings produced
per hour”. Using this method, the cost of the machine
downtime can be estimated to be $US300 per hour on average
for industrialised countries. All data used for this calculation
for a generic die casting plant are listed in Table 1. Readers can
use their own data as an input for the calculation.
Fig. 4: The approximate cost of using mechanical valve and
CASTvacTM ($US/annum/machine)
Cost of machine time
300
$US/hour
Cost of labour in tool room
80
$US/hour
Time for changing valves during machine
stop
30
minutes/
change
Time for machine warm-up
15
minutes
Warm-up shots per stoppage
6
shots
0.10
$US/kg
10
kg
Cost of re-melting alloy
Weight of a full shot
Table 1: Basic data used for the cost model
The $US300/hour cost of machine downtime shown in Table
1 already includes operator costs. A stoppage of 30 minutes
for the valve change-over, for example, plus 15 minutes for
the machine warm-ups will cost $US225. The cost to remelt
60kg of aluminium is small (~$US6). Therefore, each machine
stoppage will cost approximately $US231. It is not uncommon
for a mechanical valve to be blocked once per day. For a die
casting plant running six days a week and 50 weeks a year,
the downtime will cost $US69,300. If the stoppage is reduced
to once per week, the cost will be reduced to $US11,550,
representing a direct saving of $US57,750 per machine per
year just from fewer machine stoppages. It has been proven
in a die casting plant that this is achievable by replacing the
mechanical valve with CASTvacTM valve.
Another significant component of the cost is the service of
the valves. This again relates to valve blockage. It is estimated
that one hour is required for the toolmaker to clean the valve
and the vacuum line, and then recondition the valve back to
47
an operational condition. This will cost $US24,000 per year
for the mechanical valve. Changing to CASTvacM will save
$US16,000, based on the same assumption above.
The other sources of costs include spare parts for the
valve, repair (refurbishing) of the valve, and the capital
cost to purchase the valve. When all of the costs are added
together, it will cost $US109,233/annum/machine to run
mechanical valves, compared to $US28,283 for CASTvacM. This
has been plotted in Figure 4. The direct cost saving will be
approximately $US81,000.
The same data are plotted in a pie chart and shown in
Figure 5. This shows the major saving, by using CASTvacTM,
comes from improved machine downtime rates. The second
largest contribution to the saving is the reduction of service
time, which is related to valve blockage. The valve cost is
relatively small compared with the operational costs.
Fig. 5: The cost saving distributions.
Conclusion
The technical and cost benefits in using vacuum-assisted die
casting have been discussed in this paper. The additional cost
associated with the operation of the valve is an issue to many
die casters.
The cost model developed in this paper has indicated that
machine downtime is the biggest cost component of using
a conventional mechanical vacuum valve. CASTvacTM is an
efficient and reliable vacuum valve that will significantly
reduce the operational cost of vacuum die casting.
Gary Savage BAppSc (Metallurgy) (UniSA),
GradDip (Computing) (Monash)
Gary Savage is the Program
Manager for Casting Technology
at CAST, and Stream Leader for
Light Weighting and Durability at the CSIRO’s Future
Manufacturing Flagship. His responsibilities include
providing research leadership and project management
in the fields of die casting and continuous casting.
Gary’s primary research interests focus on high
pressure die casting of aluminium and magnesium
alloys. He has a strong record of transferring research
outcomes into industry through adoption, licenses, and
commercialisation. Gary has been with CSIRO since
1999. Prior to this, he spent 10 years at BHP Research
with a focus on rolling mill rolls, thermal fatigue, wear,
and hot rolling technologies.
References
1. A. Badal, Y. Longa, P. Hairy, “Effectiveness of the Vacuum Technique
in Pressure Die Casting” in Die Casting Engineer, July 2001, pp 54-60.
2. A. Wolodkowicz, “Vacuum Die Casting: Its Benefits and Guidelines”,
NADCA 16th International Die Casting Congress and Exposition, 30
September–3 October 1991, paper T91-071.
3. L. Wang, M. Gershenzon, V. Nguyen, G. Savage, “An Innovative
Device for Vacuum and Air Venting”, CastExpo’05, St Louis, Missouri,
16–19 April 2005, paper T05-073.
4. P. Robbins, http://www.castool.com/blog/2009/10/for-survival-cutdowntime/
Laihua Wang
BAppSc (Eng.)
(Beijing Univ Sc &Tech), PhD
(Central Iron & Steel Research
Institute, Beijing)
Laihua Wang is a senior research
scientist in the Casting Technology Group of CSIRO’s
Process Science and Engineering division. He graduated
from Beijing University of Science and Technology in
Bachelor degree in 1982, and attained his PhD in 1990.
He has worked in steelmaking and die casting research
for the past 25 years, specialising in fluid flow and
solidification modelling, and technology development.
He has led a number of research and development
projects, and developed CASTvacTM, an innovative
vacuum valve for the high pressure die casting process.
He has authored or co-authored more than 20 papers in
the field.
Use of PoDFA technique
for rapid melt cleanliness
assessment: a practical
shop-floor tool for production
of aluminum casting
By Thawatchai Kantisitthiporn and Julathep Kajornchaiyakul
Abstract
T
he present study demonstrates how the PoDFA
(Porous Disc Filtration Apparatus) technique can be
enhanced for rapid melt cleanliness assessment.
This is based on an additional analysis of data in terms
of weight of the filtered aluminum versus time duration
pertaining to the filtration. A series of PoDFA tests on an
aluminum casting alloy were conducted. During each PoDFA
test corresponding data set of filtration weight and time were
recorded and analyzed. The longer the time duration required
for one kilogram of the aluminum to flow through the filter
suggested that the liquid metal exhibited lesser cleanliness.
The analysis was in good agreement with metallographic
investigation based on standard PoDFA practice. The analysis
yields characteristic data that can be made useful as a practical
shop-floor tool.
1. Introduction
Liquid metal quality is one of the important factors influencing
final quality of cast aluminum alloy. Inclusions in molten metal
can degrade castability, formability, machinability, surface
finishing and mechanical properties. Several techniques
may be used to evaluate cleanliness of liquid aluminum, for
example, K-Mold, LAIS, LiMCA, ALSPEK, ultrasonic techniques,
and filtration techniques [1, 2]. A rapid or real-time method
for practical assessment in the foundry is preferrable. Among
these techniques, the Prefil Footprinter is claimed as the only
method that can provide both real-time assessment via a
characteristic curve of filtrated weight versus filtation time as
well as metallographic analysis for indentifying inclusions [3].
Prefill Footprinter (developed by N-Tech) and PoDFA (Porous
Disc Filtration Apparatus; developed by Alcan) are based
on filtration techniques which employ different principles
for melt cleaniness assessment. The Prefill Footprinter can
be used for evaluating melt cleanliness via both real-time
and metallographic analysis. The PoDFA is based only on
metallographic examination. Figure 1 shows principle of the
Prefill Footprinter technique. The liquid aluminium is forced
through a fine filter by pressurization and the progression of
filtrated weight versus filtration time recorded for real-time
assessment [4, 5]. Flow behavior based on such data, i.e.
filtrated weight vs. filtration time, may be analysed further by
first and second derivations as presented by X. Cao [3, 6-9]. On
the other hand, the PoDFA technique is based on a vacuum
method as shown in Figure 2 [5, 10-14]. Liquid aluminium is
encouraged to flow through a fine filter by reduced pressure
but there is no characteristic data recording for real-time
assessessment. Both types of filtration technique are able to
indentify and quantify inclusions in the cake solidified on-top
of the filter using suitable metallographic examination.
Liquid aluminium is encouraged to flow through a fine
filter by reduced pressure but there is no characteristic
data recording for real-time assessessment.
49
Fig 1. Schematic Showing Principle of Prefill Footprinter Technique.
Fig 2. Schematic Showing Principle of PoDFA Technique.
One objective of this present work is to study feasibility
of using the PoDFA technique as a practical real-time
assessement without any modification of the standard
apparatus. Data recording by a stopwatch was used for
evaluating melt cleanliness of an aluminium alloy. Using
ADC12, a high pressure die casting Al alloy, as test material
characteristic curves were obtained by recording the
progession of filtration time at each 0.05 kilogram filtered
weight of liquid metal by standard PoDFA practice. These
curves were analyzed for comparison with the results of
metallographic examination of the residual filter cake.
technique. Each sample whose weight was about 2 kilogram
was charged into a SiC crucible and heated up to 8000C. Each
molten sample was poured into a preheated PoDFA crucible
fitted with a standard alumina filter containing 30 pores per
inch (ppi). The pouring was controlled with careful tilting in
order to avoid turbulence and additional oxide formation. At
6850C a vacuum was applied to initiate flow through the filter.
Progession of filtration time was recorded by a stopwatch at
each 0.05 kilogram of filtrated weight of the melt. Plotted data
of corresponding characteristic flow curves were then made for
real-time assessment.
Testpieces in form of the aluminium cake solidified on-top of
the filter at the end of testing were subjected to metallographic
examimnation. Inclusion type and content were investigated.
The cakes were prepared in accordance with the PoDFA test
standard practice. Complete details of the PoDFA test and
analysis procedures are available [10, 12-13]. Total inclusion
concentration area per kilogram was calculated as follows:
2. Experimental details
Table 1 shows the standard composition of the aluminium
alloy used in this study. Two samples of the alloy were
taken from a die casting foundry. The samples were
subjected to remelting using an electric resistance furnace
prior to melt cleanliness assessment by the PoDFA
Total Inclusion (mm2/kg) =
Mean Measured Residue Area (mm2) x Inclusion Area Fraction
Filtered Metal Mass (kg)
Alloy
ADC12
Fig 3. Filtration time versus filtrate weight curves of PoDFA technique
Alloying Elements (wt. %)
Cu
Mg
Si
Fe
Mn
Ni
Zn
Cr
Sn
Ti
Al
1.5-3.5
0.3 max
9.6-12
1.3 max
0.5 max
0.5 max
1.0 max
-
0.3 max
-
balanced
Table 1. Standard composition of the aluminum alloy used in the experiment.
Sample No.
Inclusion Concentration (mm2/kg)
Aluminium Oxide
Films Concentration (count/kg)
Type of Inclusions in Cake Area
ADC12 No.01
32
0.88
MgO, Oxide Film, Spinel, Al4C3B
ADC12 No.02
40
2.81
Spinel Crystal, Al4C3B, Oxide Film
Table 2. Summary of oxide and inclusions content by metallographic analysis of PoDFA technique.
3. Results and discussion
Figure 3 is characteristics of the test data from
the application of PoDFA technique. The figure
shows the progression of filtration time versus
filtrated weight of each melt sample. There are
clear differences in filtration time between the
two samples based on an equal filtered weight.
The filtration time of sample ADC12 No.2
appears to increase at a higher rate than that
of ADC12 No.1 after the filtrated weigh reached
about 0.5 kg. Based on this characteristic curve,
ADC12 No.02 is expected be less clean compared
to ADC12 No.01. This is in good agreement
with metallographic examination following
the standard PoDFA technique as summarized
in Table 2. The amount of oxides and other
inclusions content are 32 and 40 counts/ kg,
and 0.88 and 2.81 mm2/kg for ADC12 No.01
and ADC12 No.02, respectively. The nature and
distribution of the oxides and inclusions as
examined by optical microscopy are illustrated
in Figure 4. In addition to the amount of oxides
and inclusions content, the decrease in fluidity
of the melt sample due to decreasing melt
temperature during the test is another factor
affecting the filtration time. Thus it is important
to closely control the melt temperature when
performing this test. Other factors such
as vacuum pressure, variation in chemical
composition, and so on, that may affect the
characteristic test data, must also
be considered.
Fig 4a. Sample number 01.
Fig 4b. Sample number 02.
Figs 4a & 4b. Representative micrographs of the PoDFA samples showing oxide
and inclusions in the cake area: (a) ADC12 No.01 and (b) ADC12 No.02.
51
Back to
4. Concluding remarks
1. This technique may be suitable for use
as a “Go: No-Go” tool by comparing
characteristic curves with a reference
curve from the same alloy with acceptable
cleanliness.
2. Testing conditions such as vacuum
pressure, melting temperature and
chemical composition of test samples
and reference samples must be suitably
controlled to avoid misleading results
caused by variations in liquid aluminium
fluidity.
3. The metallographic analysis based on
the standard PoDFA technique is still
necessary in order to determine types
and amount of oxides and inclusions
content. This is very important for proper
improvement of melt treatment practices
toward favorable cleanliness.
Acknowledgements
This present investigation was sponsored
by Foundry Engineering Laboratory,
National Metal and Materials Technology
Center (MTEC). n
B a s i c s
[4] P.G. Enright et al: “Characterisation of Molten Metal Quality Using the Pressure Filtration
Technique”. American Foundry Society, 2003.
Balancing flow in vertically
parted moulds
[5] B. Prillhofer et al: “Nonmetallic Inclusions in The Secondary Aluminum Industry for The
Production of Aerospace Alloys”. TMS, 2008, pp.603-608.
J. F. Meredith, Casting Solutions Pty Ltd
References
[1] M.B. Djurdjevic et al: “Melt Quality Control at Aluminum Casting Plants”. Association of
Metallurgical Engineers of Serbia (AMES), MJoM 2010 Vol.16 (1), pp.63-76.
[2] D.V. Neff: “Evaluating Molten Metal Cleanliness for Producing High Integrity Aluminum Die
Castings”. Die Casting Engineer, September 2004.
[3] Xinjin Cao: “A New Analysis of Pressure Filtration Curves for Liquid Aluminum Alloys”. Scripta
Materialia, 2005 Vol.52, pp.839–842.
[6] X. Cao: “A New Indirect Method of Measuring The Contents of Solid Inclusions in Liquid
Aluminium Alloys”. J Mater Sci, 2006 Vol.41, pp.4285–4292.
[7] X. Cao: “Pressure Filtration Tests of Liquid Al–Si Cast Alloys: I. Flow Behaviour”. Materials Science
and Engineering A, 2005 Vol.403, pp.101-111.
[8] X. Cao: “Pressure Filtration Tests of Liquid Al–Si Cast Alloys: II. Best-Fitted Equations for Filtrate
Weight versus Filtration Time Curves”. Materials Science and Engineering A, 2005 Vol.403, pp.94100.
[9] X. Cao et al: “Examination and verification of the filtration mechanism of cake mode during the
pressure filtration tests of liquid Al–Si cast alloys”. Materials Science and Engineering A, 2005
Vol.408, pp.234-242.
[10] C. Stanica et al: “Aluminum Melt Cleanliness Performance Evaluation Using PoDFA
Technology”. U.P.B. Sci. Bull. Series B, 2009 Vol.71, pp.107-114
[11] J. Wannasin et al” “Evaluation of Methods for Metal Cleanliness Assessment in Die Casting”.
Journal of Materials Processing Technology, 2007 Vol.191, pp.242-246.
[12] L.Liu et al: “Assessment of Melt Cleanliness in A356.2 Aluminium Casting Alloy Using the
Porous Disc Filtration Apparatus Technique: Part I Inclusion Measurements”. Journal of Materials
Science, 1997 Vol.32, pp.5901-5925.
[13] L.Liu et al: “Assessment of Melt Cleanliness in A356.2 Aluminium Casting Alloy Using the Porous
Disc Filtration Apparatus Technique: Part II Inclusion Analysis”. Journal of Materials Science, 1997
Vol.32, pp.5927-5944.
[14] K. Haberl et al: “Characterization of the Melt Quality and Impurity Content of an LM25 Alloy”,
Metallurgical and Materials Transactions B, 2009 Vol.40B, pp.812-821.
Introduction
T
he production of castings using high speed
vertically parted green sand moulding lines is
well established in the foundry industry. The
mould production rates of these machines are such that cycle
times are often significantly less than 10 seconds. The total
pouring time of a mould must be less than the machine cycle
time, otherwise the pouring sequence would slow down
the moulding machine. This requirement, and the vertical
orientation of the mould usually necessitate high flow rates
and stream velocities which in turn can lead to defects such as
sand and slag inclusions and poor surface finish.
Often, there are multiple pattern impressions arranged on
different levels in the mould. In order to avoid excessively high
flow rates and velocities it is desirable to balance the flow in
the gating system so that castings on all levels are filling at the
same time.
Fig 1. Computer flow modelling of the above design confirms
the flow rate at each level is reasonably uniform.
Basic theory of gating design
Mr. Thawatchai Khantisitthiporn
e-mail : thawatt@mtec.or.th
Mr. Thawatchai Khantisitthiporn
received his Bachelor and Master
Degrees in Production Engineering
and Metallurgical Engineering,
respectively, from King Mongkut’s
University of Technology Thonburi. His research thesis
was based on a study of the mechanical metallurgy of
wrought aluminium alloys for extrusion. He is a research
engineer at MTEC, where his work involves processing of
aluminium alloys with special emphasis on melt quality.
Dr. Julathep Kajornchaiyakul
email : julathek@mtec.or.th
Dr. Julathep Kajornchaiyakul
graduated in 1992 with a B.Eng.
in Metallurgical Engineering from
Chulalongkorn University, Bangkok,
Thailand. He then undertook post-graduate studies in
the US obtaining his M.Sc. in “Mechanical Metallurgy:
Deformation Processing of Metals” from the Colorado
School of Mines, Golden in 1996, and his Ph.D. in
“Brittle Materials Manufacturing: Abrasive Machining
& Processing” at University of Connecticut in Storrs
in June 2000. Since September 2000 he has been
working as a R&D Engineer at MTEC – the National
Metal and Materials Technology Center under the
National Science and Technology Development Agency
(NSTDA) of Thailand. He is now a Principal Researcher
in the Design & Engineering Research Unit at MTEC
working mainly on Foundry Engineering and Aluminium
Processing. He is also the Research Unit Director. He is
the current Chairperson of the Aluminium Technology
Forum of Thailand and an Advisory Board Committee
Member of the Thai Foundry Association (former Thai
Foundrymen’s Society). He is also a member of the
Technical Committer of the Federation of Thai Industry’s
Clustering Development Board relating to Machinery
and Metallurgical Industries.
The design of a gating system is often based on the
requirement to meet a desired fill time. This may be based
on experience with certain types of castings or it may also be
based on a calculation involving the weight poured, the type
of alloy and the critical section thickness to be poured or it
may be determined by a machine cycle time.
Having established a fill time, and given the weight and
density of the casting, it is possible to calculate a volumetric
flow rate (cubic inches/sec or cc/sec) using the formula:
Fig 2. Mould Filling sequence at 10% filled.
Flow rate = Volume/Fill Time
Next, it is necessary consider how far the metal will
fall when it is poured, which gives a metal velocity (using
Newton’s laws of motion for a free-falling body). Knowing
the velocity and the volumetric flow rate, the cross-sectional
area of flow required can be calculated. It is then necessary
to adjust this flow area for friction loss or shape factors, and
finally to apportion this area so that there is the desired rate
of flow at all of the various gates into the casting. It is also
necessary to establish the “choke” point of the gating system,
so that elements downstream (or upstream) from the choke
can be oversized sufficiently to avoid excessive velocities and
Fig 3. Mould Filling sequence at 30% filled.
53
maintain the choke (the point of maximum velocity) at the
correct point in the gating system. This will generally ensure
the correct rate of flow in all portions of the gating system,
with liquid metal delivered at the required flow rate into the
casting cavity.
The next piece of information required for gating calculations
is the height through which the metal will drop. In the case of
horizontal gating, this is the effective height of the sprue (the
vertical pipe down which the metal initially flows). For vertical
gating, this may be the cumulative height from the top of the
mould down to each component. In any case, the velocity of the
metal after falling through this height can be calculated from a
fairly simple relationship:
V = √(2gH)
Where:
V = velocity, g = acceleration of gravity
H = height through which the liquid has fallen
This formula is based on basic Newtonian physics,
and describes the velocity of any body free-falling in a
gravitational field.
Now, given the known velocity and the known volumetric flow
rate, the cross-sectional area of flow of the liquid metal can be
calculated simply from the following equation:
Flow Area = Volumetric Flow Rate/Velocity
This is the basic calculation which is used in gating design.
When calculating flow areas, consideration must also be given to
shape efficiencies and friction losses. According to research, for
example, a square tapered sprue has an efficiency of around 74%;
this means that an area calculated according to the above formula
must be increased by a factor of (1/0.74) or 1.351 to account for the
energy losses associated with flowing through this type of shape.
Also, in flowing through runner systems, the liquid metal loses
energy through friction with the channel walls. This friction loss,
which is usually expressed as a percentage, must be compensated
for by increasing the area of the downstream runner segments.
Balancing flow rates on all levels
As the flow rate at each level is proportional to the height the
metal stream has fallen and the cross sectional area of the choke
at that level, it follows that a countermeasure to variable flow
rates at different levels in the mould is to proportion the choke
cross sections at each level in such a way as to get similar flow
rates through them. This approach requires the cross sectional
area of the chokes to reduce as the height the metal stream drop
increases which means the castings at the lowest level have the
smallest choke area and this area increases at each level towards
the upper most.
The following formula provides a means of determining the
appropriate choke area to achieve balanced flow rates at each level
in the mould.
A = G/t x d x f√(2gH)
Where: A = Area of choke
G = Weight of metal required to pass through choke
t = Required fill time
d = density of molten metal
f = loss factor
g = acceleration of gravity (9810 mm/s2)
H = height through which the liquid has fallen
This formula can be simplified if it is made specific for a
particular alloy type where the density of the molten metal is
known and the gravitational constant ignored. In which case the
formula becomes:
Cast Irons: - A = 1036 x G/t x f√H
Copper Base: - A = 850 x G/t x f√H
Aluminium Alloys: - A = 3100 x G/t x f√H
In the above:
A = mm2,
G = kg
t = seconds
H = mm
Practical example
In the example shown in figure 1, there are 12 ductile iron castings
arranged on 6 levels. Figures 2 – 6 show the Mould Filling
sequence. The choke areas were calculated according to the above
formula for cast irons. It can be seen the choke areas reduce from
position 1 through to the lowest level at position 6.
The plot in figure 7 shows the time (represented by colour) at
which each part of the entire mould was filled. The relatively even
banding of colour on each casting indicates a balanced flow rate. n
References
1. Finite Solutions Inc literature
PACIFIC RIM FOUNDRY SERVICES
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Fig 4. Mould Filling sequence at 50% filled
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Fig 7. Colour representation of Fill Time.
55
EVENTS
ALUMINIUM 2012
When: 9-11 October 2012
Where: Messe Düsseldorf - Germany
Summary: ALUMINIUM is the world’s leading trade show and
B2B-meeting place for the aluminium industry. It brings together
high-calibre buyers, manufacturers, processors and suppliers. In
Düsseldorf innovative products, the latest technology and services
from primary aluminium production to semi-finished and finished
products will be showcased.
Web: http://www.aluminium-messe.com/
43rd Australasian Conference & Exhibition: Advanced
Foundry Innovation
When: 21-24 October 2012
Where: Crown Plaza Coogee Beach – Coogee –
Sydney, Australia
Summary: The conference series is an effective peer discussion
and practical forum bringing together Foundry Managers, CEOs,
suppliers, technologists and operating personnel, in a social yet
informative forum. The conference will include a large trade
exhibition allowing suppliers to the industry an opportunity to
exhibit their products and services, while giving foundry operators
the opportunity to view and inspect the latest developments in the
industry.
For those that like to get out and about, we have site tours
organised to Safety Expo at Homebush Bay, Nuclear Reactor
(ANSTO) at Lucas Heights and the Sell & Parker Steel Shredding
Facility.
Web: http://afiaustralia.org/nsw
Tube India International 2012 & Metallurgy India 2012
When:
30 Oct – 1 November 2012
Where: Bombay convention & Exhibition Centre Mumbai, India
Summary: Also running concurrently is Energy efficiency and cost
effective technologies for the metallurgical industry.
Web: www.steelmetallurgy.com
Email: schreiberG@messe-duesseldorf.de
The 4th (2012) China (Shanghai) International Foundry
Industry Exhibition
When: 7-9 November 2012
Where: China Shanghai International Exhibition Center – Shanghai, China
Summary: The exhibition will be attended by more than 50,000
professionals from more than 20 countries around the world.
Web: http://www.foundry-expo.cn./
Email: 33380528@163.com
Indian Industrial Trade Fairs
When: 21-24 November 2012
Where: India Expo Centre, Greater Noida - Delhi, India
Summary: Five fairs CeMAT India, MDA India, Surface India,
Industrial Automation India & Laser India.
Email: brigitte.mahnken@messe.de
EVENTS
EUROMOLD -World Fair for Moldmaking and
Tooling, Design and Application Development
When:
27-30 November 2012
Where: Frankfurt am Main, Exhibition Center –
Frankfurt, Germany
Summary: EuroMold is the world-wide leading trade fair for
Moldmaking and Tooling, Design and Application Development
and presents products and services, technology and impulses for
tomorrow’s markets. The whole process chain “From Design to
Prototyping to Series Production” is represented at EuroMold. A
unique fair concept that closes the gap between industrial designers,
product developers, producers, suppliers, and end-users.
Web: http://www.euromold.com
4th International Foundry Congress & Exhibition
(IFCE) 2012
When:
5-6 December 2012
Where: Pearl Continental Hotel, Lahore - Pakistan
Summary: The THEME of Congress is “Dunya Hamari Mandi”
- Industrializing Pakistan. PFA is engaged in the development
of the foundry sector including technical gradation and skills
development. The economic development of Pakistan cannot
be over emphasized without the importance of the foundry
engineering industry. 4th IFCE – 2012 will pave the path for
development of the Pakistan foundry industry and the SME sector.
This mega event will provide an opportunity for members of
the casting industry to interact with international and domestic
machinery and equipment manufacturers, suppliers and foundry
technologists. The 4th IFCE – 2012 will provide a forum to eminent
academicians and technologist from around the world to come
together and to discuss the growth of the foundry industry in
Pakistan and Asian countries. PFA will organize multiple workshops
and discussions during the congress on certain problems faced by
the foundry industry.
Web: http://www.pfa.org.pk
IFEX 2013 – 9th edition of International Exhibition on
Foundry Technology, Equipment Supplies
When:
January 27 – 29, 2013
Where:
Salt Lake Stadium Ground, Kolkata – India
Summary: The 9th International Exhibition on Foundry
Technology, Equipment and Supplies & 4th Cast India Expo
concurrent with 61st Indian Foundry Congress will be an excellent
platform for companies from India and around the world to
showcase their state-of-the art technologies and services. Over the
years IFEX has emerged as the most important platform for the
foundry industry of the Indian Sub-Continent with its rotational
policy to organize the Fair in different zones of India (North, South,
East & West) on a pre-defined cycle helps its exhibitors to reach
their potential customers from all over the country. In addition the
success of the two previous Cast India Expo’s held concurrently
to IFEX has prompted the inclusion of the third edition Cast
India Expo 2013. The presence of these casting manufacturers as
exhibitors in the same venue will provide a ready customer base
for Indian and international suppliers.
CastExpo 2013
When:
6-9 April 2013
Where: America’s Center - St. Louis, Missouri – USA
Summary: Building upon the success of the 116th
Metalcasting Congress in Columbus, CastExpo ‘13 will be
better than ever as it brings together the Metalcasting Supply
Chain for 4 days you can’t afford to miss! Sponsored solely by
the American Foundry Society (AFS), CastExpo is the single
largest trade show and exposition for metalcasting in the
Americas. CastExpo’13 in St. Louis will offer metalcasters,
suppliers, and casting buyers and designers the opportunity
to connect and educate themselves on the latest and greatest
metalcasting has to offer.
Web: http://www.afsinc.org
117th Metalcasting Congress
When:
6-9 April 2013
Where: America’s Center - St. Louis, Missouri - USA
Summary: The American Foundry Society (AFS) has issued
a call for papers for the 117th Metalcasting Congress, to be
held in conjunction with CastExpo 2013. All papers must be
relevant to the metal casting industry and must contribute to
the enhancement of metalcasting quality and productivity,
covering topics such as operations, new technologies,
procedures, processes and other innovations, and casting
design and purchasing. For more information on submitting
on submitting a paper to the 117th Metalcasting Congress,
contact Steve Robison, AFS senior technical director.
Email: str@afsinc.org
14th Guangzhou International Die Casting &
Industrial Furnace Exhibition
When:
16-18 June 2013
Where:
China Import and Export Fair Pazhou Complex, Guangzhou – China
Summary: The 14th Guangzhou International Die Casting
& Industrial Furnace Exhibition will deliver multi-faceted
platforms for business interaction providing opportunities
to attract potential customers. Visitors will include Product
Managers, Product Developers, Designers, Purchase and Sales
Managers. Professionals related to the field of machine tools,
components & accessories, precision tools & other related
products are the target visitors. The exhibition profile includes
cold chamber die-casting machine, hot chamber die-casting
machine, low-pressure casting machine, extrusion press,
auxiliary equipment, environmental protection and safety
technology, Casting products and manufacturing technology
smelting, heat treatment equipment and energy-saving
technologies for foundry environment, labour protection
equipment and supplies for foundry, Precision Casting, Other
special products and foundry equipment.
Email: exhibition.julang@gmail.com
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M e ta l : M a n u fa ct u r i n g : r e S e a r c H
Back to the
Melting metal for the
virtual bronze foundry
By Prof. John H. D. Bautista, PEE, RMetE, MBA; Technical Consultant, Phil. Metalcasting Association., Inc.
T
he choice of melting furnace depends on the types
and sizes of castings to be made. If small melts are
needed to produce small castings, the pit-type, cokefired furnace may be used. If larger melts are needed, the oil-fired,
crucible furnace of the fixed pouring type would be indicated,
especially if large quantities of borings and turnings are used in
the charge. Where the castings required are average – for example,
from 50 to 100 kgs. (100 to 200 lbs.) – and where it is necessary at
times to melt nickel or other high melting point alloys, and where
ideal working conditions around the furnaces are considered
important with particular regard to the absence of heat and
noise, then the high-frequency, lift-coil type of crucible furnace is
indicated. In this type, no ladles or ladle heaters are required, and
no mixing is needed.
Pit-type coke-fired furnaces
In pit-type, coke-fired furnaces, the crucible in placed into a pit
that contains the foundry coke. The coke is fired and the crucible is
preheated. It should be carefully packed so that as much metal as
possible is charged at the first loading. None of the metal charged
should project above the crucible; this helps to keep the metal
from coming into contact with the furnace gases. To ensure this,
a lid consisting of an old crucible bottom could be used; this will
fit nicely over the crucible and prevent overloading. It should be
borne in mind that copper and high-copper alloys absorb gas
when red hot, even while in the solid state. There is no objection
to preheating the metal to be charged so long as it is not allowed
to get red-hot. In all melting processes of this nature, speed is of
the essence. The crucible should therefore have reached red-heat
in the furnace before the metal is charged into it.
The practice is to avoid the use of charcoal or flux cover, thus
giving the gases already in the metal a chance to escape. The melt
should be considered ready when the temperature is about 500C.
(100º F.) above the pouring temperature. As a matter of routine, it is
hardly practicable to take the temperature with a pyrometer while
the crucible is in the furnace, but a good melter soon gets to be
able to judge when the metal is ready.
In removing the crucible from the furnace, care should be taken
to see that the tongs fit around the contour of the crucible so
that the pressure is distributed and squeezing of the more or less
plastic hot crucible avoided. After the tongs have been removed
and the crucible placed in the pouring shank, the metal should
be stirred quietly in a manner to mix well, but not to expose the
surface any more than is necessary. It should then be skimmed,
and if any deoxidizer is to be added, this should be carefully
stirred-in and the temperature taken. The crucible should then be
allowed to stand until the predetermined casting temperature is
reached, the temperature being tested with the pyrometer from
time to time, stirring just before taking the temperature. When the
correct temperature is reached, the metal is again skimmed and
poured. In some cases, it may be an advantage to cover the metal
with thoroughly dry charcoal (pieces of about 1 cm. or ½-inch
diameter, free from all fine dust), or a carbon disk may be floated
on the metal.
Oil-fired, crucible-type furnaces
With this type of furnaces, care should be taken to effectively
ventilate the furnace area. The best thing is to have a large pipe
hung in front of the furnace flame into which the flame can easily
enter. This tube connects with a blower system and discharges into
the outside atmosphere. The whole of the furnace is covered by
a hood that itself has a large pipe connected to the same blower
system. This hood should extend far enough in front to cover
the ladle into which the furnace is to be emptied. This will catch
any lead and zinc fumes that are evolved during the pouring of
the metal. Successful melting in this type of furnace depends on
keeping the flame properly adjusted at all times. To do this, each
furnace should have its own blower and its own oil pressure
system; having a battery of furnaces on one pressure system
for air and oil means that a change in pressure occurs as one or
more furnaces are added to or subtracted from the battery. There
should be a good ordinary valve away from the furnace burner
and another, a needle valve capable of very fine adjustment, at the
burner itself.
In operating the furnace, the flame is controlled so that the
exit flame is sharp in outline, not lambent, and nearly, but not
quite, yellowish-white in color with possibly a greenish tinge. If it
is definitely yellowish-white, there is an excess of oil. This flame
control is the secret of good furnace operation, with its attendant
fast melting and satisfactory metal. A slightly oxidizing flame is
desired in order to prevent the absorption of hydrogen gas into
the melt as the excess oxygen in the flame will react with the
hydrogen and produce water vapor that can be discharged into
the atmosphere. The oxygen absorbed in the melt can afterwards
be removed by deoxidizers. There is no way that hydrogen in the
melt could be removed, so prevent it in getting into the melt.
The condition of the flame as to oxidizing or reducing may be
determined by placing in it a piece of zinc slab, about 20-cms. x
3-cms. square (8-inches long x 1¼-inch square). Hold it there for 5
seconds. If the zinc has a smoky or black appearance, the flame is
reducing; if oxidizing, the zinc remains unchanged.
The furnace should be at a bright red heat before metal is
charged and as much of the metal as possible put into the
furnace at one time – unless there are borings or turnings in the
charge, in which case these are placed in brown paper bags and
thrown into the bath of molten metal and stirred-in well. The
furnace is emptied into a ladle. This ladle is lined with refractory;
it is thoroughly dried and then brought to a red heat each time
it is used. The ladle should be thoroughly scraped out after each
pour and kept as clean as possible, especially at the lip, otherwise
dross and dirt will get into the molds when castings are poured.
Corrective additions such as tin, lead, zinc, and phosphor-copper
are placed on the bottom of the ladle just before tapping so the
molten metal covers them and the general disturbance of the
tapping-pour mixes them. In addition, the melt should be stirred
well with a clean, heavy iron skimmer, which should be replaced
before it gets too hot, in order to reduce iron contamination.
In general, no covering of charcoal or flux is used. An exception
to this is when the fuel is natural gas having a high and variable
content of sulphur. In such a case, it has been found beneficial to
throw in with the charge a sufficient amount of soda ash to form
a covering over the molten metal, not less than 4 mm. (1/8-inch)
thick, thus preventing the sulphurous gas from entering the metal.
In the interest of economy, and as a further check on furnace
operation, a reliable oil meter should be put in the fuel line of
each furnace. Regular forms should be provided and the furnacetender should keep track of the oil consumed for each heat. If the
oil consumption goes up it indicates the probability of the furnace
flame having been wrong, too little air or too much oil having
been present.
High-frequency, lift-coil induction furnace
The operation of this type of furnace is simplicity itself. The crucible
is the furnace and is placed on a truck running on a short track,
long enough to hold two crucibles; one is surrounded by a liftcoil while the other is being loaded. The fact that the crucibles
are some 45 cms. (2½ feet) from the ground does away with any
stooping during loading or carrying to the pouring point. The
crucible is loaded, the hood lowered, the current turned on, and
the melting proceeds. When the pouring temperature is reached,
the lift-coil is raised, the crucible carried to the molding floor and
the molds poured, and the other crucible that has been previously
loaded is moved over to the lift-coil. As the crucible is taken
directly from the truck to the pouring spot, a temperature of only
250C. (500F.) above the pouring temperature is required. There is
no need to mix the metal as this has been done automatically by
the induced currents that were set up in the melt. Ordinarily no
charcoal or flux is used. This is the best type of melting furnace;
but it is more expensive than the oil-fired, crucible-type of furnace
which could be fabricated in-house, if necessary.
Items
Gun Metal
Bearing Metal
Ounce Metal
Copper
88.0%
80.0%
85.0%
Tin
8.0%
10.0%
5.0%
Lead
0.0%
10.0%
5.0%
Zinc
4.0%
0.0%
5.0%
High castability
High castability
High castability
Yield strength, psi
18,000
17,000
17,000
Tensile strength, psi
40,000
32,000
34,000
Elongation, % in 2 inches
20
12
25
Brinell hardness, (500kg.)
68
65
60
Casting temperature, 0F
1900
1900
1900
Heat treatment
None
None
None
General purpose
General bearings
Plumbing fittings
Properties:
Applications
Product composition
Back to the
WEBSITE SHOWCASE
Sample foundry procedure in melting tin bronzes
Metal. It is assumed that composition ingots shall be used for the
main charge.
Melting. Using an oil-fired, crucible furnace and where pressure
tightness is not a consideration, nor maximum density a
requisite, these alloys may be melted without flux in an oxidizing
atmosphere, taking the usual precautions mentioned above. (For
use as bearings, porosity is a beneficent factor as this helps in
retaining an oil film.) Efficient stirring is essential, as the lead will
2011 11:43 Seite 1
segregate rapidly when molten metal containing it is in a quiescent
state.
In cases where pressure-tightness and maximum density are
desired, the following procedure should be followed, based on
Walpole’s flux method.
1. Prepare the flux by mixing equal parts by weight of dry copper
mill scale (this is the cheapest from of CuO), dry clean silica sand,
powdered fused borax. Keep in a suitable container to avoid
la\MCT and
2011
2012.qxp 90 x 135 mm
absorption of moisture.
2. Use enough flux to maintain a cover ¼-inch thick over the
molten metal under the conditions of melting. Generally 3%
References:
(a) Harold J. Roast, Cast Bronze, The American Society for Metals.
(b) Metals Handbook, Desk Edition, 1985
Beckwith Macbro
www.linn.de
Turbine blades,
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γ-TiAl, Ti, Ni-basis, Al, Mg.
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annealing of castings under
protective gas and
centrifugal casting unit.
Rotary hearth furnace for
pre heating of ceramic
casting moulds for TiAl,
Ti, Pt, Ni-basis. Up to 1100 °C.
3 turn tables (Ø 940 mm).
of the weight of the metal to be treated is sufficient. Where
the phosphorus content of the charge exceeds 0.05%, a larger
amount of flux may be required.
3. Put the flux in with the metal as it is charged to the melting unit.
4. Melt as rapidly as possible under an oxidizing atmosphere.
5. When the metal has reached the desired temperature, stir the
flux well into it, to further the oxidizing process.
6. Transfer to a pouring container and throw dry silica sand onto
and over the metal to thicken the flux and facilitate its removal
by skimming.
7. Skim and add 100 grams (4 oz.) of the 15% phosphor-copper per
50 kgs. (100 lbs.) of metal for purpose of deoxidation.
8. Stir well, exposing as little of the metal to the air as is
practicable, and leave for at least 2 minutes before pouring.
9. Pour into the molds; a residual phosphorus content of 0.05 to
0.03% is desirable.
All grades of resin coated sand used for
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Telephone: +61 3 5995 4244
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E-mail: macbrosands@bigpond.com
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63
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65
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All grades of resin coated sand used for
shell molding and shell cores for ferrous
and non-ferrous applications
PRODUCTS
n Range of resin strengths from 1.0% to 5.0%.
n Silica, Zircon, Chromite coated sands
or blended mixes.
FOR SAL
E
n Coated Sands of different AFS
SHELL C
typically from 50-90 AFS.
MACHINORE
ES
n Thermal Reclaimed Coated Sands. SHEL
L MOULD
M
ACHINES
n Frac Sand.
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High Power Jet
Flow Inductors
Solutions for Metal Analysis
Out of One Hand:
Optical Emission Spectrometers
CS/ONH-Analyzers
Ajax TOCCO Magnethermic®
Corporation
Handheld XRF Analyzers
1745 Overland Ave
Warren, OH U.S.A. 44483
Tel: 800-547-1527
Tel: +1-330-372-8511
THE GLOBAL FORCE IN
INDUCTION TECHNOLOGY
Fax: +1-330-372-8608
www.ajaxtocco.com
Optimize your Analysis Process and Quality
www.bruker.com
ELEMENTAL ANALYSIS
Innovation with Integrity
69
BE One Stop Shop_engl_190x135 .indd 1
26.07.2011 14:46:27
67
Casting Solutions Pty Ltd
PO Box 131, Moorebank, NSW, 2170 Australia
Tel: +61 2 9792 3782, Fax: +61 2 9792 3782,
Email: casting@ozemail.com.au, Mob: 0412 178 895
Contact: Jeff Meredith – Director
Category: Foundry Consultants
Products & Services
SORELMETAL High Purity Pig Iron:
Australian agents for SorelMetal High Purity
Pig Iron. Produced by Richards Bay Iron and
Titanium Pty Ltd South Africa
Nodulants & Inoculants:
• Elkem a/s Norway. Exclusive Australian Agent
Refractories:
• CMS manufactures a selected range of
premium grade Castables, Ramming
Materials, Mortars and Furnace Linings
etc. developed to suit the customer’s
Specifications and applications.
Nickel:
• Stocks held in all Australian states
• Mayerton Refractories UK. Australasian Agent
(Furnace & Ladle Refractory Bricks)
• CMS manufacture a complete range of
Refractories and Pre-cast shapes
• Services include selection, installation auditing
and supply for Foundry EAF. Induction and
Heat Treatment Furnaces and Ladles.
Refractory Hollowware:
• Mayerton Refractories UK.- Australasian
Distributors
• Cooinda Ceramics - manufactures of the
EZY-FLO range of first quality Ceramic
Hollowware
Foundry Equipment:
• Omega Foundry Equipment UK. Australian
Agent
• A1 Roper UK. Ladles and accessories –
Australian Distributors
• Whiting Equipment Canada Inc. Electric
Arc Furnaces & metallurgical EquipmentAustralian Agent
• PowerHammer Riser removal equipment –
Australian Agent
• Equipois Inc. manufactures of the Zero Gravity
Arm - Australasian agent
Ferro Alloys:
• CMS can offer the largest, most
comprehensive, complete range of Ferro
Alloys and Metal Powders
• Services include Charge calculations, melting
procedures etc., for Grey and Nodular Irons.
Indium:
• Australian Agent for Indium Corporation of
America
Recarburiser:
• Synthetic Graphite, Graphitised Petroeum
Coke & Gas Calcined Anthracite
Oxy Lance Pipes:
• Shinto Japan – Australian/NZ Agent
Filters:
• Exclusive distributors for the SQ range of
ceramic filters for all grades of ferrous and
non-ferrous metals
Slag Coagulant:
• Castkleen range of Slag Coagulants for all
applications
Sands:
• Southern Pacific Sands. Exclusive Foundry
distribution of local Silica Moulding Sands
• Premium grade Zircon Sand Australian
distributors for Sibelco
• Chromite Sand - CMS are distributors for
Rand York Minerals Premium Foundry Grade
Chromite Sand
• Olivine Sand
Bentonite:
• CMS Superior Bond High Performance
Bentonite
Mould and Core Binder Systems:
• CMS are the exclusive agents for the full
range of SQ Resin Binders and Catalysts
– including Furan, Alkaline Phenolic Co2 and
liquid hardener cured, Air Setting Polyurethane
Resin, Cold Box and Hot Box Resin Systems
Refractory Mould Coatings:
• CMS manufacture a full range of Foundry
refractory Mould Coatings, in water and
Solvent suspensions and dry powder blends
based on Zircon, Graphite, Magnesite,
Olivine and Alumina and a range of auxlilary
products including adhesives, RIMS Anti
Veining additive
Methoding Software & Service
• CMS use and recommend NovaCast
Methoding Software - CMS are the exculsive
agents for Australia and New Zealand for
NovaCast AB Sweden
• CMS services include technical support in
casting methoding, gating, and riser design
/ selection, 3D modeling filling / solidification
simulation plus general technical support
FEEDING AIDS:
• CMS insulating riser tiles – ISOtop hot topping
and insulating compounds.
Pattern Making Supplies:
• Ebalta pattern resins and toolong boards
Australian agents.
• CB Vents, Dowels & Sockets etc.,
Steel Shot:
• TAIWANABRATOR Steel Shot – Australian
Distributors
Abrasives:
• CMS can offer a complete range of high
quality Abrasives especially formulated for
the Foundry Industry
Welding wire:
CMS offer a competitive range of Welding Wire
Grahite Electrodes:
• Graphite Electrodes 6inch to 28inch all
lengths, HP, SHP, UHP CMS are exclusive
agents for Fangda China
HEAD OFFICE
Postal: PO Box 22 Northgate Qld 4013. Offices: 275-277 Toombul Road, Northgate Qld 4013
T: +61 7 3266 6266 F: +61 7 3266 6366 E: enquiries@castmetal.com.au
Australian Branches: Sydney, Melbourne, Adelaide & Perth. NZ Distributors: Metcast Services Limited. Auckland NZ
Overseas Offices: UK, China & Malaysia
Products: SOLIDCast,
FLOWCast, OPTICast
simulation software.
Services:
l metallurgical
l solid modelling
l flow, solidification and
optimisation modelling
of castings
l casting methoding
service
l defect analysis
l training
Level 5, 4-8 Woodville Street Hurstville NSW 2220
PO Box 113, Hurstville BC NSW 1481
Tel: 61 2 9585 6222 Fax: 61 2 9580 8680
Email: Enquiries@cometals.com.au Website: www.cometals.com.au
Contact:
General manager: Colin ILES – colin.iles@cmc.com
NSW: Gary Bartlett – gary.bartlett@cmc.com
QLD: Dave Miller – dave.miller@cmc.com
VIC: Kathy Sevald – kathy.sevald@cmc.com
SA: Brad Walsh – brad.walsh@cmc.com
WA: Alan Dunn – alan.dunn@cmc.com
Ferro alloys: David Osborne – david.osborne@cmc.com
Foundry: Martin Spence – martin.spence@cmc.com
Aluminium: Chris Baker – chris.baker@cmc.com
Categories: Equipment and Suppliers
Industries served: Foundry, steel, aluminium smelter
Product range:
• Ferro alloys • Steel Shot
• Inoculants • Master Alloys
• Metals • Grain Refiners
• Minerals • Fluxes
• Refractories • Electrodes
• Nodulrisers • Pig Iron
• Nickel • Recarburisers
Distributors for Ashland Pacific products:
• Resins
• Catalysts
• Refractory Coatings
• Feeding Aids
Services: Stocking, financing, delivery and storage of raw
materials for foundries steel mills and smelters.
HIT THE
BULLSYEYE
EVERY TIME
METAL CASTING
TECHNOLOGIES
Integrated communication platforms
SUPPLIERS – Exclusive email broadcasts
INTEGRATED – Print and ONLINE reader engagement
POWERFUL Database reach –
FASTER Connection and response
Score a direct hit with
your communications
Speak with Adam for details on +61 2 9420 2080 / adam@rala.com.au
69
Why Use Casting
Simulation From
FSI?
Largest User Base
in the World
Easiest to Use
Fastest Results
Solidification Analysis
Integrated Gating
and Riser Design
Lowest Cost to
Buy and Use
Flexible Payment
Plans Available
Multiple Language
Versions
Mold Filling
World Wide
Support
Visit us
at Stand 14 AFI
Conference
Feeding Zone Analysis for Riser Design
Casting simulation for the working foundry
71
F O S E C O
FEIN Power Tools Pty. Ltd.
Made in Germany
Since 1867
26 Fallon Drive
Dural NSW 2158
PO Box 202, Cherrybrook NSW 2126
Tel: 02 0651 5966 Fax: 02 9651 5988
Email: gweber@huettenes-albertus.com.au
Contact: Gary Weber – Managing Director,
Ryan Weber – Technical Manager
Category: Consumable supplier
Industries supplied: Foundry
Product range:
Cold box binders and catalysts Hot box resins
Resins for shell moulding
Furan resins
Resin coated sand
Inorganic binders
Special sands
Coatings
Alkaline phenolic binders Alkaline phenolic
for CO2 curing
binders for ester curing
* FEIN Angle Grinders
* FEIN Straight Grinders
FOSECO LOCATIONS
AUSTRALIA
Phone: 61 2 9914 5500
Fax: 61 2 9914 5547
MALAYSIA
Phone: 60 33176 0448
Fax: 60 33176 0608
PHILIPPINES
Phone: 63 2 850 6654
Fax: 63 2 850 6638
TAIWAN
Phone: 886 8 722 8108
Fax: 886 8 722 8182
THAILAND
Phone: 66 2 2613164
Fax: 66 2 2613168
INDIA
Phone: 91 2137 668100
Fax: 91 2137 668360
INDONESIA
Phone: 62 21 460 5555
Fax: 62 21 460 3489
NEW ZEALAND
Phone: 64 9 274 4559
Fax: 64 9 274 5981
CHINA
Shanghai
Phone: 86 21 3367 8188
Fax: 86 21 3367 8166
WEBSITES
www.foseco.com.cn
www.foseco.com.au
www.foseco.com
www.vesuvius.com
YOUR TOTAL
SOLUTION PROVIDER
* FEIN High Frequency Grinders
Foseco is part of the worldwide Foseco Group of companies, which
has been associated with global metallurgical industries for more than
70 years, and, is an innovative and progressive organisation. Foseco’s
regional laboratory facilities allow our products to be
tailor-made to the exact requirements of our local customers. These
same facilities also provide technical support to many of our customers’
processes and allows for local research and development. Foseco supply
a wide range of products to the metal casting industry, further product
information is available from your local Foseco office.
* GRIT Belt Grinders
ISOMOL*
HOLCOTE*
RHEOTEC*
FENOTEC*
FUROTEC*
ECOLOTEC*
POLITEC*
POLISET
VELOSET*
KALMIN*
KALMINEX*
KALPUR*
SEDEX*
STELEX*
SIVEX* FC
CARBONIN*
INOCULIN*
COVERAL*
FEEDEX*
KALTEK*
INSURAL*
MTS
VESUVIUS
Refractory solvent based coatings
Refractory water based coatings
Refractory water based dip coatings
Selfset alkaline phenolic binder system
Furane binder system
CO2 cured cold box system
Phenolic urethane Amine cured cold box
Selfset phenolic urethane binder system
Sodium silicate self set systems
Range of insulating feeder sleeves
Range of exothermic feeder sleeves
Direct pour systems
Iron filtration
Steel filtration
Aluminium filtration
Range of melt carbon raisers
Range of inoculants
Fluxes for aluminium
Exothermic feeder Sleeves
Insulating ladle lining system
Insulating refractories for aluminium
Automated Metal Treatment Station for Aluminium
Crucible range
Foseco also supply, release agents, die coatings, furnace and ladle linings & refractories
LOCAL KNOWLEDGE
GLOBAL RESOURCES
*registered trade marks of the Vesuvius Group registered in certain countries.
* FEIN Drills
* FEIN MultiMaster
Call us today - 1300 798 688
Visit - www.fein.com.au
Office Locations:New South Wales, Victoria, Queensland, Western Australia and South Australia
PART OF THE HAYES METAL REFINERIES GROUP - ESTABLISHED 1927
FOR AUSTRALIA’S AND NEW ZEALAND’S
LARGEST RANGE OF ALLOY INGOTS FOR
FOUNDRIES AND THE DIE CASTING INDUSTRY
Producers and / or Distributors of a Comprehensive Range of:
■ Copper Alloy Ingots & 15% Phosphor Copper Shot
■ Primary Grade Aluminium Foundry Alloy Ingots
■ Secondary Aluminium Foundry & Diecasting Alloys
■ White Metal Alloys & Specialty Solder Alloy Ingots
■ Zinc Aluminium Alloy Ingots
Technical Support by way of full in-house Analytical Laboratory
Call
CallAustralian
AustralianSales
Sales
on
on+61
+61229627
96277150
7150
Hayes
Hayes Metals Pty Ltd - Sydney Offices
Office
(Incorporating
(incorporating Dinga Enterprises)
25-31
Riverstone NSW 2765 and
25-31 Hobart
Hobart St.,
Street
106
Mileham
St.,2765
South Windsor NSW 2756
Riverstone
NSW
Fax:
Fax: +61
+61 22 9627
9627 7041
7041
E-mail:
E-mail: KeiranSlattery@hayesmetals.com.au
KeiranSlattery@hayesmetals.com.au
CallNew
NewZealand
ZealandSales
Sales
Call
+649 9633
6334000
4000
onon+64
Hayes
Metals
Ltd -Limited Hayes
Metal
RefiPty
neries
Auckland
Office
Auckland
Offi
ce
8 Edinburgh
Street
8 Edinburgh
Street
Onehunga
Auckland
1061
Onehunga
Auckland
1061
NZNZ
Fax:
+61
2 9627
7041
Fax:
+64
9 636
4004
E-mail:
jhastie@hayesmetals.co.nz
E-mail:
pwilcox@hayesmetals.co.nz
www.hayesmetals.co.nz
www.hayesmetals.co.nz
73
FND CORP 1FA4-UAL_FND.CORP1F-A4-UAL 11-08-22 9:10 AM Page 1
SHAPE THE FUTURE !
Quality Castings
Start Here
Supplier selection is more than physical properties
and delivered prices. It represents the selection of
a partner with the resources to help achieve your
quality, productivity and environmental goals.
Sibelco offers a complete portfolio of silica and
low expansion refractory sands, bentonite clays and
custom blends. Given more options, foundries can
more effectively match mineral performance with
casting objectives. Our organisation is applications
driven. With a dedicated materials research lab and
proven foundry experts, our strength is the ability to
deliver products, technology and service as a single,
integrated system.
Whether your goal is to optimise performance,
maximise strength, improve finish, increase yield
or speed up shakeout, we have a solution.
Sibelco Australia Limited
Tel.: +613 9586 5400 Fax: +613 9586 5411
E-mail: ContactUs@metalcaster.com
Worldwide: www.metalcaster.com
Casting process simulation is geared toward the reduction of energy consumption, raw material use and the
environmental impact of your foundry. Increasing demands require even more ﬂexibility and faster decisions
on your part. Meeting these challenges depends on technically and economically sound solutions.
Optimized Reality – this is where simulation with MAGMA shows its strength.
MAGMA Engineering Asia-Paciﬁc Pte Ltd
25 International Business Park
#03-76/79 German Centre
Singapore 609916
Phone +65 656 434 35
Fax +65 656 406 65
info@magmasoft.com.sg
www.magmasoft.com.sg
All rights reserved. © 2011
75
Model #
m
Model 55
mm
KG
Joules
xmm
m KG
55
45
2
500
115
110
115
65
5
1000
165
175
$
Casting Degating
Hammers
铸件浇口清除锤
Model 115
m
Marteaux de fonderie
pneumatiques
Model 815
Model 215
Giesserei Schusshammer
215
m
90
10
2000
225
250
Martelli pneumatici
per le fonderie
: 캐스팅 게이트 브레이크 해머
415
Model 415
120
20
3000
300
450
m
Martelos para quebrar os
canales de vazamento
Молотки для отбивки литников
Martillos para quebrar
canales de colada
Model 615
615
140
5000
350
600
815
190
8000
480
850
1655 250
16000
625
2950
m
Model 815
m
m
Model 1655
x
PowerHammer Company
16295 SW 85th Ave
Portland, OR 97224 • USA
www.powerhammer.com
Tel: +503 598 9894
www.linn.de
Turbine blades,
turbocharger wheels.
γ-TiAl, Ti, Ni-basis, Al, Mg.
Induction heated precision
centrifugal fine casting
systems up to
2 kg Ti /TiAl,
3 kg Steel,
1 kg Al/Mg, e.g.
Production line for γ-TiAl
consisting of
mould pre heating rotary hearth
furnace, conveyor furnace for
annealing of castings under
protective gas and
centrifugal casting unit.
The Best
in Metal Analysis
Unique flexibility, highest precision, stability and
analytical speed – when your daily analyses require more
than mediocrity, you’re equipped with the best for every
analytical task with the new SPECTROLAB.
For demanding metal analysis, the SPECTROLAB offers you:
– Lowest operating costs due to reduced argon consumption and
lengthened maintenance intervals
– Unique flexibility and precision due to the hybrid optic that combines
the advantages of PMT and CCD technology
– Highest stability and speed due to the simultaneous signal processing
and optimized excitation conditions with a plasma generator
Find details at
Tel +852.2976.9162,
spectro.info@ametek.com.hk
www.spectro.com/lab.
Please visit us at:
JAIMA/JASIS 2012, 5 - 7 September, Tokyo, Japan
Guangzhou Mould Exhibition 2012,
19 - 21 September, Guangzhou, China
NDT 2012, 31 October - 2 November, Shanghai, China
Rotary hearth furnace for
pre heating of ceramic
casting moulds for TiAl,
Ti, Pt, Ni-basis. Up to 1100 °C.
3 turn tables (Ø 940 mm).
HIT THE
BULLSYEYE
EVERY TIME
METAL CASTING
TECHNOLOGIES
Integrated communication platforms
SUPPLIERS – Exclusive email broadcasts
INTEGRATED – Print and ONLINE reader engagement
POWERFUL Database reach –
FASTER Connection and response
Score a direct hit with
your communications
Speak with Adam for details on +61 2 9420 2080 / adam@rala.com.au
79
WES OMEGA FOUNDRY
MACHINERY PTY LTD
16 Lanyon Street
Dandenong Vic 3175
Tel: +61 3 9794 8400
Fax: +61 3 9794 7232
Email: info@wesomega.com.au
Contact: Les Craig and Peter Domopoulos
l
l
l
l
l
l
l
SPECIALISING IN:
l Foundry Equipment and Engineering
l Foundry layout drawings
l Research and Development of new equipment
l Modify existing equipment designs to suit a
variety of applications
l Service and Spare parts
INDUSTRIES SUPPLIED:
Foundry equipment for a wide range of materials
handling applications
PRODUCT RANGE:
l Foundry engineering
l Chemically bonded sand moulding systems
l Continuous sand mixers
l Vibrating compaction tables
l Rollover draw machines
l Mould painting manipulators
l Mould closing manipulators
l Indexing belt & rollover conveyors
l Dry attrition sand reclamation systems
l Primary lump reducers
l Pneumatic sand transporter
l Secondary scrubbing equipment
l Fluid bed cooler classifier
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
Dust collection systems
Sand storage silos
Thermal reclamation systems
Cold box core machines
Shell core machines
Gas generators
Fume scrubbers
Sand heaters
Sand coolers
Full range of vibratory equipment
Vibratory furnace scrap charge feeders
Vibratory sand/casting conveyors
Vibratory accumulating and
sorting conveyors
Vibratory sand lump reducers
Vibratory compaction tables
Full range of sand testing equipment
Full range of geared ladles
Simpson green sand mixing equipment
Didion rotary media drums
Hunter match plate moulding and handling
systems
Vulcan Engineering fox grinders and action
robots
EMI Equipment automated moulding
systems and re-manufactured equipment.
SERVICES:
Application evaluation; foundry design
engineering; in house manufacturing
programme; in house testing of equipment;
supervision of installation of equipment on
site commissioning of equipment; after sales
service and equipment spare parts.
ASSOCIATED COMPANIES:
Hunter Automated Machinery –
Match Plate Moulding and Mould
Handlings Systems
Didion International –
Rotary Media Drums and Sand
Casting Separation
Simpson Technologies –
Green Sand Mixing and Sand
testing Equipment
Vulcan Engineering –
Fox Grinders and Action Robots.
EMI Equipment –
Automated Moulding Systems and
Re-Manufactured Equipment.
The 14th
Guangzhou International
Die Casting & Industrial Furnace
Exhibition
World Equipment and Machine Sales
Company specialize in Exporting
Second Hand Foundry Machines
l DISAmatic Molding Machine
l INDUCTOTHERM Induction Melting Furnaces
l SINTO and HUNTER Molding Lines, With Handling
l SPECTRO and BAIRD Spectrometers
l LECO Carbon, Sulfur, Hydrogen, Nitrogen Testers
l LAEMPE and LORAMENDI Core Cells. Complete
l Core Making Equipment, Shell, Cold Box, Isocure
l Shot Blast and Fettling Equipment, Wheelabrator
l BMM and OSBORN Jolt Squeeze Molding Machines
l COMPLETE FOUNDRIES FOR RE-LOCATION!!!
AUTOMOTIVE FOUNDRY
LINE FOR SALE, 1997
ABB 12T Twin Power Induction Melting Furnace,
6000 Kw, w/Spectro
Disa 2013 Mk5B, 535 X 650, Pattern Changer, Core Setter,
AMC, SBC Didion MD-100 Media Drum
Wheelabrator Continuous Type Rocker
Barrel Shot Blast Machine
Governed By:
Ministry of Commerce of the People's Republic of China Department of Foreign Trade
Approved By：
The Department of Foreign Trade & Economic Cooperation of Guangdong Province
Organized By：
Come visit us at our new 100,000 sq ft warehouse.
Home of over 500 used foundry machines
World Equipment & Machine Sales Co.
611 Cochran Road, Solon, Ohio 44139
U.S.A., Tel: 440-519-1745 Fax: 440-519-1748
www.foundry-eqpt.com mike@foundry-eqpt.com
Contact
Guangzhou Julang Exhibition Design Co., Ltd.
Andy Cheng
Tel: 0086-20-38621253
Fax: 0086-20-3862 0781
Email: exhibition.julang@gmail.com
Show time: 16-18June, 2013
Venue: Ground Floor, B Area, China Import and Export Fair Pazhou Complex
(No.380,Yuejiang Zhong Road, Guangzhou, China)
The 14th CHINA (GUANGZHOU) INT'L METAL & METALLURGY EXHIBITION
www.castingchina-gz.com
COATINGS
FILTRATION
FEEDING SYSTEMS
MELT SHOP
REFRACTORIES
METAL
TREATMENT
BINDERS
CRUCIBLES
COVERAL* I FDU I MTS I ALSPEK*
THE POWER OF 2
The world is full of great double acts. Our technology and your foundry, for
instance, to make premium-grade casting products. Or your castings in the
hands of engineers who produce great technology that serves us every day.
Our locally based teams of foundry specialists are on hand to help you
develop innovative solutions to suit your metallurgical needs.
Our products, services and expertise coupled with your skills and process
knowledge can unlock the full potential of your foundry operations.
As a reliable and trusted supplier, Foseco can help you to improve
mechanical properties, increase casting integrity, lower fume emissions,
reduce waste or perhaps improve process control.
Whatever your foundry requirements are, talk to us.
Your foundry and Foseco. The power of two.
COMMITTED TO FOUNDRIES
* COVERAL and ALSPEK are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Phone: + (61) 2 9914 5500
Fax: + (61) 2 9914 5547
www.foseco.com.au

casting technologies

Transcription

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