1st QTR 2011 - Pakistan Foundry Association

ELEMENT
Your Guide to Foundries in Pakistan
w w w. p f a . o r g. p k
1 s t Q t r. 2 0 1 1
INDUSTRIALIZING PAKISTAN
3rd IFCE 2010
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President Message
It is a matter of great satisfaction for me that Pakistan Foundry Association has
successfully organized the 3rd International Foundry Congress & Exhibition at
Pearl Continental Hotel Lahore on December 01 & 02, 2010. It was largely
attended by around 3000 foundrymen, Engineers, Technical Managers,
Exhibitors, Buyers, Sellers and Students etc from all walks of Industrial Sector in
Pakistan. This year we had an ever increased participation by local & overseas all
those who are concerned with the Foundry Industry.
The participation from foreign countries i.e. Turkey, India, China, UK, Czech
Republic etc was encouraging for us. Few important visitors Mr. Basar
Oztopcular - Cukurova Kimya End. A.S, Turkey, Mr. Chavan Pruthviraj Ravindra,
Mr. Shinde Sunil Shivajirao, Mr. Singh Subodh Rajan, Mr. Vinay kumar luthra Gargi Huttenes-Albertus (Pvt) Ltd -India, Mr. Vikas - Director Marketing and Mr.
Ashok Sharma -Engineer Megatherm-India and many more. I highly acknowledge their participation as they
travelled all the way for this event.
Since our first IFCE 2006 the PFA has gained the attention of the Foundry Industry globally and now IFCE is
becoming one of the most important event in the region. Special added feature this year was more focused
platform for local & International sourcing. A very encouraging response from the major casting users like Defense,
Automobile, Sugar, Fertilizer, Cement, Paper, Power and Engineering Sector and provided good opportunity for the
foundry men to interact with potential buyers of castings.
The major objective of the Pakistan Foundry Association (PFA) is to support the progress & development of
Foundries in Pakistan by improving skills and up-grading technology. After 3rd IFCE 2010 some positive response
has been seen by the government. In this regard National Productivity Organization - Ministry of Industries,
Islamabad provided the services of a Foundry Expert Mr. Ram Chandra Narayan Bhome to visit certain foundries in
Lahore for the improvement of this industry. His observations and technical advice for improving quality,
productivity and cast reduction will provide positive result in the growth of light engineering sectors particularly
SMEs.
In Pakistan, Foundry Industry's basic problem is scarcity of skilled man-power, which is resulting in low productivity
and quality. PFA and TEVTA (Technical Education & Vocational Training Authority) Lahore, Govt. of Punjab is
developing a training centre for un-skilled labour on the direction of Mian Shahbaz Sharif -Chief Minister Punjab.
Mr. Saeed A. Alvi-Chairman TEVTA has assured his full possible support and would be flexible to any model of
cooperation with PFA as long as the requirement of Industry exists.
I once again thank all those concerned with the foundry industry who participated in the
Sikandar Mustafa Khan
3rd IFCE and assure a dynamic business platform for their growth in future.
President – PFA
Contents
Chief Editor
Mr. Fahad Iqbal
Event Report of 3rd International Foundry
Congress and Exhibition Lahore Organized
by Pakistan Foundry Association
2
44th Census of World Casting Production
9
Joint Secretary - PFA
Editor
Mr. Abdul Waheed
The Potential of Casting in Pakistan
16
G.M. Foundry
Pakistan Engineering Company Limited(PECO)
Kot Lakhpat, Lahore
Ph: +92 42 35880071-4 Cell: 92 321 4989797
Email: pecoklw@gmail.com
Case Study - Effect of Core Material on
Shrinkage Ravi Autos (pvt) Ltd.
22
Coordinator
Hardening & Nitriding of Dies & Moulds
in Vacuum Furnaces
24
59th Indian Foundry Congress &
International Foundry Exhibition
30
Mr. Abdul Rashid
Secretary - PFA
93-B, Hali Road, Gulberg-II, Lahore Pakistan
Ph: +92 42 35023525, 35753619 Fax: 92 42 35755743
Cell: +92 322 8487873
Email: info@pfa.org.pk
pakistanfoundryassociation@gmail.com
URL: www.pfa.org.pk
Event Report of
3rd International Foundry
Congress and Exhibition Lahore
Organized by
Pakistan Foundry Association
Pakistan Foundry Association has organized 3rd International Foundry Congress & Exhibition (IFCE- 2010) on
December 1st & 2nd 2010 at Pearl Continental Hotel, Lahore Pakistan.
PFA is engaged for the up gradation of technology and skills development of foundry sector in Pakistan. The objective
of Pakistan Foundry Association is to provide a platform for the growth of Foundry Industry. Pakistan Foundry
Association has organized two such exhibitions in the year 2006 & 2008 before this Mega Event. The objective
behind these IFCEs is to correlate the foundry industries of Pakistan with the latest International Manufacturing
practices and to promote Trade, Commerce and manufacture of foundry products for the local & global markets.
Mian Muhammad Shahbaz Sharif - Chief Minister Punjab inaugurated 3rd International Foundry Congress &
Exhibition. The Punjab Chief Minister Mian Muhammad Shahbaz Sharif while addressing the Inaugural Ceremony of
3rd International Foundry Congress & Exhibition had emphasized there is a vast scope of development of
Engineering Sector. The Government of Punjab will provide all out facilities for this purpose including technical
courses in accordance with the market needs, introduced in TEVTA and other vocational Institutions.
The Chief Minister said the International Foundry Conference on the topic of “DUNYA HAMARI MANDI” would help
and provide a strong basis to engineering sector in Pakistan and every effort would be made to make Pakistan lead
other countries of the region in Engineering Industry. The Punjab Government is extending all out cooperation to
Pakistani & Foreign Industries for this purpose. The Industrialists associated with Pakistan Foundry Association are
playing an important role in saving foreign exchange by producing quality products. He appreciated the performance
of Mr. Sikandar Mustafa Khan - Chairman (Ex) Punjab Vocational training council, in this regard. “TEVTA and Punjab
Vocational Training council have been modernized and skilled work force according to market needs is being
produced” by his efforts he said.
The Chief Minister said he is ready to resolve all problems of the foundry industry and persons associated with the
sector should come to him for evolving an effective strategy. “Facilities within the scope of Punjab Government will
be provided and Federal Government will also be contacted regarding their problems” he promised.
Earlier Mr. Sikandar Mustafa Khan – President PFA also addressed the conference. He welcomed Mian Muhamamd
Shahbaz Sharif - Chief Minister Punjab and thanked him sparing his valuable time to inaugurate 3rd IFCE 2010. He
said PFA was established with the vision to develop Small & Medium Enterprises in Pakistan. In this regard he
especially thanked and appreciated SMEDA for the support in the development of Foundry Service Centre which will
2
be a mile stone for the Foundry Industry. He said Pakistan Foundry Association was established in 2003 by few foundrymen with
the vision to provide a platform for the growth of the foundry industry by improving skills and upgrading technology with the
special emphasis on Small & Medium size foundries. SMEDA (Small & Medium Enterprises Development Authority) guided PFA
through the stage of its inception.
Earlier the Chief Minister Inaugurated the Exhibition of Engineering Industry and appreciated the standard of casting
equipment, Machinery tools and heavy duty machinery produced in Pakistan.
Mr. Shahid Ahmed Hakim – CEO Bolan Castings (Pvt) Ltd, Karachi thanked the Chief Guest, Senior Government Officials,
Industrialist, Academician, Foundrymen and all participants for sparing their precious time to be here.
SUPPORTERS
3rd International Foundry Congress/ Exhibition was organized with the major financial support by the following PFA
members and have been acknowledged with the mementos presented by Chief Minister Punjab Mian Muhamamd
Shahbaz Sharif.
1.
Mr. Laeeq ud Din Ansari
Director, M/s Millat Tractors (Pvt) Ltd
2.
Mr. Shahid Ahmed Hakim
CEO, M/s Bolan Castings (Pvt) Ltd
3.
Mr. Ahmed Hassan
CEO, M/s Chenab Engineering Works & Foundries (Pvt) Ltd
4.
Mr. Adil J. Mansoor
Chief Executive, M/s Excel Engineering (Pvt) Ltd
5.
Mr. Masud Akhtar
Managing Director, M/s KSB Pumps (Pvt) Ltd
6.
Mr. Haroon Arshad
Director, M/s Ravi Autos (Pvt) Ltd
7.
Mr. Rizwan Qadri
Director M/s, Qadri Group (Pvt) Ltd
3
Mr. Sikandar Mustafa Khan presented a memento to the Chief Minister Mian Muhammad Shahbaz Sharif.
In this event various Government Officials including Maj. Gen. M. Owais Mustafa –DG-MVRDE, Rear Admiral
Muhammad Mushtaq – NUST, Mr. Aitazaz A. Niazi - CEO-EDB, Mr. M. Irfan Tarar –DG TDAP, Mr. Muhammad Ali -DG,
TDAP, Mr. Anwar A. Khan –CEO SMEDA, Mr. Khawaj Muhammad Yousaf – CEO NPO, Mr. Razzaq Dawud – CEO Descon,
Commercial Counselor from USA, Dr. Shujat Secretary Industry, Mr. Saeed Ahmed Alvi –Chairman TEVTA, Chairman
Metallurgy Dept. of UET, Punjab University, GIKI and a large number of academicians, visitors from various industrial
sectors and students from the Institutions have participated.
Delegates
Maj. Gen. Muhammad Ovais Mustafa - D.G. MVRDE also visited the exhibition on day one. He was highly impressed
while visiting stalls of local foundrymen and appreciated the skills development. He also chaired the first technical
session of the 3rd IFCE - 2010.
According to survey report the exhibition was visited by around 3000 foundrymen, Engineers, Technical Managers,
students etc from all walks of Industrial Sector. The major visitors were from Lahore, Gujranwala, Faisalabad,
Sargodha, Rawalpindi/ Islamabad, Daska/Sialkot, Sheikhupoora, Karachi.
Few important visitors from foreign countries like Mr. Basar Oztopcular – Cukurova Kimya End. A.S, Turkey, Mr.
Chavan Pruthviraj Ravindra, Mr. Shinde Sunil Shivajirao, Mr. Singh Subodh Rajan, Mr. Vinay kumar luthra – Gargi
Huttenes-Albertus (Pvt) Ltd -India, Mr. Vikas – Director Marketing and Mr. Ashok Sharma -Engineer MegathermIndia and many more.
Those who could not participate due to political situation of Pakistan and certain restriction on travelling but have
sent their best wishes and congratulations for the successful 3rd International Foundry Congress & Exhibition i.e. Mr.
Andrew Turner – Secretary General World Foundry Organization (WFO), Libo Zhang –Senior Vice President &
Secretary General –CFA, Mr. Tam Chi Ho –President Hongkong Diecasting, Mr. Tsedev MUNKHJARGAL- President,
Mongolian Metallurgical Association – Mongolia, Mr. Subodh Panchal –Kastwel India, Mr. Vinod Kapoor-Gargi,
Oxana Michel-Lativia, Dalian Dashan – China, Tarun Sangal, Benan Betik- Omega Foundry Machinery Ltd – UK.
4
The 3rd IFCE 2010 also provided an opportunity to investors, machinery makers, foundry supply companies and
service providers to showcase their products and services to their counterparts and potential customers and make
alliances. The forum also provided a platform to eminent academicians and technologist from worldwide to come
together and discuss advances and technical opportunities. PFA made the 3rd IFCE a SOURCING EVENT and
Industrialist, Technical Managers and Purchase Managers from Sugar, Paper, Cement, Fertilizers, and Chemical
participated in this mega event. Industrial delegates from England, Turkey, Czech Republic, China, India and other
countries also participated in the congress and exhibition.
PFA organized special one to one meeting of Pakistan Foundrymen with their Managers to propose their local
requirements and ways and means on technical grounds. Such exchange of views will benefit both the sectors and
will save foreign exchange. Foundry sector in Pakistan has been experiencing an unprecedented growth from the last
few years as the European & US Markets are focusing on this region of the World.
This mega event turned out to be an opportunity for the members of the casting industry to interact with
international and domestic machinery and equipment manufacturers, suppliers and foundry technologists. Overall
the 3rd IFCE has been regarded a successful and beneficiary event by the visitors & participants.
Scientific Session
Internationally renowned speakers discussed various foundry issues and shared their knowledge and experience
through technical papers. They provided an insight into the global technology developments, future market
prospects & raw materials. Pakistani speakers gave an insight about present growth and development in Pakistan
foundry sector. The eminent speakers discussed innovative technologies, quality improvements, application of
computer aided process
in foundry industry. The objectives were disseminating knowledge among the
foundrymen and benefit from the latest technology in the respective fields.
There were 6 technical session held in two days and eighteen technical papers were presented by the authors and
presenters. Total papers received were around thirty but due to lack of time only eighteen presenters could deliver.
Mr. Abdul Ghaffar Soomro – Secretary Ministry of Industry & Production, Dr. Syed Aftab Ahmed
Managing Director - KRL Foundation Rawalpindi, Mr. Tariq Iqbal Puri – Chairman TDAP was unable to come due to
their last moment official commitments.
5
THE SCIENTIFIC SESSION OF 3RD IFCE 2010
TECHNICAL SESSION # 1 ON DAY ONE (DEC 01, 2010)
SESSION CHAIRMAN: Maj. Gen. Muhammad Ovais Mustafa- D.G. MVRDE
Time
11:30
12:00
12:30
12:50
Topic
Strategic Directions for Pakistan Foundry Industry
By: Mr. Imtiaz Ali Rastgar – CEO Rastgar Engineering Company.
Development of Ferritic Grade SG Iron UtililizingHigh Manganese Pig Iron
By: Mr. Munir Ahmed - Consultant SMEDA
Concepts & Advantages of Heat Treatment
By: Mr. Muhammad Yousaf Khan - GM Matiari Sugar Mill
Comments by Chair / Question & Answers
Lunch & Prayer Break - FROM 1:00pm - 2:00 pm
02:00
02:20
02:40
3:00
TECHNICAL SESSION # 2 on DAY ONE (DEC 01, 2010)
SESSION CHAIRMAN: Rear Admiral (R) Muhammad Mushtaq Pro Rector NUST
Foundry Production in Pakistan
By: Dr. Khalid Akhtar - SSME NUST Sector - ISB
Gas Carburizing & Nitriding
By: Mr. Ahsan Arshad - Fornie Engineering
Hardening & Nitriding of Dies and Moulds in Vacuum Furnace
By: Mohammad Ali - Executive Heat Treatment, Karachi Tools Dies & Moulds Centre
Question & Answers / Comments by Chairman
Tea Break - From 3:15pm - 3:45pm
3:45
4:15
4:45
TECHNICAL SESSION # 3 on DAY ONE (DEC 01, 2010)
SESSION CHAIRMAN: Mr. Aitazaz A. Niazi - CEO EDB
Case Study - Effect of Core Material on Shrinkage
By: Mr. Pervaiz Mehmood - GM - Ravi Autos
Local Development of CNG Compressors
By: Mr. M. Asim- Development Engg. Hyper Comp. Pvt. Ltd
Question & Answers / Comments by Chairman
Dinner & Cultural Show - 8:00 pm
TECHNICAL SESSION #1 on DAY TWO (DEC 02, 2010)
9:30
9:50
10:10
10:30
11:00
SESSION CHAIRMAN: Mr. Saeed Ahmed Alvi - Chairman TEVTA
Rejection Control in Cast Iron Foundry
By: Engr. Allah Ditta - M/s Excel Engineering (Pvt) Ltd
Effect of Heat Treatment on Micro Structure & Tensile Strength of ductile Iron
By: Dr. M. Ashraf Sheikh- Rachna College of Engineering &Technology - Gujranwala
Die Casting porosity mechanical properties
By: Engr. Feroz Shah Wazir- University of Engineering & Technology- Peshawar
Importance of Sand Grades in Foundry
By: Mr. Atif Makhdoom - Punjab University
Question & Answers / Comments by Chairman
Tea Break - From 11:15am to 11:30am
TECHNICAL SESSION #2 on DAY TWO (DEC 02, 2010)
SESSION CHAIRMAN: Mr. Anwar A. Khan- CEO SMEDA
6
11:30
12:00
12:30
12:50
Design of Experiments & Casting Process Simulation
By: Mr. Fatih Murat Akcin- M/s, Trojans & Magma Soft
The Best practical Optimization of CO2- Silicate Core Process
By: Mr. Sirajuddin Khan- DGM- M/s, Bolan Castings (Pvt) Ltd
Aluminium & Aluminium Alloys
By: Mr. Javed Iraqi - GM Support Services- M/s, Atlas Engineering
Question & Answers / Comments by Chairman
Lunch & Prayer Break - FROM 1:00pm - 2:00 pm
7
Special Thanks
PFA highly appreciates and thanks for the services of Mr. Fahad Iqbal – Anchor person and Mr. Asim Qadri Conference Coordinator for conducting two days Scientific Session of 3rd IFCE 2010.
Exhibition
There were around 80 stalls and 47 companies have showcased their products.
Due to lack of space, late entrants could not be accommodated to provide them stalls. It is interesting to note that
the whole exhibition had been sold out. The Exhibitors names are mentioned below:-
Total around 80 Stalls of 47 different companies
A.N Engineering Industries (Pvt) Ltd
Al-Shafi Steels (Pvt.) Ltd. ( Ittefaq
Al-Zarooni Al-Khawja Enterpirses
Bolan Castings (Pvt) Limited
EXCEL Engineering (Pvt) Ltd
Eehab Engineering Company Pvt ltd
E - TECH
Infinity Engineering (Pvt) L td
Ideal Foundries & Engineering
Works
K.M. Enterprises (Novacast)
KB Enterprises
Matchless Engineering (Pvt) Ltd
New Era Industries (SMC -Pvt) Ltd
Pakistan Engineering Company Ltd
Ravi Spherocast (Pvt) Ltd
Sun Metal Industries
Spectra Corporation
Ijaz Brothers (Pvt) Ltd
Small and Medium Enterprises
Development Authority (SMEDA)
Trojans
Zaid Products (Pvt) Ltd
Steel Casting & Engineering
Works
We Brothers Scientific Pvt Ltd
Steels)
Jameh Engineering (Pvt) Ltd
Kamraj Enterprises (Pvt) Ltd
Madina Group of Industries
Marriala Consultants
PSQCA – Technical services centre
QADBros Engineering (Pvt) Ltd
Rastgar Engineering Co (Pvt) Ltd.
Sajid Brothers Engineering
Industries
Super Tech Industries (Pvt.) Ltd
Transfopower Industries (Pvt) Ltd
Western technologies (Pvt ) Ltd
Electrotherm India Ltd
Atlas Copco Pakistan (Pvt) Ltd
Chenab Engineering Works &
Foundries (Pvt) Ltd
Electro Heat (Pvt) Ltd.
Gohar Industries (Regd )
KSB Pumps Company (Pvt) Ltd
Mosh Pakistan
Millat Group of Companies
Paktherm (Pvt) Ltd
Quality Casting (Pvt) Ltd
Ravi Autos (Pvt) Ltd.
Supraa Steel (Pvt) Ltd
S.G.I. Foundries
Media Participation
3rd IFCE 2010 inaugural ceremony News were flashed and interviews displayed on various TV Channels like GEO,
Sama, Express TV, Aaj Tv, PTV, Dawn, Dunya TV etc.
The following daily News Papers gave a wide coverage of 3rd IFCE 2010:- Jang News, The Nation, The News,
Business Recorder, Jang News, Pakistan, Express, Ausaaf, Al- Sharq, Khabrain, Din, Asaas, Jinnah & Awaaz News
paper etc.
Magazines: International Foundry Magazine: The Foundry Plannet, Foundry Trade Journal, Foundry Gate, Casting Area, Alu
Scout placed the News of 3rd IFCE on their websites under the heading of events from the last so many months .
Local Industrial Magazines: Industrial Bulletin by Engineering Development Board (EDB), Lahore Chamber News,
The Engineering Horizon Magazine, Auto Mark Magazine & Build Plus Magazine advertised our news as an
advertisement and published the report of the Event.
Awards
-
Mr. Sikandar Mustafa Khan visited each stalls and thanked for their participation for successful organization of
3rd IFCE and presented Certificates and Souvenir (Conference Bag).
Mr. Abdul Rashid – Secretary PFA services were recognized for his tiring efforts for the successful organization
of 3rd IFCE 2010 by Sikandar Mustafa Khan - President & Mr. Asim Qadri – Secretary General PFA. Both of them
highly appreciated his efforts and were also acclaimed by the audience.
Volunteers Role for 3rd IFCE 2010
The worthy volunteers who put their efforts to make 3rd IFCE a successful event were acknowledged by presenting a
Shield. They are Mr. Munir Ahmed – Chairman, Mr. Asim Qadri- General Secretary PFA, Mr. Irfan Ahmed Qureshi –
Joint Secretary, Mr. Iqbal Khalid – Senior Executive Member, Mr. Abdul Rashid – Secretary PFA, Mr. Zaid Bin Maqbool,
Mr. Waqas Gohar, Mr. Munir Ahmed, Mr. Ashraf Sheikh, Mr. Faisal Saeed Qureshi, Mr. Ghazanfer Nazir Malik, Mr.
Larry Heatherly, Mr. Waqas Haroon and Mr. Abdul Jabbar.
Gala Dinner & Musical Evening
PFA arranged Gala Dinner & Musical Program in the honour of their guests 3rd IFCE 2010 at Kohinoor Hall –Pear
Continental Hotel Lahore. Madam Shabnam Majeed –vocalist entertained the audience with her special Songs and
Ghazals.
8
44th Census of World
Casting Production
The global casting market experienced a marked contraction
in 2009, with overall shipments decreasing 14% from 2008.
A MODERN CASTING Staff Report
Worldwide casting shipments in 2009 fell to 80,343,048 tons, down 14% from 2008, according to this year’s
MODERN CASTING Census of World Casting Production. Of the 34 countries participating in the production survey
this year, only five reported growth—China, India, Korea, Portugal and South Africa. The average percentage
decrease in shipments for the remaining countries with declining production was 30%. As a result, production per
plant decreased, as well. Germany still has the most production per plant, but it fell from 9,639 tons per metalcasting
company in 2008 to 6,481 tons in 2009.
China’s production improved from 1,117 tons to 1,357 tons per plant as shipment volume increased and the number
of casting facilities decreased. Seven of the top-10 casting-producing nations shifted up or down in the rankings in
2009, reflecting the fluctuating markets during the recession. Brazil, which had been one of two top-10 countries to
show growth in 2008, experienced a 31.5% decrease in shipments from 2008 to 2009, the biggest drop of any top-10
nation during that time period. India was the fastest growing top-10 nation, increasing its casting tonnage by 9%. The
top 10 nations produced a total of 70,476,338 tons, 88% of the global total.
The year 2009 marked the fourth year in a row the U.S. has reported a reduction of casting volume. It was the first
year it has been surpassed in production (by 35,000 tons) by India, which became the second-largest casting
producer by volume. The data reported in the 44th Census of World Casting Production is supplied by each nation’s
metalcasting association or similar representative. Countries that did not participate this year were Denmark, The
Netherlands and Thailand. These countries remain listed according to the last year they participated. New to the list
are Bosnia and Herzegovina, Mongolia and Serbia. MC
China: 1,357
India: 1,618
Production Per Plant
Top 10 Casting Countries
The average production per metalcasting plant for the top10 nations decreased across the board, likely due to plants
operating at lower capacity during the 2009 recession. China
and Korea, which showed increases in casting shipments
from 2008 to 2009, improved their productivity.
U.S: 3,596
Japan: 2,584
Russia: 3,111
Germany: 6,481
Brazil: 1,725
Korea: 2,454
France: 3,783
Italy: 1,488
World Casting Production by Metal
0
1
2
3
4
5
6
7
8
Thousands of Tons
While gray iron continues to make up the largest piece of the
global production pie, its sliceis growing smaller. Since 1999,
gray iron production has increased 9.3%. Compare that with
a 39.6% increase in ductile iron production, 50% growth in
steel production, and a 41.1% increase in nonferrous
production.
Want to compare 2009’s
production to previous years?
Visit www.moderncasting.com
for past census results.
Nonferrous
13.6 million tons
17%
Steel
9 million tons
12%
Gray Iron
38.16 million tons
47%
Ductile Iron
19.4 million tons
224%
MODERN CASTING / December 2010
9
2009 World Casting Census
Country
Gray Iron
Austria
29,200
Belgium
49,100 B
Bosnia Herzegovina
Brazil
Canada
89,700
3,826
na
3,176 D
na
na
na
16,669
2,296,916
na
48,020
Finland
28,041
31,363
France
562,000
26,850
166,382
12,075
194,569
3,233
2,806
na
na
111,720E
17,656 E
146,879
na
na
na
3,350,000 C
na
na
600,000
4,800,000
600,000
1,313
459
11,652
52,392
888
34,772
na
1,881
na
na
1,433
C
na
243,468
735,105
250,000 F
na
230
na
1,368
na
6
661 G
35,300,000
53,797
144
270,970
5,778 D
87,604
A
na
9,413
3,052
3,612
na
260
869,000 A
na
59,500
18,818
205,924
na
19,513
1,949
1,736,704
19,859
51,193
1,475
3,901,665
na
3,738
262
132,304
1,806,480
1,191,786
31,273
182,435
76,720
540,444
25,834
15,221
11
5,695
1,442
80,10
566,068
78,812
na
32,367
5,050,000
na
na
525,971
Italy
na
530
1,582 C
1,365,030
India
10,191
na
40,678
Germany
4,676
2,203
28,100
138,838
Hungary
TOTAL
19,800
17,375
E
Zinc
na
1,100
87,698
Other
Non-Fe
Mg
na
22,107
Denmark
Cu-Base Aluminum
500A
8,700,000
CzechRepublic
Steel
A
17,000,000
Croatia
Malleable
8,567
458,850 E
China
Ductile
800,000
60,200
372,449 A
na
880,000
D
na
75,741
na
653,000
65,283
14,386
549,400
6,700
49,000
45,516
1,668,802
6,280
20,563
4,336
4,385,998
11,200CF
2,135,000
na
na
na
7,443,200
Japan
1,653,901
1,364,644
37,235
198,248
75,284
1,025,507
Korea
1,020,600
607,600
38,500
153,500
24,500
279,100
693,975
53,010
70,815
126,530
539,990
2,000
120
12,000
60
180
na
na
na
na
84,888
2,177
4,058
na
na
na
72,535
na
na
na
770,000
Mexico
Mongolia
na
100
na
na
98
na
906
na
na
1,485,324
240
Netherlands
78,241
6,209
Norway
15,200
48,400 A
na
2,700
Poland
570,000 I
na
na
na
Portugal
30,995
60,165
8,803
10,800
15,800
na
480
Romania
29,485
1,471
712
22,955
1,814
31,163
1,750
535
9
1,740,000
1,200,000
60,000
700,000
90,000
340,000
35,000
15,000
20,000
500
H
Russia
438
A
Serbia
43,150
2,320
Slovenia
74,000
14,900 A
SouthAfrica
na
na
1,460
na
na
200,000
25,040
995
1,420
27,900
2,976
18,144
D
na
495
na
89,145
140,494
na
68,832
147,235
17,220
47,364
na
2,730
461,300 A
na
65,200
6,791
86,212
na
8,084
Sweden
113,300
27,700
na
15,300
8,400
24,600
1,300
4,000
na
17,600
31,000 A
na
1,806
1,807
14,613
na
1,308
na
na
50,849
33,166
230,059
5,159
74,629
ThailandJ
175,902
4,200,000
na
95,565
343,854
89,894
14,260
274,000
Taiwan
127,043
G
2,079
Spain
Switzerland
114,276
na
14,700
491
1,065
493,222
902,078
194,600
68,134
914,683
70,000
30,000
30,000
28,600
28,600
100,000
na
16,900
na
304,100
Turkey
456,000
352,000
2,000
98,000
12,500
96,500
na
13,500
na
1,030,500
Ukraine
640,000
40,000
na
45,000D
na
na
1,000,000
UnitedKingdom
UnitedStates
TOTALS
na
275,000
na
102,000
137,000
56,000
8,000
78,000
2,000
6,200
700
389,900
2,409,483
2,553,725
35,380
686,739
178,715
1,191,1345
66,224
166,922
119,748
7,408,069
37,615,831
19,939,470
1,040,316
9,032,549
1,379,467
10,237,431
152,774
473,170
472,056
80,343,064
A
na
A) includes malleable iron
Note: All data given in metric tons
F) includes zinc G) lead casting H) 2004 data I) all ferrus J) 2006 data
B) includes ductile Iron C) includes mg
D) all nonferrous E) 2008 data
New to the List
A few new countries have been added to this year’s census of casting producers and another has been updated after
seven years of incomplete data. Ukraine: Before this year, the most recent production data from Ukraine dated to
2002, when the country was producing 974,170 tons of castings a year. Not much has changed. The Foundry
Association of Ukraine reports the country produced about 1 million tons of castings in 2009. Ferrous casting makes
up the lion’s share of production (95.5%), but nonferrous casting has improved 42.9% since 2002. Serbia: For many
years, this country has been in turmoil, with much of the casting activity shut down or severely hampered.
10
From 1990 through 1999, its economy was cut in half. Since then, Serbia has been making up ground. In 2008, the
Serbian Foundrymen Society was formed. The country’s casting industry is 81% ferrous and 19% nonferrous by
tonnage produced. Production per plant is 2,345 tons. Mongolia: More than two-thirds of all of Mongolia’s exports
go to China, its neighbor to the south. Its largest casting market is steel, which makes up 81.6% of total production.
With the exception of a few nations, the global casting industry reported a dip in production in 2009. But some
countries fared worse than others.
Russia: From 2007 to 2009, Russia’s production decreased by 46.2%, from 7.8 million tons to 4.2 million tons. The
third largest casting producing nation in 2007, Russia has since fallen behind India and Japan. It saw a reduction of
300 metalcasting facilities in 2009.
20
Finland: In one year, Finland’s casting production was
cut in half, from 152,888 tons to 75,741 tons. Casting
production value decreased 46% to $350 million. Zero
metalcasting facilities closed, according to the European
Foundry Assocation, but employment in the industry
constricted by 700— 15.7% of the workforce.
Metalcasting Plants by Nation
Country
Austria
Belgium
Bosnia Herzegovina
Brazil
Canada A
China
Croatia
CzechRepublic
Denmark A
Finland
France
Ger\bany
Hunary
India
Italy
Japan
Korea
Mexico
Mongolia
NetherlandsB
Norway
Poland C
Portugal
Romania
Russia
Serbia
Slovenia
SouthAfrica
Spain
Sweden
Switzerland
Taiwan C
Thailand D
Turkey
Ukraine E
UnitedKingdom
UnitedStates
Iron
29
16
5
552
41
17,000
15
84
7
14
103
205
62
157
456
508
181
24
16
8
185
47
53
14
8
88
60
32
18
478
230
741
400
230*
659
Steel
4
7
2
191
29
4,700
3
34
0
6
37
53
31
44
75
142
162
15
0
3
0
6
45
8
3
51
32
13
4
40
26
72
233
416
*Includes iron and steel facilities. A) 2008 data
E) 2002 data
Nonfferrous
39
8
4
588
115
4,300
24
62
10
16
319
344
97
920
1,166
223
350
3
5
11
245
39
71
16
16
117
50
73
43
330
220
433
437
220
985
10
0
Million of Tons
Czech Republic: The nation’s production fell 49.5% from
536,789 tons to 270,970 tons. Productivity dropped
from 2,684 tons/plant to 1,505 tons/plant. MC
15
0
China
India
U.S
Grey Iron
Total
72
31
11
1,331
185
26,000
42
180
17
36
459
602
190
4,600
1,121
1,697
873
647
42
21
22
430
92
169
1,350
38
27
256
142
118
65
848
476
1,246
960
450
2,060
Japan
Russia
Ductile Iron
Gray Iron vs. Ductile Iron
Globally, 65% of iron castings
produced are in gray iron, compared
to 35% produced in ductile
iron. But this type of disparity is not
present in every country. Among the
top five casting
nations, the U.S. produces more
ductile iron castings than gray iron,
while Russia and Japan
show closer gaps between the two
materials than do China and India.
B) 2004 data C) 2007 data D) 2006 data
11
Russia
Japan
4.2 million tons 4.4 million tons
Europe
12 million tons
China
35.3 million tons
North America
9.6 million tons
India
7.4 million tons
Brazil
2.3 million tons
Regional Production
Top-10 Casting Producers
Europe’s total production fell 31.5% since 2008;
North America’s production dropped 28.5%.
North and Southeast Asia fared best, with India,
China and Korea showing gains in 2009.
(Last year’s rank in
1. China (1)
35.3 million tons
Gray iron
17 million tons
Ductile iron
8.7 million tons
Steel
4.8 million tons
Nonferrous
4.2 million tons
6. Germany (5)
3.9 million tons
Gray iron
Ductile iron
Steel
Nonferrous
2. India (4)
7.4 million tons
Gray iron
Ductile iron
Steel
Nonferrous
7. Brazil (7)
2.3million tons
5.05 million tons
800,000 tons
900,000 tons
650,000 tons
3. U.S. (2)
7.4 million tons
Gray iron
Ductile iron
Steel
Nonferrous
2.4 million tons
2.6 million tons
690,000 tons
1.7 million tons
4. Japan (6)
4.4 million tons
Gray iron
Ductile iron
Steel
Nonferrous
1.7 million tons
1.4 million tons
200,000 tons
1.1 million tons
4.2 million tons
Gray iron
Ductile iron
Steel
Nonferrous
1.7 million tons
1.2 million tons
700,000 tons
500,000 tons million tons
I\f\bia: 1,7
Chi\fa:
1,202
5. Russia (3)
12
1. million tons
1.2 million tons
180,000 tons
690,000 tons
All iron
Steel
Nonferrous
1.9 million tons
170,000 tons
210,000 tons
8. Korea (10)
2.1 million tons
Gray iron
Ductile iron
Steel
Nonferrous
1 million tons
610,000 tons
150,000 tons
310,000 tons
9. France (9)
1.74 milli\bn t\b
Gray iron
Ductile iron
Steel
Nonferrous
560,000 tons
870,000 tons
60,000 tons
250,000 tons
10. Italy (8)
1.67 million tons
Gray iron
570,000 tons
Ductile iron
370,000 tons
Steel
65,000 tons
Nonferrous
665,000 tons
Visit of Mr. Ram Chandra Narayan – Foundry Expert
Courtesy: National Productivity organization (NPO)
Pakistan Foundry Association successfully organized
3rd International Foundry Congress & Exhibition on
Dec 01/02-2010. The success of 3rd IFCE was realized
by various government departments and approached
PFA to extend their favour for the development of
foundry industry.
In this regards a meeting was arranged between Mr.
Sikandar Mustafa Khan – President PFA, Mr. Asim
Qadri – Secretary General and the Executive
Committee of Pakistan Foundry Association with Mr.
Khawaja Muhammad Yousaf – CEO, National
Productivity Organization (NPO) - Ministry of
Industries, Islamabad, Mr. Ejaz Rasul Chawdhry -GM
and their Expert Team. They offered the services of Mr.
Ram Chandra Narayan Bhome an Engineering
Professional with a great experience of 37 years who
will be visiting Pakistan for about 2 weeks.
Mr. Ramchandra Narayan visit was planned from Jan
24 to Feb 05, 2011 with a Tentative Schedule to fulfill
the needs of our foundry members industries for
Technical Guidance, Efficiency Enhancements,
Process Engineering and Cast control.
Mr. Ram Chandra visited 12 foundries in Lahore and
made certain observations in different foundries and
suggested remedial actions on the spot. He spent
sufficient time for their guidance in each foundry as
desired by the foundry members.
According to PFA Plan, Mr. Ram Chandra Narayan
Bhome had to visit foundries in Gujranwala and
Faisalabad also but due to limited visa facility he could
visit foundries in Lahore only.
A seminar for the training of technical managers was
organized for two days in PITAC – Lahore. It was a joint
venture of NPO & PITAC on the foundry production
system.
The purpose of this workshop was to create
awareness and understanding to improve and
enhance production efficiency according to his
observations during his visits to foundries.
Pakistan Foundry Association is obliged by the visit of
Mr. Ram Chandra Narayan and believes his visit will
definitely benefit our members.
Mr. Sikandar Mustafa Khan – President PFA thanked
him once again in a get together at High Tea arranged
in his honour for his visit to foundries in Lahore and
observations along with the suggested remedial
actions. These will benefit in improving quality of our
production. He said, your suggestions for the
improvement of foundries in Pakistan are quite
valuable and we are thinking on the same lines as
proposed.
It will be my pleasure to welcome you again in Pakistan
for the assistance & cooperation of Foundry Industry. I
will suggest there should be two way communications
between you and your visited foundries during your
stay for continued growth.
On returning home he conveyed his satisfaction and
thanked Mr. Sikandar Mustafa Khan, members of PFA
and Mr. Abdul Rashid – Secretary PFA for the services
provided to him during his comfortable stay, “He
remarked I never felt away from home”. He admired
the enthusiasm shown by PFA Members to learn new
technologies and to improve the performance of their
individual foundry.
13
14
Mohammad Sajjad
President
Ph: 042 36167117 / 37722750
Cell: 00923334257790
email: blackstonesajjad@yahoo.com
“The Potential of Casting in Pakistan”
Prepared by: Ahmad Hassan (CEO Chenab Engineering Works & Foundries)
Special thanks to Munir Ahmed (Consultant CFC)
Presented by Ms. Nadia Hassan
Structure of the Report
·
·
·
·
·
·
·
Overview of Casting Industry
Comparison of Pakistan with China
Comparison of Pakistan with India
Feasibility of achieving targeted production ( in comparison with India)
Standard model and calculation for payback period
Benefits from exporting to foreign Market
Conclusion
Overview of Casting Industry
•
The foundry engineering is the mother of all engineering and its contribution is noteworthy towards the
development of any country.
•
There are 2 types of Casting:
i- Ferrous
ii- Non-Ferrous
•
According to the 43rd census of world casting production 2008:
Total production of the world is 93.4 million metric ton
Production of Asia is 58.9 million metric ton (63.11% of the world's production)
Prominent Countries in Asia which majority
contribute towards casting:
Top 10 Casting Producers of the world
Sr. No
Country
%
Production
(Million ton) production
Sr.
No
Country
Production
%age
No. of
(Million ton) Production plants
1
China
33.5
35.8
1
China
33.5
35.8
3000
2
USA
10.8
11.5
2
India
6.8
7.32
4700
3
Russia
7.8
8.4
4
India
6.8
7.3
3
Turkey
1.2
1.3
1246
5
Germany
5.8
6.2
4
Japan
5.6
6.0
1702
6
Japan
5.7
6.1
5
Brazil
Thailand
0.3
0.3
476
7
3.4
3.6
8
Italy
2.6
2.8
6
Taiwan
1.4
1.5
848
9
France
2.4
2.6
7
Korea
2.0
2.1
873
10
Korea
2.1
2.2
8
Pakistan
0.35
0.37
250
One major question that arises from this overview is:
“ If countries like India and China can prosper so much then why can not a country (Pakistan) enriched with ample
resources flourish? “
Few of the problems facing India and China are similar to that of Pakistan:
- India for example is currently facing electricity crises but they have intelligently manage it to cope with
their production targets. Why not Pakistan follow the same steps????
China for example, with the help of coal gasification and washing plants, has successfully used their coal
16
reserves for power generation. Then why can not Pakistan use these cheap plants for upgrading the available coal
reserves for power generation?????
- Thar coal reserves are the largest coal reserves in the world. The only problem is that coal need washing
(sulphur 6 -10 %).Otherwise rest of the specifications e.g. caloric value, ash content and fixed carbon etc
are within limit.
Comparison of Pakistan with other Asian countries
Comparison of Pakistan and China with respect to respective countries' prices and potential in casting.
Comparison of Pakistan and India with respect to the countries potential and resources availability.
Comparison of Pakistan with China
According to year 2008 figures:
China:
- Population: 1.3 Billions
- Production: 33.5 Million tons
Pakistan:
- Population: 0.18 Billions
- Production: 0.35 Million tons
Analysis of the figures:
The population of China is almost 7.2 times more than that of Pakistan. Following this the production of Pakistan
should be 4.65 million tons which at present is only 0.35 million tons. This means that Pakistan's production is 4.3
million tons less than the expected value.
•
Comparison of prices :
•
Price break up of a standard firm casting in Pakistan
•
Total cost on raw material (less foundry return) per kg
•
Total cost of other materials per kg
•
Total cost of fuel and power per kg
•
Total cost of molding, melting, all other felting, painting, short blasting etc per kg
•
Bank Charges per kg
•
Non productive expenses
•
Total COST PRICE per kg
•
With a profit margin of 10% - SELLING PRICE
Whereas , casting prices in China vary within the following range :
Rs 104 ≒Price per kg ≒Rs 130
Where Rs 104 refers to a typical low cost firm's price and 130 refers to a typical high
= Rs 47.14
= Rs 12.65
= Rs 14.25
= Rs. 8.41
= Rs 1.25
= Rs 6
= Rs 89.7
= Rs 98.7
cost firm's price.
Comparison of prices clearly shows that Pakistan has a price edge over China. Likely reasons for such a price
edge can be excess supply of cheap labor, availability of natural resources and likewise other related factors.
However, comparing the production scale of Pakistan with China will be inappropriate given the size of the
economies and development scale. On the other hand comparison with India will make more sense as Pakistan
shares a lot of common features with this neighboring country.
Comparison of Pakistan with India
•
According to Modern Casting December 2009:
“India's metal casting industry is poised to become one of the top-three casting producing nations in the
world. The key is establishing the infrastructure to support it.”
17
•
The growth in casting production of India is remarkable since year 2002. India benefits from:
i) low labor costs,
ii) large population with a strong domestic demand,
iii) financially strong companies with revenues to invest in metal casting.
iv) Furthermore India's economic environment is suitable for metal casting.
v) Construction costs for new casting facilities, as well as time to complete construction and
permitting are low.
vi) Health and safety compliance requirements for molding binders are nearly non-existent and tooling
costs are significantly lower than in developed countries.
• Hurdles faced by india:
i) Even though tooling costs are lower but tooling quality is still lagging
ii) lack of sufficient infrastructure
iii) consumable costs are higher than developed countries
iv) energy supply problems, especially a reliable supply of electricity
v) attracting and maintaining an enthusiastic, younger force is a challenge in India.
•
Hence we can see that most of the advantages enjoyed by India as well as problems faced by the Indian
economy are quite similar to our Pakistani economy. Therefore comparing our economy with the Indian
economy and setting it as our benchmark will be wiser rather than comparing with economies like China.
•
According to year 2008 figures:
India:
- Population: 1.14 Billions
- Production: 6.8 Million Tons
Pakistan:
- Population: 0.18 Billions
- Production: 0.35 Million Tons
•
Analysis of the figures:
The population of India is almost 6.3 times Pakistan's population. Following that Pakistan's production
should be 1.07 Million Tons. At present it is 0.35 million tons which is 0.73 million tons less than the
expected value.
•
As mentioned earlier too, Pakistan's casting is cheaper than both India and China. Hence Pakistan should
make efforts to utilize its potential to the maximum and increase its production. Increasing production by
0.73 million tons might not currently be possible due to the energy and policy constraints in Pakistan but a
step forward will not hurt the country's development plan.
Feasibility of achieving targeted production ( in comparison with India)
•
•
•
•
•
•
•
18
Assume the target is to increase casting production by 0.73 million ton
1 ton = 1000 kg
Cost price = Rs 89.7/kg
Selling Price = Rs Rs 98.7/kg
Gross Profit = Rs 9/kg
Taxes and other miscellaneous charges = Rs 3/kg
Net Profit = Rs 6/kg
•
Given the net profit per kg = Rs 6 , if Pakistan increases its production by 0.73 million tons. The additional
profit earned by Pakistan will be :
:
Ð = 0.73 million tons x 6000/ton
= Rs 4380 million ( minimum profit)
Graph ( price & profit) - Feasibility of achieving targeted production ( in comparison with India)
Feasibility of achieving targeted production ( in comparison with India)
•
Major Constraints to achieve the targeted production :
1- Utility expenses
2- High fluctuation in the price of imported raw material
•
Remedies:
1- Government should invest in exploring iron ore.
2- Use of wind energy and hydro energy etc in power generation
3- Coal gasification and washing plants for power generation
4- Proper government plan and cooperation with foundry engineering
•
Current Scenario :
None of the remedies suggested are currently being implemented but through asuccessfulimplementation
of these remedies, an additional target of 0.73 million ton ( casting production) can be achieved in next
couple of years.
•
Potential gains from additional Production of 0.73 million tons in future:
- Figure of 0.73 million tons is not a huge threat to India or China given their casting
production, but Pakistan can gain a lot through this additional production
- Through this additional production Pakistan can not only meet the additional demand of
domestic economy ( currently imported) but can even export the surplus production.
19
Standard Model
•
•
•
•
•
•
•
•
Assume a plant has a yearly production = 12000 tons
Net Profit/ ton (calculated before) = 6000/ton
Total Net Yearly Profit = (12000 x 6000) = Rs 72 millions
Assume Fixed Cost investment = 40 million (Land) + 100 million (machinery) + 30 million ( utilities) = Rs 200
millions
Assume working capital = Rs 100 million
Assume interest payment = Rs 60 million
Total investment = Rs 360 millions
Pay back Period = (Total Investment) / (Total net yearly profit)
Therefore payback period with casting production = 12000 ton and minimum profit margin = 6000/ton will
be = Rs 280m / Rs 84m = 5 years.
Model (graph) – payback
period with yearly production of 24000 tons
Model (graph) – payback period with yearly
production of 12000 tons
140
6
120
5
100
4
140
3.0
120
2.5
100
2.0
80
3
80
1.5
60
2
60
1.0
40
1
0
20
1
3
2
4
5
Playback period in years
6
Price
7
0
40
0.5
0.0
20
1
2
3
4
5
Playback period in years
6
7
0
Price
Model
Analysis of graphs:
Above graphs clearly shows that when the firms will be producing high value casting products or selling low value
casting products at a high price price per ton will increase profits will increase payback period will decrease !
Benefits from exporting to foreign market
Comparative advantage through low relative price as compared to India and China attracting wider consumer
baseCheap product in the international market due to depreciation of the Pakistani currency. e.g. exchange rate of
Pakistan with china increased from 1Yuan = Rs 7.8 (year 2007) to 1 Yuan = Rs 13 (year 2010)
·
Inflow of technology
·
Increase consumer base through international market
·
Inflow of Foreign currency increase foreign reserves
·
Positive effect on the Balance of payment
Export demand increases Total domestic production increases Average Cost per unit will fall through Economies of
scale Net profit/ton increases!
Export demand increases Total domestic production increases domestic employment increases disposable
income increases Aggregate demand for goods and services will increase Real GDP increase Economic growth and
overall standard of living of the economy will increase!
20
Conclusion
It is fair to conclude that Pakistan which is rich in factors of production e.g. land , labour , natural resources and
entrepreneur skills , should efficiently utilize these resources to meet at least reasonable future targets.
In the coming future major production is shifting from USA and European countries to China and India. Then why not
Pakistan (which is the part of the same subcontinent) increases its % production and be one of the prominent
producers supplying to the foreign markets?????
•
Pakistan is a home of several bright people. I believe that we have radiant minds sitting amongst us today
that can not only help in the nourishment of the industry, they can also enrich our minds with their brilliant ideas.
This will help country develop successful future strategies and their implementation will help country efficiently
compete in the international market at all standards.
I also believe that the youth of the nation has a lot to offer. A concoction of our experiences with their minds can
definitely prove to be beneficial for the burgeon of the casting industry.
Welcome Omega in Pakistan
Omega foundry machinery was formed 1984, following
management buy out from parent company Baker Perkins
who had been manufacturing foundry equipment since 1957.
The company has continued to specialize in the manufacture
of equipment for, Chemically Bonded sand or No bake
process. Their productions are Sand mixing, Mould Handling,
sand reclamation, core making, Trunkey projects and Ancillary
Items i.e. Sand driers, Sand heaters, Dust extractor, batch
mixer, Mould driers etc.
Mr. Benan Betik – Area Sales Manager was expected to
participate in 3rd International Foundry Congress & Exhibition
- 2010 but due to visa issues he could not join us. Recently he
managed to come to Pakistan and visited certain important
foundries for the introduction of Omega Machinery Products.
He was also invited by Mr. Faheem A. Malik – Project Director,
PCSIR Daska for a presentation on his projects. Mr. Benan Betik
had a very thought provoking presentation on the above
mentioned productions. The participants were from major
foundries in Lahore & Gujranwala i.e. Qadbros, Ravi Autos,
Quality Casting, Excel, Chicago Metals, Supra Steel, Asian
trading corporation, International Fabrication . The
participants were highly impressed from his presentation.
I am sure Omega Machinery products will be available in
Pakistan very soon and PFA wish great success for Omega
Foundry Machinery.
21
Case Study - Effect of Core Material on Shrinkage
Ravi Autos (pvt) Ltd.
Part Name
Arm Hydraulic Lift Ram
Grade
BS 3100 Grade A3
C:0.40 – 0.45 % Max
Mn:0.70 % Min
Hardness: HB 163 ~ 207 (Prior to Induction Hardening)
Molding Process
Sodium Silicate sand process used for Molding
Core Material
Sodium Silicate Sand Process Cores
Melting
Melting is done on high frequency induction furnace
Pouring temperature range: 1600°C - 1620°C
Pattern & Casting
Problem-Shrinkage:
Shrinkage occurred inside thick portion of
casting
Problem-Shrinkage:
Simulation done with little improvement
Better results but Pattern also needed modification
As suggested Chill was also tried but production
rate was low due to placing of chill
22
Problem-Shrinkage:
During this period due to ro ugh surface finish in
the hole the machining section was complaining.
Problem-Shrinkage:
We were already working on the Die of Core
for “Shell Core Sand”. When started using Shell
Core it was observed that the riser had much
more shrinkage at the top then the usual practice.
Pieces were sectioned to see if it has contributed
to shrinkage. Surprisingly the shrinkage was
eliminated.
Cross-Section of Arm Hyd.
Lift Ram with no Shrinkage
It gave us motivation & encouragement
to do more research on Shell Core Sand.
More samples were casted using Shell
Cores and their cross-section exposed
elimination of shrinkage problem.
Comparison of Cores
CO2 & Shell Cores
Coclusion
Sodium Silicate Cores exhibit Endothermic Reaction after pouring.
Shell Cores show Exothermic Reaction when contact with hot metal.
Shell Core Sand, beside shrinkage elimination, are very easy to remove & give good surface finish.
The Exothermic Reaction of Resin Coated Sand Cores, when contact with hot metal, helps keeping the
metal flowing from riser into the casting and hence eliminates shrinkage.
23
Hardening & Nitriding of Dies & Moulds in Vacuum Furnaces
Engr. Muhammad Ali - B.E (Metallurgy & Materials), M.E (Material Science & Technology),
Karachi Tools, Dies & Moulds Centre - Karachi
Introduction:
Vacuum Heat treatment is one of the modern heat treatment technologies which helps to determine the right
process & right cycle to meet the metallurgical requirements in hardening and nitriding of dies & moulds through
precise temperature and atmospheric control. Customers specifications are achieved with minimal distortion and
bright, scale free results in the finished products.
Vacuum hardening & nitriding furnaces
Vacuum Hardening Furnace
Introduction:
Vacuum Heat treatment is one of the modern heat treatment technologies which helps to determine the
right process & right cycle to meet the metallurgical requirements in hardening and nitriding of dies &
moulds through precise temperature and atmospheric control. Customers specifications are achieved
with minimal distortion and bright, scale free results in the finished products.
Advantage of vacuum heat treatment process:
Heating metals to high temperatures normally causes rapid oxidation, which is undesirable. Vacuum heat treatment
removes the oxygen and prevents this from happening.
The need for precise control of temperature and time, as well as the process environmental chemistry, has led to the
application of computerized control systems for most types of modern vacuum furnaces. Following are some of the
advantages of this process:
·
·
·
·
·
·
·
·
·
·
No decarburization
No oxidation of components – bright surfaces
High temperature uniformity – low distortion
Full automation of heat treatment process
Environment friendly
No heat radiation to atmosphere
Low contamination of the product by oxygen and other gases
Quick cooling (quenching) of product
Computer control to ensure batch to batch consistency
Precise control of case depth, microstructure & hardness
Processes Facility:
The processes which can be carried out by vacuum heat treatment furnaces are:
·
Annealing,
·
Stress relieving,
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·
Hardening,
·
Tempering
·
Nitriding
Different ranges of temperatures for
carrying out above processes are
carefully determined with the help of
TTT and Iron-Carbon Diagrams as in
figure number 3 and 4.
Tool Steels suitable for heat treatment in vacuum furnaces:
· Hot Work Tool Steels like H-11 & H-13
· Cold Work Tool Steel Like D2 & D3
· Moly High Speed Steels
Vacuum Heat Treatment Process:
Heat treatment of hot & cold work tool steels in vacuum furnaces is today state of the art technology with
fully automatic process which employs latest HMI system (human machine interface).All parameters like
temperature of the surface and core of heating stock, pressure levels of nitrogen/ammonia gas and
information on various levels of vacuum etc are displayed continuously on furnaces screen and can be
reset as per behavior of the charge components.
Like other processes, this process also involves heating, holding & cooling.
However in other processes during heating up & cooling, temperature
difference occurs in surface & core of the component. This temperature
difference in other processes can not be avoided and is reason for
component distortion due to residual stresses. This component distortion
can be reduced by CONTROLLED step by step heating and cooling in vacuum
heat treatment furnaces. Desired microstructure & ultimate hardness is
achieved by a predetermined programme of phase transformation which is
the specialty of vacuum heat treatment process.
Figure: 5 HMI System Screens
Normally oxidation occurs on the part's surface when exposed to the atmosphere (air). This results in
costly and time-consuming post treatments. Therefore, heat treatment in vacuum is conducted in an
oxygen-free atmosphere. In addition to the use of high-purity protective gases, vacuum allows the best
protection against oxidation.
Due to limited time, here I shall discuss only the hardening and nitriding processes for dies and molds
made out of H-13 steel.
Hardening Process:
Dies/Molds or other tool steel components are loaded on top of a tray made for this purpose in furnaces
along with a test sample. After closing the door the atmospheric pressure/air in the chamber is removed
automatically by using vacuum pumps.
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Test Sample
Load Tray (L-885, W-585mm)
Job Loading
Furnace Engineer panel
As the required vacuum level (10-3mbar) is achieved, the selected reciepe/programme is run to meet required
hardening process which contains fallowing steps.
(a)Nitrogen Purging:
During purging segment duly evacuated furnace chamber is backfilled with inert gas to an ambient pressure. This is
done to provide better quality of the furnace atmosphere and a higher vacuum level for removing any trace of air or
humidity in the
furnace chamber.
(b) 1st Stage / Gas Heating:
The temperature of furnace is raised by employing a convection fan to 650°C while keeping the pressure of inert gas
at two bars (max).
(c)Vacuum Heating:
Under this step the temperature of furnace is further raised to 850°C under vacuum 10-1mbar.
(d) Partial Pressure Heating:
This is the last step of continues heating during which temperature of the furnace is raised to about 10300C under
controlled partial pressure of inert gas. Soaking time of 30 minutes for each inch thickness of components is allowed
now to bring them in austenitic range (hardening temperature).
(e) High Speed Cooling:
This is a quenching process but the quenching media is now nitrogen gas which is sprayed on heated stock at a
pressure 5 bars to obtain best martensitic structure.
Recipe/programme of H-13
Tempering Process:
The process of tempering is best carried out in these furnaces to:
(1) Remove thermal stresses induced in the stock due to quenching.
(2) Convert any retained austenite into fully martensitic structure.
To achieve above results the tempered stock is again heated to about
5700C under an environment of nitrogen. Proper soaking time is
allowed as per thickness of the material and then slow speed cooling
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Trends of H-13
is done with nitrogen at 2 bars. Hardness in the range of 44-48 HRC can be achieved by following reciepe. To get still
better structure, 2nd cycle of tempering is also carried out as per figure number 12.
Vacuum Nitriding process
This is a special case hardening process that depends on the absorption of nitrogen into steel components. All sort of
machining, stress relieving, as well as hardening & tempering processes are normally carried out before nitriding.
The parts are heated in a vacuum chamber through which ammonia gas is allowed to pass. The Ammonia is split at
4900C into hydrogen and nitrogen and the atomic nitrogen creates bonds with nitriding forming elements
penetrating the surface to form nitrides.
Nitriding steel offers many advantages: a much higher surface hardness is obtainable when compared with case
hardening steels; they are extremely resistant to abrasion and have high fatigue strength.
Reciepe/programme Nitriding
Trends H-13 Nitriding
In nitriding process, same steps are taken till the 1st stage i.e. (gas heating), which were adapted while doing
hardening of components.
Later on further processing is carried out as explained now:
(a)Ammonia Purging:
Purging with ammonia gas which dissociates at 4900C.
(b) Stage 1 & Stage 2 Nitriding:
During this segment nitriding procedure is carried out in stages. Stage one is carried out at temperature of about
5100C in which nitrogen is diffused at low rate of diffusion, in order to avoid formation of white layer, which is brittle.
Stage 2 nitriding is carried out for long term diffusion at a temperature higher than stage one as it diffuses more
nitrogen into components. As a result of above treatment, a nitrided layer of 0.1mm to 0.15mm thick is formed with
HRC in the range of about 65-67..
Hardened & Nitrided Jobs:
(c) Nitrogen Purging:
After completing the nitriding process, nitrogen purging is carried out and at
the same time temperature is brought down from 5500C to 4500C.
(d) Blower Cooling:
Cooling in nitrogen gas with external gas blower at pressure of 0.05 bars.
(e) End of Cycle:
End of nitriding cycle and readiness for unloading.
Nitriding results H-13
Hardening with three tempering
Nitrided Gears
Hardening with two tempering
Nitriding for H-13
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59th Indian Foundry Congress & International Foundry Exhibition
Feb. 11th to 13th - 2011 in Chandigarh, India (IFEX 2011)
59th IFEX 2011 was attended by over 1300 delegates from
India & abroad. International Foundry Exhibition 2011 had
four country pavilions i.e. Italy, Japan, China and Germany
along with 204 companies from India and abroad. The
delegates were from Leading Foundry Units, Pan India,
Leading equipment & material suppliers, Foundry
Consultants etc. Trade delegation from Italian Trade
Commission and VDMA Germany, Pakistan Foundry
Association and China Foundry Association also
participated in both the events.
A Fifteen Member Delegation of Pakistan Foundry
Association has participated in 59th IFEX 2011 on Feb 11 to 13, 2011. The delegation from PFA was very well received
by the organizers and called on at the stage for the WELCOME & Introduction. In the Inaugural Ceremony on 11th Feb
2011, it is worth mentioning that Shri Pawan Kumar
Bensal, honourable Minister for Parliamentary Affairs,
Science and Technology and Earth Sciences, Govt. of India
in his inaugural address welcome and thanked PFA
delegation for their participation. Overall it was a very
successful event from the feed back received. Several
useful businesses enquires generated for supply of cast
and machined components, foundry equipments,
materials & services which will give fillip to the Indian
foundry industry. Total serious business enquiries were
generated Rs. Four fifty crore (450,0000000/-).
59th Indian Foundry Congress (IFC) 2011
The main highlights were plenary session on “foundry resurgence- India and Energy conservation in foundries, along
with 45 technical papers presented by authors & speakers in 12 technical sessions on Foundry Processes, innovative
technologies, quality improvement, raw materials
scenario, applications of computers in foundry industry,
energy economy and pollution control.
PFA is highly obliged and thankful for the favour by Mr. A.K.
Anand – Director, Indian Institute of Foundrymen for his
support in getting visa for our delegate members and Vinay
Kumar Luthra - Gargi, India for his visit to 3rd IFCE 2010 and
invitation and for extending favour for Hotel reservation
etc in 59th IFEX 2011.
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