BRICS Foundry-Gallery 2017 SA - Speakers Gallery 2017 Gala - Night Gallery 2017
South Africa was, as always, the perfect conference host. John Davies and his fabulous team did a great job organizing an international metal casting conference for the 7th BRICS Foundry Forum, WFO technical Forum and South African metalcasters.
The conference included a number of national and international industry presentations, academic papers, and technical papers. The 291 delegates heard emphasis being given to new markets and strategies, as well as leaders for the future in the plenary sessions. Metallurgy, technology, and processes were covered in industry and technical presentations as well as academic streams. 28 exhibitors participated in the exhibition.
South Africa has about 170 foundries which directly employ about 9,500 people. Mostly small and medium-sized enterprises, a total of 25 foundries have closed in South Africa since 2010, shedding 1,600 jobs.
John Davies, CEO of the South African Institute of Foundrymen, said, “Foundries need to embrace and adapt to the new manufacturing technologies of the fourth industrial revolution by being informed of the latest research and developments. While there are challenges, ultimately there is a need to modernize for sustainability.”
In addition, South African metal casting businesses need to transform in terms of human capital, innovation and sustainability to arrest the decline of the sector and compete on a global scale.
Some of the challenges faced by foundries include the costs of compliance with new regulations, such as air emissions standards. They put a strain on small and medium sized foundry businesses, which are also dealing with a lack of off-take agreements and high levels of capital investment requirements due to aging infrastructure and capital equipment.
"In the next Industrial Policy Action Plan (IPAP), we are emphasising the importance of supporting the metals and casting industries to modernise and grow. This requires support in terms of research and development, human resource development and supply-side support in the form of incentives for the metals and agro-processing industries. Along with demand-side initiatives, such as local procurement designations, this support will help to grow demand," said October.
“The foundry industry in South Africa is mature and many foundries have the capacity and capabilities to produce for designated sectors, including those that export,” said Ashley Bhugwandin, Manager: National Foundry Technology Network (NFTN). Through the DTI, the NFTN aims to make funding available for recapitalisation and to address the low capacity utilisation through technical and regulatory support, engaging local buyers and developing the industries' collective capacity and capabilities.
Taking a look at the impact of the foundry industry on manufacturing in South Africa, Henk Langenhoven, Chief Economist: Chamber of Mines of South Africa, said that it is not manufacturing that is declining, but rather manufacturing is declining as a percentage of the economy.
“If one looks at GDP growth in correlation with physical tonnage of castings produced in the country, it begs the question of whether we are giving away too much market share in imports. Or is our domestic base too small? In the 1990s, there were massive investments in infrastructure and in the economy. This has subsided and now the consumption part of our economy is driving the demand for castings.”
Collaboration emerged as an important factor in success for foundries. To this end, sessions were held that focused on information sharing to collectively address common issues and improve knowledge on new technologies.
One common issue is the shortage of young people in the industry and the need to improve skills. The 7th BRICS Foundry Forum, in conjunction with the World Foundry Organisation working group for Human Capital Development, hosted a collaboration workshop with international and local industry players to find practical and immediate actions to drive the growth of the global industry.
Conference Presentations Downloads - South Africa
Markets, Strategy and Leaders for the future
A new movement in the foundry industry: Professor Myungho Kim, President, World Foundry OrganizationGovernment support to revitalise the Foundry Sector in South Africa: Ashley Bhugwandin, Manager, Technology Localisation Implementation Unit, CSIRThe Impact of the Foundry Industry on Manufacturing in South Africa: Henk Langenhoven, Chief Economist, Steel and Engineering Industries Federation of Southern Africa (SEIFSA)Leadership for Innovation: Dr Willie Visser, Director of the Centre for Positive People @ Work at USB-ED (University of Stellenbosch Business School – Executive Development)Aluminium Casting Supply to the Automotive Sector: Mark Krieg, Executive Director, Aluminium Federation of South Africa (AFSA)Recent Zinc Casting Alloy Developments: Technology and Markets: Dr Frank Goodwin, Director of Technology and Market Development, International Zinc AssociationThe present situation and the development trends of the worldwide foundry industry: Prof Gotthard Wolf, Institute Director, Gießerei-Institut, der TU Bergakademie, FreibergThe 5-year strategic plan for China’s foundry industry: Wei Gao, Vice Secretary General, ChinaFrom fabricated to casting: Per Rolf Roland, Owner, P R Roland Foundry Consultant AS, NorwayDesign and implementation of a strategy to modernise a jobbing foundry: Clayton Anderson, Chief Executive Officer, Thomas FoundryLessons from the Metal Casting Technology Station (MCTS) and the National Foundry Technology Network (NFTN)’s technical assistance programme to South African sand: Dr Kasango Nyembwe, Head of Department, Metallurgy, University of JohannesburgEnvironmental Management – A driver for business growth and efficiency: Phil Rawnson FICME, Managing Director, MRT Castings Ltd
Technology and Processes
Metallurgical aspects of the production of High Chromium Irons: Professor Adel Nofal, Professor of Foundry Technology, CMRDI, EgyptEnergy savings, safety for operators and the digital foundry world, (Industry 4.0) – State-of-theart induction furnace technology: Hermann-Josef Kroes, Director of Global Sales, New Systems, Foundries, ABP Induction Systems GmbHEco Form a concept for hand moulded no bake castings: Dipl.-Ing. Jens Mueller-Spaeth, Managing Director, G U TChances and limits of High silicon ductile iron: Dr.-Ing. Claudia Dommaschk, Foundry Department, TU Bergakademie Freiberg, Germany
Cast iron inoculation enhancing by oxy – sulphides forming elements contribution: Prof Iulian Riposan, Professor Materials Science and Engineering, POLITEHNICA University of Bucharest / Romanian Foundry Technical Association Technical Requirements for Profitability in Die Casting: Dr Ioannis Ioannidis, President and CEO, Oskar Frech GmbH, (please contact us to receive the lecture: service@foundry-planet.com) Machinability of Austempered Ductile Iron (ADI) as related to microstructure and strain hardening behaviour: Mostafa Ahmed Othman, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt Study on Metal-Die Interface Heat Transfer in Squeeze Casting Process: Dr Zhiqiang Han, Key Laboratory for Advanced Materials Processing Technology (MOE), China The effect of heat treatment on the mechanical properties and machinability of AAR Grade E Steel: Abdul Esakjee Business and Product Development, Transnet Engineering, South Africa Macrosegregation simulation analysis for a large rotor steel casting: Henk Kleynhans, Research Student, Department of Mechanical and Mechatronic Engineering, Stellenbosch Dr Nawaz Mahomed, Associate Professor: Mechanics Department of Mechanical and Mechatronic Engineering, Stellenbosch University Centre for Renewable and Sustainable Energy Studies, Stellenbosch University Metals Technology Laboratory (METL), Cape Peninsula University of Technology Advanced coating systems for cleaner engine blocks and heads: Simon Turley, Huettenes Albertus Group Casting technology and development of magnesium alloys for industrial applications: Dr Mohamed Eissa Moussa, Department of Manufacturing Technology, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt Optimal Feeding System Design of steel casting by IPOPT based on Casting Simulation Technology: Zhou Jainxin, State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science & Technology, Wuhan, China Procarb SG – Based on Sasol´s waxy coke, a clean, high performance carbon raiser soon to be manufactured in SA: Andreas Jentsch, Sales Director,Carbon International LTD, Member Company of James Durrans & Sons Investigation of Microstructural Features of AlMg9 alloy: Prof Zdenka Zovko Brodarac, Vice Dean Science and Finance, Faculty of Metallurgy, University of Zagreb, Croatia Clean Steel Castings – Exploring the dynamics of producing clean steel castings with modern technology: Nick Child, International Marketing Manager Clean Steel, Foseco Comparison of the Effectiveness of Primecast and PMMA Additive Manufacturing Processes to produce patterns for Investment Casting of Ti6Al4V and Al 206: Nthateng Nkhasi, Centre for Rapid Prototyping and Manufacturing, Central University of Technology, Free State Weldability of austempered ductile iron (ADI) and the applied NDT Methods: Mohamed Sayed, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt
Material and Energy efficiency in Melting Systems: Dr Ralf Jennes, Team Manager, Shaft furnaces for iron production in foundry and steel industry, KuttnerGmbH & Co. KG How to improve performance and delivery time, in an environmentally way, by using PENTEX binder system: Manuel Vargas, International Product Manager, Huettenes Albertus Group Viability of casting a bearing bronze using a permanent mould for a small foundry: Chozi Lungu, School of Chemical and Metallurgical Engineering, University of Witswatersrand Study on the post-solidification intensive riser cooling for heavy steel castings: Dr Jinwu Kang, Associate Professor, School of Materials Science and Engineering, Tsinghua University True precision since 1993: Markus Weck, Technical Director, ZPF GmbH Inorganic binders: Benefits, state of the art, actual use: Thomas Steinhauser, Professor for foundry technology, University of Duisburg-Essen Payback period for the acquisition of a Three Dimensional Printer in the South African foundry Industry: Elvis Gonya, Department of Metallurgy, University of Johannesburg Specialized cold-box binder systems and additives for complex foundry applications: Peter Groning, Product Manager EMEA Cold-box, Huettenes Albertus Group Design of a sand control system for a no-bake aluminium foundry: Farai Banganayi, Metal Casting Technology Station, University of Johannesburg (MCTS)
Furan-Phenol Hybrid Resins, a choice for high-quality castings: Dr Ion Bacanu, Director Global Product Management, Huettenes Albertus Group Innovative latest technology and measurement system on refractory coatings: Chandan Panda, Vice President, Technical Services, Forace Polymers Comparison of South African Bentonites for Greensand Casting Application: Justin de Beer, Department of Metallurgy, School of Mining, Metallurgy and Chemical Engineering, Faculty of Engineering and the Built Environment, University of Johannesburg Research and Application of the Triangular Collaborative Management Model among the Casting Quality, Process, and Producing: Ji Xiaoyuan, State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science & Technology The latest development in coatings for heavy iron and steel castings: Tim Birch, International Marketing Manager, Mold & Core, Foseco Netherlands Design principles applicable to three dimensional printing of sand mould for metal casting: Case of a cast iron valve housing component: Mashila Motadi, Metal Casting Technology Station, University of Johannesburg (MCTS) Thermal Distortion Test for Chemically Bonded Sands: Prof Sam Ramrattan, Foundry Education Foundation Key Professor, Department of Industrial and Manufacturing Engineering, Western Michigan University, Kalamazoo Total low cost innovative greensand solutions for small and medium sized foundries: Bo Wolff Haugbolle, General Product Manager, DISA Industries AS Thermal reclamation of used sand from a Voxeljet VX 1000: Oyombo Dady, Metal Casting Technology Station, University of Johannesburg (MCTS)
Technology & Proccess continued
ExOne – Patternless and Digital Production of Molds and Cores For Sand Casting Applications using Three-Dimensional Printing: Peter Bird Independent Metallurgical Consultant, ExOne GmbH, (please contact us to receive the lecture: service@foundry-planet.com) A new simulation system with the inclusion of metallurgical quality in the production line: Ramon Suarez, Engineering and Foundry Department, IK4 AZTERLAN, Durango, Bizkaia, Spain, Alberto Montenegro, Director General, AMV Soluciones, SpainPerfection in Every Single Mould: Frank Hohn, Area Sales Manager, Heinrich Wagner Sinto Maschinenfabrik GmbH, (please contact us to receive the lecture: service@foundry-planet.com) Voxeljet – 3D printing solutions for the foundry industry:David A. Mauchline, Manager of Additive Manufacturing, Vaal University of Technology A framework for Concept Design for Efficient Manufacturing: Merging Topology Optimization, Additive Manufacturing with Traditional Casting: Ravi Kunju, Vice President, Manufacturing Solutions, SolidThinking (A division of Altair) Waste to Energy – Renewable Energy Solution for Foundries: Garth Sinclair, Managing Director, Met-Link, representing Ecorevert Recent developments in mould and core making: Dr Harmut Polzin, TU Bergakademie Freiberg, GieBerei-Institut Foundry Binders – 3R to improve workplace environment: Dipak Ghosh, Head Techical Operations, Forace Polymers Pvt. Ltd Mechanical Characterization of Austempered Ductile Iron Obtained by Two Step Austempering Process: Ajay Likhite, Associate Professor, Department of Metallurgical and Materials Engineering VNIT, India
