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South Africa hosted BRICS Forum, WFO and Metal Casting Conference 2017

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<link http: www.foundry-planet.com media-world galleries gallery-archive _top external-link-new-window external link in new> BRICS Foundry-Gallery 2017
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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

<link file:34577 _blank download file> A new movement in the foundry industry: Professor Myungho Kim, President, World Foundry Organization

<link file:34576 _blank download file> Government support to revitalise the Foundry Sector in South Africa: Ashley Bhugwandin, Manager, Technology Localisation Implementation Unit, CSIR

<link file:34573 _blank download file> The Impact of the Foundry Industry on Manufacturing in South Africa: Henk Langenhoven, Chief Economist, Steel and Engineering Industries Federation of Southern Africa (SEIFSA)

<link file:34572 _blank download file> Leadership for Innovation: Dr Willie Visser, Director of the Centre for Positive People @ Work at USB-ED (University of Stellenbosch Business School – Executive Development)

<link file:34574 _blank download file> Aluminium Casting Supply to the Automotive Sector: Mark Krieg, Executive Director, Aluminium Federation of South Africa (AFSA)

<link file:34583 _blank download file> Recent Zinc Casting Alloy Developments: Technology and Markets: Dr Frank Goodwin, Director of Technology and Market Development, International Zinc Association

<link file:34575 _blank download file> The present situation and the development trends of the worldwide foundry industry: Prof Gotthard Wolf, Institute Director, Gießerei-Institut, der TU Bergakademie, Freiberg

<link file:34579 _blank download file> The 5-year strategic plan for China’s foundry industry: Wei Gao, Vice Secretary General, China

<link file:34582 _blank download file> From fabricated to casting: Per Rolf Roland, Owner, P R Roland Foundry Consultant AS, Norway

<link file:34581 _blank download file> Design and implementation of a strategy to modernise a jobbing foundry: Clayton Anderson, Chief Executive Officer, Thomas Foundry

<link file:34578 _blank download file> Lessons from the Metal Casting Technology Station (MCTS) and the National Foundry Technology Network (NFTN)’s technical assistance programme to South African sand: Dr Kasango Nyembwe, Head of Department, Metallurgy, University of Johannesburg

<link file:34585 _blank download file> Environmental Management – A driver for business growth and efficiency: Phil Rawnson FICME, Managing Director, MRT Castings Ltd

Technology and Processes

<link file:34584 _blank download file> Metallurgical aspects of the production of High Chromium Irons: Professor Adel Nofal, Professor of Foundry Technology, CMRDI, Egypt

<link file:34586 _blank download file> Energy 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 GmbH

<link file:34587 _blank download file> Eco Form a concept for hand moulded no bake castings: Dipl.-Ing. Jens Mueller-Spaeth, Managing Director, G U T

<link file:34580 _blank download file> Chances and limits of High silicon ductile iron: Dr.-Ing. Claudia Dommaschk, Foundry Department, TU Bergakademie Freiberg, Germany


<link file:34605 _blank download file> 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: <link>service@foundry-planet.com)

<link file:34609 _blank download file> 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

<link file:34604 _blank download file> Study on Metal-Die Interface Heat Transfer in Squeeze Casting Process: Dr Zhiqiang Han, Key Laboratory for Advanced Materials Processing Technology (MOE), China

<link file:34606 _blank download file> 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

<link file:34608 _blank download file> 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

<link file:34607 _blank download file> Advanced coating systems for cleaner engine blocks and heads: Simon Turley, Huettenes Albertus Group

<link file:34612 _blank download file> 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

<link file:34610 _blank download file> 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

<link file:34620 _blank download file> 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

<link file:34611 _blank download file> Investigation of Microstructural Features of AlMg9 alloy: Prof Zdenka Zovko Brodarac, Vice Dean Science and Finance, Faculty of Metallurgy, University of Zagreb, Croatia

<link file:34613 _blank download file> Clean Steel Castings – Exploring the dynamics of producing clean steel castings with modern technology: Nick Child, International Marketing Manager Clean Steel, Foseco

<link file:34616 _blank download file> 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

<link file:34617 _blank download file> Weldability of austempered ductile iron (ADI) and the applied NDT Methods: Mohamed Sayed, Central Metallurgical Research and Development Institute (CMRDI) Cairo, Egypt

<link file:34619 _blank download file> 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

<link file:34615 _blank download file> How to improve performance and delivery time, in an environmentally way, by using PENTEX binder system: Manuel Vargas, International Product Manager, Huettenes Albertus Group

<link file:34614 _blank download file> 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

<link file:34621 _blank download file> 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

<link file:34631 _blank download file> True precision since 1993: Markus Weck, Technical Director, ZPF GmbH

<link file:34623 _blank download file> Inorganic binders: Benefits, state of the art, actual use: Thomas Steinhauser, Professor for foundry technology, University of Duisburg-Essen

<link file:34618 _blank download file> Payback period for the acquisition of a Three Dimensional Printer in the South African foundry Industry: Elvis Gonya, Department of Metallurgy, University of Johannesburg

<link file:34626 _blank download file> Specialized cold-box binder systems and additives for complex foundry applications: Peter Groning, Product Manager EMEA Cold-box, Huettenes Albertus Group

<link file:34622 _blank download file> Design of a sand control system for a no-bake aluminium foundry: Farai Banganayi, Metal Casting Technology Station, University of Johannesburg (MCTS)

<link file:34624 _blank download file> Furan-Phenol Hybrid Resins, a choice for high-quality castings: Dr Ion Bacanu, Director Global Product Management, Huettenes Albertus Group

<link file:34630 _blank download file> Innovative latest technology and measurement system on refractory coatings: Chandan Panda, Vice President, Technical Services, Forace Polymers

<link file:34625 _blank download file> 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

<link file:34628 _blank download file> 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

<link file:34633 _blank download file> The latest development in coatings for heavy iron and steel castings: Tim Birch, International Marketing Manager, Mold & Core, Foseco Netherlands

<link file:34627 _blank download file> 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)

<link file:34637 _blank download file> 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

<link file:34632 _blank download file> Total low cost innovative greensand solutions for small and medium sized foundries: Bo Wolff Haugbolle, General Product Manager, DISA Industries AS

<link file:34629 _blank download file> 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: <link>service@foundry-planet.com)

<link file:34638 _blank download file> 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, Spain

Perfection in Every Single Mould: Frank Hohn, Area Sales Manager, Heinrich Wagner Sinto Maschinenfabrik GmbH, (please contact us to receive the lecture: <link>service@foundry-planet.com)

<link file:34636 _blank download file> Voxeljet – 3D printing solutions for the foundry industry:David A. Mauchline, Manager of Additive Manufacturing, Vaal University of Technology

<link file:34635 _blank download file> 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)

<link file:34634 _blank download file> Waste to Energy – Renewable Energy Solution for Foundries: Garth Sinclair, Managing Director, Met-Link, representing Ecorevert

<link file:34640 _blank download file> Recent developments in mould and core making: Dr Harmut Polzin, TU Bergakademie Freiberg, GieBerei-Institut

<link file:34641 _blank download file> Foundry Binders – 3R to improve workplace environment: Dipak Ghosh, Head Techical Operations, Forace Polymers Pvt. Ltd

<link file:34639 _blank download file> Mechanical Characterization of Austempered Ductile Iron Obtained by Two Step Austempering Process: Ajay Likhite, Associate Professor, Department of Metallurgical and Materials Engineering VNIT, India


Firmeninfo

South African Institute of Foundrymen (S.A.I.F.)

P.O. Box 14863
1422 Wadeville
South Africa

Telefon: +27 (11) 559 6468