New process combines best of 3D printing and metal casting
A British manufacturer says it has combined the best of 3D printing and casting by offering a wide range of materials without the high costs and limitations of tooling. Every manufacturing process has its limitations, whether it is traditional casting or direct 3D metal printing. High tooling cost and long lead-time are challenges of the traditional casting process whilst material compatibility is a restricting factor for direct 3D metal printing.
Brazil’s Asia steel scrap export route blooms amid renewed trade opportunities
Brazilian sellers have ramped up containerised exports of steel scrap into South Asian markets over the past year but this explosion in export sales is unlikely to be a long-term trend, sources have told Fastmarkets. Scrap collectors and processors in the country have traditionally sold the vast majority of their stocks in the domestic market, with only the excess being exported.
Production of high-tech components for the BMW iNEXT starts in Landshut
The light metal casting department provides the housing for the future electric drive motor and also developed the globally unique Injector Casting Process. Preparations to launch the all-new BMW iNEXT are progressing at full swing. The company intends to start production of this new model in 2021 at its Dingolfing plant.
3D printing technology optimises pistons for the powerful Porsche 911 GT2 RS
Porsche starts testing 3D printed pistons that are 10% lighter. Automakers are experimenting extensively with 3D printing for all variety of automotive parts from simple interior trim pieces to parts as complex as brake callipers. Porsche is taking the technology a step further by experimenting with 3D printing engine internals.
Tesla’s single-piece Model Y casting has not been kept a secret
When Elon Musk was interviewed in an episode of the Third Row Podcast earlier this year, he noted that the Model Y crossover’s rear underbody would eventually be built with a single-piece casting. This is quite a bold target, and one that can make the Model Y into one of the most cost-effective vehicles on the market today, electric or otherwise.
What’s the difference between a $20 and $200 cast iron skillet?
A cast iron skillet should retain heat well and put satisfying sears on all sorts of food. So what makes the $200 versions better at that than the $20 ones? New cooks can be intimidated by cast iron cookware’s need for seasoning, the age-old soap or no soap cleaning question and the seemingly infinite crackpot cast iron hacks, writes Will Price of Gear Patrol.
First 3D printed sump cover for F110 engine
General Electric (GE) recently shared the results of their year-long partnership with the US Air Force (USAF) to create additive manufacturing solutions for their aircraft supply chain. GE Additive and GE Aviation proposed the collaboration in 2019 for the Air Force to adopt metal additive technology to address gaps in readiness, sustainment and affordability. The Rapid Sustainment Office (RSO) oversaw the application and scaling of technology.
ExOne launches sand 3D printing network powered by over 40 binder jetting machines
ExOne has announced the launch of an international Sand 3D printing network made up of more than 40 binder jet printing platforms throughout North America. The network has been set up to provide greater access of ExOne’s sand 3D printing technologies to manufacturers working in industries such as aerospace and automotive.
3D Systems opens up 3D printing applications with new materials
3D Systems has added five new materials to its polymer 3D printing portfolio as the company aims to address a broader portfolio of additive applications for its Figure 4 technology. The new resins include Figure 4 Rubber-65A BLK, Accura Fidelity, Accura Bond, Accura Patch and Jewel Master GRY, with each catering to specific uses across industrial and casting applications.
GA-ASI completes first test flight with metal 3D printed part
General Atomics Aeronautical Systems, Inc (GA-ASI), a US aeronautics company, has completed its first test flight with a metal 3D printed part featured onboard its SkyGuardian Remotely Piloted Aircraft (RPA) system. GA-ASI’s strategy for scaling metal additive manufacturing across its RPA platforms has been supported by AddWorks, the consultation service of 3D printer OEM GE Additive, since the first half of 2019.
Improve wear characteristics with cryogenic processing
Cryogenic processing, the deep chilling of tool steel so that the molecular makeup of the metal is brought to cryogenic stillness in order to improve wear characteristics, is not a new technology. In the past, tool makers would bury components in snow banks for weeks or even months to improve their wear resistance. Castings were always left outside in the cold for months or years to age and stabilise.
Norican launches Monitizer | PRESCRIBE for automatic process optimisation
First product launched since Norican’s industry-exclusive partnership with South African company DataProphet. Norican Global A/S (Norican), a leading metallic parts enhancement company, has launched Monitizer | PRESCRIBE, an Artificial Intelligence (AI) service that rapidly optimises production and reduces scrap in real-life foundry environments.
Mozambique: Stolen rails found in Chinese foundry
Maputo: Earlier this year the Mozambican police on found a large number of stolen rails and other railway material in a Chinese-owned foundry in the Ceramica neighbourhood of the central city of Beira, according to a report in the independent daily O Pais. The police had difficulty accessing the interior of the foundry.
Metso reviewing Vereeniging operations in South Africa
Metso says it is initiating consultations to evaluate the potential closure or other alternatives for its operations in Vereeniging, Gauteng, South Africa. The Vereeniging unit provides pumps, spare parts, consumables, and repair services for the mining industry and has around 200 employees, the company says.
Lack of synergy between Denel and Armscor concerns joint committee on defence
Parliamentary committee concerned at failure of Denel to deliver on key army project. The Joint Standing Committee on Defence has resolved to ask the Minister of Defence and Military Veterans to intervene in the inability of Denel Land Systems to meet its contractual obligations to Armscor with respect to the Hoefyester project, and report back to the committee.
Automotive industry achieves record trade surplus
And expects to improve trade balance further in 2020, subject to the global impact of COVID-19. South Africa’s automotive industry achieved its fifth consecutive trade surplus in 2019 and its highest level on record. Subject to the global impact of COVID-19 and an anticipated weak domestic market, it is expected to improve its trade balance further in 2020, according to the latest Automotive Industry Export Council (AIEC) export manual.
Steel industry in financial distress because of lockdown
The Department of Trade and Industry has warned that the steel industry would exit the coronavirus (COVID-19) lockdown in severe financial distress with potential plant closures and job losses. The department’s Trade and Industrial Policy Strategies (Tips) said the industry could experience a devastating R1 billion negative cash cost on the five-week lockdown unless the government intervened.
World Foundry Organisation elects new president
The World Foundry Organisation (WFO) has elected Umur Denizci of the Turkish Foundry Denizciler Dokumculuk as the organisation’s new president for 2020 and 2021. The honorary role will see Denizci work with the WFO secretariat team, its executive board and the WFO member associations to further develop the organisation in the coming years.
Electra Mining Africa 2020 cancelled
Organisers of Southern Africa’s mining, manufacturing, automation, electrical and power trade exhibition Electra Mining Africa, Specialised Exhibitions, reports that the 2020 edition of the trade fair has been cancelled as a result of the COVID-19 pandemic. This year’s show had been scheduled to take place from September 7 to 11 in Johannesburg. The next edition of the trade fair will now be held from September 5 to 9, 2022.
Ford on track to build 700 000th Ranger in South Africa this year
Local production of the Ford Ranger continues to make a significant impact on the South African economy. Overall, Ford Motor Company of Southern Africa contributes over one per cent to the country’s GDP and tops the country’s light commercial vehicle exports, with Rangers exported from Ford’s Silverton Assembly Plant in Pretoria to more than 100 global markets.
AMSA acquires South Africa’s only producer of heavy sections of long steel
The Competition Tribunal has unconditionally approved steel manufacturer ArcelorMittal South Africa’s (AMSA’s) acquisition of the manufacturing and production of the structural steel and rail business of Highveld Structural Mill (HSM), a subsidiary of Evraz Highveld Steel and Vanadium.
Foundry sector in India seeks government help to double exports
The Indian foundry industry has sought government intervention to more than double its exports in the next five years. The domestic foundry sector is the second largest globally in terms of production, and believes it has huge advantages over others, including the market leader China, in terms of labour and manufacturing costs.
ExOne have announced that 15 new metal, ceramic and composite materials have been qualified for 3D printing
The ExOne Company, a global leader in industrial sand and metal 3D printers using binder jetting technology, has announced that 15 new metal, ceramic and composite materials have been qualified by ExOne and its customers for 3D printing on the company’s family of metal 3D printers.
Metso opens new foundry in India
Metso announced in 2018 a greenfield foundry project in Vadodara, India, with a target to increase the casting wear parts capacity for the mining and aggregate industries. The first pour event was celebrated in India in February 2020 when the foundry started production for customer deliveries for local and global markets. “The state-of-the-art foundry will have a strong role in our global foundry network.”
Foseco opens Ramos Arizpe, Mexico plant with an investment of US$20 million
With an investment of 20 million dollars, the British brand Foseco, a company dedicated to the foundry sector, belonging to the Vesuvius Group, has celebrated the official opening of its plant in Ramos Arizpe, Coahuila, Mexico. The industrial building features an area of 10 000m² and started operations in mid-October 2019, generating about 200 direct jobs gradually.
Mechanical engineering industry in Germany experiences a difficult year
The mechanical engineering industry in Germany is experiencing an even more difficult year than expected. The burdens that have already been felt for some time – trade conflicts, global economic weakness, structural change in the automotive industry – are now being compounded by the Coronavirus with its unforeseeable consequences for the economy as a whole.
Jingye Group completes its buyout of British Steel
Jingye Group, the steelmaker, has completed its buyout of British Steel, reviving a business that was placed into compulsory liquidation last May and saving more than 3 000 jobs. In a statement the group said it had completed the acquisition of British Steel’s UK and Dutch assets from the official receiver and confirmed it planned to invest US$1.5 billion in the company.
Eskom staffers caught in cahoots with scrapyard in huge theft operation
Since President Cyril Ramaphosa pinned the return of load shedding on sabotage, Eskom has led an internal investigation into the conduct of its employees. Sure enough two employees who were under surveillance were caught preparing to courier a truckload of conductors to a scrapyard in the east side of Johannesburg.
Italpresse Gauss builds die-casting machine with a closing force of 5 700 tons
Italpresse Gauss, an Italian manufacturer of fully automated, digitally enabled die-casting technology, is set to deliver the first toggle-free two-platen die-casting machine with a closing force of 5 700 tons. The TF 5700 was introduced in 2018 and is currently being made for one of the leading car manufacturers in Germany.
Anticipation builds for Machine Tools Africa 2020
Nasrec Expo Centre, Johannesburg will be the venue for metalworking suppliers and manufacturing companies to exhibit their products from 12 to 15 May 2020. Anticipation levels are already building despite there still being five months to go before the doors open for Machine Tools Africa 2020, South Africa’s premier metalworking supplier and manufacturing technologies event.
There could still be hope for Saldanha Steel: Expressions of interest received
Government urges AMSA to take all steps possible to retain jobs but AMSA says offers are not commercially substantive. In an official statement released in December 2019 The Department of Trade, Industry and Competition (DTIC) said it has received expressions of interest by two parties to buy the Saldanha Steel works from ArcelorMittal South Africa (AMSA).
2019 a record year for Volkswagen Group South Africa
Uitenhage plant sets new record for full-year production – 161 954 vehicles manufactured by VWSA in 2019. The Volkswagen Group South Africa (VWSA) plant in Uitenhage ended 2019 on a high note, achieving an all-time record for production in a single year. This figure surpasses their previous record of 137 758 vehicles produced in 2011.
9th BRICS International Foundry Forum
The 9th BRICS International Foundry Forum took place during the 18th FENAF (Latin American Foundry Fair) exhibition that was held in the Pro Magno Event Center in São Paulo, Brazil in September 2019. At the same time ABIFA, the Brazilian Foundry Association, celebrated their 50th anniversary. However, there were two notable absentees from the forum – India and South Africa.
What does the future hold for Germany’s auto industry?
Germany’s strength for the past half-century has been its automotive industry. The big question now is whether that also will become its biggest vulnerability. Carmakers built just 4.7 million cars in Germany in 2019, industry data showed, squeezing production to its lowest level since 1997. The powerful VDA carmakers’ club said output had tumbled nine per cent year-on-year, blaming weaker international demand for the fall.
International Aluminium Die-Casting Awards 2020
For many years, the Aluminium Die-Casting Award has proven to be a successful platform for demonstrating the high quality standards of aluminium die-castings. The aim of the competition is to boost interest in aluminium. The winners of the International Aluminium Die-Casting Award 2020 have been announced. In all, four castings were awarded prizes at EUROGUSS 2020 in Nuremberg, while two others received special commendations.
MHI and Primetals Technologies to acquire ABP Induction
Mitsubishi Heavy Industries (MHI) and Primetals Technologies will acquire ABP from CM Acquisitions, a Chicago-based private equity firm. MHI and Primetals Technologies will jointly take ABP’s shares. Future business activities will be conducted in close cooperation with and under the leadership of Primetals Technologies.
Scania invests in Omega Sinto’s mechanical green sand to core sand reclamation system
Didion and Sinto will provide sand processing and reclamation systems for the 90 000 tons per annum iron casting operation, starting up in 2020. Construction is proceeding toward a 2020 start-up for Scania AB’s €129 million greenfield foundry near Södertälje, Sweden.
Steel import duties might be utilised as a weapon in a trade war. However, it is not appropriate for the South African steel industry
At the time of the introduction of duties in 2015, NEASA cautioned government of the consequences of introducing import duties to protect South Africa’s steel monopoly, Arcelor Mittal South Africa (AMSA), calling it a “slow poison” causing the inevitable and painful demise of the steel downstream.
Ramaphosa launches new hub for vehicle industry in Tshwane
President Cyril Ramaphosa has recently launched a new automotive hub outside Pretoria, which will host new factories for vehicle part suppliers. The City of Tshwane has made available 162 hectares of land for the new Tshwane Automotive Special Economic Zone (SEZ), which will be built close to Fords assembly plant in Silverton, Pretoria.
Transformation fund launched by South Africa’s seven vehicle OEMs
It means the participating OEMs – BMW, Ford, Isuzu, Nissan, Toyota, Mercedes-Benz and Volkswagen – will, for the first time, be able to meaningfully participate and comply with all five elements of the broad-based black economic empowerment (B-BBEE) generic scorecard, specifically the ownership element.
Pfisterer changes name to Vexila
Pfisterer (Pty) Ltd, one of the largest manufacturers of composite insulators and related products on the African continent, has announced the completion of its rebranding initiative. In future the company will trade under the name of Vexila. The Vexila aluminium gravity die-casting foundry has a number of furnaces at its disposal.
2019 WFO Global Foundry Report
The World Foundry Organisation has published the 2019 WFO Global Foundry Report, giving a snapshot indication of the current state of the global foundry sector. The report includes detailed analysis from 26 of the WFO member countries to provide information on output trends, market strengths and relevant issues such as energy costs and skills analysis.
Bankruptcy: Next crisis for the former Neue Halberg Guss
Just over a year after the rescue of Neue Halberg Guss, the automotive supplier Guswerke Saarbrücken has applied for insolvency, according to reports. Apparently the district court of Sulzbach, Germany appointed Franz Abel von Abel and colleagues as the provisional administrator.
Imerys promotes Durandal and Kersand moulding sand at GIFA 2019
“The final quality of the metal casting is the result of a tremendous amount of controlled parameters inside the foundry. On a daily basis, parameters such as pouring temperature, sand quality, moulding conditions, etcetera are leveraged by metal casters to balance quality versus the yield of production, which usually have an opposite trend.”
Akhani 3D commercial additive manufacturing service bureau launched by local experts
“Akhani 3D, a newly established venture between Rapid 3D and Kemtek, has been created to meet the rising demand from within the manufacturing sector for a turnkey AM (Additive manufacturing/3D printing) production service that translates ideas into objects as efficiently as possible,” said Akhani 3D Managing Director David Bullock.
Formaldehyde emission limits: HA offers solutions for the cold-box sector
Stricter emission limits for formaldehyde, which will also apply to older plants as from 2020 onwards, present many foundries with an additional challenge. Hüttenes-Albertus (HA) is ready to provide its customers with appropriate solutions, namely specifically developed innovations for cold-box binder systems, additives and coatings.
Tesla files patent to die-cast vehicle frame
Tesla has wisely made arrangements to quieten all the critics crowing about its production capabilities – the company just obtained the patent for a giant machine that will create the entire body frame of a car in a single press. It’s called the Multi-Directional Unibody Casting Machine. Tesla filed a patent for a casting machine that could help streamline production for future vehicle projects.
Loramendi and ASK Chemicals enter alliance with voxeljet to industrialise core tooling production using 3D printing
German 3D printer manufacturer voxeljet has entered into an alliance with Loramendi, a Spanish tooling maker, and ASK Chemicals, a global foundry material-science company, to develop the Industrialisation of Core Printing (ICP) technology, and is also reportedly the world’s first fully automated 3D printed core production solution.
2019 Winners announced for Altair Enlighten Award
Ferrari, FCA, Material Science Corporation, ZF, Alba Tooling & Engineering Automotive Management Consulting GmbH, csi entwicklungstechnik GmbH take top honours. Altair, a global technology company providing solutions in product development, high-performance computing and data intelligence, has announced the winners of the 7th annual Altair Enlighten Award.
Aluminium alloy breaks the critical 500 MPa UTS mark
As part of a recent research project involving aero-engine giant Rolls-Royce and additive manufacturing equipment specialist Renishaw, heat-treated parts produced using A20X™ Powder have achieved an ultimate tensile strength (UTS) of 511 MPa, a yield strength of 440 MPa and elongation of 13 per cent, putting the powder at the forefront of high-strength aluminium additive manufacturing.
Ford’s expansion unleashes new potential for South Africa
Company says it is to add 1 200 jobs from August and is introducing a third shift at the vehicle assembly plant in Silverton to the west of Pretoria. Ford Motor Company of Southern Africa (FMCSA) will employ 1 200 new employees from August 2019 to meet the growing international and local demand for the New Ranger, Ranger Raptor and Everest models.
AMSA’S 2 000 job cuts and the ongoing steel industry woes are self-inflicted
The National Employers’ Association of South Africa (NEASA) says the potential loss of 2 000 jobs at Arcelor Mittal South Africa (AMSA) will have a massive effect on the current unemployment rate in the country. Recently AMSA said it was mulling a large-scale restructuring exercise, which might affect more than 2 000 jobs, citing a difficult economic environment.
MHI and Primetals Technologies to acquire ABP Induction Systems
It has been announced that Mitsubishi Heavy Industries (MHI) and Primetals Technologies will acquire ABP Induction Systems (ABP), a global manufacturer and servicer of induction furnaces and heating systems from CM Acquisitions, a Chicago, US-based private equity firm. The completion of the acquisition of ABP is subject to the approval of the relevant authorities.
Sinto forms Joint Venture Company in Turkey
The Sinto Group, a world-leading manufacturer of foundry equipment, has announced that they reached an agreement for the establishment of a Joint Venture Company in Turkey with their current Turkish sales representative Expert Mumessillik Tur. ve Tic. Ltd. Sti. (Expert). The new company will be named Sinto Turkey Makina Sanayi ve Ticaret Anonim Sirketi (Sinto Turkey).
MAGMA, Hüttenes-Albertus (HA) and Laempe Mössner Sinto join forces to present digital core production
Three leading technology providers in their fields, MAGMA GmbH, which specialises in the virtual optimisation of foundry processes, Hüttenes-Albertus (HA), a leading supplier of foundry chemicals and Laempe Mössner Sinto GmbH, the core shooting machine manufacturer, have joined forces to establish a long-term partnership.
Amsted Rail announces name change for South African operation – Amsted Foundry Solutions SA
Amsted Rail, the global leader in manufacturing bogie systems for the heavy haul freight market, has established its latest company – Amsted Foundry Solutions SA, with its foundries located in Johannesburg, South Africa. This newly created company is partially owned by both Amsted Rail and South Africa’s Industrial Development Corporation (IDC).
No retrenchments at Hillside aluminium smelter
In addition to voluntary separation and early retirement packages, a salary freeze for the next three years has also been agreed. Retrenchments at South32’s Hillside smelter will be avoided as an estimated 400, some say 500, employees have opted for voluntary separation and early retirement packages.
Tracking trends for metalcasting
What shapes the future for foundries and diecasters? Follow these five areas of development to know what’s important to the technologies and the businesses. GIFA 2019 has been circled on many calendars as the time and place for announcing new business plans, introducing new process technologies, and unveiling new projects in design and research.
AMRC Castings enhances 3D sand printing capability
As one of the first foundries to take advantage of large-scale 3D sand printing technology, the AMRC Castings Group has recently enhanced both its capacity and physical envelope. Capable of producing complex moulds and cores for oil, gas, aerospace and automotive without the need for dedicated tooling, the technology has been exploited for R&D, pre-production and full-scale production volumes.
Foundry chemicals group ASK put up for sale – sources
ASK Chemicals, a manufacturer of chemicals used in foundries, has been put up for sale by its private equity owner amid a flurry of dealmaking in the chemicals sector, people close to the matter said, it has been reported by Reuters. Buyout group Rhone Capital is working with Citi on the deal, which may value the Germany-based supplier of binders, additives, feeders, filters and metallurgical products at up to 500 million euros ($559 million), the report indicated.
Vesuvius acquires CCPI
Acquisition sees Vesuvius expand in aluminium. Molten metal flow engineering and technology company Vesuvius has announced that it has agreed to acquire CCPI, a speciality refractory producer. CCPI focuses on tundish (steel continuous casting) applications (65% of sales) and aluminium (35% of sales). The company is based in Ohio, USA, and will become part of Vesuvius’ Advanced Refractories division.
German company KS Huayu AluTech introduces new casting process for highly complex engine block geometries and electric motor housings
KS Huayu AluTech GmbH has introduced a new casting process onto the market. This joint venture between Rheinmetall Automotive and China’s Huayu Automotive Systems has developed a production process for the new Chinese plant in Guangde, one that is particularly suitable for highly complex engine block geometries and electric motor housings.
Largest cast bronze sculpture in UK travels to Plymouth by barge
The UK’s largest cast bronze sculpture has been unveiled after two years in the making. The ‘young, powerful’ female figure, entitled Messenger, has been cast at a foundry in a tiny Welsh village, using the ancient technique of lost wax casting. It will stand in front of the Theatre Royal Plymouth, which commissioned Joseph Hillier to create the work. Hillier was inspired by the split-second pose of an actor rehearsing for Othello on the theatre’s stage.
Dongfeng and Maxion Wheels form aluminium wheel joint venture
Maxion Wheels, one of the world’s largest wheel manufacturers, has announced an agreement to form a new passenger car aluminium wheel joint venture with Dongfeng Motor Parts and Components Group, one of China’s largest automotive parts companies. The new legal entity, Dongfeng Maxion Wheels, will build a new two million per year capacity plant in Hubei Province, China, with series production scheduled for the second half of 2020.
Understanding 3D sand printers and binder technologies
AM for cores and moulds is gaining popularity because of the flexibility and complexity it offers in production, but productivity is critical to the long-term prospects. Additive manufacturing of sand cores and moulds has attracted the attention of many foundries in recent years due to the process’ unique ability to form core shapes that cannot be manufactured using conventional coremaking techniques.
US casting sales reach $33.1 billion
Following a dip in 2016 to $27.3 million, the US casting industry recovered quickly and strongly in 2017 and 2018. Growth is expected to continue in 2019 with a 1.9% to $33.7 billion in casting sales. In the short-term, through 2021, the US metal casting industry has a forecasted annual growth rate of 2.4%. Through 2027, this report is estimating a 2.4% long-term annual growth rate for the industry.
GE Additive helps Callaway Golf Company break the mould to redesign putter head
As the team from GE Additive readily admits, Callaway knows a thing or two about creating top-level golfing equipment, including the putters and irons with which the brand is globally synonymous. So, it was for a very special purpose that the additive manufacturing experts were invited to rework one of Callaway’s latest putters in its Odyssey range, a favourite among pros and amateurs alike.
GF Casting Solutions divests from iron casting plants
The trend towards lighter vehicles continues to have a substantial impact on the automotive industry. In this context, GF Casting Solutions, a division of GF, will have a stronger focus on light metal casting whilst reducing its presence in iron casting in Europe. As a consequence, the iron casting plants located in Singen and Mettmann (Germany) have been divested to members of the management of GF Casting Solutions, effective retroactively as of 1 December 2018.
Alcoa: Non-heat treat HPDC foundry alloys for car body structures
Environmental and governmental pressures continue to push automakers worldwide to search for new areas of light weighting, and car structural components prove to be the new, fast-growing application for aluminium. This is true for both conventional internal combustion engine (ICE) vehicles, and electric ones. In addition, electric vehicles extensively use aluminium for other components, such as battery housings.
Bentonite market to hit US$1.85 billion by 2024 with rising demand for smart infrastructure
A key strategy developed by players in the global bentonite market to outshine their rivals is expanding manufacturing capacity. They are seen focusing hard on manufacturing process differentiation and expansion of manufacturing product portfolio to steal a march over competitors. Regulating costs with delivering quality services is a key strategy of most businesses present in the global bentonite market.
Elkem acquires TM Technology Ltd.
Elkem ASA has acquired the UK company TM Technology Ltd, a manufacturer of the foundry alloy Tenbloc, which is used in the mould inoculation of ductile and grey iron, and its production facilities. Elkem ASA is based in Norway, and is one of the world’s leading companies for environmentally responsible production of materials. Elkem manufactures a wide range of inoculants, MgFeSi alloys and pre-conditioners for the production of cast iron.
Indian foundry industry is set to double its growth rate in the next five years
In a statement issued at the conclusion of the 67th Indian Foundry Congress (IFC) at the India Expo Mart in Greater Noida, IIF President Shashi Jain said the industry, which employs around five million people directly and two million people indirectly, will generate additional employment for three million families in the next five years.
Metso to increase its foundry capacity in India to meet the growing global demand for cast wears for mining and aggregate industries
Metso is investing in the development of its foundry capacity in Vadodara, India. The initial investment includes the acquisition of the property and foundry assets of a privately owned foundry project, Mega Cast. Metso expects to invest a total of approximately EUR 25 million to purchase the assets and to develop the foundry by 2020.
Local foundry equipment supplier loses long court battle with Omega Foundry Machinery
Omega Foundry Machinery began the proceedings against Lauds Foundry Equipment (Pty) Ltd in 2015 when it alleged that the company’s copyright had been infringed by Lauds Foundry Equipment (Pty) Ltd, and before Omega Foundry Machinery had signed a joint venture merger agreement with another South African company.
Lauds Foundry Equipment (Pty) Ltd right of reply statement
“The default judgement states that we are not to infringe on Omega’s copyright and we emphatically state that we have no problem adhering to the default judgement as we have never infringed on Omega’s copyright, and we currently have no product that will infringe on their copyright, nor will we ever have.” – Kevin van Niekerk, CEO of Lauds Foundry Equipment, assisted by Wayne Teich Attorneys.
Local Manufacturing Exhibition 2019 to take place 21 to 23 May 2019
Organised by the South African Capital Equipment Export Council (SACEEC), in association with Specialised Exhibitions Montgomery, and endorsed by the Premier of Gauteng the exhibition is scheduled to take place at the Expo Centre, Nasrec, Gauteng from 21 to 23 May 2019. The exhibition aims to showcase South Africa’s local manufacturing capabilities.
Research by Wits shows buying only South African made vehicles could boost GDP by R37 billion
New research by the University of the Witwatersrand (Wits) shows that a government policy of buying only locally produced cars, bakkies, buses and trucks at national and provincial government level could, through various multiplier effects, increase South Africa’s gross domestic product (GDP) by R36.8 billion a year it has been reported after a radio interview. The policy could also have a one-off positive growth impact of 1.18% on GDP.
ArcelorMittal South Africa looks to exports for growth opportunities
With current steel demand in South Africa almost at a 10-year low, steelmaker ArcelorMittal South Africa is looking for export opportunities in the rest of Africa. “In light of weak domestic demand, ArcelorMittal South Africa (AMSA) has implemented a strategy to enhance its short-term profitability and cashflow, thereby, ensuring the business’ sustainability and positioning it to exploit growth in the sub-Saharan Africa region,” said CEO Kobus Verster.
Omega Sinto supplies turnkey sand casting cell solution for Advanced Metal Processing Centre research facility in UK
As part of its continued growth strategy, BCAST at Brunel University has installed a complete sand casting cell at The Advanced Metal Processing Centre (AMPC) research facility. The cell encompasses a no-bake (air-set) sand casting line, for moulds up to 1m x 1m in size, comprising hopper, sand mixer, vibratory compaction, rollover, 300kg furnace for melting aluminium, heated ladle and de-coring oven.
Indian foundry sector likely to grow by 13-14 per cent in two years
The foundry sector in the country is expected to witness an annual growth of 13-14 per cent from the present five to seven per cent, captains of industry said in a report in India’s The Economic Times. This would see production of castings increase from 11.5 million tons to 14-15 million tons by 2021 and was set to reach 20 million tons by 2025.
Investigating lightweight 3D printed structures for sand casting
3D printing is often used to produce moulds for casting, and in the case of sand moulds, binder jetting is typically used. However, its high costs, due to expensive materials, need to be lowered, according to the authors of a study entitled “Mechanical Analysis of Ceramic/Polymer Composite with Mesh-Type Lightweight Design Using Binder-Jet 3D Printing.”
Elkem opens ferroalloys plant in Paraguay
Elkem ASA has opened a new plant for foundry products in Limpio, Paraguay. This plant is the first foundry plant for Elkem in Latin America, and it is a new and exciting chapter for the group. Situated in Limpio, 25km from Asunción, the capital of Paraguay, the plant has been built in alignment with Elkem’s strategy for expansion in South America. The start-up of the plant was in March 2018.
SAPSDA joins SASSDA
In 2013 the South African Pump Manufacturers Association (Sapma) was requested by the dti as well as Eskom to form the South African Pump Cluster. In order to comply with the dti requirement to form a cluster, Sapma had to change from being an employer’s association to become a development association and to register as a non-profit company and as a result the Southern African Pump Systems Development Association (SAPSDA) was formed.
Iconic artwork welcomes diners after The Bull Run’s multi-million rand revamp
A much-loved Johannesburg landmark returns to business in style, with an iconic new addition to the Sandton street scene, as The Bull Run, the city’s quintessential grill house, reopens after three months of extensive refurbishments. The Maude Street restaurant underwent a R20 million revamp, and its reopening coincides with the launch of the massive The Marc property development on the neighbouring stand.
Project to reproduce landmark Rondebosch fountain almost complete
In a radio interview on CapeTalk Max Teichmann, owner of Heritage Castings, has said the project to reproduce Rondebosch’s historic fountain is nearing completion. The iconic fountain was located at the intersection of Belmont and Main roads in Rondebosch, Cape Town for over a century. The fountain was also the first electric lamp post in South Africa. It was destroyed after a speeding car drove into it during the early hours of the morning three years ago.
Automotive Masterplan close to being finalised
The Department of Trade and Industry (dti) and the motor industry are now close to finalising the South African Automotive Masterplan which will come into effect in January 2021 and run until 2035. This was the message given by Lionel October, the director-general of the dti, addressing delegates at the NAAMSA Automotive Conference, which was held at the Kyalami Grand Prix Circuit and Conference Centre.
HA Group and F. LLI Mazzon S.p.A. join forces
Effective June 2018, the HA group and the Italian company F. LLI Mazzon S.p.A. have joined forces. The names HA Group and Mazzon are well-known throughout the foundry industry, and are synonymous with foundry chemical materials. The companies have decided to join forces in order to pursue their shared goal of providing the best possible customer satisfaction across Europe and around the world.
Foseco continues with its plan to modernise and improve competitiveness
In recent years, the casting industry in Europe has experienced notable changes in the search for a good positioning in order to face present and future challenges. These changes range from the increase in automation and the collection and management of a huge amount of process data (Industry 4.0), additive manufacturing, through to the permanent improvement of costs and competitiveness in order to maintain its leadership over other regions with cheap labour.
US exports of scrap metal to China hit by trade war
With the trade war between Beijing and Washington escalating, US scrap exporters will likely feel the pinch of a 25 per cent duty China has imposed on copper and aluminium waste. Levies on US scrap metal, waste paper, and plastics arriving in China began on August 23 after China announced new tariffs on $16 billion of US goods earlier in August 2018. Aluminium scrap was hit with tariffs in April 2018.
Vietnam to restrict surging scrap imports
Vietnam has tightened control over the imports of scrap such as plastic, paper, and metals. With China banning imports of various types of scrap metal and waste products, imports into Vietnam have increased rapidly since 2017. Going forward, the Vietnamese government will only issue import licences if the importers can prove that their shipments meet the environmental standards and they have a demand and capacity to process the scrap as raw materials for their production activities.
Aluminium scrap is becoming more and more valuable
Aluminium recycling is gaining in importance as a source of raw materials. Today, aluminium scrap is already one of the most economically valuable secondary raw materials. Around 20 per cent of the world’s aluminium requirements are covered by post-consumer scrap. Its significance is increasing in a time of shrinking raw material reserves and scarce, and above all expensive, energy.
Indian foundries must raise castings output
Sector needs $8 billion investment to support Make in India initiative: IIF official. Indian foundries have to produce 25 million tons to 30 million tons of castings a year in the next 10 years to support the Make in India initiative. Last year, the Indian foundry industry produced 11.35 million tons of cast components in ferrous and non-ferrous categories. This year, it expected a 10% growth over the last fiscal.
Precious metals recycling innovation reaches Africa Prize finals
An innovation that uses a cheap and sustainable recycling method to recover precious metals has made it into the finals of the 2018 Africa Prize for Engineering Innovation. Growing demand for platinum, palladium and rhodium made Collins Saguru decide to commercialise a metal recycling process he developed while doing his master’s degree in metallurgy and material engineering at the University of the Witwatersrand.
Lightweight construction will continue to pose the greatest challenge for the automotive industry in future
Aluminium share per automobile to rise to between 160 and 180 kilograms by 2020. Aluminium has transformed the automotive industry, and it will continue to do so in future. It offers a better cost-benefit ratio than any of the substitute materials on offer. By collaborating even more closely in future, aluminium producers, processors and vehicle manufacturers can unlock further potential for the use of aluminium.
Metal 3D printing and classic foundry techniques: Friends or foes?
The question is: What impact will this technology have on traditional foundries? The first question that is often asked when a new technology is introduced is: What of the old way of doing things? Sometimes the answer is that it fades into oblivion. Think fortran and floppy disks. Other times it falls out of use in mainstream society but becomes the domain of a small, especially devoted community, like calligraphy or pedal loom weaving.
Ferrous scrap to increasingly replace natural resources as key steel raw material
Ferrous scrap will increasingly replace natural resources as the main raw material to produce steel, according to the World Steel Association (Worldsteel) head of raw materials, Dr Baris Bekir Çiftçi. This is mainly due to ferrous scrap’s increasing availability globally, as well as structural reforms in major steelmaking countries to increase the usage of electric-arc furnaces in the steel production process.
Whitechapel Bell Foundry may be bought back from developers and reopened by royal charity
The centuries-old Whitechapel Bell Foundry, which was closed in 2016 and sold last year to developers for several million pounds, could be bought back by a royal building-preservation charity and reopened, according to the Church Times. The Whitechapel Bell Foundry, established in 1570, was one of the oldest companies in the UK, and had occupied premises on Whitechapel Road since 1738. It is the birthplace of Big Ben, Bow Bells, and the Liberty Bell in Pennsylvania.
TASA changes name to Production Technologies Association of South Africa
The Toolmaking Association of South Africa (TASA) was established in 2004 as a representative body for the South African tool, die and mouldmaking (TDM) industry. TASA was established to address the South African TDM and precision machining industry, which had been losing significant capacity, and with it, its global competitiveness and ability to enhance job creation – all to the detriment of the manufacturing sector and the economy as a whole.
10th Industrial Policy Action Plan launched
The Minister of Trade and Industry, Dr Rob Davies, has launched the 10th iteration of the Industrial Policy Action Plan. IPAP is the dti’s vision for the industrial development of South Africa. Despite a challenging few years for manufacturing, the IPAP 2018 has outlined programmes that have done well, with the automotive sector leading the pack. Other sectors it has supported have also made inroads.
The Department Of Higher Education and Training launches artisan centres of specialisation
The Department of Higher Education and Training (DHET) has kicked off the campaign for the launch of 26 Centres of Specialisation (COS) aimed at prioritising 13 occupational trades in high demand to curb trade skills shortages as well as reduce unemployment and poverty in the country. The COS are located at 26 Technical Vocational Education and Training (TVET) colleges across the country.
NAACAM show to be held in Durban in 2019
The National Association of Automotive Component and Allied Manufacturers (NAACAM) has announced that the NAACAM Show 2019 will be hosted by eThekwini Municipality in partnership with the Durban Automotive Cluster (DAC). This second iteration of the show will take place at the Durban International Convention Centre (ICC) on 12 – 14 March 2019. The inaugural NAACAM Show held in April 2017 was supported and endorsed by the Department of Trade and Industry and others.
VW cancels contracts with Prevent Group after supply problems
What do brake parts, yachts, couches, shoes and Volkswagen have in common? Top marks if you answered the Prevent Group, a little known company of Bosnian origins and many interests that has played a big part in the recent history of the German automotive giant. For many years, the Prevent Group has supplied Volkswagen with various car parts, from gearbox components to seat covers, often via various other supply companies they bought up over the years.
India goes ahead of the US and becomes the world’s second largest castings producer says IIF
India has overtaken the United States to emerge as the second largest producer of castings behind China, a spokesperson of the Indian Institute of Foundrymen (IIF) has said in reports published widely in India. The report comes four days after the news that India had overtaken Japan to become the world’s second largest crude steel manufacturer, which is all good news about the country’s growing production numbers.
Indian foundries in Coimbatore area protest against rising raw material costs
400 foundries shut for two days say reports. If companies manufacturing pumps, wet grinders and engineering components were the driving force behind the thriving manufacturing sector in Coimbatore, 600 odd foundries were the backbone of all these companies. But they are facing a bleak future and the employees there are uncertain about their fate.
EU reintroduces anti-dumping duties on iron castings from China
The European Commission has set definitive anti-dumping duties on iron castings imported from China, in a latest trade measure against the country. The duties range from 15.5 per cent to 38.1 per cent on the imports, which are a family of products that include for instance manhole covers and grates used in street drainage, according to the European Union’s official journal.
Picasso bronzes tracked back to Parisian foundry
Elemental analysis enabled researchers to delve into art history. Researchers from Northwestern University in Massachusetts and the Musée National Picasso in Paris have traced five of Pablo Picasso’s sculptures to a second world war foundry in Paris. They revealed their findings at the American Association for the Advancement of Science (AAAS) meeting in Austin, Texas on 17 February.
Indian foundry industry expects $3 billion of investments
The Indian foundry industry, the third largest globally, expects investment of USD 3 billion while the National Steel Policy has envisaged steel production to reach 110 million tons (mt) by 2019-20 with the assured estimated investment in the next 10 years in order to meet the potential demand of 30 million tons of castings. The Indian foundry industry is expected to double its revenues over the next three years.
Sale of Disa core machine business to Suzhou Mingzhi Technology Co. Ltd
The Norican Group and Suzhou Mingzhi Technology Co Ltd. have announced the signing of a binding agreement whereby Suzhou Mingzhi Technology Co Ltd. has purchased the assets of the Disa Core product business, based in Leipzig, Germany. The sale is the result of close dialogue between the parties, exploring potential cooperation within complementary business areas, to better serve customers.
GF to acquire Swiss precision casting manufacturer
GF Automotive, a division of GF, is to purchase 100% of Precicast Industrial Holding SA, the Swiss-based precision casting specialist. This is in line with the division’s strategy to increase its industrial sectors presence, in particular in the promising aerospace field. Upon closing, the division will be renamed GF Casting Solutions. Precicast Industrial SA (Precicast) is one of the only independent precision casting, also called investment casting, companies in Europe.
The humble post box
The Pillar Box for collecting mail, known as a post box in most countries, made of cast-iron and painted a distinctive red colour, is a feature of virtually every British street. The design has remained basically unchanged for 150 years and is a touchstone of continuity in a changing world. Firmly protected from change by a loving public, these boxes affirm the ritual of communication, even as more and more people stop sending physical mail and rely on virtual communication.
Historic Coalbrookdale Aga foundry site up for sale
The Aga foundry shut for the final time in November 2017, with the 42 remaining workers leaving their boots and helmets on the famous Coalbrookdale Co gates as they left. Telford & Wrekin Councillor Nicola Lowery, who represents the Ironbridge Gorge ward, said she had spoken to the site owner and understands the site will be put on the market with the industrial units intact.
Bells of St Paul’s to fall silent for first time since Second World War as they are removed for cleaning and repairs
The bells of St Paul’s are to fall silent for the first time since the Second World War so they can be cleaned and restored. A successful funding campaign raised almost £400 000 to pay for the work amid concerns that the bells could fall from their mounts if they were not repaired.
Scania invests EUR 150 million (SEK 1.5 Billion) in energy-efficient foundry
Scania plans to invest about EUR 150 million in a new foundry in Södertälje, Sweden, in order to triple production capacity and achieve a 50 per cent reduction in energy consumption compared to the technology and methods used in the current foundry. Through more efficient materials handling and recycling, a sharp reduction will also be achieved in the transport need per manufactured unit.
Coca-Cola sets ambitious recycling goals
By 2030, for every bottle or can Coca-Cola sells globally, the company aims to help take one back so it has more than one life. To accomplish this the company states it is investing to support the collection of packaging throughout the industry, including bottles and cans from other companies. The programme includes a multi-year investment designed to make packaging 100 per cent recyclable.
AMRC Castings unveil largest ceramic shell titanium casting created in Europe
The Castings Group of the Advanced Manufacturing Research Centre (AMRC) has unveiled the largest ceramic shell titanium casting ever created from a single pour in Europe. The casting is a milestone test piece and will become a showcase for development of the AMRC’s titanium casting facility, which became operational earlier this year.