Casting Related Interventions for

Foundry Firms

Jones Papo

20 May 2010

THE DST TECHNOLOGY LOCALIZATION PROGRAMME

Overview

• Objective

• Reduction of Scrap

• Mintek Competences

• Planning and Implementation

• Facilities and Equipment

Project Objective

To Assist 28 Foundry Firms in Solving

Casting-Related Problems and

Challenges

The Reduction of Casting Scrap

Reduction of Scrap

Improving

In-house

Metallurgical

Expertise

Assistance with Design

Packages

Improvement of

Fettling Sophistication

Mould, Pattern and

Tooling Improvement

Skills Development

and Improvement

Mintek Competences

Casting Technology:

A dedicated foundry pilot-plant facility

Staffed by Senior Metallurgists, Technicians and Artisans

Green Sand and CO2 sand capability

Mintek Competences (cont)

Skills Development and Improvement:

Incidental and tailored to the needs

Linked directly to skills gaps that impact on the

Reduction of Scrap

Short training courses for operators carrying jobs such as

mechanical testing and specimen prep for QC purposes

Mintek Competences (cont)

Improving In-house Metallurgical Expertise:

This service to be provided by the Metals Technology Centre (MTC)

at Mintek

Metallurgical Testing Services:

• Includes characterization of castings to ensure integrity

Mintek Competences (cont)

Improving In-house Metallurgical Expertise:

This service to be provided by the Metals Technology Centre (MTC)

at Mintek

Metals Information through a Web-based Helpline

• Mechanical and physical property data for cast alloys

Failure Investigations

• To identify the causes of casting defects and suggest

remedies

Project Investigation, Evaluation and Management

Assist firms in auditing, improving and establishing their own facilities

Mintek Competences (cont)

• Assistance with Design Packages: Service to be provided in partnership with technical experts and

service providers

Capability Proposed Service Provider

Casting Simulation and

Modelling Software

o Metallurgical Testing & Consultation (MTC):

MagmaSoft, COMSOL - RSA

o UJ (MCTS): QuickCast - RSA

o FOSECO – the service usually provided for

free to long-standing customers - RSA

o SimLogic – providers of software solutions for

simulating metals and minerals processes -RSA

o University of Alabama-Birmingham (UAB):

Casting Engineering Laboratory (UAB - CEL)

– USA

o SINTEF Group - Norway

Improvement of Fettling Sophistication:

Local Technical Specialists: Mr. Dave van Niekerk (DVN Marketing cc)

and Mr. Percy Dalton

International Technical Specialists: Dr-Ing. Hartmut Polzin (Freiberg

Technical University, Germany) and Dr-Ing. Gotthard Wolf (Federal

Association of the German Foundry Industry)

Additional Technical Specialists are being identified during the course of

the DST-TAP progress.

Mould/Pattern/Tooling Improvements:

Institute of Advanced Tooling (IATs): e.g. TUT Tooling Station, etc.

CSIR

Local and International Technical Experts

Mintek Competences (cont)

Planning and Implementation

• Planning of the Rollout Process – Phase 1:

– Benchmarking Validation Session with NFTN, Mintek, CSIR and Benchmarking

Specialists

– Visits to Companies for Face-to-Face Meetings by the end of 31stJuly 2010

– Development of TAPs for each company

– Agreement on the Development Plans

• Phase 1 Progress:

– Benchmarking Validation - Completed

– Completed Engagements– Development Plan being Finalized

• Steloy

• PDC

– Meetings already had with a number of service providers and technical specialists

• DVN Marketing, SimLogic, Casting Services

– Face-to-face meetings currently ongoing

– Phase 1 to be completed by 31st July 2010

Planning and Implementation

• Implementation of the TAPs – Phase 2

– Implementation of the agreed development plans

– Involvement of Technical Specialists, particularly for remote foundries

– Implementation already in progress in some foundries:

• PDC, Steloy and Boschpick

• Monitoring and Evaluation

– Non Disclosure Agreements (NDA) to be signed between the company, Mintek and

service provider

– Bi-weekly Client Survey Forms during the progress of the project

– Should there be problems, an emergency meeting will be convened for re-planning

– Regular progress reports

– On Completion: Final Report and Impact Assessment Survey to rank the quality of

the service

Facilities and Equipment

Mintek:

– Melting and Casting:

– Sand Foundry Pilot Plant

– Air and Vacuum Induction Furnaces

– Heat Treatment Furnaces

– Spectrometer: SpectroMaxx for ferrous and

non-ferrous analysis

Facilities and Equipment (cont)

– Mechanical Working: Forging Presses and Rolling Mills

– Mechanical Testing:

– Instron 1175: 100 kN Static Capacity (Tension and Compression)

– Tinius Olsen: 500 kN Static Capacity (Tension and Compression)

– Instron 1342: 250 kN (dynamic) and 300 kN (static) in both tension

and compression

– Instron 1361: Servo-Electric with 250 kN (dynamic) and 300 kN

(static) capability in both tension and compression

Facilities and Equipment (cont)

Heat Treatment: A range of furnaces

Metallurgical Characterization Equipment:

HR-SEM, XRD, Complete range of

metallographic equipment

Facilities and Equipment (cont)

Others: May be required (not available at Mintek)

A Fully Equipped Pattern Shop

Sand Testing Equipment

High Volume Induction Melting Furnaces: 300-500kg units

Vacuum with a High Volume Capacity: ≈ 200kg

Non-Destructive Testing (NDT) Services

Capability Proposed Service Provider

1. Fully Equipped Pattern Shop TAP Programme Participating Companies

2. Sand Testing Equipment UJ-MCTS (Metal Casting Technology

Station)

3. High Volume Induction Melting

Units

TAP Programme Participating Companies

4. High Volume Vacuum Furnace TAP Programme Participating Companies,

CSIR

5. NDT Services NDT Society Member Companies, SAIW

Member Companies

Thank You

www.mintek.co.za