vol 17 no 4 - Castings SA SA... · global marketplace Add-on investment criteria • Market proven engineered products, well positioned in regional or niche markets and/or key accounts

castings sa vol 17 no 4 December 2016 1

Castings SAvol 17 no 4ISSN 1605-7589

Publishing EditorBruce Crawford

Online EditorDamon Crawford

Editorial BoardMarc Hindle

Production ManagerWendy Crawford

ReproductionJericho Graphic Design

Printed ByPaarlmedia - A Division of Novus Holding

Advertising Bruce Crawford/Wendy CrawfordTel: +27 11 463 0489Cell: + 27 83 628 7654E-mail: [email protected] Website: www.castingssa.co.za

castings sa is published by BA Crawford Specialised Publications (Pty) Ltd. PO Box 69 299, Bryanston, South Africa, 2021

41 Arklow Road, Bryanston, South Africa, 2021

Tel: + 27 11 463 0489E-mail: [email protected]

SubscriptionsAnnual – Local: R140.00 (incl. VAT)International: On application

CopyrightAll rights reserved. No editorial matter published in Castings SA may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

castings sa, published every second month, is the official journal of the South African Institute of Foundrymen (SAIF). The information and ideas presented in castings sa do not necessarily reflect the position of the SAIF staff, executive, advisors, sponsors or members.

4 cover storyABP Induction Systems GmbH

6 industry newsPrima Industrial casts; Questions asked - Steloy Castings; Donald Greig Gallery opens; Sculpture Casting Services and Bronze Age Art Foundry combine; Mittal; Scaw Metals; Manufacturing competitiveness enhancement programme; Manufacturing; Mineral Zone; Scrap metal prices; DTI; Electra Mining Africa '16; Thos Begbie & Co; SAIF '16 Annual Golf Day; Scrap metal dealer

28 international newsGrainger & Worrall; New ASTM standard; German metallurgy; Magnesium metal market; Hüttenes-Albertus; Robot optimises induction heating process; New book: Induction Heating; ICI’s 15th Annual Casting Design contest; Aluminium in cars; Aluminium closure; Polish Foundrymen’s Association

42 product review ASK Chemicals; Altair reveal new design processes; MAGMAsoft; Tracer 5i; Hüttenes-Albertus; ABB

castings saA specialised journal covering the technology,

processors and materials field for castings

volume 17 number 4December 2016

2 castings sa vol 17 no 4 December 2016

Hot on the heels of the news that Steloy Castings had been liquidated (see story on page

10 in this issue), reportedly owing between R120 and R130 million, and having been in business rescue proceedings since the beginning of July 2016, it was then announced that LH Power Electronics had also been put into provisional liquidation.

Both companies had been in business for over 30 years – Steloy

Castings since 1985 and LH Power Electronics since 1980. Both are well known in the foundry industry in South Africa with Steloy Castings manufacturing castings and LH Power Electronics a manufacturer of induction furnaces and high power rectifiers.

There can be many questions asked as to why these two companies, with a relatively long history of being in business, have suddenly had to be liquidated but we will never get the true story. One can speculate but even then you might not get close to the real reason/s.

When you consider that these companies had managed to trade through some extremely difficult conditions from 2008 onwards and we are now at the point where we are seeing green shoots of recovery in the engineering sector, to see two well-established business fail now is really rather sad.

There is nothing new about companies going into liquidation and closing. This is a common occurrence all over the world. But it always leaves a bitter taste, especially for the liquidated company’s creditors. Again, there are many reasons as to why debt has been allowed to occur and, 100 per cent of the time, the creditor will be caught out by the closing of a company that they have been supplying product or services to.

A liquidated company will explain that it had instituted “a comprehensive operative and financial restructuring” plan and that it had been unable to reach a debt-restructuring agreement that would have provided new operating capital, despite extensive negotiations over recent months.

“Over the last year we have incurred significant operating losses, in the midst of the economic downturn and despite considerable efforts by management to address operating issues in manufacturing, financial performance remained under pressure and resulted in a liquidity shortfall,” is another excuse always given.

The potentially disastrous knock-on effects of a business being liquidated are numerous with many creditors having to write off monies owed. Many of the larger companies are fully aware of all the legal avenues designed to help them recoup their owed monies, and they ensure that they have the correct insurance in place to account for any loss in earnings that may come about if and when a client or supplier is unable to fulfill its financial obligations.

However, spare a thought for the employees that are affected by the ‘messy’ business of a company being liquidated. They are the real victims in the whole process. “Meetings have been scheduled to explain the circumstances to workers.” And: "We regret that in spite of all efforts undertaken that the company has not been able to turn around its business,” is normally the final quote.

But as we all know the ‘timing’ is never right for the unfortunate individual. In many cases they (the workers) are usually in debt themselves – it is reported that 78 per cent of South Africans are in debt – and rely heavily on their monthly income just to service this debt. Others might be in the latter stages of their working career and have learnt to overcome such an incident but still get caught short.

So whom can we blame? I believe that someone should be held accountable. It is not unusual for the Directors of a liquidated company to be financially secure and thus not have much stress going forward. But this is my point. The Directors have been in charge of the company and through their decisions, or alternatively non-performance, the company has got into a position where it has to be iquidated. I am generalising, but more often than not this is the case and our South African laws allow the ‘culprits’ to walk away without any recourse. I believe the laws need to be changed so that they, those responsible, are held accountable.

Spare a thought for the employees

editor's comment

south african institute of foundrymenThe aim of the SAIF is to promote and develop within

Southern Africa the science, technology and application of founding for individuals and involved industries.

Council Appointments for 2016/2017

President - Takalani MadzivhandilaVice President - Janley Kotze Treasurer - Justin de BeerImmediate Past President - Enno KruegerElected Members - Kevin van Niekerk, Tiisetso Masete, Andrew McFarlane, John Taylor, Cyprian Kyalu, Nigel Pardoe

Address DetailsUniversity of Johannesburg Metal Casting Technology Station - Metallurgy; Room G101, John Orr Building, Corner Siemert and Beit Street, Doornfontein, Johannesburg, Gauteng.

Postal Address: P.O. Box 14863, Wadeville, 1422.

Website: www.foundries.org.za

John Davies - Tel: +27 (11) 559 6468;Cell: 083 630 2809; email: [email protected]

Executive Secretary - Tel: +27 (11) 559 6455;Fax: +27 (11) 559 6526; email: [email protected]

Western Cape: Alan Wood - Tel: +27 (21) 557 2868 (Home);Cell: 072 351 1391; email: [email protected]

Dates for future SAIF activities14 – 17 March 2017 — Metal Casting Conference/WFO 2017 Technical Forum/BRICS Foundry Forum 2017: Emperors Palace


cover story

ABP Induction Systems GmbH (ABP), located in Dortmund, Germany (formerly ABB Foundry Systems) has for decades been one of the world’s leading manufacturers

of high-throughput induction melting, pouring and heating equipment. This leadership position results from the combination of three industry pioneers: Asea, which built the first channel induction furnace in 1903, Brown Boveri (BBC), which in 1929 established its furnace business in Dortmund, and Pillar having introduced the first transistorised induction power supply.

Today, ABP continues the heritage of the original businesses that began over 100 years ago, providing a competitive edge to its customers around the globe with highly reliable, state-of-the-art technology.

CM Acquisitions (CMA), a USA based private equity firm specialising in middle-market, sale of private companies, going private transactions, acquisitions, divestitures, and distressed situations, acquired controlling interest in ABP Foundry Systems in 2005, providing a solution for an $18 billion annual revenue public company seeking to divest a non-strategic business unit.

CMA found the business attractive for investment due to:• CharacteristicsfittingCMA’stargetcriteria:

capital goods manufacturer with an aftermarket parts and service component, proprietary electrical engineering technology, impressive customer base and longstanding relationships, #1 or #2 position in key markets

• CMAwasuniquelyqualifiedtoestablishABPas an autonomous company in five countries (Germany, Sweden, Brazil, Thailand and the USA), replacing necessary corporate support services while enabling senior management to focus on running the business with a liberating sense of entrepreneurship

• StrategicalignmentwithCMA’sPillarinvestmentwas substantial. Combined, the ABP/Pillar induction businesses reached all key international markets

• Committed,industry-experiencedpersonnelpassionate about maintaining the ABP heritage of bringing advanced technology and superior service to a global marketplace

Add-on investment criteria• Marketprovenengineeredproducts,wellpositioned

in regional or niche markets and/or key accounts due to demonstrable competitive advantages

• Coil-repairservices• Strongmanagementdesired,notrequired• Revenueexceeding$2million,locatedinkeycasting

and forging markets

Preferences• Aftermarketserviceoperationwithoutstandingreputation• Cross-sellingequipment/servicepotential

An ABP Ecotop hood for fume extraction

ABP Induction Systems GmbH (ABP), located in Dortmund,Germany (formerly ABB Foundry Systems) has for decades been

one of the world’s leading manufacturers of high-throughput induction melting, pouring and heating equipment

ABP Induction Systems GmbH

An ABP large crucible induction

furnace forsteel production -

IFM 11/65 t/42 MW


2006 Add-On InvestmentABP Induction acquired the Pillar-related aftermarket

parts and service business of Engefor Eletronica, based in Sao Paulo, Brazil to better serve South American markets. Engefor has enjoyed a well-earned reputation for superior service and quality manufacturing of Pillar melting systems. The Engefor transaction contributed engineering, sales and technical service talent while substantially increasing the installed base of equipment requiring periodic service. The Brazil market is a strategic priority of ABP as further evidenced by the new plant constructed in Atibaia which houses all sales, engineering, manufacturing and service functions.

2007 Add-On InvestmentABP Induction Systems Pvt Ltd was formed in India to

service this robust melting market with aftermarket services, systems sales and engineering support. Manufacturing operations began within a new plant facility constructed on the outskirts of Vadodara in 2008.

2008 Pillar mergerCMA formally combined their two induction company

investments after successfully establishing ABP as an autonomous independent company in all growth markets around the world. ABP is positioned to serve its customers in both the mature economies of North America and Western Europe and the developing growth markets in Asia and South America.

2011 Divestiture Effective January 1, ABP sold its U.S. Heating Division

assets consisting of the two plant locations in Brookfield, WI and Sterling Heights, MI and the intangible assets associated with the Pillar brand products.

The ABP US Melting Division and all ABP international operations remain unaffected by the divestiture, a positive strategic transaction for both ABP investors and the buyer, a subsidiary of Park-Ohio (NASDAQ: PKOH).

2012 South African acquisitionABP Induction Systems decided to strengthen its position

in South Africa by acquiring the assets of Induction Furnaces, a company that had represented them in South Africa for a number of years.

For further details contact ABP Induction Furnaces on TEL: 011 623 1814/17 or cell number 072 158 1117 or email [email protected]. You can also visit www.abpinduction.com

ABP Induction Systems service


industry news

Prima Industrial Holdings have recently completed and shipped two castings to a North American

client that represent the largest castings that the company has ever manufactured in its 80 year history.

“The challenge of the highly engineered large casting market is that you have to get it correct from the beginning otherwise you have a large amount of scrap metal to melt and I don’t have to explain the costs that are associated with that,” said William Price who has recently been appointed Managing Director of the family owned business. William takes over from his father Keith who will now take up the position of Chairman as he begins to hand over to the younger generation management team.

“Prima has been supplying the South African mines and international clients with mining wear parts since its inception in 1937. We have evolved into one of South Africa's most respected suppliers of steel mill and crusher liners, and have received recognition in the form of numerous export awards and contracts won in a number of international markets including USA, UK, Australasia / Australia, Europe and several African countries.”

“We made a strategic decision to move into the larger size castings market last year and as a result we were asked to manufacture a bowl and mantle for our US client Optimum Crush. The castings are destined for use on a cone crusher in the Canadian gold mining industry. The bowl has a final weight of 10,7 tons and the mantle 11,1 tons once cast

fettled and finished. Previously the largest casting we had manufactured was in the region of 8,5 tons.”

“To take on this project has been a great test for our company and required meticulous planning and team work. From the engineering department to the foundry, quality, fettling and machining departments we had to plan every step. This included engaging our Magmasoft simulation software supplier Ametex. The whole process has galvanised us as a team and we now know that we can accomplish similar projects when called upon, whether it be for a local client or one based internationally,” added Price.

“We have been producing crushing machinery wear parts for some time and the castings are core to our business. However, when you are contracted to cast a component over 10 tons there are a number of factors you have to take into account. You have to account for aspects such as melt capacity, crane capabilities, box size and machining capabilities in your feasibility study,” explained David Barbour Prima’s Production Engineer who has been with company for the last three years.

“Integral during our planning stage was to use the services of Ametex and the Magmasoft software to simulate mould filling, solidification and cooling, in advance of the start of production. More critically, the software improves product design by helping to identify residual stresses and distortion, microstructure formation and property distributions in castings.”

Prima Industrial casts large crusher components for US client

Creative thinking and attention to detail assist company to enterlarge wear parts market.

Prima Industrial Holdings have made a strategic decision to move into the larger size castings market. This bowl casting used on a cone

crusher has a final weight of 10,7 tons

Prima Industrial Holdings have recently manufactured a mantle for their US client Optimum Crush. The casting weighs in at 11,1 tons


“As a result of using the software, in consultation with our client, we did make design changes to the castings to avoid ‘tearing’ of the metal. Particular emphasis was placed on feeder optimisation and control of sand entrainment so that we could minimise molten metal turbulence in the mould and optimise the yield.”

Transfer bogey system“One of the main constraints we had was that we did not

have the melt capacity, or so we thought, on site. After the disappointment of nearly acquiring an arc furnace to alleviate this problem we had to come up with an alternative. This is when Greg Mac Rae, our Quality Manager, suggested we fabricate and install a transfer bogey system so that we could easily transfer molten metal from our small component foundry to our heavy bay foundry and pour simultaneously. The melt capacity of the smaller furnace is 4,5 tons and added to our main furnace of 12 tons it gave us enough molten metal to accommodate the larger size castings.”

“The system is very simple in design but it has saved the company a sizeable amount of costs. We built rails of approximately 30 metres in length to bridge the gap between the two foundries and a mechanised transfer bogey to transport the ladle from the smaller foundry. We also installed a six metre launder to aid the pouring process,” explained Greg Mac Rae.

The castings“Bulk material processing and handling systems are

an integral operation in the mining industry. Crushing

technologies for bulk processing applications require components to be cast of high-grade steel and to be recognised for rugged structural integrity. As it is our first attempt to manufacture castings over 10 tons we have created more stringent quality specifications than previously deployed,” said Foundry Manager Cypi Kyalu.

“After finalising our 3D model it took six weeks to produce the patterns and mould setup took about five days. Melting and pouring was relatively short compared to planning and preparation and the cooling off period was about four days. The machining was done on our own vertical boring mill that has a four metre table.”

“Other interesting facts were that we used about 16,5 tons of metal per casting and the weight for the metal, boxes and sand was about 40 tons per casting. After fettling and removing feeders we would still remove between 600 and 800 kilograms of metal during the machining process.”

“The bowl and the mantle that we have manufactured only represent six percent of the total weight of the cone crusher that is one of three of its kind used in the world. The castings are on the water at the moment and should be put into production early next year,” said William Price.

“Going forward, we are looking at manufacturing at least two of each casting per month as the cone crusher wear parts such as these are changed every four weeks. As a team we have broken barriers to deliver and we are confident that our client will recognise this,” added Price.

For further details contact Prima Industrial Holdings on TEL: 011 421 6911 or visit www.primafoundry.com

The Prima Industrial Holdings’ team that was involved in manufacturing the bowl and mantle wear parts thatwill be used on a cone crusher that is deployed in the Canadian gold mining industry

“Integral during our planning stage was to use the services of Ametex and the Magmasoft software to simulate mould filling, solidification

and cooling, in advance of the start of production. More critically, the software improves product design by helping to identify residual stresses and distortion,

microstructure formation and property distributions in castings.”


Statistically the company employs approximately 10% of the working population in the Ekandustria area, where the company has two foundries and a machine shop.

It is well known in industry that Bronkhorstspruit, Mpumalanga based foundry Steloy Castings has been in business rescue proceedings since the beginning of July 2016, reportedly owing between R120 and R130 million. Now the business rescue practitioner has issued notice that they have “concluded that no reasonable prospect exists for the entity to be rescued.”

This is no surprise considering the amount needed to keep the entity operating as a going concern. The amount of money owed by Steloy Castings, including to state owned enterprisessuchasSARS,IDC,MetalIndustriesBenefitFundsAdministrators and the Mpumalanga Economic Growth Agency (Mega), who is responsible for the supply of power to Steloy Castings runs into many millions of rand. At the time of the business rescue notice it was rumoured that the company owed R6,7 million to SARS (including PAYE and VAT), R1,2milliontotheMetalIndustriesBenefitFundsAdministrators and Workman’s Compensation R3,3 million. Whether these amounts have now been paid to avoid criminal charges, is unknown.

The demise of the company has been swift when you consider the glowing press releases sent out by the company in the last quarter of 2015 expounding on how it had been in business for 30 years and how well it was doing. The company also announced that it had invested millions in the latest equipment and technology to secure lucrative railway industry contracts for the localisation projects. This included boasting about being the only foundry in South Africa to be accredited with the Iris standard, the international rail industry standard.

This publication also fell into the trap and published a lengthy article in February this year on how Steloy Castings had invested in the installation of a new sand reclamation plant at the company’s Tungsten Road foundry facility, and new state-of-the-art CNC and CMM equipment at its machine shop.

Earlier this year the IDC, one of Steloy Castings biggest funders, and now, as a result of the liquidation, one its biggest creditors, published an article that Noma Nibe, who is “no ordinary worker, but a businesswoman of note” had

approached the IDC to provide her with funding to become a major shareholder in a consortium that purchased a 26% stake in Steloy Castings in a BEE deal, and the IDC “came on board with funding”.

In the same article Steloy Castings’ CEO Danie Slabbert is quoted as saying: “It is good that unlike the banks, the IDCdoesn’tlookatthesecuritylikeassetsbuttheirfinanceschemes are more based on opportunities that exist and that is a good business principle. They came on board and an opportunity was created for young investors.”

This ultimately begs the question if this so called policy of the IDC is correct, especially as it had provided funding to Steloy Castings the company and also to the company’s BEE partners. The IDC is reportedly owed R20 million by Steloy Castings that ostensibly was funding to be used for the capital equipment purchases that were installed in the latter half of 2015. However, in the creditors list there is a capital equipment leasing company listed and other capital equipment in the foundry is known to be on a lease agreement.

The exact timing of these funding agreements is unknown but surely if the IDC has ‘invested’ such a large amount in a company it would conduct regular audits of the

company and not be surprised when the business rescue notice is issued by the CIPC. By that time it is too late and debts of between R120 and R130 million are not incurred overnight.

It has since been learnt that further funding was applied forfromtheIDCbuttheIDCconfirmedthatitwouldnotbewilling to grant additional funding to Steloy Castings. Due to the lack of operating capital, all production and trading activities of Steloy Castings came to a halt towards the end of September 2016.

It has also been learnt that numerous clients have subsequently cancelled their orders with Steloy Castings and have proceeded to uplift their patterns. This has resulted in the value of the order book dropping to approximately R2.5 million from a supposedly healthy order book of R85 million and a contract value of R1 billion, just for the railway business.

The power supply to the premises was also cut on 04 October 2016 due to the fact that the Mpumalanga Economic Growth Agency (Mega), who is responsible for

Questions need to be asked after Steloy Castings goes into liquidation

The demise of the 283-employee company leaves families, clients and suppliers angry.

The IDC also indicated that it would be willing to reconsider its position regarding funding. However, after various meetings took place by interested parties due to the high running and holding costs that would be required to sell the business

as a going concern, it was decided that this option was not feasible and hence the liquidation notice


the supply of power to Steloy Castings is owed a substantial amount of about R15 million. This has led to several incidents of theft from the Steloy Castings facilities, even though there is 24-hour security.

Third party investors have also expressed an interest in purchasing Steloy Castings as a going concern, and a period of two weeks was requested to conduct a due diligence. Two offers were made to the Business Rescue Practitioners. However, when the Business Rescue Practitioners requested payment into the trust account of its attorneys to determine whetherthefirstofferreceived would be viable and could be presented to creditors for acceptance, no payment was received. The second offer would require Steloy Castings to pay holding costs for a further two months before the offer could be implemented and, according to the Business Rescue Practitioners Steloy is not in a position to pay holding costs for a two month period.

The IDC also indicated that it would be willing to reconsider its position regarding funding. However, after various meetings took place by interested parties due to the high running and holding costs that would be required to sell the business as a going concern, it was decided that this option was not feasible and hence the liquidation notice.

As indicated earlier you have to ask yourself how such a large amount of debt can be incurred and why it was allowed to be incurred; were there not enough controls in place or was it bad business practice by the Directors? The outcome is that one of the largest stainless steel foundries in South Africa is now in liquidation. Suppliers, banks and other institutional lenders are now owed big sums of money and the suppliers in particular

will probably only get paid out 10 cents in the rand once the secured creditors have taken their share. The biggest losers are the staff at Steloy Castings and their families. While the reality of this bad news hits home just before the end of the year and the holiday period, others will not be affected drastically because they have taken care of themselves through complicated tools that allow them to do so in our law. The challenge is to negate these laws that make it ‘easy’ for one to wash ones hands of the situation and not be held responsible.


Over the years, Cape Town has evolved as one of the leading cities in South Africa for the

manufacture of bronze castings with a number of artists and foundries based in and around Cape Town.

Now the art scene has been boosted with the opening of a new Donald Greig Gallery that is situated in the vicinity of the recently revamped development of the historical grain silos and the Ocean Liner Terminal. The new cultural institution in the V&A Waterfront has as its main attraction the new Zeitz Museum of Contemporary Art Africa (Zeitz MOCAA), a major new cultural experience that will focus on collecting, preserving, researching, and exhibiting cutting edge contemporary art from Africa and its Diaspora. It is a unique not-for-profitpartnershipbetweentheV&A Waterfront and Jochen Zeitz, a German born philanthropist.

As a child, Donald Greig grew up on the Highveld and, as a result, was a huge lover of nature and animals. Over the years his interest grew and his desire to show these animals in some way or form resulted in his bronze sculpturebusiness.Hestartedsculptingin1993withhisfirstpiece being a small elephant that was later cast in silver. Greig’s intimate knowledge of animal anatomy and movement comesacrossineachsculpture.Eachoneisfilledwithsomuchdetail that it’s clear that a lot of time has been spent on both design and implementation. Look closely, and you can even see Grieg’sfingerprintinsomesculpturesaseachoneisdesignedand moulded by hand.

The more recent sculptures include leopards, rhinos and crocodiles, monkeys, tortoises, warthogs and meerkats. Greig has a particular passion for leopards and bronzes grace the halls of international and local collectors. Sculptures vary in size from small to life-size.

In 2009, together with his wife, Ali, Donald Greig opened a gallery in West Quay Road in Cape Town’s dry docks area of the V&A Waterfront, with an adjoining foundry. Donald Greig’s passion lies within the creation of bronze sculptures drawing his inspiration from Africa’s wildlife and his many safari experiences.

“Our gallery needed to grow and the associated foundry needed to expand. With this in mind, we started to look for new premises, which we found in the vicinity of the historical grain silos and the Ocean Liner Terminal that has recently been through a revamp and refurbishment to accommodate and promote the visual arts sector,” said

Donald Greig Gallery opens in V&A Waterfront’s new cultural institution

The new Donald Greig Gallery that is located in the V&A Waterfront near the new cultural institution - Zeitz Museum of Contemporary Art Africa (Zeitz MOCAA)

Access from gallery allows visitors to view foundry operations in real life.

A Donald Greig bronze -Leopard Scratching Post

A Donald Greig bronze - Life Size Warthogs


Ali Greig, who manages all aspects of the gallery.

“We have converted an “old port building” of 2800m² and have created a state-of-the-art New York styled warehouse. The new building includes two galleries and the new foundry.”

“Sculpture Casting Services is the foundry that we have always been associated with and they embraced the idea of setting up a situation where clients and the public can viewthefinishedartwhilealso being able to view the sculptures being manufactured.”

“As a result, we have created a viewing passage that is accessed from the gallery and visitors will be able to safely look in on every aspect of the work done in the foundry. This includes the preparation aspect of bronzes that features a 3D scanning and simulation space, CNC routing of moulds and components, 7-axis cutting with a Yaskawa robot and of course the lost-wax casting process and the fabrication of bronzes. A personal tour of the foundry can also be arranged.”

“The outcome is a visual experience that is unique to Cape Town and has created possibly one of the largest art foundry’s in the Southern Hemisphere. Our gallery occupies approximately

540m², the foundry 1 600m² and the remaining space is taken up by the other gallery - Harbour Gallery — which is an entity within the Sculpture Casting Holdings Group of companies.”

“This exciting new space includes antique artifacts that we retrieved from the grain silos, and with its close proximity to the V&A Waterfront’s new cultural institution and the rest of the Waterfront will guarantee good exposure for our work and unique

services of art foundries. It is said that there are twenty-four million visitors to the V&A Waterfront annually.”

“The overhaul of the facility included installing a pond in the gallery’s showroom that showcases Donald’s bronze-cast water birds and hippos, and building a raised deck with tables and chairs for clients to relax. The viewing platform allows visitors to watch live bronze pouring while different glass-walled rooms showcase the working environment of the metalworkers. It certainly will be a cultural rich experience for visitors and clients.”

For further details contact Donald Greig Gallery on TEL: 021 418 0003 or visit www.donaldgreig.co.za

An artistic vision of the new cultural institution


Theuniqueexperienceofviewingbronzesintheirfinalform as well seeing them being manufactured has become a reality with the opening of a 2800m² space

in the new cultural institution in the V&A Waterfront in Cape Town. The new building includes two art galleries (Donald Greig Gallery and the brand new Harbour Gallery) and a new foundry (Bronze Age Foundry: Sculpture Casting Services) that is said to be one of the largest art foundries in the Southern Hemisphere.

The conception of the new facility emerged when the Donald Greig Gallery was seeking to increase its exhibition space and the foundry owners needed to expand their manufacturing capabilities to accommodate the foundry’s ever-increasing order book. The outcome is a visual experience that is unique to Cape Town and will be a culturally rich experience for visitors and clients.

“We are very excited with the opening of this new facility and its unique concept that not only seeks to enhance the experience of visitors but gives us the opportunity to showcase our expanded and extensive manufacturing processes that we believe no other art foundry can offer in South Africa,” said Warren Knight, one of the brothers of the family business that was founded in the 90’s by Robert Knight, who was later joined by Warren and their other brother Bruce.

“With many sculptors looking to South Africa for quality foundry work and affordability due to the weakening rand we believe that we are now in a position to offer them a complete package, and more.”

“Sculpture Casting Services has grown from small beginnings tooneofthelargestfine-artfoundryand fabrication facilities in Africa. The business has seen some major transformations in the past few years culminating in the opening of the new foundry in the V&A Waterfront vicinity in October 2016.”

Sculpture Casting Services and Bronze Age Art Foundry team up to form Sculpture Casting Services Holdings

The new foundry and related servicesisthefirstopportunityforSculpture Casting Services and

Bronze Age Art Foundry to showcase their services as a result of their recent merger to form Sculpture Casting Services Holdings.

Bronze Age Art Foundry’s Otto du Plessis and Charles Haupt are responsible for A Modern Renaissance of The Bronze Age at their foundry in Woodstock, Cape Town. They created a creative community concept in 2012 when they opened up a new lost wax foundry in The Woodstock Foundry, a heritage building that had been renovated to combine the beautiful character and craftsmanship of the old world with the design and amenities of a modern world. With Bronze Age Foundry (formerly based in Simon’s Town) at its heart, The Woodstock Foundry at 160 Albert Road, Woodstock, Cape Town has a delightful mix of creative ateliers and stores. The ability for visitors to the building to view the working lost wax foundry in an operational environment while situated inaretailspacewasafirstatthetime.Thishasnowbeenextended to the V&A Waterfront facility but with added

services now on view.The concept for The Woodstock

Foundry is a creative community that brings together different design disciplines and makes them accessible to the public. It is a destination where you can have lunch or just a coffee, buy some furniture, visit a barber and buy a piece of jewellery for your wife and view a working lost wax foundry in operation, all under one roof.

During its history Sculpture Casting Services has been manufacturing bronzes for well-known sculptors and artists from around the world, casting from the smallest to the largest sculptures. Their ability to embrace and deploy innovation and the latest technology in the company’s manufacturing environment has enabled them to stick out amongst the crowd.

“We are not just a foundry / fabrication facility. We have used the latest technology available to increase our quality and offer more services that allow artists to express their visions without fear of failure,” said Warren Knight.

“One of our biggest enhancements was in 2013 when Sculpture Casting Services, Bronze Age and Preferred Solutions

Sculpture Casting Services and Bronze Age Art Foundry combine

to form one of the largest art foundries in the Southern Hemisphere

In the foundry at Sculpture Casting Services


formed a company — 3D Echo Tech — that uses cutting edge technology to assist anyone who requires accurate scanning and up or down scaling of sculptures. Our skilled team can replicate your design or artwork at virtually any scale you can imagine by 3D printing in plastic or powder. For larger pieces we can cut your artwork by CNC routing or robotic arm in styrene or polyurethane.”

“We can take a 70cm Marquette and scale it to the artist’s requirement and quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or “additive layer manufacturing” technology.”

“With the assistance of proprietary software packages such as Solidworks, Mach 3, ZBrush (a digital sculpting tool)

and Rhinoceros 5, a package that creates, edits, analyses and translates NURBS curves, surfaces, and solids in Windows, we are able to offer artists the assurance that their artwork will be created as they envisaged.”

“The other tools that we have at our disposal now include Creaform Go!SCAN, a 3D portable scanner that captures 3D data in full colour and Artec Space Spider, a high-resolution handheld 3D scanner based on blue light technology. These scanners are professional solutions for 3D digitising real-world objects with

complex geometry and rich texture in high resolution.”

The new foundry “The merger of Sculpture Casting Services and Bronze Age

Art Foundry and moving into the new facility in the

A large bronze in the final stages Madiba about to leave the factory


V&AWaterfronthasmanybenefitsforus.Ournewspace will make it easier for us to manage and assemble larger sculptures,” said Randell Maree of 3D Echo Tech, the company within the group that is responsiblefor3Dscanning,printing,filemodificationand archiving, CNC router services, reverse engineering, sculpture enlargement, rapid prototyping and custom architectural mouldings.

“We have ensured that this new facility has much more room than our facility in the Strand. The ceiling at the Waterfront facility has a maximum height clearance of over nine metres in places. This, combined with a muchlargerfloorspace,meansthatwecantakeonmuch larger projects than before.”

“The new foundry is now equipped with a new 120 kilogram induction furnace that has replaced an old diesel furnace. We have also installed a 3 tph continuous mixer that was manufactured by Lauds Foundry Equipment as well as a new Unicam CNC router. The existing equipment that includes the Yaskawa robot, the MakerBot Replicator 2 and Wanahao Duplicator 3D printing machines have also been relocated to the new facility.”

“We are now better equipped to produce the increasing number of quality large art scaling and movie set jobs that we have become known for.”

Improved cutting accuracy“As part of the move of our operation to the Waterfront

we have designed, had engineered and implemented a brand new bracket guidance system that allows us to rotate blocks with much better accuracy when cutting the reverse side of polyurethane blocks. We have also standardised the size of polyurethane blocks we cut to 1100mm x 2200mm or 1100mm x 1100mm as part of this change. In addition, we

have implemented an improved calibration procedure for our CNC’s and robot. As a result our completed jobs are much more accurate.”

Reduced machining costs“With improved calibration and better accuracy comes

reduced wastage and re-cuts. This translates into improved efficiencyandthereforeimprovedcosts.Wesee3DEchoTech as an extension of our customers’ operations so we are passing these cost-savings on to our customers to reward

them for their loyalty and to help them secure bigger and better projects.”

“This makes us one of the most versatile art foundries that is equipped with the latest technology at our disposal.”

Added features: In-house studio

“Many of our clients do not have studios large enough to accommodate the size of projects we cut for them. We have included someofourfloorspaceas a studio for clients tousetofinishprojects.This is especially convenient for clients who will have their projects moulded and cast in the foundry,” continued Warren Knight.

“Visiting artists will be able to work on the scaled detailed polyurethane armatures

weproducetofinishthemformoulding—completewithrotarytable and lift. This means that sculptors from abroad will now be able to plan working holidays in beautiful Cape Town, stay in the local hotels of their choice, eat at some of the best restaurants in the country, visit the many local galleries and studios and mingle with local fellow artists — all practically within walking distance from the projects they will be

A bronze lionbeing manufactured

The 8 metre lionready for shipping

More cutting with the Yaskawa robot

A polyurethane mould being cut by the Yaskawa robot


working on at our new facility.”

New Harbour Gallery“The second of the two galleries in the facility is our own

gallery. Harbour Gallery has been incorporated so as to make it available for both visiting and local artists to exhibit their work. This is going to be a huge bonus for them.”

“The close proximity to the brand new Zeitz Museum of Contemporary Art and the Donald Greig Gallery will make it a rewarding experience for both artists and visitors. We are also very excited to be part of this unique setup,” said Knight.

Sculpture Casting Services HoldingsSculpture Casting Services Holdings now includes the new

V&A Waterfront foundry and gallery, the Bronze Age Foundry in Woodstock,officesanddesignstudiointheStrand,WesternCape, branches in Somerset West and Nottingham Road (Natal Midlands), Fusion Five Art Foundry in the Strand and Art on Church Gallery in Stellenbosch. A new facility is planned for 2017 that will be located in Paardevlei, Western Cape.

For further details contact Bronze Age: Sculpture Casting Services on TEL: 021 418 0003 or visit www.sculpturecasting.co.za or www.3dechotech.co.za

Sculpture Casting Services manufacture many wildlife bronzes for various sculptors A bronze in the production stages


Mittal diluted in South Africaas elites get steel stake

A former government-appointed commissioner, a development-bankfinancechiefandanex-deputyfinanceministerareoncoursetobecomemajor

shareholders in ArcelorMittal South Africa, taking a chunk out of billionaire Lakshmi Mittal’s stake in the continent’s largest steelmaker.

Apportioning a 22 per cent stake valued at R2.3 billion ($168 million) to black investors, employees and communities is a way for the struggling company to support the government’s strategy of boosting black South Africans’ ownership of the economy.

While the company known as AMSA says the so-called black economic empowerment deal is “broad-based”, members of the country’s business elite will get 12 per cent of its equity, while workers and communities living near its operations will get less, sharing about 10 per cent. The producer scrapped a transaction in 2011 that would have benefitedPresidentJacobZuma’sson,Duduzane,afteropposition party and labour union criticism.

Black economic empowerment, aimed at redressing the inequality of whites-only rule that ended in 1994, has been criticisedforonlybenefitingasmall,oftenpolitically connected elite rather than the wider population, where the average annual household income is R120 000, or $8 771. After more than R600 billion of such deals took place from 1995 to 2013, Zuma’s government said it must do more to redistribute wealth.

Necessary evil“BEE is a necessary evil in a country like South Africa

toleveltheplayingfield,butthepolicydesignisdefective,”Mzukisi Qobo, an associate professor at the University of Johannesburg, said in an interview. “It encourages a gulf betweenthepoliticallyconnectedeliteswhobenefitthe most from these deals and the wider portion of South Africans.”

The steel producer will sell a 17 per cent stake to Likamva Resources and provide the black-owned company with a loan to cover its cost, Vanderbijlpark, South Africa -based AMSA said in a statement. The loan will be paid back through dividends over the next 10 years or through a higher share price. Should the company’s stock reach R27 a share after a decade, the whole loan will have been paid back, ChiefExecutiveOfficerWimdeKlerksaid.

Likamva will distribute a 5 per cent stake to local communities within two years, it said. Employees will receive a further 5 per cent stake through a separate trust.

Likamva, which means “heritage” and “future” in the Xhosa language, is owned by:

• NoluthandoGosa(40percent)-Shewasacommissioner who helped to design the National Development

Plan, which aims to eliminate poverty by 2030. She’s a non-executive director at Investec Asset Management and a former member of the South African Broadcasting Corporation’s board.

• LeslieMaasdorp(10percent)-Chieffinancialofficer of Shanghai-based New Development Bank, funded by Brazil, Russia, India, China and South Africa. Former board member of Barclays Africa and Telkom.

• ThembaHlengani(9.5percent)-AMSA’shead of corporate communications until December 2013.

• WarrenWheatley(11percent)-Chiefinvestment officerofTSSCapital,afinancialadvisoryfirm. He’s a former investment banker at Barclays Africa.

• OthersincludeJabuMoleketi(aformerdeputyfinance minister) and Yakhe Kwinana, who is on the board of President Jacob Zuma’s foundation and is a former board member of state-owned South African Airways.

“We wanted to partner with a consortium where it would not be - as it’s become known in the South African market - the ‘usual suspects’, where you are just perpetuating empowerment among certain regular participants,” AMSA Chairman Mpho Makwana told reporters in Johannesburg.

The company carried out “robust due diligence” on all the investors, he said. They had a good understanding of the steel business and had “chemistry” with the current board, he said.

Lakshmi Mittal, worth $12.9 billion according to the Bloomberg Billionaires Index, is the biggest shareholder in Luxembourg-based ArcelorMittal, which in turn is the majority owner of AMSA. ArcelorMittal’s stake will drop to 54 per cent from 69 per cent as a result of the BEE deal.

Price-fixingAMSA is on a charm offensive with the public and the

governmentafteradmittinginAugustthatitfixedpricesforyears on long-steel products and scrap metal. It has also pledged to cut pollution. The company has asked for, and been granted, protection from cheap Chinese imports which has decimatedearnings.AMSAhasn’tmadeaprofitsince2010and raised R4.5 billion from shareholders earlier this year.

Likamva started pursuing the deal with AMSA two-and-a-half years ago, before the company said it intended to put one together, Gosa said. She even followed Mittal to Davos, where the World Economic Forum takes place, but was told no asset was for sale. By the time the board took the decision in September 2015, “we already had a head start”, she said.

Asked whether the stake allocated to communities is sufficient,Gosasaid:“fivepercentofaR10.9billioncompanyis not small. In two years’ time, I’m sure the market cap will be higher.”

While the company known as AMSA says the so-called black economic empowerment deal is “broad-based”, members of the country’s business elite will get

12 per cent of its equity, while workers and communities living near its operations will get less, sharing about 10 per cent


The Unemployment Insurance Fund (UIF) has committed R11.9 million to the Manufacturing Engineering and Related Services Sector Education and Training Authority to

fund the training of 325 Scaw Metals employees for six months.This follows the approval

of Scaw Metals’ application to the Commission for Conciliation, Mediation and Arbitration, in March, when it faced possible retrenchments owing to difficulttradingconditionsin the steel industry.

Scaw Metals has receivedthefirstpaymentof R1.99 million from the UIF, which will be used to pay the salaries of 325 workers participating in the training lay-off scheme (TLS). The UIF will pay 75% of an employee’s basic salary up to a maximum amount of R 9 358 a month.

Inthepreviousfinancialyear, the UIF committed R46.3 million towards the scheme and paid R8.37 million to various companies participating in TLSes.

Labour Activation Programme chief director Mpumi Mnconywa noted that 2 703 learners have been registered in the previousfinancialyear,with some already having completed their training programmes through various sector education and training authorities.

Under the scheme, workers agree to forego their normal wage to attend the training programme and accept a training allowance during the training period. Employers gain a recovery period by reducing payroll costs for a stipulated period while improving the skills of their workers at limited cost to the company.

The UIF uses its excess funds to fund poverty alleviation schemes and, last year, allocated more than R400 million towards

the schemes. The fund has signed funding agreements with 23 technical vocational education and training colleges to train 356 learners in building and civil construction at a cost of R1.8 million for each college.

UIF commits nearly R12 millionto training scheme for Scaw Metals employees


It has been reported that Trade and Industry Minister Dr Rob Davies has announced the partial reopening of the popular Manufacturing Competitiveness Enhancement Programme

(MCEP), the Department of Trade and Industry’s (DTI’s) flagshipcross-industryincentivescheme,whichhasbeensuspendedsinceOctober2015,owingtoinsufficient funds.

Davies said the R1 billion loan component of MCEP was being reopened, while the DTI continued its discussions with the National Treasury on additional support for the manufacturing sector.

The MCEP was designed as an instrument to support enterprises in the production sectors of the economy soon after the onset of the global economic recession to weather very adverse market conditions, secure higher levels of investment, raise competitiveness and retain employment. It consisted of the Production Incentive that is administered by IDAD and the Industrial Financing loan facility administered by the IDC.

MCEP supported 1153 entities to the value of R7,2 billion with acquisition of capital equipment and reengineering of

business processes to improve their competitiveness under the Production Incentive, of which R4.1 billion has already been disbursed. The programme leveraged approximately R30.8 billion in private sector investment and retained over 200 000 jobs across all priority sectors.

TheIndustrialfinancingloanfacility,whichisadministeredby IDC, approved working capital loans to the value of R988 million of which 78% has been disbursed. A total of 1 553 jobs have been saved and 7 933 jobs have been created through this facility.

Thecurrentreflowsoftheindustrialfinancingloanfacilityallows for a re-opening of another window for pre and post-dispatch working capital loans, limited to R50 million for eachqualifyingmanufactureratafixedrateof4%perannum.In addition, the facility will provide funding of up to R50 million for plant and equipment to all qualifying start-up and existing Black Industrialist’s businesses at the same rate that is payable over a period of 84 months.

Entities can access the programme online at http://www.investmentincentives.co.za/mcep through the IDC website.

Manufacturing competitiveness enhancement programme reopened

The Minister of Trade and Industry, Dr Rob Davies says thatthemanufacturingsectoranddiversificationofthe economy is a key driver to attaining South Africa’s

economic growth objectives. Davies was speaking at the Manufacturing Indaba Western Cape held recently at the Cape Town International Convention Centre.

“We all know that the performance of our economy hasbeenflat,butweweresavedbythesecond-quarterGross Domestic Product manufacturing statistics. That was mainly through the implementation of a transparent localisation policy that we have developed, and this result also demonstratesthatmanufacturinganddiversificationofoureconomy is highly critical if we are to achieve our economic strategic objectives,” said Davies.

Davies also stressed that large parts of international trade were mainly focused on intermediate products. It is in this aspect where achievements have been realised mainlybecauseoftheunorthodoxdeploymentoffinancialtools.

“By the early 2000’s, domestic boatbuilding capabilities had hollowed out - with the exception of the luxury yachting sector.Governmentintroducedastrongerindustrialfinancinginstrument and boats were designated for local procurement. The sector is now witnessing the crowding-in of private sector funding and capabilities to meet demand both locally and internationally. The success of Nautic Africa, now part of the Paramount Group and Damen are testament to what can be achieved. A lot of effort has also gone into the clothing and textile clusters in the last decade in the Cape. The national governmenthasdeployedsignificantincentivestosupport,

amongst others, companies in this sector in the province. We have injected R2 billion in incentives over the last 5 years to support the industry and successfully raising productivity and competitiveness,” said Davies.

Davies also announced that the Department of Trade and Industry (the dti) was working on creating a dedicated agro-processing incentive to attract investment.

“This sector is critical because of its labour intensity across the value chain and its high economic multipliers especially with respect to exports. The incentive will contain strong conditions; including with respect to labour practices and empowerment. In this latter case it is imperative that the Western Cape embraces the effort to ensure that economic activity and economic growth is inclusive,” he said.

The MEC responsible for Economic Development and Tourism in the Western Cape, Mr Alan Winde said that the conferencefocusedspecificallyonagro-processingandoilandgas as they had demonstrated themselves to be key drivers that promote manufacturing.

“We have given ourselves a target of enabling 60 000 jobs in oil and gas at Saldanha Bay Industrial Development Zone. We are also doing work on skills, energy and for the removing ofadministrativeredtapethathamperstheflowofbusiness,”said Winde.

Winde added that the Western Cape had set itself a target of producing 32 500 apprentices in the next three years to work in the energy space and pleaded with delegates to makeuseoftheunitestablishedinhisofficetoremove red tape.

Manufacturing and diversification of economyis key driver to attaining economic growth — Davies


Mineral Zone, a specialist supply partner servicing the Metallurgical and Mining sectors in South Africa and internationally with a range of metals and minerals,

ore and services has recently been appointed as a distributor for SI Group HA South Africa and Capital Refractories Limited who are based in The United Kingdom.

“Mineral Zone, which was established just over two and a half years ago with my partner Adrian Pearson, has developed a successful track record of consistent supply and delivery during its relatively short history,” says Managing Director Brendan Homann.

“Through our experience and contacts we initially signed up distribution agreements to offer the industry foundry chrome sand, chrome ore, metallurgical chrome concentrate of all grades, chemical grade chrome concentrate, ferro alloys, recarburizer, ferro silicon magnesium, inoculants, zinc and specialised refractories, sourced both locally and from abroad.”

“We are also distributors in South Africa for refractory products produced by Norwegian Company, Elkem. These are their specialised silica based minerals such as Microsilica and the SioXX range of products for low and no cement castables. These include Sioxx, Sioxx Zero, Zioxx Quick and Sioxx Mag.”

“The Mineral Zone Export Division exports chrome ore of various grades, manganese ore and specialised industrial minerals.”

“Together with our partners, we specialise in domestic and international trade of consumables and specialised products for customer needs. Our international and local supply chain partnerships have strengthened our position in expedite delivery to our customers with sustainable and respected assurance.”

“The volume of specialised industrial minerals, alloys, foundry and steel plant consumables and ores that we supply has grown significantlyduring the company’s short history. Through our established relationships, we have developed partnerships with principles around the globe trusting us with their brands to penetrate the South African market, and this has resulted in us being appointed a preferred foundry distributor for the SI Group HA South Africa’s foundry products and Capital Refractories Limited, a specialist manufacturer of refractory linings and associated products for the metal melting, foundry, aluminium and cement industries around the world.”

SI Group HA South Africa“SI Group HA South Africa is a subsidiary of an

internationally recognised company. We represent and are distributing their foundry chemicals, coatings, resins and solvents. Our success is attributed to our relationships and partnerships and we strive daily to serve both our principles and customers in accordance with this philosophy.”

Capital Refractories Limited“Capital Refractories Limited manufactures a wide

range of dry vibration rammable products for lining coreless induction furnaces, vacuum coreless induction furnaces and channel induction furnaces for the melting of steel and high temperature alloys, iron, copper, bronze, aluminium and master alloys.”

“We complement this with a full range of ancillary products, including topping, monolithic linings for low and high temperature purposes, repair and patching materials, ladle castables and heat treatment furnace materials for ferrous and non-ferrous applications and installation equipment.”

“Capital Refractories pioneered the use of the permeable gas diffuser for use in the coreless induction furnace; this allows Argon to be purged directly from the base of the furnaceintothemoltenmetalpriortocasting.Benefitsinclude reduction of inclusions, gas holes, cleaner metal and improvements in refractory life.”

“Products are manufactured in the UK, USA, China, Taiwan, Indonesia, India and the Czech Republic. In short we

The Mineral Zone team Delene Homann, Adrian Pearson, Brendan Homann, Claude Du Toit, Simon Matshipa

and Sandy Bayne with Cyril Lepelletier (third from left) of Capital Refractories

Appointed distributors for SI Group HA South Africa and Capital Refractories.

Mineral Zone expands

Capital Refractories induction furnace linings


will now be able to include monolithic linings for induction furnaces covering all grades of ferrous and non-ferrous metal production, specialised cements for the aluminium industry specifictoallsizesofreverberatoryandrotaryfurnaces,liningpatching paste, graphite stopper rods, porous plugs and ladle castables in our product portfolio.”

Other developments“Besides these two new distribution agreements, we

have moved to a new 540m² factory/warehouse in Boksburg, Gauteng - a more centrally situated location for us to service our clients with our growing logistics infrastructure.”

“We would also like to welcome Claude du Toit to the Mineral Zone family. Claude has joined us as Sales Manager for our Foundry and Refractory division. Claude has an extensive and successful track record in the South African foundry industry and his return has been most welcomed by our suppliers and customers alike. We wish Claude every

success and his enthusiastic energy has rubbed onto all of us at Mineral Zone. This now takes our staff compliment to seven.”

Mineral Zone Safety Equipment “We have branded this side of the business Safety Zone.

Due to our vast base of varied customers extending from mining to foundry and automotive, refractory to chemicals and specialised manufacturing industries, in this day and age where health, environment and safety are so important, our customers’ needs are for a complete basket of requirements. Our health and safety services are complete and some of our products include hard hats, safety gloves, heat resistant overalls, chemical resistant gear, safety glasses, ear plugs, safetybootsandrespiratoryproductsallspecifictothefoundry, steel, welding and chemical industries.”

For further details contact Brendan Homann of Mineral Zone on TEL: 010 235 0046 or visit www.mineralzonesa.com

Uncompetitive scrap metal pricescausing further decline in industry

“Unless strong action is immediately taken to stem the export of scrap

metal and keep it in South Africa at competitive prices, the scrap beneficiatingindustrywillfurtherdecline and directly affect the aluminium sector,” said aluminium foundry alloys producer Zimco Aluminium Company (Zimalco) sales and marketing director Bob Stone in a recent Engineering News report.

“Owing to a high price for scrap metal and closures in the consuming industries,finaloriginal-equipment-manufacturer users are importing morefinishedproductsthatwereandshould be manufactured locally.”

“The effect on local industry can clearly be seen and has been adding to the current economic woes of South Africa. The local manufacturing of aluminium products can create jobs and assist government in achieving its National Development Plan goals, but, instead the current situation is further contributing to deindustrialisation.”

“Should deindustrialisation continue, the different uses of aluminium will be affected, as secondary aluminium produced from scrap metals is a necessity if South Africa is to have safe and drinkable water, a stable electrical distribution and steel industry, as well as a successfulautomotivemanufacturingandanefficientminingindustry,” Stone explained.

“Scrap aluminium is being exported because there is a high

international demand for scrap metal of all types from countries such as India,” Stone added. “Therefore, that should the exporting of aluminium, besides other metals, persist, the beneficiatingindustriesinSouthAfrica will further decline with the closing of businesses, subsequently resulting in further job losses,” warned Stone.

SO 50001:2011 certificationZimalco has recently been

certifiedtotheISO50001:2011Energy Management standard. Thiscertificationhighlightsthecompany's commitment to using its energyresourcesmoreefficientlyand managing and maintaining thesignificantenergyusersintheoperations.

Thisefficientuseofenergywillhave a positive effect on the Scope1, or direct, Greenhouse gas emissions, while a contribution to the Scope 2, or downstream Greenhouse gas emissions from energy suppliers is maintained.

The Steel and Engineering Industries Federation of Southern Africa (SEIFSA) earlier this year announced winners of its 2nd Annual Awards for Excellence. Zimco Aluminium Company, was declared the winner in the Most

Innovative Company of the Year category.For further details contact Zimalco on TEL: 011 914 4300

or visit www.zimalco.co.za

“Should deindustrialisation continue, the different uses

of aluminium will be affected, as secondary aluminium produced

from scrap metals is a necessity if South Africa is to have safe and drinkable water, a stable

electrical distribution and steel industry, as well as a successful automotive manufacturing and an

efficient mining industry,” Stone explained


ThefirstphaseoftheR49millionIsithebeIndustrialEstaterevitalisation in Mandeni, KwaZulu-Natal was launched in October 2016. Isithebe is one of ten industrial parks

that has been prioritised by the Department of Trade and Industry for upgrading under its Industrial Parks Revitalisation Programme.

“Thefirstphaseincludesthesecurityinfrastructureupgrade, fencing, street lighting and critical electricity requirements but, in the case of Isithebe, we have also upgraded the roofs of some of the factories within the industrial park,” Trade and Industry Minister Dr Rob Davies said in a statement.

He added that industries operating from Isithebe contributedsignificantlytotheeconomyofthearea,providing15 000 to 20 000 jobs.

These include textiles, clothing, weaving and dying, steel fabrication, furniture manufacturing, plastics, polypropylene bags, chemicals, paper products and packaging, foundry work,

white goods, workshops and engineering, foam manufacturing and conversion, plastic injection moulding and stationery.

KwaZulu-Natal MEC for Economic Development, Tourism and Environmental Affairs Sihle Zikalala noted that the Isithebe Industrial Estate was one of the largest in KwaZulu-Natal and was home to many industries and factories that have contributed to the growth of the provincial economy.

“The fact that so much investment is being injected into thisestateisnotonlyavoteofconfidenceinthegrowthprospectsoftheeconomyoftheprovince,buttestifiestothefact that, as government, we have placed reindustrialisation at the apex of our list of priorities in order to grow the economy and create employment,” he commented.

Davieshadannouncedthecompletionofthefirstphaseof revitalisation at the Free State-based Botshabelo Industrial Park, costing R24 million, and the R21 million Seshego Industrial Park, earlier this year.

DTI to launch latestindustrial park revitalisation

Electra Mining Africa 2016

More than 850 local and international exhibitors from the mining, industrial, electrical and power industries showcased their products and services across a

38 000m² indoor and outdoor exhibition area of Electra Mining Africa 2016 held in September at the Expo Centre, in Johannesburg.

The exhibition attracted international visitors seeking out local products, machinery, services and technology with just over 29 000 visitors attending.

Companies from the foundry industry that exhibited included Autocast Mining, Lauds Foundry Equipment/General Kinematics, HPT (Hot Platinum) and Scaw Metals.

Most metalworking related companies opt to rather exhibitat the upcoming Machine Tools Africa 2017.

Ali Brey and Dr Francois Koeslag, both from HPT (Hot Platinum)

Kevin and Nicole van Niekerk, both ofLauds Foundry Equipment with Davide Gado and David Kennedy,

both of General Kinematics


Foundry and engineering company Thos Begbie & Co has announced a number of changes to its senior management, including the retirement of company

joint CEO Edwin Dreyer and MD Eugene Rossouw. Joubert Groenewald replaces Rossouw as MD, while outgoing sales director Harry Muller is replaced by current sales managerPietduPreez,andfinancedirectorAntonMeerkotterbycurrentfinancialmanagerGabrielSekgwele.DuPreezandSekgwele will maintain their respective functions as sales managerandfinancialmanager.

Thos Begbie & Co human relations director David Fundzane continues in that position. Finally, Isaac Mogoba has been appointed foundry director and continues to manage the foundry as before.

“The Thos Begbie group, which was founded in 1887, has accumulatedasignificantamountofintellectualpropertyoverthe years that is vested in the people who have been working for the company,” said Dreyer.

“Many employees have been working for decades for the company, some as long as 40 years, and are approaching retirement age. To ensure that their engineering and technical expertise is not lost, it is important for the company to develop a succession plan to identify competent replacements who could continue the company’s success,” continued Dreyer.

“Tofindpeopleinourindustrywhoareexperiencedisalmost impossible. People with competency in manufacturing foundries, moulds and core technology is very rare. Thecompanyinvestssignificantlyinitsemployeesto ensure it retains its manufacturing and engineering competences.”

“We are on a constant programme of identifying talent to grow and developing that talent through training. To ensure that it maintains excellence in senior management, Thos Begbie had a succession plan in place to identify talented employeesinsales,manufacturing,financeandengineering.Candidates were selected and trained, which resulted in the identificationofGroenewald,Mogoba,DuPreez,Fundzaneand Sekgwele being appointed to the board of

Thos Begbie & Co.”“It is now time to allow for a new generation of bright

young stars to run the business,” said Dreyer.

Thos Begbie & Co announces retirement of Dreyer and Rossouw

New Thos Begbie MD Joubert Groenewald

Outgoing MD Eugene Rossouw and outgoing CEO Edwin Dreyer with Edwin’s wife Zonda, pictured at GIFA 2015


The following companies are thanked for sponsorship of prizes, tee boxes and greens: Adam Balances, Ametex, BSD Refractory Supplies, Ceramic & Alloy Specialists,

Chemsystems, Endeco Omega, FP Speciality, FosecoSouthAfrica,IMPScientific,InsimbiAlloySupplies,Insimbi Aluminium, Iscar Cutting Tools, JC Impellers CC, Lauds Foundry Equipment, Lil Sales, MCTS, Metal Connection, Mineral Zone, Mustang Foundry, Nicast, Procor Foundry Supplies, RelyIntraCast, SAIF, Saint Gobain Pipelines, SI Group HA South Africa, Spectech SA, Spectro Analytical, Thos Begbie, UJ, VIP Metals and Windsor Metals.

The competition on the day was four ball alliance with two scores to count.

The closest to the pin prizes on the 5th, 7th, 11th and

15th holes were sponsored by SI Group HA, Insimbi Alloy Supplies, Foseco and Chemsystems. The longest drive prizes on holes 4, 8 and 17 were sponsored by VIP Metals, Spectech SA and Lil Sales, respectively.

The competition was foreshortened because of the inclement weather on the day and as a consequence only nine holes were taken into account for scoring purposes. Withthefieldhavingstartedonfirstandtenththecompetitionresults become meaningless. Even so a score of 50 points was recorded for nine holes. That is some score for high handicaps.

The special prizes were handed out as well and here is a selection of the winners. Due to the inclement weather the longest drive prize on the 17th hole was not recorded correctly.

SAIF 2016 Annual Golf Day The South African Institute of Foundrymens' Annual Golf Day

took place on Thursday 10th November 2016.The event was held at the Reading Country Club.

Chemsystems sponsored closestto the pin on the 7th hole that was won by Joe du Bruyn.Lance Bell of Chemsystems, the new Director responsible for the foundry division was thereto hand out the prize

Francine Clark ofSI Group HA South Africa handedout the prize to Tommy Tomlinson

for closest to the pinon the 5th hole

Johan Nagel wasclosest to the pin on the 11th hole.

He is seen receiving his prizefrom Len Hutton

of Insimbi Alloy Supplies

Longest drive on the 8th hole was sponsored by Spectech

SA. John Taylor of Spectech SA was there to hand over the

prize to winner Dijon Brivik

It was a Foseco South Africa affairon the 15th hole. Closest to the pin wasWarren Zandberg (right) of Foseco.He is seen receiving his prize fromEnno Krueger of Foseco

Longest drive on the 4th hole,sponsored by VIP Metals,

went to Charles McGeer. He is seenreceiving his prize from the tall

Riaan van Tonder

Scrap metal dealer Ben Jacobs Iron and Steel has been finedR2.99millionafteradmittingtocontraveningtheCompetition Act by agreeing with its competitors to

fixpurchasingpricesofcertainferrousscrapmetalsandtoallocate suppliers among the large scrap metal merchants, according to Business Report.

Thepenalty,whichwasconfirmedbytheCompetitionTribunalfollowingahearing,amountstofivepercentof Ben Jacobs Iron and Steel’s total annual turnover related to ferrousscrapmetalinitsfinancialyeartoJune2006.

SettlementThe hearing is the last in a series of settlement

agreements reached between the Competition Commission and companies in the ferrous and non-ferrous scrap metal marketsthathadadmittedtoengaginginprice-fixing,dividingup the market and collusive tendering.

Sevenothercompanieshavetodatepaidfinesamountingto a total of R225 million related to these contraventions of the Competition Act.

The settlement followed an investigation initiated by the Competition Commission in August 2006 that emanated from alargemergerfilingtothecommissionin2005related to the proposed acquisition by the New Reclamation Group of SA Metal Group and its associated company, Waste Control.

Jabu Ngobeni, appearing for the commission, said it appeared from information requested from the parties that there was cartel activity in both the ferrous and non-ferrous scrap metal markets.

Ngobeni said the proposed acquisition was prohibited by the commission and it thereafter initiated a complaint against the New Reclamation Group, SA Metals, National Scrap Metal and Cape Town Iron and Steel.

He said the commission received further information pointing towards collusive tendering as a result of that investigation and had expanded that complaint to other parties.

Ngobeni said the commission also conducted dawn raids on the premises of New Reclamation Group all over South Africa and information from these raids resulted in the initiation of another complaint.

He said Ben Jacobs Iron and Steel was only implicated in price-fixingandmarketallocationwiththeNewReclamationGroup, Universal Recycling and Ton Scrap.

Ngobeni said the commission took a decision when the New Reclamation Group settled that it should pay six percent of its annual turnover and all the other parties involved would be given a discount on that.

He said all of the subsequent settlements with other implicatedcompanieswereatfivepercentoftheir turnover.

Ngobeni said the commission took a decision on the

percentage penalty to be imposed after looking at the history of how the conduct arose, although this could not be used as ajustificationfortheconduct.

Security of supplyHe said it was very clear and part of public record that at

that stage government itself through the Trade and Industry Department had requested the parties to meet because there was an issue around security of supply in South Africa, because companies were exporting scrap and not satisfying localcustomersfirst.

“When the commission brought it to the attention of government at the time that those discussions were in contravention of the Competition Act, government agreed and it stopped and discouraged the parties from engaging in these discussions.”

“At the time it was done, the parties had already implemented some of these arrangements,” he said.

Ngobeni said the commission took a decision on the percentage penalty to be imposed.

R2.99 million fine for scrap metal dealer


The settlement followed an investigation initiated by theCompetition Commission in August 2006 that emanated from a large merger filing

to the commission in 2005 related to the proposed acquisition by the New Reclamation Group of SA Metal Group and its associated company, Waste Control


international news

High performance casting specialist Grainger & Worrall (GW) is working in conjunction with Jaguar Land Rover (JLR) and the Advanced Propulsion Centre (APC)

to develop a new type of cylinder block that uses plasma coatings to reduce the weight and size of engines.

IdentifiedbytheAutomotiveCouncilasakeystrategicaimfor UK vehicle manufacturers, downsizing and light weighting are two challenges that are being addressed by GW’s work as part of the ALIVE6 consortium. Comprising Bosch (UK), UPA and Automotive Insulations, the group has demonstrated the inherent value of horizontal innovation — with partners from different disciplines sharing expertise and knowledge.

As part of the project, GW has developed the manufacturing process of an all-aluminium cylinder block onto which a low-friction, plasma metal coating can be reliably sprayed. This innovation removes the requirement of cylinder liners, which are replaced with the application of a plasma coating directly onto the parent cylinder bores.

Edward Grainger, managing director (prototype) at GW, said: “We have worked closely as part of the ALIVE6 team to develop a casting process and associated supply chain to support this leading-edge technology. Developing and manufacturing a cylinder block casting suitable for the plasma technology has required us to fundamentally re-assess the metallurgical properties of castings. This has involved us exploring elements such as the structural strength of the cylinders as well as the porosity and adhesive properties of the alloys to deliver a successful project outcome.”

Commentingonthebenefitsofcontributingtoprojectssuch as ALIVE6 Grainger, added: “The consortium has been an enabler to us in understanding how to design, develop and manufacture castings for the plasma spray process. Our involvement has created know-how and developed a supply

chain to deliver cylinder castings suitable for this exciting new technology.”

“This project has been valuable for the business, providinguswithasignificantleapforwardinourunderstanding of new casting methodologies. Such experiencefitswellwithourhigh-performancevehiclecustomers’ strategies, creating potential for us to apply such knowledge to other projects.”

Heconcluded:“Theplasmacoatingprocessfitsperfectlywith our vertically integrated manufacturing capability, which comprises CAD design, casting, machining, plasma coating, honingandfinalassembly.”

For further details visit www.gwcast.com

Grainger & Worrall pioneers engine blockinnovation together with JLR

A new ASTM International standard will help manufacturers and buyers who want to use 3D-printed stainless steel alloys that can be made more quickly

thanthroughtraditionalmethods.Thisnewspecificationdescribes chemical and mechanical requirements — as well as other properties — of additively manufactured parts made from 316L (UNS 31603), which is a widely used grade of stainless steel.

“Amongthecompaniesthatwillfindthestandardmostuseful are manufacturers willing to replace cast or wrought 316L parts and components, especially those with complex geometries, high inventory costs, or long lead times,” says ASTM member Dr. Amir Farzadfar, materials process engineer for Additive Manufacturing at Corning Inc.

“Also, regulatory bodies such as the American Society of MechanicalEngineerswillbenefit,sincetheavailabilityofthisstandardisthefirststeptowardtheASMEadoptionprocessofadditively manufactured parts,” Dr. Farzadfar added.

The standard, (soon to be published as F3184M, SpecificationforAdditiveManufacturingStainlessSteelAlloy(UNS S31603) with Powder Bed Fusion), was developed by ASTM International’s committee on additive manufacturing technologies (F42).

ASTM International also announced that it has hired its firstdirectorofadditivemanufacturingprogrammes (MohsenSeifi)tohelpsupportstandardsdevelopmentactivities and relationships in this fast-growing industry.

For more information, visit www.astm.org

New ASTM standard supports 3D printing of stainless steel alloys

Earlier this year Aston Martin confirmedGrainger & Worrall as its preferred engine castings supplier

for the new DB11, a luxury sports car powered by anewly developed 5,204-cc, twin-turbo V12 engine.

It is the first turbocharged vehicle Aston Martin hasdeveloped for series production


With an output of 42.7 million tons, Germany was the largest producer of raw steel

in the European Union in 2015. That makes the German steel industry an important economic factor, but it is also responsibleforasignificantamountof pollution. In fact, the industry accounted for 6.4 percent of Germany’s total carbon dioxide (CO2) emissions in 2014.

Low-CO2 futureThe problem with reducing steel

industry CO2 emissions, however, is that today’s production facilities can hardly be optimised any further. So what does the environmentally friendly, low-CO2 steel plant of the future look like? Siemens and various partner companies in the energy, chemical and steel industries are addressing this question in a joint project known as Carbon2Chem. This project, which is supported by a EUR 50 million grant from the German Federal Ministry of EducationandResearch,wasofficiallylaunchedin late June.

Climate-damaging smelting gases, such as carbon monoxide, hydrogen and methane, are produced in many parts of a steel mill. After steel production, these gases are burned in power plants to generate electricity. But the catch is that this process also generates CO2 emissions. Moreover, when excess wind and solar power are produced, it is not possible

to sell the resulting electricity to the grid. The approach being pursued by the Carbon2Chem project partners is therefore not to incinerate the smelting gases, but to convert them into reusable materials for the chemical industry.

In addition to Siemens, chemical companies such as Covestro, Evonik and Linde, with their extensive expertise, are also working on the project. Together, they are seeking to harness the simple principle of electrolysis, i.e., splitting

water into hydrogen and oxygen with the help of solar energy and wind power to produce chemicals such as methanol and other alcohols and polymers from hydrogen and smelting gases, so that steel mills that release practically no emissions can become a reality in the future.

Advantage: Expertise from the chemical industry

In the context of the project, Corporate Technology — Siemens’ global research organisation — is working closely with the company’s Hydrogen Solutions business segment. Carbon2Chem offers an opportunity to tap the expertise of chemical industry partners to generate new business opportunities for Siemens. In the case of steel production, Carbon2Chem could make a major contribution to worldwide decarbonisation. If the CO2 emissions of steel mills could be lowered to almost zero thanks to electrolysis, CO2 emissions could be reduced by up to 50 million tons per year. This isstilltheoretical,butthefirststepstowardpractical use have already been made.

German metallurgy new challenge:Steel production, without CO2 emissions

Can steel be produced without generating carbon dioxide emissions? Thanks to electrolysis, what seems unimaginable today could become a reality in the future.

Pictured is the Çolakoğlu Metalurji A.S. steel mill in Gebze, Turkey

Steel production is responsible for substantial quantities of carbon dioxide emissions. The joint Carbon2Chem project could make a major contribution to

worldwide decarbonisation


Stefan Weil, Minister-President of Germany’s state of Lower Saxony, and Dr. Carsten Kuhlgatz, CEO of Hüttenes-Albertus Chemische Werke GmbH, broke

ground on a new research and development laboratory in Hanover recently. HA has invested 8.5 million euros in the new project that will expand activities at the company’s Hannover, Germany site.

Withitsnewlaboratory,offeringupto50highlyqualifiedjobs, the foundry supplier is concentrating its German research and development activities in Lower Saxony’s state capital.

“Research and development are key factors for the future of our industry. They help us to better meet our customers’ requirements and to increase our competitiveness even further,” explained Dr. C. Kuhlgatz.

Leveraging creative potential“Until now, Hüttenes-Albertus has conducted

development activities at its Düsseldorf, Germany site. By merging research and development in Hanover, expertise can be pooled and the potential for innovation can be optimally exploited. Many developments in the foundry industry have their beginnings in Germany,” said Dr. Michael Arndt-Rosenau, Vice President of Research and Development at HA.

“So it is only natural that we base the core of our global research and development here, in the heart of the most technologically demanding foundry market. We want to develop new technologies and solutions for our customers that are in line with their needs.” The company has a global workforce of 130 employees in research and development.

For further details contact SI Group HA South Africa on TEL: 011 389 8200 or visit www.siigroup.com or www.huettenes-albertus.com

Hüttenes-Albertus invests 8.5 million euros in new research and development laboratory

Future Market Insights offers a 10-year forecast for the global primary magnesium market between 2016 and 2026. In terms of volume, the market is expected to

register a CAGR (compound annual growth rate) of 5.8% during the forecast period (2016 to 2026). This report provides market dynamics and trends on all seven regions, namely,AsiaPacificExcludingJapan(APEJ),NorthAmerica,Western Europe, Eastern Europe, Latin America, MiddleEast&AfricaandJapan,whichinfluencethecurrentnature and future status of the magnesium market over the forecast period.

Report descriptionThis Future Market Insights report examines the

'Global Magnesium market' for the period 2016 to 2026 in terms of value and volume. The primary objective of the report is to offer updates on developments in the global magnesium market and conduct quantitative as well as qualitative assessment of the market across various applications and regional market segments.

On the basis of application, the global magnesium market is segmented into aluminium alloys, die-casting, desulphurisation, metal reduction and others.

To understand and assess market opportunities and trends, the report is categorically split into sections such as market overview, global industry analysis, analysis by application and by region. Each section discusses the qualitative and quantitative aspects of the global magnesium market. To give a brief idea about revenue opportunities from various application and region/country, the report also provides absolute $ opportunity and total incremental opportunity for each segment over the forecast period.

The report starts with market overview and provides

marketdefinitionandanalysisaboutdrivers,restraints and key trends in the magnesium market. The sections that follow include global market analysis, by application and further by regional/country level analysis. All the above sections evaluate the market on the basis of various factors affecting the market, covering present scenario and future prospects. For market data analysis, the report considers 2015 as the base year, with market numbers estimated for 2016 and the forecast made for 2017 to 2026.

Read the full report: http://www.reportlinker.com/p03916530-summary/view-report.html

Magnesium metal market expected to register a CAGR of 5.8% in 2016 - 2026

The primary objective of the report is to offer updates on developments in the global magnesium market and conduct quantitative

as well as qualitative assessment of the market across various applications and regional market segments


Ambrell Corporation, a leading manufacturer of innovative induction heating solutions

worldwide, unveiled the world’s firstinductionheating“cobot”. The announcement took place at IMTS 2016 in Chicago, which is America’s largest manufacturing trade show with more than 2 000 exhibitors and attendance estimated to exceed 115 000 visitors at this year’s event.

A collaborative robot or “cobot” is a programmable machine that performs a variety of light industrial tasks, usually repetitive tasks, and interacts safely and efficientlyasitworkshand-in-handwithhumansina shared process. Using cobot technology, Ambrell has developedaninnovativesolutiondesignedspecificallytomaximise manufacturing throughput. Known as MAX by Ambrell, the cobot is integrated into the induction heating processforoptimisedproductionflow,increasedyieldsandgreater uniformity.

Jeff Kramer, Director of Product Management at Ambrell and the MAX project team leader, stated: “Withtheflexibility,portabilityandcost-effectivenessof

cobots in the manufacturing sector, Ambrell recognised how cobot-assisted automation could be designed and engineered into the heating process, especially for high mix, low volume production. And leaner applications requiring no human intervention can free-up workers to focus on utilising SPC data rather than simply collecting this data.”

The announcement of MAX was made by Tony Mazzullo, President and CEO of Ambrell. Commenting onAmbrell’sfirst-to-marketproductinnovation, Mazzullo explained: “The emergence of cobots as a new

productivity tool will substantially change the way companies work in small and medium sized enterprises (SMEs) and large factories. Using the MAX cobot heating solution, fast set-up times, intuitive programming, space-savingfootprintsandsignificantlylowersafetyrequirements will reduce the amount of time and labour required to meet production targets. Additionally, customers seeking ways to improve their competitive position will recognise a fast payback period coupled with a high return on investment.”

Robot optimises induction heating process

Using cobot technology,Ambrell developed an induction

heating system designed to maximise manufacturing throughput

Induction heating processes and technologies are used in many industrial sectors. Due to the permanently increasing requirements on the reliable high quality of the products,

on the effectiveness of the whole process chain, on the levelofflexibilityandautomation,ontheenvironmentalsustainability of the heating processes and last but not leastontheproductivityandprofitability,theimportanceof induction heating in industrial applications is continually growing.

In order to utilise the advantages of induction heating, particular knowledge of the physical basics of induction heating and thespecificprocess metallurgy, as well as knowledge of the set-up and operation

of induction heating equipment are indispensable. This book provides selected physical and technical basics of induction heating and informs in a practical oriented style, along with numerous application examples about the construction, the setup and design of up-to-date equipment and processes of induction heating used for forming, heat treatment, joining and cutting as well as for various special applications.

Furthermore, a separate chapter is devoted to the detailed description of power supply technologies of induction heating processes. The book is of particular assistance to users, manufacturers and designers of induction heating equipment, but also to engineers and students of pertinent specialisation.

For further information visit www.vv-publishing.com/induction-heating

New book: Induction Heating — Knowledge for practitioners

The award-winning designs for the Investment Casting Institute’s 15th Casting Design Contest were recently announced at the

63rd Annual ICI Technical Conference & Expo, in Columbus, Ohio, USA.

The annual contest seeks to identify the best work of the preceding year, works that succeed not only by the aesthetic achievement but equally or, more importantly, by the function they serve. The contest also expresses the necessity of investment casting in industry and society. After all, investment casters are the segment of the metalcasting industry that gives the highest emphasis to product design. Often, it is the possibility for complexity and virtuosity in investment casting that gives metalcasting an edge over welding, extrusion, or precision machining. In an age when design is gaining new relevance, with the prevalence of CAE and CAD, and the emergence of additive manufacturing, the investment casters are carrying a message for the rest of their metalcasting cohort: We can accomplish as much, now.

With this annual contest, ICI helps project a message of versatility by recognising designs for products developed for different industrial and commercial applications in aerospace, defence,fineartandothers.Thus,the scope of investment casting’s applications are highlighted and

celebrated.In addition, the winning castings project the

unity and precision of design that merely hints at the depth of engineering skill involved in linking the performance requirements to the material qualities available via the various alloys, and the design flexibilityoftheinvestmentcastingprocess.

And, of course, there is the beauty, some of which is in the eye of the beholder. If you’re an engine designer, you’ll see the value of thin walls and heat-dissipating materials. If you’re a vehicle or machine designer, you’ll appreciate the unity of forms and the simplicity of functions. And, of course, if you’re a metalcaster, you’ll see the timelessness of human ingenuity, earthly materials, and physical energy joined forever in a unique, and award-winning, investment cast part.

ICI’s 15th Annual Casting Design contest

This stator housing was designed and producedby Carley Foundry Inc. in A357 to replace a two-piece structure. Carley Foundry Inc. was awarded theAerospace award for this casting

Barron Industries was awarded the Defense

award. This casting represents a successful

conversion of a part formerly as two, separate

welded fabrications, 12 pieces in total. It functions as both an

engine mount and an alternator mount for a power pack used on a

new-generation armored personal carrier

Shellcast Inc. was awarded the Top Commercial Casting prize. The foundry was contacted by a

customer that indicated a need for a high-integrity component - a diving helmet - that they had concluded could not be made by fabrication

and/or sand casting


Aristo-Cast Inc. casts award to recognise "Fine Art Excellence". ICI chose Aristo-Cast to

produce an award - Fine Art Excellence - to acknowledge outstanding contributors to the investment casting industry and the Institute,

because of the company’s record for producing high-quality castings with intricate detail.Aristo-Cast brought the concept to life by

3D-scanning a foundryman outfitted in full safety gear, standing as a representation of

the prestigious award. The aluminium casting measures 70 x 210mm. ICI presents its

Hall of Honor Award each fall at itsAnnual Technical Conference

and Exposition

With this annual contest, ICI helps project a message of versatility by recognising designs for products developed for different industrial and commercial applications in aerospace, defence, fine art and others


A Ducker Worldwide study forecasts the aluminium content in cars to increase

by up to 30% over the next 10 years.

This surge is mainly from rolled and extruded products, where Auto Body Sheet leads the growth with an expected increase of 110% over the same period. The growth is largely attributed to aluminium’s role in lightweighting cars, thereby contributing to low emission mobility.

The amount of aluminium used in cars is expected to see asignificantincreaseby2025,according to a study recently published by consulting and researchfirmDuckerWorldwide.The study, commissioned by European Aluminium, predicts that the aluminium content of cars produced in Europe could reach nearly 200 kilograms per vehicle by 2025, up from 150 kilograms currently.

“We expect the aluminium content in cars to continue its growth trajectory by as much as 30% in the next ten years,” stated Wouter Vogelaar from Ducker Worldwide.

“Althoughwefindtotalcontentgrowthinallformingprocesses, rolled and extruded products have been particularly identifiedasreplacingsteelinmanyinstancesforproductsused in body closures and body structures. For example, we expect the use of Auto Body Sheet to double over the next decade.”

Carmakers’ preference for aluminium is largely linked to its lightweight nature, contributing to CO2 reduction. Due to its inherent strength and its excellent ability to absorb crash energy, well-engineered aluminium car parts can be both safer than steel and up to 50% lighter.

Lighter cars substantially contribute to reducing CO2 emissionsandimprovingfuelefficiency.Infact,using

200 kilograms of aluminium in a car could reduce CO2 emissions by up to 16 grams per kilometre travelled. With the 2014 average at 123g/km, increasing the aluminium content incarscouldplayasignificantroleinenablingtheEUtoachieve its target of 95g/km by 2021.

“Withoutlightweightcarstherecanbenoenergyefficientmobility. Aluminium is therefore an integral part of the EU’s transition to a low carbon society,” said Dieter Höll, Chairman of the Automotive & Transport Board at European Aluminium. “We hope the European Commission’s strategy to decarbonise transportwillstressthebenefitsoflightweightmaterialssuchas aluminium.”

Ducker Worldwide also found that the share of rolled productsgrewsignificantlyinthelastfouryearsduetothe increased penetration rate for body closures and body structures. The share of forgings and extrusions in the total aluminium consumption remained relatively stable.

The study includes data from automotive companies and suppliers, European Aluminium member companies

and past Ducker Worldwide data. It is based on a detailed analysis of the use of

aluminium castings, extrusions, forgings and sheets for

33 component groups across a sample of 93 car models, subsequently extrapolated to the entire 2016 production forecast in EU 28.

The public summary can be found here:

http:// european-aluminium.eu/

media/1719/european-aluminium-ducker-

study-summary-report_10-august.pdf

Aluminium in cars up 30%


The average recycling rate for aluminium closures in Europe has increased to more than 50%, according to figuresreleasedrecentlybythe“AluminiumClosures

— Turn 360°” campaign by the European Aluminium Foil Association.

Much of this improvement is due to national initiatives and better collection and recycling schemes across Europe, according to the Association.

Aluminium closures, mainly used on bottles of wine, spirits, water and olive oil, can be collected either with the mixed packaging fraction or together with the glass collection stream. Thanks to modern processes the aluminium is easily extracted and recycled, from both material streams.

Because packaging collection and recycling systems in Europe vary considerably from country to country, national initiatives are proving to be most effective. For example, the UK’s “You Can Leave Your Cap On” scheme has enabled local authorities to increase the recovery of aluminium closures for recycling. Initiated by ALUPRO, in partnership with British Glass and EAFA, it encourages recyclers to screw the closures back on their empty bottles before recycling so that more aluminium can be successfully recovered.

Sharing best practices in the European network of

aluminium packaging recycling organisations, ALU DK initiated a similar project in Denmark with the “Keep the Cap on” campaign, supported by the Danish government. Other national organisations like CIAL in Italy increasingly refer to aluminium closures in their general and special announcements to raise the awareness that aluminium closures are perfectly suitable to be collected and recycled.

Commentingonthefigures,EAFA’sClosuresGroupChairFranco Bove said, “It is encouraging to see the industry continues to support national initiatives which enhance the collection and recycling of aluminium closures. Recycled aluminium is a valuable commodity, so supports the economics of the recycling process.”

These aluminium closure recycling rates are calculated on the basis of publicly available national overall aluminium recycling rates, plus consumption data from market research companies.

Over past two years Poland's foundry industry has advanced to become one of the major sectors of the Polish economy. The global tendency is that the number

of orders for castings has been increasing and that translates into high production volumes in foundries. Most developed countries have attached increased attention to environmental problems. Some investments have moved outside the "old" Western Europe to Poland for example.

The 73rd World Foundry Congress will take place in Krakow and it will be complemented with Kielce's foundry expo - METAL.

The World Foundry Congress in Krakow will include lecturesandscientificpresentations.Kielcewillbethestagefor companies to present numerous developments and cutting-edge solutions. 2018's Poland-staged WFO Congress will be the only congress over the next few years to be held in Europe. In 2020 the World Foundry Congress will be held in South Korea and 2017 will see the Technological Forum in Africa. Therefore in two years' time, the Krakow Congress will be the only European event of this magnitude.

More information can be found on the website: www.73wfc.com

Set to take place from 23 to 27 September 2018 in Krakow, Poland.

Polish Foundrymen’s Association to host 73rd World Foundry Congress — "Creative Foundry"

Every second aluminium closure in Europe is now recycled

product review

The newly developed release agent Ecopart H-INO 50, which is suitable for all inorganic core and mould-making processes

such as the Inotec system, impresses due to its application properties while at the same time being free from any harmful constituents and solvents.

The release agent Ecopart H-INO 50 has been specially developed for inorganic core and mould-making processes. The foundry supplier from Hilden, which rolled out the Inotec system in 2005, has focused its knowledge and expertise onthefieldofinorganicstodevelopapowerfulrelease agent for inorganic core and mould-making processes.

Ecopart H-INO 50 is an eco-friendly water-based emulsion and dispersion of release-active substances and additives,

which is virtually odourless even at temperatures of 200 °C. The new release agent requires no special labelling and is free from any harmful constituents and solvents.

The excellent creep properties of the highly effective release-active substances contained in the formulationalsoguaranteethatdifficult-to-access delicately engraved areas can be reached and thus allow shakeout of even the most complex models to occur with ease.Theuseofspecialadditivessignificantlyprolongs the life of the release agent on the tooling, saving material costs on the one hand and processing steps on the other. Depending on the tool and mould, the new release agent has up to four times as long a service life as comparable release agents for inorganic core and mould-making processes.

Experience also shows that Ecopart H-INO-50 wears away evenly on the tooling over time, preventing material build-up. This makes regular cleaning of the tools and moulds easier. Finally, due to its economical use, a perfect surface to the produced cores is achieved.

With the development of the new release agent Ecopart H-INO 50, ASK Chemicals is bringing another product to the market that effectively manages the balancing act between environment and workplace compatibility, on the one hand, and the strictest foundry requirements, on the other. The product is already now being successfully used at prestigious automotive foundries just a short time after its market launch.

For more information contact ChemSystems on TEL: 011 922 1600 or visit www.chemsystems.co.za

ASK Chemicals successfully rolls out new release agent for inorganic processes



Altair reveal new design processes and software tools for additive manufacturing

At this year's formnext 2016 in Frankfurt, Germany Altair presented the latest versions

of its simulation software suite HyperWorks® 14.0, concept design and optimisation tools solidThinking Evolve® as well as Inspire® 2016, highlighting new design processes for the development and manufacturing of innovative products.

Highlights were Altair's Simulation-driven Innovation™ approach, the development process chain of the Airbus APWorks' Light Rider, the world'sfirstprototypeofa3Dprintedelectric motorcycle, the 3D printed antenna bracket by Ruag Space and the entire development and manufacturing processes of a cast aluminium component, developed jointly with Altair's partners HBM nCode and voxeljet.

The frame design of the Airbus APWorks' Light Rider that was displayed at the event is an excellent example of the symbiosis of topology optimisation and additive manufacturing. Its structure is based on optimisation results generated with Altair's OptiStruct® technology, supported by HyperMesh® for pre-processing tasks such as meshing, and HyperView® for post-processing the analysis results. All products are part of the HyperWorks CAE simulation suite. Applying a typical topology optimisation

OptiStructrun,theAPWorksengineersfirstdefinedthedesign space (areas where the optimisation technology can andcannotremovematerial,suchasfixingpointsoraccessholes) and applied general loads and boundary conditions. The optimisation software then created a design proposal that fulfilledtheframe'sstructuralrequirements,bygenerating

highly innovative geometries.The cast aluminium component displayed

was designed and optimised with Inspire, then nCode DesignLife was applied to conduct a fatigueanalysisandfinallysolidThinking'sClick2Cast® software was used for a casting simulation. The created design resulted in a casting mould, 3D-printed by voxeljet. This processensuredthatthecomponentbenefitedfrom all of the positive characteristics 3D printing and casting offer.

"Additive manufacturing (AM) is making headlines across industry as companies discover andtakeadvantageoftheinherentflexibilityas well as the potential weight advantages the method offers, when combined with design optimisation techniques. The example of the Light Rider shows when topology optimisation and additive manufacturing are combined, it is possible to produce a structure that is lighter and stiffer than a traditionally manufactured part,” said Mirko Bromberger, Director Marketing and Additive Manufacturing Strategies at Altair Engineering.

For further details contact Fiona Richardson or Gronum Smith of Altair South Africa on TEL: 021 831 1500, email [email protected] or visit www.altair.com

The example of the Light Rider shows when topology optimisationand additive manufacturing are combined, it is possible to produce a structure that is lighter

and stiffer than a traditionally manufactured part

A collaboration of cutting edge technology and companies, anthropometry, and years of experience has led to the unveiling of the new Robot Bike Co. R160 mountain bike

frame — designed and manufactured in the UK with partner companies Altair, HiETA Technologies and Renishaw using metal additive manufacturing (3D printing)

Typically, during the development phase, the freedom to make improvements to rigging is in practice reduced to a small

number of real trials and is limited by the effort connected with the changes.

As opposed to real-world trials autonomous optimisation using simulation toolsprovidessignificantadvantagesinthethoroughness of the search for solutions and in the speed of the search. It can also handle many interconnected variables at the same timeandautomaticallyranktheirinfluenceonthe outcomes.

Autonomous optimisation allows for thesimultaneousmodificationofmanyparameters. As well, the quality criteria resulting from the changes can be individually and quantitatively evaluated. Combined with established tools from statistical design of experiments, casting process simulation can be used to autonomously optimise casting processes and designs.

The software follows several targeted outcomes simultaneouslyandfindsthebestcompromisebetweenthembasedonfirstprinciples.Theautomatedassessmentofallsimulated quality criteria automatically throws up the most successful design candidates for consideration by the methods engineer.

The casting process simulation tool MAGMA5 can be used to ensure optimised and robust casting layouts and process windowsbeforethefirstmetalispoured.Thesoftwaresearches

for the best possible process parameters, optimal runner and gate positions and dimensions, as well as locations and sizes of risers and chills. Foundry engineers can use autonomous optimisation as a virtual fieldforexperimentation,tosimultaneouslyachieve different quality and cost targets.

The goal of retaining the user-friendliness of the simulation tool while integrating this new methodology was achieved through the implementation of capabilities for parametric geometry creation and automatic parameter variation, together with tools for statistical analysis of autonomous designs of experiments

and genetic algorithms for autonomous optimisation. The simultaneous assessment of the derived results enables the foundry engineer to easily compare and evaluate outcomes from numerous simulations. Dependencies between design and process variables, quality criteria and objectives are clearly visualised.

Thirty years after the introduction of casting process simulation, foundry engineers now can combine single simulations, autonomous DOEs and autonomous optimisations to gain better process understanding and to establish robust casting processes making quality castings at the lowest possible cost.

For further details contact Ametex on 083 306 1867 or visit www.ametex.co.za

Simulation evolves to optimisation — MAGMAsoft

ThenewTracer5iisreconfiguredtobemorepowerful,flexibleandfullyfieldinteractive,whileretainingtheunique features and comprehensive analytical software

that the Tracer is recognised for. Bruker’s new Tracer 5i synchronizes power, function,

precisionandaccuracytoprovidedynamic,fieldcapableelemental analysis from everyday point-and-shoot testing to the ever-changing challenges and complexities of advanced applications and research.

The new Tracer 5i retains the trademark ability to use an air, vacuum or helium beam path and to interactivelycontrolpower,filters,collimatorsand atmosphere, along with comprehensive data analysis capabilities to provide the ultimate in on-site interaction for faster analysis at lower LODs, especially for light elements like sodium.

The new analytical software preserves the Tracer’s comprehensive analytical software features for complex materials, but has a more streamlinedworkflowandadditionallyincorporatesEasyCalsoftwaretoprovidesimplecorrelationfitsfor standard materials.

Whether it is in art conservation and archaeology, for teaching, in food safety and

agriculture applications, for geochemistry or advanced materials, Tracers can thoroughly and accurately analyse the elemental composition and identify standard or complex materials.

Tracers can analyse multiple sample types, including liquids, slurries, powders, soils, sediment, sludge, cellulose, polymers, paper, solids, metals and alloys.

Specialist calibrationsThe Tracer can be equipped with calibrations that allow you

to measure metals (including precious metals), ore and mineral samples, and many other types of sample.

Available calibrations are as diverse as the list of applications, but if you have a desired application

that is not offered as an existing calibration, IMP is able to customise a calibration to perfectly suit your requirements.

For more information, contact your nearest IMP Branch, Gauteng TEL: 011 916 5000, KwaZulu Natal TEL: 031 764 2821,

Western Cape TEL: 021 852 6133, Eastern Cape TEL: 041 364 2544, Free State TEL: 018 293 3333 or email [email protected] or visit the website www.imp.co.za

Tracer 5i handheld XRF spectrometerBruker introduces the next generation Tracer handheld XRF spectrometer ideal for

methods development, research and complex materials.



Kerphalite™ KF for special applications in the foundry industry — Hüttenes-Albertus

Complex cast parts such as turbocharger housings play a central role in the design of modern high-performance engines. Due to its particular characteristics silica sand

has its limits as a moulding material when it comes to casting finelystructuredcomponents,reducedwallthicknessesandperfect surfaces. Thanks to its high temperature load strength and a strong resistance to metal penetration, Kerphalite™ KF, a special sand, has proven itself suitable for these types of applications in many foundries.

In central Europe, silica sand is available in large quantities and in good qualities, and is widely used in foundries as an economical basic moulding material. But it also has negative properties, which may lead to problems when producing sophisticated castings. These particularly include the so-called quartzinversion,i.e.theabruptexpansionofthespecificvolume at 573°C. It occurs during virtually every casting process and may lead to sand expansion defects, mainly in the formoffinning(alsocalledveining).Themouldingmaterialcancrack under high temperature load, allowing liquid metal to seep into the resulting cracks and cavities.

Suitable alternative for silica sandFoundries aim to avoid these casting defects and reduce

the costly effort needed to rework the casting. This is all the more important when considering that casting geometries

are becoming ever more complex and the demands for their dimensional accuracy and surface quality are becoming ever more exacting. If foundries want to avoid using more binding agents or adding gas-forming additives, they need a suitable alternative to silica sand as a moulding material. Kerphalite KF is a special sand with low thermal expansion, high refractoriness and a special grain geometry that enables very high core surface densities.

From stalky crystals to a special sand Kerphalite KF is a natural material based on andalusite and

processable with all binder systems and moulding processes. Kerphalite KF has a low density (similar to silica sand) and can be used in pure form or as a blend with silica sand, as required. When blended, the share of Kerphalite KF should be between 30 and 100 percent. In this way, the user is able to adjust the sandblendtobebothcost-effectiveandprocessefficient.The special moulding material is easily processable with all common binder systems. It is suitable for the Cold-Box as well as for the shell moulding process or the furan resin processes in iron as well as in steel castings. Kerphalite KF has also been used for 3D printing cores for over ten years.

For further details contact SI Group HA South Africa on TEL: 011 389 8200 or visit www.siigroup.com or www.huettenes-albertus.com

ABB Robotics has unveiled its latest foundry robot for material handling and machine tending, the IRB 1200 Foundry Plus 2. The smallest foundry robot

initsclass,thiscompactrobotcanincreaseflexibilityandreduce cycle times for precision die casting processes such as smart phone cases and other electrical components.

Now protected with Foundry Plus 2, ABB’s optional protection system, the IRB 1200 can withstand harsh environments and meets the requirements of protection ratings IP66/67. The IRB 1200 Foundry Plus 2 is IP66/67 compliant from base to wrist, meaning that the robot’s electrical compartments are sealed against liquid and solid contaminants. ABB Foundry Plus 2 robots are also unique due to their superior resistance to corrosion and capability to withstand high-pressure steam washing.

“Foundry robots have long contributed to the productivity and speed of heavy-duty metal casting and automotive applications, and are now becoming increasingly important in consumer electronics applications to cast light weight metals,” says Dr. Hui Zhang, head of product management, ABB Robotics. “This robot will allow our customers to increase productivity, deliver better work piece quality and reduce cycle times.”

First introduced in 2014, the IRB 1200 comes in two variants which can handle a wide range of applications and

are cost effective due to commonality of parts. The 700mm reach variant can carry a payload of up to 7kg, while the longer reach 900mm variant can carry up to 5kg of payload.

The IRB 1200 is also available with Clean Room protection.

For further details visit www.abbrobotics.com

ABB Robotics’ new IRB 1200 Foundry Plus 2 is the smallest foundry-duty robot in its class, and is expected to increase flexibility and reduce cycle times for precision diecasting processes, for example

ABB introduces IRB 1200 Foundry Plus 2, smallest foundry robot in its class

Documents

vol 17 no 4 - Castings SA SA... · global marketplace Add-on investment criteria • Market proven engineered products, well positioned in regional or niche markets and/or key accounts