Metal Casting Technologies : MCT-DEC-2014
16 www.metals.rala.com.au METAL casting Technologies December 2014 17 BrIEFINGS BrIEFINGS particularly for the Melt Shop, Foundry and machine shops.” SFIL has previously worked with SMS Meer, a world leader in the production of metals processing and manufacturing machinery to produce a broad range of technically challenging, ultra-large castings including the world’s largest single casting for a closed-die forging press - weighing in at 325 tonnes. Energy saving with improved solid forklift tyres A research group headed by Dr. Pairote Jittham from the Natural Rubber Focus Unit at MTEC-the National Metal & Materials Technology Research Centre has received an Outstanding Research Award presented by the Thailand Research Fund for work on developing energy saving solid tyres for forklift trucks. Deformation and abrasive wear of the tyres during service can be reduced through improved rubber formulation and tyre design. Reduced deformation decreases energy losses through the tyres giving a 23% in energy consumption when compared to existing tyres. In field tests the new tyres also gave much better wear lives of up to 70% improvement for front wheels and up to 55% for the rear. The group estimates that use of the new tyres in Thailand could save up to 60,000 Baht per forklift over a year. First edition of Magma News in Thai Following the opening of a new office and training centre in Bangkok under M5 Engineering (Thailand) Limited, Magma Engineering Asia Pacific is to issue a monthly newsletter in both Thai and English language to Thai foundries. Issue No.1 in September reported on the first User Group Meeting Thailand held in Bangkok during March 2014 which was attended by over 60 delegates from 25 companies. The 2nd Meeting will be held on 12th March 2015, again at the Dusit Princess Hotel. rösler expands in India A new manufacturing facility was opened in Pune, India. The opening was celebrated with a traditional ceremony attended by the employees of Rösler India together with Mr. Stephan Rösler majority shareholder and chairman – and Mr. Sandeep Gulati -- partner in this joint venture and managing director of Acton Finishing Ltd. UK. This facility with attached office space represents a significant expansion of the Rösler operations in India, R Rösler SurfaceTech Pvt, Ltd in Bangalore. In the new premises with a manufacturing area under roof of 2,680 m2 (26,800 sqft), including a test lab and job shop as well as office space of 240 m2 (2,400 sqft) standard shot blast machines and rotary vibrators will be manufactured. The first pieces of equipment have already been produced. It is planned to exclusively utilize the German equipment designs and adapt the manufacturing process to the Indian facility including the search for local component suppliers. This is an important strategic step with the goal to successfully compete with Indian low cost equipment suppliers and to gain a dominant market position in India and South-East Asia. dates for rOBOTECH announced ROBOTECH, an exhibition on next- generation service robot manufacturing technologies will be held with Nano Micro Biz along with OPIE – OPTICS & PHOTONICS International Exhibition. The shows are scheduled to take place from 22 – 24 April 2015, at Pacifico Yokohama in Japan. ROBOTECH introduces the elemental technologies which support the practical application and advancement of next generation robots (service robots), a field in which MEMS devices are applied as sensors. Service robots, which can compensate for low birth rates, aging populations and labour shortages, are the second largest growth field after the motor industry. For further details on ROBOTECH, please visit the official website at http://www.micromachine.jp/en/ Trial of thermocouple assembly delivers promising results for global automotive component manufacturer Trials of an alternative thermocouple sheath have delivered significant cost and time savings for a components manufacturer. In tests carried out at its plant in Aurangabadin India; High Technology Transmission Systems Pvt Ltd found that thermocouple assemblies supplied by Morgan’s Molten Metal Systems business outlasted the manufacturer’s estimated operational life as well as the existing solutions available to the company. High Technology Transmission Systems (HTTS) is part of the Endurance Group, a supplier of aluminium castings for the automotive sector with 19 plants across India, Italy and Germany. A high-performance die casting (HPDC) operation, HTTS produces cast aluminium clutch assemblies and other cast components. The company approached Morgan looking for improved performance for the thermocouple assemblies used for the continuous measurement of the temperatures in its holding furnaces. HTTS has been using two different types of assemblies, both of which had inherent shortcomings. One is an L-shaped CI tube which lasts an average of seven to eight days. Although a low-cost option, this type of assembly requires a protective coating, which represents additional work, while the subsequent chance of metal contamination, which is very high, could compromise the quality of the end casting. The second product being used is silicon nitride (SS316) which, although it has a recommended operational life of nine months, carries a high purchase cost and has considerably lower impact resistance, making it very vulnerable to breakage during the aluminium pouring process. The trial involved Morgan’s Blue Lightning thermocouple sheath supplied as a complete pyrometer assembly, which was installed in a 500kg furnace. The recommended life of the Blue Lightning is 42 to 48 days, but at the end of the 122-day trial, the sheath was still fully functional and capable of continuing in operation. HTTS maintenance manager Sambhaji Bachkar, who oversaw the trial, says: “The thermocouple assembly performed well throughout the trial, maintaining and controlling the temperature in the holding furnace. When we removed it from the furnace, it was still in good condition, with no signs of deterioration.” The Blue Lightning delivered a number of benefits for HTTS, as Ramdas Chitalkar, Technology Manager at Morgan Advanced Materials explains: “Apart from the extended life of the product, it proved to be a cost-effective solution in a number of other ways. There was no need for any additional coating, which requires time and manpower, so changeover time is reduced, and there is no danger of metal contamination, which has an impact on the end quality of the casting, so the risk of rejects is minimised.” Tea with two sugars please! These extraordinary images of a cup, saucer and spoon with two lumps of sugar is a ductile iron casting moulded and cast by master moulder Rick Teudt from a normal cup, saucer, spoon and sugar lumps found in the foundry kitchen. While having a cuppa with a foundry colleague Rick was challenged to create these moulds by his visitor who had seen the article in the September edition of MCT about the cast chain Rick had made. Rick is a mature age foundry supervisor at an Australian iron and steel foundry, with over 50 years of experience including training apprentices and managing his own foundry business. After accepting the challenge Rick said, “It’s been many years since I dusted off my old moulding tools, but the old trade skills are still there. I may be a bit older and slower now but I only needed one go at making it. When you get into the twilight years it’s important to get it right the first time, anyhow in the old days we rarely had to have two goes at a job”. We at MCT say ... job well done Rick! Vale John Adlard Nev Murray, President Australian Master Patternmakers Association Inc. Sadly we report the passing of John Adlard a great foundry industry identity who died on 27 October 2014, aged 93. John Adlard served his apprenticeship as a patternmaker at Hadfields Steelworks in 1938 and started his master patternshop in Kirrawee NSW in 1949. John jointly founded the Australian Master Patternmakers Association in 1965 and was an active member until recent years. John was a long serving member of the Australian Foundry Institute as a committee member and a foundation member of Sutherland Rotary Club. John is survived by his wife Lois, son Rodney, daughter Kerri and grandchildren. He will be remembered and sadly missed by all who knew him.