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Metal Casting Technologies : June 2006
BRIEFINGS very relevant to the developing situation in Thailand where there is a need to provide much wider and more advanced testing facilities especially for automotive and consumer goods parts. He outlined the history of testing in Europe, gave examples of past and present work at BAM, and discussed budget and funding matters for testing centres in general. In the second talk Mr. Funahasi of Corrpro Companies Inc., Ohio looked at practical corrosion engineering to prevent and tackle corrosion problems in built structures, roads and in plant and equipment. Using a wide variety of real situations he stressed the importance of design, maintenance and the correct application of corrosion protection measures, in particular showing examples of correct and incorrect use of impressed current cathodic protection. It would be an interesting exercise to find out how much the lack of adequate anti-corrosion measures in production plants was costing the foundry industry each year In the Metals sessions all the papers on cast metals were on Aluminium Alloys, for example: ● Influence of residual Ti and B on grain refinement of recycled Al-7Si-0.3Mg alloy. ● Extraction of Al from its dross by fusion with sodium hydroxide. ● Hot tearing and its prevention in D.C. billet of high strength Al-Mg-Si alloy. ● Numerical analysis of near net shape continuous casting of aluminium. Likewise in the Heat and Surface Treatment sessions the only casting alloy covered was Aluminium in papers on: ● Effect of solution treatment times on properties of Al-12Si-2.5Cu-1Ni alloy. ● Fatigue lifetime improvement of Al alloys by mechanical surface treatment. These sessions included a number of papers on techniques to improve die and tool life using surface treatments such as VC coating using TRD process, nitriding by direct current plasma, super-hard Ti/TiB2 multilayer coatings and plasma spraying. Awards for best papers on Surface & Heat Treatments were sponsored by Thai Parkerizing Co. Ltd that is part of the Nihon Parkerizing Group of Japan. The group now has three plants in the area around Bangkok and recently celebrated its 25th Anniversary in Thailand. To mark this silver event Thai Parkerizing is providing eight undergraduate scholarships in science and metallurgy for Thai students at universities in Thailand. The company is also supporting special seminars in Surface Engineering, and an annual student lecture competition. For the first time this year a Parker Chair Professor Award has been set up to fund research in surface or heat treatment at a Thai university. The first recipient is Dr. Patama Visuttipikul in the Dept. of Metallurgical Engineering at Chulalongkorn University for a study on improving the properties of hot work die steel grade H13. Ausmelt wins major contracts in China and Korea Ausmelt Limited in Australia has won two new major contracts in the Chinese copper industry and another in Korea for the construction of two furnaces for zinc production. This adds to previous contracts for five new non-ferrous smelting projects -- 4 in China and one in Japan Ausmelt will provide technology for two new copper smelting plants, one which will be built by Chifeng Jinjian Copper Group (Jinjian) at Chifeng, Inner Mongolia in China. The smelter will be designed to treat 480,000 tonnes a year of copper concentrates to produce around 120,000 tonnes a year of copper contained in matte. The other will be built by Huludao Nonferrous Metals Group (Huludao) at Huludao, Liaoning Province in China. The new plant will replace two existing blast furnaces with expanded capacity. The contract is unique in that Huludao will use a carbon residue material from its existing zinc retort operation to fuel the Ausmelt process. The retort residues are currently dumped and the combination of dramatic reductions in emissions from the blast furnace operation and the use of the retort residues make this a ground-breaking project from an environmental viewpoint. Design work will start immediately. The smelter will be designed to treat 500,000 tonnes a year of copper concentrates to produce around 100,000 tonnes a year of copper contained in matte. Ausmelt has also signed a contract with Korea Zinc co for the construction of two new Ausmelt technology furnaces at its zinc production facilities at Onsan in Korea. Korea Zinc is the world's largest producer of zinc metal and is widely recognised as a low-cost zinc producer with a reputation for successfully adopting leading-edge technologies. The two new furnaces will be built at Onsan to recover lead and zinc from up to 120,000 tonnes per annum of zinc leach residues. CEC Installs Roller Hearth furnace in China In April, PAT Dalian, a subsidiary of PBR International, signed a contract with Consolidated Engineering Company (CEC) to install a 3 Position Continuous Roller Hearth Furnace in their Dalian, China aluminum casting production facility. This furnace will enable the company to solution heat treat and age their brake calipers directly after casting, making the manufacture of their braking systems more efficient. The Roller Hearth Furnace that is being installed at PAT Dalian will garner a continuous throughput of cast brake components at a temperature of 535° C for solution and 70° C for age. PBR International is a subsidiary of Pacifica Group Ltd and is Australia's leading supplier of brake system technology specialising in the development of braking systems for OEMs in Australia, North America, Europe and Asia and the supply of replacement brake components METAL Casting Technologies June 2006 12