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Metal Casting Technologies : June 2008
BRIEFINGS at a nominal cost. This is the biggest investment by Government of India in Coimbatore after Independence. Beneficiaries of COINDIA: The Country’s major requirement of water lifting pump sets is being produced in Coimbatore region. Foundries are the supporting industry for the production of Motors and Pumps. This foundry industry has grown well and is reputed for its quality and reliability through out India. Both the Motor Pump and Foundry industry are doing business of around Rs.3200 crores per annum and providing employment to around 1,00,000 people. While both the sectors have grown to a large extent, the industry as such is facing stagnancy in growth due to foreign competition and lack of current technology. There is no opportunity for many companies to access the latest technology as most of them are in tiny and small scale sector. These companies are not in a position to invest in developing new designs, technology up-gradation, skill development for workers and infrastructure to sell their products in International markets. Moreover, the foundry industry is forced to shift their units to outside city limits to protect the environment of the city. COINDIA has been established to overcome these challenges faced by the motor, pump and foundry industry. www.coindia.in NEW ALUMINIUM RECYCLING PLANT IN THAILAND Alva Aluminium Ltd and Furnace Engineering Pty Ltd have recently completed a state of the art aluminium recycling plant in the industrial belt in eastern seaboard of Thailand. The complete facility was built in record time on a green field site in 154 days, from ground breaking to first cast. The plant is designed to initially process 100 tonnes of commercially available aluminium scrap over 24 hours. Further details of the plant and process appear on page 22. 10 www.metals.rala.com.au DOUG MAXWELL HONOURED FOR ACHIEVEMENTS TO FOUNDRY INDUSTRY Doug Maxwell, Managing Director of Steele and Lincoln Foundry in Victoria, Australia has been inducted to the Victorian Manufacturing Hall of Fame Honour Roll. The Victorian Government, in partnership with the Manufacturing Industry Consultative Council, selects individuals or organisations that have made outstanding contributions to sustained manufacturing excellence in Victoria to be acclaimed on the Manufacturing Hall of Fame Honour Roll. The award was presented by the Minister for Industry and Trade, Theo Theophanous at the Manufacturing Hall of Fame dinner in Melbourne on May 19th.Doug now joins only 19 others to have been inducted into the Hall of Fame Honour Roll. His induction is in recognition for his achievements in manufacturing and for the passion and dedication that he has demonstrated to the foundry industry in particular. found to contain a manufacturing defect. The USAF allowed the defect to stay in the aircraft because fixing the parts would result in unacceptable costs and delays. There is no safety- of-flight issue. However, Boeing will have to carry out more frequent inspections because of the potential for catastrophic failure in flight. Although Lockheed Martin is the prime contractor on the F-22, Boeing was the subcontractor which built the Raptor wings and aft fuselage. From 2000 through 2005, Alcoa supplied Boeing with forged titanium parts meant to provide structural support in a section of the aft fuselage that connects the wings to the fuselage. Failure in these parts could result in the wings being ripped off in flight. The support parts needed to be heat-treated in a furnace during manufacturing under precise conditions. This procedure would have strengthened the metal’s microstructure. According to Boeing, Alcoa failed to follow the procedure, neglecting to add an extra 20 minutes in the furnace. This meant the forging was not properly completed. This increased the rate of crack growth, reducing the damage tolerance life of the parts. Rosemary and Doug Maxwell with his award DEFECTIVE TITANIUM PARTS Boeing has sued Alcoa for US$12m in costs for providing defective titanium aircraft parts. The crucial titanium supports in the United States Air Force (USAF) F-22 Raptor fighter jets were Alcoa delivered 695 forged titanium support parts. Of the 459 forgings inspected so far, 71 were defective. Although the companies attempted to use a reheating procedure to fix the parts, the process caused metal distortion and was too costly. The inspections and the failed reheating procedure development cost Boeing US$5.3m. In a settlement with the USAF, Boeing was required to perform $6.4m worth of extra work at no cost. Boeing says Alcoa should reimburse these extra costs, plus legal fees. Alcoa acknowledged the defect present in the parts, but said it would defend itself in court. (Source: Metalworker newsletter)