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Foundries, Forges and Die-Casting

Cast process ensures cost-effective production

     10th March 2017 High pressure die-casting provides the shortest route from molten metal to completed component and comprises injecting molten metal into a hardened steel mold and allowing it to solidify under pressure before ejection, says casting supplier MRT Castings, based in Andover, England. 

Conference to broaden industry’s business opportunities and technology horizons

By: Simone Liedtke     10th March 2017 Owing to foundries in South Africa being isolated in their approach to problem solving, the South African Metal Casting Conference (MCC) will serve as a platform to broaden the industry’s horizons by showcasing new technologies, and providing opportunities for international and local foundry... 

Conference to broaden industry’s business opportunities and technology horizons
DALMARI MCQUEEN Owing to the interest in exhibition spaces at the 2013 pilot conference, the 2017 MCC will have 28 exhibition stands

Deep surface salt bath hardening technique offered locally

By: Simone Liedtke     10th March 2017 Diversified manufacturing facility Frankwen Forge is now offering a unique tailor-made salt-bath hardening technique, the company states, explaining that the surface of the item is run through heated molten salt and then undergoes a water quench. 

Deep surface salt bath hardening technique offered locally
INCREASED PRODUCTION The facility will be able to produce ingots of up to 12 t in various grades of carbon and alloy steels

Die-caster prepared for next growth cycle in industry

     10th March 2017 An increasing number of car parts such as engine blocks or structural parts are being manufactured from aluminum using high-pressure die casting, says die-casting technology supplier Bühler Die-Casting. 

Early signs pointing to recovery in foundry industry 

By: Simone Liedtke     10th March 2017 With the foundry industry having been under pressure last year owing to very low levels of economic growth, the drought and continuing import leakage, the South African Institute of Foundrymen (Saif) believes that signs to date this year point towards some form of industry recovery. 

Early signs pointing  to recovery in  foundry industry
Saif CEO John Davies and Saif president Takalani Madzivhandila discuss the challenges of the foundry industry. Camerawork: Nicholas Boyd. Editing: Lionel da Silva

Forging market for automotive application to be valued at $56-billion by 2022

     10th March 2017 Market research company Zion Market Research has published a new report highlighting that the global steel forging market for automotive applications was valued at $41.77-billion in 2016 and is expected to reach $56-billion in 2022, growing at a compound annual growth rate (CAGR) of 5.1% between... 

Forging market for automotive application to be valued at $56-billion by 2022
Photo by Duane Daws
INCREASED DRIVE Increasing cars sales are expected to drive the European automotive and automotive components market within the forecast period

Foundry process developer expands wafer-fabrication facility

     10th March 2017 Specialty foundry process developer and fabricator Noel Technologies has expanded its wafer-fabrication facility in Silicon Valley by adding square footage and installing additional equipment that boosts its production capacity by 25%. 

Foundry process  developer expands  wafer-fabrication facility
Photo by Duane Daws
EXTENSIVE CAPABILITIES The foundry’s extensive process capabilities enable short manufacturing lead times while improving device yield and performance

Industrial manufacturers to implement energy management systems

By: Simone Liedtke     10th March 2017 The National Cleaner Production Centre of South Africa (NCPC-SA) is assisting industrial manufacturing companies – such as foundries – to develop and implement energy management systems (EnMS) in line with ISO 50001 through its EnMS training programme. 

Industrial manufacturers to implement energy management systems
FAITH MKHACWA EnMSes are not ‘one-off’ projects, but rather need to becontinuously implemented on site

Metal casting technology station provides added value for industry 

By: Simone Liedtke     10th March 2017 As a means to add value to the casting industry in South Africa, the Metal Casting Technology Station (MCTS) – located at the University of Johannesburg (UJ) – provides technical services such as testing, failure analyses, research and development (R&D) work in laboratories, as well as product... 

Metal casting technology  station provides added value for industry
Former MCTS station manager and MCC Core Committee member Farouk Varachia and current MCTS station manager Kulani Mageza discuss the skills gap and current technologies in industry. Camerawork: Nicholas Boyd. Editing: Lionel da Silva

Trial castings successfully completed at foundry

By: Simone Liedtke     10th March 2017 Engineering solutions provider Weir Minerals successfully completed trial castings on new materials for the business’s Trio product range at its Heavy Bay Foundry, in Port Elizabeth, last month. 

Trial castings successfully completed  at foundry
RAPID PROTOTYPING Investments in the rapid prototyping process have enabled the foundry to make new patterns to manufacture parts

Cost reduction an option for survival

By: Sascha Solomons     8th April 2016 Nonferrous metal and plastic component manufacturer Wam Metals is acquiring robot automation of a forging press to reduce operational costs and improve output. Wam Metals will be in production for 30 years this year and has plans to continue operations as well as make use of opportunities to... 

Cost reduction an option  for survival
Photo by Wam_Metals_Robot_welding
WAM METALS Acquiring robot automation to reduce operational costs and improve output

Forging opportunity amid economic decline

By: Sascha Solomons     8th April 2016 Although the state of the forging industry has resulted in businesses having to reduce production, diversified manufacturing company Frankwen Forge says this has presented it with an opportunity. “The economic downturn has meant that there is a lack of major capital projects  coupled with an... 

Grain refiner breakthrough for magnesium alloys

     8th April 2016 Through the process of high pressure die casting, or direct-chill casting, of aluminum-containing magnesium alloys, scientists at Brunel University, in London, have perfected the first ever grain refiner master alloy for magnesium-aluminium alloys. A team led by Dr Hari Babu Nadendla from the... 

Grain refiner breakthrough for magnesium alloys
DR HARI BABU NADENDLA Scientists at the Brunel University, have perfected the first ever grain refiner master alloy for magnesium-aluminum alloys

Hope for aluminium casting industry

By: Sascha Solomons     8th April 2016 The Aluminium Federation of South Africa (Afsa) believes that potential for growth of the foundry industry currently lies in the automotive sector, as this is the largest market for aluminium castings. “Legislation worldwide is driving automotive companies and original-equipment manufacturers to... 

Hope for aluminium casting industry
Photo by Reuters
ALUMINUNUM GROWTH The aluminium foundry sector produces about 5 000 t/y of components

Potential growth in technology 

By: Sascha Solomons     8th April 2016 Amid the economic downturn and lack of skills in the foundry industry, the South African Institute of Foundrymen (SAIF) believes that growth opportunities for the industry lies in embracing technological development that will create new market opportunities. “To become more competitive, we, as an... 

Potential growth in technology
Photo by Cumulus
SURVIVAL OF THE FOUNDRY INDUSTRY To be more competitive the industry has to strive to be technologically advanced to cater for new market demands

Technology ensures efficiency for foundry industry

By: Sascha Solomons     8th April 2016 The future of the local foundry industry is promising, owing to technological advancements which accelerate turnaround times, says local castings supplier NI-Foundry, previously known as Guestro Casting and Machining.  

Technology ensures efficiency for foundry industry
EFFICIENCY INCREASED Technological advancements result in quicker turnaround times

Auto components crucial for aluminium industry

By: Dylan Slater     10th April 2015 South Africa’s automotive sector is currently one of the key drivers of aluminium demand in the country, which stakeholders attribute to the global trend of manufacturers using an increasing amount of aluminium for vehicle components, particularly for passenger vehicles. 

Auto components crucial for aluminium industry
VISION 2020 The aluminium industry is embarking on a strategy aimed at doubling the volume of cars manufactured a year in South Africa by 2020, from 600 000 to 1.2-million

High Duty Castings

     10th April 2015 Established in 1991, privately owned South African foundry High Duty Castings (HDC) has provided its customers with more than two decades of quality components. The company prides itself on having close relationships with its clients, 40% of whom have been loyal customers since HDC’s inception.... 

High Duty Castings

Hope for dwindling foundry industry

By: Dylan Slater     10th April 2015 The sustainability of South Africa’s foundry industry can be maintained if stakeholders shift their focus to upgrading equipment and technologies, boosting skills development and reducing imports, says foundry industry body the South African Institute of Foundrymen (SAIF). 

Hope for dwindling foundry industry
INDUSTRY HOPE There is some optimism from industry regarding an increased allocation for infrastructure developments from government

Local foundry benefits from State rail expansion

By: Dylan Slater     10th April 2015 State-owned rail utility the Passenger Rail Agency of South Africa’s (PRASA’s) rail expansion and renewal project is prompting much-needed large-scale orders for the casting industry, which is encouraging Bronkhorstspruit-based specialist foundry Steloy Castings to invest in new equipment... 

Local foundry benefits from State rail expansion
NEW EQUIPMENT Steloy has upgraded its design, project management, castings, machining and nondestructive testing facilities

Programmes set to bridge widening skills gap

By: Dylan Slater     10th April 2015 Initiative of the Department of Trade and Industry (DTI) the National Foundry Technology Network (NFTN) last year updated several industry-focused skills development programmes to bridge the widening skills gap and mitigate the effects of an ageing industry, as many skilled foundrymen are nearing... 

Programmes set to bridge widening skills gap
BRIDGING THE SKILLS GAP The National Foundry Technology Network offers programmes aimed at developing students’ skills from a basic foundry level through to a qualified artisan level

Bright future for multifaceted foundry industry, despite decline  

By: Jonathan Rodin     11th April 2014 The metal-casting industry has experienced a period of decline, with several closures of foundries in recent years. However, the recent signs of economic recovery in Europe and North America, the continued strong growth of the African continent’s economy and the weakening of the Rand, are all... 

Bright future for multifaceted foundry industry, despite decline
SAIF CEO John Davies discusses tackling the forging industry’s challenges and Viking Foundry operations manager Greg Estman discusses the foundry.

Company commissions new coatings plant

By: Jonathan Rodin     11th April 2014 A coating preparation plant (CPP) and dip tank were installed and commissioned by local foundry consumable supplier Foseco – the foundry division of Vesuvius – in January, says Foseco South Africa sales and marketing manager Enno Krueger. There is a continuing requirement for foundries to... 

Forging company improves BBBEE rating

     11th April 2014 Steel and steel product manufacturer Scaw Metals Group has been awarded a Level 3 broad-based black economic empowerment (BBBEE) rating, emphasising its commitment to being a responsible corporate in South Africa. 

Forum tackles industry challenges

By: Jonathan Rodin     11th April 2014 The New Foundry Generation Forum, launched in August last year, enhances a chosen group of young leaders in the foundry industry, identified and selected by a committee. The forum aims to develop skills in the industry by dealing with problem- solving, productivity, quality, cost and delivery... 

Foundries get competitive boost from network

     11th April 2014 One of the most significant steps in many years towards assisting local aluminium foundries to compete in the highly competitive global market, has come in the form a benchmarking programme for a selected number of foundries by the National Foundry Technology Network (NFTN), which is partly... 

Foundry training centre begins training candidates

By: Jonathan Rodin     11th April 2014 Gauteng’s first foundry training centre was officially launched in September last year at the Ekurhuleni East College (EEC) for further education and training in Kwa Thema, Springs, to create a hub for foundry-related skills training and technology transfer. The first intake of apprentices... 

New machine increases forging company’s forging capability

     11th April 2014 Product supplier and manufacturer Frankwen Forge installed a four-axis computer numerical controlled machine during the late last year, says Frankwen Forge sales manager Vince Horsburgh. He says that the machine enables the company to machine complex, integrally reinforced lip-type nozzles, final... 

Steloy

     11th April 2014 Steloy Castings, which was founded in 1984, is a specialist foundry group based in South Africa, supplying static and centrifugally cast components for heat, wear, corrosion and abrasion resistance to a myriad of local and international customers. From its three foundry complexes, including two... 

Steloy

Solutions to survive electricity crisis presented

By: Sashnee Moodley     12th April 2013 Foundries need to ensure energy efficiency without compromising production to deal with rising energy costs in South Africa. 

Foundries must collaborate, cooperate to combat industry challenges

By: Sashnee Moodley     12th April 2013 The local and international foundry sectors need to work together to deal with the challenges that affect the industry, as every foundry faces these challenges, says industry-led, government-funded National Foundry Technology Network (NFTN) project leader Adrie el-Mohamadi. 

Foundry waste beneficial to other industries

By: Sashnee Moodley     12th April 2013 The foundry industry is one of the greatest recyclers; however, it generates many waste products that end up in landfills when, in fact, they can be used in several applications, says US Department of Agriculture research soil scientist Robert Dungan.  

Material efficiency can improve energy efficiency

By: Sashnee Moodley     12th April 2013 Improved understanding of material efficiency at different stages of the casting process and the associated energy and operating materials required at each of these stages can be used to gather important information needed to promote efficiency improvements at foundries, says local consultancy... 

Metal casting a global growth market, but challenges remain

By: Sashnee Moodley     12th April 2013 Global metal casting production is expected to reach 115-million tons by 2015, but the role South Africa plays in the global industry continues to decline. 

New range of furnaces enters local industry

By: Sashnee Moodley     12th April 2013 In light of the electricity supply constraints in South Africa, the new-generation energy efficient induction tilt melting (ITM) range of furnaces from induction-heating solutions company Hot Platinum (HPT), was launched to the foundry industry in January. 

New range of glass tempering furnaces launched in SA

     12th April 2013 A new range of energy efficient glass tempering furnaces, from glass processing solutions company Cooltemper, has been launched in South Africa to provide glass processors with broader options when choosing machinery. 

PE foundry acquisition to support global growth objectives

     12th April 2013 Global minerals solutions supplier Weir Group announced that it would purchase the Port Elizabeth-based Xmeco Foundry, which will form part of their Weir Minerals Africa business unit.  

SA foundries follow global trends – conference

     12th April 2013 Delegates at the 2013 South African Metal Casting Conference, held in the North West, between March 13 and 16 heard that the challenges faced by foundries in South Africa are not unique in the global context and that growth in the industry will come from closer attention to the needs of foundry... 

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