EDITOR'S COMMENT
Indian foundries need to consolidate for achieving better techniques & enhancing efficiency
There exists limitless opportunities in every industry. Where there is an open mind, there will always be a new frontier. The theme for the recently held World Foundry Congress in Chennai was 'Cast for competitive edge'. The main aspect that came out of the conference discussions was in order to sustain continuous growth in every aspect; the foundry industry in the country has to embrace change mainly in the areas of change to technological innovation, adaption of newer and advanced techniques, change to improved manufacturing practices to enhance cost-effectiveness and change to upgrade human resource skills.
FOUNDRY APPLICATION
Strategies and methods for foundries
In 1999 the European tool and die making industry reached an annual turnover of more than 8 billion Euro [VDMA 2000].
Foundry applications make up 40% of this turnover. Consequently the tool and die making for metal casting applications forms
an important element of Europe’s manufacturing industry. Today Japanese and U.S. tool making industries have a competitive advantage over their European competitors in terms of efficiency. The Japanese achieved a 32% higher added value per person and year in 1998 compared to Germany [Sengebusch 2001]. With regard to the global competition the need for improvements in Europe is obvious.
News Corner
- High revenue losses due to corrosion observed in India
- Bharat Forge -NTPC joint venture to come up
- Tata-ISRO to launch Hydrogen-powered vehicle
- Ashok Leyland to partner with Alteams Group of Finland
- Eicher-Volvo Joint Venture to proceed
IN FOCUS
Prediction of burn-on and mold penetration in steel casting using simulation
Burn-on (also known as burned-onsand or burnt-on-sand) and metal penetration are common surface defects encountered in sand casting of steel. The Glossary of Foundry Terms defines burned-on sand as “A misnomer usually indicating metal penetration into sand resulting in a mixture of sand and metal adhering to the surface of a casting. Sand adhering to the surface of the casting which [sic] is extremely difficult to remove.
SPECIAL COVERAGE
Metal Casting - Industry of the future
Cast metal products are found in 90 percent of manufactured goods and equipment. From critical components for aircraft and automobiles to home appliances and surgical equipment, cast metal products are integral to our economy and our way of life. The U.S.
metal casting industry is the world’s largest supplier of castings, shipping cast products valued at over $18 billion annually and directly employing 225,000 people. Metal casting companies are often at the heart of the economy in the communities where they reside. Of the 2,950 metal casting establishments located throughout the United States, over 80 percent are small businesses.
TECHNOLOGY FOCUS
Improved Corrosion resistance of alumina refractories
In order to increase the efficiency of advanced coal-fired power systems, higher working fluid temperatures must be reached. Some system surfaces will have to be protected by covering them with corrosionresistant refractories. Corrosion is the degradation of the material surfaces or grain boundaries by chemical reactions with melts, liquids, or gases causing loss of material and consequently a decrease in strength of the structure. In order to develop methods of reducing corrosion, the microstructure that is attacked must be identified along with the mechanism and rates of attack. Once these are identified, methods for reducing corrosion rates can be developed.
TECHNOLOGY/PROCESS REVIEW
Energy conservation in Indian Foundries: planning and methodologies
In most Indian foundries, the area of energy consumption ios a confusing and little studied area. So it is required to cover the following key elements like performing energy audits and determining the gaps, gathering energy conservation ideas, selecting and prioritising projects and charting the course of improved energy performance.
|
IRON & STEEL REVIEW