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Vol 61 � No. 3 � March 2015Indian Foundry Journal 3


Vol 61 � No. 3 � March 2015 Indian Foundry Journal 4


C O N T E N T S

The Institute of Indian Foundrymen“IIF Center”, 335, Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107

Phone : +91 (033) 2442 4489 / 6825 / 7384-87 � Fax : +91 (033) 2442 4491

E-mail : [email protected] l Website : www.indianfoundry.org

Experience with Al-Mg Alloy

Castings in Defence Application

– V. N. R. Nayudu 25Effect of Tin on Mechanical and

Microstructural Properties of ISO 250

Grade Grey Cast Iron

– The Research Team,

Snam Alloys Pvt. Ltd. 30��

with Practical Tips

– S. K. Paknikar 37

Vol.61 No.3 March 2015

President’s Message 7 Editorial 11

Price Trend of Foundry

Raw Materials 54

63rd Indian Foundry

Congress 15

Feedback on 63rd IFC 81

Indian FoundryIndustry – The Way Ahead 79

IFEX 2015 61

IIF Fellowship 73

CFO Writes 23

Forthcoming Events 119

CET News 87Workshops on :� Investment Casting Process

Technology (NWIC-2015)

� Basic Principles of Methoding for SG Iron Casting

News & Trends 111

List of Exhibitors at IFEX 2015 103

Statistics : Automobile 105

NEWS


Indian Foundry Journal 7

President’s MessageDear Members of Foundry Fraternity,

It is my great pleasure to inform you that the just concluded 63rd Indian Foundry Congress (IFC) held concurrently with IFEX 2015 & CAST INDIA EXPO at Greater Noida, which drew to a close on 1st March, 2015 was a resounding success. With around 7000 visitors (including more than 1300 registered delegates for IFC and �� !�� !��"�#�� $��%��"�'�Italy, the event emerged as the most well-attended foundry conclave in Northern India and brought the much needed fresh breeze of optimism to the casting sector. Leading Indian and international suppliers to the foundry industry of materials, chemicals, machinery, technology, process, instruments, software, among others displayed their latest products and services at IFEX 2015.

63rd IFC had several value-added sessions, where senior Ministers from the Government of India rubbed shoulders with bureaucrats, business leaders and academicians to share their vision and thoughts on sustainable growth of the foundry industry. Presentations were made by eminent persons from India and �� ! �� #�� protection, effective energy and resource management.

*��"� ��+/#��/��/�� 4�/8�� ! ��"��$9:�� #��#�� /#��/��"��;/;9<�;=�'�$9:��NSDC along with captains of industry, deliberate to charter future roadmap for ��!��"� ��#��#��#��##��!�� "��+;��>��+�#��"��%��?�

One of the major attractions of the event was the ‘Cast Source Meet’ which provided ��##��!��"��#��! �� # �� casting manufacturers and large-scale national or international casting buyers and � �! �� ##��!�� #� ��!�!�� !�!��@�?

*� �4$�� !� ��#� !�� practices in the foundry sector.

>>B�H�� #��"��! �� B�� # ��on foundries and foundrymen at the inaugural session.

A new addition this time was the Budget Session where decoding of just released K��Q!�� "�@��#�� !��>>BR �$B:��@��of metal-casters present on the occasion.

IFC and IFEX also received substantial Press Coverage in print and electronic media both prior to and after the event.

I dedicate this grand success to all foundrymen whose support and cooperation has enabled the event to scale new heights.

With best wishes,

Vikas GargPresident, IIF

“

”

Vol 61 � No. 3 � March 2015

I dedicate this grand success to all foundrymen whose support and cooperation has enabled the event 63rd IFC & IFEX 2015 to scale new heights.



EditorialFellow Foundrymen & Friends,

In the technical sessions of just concluded 63rd IFC, papers were presented by select authors on various areas of foundry industry. Apart from Ferrous and Non-ferrous Castings & Moulding, host ��#�#� �� !��"��"��B�!��"�;��/��!��/��=��#�� were also presented. The sessions saw authors from India and ��#� ��#�#� ��9��"�9�@��"��U!��"�;��/��/��V��;��!��!��B�!��"�9!��=�*��and Computer Simulation in front of an appreciative audience of foundrymen eager to absorb and adopt newer technologies �� #��?

Indian foundry industry is undergoing a paradigm shift and � ��#��?� �Y��%��R ��#�� +;��>��8�#��"��#�� companies to set up business units in India and despite India ��R �� "�!��#�#!��availability of newest technologies and management techniques, �� !�� #� �� !##�"� �� manpower, inadequacy of silica sand and erratic power supply. Further, most of the foundries being in MSME sector, are low on @�� ?�

Metal-casting industry being the pillar for growth and ��#��!��!�� %�� special effort for the up-gradation of MSME foundries through the National Manufacturing and Competitiveness Council (NMCC) and by raising credit limit for technology up-gradation and funding of MSMEs. The newly formed Foundry Development $�!�� #��#��"��!��#��>��!��"� ��?�/��!#�� !� Z�� !#4��#�� !��"�� need of the hour.

In the technical paper section of the current issue, read about the role of aluminium-magnesium alloys in defence application, �� #��#�� "� �� @�� !#��furnace operation and way ahead for the Indian Foundry industry.

News & Trends, covers direct and indirect impacts of the Union Budget on the foundry sector. Partial reduction of duties on �� #<� �� #��!�"�� '� ��!�� <��#�� !�"��#��/%��and ferro-silicon magnesium for production of cast components ��4�#��"�� <�� "�cess to boost renewable energy generation are some of the measures that would directly or indirectly, positively impact the foundry sector.

We invite comments and views from readers on the recent Union Budget, just concluded IFC and different features of the Journal.

9�]�"�� "�!��! ?�

Ravi SehgalEditor

Editorial Board

� All correspondence on Editorial Matters, Subscriptions and Advertisements should be addressed, The Institute of Indian Foundrymen, ‘IIF Center’, 335, Rajdanga ;�� _�� 9� �� `�� k�� #� *?:?��`��4��xx��x�?

�� k�� #�� #� ��#��in the INDIAN FOUNDRY JOURNAL are those of the authors and do not necessarily �� >>B?�K� �� #�� R � �� and the publisher accepts no liability for loss or damage. Material in this publication cannot be reproduced whether in part or in whole, without the consent of IIF.

� IIF reserves the right to reject advertisements. The IIF is not in any way responsible for the � !��"�� advertisement published in the journal.

Mr. Ravi Sehgal - Editor

Dr. B. Ravi - Associate Editor

Dr. P. S. Banerjee - Member

Dr. S. K. Goel - Member

Mr. V. Narasimhan - Member

Dr. N. P. Sinha - Member

Mr. B. Ramachandran - Member

Dr. Dewan D. Lal Chopra - Member

*��?�/?�`?�*�� 4� ;��

;�?�Q��"��=!�� 4� 9��!��=��

IIF & Convenor,

Editorial Board

;�?�%?�;!��]� 4� =��$9k

Mr. A. K. Anand - Director, FIC

Mr. Anil Agashe - Director, NCTS

Invited Members

Mr. Anant Bam - Chairman

Western Region

Mr. C. Ravichandramouli - Chairman

Southern Region

Mr. Pradeep Mittal - Chairman

Northern Region

Articles/Write-ups (soft copy) may be forwarded to : [email protected]


THE INSTITUTE OF INDIAN FOUNDRYMENAffiliated Member of the World Foundry Organization

[Founded 1950]

Dr V Krishnamurthy, Chairman, NMCC � Mr B Muthuraman, Vice-Chairman, Tata Steel

IIF NATIONAL COUNCIL (2014-15)

Patron-in-Chief

Elected Members

Nominated Members

Co-Opted Members

Past Presidents Councils

IIF Centres of Excellence

OFFICE BEARERS President Vice President Hon. Secretary Hon. Treasurer Immediate Past President Mr Vikas Garg Mr N Krishna Samaraj Mr Shashi Kumar Jain Mr Anil Vaswani Ms Reena Bhagwati

Mr D S Chandrasekar Mr Vineet Jain Mr Sanjay Shroff Mr Swapan Kr Ghosh

Mr N Krishna Samaraj Mr S K Saxena Mr R K Raijada Mr K C Mathew

Mr Jayant S Shah Mr K E Moidu Mr Gautam Mukhopadhyay Mr Sudhir Pal

Mr Devendra Jain Mr Anil Vaswani Mr R K Mehta Mr Yatin P. Shah

Mr V P Premkumar Mr P A Patel

Eastern Region Western Region Southern Region Northern Region

Mr Anant Bam Mr C Ravichandramouli Mr Pradeep Mittal Mr Jignesh Patel Mr K Balasubramanian Mr Kanishka Jain Mr Amish Panchal Mr S Kuppusamy Mr Vikas Garg Ms Sudha Kurupp Mr K S Anbuselvan Mr S H Arjunwadkar Mr Sanchit Kutir Mr Prasad P Mantri Mr Damodar Baliga Mr Dhananjay Navangul Mr N Viswanathan Mr P D Pant

Mr Ravi Sehgal Mr Naresh Garg Mr Harsh K Jha [All Other Past Presidents Mr Jagat Shah Dr H Sundara Murthy Ms Reena Bhagwati are Invitees to the NC]

National Centre for Technical Services (NCTS)Mr S H Arjunwadkar, Chairman � Mr Anil Agashe, Director

Flat No. 104, Sharmad Residency, S. N. 291, Shilavihar ColonyBehind Hotel Olivia, Erandwana, Karve Road, Pune - 411 038

Phone : (020) 25422902/25437374/65004705E-mail : [email protected]

Foundry Informatics Centre67, Tughlakabad Institutional Area, New Delhi - 110 062

Tel. : (011) 29960601, Telefax : (011) 29958028E-mail : [email protected]

Centre for Education & Training (CET)Dr N P Sinha, Chairman ��Mr G Mukherjee, Director

“IIF Center” 335, Rajdanga Main RoadEast Kolkata Township P.O., Kolkata -700 107

Tel. : (033) 2442-4489/6825, Fax: 2442-4491E-mail : [email protected]

SECRETARIATMr Baidyanath Dutta

Executive DirectorE-mail : [email protected]

�� Kolkata

Mr A K AnandDirector

IIF-NR & FIC, New Delhi

E-mail : [email protected]


Mr Surendra Verma Mr Shashi Kumar Jain Mr Dinesh Gupta Dr Dewan D Lal Chopra Dr Nithyanandan Devaraaj

63rd IFC

Vol 61 � No. 3 � March 201515

Indian Foundry Journal

63rd Indian Foundry Congress

� According to the Government officials, industry captains and others, Governments’ help and support are a must for helping foundries rise to the occasion.

63rd IFC Highlights

� Indian foundry industry urgently needs to be branded globally.

� The country’s foundry sector has to respond positively to ‘Make in India’ programme.

� Foundry Development Council would play a crucial role in developing Indian foundry sector.

� Setting up of more and more institutes/toolrooms, for skill upgradation in Foundry sector, is need of the hour.

� To support ‘Make in India’ initiative, foundry industry has to grow three-fold in next 10 years.

Focuses on making Indian Foundry Industry a vehicle for Prime Minister’s Make in India Programme� At various programmes of 63rd IFC at India Expo Mart,

Greater Noida during Feb. 27 – March 1, 2015 Hon’ble Central Ministers, Secretraries of the Union Govt, IIF President, Chairman of Organising Committee, 63rd IFC, CEOs of large corporate houses focused on a number of issues pertaining to Indian metal casting industry. They highlighted several challenges faced by the foundry industry and tried to find out the ways to overcome them.

� Chief Guest, Guests of Honour and other dignitaries at all events of 63rd IFC called upon foundrymen to enhance competitiveness by adding value to the products, upgrading workers’ skill, adopting green technology etc. in tune with the Prime Minister’s ‘Make in India’ programme. It is felt that the country’s foundry industry, mother of all manufacturing and engineering activities, urgently needs to be branded globally.


63rd IFC

Germany; the Minister stressed the need for boosting small entrepreneurship for the country’s industrial/economic development. Foundry, as he said, being the main support industry to manufacturing sector has to play an important role. However, they have to upgrade in respect of technology to produce quality products.

The Hon’ble Minister also said that newly formed Foundry Development Council would play a crucial role in developing Indian foundry sector. The Chief Guest also felt the urgency of setting up of more and more institutes/toolrooms, for skill upgradation of huge workforce, is the need of the hour to ensure supply of skilled workers to the foundry industry.

Guest of Honour Prof. (Dr.) Ramshankar Katheria, Hon’ble Minister of State for Human Resource Development, Govt. of India while addressing a large gathering in the inaugural function of the Congress thanked and appreciated the country’s entrepreneurs for their achievements in various sectors that has raised the status of the country in the global arena. He said that the farmers and industrialists are the designers of the country. The Hon’ble Minister acknowledged contribution of entrepreneurs and agriculturists to the country’s development and growth.

Prof. Katheria mentioned of the endangered foundry industry in Agra area due to Government ban on it for causing harm to

Inauguration of 63rd IFC“New Government’s new concept ‘Make in India’, launched by Hon’ble Minister Narendra Modi is now a matter of discussion not in India but also across the globe”, said Shri Kalraj Mishra, Hon’ble Cabinet Minister for MSME, Govt. of India at the inaugural function of 63rd Indian Foundry Congress, the flagship event of the country’s foundry fraternity, on the first day of three-day mega event. Shri Mishra graced the occasion as Chief Guest.

He observed that ‘Make in India’ is not mere an industry-related affair, rather it covers every sphere of society whether it is in city or rural area. The concept is meant for the people of India for every walk of life. Youngsters are the focus group in this programme to make them the architect of future of the country while women are also part and parcel of of the programme. Enterpreneurs, be small or large, will participate in this programme to make India shine in the global industrial map.

According to the Minister, as foundry is the mother industry to the manufacturing and engineering sectors, it has to respond positively to the programme. In his opinion, metalcasting industry is the pillar of development and growth of the country’s industry/economy.

He further said that foundries in India urgently need to be upgraded technologically to enhance their competitiveness to compete sustainably in the global market. In this respect, the Chief Guest referred to the Government schemes available especially for MSMEs. He mentioned of the present Government’s intention of making India the hub of best quality products at moderate cost. According to him, National Manufacturing Competitiveness Council (NMCC) would take the key role in this mission. Credit limit for technology upgradation for MSMEs would be raised, he said.

Citing examples of Japan, America,

63rd IFC

Vol 61 � No. 3 � March 201517


the Taj Mahal. He urged the Government to take suitable measures to save the industry without causing any damage to the world heritage.

Mr. Vikas Garg, President, IIF in his address informed the House of IIF’s gaining of BMO (Business Membership Organisation) accreditation in Gold Grade under the initiative of the Ministry of MSME. He described IFC & IFEX as very effective twin platforms for showcasing the strength of Indian foundry industry, promoting mutual cooperation among technology providers and users, thereby creating all-round value. He announced that this unique platform to all stakeholders, policy makers in Govt., CEOs of industry, technology providers, technology seekers, academia, 63rd IFC & IFEX 2015 is an opportunity to deliberate on roadmap forward for promoting growth of foundry sector to nourish and support “Make in India’.

Mr. Garg further said that with the Government pursuing the goal of ‘Make in India’ through various policy initiatives for increasing ease of doing business, raising the FDI caps in different sectors and skill upgradation; the Congress was the harbinger of changing business environment and new hope.

According to IIF President, to ensure rapid growth of manufacturing in India and to support ‘Make in India’ initiative, foundry industry – mother of all engineering industries – needs to grow three-fold in next 10 years. He also pronounced that in recognition of the potential of foundry sector and its key role in manufacturing industries; DIPP, Ministry of Commerce & Industry has formed Foundry Development Council consisting of various stakeholders to initiate various sector-specific policy interventions. He thanked Shri Amitabh Kant, Secretary, DIPP for this initiative and valuable support in this regard.

He further said that the third ranking

US$ 18 billion Indian foundry industry producing 9.5 million tonnes of castings per annum, urgently needs to upgrade its production technology, innovate, and adopt good practices in areas of quality, energy, resource, sand system, skill enhancement etc.

Mr. Garg also mentioned a few issues faced by foundry industry in the country for which he sought for Government intervention. Further, he lamented that at a very few institutes in the country, curricula include foundry as a subject. He stressed the need for introducing specific training courses on foundry at ITIs, toolrooms, polytechnics and engineering colleges, close to foundry clusters across India. He urged the Government to support technology and skill upgradation in foundries by setting up of Technology Upgradation Fund.

Earlier, Mr. Naresh Garg, Chairman, Organising Committee of 63rd IFC while delivering welcome address had highlighted the Theme of the Congress by quoting “Growth is never by mere chance, but the result of forces that work together. And, the best of teamwork comes from persons who work independently towards one goal together.” He also said that growth is synonymous with synchronisation, which is implied in the Theme of IFC. He further said that with the Prime Minister’s ‘Make in India’ initiative, Indian manufacturing sector had entered a new era. Inspired by the initiative, the country’s foundry industry is also taking steps towards becoming a global leader and trusted supplier.

The Organising Committee Chairman stressed the need for all working together, networking and building a stronger foundation for the engine of India’s manufacturing industry, powered by value-added castings. According to him, the country’s metalcasting sector needs to increase its operations by about three times to support the country’s surging economy to become the fastest growing economy in world. In his opinion, advancements in


63rd IFC

process and technology in the foundry industry is vital for benefiting other sectors like Railways, aerospace, defence, auto, infra, mining, heavy machinery, power generation etc.

IIF Annual Awards 2014 were distributed by Dr. Ram Shankar Katheria along with IIF President Mr. Vikas Garg. The awards were for recognising outstanding contributions to various fields of foundry industry by individuals and organisations.

The honour IIF Fellowship was also conferred on prominent personalities at the inaugural function.

The Office Bearers (2013-14) of IIF were honoured with mementos.

High profile delegates belonging to foundry, foundry equipment & input industries, software development sector,

researcher from R&D laboratories, Industry Associations, Government officials, academicians, engineering students from India and many other countries like USA, UK, Canada, Italy, Spain, Poland, Germany, Belgium, Nigeria, Indonesia, Sweden, Zimbabwe, China, UAE participated in this mega event.

A promotional video on forthcoming 64th IFC to be held in Coimbatore in January 2016 was run by Mr. C. R. Swaminathan, Chairman, Organising Committee, 64th IFC.

Mr. Krishna Samaraj, Vice President, IIF offered a hearty vote of thanks.

Vol 61 � No. 3 � March 201523

Dear Members/Readers,The Budget for the year 2015-16 has been placed by the Union Finance Minister in the Parliament. I would like to share some key features here in brief to have an overall idea of the 1st full year budget of the new Government.HIGHLIGHTS�� !��"��#��$%�� &'��#��#��#��(�&)&��*�+�3�')'��3��)��4�� 7��4��#��#��"78��+�� 9�#��4��#��:%��44��(��#��;<=%��=;(=>�� "��#�?� ��#�@�A��44��=#��'��4��=C�� A��#��A��#��=�%��=;%�� 8��#��4�#��E�#��#� '7��#�� E��A��#��:�%��>%�� H��4� ��44#�E��##��J��#��#��44��4�� "''K�7��#��4��9#�� H��4��A�#4��#��#��;<;�4�� !A��#��#��#��#��=�<>%�� 8��#��4�#��4��A��#��%�#��#��(��A�#4�� E��+�#��44��=��#��L��OPINION�� #��4��4��8��4��4��#��#�� #��4�##�#��#��4�� #�A��4�#��N:C=<>��3��=;=<:$�

��#�O�<;$%Q��H��#��$N�=<$>3��>S<�>��#��O�<C>%Q��placed

�� @��#��4��4��"��4��4��4��4�#��?��4��4��4��

�� 44��4��4��#�� '��#��#�#�#��4��+��#��4��

of world economy in near future �� '��4��#��4��4��#��H��3��4��4��4��4��4��##��V(HEW�!�9KW��@K'7!�9'K �X�&��7�4��Y��E��@�� @�A� '�� 4�� #� �� A��#� �� 4��<� '��#��4��A��#��4��4��#��#��4��to the promotion of Indian trade which shall fall within the ambit of “advancement of any other ��+��4��4��4��Z<�� #��O=>Q3� ��#��+��#��regarded as charitable purpose. The Revenue authority contended that the organisation has ��#��4�#��#��<�@��Y��E��+��4��#��A��##��[E��4��#�Z��4��#��4��44��#��4��8��4��!\��4��'��4��=;��E�#��of India and thereby allowed the petition of the organisation. Surajit Datta9E'3�9E�'3�'3��'

CFO Writes


Exclusive Opportunity for Leading Foundriesfor Listing in CAST INDIA 15 CD DIRECTORYto be Distributed among Serious Global Buyers at

NEWCAST-GIFA 2015Last date for Submission : 25th April, 2015

IIF will be participating in the GIFA/NEWCAST at Dusseldorf, Germany from June16- 20, 2015 which is the largest international event for the foundry sector and provides unique opportunity to reach out to a large number of potential buyers from across the globe. Your entry can also explore new partnerships, buy–back and business opportunities in the international market.

IIF will be compiling the data of selected export-worthy foundries for listing in the CD, which will be distributed to the international castings buyers visiting IIF Stand at GIFA–NEWCAST opening new windows of export market.

IIF will also be organising the Buyers–Sellers Meet during the show on 18th June 2015 and inviting a large number of potential castings buyers mainly from Europe and USA, from various manufacturing sectors to promote the Indian foundry industry and strengthen the “Make in India” policy of Govt of India.

There is nominal Fee of Rs 7000/- (including service tax) for listing in the CAST INDIA 2015 CD Directory being produced specially for the event. The payment can be remitted by bank transfer as per bank details given below :

Bank Details :

Name of account : THE IIF A/C EXHIBITION

ICICI Bank A/C No : 098301001787

IFS Code : ICIC 0000983

Branch.: Kasba Branch, Kolkata-700042

MICR Code: 700229034

The format for data can be obtained from [email protected] which may be returned duly filled in along with payment positively by 25th April 2015 to:

Mr. A.K. Anand, Director, IIF (Foundry Informatics Centre ), The Institute of Indian Foundrymen, 67, Tughlakabad Institutional Area, New Delhi-110062

E-mail : [email protected] / [email protected] Ph: 011-29960601; Fax: 011-29958028(copy of payment details may also be sent to [email protected] and [email protected])

Mr. Subodh Panchal, Chairman, International Affairs Committee, IIFCell: 9824015380, E-mail: [email protected]



Experience with Al-Mg Alloy Castings in Defence ApplicationV. N. R. NayuduJt. General Manager, Ordnance Factory, Medak - 502 205

E-mail: [email protected]

Aluminium magnesium alloy AMg6lch with minimal amount of Impurities and ancillary additions of Zr, Ti, and Be possess the best mechanical and corrosion properties useful in production of critical aluminium castings required for Naval Gun weapon system. The chemical composition and mechanical properties are very vital for these castings as this alloy has to withstand a rapid @�� #��"� �� xx� ��!� Z��?� �� ?� k�� #��!�� @� ��time in India. The process of development started from the initial stage of design and manufacture of tooling and by proper selection of raw materials, melting furnace, special ladles and testing equipment. The heavy castings with intricate shape were produced using high purity of Al of 99.95 (3N5- electrolytic grade). The Al-Mg alloys are very sensitive to iron impurities which grow with increased magnesium concentration. The subject castings have the limitations of Fe and Si each max 0.05%. To lower the impurities in the raw material and to reduce the hydrogen gas pick-up, several process control techniques were adopted which have resulted in the development of �!�� #��@��#��#�� ?�k��indigenous development of the castings is a step towards country’s self-reliance in Defence Production.

Keywords: AMg6lch, 3N5, Degassing, Zirconium, Titanium, Beryllium, TOT, Wash melt, ATL ladle, Superheating.

Introduction

H��"� H;�� #��@�� %:/k� ��4�� 6-7%Mg, concentrations of ancillary additions of Zr, Ti and Be. Impurities include Fe and Si will not exceed 0.2%. Iron in Al-Mg alloys, in the absence of manganese and silicon, will form the Al3Fe phase. Its needle-like inclusions dramatically reduce the level of mechanical properties. Alloy AMg6lch has much tougher restrictions on the presence of impurities (Fe and Si less than 0.05%); for this reason it has to be cast out of high purity primary materials. This is because of the ��!��"�!#��#��#�� !��also upon corrosion resistance, the development of Al-Mg alloy with improved mechanical properties, corrosion resistance, weldability etc., was necessitated. This alloy in the quenched state has single-phase microstructure and is the most corrosion-resistant material among all aluminium alloy castings.

Effect of Alloying ElementsBeryllium: It is used in aluminium alloys containing magnesium to reduce oxidation at elevated temperatures. K#�� x?�� Q� � � ! � �� !�� #�� !��!��@�� formation of the deleterious iron-aluminium complex.

Zirconium: H�� !�� x?�� x?��! ��@��4��#��#��inhibits recovery and recrystallisation.

Effect of Impurities

Iron: Iron in Al-Mg Alloys, in the absence of manganese and silicon, will form the Al, Fe phase. Its needle-like inclusions dramatically reduce the level of mechanical properties. In alloys for complex high quality castings, the maximum iron impurity concentration is strictly limited (not more than 0.05%).

Silicon: Silicon, by binding magnesium into the MgSi #�� !� ��#�� "��!�� @��"��!�� castability to some extent. In Al-Mg alloys (AMg6lch), the maximum allowable concentration of the silicon impurity is rigorously limited.

Experimental Details

The initial facilities at foundry were mainly catered for manufacture of Al-Si alloy castings and the task of production of Al-Mg alloy castings with existing melting and moulding facilities is a challenging task and ��!�� @�� ! � �� #�� improvements.

Indigenous Development of Castings

The indigenous development of these special Naval Gun �� @� �� !��"?�:!�� types of castings developed for Naval Gun weapon system, ��!��!�� $�� $�� B�� ?� �4��are most critical in nature and the chemical composition and mechanical properties are very vital as this alloy has to

+The paper was originally presented at 63rd Indian Foundry Congress held during February 27 to March 1, 2015 in Greater Noida, U.P.


�� #��@��#��"��xx��!� Z��?�� !�� @�� the block of 6 guns of 30 mm caliber. These castings are weighing heavy with intricate shape and size and were to be produced with high purity of aluminium. Earlier, these �� Z��#�� " �� #� �� #��sources.

Fig. 1: Carriage casting after knock-out.

Fig. 2 : Carriage casting after removal of risers.

Fig. 3 : Cradle casting after removal of risers.

Methodology and Process Selection

The castings were taken up for development at the foundry without TOT (Transfer of Technology) and the required drawings (casting drags, tool drag, etc.) were developed ��! �"?��#�� Z��@��every stage of foundry practice is necessitated since the earlier foundry setup was catered for manufacture of Al-Si alloy castings.

Design and Manufacture of Tooling

The design and manufacture of tooling was initially planned for prototype production of castings with teak wood core boxes and teak wood patterns which lowered the cost of manufacture drastically. The development of tooling has been made by following the sand casting method and accordingly, the patterns, core boxes, gating system and mould boxes etc. were planned (Fig. 4 and 5).

Fig. 4 : Carriage Pattern.

Fig. 5 : Cradle pattern.

Core Making and Moulding

CO2 cured phenolic resin process has been adopted for carrying out core and mould making operations. The requirement of moulding sand for the assembly is around


6 tonnes. Handling of heavy cores requires the use of �� #�� B�� ?��?

Fig. 6 : Core Boxes for Carriage.

Fig. 7 : Sand Core for Carriage.

Fig.8 : Mould with core for Carriage.

Melting and Metal Treatment

k�� #� �� @�� from the pure Al raw material with high percentage of Mg

was a task as the crucible used for melting was catching

the impurities.

Wash melt was introduced before the actual Al melt

material was tapped in the crucible to avoid any kind of

contamination due to reaction of molten material with

the inside surface of the crucible. This yielded results in

�� #��H��@��#��!��?

Use of High Purity (99.95%) Al Ingots (3N5)

The initial comparison of alloy composition with

#��@�� #� ��

��#!�� #��@��?�/!��

of Fe and Si is likely to reduce tensile strength and ductility

of the alloy. To achieve the desired values of Fe and Si

�� @�� "�� #!��"� ��?�� !��!��

ingots were used and controlled the pickup of Fe and

Si from melting tools, refractoriness during melting by

reducing melt overheating, reducing melt holding in the

furnace and proper coating of the tools and proper care

of furnace linings and use of pre-alloyed high purity alloy

ingots for remelting and casting.

Gas Porosity and Inclusions in the Melt

The presence of porosity became even more problematic

when age hardening alloys were developed, because

near surface porosity invariably blistered on the surface.

H��"�� @�� #��#��

such as tensile strength was found with increasing porosity

levels.

The AMg6lch alloy was a high freeze range alloy which has

��!�� ?�k��"� ��@ ��

range when compared to the other alloys which results in

shrinkage porosity.

Sources of Hydrogen in Molten Aluminum:

� Atmosphere humidity;

� Wet metallic charge;

� Wet furnace lining (crucible, transfer ladles);

� Wet foundry instruments;

�� Y��!� �� !�� <

� Furnace fuel combustion products containing

hydrogen.


Hydrogen Solubility is Temperature Dependent

Fig. 9

Degassing PrinciplesHydrogen degassing of aluminium works on the principle that the hydrogen gas will move from an area of high pressure (in the melt) to an area of low pressure (the inert gas). Hydrogen gas disperses in the molten metal as it would, if it were released in the air. It will maintain an even pressure throughout the melt. When you introduce the inert �� "�� ?��As hydrogen gas is removed, it will equalise its pressure throughout the melt. The ability of hydrogen gas to move through and equalise its pressure in liquid metal is almost as fast as it is in air. It is therefore unnecessary to bring all of the metal in contact with the inert gas. Two factors, the �� Z�� !��area of gas exposed to the metal determine how well and how fast a heat of aluminium can be degassed.

Rotary DegasserRotary degassing works on the principle of increasing the surface area of an inert gas exposed to the metal. The greater the surface area, the faster is the degassing. In the rotary degassing method, an inert or chemically inactive gas (argon, nitrogen) is purged through a rotating shaft and rotor. Energy of the rotating shaft causes formation of ��!��@��!�� #��"�� !��area to volume ratio. Large surface area promotes fast and effective diffusion of hydrogen into the gas bubbles resulting in equalising activity of hydrogen in liquid and gaseous phases.

_��"� �� B��?� �x�� #��"�� #��!�� ?��Additionally, rotary degasser does not use harmful chlorine �� !�� ?� _��"� �� "� �� !�� !��!��?�In this case, the inert gas serves as carrier for granulated �!�?

Fig. 10 : Rotary Degasser.

Metal Pouring and Fettling

The pouring temperature was maintained below 7200C to avoid superheating and hydrogen pickup. To minimise the drop in melt temperature before pouring, ladles made with Insural ATL lining were used which enabled a lower tapping temperature of 7000C.

k�� #�� !�@�� !�� wherever machining allowance is required by modifying the wooden core and mould as per the shrinkage noticed during the process and used exothermic sleeves wherever necessary.

Heat Treatment

To achieve mechanical properties on the test samples derived from the same casting by setting proper heat treatment process. Successfully established the process by achieving the required quality level and mechanical properties of the casting after the heat treatment.

Radiography and Fractography Inspection

Stringent norms for radiography testing were followed and the inspection of castings was carried out as per #��@�� !��!�� fractographic results.

Fractography is the study of the fracture surfaces of


the materials. The aim of fractographic examination is to determine the cause of failure by studying the �� !�� !��B��?��?

Fig. 11

Results and Discussion

Critical Process Improvements

�?� k�� !#� �� #�� foundry without TOT (Transfer of Technology) and the required drawings (casting drawings, tool drawings etc.) were developed indigenously.

2. The process (sand casting route) and moulding (CO2 cured phenolic resin process) was selected for the castings as per the foundry equipment available.

3. The design and manufacture of tooling and method of gating system was selected to suit to the casting process which includes patterns, core boxes, gating system, mould boxes etc.

4. The chemical composition and mechanical properties are very vital for these castings and the required high purity of aluminium of 99.95% (3N5 – electrolytic grade) and other master alloys like Al-Mg, Al-Zr, Al-Be

and Al-Ti were positioned from import sources.

5. The AMg6lch alloy was a high freezing range alloy which has to be dealt with utmost care, thus perfect process control at every stage of melting and pouring are to be established and maintained to achieve the stringent quality parameters.

6. Liquid aluminium actively dissolves hydrogen and the hydrogen solubility is temperature dependent, thus, the temperature control in the furnace and in the ladle is vital for the aluminium alloys. Wash melt was introduced before the actual Al melt material was tapped in the crucible.

7. Sequence of master alloy additions in the melt was established after thorough experiment and foundry practice.

�?� _��"�� x?�x�ppm hydrogen in the melt before pouring.

9. To minimise the drop in liquid metal temperature, the ladle (ATL) was lined with special lining materials.

�x?� �"�� " �� ! � ��measuring the hydrogen in the melt.

��?�$��@�� ! ��@�� and impurities.

ConclusionsIndigenously established the AMg6lch alloy castings production for use in Naval Gun weapon system in highly corrosive sea environment for defence requirement.

References�?�� K�� H�!��!�� =�� =�?� =�� ?�

Neff.

�?� $� ��H�!��!��H��" �� "��Belov, Michael Glazoff, Alcoa Technical Center, Alcoa Center, PA, U.S.A.

3. Aluminum Alloys : Impurity and Alloying Elements, N. A. Belov, A. A. Aksenov, D. G. Eskin.


Effect of Tin on Mechanical and Microstructural Properties of ISO 250 Grade Grey Cast IronThe Research TeamSNAM Alloys Pvt. Ltd., R & D Centre, Hosur, Tamil Nadu, IndiaE-mail : [email protected]

Introduction

The production of as-cast high strength cast iron grades

requires a completely pearlitic matrix. Common pearlite

promoting elements are Cu, Sn, Mn, Cr etc.�� But the

relative effectiveness in producing pearlitic matrix varies

from element to element��. Also Cr promotes carbides��.

So, an element which ensures pearlitic matrix without

forming primary carbides is important. Cu and Sn produce

pearlite but do not form primary carbides. Tin is more

powerful than Cu in promoting the pearlitic matrix. The

#��!��k�� "��@�!��

be annealed out. So control of Tin is very critical in as-cast

as well as annealed ferritic grade cast irons.

Tin is known to stabilise pearlite. The adverse effect of

Tin in ductile iron is available in literature. The limiting

percentage of Tin in ductile iron is determined by the effect

on strength and ductility. As the amount of Tin increases,

the strength increases and ductility reduces. But after a

certain amount, the ductility and strength both reduce.

This is due to the fact that Tin segregates to the grain

boundary and imparts brittleness to the casting.

Literature available on the effect of Tin in grey cast iron

is limited. The safe amount of Tin in grey cast iron is of

interest to foundries producing high strength grey iron

castings. The current work is concentrated on the effect of

Tin in ISO 250 grade grey cast iron.

Experimental Procedure

The experiments were conducted with ISO 250 grade

grey cast iron. The charge-mix was melted in induction

�!��##��#��!��xx0C and taken in

�� #��"?�k��k��

along with inoculation in the hand shank while transferring

the metal.

The inoculant used was

zirconium based at 0.25%

addition by weight of

molten metal.

For the purpose of

analysis, the inoculated

metal was poured into:

�?� HkH/� �!#� ��

analysis

2. Copper die for spectro-coin

�?� /�#�� x��x��x��

�?� k� �� !#�� H/k;�H��;�?

Analysis done for every trial

� Thermal Analysis: TA software was used for

characterising the cooling curve parameters.

� Chemistry: Spectro coin poured was used to analyse

the chemistry of both the base and inoculated metal.

� Hardness: The mould for step-block was made of

sodium silicate sand. The specimen for microscopic

analysis and hardness was taken from the 20 mm thick

part.

� Micro Analysis: Analysis was done at a section 5

mm from the surface of the 20 mm section of the

step-block using optical microscope. Image analysis

software was used to characterise the graphite type.

� Tensile Test: The tensile bar was poured in separate

coupon made of sodium silicate mould. It was

machined to get the standard tensile test specimen as

#��H/k;�H��?

Chemistry

Elements RangeC �?��?��Si �?��?��

Mn x?��x?��P 0.03 – 0.06 %S x?x��x?��Cr x?x��x?x��Cu ��x?��Sn x?x��x?��


Results and Discussion

Table-1: Tensile, Hardness and Micro Analysis Result for the Trials

Sl No. Tin % UTS (MPa) Hardness (BHN) A Type graphite (%)

1st trial 2nd trial 1st trial 2nd trial 1st trial 2nd trial

� x?x� �x� 239 �x� �� 92 ��

2 0.02 295 277 220 �x� ��

3 0.03 305 263 220 ��? ��

4 0.04 �� 249 ��

5 0.05 305 272 225 ��x 90 ��

6 0.06 309 255 226 �� 92 ��

7 0.07 ��

� x?x� 302 249 �� 202 �x 90

9 0.09 257 264 �� 95 ��

�x x?�x 242 �� 202 �� 92

�� x?�� 272 244 �� 203 94 90

�� x?�� 263 240 �� 202 96 90

Fig. 2: Percentage of A type graphite vs Sn % for 2nd trial.

Fig. 3: Kk/�� /�� ?

Fig. 4: UTS vs Sn % for 2nd trial.

Fig. 1:�*��H��"#��#�� /�� ?


Table-2: Thermal Analysis Result for the Trial upto 0.12% Sn

Sn % TL TELow TS TES R GRF1 GRF2 S1

x?x� ��?� ��?� �� x?� 4.9 65 34 54.9

0.02 ��?� ��?� �� ?� 4.3 72 27 ��?�

0.03 ��?� ��?� �� ?� 4.3 �� 53.9

0.04 ��?� ��?� ��x� ��x�?� 3.2 70 33 52.5

0.05 ��x�?� ��?� �� ?� �?� 70 27 46.9

0.06* ��?� ��?� �� ?� 0 �� 7.43

0.07 ��?� ��?� �� ?� 2.9 75 �� 45.5

x?x� ��?� �� x� ��?� 2.6 73 27 46.2

0.09 ��x?� ��?� �� ?� 3.6 73 26 49.2

x?�x ��x?� ��?� ��x� ��?� 3.6 63 43 47.7

x?�� ?� ��?� �� x?� �?� �� 26 50.7

x?�� ?� ��?� ��x� ��?� 3.6 �� ?�

*Since the thermal analysis for 0.06% did not come out correctly, the parameters are omitted from analysis.

Table-3: Un-etched and Etched Microstructure for the Samples

Sn %

0.01

Un-etched Micro Etched Micro (analysed by comparing with AFS chart)

Pearlite fraction= 95%

Fig. 5��Q�� /�� ? Fig. 6: BHN vs Sn % for 2nd trial.


0.02


0.03


0.04


0.05



0.06


0.07


0.08


0.09



0.10


0.11


0.12


Effect on Graphite Morphology and Type

k��#��H4�"#��#�� #� ��k��4�?�These values are obtained from the image analyser �� ! ?� k�� " � �� H4�"#��#�� #�� #�� ?� k�� no appreciable change in percentage of A-type graphite ��!#��x?��/��?�k��#��H4�"#��#�� !�� ! !��"� #��@� �"� �� ! ��as per the service requirement. The representative microstructure images of un-etched samples are given in Table-3. This shows that the presence of Sn does not affect the eutectic undercooling. The same can be inferred from the cooling curve parameters given in Table-2. The value of eutectic arrest temperature (TELow) is always above

��0C. This shows the absence on D-type graphite, which is the undercooled form.

The etched matrix is shown in Table-3. The microstructure �� #��"� #�� x?x�� /�� x?�� $!�!#��x?��/�?�k�� #� ��#��"�� ?�k�� @�� /�� promote carbides. Sn being a low melting metal, the effect on steadite formation and distribution was also checked. The amount and distribution of steadite is also not affected by the Sn addition.

Effect on Mechanical Properties

The tensile strength values for the samples poured are �� k��4�?� B��x?�x��/�� Kk/��! ��


�� #��@��!��x�;*�� ?�k��Kk/��! �� #��@��9��in either one of the two trials or in both. Since the tensile ��x?��x?�� !��!�� 4��"� �� x?�x�� !�� !� �� testing. The microstructure compliments the tensile test results. Since a completely pearlitic matrix was obtained ��x?x��/��Kk/�� !��?�The pearlite fraction was obtained by comparing the microstructure with AFS Grey Iron microstructure rating chart.

The hardness values, in BHN, conformed to the grade �� x?x�� /�?� Y�� !�� /�� x?x��!#��x?�� ##��Q��?�k�� means that the required hardness can be obtained from x?x��!#��x?�� ! ��"�Sn on hardness.

Conclusions

�� >��x?��$!��!��!��Sn required for obtaining a completely pearlitic matrix � �x?x�?

�� K#��x?��/�� #�� #��x?��/��?

�� k�� #� �� /�� !#�� x?�� graphite type or undercooling.

�� k��#� ��/��!#��x?��! �#��"�carbides.

�� k�� #� �� /�� !#�� x?�� steadite formation or distribution.

Future Scope

�� H��!#��x?�� strength beyond 309 MPa. This could be investigated for the effect of Sn on brittleness in Grey Cast Iron.

�� !��/�� @��the limiting percentage of Sn in Grey Cast iron.

� Combinations of Cu, Cr and Sn can be tried out to get high strength grades without causing primary carbides.

�� k�� 4��"� � !� �� x?�x�� /�� !�� investigated by conducting further trials.

Appendix

�� /#��! ��k��/��@��<�H_V��x�:9/�Metals Analyser).

� Hardness (BHN) Testing Machine used: BLUE STAR B – 3000 (O).

�� :#�� ;�� #� ! �� $�� H�� ?� H�� <�(50x – 500x)).

�� >��" ��! ��=�/��?x�?

� Universal Testing Machine used: BLUE STAR UTE – 40.

References

�?� HB/�=!��>��_�� #?��4�x�?

2. Roy Elliott, Cast Iron Technology, Butterworth & Co. V�?��#?��4��?

3. Effect of Tin in High Strength Ductile Iron, Hot Topics =>/��> !��xx�?


�� Practical TipsS. K. PaknikarMetallurgical & Foundry Consultant, Pune


Introduction

In any foundry, Melting Practice is of paramount importance whether it is a very small or a very large foundry. Normally, cost of melting is almost one third of total cost of castings produced. The type of furnace to be used depends on the metal to be melted.

Some of the furnaces of different types are as under:

� Pit Type Crucible Furnace: Crucible furnace commonly used in small foundries for melting in aluminium alloys.

� Electrical Resistance Furnace: These types of electrical furnaces are used in small or medium-size non-ferrous alloys that include aluminium and copper alloys.

� Cupola Furnace: This furnace is very common for the production of grey cast iron as they require comparatively less investment as compared to any type of induction furnaces.

� Induction Furnace: This is widely-used melting unit for melting of grey iron, ductile iron, steel and special metals like austempered ductile iron (ADI) and compacted graphite Iron (CGI).

� Combination of Cupola and Induction Furnace: Needed for production of SGI, ADI and CGI.

� Reverberatory Furnace: It can be stationary or tilting type. It is used for aluminium alloys or in combination of cupola Furnace for production of ductile iron.

� Cupola Furnace can be used in Combination with Induction Furnace for ductile Iron production.

Fig. 1: Cross-section of a conventional cupola used in foundry.

Cupola Furnace Construction

As� ��B��?��!#�� from bottom to top zone. Basically, cupola is constructed � �� !��4��refractories down the complete shell. The lining is thick at the lower part of cupola, as there, the temperatures are higher than that at top side. Normally, there is a gap of ��!�� "� �� @�� ?�k�� o transfer inside


heat through lining and this sand effectively controls the temperature of steel shell.

Cupola Zones

Normally, the zones in vertical height of cupola are divided as:

�� Well – It is the space between the bottom of the tuyers and the sand bed. Molten metal is collected in this space during operation of cupola.

2) Superheating – This is also known as Combustion or Oxidizing Zone.

3) Reducing or Protective zone – It extends from the top of the combustion zone to the top of the initial coke bed.

4) Melting zone�� >�� ! ��@� �� "��#��

Fig. 2:�V��@��"�� ]��

bricks.

(a)

(b)

above the initial coke bed.

5) Preheating zone – It includes all the layers of cupola charges placed above the melting zone to the top of the last charge of metal.

6) Stack zone – It is a zone above the preheating zone through which hot gases pass to the atmosphere.

The more details of these zones will be discussed in actual cupola working.

The parts of cupola in ascending order are as under:

� Bottom door, in two semicircular-shape, hinged to bottom plate.

� Bottom plate with four legs supporting entire cupola structure.

� Sand bottom rammed after closing the bottom doors.

� Slag spout for slag removal. It is closed for starting of cupola and opened during entire cupola operation.

� Tap spout on opposite side of slag hole and just at bottom of well.

� Tuyers in single or in two rows connected to wind box for air blast.

�� 9�� !�@�� !�� during heat.

� Wind box surrounding the shell of cupola and blast pipe connecting to air blower at one side of wind box.

� Cupola Instrumentation such as measure of volume and pressure of blast.

� Coke bed height.

� Total charge materials in preheating zone.

� Stack of cupola- it extends from top of last charge and top of cupola.

� Charging door on a platform where charge materials are placed.

� Ladder for skip car to take material to charging platform.

� Spark arrester.

Lining of Cupola ��"�� !#�� +@�� "�bricks” of proper size and compositions. Sometimes, basic brickwork is used as lining requirement to respond basic reactions inside the cupola.

B�� !#�� @��"� �� "� ��in such way that the gap in two bricks is not continuous which gives longer life of lining (Fig.2).

Cupola Tuyers Design

The most valuable air blast supplied through tuyers is that how many tuyers are provided for supplying proper volume and required pressure depending upon how they


are located and size of each tuyer. It also depends on how the blast pipe is connected to the wind box. The blast should be connected to wind box at tangent location so air will be circulated properly.

One practical point is that normally tuyers �� !��#�� size of cupola (inside diameter at tuyer level). The tuyer design must consider that the tuyer which is farthest from blast pipe will supply maximum volume of air to the cupola. Due to this, all tuyers may not supply air uniformly inside the cupola. So, the reactions inside will not be uniform.

The combined area of air blast inlet should be about one-fourth of the cupola’s inside cross-sectional area. The height of tuyers from the bed of cupola is about 450 to

500 mm. The tuyers are usually attached from below to the wind box. A small window with mica covers facilitates the inspection of metal condition inside during operation ��!#��?�_��k��4�?�The Tuyer Ratio depends on ash content in the coke used as coke charge.

Wind Box Design

The next point of cupola design is blower and how it is connected to the wind box as it controls in blast input for combustion of coke as a fuel. The number of tuyers required depends on quantity of coke to metal charge ratio. It varies �� k��4�?

Conventional Cupola

The wind box surrounds the outer plane of cupola shell and blast pipe is connected at the centre of the wind box. The tuyers are located at the bottom of wind box. (Fig. 4)

Tuyers

Fig.4 : Wind box, air blast inlet and position of tuyers in the conventional cupola.

Divided Blast Cupola

In the Divided Blast Cupola, there are two rows of tuyers Fig.3: Another view of lining system in various cupolas.

Table 1: Design of Lining and Tuyers related to cross-section of Cupola

Inside Diameter

of cupola (mm)

Cross- Section

of cupola in cm2

Lining thickness

in melting

zone (mm)

Total Tuyer area (cm) for tuyer ratio

Number of

Tuyers��

600 �� x4��x 750 565 470 405 4

750 �� x�� x�� 735 630 �Z�

900 6360 �� x ��x �x�x ��x�� 6

�x�x �� x ��x �� Z�

��xx ��xx �� 2260 ��

��x ��xx �� 3575 ��x �� 2045 �Z�x

��xx ��x 2025 4400 3530 2945 2525 �x

��x ��x �� 5340 4275 3560 3055 �x

��xx 25430 2455 6360 �x�� 4240 3625 �x

��x ��x 2605 7460 5970 4975 4265 �xZ��

��xx 34620 2755 �� 6240 5770 4945 ��


with separate wind boxes. The Divided Blast Cupolas are ��"� ��@�� #�� !�� #��!�� xx0C along with better ultimate quality of molten metal composition at the spout at reduced coke consumtion. The instrument for measuring �� #� !��!�� @�� blast pipes.

k�� !"� �� xx�� x�x� ��?� k�� !�� tuyers to that in the upper row varies from 70:30 to 50:50. Now-a-days, the divided blast cupola has become very common.

Fig.5: Design of tuyer rows in divided blast cupola.

Important Zones in Cupola with respect to reactions in Cupola:

Well of Cupola

�� /#��!"� �� bed.

�� ;�� #��?� k�� contains coke and metal 50:50 %. There may be some carbon pick-up in liquid metal.

Combustion Zone:

�� $��! �� #�� ?�>�� as oxidising zone.

�� >�� ?

�� "��x��?

�� >�� #��!�� x��x0C.

�� k�� #�� given below :

�� $�:2 ��CO2��

�� /��:2 � SiO2��

�� ;��:2 ��;�:��

Reducing Zone

�� k�� !##��

combustion zone and upper level of bed coke.

�� >�� #��!�� !��xx0C.

�� >�� $:2 is converted into CO by reaction

�� $:2��$��$��x0C ��2CO

Melting Zone

�� #��?

�� >�� #�� ! ��zones.

�� _�� #�� B��$:�� Fe3C �$:2

Preheating Zone

�� k�� #�� !##�� melting zone and continues upto the bottom level of the charging door.

�� :�]�� #�� #��!�� !�� x�x0C before entering the metal charge into melting zone.

Stack Zone

�� k�� #�"� #�� !#�� #��zone is called Stack. It provides the passage to hot gases to go to atmosphere from cupola furnace. Spark arrester eliminates the spark, if any.

B��!�� !#��?

Effective Cupola Operation

��! � �� !#��#�� ! ��?

�� Preparation of cupola - The slag and fused metal on the lining of cupola from the previous heat must be cleaned and lining should also be repaired. The bottom plate should be closed and supported by prop.

Then sand bottom is prepared with moulding sand and proper slope should be given towards the tapping hole.

2) Firing the cupola - Firing of cupola is done by kindling wood at the bottom. This should be done 2.5 to 3 hours before the molten metal is required. On top of kindling wood, a bed of coke is built up. The height of coke bed is calculated on the basis of pressure of air supplied.

� $��Q�� x?� �P��Y��* �H��*� !��in mm of Hg.

>��"��"��x�� #�� !#��?


3) Charging of cupola - When the bed coke is ignited, ��"� ��*��>��!�� are charged from charging door only. Suitable steel scrap with pig iron, to control chemical composition of the metal to be produced. The thickness of each ��"�� #�� !�� x� �� xx� ��?� k�� #!�#� �� !�� #!�� @�� !�� "� �� ?� Q � � �� !�� #��and soda ash sometimes are also used. The quantity of limestone required may be 30 to 40 kg per tonne of iron melted or 25% by weight of coke charged. As #�� >/��x4�� ?�The CaO content will be 52, 50 and 45% in the three grades.

4) Soaking of iron – After the furnace is fully charged, it is so maintained for about 45 minutes. The charge gets slowly heated since air blast is kept shut during time. This causes the metal charge to get soaked.

5) Opening of air blast – At the end of soaking period, the air blast is opened. Tapping hole is kept closed by a plug called bot, till the time metal gets molten �� !�@�� !�!��?�H ��proceeds, the contents of charge move downwards. The charging must be continued and the furnace be �#��@��!��furnace operation. The more details of air consumption will be discussed later in this paper.

6) Pouring the molten iron ��Y�� !�@�� @� �� is opened to allow slag to get ejected, then bot from tap hole is removed. The process is repeated during full day and then metal is poured into moulds.

7) Closing the cupola – When the entire heat is completed, the air blast is shut off. Then the prop is knocked down and furnace bottom is opened. This �� !��# ��which is then collected for next heat of the cupola.

Air Blast Requirements, Melting Rate and Composition Control

Air Blast Requirement

For complete combustion of fuel, requirement of air is ��!��?��!?��#�� #��pressure and temperature. The relation between amount of metal melted and the coke burnt is termed as the metal: �!��?�k�� ?�k�� "�� ?�k��!��#��xxZ��?��??��?�/��!��!��#�� ?�� x�x��!��<�� xx��!��#��?

The inside area of the cupola determines the amount of

coke that is to be burnt and the amount of iron that can be ��#��!��?�>�� ?��!#�� !�� !��#��!�?�Thus, the cupola having capacity of 5 tonnes per hour ��!�� #��!�� !�� !�� ?� � B�� 4 ��!�� x� �?��?�k�� diameter of cupola will be then –

Diameter in cm = ¢��x��Z�£� ��x��?

Cupola Capacity: The capacity of cupola is related to cross- sectional area of cupola. It is rated as metal in tonnes per ��!�?�k��!#�� !��"��!�! �"��x�hours per day. Sometimes. heat is taken on alternate day in practice.

Melting Rate: The melting rate of cupola is related to inside cross-section of cupola. Practically, melting rate is given as 0.6 x cross-section area (kg) and then it is given as tonnes per hour.

Fig. 6: Relation between well capacity and Inside diameter of cupola.

Melting Rate of Cupola

Melting rate of cupola depends on the ratio of coke to metal in the charge and how quickly the coke is burnt. The rate at which coke is burnt is decided by the blast rate supplied. The relation between the blast rate, coke to metal


ratio in charge and melting rate may be found as under –

Q =Blast rate in cubic metre per minute at standard temperature 00$��x�?��*�

;� �U!��"��!��Z��?

L = Quantity of air consumed in cubic metres per kg of carbon burnt.

$� �U!��"��!��#��xx�>��?

/� ��;�� Z��!�

Q = L x M M = /��xxx�x

C = S x C

�x� �xx� ��

Q = L x S x C

6

In Imperial Units –

U� �Q�� $!��B�Z��!��x0B��?��Z��2 pressure)

;� �U!��"��!��Z��!�?

L = Quantity of air consumed per lb of carbon burnt.

$� �U!��"��!��#��xx��?��?

/� �;��Z��!�?

M = S x 2240 x

C = S x C

�x� �xx� ��

M = 2240 x S x C x L

�x� �xx� ��

Therefore, Q = 0.363 x S x C x L, Equation for blast.

Example: Calculate blast required for a Melting rate �x��Z��!�?

=��4� ��$��?��$��$��$�#��4!#�x?��?

/�#��?��$��!��Q!��?��#��xx��(lb) iron melted.

$� ��4�x?�� ?�� xx

Fig. 7: Graph of relation of C burnt, L and melting rate.

/�#��9��!��V� ��?��H��$ ��?��V� ��?��!��x��!��

Step 3: Calculate blast volume from above equation

Q = L X S X C = �?��¥��x�¥��?�� x��!�� Z��!�?

6 6

Cupola Charge Composition and Ultimate Composition of Metal

Case Study

Charge composition to be used for an ultimate composition given by customer as follows :

Table-2: Final composition of the metal from cupola

Carbon Silicon Manganese Phosphorous Sulphur

3.20–3.50 2.30–2.60 0.40–0.60 0.40–0.50 x?x��;��?

Table-3: The Composition of Raw Materials Available in Foundry

Metal Carbon Silicon Manganese Phosphorus Sulphur

Pig iron �

3.50 2.50 0.40 0.40 x?x�

Pig iron 2

3.20 �?�x �?xx 0.60 0.02

Home scrap

3.50 �?�x 0.60 0.50 0.09

Outside scrap

3.20 �?�x 0.50 0.40 x?�x

Ferro-silicon

----- 50 % ------- ------ -------

Table-4: Correct Analysis of the Cupola Mixture Used

Charge metals Weight in kg Percentage (%)

*��?�� ?�x

Pig iron No. 2 200 20.00

Home scrap �xx �x?xx

Outside scrap �xx �x?xx

Ferro-silicon x�� x�?�x

Total �xxx �xxx

Y�� !�� @�� #� ��achieved was within limits.

Effect of Composition Control

The important elements for which loss or gain allowance are provided in the metal composition are given below.

Carbon: During the passage of molten metal through incandescent coke, carbon from latter is absorbed by the ��?�k�� >��carbon content (2) Size of coke (3) Temperature (4) Time


allowed for molten metal to remain in the cupola. With #��#�� x?��"�be expected.

Silicon: Silicon has a tendency to get oxidised and lost during melting process. Even under controlled conditions �� x�� charge. In abnormal conditions, the loss may be as higher as 30%. Thus, to obtain certain silicon %, the charge has to be calculated précisely. The loss has to be compensated by addition of ferro-silicon in the charge or in metal tapped in the ladle.

Manganese: Manganese also has tendency to get lost along with silicon during melting. The loss may be about ��x�� ?�k��#� ��the manganese lost, the charge metal calculations are to be checked. Otherwise, external addition of ferro-manganese has to be done. The manganese % decides the amount of pearlite in the microstructure.

Phosphorus: There is no effect of oxidation of phosphorus during entire melting operation in cupola. Whatever phosphorus is entering through the charge, all will be in ��@��#��?

Sulphur: Like carbon, sulphur also tends to increase due to its absorption by the metal from the ash content from coke. Generally, the gain in sulphur % is to be about 0.03 to 0.05%. Therefore, coke to metal ratio is very important.

Iron: The base metal iron is also shows tendency of being oxidised and lost by about 3.0 to 4.0 %.

Practical Tips for Cupola Operation

�� =!� #��!�� ##��cupola bottom doors after end of heat. Similarly, the lining inside cupola must be repaired before starting the cupola charging. If the cupola is large, a person can enter the cupola and patch lining effectively.

2) The bed coke height must be charged carefully with dense coke. The coke size and quantity are important �� @��"?� >�� observed that smaller the coke size, lower is the �� @��"�� #��!�� less complete combustion of carbon into carbon dioxide. Quantity of coke has appreciable effect on the melting rate, metal temperature and quantity of cast metal produced. The coke charged must have following properties.

� *�� "� �� x?�� ?x�� H ��?��/��by weight.

� /��x��x��x��"��?

� /!�#�!��x?��?x��*�� #��! ��x?��0.3%

3) The size of coke used may be as follows:

(a) For cupola under 900 mm dia. 50 mm for charge ��x��?

(b) For cupola of 900 mm dia. and above 75 mm for ��x��?�k��must be very dense to sustain charges above.

4) The performance of cupola may be judged in terms of following factors.Fig. 8

Fig. 9


��;��!��#��!��xx��x0C.

��;��>��"��"�� per sq. metre area of cupola per hour.

(c) Combustion ratio: It is given as –

CO2 ��xx

CO2��$:

The quantities of CO2 and CO are expressed volumetrically. The ratio may vary from 45 to 90%. For this reaction, porosity of coke is very important.

(d) Percentage of total heat input absorbed by metal �� @��"�� "� ��"��?

�� Q�� >�� "� ��"� �� x� �� !� �� #�� ?�metre of cupola cross-section area per minute at 0C and 760 mm pressure of mercury.

B��!��

ratio, the blast rate, and metal temperature. Figure 9 further shows the relationship between the cupola diameter, melting rate and the blast rate.

Conclusions

Cupola is the most important melting unit for small and medium-size foundries. Now lots of modern developments are being done in cupola designs. Now cupola in combination of rotary furnace can be used for production of ductile iron.

References

�� HB/�$!#��:#��?

2) Principles of Foundry Technology by Mr. P.L.Jain.

3) Experience in Meehanite Foundry at Cooper Engineering Ltd., Satara Road.

4) Modern Foundry, Ahmednagar.

5) Search on Internet.


THE INSTITUTE OF INDIAN FOUNDRYMENMembership Strength as on February 28, 2015

Those members who have paid their Annual Subscription for 2014 and beyond have been included

� � �� !��"#$��%��&��'()� � )�$�� * � ��!��"#$��%��&��+��'( ��, � ��!��"#$��%��&+��/��'(�� 4��$�� 7 � ��!��"#$��%��&��%��/��'(

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;��48��$� �/ B B * I � 7 *� B � 7+

=�� 8� H B B B B * � 7� I, B ��I

Total 51 0 0 22 29 11 34 205 67 12 431Foreign 0 0 0 0 0 0 0 0 0 0 0Northern �9�� * B B �/ , , B *� , B 7*

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Total 27 1 0 50 52 17 32 260 17 2 458Southern <��9�� *G � B �, H + �/ IH H� 7 **H

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?�� B * � B B � 7, * � +�

��9�� + B B B B B B G B B �*

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Total 175 5 9 69 67 34 88 464 1258 13 2182 Western �8�� ,I B � I �� , H HG �I 7 �F,

Q�� HI � B G G * 7 �+ B B �,*

<8�� F B B B B B � �� B *�

R�'�$�� *7 B B *, �I I �H GG �7 * �F�

�� * B B * � B + ,H B B 7H

?��8��$� G B B F F � I �GF GG � *FI

U�9�$� ,/ B B + * B , ��7 + B �+H

W$�� ,� B B + H + �+ GI � , �7+

=�JA�� 7+ B B H I 7 7 G+ 7 B �7G

Total 279 1 1 65 60 21 66 682 118 10 1303Grand Total 532 7 10 206 208 83 220 1611 1460 37 4374


Price Trend of Foundry Raw MaterialsFerro-Chrome, Ferro-Si / Pure Mg, Ferro-Mn, Steel Scrap, Pig Iron, LAM Coke, Al Ingot

NOTE : Freight from China to India Port is about 60-80 USD PMT for container load.



Ferro-Chrome

Ferro-Si / Pure Mg

Ferro-Mn

US

Cen

ts/l

bFO

B C

hin

a P

ort

USD

/To

nn

e Ex

Pla

nt

Ch

ina

USD

/To

nn

e FO

B C

hin

a P

ort


Price Trend of Foundry Raw MaterialsMELTING STEEL SCRAP IN ` PER KG INCLUSIVE OF EXCISE

PIG IRON IN ` PER KG INCLUSIVE OF EXCISE

LAM COKE

PRICE OF AL INGOT

` / KG

` / KG

` / KG


Visit us at Hall 15/F02, GIFA Dusseldorf, 16-20 June 2015

Vol 61 � No. 3 � March 201557


New Rates of Membership Subscription

�� !�� "�� #

$��"��%�� "�� &��'��&��(�� !��)��*��+� �,��-��.��#��/��*"�� #��

INDIVIDUAL MEMBER

Category Annual Subscription Annual Subscription for 2015–2016 for 2016–2017

�0�102� 2�#��3&� 2�#��3 &��

.$4,0+$��0�102� 2�#��3&� 2�#!��3&��

�55�6��$0��0�102� 2�#��3&� 2�#!��3&

COMPANY MEMBER

Annual Sales Turnover Annual Subscription Annual Subscription for 2015–2016 for 2016–2017

1�� %�� 2�#��3&� 2�#!��3&1�� %��%�� 2�#/��3&� 2�#��3&1�� %��%�� 2�#��3&� 2�#8��3&��"��%�� 2�#�!��3&� 2�#��3&

INSTITUTIONAL MEMBER

Annual Subscription Annual Subscription for 2015-16 for 2016-17

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.��" ��$�9��"��*��9�� #

��5�� *�� *��#

$�� "�� "�� &�� :�� "��3�#

$��9�� !�� ;��:��<��"�� #�$�� "�� 3�� ;�� *��#


1. Module-I Pre-Diploma (ITI Level) Eligibility : Class 10 passed of 10 + 2 schemes or equivalent

�!��@��?

Registration : Eligible candidates are to register themselves

� � �!�� *�4=�#�� $��@�� 9��?� :��

registered, student will receive Syllabus and Study Materials

of all the 10 subjects. Students willing to register have to

send a DD of `2,000/- drawn in favour of “The Institute of

Indian Foundrymen” payable at Kolkata.

Examination Fee : ` 100/- for each paper or `900/- for TEN

papers at a time.

Student Question Bank : Last year’s question papers are

available against payment of `50/- per set (inclusive of

mailing charges).

2. Module-II Diploma Examination Eligibility:

� Class 10 Passed of 10 +2 in Science or its equivalent

with Physics, Chemistry and Mathematics.

� ITI Passed or Module -I of IIF passed.

Practical Experience: ��:�9��"��#��#��

foundry or allied industry before/after successful completion

�� !� ?�� :�9��

"��R ��#��"�� ##��/��+H8�#��

�Z �� !�� #�� #��

�##��/��+Q8��:�9��"��R ��#��

training in an approved foundry or related organisation for

��;�!��>>��=�#��$��@��?

Syllabus: Cost of Syllabus along with Registration Form is

` 100/-. Candidates need to send the amount by a Demand

Draft in favour of” The Institute of Indian Foundrymen”

payable at Kolkata.

Registration : Eligible candidates are to register themselves

� � �!�� ;�!��4�>>�9��?�B�� #!�#� ��

�� !�� !�� _�� B��?� !�"� @��4��

��Q��=��̀ 800/- to get his/her Registration

Number.

Examination Fee: `500/- for each paper or Rs.2000/- for

appearing in FIVE papers under one Section at a time.

3. Graduateship Examination (Grad IIF) (Recognised by Govt. of India, Ministry of HRD)

�� 10+2 in Science or its equivalent

with Physics, Chemistry and Mathematics.

Examination on Foundry Technology– SUMMER (JUNE 2015) Practical Experience :

� �� k��"�� #��B�!��"?

(b) Engineering Graduates in Metallurgy / Mechanical / Production / Manufacturing etc. where Foundry is a �� !�]��!��"�#��#��?

� �� $�� "�� #�� #�� #��"�� ##��#��

� �� Z/�� !�� R�#��#�� ##��/�?�©QR��

� �� *�� #�� "�� approved foundry or related organisation before he/ �� @��"��>� ��!�?

Syllabus : Cost of Syllabus along with Registration Form is ` 100/-. Candidates need to send the amount by a Demand Draft in favour of “The Institute of Indian Foundrymen CET” payable at Kolkata.

Study Materials : For Study Materials, please contact CET at IIF Center, Kolkata

Registration : Eligible candidates are to register themselves � � �!�� %��4>>B� 9��?� B�� #!�#� �� !�� !�� _�� B�� !�"� @��4�� Q�� =�� `1000/- to get his/her Registration Numbers.

Examination Fee : `600/- for each paper or `2500/- for appearing in FIVE papers under one Section at a time.

Note : H��=��=�� !��+k��Institute of Indian Foundrymen, CET” payable at Kolkata in advance as per requirement.

Schedule of Examinations : 22nd to 26th June, 2015

Last date of application for appearing in Examinations for all modules : 30th May, 2015

Last Year’s Question Papers : H�� *�"�� ` 50/- per year (inclusive of mailing charges).

H��$��!�� H� ��

The Institute of Indian FoundrymenCentre for Education and Training

‘IIF CENTER’, 335 Rajdanga Main Road9� ��`��k�� #�*?:?��

Kolkata - 700 107Ph : (033) 2442-4489 / 6825, (Direct) 40630074

E-mail : [email protected] / [email protected]

Website : http://www.indianfoundry.org

Candidates appearing in

Module-I (Pre-Diploma) Examination

are eligible to write in Vernacular.


Day/Date 10:00 am to 1:00 pm 2:00 pm to 5:00 pm

Monday/22.06.2015 ;�� H4�� >��!��$��#!��H4��

Tuesday/23.06.2015 *�" �� H�� $�� "��H��

Wednesday/24.06.2015 ;�� /�� B�!� ��H�� >��!��;�� H��

Thursday/25.06.2015 Y�� #�k��"��B�!��"��H�� Q� ��9��'�9�� 9��H��

Friday/26.06.2015 9�� k��$��!��H�� 9��=��H4�x�

SECTION:B


Monday/22.06.2015 k��"��B�!��"�*�� Q�� *��#� ��;��'�$� ��?= ��Q��

Tuesday/23.06.2015 k ��;�� 'H��" ��Q�� B!� ��B!�� '�_�� Q��

Wednesday/24.06.2015 B�!��"�;��Q�� ;��!��"��$� ��H��" ��Q��

Thursday/25.06.2015 9��"�9�@��"�'�*��!��$��Q�� H�� $� ��k��"��Q��

Friday/26.06.2015 9��>��Q��"��!# Elective II any one of the following each group

a) Technology of Iron Casting a) Welding Technology

b) Steel Foundry Technology ��B�!��"�>� ��!��'�$��

c) Non-Ferrous Foundry Technology ��B�!��"�;�� H!��'�V�"�!�

��*�" ��;�?��B��! �'��4B��! �H��"

Module – II (DIPLOMA) SECTION:A


Monday/22.06.2015 ;�� H4�� 9��?�*�" �� H��

Tuesday/23.06.2015 H##��$�� "��H�� 9�� $��!��H��

Wednesday/24.06.2015 9��?�=��H�� >��!��$��#!��H��

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Friday/26.06.2015 Q� ��;��9��?��H��

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Tuesday/23.06.2015 ;��'�$� ��k��"��Q�� /#��$� ��*�� Q��

Wednesday/24.06.2015 ��k��$� ��?�_��9�!�#�� Q�� k ��'�>� #��B�!��"��Q��

Thursday/25.06.2015 >�! ��;��Q�� Elective -I (any one of the following)

��*�� *��'�$� ��9 ��9>�

��*��?�$��'�:��!#��B"��9>>�

��*��#� ��;��'�$� ��= ��9��>>>�

Friday/26.06.2015 Elective-II (any one of the following)

a) Technology of Cast iron (EIV)

b) Technology of Cast Steel (EV)

��k��4��! �;�� '�H��" ��9�>�

Module-I (Pre-Diploma-ITI Level)

Day/Date 10:00 am to 1.00 pm 2:00 pm to 5:00 pm

Monday/22.06.2015 English (P1) Physics (P2)

Tuesday/23.06.2015 Chemistry (P3) Mathematics (P4)

Wednesday/24.06.2015 Engineering Drawing (P5) Workshop Technology (P6)

Thursday/25.06.2015 Pattern Construction (P7) Moulding Technology (P8)

Friday/26.06.2015 Melting Tech./Cupola Melting Emission Control (P9) Cast Metal Technology (P10)

EXAMINATION PROGRAMME FOR SUMMER 2015 (22ND to 26TH JUNE, 2015)Module-IV (GRAD IIF) SECTION : A


The country’s largest international exhibition of foundry products, equipments, input items,

simulation software, logistics - IFEX 2015, organised concurrently with 63rd IFC during Feb. 27 to March 1, 2015 at India Expo Centre, Greater Noida was a platform for exchanging latest know-how of casting production process and information on newer cast materials. Spread over an area of 15000 sqm, the exhibition, housed 242 modern stalls showcasing inputs, technology and process for foundry and its allied industries. ‘Cast India Expo’, part of IFEX 2015, showcased capacity and capabilities of Indian foundry industry to produce value-added castings. Exhibitors from various countries like USA, UK, Germany, Italy, China, Australia, Japan, Spain, Taiwan, The Netherlands, Sweden, etc. participated in this biggest ever foundry exhibition held in Northern India.

Inauguration FunctionOn Feb. 27, 2015 morning, the exhibition was formally inaugurated by Chief Guest Mr. Madhav Lal, Secretary to Ministry of MSME, Govt. of India by lighting the holy �� WFO President and other dignitaries. Then the dignitaries unvailed the exhibition for visitors by cutting the ribbon.

Mr. Naresh Garg, Chairman, Organising Committee of 63rd IFC while delivering his welcome address stated the aim of organising IFC and IFEX include building networks, creating business and strengthening Indian economy. He also said that the programmes of the mega event were also designed to encourage, innovation and exchange of ideas.According to the IFC Chairman, IFEX is a forum to launch

IFEX 2015

A Global Window for Technology Transfer, Buyer-Seller Interface and Many More


IFEX-2015 & Cast India Expo

latest technologies, products, etc. Here opportunities galore as many people of same interest come closer under one rooof from different corners of the globe to interact face-to-face on their common issues.

Focus of ‘Cast India Expo’ now is supporting the Hon’ble Prme Minister’s ‘Make in India’ initiative by foundry sector. To grow at faster rate, new technologies and strategic alliances are urgently required. He added that IFEX enables the exhibitors from various countries to avail of the opportunity of building wider business network. Mr. Vikas Garg, President of IIF in his address described IFEX as a vibrant platform for both technology providers as well as technology seekers. He hoped that participants of IFEX would be able to explore new markets for their products/services.



Mr. Madhav Lal in his address appreciated IIF’s endeavour for organising such a large exhibition over years in association with Koelnmesse YA Tradefair. He also congratulated IIF for obtaining ��

Mr. Vinod Kapur, President, WFO and Past President, IIF while speaking on the occasion praised the organisers of IFEX for covering such a wide range of products/services with a large number of exhibitors from India and foreign countries.

Mr. Kapur presented a memento to IIF President Mr. Vikas Garg �� !�� "�

industry prominently in the world map.

Mr. Ashwini Pande of Koelnmesse YA Tradefair thanked IIF for extending cooperation for organising such a mega trade fair. He mentioned that there was a 30 per cent increase in the number of exhibitors in IFEX 2015 compared to its last edition held in Northern Region.

After start off the exhibition with ribbon cutting, the Chief Guest along with other dignitaries went around the exhibition, observed various exhibits and also stopped for a while in a few stalls including IIF stall.


IFEX-2015 & Cast India ExpoIFEX-2015 & Cast India Expo

IIF Fellowship ConferredIIF Fellowship has been conferred this year at inaugural ceremony of 63rd IFC in Greater Noida. Four distinguished members of IIF have been conferred with this honoured before a large audience in the Forace Hall B of India Expo Mart. Guest of Honour Dr. Ram Shankar Katheria along with IIF President Mr. Vikas Garg ��#�� $��%�&��'�� personalities from different Regions of IIF have been honoured in recognition of their outstanding contribution to the Institute as well as to the industry. They have been actively associated with IIF for a long time. However, one of the recipients Mr. N. D. Desai could not be present due to illness. On his behalf, Mr. Anant Bam received the honour.

Mr. Garg was instrumental in pursuing the central Govt. on behalf of IIF to introduce vocational course on foundry at Plus 2 level by the Ministry of HRD. He has been interacting with several ministries on different issues pertaining to foundry industry. He took keen interest in IIF’s application for BMO accreditation which has recently been awarded to IIF under Gold Grade.

Mr. Garg is associated with several charitable and educational organisations.

Past President of IIF Mr. Naresh Garg has been actively associated with the Institute for 20 years. He has been serving IIF at various capacities at Regional as well as

National level.

A Graduate in Economics with Hons. from St. Stephens College, Delhi University, Mr. Garg also obtained his Degree in Law from Campus Law Centre from the same university.

He is Managing Director of Ratan Engg. Co. (P) Ltd., Novino Marketing (P) Ltd. and Jai Bharat Industries. Ratan Engg., a steel casting unit, at Bhiwandi, Rajasthan supplies castings to valve industry, railways, mining and power generation sectors. Novino at Faridabad manufactures ground engaging tools and undercarriage �� #"�� #��&�� *�� specialises in producing heavy duty bi-metal hushes and precision components for Indian Railways.

��+��'��has served the Institute as Chairman of various Committees and of Foundry Informatics Centre in Delhi.

Mr. Garg played crucial role in organising 46th, 49th, 51st and 63rd editions of Indian Foundry Congress.

Mr. Naresh Garg

Mr. Ram Bhandare

A seasoned foundryman Mr. Ram Bhandare is Chairman of Belgaum Foundry Cluster – one of the Best and Model Clusters in India, recognised by DIPP, Government of

India.

He has been actively associated with IIF for a long time. He is the main force in organising various activities of IIF-Belgaum Chapter regularly. Mr. Bhandare’s leadership role contributed a lot to the success of the foundry cluster.

The Chairman & Managing Director of AKP Foundries Pvt. Ltd., Mr. Bhandare is a Metallurgical Engineer from Karnataka Regional Engg. College (now NIT), Surathkal.

�:;� �� $�<=$� >?@Q@� Z� �$�� >Q[[>\][[Q� ��company with a total production capacity of 23000 tonnes/annum produces ductile and grey iron castings for automotive, power generation, compressors, valves, construction and mining

�� ^�� :;� �� #�� a number of units. His company is the winner of a number of awards from EEPC and other associations for excellence in export ��&��"��development.


A �� #�� +�� %�&�� with the Institute for a long time. He has been serving IIF at Chapter as well as Regional level commendably.

He was Chairman of Howrah Chapter from 1997-2003 when the Chapter was adjudged as Best Chapter for three consecutive years. He was also Hon. Treasurer and Chairman of IIF Eastern Region.

A Mechanical Engineer from Bengal Engg. College (now BESU), $ �+�� %�&�� "� �� $�� %��_��%�&��+��#��responsible positions, served a number of organisations like MMC Ltd., Kolkata; Rehabilitation Industries Ltd., Durgapur; BESCO Ltd., Kolkata; Pench Steels Ltd., Bandel; Kankeswar Iron & Steel Co. Pvt. Ltd., Panagarh; Hyderabad Castings (HM), Kolkata; Hindusthan Udyog Ltd., Kolkata; Texmaco Ltd., Belghoria; RRL Steels Ltd., Howrah. Presently he is President of Adak Metcast Engineers Pvt. Ltd., Howrah.

Mr. Samsul Haque

Mr. N. D. Desai

��%�&�� +�� z��He also made presentations on various aspects of metalcasting technology at different workshops.

��%��&�� {��|��

A member of IIF for near about half a century, Mr. N. D. Desai always takes part in IIF activities enthusiastically. He was the Chairman

of IIF-WR in 2011-12 and a National Council member for 10 years. He is also in the council of IIF-WR since 1968. 58th Indian Foundry Congress was organised in Ahmedabad when Mr. Desai, Chairman, IIF-Western Region played a crucial role in its success.

An MA in Economics, Mr. Desai joined Chunnilal

Foundry & Engineering Co., Khambhat as Commercial Manager in 1960 and rose to the position of CEO of the company in 1970. Chunnilal Foundry, where he served for 27 years was a reputed casting supplier to automobile and tractor industries. At present, his own Marketing Organisation is taking care of product of 8 prominent foundries from South, West and North India.

64th Indian Foundry Congress &

IFEX 2016January 29-31, 2016

CoimbatoreDetails are Available from :

Mr. C. R. Swaminathan, Chairman, Organising Committee, 64th IFC




DVDs on Workshops/Trainings

Conducted Recently by Renowned FacultyPrepared by

Centre for Education & Training of IIF� Elementary Metallurgy for Foundrymen (1-DVD ) CET/DVD/MET-1 Price : (Inclusive of Postage) : ` 850/-

� Operating Aspects on the Use of Resin Binders & No-Bake Equipment (2- DVDs) CET/DVD/NO-BAKE-1 Price : (Inclusive of Postage) : ` 1150/-

� Technology of Ductile Iron & Defect Analysis of SG Iron Castings (2- DVDs) CET/DVD/DI-1 Price : (Inclusive of Postage) : ` 1,550/-

� Austempered Ductile Iron (ADI) and Compacted Graphite Iron (CGI) CET/DVD/DI-2 Price : (Inclusive of Postage) : ` 850/-

� Subjective Moulding Process for Improvement in Methoding CET/DVD/METHOD-1 &� Metallurgical Aspects of Methoding for Steel & Ductile Iron Castings Price : (2 DVDs) (Inclusive of Postage) : ` 1150/-

� Casting Defects and Remedies (Ductile Iron, Grey Iron & Steel Castings) (2 DVDs) (CET/DVD/ CAST-DEFECT-1) Price : (Inclusive of Postage) : ` 1150/-

� Metallurgy Made Easy for Foundrymen (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Sand-Related Defects and Their Remedies in Producing Quality Casting (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Safety Operation and Maintenance in Induction Melting System (2 DVDs ) Price : (Inclusive of Postage) : ` 1150/-� Selection Installation and Maintenance of Refractory Lining in Coreless Induction Furnaces (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Practical Pathway to Rejection Control in Grey and Ductile Iron Casting Production (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Foundry Process of Core and Mould Making Relevant to Ductile and Grey Iron Castings (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Using Casting Simulation to Increase the Yield and Reduce Rejections in Castings – Arun Pandion (1 DVD) Price : (Inclusive of Postage) : ` 850/-� Analysis of Casting Defects in Foundry by CAE – Tapan Roy (1 DVD) Price : (Inclusive of Postage) : ` 850/-

All payments should be made by at Par Cheque or Demand Draft favouring “The Institute of Indian Foundrymen CET” payable at Kolkata.

Please Contact : Centre for Education and Training (CET)The Institute of Indian Foundrymen

IIF Center, 335, Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107Phone : 033 2442 4489 / 6825, Fax : 033 2442 4491


�� 77



Indian Foundry Industry - The Way Ahead ��

Economic factors include the political will, business environment, and demography.

The Government is to be commended for its � �� campaign and incentives for foreign companies to set up their manufacturing units here, bringing in investment and creating employment opportunities. We need to equally focus on � �� technologies and products that better match local requirements and lead to long-term development.

Business environment is yet to revive in India, even as foundry industry is losing experienced personnel at an alarming rate. On the other hand, China is consolidating its global dominance on low-cost large-order castings. Is there any hope? Yes. Many new sectors are coming up on the horizon: aerospace, defence, renewable energy and medical devices. These need a different approach: knowledge-based �� and quality assurance, where India can lead.

Demographically, India has the world's youngest population - over 50% below 25 years, and is adding 1 million new job seekers �� ! But we don't �� !�@�� !�� !��!��experience. As a result, our students are �� in manufacturing sector, including metal casting and are going away to service sector. We need to bring them back to engineering.

Technological factors -There are many, so let us look at the top three:

3D printing has taken the world by storm. Overnight fabrication of a plastic pattern of a small valve for about Rs.5,000 is now possible. Sample castings can reach a customer within a week. There are 3D metal printers too, but these machines and the parts produced by them are still too expensive to be a real threat to foundry industry (after 5 years, perhaps, that too only for intricate parts required in small numbers).

Cloud Computing has changed the way we communicate - storing and transmitting our emails and documents. In future, this technology will be extended to online training, casting simulation, and other activities that can be used in self-service mode. E-Foundry (funded by the National Knowledge Network) is a good example: it crossed 50,000 visitors and half million page views within two years, and accounts for several hundred casting simulations every month.

Smart Sensors and Big Data are transforming our daily life. Modern cars have 50-100 sensors, enabling better �!�� @��"�� #�� ?�Thanks to sensors and automation, the number of workers per foundry will keep reducing. They will be replaced by data workers for monitoring sensor output, to control and optimise the entire process.

�� into digital, dynamic and dependable using new technologies to design, develop and deliver high-value castings.

RecommendationsIndian foundries need to quickly reinvent themselves - become keen, lean and green. Not �� horizon and rapidly grow in future.

Keen implies sharp; a burning desire to excel. Indian foundries have to shake off despair and unhealthy competition. The younger generation (children of foundry owners) trained in Western Institutes are showing the way. They know that the knowledge gained from years of experience (read, mistakes) is more valuable than machines. They know how to properly document, protect and leverage their past knowledge for business development and value addition.

Lean� ��#�� "� �� !�� @��

space, materials, energy and human resources, leading to 10x or more value-addition. We will see compact casting units, operating from space as small as 1000 sq.ft., manufacturing high quality parts for new sectors (like aerospace and biomedical). They will use 3D technologies for scanning, modelling, simulation and inspection, along with smart low-cost automation to achieve consistent high quality.

Green implies clean foundries, inside and outside. Foundries can become like hospital OTs, but need a


change of attitude and obsessive maintenance. New as well as hybrid manufacturing processes, including novel equipment can be indigenously developed and locally adapted, so (unlike China) we do not pollute our air, water and soil.

Discussion PointsBringing these ideas into reality requires a close collaboration with researchers and teachers, but where are they? Most of the new engineering colleges do not have metallurgy departments at all and the older Institutes are converting them into material science!

Can we set up model !�� !�� in all clusters to attract & train youngsters, as well as retain & retrain experienced engineers?

Can we ensure inclusive sustainable development of

foundries through a �� of committed leaders from industry, academia, research and Government, asking them to:

1. Evolve (actionable) short-term, medium-term and long-term plans

2. Interface with Government agencies for suitable policy interventions

3. Identify, motivate and support the next generation of industry leaders.

"�� #�� $�� % ��%�� &�'�� '�

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(�� ,.9� ��A3��!��,�� !��2B�� 0��240C��?��<��)��<,+�

This book is a compilation of 33 casting simulation case studies. including 9 cast iron, 9 ductile iron, 7 steel and 8 non-ferrous parts. Most of these case studies were originally published in the Indian Foundry Journal. A few more cases have been added, and all of them have been expanded into two pages for better clarity and understanding.

Each case offers interesting insights regarding the application and effect of various Methods design parameters including the location, size and shape of feeders, neck and feedaids. Each project represents a different combination of part geometry, metal, process and application sector. The solid model and simulation, results of both defect-prone layout and the improved layout are presented in the form of captioned images. The cases were contributed by different researchers and simulation experts and edited by Dr. B. Ravi, Chair Professor of Mechanical Engineering at lIT, Bombay.

Send your Order for this book to :

Mr. G. Mukherjee, Director, CET-IIF � E-mail : [email protected]

Casting Simulation Case Studies Published by : Centre for Education & Training, IIF

Price : ` 950/-

Vol 61 • No. 3 • March 2015Indian Foundry Journal 81

Dear Nareshji,

Congratulations!! for having given a wonderful and memorable event, which was action packed and smooth. The credit goes to the entire team who made the above event a great success through the synergetic efforts. I congratulate all the members of the team for this success.

Many thanks for having taken extra care for WFO Executive members and inviting them to all the programs. They have gone back with pleasure and definitely they will remember the warm hospitality extended to them.

Thanks for inviting me to the inaugural ceremony of IFEX 2015. The memento presented to me was beautiful which has been nicely designed and very well crafted. It occupies a very prominent place in my office.

Once again thank you for all your support and help in arranging our meeting.

With warm regards,

Vinod Kapur, President-WFO

Congratulations for mega success of IFC at Noida to you and your team.

Greetings,

Ashok Sharma

Thanks for all that you did! I had high expectations for my first trip to India and they were exceeded. Can’t wait for my second trip. The trip to the Taj was fantastic, I had a great drive and guide.

Enjoy,Denny

Dear Mr Naresh Garg & Organising Team,Congratulation, for excellent arrangements, good food and hospitality during the 63rd Indian Foundry congress and IFEX 2015 The technical sessions were well attended, however footfalls could have been better.

Subodh Panchal, Past President, IIF

Feedback on “63rd IFC & IFEX”

Dear Vinod Kapur,

Many thanks for your mail on 12th March 2015.

Congratulation you have had great success of the 63rd Indian Foundry Congress.

I have really impressed how Indian foundry have young mind and great power to develop the business.

I am one of the leaders in Japanese foundry business, so we need to touch Indian foundry power.

I hope to keep the good relationship in between Indian and Japanese foundry people.

We thoroughly enjoyed to stay in India on this time.

I would say again many thanks for you and your wife.

I hope to see you in Germany on the time of GIFA.

Best regards

Hiroyoshi KimuraHon. ChairmanKimura Chuzosho Co. Ltd.

Dear Vinod,

Thank you very much for your kind words and for your extraordinary hospitality during our last stay in Delhi.

One could personally feel that the country has a strong foundry industry and is in a positive trend to increase its competitiveness level.

The visit to the Taj was a bit tight but we managed to make it within one day trip. A marvelous experience !!!!

Once again it was a real pleasure to meet you and to attend this WFO Executive Meeting, as well as the 63rd Indian Foundry Congress with the Foundry Exhibition.

I think that it was a very positive meeting. I saw a real implication within the Executives (specially remarkable the compromise of Carsten and Dennis), which will allow us to go in the right direction ……… not without the corresponding efforts.

Kindest regards and we see you once again in Düsseldorf.

Xabier González Azpiri, Director General, Zuzendari Nagusia, General Manager, IK4 Azterlan

Message

It was indeed my pleasure to attend 63rd Indian Foundry Congress held at

World Class Venue at Greater Noida from 27th February to 1st March, 2015.

All the technical sessions and meetings were nicely coordinated and attended

by participants in large Nos. The latest technologies demonstrated in exhibition

Cast Expo would motivate foundry entrepreneurs to modernize their foundries

to become globally competitive. I thank organizing committee for successfully

organizing this world class event.

R. Panneerselvam, Principal Director, PPDC, Agra

R. Panneerselvam

Principal Director

Dear Mr. Vikas Garg,

The 63rd IFC under your able leadership

had been a memorable one in many respects.

The CEO Meet and the KSS Memorial

Plenary Session on 3S were very useful and

timely. Congratulations to you and your

team.

Warm regards,

Prof. G. L. Datta, Former Professor,

Dean of IIT Kharagpur Vice Chancellor,

Chancellor of K L University, AP


Contents – l Evolution of Moulding Systeml Quality of Foundry Sand and its Application l Basics of Sand Mixingl Moulding, Core Making and Fettling l Coatingsl Sand related Casting Defects

NEW RELEASES FROM CETCET-Guide Notes for Module –II (Diploma)

Process Planning and Cost Estimation Contents – l Product Design and Process Selection l Process Selection and Facility Layout l Capacity Planning l Shop-Floor Planning and Control in Manufacturing l Resource Requirements l Quality Requirement l Cost Estimation in Foundry Practices

CET-Study MaterialPractical Aspects of Cupola Operation Foundry Sand Related Topics Contents –

l Practical Aspects of Best Operating Practice in Cupola Melting

l InsightsinEfficientCupolaOperation l Heat Balance of a Cupola Operation l Deciding Metal : Coke Ratio l Do’s and dont’s to Conserve Energyl Occupational Hazards in the Foundryl Pollution Control Devices Commonly Used

Send your Order for these books to : Mr. G. Mukherjee, Director, CET-IIF l E-mail : [email protected]

We are looking for a Joint Venture or to lease a Steel Foundry currently engaged in manufacturing Grinding Media Balls, High Chrome Liners and Manganese Steel Castings.

Foundry must have the necessary infrastructure like High Pressure Green Sand Molding Lines and Heat Treatment along with Oil Quenching facilities.

Foundry must have 5+ years experience in manufacturing the above at competitive prices.

If interested, write to us at [email protected]

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Reliable Source for :

Base Metals & Alloys Minor Metals

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Copper Phosphorus 85 / 15% Nickel Metal Ni : 99.9% min Lead Ingot Pb : 99.97%minTin Metal Sn : 99.85% minSecondary Zinc Ingot 98.5%Zinc Metal Zn : 99.95% minS. S. Scrap 304/304 L/316/316LTitanium Scrap Ti : 99% min

Antimony 99.65% min Arsenic 99% minBismuth 99.99% min Antimony Trioxide 99.5% minCalcium Aluminium Alloy : 75 / 25%

Chromium 99% min Cobalt 99.65% minCerium Misch Metal Megnesium 99.9% minManganese Flakes 99.7%min Manganese Briquettes 97% min Nickel Oxide : 75 % min.Menganese Metal LampsMolybdenum Metal 99.8%min Cobalt Oxide 70% minSelenium Metal 99.9% min Silicon Metal Si : 99% min(Powder 200 mesh/Granules) (553/441/3303/2202)

Noble Alloys & Ores Ferro AlloysCalcium Silicide Lumps/Granules/ Ferro Aluminium Al : 30% / 35%min Powder Ferro Boron B : 18%min Ferro ChromeFerro Molybdenum 57% min HC HC Cr : 60%min, C : 5-8% P : 0.01%max /0.35%max MC MC Cr : 50-55%, C : 2% maxFerro Niobium 63% min LC LC Cr : 60%min, C : 0.03% / 0.05% / 0.1% max Nitrited Low Carbon Ferro Chrome Cr : 60% min, N :8-10%Ferro Titanium 30 - 35% 68 - 72%, Al : 2%max Ferro ManganeseFerro Vanadium 50% & 80% HC Mn : 70% min. Si : 0.5%max/1.5% max P : 0.1%max /0.4%max MC Mn : 70% /80%, Si : 1%max /3%max P : 0.15%max /0.35%maxMoly Vandaium 57% min LC Mn : 70% /80%, C : 0.1%max, P : 0.15% max(Powder/Briquette)

Chromicte Sand Cr2O3 46%min Ferro Silicon Si : 70% min, Al : 1.5%max, C : 0.1%max(Samchrome - South Africa) Ferro Silicon Magnesium Mg : 5-7%, Si : 40%min Perlite Ore SiO2 71%min Mg : 8-10%, Si : 40%min Ferro Silicon Zirconium Zr : 15%min. Si :38%min Carbon Additive (Raiser) Zr : 30%min. Si : 38%min FC : 90% min Ferro Sulphur S : 50% min Silico Manganese Mn : 60%min, Si: 15%min

Block No 800/801, Cadilla Estate, Opp Tulsi 5623, Basti Harphoolsingh, 3rd Floor, No.7, North Railway Terminus Rd.Phone : 02718 - 261073 Phone : 011-2351 1194 /2351 3657Fax : 02718 - 261074 Fax : 011-2351 1182 Fax : 044 - 2590 3006E-mail : [email protected] E-mail : [email protected] E-mail : [email protected] : Mr. Shalaj Gupta [email protected] 09375033830 Contact : Mr. Ajay Gupta (Chennai) Mr. Shameer Babu : 09381060001 9811084240 / 9313281075 (Coimbatore) Mr. G. Ramesh : 09443062100 Mr. Santosh Khandelwal 9310611122 / 9313611008

Head Office : Shop No. 15, Hi Life Mall, P.M. Road, Santacruz (W), Mumbai - 400 054, Ph : (022) 61120500Contact Person : Mr. Rajiv B. Khandelwal - 09820080250/09323880250, Mr. Sanjiv B. Khandelwal - 09323160250,

Mr. Mahavir J. Jain - 09820189931/ 09321044897, Mr. Rajesh J. Jain - 09869214950, Mr. Aakash S. Khandelwal - 09324612137, E-mail : [email protected]

Vol 61 • No. 3 • March 2015 Indian Foundry Journal 86

Ace Designers LimitedFoundry Division (Established : 2013)

Vision : Large-Scale Producer of World-class Casting and Machine Tools.

Mission : We will recognise our responsibilities as corporate citizens to faster progress, to promote general welfare of the society, create an environment to our staff to grow and advance to prosperity and thus promote a sense of belongingness.We will exceed customer expectations through reliable product, on-time delivery, cost-effective solution with an added assurance of prompt service.

Capacity: 1000 MT/ Month Total Area: 16000 SQ. MTR No. of Employees: 125

Weight Range: Grey Iron: 300 kg to 6000 kg - SG Iron: 500 kg to 3000 kg

InfrastructureMelting : 4 MT Dual-track, Medium Frequency Induction Furnace.

Moulding and Core Shop : IMF-make Continuous Sand Mixer 60 MT cap/ 10 MT cap, Moulding Line with Rollover. Infrared Oven / Gas Oven, Closing Station with Mould Handler, Pouring & Cooling line, Mould Pusher & Shake-out.

Thermal and Mechanical ReclamationFettling: Shot Blasting Machine, Stress Relieving Furnace and Primering.

LaboratorySpectrometer, Mechanical Testing, Sand Testing, Carbon Silicon Analyser, Temperature Measurement.

Other InformationGreenfieldfoundrycaterstothecaptiveandjobbingrequirement.

Typical PartsLathe beds, Grinding beds, Columns, etc.

Customer SectorsMachine Tools, Pumps, Earthmoving, Agriculture, Printing, General Engineering, Energy.

Contact Persons:

Mr. E. R. Badreesh, General Manager, Foundry; M: +91 9845995165, E-mail: [email protected]

Mr. Ramesh A., Deputy General Manager; M: +919845102870, E-mail: [email protected]

Corporate Office: Works:Ace Designers Ltd. Ace Designers Ltd. – Foundry DivisionPlot No. 7&8, Phase-II Sy. No. 53/4 to 53/8, Minnapura VillagePeenya Industrial Area Thyamagondu Road, NelamangalaTq.Bangalore - 560058, Karnataka Bangalore - 562132, Karnataka


CET NEWS

National Workshop on “Investment Casting Process Technology”(NWIC-2015)

Investment Casting Society (ICS) of India and CSIR-Central Mechanical Engineering Research Institute (CSIR-CMERI), Durgapur

in association with The Institute of Indian Foundrymen (IIF) organised the above workshop at APC Roy Seminar Hall, CSIR-CGCRI, Kolkata on February 14, 2015.

The workshop aimed at bringing together experts researchers, industry captains, etc. from industries, R&D organisations and academic institutions to focus on future trend and challenges of manufacturing of net-shape castings through Investment Casting process.

The workshop was very useful to the students, researchers, professionals, etc. The programme was designed for further

development of their knowledge and skill in Investment Casting process, its newer/commercial applications and many more.

About 100 participants including academicians, researchers, students and industrialists from different organisations and institutions were present in this workshop. Eminent domain experts made their indepth presentations on different aspects of Investment Casting technology. The participants also took part in interaction among themselves and the speakers to share their experience as well as get �� ! � �!�� @?� k�"� � �! � � ! � ��#��!��"��!��"�� Z��"��@��"�and management in Investment casting production/business.

Technical presentations at the workshop covered recent advances in Investment Casting process. Several presentations delineated problem areas of immediate interest to the industry. In two Technical Sessions, quality presentations were made by prominent personalities. Prof. G. L. Datta, Former Dean, IIT Kharagpur and Former Chancellor of K L University, Guntur, AP inaugurated the workshop and delivered welcome address.

Dr. A. K. Chakrabarti, Former Professor, Met. & Matls. Engg. Department, IIT Kharagpur graced the occasion as Chief Guest.

Dr. N.P. Sinha, Director, CET-IIF was Guest of Honour. Prof. H.S. Maiti, Former Director, CSIR-CGCRI; Dr. Pijush Pal Roy, Chief Patron and Director, CSIR-CMERI were present at the workshop.

The following presentations were made at the Technical Sessions of the workshop:

� Production of Near-Net Shape Castings – Past, Present and Future : G. L. Datta

� Design and Development of Novel Ceramic Shelling for Investment Casting Process Technology : B.N. Mondal

��"��"��!��particulates for stuccoing on the wet layer of Ceramic Shell for Investment Casting process: Chanchal Loha, Pradip K. Chatterjee, Biswanath Mondal

� Application of Additive Manufacturing Technology in Engineering and Biomedical Application- A Few Case Studies: Palash Kumar Maji

� Numerical Simulation of Flow Behavior of molten Al-Si Alloy during High Pressure Die Casting Mould Filling of Knuckle Housing: Bikash Bhuniya, Prosenjit Das, Adwaita Maity, Tapan Ray, Santanu Das


CET NEWS

CET-Coimbatore

Workshop on “Basic Principles of Methoding for SG Iron Casting”

Ø Rapid Prototyping and Rapid Tooling for Rapid Response Manufacturing: Concurrent Engineering Approach: B. Doloi

Ø Transport phenomena and its modeling for Investment casting process: Himadri Chattopadhay

Ø Investment Casting: A Growing opportunity for micro metal components: Nagahanumaiah

The Organising Committee of NWIC-2015 expressed their

gratitude to the individuals and organisations who had

extended their help and support to successfully organise

the workshop.

CET, a centre of excellence of IIF organised an

inplant workshop at J.S. Autocast India Pvt.

Ltd., in Coimbatore.

Mr. Hari Baskar of Marriko Industries

deliberated on basic principles of Methoding

for SG iron casting. Object of organising such

inplant workshop was to upgrade knowledge

and skill of the shop-floor employees of the

foundry on Methoding – a very important step

of metalcasting production process which has

significant impact on quality and cost of the

cast products.

Mr. S. Muthukumar, Hon. Secretary, IIF-

Coimbatore Chapter delivered welcome

address and praised the management of J.S. Autocast for

their initiative for upgrading their shop-floor employees’

knowledge and skill.

Mr. S.K. Shankar Raman, CET Coordinator in Coimbatore

while speaking on the occasion had introduced the faculty

Mr. Hari Baskar and explained various activities of CET.

Soft Copy of IFJ Now Available to IIF Student MembersStudent Members of IIF can now access the web version of the IndIan Foundry Journal at www.indianfoundry.org/onlinelibrary

It has been decided that print version of the Journal will no longer be sent to them.


STUDY NOTES AVAILABLE FOR PRACTISING FOUNDRYMEN

CET WORKSHOP STUDY MATERIALSCasting Defects `

� Analysis of Casting Defects - Causes & Remedies (CI, DI) - Vol.I .................................... 350� Analysis of Casting Defects - Causes & Remedies (Steel) - Vol.II ................................... 350

Cast Iron / Ductile Iron� Alloy Cast Iron ................... 800� Ductile Iron Foundry Practice 550� Ductile Iron Production ....... 550� Ductile Iron Technology - Defects Analysis and In-mould and Stream Treatment .......................... 550� Grey Cast Iron Technology .. 350

Energy and Pollution Management� Air Pollution Measurement and Control in Foundries ..... 350� Energy Management and Audit in Foundries .............. 350� Energy Efficiency & Pollution Control ............................... 350

Foundry Furnaces� Cupola Practice .................. 350� Induction Furnace and Electric Arc Furnace (Operation Optimisation of Melting, Refractory Lining and Maintenance) ...................... 350

Foundry Practice� Advances in Casting Technology .......................... 400� Special Casting Processes .... 350� Some Aspects of Foundry Practice ............................... 350

Foundry Metallurgy� Basic Metallurgy of Steel Castings ............................. 450� Metallurgy for Foundrymen 350

Handbook � Cast Iron ............................. 350 � Foundry Raw Materials ........ 350

Methoding� Casting Simulation Case Studies ................................ 950� Conventional Methoding, Simulation and Solid Modelling ........................... 350

�� Indian Foundry Journal 95

� Engineering Methoding Practice in a Foundry .......... 350� Gating System Design for Steel Casting ...................... 350� Methoding Principle for Ferrous Casting – Major ..... 350 Pattern Making Technique & Methods � Methoding/Solidification Related Defects and Their Remedies for Iron and Steel Castings .................... 550

Moulding� A Guide of Sand Control Practice in Ferrous Foundries ............................ 350� Mould and Core Making (B-2) ................................... 350� CO2 - Silicate Moulding Process ............................... 350� Moulding Practices for Grey Iron Castings ...................... 200� Moulding Processes and Sand System ...................... 350� Moulding Sands and Processes for Steel Castings ............................. 350� Resin Binders & No-bake Related Equipments ............ 350

Repair/Welding/Machining� Application of Welding in Foundry Casting ................. 350� Machining Technology for Cast Iron Castings .............. 200� Repair and Reclamation Technology of Casting ........ 350

Steel� Steel Foundry Technology .... 450

Testing� Heat Treatment of Quality Ferrous Castings ................ 350� Inspection and Quality Control ............................... 200� Non-Destructive Testing ..... 350� Laboratory and Shop-floor Testing for Ferrous Foundry . 350


STUDY NOTES AVAILABLE FOR PRACTISING FOUNDRYMEN

CET GUIDE NOTES FOR MODULAR EXAMINATION

Grad – IIF : (Graduateship) `

� Advances in Casting Technology (B-8) ...................400� Energy Efficiency & Pollution Control (B-7) .........................350� Engineering Drawing I & II (Module IV) (A-10) ................400� Foundry Management (B-5) ..500� Foundry Mechanisation Automation (B-10) [E-IIc] .......350� Fuels, Furnaces & Refractories (B-4) ..................450� Introduction to Materials (A-6) .350� Metallurgy of Cast Alloys (B-6) .350� Physical Metallurgy for Ferrous and Non-Ferrous Alloys (B-9) [E-Ic] ..................350� Principles of Methoding & Casting Design (B-2) – Vol.II ..450� Steel Foundry Technology (B-9b) ...................................450� Technology of Iron Casting (B-9) [E-Ia] ............................350� Testing of Metals and Alloys (B-3) .....................................400� Theory of Foundry Processes (B-1) .....................................350� Workshop Technology for Foundrymen (A-7) .................700

Module : II (Diploma)� Basic Mechanical Engineering (A-9) .....................................350� Casting Technology (B-1) .......350� Electrical Technology and

Price (including Postage)

50% Discount on CET Guide Notes for Students registered in IIF Courses

Payment : All payments should be made by at Par Cheque or Demand Draft favouring “The Institute of Indian Foundrymen CET” payable at Kolkata.

Please Contact : Centre for Education and Training (CET)The Institute of Indian Foundrymen,

IIF Center, 335, Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107

Phone : 033 2442 4489 / 6825, Fax : 033 2442 4491, E-mail : [email protected]


Electronic Devices (A-7) .........350� Engineering Drawing - I (A-5) . 350� Heat Treatment of Castings & Related Equipments (B-5) ......350� Industrial Management (B-7) .400� Introduction to Engineering Materials (A-8) ......................350� Melting & Casting Technology (B-3) .....................................350� Mould and Core Making (B-2) .350� Pollution Control and Occupational Health in Foundry Industry (B-8) (E-II) ...400� Principles of Methoding & Casting Design (B-8) [E-III] – Vol.I ..........................450� Special Casting Processes (B-4) ..350� Technology of Cast Iron .........350� Testing and Inspection in Foundry (B-6) ........................400

Module : I (Pre-Diploma)� Cast Metal Technology (P-10) 100� Chemistry (P-3) .....................100� Cupola Melting Emission Control (P-9) [B] ....................100� Engg. Drawing (P-5) ..............100� English (P-1) ..........................100� Mathematics (P-4) .................100� Melting Technology (P-9) [A] ..100� Moulding Technology (P-8) ....100� Pattern Construction (P-7) ......100� Physics (P-2) ..........................100� Workshop Technology (P-6) ...100


List of Exhibitors at IFEX 2015

ABM China Co. Ltd. ................................... China

Andromat Henschel

Industrietechnik GmbH .......................Germany

Astral Material Industrial Co. Ltd. ............ China Aurrenak S. Coop ......................................... Spain

Bruker Elemental GmbH ....................Germany

Centrifugal Casting Machine

Company Inc. ................................................ USA

China Foundry Association ....................... China

Dorentrup Feuerfestprodukte

GmbH & Co. KG .................................Germany

Duratight Corporation Qingdao ............... China

EHP Wagetechnik GmbH ...................Germany

Elster GmbH .........................................Germany

ExOne GmbH .......................................Germany

F.lli Mazzon S.p.A. .......................................... Italy

FATA Aluminum ........................................... Italy

FESA ................................................................. UK

FlexiCAM GmbH .................................Germany

Fomet Srl ......................................................... Italy

Forbes Corporation ..................................Taiwan

Fritz Hansberg S.p.A...................................... Italy

Gemco Cast Metal Tech. .........The Netherlands

Hailing Far East Ltd ................................... China

Hangzhou Xiaoshan Daxing

Machinery Foundry Co. Ltd ...................... China

Holmatro ...................................The Netherlands

Huttenes Albertus Chemische

Werke GmbH .......................................Germany

IMF Impianti Macchine Fonderia Srl

(IMF Group) .................................................. Italy

Koyo Ltd. ...................................................... Japan

Maus S.r.l ......................................................... Italy

Modelleria Brambilla S.p.A. .......................... Italy

NovaCast Systems AB ............................. Sweden

Omega Foundry Machinery Ltd. ................. UK

Prince Minerals .............................................. USA Qingdao Duratight Carbon Co. Ltd. ........ China Qingdao Kaijie Foundry Machinery Co. Ltd. ..................................... ChinaSogemi Engineering Srl ................................. ItalyZiheng (Tianjin) Industry Co. Ltd. ........... China Tokyu Co. Ltd. .............................................. Japan FTL Foundry Equipment Ltd. ...................... UKSuzhou Hawk Foundry Equipment Co. Ltd. .................................... ChinaTangshan Iron & Steel Group Heavy Machinery Equipment Co. Ltd. ................ ChinaVibro Process Srl ............................................ ItalyVoxeljet AG ............................................GermanyVulkan Inox GmbH ..............................GermanyXinxieli Group (Suzhou) Co. Ltd. ............ China Zhejiang Wanfeng Technology

Development Co. Ltd. ................................ China

Zhenwu Electric Furnace Co. Ltd. ........... China

FOREIGN

INDIAN

20 Microns Ltd. .......................................Mumbai3D Foundry Tech Pvt. Ltd. ...................Mumbai Absortech India Pvt. Ltd. ......................ChennaiAirblast Equipment India Pvt. Ltd. .... HyderabadAjay Syscon Pvt. Ltd. ....................................Pune Akshit Enterprises (P) Ltd. .........................Delhi Alicon Castalloy Ltd. ....................................PuneAllahabad Sands ...................................AllahabadAllied Refractory ProductsIndia Pvt. Ltd. ................................... AhmedabadAlloysmin Industries .......................... New DelhiAlstom India Ltd. ........................................NoidaAmar Udyog .......................................... FaridabadAmetek Instruments India Pvt. Ltd. .Bengaluru Amtek................................................... New DelhiAnfaa Masbak Pvt. Ltd. ................... AhmedabadAPM Technologies ............................. New DelhiAsahi Modi Materials Pvt. Ltd. ...... AhmedabadAthern Thermal Solutions (I) Pvt. Ltd. ..........................BengaluruAvinash Industries (India) ..................... Belgaum Baroda MachineryManufacturers Pvt. Ltd. ........................... Baroda Bhartia Pulverisers ...................................NagpurBLA Coke Pvt. Ltd. ................................Mumbai

Blastline India Pvt. Ltd. ..............................KochiBMD Machinery India Pvt. Ltd. ........Bangalore Bosphorus Impex Pvt. Ltd. ...................MumbaiBruker AXS AnalyticalInstruments Pvt. Ltd. .............................Mumbai Calderys India Refractories Ltd. ............ Nagpur Capital Refractories Ltd. ........................Chennai Carraro Technologies Pvt. Ltd. ...................Pune ��{��;#��_�� ........................KolhapurCompax Industrial Systems Pvt. Ltd..........Pune Copper Engineering Services Pvt. Ltd......................................Chennai Crescent Foundry Co. Pvt. Ltd. .............Kolkata Cyrus Vibration Machines India Pvt. Ltd. ................................................Pune Daka Monolithics Pvt. Ltd. ...................Mumbai Delhi Metco ........................................ New DelhiDesai Impex Pvt. Ltd. ..................... Ahmedabad Dewinter Optical Inc. ........................ New Delhi Disa India Ltd. ......................................Bangalore EHP India ................................................Chennai Eirich India Pvt. Ltd. ..............................Mumbai Electro Flux Equipments Pvt. Ltd. ...... ChennaiElectro Magnetic Industries ................VadodaraElectronic & Engineering

Co.(I) P. Ltd. .............................................MumbaiElectrotherm (India) Ltd. ............... Ahmedabad Elektromag Devices Pvt. Ltd. ...............Mumbai Elektromag-Joest Vibration Pvt. Ltd. ..................................Mumbai Elkem South Asia Pvt. Ltd. ...................Mumbai EMT Megatherm Pvt. Ltd. .....................Kolkata Ennore Coke Ltd. ....................................KolkataEriez Magnetics India Pvt. Ltd. ............ ChennaiESI Software (I) Pvt. Ltd. ...................Bangalore Faro Business Technologies (I) Pvt. Ltd. ................ New DelhiFerropem - Foundry Division ............Bangalore FOAMCAST - Jayshree Machinesand Tools ..................................................Mumbai Forace Polymers Pvt. Ltd. ..................... Hardwar Foseco India Ltd. ..........................................Pune Gargi EngineeringEnterprises P. Ltd. ...................................Mumbai Gargi Huttenes Albertus Pvt. Ltd. .......Mumbai Gargi Industries .......................................MumbaiGeneral Kinematics Corporation .... New Delhi GNR India ...............................................Mumbai Godawri Spherocast Ltd. ......................... MohaliGoyal Dhatu Udyog Pvt. Ltd. ............... Nagpur


Grindwell Norton Ltd. ........................Bangalore Hi-Mac Castings Pvt. Ltd. ........................ Rajkot Hunter Automated Machinery (Shanghai) Ltd. .................................CoimbatoreImerys Minerals India Pvt. Ltd. ..................Pune IMI Abrasives Pvt. Ltd ..............................Raipur Incastt Machines ........................................MysoreIndaid Engineers Pvt. Ltd. .....................Chennai Indian Core Oils Pvt. Ltd. .................. Faridabad Indian Metalloy Recyclers Pvt. Ltd. ......MumbaiIndo Power Engineers .................... Ahmedabad Indu Engineering & Textiles Ltd. ............... AgraInductotherm (India) Pvt. Ltd. ...... Ahmedabad Isovolta (India) Pvt. Ltd. ........................Mumbai IVP Ltd. ...................................................MumbaiJ. K. Foundry Engineers .................GandhinagarJaycee Steels Pvt. Ltd. .........................Ghaziabad J.P. Trading Co. ................................. AhmedabadJinfei Trading India Pvt. Ltd............. New DelhiJolly Metal Abrasives (P) Ltd. .................KochiK.I.E. Engineering Pvt. Ltd. .................Roorkee Kastwel Foundries ........................... Ahmedabad Kaushiks International ........................Bangalore Kelsons Engineers and Fabricators ....KolhapurKelsons Testing Equipments ..............KolhapurKiswok Industries Pvt. Ltd. ....................Kolkata Kunkel Wagner India Pvt. Ltd. ...........Vadodara Labindia Equipments Pvt. Ltd. .................ThaneLaempe Foundry Technology Pvt. Ltd. ........................ HyderabadLalwani Ferro Alloys Ltd. .......................Kolkata Laviosa Chimica Mineraria S.p.A/Laviosa Trimex .............................MumbaiLaxmi Stain Alloys P. Ltd. ......................MumbaiLeistertech ......................................... AhmedabadLitel Infrared Systems Pvt. Ltd. ..................Pune Loramendi India Pvt. Ltd. ...........................Pune Magma Engineering Asia;��;��_�� ................................... Hyderabad Manek Minerals ...........................................Kutch Mangalore Minerals Pvt. Ltd. ............MangaloreMeasure India Corporation .............. HyderabadMec Shot Blasting Equipments Pvt. Ltd. ............................ Jodhpur Metal Power Analytical (I) P. Ltd. .........Mumbai Minex Metallurgical Co. Ltd. .................Mumbai Modsonic InstrumentsMfg. Co. Pvt. Ltd. ............................ AhmedabadMorgan Advanced Materials.................Gurgaon

INDIAN

MPM Pvt. Ltd. ..........................................NagpurMSME Technology Development Centre .................................... AgraNeoairtech India Pvt. Ltd. ..................Bangalore Nesara Instruments & Services .........BangaloreNice and New Industries .......................... RajkotNickunj Eximp Entp. P. Ltd. .................Mumbai Novacast India Pvt. Ltd. ....................BangaloreOlympus Medical Systems India Pvt. Ltd. ........................................GurgaonOmega Sane FoundryMachinery Pvt. Ltd. ......................................Pune Oritech Solutions ............................. AhmedabadOswal Minerals Ltd. .............................BangaloreOxford Instruments India Pvt. Ltd. .....MumbaiPatel Furnace & Forging Pvt. Ltd. .....VadodaraPeekay Steel Castings (P) Ltd. .......... KozhikodePIC International Metals& Alloys Pvt. Ltd. .............................Thane West Power Adhesive India Pvt. Ltd. .........BangalorePrakash Iron Foundry .................................. AgraPolo Queen Minchems ...........................Mumbai Pritika Autocast Ltd. ................................. MohaliProsim R&D Pvt. Ltd. ........................BangaloreQuality Spares Centre .......................... Faridabad Rhino Machines Pvt. Ltd. .........................Anand Rinku Industries ....................................Vadodara Rockwell Testng Aids ..................................DelhiRosler Surfacetech Pvt. Ltd. ........................PuneRotocast Industries Ltd. ............................RaipurRuby Ceramics Pvt. Ltd. ..............................Pune Sane Equipments Pvt. Ltd. ..........................Pune Saru Aikoh Chemicals Ltd. ......................Meerut Schneider Prototyping India Pvt. Ltd. .....NoidaScouter EngineeringTechnologies Pvt. Ltd. ............................Chennai Shamlax Metachem Pvt. Ltd. ................. Nagpur Shilpa Alloys Pvt. Ltd. ................................ JaipurShimadzu Analytical (India) Pvt. Ltd. .................................. New DelhiShree Satya Minerals Pvt. Ltd................Mumbai SHV Energy Pvt. Ltd. ....................... HyderabadSilcarb Recrystallized Pvt. Ltd. ...........BangaloreSinto Bharat Manufacturing Pvt. Ltd. .. Chennai SKG Refractories Ltd. .............................NagpurSnam Alloys Pvt. Ltd. ...................... Pondicherry Spectra Analytical Pvt. Ltd. ...................Mumbai Spincast Solution Pvt. Ltd. ............ AhmedabadSPS Intrad Pvt. Ltd. .............................Bangalore

SQ Enterprises Pvt. Ltd. ..................Coimbatore Sree Abirami Equipments ................CoimbatoreSree Sakthi Equipments Company .Coimbatore Sri Vivegha Engineering Pvt. Ltd. ..Coimbatore State Bank of India SME Business Unit .................................MumbaiStead Fast Engineers Pvt. Ltd. ........... Faridabad Steels & Scrap ..........................................MumbaiStoker Concast Pvt. Ltd. ..................... FaridabadSuper Thermo Sensors Pvt. Ltd. ................Pune Surface Preparation Solution & Technologies India Pvt. Ltd. .............PithampurSuyash Solutions Pvt. Ltd. ...........................PuneSwell Well Minechem Pvt. Ltd. .................Kutch =�� ;��_�� .......... Ahmedabad Technostar Equipments ................... IchalkaranjiTechnosys Instruments & Equipments ...........................................Bangalore The Institute of Indian Foundrymen ...Kolkata The Wesman EngineeringCompany Pvt. Ltd. ...................................Kolkata= �� $��India Pvt. Ltd. ..........................................Mumbai Tii Techno Testing Instruments Pvt. Ltd. .Pune Titan Engineers ....................................BangaloreToyota Tsusho India Pvt. Ltd. ..............Gurgaon=��Z�'��_�� AhmedabadUmashakti Steels Pvt. Ltd. ..............UttarakhandUnison Lawn Equipments ................... JalandharUniversal Auto Foundry Pvt. Ltd. ............ JaipurUrja Products Pvt. Ltd. ................... AhmedabadV-Analytik Systems .................................MumbaiVan-Bent Minerals Pvt. Ltd. ........................ BhujVAP Induction (India) Pvt. Ltd. ........... Chennai Vardhman Ferro Alloys ..........................Mumbai Versatile Equipments Pvt. Ltd. ...........Kolhapur Vijay Spheroidals Pvt. Ltd. .................BangaloreVinar Systems Pvt. Ltd. ...........................KolkataVirami Alloys Pvt. Ltd. ...........................Mumbai Vishwakarma Automotive Pvt. Ltd. .. FaridabadV-Smart Thermotech Pvt. Ltd. ...................Pune Wam India Pvt. Ltd. ....................................Thane Wesman SimpsonTechnologies Pvt. Ltd. .............................KolkataWesman Thermal EngineeringProcesses Pvt. Ltd. ...................................Kolkata Western Refra-cast Pvt. Ltd. ........... Ahmedabad Winoa Abrasives India Pvt. Ltd. ..... New Delhi Yuken India Ltd. ...................................BangaloreZeta India Inc. ......................................Bangalore


Statistics of Indian Automobile SectorProduction Domestic Sales Exports

January 2015

January 2014

January 2015

January 2014

January 2015

January 2014

Passenger Vehicles (PVs)Passenger Cars 219,820 203,635 169,300 164,149 41,785 35,864Utility Vehicles 54,891 54,273 48,681 45,797 3,195 4,563Multi Purpose Vehicles 12,632 13,824 12,638 13,579 307 94Total 287,343 271,732 230,619 223,525 45,287 40,521Commercial Vehicles (CVs)M&HCVsPassenger Carriers 4,824 3,407 3,000 2,660 1,246 659Goods Carriers 20,734 15,158 18,363 12,955 1,398 1,365Total 25,558 18,565 21,363 15,615 2,644 2,024Light Commercial Vehicles (LCVs)Passenger Carriers 4,246 3,281 3,194 3,037 347 102Goods Carriers 31,044 34,008 27,924 31,189 3,936 3,840Total 35,290 37,289 31,118 34,226 4,283 3,942Total Commercial Vehicles 60,848 55,854 52,481 49,841 6,927 5,966Three-WheelersPassenger Carriers 68,277 58,104 30,819 27,605 33,266 31,544Goods Carriers 8,937 9,132 8,506 8,500 233 86Total 77,214 67,236 39,325 36,105 33,499 31,630Two-WheelersScooters/Scooterette 416,715 343,642 404,919 323,162 7,391 7,425Motorcycles/Step-throughs 1,078,599 1,131,306 868,507 922,485 171,967 163,010Mopeds 55,551 67,719 54,531 68,311 1,004 618Total 1,550,865 1,542,667 1,327,957 1,313,958 180,362 171,053Grand Total 1,976,270 1,937,489 1,650,382 1,623,429 266,075 249,170

Source : Steelworld

Subscription Rates of Indian Foundry JournalFor 12 Issues :

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NEWS&TRENDS


Metal

Energy

Aluminium Production Trend in India in 2013-14

Producer 2013-14(tonnes) 2012-13(tonnes) %Change

NALCO 316492 403383 -21.54

BALCO 253806 248239 2.24

HINDALCO 403615 396970 1.67

SesaSterlite 542496 526612 3.01

Total 1516409 1575204 3.72

Source:Metalworld

Novelis to Invest in Aluminium Recycling FacilityNovelis, the aluminium rolling andrecycling outfit of Atlanta recentlyinvested $48 million at its scraprecycling facility in Oswego, NewYork to meet increased demand ofaluminium sheet in North America.Theplant isequipped foraluminiumscrapremelting,ingotcastingaswellashotandcoldrolling.Productionoftheplantismorethan1billionpoundsofhighqualitysheetperannum.

The investment includes81,000-square-foot building whichwould be capable of processing,sortingandstoringautomotivescrapaluminiumproducedbythealuminumproductionplantofOswego.Thenewrecycling facilitywould feature scraprecovery and conversion technologyenabling to process nearly 10,000tonnes of recycled aluminium permonth.

BALCO to Receive Approval for Power PlantBharat Aluminium Company(BALCO), a subsidiary of VedantaGroup company Sesa Sterlite, hasrecently received approval from theChhattisgarh Government to start1200-megawatt captive power plant.Investment for the project would beRs.5,000croreintheplantcomprisingfourunitsof300megawatteach.

With approval from the StateGovernment, the capacity of state-of-the-art aluminium smelter hasbeen increased to 570,000 tonnesof aluminium per annum. With thisexpansion of BALCO, Chhattisgarhwould emerge as the third largestaluminium producer in Indiaaccounting for nearly 25% of India’saluminiumoutput.

Rooftop Solar Project of NALCONational Aluminium Company

(NALCO) has recently commissioneda 160 kilowatt rooftop solar powerprojectattheirofficeinBhubaneswarwhich is the first solar project inOdisha.Costoftheproject isRs.1.25crore. The company is planning toinstall another rooftop solar unitof 100 kilowatt at their township inNALCONagar.They are also evaluatingpossibilitiesofsettingupplantinotherlocationsinIndia.Further,NALCOisplanningtodouble their wind power generationcapacity to 200 megawatt withinvestment of Rs.700 crore. Theirexisting 100 megawatt capacity islocated in plants at Gandikota (50.4mw)inAndhraPradeshandJaisalmir(47.6mw)inRajasthan.

Bereavement

Mr. Sashi Kumar Jain, NationalSecretary of IIF, lost his belovedmother Smt. Janak Rani Jain on3rd March 2015 at Agra. She was76yearsold.Sheissurvivedbyoneson (Shashi Kumar Jain) and twomarried daughters Mrs SushamaJain andMrs. Sonia Jain.Withherdemise, Sashijee’s father, ShreeSurajPrakashJainhasalsolosthislifepartner.

The deceased was very pious,religious and philanthropic. Shewas associated with many social,religiousandcharitableservices.Toavoidattention,shegavedonationson condition that her identitywouldnotbedisclosed.

May the departed soul rest inpeace in theHeavenlyAbode. LetusallpraytotheAlmightytogiveenough strength to Sashijee andhis family tobear this irreparableloss.

JanakRaniJain


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�� Indian Foundry Journal ��

Declaration for the Indian Foundry Journal

1. Place of Publication : Kolkata

2. Periodicity of the Publication : Monthly

3. Printer’s Name : Baidyanath Dutta

Nationality : Indian

Address : 40C, Enayet Khan Avenue Kolkata - 700 017

4. Publisher’s Name : Baidyanath Dutta


Address : 40C, Enayet Khan Avenue Kolkata - 700 017

5. Editor’s Name : Ravindra Prakash Sehgal


Address : The Institute of Indian Foundrymen ‘IIF Center’, 335 Rajdanga Main Road East Kolkata Township P.O. Kolkata - 700 107

6. Names & Addresses of Individuals holding : The Institute of Indian Foundrymen more than one per cent of the share ‘IIF Center’, 335 Rajdanga Main Road, East Kolkata Township P.O., Kolkata - 700 107

7. Name of the Printing Press : CDC Printers (Pvt.) Ltd. Plot No. 5, 6, 16, 17 Tangra Industrial Estate - II (Bengal Pottery) 45, Radhanath Chowdhury Road Kolkata - 700 015

I, Baidyanath Dutta, Executive Director, IIF, hereby declare that the particulars given above are true to the best of my knowledge and belief.

Dated : 23rd March, 2015 Sd/-

Baidyanath Dutta


WHERE QUALITY SPEAKS EXCELLENCE..........��

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ELCA LABORATORIESAccredited by NABL as per ISO/IEC 17025, 2005

Approved By Classification Societies, Various Inspection Agencies and Project Consultants Cert No: Chem T-0296

Mech T-0297

PREMIUM SERVICES OFFERED

�

SPECIALIZATION

Thane Lab: Navi Mumbai Lab: Pune Lab:

Visit us at : www.elcalabs.com


MACHINERY FOR SALE

a. 250 KW Dual-track Inductotherm-make Medium Frequency Induction Melting Furnace in excellent working condition with one Crucible of capacity 500 kg and 2 Nos. Crucibles of capacity 300 kg along with hydraulic tilting, cooling system etc.

b. 750 KW Power-track Inductotherm-make Medium Frequency Induction Melting Furnace in excellent working condition with Crucibles sizes 1500 kg, 1000 kg & 500 kg, along with cooling system, cooling tower, hydraulic system for tilting and Argo-make transformer 865KVA, 22000/575V.

c. 750 KW Power-track Inductotherm-make Medium Frequency Induction Melting Furnace in excellent working condition with Crucible size 1000 kg, along with cooling system, cooling tower and Crompton-make transformer 1000 KVA 22000/460V.

d. Indabrator-make Skew Roll Tube Shot Blasting Machine size 24" OD in excellent working condition with Dust Collector.

Contact: C.V. Gopalakrishnan

Cell: 9004147216, Homiyar Jilla : 09892583652E-mail : [email protected] / [email protected]

Uni Abex Alloy Products Ltd.Mullabagh, SV Road, Manpada, Thane - 400610

Website : www.uniabex.com


In Running Condition :

Resin–Coated Sand Plant 600 Kg Batch TypeRLC & PLC Operated Machine

Fully Automatic with Auto Weighing System Diesel–Fired Sand Dryer with VFD Screw Feeder Hopper

Total Laboratory Equipments

Shell Core Shooter Machine : 3 Nos800 x 600 Swing Door & Rollover Type

Fully Automatic - RLC Operated, Pneumatic MachineAuto Sand Feed System

Please Contact :

Cell : 9822045888 / 9881731081

FOR SALE

FOR SALE

Span Make Four Station Shell Moulding Machine – 01 No.Match Plate – size – 16" x 32"

In good working condition.

For further details contact:

Mr. M.N. Acharya, Director

Abhishek Alloys P. Ltd.Plot No. 58, Machhe Industrial Estate, Machhe,

BELGAUM – 590014Cell : 9448146799


FOR SALE

Unused Aluminium Foundry Equipment

1. Aluminium Melting Furnace 350kg/HR Batch Type–Dual Burner (FO/LDO/HSD) – Furntech Engineers, Pune

2. Susha Automatic Shell Core Shooter 1818VT – Susha Engineers, Surat

3. Low Pressure Die Casting Machine Crucible Type 500 kg Capacity with Die Cooling System – Vermaco, Gurgaon

4. Hand Held Alspek-H Hydrogen Analyser for Checking Hydrogen Content in Aluminium Alloy – Foseco, UK

5. Thermal Analyser for Checking Grain Refinement Levels in Aluminium Alloy – MK–GmbH

6. Ingot Casting Machine Having 180 CI Moulds to be Used for Aluminium Alloy Casting.

7. MAHR MMQ-400 for Checking Geometrical Profiles.

8. Electron Microscope DSx500I from Olympus, Japan

9. Shot Blast Cabinet Venti-Compact 1250l– Shot Blasting Machine for Dies and Moulds – Staalteckneik, B.V.

10. Ultrasonic Cleaning and Washing Machine

11. Jaw Crusher

12. Immersion Heaters For Aluminium Holding Furnace – Atherm, France

Interested Parties may contact for more details:

Mobile: +91-9810063686



REQUIRED

Marketing Consultants for Steel Casting Foundry

(Valves, Pumps, Engineering Castings and Spares)

Contact:

Cell: +91-99523 66909 / +91-99441 77223


SITU

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APPOINTMENTSSiddhi Ferrous is an ISO 9001:2008 and RDSO Certification Company producing Ductile Iron Castings using DISAMATIC HPML, having plant capacity 1,200 tonnes per month. We are located at Silvassa (UT of Dadra & Nagar Haveli) near Vapi, South Gujarat.

We need competent & experienced Foundrymen for our following needs :

Production Manager

�� Education : B.E. /Diploma (Metallurgy) ; Age : 35-45 years.�� Experience : Having sound background in SG Iron Foundry

practices, 10 to 15 years Experience in a foundry using DISA HPML/Induction Furnace/Sand Plant.

�� Responsibility : To lead production team and achieve production targets.

��

Maintenance Manager

�� Education : B.E. /Diploma (Mech/Elect. Engg.) ; Age : 35-45 years.

�� Experience : 10 to 15 years Experience in a foundry using DISA HPML/Induction Furnace/Sand Plant.

�� Responsibility : To lead maintenance team for maintenance work of fully automatic foundry plant.

��

Vendor Development (Machine Shop)

�� Education : B.E. /Diploma (Mech. Engg.). �� Experience : 7 to 15 years experience in Machine Shop of Auto

& Engineering cast-parts setup.�� Responsibility : To establish & develop new Machine Shop for

the Raw Parts of OEM & Tier-1 Customers like TML, AAM and Knoor Bremess. Knowledge of ISO/TS Supplier Audit, PPAP, SPC, MSA and Layout is essential.

Management Representative

�� Education : B.E. /Diploma (Mech Engg.). �� Experience : 5 to 10 years Experience of implementing ISO/

TS, RDSO, EMS, OHSAS and Quality concepts practised in an Automobile Engineering Unit.

�� Responsibility : Establish & implement ISO/TS. Perform internal & external Audit. Prepare MIS Report, MRM.

Sand Plant Operator

(For Rhino-make Sand Plant) (Posts-03)�� Education : Diploma /ITI (Electrical)� Experience : Minimum 2 to 3 years Experience in Operation &

Maintenance of Sand Plant with RTC & Intensive Mixer.

If interested, please apply with details of your experience and achievements to :

SIDDHI FERROUS LLP

Survey No. 103, Village-Falandi, Umerkoi Road, SILVASSA-396 210 (UT of D & NH)

E-mail : [email protected], [email protected] : �"#%'*+�<<""=��"#++=>�<<""=��Phone : (0260) 329 2871If any Fettling Contractor is interested to supply Workmen in our

company, he may also contact.

Required Manager (Marketing)

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` 48,000/-` 30,000/-

` 24,000/-` 36,000/-` 12,000/-

` 12,000/-

` 12,000/-

` 12,000/-

` 12,000/-

` 2,400/-

` 4,800/-

` 9,700/-


ADVERTISERS’ INDEX

ABP Induction Systems Pvt. Ltd. ...............6Abhishek Alloys .........................................126ACE Designers Ltd. ..................................... 86Ajay Syscon Pvt. Ltd. .................................. 72Baroda Machinery Mfgrs. ........................ 78Bhartia Pulverisers ...................................... 99Ceraflux India Pvt. Ltd. .............................. 76Coatings & Coatings (I) Pvt. Ltd. ........... 47Daka Monolithics Pvt. Ltd. .........................3EHP INDIA ...................................................... 46Elca Laboratories .......................................124Electro Power Engineers .........................134Electrotherm (India) Ltd. ........... 2nd CoverForace Polymers (P) Ltd. ..............................8Gargi Engg. Enterprises Pvt. Ltd. ........... 13Gargi Huttenes-Albertus Pvt. Ltd. ............4Gargi Industries .......................................... 10GN-Altech ....................................................128Gem Equipments .......................................100Inductotherm (I) Pvt .Ltd. .......... 4th CoverIndustrial Minerals ....................................136IVP Limited .................................................... 52J. K. Foundry Engineers ............................. 70

Kastwel Foundries ....................................... 14Kaybee Foundry Services (P) Ltd. ........122Kelsons Enggrs. & Fabs. ................. 102,117Kelsons Metallurgical Equipment ......... 58Kelsons Testing Equipment ..................... 84Krishna Ceramic Industries ....................106Lanik Ceramic Foam Filters India .......... 96Leampe Foundry Tech. Pvt. Ltd. ............. 56Mahasakti Engineering Company .......117Mangalore Minerals Pvt Ltd. ................... 75Megatherm Electronics Pvt. Ltd. ..........101Metal Power Analytical (I) Pvt. Ltd. ....... 51MPM-Durrans Refracoat Pvt. Ltd. ........109MTD Foundry Material Pvt. Ltd. ...........135New Shakti Enterprises ............................. 98Oritech Solutions ........................................ 90PCI Limited ..................................................129 Phoolchand Bhagatsingh ......................... 85Rhino Machines Pvt. Ltd. .......................... 50Royals Enterprises .....................................110Saru Aikoh Chemicals Ltd. ....................... 48Sastha Scientific Agencies .....................118Siddhi Ferrous LLP ....................................130Sinto Bharat Mfg. Pvt. Ltd. ....................... 71

Snam Alloys Pvt. Ltd. .................. 3rd CoverSpan Met Tech Enterprises Pvt. Ltd. ..... 94Sree Abirami Equipments .................. 92,93Sree Sakthi Equipments Co. ..................107Sri Murugan Foundry Equipt ..........82,115Standard Alloys Industries .....................108Suraiya Pvt. Ltd. ..........................................122Suyash Solutions Pvt. Ltd. ........................ 89The Advertiser ( [email protected]) . 83The Advertiser (Cell : 9822045888) ....126The Advertiser (Cell : 9810063686) ....127The Advertiser (Cell : 9952366909) ....128The Advertiser (Cell : 9903390765) ....132Toyo Metallurgicals Limited ..................130Uni Abex Alloy Products Ltd. ................125Vacunair Engineering Co Pvt. Ltd........106Vardhan Works Pvt. Ltd. ..........................116Versatile Equipments Pvt. Ltd. ................ 49Vijayesh Instruments Pvt. Ltd. ..............116Voxeljet AG .................................................... 22Wesman Simpson Tech. Pvt. Ltd. ........... 45Wesman ......................................................... 21Winoa Abrasives India Pvt. Ltd. ............. 20

Yashi Foundry Tools .................................123

REQUIRED

A Technical

STEEL FOUNDRY MANAGER

with five years minimum experience in

No-Bake Sand System for our ASANSOL UNIT.

Mail your CV to: [email protected]

Cell : 9903390765

SITU

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NT



Terms and Conditions:1. Above prices are inclusive of packing and forwarding charges for IIF Members and Technical Institutes. IIF members will get 20% discount on list price on presentation of membership number.2. Material will be sent by courier on receipt of payment.3. Please send At Par Cheque / D. D. in favour of “The Institute of Indian Foundrymen NCTS”, payable at Pune.4. The above prices are for India only.

CDs, BOOKS AND TECHNICAL INFORMATION SHEETS OF NCTS

Sl.No. Product Description Price

CD / DVD1. Set of Two Introduction to Casting Defects, Blow Holes, Shrinkage, Inclusions, ` 3,900 DVDs Scab, Discontinuities, Pinhole Porosity in Aluminium (Part 1 to 3 & Part 4 to 7) Per Set2. CD-101 Melt Quality Control and Productivity in Foundry ` 700 Each3. CD-102 EfficientCupolaOperationandProductivityinFoundry ` 700 ''4. CD-103 Computer-based Programme on Microstructures of Cast Iron ` 3,400 ''5. CD-104 Temperature Measurements & Instruments & Thermal Analysis Techniques ` 2,100 ''6. DVD-105 Green Sand Moulding Practices (along with Technical Booklet) ` 2,100 ''7. DVD-106 Interactive CD on Manufacturing Techniques and Heat Treatment of S. G. Iron ` 3,400 ''8. DVD-107 EfficientAluminiumMeltingPractices(English/Hindi) ` 2,800 ''9. CD-108 Gravity Die-Casting Techniques for Aluminium Casting ` 3,400 ''10. DVD -109 Shell Moulding Process ` 3,400 ''11. DVD -110 Investment Casting Process - Defect Control Instructor ` 4,000 ''12. DVD-111 Divided Blast Cupola – Process & Technology ` 2,600 ''13. DVD-112 A Journey Through Cold Box Process ` 3,400 ''14. DVD-113 Analysis of Defects in Aluminium Castings – Compendium of Case Studies ` 3,400 ''15. DVD-115 Inoculation of Cast Irons - Science and Practices ` 2,500 ''16. DVD-116 Green Sand Moulding Technology - Emphasis on Sand Control ` 2,000 ''

Books1. EfficientCupolaDesignandOperation ` 200 ''

2. Green Sand Preparation and Control – Mr. A. R. Krishnamurthy ` 500 ''

3. High Manganese Steel Casting ` 325 ''

4. Pattern Design – Practical Guidelines ` 460 ''

5. Green Sand Practices for Defect-Free Casting – Mr. S. Subramanian ` 650 ''

Technical Information Sheets

1. NCTSINFOSHEETS(FullSetof120sheets)(Detailsofeachsheetavailableonwebsite) ` 2,800 per set

Available from :The Institute of Indian Foundrymen

NATIONAL CENTRE FOR TECHNICAL SERVICESFlatNo.104,SharmadResidency,S.No.291,ShilaviharColony,BehindHotelOlivia,OffKarveRoad,Pune-411038

Telephone : +91-020-2543 7374 / 2542 2902 / 6500 4705 (1pm to 7pm) E-mail : [email protected] lWebsite : www.iifncts.org

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