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ContentsCover Story4 No Small Sacrifice

Tool & Die Making7 Tooling; A Dying Trade

Machine Tools

10 Selling by Education13 Investing in Machines

Corrosion15 Corrosion Testing Stainless Steel

19 New Technology, New Problems?

Stockists & Service Centres23 Mixed Fortunes for Stockists

Non-Ferrous and Ferrous25 Use It, Dont Lose it

Manufacturing30 Funtastic Balls

Castings, Forgings, Furnaces and

Refractories33 Piping Hot Performance

Industry News35 Industry News

Endorsing Bodies

SAIMechE (SA Institution of Mechanical

Engineering)

AFSA (Aluminium Federation of SA)

Proprietor and Publisher:

PROMECH PUBLISHING

Tel: (011) 781-1401

Fax: (011) 781-1403

E-mail: [email protected]

Website: www.promech.co.za

Managing Editor:Susan Custers

Editor:

Raymond Campling

Advertising Sales:

Di Bluck

DTP: Zinobia Docrat and

Sanette Lehanie

Disclaimer

Neither PROMECH Publishing

nor its endorsing bodies are

responsible for the opinionsexpressed by individuals.

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The monthly circulation is 5 840

CopyrightAll rights reserved. No edi-

torial matter published in

Advanced Materials Today

may be reproduced in any form

or language without written

permission of the publishers.

While every effort is made to

ensure accurate reproduction

the editor, authors, publishers

and their employees or agents

shall not be responsible or in

any way liable for any errors,

omissions or inaccuracies

in the publication whether

arising from negligence or

otherwise or for any conse-

quences arising therefrom.

The inclusion or exclusion of

any product does not mean

that the publisher or editorial

board advocates or rejects its

use either generally or in any

particular field or fields.

UretechTel: (011) 268-8860

Fax: (011) 447-2212

Email:george.hoffmann@

uretech.co.za

Web: www.uretech.co.za

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Fortunately technology has also advanced

rapidly and solutions that were appropriate

just a few years ago are being superseded

by new longer lasting technologies that can

reduce total cost of ownership dramatically.

In light of the changing technologies wear, corrosion

and insulation specialist, Uretech, is on a drive

to take the guess-work out of specifying the right

lining for the right application. Through applying

knowledge gained over decades, the companysphilosophy is one of establishing and understanding

the influences that affect the performance of linings

against corrosion, wear and heat and providing

customers with solutions that work.

Protecting assetsLiners are used in processing and manufacturing

plants to protect surfaces against heat, wear or

corrosion. If correctly specified, they can elimi-

nate damage to the underlying surface material.

No Small SacrificeCosts of linings and sacrificial linings for industry have escalated to a point where they can no longer be

regarded as a consumable commodity that can be replaced at the drop-of-a-hat.

COVER STORY

In most instances, the surfaces are protected at

the expense of the lining - that will take the brunt

of the abuse and deteriorate with time. Like the

proverbial sacrificial lamb, it is sacrificed for the

good of the overall process.

Industries such as mining rely on liners to protect

infrastructure from corrosive or abrasive environ-

ments. Pipes and ore chutes are commonly lined

with materials ranging from steel to polyurethane,

rubber and ceramics. Linings are also used as heatshields in processing plants and a myriad of other

applications.

This important field is often poorly understood

due to the many outside influences that can affect

a linings performance and the complex analysis

thereof. Our aim is to use our experience to specify

the right lining whether it be rubber, plastic, steel

or ceramic, George Hoffmann, managing director

of Uretech, tells :Advanced Materials Today.

Material selectionStrategically, the recent merger with Dot Steel and

Insulcon, allows Uretech to offer solutions in steel,ceramic, plastics and rubber composites. They of-

fer 99% of the different linings used in industry.

It is true that sacrificial rituals have been practiced

throughout the ages in one form or another in the belief

that higher powers would rain benefits on those

responsible for the sacrifice

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George adds, The merger puts

us in a unique position to study

applications and supply the appro-

priate liner from our vast product

range.

One of the reasons for the merger

was that we realised that we had to

broaden our offering to ensure we

have products that are best suited

to the application. All too often in

our industry, lining experts sell

unsuitable solutions because they

have to support their own technolo-

gies of single product offering.

This is compounded by the fact

that customers regard linings as

consumables and pay less atten-tion to technological advancements

than perhaps they should. As a result, procure-

ment decisions are based on tried and trusted

technologies that may no longer provide the best

solution, George says.

According to George, the solution is simply to bench-

mark materials and to document the performance

of materials, either on a trail basis or in actual ap-

plications, and then base buying decisions on fact.

In order to assist with accurate benchmarking, the

company has specially-trained technical staff around

the country to undertake any tests required.

Errors of judgementAlthough the specification of liners is not an exact

science, the use of historical data from around the

world provides findings that can be used as the basis

for similar installations in South Africa. Uretech

continually gathers this data, as well as data from

the field in order to make informed decisions.

George says their technical staff does encounter

instances where poorly-specified linings have failed

prematurely leading to the damage of the very

equipment they were meant to protect. In these

instances, Uretech is able to collect physical data

and recommend alternatives that are more suited

George Hoffmann

to the application at hand.

Problems can be avoided if plants

are designed correctly and al-

lowance made for suitable liner

materials. Ideally operators and

owners of plants should specify

the use of liners before designing

and building. This will avoid over-

or under-engineering structures

where unnecessarily heavy liners

are not called for, or vice versa.

In reality the weight of the liner

has little bearing on its ability to

resist wear, corrosion or heat and

civil or structural engineers should

be made aware of the choices that

are suitable.

Ahead of the gameWhether designing for new projects or refurbishing

old processes, George suggests that close attention

be paid to the process in its entirety and that lin-

ings are carefully selected with the assistance of

professionals. The right lining means the process

will work optimally and endure less downtime in

the long run.

It is true that sacrificial rituals have been practiced

throughout the ages in one form or another in the

belief that higher powers would rain benefits on

those responsible for the sacrifice. The correct use

of linings and sacrificial linings will also rain ben-

efits on its users and ensure that loss of production

due to downtime does not sacrifice a companys

hard-earned money.

Uretech, George Hoffmann, Tel: (011) 268 8860, Fax: (011)

447 2212, Email: [email protected], Web:

www.uretech.co.za

All too often in our industry, lining experts sell

unsuitable solutions because they have to support their

own technologies of a single product offering

COVER STORY

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This is according to findings of a study un-

dertaken for the National Tooling Initiative

Programme (NTIP) by the University of

Aachen in conjunction with the University

of Stellenbosch. It found the industry to be in

crisis due to massive skills shortages, as well as

uncompetitive practices that continue to be used

in an industry that is already under threat fromcheap imports from China and India.

Already the countrys manufacturing sector uses

only 20% local tools, dies and moulds (TDM). The

problem is that certain manufacturing processes

require local tooling and, at the very least, skilful

toolmakers who can support increasingly complex

tooling from abroad.

At the moment the country relies on an ageing

force of toolmakers who are still able to produce

and support manufacturing, but the study has found

that these skilled artisans are on average over 50

years old and will be lost to the economy within

the next few years, says Dirk van Dyk, NTIP chief

executive.

Global scaleIn a global village and against the backdrop of

fierce competition among traditional manufactur-

ing economies and new-comers from the East, it

is important to maintain and grow the tool and

die making industries. A lack of skills at this level

means that the entire manufacturing sector is at

risk and will become uncompetitive. It also ham-

pers innovation locally as prototyping, research

and development of home-grown products will

not be possible.

Probably the main cause of the skills shortage

was the downscaling and subsequent abolition of

apprenticeship programmes that were run by gov-

ernment entities such as Spoornet, Eskom, Iscor

and Sasol among others. The closing of national

trade testing and apprentice

training centres and subse-

quent unreadiness of tertiary

institutions to fill the void,

resulted in very few trades-

men entering the market,

adds Dirk.

He continues that South Afri-

cas woes should be seen incontext against countries like

China that produces in excess of

500 000 technically trained

graduates per year. Although

small compared with China,

countries like Germany still

produce about 5 000 qualified

artisans per year and are put-

ting in place urgent measures

to increase this number in order

to remain competitive.

Mission possible

Despite the findings, the situ-ation can be saved and steps

to turn the situation around by

the NTIP in partnership with

the Department of Trade and

Industry (DTI) and the Toolmakers Association of

South Africa (TASA), are being implemented already.

The initiative is guiding 175 candidates through

a pre-apprenticeship programme at seven sites

around the country. The programme is designed to

orientate learners and polish-up their skills in order

to ready them for apprenticeships. They will join

245 other apprentices when the full programme

kicks off with a pilot programme next year. Thesefigures will swell in following years as more training

institutions adopt the curriculae.

Locally only about 15% of candidates who start

training for a career in manufacturing complete

TOOL & DIE-MAKING

Tooling; ADying TradeTool and die making skills are in dire straits in South Africa

and if the situation is not addressed immediately the

industry will collapse taking the countrys manufacturing

abilities with it.

The wheels of industry in South Africa will grind slowly to a halt if we dont produce enough toolmakers

Already the countrys manufacturing sector uses only

20% local tools, dies and moulds

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the course. This is often due to unreadiness of

the candidate for the courses often as a result of

factors such as poor education foundations, lan-

guage difficulties or attraction of the wrong profileof candidate who has a poor understanding of the

work involved. The pre-apprenticeship programme

will iron out these issues and ensure candidates are

properly prepared when training starts next year,

Importance of benchmarkingSince the inception of the NTIP in 2004,

issues were identified and a roadmap

for the future put in place. The interven-

tion started with analysis of the mainproblems facing the industry and formal

planning of the steps to be taken in order

to rescue the situation. The next step

was the formulation of the up-to-date

curriculum to be implemented at further

education and training authorities. The

study mentioned in this article was the

third step and included the benchmarking

of the industry against European, South

American and other countries tool mak-

ing industries.

With the knowledge gained through the

Aachen University, it is possible to look

at the state of the local industry and

compare practices with other developing

countries as well as developed countries

like Germany and Europe.

The benchmarking studies uncovered a

number of potentially serious flaws that

contribute to the state of the industry inSouth Africa. The benchmark revealed

that the main cause for concern was lack

of skills development. Other serious is-

sues highlighted were the uncompetitive

nature of business in South Africa, lack of

focus on exports, lack of automation and

a lack of recapitalisation of equipment and

skills following the closure of the nuclear

project and downscaling of the arms and

aerospace industries that fed the precision

manufacturing industry.

Not art

South Africa, like Germany a few yearsago, still clings to the belief that a tool-

maker is an artist and that handcrafted

tools are the way to go. As a result, tool

rooms are mostly set up to support this

type of manufacture, when they should

rather be geared to industrialised products

that are manufactured in a quick and

efficient manner.

We found most tool, die and mould

making operations to be quite inefficient and, on

average, served only two main customers. This is a

problem as reliance breeds an environment where

the customer has the ability to squeeze margins and

as a result the companies are subject to dwindling

turnover, low profits and tight cash flows.

The customer bases locally cannot and will not

Benchmark findings reveal that on average South African tool, die and mould

making operations are inefficient compared to a sample of equivalent sized Eu-

ropean and South American companies. The following findings were made:

The level of technology usage is lower with 50% of programming done at the

machine as opposed to CAD / CAM stations.

Lack of CAD / CAM usage means sophisticated designs cannot be effectively

programmed.

Automation levels are low.

Average skill levels are lower with far fewer engineers and master artisanson site.

Manufacturing capacity is low. South African operations run one shift on aver-

age opposed to two overseas.

Average age of toolmaker is 55 in South Africa and in Europe is 30s.

Local operations have fixed remuneration structures as opposed to performance

related packages elsewhere

On average the local operations service two main customers opposed to seven

overseas.

Poor marketing contributes to lack of new business in South Africa.

European comparisons

TOOL & DIE-MAKING

South Africa, like Germany a

few years ago, still clings to the

belief that a toolmaker is an

artist

8/7/2019 AMT: May / Jun 2010


s, dies and moulds shape modern society

Local tool rooms need to be modernised

provide sufficient business to sustain the sector

and businesses are not set-up to compete globally

with exports. Perhaps the biggest concern is the

unparalleled lack of urgency in South African tool

rooms and this can only start being addressedthrough the creation of an environment that is

geared to competing on a global scale, says Aachen

University scientist, Stefan Kozielski.

Future projectsThe NTIP is not sitting on its laurels though. It is

mobilising support from industry and government to

seek ways of competing on the global stage through

specialisation in certain fields where expertise does

already exist and expanding on that.

It makes sense to become a country known

for certain specialities rather than being a jack

of all trades, but master of none, says Dirk.

For this reason we are working with the DTI

to identify niches that we can serve and to

form business clusters specialising in providing

services to certain industries.He puts forward the notion that TDMs can be

competitive if they work together as specialist

serving industries like, for example, mining,

packaging and automotive industries. The

pooled skills and resources of companies that

would normally compete can create globally

competitive offerings.

In some instances possible areas of coopera-

tion have already been identified and the NTIP

and DTI are already undertaking feasibility

studies.

National Tooling Initiative Programme, Dirk van Dyk,Tel: (012) 643-9360, Fax: (012) 663-9418, Email:

[email protected]

The local automotive industry

will suffer as a result of the tool

and die maker skills shortage

in the country

TOOL & DIE-MAKING

It makes sense to become a country

known for jack of all trades, but master

of none

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The longer this work in progress takes, the

more you eat into your profit.

Acting on these wise words is not always easy

when one considers that a skills shortage

is gripping the metalworking industry worldwide.

That is why Peter tells Advanced Materials Today

that he and his team have built Hi-Tech around hisproposition to sell by education.

He has set up a state-of-the-art, Merseta accredited

training facility at his Modderfontein warehouse to

do just that. Since the abolishment of the states

apprenticeship programs and trade tests, the level of

skills available for both CNC operators and program-

mers is low. We believe in upskilling our customers

workforces to ensure they are competitive locally

and internationally.

Centre for excellenceHi-Techs training centre lecture rooms are equipped

with12 desk top computers installed with Mazatrol

(Turning) and (Milling) and (MT Mill-Turn) software

to replicate actual programs and jobs. The trainee

first needs to master the simulator before moving

to the next level where the Mazatrol CNC controls

are linked to actual Mazak CNC machines and the

raw material is physically machined. The training

is aimed at operators and programmers who are

already employed in the machining industry and

includes training on the operation of Mazatrol and

ISO controlled CNC machines, best practices,

techniques and maintenance of machines.ExcellentI believe that our training equips learners with the

know-how to effectively operate a CNC machine.

It should turn a mediocre operator into a good one

and a good operator into an excellent one. As long

as they have learned the fundamentals at technical

school or college, they can be equipped with the

skills to operate a machine and later undertake

basic programming, Peter adds.

His effective training program helps him sell more

machines. As soon as the customer sees what

can be achieved when our machines are operated

effectively by a competent operator, they generally

remain loyal. Operators too become loyal to our

Mazak brand because it never lets them down and

despite its high-tech abilities, it is so easy to use.

Educating Mazak users is a rewarding job and helps

me to sell machines to an audience who understands

the value of buying quality equipment.

Saleable solutionsAnd sell he does. Hi-Tech

Machine Tools has sold

many hundreds of CNC

machines into the local

market in the 20 years thatit has been in existence.

Peters relationship with

Yamazaki Mazak goes back

even further to 1978.

He has nothing but ad-

miration for the Japanese

company and its way, of

doing business. I feel I

am lucky to stand on the

shoulders of this giant.

Wherever they can see a

way they have a vision and

Hi-Tech has always beenpart of their plans.

Despite this Peter has

maintained his indepen-

dence and adapted his

Selling by

Education

More than 30 years in the business of selling

machine tools has taught Peter Killian that the

quickest route for his customers to make money

from their machines is to have the raw materialto finished machined product, complete with

invoice, delivered to their customer in the fastest

time possible.

A skills shortage is gripping the metalworking industry

worldwide

MACHINE TOOLS

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MACHINE TOOLS

unique techniques and understanding of the local

market to sell more product. His no-nonsense and

enthusiastic approach to introducing his machines

to new clients is often seen as a forceful approach,

but nothing could be further from the truth.

After 30 years in the market I still get excited when

I go and see a client and if I have solutions for them

I like to show them hands-on, says Peter.

Peter and his loyal team of Technicians and Product

Support Engineers have gained many new customers

by guiding them to buy the right machine for the

right job. At his charismatic best he can be quite

persuasive and his firm belief in assisting customers

to optimise productivity rather than save a few rands

on the purchase price is a hard proposition to beat

when a customer watches a live demonstration of

their own product being made.Right or wrongPeters stance is black or white, its right or its

wrong. He believes businesses should buy the

right machine to do the job cost effectively rather

than substituting machines that are not capable

of quick set-ups.

Peters stern belief in his products comes from his

background where he started as an apprentice fitter

and turner and a lifelong career spent in service

in the machine tool industry. I back my products

and readily put my neck on the line by inviting

clients to see how we make their work-pieces on

Peter Killian

Sell machines to an audience who understands the value

of buying quality equipment

8/7/2019 AMT: May / Jun 2010


our Mazak CNC machines. If they like what they

see they buy it and in the unlikely event they dont,

then Ill acknowledge that somebody elses machine

is more suited, laughs Peter.

At least onceIf ever there was a man that is cut out to be in

the job, its Peter. His true character comes to the

fore when he is talking machine tools and produc-

tion. An ever-present desire to get involved andfind out more contributes

to his already massive

knowledge of production

and his ability to relay

real-life scenarios makes

him an effective agent for

the Mazak range of CNC

machine tools.

Many people in the steel

working and manufacturing

industry would recommend

that users of machine

tools speak to Peter at

least once in their career.

If you dont buy his ma-

chines you certainly will

learn a few things about

manufacturing,

Hi-Tech Machine Tools, Peter

Killian, Tel: (011) 608 0088,

Fax: (011) 608 0148, Email:

[email protected], Web: www.

hitech.co.za

MACHINE TOOLS

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That is why Aurelio Grech-

Cumbo of RGC Engineering

is somewhat of an activist

to stop slow but

steady demise of our

manufacturing output.

The opening of markets

in recent years couldhave spelt boom-time

for local companies able

to capitalise on broader

market penetration, but

instead the culmination

of skills shortages and

inward thinking has led

to a situation where locals

have seen their market

share eroded or vanish

in the face of cheaper or

superior imports.

RGC Engineering has traditionally served

the top end of the market supplying

products like Hermle machine tools and

Mitutoyo and Gom measuring equipment to the

industry. These machines are not cheap, but they

offer excellent return on investment when they are

employed at 90% or more of their capacity.

The problem in South Africa is finding enough

work to keep machines productive. The only solu-

tion is for our manufacturers to uphold world-class

production standards and compete for business

abroad. We really have to

look towards industrialis-

ing products for export,

Aurelio tells Advanced

Materials Today.

Industry developmentRGC Engineering is a ma-

jor supplier of machines,accessories and tooling

for the metalworking and

manufacturing industries

in South Africa. In order

to secure its position as

a leading player in the

market, it has developed

a customer centric ap-

proach to customers and

the market it serves.

We want to promote high

quality production and

global competitiveness andin order to achieve this we

have placed a strong focus

on providing solutions that

are suited to the local

Investing in MachinesDriving world class manufacturing practices among local busi-

nesses should be one of the prime objectives of engineering

industry role-players and government.

MACHINE TOOLS

Aurelio Grech-Cumbo 03

Clamping xture for grinding application

Gauging and control system for checking disk brakes

8/7/2019 AMT: May / Jun 2010


Machines available from RGC

EngineeringMachine tools

Agents for JOBS, Hermle and ELB-Schliff.

Range includes CNC Milling, CNC Turning,

CNC Grinding

Metal forming, punching and pressingAgents for Schuler Pressen.

Measuring systems and equipmentAgents for Marposs, Mitutoyo and GOM.

Marking and engraving systemsIncluding industrial marking systems laser

marking, engraving systems and micro-impact

indent marking.

Other products and services include:Tool presetters, industr ial polishing and washing

systems, tooling and accessories.

Turnkey project offeringsIntegrated manufacturing systems for metal

removing industry

Customised integrated measuring systems

SoftwareStatistical process control

Customised software for CAD, CAM measur-

ing

Applications & Integration of Systems

market and its unique requirements.

Through active involvements in initiatives like the

National Tooling Initiative Programme (NTIP), weare not only committed to supplying high quality

equipment to the industry, but also want to ensure

that skills are developed to operate the machinery

effectively and ultimately strengthen our customers

and the countrys position as world-class manu-

facturers, says Aurelio.

Promoting performance

Local machine shops must work smarter in orderto compete in a market that is either dominated by

cheap imports from the East or that is threathened

by perceived superior quality from traditional global

manufacturing centres such as Europe and the

United States.

Plastic injection moulding tool core for safety helmet

Machining of helmet core

MACHINE TOOLS

Crysta-Apex co-ordinate measuring machineTurn the tide and emerge as a global manufacturing

power

If we are going to turn the tide and emerge as a

global manufacturing power, then we have to start

now by investing in world-class machines, adopt-

ing international best-practices and training for thefuture, concludes Aurelio.

RGC Engineering, Aurelio Grech-Cumbo, Tel: (011) 887

0800, Fax: (011) 887 7833, Email: aurelio.grech-cumbo@

rgcengineering.co.za

8/7/2019 AMT: May / Jun 2010


CORROSION

According to Simon Norton, principal consul-

tant of Chemical Investigation Services, the

company was approached late last year byan internationally-renowned food industry

supplier to assist with the development of a food

processing machine. The company concerned had

carried out a pilot trial of a newly-designed and

manufactured food processing machine, only to

discover that the process fluid caused severe pittingcorrosion on the upper machine surfaces.

Corrosion strikesThe machine had been manufactured using AISI

316 stainless steel and the designers and manufac-

turers had expected that the stainless steel would

have withstood the process fluid environment. So

just what caused these corrosion problems is what

we had to find out, says Simon.

Which advanced materials, ie, stainless steels

should have been considered for application in

their new food machinery? What corrosion testing

should they have carried out to ensure that the cor-

rect stainless steel was selected before completing

the final design, begged the question.

He says at the root of the problem is the need for

designers and engineers to know the properties of

various stainless steels as well as their capabilities

and limitations.

Corrosion causesSimons continues that it is a well known fact that

chloride ions in solution will attack the passive

oxide layer formed on the surface of stainless

steels. Steels need > 13% chromium to make them

stainless steels or else at lower Cr concentrations

the material behaves much like iron. It is less well

known that sulphide inclusions in the stainless

steel and the possible presence of manganese in

the stainless act to enhance the pitting of stainless

steels by forming manganese sulphide inclusions.

These local chemical variations in the stainless

can trigger off the formation of pits.

In addition to the presence of chloride ions, if a

solution has a low pH ( pH < 5 ) it will furtherenhance corrosion and pitting. Add to this elevated

temperature in a system, and corrosion takes place

very much quicker.

Chemical kinetic theory (how fast chemical reac-Figure1 - Pitted AISI 316 stainless steel exposed to chloride ions at elevated tem-

perature under wet/dry conditions during a cyclic corrosion test

Corrosion Testing

Stainless SteelsFew engineers and designers seem to be aware of the range of stainless steels that are available to

fulfill a multitude of roles in the fabrication and manufacture of equipment for the process industry

and food industries.

The table below shows the chemical composition of the 5 different stainless steels

used in the corrosion testing to be described in this article

% element C Mn Cr Ni Mo N Other

AISI 316

Austenitic

0,08 2,00 17,0 12,0 2,5 0,07 -

AISI 904L

Super Austenitic

0,017 1,43 20,05 24,13 4,40 0,06 Cu 1,46%

AISI 2205

Duplex

0,021 1,52 22,38 5,75 3,14 0,18 Cu 0,21%

SAF 2507

Super Duplex

0,02 0,83 25,07 6,91 3,82 0,27 Cu 0,22%

254 SMO

Super Austenitic

0,02 - 20,0 18,0 6,1 0,20 Cu 0,7%

Local chemical variations in the

stainless can trigger off the formation of

pits

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tions proceed) demonstrates that if the

temperature of a chemical reaction

system is increased by 10 degrees cen-

tigrade, then the speed of the reaction

will double.

The cooking fluid used to prepare the

food products that would be processed

in the newly-designed machine contained

6400 mg/l of chloride ions, had a pH

~ 3,5 and the process fluid had to be

heated to over 80 oC to ensure proper

cooking of the product.

The pitting corrosion of the machine ap-

peared to occur only on the top surfaces

and covering lid of the entire machine,

which was consistent with areas of the

machine that were wet by hot process fluidand then dried out later thus depositing

chloride ions on the stainless steel.

Thus all the conditions necessary for

attacking the magic chromium oxide

layer on stainless steel were met and

the stainless steel surface became cor-

roded.

Bring on advanced materialsIt was now necessary to take a whole new look

at the material selection for this food processing

application and start to examine other stainless

steels and their suitability for the application.To start the process off, a literature review was

initiated looking at stainless steel and the impact

of elevated temperature, high chloride ion content

and low pH ( acidity ) on the performance of vari-

ous types and grades of stainless. Also, test work

done to examine the impact of surface finish on

pitting corrosion was reviewed.

The test work that was described in the published

technical papers gave us the clues to selecting a

range of stainless steels which could be tested to see

if they could withstand the tough process conditions

imposed by the food processing application.

Four types testedSimon explains that one could say that these are the

advanced materials necessary to fabricate equip-

ment where environmental and process conditions

are difficult and where conventional AISI 304 and

AISI 316 stainless steel just wont work.

The challenge to engineers and designers is to

open their minds to the range of stainless steels

and advanced materials that are available while

making sure to consider material selection at the

design stage. If the food equipment manufacturer

had considered the material selection and fluid

composition initially, a different outcome wouldhave been achieved, Simon says.

AISI 316 stainless steel which was originally

used to fabricate the food machine, is an aus-

tenitic stainless steel and has a face centred

cubic crystal structure. The nickel content

increases the size of the austenite field in the

microstructure and eliminates all ferrite from

the iron chromium alloy. The molybdenum

content provides some form of corrosion re-

sistance to chloride ions but not sufficient for

this extreme application.

The Duplex stainless steels namely SAF 2507

and AISI 2205 are made up of 50 % ferrite

and 50 % austenite and offer the designer and

fabricator the best of both worlds in terms of

mechanical properties and excellent corrosion

resistance under tougher conditions.

AISI 904 L and 254 SMO are specialised stain-

less steels that offer outstanding performanceunder severe environmental and operating

conditions.

AISI 904 L is a low carbon non-stabilized

austenitic stainless steel and is resistant to

chloride attack, pitting and crevice corrosion

and stress corrosion cracking.

Figure 2 - Corrosion test chamber with stainless steel panels hot mist gets fed into the sealed

chamber during the wet cycle the chamber is surrounded by a heating jacket

CORROSION

The table illustrates the relative costs of the 5 different stainless steels and shows

their relative ranking with regard to critical pitting temperatures

Stainless steel type Critical pitting temperature by

ASTM G 150 in oC

Relative cost

@April 2010

316 Austenitic 18 1

2205 Duplex 50 1,2

2507 Super Duplex 82 2,0

904L Super Austenitic 52 2,6

254 SMO Super Austenitic 83 3,0

Where conventional AISI 304 and AISI 316 stainless

steel just wont work

8/7/2019 AMT: May / Jun 2010


254 SMO is a high molybdenum and high

strength stainless steel with excellent corrosion

resistance due to its higher alloying element

composition.

The selection process used to find stainless steels

that may withstand the very corrosive conditions

created by the hot cooking fluid were:

Critical pitting corrosion performance

Suitable mechanical properties

Ease of welding and fabrication

Cost

Advanced materials to the testThe next step in the process was to design a cor-

rosion test pattern that would subject the chosen

stainless steels to an environment that would allow

discrimination between the steels performance and,

at the same time, mimic the wet and dry environ-

ment they would experience.

Furthermore, the stainless steel would be subjected

to elevated temperature >80 oC and a high chloride

containing process fluid. The evaporation of the

process fluid on the stainless steel would lead to

a concentration of chlorides on the surface of the

steel and so exacerbate the corrosive impact.

It was known from the literature reviewed that whenchloride containing solutions evaporate and dry on

the surface of stainless steels they speed up cor-

rosive attack and pitting. The question now to be

answered was whether the selected stainless steels

CORROSION

could withstand the severe conditions imposed by

the process fluid?

First corrosion testFirst we attempted to test the 5 different stain-

less steels in the brushed finish condition using a

CYCLIC wet + dry test pattern for a 28-day period.

The actual fluid used in the food cooking process

was misted hot into the corrosion chamber, which

was set at an elevated temperature matching the

actual food process conditions.

The stainless steels all failed after just 9 days

testing showing extensive pitting corrosion. Clearly

it was back to the drawing board.

From our literature review we knew that

surface finish can increase the critical

pitting temperature and improve the cor-

rosive resistance of stainless, but we hadto find out whether the stainless steels

could withstand the high chloride and

elevated fluid temperatures

Second corrosion testThe samples of stainless steel were cut

into suitably-sized test pieces and sur-

face prepared to a 600 grit mirror finish,

detergent washed, rinsed in distilled

water and dried.

They were then placed in a test chamber

and subjected to a wet and dry cycle for

28 days. During the wet cycle they wereexposed to a hot mist of the process fluid

with the chamber temperature between

65-69 oC. During the drying cycle they

were at ambient temperature and left

to dry with the wet misting system

switched off.

This time it was clear that discrimination

could be obtained between the pitting corrosion

performance of the various stainless steels. While

316 failed early in the test, the remaining stainless

steels only started to fail towards the very end of

the severe 28-day cyclic wet and dry test.

Rethinking designThis process of corrosion testing has lead the food

equipment supplier to re-examine the process fluid

composition and to try to eliminate the chloride

and raise the pH. At the same time the choice of

stainless has become clearer and a new round of

testing with a modified fluid composition and duplex

stainless steels will soon be undertaken.

The moral of the story is that design is key and

material selection is critical at the design stage

taking all environmental and process conditions

into consideration.

Chemical Investigation Services, Simon Norton, Tel: (021)

788 9980, Email: [email protected], Email: www.

chemdetect.co.za

Figure 3 - Corrosion test chamber with heated perspex inner chamber where the stainless steel

samples seen in Figure 2 are located

The stainless steels all failed after just 9 days testing

showing extensive pitting corrosion. Clearly it was back

to the drawing board

8/7/2019 AMT: May / Jun 2010


Advanced Materials Today learnt aboutthis new problem in the installation of

corrosion protection systems while talking

to Neil Webb, director of Isinyithi Cathodic

Protection (ICP), about the latest developments

in cathodic protection systems. Steel pipeline

coatings have become so good that the CP system

of today only delivers in the region of five amps

per rectifier, compared with the earlier systemsof fifty-plus amps for a pipeline coated in the old

bitumen-fibreglass coatings, he says. This means

that just one four-millimetre cable inside an actua-

tor which is wrongly connected can flatten the CP

system completely.

FaultsThis is just one example of how a seemingly simple

aspect of a pipeline protection system can create a

problem that could be avoided, thus saving on the

significant retrofit costs that can be incurred if the

problem is only discovered after the pipeline has

been installed. In terms of pipelines, we

are increasingly picking up problems related

to the interfacing between the mechanical

design of the pump station and the CP

systems operation, explains Neil. This

is mainly due to the mechanical side not

paying enough attention to the detailing

of the design.

Basically it boils down to the fact that,

when you have a cathodically protected

pipeline, it needs to be isolated electrically

from the pump station so that the current

for the CP system does not get drained

off to earth, he explains. This is usuallyachieved by using insulating flange kits that

are installed in specific places. Typically

however, someone comes along to install a

pipe to draw cooling water for a pump and

Effective cathodic protection (CP) works with the flow of relatively low current to the surface of the steel

structure that needs to be protected. With protective coatings becoming increasingly effective, this current

has been reduced to less than ever before. Although this is an energy saving feature, the result is that even

the slightest leakage of current through faulty grounding of ancillary equipment in the system can render the

entire CP system useless, because the electrical power has been drained of f to earth.

CORROSION

Just one four-millimetre cable inside an actuator which

is wrongly connected can flatten the CP system

completely

Neil Webb of ICP

NewTechnology,

New

Problems?

Special ange seals and bolts with a sleeve for poper insulation

8/7/2019 AMT: May / Jun 2010


The AC threatA further spin-off problem resulting from the

improvement in pipeline coatings is the factthat HVAC overhead power lines are now

causing interference currents in the pipeline,

which are more than just a light electrical

shock.Induced AC volages can become life

threatening, if not controlled properly.

Neil Webb, of Isinyithi Cathodic Protection,

explains. Improved pipe coatings provide

better insulation of the pipeline. Less cur-

rent is needed for a Cathodic Protection (CP)

system, but there is an interesting side-ef-

fect which is a relatively new phenomenon

that we have to deal with today, he says.

As the insulation properties of the coat-ings have improved, so has the pipelines

susceptibility to electrical interference. The

older pipelines were relatively well earthed,

because bitumen/fibreglass is a fairly conduc-

tive coating, compared to the wide range of

new coatings including fusion bonded epoxy,

liquid applied polyurethane and extruded or

sintered polyethylene which are all extremely

good insulators.

Apart from that, South Africa is fast running

out of space in certain areas and services are

increasingly being directed down servitude

corridors, where they run parallel to each

other in close proximity for long distances.

Where a well- insulated pipeline is now be-

ing laid in parallel to a power line, we have

started picking up AC interference and this

has increased since the loads on power lines

have been increased in general, explains

Neil. Primarily this is a concern in terms of

personnel safety, because the induction from

the power line into the pipeline represents

an electrical shock hazard to anyone who

may come into physical contact with the

pipe or valve attached to the pipeline. In

extreme cases, were now also experienc-

ing corrosion due to AC interference, where

traditionally it had only been DC current that

posed a threat.

Now it has become a whole new ball-game.

Weve gone to these lengths to protect a

pipeline by insulating it and now we have to

earth the pipe again to get rid of the danger

of the AC., explains Neil. To solve the two

contradictory requirements, we now use

what is called a de-coupled earthing unit,

which works like a glorified capacitor. The

unit conducts AC but blocks DC , in orderto provide safety earthing whilst maintain-

ing the pipelines isolation from earth from

a DC perspective.

Remote controlled valves have been installed on the

live side of the system and the actuators on the valve

system therefore earth the pipeline back to the electrical

sub-station

Even the slightest leakage of current through faulty grounding of ancillary equipment

in the system can render the entire CP system useless

CORROSION

8/7/2019 AMT: May / Jun 2010


CORROSION

they fit this pipe on the wrong side of the insulating

flange, effectively earthing the whole system that

has just been painstakingly insulated.

ExamplesThis is when Neils company is called in to tr y and

solve the problem. Once weve identified and fixed

a typical problem like this, you may very well find

that the system still does not work. On further in-

vestigation, we might find that

remote controlled valves have

been installed, but theyve been

fitted on the live side of the

system and the actuators on the

valve system therefore earth the

pipeline back to the electrical

sub-station, he says.

Once weve fixed that, we may

find that the system still does

not work and, delving deeper,

discover that the client usedactuators from two different

manufacturers. In one case, we

were familiar with the actuators

from one but not the other, so

we first fixed the earth on the

unfamiliar actuators, but still

the system did not work.

Wed been working with the

actuators from the familiar

manufacturer for many years

and assumed that they would

be the same as always, but

soon discovered that they hadchanged the design to a sys-

tem that now has an earth to

the casing, requiring a special

insulating link which had not

The wrong way of doing things. The pipeline is earthed to the steel in the structure

and renders the CP system useless

been the case previously. Once

wed done all that and all the

actuators had been isolated

from the pipeline, we then had

to deal with a new problemwhich involves surge protection:

installing spark gaps to avoid

damage to the equipment in

the systems.

Flow metersOver and above all this, flow

meters that work on a mag-

netic principle are extensively

used on pipelines and have to

be isolated from the pipeline

to avoid interfering with its

functioning. Inevitably the

installation contractor does not

fit this flow meter one hundred

percent correctly and theyre

not isolated properly. Then the

meters have to be retrofitted

in an working pipeline, which is a very expensive

operation, says Neil.

Recurring problemIn spite of warning project engineers and design

They all know the pipeline has cathodic protection

because it is on the bill of materials, but it lacks the

detail to specify that the actuators used have be isolatedactuators

An actuator on a pipeline

8/7/2019 AMT: May / Jun 2010


engineers time and again, project after project,

about all of these problems, we get called back

to deal with the same faults and problems almost

every time, adds Neil. It all boils down to a lack

of awareness on the part of the mechanical design

engineer, the mechanical installation contractor and

sometimes even the pipeline contractor. They all

know the pipeline has cathodic protection because

it is on the bill of materials, but it lacks the detail

to specify that the actuators used have be isolated

actuators.

If this is picked up while the contractor is still

on site, the problem can be rectified fairly easily,

without huge costs. However, on every single one

CORROSION

A nut and bolt with insulation sleeve

of the five large projects weve done recently, weve

had to go back to go and fix insulation problems

after the pipeline had been commissioned.

SolutionsThe solution to the problem is twofold and should

be addressed by equipment suppliers as much as

the installation contractor. The supplier should

ask the contractor whether the equipment will be

used on a cathodically protected pipeline, just as

the contractor should ask the supplier whether his

equipment is suitable for a CP installation, in terms

of it being isolated, or whether it can be isolated

and what would be needed to isolate it properly,

suggests Neil.

Over and above that, the installation contractor

would need to have a certain amount of training as

far as correct procedures are concerned for install-ing insulating flange kits, because these kits can

easily be damaged if not handled correctly. As far

as the mechanical design engineer is concerned, I

would suggest that they get expert opinion when

it comes a speciality like CP. Dont hold back; as-

sistance is as far away as a call to the Corrosion

Institute, who will direct you to a specialist in the

area you need assistance.

Neil Webb, ICP, Tel: (011) 465-1807, Email: neil@isinyithi.

co.za

8/7/2019 AMT: May / Jun 2010


In sectors like aluminium

and stainless steel, wherecommodity prices were

driven lower by the un-

derperforming global market,

our local stockists have had

to hang in there, work extra-

hard and run lean operations

in order to continue trading.

Stockists of other metals can

take small consolation from

pricing stability as they still

have to deal with thin order

books and more erratic order-

ing from their customers.

Lack of confidenceA snap survey of stockist and

Mixed Fortunes for

StockistsAftershocks from the world-wide recession continue to reverberate through South Africas manufacturing

industry and are having a dramatic effect on metals stockists and service providers. Although resilience is

the name of the game some companies have not given any ground and

remain profitable, while others have had to take drastic action to avoid

becoming a victim of the down-turn in manufacturing.

service centres by Advanced Materials Today

reveals that a recovery is underway albeit slowand less than spectacular. The vast majority of

company leaders indicate that business is getting

better slowly, but that turnovers are lagging way

behind 2008 figures.

As the first line in manufacturing processes this

sector is a good indicator for the manufacturing

sector and these findings would seem to indicate

that manufacturing volumes are ticking up equally

slowly.

Overwhelmingly respondents say the main reasons

for the slow recovery is that the market stills lacks

confidence and stock levels are being kept low.With little pressure on supply, manufacturers are

confident enough to order materials only when

they are required.

STOCKISTS & SERVICE CENTRES

Ross Teichmann

8/7/2019 AMT: May / Jun 2010


Business is out thereBusiness is not in your of fice, it is not in the pub,

nor is it on the golf course, if you want to maintain

your business in the same condition as it was before

the recession you have to get out there and go findit, says Alex Russell, director of Pegasus Steel.

This reinforces the sentiments of most business

leaders within the industry, who have adopted a

never say die attitude to seeing through the reces-

sion. Andrew Broekhuizen, managing director of

Aluminium Traders, is realistic about the companys

current position. With aluminium prices at lows

that were last experienced in the late 1980s we

have to work much harder to make the same

amount of money.

He adds that volumes are 120% higher than

pre-recession in 2008, but that the low price of

aluminium means that turnover in money value is

nowhere near that period. Likewise, despite dismal

times the company is trading its way out of tough

times and he foresees good revenues made in the

mining industry, as well as in the rest of Africa.

We are just putting our shoulders to the wheel

and working hard, thats all we can do right now

while prices are low.

Tide is turning

Ross Teichmann, chief executive of BSI Steel (SAStockists), says that the company has noticed a

significant upturn in the market since the beginning

of the year. Last year a number of our customers

were working four-day weeks and some even had to

lay off staff. Now our clients are going full-steam-

ahead and production is back in full-swing.

Although we are not yet at 2008 levels it is getting

much better. Recent steel price increases and talk

of another in July has led to some stocking-up from

our clients, but they are not going to be too bullish

in the current climate, he says.

Ross adds that segments of the manufacturing in-dustry that were hardest hit by recessionary woes,

have bounced back the quickest and strongest.

As is always the case in a crisis, some businesses

were able to adapt their approach and actually gain

ground. According to Alex, Pegasus Steel managed

to maintain its position during the recession and has

gained business as the recession drew to an end.

Last year the outlook was bleak, but we managed

to pull it off and the year ended as one of the better

years we have had in a while it was a good year

for us. We invested in new machines that enables

us to work smarter and gain business from new

quarters so as they come on line we are seeing agood upturn in our business, he says.

Headed upDespite current fears of a bounce or market cor-

rection downwards, and with fears over Greeces

liquidity growing, the resilient manufacturing sec-

tor is recovering slowly, but surely. Stockists and

value-adding service centres are recording increased

sales and when the recessionary bubble finally

bursts and confidence returns the stalwarts of the

industry are standing ready to supply whatever is

needed wherever it is needed and whenever is is

needed.

STOCKISTS & SERVICE CENTRES

8/7/2019 AMT: May / Jun 2010


NON-FERROUS AND FERROUS

You wouldnt take your hard earned Rands

and Cents and bury them in the garden,

under the bed and in the neighbours

property in the hope that one day you will

find all your money and use it when you

next need it.

N

either should businesses with valuable

items lose track of their assets. Identifica-

tion and tracking of items is big business

in the industrial sector where anythingfrom raw materials to tools and capital equipment

are registered and tracked using technology.

Advanced Materials Today pops in at Traceability

Solutions in Honeydew has a number of innovative

solutions that are tailor-made to the industrial re-

quirements of their clients. These range from simple

markings to highly sophisticated computerised

systems that log, track and trace goods through the

use of high tech 2 dimensional (2D) codes.

Effective markingsIn the past it used to be about marking goods for

identification and ownership purposes, but today

markings are used for a far greater number of pur-

poses. Industrial clients nowadays not only want

to locate and identify their products, but also want

to use the marking to reflect a number of other

criteria such as time and date of manufacture,

batches, descriptions and details, says Kyle Parker

of Traceability Solutions.

He continues by saying that markings have gone

from the use of readable digits or letters in years

gone by, to barcodes more recently. These systems

had shortcomings in the field and even the trusted

ever prevalent barcoding system is not sufficientfor todays requirements.

The latest 2D marking technology available from

Traceability Solutions allows users to enter more

data per mark than previous methods. It is also less

susceptible to the type of reader errors that plague

barcoding systems and for security purposes can

be miniaturised or hidden to avoid detection.

CodingJust like other markings, it uses a mark and se-

quence to form a code that identifies the product.

The main difference is that it is read vertically and

horizontally as opposed to older techniques.Both person-readable codes and barcodes are read

horizontally from one side to the other. If a digit or

line is damaged, obscured or removed, the code

is rendered useless and all the information associ-

ated with that item cannot be obtained. In heavy

industrial applications, like the steel industry, this

is a problem and, as a result, a smarter technique

has been developed and adopted by industry role-

players, says Kyle.

The main advantage of using a 2D code is the

ability to store more information. This allows more

efficient usage of information for storage, tracking

and tracing. It also allows up to 25% of the code

to be obscured without affecting readability.

Direct code markingDirect Part marking (DPM) allows users to put mark-

Use It, Dont Lose It

Examples of 2D markings

Kyle Parker of Traeability Solutions

These systems had shortcomings in the

field and even the trusted ever prevalent

barcoding system is not sufficient

8/7/2019 AMT: May / Jun 2010


ings directly onto items thereby reducing

manpower requirements and cost.

Most materials can be marked directly

by means of pinstamp or laser marking

techniques. This means that materials

as diverse as metal, steel or even a bird

Miniaturised markings on a bearing housing

A hand help pinstamp marker


feather can be marked without the need

for consumables such as paint, ink or

labels.

Where specialised markings or colour

codes are required, laser markers use the

thermal properties of the item to change

the colour of the materials as required.

It is possible to mark stainless steel in

almost any colour of the rainbow without

the addition of paints or inks.

When the electronic marking device

is used, it is possible to store informa-

tion relating to the item directly to an

enterprise resource planning (ERP)

8/7/2019 AMT: May / Jun 2010


system which can be made available

across a network to users anywhere in

the world. When the item needs to be

identified, a user will scan the code in

much the same manner as a barcodereader, Kyle adds.

Industrial suppliersTraceability Solutions provides marking

hardware such as marking devices, read-

ers and consumables for the marking

and tracing of items. Solutions range

from high-tech 2D markings to barcod-

ing and specialised labelling systems.

These include heat resistant and abrasion

resistant labels for the steel industry,

indestructible labels for military, and

specialised retail labels that cannot be

removed and placed onto other items.

The company is also involved in research

and development of suitable markings

for a number of unique applications

within the manufacturing industr y. One

of the most noticeable developments is

its application of 2D technology to mark

strands of cable before it is wound to

identify stolen telecommunication and

electrical cables.

A number of innovative uses have already

appeared in the metals and manufacturing

environment. As the technology develops

and becomes more widely used in our

industry, it is likely that 2D coding and

marking will supersede barcoding and

other methods of marking within an

industry that requires rugged, reliable

technology.

We are eager to work with manufacturers

and anyone involved in the metals and

other advanced materials industries to

develop technologies and solutions for

the marking, tracking and tracing of ma-

terials within this specialised industry,

concludes Kyle.

Traceability Solutions, Kyle Parker, Tel: (011)

794 5299, Fax: (011) 794 2844, Email: kyle@

tracesol.co.za, Web: www.tracesol.co.za


Indestructible labels for mili-

tary and specialised retail la-bels that cannot be removed

and placed onto other items

Close-up of a pinstamp in operation

An example of the versatility of 2D marking equipment is the permanent laser mark-

ing of a car manifold

8/7/2019 AMT: May / Jun 2010


S

occer emerged from its many different forms

around the globe using balls as exotic as

human and animal heads, animal skins,

bladders and almost anything that was re-motely round and rolled. Not so today, the modern

ball is a masterpiece.

Modern balls by contrast are made from advanced

materials using precise manufacturing techniques to

provide players with an even bounce and perfectly

weighted glide through the air. The official ball of

the 2010 Fifa World Cup, the Jabulani, is a perfect

example of a ball engineered for the sort of preci-

sion required by modern footballers.

A goats bladder just wont do in the modern game.

The technology put into producing a football is as-

tonishing and, to some people, is pricey beyondtheir means.

That is why in poor areas around the globe, imagi-

native techniques are used to keep the beautiful

game alive and flourishing. They are cheap and

cheerful and dont cost an arm and a leg. One of

the better examples of an improvised ball is the

Plastic Packet Ball that is easy to make, rugged

and reliable.

It is true that its bounce is less even than a Jabulani,

its flight Mmmm lets say, is not perfect - but it

works. Considering the popularity of both balls we

decided to look at how they are made.

The Adidas JabulaniIt is hard to believe that a mere soccer ball can

generate such excitement, with glitzy launch events

across the globe and throngs of soccer-mad fans

clamouring to add the official World Cup ball to their

collections. Playgrounds across the world have tags

of crazed 10-year olds chasing Jabulanis around the

park and dreaming of one day becoming the next

Wayne Rooney or Christiano Ronaldo. With notice-

ably thinner wallets, parents too

proclaim the quality andfeel of the ball is worth

every penny they spent

on it.

The story of the Jabu-

lani is an interesting

one. The name originates

from isiZulu and means to

celebrate. As such, it pays

tribute to the passionate football

celebration international fans will

enjoy in South Africa. Eleven different

colours are used in Adidas eleventh World

Cup ball. These 11 colours represent the 11players in every team, the 11 official languages

of South Africa and the 11 South African tribes that

make the country one of the most ethnologically

diverse countries on the African continent.

Had mankind not advanced to become more civilised and

genteel the game of football may as easily have been called

headball in honour of the beautiful games early origins. In

those early days, in South America, for example, you were

more likely to pluck your enemys head off and kick it about

the village than to use anything that resembles the modern

soccer ball.

Funtastic Balls

Who knows where the next shooting star will come from. It

may be a child that grew up kicking a Plastic Bag Ball

A goats bladder just wont do in the modern game

South Africa 2010 WorldCup Ball in front and

predecessors

MANUFACTURING

8/7/2019 AMT: May / Jun 2010


MANUFACTURING

Cheerleaders stand straight and proud for their countries

The evolution of the soccer ballCharles Goodyear revolutionised soccer ball manufacture when he patented

vulcanised rubber back in 1836. In 1855 he introduced rubber bladders to

replace animal bladders and this enabled balls to be manufactured round witha predictable bounce. In 1872 the English Football Association laid down the

rules regarding size and weight of the ball and since then little has remained

almost unchanged.

(Photo www.soccerballworld.com)

A Charles Goodyear ball on display at the

National Soccer Hall of Fame in New York

Match Ball used in the FA Cup Fi-

nal of 1893 the score was Wolves

1, Everton 0

A ball

used in

the 1950s

The ofcial 1930 World Cup ball

8/7/2019 AMT: May / Jun 2010


Stable flightAccording to Adidas, the ball uses a South African

inspired design and radically new technology with

a newly developed GripnGroove profile that

provides the best players in the world with an

exceptionally stable flight and perfect grip under

all conditions.

Under the skin, the ball has a specially-designed

inner bladder that provides spring and cushion-

ing for kickers. Its outer is thermally bonded and

comprises eight, 3-dimensional panels. These are,

for the first time, spherically moulded to ensure

the ball is perfectly round and more accurate than

ever before. In fact, each ball undergoes rigoroustesting to ensure it is perfectly round and will stay

so before it is released onto the market.

Goose bumpsThe eight panels are moulded together to envelope

the inner carcass using a 0,3 mm layer of Ther-

moplastic polyurethane-elastomer (TPU) and 3.5

mm Ethylene vinyl acetate (EVA). The surface has

a pattern texture, called aero grooves, that creates

a clearly visible profile on the balls surface.

Since the introduction of the goose bumps surface

for the last European Championship ball, the micro-

texture of the new balls outer skin has also beengiven a visible facelift. The Jabulani has a futuristic

texture with high grip, giving players full control

over the ball under all weather conditions.

The ball is shaped and manufactured in Adidas

plants and factories in Asia using the latest ma-

chinery and materials.

Plastic bag ballNever mind the fancy balls. Just watching a game

played with the Plastic Bag Ball gives you goose

bumps, for this is a ball dreamed up by children

without the means to afford a ball and no access

to a convenient sports shop around the corner. Farfrom hi-tech factories, it is crafted at home. All

that is needed is an inner made from a condom,

balloon or even crumpled-up plastic bags or paper

which is then wrapped in packets.

Techno-speakMaterials used to make the Adidas Jabulani ball include:

Thermoplastic polyurethane-elastomer (TPU)These are versatile materials that behave as cross-linkedelastomers at room temperature but, unlike conventional

elastomers, they can be processed, shaped, and formed when

heated in an industrial process. They form the outer surface

of the ball.

Latex bladderNatural rubber is the most important product obtained from latex;

more than 12,000 plant species yield latex containing rubber,

though in the vast majority of those species the rubber is not

suitable for commercial use. The latex bladder in the ball gives

it bounce and lightweight characteristics. This latex is used to

make many other products as well, including gloves, swim caps,

condoms, catheters and balloons.

Ethylene vinyl acetate (EVA) is a polymer that approaches

elastomeric materials in softness and flexibility, yet can be

processed like other thermoplastics. The material has good

clarity and gloss, barrier properties, low-temperature tough-

ness, stress-crack resistance, hot-melt adhesive water proof

properties, and resistance to UV radiation. EVA has little or

no odour and is competitive with rubber and vinyl products

in many electrical applications.

Isotropic polyester/cotton fabric, glue and ink (11 colours) are

also used and despite the vast number of materials the balls still

adhere to football rules regarding size and weight.

All official match balls for the 2010 FIFA World Cup, CAF,FIFA and UEFA competitions and local leagues have the same

weight and the same circumference and are therefore always

the same size. Jabulani is manufactured to Fifa requirements

for the between 420 445 g category. The circumference is

69 cm.

MANUFACTURING

Soccer is the most popular sport in the world because it can

be played anywhere, anytime and all you need is a ball

The quality and feel of the ball is worth every penny

they spent on it

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MANUFACTURING

The technique is really quite simple. Create a shape

that is roughly round and put this inside the bag. Wrap

the bag tightly around and twist the handles around to

secure it. Keep doing so with more bags until the ball

is about the size of a soccer ball. Then, using tape,

string or even the individual strands from a mielie

bag, wrap it evenly and tighly around the ball.

This forms the outer skin and should provide enough

grip and wear resistance to provide many hours

of soccer. By comparison to the Jabulani, it is not

perfectly round, nor does it have aerodynamic grip

and groove technology to ensure it flies straight and

true. In weight it ranges between very light and very

heavy. But, it does provide less fortunate children

with a ball and the ability to play soccer.

A beautiful gameSoccer is a game for the masses and across the globe

more people play and watch this sport than any other.

Its popularity is due largely to its simplicity - all that

is needed to play is a ball - whether it be a home-

made plastic ball or the fabulous Jabulani.

The construction of the Adidas Jabulani ball

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The beat goes onThe 2010 Soccer World Cup will offer many

challenges for the operations management

profession. But what happens when it is all over?Supply Chain and Operations Management

professionals must maintain a steady, reliable

beat as we continue to move African industry

forward to ensure our sustainable footprint.

25 - 28 July 2010

Sun City

The SAPICS Annual Conference is the LeadingEvent in Africa for Supply Chain and Operations

Management Professionals.

32nd Annual Conference & Exhibition

T 011 023 6707, F 086 575 2979 [email protected]

With the participation of: Principal sponsor:

Silver sponsor:Gold sponsor:

Platinum sponsors:

8/7/2019 AMT: May / Jun 2010


CASTINGS, FORGINGS, FURNACES AND REFRACTORIES

Exothermic foundry sleeves are manufactured

from a mixture of newspaper and specialised

compounds to keep metal molten for as

long as possible to feed the casting. The

riser serves as an outlet for gasses when molten

materials are poured into the casting and the use of

exothermic sleeves prevents the metal cooling too

fast and shrinking beyond the level of the cast.

Vacuum formed or blown sleeves are produced in

their hundreds by Procor Steel and Foundry Supplies

on a daily basis. The consumption of sleeves by thecountrys foundries is therefore a good indicator of

state of the industry and if sales in the first two

months of the year are anything to go by then

somebody has switched the light at the end of the

tunnel back on.

Foundry consumablesProcor has established a solid reputation for provid-

ing solutions to our foundries. It manufactures and

supplies a wide range of products and consumables

to this ever-changing industry and as new require-

ments come to the fore it is quick to seize the

initiative to meet demands.

Its products include sleeves, mould dressings,

ceramic fibres and insulation products that are sup-

plied in standard sizes and shapes or customised

to requirements.

Having a manufacturing plant locally stands us ingood stead because we are able to respond quickly

to clients requirements and really get involved in

working with them to find solutions that are tailor

made to the requirements.

Importing completed products may be a tempting

proposition at face value, but it really excludes the

possibility of customising products to exact require-

ments, says Derick Elliott of Procor.

Best-of-breedBy sourcing and, where necessary, importing raw

materials and compounds for the manufacture of

its products it is possible to keep a tight controlof the quality of manufactured goods. Despite

recent declines in manufacturing outputs locally

and abroad, Procor has maintained its standards

and although sales volumes have fallen its market

share has not been affected.

We strive to maintain consistently high quality

standards so that each product that leaves our

gates performs as it should time after time. This

is not the time to save costs by experimenting with

unknown suppliers and products.

Procor maintains records of all raw materials and

tests the performance of each batch to ensure it

meets specification. Likewise, we test end products

and maintain batch records for each production

cycle, which means we have full traceability of our

products in the marketplace, comments Derick.

Simple yet effectiveMan has been casting metals for millennia and has

perfected techniques to the extent that precision

casting is now possible. Wastage has been almost

eliminated thanks to these techniques and if the

right materials and equipment are used, casting is

a straight forward process.

So too is the manufacture of foundry consumables.

The somewhat old-fashioned and labour intensivefactory belies a specialised yet simple manufactur-

ing process. Sleeve manufacture, for example, uses

paper pulp as a basis and is blended with various

compounds to ensure hot and even-burning prop-

Piping Hot PerformanceBad news travels fast, but burns well in an industry that has

been shaken by the world-wide recession. Whether the days

headline screams of economic gloom, some crazy chap named

Julius or the death of ET, it all lands up serving a valuable

purpose in the countrys foundries.

Derick Elliott of Procor

Procor Foundry and Steel Supplies factory

Wastage has been almost eliminated thanks to these

techniques

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available at any time.

Mould dressings, paints and powders and addi-

tives are also blended by the company to provide

foundries with a one-stop solutions for consumables

and insulation products.

Trick up the sleeveUnless you have worked in a foundry you cant

help being impressed by the properties of foundry

products. Thanks to a breath-taking impromptu

display by Derick it is impressive to see the enor-

mous heat resistance properties (beyond 1600

C) of the insulation products. More impressive is

the heat generated through the burning of a sleeve

that easily melts glass and metal.

In instances where a steel casting requires more

metal the addition of metal producing powders can

supplement the casting and is an impressive site,

motions Derick as he ignites the powder in a shower

of sparks. Just like the other products the display

of producing metal from powder gives a realisa-

tion that there is more to casting than meets the

eye and the addition of the right consumables at

the right place and time can makes the difference

between a good casting or scrap.

Procor Foundry and Steel Supplies, Derick Elliott, Tel:

(011) 740 1450, Fax: (011) 740 1503, Email: procor@

megaweb.co.za

Metal producing powder ignites to convert to a molten form

A foundry sleeve burns hot to ensure molten materials cool evenly

Ceramic insulation products

CASTINGS, FORGINGS, FURNACES AND REFRACTORIES

More impressive is the heat

generated through the burning of asleeve

erties. The slurry is vacuum formed with

hand-tools and moulded products left to

dry for several hours on simple racks before

being fired in a furnace.

Likewise, ceramic products such as insulat-

ing sleeves, taper seals, botting cones, and

ceramic fibre tubes are hand formed using

vacuum moulds. More complex or thick walled

product are made using vacuum forms and

can be made of rigid, semi-rigid or flexiblematerials to suit the requirement of the user.

Blankets and fibre insulation products such

as insulation boards (1260 C, 1400 C, and

1600 C) are always a stocked product and

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New sheetingTransvaal Rubber Company (Truco) has

announced the addition of compressed

non asbestos fibre (CNAF) sheeting to

its product range. This complementaryrange is being offered by the company

predominantly for use in the manufacture

of gaskets.

Truco is offering five variants in the range

to address a wide range of applications.

The variants on offer include CNAF sheet-

ing for low, medium and high pressure

applications, oil resistant and steel wire

mesh blend sheeting.

The low, medium and high pressure

CNAF sheeting is manufactured from

Aramid fibres blended with NR/NBRrubber, making the products ideal for

use in a diverse range of applications.

The oil resistant medium pressure vari-

ant is also manufactured using Aramid

fibres but is blended with oil-resistant

rubber to make it resistant to oil-based material contact.

The steel mesh variant is made from Aramid fibres blended

with NR/NBR rubber and reinforced with 304 stainless

steel. This sheeting is ideal for use in high pressure, high

temperature applications.

According to Pierre Morgenrood, a divisional director of

Truco, the company has found that with the ban on the use

of asbestos fibre products, the demand from customers for

alternative products has grown. We identified the appro-

priate alternative and have introduced CNAF to replace the

traditional asbestos sheeting that has been used for many

years. The CNAF sheeting is used to complement rubber in

the manufacture of gaskets when high temperature or pres-

sure resistance is required.

The CNAF sheeting is imported and the company has a

significant stockholding to ensure that customer demand

can be supplied.

Truco, Pierre Morgenrood, Tel: (011) 839-2370, Fax: (011) 830-1629,

Email: [email protected]

Truco has added compressed non asbestos bre (CNAF) sheetingto its product range

Industry News

A cute solutionFor those in the business of profiling and fabrication the

Amada Acute (AC) series is a lightweight electric servodrive

punching machine with a big punch.

In European markets it has found a niche. It builds on the

success of the companys existing (EM) range of energy ef-

ficient, ecological, electric servodrive punching machines,

but is essentially an entry level machine. The Acute ispitched at small-to-medium sized subcontract profiling and

fabrication shops. However, this isnt to say it lacks many

of the features found on Amadas EM range.

In fact, little could be further from the truth. For example,

the drive system employs Amadas innovative electric servo-

drive technology, giving a healthy reduction (50%) in power

consumption without any compromise in performance or

component quality: a combination of factors that deliver

maximum productivity at the lowest cost per part.

The all-electric drive system not only helps manufacturers

counter the pinch of ever increasing energy bills, but also

lessens the effect that engineering operations have on theenvironment in tandem with reduced maintenance require-

ments: the cost of oil or filter changes, along with recycling

or disposal is eliminated.

The secret of this revolutionary innovation lies in the load

levelling power circuit. This mechanism collects and stores

in a capacitor the energy generated while brake is applied

to the ram, enabling the stored energy to be re-used to ac-

celerate the ram.

Its an industry development that has generated exceptional

levels of acclaim as it combines the best qualities of con-

ventional mechanical and hydraulic machines.

With no fabrication shop too small for the Acute, the machineoffers efficient use of valuable floor space while still having a

full sheet capacity of up to 2500 by 1250mm (AC2510NT)

or 1250 by 1250mm (AC255NT) without repositioning.

Amada, Tel: (011) 453 5459, Fax: (011) 453 5442, Email: sales@

amadajhb.co.za

Amada AC 255

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Industry NewsTrusted name, new distributorsDurma, one of the worlds largest builders of

metal fabricating machinery will be distributed

Rijva Quality Machines and GB Machine Tools

in South Africa.

Durma manufactures CNC press brakes, shears,

rolls, saws, turret presses, punching machines,

laser and plasma cutters, notchers and ironwork-

ers. Durmas ISO certified manufacturing facilities

encompass nearly 1,000,000 sq. ft.

Rijva Quality Machines has a reputation of sup-

plying good quality new and used engineering

equipment to the manufacturing industry with a

firm emphasis on service and customer satisfac-

tion. It carries the largest amount of new and

used machines in Southern Africa at i ts 2400m

craned warehouse in Wadeville.GB

AMT: May / Jun 2010

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Transcript of AMT: May / Jun 2010