ELEMENTYour Guide to Foundries in Pakistan w w w. p f a . o r g . p k

Foundry News Technical Articles Events

Special Edition 2010

Shree Satya Minerals Pvt. ltd., is the largest manufacturer of resin coated sand in India with a fully automatic unit. Different Grades of resin coated sand manufactured by us:Ceramic Grade I : > For making hollow cores for hollow camshafts with outer diameter ranging from 6mm to 13mm. > For intricate valve body cores. > This is low thermal expansion sand. Ceramic Grade II: > For water jacket cores for cylinder head and cylinder block. > Cores with minimum thickness of 1mm can be made. > For oil canal core for water cooled bearing housing. Ceramic Grade III: > for making water jacket cores with minimum thickness of 2mm. >Outer body of water cooled bearing housing. THE ABOVE ARE IMPORT SUBSTITUTED GRADES DEVLOPED BY US FOR INDIAN F O U N D R I E S W H O U S E D T O PREVIOUSLY IMPORT THE SAND. BLG Grade: Suitable for making moulds for valve guide, low alloy cast iron, for tappet cores and barrel cores for cylinder block. Low gas content sand. LNC Grade: > For stainless steel, Ni-Hard Castings, high alloy cat iron Black Grade: >For carbon Steel Castings, low alloy steel castings. Regular Grade: > for gunmetal and brass castings. MGAF Grade > For magnesium base castings: Aluminium Grade: > Good collapsibility and good surface finish. Testing Facilities: Fully equipped laboratory for testing raw materials and finished goods. email i.d. e.k.merchant@shreesatya.com satish@shreesatya.com Agency: We are willing to give agency for Karachi and also for Lahore/Gujranwalla."

Shree Satya Group of CompaniesShree Satya Group of Companies

PFA objective to support the progress of Foundries in Pakistan, by improving skills and up-grading technology with special emphasis on skills and expert's advice has been initiated and gained reasonable momentum over the past few months.

Foundry industry's basic problem is the scarcity of trained manpower. The current situation of the foundry sector and the need of skilled force as majority of the foundries are facing with the issue of low productivity and low quality due to untrained manpower. The Ground Breaking Ceremony of Foundry Service Center (FSC) has been undertaken as a joint project of SMEDA, UET and Pakistan Foundry Association (PFA). The completion of FSC will help to bridge the gap between existing level of foundry workers and today's foundry requirements globally.

The main objective of this centre would be to impart knowledge regarding latest foundry techniques, provide training to middle and lower tier of skilled and semi skilled workers and extend testing facilities to the foundries.

The Vice chancellor, UET had offered to participate in this Foundry Service Centre (FSC) by providing land within its premises, to bring in foundry technology as part of their academic course. Their existing Mechanical, Metallurgical and other departments would supplement and also benefit from this effort.

In order to address today's need for implementation of computer simulation in Foundry technology, PFA Secretariat has taken the initiative of establishing a temporary Common Facility Center (CFC) where computer simulation of various casting components will be done for foundries ensuring lower rejection rate. We welcome all the foundries to use these facilities and benefit from this service.

Sikandar Mustafa KhanPresident – PFA

Chief Editor

Editor

Coordinator

Mr. Fahad IqbalJoint Secretary - PFA

Mr. Abdul WaheedG.M. FoundryPakistan Engineering Company Limited (PECO)Kot Lakhpat, LahorePh: +92 42 35880071-4 Cell: +92 321 4989797Email: pecoklw@gmail.com

Mr. Abdul RashidSecretary - PFA93-B, Hali Road, Gulberg-ll, Lahore-PakistanPh: +92 42 35023525, 35753619 Fax: +92 42 35755743Cell: +92 322 8487873Email: info@pfa.org.pk pakistanfoundryassociation@gmail.comURL: www.pfa.org.pkMr. M. Awais ZakaAdmin - PFA

President's Message:

C O N T E N T S

43rd Census of World Casting Production......

Different Methods of SG Iron Production.......

Certificate Distribution Ceremony for Internship Program...............................................

News of Foundry Events.......................................

Ground Breaking Ceremony of Foundry Service Center, Lahore..........................................

Aluminum and Aluminum Alloys.....................

Visit to Ghulam Ishaq Khan Institute of Engineering.............................................................

The Role of Pakistan Foundry Association in MTAP...........................................................................

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Number of Operating Metalcasting Plants By Nation—2008

43rd Census of World Casting

Production

Global casting production in 2008 dipped below 2007’s p roduction,dropping 1.5% t o 93.5 million metrictons f r om 94.9 million metric

tons, according to this year’s MOD-ERN CASTING Census of World Cast -ing Production.

Most countries reported that pro -duction numbers were growing or re -maining steady through the frst three quarters of 2008 but began to wane in the fnal few months as industries started to refect the global recession. Of the 28 countries who participated in the production survey this year, 22 reported casting shipments had decreased from 2007, including ma -jor casting producing nations Japan, India and the U.S. It is the third year in a row the U.S. has reported a re -duction of casting volume, and the second year in a row Japan’s casting industry has contracted.

China’s rate of growth slowed in 2008 to 7.1%, down from double digit percentage increases the prior two years. However, its growth still refects the world’s largest gain. At 33,500,000 tons produced, China now produces 36% of the total supply of castings worldwide. Brazil, Korea, Poland, Norway and Denmark made gains of 5% or less.

The reduction in casting shipments was refected in the top 10 nations’ average production per metalcasting plant. With the exception of Brazil and Korea, both of which increased tonnage shipped, the countries’ pro -duction fell. Germany remains the most productive nation, producing 9,639 tons per metalcasting facility.

rdThe data reported in the 43 An-nual Census of Casting Production are production numbers supplied by each nation’s metalcasting association or similar representative. Countries that did not participate this year were Ukraine, Slovokia, South Africa, the Netherlands, and Russia. These countries remain listed according to the last year they participated.

Country Iron Steel Nonferrous Total

Austria 30 4 43 77

Belgium 16 7 10 33

Brazil 566 177 597 1,340

Canada 41 29 115 185

China 18,000 5,500 6,500 30,000

Croatia 15 3 23 41

Czech Republic 95 32 73 200

Denmark 7 0 10 17

Finland 9 6 16 31

France 107 37 335 479

Germany 201 53 346 600

Hungary 62 31 97 190

India 4,700

Italy 180 27 960 1,167

Japan 458 75 1,169 1,702

Korea 508 142 223 873

MexicoA

1,500

NetherlandsB

16 0 5 21

Norway 7 3 10 20

PolandC

185 0 245 430

Portugal 47 6 39 92

Romania 59 43 74 176

RussiaC

1,650

Slovenia 15 5 58 78

SlovokiaA

12 7 32 51

South AfricaA

87 51 117 255

Spain 60 31 52 143

Sweden 34 14 83 131

Switzerland 17 3 43 63

TaiwanC

478 40 330 848

ThailandA

230 26 220 476

Turkey 741 72 433 1,246

UkraineD

400 233 437 960

United Kingdom 193 46 236 475

U.S. 564 239 1,367 2,170

A)2006 data B)2004 data C)2007 data D)2002 data

Want to compare 2008’s production to previous years? Visit www.moderncasting.com for past census results.

Gray iron and aluminum casting production dipped worldwide in 2008, accordingto the an-nual census of casting nations.

Global production dipped below 2007’s volume, refecting the worldwide

A MODERN CASTING Staff Report

recession that started in the fnal quarter of 2008.

rd43 Census of World Casting Production—2008

Courtesy by:

Mr. Imtiaz Ali Rastgar

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Country Gray Ductile Malleable Steel Copper- Aluminum Mag. Zinc Other TOTAL

Iron Iron Iron Base

Nonfe

Census of World Casting Production—2008 (metric tons)

Austria 48,400 153,000 A

na 20,800 na 112,155 8,039 12,740 na 355,134

Belgium 61,100 8,900 A

na 45,800 na na na 742 na 116,542

Brazil 1,589,886 677,611 509,596 323,818 19,888 224,966 6,005 3,462 na 3,355,232

Canada 458,850 na na 111,720 17,656 268,090 na na na 856,316

China 16,400,000 8,200,000 500,000 4,600,000 600,000 3,000,000 B

na na 200,000 33,500,000

Croatia 29,528 21,849 27 2,517 465 16,715 na 420 927 C

72,448

Czech Republic 252,964 52,150 11,644 97,863 2,662 114,973 B

na 4,101 432 536,789

Denmark 32,367 48,020 na na 1,433 na na 6 5,778 D

87,604

Finland 42,852 77,423 na 20,371 4,589 7,406 na 247 na 152,888

France 861,488 1,089,555 na 109,642 24,685 274,902 na 24,518 3,248 2,388,038

Germany 2,677,674 1,846,793 40,838 220,132 94,588 802,202 31,532 67,908 2,024 5,783,691

Hungary 31,133 15,750 16 7,638 1,407 90,342 46 2,950 490 149,772

India 4,532,000 785,000 60,500 916,000 na na na na 547,000 E

6,840,500

Italy 915,811 646,778 A

na 93,122 81,000 820,000 10,000 70,000 1,300 2,638,011

Japan 2,753,476 1,995,349 48,082 298,720 98,782 414,002 9,268 30,207 5,912 5,653,798

Korea 1,010,500 595,700 40,300 152,000 24,100 232,500 na na 10,800 BF

2,065,900

Mexico 801,210 59,740 na 77,650 202,407 680,958 171 1,264 4,295 1,827,665

NetherlandsG

78,241 6,209 438 na na na na na na 84,888

Norway 19,115 55,639 na 3,255 4,517 13,466 na na 17,983 113,975

Poland 513,800 167,100 A

na 3,300 8,200 236,800 B

na 6,000 1,400 936,600

Portugal 22,324 57,305 na 7,859 11,400 19,800 na 500 60 119,249

Romania 46,718 4,574 836 31,596 3,509 33,651 2,500 558 4 123,946

RussiaH 3,320,000 1,800,000 180,000 1,300,000 200,000 840,000 80,000 30,000 50,000 7,800,000

Slovenia 76,820 33,353 na 38,114 B na 26,472 na na 7,645 182,404

SlovokiaI 8,760 na 4,300 2,160 2,160 26,260 na 1,800 5 45,445

Spain 493,600 641,400 A na 86,600 9,472 115,155 na 11,674 1,212 1,359,113

South AfricaJ 14,700 86,000 na 184,000 3,000 77,000 na 4,000 na 368,700

Sweden 170,700 66,300 na 22,000 12,500 43,300 2,000 5,400 na 322,200

Switzerland 28,000 49,800 A na 2,421 2,315 21,919 B

na 1,696 na 106,151

Taiwan 780,175 211,052 na 77,945 35,588 309,503 5,845 63,968 2,934 1,487,010

ThailandJ 70,000 30,000 30,000 28,600 28,600 100,000 na 16,900 na 304,100

Turkey 565,000 400,000 5,000 140,000 16,000 122,080 na 17,000 na 1,265,080

UkraineK 626,610 40,000 10,000 266,060 11,000 20,500 na na na 974,170

United Kingdom 192,000 215,000 3,200 72,000 12,000 110,000 3,500 9,500 1,000 618,200

United States 3,502,640 3,597,894 60,000 1,172,082 274,877 1,739,980 109,769 273,970 52,617 10,783,829

TOTALS 42,958,542 23,841,444 1,504,777 10,538,385 1,808,580 10,932,434 268,675 664,136 916,997 93,449,270

A) includes malleable iron B) includes mg C) lead castings D) mostly aluminum E) all nonferrous F) includes zinc G) 2004 data H) 2007 data I) 2005 data J) 2006 data K) 2002 data

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North America: 13.5 million tons

Europe: 17.6 million tons

Top 10Casting Producers

33.5 million tonsGray iron 16.4 million tonsDuctile iron 8.2 million tonsSteel 4.6 million tonsNonferrous 3.8 million tons

1. China

2. U.S.

3. Russia*

4. India

5. Germany

6. Japan

7. Brazil

8. Italy

9. France

10.8 million tons

10. Korea

Gray iron 3.5 million tonsDuctile iron 3.6 million tonsSteel 1.2 million tonsNonferrous 2.5 million tons

7.8 million tonsGray iron 3.3 million tonsDuctile iron 1.8 million tonsSteel 1.3 million tonsNonferrous 1.2 million tons

6.8 million tonsGray iron 4.5 million tonsDuctile iron 790,000 tonsSteel 910 million tonsNonferrous 550,000 tons

5.7 million tonsGray iron 2.8 million tonsDuctile iron 2 million tonsSteel 300,000 tonsNonferrous 560,000 tons

5.8 million tonsGray iron 2.7 million tonsDuctile iron 1.8 million tonsSteel 220,000 tonsNonferrous 900,000 tons

3.4 million tonsGray iron 1.6 million tonsDuctile iron 680,000 tonsSteel 320,000 tonsNonferrous 250,000 tons

2.6 million tonsGray iron 920,000 tonsDuctile iron 650,000 tonsSteel 90,000 tonsNonferrous 980,000 tons

2.4 million tonsGray iron 860,000 tonsDuctile iron 1.1 million tonsSteel 110,000 tonsNonferrous 330,000 tons

2.1 million tonsGray iron 1 million tonsDuctile iron 600,000 tonsSteel 150,000 tonsNonferrous 270,000 tons

Without ChinaChina’s production makes up 36% of the total global

casting production, which can skew the global outlook. Below are the global casting tonnages over the last fve years without China.

Million Tons Percent Change Percent Change

Produced Without China With China

2004 57.32 +3.5 +8.4

2005 61.32 +7 +7.5

2006 63.27 +3.2 +7.2

2007 63.65 +0.6 +4

2008 59.95 -5.8 -1.5*Production total for Russia based on 2007 numbers.

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India: 6.8 million tons

Russia:* 7.8 million tons

China: 33.5 million tons

Japan: 5.6 million tons

Some countries felt the pinch of the beginnings of the worldwide recession more than others.

Japan: In 2006, Japan produced 7.9 million tons of castings, a 19.9% increase from 2005, but that gain is gone after two years of double-digit percent decreases. Of the top-10 countries, Japan’s production shrank the most, reaching 5.6 million tons in 2008, an 18.8% decrease from 2007. It has dropped behind India and Germany in rankings.

India: This country has been the fastest growing large casting producing nation in the last fve years, but 2008 proved to hold a yield sign. Casting production dropped from 7.8 million tons in 2007 to 6.8 million tons in 2008.

U.S.: An 8.8% decrease in casting tonnage is the third largest percentage loss of the top-10 casting countries. The U.S., which produced 11.8 million tons in 2007, shipped 10.8 million tons in 2008. It remains the second-largest casting producing nation. MC

Hit Hardest

The majority of the world’s casting producing nations saw production volumes decrease, but a handful made modest gains in 2008. Besides China, which grew 7%, below are other no-table growing countries.

Brazil: This South American nation continues to make gains, growing 4% from 2007 to 2008 to 3.35 million tons.

th Korea: Korea experienced its 10consecutive growth year in 2008 with

a 2.2% increase to 2.06 million tons. In the last fve years, this Asian country has seen its aluminum casting produc-tion grow leaps and bounds, increasing from 78,000 tons in 2003 to 232,500 tons in 2008—an improvement of nearly 200%.

Poland: Its increase in casting pro-duction was slight at 1.6%, but it came in a year where the rest of Europe saw a combined decrease in produc-tion of 3.8%. Poland as a whole saw a gradual economic slowdown but still experienced relatively high economic growth (4.8% GDP growth).

Regional ProductionChina dwarfs other world regions in casting production, but European and North American production are fairly comparable to each other.

Production Per Plant

India: 1,707

China: 1,202

Ilustrated above are the top-10 nations’ average productivity per metalcasting plant

in 2008. Germany continues to be the most effcient country according to this

formula. Only eight of the top-10 nations improved productivity in 2008.

Ahead of the Curve

*Production total for Russia based on 2007 numbers.

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Advanced Equipment & Technologies (Pvt) Ltd

Established: In 1990 as Suppliers/Consultants of Q.C. Equipment with Technical Backup Services & Support.

Engineers: Sales & Service: Foreign Trained in Germany, England, Japan and USA

Field of Business: 1) MATERIALS (FERROUS & NON- FERROUS) i) Steel Castings, Forgings, Extrusions ii) Aluminum alloys and Copper alloys iii) Nickel and Cobalt base special alloys

2) Quality Control / Research Equipment / Instruments For Productrion & Reverse Engineering: 2.1) Mechanical & Non-DestructiveTesting: i) Universal Testing Machine ii) Hardness Testing Machines ii) Stress & Strain Measurement Instruments, Data Loggers, Strain Gauges,

Transducers, Load Cells. iii) Ultra Sonic, Magnetic Particle, Coating Thickness 3) EMISSION & XRF SPECTROMETERS FOR:i) Ferrous & Non Ferrous Metals and Alloysii) Fuels and Lubesiii) Goldiv) Minerals

4) PETROLEUM PRODUCTS TESTING EQUIPMENT (Complete Line). i) Distillation, Flash Point, Viscosity etc.

5) METALLOGRAPHY LABORATORY EQUIPMENT (Complete Line) i) Sample Preparation Equipment including Cutting, Mounting,Grinding and

Polishingii) Metallurgical Microscopes with Photomicrography Equipmentiii) Micro hardness Testers

6) WORKSHOP EQUIPMENT AND TOOLINGS i) Complete line of Machine Tools Conventional and CNC type ii) Machines, Tool Grinding, Gear Cutting, Hobbing Machines, iii) Shaping, and Drilling Machines etc.

7) CALIBRATION / REPAIR / MAINTENANCE OF: i) Hardness Testers, Tensile Strength & Compression Testingii) Machines to BSS 1610 Clients:Steel Mills , Foundries, Refineries, Oil Marketing Companies,Power Plants, Research Organizations, Metal Industries, Auto Parts Manufacturers, Aerospace Industry, Railways, Universities, Vocational Institutes, Army, Navy, Air Force.

Head Office: 502 NOOR ESTATE, SHAREA FAISAL, KARACHI-75350, PAKISTAN. PHONE: (+92 21) 3-454-2740, 3-453-7015, 3-453-7016 FAX: (+92 21) 3-454-1134 E-mail: aet01@cyber.net.pk

The purpose of this presentation is to give A to Z information in summarized form to those a) foundries already producingSG iron as to reduce their cost and improve their quality by yesterday, b) foundries having induction furnaces but notproducing SG Iron as to start its production by today and, c) manufacturing concerns or SMEs neither having anyexperience and know-how nor any furnaces and equipment to make SG Iron as to start thinking right now to produce SGIron by tomorrow with little investment.

In the beginning, I would like to refresh our knowledge about ferrous casting alloys. It is therefore, essential to knowfollowing basic classifications, chemical compositions, microstructures, mechanical properties, casting properties,methoding and cost of commonly used ferrous alloys. The same has been summarized below:

Mr. Mujtaba AhmadDeputy Chief Executive Officer

BOLAN CASTINGS LIMITED

DIFFERENT METHODS OF SG IRON PRODUCTION WITH THEIRTEHNICAL AND ECONOMICAL ADVANTAGES AND

DISADVANTAGES

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Secondly, we should know more about raw materials and additives with their prices which can be used in making SG IronThe same information is given below in the tabular form.

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Cupola

Furnace

Porous Plug Ladle

Treatment Ladle

Induction Furnace

Pouring

ladle

Induction Furnace

Treatment Ladle

Pouring

ladle

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In the end, cost to OEMs and other customers was explained. The same has been reproduced below.

Last but not least, the general feature of the two mainproduction methods and their short cuts covering theirtechnical environmental and financial aspects were explained to the audience as under.

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CERTIFICATE DISTRIBUTION CEREMONYFOR INTERNSHIP PROGRAM

Pakistan Foundry Association members provided an opportunity of Internship for the first time to the students of B.Sc Metallurgical and Materials Engineering, UET Lahore. The first batch of students has successfully completed their Six weeks internship, on the job training in different Foundries of Pakistan, organized by PFA. These students are now exposed to the shop floor working of foundry essentials for their future working.

To motivate and recognize the interest and effort of these students PFA organized certificate distribution ceremony by PFA and Metal + Metallugy Department, UET, Lahore. It was addressed by the following guests.

Dr. Muhammad Ajmal – Chairman, Metal + Metallurgy Department, UET, Lahore, welcomed Mr. Sikandar Mustafa Khan – President, Pakistan Foundry Association, Mr. Muhammad Akram Khan Lt. General (Rtd.) – The Vice Chancellor, UET, Lahore and the participants. He assured the guests that their presence amongst them on this auspicious occasion is a great source of encouragement for the department.

The Chairman stated that the foundry industry is a very important parameter to measure progress of a country. There is a Russian saying that “a country can never progress unless its production of iron is 50% more than its own requirement”. In Pakistan, this awareness has been well established for some decades. There have been various developments in the foundry industry that has raised the production levels as well as the quality standards. However, there is always room for improvement. During their internship, our students made many observations in terms of possible areas of improvement. Their reports have been submitted to the foundries concerned.

Mr. Sikandar Mustafa Khan – President, Pakistan Foundry Association, said in his address, PFA's constant struggle for Technology up-gradation from the last few years has become visible. PFA is building up bridges between Academia and Manufacturers resulting in Technical and Human Resource development. Our objective to promote the progress and prosperity of Foundries in Pakistan, improving skills and up-grading Technology with special emphasis on the training and expert's advice has been initiated by providing opportunity to the students of B.Sc Metallurgical and Materials Engineering, UET, Lahore on the job training of Six weeks Internship.He assured that PFA will continue providing internship to other Engineering Universities i.e. GIKI, NED, Punjab University, etc.

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Mr. Muhammad Akram Khan Lt. General (Rtd.) – The Vice Chancellor, UET, Lahore, appreciated the collaboration between the Metallurgy and Materials Department with the foundry industry. He mentioned that such collaboration between the industry and the department is beneficial for both the university and the industry. Due to this collaboration, industry can solve their problems on the research oriented platform of university and university students can be benefitted by the industry to learn practically.

The vice chancellor advised the industry to share their chair in the research and industrial oriented problems. He mentioned that such practice is under way in the other departments of the university and Metallurgy department also has a great potential of benefitting industry.After his address, internship certificates were distributed amongst the students.

1. Pakistan Foundry Association's website ( ) is placed on Foundry Planet's (

) platform. It is a long time effort of PFA that has now been successful ly accomplished. This is a great achievement as it

stis the 1 time that Pakistan Foundry Association is in the list of Foundry Planet, the worlds leading source of information for the Foundry Sector. PFA is among the International “Fairs & Congresses” and “Associations” list. Pakistan Foundry Association's website and other International Exhibition and Congresses will be displayed by clicking

Foundry Planet is B to B portal for Technical and Commercial Magazine. You can find different Topics, Suppliers profiles, Foundries profiles, Foundry dictionary, Fairs & Congresses, Industrial jobs, Listed Equipment, Associations, Universities & Institutes, News Archive, Foundry Trading and News Letter.

http://www.pfa.org.pkhttp://www.foundry-

planet.com

http://www.foundry-planet.com/fairs-congresses.html

News of Foundry Events2. Metal China 2010 and Casting China 2010 International is to take place from May 11 to 14, 2010, Beijing, China on behalf of China Foundry Association (CFA). Mr. Libo Zhang – General Secretary, CFA has invited Pakistan Foundry Association to participate in four concurrent events.PFA has formulated a Delegation of 25 stalwarts to attend this prestigious forum. It is a matter of great pleasure that the delegation of PFA will be received officially and Official Welcome Ceremony will be arranged on May 11, 2010 in Metal China Expo. The General Secretary, CFA has invited Mr. Sikandar Mustafa Khan – President and Mr. Asim Qadri – General Secretary, Pakistan Foundry Association as VIP guests to participate in Asia Foundry forum on May 10, 2010. In this forum, the matter related to Growth and many other issues of Asian Foundry Industry will be under discussion. Mr. Asim Qadri will give a presentation on the review of Pakistan Foundry Industry.

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3. Mr. Vacca Roberto – Purchase and Logistics Manager, SATA Group, Italy were on a visit to Lahore, Pakistan. Their production is based exclusively in Machining components related to Automotive, Truck, Agriculture Engine and Transmission Components. Their Cast ing par ts are total ly (100%) as outsourcing, annual need of their group is around 40000 Tons. Mr. Sikandar Mustafa Khan – President, PFA had arranged a dinner meeting with the Executive members and Mr. Vacca Roberto to avail this business opportunity. He visited some of the important foundries in Lahore… Millat Tractors, QadBros, Ravi Autos, Matchless, Excel Engineering, Mecas, Infinity, KSB Pumps and Eehab. He also had meetings with Mr. Umer Farooq – Supraa Steels, Mr. Abdul Rauf – Golden Pumps and Mr. Ahmad Hassan – Chenab.

4. Association for Overseas Technical Scholarship (AOTS), Japan announced scholarships for different programs for Pakistani Nationals only with the corporation of Pakistan – Japan Business Forum. During the last six months AOTS conducted two technical and management training programs in Japan.i) Program on Production Management for Pakistan (PKPM) in Oct, 2009ii) Program on Corporate Management (PKCM) for CEO, General Managers and Senior Managers in Feb, 2010

The participants of these training programs had to pay just 1/3 cost of the total and the remainder amount was paid by the Government of Japan. The participation in AOTS training program is open to all so Industry should benefit from this facility.

5. A g r o u p o f c o m m e r c i a l counselors/secretaries posted abroad in Belgium, Czech Republic, Chile and Mauritius by Trade Development Authority of Pakistan (TDAP) had a meeting with Executive members of Pakistan Foundry Association Mr. Asim Qadri, Mr. Irfan Ahmad and Mr. Iqbal Khalid. They apprised them about the development in the foundry and engineering sector in Pakistan and their export to various countries. It was emphasized that the foundry sector can help them to explore potential from these countries to bring in foreign exchange in Pakistan because of competitive prices as compared to neighboring countries. These counselors have assured their complete support to the foundry industry to assist them with the growth of export.

6. Lahore Chamber of Commerce and Industries (LCCI) organized two seminars on “Awareness of Engineering Sector”, Mr. Asim Qadri – General Secretary, PFA had a presentation on the “growth of foundry industry in SME sector and the importance of training”.“Open House Discussion Forum on How to Develop Interaction Between Industry and Technical Institutions”, The main objective is to highlight ways of developing close interaction between the business community and various institutions for smooth and efficient working which in return ensures a strong and robust economy. Mr. Asim Qadri and Mr. Irfan Ahmad represented Pakistan Foundry Association.

News of Foundry Events

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Ground Breaking Ceremony ofFoundry Service Center, Lahore

Foundry Service Center (FSC), Lahore is a joint project of SMEDA, PFA and UET designed to provide various facilities/services like virtual casting, design and pattern making, prototype development, testing and consultancy to foundrymen. The funds for the project Rs. 179.40 million has been approved by Government of Pakistan and subsequently the project implementation have been initiated. PFA support and valueable inputs during the entire process of proposal development were of significant value.

Mr. Shahid Rashid – Chief Executive Officer, Small and Medium Enterprises Development Authority (SMEDA), Lt. Gen. (Retd) Muhammad Akram Khan – Vice Chancellor, University of Engineering and Technology (UET) and Mr. Sikandar Mustafa Khan – President, Pakistan Foundry Association (PFA) laid down on Feb 25, 2010 the foundation stone of Foundry Service Center (FSC) at UET premises. The Ground Breaking Ceremony was attended by a large number of SMEs belonging to foundry sector.

Mr. Sikandar Mustafa Khan – President, Pakistan Foundry Association (PFA), in his address, pointed out that foundry industry's basic problem was the scarcity of trained manpower. He was confident that completion of FSC will be able to arrest this issue amicably. He thanked and appreciated the generosity for the provision of a piece of land measuring approximately 4 canals by Lt. Gen. (Retd) M. Akram Khan – Vice Chancellor, UET.

Lt. Gen. (Retd) M. Akram Khan – Vice Chancellor, University of Engineering and Technology (UET), in his address, assured all possible assistance from his university for completion of the said project.

The operation of Foundry Service Center at Lahore will enable the foundry sector to avail all modern facilities like Computer Aided Pattern Designing, Material Testing, Training and R & D.

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Casting FacilitiesÞ03 Nos. Cupola Furnaces 1 Ton, 3 Tons & 5 TonsÞ3.5 Tons Induction FurnaceÞ300 Kg Induction Furnace Þ03 Nos. Gas Fired CrucibleÞ60 Kg, 120 Kg & 150 Kg Þ02 Mechanized moulding lines for green sand, having 16 moulding machines along with two heavy duty Sand MixerÞHand Moulding facilities for grams castings to 10 Tons.ÞNon-Ferrious Foundry for brass, Bronzes & Aluminum alloy.ÞMould handling system ÞPattern shop facilitiesÞSand washing & Drying equipment

Testing FacilitiesÞSpectrometer ÞTensile Testing MachinesÞHardness testing MachineÞMicroscopeÞCarbon-Silicon DeterminatorÞThermocouples.ÞMould Hardness TesterÞWet analysis LabÞSand Testing Lab

Finishing Facilities ÞShot Blast MachineÞPedestal Grinders ÞHand Grinders

AddressesHead Office:6/7 Sir Ganga Ram Trust Building, Shahrah-e-Quaid-e-Azam Lahore.Phone: PABX (0092-42)37320225-27,37243869, 37324544, 37324886. Fax: (0092-42)37323108E-mail: info@peco.com.pkFactory: Kot Lakhpat Works Lahore. Phone:PABX (0092-42)35880071-74, 35116733. Fax: (0092-42) 35120754E-mail: pecoklw@gmail.com

PAKISTAN ENGINEERING COMPANY LIMITED

CupolaFurnace

MouldingLine

ShotBlastingMachine

Pumps

Motors

AutoParts

Spectrometer

Products

All Grades of Aluminum Alloys

Aluminum Deoxidize Ingots of

95% & 97%

Master Alloys

Others Aluminum Metals Alloys

as per Buyers Specifications.

OFFICE :

Suite # 108, First Floor

Anum Trade Center

Estate Avenue,

S.I.T.E, Karachi.

Tel : 92-21 - 32587874-5

Fax : 92-21- 32587876

Email: sunmetal@cyber.net.pk

FACTORY :

Plot # C3-4, S.G.M Industrial Area

Phase-II, Memon Goth

Malir, Karachi.

Tel : 92-21 - 34560527, 34560907-8

Fax : 92-21 - 34560551

Email : sunmetal@eworld.net.pk

Manufacturer of Aluminum Alloys

ADVANTAGES OF ALUMINIUM:

DISADVANTAGES OF ALUMINIUM:

PURPOSE OF ALLOYING :

·A soft and light weight metal.·High electrical and thermal conductivity.·High resistance to corrosion.·Low melting point.·Non-toxicity -ideal for packaging and cooking material ·High strength-to-weight ratio ·Ductility - easy to coldwork and fabricate.

·Low strength and hardness.·It presents many gating problems.·Poor foundry characteristics.·Poor wear resistance and machinability.·Poor fatigue.·Poor creep strength.

Alloying with other elements improves mechanical properties as well as foundry characteristics of aluminum. The most common alloying elements are silicon, copper and magnesium. Less common elements are manganese, iron, zinc, nickel, tin, and titanium. In general, the total percentage of all alloying elements is limited to about 15%. Beyond this level, the alloy becomes brittle. The effect of alloying elements is to increase the fluidity of molten alloy, increase strength and hardness of casting. Machininablity also improves. Ductility, electrical resistance and corrosion resistance is lowered.

MAJOR EFFECTS OF ALLOYING ELEMENTS:

SILICON When silicon is added to alumimium, tensile strength and hardness of the alloy improve progressively and ductility decreases steadily till about 13% silicon addition is reached. It greatly improves the foundry characteristics and decrease the shrinkage and hot cracking. COPPER Increases strength, hardness up to 12% , Further addition makes the alloy brittle.Hot cracking tendency increases up to 4~5% and decreases on further addition. MAGNESIUM Increases strength, hardness, corrosion resistance and machinability. These alloys have high tendency for dross formation as Mg is highly reactive and gets oxidized. IRON High Fe contents decrease castability, ductility, shock resistance and machinability MANGANESE Improves casting soundness and ductility but reduces shrinkage tendencies. NICKLE It helps to retain higher strength at elevated temperature. TITANIUM It is usually added to molten alloy before pouring as grain refiner. LEAD Improves machinability at levels over 0.1%SODIUM Modifies the eutectic structure. ZINC Improves ageing characteristics. The fluidity is increased but shrinkage may occur.

The basic purpose of this presentation is to familiarize the Non-Ferrous foundrymen about Aluminum & Aluminum Alloys for automotive parts castings.This study will strengthen the understanding of metallurgists regarding the heat treatment process of LM-13 Aluminum Alloy used for automotive piston casting.

Mr. Sikander Ali

ALUMINIUM AND ALUMINIUM ALLOYS

18

CASE STUDY (Process Improvement)How to reduce the process time of heattreatment of LM-13 grade used for dieselpiston casting.

HEAT TREATMENT PROCESS FOR AL – Lot many aluminum alloys used for the manufacturing of automotive parts but following are most common for piston casting; ·LM– 13·LM – 28·AC8HDIE CASTING TYPES FOR AL-ALLOYS :

LM -13 ALLOY (FOR PISTON CASTING) CHARACTERISITICS ·Excellent heat resistance.·Excellent wear resistance·Less expansion coefficient·High proof stress.

CHEMICAL COMPOSITION:

% Si %Fe %Cu %Ni %Mg 10.0 < 0.8 0.7 0.7 0.8 ~ ~ ~ ~ 13.0 1.5 2.5 1.5

MECHANICAL PROPERTIES: Hardness Tensile Elongation Impact

Strength Sterngth 65 - 75 15 - 25 3 - 5 8 - 10

HRB Kg/mm2 % Joules

Aluminum alloys are generally subjected to

the following types of heat treatments.

- Solution heat treatment.

- Precipitation (Hardening) treatment.

- Annealing Treatment.

Heat treatment process carried out as per following parameters;

Test specimen for analysis: TENSILE BAR IMPACT BAR

BELL TYPEFURNACE

FOR

HEATTREATMENT

PROCESS

PROCESS PARAMETERS

Solutionizing Temperature

Solutionizing Time

Cooling Medium

Cooling Temperature

Aging Temperature

Aging Time

Cooling Medium

510 Deg. C

6 Hrs

Water

60 Deg. C

160 - 180 Deg. C

5 Hrs

Air

HEAT TREATMENT PROCESS FOR AL – ALLOYS

19

• The solution treatment temperature was carried out at 510 Deg.C with various solution treatment

times for 0.5hr, 1hr, 1.5hrs, 2hrs and 4hrs, followed by water quenching

• Subsequent aging treatment was carried out at 175 Deg.C for 5 hrs (T6 condition)

0.5 hr

1 hr

1.5 hrs

2 hrs

4 hrs

Solutionizing Time Vs Hardness - HRB

Solutionizing Time Hardness - HRB

59

54

45

39

32

0

10

20

30

40

50

60

70

0.5 hr 1 hr 1.5 hrs 2 hrs 4 hrs

Solutionizing Time Vs Hardness - HRBHEAT TREATMENT PROCESS FOR AL – ALLOYS

Time Vs Temperature

20

CONCLUSION :

In view of above study it has observed that desired microstructure, mechanical and physical properties of this alloy can be achieved by direct cooling of casting in water and subsequent aging process.

Due to this process improvement, we have contributed appreciable cost saving by minimizing the labor, energy associated with the reduced process time of 6 Hrs for Solutionizing treatment.

At the end, I hope that this article would assist some readers creating interest regarding Alumiuium and its alloys in various applications.

AFTER IMPROVEMENT

Solutionizing Temperature

Solutionizing Time

Cooling Medium

Cooling Temperature

Aging Temperature

Aging Time

Cooling Medium

NIL

NIL

NIL

Room Temp.

160 ~ 180 Deg.C

5 Hrs

Air

Conclusion:

Structure 1.Spherical particles of eutectic Si is in very low range while the dentritic alpha aluminum in higher range.Structure 2.The dentritic alpha aluminum is still present.Structure 3.Short range of eutectic silicon on the left side.Structure 4.Slightly higher range of spherical particles of eutectic Si.Structure 5.

BEFORE IMPROVEMENT

Solutionizing Temperature

Solutionizing Time

Cooling Medium

Cooling Temperature

Aging Temperature

Aging Time

Cooling Medium

510 Deg. C

6 Hrs

Water

60 ~ 80 Deg. C

160 ~ 180 Deg.C

5 Hrs

Air

PROCESS PARAMETERS

21

The Ghulam Ishaq Khan Institute of Engineering Sciences and Technology (GIKI) is one of the most prestigious engineering institutes of Pakistan. GIKI is known the world over for setting a standard of excellence in the field of engineering. The Institute aspires to be a center of excellence in engineering sciences and technology, which acts as an effective agent of change and a model for others to emulate. Over the years, the institute has produced bright, innovative graduates employed at some of the most respectable firms all over the world.

Metallographic Laboratory;

· Sample preparation facilities: cutting, grinding, polishing, chemical and electrochemical etching.

· Optical microscopes for micro-structural examination of metals, alloys, ceramic, polymer and composite materials; Nomarski interference contrast; photomicrographic printing, video display of microstructures; micro-hardness testing. Facilities for computer based image analysis are being developed.

Pakistan Foundry Association's members had a long awaited desire to visit these Laborites to update their knowledge and how their foundries can be benefited from the facilities available in this Institute. So a delegation of Pakistan Foundry Association visited this institute and met Dr. Fazal Ahmad Khalid – Pro-Rector, GIKI along with his faculty members. He gave us a presentation about his faculty and the scientific laborites to maintain a good level of Technical Education and updated curriculum in Material Sciences which was one of the purpose of our visit. Their material testing labs are most impressive and we assure them that they will be seeing more of us from Industry interacting them you for optimum commercial use of these facilities.

With reference to our discussion a road map for the collaboration of GIKI – Pakistan Foundry Association has been developed for joint effort between Academia and Industry Interaction. Dr. Fazal Ahmad Khalid is willing to give a presentation to the members of Pakistan Foundry Association in Lahore, which will be decided later on.

It was a privilege for the delegation of Pakistan Foundry Association to meet with Mr. Jhangir Bashar – Rector, GIK Institute of Engineering Science and Technology and discussed matters of mutual interest and corporation between GIK Institute and PFA.

VISIT TO GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES AND TECHNOLOGY

The exhibition is aimed to display the latest State of the Art Technology and Equipments related to Machine Tools and thManufacturing Industry. We are pleased to describe that a high profile Foundry Workshop was organized last year and also in 5

International Machine Tools and Automation Industry – 2009.Pakistan Foundry Association participated actively to support and extended corporation in the Foundry Sector of Pakistan organized a half day workshop in the light of the growth potential and technology requirements of the foundry industry. The workshop featured to technical papers presented by…

· Different Methods of SG Iron Production with their Technical and Economical Advantages and DisadvantagesBy: Mr. Mujtaba Ahmad – Deputy CEO, Bolan Casting Limited

· Aluminum & Aluminum Alloys for automotive parts castingsBy: Mr. Sikandar Ali – Manager Foundry, Atlas Engineering

Following the presentations a session of questions / answers took great importance to help the audience providing solution to their problems. The workshop was presided over by Mr. Shahid A. Khakim – CEO, Bolan Casting Limited and Mr. Asim Qadri – General Secretary, PFA and Mr. Javaid Ashraf – Consultant, PFA were also in the panel of discussions. Earlier Mr.

Javaid Ashraf welcomes the guest and highlighted the Aims and Objectives of the Workshop. It was very encouraging for PFA that the workshop was attended by more then 250 participants. This workshop actually gave life to the MTAP Exhibition.

Pakistan Foundry Association's members purchased eight stalls and displayed their productions. Those who exhibited are Ravi Autos, Hussein Engineering, Bolan Casting and Atlas Engineering.

Pakistan Foundry Association also took part in exhibition actively and put up their stall. Mr. Asim Qadri – General Secretary and Mr. Abdul Rashid – Secretary, PFA highlighted the objectives of Pakistan Foundry Association and offered membership to the visitors. “Element” bi-monthly Magazine copies were also presented to them. It was a high time to introduce ourselves to Academia and Foundrymen.

The role of Pakistan Foundry Association in

th5 International Machine Tools and Automation Industry

thMTAP, 12 - 14 Nov, 2009, at Expo Center,

Karachi

BLACKSTONE IS The CHOICE OF PROFESSIONALS

Mohammad SajjadPh 042 36167117 / 37722750 Cell: 00923334257790email: blackstonesajjad@yahoo.com

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