Dr Roger Lumley is Senior Technical Specialist at AWBell Pty Ltd. He has over 25 years’ experience in materials science & engineering, manufacturing, research, and project management. Roger has science and engineering degrees from the University of Queensland. Roger is an elected Fellow of the Australian Academy of Technological Sciences and Engineering (FTSE) and is National President of Materials Australia.

Roger is an advocate for Australian manufacturing, and is a part of the Victorian Skills Authority Manufacturing Industry Advisory Group. Roger has led business-to-business R&D initiatives and has an outstanding record of technology commercialisation in global manufacturing industries.

Adding Value Through Metal Casting Innovation

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Perceptions of what constitutes innovation or an innovative approach to manufacturing are especially subjective and not always well understood by many professionals, particularly as it relates to established industries. In reality, a failure to recognise innovation and properly capture it may lead to loss of business and intellectual property. We typically hear from press releases or media of the latest digital technologies, but these are not always a great fit for metal casting and manufacturing businesses whose core activities are different, and where there is an overwhelming priority to produce positive revenue streams. However, it is also clear that without innovation we cannot increase profits, decrease overheads, or develop new products in the marketplace.

This seminar will present a selection of case studies and examples of where innovative approaches to product and process development in metal casting has led to demonstrated value adding outcomes and to problem solving. Examples will be given of some successes and learnings from different processes, including sand casting, investment casting and diecasting.

Some of the key takeaways for establishing an organisational innovation culture will be discussed together with suggestions on how to foster an environment of positive creativity and innovation in metal casting businesses.

Some Observations of the Role and Importance of Oxide Films in Castings

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The presence of oxide films in metalcasting is a well-known phenomenon. In particular, alloys which have aluminium present as a major component (e.g. aluminium, aluminium bronze, or manganese bronze) are known to characteristically be affected. Similarly, some other alloys such as ductile iron are adversely impacted by the presence of oxide films, arising from the presence of magnesium introduced during spheroidization treatments. Nickel alloys containing tin and bismuth for anti-galling resistance may have a similar issue. However, millions of tons of castings are made globally every year which contain oxides in some form, and the vast majority function adequately without negatively impacting engineering performance or service life. Clearly there is an opportunity for improvement of metal casting operations that may be realised if this trade-off was better understood.

In this paper, observations and studies of oxide films and their occurrence in different materials will be presented, including learnings from sintered powder metallurgy alloys, high pressure diecastings, investment castings and sand castings. Importantly, defect hierarchies can be established in cast materials, and depending on the processing conditions, thermal history, alloy composition and design safety factors, oxides may or may not be deleterious to the function of a part. They may also not be the defect which would ultimately cause failure in a casting. If defect hierarchies are addressed in the correct sequence, it may readily be established that the elimination of oxides has major benefits. Identifying the defect hierarchy for any given material, part or process, means that a more structured and methodical approach to casting quality improvement may be realised.

A study on the homogeneity of plastic deformation and its importance to tensile ductility in Al-Si-Cu-Mg (C355) investment castings

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Deepak has more than 15 years’ experience in Defence in Australia and aboard. He holds a master’s in engineering, master’s in business administration and is an accredited project management professional. Deepak has worked in senior engineering and management roles leading the delivery of multiple programs in the areas of armoured vehicles and solider systems. More recently Deepak has led DMTC’s enterprise program management function and the transformation its program management operations.

Charlotte has over 12 years of supporting SMEs in the defence sector through a range of roles including 5 years in the State Government of Victoria in the Defence Industry Unit, followed by 3 years working with the Defence Science Institute facilitating greater industry/academia connections. For the last 5 years Charlotte managed the Victorian Defence Alliances, industry clusters of over 600 SMEs targeting work in the defence supply chain. More recently Charlotte has been leading the DMTC’s Industry Capability Development Program, which aims to create a network of Defence-ready companies with benchmarked, globally competitive capabilities.

Manufacturing – Sovereign capability

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The phrase sovereign industry capability has been present in Australia for over eleven years. The approach of Governments to building sovereign industry capability over that time have been lists of priority areas and grant programs of one form or another. There has also been no consensus on what sovereign industry capability means in the Australian context. Today, if you ask five different people what sovereign industry capability means you will get five different answers.

The effectiveness of the programs over ten years is debatable. Only a handful of Small to Medium-sized Enterprises (SMEs) have achieved the growth and success in both Defence and export markets to be considered a sovereign capability. Many of those business where either acquired by overseas companies or secured private equity investment on the journey. What is apparent though is the disconnect between Government initiatives to build sovereign industry capability and the market realities which small business face.

SMEs with ambitions to enter the defence sector or grow their existing share of defence business face many barriers. Strict quality standards and accreditation requirements can vary depending on the defence contract. Security clearances and Defence Industry Security Program membership (including cyber security protocols) can take many hours of paperwork to attain and maintain. Knowing who to speak to and how best to communicate your unique capabilities is challenging.

The investment in business systems and human capital required to establish a presence in the Defence sector requires a long gestation period. Many SMEs shy away at this prospect when in reality investments and benefits thereof occur incrementally. For those SMEs who stay the course defence sector provides a rich and rewarding opportunity to apply their capabilities and perform at the leading edge of technology for the ultimate benefit of Australia’s Defence Force.

Peter Canavan is a Senior Policy Officer at Ai Group Centre for Education and Training, contributing to education and training policy and managing projects including state industry skills advisory projects and apprenticeship and traineeship projects. Peter has over 25 years’ experience in the vocational training sector, and has also managed projects for the Victorian Government, including apprenticeship projects and projects supporting workers retrenched from the automotive manufacturing sector. Peter sits on a number of steering committees and advisory groups at national and state levels advising on vocational skills issues.

Apprentice/Technical training

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Apprenticeships have seen some changes over recent years. There was the shift to competency based progression and completion a few years ago, which essentially shortened most apprenticeships by up to a year, and there were substantial wage rises some years ago.

For the foundry sector, the biggest change has been the decreasing number of training providers, which has seen some states offer only workplace-based delivery and others offer no foundry training at all.

Across Australia, apprenticeship commencement numbers continue to decline. There were just over 75,000 commencements in 2020. This was up slightly over previous years but it was showing a downward trend before the big jump in incentives announced in the budget. Apprenticeship commencement numbers peaked in 2012 and have been declining since then.

There have been recent moves to inject more life into the apprenticeship system. Higher apprenticeships were trialled in 2016 and are becoming more mainstream. A group of companies in Victoria are discussing the piloting of degree-level apprenticeships.

In NSW, the Government announced the creation of Trade Skills Pathways Centres to offer alternatives to apprenticeships for people who can’t find an employer or have prior skills.

Peter Canavan, Senior Policy Officer with Ai Group’s Centre for Education and Training, will discuss the current state of the apprenticeship system, talk about some of the newest innovations and offer some thoughts on future directions.

John Gardner is the National Education Manager – Technical and the Queensland & Northern Territory Manager for the Australian Steel Institute.

As a qualified structural engineer, john began his professional career working in the steel fabrication and steel detailing sector before progressing to consulting engineering and later government building control.

His responsibilities with the Australian Steel Institute include growing steel intensity in projects, creating opportunities to increase local content, building a robust local steel supply chain, supporting safety and compliance in steel supply and fabrication, and providing steel related education.

He is a contributor to various industry groups, including Engineers Australia, the Australian Construction Modellers Association, the Institute of Public Works Engineering Australasia Qld and Master Builders Queensland.

The Australian Steel Industry – Opportunities for engagement with the Australian Foundry Industry

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The Australian steel industry is the backbone of Australia’s construction, resources, infrastructure and manufacturing sectors. It is a substantial contributor to the Australian economy employing approximately 110,000 Australians from roles in basic iron and steel production through to downstream roles in steel fabrication and generates annual revenue in the order of $29 billion.

The Australian Steel Institute (ASI) acts as the focal point for the steel industry providing leadership on all major strategic issues impacting the industry, particularly focusing on economic, environmental and social sustainability. A member-based organisation, the ASIs activities cover and promote advocacy and support, steel excellence, standards and compliance, training, events and publications. The ASI works with government, the media and other associations to provide an independent voice for industry representation across vital issues such as promoting the advantages of local content procurement in the nation’s interest, both to the client and to government.

The key directional Imperatives for the ASI are Growing Steel Intensity, Creating Opportunities to increase Local Content, Building a Robust Steel Supply Chain with support objectives being Leadership in Safety and Compliance and providing Steel-Related Education.

The ASI has recently signed a Memorandum of Understanding with the AFI to explore opportunities for cooperation and collaboration in areas of mutual benefit including advocacy to government and sustainability.

Andrew has 30+ years experience and has worked in a variety of roles across the steel and chemical industries including operations management, and process design and improvement.

Since entering the energy and carbon industry as a consultant in 2008, Andrew has helped many businesses reduce their energy costs and carbon footprints, including mineral processing, food processing, foundries, leather tanning and numerous other manufacturing industries.

He has been working on an ongoing basis since 2008 to facilitate and support Energy Management Programs in steel manufacturing.

Andrew holds professional certifications in Measurement and Verification and in Energy Management, and has significant experience in carbon certificate creation under the NSW Energy Savings Scheme, Victorian Energy Upgrades scheme and the federal Carbon Farming Initiative.

Why do I need to plan for my business to achieve net zero carbon emissions, and what does that look like?

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Aside from the issue of urgent action needed on climate change, carbon emissions are becoming a business risk. Foundries, which are heavy users of energy, are facing (yes it’s already starting) a future where your carbon footprint and stated targets and plans for reduction in emissions will become an important factor for competing in the market.

What do businesses need to consider, and how can I develop a plan? Should I work on energy efficiency, install solar panels, convert from natural gas to electric heating or hydrogen or biomethane. Should I wait for technological innovation, and what is on the horizon anyway? Should I buy green power, buy offsets and when does it make sense to? Power Purchase Agreements and Aggregated PPAs?

There are a lot of things to consider.

Andrew will give an outline of the current state of the energy and carbon emissions world, how it may impact on AFI member businesses, and what you can do about it.

Hamid Pourasiabi is a Materials and Metallurgical Engineer (BEng, MEng, PhD) with 13+ years of professional engineering, research and teaching experience in the areas of ferrous/physical metallurgy; foundry and casting; heat treatment; characterization of materials; evaluation of mechanical, tribological and physical properties of materials; wear, tribology and abrasion science. As an R&D engineer in large commercial foundry, he has successfully replaced several industrial steel parts with austempered ductile irons, developing highly profitable technology. Hamid has also conducted several outstanding alloy/production development and consultancy projects. He has great experience in the application of the data science techniques in metallurgical processes.

NbC-bearing hypo-eutectic high chromium white cast irons: Production and properties

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Abrasive wear imposes an estimated cost of about 2-4% of the gross national product (GNP) of countries, with mining and mineral processing being the industries majorly affected. Hundreds of billions dollars could be annually saved by increasing the life of wear consumables and associated energy consumption.  Worldwide mining activities constitute 6.2% of total global energy consumption; 16.5% of this is used for re-manufacturing, replacing, and sourcing wear parts due to abrasive wear failures.

High chromium white cast irons (WCIs) are a class of high-performing abrasion-resistant cast alloys employed to reduce the wear. The excellent abrasion resistance combined with satisfactory fracture toughness, positions these in-situ particle-reinforced metal-matrix composites as the most advantageous wear consumables in handling, conveying, crushing, grinding, and classifying of mined minerals, particularly in mill and transfer chute liners.

The proposed approach to further improve the abrasion properties of high-Cr WCIs is introducing other forms of hard reinforcing particles. Strong or cubic carbide formers (SCF or CFC), due to the superior hardness of their carbides, show great potential. Among the alloying elements in this class (V, Ti, W, Nb, etc.), niobium forms carbides which are much harder than Cr-rich carbides (2400-2850HV vs 1400HV).

In this work, the experiments conducted to develop viable melting and casting process for production of NbC-bearing high-Cr WCIs have been presented. These include developments for prevention of thermo-chemical reactions between Nb-containing melt and refractory material, air exclusion during melting, casting defects assessments semi-numerical scale and NbC morphology designation system. Microstructural examinations and Vickers hardness of the produced alloys confirm the success of the production route and beneficial impact of the NbC in further reinforcing these irons. Their higher hardness and discrete morphology of NbCs promise excellent abrasive wear performance.

Simo Saletic is a senior professional engineer with 25 years of experience, specialising in Product Development, Design for Manufacturing, Computer Integrated Manufacturing, Product Lifecycle Management and Technical Marketing. He has delivered numerous projects for the water industry, mining, industrial machinery and devices, foundry equipment, special metal castings, lifting equipment, harbour infrastructure and airport infrastructure projects. He currently provides consulting services to Australian and international clients. Simo is based in Melbourne, Victoria.

Structure of and integrated CAD/CAE system for design and electronic prototyping of products in the foundry industry

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Rightfully the requirements for product safety and reliability are the paramount and managing the technical risks associated with manufactured products through quality assurance in every stage of product development and production is nonnegotiable.

Ability of engineers to create reliable products heavily depends on digital technologies in all stages of the product life, particularly in the design and development. Adequate considerations must be given to all aspects of the operating scenarios, such us mechanical and thermal loads during the production, installation and use.

Modern CAD packages offer to design engineers a flexibility to easily create and test shapes and forms that are “foundry friendly”, i.e. the specific design requirements and constraints of the foundry technology, such as transitions, section junctions, heat sinks, etc.

With advances in numerical algorithms and increased computational power the design engineers can also quickly test their designs for structural and thermal integrity using (mainly) FEA and CFD packages, each with varying goals and level of output details.

A contemporary integrated CAD/CAE system for the foundry application should have the following functionality:

– Solid modelling of basic and organic shapes with a set of casting features (CAD)

– Mechanical and thermal simulation with fatigue and casting defects features, such as random internal cracks and voids (FEA)

– Casting simulation (CFD)

– Central data repository (PDM)

Parts are predominantly designed to withstand stresses and deflections induced by prescribed static and dynamic loads. Unlikely loads above these prescribed levels are covered with safety factors. However, in certain instances the safety factors can not cover for both the extra loads and for the manufacturing defects, such as voids and internal cracks, which sometimes remain undetected.

It is important that potential presence of these casting defects and their impact on product performance is appropriately investigated in the early stages of the product development.

Damian has been working in the simulation of complex physical processes for over four decades. In the early 1980s, he worked in Europe in the aerospace industry including using virtual prototyping (VP) software as part of the design of the protection shield to protect the Giotto satellite from micro-meteorite impact. Since starting Pacific ESI in 1986, he has helped Australian industry exploit the benefits of such VP technology, especially in the context of virtual manufacturing processes, virtual acceptance testing and virtual sustainment. He has been involved in the virtual casting of metals for over two decades. He has worked with a range of industrial customers and research consortia in Australia, New Zealand, Japan, Korea, Europe and the US in the aerospace, automotive, mining, maritime, off-shore and defence sectors.

For six years from 1994, Gui spent at the Beijing University of Aeronautics and Astronautics in the research group of near net shape casting technology of aircraft and aero-engine structures and rapid prototyping. After moving to Brisbane (Australia) in 2001, he worked initially at QMI Solutions as a research and development engineer and later at Advanced Moulding Technologies and BoCAR Automotive Products, both in senior engineering roles. He joined the University of Queensland in 2008 as a senior research fellow. His primary activities lie in casting technology, aluminium alloy solidification, advanced engineering design and the use of advanced manufacturing techniques including additive manufacturing.

The Prediction of Microstructure and Stress within an Aluminium Casting

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Hot tearing and cold cracking continue to be a major problem in both Direct Chill (DC) and large shape casting of aluminium alloys. To attain high performance and address critical applications of wrought aluminium alloys for aerospace structure, alloys are being developed that allow high alloying content and increasing ingot size. These tend to lead to serious tearing/cracking defects during DC casting. This paper aims to develop a better understanding of the defect formation and their relationship with the cast grain structure through laboratory testing and numerical simulation. Casting experiments were conducted using an experimental rig using Al-Zn-Cu-Mg alloys that matched the DC casting cooling condition. Data from the experiments was used to validate DC casting simulation models.

Robert Olds is the Managing Director of Olds Engineering, established in 1918. The firm manufactures equipment for and services a wide range of industries. Robert has Advanced Trade qualifications and a wealth of practical experience. He has been involved in making and designing ships’ propellers and nozzles, components for the rail industry, street furniture and many different products. He also helped develop the Olds Elevator, which was invented by his father, Peter Olds. Robert has taught vocational courses, teaches boiler and steam engine operators and assists with boiler inspections.

William Olds obtained a Bachelor of Applied Science with Honours, majoring in physics, at Queensland University of Technology in 2005. He completed a PhD in 2010 at QUT’s School of Public Health. After working in research laboratories, he joined Olds Engineering in 2014. In speaking about silica dust and workers’ health, William brings an understanding of how scientific research can form a foundation for understanding risks to health and making decisions about protecting workers.

Respirable Crystalline Silica: Recent Experiences in Protecting Workers Against Silica Dust in a Small Foundry

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Silica is an abundant, natural mineral that is found in common foundry materials, including silica sand and furnace refractory cement. Respirable crystalline silica (RCS) may be released whenever these materials are handled or processed. RCS is invisible to the naked eye (less than approximately 5 microns diameter) and readily inhaled into the deepest parts of the lungs. Over time, the particles can cause silicosis, an incurable lung condition, as well as lung cancer. RCS exposure can also contribute to various cancers, chronic obstructive pulmonary disorder (COPD), renal failure, chronic emphysema and chronic bronchitis. The Workplace Exposure Standard was recently reduced in Australia to 0.05 mg/m3, 8-hour time-weighted average. It is essential that foundries identify sources of RCS and take steps to mitigate exposure. This presentation discusses the recent experiences of a small sand-casting foundry in measuring and controlling its RCS levels. An occupational hygienist was engaged, who deployed worker-worn monitors to assess personal exposures of airborne dust and RCS. One of the monitors was an advanced real-time monitor that charted dust levels across the activities of a typical workday. The controls used to reduce RCS levels included ventilation, extraction, enclosure of processes, use of an H-class, H13 high efficiency particulate air (HEPA) vacuum cleaner, respiratory protective equipment and housekeeping schedules. Another key tool for reducing dust has been the Olds Elevator, a sand conveyor that can replace screw, bucket and pneumatic conveyors. The effectiveness of these controls will be discussed and compared. With careful planning and the use of multiple protective measures, foundries can help keep their RCS levels under control and protect their workers from the harmful effects of RCS exposure.

Jenny Thistlethwaite is a Product Manager for DKSH Scientific Instrumentation, Australia. She is solely responsible for providing the latest state-of-the-art technology to the Australian market offering equipment and instrumentation from researchers to actual industrial/field application. Her 15 years plus of hands-on, industrial experience included work in the Petrochemical refineries as an Industrial Chemist and Refinery Instrument Engineer in both Queensland and Western Australia. She then went on to work on a Greenfields LNG project in Darwin before returning to Brisbane to take up a sales and product management role in 2017 with DKSH. With a BSc in Applied and Analytical Chemistry, Physics and Mathematics Jenny is able to offer valuable technical insight and advice to her customers and clients alike.

The Paradigm shift in metal analyser detector technologies

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Testing metal samples can pose complex challenges. Demanding examples come from large foundries and primary producers of steel, aluminium, or copper, as well as many secondary metal processors, aerospace and automotive companies, testing laboratories, governmental and academic labs, and more. These users must identify and measure — with especially high accuracy and precision — all the elements and compounds in their incoming, in-production, and outgoing materials. Most utilize a high-end stationary metal analyser.

A key factor for analyser performance: its detector technology.

Today, most users meet these challenges with instruments containing legacy PMT detectors. Now, however, specialized CMOS-based detectors have been perfected for this use.

David has been involved in the foundry industry for the last 40 years and began his career at Warman International as a trainee Metallurgist and is a qualified Metallurgist with an Associate Diploma in Metallurgy from the Sydney Technical College.

He worked at Warman International for approximately seven years and then moved to Foseco as a Product Manager for Ferrous and Non Ferrous Metal Treatments. In the early 2000’s he moved to Brisbane and started a position with QMI as a Foundry Specialist managing government funded projects to encourage best practice in the Foundry Industry.

From there he transferred to Bradken and over a period of 4 years worked in the Runcorn, Bassendean and the Welshpool plants as a Metallurgist and Technical Manager. In the mid 2000’s he took up a position as a Product Manager for Commercial Metals overseeing their range of Ferroalloys.

In 2018 Commercial Metals sold this business to Sanwa, where David has been managing the Raw Materials portfolio.

What will Raw Material Pricing look like tomorrow!

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Brett began his career in the foundry industry June 1985 at an aluminium diecasting plant in Sydney (Lawrenson Diecasting). At Lawrenson’s I held positions in all areas of Administration (including product costing, accounts payable / receivable, human resources and management information systems).

I transferred as Financial Controller to our Adelaide iron foundry in 1997 which was subsequently replaced in 1998 with a greenfield site which doubled the output capacity.

Following the 2006 installation of an additional furnace and the largest vertical moulding line in Australia I became General Manager of the site. Our foundry has a capacity of 45,000 MT sold p.a. with up to 60% of our output exported, primarily for the rail infrastructure market

My qualifications include Associate Diploma of Business – major in Accounting, Graduate Diploma in Business Management (Executive).

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After interning at HA Germany, I started at HAA in 2001 and have been part of the sales and technical department for over 20 years. I have been Technical Director for Australia and New Zealand since 2009 and was Director of Sales and Technology for HA Southeast Asia from 2015 to 2020.

33 years of working at Ford Motor Company, ended in December 2016. Through this period I was fortunate to develop a level of manufacturing know-how covering Quality Systems, Product Development, People Management, Lean Manufacturing Principles, Supplier Quality Development and Metal Casting Processes (Greensand Moulding, Coldbox Coremaking, Al and Fe Casting, Induction Melting) in a high volume manufacturing environment.

Through my early years at Ford, I completed a Metallurgy qualification at RMIT, Melbourne. Since finishing at Ford, I’ve been able to apply my manufacturing knowledge in the building industry working a casual, part time role at Stegbar.

Now in semi-retirement I enjoy Family, Footy, Rogaining, StreetO, Running, Community Choir and being involved in the Australian Foundry Institute.

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