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Advanced Materials Today

May/June 2011

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Advanced Materials Today

May/June 2011


May/June 2011

Contents Cover Story

Lighter Side

Machine Tools

Industry News

4 Go Anywhere Liner

Uretech

Tel: (011) 268 8860 Fax: (011) 447 2212 Web: www.uretech.co.za

30 Shooting for the Sky

8 Service Worth a Fortune 12 Puma Project Roars In

Stockists and Service Centres 14 Steel in the Veins

33 SAIW News 34 International News 36 Industry News

Endorsing Bodies

TDM Today (Tool, Die & Mould Making) 17 CEO’s Comments 18 Printing Prototypes 21 Afrimold Keeps It Local 22 Laser Welding 23 Assistance Needed

Corrosion, Surface Finishing 24 Aluminium For All Seasons

• SAIMechE (SA Institution of Mechanical Engineering) • AFSA (Aluminium Federation of SA) • CorriSA • NTIP • TASA (Toolmakers Association of South Africa) • Intsimbi

Plastics, Processing Machines & Equipment 27 Passionate About Plastics

Copyright

All rights reserved. No editorial 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 consequences 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.

The monthly circulation is 6 034 Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 E-mail: editorial@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editor: Raymond Campling Advertising Sales: Louise Taylor

DTP: Zinobia Docrat, Yolanda Flowerday and Lilian Kemp Disclaimer Neither PROMECH Publishing nor its endorsing bodies are responsible for the opinions expressed by individuals. Printed by: Typo Colour Printing Tel: (011) 402-3468

Advanced Materials Today

May/June 2011

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COVER STORY

Go Anywhere Liner Imagine a wear lining on an important piece of processing equipment has failed. You pick up the telephone and call the repairman who arrives a short while later with a few boxes and proceeds to repair the job in a matter of hours.

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n the past such failures could lead to the closure of a plant for an extended period of time while a team of professional lining experts undertook relining by grouting new ceramic tiles into place or in some instances painstakingly cutting polyurethane sheets to fit complex shapes.

Like all things the best ideas are often the simplest The first scenario is quick and painless with minimum disruption, while the second is time consuming – especially waiting for grouting to cure. It requires specialised tiling skills due to the complexity and the weight of the products causes difficulties getting to site.

The solution

Wear linings experts, Uretech, have designed a new range of “peel and stick” polyurethane tiles to replace ceramics in applications not subjected to high temperatures. For applications such as bulk handling of ore, soil, grains and other abrasives the polyurethane tiles have been shown to outperform and outlast ceramic tile linings in a variety of applications. Although polyurethane linings in industry are not new, the idea of adapting the relative flexibility of tiles with a better, more resistant wear lining that

Comparison vs Ceramics

1. Reduced risk of downstream damages 2. Reduction in weight (2.5 times lighter) 3. Time to install is dramatically reduced 4. Risk of breakages during installation is completely eliminated 5. Risk of mixing grout incorrectly is eliminated 6. PU tiles can be installed upside down 7. PU tiles are brilliant with impact and wear 8. PU tiles can be used with soft and hard ore types 9. PU tiles will not crack or break if the substrate it is installed on moves 10. PU tiles are manufactured with a wear indicator, showing the user when it is time to change the lining 11. PU tiles creates substantial noise reduction

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Advanced Materials Today

May/June 2011

is lighter and easier to install is a breakthrough. “It’s an adaptation that allows us to make use of the best of both technologies. Modern polyurethanes can match ceramics for flow ability, outlast ceramics in wear resistance, but could not easily match the versatility of sticking the tiles to any shape or surface.

Development

“So our engineers dreamed up the idea of making polyurethane tiles and instead of using grout we wanted to use something more durable and less dependent on outside factors. Where a grouter may get the mixture wrong or allow the grout to be contaminated it can cause quality problems later on,” says George Hoffmann, managing director of Uretech. He continues that the company works closely with international giant, 3M, to match the application with an adhesive surface that provides industrial strength adhesion to the kind of surfaces that will


COVER STORY

be experienced out in the field. Exhaustive tests and trials show 3M’s VHB adhesive tape provides the best adhesion to any surface. Polyurethane tiles stuck onto a surface with VHB tape will not easily be removed.

allows some movement that acts as a shock absorption layer. By contrast, hard adhesives or grouting can be dislodged with sharp impacts, but the flexibility of the tape means that knocks either on or from behind the liner will not easily dislodge them.

Battling to contain his excitement at the prospect of supplying new clients, George runs through the potential industries that can make use of the tiles and continues that the company expects the range to be highly successful.

Evergreen polyurethane

With kits they can be flown in and installed the same day in some instances Unique solution

“We have come up with a simple, yet effective solution for linings. It is hard to believe that nobody else has thought about the idea, but like all things the best ideas are often the simplest,” he adds. A simple solution it may be, but it has so many features and benefits over traditional linings that it makes for a good case to switch to the new tiles. Each tile, for example, is moulded in two colour layers to act as a wear indicator to effectively show operators when the lifespan of the lining is halfway. 3M’s VHB adhesive tape enables the tiles to adhere to a wide range of surfaces and

Properties of polyurethane are already well documented with exceptional wearability, good strength properties as well as its ability to absorb and

3M tape specifications

Typical physical properties of 3M VHB adhesive tape: Peel Adhesion (stainless steel) – 35 N/10mm Normal Tensile:(aluminium T-block) – 620 kPa Dynamic Shear (stainless steel) – 550 kPa Static Shear (stainless steel) – 1500 g/0.5 sq. in. (holds 10,000 min.)

– 500 g/0.5 sq. in. (holds 10,000 min.)

– 500 g/0.5 sq. in. (holds 10,000 min.)

– 250 g/0.5 sq. in. (holds 10,000 min.)

Solvent Resistance – High Shelf Life – 24 months from date of manufacture (stored in original cartons, 20°C 50% RH) Temperature Resistance: Short Term: (minutes,hours) – 150°C Long Term: (days, weeks) – 120°C

Advanced Materials Today

May/June 2011

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Advanced Materials Today

May/June 2011

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COVER STORY

maintain its shape under high impact. This makes it ideal for linings on a wide range of applications. It’s one Achilles Heal is temperature as polyurethane is prone to deformation at temperatures exceeding 80-90°C. Until such time as Uretech’s technical gurus formulate heat resistant polyurethane the new tile linings are suitable for lower temperature processes only (below 70°C). The light weight and easy application of the tile linings enables Uretech to create pre-packaged kits for repairs and remote installations. “We expect to sell thousands of kits to mines and process plants up in Africa where supply normally takes a long time due to inaccessibility or inefficient transport networks. With kits they can be flown in and installed the same day in some instances,” says George.

Trials no tribulations

Customer trials are already underway and initial findings indicate that the product is performing beyond even the high expectations of Uretech. Test clients are ecstatic and for this reason the company has applied for a worldwide patent of the technology. The tiles are not the only new innovation from Uretech. Another exciting development is the formulation of Urego, industrial polyurethane with built in lubrication for extra flowability of materials. It has applications in a number of industries from chutes to slipways and even lining massive off-road dump trucks in mining applications where the Urego lining prevents carry-back of materials. The lining helps where substances are prone to “cake” or build up on surfaces and ensures the materials slide off with ease. Unlike polyethylene the new lining is not as susceptible to scratching and flowability actually improves as the lining wears.

Sticky situation

“Initially some clients in the bulk materials handling industry approached us to supply Ultra High Molecule Weighted Polyethylene (UHMWPE) liners, but after conducting tests it soon became obvious that UHMWPE is a hard-compound polymer that cannot withstand impact or compression and is prone to scratching. “This unfortunately excluded the materials from being used in 90% of the applications where impacts from falling rocks or other high density objects would ultimately destroy the lining. “Instead, we developed Urego that has similar flow as UHMWPE due to its built-in lubricant, but has the ability to rebound

and resist scratching, breaking or snapping under pressure or where it is subject to sharp impacts. Urego is available in sheets or tiles depending on the application requirements.”

On the market

Both innovations are available from Uretech where their team of technical experts will be able to advise clients on materials that are suitable for applications at hand. Uretech, George Hoffmann, Tel: (011) 268 8860, Fax: (011) 447 2212, Email: george.hoffmann@uretech.co.za, Web: www.uretech.co.za

BASF Polyurethane developments

BASF develops ideas and concepts with its clients. Through its global network of research and development competency centres in Germany, USA and China it is able to provide innovative customised polyurethane system solutions to make businesses more successful. The chemical giant has a local systems house with the ability to provide technical services and support to customers, including formulation, blending and testing of products. Specialists and technical services chemists support products on site at clients’ sites if needed and Uretech has benefitted through their close support on an ongoing basis. BASF Polyurethanes South Africa is a market leader in the local market. It supplies five core markets in vastly different industries giving an indication of the many different applications for this unique material. The five core markets include: • Automotive (seating, headliners, oil and air filters) • Appliance (domestic and commercial refrigeration, geysers and boilers) • Construction (insulated panels, insulating spray foam, rigid block foam) • Footwear (safety and leisure) • CASE (coatings, adhesives, sealants and elastomers) for mining, metallurgical and general manufacturing

Advanced Materials Today

May/June 2011

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MACHINE TOOLS

Service Worth a Fortune In the last quarter of a century a lot has changed in the world of machine tools. Brand names have changed, come and gone at a regular pace. Only the fittest survived the turbulent eighties, suppressed nineties and the globalised economy that was ushered in during the first decade of the new century.

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ne company that has survived and thrived during this time is Victor Fortune (Pty) Ltd that was founded in the mid-eighties and has grown to become one of the best known machine tool suppliers in the country. In some ways it owes its success to the political upheavals of the time.

“When sanctions strangled the supply of machines from traditional markets in Europe and Japan, Alan Meredith the founder of the business, travelled the Ian Simpson, globe in search of machines Victor Fortune suitable for local operations until he found what he was looking for in Taiwan,” says Victor Fortune’s Ian Simpson.

Out of Asia

have been sold around the country and as Ian proudly points out the vast majority of the machines sold in the early years are still operational and working as hard as ever.

Milestones

Among the machines are some 50 Victor Taichung machines that were commissioned by Toyota through the years. In 1995, 18 machines were supplied on a new manifold production line that is still in service today. The machines are ideal for industries where high production outputs are required, such as aluminium wheel manufacturers, automotive, mining and general engineering works which is what has made them so popular. In terms of quality, what sets the machines apart is the sturdy and rigid design to guides, spindles and assemblies that are made to be durable. This gives the machines a solid base and as a result the ability to work accurately to close tolerances. Apart from their accuracy, they have a reputation

“At the time Taiwan was not recognised as a world-class supplier of machine tools, but Alan was well-experienced and recognised the high quality of machines manufactured at the Victor Taichung factory and proceeded to conclude an agency agreement on the spot.

We had the pick of the bunch and took the best “He was able to import the machines to the country and provide local manufacturers with muchneeded equipment to continue their operations. Although the name was unknown at the time we were one of only a few suppliers and as a result sold many machines into the market,” Ian explains. “After that, the name was entrenched and local engineering works have been buying our machines ever since.” To date more than 900 machines

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Machine base


MACHINE TOOLS

Victor Fortune Machine Tools has an extensive range of CNC milling and turning machines for the South African market. These include:

Lathes

VT Plus Range are small, but faster machines with linear guideways, that are ideal for high volume production of smaller precision parts. They are often fitted with bar feeders and part catchers for fully automated no-hands operation OR_VC-A110 (with new guarding)

for speed of operation and are more than able to hold their own against European and Japanese competitor machines.

Pick of the crop

“Being the first South African company to source machine tools in Taiwan, we had the choice of machines and chose the best there was available. As a result our machines offer excellent quality at reasonable prices. We had the pick of the bunch and took the best,” Ian adds.

VT-Range are rigid machines up to 2,2m between centres for precision and heavier turning operations. The machines are able to maintain tight tolerances due to the rigid construction and box slides making them ideal for materials that have been flame cut or with interrupted cuts. A-Series lathes with milling and drilling applications can be supplied inclusive of sub-spindles for continuous operation and the ability to machine work pieces on both ends allowing for completely finished components to come off the machine in each cycle Vertical lathes are available for heavy parts and specialist machines for machining aluminium wheels and other custom high volume work are available.

Ian is an old hand within the machine tool market having served the industry for more than 40 years. He knowingly adds that machines sales are just one part of the picture and service and support are the other more important aspects of maintaining relationships with clients that last through good times and bad.

Machining Centres

“This is what the company has built upon and despite the temptation to diversify, we’ve stayed focussed on supplying CNC turning and milling machines to the market and nothing else. Likewise, we stayed with a single agency approach and as a result know our products inside and out. We are able to maintain spares holdings at a manageable level so whatever a client needs we will almost always have in stock right here in South Africa.”

VC Range has a machine for every application. From small light machines with a 700mm X-axis to the 14 ton VC 145 with its 1450mm x 700mm travel and sturdy construction for big heavy machining. The range is well designed with sturdy frame and minimal overhand to ensure that maximum use of space and to ensure weight distribution is carried on the frame. All Victor Taichung machining centres have double arm tool changers for quick operation.

Single supplier

In fact the single-suppliers approach paid off to such an extent that Victor Taichung in Taiwan bought an equal shareholding in the local operation in 1995 and has since had a vested interest in the success of the business.

Despite the temptation to diversify, we’ve stayed focussed on supplying CNC turning and milling machines to the market and nothing else “This means that we are not the forgotten supplier at the bottom tip of Africa, but rather an important stake-holder of the manufacturer which gives us access to the very latest and best technology that it has to offer,” Ian says. And, Victor Taichung has a lot of technology to offer. It is at the forefront of technology when it comes to building and developing machine tools that are

All Victor Taichung milling machines have oil cooled spindles to ensure accurate machining. A wide range of machines are available from fast production type machines to precision machining centres and speciality tool making machines to economy machines that were launched during the recession to assist manufacturers in trying times.

A-Series machining centres are specially designed for tool rooms with high speed spindles, fast feed rates and extra heavy cast frames with advanced controls to accommodate the high speed of operation of these machines. Machine acceleration of this series is fast enough to be measured in G-force.

Specialty machining

Large and specialised machines are available such as the moving column machining centre for extra long work pieces, horizontal machining centres with pallet changers for 4 axis and automated work, as well as a full range of 5-axis machining centres for precision engineering. In order to keep the wheels of the manufacturing industry turning world wide the factory also released economy machines that are based on the same rigid frames as the standard machines, but with single wind motors and a more basic version of the Fanuc control system. The economy series has been well received and will continue to be offered to local buyers. Victor Fortune has been a member of the Machine Tool Merchants Association of South Africa for many years.

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MACHINE TOOLS

OR_VC-H1000 (left view)

this facility among the best in the world – so we are fortunate that we have such a good relationship with them.” Ian continues that the machines in South Africa are paired with a team of service engineers OR_VturnA26CV_left view (door open) who have long track records with the fit-for-purpose for the manufacturing industry. It company and are experts in maintaining the mahas a massive research and development operation chines. Everything from regular maintenance to dedicated entirely to ensuring that their machine repairs and programming on the Fanuc controls, tools are as efficient and reliable as possible to as well as installations and optimisation, is all in a day’s work. deliver for any application.

World-class

“Victor Taichung operates a world class precisionfoundry where castings are made for their own machines and the likes of some of Japan’s best known manufacturers as well. To improve efficiency, a new sheet metal factory has recently been established with a fully integrated computer manufacturing system and the very latest CNC sheet metal machines as well as an advanced powder coating plant making

“The majority of our service engineers have been extensively trained in Taiwan and are tasked with maintaining machines in out-of-the-box condition. This is why the vast majority of the 900 machines we have sold in South Africa are still operational today,” Ian concludes. Victor Fortune Machine Tools, Ian Simpson, Tel: (011) 392 3800, Fax: (011) 392 3899, Email: ian@victor.co.za, Web: www.victor.co.za

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MACHINE TOOLS

Puma Project Roars In One of the most significant deals in the machine tool market in South Africa last year was the supply and installation of more than 60 horizontal machining centres for the new Ford Puma production line in Port Elizabeth.

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or the Cape Town based supplier, WD Hearn Machine Tools, the deal was a sweet one and one that could not have come at a better time with the local machine tool market under severe pressure. It supported the company’s long-standing thinking that it is more lucrative to deal with the world’s leading machine tool manufacturers than to take on agencies for the sake of price advantages.

If you cannot meet the terms and conditions associated with global supply to Ford, they simply make another plan MAG Powertrain have supplied 60 Gantry Loaded Horizontal Maching Centers to Ford South Africa in Port Elizabeth and six MAG Boehringer Crank Milling machines. This is part of Ford’s major expansion at its Port Elizabeth factory. The project is well under way with production due to start in the middle of 2011. Father and son, Ray and Graeme Cooper, share some of the secrets of the trade with “Advanced Materials Today” and explain how

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the company’s suppliers are integral to long-term strategies.

Global supplier

“Ford uses MAG Industrial Automation System’s machines at all its plants globally. But, it is by no means a certainty that as the local supplier you are guaranteed to get the order. “If you cannot meet the terms and conditions associated with global supply to Ford, they simply make another plan. So it is a great achievement that we were able to meet both Ford and MAG’s criteria for supply and service. “With its head office in the US, MAG is a company that has grown through acquisition of the world’s top machine tool manufacturers in Europe and elsewhere in the world. As a result it has become a global manufacturing giant with plants in all corners of the globe,” says Graeme Cooper. Original Companies that now form part of the MAG Group include Cincinnati, Gidings & Lewis, Boehringer, Huller Hille Hesapp, Cross Huller, and Ex –Cello-O.

Worldwide manufacture

With these acquisitions it meant that different agents in South Africa represented the MAG group indirectly through the supplier contracts in place with the original companies – including WD Hearn which had for years been the agents for Cross-Huller before MAG acquired the company. “When the Puma project was confirmed, MAG needed to appoint one local agent to support MAG


MACHINE TOOLS

for the sales and service support for all companies in the MAG Group. W D Hearn Machine Tools have been appointed the Sole Agents for the MAG group for South Africa. The machines are to be used to machine the cylinder head, block and crankshafts for the derivatives of Ford’s new Puma Diesel engine. The engine is a high-tech turbocharged common-rail diesel engine and the South African plant is expected to produce about 180 000 of these units every year.

Reliability required

This demands extreme reliability of the machines in the process and all activities surrounding their manufacture need to be in line with the company’s ISO 9001: 2000 certification by the BSI, as well as compliance to TS 16949 and ISO 14001 for its assembly operations, supply, engineering and human resources.

The engine is a high-tech turbo charged common-rail diesel engine and the South African plant is expected to produce about 180 000 of these units every year. “We are market leaders in Cape Town and surrounds with a strong and growing footprint in Gauteng and all other major centres in South Africa. The Puma project was just one of the many successes that we celebrated last year and if that is an indication of things to come, then 2011 is going to be an even better year for us,” concludes Graeme. WD Hearn, Graeme Cooper, Tel: (021) 534 5351, Fax: (021) 534 3374, Email: hearn@wdhearn.co.za

WD Hearn has a long history and in the 77 years that it has been servicing South Africa’s industry has built up a reputation for supplying quality goods. Since the early 1980s Ray Cooper and partner George Mills have maintained a steady focus on supplying a focussed range of metal cutting (removal) and measuring equipment. Through the years the partners have slowly and carefully selected agencies that fulfilled a specific requirement of the local market.

Top agencies

Apart from the highly sought-after MAG agency, the company has agencies for the well-known, technologically advanced range of Leadwell machining centres and CNC turning and gantry type machines. These Leadwell machines fill the mid-budget requirement for quality machines at a competitive price. Last year WD Hearn sales of Leadwell machines increased substantially with a wide range of models being sold all over South Africa. The company also has agencies for Nikon metrology systems, Jones and Shipmann grinding machines and Chiah-Chyun multiaxis precision lathes. These lathes are popular in the local market and to date nine Twin Plattern Twin Spindle machines have been sold to Cambro Components for mainly automotive precision parts. Other agencies include Bermaq, Electronica and Annway Tooling among the main brands.

Support

To support its strong line-up of agencies from leading manufacturers, the company has a permanent force of 12 field technicians, as well as sales and support staff to ensure clients’ machines run optimally and trouble-free. Advanced Materials Today

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STOCKISTS AND SERVICE CENTRES

Steel in the Veins Well-known steel merchants, Stewarts & Lloyds, has a long history in South Africa and is a household name to many, including the farming community who still operate Lister engines and windmills supplied by them.

A

dvanced Materials Today” delves into the history of the company to find out some of its history and looks to its future plans.

It all started in 1898 when the British owned Lloyd & Lloyd opened two branches in South Africa, one in Cape Town and one in Kimberley. At the time, A&J Stewart & Menzies, also a British company was being represented in South Africa through Brown & McKenzie.

Early days

Seeing the need to consolidate their South African interests, the companies amalgamated in 1903 to form Stewarts & Lloyds (South Africa) Limited. They then expanded their branch network to include Bloemfontein, Durban, Port Elizabeth, East London and Johannesburg.

Today they operate out of 45 000 square metres of warehouses throughout the country. Inventory levels are in the region of R100 million and they employ over 450 people. The future looks bright too; having been purchased by Stockwell from Barloworld in 2002, they are now privately owned and are achieving good growth in all products throughout their extensive range.

We have developed a big customer base, both nationally and internationally The industries the company operate in include light and general engineering, building and construction, mining, rural water, chemical, petro-

Advertisement in ‘The Friend’, 16th January 1903

chemical, automotive, agriculture, water reticulation, fire protection and local authorities. But they don’t feel they’ve reached their peak and are always looking to grow.

New services

Stewarts & Lloyds Laser Products, previously known as Global Laser Products (a 12 year old company), has recently been added to its branch network, increasing the countrywide branch count to 29. Products and services of this new addition include laser cutting and fabrication of all sheet metal products, CNC bending, robotic welding, Tig welding and CO2 welding. “We have developed a big customer base, both nationally and internationally,” says Mark Wakeford, one of the shareholders.

New range of fences

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STOCKISTS AND SERVICE CENTRES

benefits of motivating and retaining staff and thus have invested in training in a big way. In addition to product training, courses in management, external and internal sales, warehousing and finance are offered with all staff encouraged to attend. “With regard to our BEE program, we are close to finalisation and are also involved in social upliftment programs in the outlying areas,” says Mark.

Stewarts & Lloyds has state of the art machinery

In conjunction with a manufacturer of steel fencing, Barkers UK, they will now expand their portfolio of products to include security fencing. Barkers UK quality and specifications fulfil Stewarts & Lloyds criteria, and with BSEN ISO 9001:2000 compliant quality control management, the manufacturer meets the most stringent global environmental standards as well as manufacturing quality required of this type of fencing.

The company has always provided continual flow of suitably trained personnel, available to staff the group’s extensive branch network. There is a dedicated training centre to put personnel through their paces and a trainee scheme is in place.

Fencing

The range of fences available include pre-galvanized palisade fencing, railing systems, a customer specified designer range, mesh fencing systems, a sports range of fences, as well as gates, including cantilever and protector gates. These will cater for applications in schools, public areas, Steel bending is one of many services offered sports complexes, mining, military, Looking to the future commercial, industrial and high security sites. The combination of a well-renowned company of The company also offers a free consultancy and 100 years plus, a comprehensive product range of design service so that its customers’ unique needs good quality products, a nationwide branch network are satisfied. and motivated, well-trained staff, leaves Stewarts Put personnel through their paces and a and Lloyds well poised to conduct business for many years to come. All this, with the backing of trainee scheme is in place reliable and professional suppliers, bodes well for Of course, their existing products continue to be the future. offered. These include steel and tubes, pipes and The group has a retail outlet at each branch. This fittings, valves, pumps and irrigation equipment, cash and carry business sells a range of steel, as well as value added servicing such as profiling, tube and industrial hardware including cutting and guillotining, bending, rolling and plasma cutting. grinding discs, abrasives, paint, welding accessories Importance of people and fasteners. With people being the most important aspect of Stewarts & Lloyds, Mark Wakeford, Tel: 0860 10 27 99 the business, Stewarts & Lloyds have realised the Advanced Materials Today

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Advanced Materials Today

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May/June 2011

2011/05/26 11:30 AM


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Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123 Republic of South Africa Tel: (011) 781-1401 Fax: (011) 781-1403 Email: editorial@promech.co.za Website: www.promech.co.za Managing Editor Susan Custers

Editor: Raymond Campling Advertising Louise Taylor Circulation Catherine Macdiva DTP Zinobia Docrat/Sean Bacher Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals. Printed by: Typo Colour Printing Tel: (011) 402-3468/9

Copyright

All rights reserved. No editorial matter published in “TDM Today (Tool, Die & Mould Making)” 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 consequences 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.

CEO’s Comments The NTI Programme is a Public Partnership Programme (PPP) between the Toolmaking Association of South Africa (TASA) and National Government through the Department of Trade and Industry (DTI).

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key aspect of this programme is to develop and test the methodology of such partnerships at implementation level through the processes of: stakeholder mobilization - alignment of stakeholder objectives, areas of responsibility, key focus areas and strengths, resource identification and capacity building, as well as cooperation extraction through Memoranda of Understanding and specific Service Level Agreements.

Own destiny

The Tooling Sector has taken the lead in determining its own destiny by actively spearheading a sector “turnaround” programme by focusing the NTI interventions on long term sustainable solutions for: skills development and deployment, aligned to industry needs; ‘enterprise development’;and expanding local and export capacity.

Key interventions

A case in point is the recent analysis of the results of the first pilot year of the Pre-Apprenticeship orientation programme that demonstrated that a key hurdle facing young students from disadvantaged backgrounds, causing them to drop out of training programmes, is the lack of access to transport, suitable accommodation and access to basic food needs. Through efforts of the NTI partnership with Gauteng Provincial Government, industry and the Gauteng City Regional Academy(GCRA), 280 students were coupled to a bursary scheme from GCRA that provided a solution to these problems. Based on this new partnership, the NTI programme is actively pursuing similar partnerships in the other provinces, that will effectively address non- learning performancerelated drop-out causes. In partnership with Xstrata in Limpopo province, a similar support system has been created.

Solutions driven

The NTI hereby demonstrates that key solu-

Dirk van Dyk

tions to challenges can be found through partnerships, but partnerships require planning and management capacity, which is effectively supplied through the NTI Project Management support structures. Through this unique approach the NTI takes the burden off Government and industry in finding and managing solutions and communicating with stakeholders.

Effectively address non-learning performance-related drop-out causes This approach also ensures that industry takes the lead in developing and managing solutions to unique problems facing industry and its battle to become competitive in a global market, where competitors like China have invested heavily in their manufacturing and skills capacity. By uniting the capacity of industry, government, skills institutions, labour, education and support institutions at international, national, provincial and local levels, South Africa stands a fair chance to capitalize on opportunities to have a strong growing local manufacturing sector that can drive job and wealth creation on a sustainable basis. The Tooling industry invites you to get involved in the National Tooling Initiative to make a difference. Dirk van Dyk, National Tooling Initiative, Tel: (012) 643 9360, Email: dirkvd@ntipweb.co.za, Web: www.ntipweb.co.zs

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Printing Prototypes

A look into the future of manufacturing may hold some pleasant and unpleasant surprises for many in the tool, die and mould making industry depending on which side of design you’re on.

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dvances in the field of 3D printing and additive manufacturing show that, in future, complex one-off designs may be printed straight off CAD rather than machined and manufactured as we do today.

About Objet Geometries

Objet Geometries is an innovation leader in 3D printing for rapid prototyping and additive manufacturing, providing 3-dimensional printing systems that enable manufacturers and industrial designers to reduce cost of product development and dramatically shorten time-to-market of new products. Objet’s ultra-thin-layer, high-resolution 3-dimensional printing systems and materials use PolyJet polymer jetting technology, to print ultra-thin 16-micron layers. The Objet Connex multimaterial family is based on Objet’s PolyJet Matrix Technology, which jets multiple model materials simultaneously to create composite digital materials. Objet systems are in use by customers worldwide, including Fortune 100 companies, in multiple industries such as dental, medical, medical devices, education, consumer electronics, automotive, toys, consumer goods and footwear industries.

Traditionally 3D printing in the tool making industry is used for rapid prototyping so that manufacturers can get an exact replica of goods from their drawings without the need to make tools or moulds upfront.

Material rich

Machines like the Objet 3D printers available from Demaplastech are already far advanced and can currently print up to 65 digital materials including 51 composite materials with properties similar to common plastics such as polyethylene, PVC or even rubber. What’s more, the printers can print different materials simultaneously in different colours (including clear) so that manufactured pieces can be accurately prototyped.

Will additive manufacturing put milling machines out of work “Advanced Materials Today” attended a recent press function to announce the awarding of the Objet agency to Demaplastech. During the event, printed prototypes were shown that had o-rings printed into hard valves

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TDM PROFILE

and a toy motorbike wheel with an ABS type mag and rubber-like tyre. These were printed from CAD drawings in a couple of hours.

Working prototypes

“One of the amazing things about printing prototypes is that working components within a manufactured piece can be printed and will work without having to assemble the pieces,” says Jacques Kleynhans, director of Demaplastech. Holding a small set of complexly angled gears that mesh perfectly and run smoothly on their spindles, he explains that the 3D printers build up the internals and all the fittings exactly like a 3D image so the internals, attachments and spacings are printed in place - already in. In some instances the accuracy of the Objet 3D printers and the ability to directly print complex designs in a myriad of materials can enable specialty manufacturers to print products directly without

the need for machining or casting of materials. An example is hearing aids where each individuals ear canal is shaped differently. The hearing aids require an exact fit and by modelling them directly from scans to CAD and printing the hearing aids in digital plastic materials, the entire process is dramatically shortened. There is no need for moulds or tooling and the customer can be wearing the hearing aid in a matter of hours rather than days or weeks.

Metal printing

In the run-up to EMO Hannover 2011, similar advances in additive manufacture where metals are “printed” in 3D on a similar principal recently caused a stir among manufacturers begging the question, “Will additive manufacturing put milling machines out of work”? An interview with Andrzej Grzesiak who heads the Fraunhofer Additive Manufacturing Alliance at the Stuttgart-based Fraunhofer Institute for Production Technology and Automation (IPA), shed some interesting light on the subject. He responded to the question as follows: “Additive manufacturing cannot replace conventional work. The right approach is to define the correct application categories and to replace existing conventional technologies only where commercial

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TDM PROFILE

more and more, particularly in micro-systems engineering and biotechnology. There’s going to be a lot happening here in the next three to five years. and technical advantages are to be gained. The technologies should co-exist and complement each other to optimum effect.”

Free designs

“This technology is hardly going to leave foresightful machine tool manufacturers cold. The advantage of layer-forming processes is that any conceivable shape that can be created in a 3D CAD program can actually be produced. There are no restrictions in terms of manufacturing transparent or hollow structures. Nor are there any problems with complex geometries and freeform designs. “We’re only at the very beginning of developments. New, improved materials and more stable processes are being developed. Nonetheless, we’re already seeing the first best-case applications with implants, dental technology and light automation components. Individualised mass production is up and running almost everywhere in these fields. We’re also seeing new applications in aircraft manufacture, where metal-based lightweight construction using titanium is set to play a particularly large role. “Depending on the particular application being planned, you have to choose the appropriate technology. This is also important for newcomers: first the application, then the technology. Nowadays, the laser systems are being used especially in the field of end-part production.

Specialist applications

“In future, printing technology systems will be used

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“Although the integration of new manufacturing methods into industrial process chains offers farreaching options for optimising production operations, due to the lack of organisation and the stand-alone machines, implementation is as yet not very far advanced. By reason of minimal batch sizes and the elimination of assembly processes thanks to complete manufacture, there is concomitant potential for streamlining, though this, of course, has to be supported by the correct organisation. “Additive manufacturing enables certain problems to be solved in conventional production structures, though the integration of these systems in the triangular matrix of time/costs/quality is being made rather difficult by the current lack of comprehensive production models.”

Toolmakers secure

It is clear that 3D printing and additive manufacturing will play an increasingly important role in manufacturing. Toolmakers are already able to save thousands of Rands on prototyping tools and moulds before physically making them. For the foreseeable future the low production yields of 3D machines will mean that they will be used in low volume applications rather than in full-blown production processes. It is, however, a good idea to stay abreast of the technology and embrace it as yet another potential manufacturing technique. Demaplastech, Grant Ravenscroft., Tel: (011) 462 2990, Fax: (011) 462 8229, Email: grant@demaplastech.co.za. Fraunhofer Institute, Andrzej Grzesiak, Email: andrzej. grzesiak@ipa.fraunhofer.de, www.ipa.fraunhofer.de


TDM NEWS

Afrimold Keeps It Local Major local industries such as automotive and packaging are spending millions of Rand on local design, engineering and manufacturing equipment and services - only to have the tooling, dies and moulds manufactured overseas instead of in the local economy.

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his is a situation that the second AfriMold Exhibition from 27-29 September at the Sandton Convention Centre, aims to address. Exhibition managing director Ron MacLarty comments that tooling, dies and moulds made overseas can be less expensive if they are correctly made, BUT if they are wrong it becomes a very expensive experience.

share of that is just R1.2-billion with the remainder of the work being placed overseas. In essence, we are importing more than 60 percent of the tools we are using in manufacturing,” concludes Ron. Afrimold, Ron McLarty, Tel: 072 353 6699, Email: ron@ afrimold.co.za, Web: www.afrimold.co.za

“AfriMold 2011 is a very focused and specialised opportunity for local tooling, die and mould makers to meet local manufacturing companies so that they can do business together in South Africa. Also, for SA based industries that need such services to meet highly skilled and competent tooling, die and mould making companies in this region. “The exhibition is a vehicle for local tooling, die and mould makers to get into the market and find selective work which suits a particular toolroom,” adds Ron. “It has been proven as an excellent means of showing local capability and expertise. Last year business worth R6.5-million was concluded and two agencies were acquired within the three days of the show itself. Significant other business was concluded in follow-ups after the show.” Ron points out that AfriMold expects to have exhibitors representing each step in the cycle, which runs from design, materials, simulation, visualisation, engineering / CAE, virtual reality, CAD and CAM, rapid prototyping and tooling, pattern making and prototyping, mould making and tooling, tools, machine tools, quality assurance and automation and finally to processing and finishing. “One of our major objectives is to encourage the South African tooling industry to adopt and invest in the technologies that make up the product development design cycle. The more innovative and competitive they are, the more major local industries will be encouraged to place their tooling, die and mould requirements locally.

BE REMEMBERED BEFORE, DURING AND AFTER AFRIMOLD

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he organisers has got together with “Advanced Materials Today” to make this year’s Afrimold Exhibition one to remember.

We are preparing a Visitors Catalogue which will feature a floor plan, a list of exhibitors and sponsor details. The catalogue will be in all the delegate bags and will be given out from our stand at Afrimold. We are all hard at work publicising the Exhibition and your presence in the Afrimold Catalogue will serve as a permanent record of your company’s products and services, before, during and after Afrimold. Get in touch with us to place your advertising and/ or to buy editorial in this prestigious issue.

Advertising Contact: LOUISE TAYLOR, “ADVANCED MATERIALS TODAY” on Tel: (011) 781-1401, Cell: 082 898 3073 Email: editorial@promech.co.za

“Tooling is a R6-billion industry in SA yet the local Advanced Materials Today

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TDM NEWS

Laser Welding

New laser technology has opened up new and universal fields of application to welding technology for the repair sector.

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ith the ALM 200 mobile welding laser it is possible to join and deposit-welding on moulds, chassis and mechanical parts of any size, particularly for big moulds whether it be at a customer’s site or in the home workshop. The laser arm can be positioned flexibly and with the turn and tiltable processing head and focus distances of some 100 mm, welding at any point of the work piece is possible even in deep cavities. The movement of the processing head over the work piece can either be carried out manually by joystick or semi automatically with preselected speed and direction of the motion axes.

Photo from L&A Lasertechnik

While welding in extreme positions, a remote control with 4-axes control and laser pulse triggering via joystick offers optimal comfort. Even complex work piece geometries can be handled in an ergonomic working position due to the optional turn and tiltable optics for the processing head. Small cylindrical parts may be welded by connecting a tilting turntable with chuck to the ALM. Alpha Laser GMBH, Email: info@alphalaser.de, Web: www.alphalaser.de

Repair of a roller (nickel-plated)

Welding in a deep cavity

Modification of a complex injection die-mould for headlamp housing

Mobile repair welding in the machine on an injection die-cast mould

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Remote control for 4-axes and laser pulse release

May/June 2011

Additional turn- and tiltable optics on the movable processing head


TDM NEWS

Assistance Needed

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CORROSION, SURFACE FINISHING

Aluminium For All Seasons

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ccording to Mark Coetzee, accounts manager for Astro Holdings in Edenvale, the reason is strong competition from Eastern countries especially China. He tells “Advanced Materials Today” that landed prices of finished goods from China are often lower than raw material cost in South Africa. This makes competing with imports near impossible unless, like companies in the Astro Holdings fold, they have unique offerings that are not based on price alone.

If you buy a product from us today and again in six months time you’ll get the same quality “We differentiate ourselves by offering customised solution backed by technical expertise and helpful customer service. Another reason our customers stay with us is our attention to quality and providing uniform quality always. “If you buy a product from us today and again in six months time you’ll get the same quality and same standards time and again. The same cannot be said for many of the exporters shipping their goods to South Africa,” he says.

Tidy operation

“Advanced Materials Today” paid a visit to Astro Holdings main operation in Edenvale where we were given a no-holds-barred tour by our multi-talented host, Mark. He is not only one of the most enthusiastic sales and marketing persons we have ever come across, but is the company accountant as well. He fills a dual role within the company taking care of the books and still somehow finding the time to brand the company, call on clients and hunt for new business. Mark is part of

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In South Africa the appetite for anodised aluminium is as strong as ever in all industries, but, the number of anodisers plying their trade has shrunk significantly in recent times.

Lightweight aluminium is one of the modern world’s wonder materials having an exceptional strength to weight ratio, good corrosion resistance under normal weathering conditions and exceptional conductivity. Yet it can be susceptible to chemical attack under certain conditions and standard aluminium is comparatively soft, so it can get scratched and damaged relatively easily. But, this wonder material has another trick up the sleeve, it is able to change its surface structure through a simple process called anodising. Anodising aluminium ensures improved performance of aluminium where durability and corrosion resistance is required. Anodising is a process which involves anodic charging of the work piece while submerging it in acid which effectively changes the structure and causes the metallic crystals to rise to the exposed surface of the aluminium forming a hard protective layer. Depending on the acid used, the anodised surface can achieve different properties of hardness and corrosion resistance that makes the aluminium able to withstand damage from weathering, chemical corrosion or scratching. The surface layer of anodised aluminium is said to be one of the hardest substances known to man and depending on the formulation of acid and the time submerged, the thickness can be tailored for the requirement at hand. The anodised surface is microscopically porous which enables the addition of dyes to colour the material before it is sealed in another process. Anodising cannot be compared to coating or plating as it is intrinsically part of the aluminium and can therefore not peel or flake off. Typical applications for anodised aluminium include the ordinary, such as decorative fixtures like picture frames and curtain rails, functional items like door and window frames, industrial applications process conveying equipment and specialised applications in automobile, aviation and even outer space.


CORROSION, SURFACE FINISHING

a team of workers who are committed to making the business competitive and proving that local is still “lekker”. Mark tells us that Astro Holdings comprises the founding company Astro Aluminium, an aluminium extrusion and rolled products retailer, Astro Anodising whose main area of expertise is aluminium finishing, Alu Anodisers specialising in component anodising and Astro Coating, aluminium and steel powder coaters.

Automated plant

Astro Holdings owner, Andrew Dawson, says the businesses share premises in Edenvale where anodising and powder coating is undertaken manually. Another fully automated plant situated in Stormill, with 3m X 3m tanks is available to service clientele in the West Rand.

ready for shipping to a medical supply company.

Made to order

The process is quite simple. As we watch, the aluminium crutches are attached to a specially made jig that is charged and lowered into a large

He is one of the most enthusiastic sales and marketing persons we have ever come across 3.2m X 1.2m tank containing a sulphuric acid solution. They are submerged for a predetermined time in order to meet the customers’ specification

Anodising is not a clean business and it is hard to believe that such fine textures and beautiful colours are produced from what looks like a set of dirty tanks. Of course that is the nature of working with acids and the stained floors and corrosion marked walls and roofs are all part and parcel of anodising. The acid vapour tends to attack and corrode the building structures and floor where the inevitable spills and drips leave the floors marked, but this is a sign of a busy workshop. As we move to the end of the process, set after set of brightened aluminium crutches are dyed emerald green, sealed and dried

Group companies

Astro Anodising caters for mainly the automotive, household and decorative aluminium industries. It is also the only local company to undertake brightening of aluminium as an optional addition to the anodising process. Also, Astro Anodising runs a fully automated plant on the West Rand and provides services to aftermarket as well as suppliers to the large vehicle OEMs among others. The main market for the brightened aluminium in South Africa is curtain railings, motorbike accessories, lighting and interior décor. Alu Anodisers was started to provide component anodising services for all industries. Like all the companies in the group its specialists are able to undertake customised work for industrial applications such as aerospace, mining and general industries. Lastly, Astro Coatings was set up to provide a full array of surface finishing to clients. Astro Coating specialises in aluminium and steel powder coating and provides customers with alternatives to the anodising process.

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the jig is lifted and placed into a rinsing bath where the acid is removed. With that the anodising process is effectively complete and all that remains is finishing. Finishes depend on the requirement and entail brightening processes, dying and sealing which are carried out in the same line when required. A shor t walk away at the far end of the workshop the component anodising production bays are equally busy. Exactly the same process is followed but on a smaller scale. In the store rooms we examine a number of finished goods ready for dispatch to customers around the country. These include picture frames, railings for doors and windows, roof racks for SUVs and bakkies, motorcycle rims and parts, as well as a section for interior home décor. All powder coating takes place in a separate workshop to ensure the environment is clean and free of potential airborne pollutants that could interfere with the electrostatic coating process.

Room for growth

“We have a simple yet efficient operation at both our plants and most importantly they work. Although we are busy we have capacity to take on more work. For this reason we are constantly looking out for new opportunities and introducing customers to the capabilities of anodised aluminium,” adds Mark. As we finish the tour, our intrepid guide shows us one of the fleet of four Toyota Quantum panel vans with its shiny new sign written exterior advertising the group companies’ services – another of his innovations! It is clear that the company is doing well even in tough times. “Proof that despite recession and stiff competition from China quality and service always win the day,” concludes Mark. Astro Holdings, Mark Coetzee, Tel: (011) 452 9748, Fax: (011) 609 2628, Email: admin@astroholdings.co.za

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PLASTICS, PROCESSING MACHINES & EQUIPMENT

Passionate About Plastics The era of metal has lasted 1 000 years and its development is nearing its end. Now is the time of thermoplastic polymers, materials that are enablers of new technologies.

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o says Lutz Beier, managing director of Maizey Engineering Plastic Products, who is spearheading a drive to change the mindsets of specifiers and engineers and to promote the use of engineering plastics instead of metals and other traditional materials.

Plastic can be used to protect and improve the performance of metals Even replacing small metal parts with plastic comes with benefits

In an exclusive interview with “Advanced Materials Today� Lutz explains that plastics are often used automatically in new applications, but it is in existing applications that they offer the biggest improvements.

Just as well, there need to be substantial benefits to convince customers to move over to plastic products from existing materials, as people tend to stick with what they know.

Economical and effective

He describes an example of the sheave wheels fitted to cranes at Durban harbour, which were traditionally made of metal but have recently been replaced with nylon. They were fitted without modification to the cranes and were supplied at a greatly reduced parts price. This departure from the original metal is considerably lighter and as a result enables a higher carrying weight capacity. In addition the nylon wheel causes less friction and wear on the cable and it is not subject to deterioration due to corrosion.

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PLASTICS, PROCESSING MACHINES & EQUIPMENT

“The most common benefits that plastics offer over their metal equivalents are more efficient operation, cheaper parts cost and lower failure rate, but plastic doesn’t have to replace metal to be useful. Plastic can be used to protect and improve the performance of metals, for example, lining a harvester chute with polyethylene sheets reduces friction and protects the metal, making the machine operate more efficiently,” adds Lutz.

Pave the way for a greener environment in years to come He points to another example where the load bays of trucks that transport sand are lined with polyethylene sheeting. The low friction surface means sand slides out easier when dumped. This also prevents sand from caking and sticking to the load bay. Over the course of the day this sand would build up, decreasing space and adding unnecessary weight. The simple solution of lining the bay increases efficiency and decreases running costs, so the thermoplastic lining quickly pays for itself.

Times change

Changing circumstances are also a reason people are turning to plastic. Remember when asbestos was commonly used? Legislation evolves and so must the specification of products. The sheer versatility of plastic means that there are few applications that cannot be fulfilled by plastics and polymers. Polypropylene, for example, is known for its ruggedness and high resistance to chemicals and acids. This makes it ideal for storing chemicals or for lining pipes that transport chemicals. But this material is so versatile that it is also being used to make banknotes, clothing and loudspeakers. As a result plastics are replacing many other materials, not just metal.

Amazing record

With 60 years trading experience, Maizey Plastics has been steadily increasing its footprint to the point that their commercial plastics division is the biggest distributor of plastics in the southern hemisphere. In partnership with the German based company, Röchling EPP, Maizey Engineering Plastic Products intends to grow the existing engineering plastics industry in South Africa substantially by identifying new applications for their products. Röchling has developed over 30 different types of plastics to cover all applications. “There is no application we can’t help with due to our extensive

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PLASTICS, PROCESSING MACHINES

product range” says Lutz, and they are able to always provide the best material for the specific application. These include nylon and a variety of ‘poly’s’ such as UHMW (Ultra-high-molecular-weight polyethylene), which has the highest impact strength of any thermoplastic currently made. These thermoplastics are very versatile and can be machined, bent or moulded. They can also be engineered to be anti-static, or have high anti-corrosive properties depending on the application. Plastics which have been strengthened via a vulcanization process are also available. All of these products are being distributed in Southern Africa.

Plethora of plastic

Outside of industrial applications, plastics now play an important role in medicine and construction, to name just a few of the industries. For example, plastic prostheses disks make for easier surgical procedures and quicker recovery times in the event of injury. “Plastics are the enabler of the 21st century “according to Lutz. When one looks at the array of technogical innovations available today and the materials they are made of, it is clear that there is truth in what Lutz says. We have plastic to thank for much of the technology that has infiltrated our lives and even the humble microchip requires plastic for its manufacture. “Go through your house to see the progressive change from metal to plastic” says Lutz. “Fibre optic cables are yet another example of this progression. Metal is becoming an increasingly scarce commodity but the ingredients for plastic remain abundant, needing only carbon and the energy of the sun to create.” Plastics are all oil-based products and are potentially regenerable. They are now being made from renewable sources and are being recycled, but although these developments are still in their infancy, they will pave the way for a greener environment in years to come,” Lutz concludes confidently. Maizey Engineering Plastic Products, Lutz Beier, Tel: (011) 824 2751, Fax: (011) 824 1829, Email: lutzb@maizey.co.za

Maizey manufactures a wide variety of plastics to suit different applications

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LIGHTER SIDE

Shooting for the Sky When Richard Schultz and his team set out to build an aircraft engine to replace the current “tried and tested” design that has powered almost all the world’s general aviation aircraft for the last 40 years, some of the country’s aviation experts laughed it off and told them their design would never work.

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aving just won a SABS Design Award and the SABS Prestigious Chairpersons Award for their revolutionary new engine, needless to say there are some experts out there with egg on their faces, including a senior engineer from a major Japanese car manufacturer who was emphatic that the cylinder heads that the company produces could simply not be “made in SA.” “Advanced Materials Today” caught up with Richard after the awards to find out more about the engine and what the future has in store for Adept Airmotive, the company set up to conceptualise, design and manufacture the Adept Aircraft Engine.

Clever airheads

Being a self-confessed petrol head and airjunkie, the idea came to Richard to design and build an improved general aviation aircraft engine one day while attending an air show with his friend and later his partner in Adept Airmotive, the late Jeff Cronje. “Jeff had dragged me over to look at a “remarkable new engine” which was a 100hp Rotax, and which featured water-cooled cylinder heads and could run on Mogas (automotive petrol). I was less than enthusiastic about the level of technology, so Jeff responded with “can you design a better one” Answer: ‘Yes”, and that’s how we started.”

Make sure it is at least 16% more powerful, smaller, smoother, lighter and more reliable while you’re at it

From day one we agreed that we needed multi- and unleaded fuel capability. The aviation industry is aware that lead will be phased out, but have done little in the last 20 years to address the problem.

Ignition

“We discussed the fact that leaded aviation fuel would have to be phased out in the not too distant future and the unsuitability of the current engines for available alternatives. That was the spark that got us thinking about designing a new improved engine that can run on almost any fuel. It was the beginning of a long journey of learning and development,” he says. A small team comprising Richard, Jeff and Raymond Bakker was assembled, and work on the Adept engine began. From the outset the idea was to create an engine that was different and centred around the economy, reliability and lowest possible environmental impact.

Going like a Boeing

The team design brief went something like this: “Unlike its predecessor the engine should not puff and splutter heavy leaded fumes into the environment, nor should it be picky about the fuel it drinks,

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LIGHTER SIDE

In production

“We have entered into low volume production and recently dropped the engine into a locally-designed and built advanced composite construction SA Raven to complete a 100% indigenous aircraft. Like our engine, the SA Raven is an advanced light aircraft with a South African manufactured fully electronic cockpit for pinpoint flying ability. “In a way, this was the fulfilment of a dream to fly a completely locally manufactured aircraft. But, the South African market is small and we are in the process of industrialising and commercialising it for international markets as well. This includes getting the necessary certification through the South African Civil Aviation Authority and the European Aviation Safety Authority”

nor should it drink too much. And oh yes, it should have fewer moving parts, must be 100 % carbon neutral in manufacture and must be easy and economical to produce and be easy to maintain and be competitively priced. It should use a level of technology that allows future-proofing of the design, and should also look good, “And another thing, make sure it is at least 16% more powerful, smaller, smoother, lighter and more reliable while you’re at it.” The engine fulfils the brief and has taken flying technology to a new high by disregarding previouslyheld notions about the configurations of aviation engines. A good example is the fact that the engine is designed as a 120° V6 rather than the traditional flat horizontally opposed 4, 6 or 8 cylinder engine.

Direct drive

This allows a propeller speed reduction unit to be used to optimise engine speed and propeller speed requirements. This decouples the specific requirements of the crankshaft and the propeller shaft (that on conventional engines are shared by the crankshaft only) and leads to higher load bearing ability. Unbelievably the engine has a lower profile than a horizontally-opposed engine. Considering the engine has a Catholic diet and can operate on conventional lead-free Mogas (automotive petrol), Avgas, biofuels, LPG and on fuels with octane ratings below 100, it is up to 30% more economical than comparatively-powered engines, and has a much better power to weight ratio than current engines. And it is environmentally friendly too. It is designed to be the greenest aviation engine in the industry – both in manufacture and in operation. The ADEPT engine has the lowest Nox, CO2, unburned hydrocarbons, lead emissions and noise levels and has up to 30% better fuel efficiency than existing light aircraft engines.

Building an aircraft engine is no mean feat and probably explains why it took 40 years for the world to produce an improvement on the commonly-used engine designs that do service in the world’s small aircraft today. And it took a South African design team to do it.

Manufacturing excellence

The Adept engine was a winner from the very beginning. In 2008 after the design and prototyping of the engine was complete, the company received its first award as the winner of the Autodesk Inventor of the year worldwide for excellence of design. By designing, testing, prototyping and changing the design on this advanced CAD system they were able to design a cast block engine that minimises machining, lowers part count and makes the most of the properties of certain lightweight materials to accomplish the required strength.

And the new foundry is the only 0% emissions foundry in the world “We also relied on technology stations at Central University of Technology, University of Johannesburg, Durban Institute of Technology, and Vaal Technikon to analyse and test design concepts, and local engineering companies to manufacture prototypes and finally to produce the end product.

All aluminium

“While casting of the A356 aerospace grade aluminium is still undertaken at the University of Johannesburg’s facilities and final machining by Rost Engineering, we maintain tight control of the entire process and aim to create an in-house casting operation in time. “By designing from the start with the aim to minimise machining of the cylinder head and block, we are able to push the yield up to 90% with minimum wastage. Good when considering that the major automotive manufacturers around the world have a yield of about 50-60%. In fact everything in the casting process is reusable and the new foundry is the only 0% emissions foundry in the world,” adds Richard. Advanced Materials Today

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An all aluminium assembly including the pistons is rounded off with a high alloy steel billet crankshaft and chill-cast iron camshafts, chromenickel –molybdenum gear sets and with a lot of carbon fibre and other advanced materials used for bolt-on components.

major law-suits are currently being fought by environmentalists over the continued use of leaded fuel in the USA. Its continued use in aviation is doubtful as a result. While the world is scrambling to develop a replacement fuel or to develop suitable engines, the answer already lies on our shores in the Adept engine.

Aerobatic capability

As Richard and his team continue to commercialise the engine, they are preparing for full-scale high volume production to meet the expected demand from aviators worldwide. Traditional markets such as the USA and Europe will be target markets as will India and China who have potential for massive and growing fleets of general aviation aircraft. Even the local market comprises a few thousand aircraft that could find themselves high-and-dry without fuel and in need of a solution. Enter the Adept.

This brings the weight of the engine in at only 160 kg compared with the standard type engine which weighs about 210 kg. At the same time it produces 238 Kw of torque compared with about 200 Kw for a similar class currently available engine. Considering that an aircraft can go from 0-20 000 feet and then descend again, in a matter of minutes with a vast difference in temperature along the way ,a lot of peripheral engineering is needed to ensure the right coolant, fuelling and lubrication gets where it is needed when its needed.

Lastly, there may be another twist in the tale as the engine’s potential for very high power output has also prickled the interest of a number of other aviation applications, such as Unmanned Air Systems, and there could be some breakthrough technology developed that has applications in the automotive as well as aviation sectors. Watch this space!

The engine also uses some slick engineering to ensure it performs when inclined, upside-down, flipped or looped. It can also be used in pusher or tractor configurations, and can be vertically mounted for helicopter use.

Adept Airmotive, Richard Schulz, Tel: (031) 573 2214, Fax: (031) 563 1351, Email: Richard@adeptairmotive. com, Web: www.adeptairmotive.com

For the future

Time has run out for leaded aviation fuel and two KEW Foundry Ad 1/2 PG.fh11 4/21/11 3:06 PM Page 1 C

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SAIW News Heat treatment training

The Southern African Institute of Welding reports that the first batch of students recently completed the inaugural course in Heat Treatment and the next few courses are already fully booked. “Heat treatment is a critical activity in welding and fabrication and the independent training and evaluation of the personnel performing it has largely been neglected up to now,” says SAIW executive director, Jim Guild. He adds that there is not sufficient awareness about the importance of heat treatment in ensuring that equipment is suitable and safe for service. “Pre-heating welding operations can be crucial in Jim Kirwan, Cooperheat of Africa RSA opera- ensuring that cracktions manager, with heat treatment equipment ing does not occur in the Cooperheat workshop during welding and post-weld heat treatment is key in ensuring that the correct strength properties are achieved in a weld and that the weld joint is left free of residual stresses. This stress relief can be extremely important in avoiding catastrophic structural failures and in-service degradation through stress corrosion cracking mechanisms,” he says.

The OHE350 welding helmet

New welding helmet

Afrox’s new Transarc OHE350 electronic arc welding helmet is attracting attention in the market place owing to its high quality and competitive price. “This innovative new welding helmet provides optimal protection for the eyes during arc welding, as well as permanent protection against ultraviolet and infrared rays, heat and spark, in any state from clear to dark,” says Afrox’s Lourens le Roux. “This allows the user to see the point of arc strike precisely and efficiently.” The OHE350 is built to exacting professional standards and is designed for industrial welders who weld infrequently. It provides complete, reliable protection and is also lightweight and extremely comfortable to wear. The shell is designed to reduce the amount of welding fumes in the welder’s breathing zone and the new and unique headgear allows the user maximum adjustment and comfort. It is equipped with a high quality 4/9-13 electronic Auto Darkening Filter (ADF) lens. Switching time from clear to dark is approx 0.005 seconds (0.5ms), providing quick and effective protection. Afrox, Lourens le Roux, Tel: (011) 490 0400, Email: lourens.leroux@ afrox.linde.com, Web: www.afrox.com

SAIW adds diploma benefit

The Southern African Institute of Welding (SAIW) has announced that as of this year, inspectors achieving the SAIW level 2 qualification will automatically receive the International Institute of Welding (IIW) International Welding Inspector (IWI) Standard Level diploma as well as the SAIW diploma, provided they meet the IIW access conditions.

Jim emphasises that the SAIW heat treatment qualification will enable users to specify the skill levels of heat treatment technicians. “Heat treatment of welded joints is widely practised, especially in the process and SAIW Certification’s John McLeish says that in 2008 the SAIW Certification’s power generation industries and we want to John McLeish content of SAIW levels 1 and 2 was completely aligned help both the user and the service provider with the IWI Standard level diploma content. “In fact, the by ensuring the qualification gives both par- SAIW courses cover much more material than the IIW programme but we did ties confidence in the personnel performing have to amend the course content to include two days devoted to construction critical heat treatment operations.” and design,” says John. The course is aimed primarily at heat treat- He adds there is no additional cost. “Until now we have made a nominal charge ment operators performing site and shop for issuing the IIW diploma but this has now been waived so we will issue the heat treatments using electrical resistance diploma automatically for new students. Anyone who qualified between 2008 heating. SAIW is investigating the possibility and 2010 can apply and, provided they meet the necessary access conditions, of introducing a level 2 course which would they will be eligible to receive the diploma,” he says. incorporate other heating methods, such as Explaining the need for meeting access conditions before the diploma can gas and salt baths. “In the meantime the be issued, John says the IIW system is linked to national education systems current course includes excellent general and it is essential that course attendees meet certain educational standards. information,” he adds. “The IIW diploma is a significant added benefit as IIW has 56 member counJim says he is grateful to Cooperheat of tries and its diplomas receive worldwide recognition” he adds. Africa MD Yusef Patel and RSA operations manager, Jim Kirwan for prompting the The SAIW calls on all those who have a SAIW Inspector Level 2 under their Institute to introduce the course and for the belts to urgently contact the Institute to find out whether or not they are help they have given in getting the course automatically eligible for the IWI Standard diploma. Even inspectors who qualified before 2008 can have access to the diploma simply by attending off the ground. Southern African Institute of Welding, Jim Guild, a two day construction and design course and passing a short examination Tel: (011) 298.2100, Fax: (011) 836.4132, Email: covering the course material. guildj@saiw.co.za, Web: www.saiw.co.za

Southern African Institute of Welding, Jim Guild, Tel: (011) 298.2100, Fax: (011) 836.4132, Email: guildj@saiw.co.za, Web: www.saiw.co.za

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International News Focus on aerospace

EMO Hannover 2011 will be showcasing new production technologies for the aerospace sector conference and complementary special show to highlight ongoing trends in aircraft construction

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For the eleventh time, the Institute of Production Engineering and Machine Tools (IFW) at Leibniz Hannover University will host its prestigious conference entitled “New Production Technologies in the Aerospace Industry” on 22 and 23 September 2011 – this time in Hanover.

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As was the case last year, the event is being co-organised by the nationwide Machining Innovations Network (MIN). “It makes us very proud to know that our conference will this year be part of the world’s biggest trade fair for the metalworking sector”, says Professor Berend Denkena, director of the IFW.

“We will be offering visitors to the EMO from the aerospace industry a top-class forum for acquiring new information and exchanging news and views about the status of research work on an international level.” Besides the metallic materials (particularly titanium and aluminium), fibre-reinforced plastics and material combinations will this year, too, be a major focus. The agenda includes new machinery and production technologies, plus automation concepts in the aerospace sector, and the planning and repair of CFRP components. Institute of Production Engineering and Machine Tools, Eike Hasselberg, Tel. +49 (0)511 762 18074, Email: hasselberg@ifw.unihannover.de

Mega machine tool upturn

In the first quarter of 2011, order bookings in the German machine tool industry showed three-figure growth

rates. Compared with the preceding year’s equivalent period, orders in the months January to March rose by 130 percent. Domestic and export demand developed identically. “The sector has picked up speed very much faster and more vigorously than we anticipated back in the autumn”, reports a gratified Dr Wilfried Schäfer, executive director of the VDW (German Machine Tool Builders’ Association) in Frankfurt am Main.

Dr Wilfried Schäfer, executive director

This, he continued, of the VDW (German Machine Tool is now showing up Builders’ Asso-ciation) spectacularly in the sales figures, with a steep rise of 45 per cent in the year’s first quarter. With these good results order bookings are rapidly ap-proaching the all-time high of 2007. The good performance is also being reflected in the capacity utilisation level, which at 93.8 per cent in April of this year had almost returned to the figure last achieved in the boom year of 2008. The order backlog, too, at 8.7 months in February of this year, is not far below the peak figure of 2008. The sector is currently employing a total of 64,100 people, roughly the previous year’s figure. VDW, Sylke Becker, Tel +49 69 756081-33, Fax +49 69 756081-11, Email: s.becker@vdw.de

All about plastics and rubber

Having put the aftermath of the global financial and economic crisis quickly behind it, the plastics and rubber industry is now demonstrating its capacity for innovation and growth. Worldwide, it is thought to have outstanding prospects for the future. Machine and plant manufacturers, raw materials producers and processers of plastics and rubber are presenting their latest technological advances at trade fairs around the globe. Further information is available at:

Messe-Duesseldorf, Eva Rugenstein/Desislava Angelova, Email: RugensteinE@messe-duesseldorf.de or AngelovaD@messe-duesseldorf.de

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International News Laser marking

Foba Laser Marking and Engraving recently introduced a novel workstation for the high-precision and repeatable laser marking and engraving of small workpieces. Foba G3, laser workstation for material processing, belongs to Foba’s line of laser engraving machines but bridges the gap to Bone screw marked with a barcode Foba’s all-laser marking machines: The G3 station is ideal for highly-precise deep engravings but also for brilliant laser markings in small and premium parts. This predestines Foba G3 for varied laser marking and engraving applications in the medical technology industry and fine engraving sector as well as for numerous applications in the metal, tool and mold pro¬duction. The 2-in-1 laser marking and engraving machine applies finest 2D/3D engravings on 3D surfaces and marks medical instruments, equipment and implants as well as luxury goods such as premium watches and jewelry.

brand-new welding heads that are easy to use and that are of ergonomic and futuristic design at the same time. These new orbital welding heads also make tube to tubesheet welding and tube-tube welding particularly easy for the operator. During the development of the TS 8/75 tube/tubesheet welding head, the requirement was for more compact, more ergonomic, more productive, more straightforward, more fully automatic, and more precise welds. The Polysoude team improved upon these requirements – the TS 8/75 impresses with its low weight and compact shape when applied to the workpiece; its ergonomic double grip with integrated control buttons for clamping and welding; the integrated pneumatically operated clamping/centring system makes it possible to work with several welding heads simultaneously; the wire feed and support legs are particularly easy to adjust; the standard arc height adjustment (AVC) assists the fully automatic joining process; the integrated simultaneously rotating wire feed ensures the feed velocity is constant and the impact position for the filler wire is also constant. Polysoude, Andrea Husson, a.husson@polysoude.com

New fuel tank material

A new material has been developed to prevent hydrocarbons escaping from fuel tanks of petrol-driven engines. The Foba G#

Powerful solid state lasers, the automatic vision system IMP (Intelligent Mark Positioning) and the manual vision system Point & ShootT ensure short processing times and high-precision. Foba G3 excels wherever absolute marking and reproduction accuracy are demanded: from the marking of small plastic and metal parts to the engraving of filigree 2D/3D textures and patterns on 3D surfaces. The patented camera system IMP automatically detects workpieces and their positioning, and adjusts the marking/ engraving accordingly. With a width of 80cm, a height of 1.90m and a footprint of 1.4 m², Foba G3 fits through standard doors. As a result of the compact design, the workstation can easily be integrated into any lab environment. The stable machine frame and alignable and repeatable axes ensure repeatable machine operation, accurate markings and exact documentation over a significant period of time. www.Fobalaser.com

Orbital TIG welding

With modern inverter power sources such as the P4 and the larger P6, Polysoude in Nantes (France), has set a new technological standard for automated orbital TIG welding. With this advance the French market-leader is opening up new dimensions in quality and cost-effectiveness for plant construction. In a second step the company has technologically and visually adapted the other components of its hightech orbital welding systems to the new joining concept with

Leading specialty chemicals company, Lanxess is working on special blow-moldable grades of polyamide 6 that act as an extremely effective barrier against gasoline fuels. Substantial amounts of hydrocarbons leak through the walls of plastic fuel tanks in gasoline engines to the outside and pollute the atmosphere – a phenomenon known as permeation. One example of such a material is Durethan TP 142-011. “The polyamide 6 is so effective in suppressing fuel permeation that test results are well below the upper limit for motorcycle tanks, which was recently tightened considerably by the US Environmental Protection Agency (EPA). It is also impact-resistant, a quality it lends to the blowmoulded tanks it is used to make,” said Maik Schulte, a development engineer at Lanxess. The material is an especially good alternative to high-density polyethylene, which has been used to make many plastic tanks for gasoline engines until now. It also has considerable advantages over other tank materials, such as aluminum, sheet steel and multi-layer plastic composites. Plastic fuel tanks are used not only in the gasoline engines of cars, motorcycles, boats and other watercraft, but also in a number of combustion machines such as lawnmowers, leaf blowers and mobile power generators. www.lanxess.com

Lanxess has developed a new fuel tank material

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Industry News State-of-the-art centre

Afrox has officially opened its multi-million rand re-engineered Gases Operation Centre (GOC) in Germiston, the foundation of the company’s Merchant and Packaged Gases (MPG) business in Africa. The newly upgraded GOC is the company’s largest special gases facility and laboratory on the continent and the only nitrous oxide production plant in the country. The GOC is the most advanced facility of its kind in the southern hemisphere and is Afrox’s largest filling site on the African continent, filling an average of 5 500 cylinders a day, accounting for a large portion of the company’s total South African production (excluding LPG).

New compressors

Swedish multi-national Atlas Copco, an international leader in clean compressed air technology, designed and manufactured the two-stage GR110 and 200 oil-injected screw compressor series for higher pressure air applications from 13 bar up to 20 bar. Available in a Full Feature (FF) version (built-in refrigerant dryer), the GR series presents a complete and efficient package compressor for applications that demand higher air pressure. An extremely efficient TEFC electric motor (IP-55, Class F insulation), drives the two-stage compressor to deliver optimum performance at high pressure. The GR range’s cost saving features include: quick, easy installation, proven reliability and efficient performance in high pressure applications. The energy efficient GR range operates silently and the built in dryer uses R404 refrigerant in compliance with environmental regulations.

The facility services more than 3 500 customers and 41 Afrox branches throughout Africa. The re-engineered GOC has capably taken on the load previously handled by five Afrox industrial filling sites in and around Gauteng and three medical filling sites. The GOC was originally constructed in the late 1920s and has evolved over the years to include a diversity of activities.

Atlas Copco’s extensive product portfolio includes a comprehensive range of in-house designed stand-alone and integrated air treatment products, refrigeration, adsorption and membrane dryers, as well as filters and condensate treatment equipment to meet increasingly sophisticated application requirements. All products are manufactured to the highest quality and maximum efficiency standards and comply with international ISO 14001 environmental safety standards. Atlas Copco South Africa Tel: (011) 821 9106, Fax: (011) 821 9000, Email: www.atlascopco.co.za

“By the time we took the decision to re-engineer this facility in 2005, the site was starting to become congested, compromising the function of equipment and processes,” says Afrox’s group cylinder production manager, Brett Wheatcroft. “The facility upgrade was set in motion to ensure that GOC would continue serving our markets to world class standards, well into the future. “The facility has been re-designed to deliver enhanced efficiencies and significantly increased on-site safety. Expected benefits include improved operational efficiencies and potential sales growth. “In re-designing the facility, special consideration was given to increasing workflow and to meeting the changing needs of our customers. The reengineered GOC will allow us to be more systems oriented and electronically driven, significantly reducing the risk of error and greatly reducing lead times.” Afrox customer service centre on 0860-020202 or visit www. afrox.com

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A GR-200FF showing the internal workings


Industry News

R&D centre certified

Launched just over a year ago the research and development centre of Durma machine tools has recently been awarded certification by the Government of Turkey. During a ceremony organised for the event, the Turkish Prime Minister Erdogan handed over the “R&D Centre Certificate to Durma head Mr.Durmaz. As the first and the only R&D Centre in the Turkish Machine Tool Industry, Durma employs 56 personnel on 2700m² footprint consisting of offices, laboratories and application rooms. Durma engineers continue their research and development activities on mechanical systems, electronics and mechatronics as well as software in order to design new technologies for Durma products. This is a future commitment of Durma to research future trends, evaluate them and create future technologies for their own machines. Durma SA, Byron Gueffroy, Tel: (011) 827 0639, Email: sales@durma. co.za, www.durma.co.za

Gutters for the long run

Specialist roof gutter manufacturer, Longspan Gutters, has increased its roof gutter manufacturing output and further tighten its quality standards by installing two advanced Durma sheet metal working machines for the manufacture of its range of box gutters. In the past the Cape Town based company outsourced bending and cutting of its box gutters. By bringing the production in-house the company is able to respond quickly to stock requirements and maintain its own high quality standards. The Durma machines were supplied by Rijva Quality Machines and include a large 6m press brake with a force of 250 tons. Specialised tooling was supplied to bend the thin sheeting into the fairly complex shape required for box gutters.At the same time the company installed a 4m X 6mm Durma guillotine with an easy to use touch screen display and thin sheet support system to ensure no deformation. “Manufacturing box gutters calls for specialised equipment that is able to bend a fairly complex shape with either two bends or 6 and very tight angles in thin material. The length of the gutters and thin materials mean tolerances are tight,” says Paul Marais, director of Longspan Gutters. Rijva Quality Machines’ Byron Gueffroy says customers supplying steel and metal products to the building industry have found favour with the Durma machines as the rugged quality and high output of the machines, combined with the range’s easy to use operation means that they are able to keep up with demanding supply schedules.

Durma taken R&D center certification from the primeminister

Rijva Quality Machines, Byron Gueffroy, Tel: (011) 827 0639, Fax: (011) 827 0643, Email: byron@rijva-sa.co.za. Longspan Gutters, Paul Marais, Tel: (021) 556 8522, Email: paul@longspangutters.com

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Industry News Reaping cutting benefits

Special Steels, one of South Africa’s leading steel merchants, has recently added two Everising circular saw machines to its cutting force. This investment has already positively impacted the company’s customer service offering, as well as its productivity levels. “The accuracy of the Everising P-150 circular saws led to a growth in customer demand, which justified our installing a second P-150”, says Theuns van der Merwe, general manager at Special Steels. He refers to the P-150 as the “Rolls Royce of cutting machines” because of its high accuracy levels and ultra smooth finish. “Our customers now want nothing less”, he notes. Apart from bringing high-precision cutting to individual jobs, the P-150 circular saw has added significantly to Special Steels’ general cutting capacity. “The P-150’s cutting capacity is five times the capacity of a normal bandsaw machine, allowing for a much quicker turnover. It is designed for both high-volume cutting and multiple jobs, in contrast to our bandsaw machines which perform one job at a time,” he explains.

“Chromium carbide has a high tolerance to impact and is, therefore, a more suitable option to fragile ceramics. What’s more, Rio-Carb CrC material does not lose its hardness at higher temperatures and is unaffected by heating and cooling cycles. Martin points out that Rio-Carb has developed a unique welding process that is splatter-free, and eliminates the risk of uneven bumps and indentations, which can negatively affect the performance of the product. Rio-Carb, Martin Maine, Tel: (011) 908 1014, Fax: (011) 908 4139, Email: info@riocarb.co.za

Subscription Please fax us if you wish to subscribe to “Advanced Materials Today” at R375,00 (incl postage and VAT) per year; R875,00 per year for Africa/Overseas. We will post you an invoice on receipt of your fax.

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Theuns concludes: “We are proud to have some of the best maintained saws in the industry, which is why our downtime and wastage is at a minimum. But more importantly, our rigorous maintenance keeps our cutting at its accurate and consistent best.”

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Special Steels, Tel: (011) 865 4939 Fax: (086) 555 3624, Email: sales@specialsteels.co.za

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New product in the pipeline

The possibility of expansion is in the pipeline for Rio-Carb, as the company launches its exclusive range of chromium carbide-lined industrial pipes. A new-generation range of abrasion-resistant Chromium Carbide (CrC)-lined pipes, designed specifically for heavy industries in South Africa, has been introduced to the local market by leading liner plate expert, Rio-Carb. The new pipes are available in diameters of 100, 150 and 200 mm, and are ideally-suited for backfilling, smelters, refineries and for the transportation of sludge. Rio-Carb director Martin Maine notes that the CrC lining provides the pipes with higher abrasion resistance than industr y-standard ceramic and rubber lining, which ultimately improves the performance and lifespan of the product.

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Index to Advertisers Afrimold 16 Afzelia 10 First Cut Hi-Tech

Inside Front Cover Outside Back Cover

KEW Foundries

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Nkosi’s Haven

6

Opticor 29 Plastix Portal

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RelyIntraCast 26 SAEEC

Inside Back Cover

Sapics

Inside Front Cove

Uretech Urethane Moulded Products

Outside Front Cover 19


BLACK OR BRIGHT you choose

energy efficiency @ work

Taking energy efficiency light years ahead 16-17 November 2 011, Emperors Palace, Gauteng SAEEC2011EXHIBITORS

An exhibition hall packed with decision-makers, more than at any other event. Exhibition space available at affordable rates. EXHIBITION SPACE (3x3m2) Your exhibit includes: • Standard shell scheme cubicle • Standard company name on fascia • 1 x 15A power point with shared DB • 1 x double fluorescent light • Exhibitor manual for planning, installation, dismantling of booth R11,600 for corporate members (R13,200 non-members)

2x EXHIBITION SPACE (3x3m2) Your exhibit includes: • Standard shell scheme cubicle • Standard company name on fascia • 2 x 15A power point with shared DB • 2 x double fluorescent lights • Exhibitor manual for planning, installation, dismantling of booth R20,400 for corporate members (R23,800 non-members)

SAEEC2011DELEGATES

SAEEC2011SPONSORS

Full delegate: Student delegate: Group discount (5+): SAEE member delegate:

R4,400 R3,300 R4,200 R3,900

Registration fees include entrance to seminar sessions, registration pack, proceedings on CD, daily lunch and refreshments during break.

Enhance your company’s prominence and visibility at this niche event by taking up one of the range of sponsorship opportunities offered.

When booking quote: BW4SAM to qualify for a prize. PRESENTED BY:

For more information contact: Erika Kruger Tel: +27(0)18 290 5130 Cell: +27(0)82 428 7386 Fax: +27(0)86 512 7122 Email: convention@saee.org.za

The Southern African Association for Energy Efficiency (SAEE), chapter of the American Association of Energy Engineers (AEE).

To register and view information about the SAEEC2011 logon to www.saeec2011.org.za.

Advanced Materials Today

May/June 2011

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EXCLUSIVE AGENTS FOR E

CNC MACHINES 16 Nguni Drive, Longmeadow West, Modderfontein PO Box 931, Bedfordview, 2008, South Africa Tel: 011 608-0088 • Fax: 011 608-0148 E-mail: info@hitech.co.za

www.hitech.co.za

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