NEWCAST: International Trade Fair for Precision Castings

Issue 10 - November 2010
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In the Spotlight
“Bright World of Metals”
“Our lives are inconceivable
without metal,” states Mr
Kehrer. “We encounter high
tech metal products every
day and are impressed by the
astonishing things people
manage to create with metal.
Metal is more than just a raw
material, it is an all-round
performer. Metal in many
different shapes and structures
can be found not only
in huge bridges, railway lines
and the shipbuilding industry
but also in tiny components
that are used in communication
technology.”
He continues, “Metals
and the processing of them
also form the joint platform
for the ‘Bright World of Metals’.
This is the motto for the
GIFA, METEC, THERM -
PROCESS and NEWCAST
trade fairs because these four
trade fairs of ours are all
about metals and how they
are processed.” These combined
events cover the entire
value-added chain from
foundry technology to finished
product. Mr Kehrer
continues, “All in all, 1,700
companies showed their latest
developments and products
to some 77,000 trade
visitors from 84 different
countries. We are expecting
the trade fairs in 2011 to attract
a similarly large number
of exhibitors and visitors.”
2 www.castings-forgings-news.com
NEWCAST: International Trade
Fair for Precision Castings
NEWCAST, the world’s leading international trade fair for precision castings, will take place in Dusseldorf, Germany, June 28 through July 2, 2011. This
event only takes place every four years and runs in conjunction with GIFA (International Foundry Trade Fair with WFO Technical Forum), METEC
(International Metallurgical Technology Trade Fair with Congresses) and THERMPROCESS (International Trade Fair and Symposium for Thermo
Process Technology). CFN had the pleasure of speaking with Mr Friedrich-Georg Kehrer, Director, GIFA, METEC, THERMPROCESS and NEW-
CAST, to learn more about some exciting things to expect from this upcoming event.
Mr Friedrich-Georg Kehrer,
Dipl.-Betriebswirt and Director,
GIFA, METEC, THERMPROCESS
and NEWCAST
NEWCAST
Today, our focus is on Newcast
and how it became to be
such an important part of
these events. Mr Kehrer begins
by sharing a brief history
of the event. “For many
years, extending as far back
as the 1950s, there were large
scale trade fairs where
foundry technologies were
the main focus, only foundry
machines and equipment
were exhibited. As time went
by those working in the
foundry’s voiced the need for
a separate event. A platform
was needed for casting
foundries to showcase their
end products and solutions.
The idea was to remain associated
with the foundry technology
events, such as GIFA.
So, in 2003 the first NEW-
CAST was born,” he explains.
Exhibitors and Visitors
Today, NEWCAST draws
over 300 exhibitors from all
around the globe. “More
than 3,500 international visitors
from industries such as
automotive manufacturing,
machine manufacturing,
mining, shipbuilding and au-
tomation, just to name a few,
attend the event in search of
solutions and potential investment
opportunities,” says
Mr Kehrer. Over 50% of visitors
come from outside of
Germany.
NEWCAST is of particular
interest to experts from
the car industry, who account
for the largest percentage of
the NEWCAST visitors
(over 20%). Further major
customers and target groups
for the trade fair are designers,
production managers or
buyers from the aviation,
construction, electronics,
space and medical industries
– all of the many different
sectors in which castings
play a role in the production
process.
Innovation
As the event continues to
grow and change so has the
global economic situation.
Mr Kehrer tells us more
about some of the important
challenges facing foundries
today and some of the things
NEWCAST can offer related
to these challenges. “With
the shortage of energy resources
and the increasing
demands on foundries inno-
Newcast covers three
main areas:
vative, sustainable, environmentally-friendly
solutions
with low CO2 emission have
become increasingly important,”
he says. “NEWCAST
is the ideal platform to exchange
ideas and to present
the latest sustainable solutions
for cast iron products
and for casting components
in non-ferrous metals.” The
show draws top decision
makers looking to invest in
innovative casting solutions
and in sustainable casting
concepts.
ecoMetals
To better promote some exhibitors
and their sustainability
efforts, Messe Düsseldorf
has initiated an “ecoMetals”
campaign. With the motto
“ecoMetals – Efficient Pro -
cess Solutions” any exhibitor
at NEWCAST, GIFA, ME -
TEC or THERM PRO CESS
can apply. Herr Kehrer encourages
exhibitors to apply.
• Ferrous castings
(iron, steel and malleable foundries)
• Nonferrous metal castings
(aluminium, zinc, copper, magnesium,
nickel and other nonferrous metal foundries)
• Services
(foundries that act as service providers or supply
IT solutions especially for the foundry industry)
www.newcast.de
Visit NEWCAST 2011
www.gifa.com

He says, “This promotion is
applicable for energy savings,
improved materials efficiencies,
recycling – the list
goes on and on.” Exhibitors
can submit their product,
processes or technical solutions
for more economic use
of energy and/or resources to
Messe Düsseldorf through
January 2011. Mr Kehrer
continues, “Exhibitors with
an ecoMetals designation
will be promoted via the
website and through an onsite
guide, directing visitors
to this specially selected
group.”
NEWCAST Forum 2011
The foundation for outstanding
foundry products is technology
and the spirit of
research. NEWCAST
Forum 2011 brings together
researchers, scientists, engineers
and technicians to discuss
and demonstrate new
perspectives for users of casting
components. The active
dialogue between research
and practice ensures that
new, sustainable casting
products meet and satisfy
customer demands. This
forum highlights perspectives
for a bigger and more
sustainable creation of value,
which is gentle on resources
and more environmentallyfriendly.
Visit NEWCAST 2011
www.newcast.com
NEWCAST Award
In 2007, NEWCAST initiated
a competition aimed at
highlighting exhibits from
the many castings present on
the show floor. Mr Kehrer
says, “The NEWCAST
Award was developed in
order to highlight castings –
to bring them out of the shadows
and into the light.” The
award is given for castings at
the show that present advantages
of the cast component
outstandingly well by comparison
with other manufacturing
processes. “Awards
are given in three categories,”
explains Mr Kehrer.
“Best substitution for another
manufacturing process, cast
part with the best functional
integration, and for the best
casting technical solution
broadening technical casting
borders or limits of the casting
process.”
Side Programme
Since the areas covered by
the four trade fairs are
closely associated with each
other the forums and con-
gresses surround the fair are
designed so the entire industrial
sector can meet to obtain
and share ideas. The events
involved include: the European
Metallurgical Conference
(EMC) 2011, GIFA
NEWCAST Visitors 2007:
Exhibitors 307
Germany 57
Other countries 247
Number of countries 33
Space 5,425 m 2
Visitors 3, 668
From Germany 50%
From other countries 50%
Industrial sectors
Vehicle Industry
Iron, steel and nonferrous
20%
metals industry 18%
Machine engineering 15%
Other Industry 22%
Services 8%
Skilled Trade 5%
Trade 2%
Reasearch/teaching 3%
Other 1%
Treff which is organized by
Bundesverband der Deu -
tschen Gießerei Industrie e.V.
(BDGuss), the Technical
Forum held by the World
Foundrymen Organisation in
liaison with the BDGuss, In-
SteelCon organized by the
steel institute Verein
Deutscher Eisenhüttenleute
(VDEh), the NEWCAST Fo -
rum, the THERM PRO CESS
Symposium, the special
FOGI show and VDMA
Feuerfest Kolloquium.
Location
Visitors from around the
globe will not be disappointed
with their visit to Düsseldorf.
The city is not only the capital
of North Rhine-Westphalia it
is also an international media
and business centre. The city
offers very good communication,
transportation, acco mmo
dations and entertainment.
There is much to do and see if
time between the events is allowed.
Take a stroll along the
Rhine River, enjoy the restaurants,
bars and shops in the
Alt Stadt (Old City), or visit
one of the many museums.
In the Spotlight
Bulletins
Demand-Control
Seattle-based Powerit Solutions
has added four new
metalcasting operations to its
customer list. Atlas Foundry
(Indiana), Grede Holdings
LLC foundry (Indiana), Griffin
Wheel (Kansas), and Prospect
Foundry (Minnesota) are all
using Powerit’s demand control
capability to save a total
of US$ 400,000 in electrical
costs annually. “Demand control”
is one of four ways that
Powerit’s Spara energy-management
system allows almost
all industrial facilities to
use melting furnace energy
more efficiently by managing
peaks and valleys of demand
over a 24-hour period. Griffin
Wheel plans to manage energy
demand on dust and
fume collectors, air compressors,
and A/C units, as well as
on its melting furnace. Prospect
Foundry and Atlas Foundry received
grants from the State of
Indiana to implement the
Spara system. Atlas Foundry
plans to participate in demand
response programs when they
become available locally.
Production
Overview
Shougang Qian’An Iron and
Steel Co Ltd has awarded PSI
Information Technology Co
Ltd with the implementation
of the production management
system PSImetals 5 for
the planning of two steel making
plants and two hot rolling
mills. PSImetals 5 met the main
re quire ment organizing an integrated
capacity time planning
which provides a de tailed
overview of the casting and
rolling sequences for several
weeks or for several months.
PSImetals 5 calculates the line
schedules by considering the
rules of casters and hot rolling
mill as well as shipping and
furnace age. The customer
gets a clear production over -
view for the whole month or a
scenario for several months.
Record Breaking
Earlier this year, Siempelkamp
broke its May 2009
record for producing what at
that time was the heaviest
ever produced nodular iron
casting, weighing 270tn. The
record breaking upper cross
beam for Alcoa’s “Super
Giant”, the world’s largest
closed-die forging press, was
283tn of molten iron. Siempelkamp
was contracted to
engineer and produce the
castings for an upgrade of
the “Super Giant”: a total of
14 castings for the upper,
moving and lower beams as
well as the foundation stools
of the press. Ten of these parts
weigh between 200 and
250tn. The heaviest part, the
upper beam sized 10,900 x
3950 x 2740mm (l x w x h),
was cast at a temperature of
about 1350C from five casting
ladles in 120 seconds. The
special challenge for the design
engineers was that the
new parts, which incorporate
50 years of technological development,
had to be fitted
with the accuracy of a millimeter
into the existing structure
of the press which had
original design components
dating back to the 1950s.
www.castings-forgings-news.com
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