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L J Foax showing the difference between a
rusted metal rope and a new one. |
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The two metal ropes, mostly used in mines,
show how a new rope should look like and
how an old one looks like. |
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| L J Foax in his laboratory.
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Rust-less automobiles feasible
The automobile has evolved into a day-to-day necessity with industrial nations using the level of its production as a barometer of the economy. Automobile sales are closely watched by different stakeholders, including political leaders and business analysts. Because of growing demand, industry is trying to come up with methods to prolong the life of vehicles and significant research effort is directed at it. CSIR researcher Letsatsi Jay Foax investigates ways to protect automotive components and other metals, such as mining ropes, pipes, valves and other material of construction, from corrosion, or rust, as it is commonly known. Corrosion is the primary means by which metals deteriorate.
Research on corrosion behaviour
Foax loves his type of research because it is two-fold: he researches new ways of protecting metals from rusting and he also uses the knowledge from his research, almost immediately, to solve accidents that occurred as a result of corrosion, for example in mines.
The researcher
In his research, he tests the extent to which anodising parameters or simply adding a coating, usually coloured, to a metal would maximise its resistance to corrosion. These aluminium alloys are anodised to increase corrosion resistance and to increase surface hardness.
Anodised aluminium can also be found in mp3 players, flashlights, cookware, cameras, sporting goods, window frames, roofs, in electrolytic capacitors, and on many other products - both for corrosion resistance and aesthetic or decorative purposes.
Foax also devotes a lot of his time doing research on heat treatment, a method used to alter the physical, and sometimes chemical, properties of a metal to increase its resistance to rust. And this is the main objective of his research project: to investigate the influences of heat treatment and anodising parameters on the corrosion behaviour of the A356 aluminium alloy castings manufactured by the semi-solid metal (SSM) rheocasting process. This process was developed by the CSIR.
Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Complex heat treating schedules are often devised by metallurgists to optimise an alloy's mechanical properties.
The detective
In his work as an investigator he uses his knowledge on metallurgy and corrosion or his research findings to determine why an accident occurred.
He says forensic failure investigations seek to offer explanations as to why and how metallic components had fractured; provide recommendations on what needs to be done to prevent the re-occurrence or minimise future risks.
For example, if there is an accident in a mine, Foax uses his expertise to determine why a rope snapped, if that is the case. He then investigates why the accident could not be prevented or how it should have been avoided.
“By giving advice to my clients, I help keep people alive and this makes me proud of the work that I do,” he says.
Semi-solid metal finding its niche in industry
Semi-solid forming of aluminium is finding its main niche today in its growing ability to control metal viscosity and hence mould filling behaviour; reduce die casting cycle time; improve die life; improve casting soundness and quality; and produce parts at a competitive cost.
“Currently, liquid metal high-pressure die-casting (HPDC) fulfils the bulk of the automotive industry’s needs. However, the ever-increasing demands on quality and weight reduction have driven the development of new processing technologies,” he says.
Personal passions
Foax is also ardent about in-service training/internship of metallurgical engineering graduates. This, according to him, is his small way of helping to alleviate the skills shortage in the country. “And our country also needs a lot of artisans,” he points out.
Foax has offered in-service training to nine National Diploma (Engineering) graduates, two Bachelor of Technology (Engineering) graduates, as well as one graduate with a Higher National Diploma (Engineering).
“This may seem like a small number for such a big organisation, but we know that there are 12 skilled people, from our ranks, who are helping to develop our country,” says Foax.
Foax has been working for the CSIR for over 15 years and has produced more than 200 technical reports in forensic failure investigations, across various industries.
“In this respect the CSIR is expected to be impartial and deliver high quality technical reports that are beyond reproach, as there are two parties involved in litigation with most forensic investigations,” he says.
Foax is also a member of the Air Pollution Information Network for Africa, APINA. As a corrosion task team member, he is involved in various research programmes in atmospheric corrosion and the influences or effects of air pollutants on metallic components, machinery and plant infrastructure.
Foax says there are many advantages to working for CSIR Consulting and Analytical Services.
“My research extends across other research groups at the CSIR, government departments, private sector companies, international agencies and different governments in Africa,” he says.
Greener pastures beyond geography
Foax is originally from the Free State. He comes from a family of nine children and his parents were farm labourers. “This has sort of shaped who I am and contributed to my hard working nature,” he says.
He says his life was that of hardship and poverty while he was growing up on the farm. Foax left his home in the deep farming area of Viljoenskroon when he was only 14-years old. And he has been fending for himself and his family ever since.
“I moved to Kroonstad, where I completed my matric. After that I found a job and made sure that my family moved in with me so that my younger siblings could be nearer to better schools and not end up working on farms for life,” says the man whose passion for education is evident.
But since then Foax has worked harder and denied himself play time. He is currently studying towards an MSc in engineering.
He says it is sometimes difficult to find the balance in life. “I am not married and do not have children but I am hopeful that I will strike the balance. The problem is that there is just too much work and too few people to do it,” he concludes.
http://en.wikipedia.org/wiki/Anodizing
http://en.wikipedia.org/wiki/Heat_treatment
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