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VOLUME 3 / MARCH 2016 12th Technical Forum of Mint Perceptions In the context of the Technical Forum at the World Money Fair, Royal Mint Chief the World Money Fair Engraver Gordon Summers raised an interesting question: how to deal with the fact that our products are achieved by a modern high-performance industry, whereas our customers perceive us as craftsmen like those that created in the 19th century? The minting industry faces the same problem as other sectors. While we grant, or rather expect from, car manufacturers state-of- the-art technology, other sectors such as the food industry promote their products with advertising texts featuring terms such as 'homemade'. How about the minting industry? Does it want to sell its products under the label 'high-tech' or rather as 'craft'? When we ask the customers, we see that the decision has already been made. Despite The Royal Mint presented its new masterpiece, the Phoenix Ascendant. the boom of modern art, there is no market for art medals carefully handmade by artists. The Technical Forum of the World Virtually every modern technical method Commemorative coins, on the other hand, Money Fair has grown into a showcase has been applied to create this medal are sold out immediately if they are produced displaying the latest developments that is a unique work of art. Only two using some new technology. of the various mints. Hosted and examples of this creation will be available organised by Dieter Merkle of Schuler on the market. Why can’t the minting industry get rid of its image as a traditional manufacturer? Is Pressen and Thomas Hogenkamp Second, Alexander Aminidis of ACSYS it because of the widening gap between of Spaleck, this event has become a Lasertechnik introduced a produced marketing and the coin technician? ‘must’ in the numismatic year. This by the use of state-of-the-art laser Marketing places the emphasis on a growth time, 340 applications for participation technology. Every security feature in sales and, therefore, on the promotion of were received by Barbara Balz and her currently possible has been implemented the issue whose design very often refers to World Money Fair team. in this coin. The dies were used by the an event in the distant past. The image of 12 speakers talked about their latest Staatliche Münze Baden-Württemberg to the Mint, in contrast, is only rarely promoted production solutions. Michael Groves mint actual specimens. consistently. Even if it is, the focus is more of the impressed Other new developments will be presented on the past than on the present. with swift progress in matters of colour in this issue. applications on commemorative coins. Will this cause damage in the long run? Summaries of all the presentations can be The food industry has experienced a loss of Ralf Freiberger of Mühlbauer Group found at the CoinsWeekly website at: credibility in recent decades, partly because illustrated how effectively counterfeits advertising claims no longer bear any relation can be withdrawn from circulation when www.coinsweekly.com/en/News/News- to reality. optical methods are combined. from-the-world-of-minting-technology-- Part-1/4?&id=3907 We should therefore make it our goal to Two speakers re-defined the existing ensure that public perception doesn’t deviate practical limits for coin pressing. First www.coinsweekly.com/en/News/News- from our self-perception too much. was Gordon Summers, The Royal Mint's from-the-world-of-minting-technology-- Ursula Kampmann, Editor Chief Engraver, who presented his newly Part-2/4?&id=3920 developed ‘masterpiece’. www.currency-news.com Direct 3D Printing By David Fletcher, CooksonGold Cooksongold, the precious metal supplier The process enables a true 3D image to based in the UK and part of the Heimerle be produced directly onto the face of the + Meule Group, has collaborated with coin. The resulting coin (see below) has the machine manufacturer EOS to create undercuts and intricate detail that cannot the M 080 system and the advanced be achieved through pressing. They could metal powders required for direct metal of course, print the crown in the same alloy 3D. This has resulted in the production as the coin, but wanted to demonstrate the of designs which cannot be achieved by possibility of producing coins containing traditional coin presses. So what is this different metals and colours. technology and how can it be used by In the second case study, they once again mints around the world? used the crown CAD file. but this time Direct precious metal 3D printing is an printed it on both sides in platinum on to a additive manufacturing technology that fine gold coin blank (see right). These coins produces high quality, ready to finish, dense were completely unique and were the first parts directly from 3D CAD data. truly 3D coins. The process uses a laser to selectively melt It’s clear that other possible applications for and fuse together precious metal powder, the technology are to effectively pad print using a layer by layer build process until the precious metal in selected areas of the coin required geometry has been created. blank that then goes on to be struck in the The technology provides the following usual way – giving colour and contrast to benefits opening up new possibilities for the commemorative coins that could not be numismatic industry: achieved until now. Freedom of design Cooksongold will continue to develop the technology adding new alloys to their Complex shapes, impossible to produce current portfolio of 18y, 18w, 18r, 925 silver by machining and 950 platinum. Articulating parts More information is available at Thin walls and shapes which are www.cooksongold-emanufacturing.com or impossible to produce by casting email [email protected] Lightweight parts with hollow or lattice End shot of the world's first truly 3D coin. inner structures Flexibility in design change Simple customisation Produce parts in different colours Printing directly onto existing products and coins No tooling, masters or wax/resins required Short production time (a few hours) Removal of production steps Cooksongold showed two case studies at the World Money Fair. In the first case study, they created a CAD file containing a crown, lettering, beading and coin rim. Then, they fixed an 18 carat yellow gold coin blank into the build platform and printed the CAD file in 18 carat white gold directly onto the obverse of the blank.

Intricate effects produced by 3D printing.

2 MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 Anti-Tarnishing-Technology at the Mint of Poland by Siemowit Kalukiewicz At the beginning of 2014, the Mint The Mint of Poland, in cooperation with of Poland implemented an effective BENEQ, implemented an ALD (Atomic "In our tests, the protective technology protecting coins against Layer Deposition) anti-tarnish coating layer remains unchanged corrosion. Today, this method is applied – nSilver. This method, patented by a 4,000 times longer when over all of our products, with the Finnish company, seems to be the most emphasis put on the silver coins. appropriate one in comparison with the compared with the Silver is very sensitive to airborne sulphur. PVD (Physical Vapour Deposition) and CVD reference coin." High humidity and air pollution accelerate (Chemical Vapour Deposition) methods. the tarnishing process. As we all know, The new method There is a great variety of testing methods tarnishing has always been a worldwide In the ALD method, the coating layer available on the market. However, we problem concerning silver and other alloys. is applied over the entire surface of the opted for the most reliable ones that It is caused by a thin layer of corrosion (ie. product, regardless of its origin and the are conducted in an atmosphere of silver sulphide). relief height. Its anti-tarnish property thioacetamide and immersion in a sodium Thickness of the silver sulphide layer is based on coating silver with a fully sulphide solution. In the latter method, the produced on the product’s surface depends transparent and ultrathin (10-90µm) sample is immersed in a 1-3% sodium on the alloy. The finer the alloy, the thinner protective film of inorganic oxides sulphide solution for 30 minutes. If the the silver sulfide layer. In normal conditions (aluminum oxide/titanium dioxide). sample does not change after 30 minutes, then the protection is sufficient. The nSilver of use, silver and its alloys get progressively First, the coin is struck and washed. Next, protective layer should remain unchanged covered with a yellowish, brown or black it undergoes a process of coating with a 100 times longer in comparison to the coating. If coins are manufactured with nano-layer. During 4.5 hours, in a nitrogen unprotected reference coin. the use of various advanced minting protective atmosphere, coins are heated techniques, the process of tarnishing can to a temperature of 100°C. Then, during a In our tests, the protective layer remains be accelerated. 5-hour process applicable to a vacuum with unchanged 4,000 times longer when There are different methods used to protect the use of suitable precursors, including compared with the reference coin. This silver from tarnishing: placing coins in special TMA (Tri-Methyl Aluminum), water and should provide 50-year protection period. capsules; inorganic coating (chromating); titanium tetrachloride, they are covered with The process has been in use for two years organic coatings, including cataphoretic the nSilver protective layer. already, and I can say without hesitation painting (e-coating); or corrosion-resistant We obtain the first 45µm layer of aluminum that the tarnishing problem at the Mint of metal coating with a thin layer of another, oxide with applying TMA (Tri-Methyl Poland is removed forever. Our coins are more corrosion-resistant metal (rhodium, Aluminum) precursors and water in protected for years to come. palladium, gold, platinum). However, none repeated cycles. The side effect is methane. https://en.mennica.com.pl of these methods have 100% anti-tarnish A 45μm layer of titanium dioxide is formed properties. What is more, every method to of titanium tetrachloride and water in the some extent changes our product. corresponding cycle, and the side effect is hydrochloric acid.

Examples of anti-tarnish treated coins. Loading the coins into Beneq equipment for ALD process.

MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 3 Polishing of Coining Dies By Rüdiger Böhm, Rösler Key to producing high quality coins The objective of the second process step, are perfectly made coining dies. It the ‘polishing’ phase, is the creation of is not surprising that even in today’s a mirror image surface finish. After this manufacturing environment the precision step, the motif on the coin die shows surface grinding and polishing of the raw an immaculate, high gloss appearance dies is still done by hand. without any mechanical imperfections In close cooperation with a German mint, whatsoever. A surface reading of Rz Rösler was able to develop a mechanical = 0.08µm underlines the enormous grinding and polishing process with smoothness, which is essential for astonishing finishing results. impeccable coining results. After embossing of the coin motif and Depending on the condition of the raw annealing, the raw die is firmly clamped to dies, the entire process for finishing the a fixture located in the processing bowl of a surface of coining dies requires between special rotary vibrator. The actual finishing five and eight hours. The system allows the process begins with a pre-grinding phase: simultaneous processing of multiple dies. small surface imperfections on the coin Nevertheless, prior production stages motive stemming from previous production are important. Because of the complex Production of raw slugs. stages are removed with grinding media set manufacturing process and the stringent in motion by vibration. quality requirements, mints are usually The fixtures with the mounted raw dies making their coining dies in-house. During this step, the initial surface reading are then fastened to the workstations of of Rz = 2.0µm is reduced to Rz = 0.13µm. The process starts with the production a drag finishing machine. Depending on The intricate contours of the coin motifs are of raw slugs. In their soft (pre-annealing) the machine type, up to 18 dies can be not affected but are perfectly maintained. condition, these cylindrical pieces are then processed simultaneously. turned to receive a cone shaped surface The finishing process is divided into two profile. In a grinding step the turning steps: During the initial fine grinding lines are removed as preparation for the operation the turning lines, with surface subsequent embossing of the coin motive. readings between Ra = 0.5 and 1.9µm, This is extremely important, for any surface must be removed. The clearly visible impurities would result in a less than perfect turning lines are transformed into a smooth quality of the motive on the coining die. isotropic surface. To date, this grinding step, which must Depending on the respective customer, not change any of the motif contours, has in a second step the surface can then be been done by hand. Our process engineers polished. This operation takes place in the succeeded in replacing this manual same machine, but with a different medium. operation with a specifically adapted drag Either porcelain polishing media or a dry finishing process. polishing process can be used. The result is After turning, the raw dies are mounted a high gloss polish on the surface of the die, to special workpiece fixtures. This which is now ready for embossing the coin prevents any scratching or nicking by motive. The excellent surface smoothness part-on-part contact. of Ra = 0.08µm is the ideal precondition for a perfect coining die. Mechanical grinding and polishing process. www.rosler.com

Royal Canadian Mint Brings Bullion DNA To Europe After the North American launch, the The Bullion DNA device works by reading The Mint’s digital non-destructive activation Royal Canadian Mint has introduced a micro-engraved security mark appearing (DNA) technology, developed in partnership its Bullion DNA anti-counterfeiting on the reverse of every GML bullion dated with ArjoSolutions, captures images of the technology to the European market. 2014 and later, as well as every SML mark encrypted with a string of code, and The Mint’s Bullion DNA counter-top device, coin dated 2015 and beyond. The mark, stores these in the Royal Canadian Mint’s which now allows genuine Gold Maple Leaf consisting of a textured maple leaf and the secure database. When a GML or SML (GML) and Silver Maple Leaf (SML) bullion last two numerals of the coin’s production coin is placed in the Bullion DNA device, coins to be certified in-store, was unveiled year, visible only under magnification, is it communicates with the Mint’s secure before European bullion dealers and laser-engraved on the dies which are used servers to decode the encrypted signature distributors at the 2016 World Money Fair. to strike these coins. and search for a match registered during coin production.

4 MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 Rebranding New Centrifugal Finishing the South Machine for the Treatment of African Mint Circulation Blanks The South African Mint revealed a new By Ingo Löken , Spaleck Oberflächentechnik corporate identity at the World Money At the Technical Forum, Spaleck That means that the operator tells the PLC Fair. According to Managing Director presented a completely new a dedicated volume to be separated in a Tumi Tsehlo, 'the rebranding of our technology for polishing circulating certain period of time (eg. 80kg/minute). identity is an outward declaration of who coin blanks, combining the advantages we are internally. From there the blanks go to a rinsing of hot air drying technology with the and separation area, where the blanks We are a first-class mint with an enviable linear textile dryer. The Z44 is able to are separated from the stainless steel track record in coin minting and huge run up to 1,600kg blanks per hour. media. Before the blanks go into the growth aspirations. We want the industry The new generation of centrifugal finishing dryer, an air knife arrangement pre-dries and the public to see this new look as a machines for the polishing of circulating blanks from obvious water sitting on reclaiming of our rightful place in the global coin blanks last December. The new the blank's surface. This elimination of mint industry.’ generation is remarkable because, macro humidity brings the blanks into The design of the South African Mint’s compared to the existing smaller sister the perfect conditions to be dried with a new logo and corporate identity involved a model Z33BFC with a capacity of worldwide new drying technology. stringent development process to ensure about 800kh/hour, the Z44 finisher is Due to the advanced challenges in the that key criteria were met. now capable of running up to 1,600kg marketplace, Spaleck walked away Among these were to denote the circulation coin blanks/hour. from the well-established hot air drying organisation’s South African origin and its Along these lines of increased capacity, technology. Spaleck has combined identity as a premium coin manufacturer. there have been various technical the benefits from the hot air drying The new logo also had to convey a sense improvements implemented into this new technology with the well-established of gravitas and officialdom as well as serve generation. The blanks are loaded from linear textile dryer, which is very as an affirmation of attributes ranging from the operator into the storage hopper with successfully working for gold and silver artistic integrity to technical excellence. a capacity of about 4 tonnes. This gives blanks. The technical result is the creation In addition, given the timelessness of the operator the opportunity to focus of blanks with proof quality. the South African Mint’s products, it was on other tasks for about 2.5 hours fully So a new specification for the perfect essential that the identity remain stylistically automatic operation of the machine. drying technology has been formulated. relevant in future and also scalable. From the storage hopper, the blanks are The requirements are: loaded into the working tub. Here, a batch Drying capacity 1,600kg/hour of about 400kg blanks are treated with 400kg of stainless steel media. Ready for mass production which is requested in the circulation coin blank During the treatment, the pickling phase business and polishing process takes place. Spaleck has optimised the treatment conditions No spots or damages are allowed on using just mild acids, so we generate the blanks bright surfaces without the use of sulphuric No contamination Vienna acid or peroxide. The mild acid can be Low noise level recycled by the system and re-used in The drying temperature has to be on a the next treatment cycle. These efforts Philharmonic lower level, preferably less than 80°C were made to achieve the most effective and environmental friendly system; we are After an extensive study for the drying proud to claim that the water consumption conditions and a prototype phase, The Austrian Mint unveiled at the per hour is about 1,000 litres. Spaleck Oberflächentechnik was World Money Fair their first platinum very proud to present this new drying After the treatment process, the mix of bullion coin. Produced from 999.5 pure technology SFT 200 during the World media and blanks are unloaded onto a platinum, the new Vienna Philharmonic Money Fair 2016. coin shares the famous design with the storage hopper from which the separation www.spaleck.biz/en/home/ gold and silver Vienna Philharmonic process is started. For the benefit of the Bullion Coin. operator, the separation conditions are controlled by weight cells. Gerhard Starsich, CEO and Chairman of the Executive Board of the Austrian Mint said: 'expanding into platinum is a natural step for us.' The new platinum coin will initially be available in 1 ounce denominations, and will be sold throughout Europe and in overseas markets, including Japan and the US.

MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 5 Making a Mint: Holographic Coins Brief history highlights Australia’s centenary Using holograms to What is ‘claimed’ to be the world’s first In 2001, the Royal Australian Mint (RAM) holographic coin was a ‘’ for the released an A$5 hologram coin to mark the create optically variable (IoM), minted by Pobjoy Mint, end of Australia’s Centenary of Federation. effects on coins can be a privately-owned company in the UK. This is believed to be the first two-channel The coin is made of platinum and depicts hologram coin. Depending on the angle of challenging. While the a Viking ship with the sail made from a view, two separate images are visible. dream of holographic patterned hologram. The design for the One depicts the Federation Rotunda coin was first issued in 1983 and the IoM while the other is a map of Australia coins being used in re-issued 10,000 in 1996, which included showing the states and territories in general circulation the hologram. different colours.10,000 of these coins In 1999 the Royal Canadian Mint (RCM), were produced and the hologram utilised has not yet been which has a history of issuing coins a method pioneered and patented by featuring holograms, unveiled a holographic Australia’s Commonwealth Scientific & realised, several special gold maple leaf coin to commemorate Industrial Research Organisation (CSIRO). or commemorative the 20th anniversary of its gold maple The following year, the RAM produced a leaf programme. This coin received further hologram coin for the ‘Year of the holographic coins an Excellence in Holographic Product Outback Finale’. This A$5 silver holographic have been produced in award from the International Hologram coin was the first to feature three channels. Manufacturers Association (IHMA). With improved technology, this coin recent years. In commemoration of the 100th anniversary had a much larger hologram occupying of the birth of Dennis Gabor (the inventor almost half of one side. The three-channel Given the need for mints to of holography), the National Bank of hologram showed the mountain in morning, innovate (particularly those that Hungary issued a 3,000 Forint silver coin in day and night lighting, and 15,000 were rely on commemorative coins June 2000. The obverse side, bearing the minted. principal design of the coin, featured the for a large part of their output), In 2003, the RAM issued a holographic holographic depiction of the initials of G.D. coin as the finale to its series on Australia’s together with the reduced Volunteers, while in 2004 it issued number of available technologies holographic coins for a standard issue for making coins resistant to design, albeit the holograms were only counterfeiting compared to used on the proof set. These coins of banknotes, holograms could kangaroos were produced using a new provide a solution – if and when method developed by CSIRO, which entailed coating the hologram side of the the technical issues relating to coin with a resin, into which the hologram is durability are overcome. Gabor coin – Hungary, 2000. embossed.

The Evolution of Holographic Coins

1996 2001 Over the past 20 years, the use of holograms within commemorative and collector coins has developed in sophistication. Isle of Man platinum coin, ‘claimed’ to be A$5 federation hologram finale silver coin, believed the world’s first holographic coin. to be the first two-channel hologram coin.

6 MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 Commonwealth coin Very heavy hologram In 2004, the Pacific Ocean Commonwealth coins from of the Northern Mariana Islands issued In addition to the more ‘regular’ sized a non-circulating coin incorporating a holographic coins, there are also very heavy stereogram image of Albert Einstein, holographic coins available. and in the following year a coin featuring The first Canadian $250 – 1 kilogram silver holographic images of crop circles. coin with a hologram – was released in Cambodia too has joined the hologram 2015: The ‘Maple Leaf Forever’ silver coin, bandwagon and, in 2005-2006, the country of which only 500 were produced, features issued a coin featuring the famous Taj two sugar maple leaves with crossed stems Mahal as part of ‘The Wonders of the World A commemorative $25 sterling silver holographic overlapping in the hologram design. Series’. Only 3,000 of these 10,000 riel coin celebrating the 2010 Olympics, depicting curling. A similar but an even more expensive coins were issued. heavy coin is the Canadian $2,500. This Three years later RCM, official licensee of 1 kilogram gold coin (Maple Leaf Forever), DC Comics, introduced the first achromatic of which only ten were produced, was hologram coin in the world, as a tribute to also released in 2015. The design features Superman’s 75th anniversary. a hologram across the entirety of the More recently in 2014, the RCM released engraved leaf’s undulating surface on the a new limited mintage (10,000) silver $20 coin, allowing natural light to be diffracted collector coin for the 25th anniversary of from different angles as it is tilted from side the Canadian Space Agency. The silver to side. This creates an iridescent rainbow Cambodia’s silver coin featuring a hologram of the coin featured an achromatic hologram of effect which is enhanced by the use of Taj Mahal, 2005. the International Space Station’s robotic multiple polishes. arm and a spacewalking astronaut. The In 2006, Holography Industry JV in Belarus hologram was originated by Optaglio. This – in cooperation with the Kazakhstan Mint coin was commended with an IHMA ‘Best – produced their first holographic coin with Applied Decorative or Packaging Product’ the theme ‘cycle racing.’ The image on award in December 2015. the coin was produced using matrix In 2015 RCM, in collaboration with embossing. NovaVision and Pacific Holographics, To commemorate the Vancouver Olympic issued a five ounce fine silver hologram and Paralympic Winter Games, the RCM coin, the first ever to feature a hologram, The $250 silver and $2500 gold One-kilogram Maple issued a 15-coin series in 2010, featuring incorporating Canada’s national symbol, the Leaf Forever coins – Canada 2015. winter sports with a holographic element maple leaf as a hologram. highlighting the sporting side of the coin. The coin was also commended in the 2015 45,000 of each coin were produced. IHMA ‘Best Applied Decorative or Packaging Product’ Category in December 2015 at The Holography Conference in China.

2004 2014 2015

A non-circulating coin incorporating stereogram of A Canadian silver $20 coin featuring an achromatic Award winning five ounce silver coin Albert Einstein. hologram of the International Space Station. featuring a maple leaf hologram.

MINT NEWS QUARTERLY VOLUME 3 | MARCH 2016 7 Commission Investigates Costs and Benefits of New US Coins Cost savings for the state means high In the light of increasing metal prices, the The GAO investigated the costs for the costs for the free economy. This is the US Congress had requested the Treasury industry incurred by the necessary adjusting dilemma of the conversion of material of to reconsider the change in the metal of the vending machines. Representatives US circulating coins, and is one that was composition of circulating coins. A report of the industry sectors concerned covered by Jon Cameron of the US Mint from the Treasury is still awaited. estimated the additional costs between at the Coin Conference last October, The Congress also commissioned the $2.4 billion and $10 billion. The GAO calls when he explained that the estimated GAO (Government Accountability Office) these numbers into question as well. costs to society of making changes to to investigate what efforts the US Mint has This appraisal is based on 7 million US coins far exceeded the savings (see already taken to reduce the costs of the machines whereas a 2015 industry study MNQ December 2015). coin production. The GAO submitted its spoke of only 4.5 million vending machines final report in December 2015, reaching a in the US. Furthermore, machines that different conclusion than the US Mint. only accept quarters (eg. coin washing In 2014, the US produced about 13 machines) should not have been billion new coins. An alternative material considered since no material conversion is was taken into consideration for three planned for this denomination. denominations: the nickel (5 cents), the As a matter of fact, the GAO report dime (10 cents), and the (25 cents). likewise stresses that the cost- These three denominations are made of effectiveness was linked between state different -nickel alloys. If the coins and industry: while maximum savings for would be made of plated steel, the US the state (full conversion to stainless steel) Mint initially hoped for annual savings would generate highest modification costs of up to $83 million. Given the potential for the industry, minimal costs for the savings regarding the nickel and the dime, companies (minor changes in the alloy), by the US Mint thinks that annual savings of contrast, would result in the lowest savings between $8 million (for minor changes in for the state. Publisher: Currency Publications Ltd the metal composition) and $39 million In this context, the GAO points to a in association with Monea. (with a full conversion to stainless steel) legislative specification. The 2010 Coin Editor: Dr Ursula are within reach. Modernization, Oversight, and Continuity Kampmann (left) In the GAO’s view, the Mint has not applied Act stipulates that newly introduced in cooperation with the best practice guidelines correctly. coins in existing vending machines Dr Björn Schöpe For example, it had not accounted for have to function 'to the greatest extent Translator: possible changes in the metals’ market practicable'. Representatives of the mints Dr Annika Backe and price. Nevertheless, the GAO deemed the stated to the GAO that this specification Teresa Teklic estimates a useful point of departure. has to be considered when the Congress receives recommendations on the part of the Treasury. Mint News Quarterly™ is produced every three months and only distributed with Currency News™. 4 Windmill Business Village, Brooklands Close, Sunbury, TW16 7DY, UK www.currency-news.com

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