Foundry

Modern steel production

Stages of construction: 2016-2018

Foundry capacity —

7-8 thousand tons of casting per year.

Investments - RUB1.7billion.

Area - 20 thousand sq. m.

Opening of the facility – February, 2018.

 

Modern steel production was commissioned for operation at LLC Gusar in December of 2017 with an annual volume of 6 thousand tons of steel shaped castings.

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The new workshop provides the Valves Plant Gusar with high-quality work pieces meeting all the standards and requirements for manufacture of wedge and slab gate valves.
The foundry facility is furnished with modern equipment: melting furnaces manufactured by Induktoterm (England), molding line manufactured by FAT (Germany), Bosio thermal furnaces (Slovenia), Wheelabrator (Germany) shot-blasting equipment.
The patterns are made on 3 and 5 axial CNC machines using CAD / CAM / CAE design systems. The casting design is made using MagmaSoft, a specialized software for simulation of crystallization conditions.

The advantages of the LLC Gusar foundry:

  1. In-house design department provides development of the cast design in the SolidWorks environment using the MagmaSoft software for crystallization process simulation;
  2. Pattern manufacture on CNC machines reduces time and increases the geometric accuracy for patterns manufacture;
  3. Use of chromite sand for the facing mixture improves the quality of the casting surface and increases the metal density and continuity, eliminates shrinkage porosity;
  4. Control of the melting furnaces using software tools provides improved metal quality;
  5. Pouring-in of the casting molds from stopper ladles eliminates the appearance of slag-shell-like defects in castings;
  6. Thermal program-controlled furnaces provide uniform temperature distribution in the working space of the furnace, which improves the heat treatment quality.
  7. All foundry process stages are controlled with the data entry into the factory control logs and a centralized electronic database.



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The LLC Gusar foundry capabilities allow manufacturing shaped casting for various branches of engineering: work pieces for nuclear energy, for the needs of Russian Railways, valves, shipbuilding, etc. The Castings can be made according to National Standards (GOST), as well as according to international standards and according to individual technical requirements of the Customer.

Installed and operated existing main technological and laboratory equipment allows to obtain castings:
Installed and operated existing main technological and laboratory equipment allows to obtain castings:

  • from carbon (low carbon and medium carbon) unalloyed steels of ferritic and ferritic-pearlitic classes;
  • from carbon low-alloy steels, including cold-resistant, pearlitic class;
  • from medium alloy steels, including thermally stable, heat-resistant pearlite-ferritic and pearlitic-martensitic classes;
  • from high-alloyed corrosion-resistant, heat-resistant steels of ferritic, martensitic, martensitic-ferritic, austenitic-ferritic and austenitic classes.


According to the requirements and purpose of the cast part the critical duty castings (group 2 of GOST 977) and special critical duty castings (group 3 of GOST 977) with destructive and non-destructive types of control (hardness, mechanical properties at normal and low temperatures, metallographic analysis of grain size and nonmetallic contamination inclusions, RK (radiographic control), UZK (ultrasonic test), CD (dye penetration test), MPD (magnetic particle inspection).
By weight of castings: small - from 5 to 100 kg, medium - from 100 to 1000 kg and large - from 1000 to 3000 kg.

By overall dimensions: the maximum dimensions of the castings are up to 2000 × 1500 × 500 mm.

According to the dimensional accuracy class of steel castings 9T ... 11T and accuracy by weight are not more than 5 class per GOST 53464-2009.

According to the method of steel smelting – the castings are made of electric steel smelted in industrial-frequency induction furnaces with neutral lining.


The Melting Department:

  • induction melting furnaces from Inductoterm (England) in an amount of 3 pieces with a capacity of 0.5; 2; 4 tons.


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Molding Department:

  • equipment manufactured by FAT (Germany)
  • production line of small and medium-sized molds, making castings weighing up to 250 kg, capacity 4 molds / hour, it is equipped with a mixer with a capacity of 40 tons / hour, a vibrating table for mixture compacting, an automatic pulling tool for half-molds, a painting bath for applying a nonstick coating, a roller table system. Mold assembling is automatic.
  • a section for the manufacture of large molds, the manufacture of castings weighing from 250 to 3000 kg, capacity is 1 mold per hour, it is equipped with a mixer having a capacity of 60 tons / hour, a vibrating table for compacting the mixture, a device for automatic pulling of the semi-molds, a painting bath for applying a nonstick coating, a roller table system.


Core Section:

  • equipment manufactured by FAT (Germany);
  • it is equipped with a mixer having a capacity of 5 tons / hour, a vibrating table for compacting the mixture, a painting bath for applying a nonstick coating, a roller table system.


Thermal Department:

  • thermal furnaces with roll-out hearth produced by Bosio (Slovenia) in the quantity of 4 units, the maximum heating temperature is 1200 ° С, the uniformity of temperature in the furnace working space is ± 5 ° С.
  • quenching baths have temperature control system, the quenching medium is water.


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Pattern Making Section:

  • materials used are plywood, plastic;
  • materials used are plywood, plastic;
  • painting booth for painting mold pattern kits


The production has laboratories that are equipped with modern laboratory equipment:

  • laboratory for the control of molding and core materials and mixtures;
  • laboratory for express analysis of the metal chemical composition;
  • laboratory for analysis of the ferroalloys chemical composition;
  • laboratory for control of yield strength at room temperature; impact strength, both at normal and negative temperatures;
  • laboratory for metallographic tests;
  • laboratory of non-destructive methods of control (UZK(ultrasonic test), MPD(magnetic particle inspection), PVK (penetrant method test), RK(radiographic control).