Reliable Manufacturer
and Supplier of Castings and Forgings

IRON CASTINGS

The Foundry of  KAMAZ-Metallurgy Plc. will accept for consideration the orders for manufacture of castings and their subsequent machining.
Contact phone number:  +7 (8552) 37-34-05.

Total area of production building :  172 800 sq. m
Production capacity :  238 270 tons of  castings per year,  including grey iron, SGI and CGI castings.
Number of employees: more than 1000 people.
Complete technological cycle for mass production of castings.

   The duplex process of metal melting takes place in the Swindell-Dressler Direct Arc furnaces. The facility is equipped with 9 off , 50 ton melting furnaces and 7 off, 75 ton  holding furnaces.

Liquid metal is transported by means of the Cleveland Crane Liquid Metal Delivery System;  Georg Fisher and Seaton  pouring units are provided for its pouring.

The existing facility is equipped with five CE-Cast and three Disamatic automatic molding lines. The molding equipment enables to produce castings of any complexity and to high precision such as cylinder heads for trucks and cars.

    For core making, two processes are used: the Hot-Box and the Cold-Box process with SO2 cure on  the Sutter core making machines (67 cores).
For the period 2008-2010, the core-making complex has been erected and put into operation in the cast iron foundry where cores are made of sand-cold-curing-resin mixtures (cold-box  process and  amine process). The complex is a transfer line comprised of a LAEMPE core-making machine, paint bath, drying oven, stacking area, balancers. This complex allows to create in one the same area a continuous process flow with a core sand preparation when it starts and stacking of finished cores in the storage area at the end.

    The state-of-art methods and means of control are used for rapid analysis and quality control with Baird, Perkin-Elmer, Spectro and ARL spectrometers. 

   Heat treatment, cleaning and dressing operations are carried out on the equipment from Holcroft, Pangborn and Cross-Freser companies.

    In 2010, two grinding machines bought from MAUS Spa. and  AutoGrinding Ltd., were put in service. The MAUS machine is designed to machine castings of  brake drums and is used to grind their inside and outside diameters. The AutoGrinding Ltd. machine was meant for cylinder block and cylinder head castings.

  There were put in operation Heinrich Wagner Sinto (HWS) automatic molding lines that have flask sizes 1500 x 1100 x  400 / 400 mm and 1100 x 750 x  300 / 300 mm. The lines assure the main conditions for the facility to be able to meet the competition such as possibility to produce complicated and thin wall castings to high precision as required for the machine-building industry.

   The castings made on the new molding lines will have the accuracy by 2 grades higher (e.g.,  8 instead of 10).
 The higher accuracy of casting will allow to limit significantly dimensional tolerances (by 1.6 to 2 times). The mass of castings of crankcase and housing parts manufactured on the new lines can be reduced by 5 to 10 % while the consumer’s quality maintained.  In fact, under the same production conditions it is expected to manufacture the most complicated iron castings for KAMAZ-trucks, a range of sophisticated products  for cooperation within Russia (cylinder blocks and heads, light car housings) and for export.

    The ladle iron-spheroidizing technology is used to produce a spheroidal-graphite (or ductile) iron. The technology developed by PROGELTA s.r.l. (Italy) became an unfailing alternative to the mold iron inoculation. The stable technological process with minimal influence of human factor permits to achieve a specified quality in any casting and considerable economic effect.  In March 2008, the spheroidizing cored-wire production area was open in the Cast Iron Foundry.