Reliable Manufacturer
and Supplier of Castings and Forgings

NONFERROUS CASTING

Total area of production building :  61 400 sq. m.
Production capacity :  34 280  tons of  castings annually.
Number of employees: about 1000 people.

   There are 8 melting blocks of gas furnaces installed in the Nonferrous Foundry to produce aluminium alloys. Each block comprises a 27 ton melting furnace and an 18 ton holding furnace and its operative capacity is 4.3 tons/hour.

   In 2010, the complex based on low-pressure die-casting machines from LPM Srl was put into operation to manufacture castings in aluminium. The foundry equipment of a new generation that is computerized and software supported, allows the manufacture of complicated castings and assures high quality.

    The following melting equipment is used to prepare copper and zinc alloys:

- 4.5 ton channel-type induction furnaces, model TET-13; production capacity: 2.0 tons/hour;
- ET17 furnaces, production capacity: 1.7 tons/hour;
- IAT-2.5 and IAT-0.4 furnaces to melt aluminium chips and prepare alloys.

    The technologies in use:

• High-pressure die casting  of  aluminium alloys.       
Weight of castings   : 0.035  to  6.2 kg
Castings are produced on the WOTAN high-pressure die-casting machines and IDRA cold chamber die-casting machines having a closing force of  400, 700, 1100 tons.
Alloys in use    : G-/GK-AlSi10Mg(Cu);  GK-AlSi12(Cu); GD-AlS9Cu3; AlSi12;  GD
                            AlSi12Cu  DIN 1725.

• Low-pressure die casting of  aluminium alloys.                 
            Weight of castings   :  0.96 to 25 kg
            Foundry equipment  used : DIMO low-pressure die-casting machines.
            Alloys in use    :         G-/GK-AlSi10Mg(Cu)  DIN 1725.

• Gravity die casting (or permanent-mold casting) of  aluminium alloys.
            Weight of castings   :  0.20 to 10.2 kg
            Foundry equipment used: FATA  4-, 5-, 8- position carrousel-type and 1-position
                                               machines.
            Alloys in use    :         G-/GK-AlSi10Mg(Cu); GK-AlSi7Mg;  GK-AlSi18CuNiMg  DIN
                                                1725; AMKO –8-1-3 =  7.0-9.0 % Cu; 0.6-1.2%  Si;  2.5-3.5% Sn;
                                                alcusin D.                                 

• High-pressure die-casting of zinc alloys.              
            Weight of castings   :  0.008 to 1.3 kg
            Foundry equipment used  : IDRA hot chamber high-pressure die-casting machines.
            Alloys in use    :   GD-ZnA14Cu1  DIN  1743 and others.     

• Liquid forging of copper alloys (AUTOFORGE  process).        
            Weight of castings   :  0.03 to 0.5 kg
            Foundry equipment used:  Albany Machine equipment
            Alloys in use    :     GK-CuZn37Pb;  GD- CuZn37Pb  DIN  1709.                                   
• Continuous  casting  (pipes in brass and bronze)         
Diameter                  :  25 to 200 mm
Length                      :  up to 3 000 mm
            Foundry equipment used:  Technica Guss GmbH  continuous casting machine.
            Alloys in use    :  GK-CuZn37Pb;  GD- CuZn37Pb  DIN 1709;  GB-CuSn5ZnPb  and 
                                         GB-CuSn5ZnPb DIN 17656, others that have no equivalents in DIN.
AUTOFORGE process and continuous casting processes are used to manufacture the castings of spiders, angles, tee joints, adapters, housings, pipes, etc.. The castings are characterized with high density of structure, good quality of surface, minimum allowances required for machining.

The facility is equipped with Wotan, Idra Press S.p.a. and Gebovah die-casting machines (closing force of 400 to 1100 tons). Manufacture of castings that require especially high-precision technologies such as low-pressure die casting, gravity die casting plus liquid forging.
Alloys used: aluminium, zinc, copper-based (brass, bronze).
Completed the starting-up and adjustment of  two aluminium melting furnaces IÀÒ – 2.5 in the Nonferrous Foundry. The furnaces are required to make piston castings and to improve their quality. The technological level will permit to increase the output of pistons in AK18 alloy up to 1 million pieces per year.

The installed furnaces met today’s safety requirements. Their technological features simplify the control over their condition and make them easier in use.

The introduction of the new-level technology furnaces permits to speak about the beginning of technical re-equipment of the nonferrous castings production area with regard to aluminium alloys.
MAIN CASTING METHODS USED IN THE NONFERROUS FOUNDRY

Aluminium  High-Pressure Die-Casting

Aluminium Low-Pressure Die-Casting

Zinc High-Pressure Die-Casting

Continuous Casting (pipes in brass and bronze)

Gravity Die-Casting