- ET17 furnaces, production capacity: 1.7 tons/hour;
- IAT-2.5 and IAT-0.4 furnaces to melt aluminium chips and prepare alloys.
Total area of production building : 61 400 sq. m.
Production capacity : 35 200 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 IАТ – 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
| Standard: | DIN 1725 (Germany) |
| Wide range of castings: | 128 items |
| Weight: | 0.035 to 6.2 kg |
Aluminium Low-Pressure Die-Casting
| Standard: | DIN 1725 (Germany) |
| Weight: | up to 22 kg, including the casting of a compressor impeller |
Zinc High-Pressure Die-Casting
| Standard: | DIN 1725 (Germany) |
Continuous Casting (pipes in brass and bronze)
| Standard: | DIN 1725 (Germany) |
| Section: | 15 to 250 mm |
| Aluminium alloys used in the technological processes | AK9Ч, AK9ПЧ, АК18, GD AlSi9Cu3 (226), GD AlSi12 (230), GD AlSi12 (Cu) (231) |
Gravity Die-Casting
Material:
Aluminium base alloys (АК18, AK9Ч, AMKO)
Weight:
0.25 to 10 kg
Maximum dimensions:
400 x 400 x 300 mm
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