INVESTMENT CASTING

 Total area of production building :  25 800 sq. m.
Number of employees: about 500 people.

The production area realizes a complete technological cycle of mass production.
Methods of casting: lost-wax casting (vacuum embedding), centrifugal casting, piston ring casting by stack molding, Croning process (shell casting), vacuum film casting.

Lost -Wax Casting

Production capacity:  3 950 tons of castings per year, including 1 920 tons of piston ring castings (Piston Rings Shop).
The melting of castable alloys is carried out in 28 off, 250-400 kg,  AJAX coreless induction furnaces with  acid lining.
Patterns and pattern elements are made on the 10-position automatic carrousel machines by pressing the wax compound into dies. The elements of patterns are assembled into blocks that have one common sprue.
Refractory molds are made on the semiautomatic lines where the wax patterns are coated, powdered, dried and a refractory coating is subsequently applied to them. The molds dry in the open. The wax compound is melted out in the atmosphere of superheated vapor and hot air. Ethyl Silicate 40 base refractory envelope, acetone used as a solvent. Also used the method of  making envelopes using the ethyl silicate and water glass base with a ready-to-use binder.

Before pouring, the molds are calcinated  in the through-type installations and then the envelopes are molded in a hot  fluidized layer of sand.
The process of calcination, pouring and cooling of castings takes place in a special installation. 
The castings are separated from gating systems and ceramic in special vibrators. The remaining ceramic is removed in the alkaline-medium of gas-heated drums. As cleaned, the castings are heat treated in the through-type furnaces with protective atmosphere. The trimming of remaining runners and straightening of castings is carried out in special presses.

Centrifugal Casting
The centrifugal casting process runs in special 1-position roller-type horizontal rotary machines.

Vacuum Casting
The vacuum casting process occurs on the TRUCAST machine, and the castings (impellers) produced should meet special requirements for strength and heat resistance parameters.
PISTON RING PRODUCTION

Production capacity: 1 920 tons.
The production area is intended to manufacture castings (rough parts) of piston rings, valve seats, O-rings, etc. (over 100 different parts).

The metal is melted in 2500 kg coreless induction furnaces.

The iron is inoculated with special inoculants placed in pouring ladles.

The molds are made to metal patterns on the semiautomatic molding lines and stacked. The stacks of moulds are transported to the pouring position.
 The molding sand is prepared in mixers with vertically rotating and batch-operated rollers. 

Castings shake-out is carried out on vibratory units.  Cleaning is provided by shot-blasting in the drum-type batch-operated installations.
Any witnesses produced during the removal of runners are removed on the special semiautomatic machines.
Heat treatment is carried out in the gas-fired through-type furnaces.

Vacuum Film Casting
This method of casting is used to manufacture the castings in high-temperature alloys which are required for maintenance needs of KAMAZ-Metallurgy Plc. and of the KAMAZ Inc. plants (trays, housings, baskets, supports, etc.). The molds are made on the 4-position horizontal machine.

In 2010, the casting area was put into operation to manufacture there the castings of dies for the Forge Plant.
Production capacity: 50 tons of castings monthly.
Weight of castings:  17 to 400 kg.
Material:  high-temperature steels.
Method of casting:  Croning process (shell casting).

KAMAZ-Metallurgy Plc (1998-2004). All rights to any materials published on the site are protected by the Russian and International legislation on the copyright and allied rights. For use of information please refer to: webmaster@kamlit.ru