Foundry

The Foundry in the KAMAZ – Metallurgy  Plc. is

In September, 1970, the first bucket of natural soil was excavated at the construction site to lay the foundation for the Cast Iron Foundry to be; and in 1975 the five-year-phase of construction work was concluded with commissioning of all the production buildings, providing them with heating and proceeding to the erection of main technological equipment.

Already by the end of 1975, the production of aluminum castings (83 descriptions) was organized in the experimental shop of the Nonferrous Foundry. Manufacturing of iron and steel castings started in 1976.  For the period from 1972 till 1976 approximately 1800 workers, engineers and technicians were trained at the best foundries of the former Soviet Union. More than 300 specialists were trained and participated in the acceptance of equipment abroad. Afterwards, either workers or engineers and technicians who presented “the Gold Capital” of the plant bore the brunt of difficulties to bring production to the design figures at the 1st and 2nd phases of construction and were engaged in active search and manufacturing application (introduction) of the latest and more advanced technologies.

Since its foundation the plant has been a part of KAMAZ Inc. until December 26, 1997 when it got an independent status and the name of   Kamsky Foundry OJSC. On August 15, 2002 the Foundry was incorporated in KAMAZ – Metallurgy Plc. as a structural division.
Total area occupied by Foundry Plant is 1 878 thousand square meters. Production area is 570,9 thousand square meters. Total employees – more than 7 thousand people.
Its five main production shops are capable to produce annually 335 720 tons of castings of any complexity, including castings in iron of different grades (lamellar and nodular graphite), in constructional and alloyed steel, in nonferrous alloys.
Moreover the plant is the owner of 81 patents for inventions and industrial designs; only in 2009 year 580 rationalization proposals were made. Economic efficiency reached 11904,18 thousand rubbles.
In 2010 year 373 rationalization proposals were introduced; the saving of this period was 11901,4 thousand rubbles.
The state-of-art equipment is used at all preproduction phases that begin with   development of a casting drawing, manufacture of foundry tooling, follow-up process control and end with the final acceptance of products.
The design and technical documentation is worked out by the following means: Unigraphics NX;   SolidEdge (3D mathematical models, programs for CNC machines); LVMFlow 3.1; ProCAST2008 (casting processes modeling).
The whole set of the required control equipment is provided to assure quality control of castings at any stage of the production process. Chemical express analysis of alloys used in production is made in the spectrum laboratory that permits to obtain the results within several minutes.

The FOSECO argon jet degassing process is used in production of the most important castings that should conform to the strictest requirements regarding the hydrogen saturation of alloys. X- Ray inspection is provided to detect internal casting defects in the case when visual inspection does not work. It is worth to note that any batch of castings is admitted to subsequent   production only when the internal structure of castings is in conformity with the reference standard agreed with a customer. If the geometry of castings does not meet specifications of the drawing and any deviations are detected on various production steps, then an up-to-date measuring machine helps operatively to get the result comparable with the software set by a design engineer at the stage of the casting development.
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