Technology

Production of forgings is based on steel refining in an integrated chain including own steel melting, heat treatment, forge with a 3600/4,500-ton press and well-equipped machining workshops. As own billets are used, total control over the entire production process from the billet through to the finished product is available. All areas of production are coordinated and monitored under ISO 9001:2008 quality system.

The technology of production of forgings (rolls, shafts, rotors, risers, cylinders, bars, plates, rings) comprises the following basic operations:

Steel melting in EAF and vacuum degassing of the steel (VAD/VOD) / ESR steel

Casting of ingot – siphon pouring; ingot weight up to 80 t

Open-die forging – 3600/4500-ton forging press with 160-ton forging manipulator; 1600-ton forging press with 40-ton forging manipulator

Gas cutting – up to 2000 mm thickness

Heat treatment:

- pre-heating – heating furnaces – 50, 100, 150-ton

- annealing – annealing furnaces – 35, 90, 150-ton

- horizontal heat treatment furnaces – 15, 25, 90, 100-ton

- differential quenching – differential rapid heating furnace

- induction hardening - dual frequency installation with max. length 7000 mm, diameter 200 – 900 mm, max. weight 13 t of the roll

- subzero treatment in liquid Nitrogen on – 195,8 ºC – chamber with max. length 7000 mm, max. diameter 900 mm, max. weight 13 t of the roll

- surface layer quenching (mist, water, air)

- vertical heat treatment furnaces – 10, 50-ton

- tempering and quenching – oil tanks, water tanks

Machining – CNC lathes, boring machines, grinding machines for rough machining of items with length 14000 mm, diameter 2500 mm, 120 t and finish machining of items with length 10000 mm and diameter 1800 mm

Control:

Express quantometric laboratory for rapid on-the-spot quantitative analysis of steel test pieces incoming from the steel production shop for the purpose of timely corrections of steel composition of the liquid metal with stationary emission quantometer, mobile and automatic analyzers, electronic scanning microscopes;

Laboratory metallographic analysis and control of mechanical properties with automatic structure analyzer, tensile strength testing machine, impact testing machine Charpy hammer;

NDT – ultrasonic, magnetic – particle, dye – penetrant, eddy – current, visual tests

Approvals by:

Det Norske Veritas, DNV

Bureau Veritas, BV

Germanischer Lloyd

Lloyds register

RINA

ABS