Steel-melting and foundry facilities

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STEEL-MELTING FACILITIES

The stem of OMZ-Special Steels steel melting facilities is a superpower Electric Arc Furnace (EAF-120), producing 118-121 thousand tons of steel per year (design capacity 636 thousand tons per year). The furnace is equipped with three gas-oxygen burners, enabling to operate as injectors. EAF-120 has transformer power 60 MWtA and is designed for producing different steel grades: carbon, low-alloyed, alloyed, rotor etc. Total number of steels exceeds 300 steel grades. 

Steel quality is ensured by application of ladle furnace treatment in vacuum treatment and refining plants ASEA-SKF and LF+VD/VOD. The latter is a computerized version of ladle refining and vacuum treatment plant for production of superduty steels: carbon, alloyed and low carbon stainless steel grades.

Teeming bay is involved in production of ingots weighing from 3.5 tons to 420.0 tons. Steel teeming is performed by three ways: vacuum, bottom and top.

ELECTROSLAG REMELTING:

Capacities of OMZ-Special Steels make it possible to produce electroslag remelting ingots with a weight up to 62 tons.

This type of melting provides higher quality of not only mold alone like absence of shrinkhole and porosity; homogeneity of structure and chemical composition but of its surface as well, which does not require preliminary processing before rolling.

Ingot produced by ESR method, by its processing properties will make it possible to satisfy the most stringent requirements of Customer to the product.

              Electroslag remelting

FOUNDRY

The production process of castings in the OMZ- Special steels is divided into several stages, ranging from basic drawings to full control of quality of manufactured products.

1. Engineering

We know how exactly your casting will look like before it is produced. We start component production by analyzing the blueprint and casting specifications, meticulously planning each stage of the production, making a 3D-model of the casting, developing casting and mechanical treatment technologies.

We use MAGMASOFT software to simulate cast filling process, metal crystallization process and post-formation stress spread. The choice of technology and materials is dictated by future product specifications and conditions in which it will be operated. Our technology experts are top specialists in their field, high-skilled and experienced.

2. Pattern production

The pattern is the prototype of your future casting. Patterns are produced individually for each specific project. In order to make the right choice of the material, ranging from wood to high-class plastics and expanded polystyrene, we take into account the pattern kit design and look into how exactly the product will be operated, while also considering the economic factor.

The pattern production is performed with two five-axis milling machines with computer numerical control and large work surface, which allows to decrease production time of both the pattern and the casting and to reach higher accuracy. Certain patterns are produced manually by our experienced patternmakers.

3. Mould production

The moulds are formed in flasks and caissons, with jolt tables and continuous flow mixers used in the production process. The majority of moulds and cores are produced via AlpHaset technology, well known for its minimal environmental impact.

The equipment used in mould and core production, including mixers produced by leading European manufacturers Omega Foundry Machinery Ltd, Wöhr and FTL, allows using modern cold hardening mixtures with enriched quartz and chromite sands.
The moulding method and mixtures are selected individually with specifics of your product taken into account

4. Steel-smelting and pouring

We use carbon, low-alloy, medium-alloy and high-alloy steels to produce our castings. Our electric furnaces facility is equipped with an arc furnace with 25 ton capacity and two arc furnaces with 12 ton capacity. Applied liquid steel treatment methods, including inoculation, inert gas refining, alloy addition, allow to increase steel quality and minimize gas, non-metallic and other impurities.

Under our contract with our Group partner OMZ-Special Steels, we use liquid steel from a ladle refining unit with 120 ton capacity to produce unique oversized castings with weight of up to 150 tons.

We use efficient liquid steel quality improvement methods: vacuum degassing and liquid synthetic slags treatment. We know how to produce high grade steel in order to achieve the highest quality of your castings. We have extensive experience in production of large castings with simultaneous pouring from three ladles, with total liquid metal mass reaching 250 tons.

5. Heat treatment

In order to improve the structure and mechanical properties of your casting we conduct a full heat treatment cycle with temperatures up to 1150 °С in chamber furnaces with hearth size ranging from 6,000x3,000 to 12,000x6,000, and furnace or air cooling. Oil and water tempering options are available.

6. Finishing processes and mechanical treatment

We perform full range of finishing operations, including cropping, shot blasting and polishing works, and also have our own mechanical treatment facilities. In case you require the finished product to be ready for immediate operation, we offer mechanical treatment services provided by our OMZ Group partners, equipped with all necessary equipment.

7. Quality control

We conduct comprehensive quality assurance procedures during every stage of the casting production. Performing control and test procedures is a three-stage process, which includes input, in-progress and output control. Each single casting undergoes visual and dimensional inspection.

Additionally, on customer’s demand, a full range of non-destructive test procedures is conducted, including ultrasound testing, dye penetrant inspection, magnetic particle inspection, radiographic testing. We also perform a full range of mechanical tests in compliance with design requirements and regulations for each casting.