STEEL CASTING & IRON CASTIING

Manufacture of the casting, foundry of Murom Industrial Valves Plant was started in 2005. The first purpose of the foundry was making casting for valves. Valves are difficult and important products thus today MIVP could make casting of different level of complexity.

Moulds are made of green sand casting process. Modern Automatic moldings lines HSP-4D of German company «Heinrich Wagner Sinto» is used for making moldings. Core shooters LL 20 of Laempe GmbH is used for constructing cores for molds.

Wide range of other equipment gives an ability of making shoot blasting, machining and heat treatment.

Analysis of the moldings is made with modern laboratory equipment.

Production capacity is 10000 tons per year.

Parameters of the casting:

  • Material – carbon steel, stainless steel, iron;
  • Maximum weight – 200 kg.;
  • Minimum weight – 5 kg.;
  • Maximum size – 1150*950*400/300 mm.;
  • Minimum size - 150*140*110 mm.;

Parameters above are for reference only. It depends on the drawing of the casting.

Fields of using:

Transport, Energetic, Construction, Marine, Railroads, Agriculture, Auto, Valves.

Description of the process:

  1. Consideration of the drawings.
  2. Patternmaking and coremaking.
  3. Molding.
  4. Melting and Pouring.
  5. Shaking out and cleaning.
  6. Heat treatment.
  7. Analysis.
  8. Machining.

1.Consideration of the drawings.

The Seller sends his drawings for the first consideration of ability of making molds and casting. During the process engineers enquires additional information and makes notes. At the end of the process conclusion is made and price is estimated.

2.Patternmaking and coremaking.

Pattern is a replica of the exterior side of the mold. Pattern has allocation for shrinkage of metal and finish machining.

Core is made if there is a cavity inside the mold. Exterior side of the core is a copy of interior contour of the casting. Cores are placed into the mold to create interior contour of the casting.

Patterns are usually made of wood, plastic or metal. Selection of material depends on required number of castings to be made from the mold, quality of the surface of the products and price. Selection of material is arranged with customer.

Cores are made of a sand mixture – sand combined with water and organic adhesives called binders, which is baked to form the core. That allows the cores to be strong and collapsible, so they can be easy removed from the finished casting. The core pattern is made of metal.

3.Molding.

Mold is contained in two section frame, called flask. One section is top and another is bottom. Molding sand is packed into a bottom section around the pattern. After that gating and runner are positioning for melting the metal. Core is also placed in the bottom section of flask and two sections (top and bottom) are closed and clamped together.

4.Melting and pouring.

Melting is a process of conversion metal to a liquid state in the furnace. Liquid metal is transferred in ladles and poured into the molds.

5.Shaking out and cleaning.

After the metal has solidified and cooled, the molds are vibrated on special equipment to remove sand from the casting. This process called shaking out.

Cleaning is a process of removing gating system, superfluous metal and sand inclusions.

Shoot blasting also could be included in cleaning.

6.Heat treatment.

Heat treatment is a process of metal treatment in high temperature with special mode of cooling for achieving required mechanical propertie

7.Analysis.

For achieving high quality products new modern laboratory equipment is used to control chemical composition and mechanical properties of the casting.

8.Machining.

Many kinds of products according to their application or customer’s requirement need machining. Machining is made according to the customer’s drawings by modern equipment (lathes, boring machines, grinding machines, milling centers etc.).