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Prototyping Large Stern Boss Castings for Container Vessel

Material:SCW420,SC480 or according to related rules

Application: Shipbuilding

Weight: 3 to 150 tons

Status:pre-machined

Class certificate:ABS,CCS,NK,LR,DNV,RINA,BV,KR

Payment terms:T/T or L/C

Availability:

Quantity:



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Material

Chemical composition
C	Si	Mn	S	P	Residual Element
					Ni	Cr	Cu	Mo
less 0.23	less0.60	less1.60	less 0.04		Total less 0.80

Tensile Strength σb	Yield Stress σs	Elongation δ	Specimen
			Reduction of Area Ψ
N/mm2		%	%
≥415	≥205	≥24	≥35

Prodution process

No.	Equipment Name	Quantity(Set)
1	Transformer substation	1
2	Full set of wooden molding equipment	10
3	Sodium silicate sand mix line	4
4	Alkaline phenol resin sand mix line	2
5	25 tons Electric arc furnace	1
6	50 tons Intermediate frequency furnace	2
7	120 tons Refining furnace	1
8	120 tons VD furnace	2
9	12m9m6m Heat treatment furnace	3
10	120 tons Large-scale shot blasting machine	1
11	150 tons Travelling crane	2
12	125 tons Travelling crane	3
13	200 tons Travelling crane	2
14	CNC gantry boring and milling machine	2
15	2.5m-10m Digital vertical lathe	16
16	Boring and milling machine	13
17	Horizontal lathe	3
18	Large dust removal equipment	7

1)The engineer will firstly prepare the technology and do a simulation before pouring.

1642741044(1)

2)We will make a pattern of the kiln tyre based on engineer's technology.

It will cost us around one week.

After that the engineer will check the dimension and make a record.

P11-1

3)Sand molding making will be made by experienced wokrers.

Sand casting has the advantages of shape and size flexibility and is very cost effective even with lower production volumes.

· Complex geometries and internal passageways

· Prototyping and low volume order availability

· Extensive range of over 200 alloys

· Ability to meet most advanced testing, heat treating and finishing requirements

· Experts in specialized castings that are difficult to make for demanding applications

· Extensive experience with 3D printed molds and cores

IMG_20180619_091321

4)Pouring and cooling.

There are one 8tons electrical arc furnace;

Two 50 tons medium frequency furnace;

One 120 tons refining furnace and one 120 tons VD furnace;

5)Clean the sand and cut the riser before heat treatment

6)Heat treatment will cost 7days( 4 days normalizing and 3 days tempring).

There are 8 heat treatment furances with max. one is 12m*9m*6m.

热处理炉

7)dimension check and draw a line for machining.

8)Rough machining

IMG_20180712_074019

9)NDT withe qualified inspector

磁粉照

10)Welding repair if needed and tempering for stress relief

11)Final machining and NDT

12)Customers' inspection and packing

8-1

About Haitai

Haian Haitai Casting Co.,Ltd. is established in 2003.

We supply large steel castings with low carbon or alloy steel from 3 tons to 150 tons per piece.

With a quick development,now we had supplied steel castings 6,000 tons per month.

There are three workshop for sand mold making,one workshop for machining and one for post procedure.

We have 9 class certificate:ABS,RINA,DNV,LR,KR,BV,CCS,NK and have cooperation with most of Chinese famous shipyards and some foreign shipyards.

Every month,we supply around 1000 tons marine castings for different shipyards in China and Korea.

Testing Equipment

No.	Equipment Name	Quantity(Set)
1	Sand analysis equipment	1
2	Impact sample low temperature meter	1
3	Direct reading spectrometer(OXFORD)	2
4	ONH analyzer	1
5	ZEISS metallurgical microscope	1
6	Pendulum impact tester	1
7	Microcomputer controlled electro-hydraulic servo universal test machine	5
8	Various hardness tester	4
9	Magnetic defect detector	5
10	Ultrasonic flaw detector(digital)	1
11	CX-52 Total station	1
12	Stylus roughness meter	1