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Punch Removal for Pipe Fittings

Material:ZG270-500,GOST 35JI
Application:Punch and Die Tooling
Weight: 2 to 80 tons
Status:pre-machined or finished machining
Class certificate:ABS,CCS,NK,LR,DNV,RINA,BV,KR
Payment terms:T/T or L/C
Availability:
Quantity:

Material

MaterialCSi
MnPS
ZG270-5000.32-0.40
0.20-0.520.45-0.90≤0.040
≤0.045



Material StandardGB, EN, DIN, ASTM, GOST, JIS, ISO
Weight3-70 tons
Heat treatment
Normalizing+tempering


The steel mold is made for pipe fittings.

We supplied them for our Russian customers.

The area for sand mold core making is 8000 m2.

The biggest hollow pit is 87m*16m*(-3.5m)

The deepest pit is 45m*16m*(-6m)


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 12m*9m*6m 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.

2

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.

IMG_2136

8)Rough machining

IMG_2815

9)NDT withe qualified inspector

IMG_20171128_091028

10)Welding repair if needed and tempering for stress relief

11)Final machining and NDT

Chemical composition

The chemical composition has a significant influence on the mechanical property and can be further affected through change of the minor alloying elements.

The scrap will be tested and stored according to the chemical composition.

There will be a record before and after pouring.

There are two direct-reading spectrometers(FOUNDRY-MASER PRO,OXFORD INSTRUMENTS) which are imported from German.

The testing equipment will be calibrated annually.

Mechanical property

Mechanical test result shows an evaluation of the metal according to customers’ requirement.

Ultrasonic test

Ultrasonic test gives an guarantee of the inside quality of the large steel castings.

A qualified UT tester will do the test with normal probe according to customers’ UT level.

The sound can detect the internal defects of the large carbon steel and alloy steel castings.

Sound waves will change according to the internal structure.During UT process,the high frequency acoustic energy is transmitted into the casting.

It travels via the casting until it hits the opposite surface,interface or defects.The interface or defects reflect portions of the energy which are collected and displayed on the test machine(the depth,width and thickness).

Magnetic powder inspection

It is not easy to find the tiny cracks,pores and other surface glitches on the large carbon or alloy steel castings by human eyes.In this situation,a colored dye solution is applied to the surface of the casting.

In general, dye-penetrant techniques identify defects on the surface of the casting and do not detect internal porosity or shrinkage that is not open to the surface. But it can detect rounded indications for porosity or gas on the casting surface.

Magnetic powder inspection is a quick,economic and sensitive way to find the surface defects on the large carbon or alloy steel castings.

IMG_20180411_073640

12)Customers' inspection and packing

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About Haitai

P5

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.

Our main products are for cement mill(around 30%).

We supply around 400pcs kiln tyres,170 sets of ring gears and 930pcs supporting rollers a year.

We also have rich experience of the castings for shipbuilding with 9 class certificate.



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


We do the test according to diffrent production step,

such as chemical composition,UT,MT and mechanical property.

In 2021,Haitai inspection and testing center got approval from CNAS.


P6-3

P10-1

P10-3

Delivery

Our company is near to Shanghai port and we can supply different packing according to customers' specification.



IMG_2190

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