Metallurgy


Metallurgical production of the plant comprises:

  • Titanium foundry having capability to cast up to 700 tons per year.
  • Steel foundry producing castings of different steel grades with weight up to 3 tons.
  • Non-ferrous foundry manufacturing castings from tin and aluminum bronze, brass, aluminium alloys.
  • Forging shop and section for thermal treatment.
  • Thermal treatment section on the base of tool maker shop.


TITANIUM CASTING

Designation:

  •  castings for shipbuilding
  • (screw propellers, stop valves, pump parts);
  • castings for chemical industry and pulp-and-paper plants (impellers, volute casings, covers, mixing devices, heat exchangers, etc. );
  • castings for oil-and-gas industry (stop valves, gate valves, valves, etc.).
  • Material grade:
  • alloys of Russian origin: VT1-00 (BT1-00), VT1-0 (BT1-0) as per GOST 19807, VT6L (ВТ6Л), VT20L (ВТ20Л), VT5 (BT5) as per OST 1.90060, TL3 (ТЛЗ), TL5 (ТЛ5) as per OST R.9071-88;
  • foreign made alloys: Grade-2, Grade-3, Grade-5, Grade-12 as per ASTM В 367.


Working medium:

Sea water, aggressive environments of chemical industry, hydrocarbons, etc.

Application of articles made of titanium alloys is in many cases more profitable than application of the similar parts made of stainless steel due to increased service life, especially in aggressive environments. Parts made of titanium alloys are two times less in weight than the steel ones, they feature similar technical properties and in most cases surpass in performance.

Titanium foundry is equipped with 9 vacuum furnaces for smelting of titanium enabling to melt any titanium alloy. The shop operates one of the world's biggest vacuum furnaces for melting and pouring of titanium alloys.


The state-of-the-art foundry equipment contributes to manufacturing of complex-shaped castings weighing up to 2 750 kg with wall thickness of 3mm and over, diameter up to 2,5m and height up to 1,5m.


The plant produces a wide range of shaped castings made of titanium alloys, employed in shipbuilding, machine-building, space and defense equipment production.

Over the last years the company has been specializing in production of valve fittings, pump casings and impellers, compressors used in aggressive environments in full compliance with the world standards.


Specified life cycle of stainless steel cast bodies is up to 5 years, whereas service life of titanium castings in corrosive mediums is not less than 25 years.

Experience of titanium castings deliveries for export, high quality of our products and their compliance with the international standards confirmed by TUV NORD CERT certificate issued for production and machining of titanium castings, compliance with the requirements of NORSOK and DUPONT classifications, high scientific potential of the plant's specialists made it possible to manufacture preproduction models of sliding shutters designed for working pressure of 70MPa during the short period of time, put them to field tests in ООО «Astrakhangasprom», receive the compliance certificate of certification institution «VNIIGAZ-Certificate» and the license to manufacture issued by the Russian Federal Service for Ecological, Technical and Atomic Supervision.

   

The enterprise is acknowledged by the Russian Maritime Register of Shipping (Certificate No.05.80019.130) and of the Russian River Register (Certificate No.VVF087).


Compliance of the plant laboratory with the requirements of the non-destructive inspection system of the the license to manufacture issued by the Russian Federal Service for Ecological, Technical and Atomic Supervision (approval certificate No.49A430323) and its acknowledgement as technically qualified (accreditation certificate of test laboratory No. ROSS RU.0001.22.AYa47), meet the requirements of foreign customers.


Basically application of titanium alloys is economically sound in view of increased service life of articles, especially in sea water and aggressive environments.


FERROTITANIUM.


Ferrotitanium is used in steel melting, casting processes and production of welding electrodes. The plant operates a powerful foundry facility to produce ferrotitanium as per GOST 4761-91 with maximum use of fine-dispersed wastes (including chippings) and lump scrap of any titanium alloys. The technology is licensed under the laws of the Russian Federation.

The foundry has the capacity to produce up to 60 tons of ferrotitanium per month.

A new method has been developed and introduced for cleaning and preparing of contaminated cutting wastes of titanium alloys preserved in storage piles.


STEEL CASTING OF CARBON AND ALLOYED STEEL GRADES


Designation:

  • castings for shipbuilding: separate screw propellers with a diameter of up to 2500 mm, anchors of all types,
  • castings for shipborne machinery and equipment, hull fittings, fittings for seawater, steam pipeline and etc.
  • castings for pulp-and-paper plants and for metallurgical production, pumps, impellers, various types of mixing equipment, volute casings, reduction gears, covers,
  • flanges and etc.
  • castings for petrochemical industry: equipment of various classes for oil extraction, castings for pumps, pipe connections, gate valves, valves and etc.
  • castings for general engineering: bodies of various types, brackets, chassis and other various articles.


Weight of castings: 2 - 3000 kg. any complexity group and strength level.

Dimensions of castings: diameter up to 3 000 mm, height up to 2000 mm.

Minimum casting wall thickness: 6 mm.

Accuracy class: 9-13 as per GOST 26645-85.


Material grade:


steel 25-45L(25-45Л), 30GSL(30ГСЛ), different grades of alloyed (stainless) steel 12Kh18N9TL (12Х18Н9ТЛ), 10Kh17NZG4D2TL (10Х17НЗГ4Д2ТЛ), 20Kh25N19S2L (20Х25Н19С2Л), 12DKhN1MFL(12flXH1 МФЛ), 08КМ4ШЦ08Х14НДЛ), 27Kh5GSML (27Х5ГСМЛ), ЗОЮпМЦЗОХМЛ), 14КЬ2СМРК14Х2ГМРЛ), 45П(45ФЛ), 08КМ8Ш0М21_(08Х18Н10МЗЛ) and other as per GOST 977-88 and other standard technical documentation and steel of grade A487GR4VMP as per ASTM A487/A487M-88.


Working medium: air; for alloyed steels: sea water, a number of aggressive environments


NON-FERROUS CASTING

COPPER (BRONZE, BRASS) - AND ALUMINIUM - BASED ALLOYS


Designation:

  • castings for shipbuilding: screw propellers with diameter up to 1500mm, hull fittings, various shipborne mechanisms articles;
  • castings for petrochemical industry: fittings of different types, valves, gate valves, castings for pumps and etc;
  • centrifugally cast bushes and liners with a diameter of up to 300 mm and length of up to 1300 mm (chill casting method);
  • castings for general machine-building: bodies of different types, bearings, plugs, brackets and etc.

Castings are made of copper-and aluminum-based alloys.


Weight of castings:

  • made of copper-based alloys: 0,2 - 500 kg,
  • made of aluminium-based alloys: 0,2 - 25 kg.


Dimensions of castings:

diameter up to 1500 mm, height up to 1000 mm.

Minimum wall thickness: 4-6 mm.

Accuracy class: 6-13 as per GOST 26645.


Material grade:

  • copper-based alloys: tin bronze, aluminium bronze, brass (grades Br010TS2, Вг010F, Br03Ts7S5Kh1, Br05Ts5S5, ВгА9Mts2L, ВгА9ZhZL, and other)
  • and other alloys as per OST 5.9209-82 and other standad technical documentation);
  • Aluminium-based alloys: silumins, series of Al-Si, Al-Mg and others as per OST 5.9397-82 and other standad technical documentation.


Working medium: air, sea water, a number of aggressive environments.


The plant is capable of melting and pouring of alloys based on tin, lead, babbit, etc.

FORGING AND THERMAL PROCESS


Designation:

  • work pieces for shipbuilding: for shipborne mechanisms and equipment, hull fittings, fittings for sea water and steam pipeline, etc.
  • work pieces for general engineering: bodies of various types, brackets, chassis and other different articles.

The plant produces work pieces:

  • hammer forgings;
  • stampings.

Weight :

  • forgings: 1 - 250 kg.
  • stampings: 1 - 7 kg.


Work pieces dimensions: diameter up to 2000 mm, height up to 200 mm. Structural complexity - medium.

Accuracy class of forgings: T5 as per GOST 7505.


Material grade:

  • carbon steel: steel 25.
  • constructional steel: 10-50, 15Kh-40Kh(15X-40X), 18KhGT(18Xn), etc.
  • high-alloy steel: 20Kh13(20X13), 08Kh18N10T(08X18H10T), 14KM7N2 (14X17H2), etc.
  • tool steel: 117(У7), и8(У8), 6KhS(6XC), 5KhNM(5XHM), etc.
  • non-ferrous alloys: bronze, brass.


Working medium: air;

for alloyed steels and non-ferrous alloys: sea water, a number of aggressive environments.


Heat treatment:

All types of heat treatment are carried out by the enterprise (volumetric hardening, tempering, annealing, normalization, and high frequency hardening) with flame and electric heating.


Thermochemical treatment:

Thermochemical treatment (hard surfacing, cementation, etc.) - changing of chemical composition in metal surface layers to obtain definite physical and chemical properties of surface.