Metallurgical production
The Foundry provides the plant with steel castings made of carbon and alloy steel and cast iron. Smelting of constructional steel and cast iron is carried out in electric arc furnaces. The development of foundry technologies takes place with the use of 3D modeling, which allows to reduce the amount of defects on the first casting.
During the production process the castings are subject to the following control methods:- Control of chemical composition;
- Control of mechanical properties;
- Defectoscopy: magnetic particle test, liquid-penetrant test, ultrasonic, kerosene sample test, as well as radiography up to 100mm thickness;
- Hydraulic tests (if necessary).
- Welding of defects;
- Second defectoscopy at the welded-up places;
- Release of castings after welding defects.
Forging carries out production of forging blanks weighing up to 550 kg, stampings up to 30 kg, cutting of blanks, heating to deformation temperature, forging, coiling of springs, as well as subsequent mechanical and heat treatment. Production of forging blanks is carried out by free forging on hammers with a weight of falling parts of 0,4 tons; 1,0 tons; 3,15 tons. Stampings are made on stamping hammers with 2 t. force.
Heating of blanks for forging and stamping is carried out in gas and electric chamber furnaces. Forging blanks are subjected to subsequent heat treatment: quenching, tempering, normalization and annealing according to the specifications of the drawing.
The plant has a wide range of types of heat treatment of forging blanks, stampings, castings, welded structures and of thermochemical treatment of parts
Production capacities of KTW Thermal Processing:
1. Annealing and normalization (carried out in electric and gas furnaces of various designs: chamber, shaft, bell, bogie type).
2. Quenching (bulk and HFC) with cooling in water, oil or air.
3. Heat treatment of large-sized structures.
4. Gas carburization.
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Annealing and Normalization |
Quenching (bulk and HFC) |
Heat treatment of large-sized structures |
Gas carburization |
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Dimensions of the largest working space — 2800х5600х2000mm at a maximum temperature of 1200° C. |
Maximum dimensions of parts subjected to quenching: - cooling in water 1650х1000х2500mm; - cooling in oil 1600х1850х2500mm. |
Maximum dimensions of working space: 6000х8600х4500mm. Maximum temperature: 800° C. |
Maximum dimensions of the machined parts: Ø500х1000mm. |
KTW has certifications for heat treatment of parts for the Marine Register and parts manufactured according to Rules and Standards of Nuclear power industry. The thermal equipment is subjected to regular control of manufacturing accuracy.