PRODUCTION OF CASTINGS
The casting production is performed in our foundry which is one of metallurgical plants within the Vítkovice Machinery Group with already over 120 years of tradition in the production of steel castings. The capacity possibilities with respect to weight and dimensions of castings rank us among the global leaders, which we have achieved in cooperation with the Magmasoft software that is mainly used to determine the optimal production technology of each casting. The annual production capacity of the foundry is 14 kilotons of steel castings which are used in various fields of industry, e.g. in the cement industry, heavy steel industry (rolling mills, pressing shops, forging shops and foundries), marine industry, off-shore, energy and mining industries.
With respect to materials, the production of castings is extremely varied, namely from carbon-manganese steels, low- and medium-alloy steels, or fine-grade steels, to high-alloy types of steel. Total volume of steel determined for our castings comes through a secondary metallurgy phase, either VD or VOD. The maximum size of a casting is actually given by our largest caissons (a moulding pit) with dimensions 35x8x5 m. We have 8 caissons in total. The maximum weight of the liquid mass produced in our foundry is 370 tons.
For own moulding process, we use chromite and silica sand of the highest quality; as a binder we use furan resin. Before and during moulding of each casting, the moulding mixture is tested for its current mechanical, and heat resistance and abrasion properties in our own laboratory for the sand mixtures. The essential part of the foundry is also a fettling shop where fettling of castings through the grinding automat ANDROMAT, hand grinding, and shot blasting including modifying the surface by sand blasting are performed.
In the fettling shop we also perform heat treatment in 5 modern furnaces in total, as normalized and homogenization annealing and tempering. Quenching into oil or water as well as dissolving annealing of our castings is done in the forging shop. The maximum temperature in our modern furnaces ranges +/- 5 °C. For controlling the heat treatment process we use furnace thermocouples and furnace thermocouples which are placed directly on the casting surface in order to obtain the most relevant data. The testing of mechanical properties and numerous types of macro and microstructure investigation of our castings is performed in our affiliated company VÍTKOVICE TESTING CENTER.
CASTINGS FOR ROLLER TRACKS
This segment of production is intended mainly for the production of rollers for producing seamless pipes.
CASTINGS FOR THE SHIPBUILDING INDUSTRY
The shipbuilding industry programme includes especially castings for the specific rudder system AZIPOD. These castings form the inner part of this diesel-electric rudder system which is used in both common tourist cruisers and icebreakers.
CASTINGS FOR CYLINDERS AND SWAGES
This traditional segment of casting production in our foundry includes the production of parts for hydraulic or mechanical press machines (upper, lower, head traverse, rolling stands, gear rings) and for mechanical, hydraulic and ram cross hammers.
CASTINGS FOR THE HYDRO INDUSTRY
This part of industry is represented by the parts for water turbines – Francis (crown and ring castings), Kaplan (hub, servo cylinders), or parts for pumped-storage hydro power plants.
CASTINGS FOR METALLURGY
This segment of castings includes rolling stands, whether as a monolith or an assembly unit consisting of several assembled or welded castings. The production includes bearings or slag pots for slag processing designed for non-ferrous ores and alloys.
CASTINGS FOR CEMENT PLANTS
The castings which are the essential parts of rotary cement kilns – toothed and untoothed supporting circles, pulleys and end mills.