SPECIAL STEEL CASTINGS

Transcription

1 SPECIAL STEEL CASTINGS The specialists for form and function

2 OUR COMPANY WE LOVE WHAT WE DO Our plants in Ründeroth, Weiershagen and Dieringhausen (on the right) 2

3 Dörrenberg worldwide Dörrenberg Edelstahl, Germany (plants in Ründeroth, Dieringhausen, Weiershagen and Herford)) Dörrenberg Tratamientos Térmicos Spain vacuum-hardening, plasma-nitriding Doerrenberg Taiwan tool steel 6 Doerrenberg Special Steels Singapore tool steel Doerrenberg South Korea tool steel Doerrenberg China tool steel History For generations Dörrenberg has been synonymous with manufacturing and finishing of high-grade steels. The company s origins stretch back over 300 years Registration as a forge and steel mill 1932 Establishment of the high-grade steel foundry 1959 Establishment of the surface finishing division 1977 Establishment of the investment casting foundry 1990 Organisation split into four business divisions 1996 Dörrenberg becomes a part of Gesco AG 2005 Commissioning of Weiershagen plant 2005 Conversion of the foundry plant Ründeroth 2007 Expansion of heat treatment facility plant Ründeroth Oelchens Hammer 2008 Commissioning of plant Herford 2010 Expansion of plant Weiershagen 2010/2011 Expansion of steel mill plant Ründeroth 2011 Expansion of fettling shop plant Ründeroth 2011/2012 Expansion of plant Weiershagen 2013 Commissioning of plant Dieringhausen 3

4 OUR CAPACITIES Moulding Our moulding facility is equipped with three conventional manual moulding lines. We use furan-resin-bonded moulding materials. Small batches are manufactured as cost effectively as individual components with a unit weight of up to 12 tonnes. A state-of-the-art sand preparation facility guarantees optimum economical and technical utilisation of the raw materials used. Since most recently we offer the possibility to scan and digitalise existing castings and subsequently construct sand moulds using patternless sand prints. This process is ideal for manufacturing replacement parts, individual components and small batches. 3coreshooters Core-makingusingmanualmouldsuptoaweightof4t 3manualmouldinglines,boxsize4500x2200mm (circular:2200mm,square:3000x3000mm) Productionofsandmouldsbyusingsandprintmachine Foundry State-of-the-art furnaces and continuous enhancement guarantee a high degree of manufacturing reliability. The range includes: Corrosion- and acid-resistant steels Duplex and super-duplex steels Tool steels Heat-resistant steels Wear-resistant steels An end-to-end ERP system from initial weighing to certification ensures certified production. Weproduceapprox.200differentmaterials Castingsuptoadeliveryweightofapprox.12,000kg (material-dependent) 4inductionfurnaces(t;1.2t;2.4t;3.5t) 1electricarcfurnace10t 1plasma-ladlefurnace15t 4

5 Fettling shop/heat treatment 2 large Arc air burner stations Various grinding facilities Various blasting booths 3 bogie hearth furnaces up to 4,500 x 3,000 x 1,800 mm Large water tank with counterflow system Various vacuum furnaces Pit furnaces, bell furnaces Fettling reveals castings in their true colours. Heat treatment unlocks the full potential of the materials. Production welding is monitored by experienced welding engineers. The technology is qualified to applicable standards and is regularly inspected. We train our staff on a continuous basis. If required all finishing procedures up to 1,250 C can be performed after welding in the attached heat treatment facility. We use a total of 20 state-of-theart furnaces. A large water tank with counterflow system and a fan cooling system are available for cooling purposes. Manual and automatic blasting booths guarantee thorough cleaning. Machining 8centrelathesCNC/conventionaluptoØ1,200mm 4verticalturningandboringmachinesCNC/ conventionaluptoø2,700mm 6millingmachines/boringmillsCNC/ conventionalupto2,000x1,600mm/ø1,500mm 6grindingmachinesCNC/ conventionaluptoø1,000x800mm A wide range of pre-machining and finishing options compliments the company s extensive vertical integration. In line with market requirements we have specifically expanded the range of machining options. Modern machining centres process components with diameters of up to 2,500 millimetres and corresponding machining heights. For special requirements we cooperate closely with affiliated partners. Slottingandkeyseatingmachines Scanningandmeasuringequipment 5

6 CORROSION- AND ACID-RESISTANT SPECIAL STEEL CASTINGS Our extensive product portfolio is applied in the following industries: Turbines and pumps industry Filtration and centrifuge equipment Kneading and mixing equipment Food-processing industry Paper and pulp industry Power station engineering Extruder systems General plant engineering Hydropower plant engineering Cast steel is regarded as corrosion-resistant if it features a particular resistance to chemical impacts. Corrosion resistant steel castings feature a carbon adjusted chromium content of at least 1 %. Stainless steel castings are standardised in accordance with EN 10213, EN and SEW 410. All these materials as well as special services and product enhancements are part of Dörrenberg Edelstahl GmbH s standard repertoire. The most important characteristic of these steels is their resistance to corrosion and acids. Soft-duplex castings (DE material SD Ni4) and the duplex and superduplex materials with a pitting resistance equivalent number (PREN) > 40 feature a particularly high resistance to corrosion as well as a high basic strength. This cast steel forms the ideal basis for, e.g. highly stressed, rotationally symmetric castings for decanters and centrifuges. Castings resistant to organic and inorganic impacts, are suitable for use in all kinds of extreme conditions. 6

7 An extensive range of corrosion- and acid-resistant special steel cast components. The patented moulding process for open and closed impellers guarantees a particularly high degree of precision. Another speciality are e.g. hollow-cast kneading blades, which can be cooled or heated during application. Irrespective of whether hollow- or full-mould casting Dörrenberg Edelstahl provides highest security in the development and design of special steel castings. The table on the right shows an extract of the most important corrosion- and acid-resistant casting materials. Mat. no. Designation Chemical Composition C Cr Mo Ni Cu Nb N GX6CrNiMo GX2CrNiMoN GX2CrNiMoN GX2CrNiMoCuN GX40CrNi GX40CrNiMo SD Ni4 Special material G Special material GX2CrNi GX5CrNiNb x%C GX2CrNiMo GX5CrNiMoNb x%C G GX3NiCrMoCu Other materials are available on request. 7

8 WEAR-RESISTANT SPECIAL STEEL CASTINGS An extensive range of wear-resistant special steel cast components. Wear refers to undesirable abrasion on the surface of a material primarily caused by mechanical interaction with other solids or materials. A wide range of different steels are used depending on the type of abrasion. As a result of many years of experience and research in this sector, Dörrenberg Edelstahl provides a range of selected highly wear-resistant materials for your specific application. In order to select the steel grades, a careful wear analysis is vital. Factors, such as mechanical, dynamic and thermal impact, as well as ductility requirements play a key role. We provide comprehensive technical advice for your particular requirements. The wear resistance is determined by the high special carbide content. Additional quenching and tempering develops the material s full potential. Hardness and ductility can be accurately set to the relevant maximum. One major product in the field of wear-resistant special steels are cast forming rolls (for pipe mills) and straightening rolls (for rail and section mills). Using the material GP4M, enables complex roll geometries to be realized more easily than using existing standard materials. The special material GP4M, is particularly wear-resistant, durable and extremely resistant to surface Applications for wear-resistant materials include the following: Straightening, forming and calibrating rolls Press tools Cutting, forming and drawings tools Rolls, roll shells Die-casting facilities, extruders Pump industry Mining industry Cement manufacturing Briquetting facilities General mould- and tool making industry 8

9 Rolls are a major product in the manufacturing of wear-resistant special steels. spallation during operational use. With an adjustable working hardness of up to approx. 60 HRC, even larger dimensions can be through hardened. In addition, we produce press tools for sheet forming and pre-moulded castings for tool- and mouldmaking. Dörrenberg Edelstahl provides comprehensive technical advice right from the start. The choice of materials, design and cast visualisation are optimally adjusted to the particular application. The table on the right shows an extract of the most important wear-resistant casting materials. Chemical Composition Mat. no. Designation C Si Mn Cr Mo Ni V Co W GX155CrVMo GX165CrMoV G45CrNiMo GX120Cr G4112 Special material G4122 Special material G47CrMn G42CrMo GP16XR Special material GP27M Special material GWP7V Special material GP4M Special material Other materials are available on request. 9

10 HEAT-RESISTANT SPECIAL STEEL CASTINGS Cast steel is regarded as heat-resistant if it features a particularly high resistance to the scaling effect of gases at temperatures above 600 C. These materials are specified in the EN and SEW 471 standards. Scaling resistance can be attributed to the chromium content in the steel. It increases with the chromium concentration and can be further increased by adding aluminium and silicon. The higher the chromium content, the higher the scaling resistance of the steel. Heat-resistant materials can be divided into three groups: ferritic, austenitic cast steel grades as well as nickel- and cobalt-based alloys. The level of oxidation resistance required for general use is achieved by adding the alloying elements silicon, chromium and nickel. At high temperatures up to approx. 1,200 C, these alloying elements form oxydic protective layers that counteract aggressive impacts on the material and prevent further oxidation. Adding nickel improves ductility and heat resistance and austenitises the structure. Applications for heat-resistant materials include the following: Industrial furnace construction Sintering plants Furnaces Hot forming Steel industry Cement industry General power station and plant engineering Long-established special materials are available for specific applications. These include ready-to-install, pre-assembled screen linings for hot 10

11 An extensive range of heat-resistant special steel cast components. sinter screening in steel mills as well as forming tools (mandrels) for fittings manufacturers. We manufacture mandrels with diameters ranging from a few millimetres to more than 1000 millimetres. The maximum delivery weight is 12 t, dependent on the particular design. Many years of manufacturing experience in special steel castings and forward-looking development of castings and materials have played a major role in the success of Dörrenberg Edelstahl. The table on the right shows an extract of the most important heat-resistant casting materials. Mat. no. Designation GX40CrNiSi GX32CrNi , GX25CrNiSi GX40CrNiSi GX25CrNiSi GX40CrNiSi GX40CrNiSi GX40NiCrSiNb GX40NiCrSi G-NiCr28W G-CoCr G-NiCr50Nb 0.1 Other materials are available on request. Chemical Composition C Si Mn Cr Mo Ni Nb Co Residue Fe 11

12 TOOL STEEL CASTINGS Range of tool steel casting services: Casting technique and materials consultancy CAD data exchange with casting technique modification Exporit pattern production by cooperation partners Manufacturing of raw castings in alloyed and non-alloyed cast steel Unit weight up to 12,000 kg, maximum size: 4,300 x 2,000 mm Moulding methods (full-mould casting method, hollow-mould casting method, sand-print method) Mechanical base machining ForDörrenberg,theterm toolsteelcastings referstoalloyedand high-alloyedcoldandhotworktoolsteelsfortoolmaking.innovative productionprocessesandthedevelopmentoftoolmaterialsmake Dörrenbergthemostimportantproduceroftoolsteelcastings. In-depthconsultingduringmethodplanninganddesignphase enablesjointtoolconcepts.toolswithcast-incoolingpipesfor presshardeningorcastingsoffiligreetoolsdetermineasuccessfulapplication. Acrucialfactorfortoollifeisheattreatment.Ifappliedincorrectly resultingfromlackofknowledge,timeorfacilities,prematurefailure islikely.heattreatmentdependsonthechemicalcompositionof thematerialandthecross-sectionofthetool.dörrenbergedelstahl offers FullService withoptimumconsultationandrealisationofall necessarymeasures. Thetableontheleftshowsanextractofthemostimportanttoolsteel castingmaterials. 12

13 Dörrenberg supplies alloy and high-alloy cold- and hot-work tool steels. Mat. no. Designation Chemical Composition C Si Mn Cr Mo V W Ni Co G40CrMnMo G45CrNiMo G47CrMn G60CrMoV G59CrMoV GP4M Special material GX100CrMoV GX155CrVMo GX165CrMoV Cast-in cooling pipe system in a forming tool. Other materials are available on request. 13

14 THE QUALITY STANDARDS Inspection, measuring, examining and testing: We are continuously improving our products and manufacturing processes. Targeted product and process enhancement is based on qualitative and quantitative evaluation of all relevant facts and parameters. For this purpose all common examination methods are applied in-house by our qualified and trained staff. For technically more complex processes or those used less frequently (such as quenching dilatomery, radiography or creep rupture) we work together in close cooperation with universities and research organisations. 14

15 Always good Quality does not happen on its own but is the result of planned working sequences and the special sense of responsibility shared by our employees. Smart resource management and a constant dialogue with the employees generate a transparent quality policy and reproducible processes. High-quality products are the result of all components in a process chain being handled diligently and self-evidently. Consultancy People do the business. People are the key to success. Therefore, personal consulting before, during and after joint projects is a core of our work. You can rely on our know-how. Shared skills transfer Research and development The central materials engineering department is where all the R&D activities for all business divisions come together. We are currently working on approx. 30 projects, often in cooperation with external research organisations. Our R&D subjects emerge directly from market requirements. Further approaches for the development of innovative solutions are gained by a holistic material analysis, ranging from metallurgy to heat treatment to surface technique. Documented quality Certifications (such as DIN EN ISO 9001:2000) are the visible expression of our quality standards. High customer satisfaction, partnership relationships and compliance with standards are the basis for long-term customer and supplier relationships. For continuous improvement our employees regularly participate in conferences in Germany and abroad. Furthermore, involvement in various committees and industry associations strengthens our competence and market knowledge. We are pleased to share our know-how with you at training sessions and presentations on your or our premises. More than just steel We support our partners wherever we can. In close collaboration with customers we define how support can be extended beyond the mere product. Research Studies Materials testing Analyses/reports 15

16 HOW TO FIND US SPECIAlSTEEl SPECIAL STEEL CASTINGS INvESTmENTCASTINgS SurFACETrEATmENT Cold work steel Hot work steel High-speed steel Plastic mould steel Powder-metallurgical steel Stainless steels Nitriding steels Tempered steel Precision flat steel Special grades Global procurement of cast products and drawingspecific metal components Materials and design engineering consultancy CAD data exchange Solidification simulation Rapid prototyping, rapid tooling Mechanical machining Range of different surface finishing processes Heat treatment Induction hardening Polishing of tools and components Plasma nitriding NOX coatings Hard material coatings using the CVD, PVD and PA-CVD method Coating removal and re-coating Treatment (coating and polishing) of complete tools, incl. removal and fitting Weiershagen plant Weiershagener Str Wiehl Germany Ründeroth plant Hammerweg Engelskirchen Germany Dieringhausen plant Stahlstr Gummersbach Germany Ründeroth plant Hammerweg Engelskirchen Germany Dörrenberg Edelstahl GmbH Postfach Engelskirchen Germany Tel.: Fax: formguss@doerrenberg.de