Report on the Visit in Funsan Foundry, Spain.

Transcription

1 Report on the Visit in Funsan Foundry, Spain. Date: 26/02/2010 Project: R2E/shielding Invitation to tender: IT3666/EN/LHC Present: Michel Monteagudo (Funsan), Stefano Sgobba (CERN), Michael Lazzaroni (CERN) Goal of the visit: Visit and presentation of Funsan foundry Funsan employs approximately 100 people The total gross production is t/y. Net production is t/y including ductile (20% to 30 %) and gray iron (rem.) Funsan owns horizontal rotative gas furnaces, dating of the 90ies. Casting T is approximately 1380 C to 1400 C. Unit of casting are 12 t to 13 t, or 16 t to 17 t They use a limited quantity of scrap and an important amount of pig iron and ferroelements, due to the type of their furnaces. Internal recycling (running system) is applied Molds are poured by hand using geared ladles The chemical analysis is a ladle analysis, performed after adjustment Funsan applies the technique of vaporizable polystyrene patterns, painted and dried 24 h at 60 C, allowing sharp edges to be achieved on the final blocks. Production of patterns is subcontracted Details concerning the metallurgy of our products Several blocks are cast from a single run, up to 6 or 8. The number of blocks per single cast allowing to achieve the specified surface quality is still being optimized. Casting is performed from bottom, in order to allow the impurities to float Cooling time is between 3 d and 4 d A fully ferritic microstructure is aimed (no FeMn added). Microstructure will be checked on final products according to the specified standards Michael Lazzaroni, Stefano Sgobba (CERN) Page 1

2 Technical discussions about the quality assurance plan 1. Dimensional controls The dimensional tolerances are acceptable. The blocks out of tolerance will be machined. The geometrical tolerances (flatness, perpendicularity) are generally acceptable (picture 1,2) Right angles are complying. (picture 3) The roughness is above specification mainly due to surface defects that reproduce the oxides present after unmolding and removed further. With the exception of some presented specific blocks or surfaces heavily affected by surface defects, that will be discarded or conditioned, respectively, these defects are generally judged acceptable. o Funsan fills the deepest defects by repairing by arc welding (picture 4). o Funsan applies a cold weld layer on the worst face in local areas (still under discussion) (Picture 5). Full results of the metrological controls shall appear in the certificate of each block. 2. UT UT control is requested from three faces in order to check the soundness of the relevant volumes, in agreement with the specified standard UT tests will be performed before machining of the threads Details of the procedure and compliance with the specified standard should be provided by Funsan 3. Chemical analysis CERN requested Funsan to assess the Co content of the castings with the help of an external laboratory. 4. Other information The proposal of the foundry is to remove adjoining samples from the casting runner. This is acceptable under reserve of a cross check of properties on samples trepaned from one cast in order to confirm that the values achieved on runners are conservative The marking of each block will be [FS ] on one face 800 mm x400 mm where the threaded hole is. Furthermore the number of this tender [IT-3666] shall appear on each block on the same face, just above the numbering [FS ]. FS stand for Funsan foundry 844 means the size of the blocks (800mmx 400mmx 400mm) Michael Lazzaroni, Stefano Sgobba (CERN) Page 2

3 1500 is the numbering of each blocks from 1 to 500. The marking should be intruding and not protruding with respect to the surface and must remain visible after painting The density of EN-GJS U-RT is 7.1/7.2. Theoretical weight is around 908 kg. The painting is defined below: 1 st layer: anti-corrosive primer 2 nd layer: radiation resist RAL: 7040 (grey) Three threaded holes M24x50 Funsan will make a load test (2t) on one block (two times the weight of a block), and has to send a picture of it. Picture 1 Michael Lazzaroni, Stefano Sgobba (CERN) Page 3

4 Picture 2 Michael Lazzaroni, Stefano Sgobba (CERN) Page 4

5 Picture 3, 4 Michael Lazzaroni, Stefano Sgobba (CERN) Page 5

6 Picture 5 Assembly of two blocks Michael Lazzaroni, Stefano Sgobba (CERN) Page 6