ESCO Corporation Foundry Capabilities

Transcription

1 ESCO Corporation Foundry Capabilities

2 ESCO Corporation With a history of proprietary products and a reputation for engineering and metallurgical expertise, ESCO is a leading manufacturer of technically-rich ground engaging tools and durable wearparts for mining, construction, dredging and other industrial applications. ESCO also produces a wide array of critical components for the aerospace and power-generation markets. By designing better products, eliminating waste, reducing costs and improving continuously ESCO is a global leader in providing customers with Quality, Value and Speed. Quality, Value and Speed ESCO s culture of Quality, Value and Speed (QVS) and lean manufacturing is integral to everything we do. From boardroom to break room, from office to plant floor ESCO employees strive to reduce waste, ensure safety, drive down costs, decrease lead times, standardize production techniques, and improve continuously. The result: ESCO production output meets strict specifications and offers customers superior flexibility and value. These business practices also create sustainable economic, environmental and social benefits for our employees and in the communities where we operate. 2

3 ESCO s Customer Commitment Founded in 1913 as the Electric Steel Foundry, ESCO has grown into a global corporation that is internationally recognized for its casting production capabilities. ESCO currently employs nearly 4000 men and women worldwide. Throughout its history ESCO has tackled the toughest engineering challenges. For nearly a century, ESCO has been a global wear solutions leader thanks to the hard work, dedication and camaraderie of these outstanding employees. ESCO s smart, friendly, reliable people are not afraid to get their hands dirty to solve customer problems. ESCO Foundries With a network of foundries located throughout North America, Europe and Asia-Pacific, ESCO is able to efficiently provide quality castings to customers around the world. ESCO plants are capable of producing alloy, manganese, stainless and other specialty steels for a wide variety of industrial applications. All ESCO facilities are ISO9001 certified and operate under a program of continuous improvement to ensure the highest quality and value for our customers. While many companies have global outsourcing capabilities, ESCO stands alone by combining cutting edge engineering expertise with cost effective global sourcing. This ensures that parts sourced from any ESCO facility possess the same quality and reliability customers expect. ESCO Locations ESCO Edmonton (EP) ESCO Nisku (EP) ESCO Guisborough (EP) ESCO Herstal (TT) ESCO Steinbach (EP) ESCO Frameries (EP) ESCO Port Hope (EP) ESCO Syracuse (TT) ESCO St. Petersburg (EP) ESCO Paris (EP) ESCO Ekaterinburg (EP) ESCO Port Coquitlam (EP) Steel Treaters, ESCO Mönchengladbach (EP) ESCO Portland (3) Oriskany (TT) ESCO AR (TT) ESCO Portland ESCO Cleveland (TT) Corporate Headquarters ESCO Bucyrus (EP) ESCO Phoenix (EP) ESCO Covington (EP) ESCO Tempe (TT) ESCO Guaymas (TT) ESCO Newton (EP) ESCO Atlacomulco (EP) ESCO Kolkata (EP) ESCO Xuzhou (EP) ESCO Shanghai (EP) SCW (EP Joint Venture) ESCO Lima (EP) ESCO Soldering (EP) ESCO Singapore (EP) Perth (EP) Brisbane (EP) Newcastle (EP) Legend EP = Engineered Products TT = Turbine Technologies Foundries Sales/Liaison/Other ESCO Facilities Australia Belgium Brazil Canada Chile China France Germany India Japan Mexico Peru Russia Singapore South Africa Slovak Republic United Kingdom United States 3

4 ESCO Foundry Capabilities Each ESCO foundry is set up to maximize casting production to service specific market segments. The range is from small (0.25 Kg), high volume components to large one-off castings over 25 tonnes. In addition to ISO9001 certification, ESCO foundries have received numerous regional certifications and recognition for metallurgical expertise Recycling & Industrial Wear Parts To ensure that customers receive the finest quality products possible, ESCO uses the state-of-the-art equipment and processes, including a wide variety of quality control techniques to monitor production. Following are some key resources utilized by ESCO foundries. Argon Oxygen Decarburization (AOD) steel purification No-bake, shell and stack molding processes Computer controlled heat treatment ovens Electric arc and induction furnaces Computerized solidification modeling Destructive materials testing Spectrometer analysis Scanning Electron Microscope (SEM) Computerized machining and milling Focused foundries are important to meet customer needs for competitively priced products that meet performance requirements and are available when needed. For example following are overviews of two foundries and their capabilities. Dredging 疏浚用耐磨件 Wear Parts Mining 矿用耐磨件 Wear Parts United Kingdom Guisborough Facility The Guisborough foundry utilizes a proprietary stack molding process to cast large volumes of commodity wear components for the construction industry. The process allows a hundred or more of one component to be cast in one pouring that are then systematically processed through the heat treat and fit check processes. Careful control of each step allows large volumes of parts to be produced to exacting standards that are priced competitively for the construction commodity wear parts market. China SCW Facility The SCW foundry has numerous capabilities that allows production of one-off to large volumes of castings in a wide range of sizes and complexity. The facility includes its own pattern shop so customer designs can be produced quickly to service to markets throughout Asia-Pacific, as well as other worldwide locations. The SCW facility is recognized as a competitively priced source for timely production of quality castings that meet or exceed customer expectations. Crushing 破碎用耐磨件 Wear Parts 4

5 ESCO Production ESCO produces and delivers a wide variety of cast and fabricated components to satisfied customers every day. Specific markets include mining, construction, aggregate, dredging, aerospace, gas turbines, wood products, marine, structural, primary metals and many other industrial applications. ESCO has the capacity to produce one-off prototypes to full production quantities. ESCO casting expertise covers a wide spectrum of steels, including low and high alloy, stainless, manganese, and chrome white iron. ESCO employs highly skilled metallurgists who develop alloys and processing methods that ensure ESCO products possess the right combination of strength, wear resistance and weldability. Through constant innovation and focus on customer needs ESCO takes metal manufacturing technology to new levels. Cone Crusher Primary Metal Molds Recycling Hammer Mining Lip System Valve Body Ball Joint 5

6 ESCO Systems and Resources Unigraphics Design Unigraphics software is a computer based design program that enables engineers to create precise 3D models of any casting component. ESCO uses this tool to optimize the fit between components and to maximize design requirements. Finite Element Analysis Computerized Finite Element Analysis (FEA) is utilized by ESCO to analyze and improve product designs. Sophisticated computer technology allows engineers to simulate the performance of a part before it is ever manufactured, allowing for modifications early in the product development process. Reverse Engineering ESCO utilizes digital laser scanning to reverse engineer existing castings for duplication. Full analysis provides a three dimensional outline of the casting which is used to create a pattern to produce an identical copy. Magma Solidification Analysis The Magma solidification analyzes how molten steel will solidify in the mold prior to pattern tooling construction. ESCO utilizes this process to help ensure that components meet the required quality and performance standards at the initial casting process. 6

7 Rapid Prototyping Rapid Prototyping technology is used to make accurate scale models of products prior to building patterns. Going from a CAD design to an actual 3-D model in less than 24 hours allows ESCO engineers to evaluate products prior to production to ensure they will satisfy customer needs. Fatigue Testing ESCO s Servo-Hydraulic Fatigue Testing System is designed to put cyclic loads on products to simulate field conditions. The system allows ESCO to quickly test components for the effects of long term field loading that can lead to fatigue failure. It also helps determine fit requirements, alloy properties and overall product performance. Rapid Load Testing ESCO s Product Test Lab performs Rapid Load Testing to determine the breaking forces on a variety of components used in mining, construction and other industrial products. The servo-hydraulic actuator creates a high speed load that typically break parts in less than one-half second. Drop Tower Testing The Instrumented Drop Tower provides quantitative load and stress data from a single impact. Typically, a 2,725 kg / 6,000 lbs. weight is dropped from 4.6m / 15 ft. Multi-channel software is used to capture impact data, including the peak load and exact time of failure. It has a maximum sample rate of 106 samples per second. Drop tower testing involves high strain rates, similar to those that parts endure in actual service conditions. 7

8 ESCO Shanghai Suite 25GH, LeKai Tower No. 660, Shangcheng Road PuDong District, Shanghai PR China Phone: ESCO (Xuzhou) Wearparts Co., Ltd. Middle Section of Yinshan Road, Tongshan Economic Development Zone, JiangSu Province PR China Phone: SCW No 53 Yuhe Street Taiyuan, Shanxi Province PR China Phone: ESCO Corporation is the preferred provider of technically rich metal components and wear solutions for industrial applications. ESCO has over 40 locations and affiliates worldwide ESCO Corporation. All Rights Reserved. P3008GEN01A0710 North America 2141 NW 25 th Avenue Portland, OR PH: Latin America Rua Engenheiro Gerhard Ett, 1215 Distrito Industrial Paulo Camilo Sul Betim Minas Gerais Brasil CEP: PH: Europe, Africa, Middle East, Commonwealth of Independent States Rue des Fours à Chaux 7080 Frameries, Belgium PH: Asia Pacific 1 Scotts Road, Number Singapore PH: