Forgings

Forgings are made of structural carbon, low-alloy, alloy, tool, corrosion-resistant, high-temperature and wear-resisting steels and non-ferrous metals by free forging and stamping.

The following equipment is used in forging complex:
JSW (Japan) hydraulic forging press of 2000 t force.
It is served through forging manipulator with load-lifting capacity of 18 tons.
The press makes possible to manufacture the following forgings:
- Solid discs and discs with a hole of diameter up to 1500 mm and weight up to 5000 kg;
- Shafts with barrels diameter to 750 mm, length to 6000 mm and weight up to 8000 kg;
- Rolled rings with external diameter up to 1800 mm and weight up to 6000 kg;
- Cylinders with external diameter up to 900 mm and length up to 1800 mm, weight up to 5000 kg;
- Bars and plates of length up to 5000 mm, weight up to 10000 kg.

«Wagner Dorthmund» the ring-rolling machine RAW 160/125 of 160 t radial force and 125 t axial force.
It makes possible to manufacture seamless rolled rings with external diameter from 450 mm up to 3500 mm, height from 60 mm to 500 mm and weight up to 3500 kg.

Pneumatic and steam-driven free forging hammer of arch and bridge type with drop parts weight from 150 kg to 3000 kg.
It makes possible to manufacture the following forgings:
- discs and rolled rings of diameter from 100 mm up to 600 mm, weight up to 320 kg;
- shafts of barrel diameter up to 400 mm, length up to 400 mm, weight up to 2000 kg;
- bars and plates of section up to 350 mm, length 3500 mm, weight up to 2000 kg;
- Shaped forgings.

Casting

The company has available powerful foundries, which provide with castings the basic production sector as well as deliveries for cooperation. The foundries comprise the casting sectors of both high and low pressure, for investment patterns as well as for continuous casting of steel and aluminium founding. The Company manufactures the castings of grey cast iron, steels, non-ferrous metals and alloys.

The JSC «Sumy Frunze NPO» manufactures the castings of the following grey cast iron grades: Sch 10, Sch 35 (GOST 1412-85), Chkh1, Chkh2, Kh3, ChKh28D2 (GOST 7769-82).These castings are intended to manufacture parts of pumps for NPP, heavy-duty compressors and chemical equipment, which are operated in conditions of aggressive, toxic, explosion and fire dangerous media, high pressure and wide temperature ranges. The finished castings meet the strict requirements for mechanical properties, microstructure, chemical composition and density. Cast iron is produced in IChT-6 induction furnaces.
Castings weight: from 50 g to 20,000 kg at maximum dimensions of 6000 x 4000 x 900 mm.

For steel castings the following steel grades are used: 20L, 25Л, 20GL, 20GSL, 35GL, 20Kh13L, 12Kh18N9TL, (GOST 977-88). The steel castings are intended to manufacture parts of pumps for NPP, centrifuges and heavy-duty compressors, which are operated in conditions of radioactive media and high pressure. Steel melting is carried out in DSP-1.5, DSP-3 electric arc and IST – 0.4 induction furnaces.
Castings weight: from 10 kg to 2500 kg at maximum dimensions of 1500 x 1000 x 1000 mm.

For investment casting the following steel grades are used: 20H13L, 12H18N9TL, 12H18N12M3TL. The main nomenclature list includes impellers and guide vanes for centrifugal pumps. Steel melting is carried out in IST – 0.4 induction furnaces.

For copper alloys casting the following grades are used: BrO5C5S5, BrO10F1, BrA9G3L, BrO7S13N3, BrO12S2, L63. Casting is carried out in IST-0.16 and IST-0.4 induction furnaces. Pouring is carried out into chill molds, moulds of centrifugal machines and partially in sand forms.
Castings weight: to 200 kg at maximum dimensions of 500x500x300 mm.

For aluminium alloys casting the following grades are used: АК12, АК5M2, АК5М7. Casting is carried out in IAT – 0.4 induction and crucible gas furnaces.
Castings weight: to 150 kg at maximum dimensions of 800x800x300 mm.

Thermal process

It makes possible to perform both preliminary and final heat and chemical-heat treatment of parts manufactured by the JSC «Sumy Frunze NPO» and the co-operation. To obtain the desired set of properties of steels and alloys the thermal divisions of workshops are equipped with tools for conducting of all types of heat treatment of forgings, castings, various welded structures and pipes. For heat treatment (normalizing, quenching in water, tempering) castings weighing up to 6t chamber gas furnace with the size of working space 2900x4500x2150mm are used. The age-hardening of cast iron is carried out in a furnace with bogie hearth working volume of 3950x8150x3800mm. Heat treatment of forgings is carried out in the gas chamber and shaft electric furnaces.

The following unique machinery is used in blanking facilities:

• Messer Grischeim computer-controlled gas-cutting plant for sophisticated configuration carbon steel blanks;
• Trumatic 300 plasma coordinate cutting machine made by the Company «Trumpf» for cutting stainless steel parts of sophisticated configuration, including segments of centrifuge screws, and for cutting ports;
• Set of equipment including a flanger making diameter 1800 - 4000 mm elliptic and box bottoms and flanging conic bottoms with set radius and 40 mm thick walls;
• Asano Seiki profile-iron bending machines for making flanges by cold bending strips;
• Hausler molding-iron-profile-bending machines for making coil pipes, optical compensators and semipipes jackets are made with diameter 800 - 3000 mm, and coils are made of pipes with diameter 25 - 159 mm;
• Unit for pipes finning with HFC heating.

Assembly facilities

The Company has available up-to-date metal-working machinery numbering over 1500 units, including 220 NC machine-tools and automated machining centers. This machinery is of high process accuracy and made by leading machine-tool companies including «Waldrich-Siegen», «Max-Muller», «Innse», «Thylenhaus», «Dorries», «Forest», «Pfauter», «Berardi», «Hofler», «Lorenz», «Kolb», «Safob» and others. The structure of species and groups of metal-cutting equipment is characterized by a high degree of universality, that provides sufficient «flexibility»of workshops and annually makes possible to develop new products without a fundamental change in the composition of equipment. Bench-assembly production has available 17 balancing machines for individual parts and rotor sets with maximum diameter up to 2100 mm, length up to 4700 mm and weight up to 7000 kg with the rotation speed when balancing up to 3150 rpm. Unique Schenck vacuum chambers are used for overspeed tests and vacuum balancing of compressor impellers with weight up to 2500 kg at rotation speed to 40000 rpm. The complex of unique testing benches makes possible to perform full load string testing of all components and units parameters and to provide equipment shipment, construction and commissioning of it to customer on turn-key basis.

Bench-assembly production has available 17 balancing machines for individual parts and rotor sets with maximum diameter up to 2100 mm, length up to 4700 mm and weight up to 7000 kg with the rotation speed when balancing up to 3150 rpm. Unique Schenck vacuum chambers are used for overspeed tests and vacuum balancing of compressor impellers with weight up to 2500 kg at rotation speed to 40000 rpm. The complex of unique testing benches makes possible to perform full load string testing of all components and units parameters and to provide equipment shipment, construction and commissioning of it to customer on turn-key basis.

Welding sector

The welding sector widely employs robotic, automatic and mechanized welding machines, test benches and equipment of «Fronius», «IGM», «ESAB», «Polisoud», «Deuma» companies with manipulators of load-lifting capacity from 10t to 100 t The following welding and facing procedures are used: automatic submerged arc, electro slag, electron-beam, machine gas-shielded solid and cored wire flux, orbital non-consumable electrode argon-arc for the connection «pipe + pipe» and «pipe + tube sheet», high-frequency in pipes manufacturing and fining, seam and spot contact, friction welding, explosion cladding and strip electrode facing. Vacuum soldering, plasma arc cutting and welding, metal gas thermal and vacuum hardening are widely used in welding works.