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The Express Moulding Laboratory controls the quality of raw materials incoming to the Steel Foundry and the technological parameters of moulding sand/plasticine and the quality of cores and moulds in the Steel Foundry.

The main laboratory device is an all-purpose instrument Type LRUTS, designed for assessment of the strength properties of moulding sand/plasticine - pressure, rupture and bending

The Express Quantometric Laboratory is established for rapid on-the-spot quantitative analysis of steel test pieces incoming from the steel production shop for the purpose of timely corrections of the chemical composition of the liquid metal. The metal samples are sent within 30 seconds directly to the laboratory by compressed air pipe.

The principal laboratory equipment and instrumentation comprise:

1. Stationery emission quantometer
Type: Spektromax
Producer: "Spectro Analytical Instruments" GmbH & Co. KG ("Ametek Group", USA)

2. Mobile analyser
Type: Spektrotest
Producer: "Spectro Analytical Instruments" GmbH & Co. KG ("Ametek Group", USA)

3. Automatic analyser

Type: Leco CS - 244
Producer: LECO Instruments GmbH, USA

4. Automatic analyser
Type: Leco RH - 1E
Producer: LECO Instruments GmbH, USA

5. Automatic analyser
Type: Leco TC - 136
Producer: LECO Instruments GmbH, USA

6. Electronic scanning microscope
Type: S 405 A
Producer: HITACHI, Japan

7. Electronic scanning microscope
Type: S 550
Producer: HITACHI, Japan

The Central Research And Analysis Laboratory functions as a facility for qualitative and quantitative metallographic analysis and control of mechanical properties of the plant's production, such as tensile strength and impact value.

The principal laboratory equipment comprises:

1.Automatic structure analyser
Enlargement: 50X; 100X; 200X; 500X; 1 000X

2.Tensile strength testing machine
Type: EDZ100, Germany
Range: 10 000 kgf, 20 000 kgf, 40 000 kgf, 100 000 kgf

3.Impact testing machine - Charpy hammer
Range: 300 J, 600 J

Established in 1986 the Non-Destructive Testing Laboratory has a highly skilled and well trained as per EN 473 personnel performs the necessary ultrasonic, magnetic-particle, dye-penetrant, eddy-current and visual tests. The specified methods are used for controlling of internal and surface condition of large-scale castings and forgings as well as welded joints. Assessment of the strict design conformity is made as per existing international standards.

For the different experiments the laboratory is equipped with modern non-destructive test instruments produced by "KRAUTKRAMER" and "KARL DEUTSCH".

Laboratory equipment includes:

» Impulse ultrasonic flow detectors

Type: USN-52, USM-3, USK-7
ECHOGRAPH-1024, ECHOGRAPH-1030, provided with testing probes with 0,5 to 6 MHz frequency.

» Magnetic particle flow detectors

Type: DEUTROPULS 3000/4000A; OMD 4.5

» Electro-potentiometric crack detectors

Type: XRT 810; RMG-401.

The shops are equipped with numerous machines for both rough and final machining of forgings and castings, namely lathes (vertical and for turning of rotating details), boring machines, drilling machines, milling cutters and grinders, mostly CNC equipped, which enables the production of rough and finish machined details.

» Lathes

Dimensions of machined details:
• For rough machining
Length: 14 000 mm
Diameter: 2 500 mm
Maximum weight: 120 ton
• For final machining
Length: 10 000 mm
Diameter: 1 800 mm

» Boring machines

Maximum dimensions of machined details:
Diameter: 3 500 mm
Height: до 3 500 mm
Width: до 1 900 mm
Length: 8 000 mm
Spindle (250 mm / 1900 mm run) can be combined with rotary table, designed for details of up to 8 tons.

» Vertical lathes

Maximum dimensions of machined details:
Diameter: 3 800 mm
Height: 2000 / 3000 mm
Weight: up to 25 tons

» Hollow Bore Drilling machines

• two-sided drilling of details up to 20 000 mm
• one-sided drilling of details up to 10 000 mm
Maximum diameter of machined details: up to 1 000 mm
Weight: up to 20 tons
Drilling of hollow bores of 40 to 200 mm has been adopted, with maximum length depending on the technical parameters of the particular single details.

» Milling cutters

3-coordinate milling cutter (type "machining center") allows machining of details with the following parameters:
Maximum dimensions: 800 W x 1 000 L x 800 H
Weight: up to 450 kg

» Honing machine

Maximum dimensions of machined details:
Diameter: 250 mm
Bore diameter: 120 mm
Length: 5 000 mm

» Alignment Grinders

Maximum dimensions of finish machined details:
Diameter: 1000 / 1 600 mm
Length: 5000 / 6 000 mm
Weight: up to 14 / 50 tons
The hardware machining park consisting of vertical lathes and boring machines enables final machining of instrumental steel products with the following parameters:
Diameter: 20 000 mm
Height: 16 000 mm
Weight: up to 120 tons

Structurally the Forging and Heat Treatment Shop comprises: Forging Press Section and Heat Treatment Section.

I.Forging Press Section with annual forging capacity of 45 000 tons.

Principal equipment includes:

» 3 600 / 4 500-ton Forging Press.

Type: vertical 4-column, oil-hydraulic
Operating pressure: max. 250 kg/cm2
Dimensions: Vertical clearance - 5 000 mm
Column distance: 4 200 x 2 300 mm
Table: 2 500 x 6 000 mm
Producer: Kobe Steel - Japan
Rotation and linear-progressive motion of the forging are implemented through 160-ton
Forging Manipulator.

» 1 600-ton Open-die Forging Press

Type: vertical 2-column, oil-hydraulic
Operating pressure: max. 250 kg/cm2
Dimensions: Vertical clearance - 3 000 mm
Column distance: 2 600 x 1 700 mm
Table: 1 600 x 3 000 mm
Producer: Kobe Steel - Japan
Forging motions are implemented through 40-ton Forging Manipulator.

» Heating Furnaces

150-ton 1
100-ton 5
50-ton 2

» Annealing Furnaces

150-ton 1 Inner dimensions: 4 000 W x 10 000 L x 3 500 H
150-ton 1 Inner dimensions: 3 000 W x 14 000 L x 3 000 H
90-ton 4 Inner dimensions: 3 000 W x 10 000 L x 2 500 H
35-ton 1 Inner dimensions: 2 500 W x 6 000 L x 2 500 H
Producer: Sankin Sangiyo - Japan

» Two Automatic Gas Cutting Machines (made in Austria and USA). Maximum cutting thickness is 2 000 mm.

II.Heat treatment section with heat treatment capacity of 3 400 tons of rolls for cold rolling and 23 000 tons of large-scale rotary and frame details. The technological equipment in this section allows implementation of all types of heat treatment of rotary parts - mainly rolls for cold rolling, back up rolls, etc.

The principal heat treatment equipment includes:

» Horizontal Heat treatment Furnaces

100-ton 1 Inner dimensions:2 500 W x 14 000 L x 2 300 H
100-ton 1 Inner dimensions:4 000 W x 8 000 L x 2 800 H
90-ton 5 Inner dimensions:2 500 W x 9 000 L x 1 800 H
25-ton 3 Inner dimensions:1 000 W x 7 500 L x 1 000 H
15-ton 2 Inner dimensions: 1 200 W x 5 000 L x 1 300 H

» 30-ton Horizontal Resistance Furnace

Inner dimensions: 1 000 W x 5 000 L x 1 800 H

» Differential Rapid Heating Furnace, designed for differential quenching of back up rolls for hot and cold rolling with capacity up to 30 tons.

Components size:
Dia: 600 - 1 450 mm
Length: до 3 000 mm

» Dual Frequency Induction Hardening Installation for forgings with weight up to 13 tons.

Components size:
Rolls' dimensions: Barrel diameter: 200 - 900 mm
Total length: 7 000 mm

Producer: Kobe Steel - Japan

» Subzero Treatment Chamber

Inner dimensions: 900 W x 7 000 L x 1 000 H
Capacity: 13 ton
Coolant: liquid nitrogen
Operating temperature: minus 195,8 0C

Producer: Kobe Steel - Japan

» Surface Layer Quenching Machine (mist, water, air type)

Capacity: 90 ton
Maximum length of processed forging: 6 000 mm
Maximum barrel diameter: 3 000 mm

» Surface Layer Quenching Machine (mist, water, air type)

Capacity: 13 тона
Maximum length of processed forging: 6 000 mm
Maximum barrel diameter: 3 000 mm

» Oil Tempering Tanks, intended for tempering up to 150 C
» 10-ton Vertical Heat Treatment Furnace
» 50-ton Vertical Heat Treatment Furnace
» Tough Quenching Oil Tanks
» Tough Quenching Water Tanks

All installations are equipped electronically and computerized for monitoring, control and recording of forging and heat treatment processes.

The Pattern shop is designed for processing of 6 000 m3 timber annually. It is intended for manufacturing of complex wooden patterns, timber drying processes, timber fumigation and preparation of wooden crating. Maximum diameter of working patterns can reach up to 8 000 mm.

The principal shop equipment comprises:

» Wood processing machines for preparation of wooden patterns - lathes, presses, milling and grinding machines.
» Timber Drying Chambers with length up to 8 000 mm.

» Spray Painting chambers for wooden patterns.
» Timber storage with total area of 50 000 m2 .
» Three-dimensional computerized pattern design system.

The Fettling shop is designed for finishing of the castings. Final treatment of castings covers removal of the gating system and the risers and repair of the casting defects. Final cleaning of the castings in Shot Blasting chamber and heat treatment for stress relief are accomplished there.

Precise dimension laying-out of the castings prior to machining is carried out. Non-destructive control, including Ultrasonic examination, Magnetic particle test, and Dye penetration examination is being carried out after rough (initial or intermediate) machining by means of modern equipment.

The principal equipment embraces:

» 4 Shot Blasting chambers of 30-tons, 60-tons and 150-tons capacity with maximum dimensions of 9 000 W x 9 000 L x 7 000 H.

» 11 Heat Treatment Furnaces of 50-tons, 80-tons, 150-tons and 250-tons capacity with maximum dimensions of 9 000 W x 13 000 L x 4 000 H. The computerised combustion control ensures achieving of high temperature homogenity within the furnace space, thus guaranteeing precise implementation of thermal conditions.
» Different tools for exterior cleaning and removal of uneven particles from the non-machineable casting surfaces.

The Steel Production Shop is designed for the production of 150 000 tons of liquid steel per year. The main technological equipment covers:

» Three electric arc furnaces of 15-tons, 25-tons and 60-tons capacity (designed and manufactured by "BBC", Switzerland) for production of liquid steel from scrap by means of powerful electric arc. The furnaces are equipped with voltage transformers of 20 000 volts, while electric arc is being ignited by means of carbon electrodes.

» Vacuum installation for post furnace vacuum treatment of steel (made by "Standard Messo", Germany) used for treatment of liquid steel under high vacuum. Structurally the installation comprises:
         VAD installation of 12 to 70-tons capacity, designed for production of forging ingots.
         VOD installation of 25 to 70-tons capacity, designed for production of high alloyed and stainless steel.

» Vacuum tanks of 80-tons capacity, used for ingot casting under high vacuum

» Teeming ladles of 15-tons, 25-tons and 60-tons capacity, used for transportation of liquid metal from electric arc furnaces to its pouring location.

75 000 tons of forging ingots with unit weight of up to 80 tons can be produced at the shop per year.

An Electro Slag Remelting Installation, designed for production of ingots up to 25 tons, is being assembled and put into operation, with a start up date end of December 2008.

The Steel Foundry is designed for annual production of 25 000 tons of castings with unit weight from 4 to 120 tons. The moulding mixtures, used in the moulding process, are self-hardening on the basis of quartz sand, water glass and catalyst, or quartz sand, furan resin and catalyst. Casting moulds are implemented by means of chromite sand at the contact points between liquid steel and casting mould, as well as at the thermal spots, in order to reduce the mechanical and chemical blind scab. The regulation of heat balances is achieved through the use of exothermic and insulating materials

The principal technological equipment comprises:

» Automatic Moulding Line for castings of 3 to 5 tons weight with annual production of 11 000 tons.
» Casting pits for castings of 20 to 50 tons and 50 to 120 tons weight with annual production of 14 000 tons.
» Core-making equipment, designed for manufacturing of cores with volume of up to 1000 dm3.
» Knock-out grids, used for rough cleaning of the castings from moulding sand residues.
» Mixers for mechanical preparation of moulding sand mixtures.
» Mobile and stationary feeders, intended for mechanical feed of moulding sand.
» Casting control and design by Magma software as well as our vast gained operational experience.

The Scrap yard's purpose is the preparation of charge through sorting the scrap by size and type of steel, crushing it to smaller pieces, filling of the scrap bucket and its transportation to the Steel production shop.

The shop equipment includes:

» Briquetting press (made by "Arnold", Austria), designed for chips sealing.
» Shears (made by "Tesuka", Japan), designed for scrap and sheet metal cutting.
» Gas-cutting machines, designed for gas-cutting of solid metal details up to 2200 mm thick.
» Weighing machines with capacity of 15, 25 and 60 tons capacity, for weighing of scrap prior to its transportation to the Steel production shop.
» Haulage trucks of (load capacity 30 tons), running on rails, connecting the plant's sections.
» Trucks (load capacity 15 tons, 25 tons and 60 tons) running on rails, for transportation of scrap buckets to the Steel production shop.

"Casting Forging Machinery Complex" LTD is an enterprise having at its disposal and commanding high-tech equipment, designed for manufacture of large-scale castings and forgings. The production cycle is implemented under Know-How and technology of Kobe Steel Ltd., considerably improved by the knowledge and solid work experience of the company's personnel.

Company products are well received in all parts of the world - Europe, America, Asia, Australia. The production is directed to structure-defining economic branches, such as Power engineering, Shipbuilding, Cement and Chemical Industry, Mining Industry, Heavy Investment Machinery, Ferrous and Non-ferrous Metal Industries, Nuclear/Conventional Energy Sector and specific military equipment.

Our main partners are Wartsila Propulsion B.V.(Holland); Wartsila Propulsion (Norway AS); Metso Minerals Industries Inc.(USA); Corus (UK); British Steel (UK); Thyssen Krupp (Germany); Steinhoff GmbH (Germany); Xtek,Inc.(USA); U.S. Steel; Rolls Royce Marine (Norway, Scotland, Poland); Mittal Steel; Akers Specialty Rolls (France); Gontermann-Peipers Ltd.(India); Mariner Ship's Equipment (Turkey) Gurdesan (Turkey); Severstal N.A., as well as certain programs implemented by Defence Ministries of different European countries.

The establishment of "Radomir Metal Industries" JSC was initiated and realized by the Government of Republic of Bulgaria from 1976 to 1986. Since 1999, as a result of a privatization contract, "Radomir Metal Industries" JSC it became a private joint-stock company with 100 % private ownership. The overall investment for this plant has been 1.5 billion US dollars.

In the years the company has been existing under different names: "Heavy Machinery", "Radomir-Metal", "Radomir - LEKO KO", "Radomir Metals", "Radomir Metal Industries" and presently "Casting Forging Machinery Complex" LTD.

During its more than 20-years period of existence, the company has developed the nomenclature of its products. The technological equipment has been maintained at high technological level. Investments of 20 million EUR have been made in buildings, procurement of new machines and production equipment and installations, and modernization/updating of the available existing equipment.

The company's engineering and technical potential and expertise are extremely high. Most of the engineers have more than 15-years service with the company, which presently endeavors for practical training of new employees during the production processes.

The main trends of our engineering activities comprise the fields of metallurgy, plastic deformation, heat treatment, machining and electrical equipment.

Our personnel have solid experience in the fields of steel making, steel casting, forging and heat treatment.

Technologically the company's activities are implemented in two main directions:

» Machined forgings
» Machined castings

Structurally the company comprises:

» Scrap yard

» Steel production shop
» Steel foundry
» Fettling shop
» Pattern shop
» Forging and Heat treatment shop
» Machining shops
» Laboratory facilities

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