Pre-Machined Large OEM Fabrication Customized Alloy/Carbon Steel Marine Casting Upper/Lower Rudder Carrier Fore /After Stern Boss Casting for Shipbuilding
Product Description
The material is low carbon or alloy steel,such as ZG270-500,SCW420,SCW450,GS52
| Material | C | Si | Mn | P | S |
| ZG270-500 | 0.32-0.40 | 0.20-0.52 | 0.45-0.90 | ≤0.035 | ≤0.035 |
| Shipyard Name | Project | Item | Unit Weight | Flag/Class | Quantity | Year |
| Jiangsu New Yangzi Shipbuilding Co.,Ltd. | 2400TEU container vessel | FWD boss | 1.5 tons | DNV/NK | 5 | 2023 |
| AFT boss | 31.5 tons | 5 | ||||
| 1800TEU container vessel | FWD boss | 1.5ton | ABS/CCS/NK | 20 | ||
| AFT boss | 30 tons | 20 | ||||
| 59000DWT bulk carrier | fore stern casting | 2 tons | CCS | 2 | ||
| after stern casting | 14 tons | 2 | ||||
| Samsung Heavy Industries | 156800DWT Crude Oil Tanker | fore stern boss casting | 2.6 tons | ABS | 4 | |
| after stern boss casting | 24.7 tons | 4 | ||||
| Jiangsu Yangzi Xinfu Shipbuilding Co.,Ltd. | 11800TEU container vessel | fore stern boss casting | 8.2 tons | LR | 6 | |
| AFT stern boss casting | 66.8 tons | 6 | ||||
| Hudong Shipyard Group Co.,Ltd. | 24100TEU container vessel | fore stern boss casting | 11.8 tons | DNV | 4 | |
| AFT stern boss casting | 59.5 tons | 4 |
What we can supply?
We are located in Sunzhuang Town,Haian county,Nantong City,Jiangsu,China
When you visit us,we can pick up you from Shanghai Pudong airport.
It will be 2.5 hours from airport to our factory.
| Weight | 3-190 tons per piece |
| Machining | rough or finished machining(max.13m vertical lathe,12 sets milling and boring machine and so on) |
| Casting Tolerance | CT13 |
| Min. wall thickness | 50mm |
| Material | low carbon or alloy steel,OEM fabrication |
| UT and MT | Level 2 |
| Application | Cement mill,vertical mill,ball mill,dryer,shipbuilding,forging press,rolling mill,crusher,mining,gearbox |
| Class certificate | DNV,LR,ABS,CCS,BV,NK,RINA,KR |
1)Pattern making
We have our own wooden pattern making workshop.
But our company is always busy,
we also have around 10 sub-contractors for pattern making.
They help us for the pattern but will be inspected according to our rules.
We will record for every pattern inspection.
We have around 80 technicans for sand core making which is divided into around 10 teams.
Most of the technicans has more than 10 years' experience.
Most of the sand core is made by silica sand with common sand inside of it.
The common sand will be used repeatly.
For some important position,such as R corner,we will use chorme ore sand.
The outside of the sand core,we will do the painting,burn and clean it.
We will assemble diffrent sand cores together and wait for pouring.
3)Melting and Pouring
We always do the melting after mid-night for cheaper electric charge.
And we normally do pouring in the early morning.
| No. | Equipment Name | Quantity(Set) |
| 1 | 25 tons Electrical Arc Furnace | 1 |
| 2 | 50 tons Intermediate Frequency Furnace | 2 |
| 3 | 120 tons Refining Furnace | 1 |
| 4 | 120 tons VD Furnace | 2 |
4)Cooling
After pouring,we will wait for different time for cooling according to casting's weight.
| Item | Weight in blank(Metric Tons) | Cooling Time(Hour) |
| 1 | <25 | 48 |
| 2 | >25-40 | 72 |
| 3 | >40-55 | 96 |
| 4 | >55-72 | 120 |
| 5 | >72-96 | 144 |
| 6 | >96-115 | 168 |
| 7 | >115 | 192 |
We have our experience and rules for cooling time.
After cooling,we will shake the casting out of the steel boxes and clean them.
5)Heat Treatment
Normalizing will be 3 days while tempering is 4 days.
We have around 10 sets of heat treatment furnaces.
The biggest one is 12m*9m*6m.
It is also the biggest size of castings we can make.
After heat treatment,we will do the mechanical property test.
Our ordinary test block's size is 230mm*70mm*50mm.
One casting part will min. have 3 pcs test blocks.
We have our testing center and it is approved by CNAS.
6)Draw the line and do the first rough machining
We can do the machining from rough to finished machining.
7)NDT after rough machining
8)Welding repair
We have rich experience for making support rollers and kiln tyres,
then there is no welding for the outside working position.
This is our special technology.
Every year we supply around 400pcs kiln tyres,930pcs support roller,170 sets gear( in two halves).
But for some other castings,if we do the welding repair,
we will do the tempering for stress relief later.
All of our welders have the SGS certficate.
9)Shot blasting and grinding
We have a robert grinder.
We have a 120 tons rotary shot blasting table.
10)Final machining
We have a lot of vertical lathes from 2.5m to 10m.
We get approval from CNAS for our laboratory.
We also have 9 class certificate,such as ABS,DNV,NK,RINA,KR,CCS,BV and so on.
We supply a lot of castings for cement mill,rolling mill,shipbuilding and so on.
We can do the packing according to our rules or according to customers' requirement.
Normally there is a 12 months quality warantty.
We do at least three times NDT:after rough,semi-finished and finished machining.
And also the customer will do the witness during or after finished machining.
If there is also any problem when you receive the castings,
please send us photos and detailed defects,
we will negotiate with you and make a compensation.
A third party inspection before shipment is welcomed.
Sand Casting
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