2017 zts-m portfolio eng v043ztsmetalurg.sk/data/filecache/a4/2017_zts-m_portfolio_eng_v043.pdf ·...

ZTS METALURG, a. s.

ZTS METALURG, a.s. Továrenská 56, 018 41 Dubnica nad Váhom IČO: 46 933 913, DIČ: 2023661684

IČ DPH: SK2023661684

Bankové spojenie/Bank connection: UniCredit Bank Czech Republic and Slovakia, a.s., Pobočka zahraničnej banky, Šancová 1/A, 813 33 Bratislava, účet/account: 1040123018, kód banky/bank code: 1111 IBAN SK24 1111 0000 0010 4012 3018, BIC (SWIFT) UNCRSKBX

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THE CONTENT: THE CONTENT:..................................................................................................................................2 1. PROFILE OF THE COMPANY ZTS METALURG, A.S. .................................................3 2. DIE FORGINGS ...........................................................................................................................4 3. FREE FORGINGS ..................................................................................................................... 15 4. INGOTS AND CASTINGS ...................................................................................................... 18 5. ROUGH MACHINING .............................................................................................................. 25 6. HEAT TREATMENT ................................................................................................................. 26 7. ACCREDITED LABORATORY ............................................................................................ 27 8. ANNOUNCEMENTS THE ADMINISTRATOR AND THE NEW OWNER ............... 30 9. CERTIFICATION ....................................................................................................................... 34 10. REFERENCES ........................................................................................................................... 38


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1. PROFILE OF THE COMPANY ZTS METALURG, a.s.

After a long period of 15 months, our company 1st November 2015 found itself on the threshold of a new stage and therefore we would like to express the belief that we are ready to continue our cooperation with you even with a higher level of effectiveness.

We firmly believe that in doing it so, not only the fact that we have just finished a difficult period in which you cooperated with us during the bankruptcy for what belongs to you our great thanks, but also a fact that we are owned by two strong and stable groups of companies that have in their portfolio several reputable companies:

Belonging to the aforementioned groups not only enjoying and stabilizes us, but above all undertake us to work so that we could feel the as an equal member of the such a significant groups of know-how, property and human potential.

Dear business partners we are convinced that you will keep us your favour in the following period of time and our company will shortly become your new stable and reliable partner with a new name and logo of the company that will better reflect our experience and tradition of what we produce. Of course, you will be updated shortly when these changes are done.


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2. DIE FORGINGS - WHEELS - HOOPS - CLAMPING RING - JOINTS FOR FREIGHT WAGONS - BODY OF TOP PIN - THE HUB FOR THE AXLES - GEAR SHAFTS - FLANGES

Die forging: counter rotating hammer UHG1 and UHG2. Heat up semi product: rotary heart furnace ø3200 mm. Semi product preparation before forging: press CKZ 1600B. Handling with semi product: manipulator Dango Dienenthal. Weight forgings: 35 up to 450 kg. The maximum diameter of forging: 750 mm Max. area forging: approx. 4 400 cm2 Design possibilities of forgings: with sandblasted or rough machined Material forgings: common steel grades 11, 12, 13, 14, 15, 16 Monthly production: 300t forgings

Forging shop has set annealing furnaces. Cutting workshop ensures material cutting circular saw Wagner WHC 1000A. Preparation of forgings for the expedition takes place at the expedition’s workshop. Sandblasting of forgings, finishing and then packing according to customer requirements.

1 Peak load 2 Max. a saw blade 3 Max. diameter of the bar

Device type pcs Dimension Max.

temperature °C

Semi product

weight kg Batch

weight t Gas Carousel Furnace 1 Ø 3 200 1 300 6 Swage hammer machines UHG 40mt 2 140 000 kp.m 250 50 - 500 Manipulator Dango Dienenthal 1 500 Press CKZ 1600B 1 Cart Type Electric Furnace CAN (Die Heating) 1 10 Annealing Furnace No.14 Gas 1 6x2,8x1,5 900 °C 50 Annealing Furnace No.15 Gas 1 6x2,8x1,5 900 °C 50 Annealing Furnace No.16 Gas 1 10x2,8x1,5 900 °C 60 Annealing Furnace No.17 Gas 1 11,5x2,9x2,2 900 °C 80 Annealing Furnace No.19 Gas 1 8,5x2,8x1,5 900 °C 80 Annealing Furnace No.20 Gas 1 8,5x2,8x1,5 900 °C 80 Annealing Furnace No.21 Gas 1 1000x8x1002 330 mm3 Saw Wagner WHC 1000A 2 Band Blasting Drum PTB5


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Visualization of the selected die (dropped) forgings:

Hmotnosť výkovku: 186 kg Rozmer výkovku: 480x280x100

Hmotnosť výkovku: 78 kg Rozmer výkovku: Ø 536,5 x 221

Hmotnosť výkovku: 151 kg Rozmer výkovku: 800x340x145



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Hmotnosť výkovku: 265 kg Rozmer výkovku: Ø 651 x 210





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Hmotnosť výkovku: 270 kg Rozmer výkovku: Ø 612 x 179,5





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Hmotnosť výkovku: 88,5 kg Rozmer výkovku: Ø 477 x 159


Hmotnosť výkovku: 216 kg Rozmer výkovku: Ø 719,5 x 112,5


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Hmotnosť výkovku: 29,7 kg Rozmer výkovku: Ø 476 x 58,4



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3. FREE FORGINGS - FITTINGS - SHAFTS AND COUPLINGS - HOLLOW SHAFTS - ROLLS - TOOL BLOCKS - RINGS, WHEELS AND WHEEL BANDS - SWAGES

Free forging forging presses CKV 2650 t and CKV 1000 t Heating and preheating of semi-product two 60 t gas reheating furnaces Manipulation with semi-product manipulators 20 t and 7,5 t Weight of forged pieces from 100 to 10 000 kg Forged piece maximum diameter bars up to 600 (980) mm, plates up to 1300

mm, rings up to 1500 mm Forged piece maximum length 4500 mm (lengths 2-4 m), 9500 mm (3-5 m) Flat bars length-to-width ratio 1:6 Options of forged pieces with sandblasted or roughed surface Material of forged pieces steel of grades 11, 12, 13, 14, 15, 16, 19 Monthly production 650t of forged pieces

Forging shop handles a set of annealing furnaces. Preparation of forged pieces for expedition takes place in manufactory – expedition of forging shop. Sandblasting of forged pieces, dressing and packaging according customers’ requirements.

Machinery type Pcs Size Max. temperatur

e °C Semi-

product weight kg

Batch weight t

Forging press CKV 2650 t 1 2650 t 20 t Forging press CKV 1000 t 1 1000 t 7,5 t Manipulator Škoda 1 20 t Manipulator Škoda 1 7,5 t Car-hearth furnace 2 3x6,5 mm 1350 °C 60 t Annealing gass furnace nr.14 1 6x2,8x1,5 900 °C 50 Annealing gass furnace nr.15 1 6x2,8x1,5 900 °C 50 Annealing gass furnace nr.16 1 10x2,8x1,5 900 °C 60 Annealing gass furnace nr.17 1 11,5x2,9x2,2 900 °C 80 Annealing gass furnace nr.19 1 8,5x2,8x1,5 900 °C 80 Annealing gass furnace nr.20 1 8,5x2,8x1,5 900 °C 80


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Basic assortment of steel free forgings (round and flat bars, blocks) STN DIN Ø mm □ mm wheel mm ring mm flat bar - width

11500 St 50-2 560 500 1300 1500 1200 11523 St 52-3 560 500 1300 1500 1200 11558 560 500 1300 1500 1200 11600 St 50-2 560 500 1300 1500 1200 11700 St 70-2 500 450 1300 1500 1200 12020 Ck 15 560 500 1300 1500 1200 12030 560 500 1300 1500 1200 12040 Ck 35 560 500 1300 1500 1200 12050 Ck 45 560 500 1300 1500 1200 12060 Ck 55 560 500 1300 1500 1200 13123 20Mn5 560 500 1300 1500 1200 14109 100Cr6 400 350 700 1500 700 14140 41Cr4 500 450 1300 1500 1000 14209 100CrMn6 400 350 700 1500 700 14220 16MnCr5 560 500 1300 1500 1200 14260 67SiCr5 450 400 1300 1500 1000 14331 450 400 1300 1500 1000 14341 450 400 1300 1500 1000 15110 480 420 1300 1500 1000 15128 480 420 1300 1500 1000 15130 25CrMo4 480 420 1300 1500 1000 15142 42CrMo4 480 420 1300 1500 1000 15230 480 420 1300 1500 800 15231 27MnCrV4 480 420 1300 1500 800 15235 24CrMo5 480 420 1300 1500 800 15240 480 420 1300 1500 800 15260 50CrV5 400 350 1000 1500 700 15261 58CrV4 400 350 1000 1500 700 15330 30CrMnV9 400 350 1000 1500 700 16220 15CrNi6 560 500 1300 1500 1200 16240 36NiCr6 560 500 1300 1500 1200 16341 36CrNiMo4 450 400 1000 1500 900 16342 450 400 1000 1500 900 16343 34CrNiMo6 450 400 1000 1500 900 16420 14NiCr14 500 450 1300 1500 1200 16440 31NiCr14 480 420 1300 1500 1200 16520 14NiCr18 480 420 1300 1500 1000 16640 35NiCr18 480 420 1300 1500 1000 16720 450 420 1000 1500 800 17021 X10Cr13 360 320 600 400 17023 360 320 600 400 17027 X8Cr17 360 320 600 600 17029 X40Cr13 360 320 600 400 17041 X8Cr17 360 320 600 400 17102 X10CrSi6 360 320 600 500 17246 X10CrNiTi86 360 320 500 500 17347 X10CrNiMoTi1

812 360 320 500 500 19083 C 45 560 500 1300 1500 1200 19133 C70W2 450 400 1000 1500 1000 19152 C85W2 420 380 1000 1500 1000 19191 C100W2 420 380 1000 1500 1000 19312 90MnV8 420 380 1000 1000 800 19426 420 380 1000 1300 800 19434 X20Cr13 350 300 600 600 19452 420 380 1000-1300 800 19486 560 500 1300-1500 1200 19552 X37CrMo51 350 300 600 600 19554 X40CrMo51 350 300 600 600 19642 35NiCrMo16 560 500 1300 1500 1000 19650 560 500 1300 1500 1000 19662 55NiCrMoV6 560 500 1300 1500 1000 19663 56NiCrMoV7 560 500 1300 1500 1000 19732 45WCrV7 320 280 600 1000 500


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4. INGOTS AND CASTINGS Liquid metal EAF with a capacity of 9, 17, 24 tons. The subsequent refining by Argon and shooting of stuffed profil CaSi

and Al wire Shaping semi-automatic kneaders, technology Alfaset Mass from 70 up to 16 000 kg . Dimensions into standardized frames 3,5x4 m, or to the

special frames according to the agreement, The design of the castings the thickness of the walls min. 12 – 14 mm in casting up to 1 000 kg min. 18 mm The possibility of drawing up of castings the degree of accuracy STN EN ISO 8062-3

DCTG 12, with sanded or rough surface and heat treatments according to the requirements of the client standard annealing without rough

machining standard annealing with rough machining annealing without rough machining annealing with rough machining soluble annealing (manganese steel) all castings are sanded and sanded before expedition

Material construction, mid alloyed and manganese steel

Acceptance STN EN ISO 8062-3 DCTG 12, STN EN 1559-1-2, VK STN EN 1370 VC 3, MT the test for cracks by STN EN 1369, Ultra Sound test according to the STN EN 12680-1 - just on the rough machined surfaces Monthly production 200 t

Type of device Basic technical parameters Pcs.

EAF 9 t 4 000 kW, melting performance 1,33 t/hrs. 1 EAF 17 t 5 500 kW, melting performance 2,72 t/hrs. 1 EAF 24 t 5 500 kW, melting performance 2,72 t/hrs. 1 Mixing arm Wehr 24 t/hrs. 2 Hanging sanding establishment HP 20 x 26 3TR - 2ST + SF08 - 2 x 2000 kg MS 1 Hanging sanding establishment HP 20 x 26 3TR - 2ST + SF08 - 2 x 1000 kg 1 Selected examples of produced castings: BRAKE DISCS TOOTHED RIM FOR ENGINES BEARING CHAMBERS UKR FREIGHT RAIL CHASSIS TYPE 70.20 - FRAME UKR FREIGHT RAIL CHASSIS TYPE 70.20 - CROSS MEMBER


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Offered ingots: Ingot - type Total weight Head weight Net weight Height Upper diameter

(D1) Lower diameter (D3)

J 2,8 2 400 kg 360 kg 2040 1500 mm 580 mm 480 mm J 4,7 4 300 kg 150 kg 4150 1480 mm 690 mm 570 mm J 5 5 800 kg 900 kg 4900 1535 mm 745 mm 620 mm

J 6,5 6 200 kg 790 kg 5410 1560 mm 785 mm 650 mm 8 K 8.4 7 600 kg 800 kg 6800 1630 mm 820 mm 974 mm

8 K 13.0 11 700 kg 1000 kg 10700 1845 mm 974 mm 1144 mm


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Hmotnosť výkovku: 1 570 kg Rozmer výkovku: Ø 1 500 x 1 400 42 4650.5

Hmotnosť výkovku: 1 570 kg Rozmer výkovku: Ø 1 500 x 1 400 42 4650.5

Hmotnosť výkovku: 1 184 kg Rozmer výkovku: Ø 1 200 x 830


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Hmotnosť výkovku: 315 kg Rozmer výkovku: Ø 1180 x 890 Rozmer výkovku: GS20Mn5

Hmotnosť výkovku: 315 kg Rozmer výkovku: Ø 1180 x 890 GS20Mn5

Hmotnosť výkovku: 1 200 kg Rozmer výkovku: 1 150 x 855 GS42CrMo4V

Hmotnosť výkovku: 16 140 kg Rozmer výkovku: Kokilová liatia


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Hmotnosť výkovku: 850 kg Rozmer výkovku: 1 090 x 790


Hmotnosť výkovku: 5 280 kg Rozmer výkovku: 42 2650.5


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5. ROUGH MACHINING

TURNING LATHES type of machine

Basic technical parameters D over bed / D over cross slide x length

Number of machines

SUR 260 Ø 550 / 300 x 3 000 1 SUR 350 Ø 740 / 440 x 2 000 1 SU 80A Ø 800 / 495 x 6 000 1

SUI RP80 Ø 800 / 530 x 4 000 1 SUR 350 Ø 740 / 440 x 8 000 1 SU 100 Ø 1000 / 530 x 10 000 1

SRM 100 Ø 1000 / 670 x 2 000 1 SRM 100 Ø 1000 / 700 x 5 000 1 SR 1000 Ø 1000 / 710 x 3 000 1 SR1000 Ø 1000 / 710 x 4 000 1

SUA 100P Ø 1000 / 660 x 11 000 1 maximum turning diameter over slide rest lathe 940 mm maximum turning length piece 10 000 mm maximum weight turning piece 9 000 kg

DEEP DRILLS STOOL type of machine

Basic technical parameters the hole x length mm

Number of machines

VHR 500 D 50 - 105 x 3 000 1 VHR 500 D 70 - 150 x 6 800 1 VHR 500 D 70 - 105 x 10 000 1 VHR 500 D 50 - 490 x 10 000 1

minimum drilled hole 45 mm maximum drilled hole 490 mm minimal length of the drilled piece 800 mm maximum length of the drilled piece 10 000 mm maximum outer D piece drilled in the bezel 750 mm maximum outer D drilled piece over bed 1000 mm minimal outer D piece drilled in the bezel 105 mm maximum weight of drilled piece10 000 kg tolerance of turned D and drilled holes according ISO 2768-C,treatment of turned D and drilled holes to Ra = 6,3 - 12,5 with the possibility ofa bad track after drilling tools VERTICAL LATHE /boring mill/ -

type of machine Maximum dimensions processing

Ø x height mm Max.

weight kg Number of machines

SK 12 D 1 200 x 1000 4 000 3 Rafamet D 2 000 x 1200 10 000 1

DKZ 2000 D 2 000 x 1000 10 000 1

CUTTERS Type of machine

Maximum dimensions processing Ø x height mm

Max. weight kg

Number of machines

Cutter portal FRA P10 1 000 x 875 x 4 000 4 000 1 Cutter portal FP 20 1 700 x 1 400 x 4 000 10 000 1

Horizontal cutter Type of machine

Maximum dimensions processing Ø x height mm

Max. weight kg

Number of machines

BFT 125/III 2 200 x 1 500 x 2 200 10 000 1 WHN 13,8A 2 200 x 1 500 x 2 200 10 000 1


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6. HEAT TREATMENT Heat treatment is carried out on the technological equipment without protective atmosphere, processing semi-finished products, manufactured and provides external cooperation. Set of car-type furnace with gas and electric heating to 1050°C. Cooling media oil, water, polymer, air

Type pcs Length Width Height Batch weight kg

Max. temperature °C

Hearth gas furnace 2 4 750 1 900 850 10 000 1 050 Electric hearth furnace CAN 1 4 750 2 350 1550 14 000 1 050 Electric hearth furnace CAN 1 4 750 2 350 1550 14 000 750 Electric hearth furnace CAN 2 2 350 1 350 1000 7 000 1 050 Electric hearth furnace RDO 1 4 000 2 200 1200 14 000 700 Furnaces ensure practically all types of annealing procedures and ways of refining the various media of cooling and are equipped with automatic control and recording thermal regime. Set deep furnace electrically heated to 950°C Cooling media oil, water, air

Type pcs Length Width Height Batch weight kg Max. temperature °C

Deep furnace HSR 2 - ø 950 10 000 8 000 950 Deep furnace HSR 7 - ø 950 8 000 8 000 950 Deep furnace HSR 5 - ø 950 6 000 8 000 950

Furnaces ensure practically all types of annealing procedures and ways of refining the various media of cooling and are equipped with automatic control and recording thermal regime. Straightening presses max. the possibility of using working pressure

max.1000 t, straightening forgings, rod shaped special components.

Testing and measurement technology hardness measurement according Brinell, Rockwell, Vickers


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7. ACCREDITED LABORATORY


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Metallographic tests Kind of test Standard A

Preparation of scratch pattern - special IP ZTS-SKL-10-06/16 Preparation of scratch pattern - classic IP ZTS -SKL-10-06/15 Etching of the sample - classic IP ZTS -SKL-10-06/15 Etching of the sample - special IP ZTS -SKL-10-06/15 Micropurity M - method DIN 50 602 Micropurity K4 - method DIN 50 602 Micropurity K3 - method DIN 50 602 Micropurity K0 - method DIN 50 602 Micropurity - method A ASTM E 45 – 87 A A The evaluation of the microstructure Literature by type of material and TS, SEP 1520 Distribution of sulphur in steel - (Baumann printing) ASTM E1180 A Check of macrostructure by deep etching STN 42 0467 The thickness of the layers after the PÚ STN EN ISO 1463 Depth of decarburization ASTM E1077, STN EN ISO 3887 Evaluation of cast iron - graphite STN 42 0461 Evaluation of cast iron - microstructure STN 42 0461 Evaluation of cast iron - cementite STN 42 0461 Evaluation of cast iron - phosphorus STN 42 0461 Digital photographic document - original Determination of grain size ASTM E 112 (method 10), ČSN EN ISO 643 (method 5a),

GOST 5639-82 (method 3.3) A

Mechanical tests Kind of test Standard A

Pulling test complete, smooth head up to 900M Pa (from 900 up to 1500 MPa) with the production of the test sample

STN EN ISO 6892-1 B10 GOST 1497-84 A Pulling test complete, die heads up to 900 MPa (from 900 up to 1500 MPa) with the production of the test sample

STN EN ISO 6892-1 B10, GOST 1497-84 A The determination of the Ru, Rpx, Fragility test – Rod finished by milling STN EN ISO 7438, Welds: STN EN ISO

5173 A

Impact bending test - normal temperature without the production of the test sample

STN EN ISO 148-1, GOST 9454-78 A Impact bending test - normal temperature with the production of the test sample STN EN ISO 148-1, GOST 9454-78 A Impact bending test - normal temperature with the production of the test sample (3 pcs.)

STN EN ISO 148-1, GOST 9454-78 A Impact bending test - other temperature without the production of the test sample STN EN ISO 148-1, GOST 9454-78 A Impact bending test - other temperature with the production of the test sample STN EN ISO 148-1, GOST 9454-78 A Impact bending test - other temperature witht the production of the test sample (3 pc.)

STN EN ISO 148-1, GOST 9454-78 A Hardness test Brinell - 1 puncture STN EN ISO 6506-1 Hardness test Rockwell - 1 puncture STN EN ISO 6508-1 Hardness test Vickers - 1 puncture STN EN ISO 6507-1, Welds: STN EN ISO

9015-1 Hardness progressions - 3 punctures See standards above Evaluation of fracture STN EN ISO 148-1 Testing of characteristics: spring coil According to the standards of the

customer Pulling test complete, flat rod up to thickness 5 mm STN EN ISO 6892-1 B10, GOST 1497-84 A Pulling test complete, flat rod over thickness 5 mm STN EN ISO 6892-1 B10, GOST 1497-84 A Strength in shear test STN 42 0342 Pulling test without production of test sample STN EN ISO 6892-1 B10, GOST 1497-84 A Measurement of the characteristics of the springs: barrel spring - before fire According to the standards of the

customer Measurement of the characteristics of the springs: arrel spring - after fire According to the standards of the

customer Measurement of the characteristics of the springs: Return spring - after fire According to the standards of the

customer


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Corrosion tests Kind of test Standard A

Separate tests of corrosion preservative goods - Corrosive test in condensing chamber -24 hrs. (continuous) - Corrosive test in condensing chamber - 21 cycles, 30 cycles (cyclic)

STN EN ISO 6270-2 STN EN ISO 6270-2

- Corrosive test in salt spray - 8 hrs. - Corrosive test in salt spray - 76 hrs., 96 hrs. STN EN ISO 9227 NSS STN EN ISO 9227 NSS A

Cyclic corrosive test VDA 621- 415, PV 1210, STN EN ISO 11997-1, corporate specifications Analysis of the operating media (AquaQuench) - viscosity, determination of concentration by refractometer, pH

(only for the use of ZTS METALURG) Analysis of cooling emulsions: - Corrosive test, determination of the concentration of

emulsions, pH (only for the use of ZTS METALURG)

Analysis of operating oils Hardening oils - appearance, viscosity, water content (only for the use of ZTS METALURG)

Chemical tests Kind of test Standard A

Chemical analysis of steel of solid samples by optical emission spectrometry method (OES) with the analyser Spektromax LMX 06

IP ZTS- SKL-10-23/16


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8. ANNOUNCEMENTS THE ADMINISTRATOR AND THE NEW OWNER


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9. CERTIFICATION


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10. REFERENCES


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BMZ a.s. castings BONATRANS GROUP, a.s. die forgings CARBIDE MORAVA s.r.o. free forgings DDO, s.r.o. tests and small jobs DEL a.s. castings DEL CASTING, a.s. thermal treatment DSP Přerov, spol. s r.o. castings EUROATEM, spol. s r.o. machining EVPÚ a.s. laboratory FIMAD, s.r.o. machining and thermal treatment HORIMEX s.r.o. thermal treatment HORNONITRIANSKE BANE castings JAMP SVORADA s.r.o. thermal treatment KARL GEORG GmbH die forgings KBZ s.r.o. castings KINEX BEARINGS, a.s. machining KOVAL SYSTEMS, a.s. machining LESEFT INTERNATIONAL s.r.o. die forgings Liebherr-Components Biberach die forgings LKT s.r.o. castings MATADOR Industries, a.s. thermal treatment MESTRA plus s.r.o. machining Metalflex, s.r.o. machining METALURGIA TS plus, s.r.o. machining and thermal treatment MEXA,s.r.o. die forgings PROFEX Dca spol. s r.o. machining and thermal treatment První brněnská strojírna machining and thermal treatment PW s.r.o machining and thermal treatment REZMAT s.r.o. laboratory SACMI IMOLA S.C. castings STM POWER a.s. machining and thermal treatment ŠKODA MACHINE TOOL a.s. machining and thermal treatment ŠKODA TRANSPORTATION a.s. free forgings Šmeral Brno a.s. castings and free forgings Tatravagónka a.s. Poprad die forgings TPV-TECHNOLOGY s.r.o. laboratory TRADE-DAM,s.r.o. laboratory TREVA s.r.o. die forgings Vítkovické slévárny, a.s. castings WAY INDUSTRIES a.s. die forgings ZLH PLUS, a.s. machining and thermal treatment ZTS-ŠPECIÁL, a.s. machining and thermal treatment ZVS IMPEX, akciová spoločnosť castings and free forgings

2017 zts-m portfolio eng v043ztsmetalurg.sk/data/filecache/a4/2017_zts-m_portfolio_eng_v043.pdf ·...

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