Foundry

Specialised in the static casting of carbon steels, stainless steel and high-grade steels, Fonderia Augusta is able to satisfy the needs of each client with efficiency and flexibility, thanks to a rational production process and cutting-edge equipment and machinery. Thanks to investments in Industry 4.0 the machinery is connected to the Manufacturing Execution System and managed and monitored directly by the ERP, a system implemented in 2009.

Production cycle

Pattern preparation

We entrust the construction of new patterns and the modification of existing ones to selected, reliable suppliers. For steel castings, clients can choose from patterns made of wood (the most common), resin, aluminium, polystyrene or with prototyping, obtaining the right balance of quality and price. There are two pattern warehouses in the plant: a mobile racking system installed in 2016, and a static warehouse for smaller patterns. Currently, the two warehouses contain a total of more than 5,000 client patterns.

Core making

Fonderia Augusta is equipped to make cores with both shell-moulding and cold box processes. According to geometric characteristics, cores are made from silica sand, chromite sand, zirconium sand or CERABEADS®.

Moulding

Moulding is carried out on two lines - one semi-automatic and one manual - with 6 and 15 ton/h mixers. Manual moulding allows flasks of up to 2300 x 2300 mm, 3000 x 1500 mm and 850 x 3200 mm to be used, while semi-automatic moulding is applicable to flasks of up to 800 x 800 mm. The use of sodium silicate as a binder allows for better quality carbon steel castings and no surface contamination of low-carbon materials, ensuring reduced environmental impact and protection of workers’ health.

Mould assembly and storing

The assembly stage involves cores positioning and moulds closing. This stage ends with the automated storage of the moulds in an underground deposit able to hold over 500 units.

Pouring and cooling

The moulds are brought to the surface via the Manufacturing Execution System and arranged on the pouring line. The laboratory processes the chemical analysis of the heat, verifies it, and the operators proceed with pouring. Fonderia Augusta uses 4 medium-frequency induction furnaces with a capacity ranging from 200 to 2,500 kg, for a total of 7,500 kg of molten metal. The induction furnaces and casting line are equipped with a fume extraction system.

After casting, an automated handling line moves the moulds to the underground storage and cooling plant, which is also equipped with a suction system.

Shakeout

After cooling, the company management system activates moulds movement, bringing them to the surface for the shakeout process. The castings are then shot-blasted and moved to the finishing department for feeders removal, grinding and a second shot-blasting.

Heat treatment

The heat treatment of the castings is carried out in accordance with sector standards and client specifications. Fonderia Augusta has one Norsok certified heat treatment furnace with a capacity up to 6,000 kg and a maximum temperature of 1260°C.

Finishing

Fonderia Augusta has designed 6 sound-proofed finishing booths equipped with high-frequency tools. Fonderia Augusta uses welding processes that are qualified according to ASME BPVC Sect. IX, EN ISO 15614, EN ISO 11970 standards and employs welders who are qualified according to the requirements of ASME BPVC Sect. IX, EN 287-1 and EN ISO 9606-1.

Tests and inspections

Fonderia Augusta performs non-destructive tests in several platforms specifically equipped for Magnetic tests, Penetrant tests, Hydraulic tests and Ultrasonic inspections. Fonderia Augusta workers are certified Level 2 in accordance with UNI EN ISO 9721 and ASNT SNT-TC1A Regulations for Non-Destructive Testing LP, MT and VT. The company also relies on selected laboratories for Radiographic checks, PMI and mechanical tests etc.

Machining

Fonderia Augusta relies on the collaboration of structured and certified machine shops, guaranteeing programmed delivery dates, excellent levels of quality and competitive prices. The range of mechanical processes includes rough machining, finishing, grinding / lapping. In addition to NDT, it is possible to request dimensional reports carried out with 3D-control instrumentation.

Our equipment

  • 2 hot box core shooter machines
  • 2 cold box core shooter machines
  • 4 electrical medium frequency induction furnaces with a capacity that goes from 200 kg to 2.5 Ton, totaling a maximum of 7.5 Tons of molten metal
  • 1 spectrometer for the chemical analysis of the heat
  • 1 semi-automatic moulding line with max flask size up to 800 x 800 mm with two mixers of 6 ton/h
  • 1 6 ton/h mixer for manual forming
  • 1 15 ton/h mixer for manual forming
  • 1 automatic mould handling and storing area with dust and fume suction system
  • 1 shake-out plant with vibrating sieve
  • 1 silica sand recovery system with separation of chromite sand
  • 1 shot-blasting machine
  • 1 sand-blasting machine for stainless steel
  • 2 sand-blasting machines for carbon steel
  • 1 sand-blasting machine for corundum sanding
  • 1 Norsok certified heat treatment furnace - maximum temperature 1,260°C and capacity up to 6,000 kg with 66 m³ tank for water quenching
  • 1 system for Liquid penetrant testing
  • 1 area for magnetic testing
  • 1 bench for hydraulic testing on the raw casings
  • 6 finishing cells equipped with high frequency power tools
  • 1 dust and fume suction and filtration system with filtering sleeves (suction flow rate: 200.000 m³/h)
  • 2 dust and fume suction and filtration system with filtering sleeves (suction flow rate: 30.000 m³/h)
  • 1 dust and fume suction scrubber (suction flow rate: 27.000 m³/h)
  • 1 mobile racking system for pattern storage
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