Regarding the aims of heavy components casting and forging factory establishment project, there are various manufacturing and ancillary sectors in original design such as melting and casting (steel, cast iron and Nonferrous alloys), melting and ingot, forging (open and closed cast), machining, heat treatment and finishing products. But In the next revisions, regarding Management and Planning Organization’s opinion, the entire project reduced to radial forging, heavy pressing, melting and casting, machining and heat treatment.
Radial Forging Workshop
This workshop is designed to supply particular products with high quality and mechanical properties. An important advantage of radial forging process is the ability to work in low tolerances and therefore is more efficient In the case of Particular steels and super alloys.
The main equipment of this workshop is:
_ Radial Forging Machine SXP-65, the maximum diameter of the client: 650 mm, made in GFM construction companies, Austria
_ Radial Forging Machine SXP-25, the maximum diameter of the client: 250 mm, made in GFM construction companies, Austria
_ Radial Forging Machine SXP-13, the maximum diameter of the client: 130 mm, made in GFM construction companies, Austria
_ 5 units of Forging & Forming furnace
_ 5 units of heat treatment furnace
_ Transport equipment for heavy and light workshop
_ Quality Control Equipment
This place has officially started its operation in 1377.
forging operation on large sections of steel requires special and unique technology. In sections with a diameter more than mm 700due to high weight and strength, forging and altering the form of ingots requires a lot of power Therefore in order to create self-sufficiency in the production of large forged sections in the country, the installation of a hydraulic press with 6300ton capacity and other necessary equipment such as heat treatment equipment has been design and implemented in heavy-press workshop of this complex.
The main equipment of this Workshop is:
_ Hydraulic presses with 6300tons of power
_ 80 tons Manipulator
_ 5 units ofForging & Forming furnace
_ 5units of heat treatment furnace
_ Light and heavy workshop transport equipment
_ Quality Control Equipment
This place has officially started its operation in 1383.
Melting and Casting Workshop
production of special alloy steel requires a process that results in a homogeneous alloy, clean from the presence of non-metallic wastes, and with the least amount of unwanted elements such as sulfur, phosphorus, and gas production. Therefore the melting and casting workshop of the complex has been implemented for preparing high-quality alloy steel bars including the processes of melting, secondary metallurgy, and ingot casting.
The main equipment and machines of workshop are:
_ Electric arc melting furnace(EAF)with a capacity of 50tons
_ Ladle furnace(LF)
_ Gas and carbon debugging system in vacuum(VD / VOD),With a capacity of 50tons
_ Current Gas debugging system in vacuum(VSD)with a capacity of 80 tons
_ Full dust control system
_ The oxygen and industrial gases production unit
_Light and heavy workshop transport equipment
_ Scrap preparation equipment
_ Quality Control Equipment
This unit has started operation since 1383.
Manufacturing capacity and capabilities
Esfarayen industrial complex, as the largest producer of forged alloy steels sections in Iran, has the capabilities to supply the country needs for many strategic and fundamental parts indifferent industries.
Production abilities of these complexes can be summarized as follows:
_ The central parts with different shapes :rectangular, hexagonal, Octagonal,round, flat and Hybrid forms and stepped axis
_ all semi-functional parts
_ Gears, forging dies, rings, drilling pipe, thick lenses light and heavy rolls, discs, flanges, pipe systems planning dies high pressure seamless pipes, power station parts such as axis turbines and etc.
This complex’sgeneratorshave annual production capacity of81.000tons fromalltypes of theseproducts.
The future prospect
in order to reach their predeterminedgoalsandenter global marketsandcreatethepossibility tocompete withpowerfulforeigncompetitors, thiscomplexandother country’s alloy steelproducersshould have theability toproduce productswithhighadded valueand global qualitystandards. To achieve this goal,thisComplex has also put different plansinitsagenda including:
_ Completion ofexistingprojectsandworkshops, including installation ofdevicessuch asrim straitening, deplating,andshot blast.
_ Laboratory equipmentand quality control
_establishment of continuous castingunitin order toproduceingotswith a diameter of250to 560mm, with ContinuousCastingmethodto provide the requirements of LoolehGostar Co. in Esfarayenand Esfarayenindustrial complex.
_Establishment of Electroslag Remeltingunit(ESR)for re-meltingThe finalINFILTRATION of ingotswith the diameter of450 to1100Mm
_Establishment of light and heavyheat treatment workshopsincludingfurnacesin order toperform annealing and normalheat treatment, , stress relievingand necessaryequipment forquenchandtemperandsurface hardness
_ Establishment oflight and heavymachineworkshopincludingCNC lathes,grinding, drilling, Karosel, cutting, andmilling machines.
implementation ofthese projects, Esfarayenindustrialcomplexcan eliminate
the country’sneedsto Strategiccomponents and product and help the
country’s industry to become independent of foreignproducers can and
also enter Asianand globalmarkets
andtake an important steptowards economic and industrialindependency o
f the coun