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 700 due 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 50 tons
_ 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’s generatorshave annual production capacity of 81.000 tons fromall types of these products.
The future prospect
in order to reach their predetermined goals and enter global markets and create thepossibility tocompete with powerful foreign competitors, this complex and other country’s alloy steel producers should have theability toproduce products with high added value and global quality standards. To achieve this goal,this Complex has also put different plans in it sagenda including:
_ Completion of existing projects and workshops, including installation of devices such asrim straitening, deplating,andshot blast.
_ Laboratory equipmentand quality control
_establishment of continuous castingunitin order to produce ingots with a diameter of 250 to 560 mm, with Continuous Casting method to provide the requirements of Looleh Gostar Co. in Esfarayenand Esfarayen industrial complex.
_Establishment of Electro slag Remelting unit(ESR)for re-melting The finalI NFILTRATION of ingotswith the diameter of450 to1100Mm
_Establishment of light and heavy heat treatment workshop sincluding furnaces in order toper form annealing and normalheat treatment, , stress relievingand necessary equipment for quench and temper and surface hardness
_ Establishment oflight and heavy machine workshop including CNC lathes,grinding, drilling, Karosel, cutting, andmilling machines.
With the implementation ofthese projects, Esfarayen industrial complexcan eliminate
the country’sneedsto Strategic components and product and help the
country’s industry to become independent of foreign producers can and
also enter Asianand globalmarkets
andtake an important steptowards economic and industrial independency
of the coun