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BASIC ACTIVITIES
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MOULDING
The foundry moulds and cores are made of furan mixtures. Bulgarian quartz sands are used. The furan resins are delivered by renowned European producers: “Huttenes Albertus”, “Furtenbach” and others. Resins with a low nitrogen content are used.
The moulding is done on three working sites specialized in “large castings”, “middle castings” and “small castings” with the following mixers:
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“Eco – mix” – Germany – vertical turbo mixer
Capacity of 30 tons per hour at the site for “large castings”.
The maximum single weight of the castings is to 10 000 kg.
The maximum dimensions of the moulding flask is to L = 9200 mm, B = 1400 mm, H = 1150 mm
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* “IMF – mix” – Italy – vertical turbo mixer
Capacity of 30 tons per hour at the site for “middle castings”.
The mechanized line with dimension of the moulding flask to:
L = 1800 mm, B = 1500 mm, Hmax = 650 mm.
The maximum single weight of the castings is to 2 000 kg.
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* “AMDR – mix” – Germany
Capacity of 10 tons per hour at the site for “small castings”.
The maximum single weight of the castings is to 600 kg.
The dimensions of the moulding flask is to L = 1500 mm, B = 1000 mm, H = 620 mm.
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CORES MAKING
The core manufacturing is on the basis of furan resins. There are three turbo mixers “Fordath-MIX” – England with capacity of 4 tons per hour, mechanized roller lines and stands for painting.
Graphite and zircon paints with isopropanol diluent are delivered by our suppliers together with furan resins.
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SAND REGENERATION
After pouring and chilling, the moulds are discharged from the moulding mixture which is totally recovered by means of installation “Klein” – Germany, with two vibrating mills, chilling and secondary recovering in a foaming layer. It is delivered automatically after that to the working sites by a low – speed pneumatic transport.
POURING OF THE METALS
“Leiarmach” JSC – Sofia produces:
- Castings from modified gray cast irons according to EN 1561/2000, from the following grades: EN – GJL – 150; EN – GJL – 200; EN – GJL – 250;EN – GJL – 300; EN – GJL – 350.
- Castings from nodular cast irons according to EN 1563/2000 from the following grades: EN – GJS 400 – 15; EN – GJS 500 – 7; EN – GJS 600 – 3; EN – GJS 700 – 2;
The melting shop where liquid metal is obtained includes the following aggregates:
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* Two hot air cupolas “Strico” - Germany
Each of cupolas with capacity of 8 tons per hour.
* Induction furnace “Radyne” - England
Equipped with two interchangeable ladles with capacities of 5 tons and 2,5 tons.
* Induction furnace “AEG – Elotherm” - Germany
Capacity of 500 kg
The foundry possesses stores and section for the preparation of the metal before the melting process. |
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Pig iron, steel and cast iron scrap, own return, ferroalloys, inoculants, carburizers and others are put in the burden, controlled by certificates and foundry analysis.
“Leiarmach” JSC – Sofia uses high quality inoculants of “ELKEM” – Norway.
CLEANING OF THE CASTINGS (SHOT BLASTING; SAND BLASTING)
The cleaning of the castings is done in a separate site and includes discharge of gating systems, rough grinding, shot blasting in the chamber “Cogeim” – Italy, with 5 turbines and shot speed – 80 m/sec. The dimension of the working chamber is: 3000 mm x 3500 mm x 5350 mm.
At customer’s request can be done sand blasting of the castings according to ISO 8501 – 1/1994.
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MANUFACTURING OF PATTERNS
The patterns workshop has existed since the establishment of the foundry and has not stopped its working process. It is specialized in the manufacturing of wooden patterns.
Most of the people who work there have long experience as workers in patterns workshops and can accomplish various complex tasks. A computer program “SolidWorks” is available in the patterns workshop.
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ROUGH MACHINING
There are 4 planer-type milling machines and 1 big milling machine available. At customer’s request preliminary rough machining of the castings is made there.
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