report on the visit in funsan foundry, spain

Michael Lazzaroni, Stefano Sgobba (CERN)

Report on the Visit in Funsan Foundry, Spain.

Date: 26/02/2010

Project: R2E/shielding

Invitation to tender: IT3666/EN/LHC

Present: Michel Monteagudo (Funsan), Stefano Sgobba (CERN), Michael

Lazzaroni (CERN)

Goal of the visit:

Visit and presentation of Funsan foundry

Funsan employs approximately 100 people

The total gross production is 20000 t/y. Net production is 16000 t/y including ductile (20% to 30 %) and gray iron (rem.)

Funsan owns horizontal rotative gas furnaces, dating of the 90ies. Casting T is approximately 1380 °C to 1400 °C. Unit of casting are 12 t to 13 t, or 16 t to 17 t

They use a limited quantity of scrap and an important amount of pig iron and ferroelements, due to the type of their furnaces. Internal recycling (running system) is applied

Molds are poured by hand using geared ladles

The chemical analysis is a ladle analysis, performed after adjustment

Funsan applies the technique of vaporizable polystyrene patterns, painted and dried 24 h at 60 °C, allowing sharp edges to be achieved on the final blocks. Production of patterns is subcontracted

Details concerning the metallurgy of our products

Several blocks are cast from a single run, up to 6 or 8. The number of blocks per single cast allowing to achieve the specified surface quality is still being optimized.

Casting is performed from bottom, in order to allow the impurities to float

Cooling time is between 3 d and 4 d

A fully ferritic microstructure is aimed (no FeMn added). Microstructure will be checked on final products according to the specified standards


Technical discussions about the quality assurance plan

1. Dimensional controls

The dimensional tolerances are acceptable. The blocks out of tolerance will be machined.

The geometrical tolerances (flatness, perpendicularity) are generally acceptable (picture 1,2)

Right angles are complying. (picture 3)

The roughness is above specification mainly due to surface defects that reproduce the oxides present after unmolding and removed further. With the exception of some presented specific blocks or surfaces heavily affected by surface defects, that will be discarded or conditioned, respectively, these defects are generally judged acceptable.

o Funsan fills the deepest defects by repairing by arc welding (picture 4). o Funsan applies a cold weld layer on the worst face in local areas (still under

discussion) (Picture 5).

Full results of the metrological controls shall appear in the certificate of each block.

2. UT

UT control is requested from three faces in order to check the soundness of the relevant volumes, in agreement with the specified standard

UT tests will be performed before machining of the threads

Details of the procedure and compliance with the specified standard should be provided by Funsan

3. Chemical analysis

CERN requested Funsan to assess the Co content of the castings with the help of an external laboratory.

4. Other information

The proposal of the foundry is to remove adjoining samples from the casting runner.

This is acceptable under reserve of a cross check of properties on samples trepaned

from one cast in order to confirm that the values achieved on runners are

conservative

The marking of each block will be [FS.844.1500] on one face 800 mm x400 mm

where the threaded hole is. Furthermore the number of this tender [IT-3666] shall

appear on each block on the same face, just above the numbering [FS.844.1500].

FS stand for Funsan foundry 844 means the size of the blocks (800mmx 400mmx 400mm)


1500 is the numbering of each blocks from 1 to 500. The marking should be intruding and not protruding with respect to the

surface and must remain visible after painting

The density of EN-GJS-400-18U-RT is 7.1/7.2. Theoretical weight is around 908 kg.

The painting is defined below: 1st layer: anti-corrosive primer 2nd layer: radiation resist RAL: 7040 (grey)

Three threaded holes M24x50 Funsan will make a load test (2t) on one block (two times the weight of a

block), and has to send a picture of it.

Picture 1


Picture 2


Picture 3, 4


Picture 5

Assembly of two blocks

report on the visit in funsan foundry, spain

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