Marcegaglia, China Yangzhou plant

Transcription

TM
China Yangzhou plant
Marcegaglia China
714,000 sqm total area
153,000 sqm first phase covered area
EN norms production quality standards
Precision tubes
from carbon and stainless steel
Beijing
Yangzhou
Shanghai
Macau
Taiwan
Hong Kong
Marcegaglia China spreads over a land
of 714,000 m² located in Guangling Economic
Development Zone, Yangzhou
(270 km from Shanghai).
The first phase of plant development includes
153,000 m² of covered production area
equipped with European manufacturing
systems, plus a 4,200 m² office building.
Marcegaglia tube production is implemented
in complete accordance with EN norms
including raw materials procurement,
production, quality control, on time delivery
and after-sale service, in order to supply
top level complete solutions to our customers.
Quality and environment
Marcegaglia China is currently
certified according to the most
advanced international standards:
•ISO 9001:2000 for the Quality
Management system
•ISO 14000 for the Environmental
Management System
•OHSAS 18000 for
the Occupational Health and
Safety management system
The ISO/TS 16949 required
by the Automotive customers
for the Quality Management System
is currently under development.
In addition we guarantee:
•strict compliance with EN norms including
raw materials procurement, production,
quality control, delivery, after-sale-service;
•same level of environmental standards
required in EU is currently implemented;
•all major certifications in the sector are
being applied for manufacturing, production
equipment are compliant with the latest
energy saving criteria;
•highest level of service to comply
with Marcegaglia worldwide standards.
Production areas
All main production lines in Marcegaglia China
are imported from Europe, represent the latest technology
in the field of tube production and are a perfect “replica”
of the lines operating within Marcegaglia European plants.
1
3
4
2
5
All the processes employed by Marcegaglia China
are the same used in Italy, so that the same quality
and efficiency of European-made products
can be guaranteed.
1) Coil slitting
5) Refrigeration tube mills
2) Carbon steel welded tube mills
6) Pickling
3) Stainless steel welded tube mills
7) Heat treatment
4) Cold-drawn precision tube mills
6
7
Carbon steel welded tubes
(ERW)
Min. thickness (mm)1,50
Max. thickness (mm)16,00
Min. diameter (mm)20
Max. diameter (mm)254
SUPPLY CONDITIONS
- Dimensional tolerances according to manufacturing standard
- Special tolerances upon request
- Control documents 2.1, 2.2, 3.1, 3.2 according to EN 10204
and specific norm requirements
Carbon steel welded tubes
(ERW)
Round carbon steel
welded precision tubes
Square carbon steel
welded precision tubes
Rectangular carbon steel
welded tubes
Main manufacturing standards
MANUFACTURING
STANDARD
PRODUCT
DESIGNATION
TREATMENT
GRADE*
SURFACE
CONDITIONS
EN 10305-3
Round and shaped
precision tubes
EN 10305-5
Square and
rectangular
precision tubes
EN 10219
Cold formed welded
structural tubes
(CE homologation)
+CR1 Welded
and sized
+A Annealed
+N Normalized
+CR2 Welded
and sized
(*) Upon request: supply of grades not included in the above mentioned standards
E190, E320,
E220, E370,
E260, E420
E155, E195,
E235, E275,
E355
S235JRH
S275J0H
S275J2H
S355J0H
S355J2H
S1 From hot-rolled strip,
black
S2 From hot-rolled strip,
pickled
Manufacturing process
COILS
SLITTING
tube forming
and welding
NORMALIZATION
STRAIGHTENING
AND CUTTING
NON
DESTRUCTIVE
TESTING
PACKAGING
Testing
STANDARD AND OPTIONAL TESTING
Chemical analysis
STANDARD TEST
Tensile test
Visual and dimensional test 100%
Flattening test or drift expanding test (*)
Roughness measurement
Eddy current test 100% acc. to EN 10246-3
OPTIONAL
TEST
Ultrasonic test 100% acc. to EN 10246-7
NDT of the full tube circumference
for longitudinal imperfections
(*) The test method is at the discretion of the manufacturer; this option only applies
for tubes supplied in the annealed or normalized delivery condition.
Typical applications
Marcegaglia has developed a unique
know-how in the manufacturing of precision
tubes to meet the strict dimensional
and surface specifications requirements
by manufacturers in key sectors such
as constructions and mechanical engineering.
Precision tubes for steel structural work
Precision tubes for piling
Precision tubes for lifting equipment
(building hoists and tower cranes)
Roller conveyor tubes
Precision tubes for pressure purposes
Precision tubes for automotive applications
The production program
of Marcegaglia carbon steel welded tubes
covers a wide range of structural
and precision mechanical applications,
guaranteeing specific suitability
for subsequent processing.
Precision tubes for the cycle
and motorcycle industry
Precision tubes for other industrial applications
Cold-drawn precision
tubes (DOM)
Product range
Welded
Seamless
Min. thickness (mm)
2
2
Max. thickness (mm)
15
24
Min. diameter (mm)
24
24
Max. diameter (mm)
245
245
SUPPLY CONDITIONS
- Tubes are supplied in 5000/8000 mm lengths unless otherwise
specified in order
- Control documents 2.1, 2.2, 3.1, 3.2 according to EN 10204 and other specific norm requirements
MANUFACTURING
STANDARD
PRODUCT
DESIGNATION
GRADE*
TREATMENT
+C Hard. No final treatment after final cold drawing.
+LC Soft. Final heat treatment is followed by a suitable
drawing pass (limited reduction of area).
EN 10305-2
Cold-drawn welded
tubes
E195
E235
E275
E355
+SRStress Relieved. After final cold drawing, the tubes
are stress relieved in a controlled atmosphere.
+A Annealed. After final cold drawing, the tubes are
annealed in a controlled atmosphere.
+N Normalized. After final cold drawing, the tubes
are normalized in a controlled atmosphere.
EN 10305-1
Cold-drawn seamless
tubes (CDS), only for
high thickness tubes
(please refer to
dimensional table)
E195
E235
E275
E355
(*) Upon request: supply of grades not included in the above mentioned standards
Testing
STANDARD AND OPTIONAL TESTING
Chemical analysis
Tensile test
STANDARD TEST
Visual and dimensional test 100%
Roughness measurement
Eddy current test 100% acc. to EN 10246-3
Ultrasonic test 100% acc. to EN 10246-7
Impact test
OPTIONAL
TEST
NDT on longitudinal imperfections
Flattening test or drift expanding test
Precision tubes for hydraulic applications
Precision tubes for mechanical
and automotive applications
Mechanical properties,
as well as strictly
controlled dimensional
tolerances,
give cold-drawn tubes
significant advantages
for several precision
applications.
China
Italy
Dedicated manufacturing plants
based in Europe and Asia
regularly supply the world markets
with a specialized production program
for the hydraulic cylinder industry
and other automotive applications.
Product range
Cold-drawn tubes for automotive
and mechanical applications
Cold-drawn tubes for cardans
TECHNICAL CHARACTERISTICS
GRADE
E195, E235, E275, E355
GRADE
E195, E235, E275, E355
TREATMENT
+C, +LC, +SR, +A, +N
TREATMENT
+C, +LC, +SR, +A, +N
surface
treatments
•Outside diameter and inside
diameter: smooth as drawn
(EN 10305-2)
•On request: roughness Ra < 0.4 m
dimensional
TOLERANCE
•Standard: according to EN 10305-2
Optional
processing
Drawing in reactive oil
Dephosphating
•Special: on request
Product range
Ready-to-use cylinder tubes
GRADE
E355
TREATMENT
+C
surface
treatments
•Outside diameter:
smooth as drawn (EN 10305-2)
•Inside diameter: roughness
Ra < 0.80 m (average 0.50÷0.60 m)
dimensional
TOLERANCE
•Inside diameter: ISO H9 (ISO H10 for thickness < 4 mm)
DELIVERY CONDITIONS
- Standard packaging with plastic caps and strapped bundles,
standard weight approx. 1500 kg
- Commercial lengths 5000-8000 mm, custom lengths upon
request
- Surface protection
- Marking: MM E355 OD x ID EN 10305-2 +C - Heath
Product range
Cylinder tubes suitable for honing,
skiving and roller burnishing
GRADE
E355
TREATMENT
+SR
surface
treatments
•Inside diameter:
with stock allowance (for honing
or skiving and roller burnishing)
DELIVERY CONDITIONS
- Standard packaging with strapped bundles,
standard weight approx. 1500 kg
- Commercial lengths 5000-8000 mm, custom lengths
upon request
- Surface protection
- Marking: MM E355 OD x ID EN 10305-2 +C - Heath
Product range
Cold-drawn tubes for telescopic cylinders
GRADE
E355
TREATMENT
+SR
surface
treatments
•Inside diameter: roughness
Ra < 1.6 m
Stainless steel welded
tubes (SS)
Product range
Min. thickness (mm)1
Max. thickness (mm) 5
Min. diameter (mm)19
Max. diameter (mm)88.9
SUPPLY CONDITIONS
- Control documents 2.2, 3.1, 3.2 according to EN 10204
and specific norm requirements
PROCESS PIPES FOR FLUIDS
EN 10217-7, (ASTM A270), (DIN 11850)
Process pipes for the food and dairy industry
EN 10217-7, (DVGW GW541)
Process pipes for drinkable water and press fitting
EN 10217-7, EN 10312
Process pipes for water treatment
EN 10217-7
Process pipes for the pulp and paper sector
EN 10217-7, (AD 2000 W2/W10),
(PED 97/23)
Process pipes for chemical applications
EN 10217-7, (DIN 11866)
Process pipes for pharmaceutical applications
EN 10217-7, (ASTM A312 / A778)
Process pipes for oil and gas applications
MECHANICAL
APPLICATIONS
AUTOMOTIVE
EN 10296
EN 10217-7
Round tubes for pumps and cylinders
EN 10217-7
Round tubes for elbows and fittings
EN 10217-7
Round tubes for heat resistances
EN 10296, (ASTM A554)
Round tubes for automotive, exhaust systems
EN 10296, (ASTM A554)
Round tubes for automotive,
hydroforming appliance
EN 10296, (ASTM A554)
Round tubes and box sections for automotive
frame construction
Precision tubes for for fluids
Precision tubes for mechanical
and automotive applications
Feedwater heater tubes for power plants
Marcegaglia stands out today
as the world’s top producer
of stainless steel welded tubes
with top-level certified manufacturing
activities worldwide and an overall capacity
of 400 thousand tons per year.
Standard delivery program
LASER welding
Round tubes EN 10217-7, EN 10296
HF welding
Round tubes EN 10217-7, EN 10296
Refrigeration tubes (TR)
diameter
mm
nominal
weight
g/m
4,75
70
5
74
6
91
6,35
98
8
126
9,50
152
SUPPLY CONDITIONS
- Outside diameter tolerance: nominal ±0,1 mm
- Wall thickness tolerance +0,05 mm / -0,10 mm
Tubes for condensers
and refrigeration components
Marcegaglia special range of refrigeration
tubes is manufactured according
to the specific sector norms and tolerances,
and is thoroughly tested to allow use
in applications such as condensers
and evaporators for heating
and cooling systems
and household appliances.
Production process design and development
The quality of the products manufactured
by Marcegaglia China is suitable
for many applications but it perfectly fit
for the high requirements of OEM
(Original Equipment Manufactures) customers.
In order to supply OEM customers with high quality
and service, Marcegaglia China has developed
an accurate Process Control system
and a special organization with Supply Chain
and Project Management.
The Quality System is also designed and
implemented in order to meet the highest
standards.
Design and sample preparation are fundamental
steps for supply new products to OEM customers.
Marcegaglia China technical team has developed
high skill and experience in product development
for many international and domestic OEM
customers.
Two are the main steps required to develop
prototypes for new products:
• Analysis of the customer requirements based on:
- Manufacturing requirement
- Steel grade (or chemical component)
- Mechanical properties
- Dimensions
- Delivery condition
- Surface conditions
- Inspection certificate
- NDT test
• Development of the manufacturing process,
which is different for each type of product.
New product development flow chart
Collect
and analyze
marketing
information
Get
customer
request
Product
process
design
Sample
production
Sample
production
validation
Manufacturing
process
confirmation
Delivery
Sample
approval by
customer
Mass
production
Carbon steel welded tubes (ERW)
• Choose the proper steel grade based on the chemical, mechanical and roughness
requirements, Marcegaglia recommends the proper
raw material based not only on EN standard, but also
JIS, ASTM and GB standard.
• Calculate the proper width of the strips thanks to many years of experience in tooling
manufacturing, Marcegaglia has successfully
developed rules to select the exact width range
for different sizes.
• Choose the tooling, including the inner scarfing
tools type for different Finpass rolls, we employ
different radius of the scarfing knife, adjusting its
height by adjusting the tooling pressure to obtain
smooth surface of the welding area.
• Set up the welding parameters Marcegaglia has a well-developed data storing
system to record all the welding parameters which
can be reference for further production.
• Set up the acceptance level of defect by eddy
current test the acceptance level is set up according
to customer requirement or general norms.
• Process and production validation dimensional test to verify the strip width, tooling
and inner scarfing process. Flattening/drift expanding
test according to different steel grade and also
different norms to check the quality of the welding.
According to customer requirement, we can also
perform specific test 3.1 according to EN 10204.
Cold-drawn tubes (DOM)
• Choose the proper hollow size the hollow size should be chosen so that the
reduction rate is located in the proper range.
The reduction rate is calculated with the following
formula:
Reduction rate=(100-((W1 / W2)*100))*100%
W1: kg per meter of finish size
W2: kg per meter of hollows
W1: =(OD1-T1)*T1*0.02466
W2: =(OD2-T2)*T2*0.02466
• Select the pickling mode based on the surface requirement, a phosphating
or saponification process is performed.
• Choose the die/Mandrel the shape of the die/
mandrel is a critical controlled characteristic. For TTC
(ready-to-use) products, special dies are required.
• Set up the Stress Relieving (SR) process
parameters according to different customer
requirement, a different heating time, cooling time
and cooling speed is set up.
• Verify the drawing stress during cold drawing, the mechanical stress should
comply with the following formula:
P/F=K < δs
P:hollows drawing force (kgf)
F: finished size section area (mm²)
K: stress of drawing (kgf/mm²)
δs: yield strength of finished tube (kgf/mm²)
• Process and production validation testing is performed before/after cold drawing
to verify the reduction rate. Test before/after SR
to verify the furnace setting parameters.
Process and production validation though statistic
evaluation of the parameters.
Comparisons between Cold-Drawn Welded (CDW)
and Cold-Drawn Seamless (CDS) tubes
The advantages of cold-drawn welded tubes when
compared to cold-drawn seamless tubes can be
summarized as:
• Better geometry (OD and ID roundness)
• Improved quality surface (less defect after painting
and improve fatigue life)
• Tighter eccentricity and wall thickness tolerances
(the eccentricity is 3% max instead of 8%-10%
normally guaranteed from seamless tubes)
• Higher tube safety (tubes are controlled 100% by
ultrasonic test and eddy current test)
• Better toughness at low temperature
For these reasons Marcegaglia China always
recommend to use CDW tubes when the thickness
permits it; indeed in Europe and USA, most cylinders
are produced with welded tubes.
Stainless steel products (SS)
• Choose the proper steel grade based on the chemical, mechanical and roughness
requirement, Marcegaglia recommends the proper
raw material based not only on EN standard,
but also JIS, ASTM and GB standard.
• Calculate the proper width of the strips thanks to many years of experience in tooling
manufacturing, Marcegaglia has successfully
developed rules to select the exact width range
for different sizes.
• Choose the tooling, including the inner scarfing
tools type for different Finpass rolls, we employ
different radius of the scarfing knife, adjusting
its height by adjusting the tooling pressure
to obtain smooth surface of the welding area.
• Set up the welding parameters Marcegaglia has a well-developed data storing
system to record all the welding parameters
which can be the reference for further production.
• Set up the acceptance level of defect by eddy
current test acceptance level is set up according
to customer requirement or general norms.
• Process and production validation dimensional test to verify the strip width,
tooling and inner scarfing process;
flattening/drift expanding test according to different
steel grade and also different norms to check
the quality of the welding.
According to customer requirement, we can also
perform specific test 3.1 according to EN 10204.
Service center
The highly specialized service center
machinery is dedicated to the the most
diverse treatments and finishings
of Marcegaglia product range of carbon
and stainless steel tubes.
Tailor-made services include cutting,
end-finishing, special packaging and on-time
scheduled delivery, plus a series of additional
processing according to customer defined
special requirements.
In addition to standard supply conditions,
additional processes or solutions
can be provided according to customers’
requirements.
Optional processing
•Suitability for subsequent galvanizing
•Complete normalization
or weld area normalization
•Additional heat treatments
•Weld seam removing
•Special end finishing
•Cut to length
•Customer defined marking
•Restricted tolerances
•Welding position control
•Surface roughness measurement
•Delivery without corrosion protection (degreased)
•Specific corrosion protection
•Specific packaging method
•Selection of tubes from a single casting
•Hot galvanization
•Drawing in reactive oil
•Dephosphating
Laboratory and testing
The tubes produced in Marcegaglia China
are strictly controlled to ensure the quality
requirements.
Tests are done both on the production lines
(as described before) and on the finished
products before shipment.
Operators are continuously trained
to guarantee that tests are performed
in the correct way.
All batches of finished tubes are tested
according to control plans defined
by the norms or according to the customers’
specific requirements, all batches
are delivered with quality certificate
to ensure the compliance.
Marcegaglia China laboratory is equipped
with the full range of testing equipments
suitable to characterize the tubes according
all main international technical standards.
All main testing equipment are imported
to guarantee the best accuracy and reliability
of the measurements.
Optical Emission Spectrometer
Chemical analysis on raw material
and final product
Hydraulic Universal Testing Machine
Mechanical analysis on raw material
and final product
Technical standard
Technical standard
GB/T 4336
GB/T 228.1
ASTM E415
EN ISO 6892-1
•100% Raw material verification
•100% Final product verification
ASTM E8M
•100% Semiproduct verification
Charpy Impact Tester
Mechanical analysis on raw material
and final productt
Technical standard
GB/T 229
EN ISO 148-1
•100% Semiproduct verification
Hardness Tester
Hardness analysis on raw material
and final product
Technical standard
GB/T 230.1; GB/T 4340
EN ISO 6508-1; EN ISO 6507-1
ASTM E18; ASTM E92
Hardness analysis on raw material,
semiproduct and final product.
HRA, HRB, HRC, HV, HR30T, HR30N
Roughness Tester
Roughness test on semi-product
and final product
Metallographic Analysis
Metallographic examination on raw material
and final product - Process verification
Technical standard
Technical standard
EN ISO 4287
GB/T 6394; GB/T10561: GB/T 224
Surface roughness on semiproduct and final product.
EN ISO 643; EN ISO 4967
ASTM E112; ASTM E45
Grain size, non-metallic inclusions, decarburization, etc.
TM
No.1 Marcegaglia Road
Guangling Economic Development Zone • Yangzhou 225006 - P.R. China
[email protected] • www.marcegaglia.cn

Marcegaglia, China Yangzhou plant

Transcription

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