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TRANSCRIPT
From pattern to finished part
Products from one mold– the perfect casting
COMPANY PROFILE
MEUSELWITZ GUSS uses latest foundry equipment in a hand and large-scale molding shop and a mechanized plant molding shop to pro-duce castings of high dimensional accuracy and surface finish in the furan resin-based molding process.
Since 1992, we have spent a total of 80.3 million Euros to upgrade and extend our busi-ness, especially in the divisions of large-scale casting and heavy casting.
We provide advisory services to our customers as early as in the design phase with a view to achieving a component design suited for smooth casting. Components are ma-nufactured according to the terms of reference and control requirements of DIN ISO 9001, ISO 14001 and ISO 50001 all of which are enshrined in our integrated manage-ment system.
A high level of reproducibility of material quality and workpiece properties and conditi-on is a quality characteristic that we guarantee. Owing to our highly qualified and moti-vated workforce, an annual production volume of 45,000 tonnes of high-quality castings can be achieved.
OUR COMPANY
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Materials› EN-GJL 200, 250, 300 according to European standard DIN EN 1561
› EN-GJS-400-18-LT, 400-15, 500-7, 600-3, 700-2 according to European standard DIN EN 1563
› solid-solution strengthened cast iron with nodular graphite
Material code Material no.
Tensile strength Rm [N/mm²]
0.2% yield strength Rp0.2 [N/mm²]
Elongation A [%] Structure
Brinell hardness no.
EN-GJS-450-18 5.3108 450 350 18 Ferritic 170 - 200
EN-GJS-500-14 5.3109 500 400 14 Ferritic 185 - 215
EN-GJS-600-10 5.3110 600 470 10 Ferritic 190 - 220
› EN-GJV
› application-related special alloys according to customer specifications
Unit weights› 200 - 85.000 kg
85.000 kg Up to casting weight
Quality assurance› Quality management system according to ISO 9001:2015
› Energy management system according to ISO 14001:2015
› Environmental management system according to ISO 50001:2011
› Accredited by DNV-GL, LR, ABS, BV
› Certified according to Directive 2014/68/EU, AD 2000 W3/1, AD 2000 W3/2
› Certified according to DIN EN ISO 3834-3:2006
› Laboratory equipment, spectrometer, thermal analysis, materials testing, molding materials testing
› Non-destructive testing: visual inspection, ultrasonic testing, magnetic particle testing, penetration testing and radiographic inspection
› Measuring machine and 3D laser measurement
› External contracted services (BDG-Service, TU BA Freiberg, Fraunhofer Institut, ZL Leipzig)
Test certificates, inspection reports› Manufacturer’s certificates according to DIN EN 10204-2.1 and -2.2
› Work’s test certificate according to DIN EN 10204-3.1
› Acceptance inspection certificate according to DIN EN 10204-3.2; this certificate is issued by the classification societies or the TÜV inspection agency.
Zertifikat
In einem Zertifizierungsaudit hat die Organisation
Meuselwitz Guss Eisengießerei GmbH
am Standort
Industriepark Nord, 04610 Meuselwitz
nachgewiesen, dass ein Energiemanagementsystem eingeführt wurde und erfolgreich angewendet wird entsprechend der Norm
ISO 50001 DIN EN ISO 50001 Ausgabe Dezember 2011
für die Tätigkeit
Herstellung und Vertrieb von Gusserzeugnissen, Warmbehandlung von Gusskörpern und deren Farbgebung, Herstellung und Reparatur von Gießereimodellen, technologischer Stahlbau, Konstruktionsberatung und mechanische Bearbeitung von Gussteilen in Zusammenarbeit mit anderen sowie verwandten Tätigkeiten
Dieses Zertifikat ist gültig vom 22. Dezember 2017 bis zum 21. Dezember 2020.
Berlin, 27. November 2017
Prof. Dr.-Ing. Jan Uwe Lieback Andreas Lemke Geschäftsführer Leiter der Zertifizierungsstelle
Nr. B-17-11332
Zertifikat
In einem Zertifizierungsaudit hat die Organisation
Meuselwitz Guss Eisengießerei GmbH
am Standort
Industriepark Nord, 04610 Meuselwitz
nachgewiesen, dass ein Umweltmanagementsystem eingeführt wurde und erfolgreich angewendet wird entsprechend der Norm
ISO 14001 Ausgabe September 2015
für die Tätigkeit
Herstellung und Vertrieb von Gusserzeugnissen, Warmbehandlung von Gusskörpern und deren Farbgebung, Herstellung und Reparatur von Gießereimodellen, technologischer Stahlbau, Konstruktionsberatung und mechanische Bearbeitung von Gussteilen in Zusammenarbeit mit anderen sowie verwandten Tätigkeiten
Dieses Zertifikat ist gültig vom 27. November 2017 bis zum 26. November 2020.
Berlin, 27. November 2017
Prof. Dr.-Ing. Jan Uwe Lieback Andreas Lemke Geschäftsführer Leiter der Zertifizierungsstelle
Nr. U-17-11332
OUR SERVICES
Meuselwitz Guss company profile6
PROCESS EQUIPMENT 1 Caisson and pit molding for parts up to 30 tonnes
2 Hand molding shop for parts up to 15 tonnes
3 Blasting cubicles up to 30 tonnes
4 Fettling shop for parts up to 5 tonnes
5 Fettling shop for large parts
6 Checking station for ultrasonic inspection and crack detection
7 Annealing furnace for heat treatment
8 Priming for parts up to 5 tonnes
9 Priming for large parts up to 30 tonnes
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Hand molding shop and casting post-treatment
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10 Melting shop
11 Mechanized molding plant
12 Casting and cooling sections of the mechanized molding plant
13 Shake-out grid
14 Mechanical sand preparation system
15 Hand molding shop for parts up to 15 tonnes
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16 Pattern making shop
17 Spectrometer room
18 Measuring machine and 3D laser measurement equipment for pattern and casting control
19 Work preparation with design engineering and simulation
Mechanized molding shop and hand molding shop
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PROCESS EQUIPMENT
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1 Provision of molten iron by means of transfer carriages
2 Molding workstation for large cores and molds
3 Mobile continuous mixer (remote controlled)
4 Absorption basin for black wash application
5 Molding and casting pits
6 Shake-out grid for large castings
7 Large and heavy casting fettling station
8 Blasting cubicle up to a load carrying capacity of 100 tonnes, with transfer carriages and rotary table
Large and heavy casting molding shop
9 Casting stations for large molds
10 Core removal for large and heavy castings
11 Checking station for ultrasonic inspection and crack detection
12 Priming for large castings
13 Shipping of large and heavy castings
14 Separation of feeders by means of a shot hammer
15 Molding workstation for series production
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PROCESS EQUIPMENT
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Application fieldsEnergy technology › test and clamping plates › mechanical and plant engineering ›
valves and compressors › drive technology › marine engineering
Plastic and injection molding machines
Machine tool manufacturing
Pump manufacturing
Cement plant and reconditioning plant; mill building
Press manufacturing
Wind energy
Gear manufacturing
Gas and steam turbine plant engineering
OUR RANGE OF SERVICES
80 million euros More than spent on modernization since 1992.
› Design consulting
› Consultancy on the use of materials
› Design engineering geared to casting and substitution of welded structures
› Mechanized hand-mold casting
› Large and heavy casting
Different quality classes – we are happy to advise you in terms of the best design of the pattern equipment depending on the batch size.
OUR SERVICE OFFERING
PATTERNS
› Consultancy services using 3D, CAD or solidification simulation as well as mold filling and stress simulations
› Pattern concept
› Shot-blasting, fettling
› Heat treatment (stress-relief annealing, ferritization, pearlitization)
› Priming / top coating
› Pre-machining and finish-machining
Temperature 13,365s 58,00 % Temperature 21,499s 76,00% Temperature 28,977s 100,00%
WE ARE ON FIRE FOR OUR CUSTOMERS
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MATERIALS
Metallurgical know-how since 1904
Properties of compacted graphite iron
Castability Strength Stiffness Thermal conductivity Surface finish
Compacted graphite iron› According to DIN EN 16079 – excerpt
Mechanical properties on cast-on samples*
* The tensile strength and Brinell hardness in the casting are strongly dependent on the wall thickness.
Material code Material no.
Tensile strength Rm[N/mm²]
0.2% yield strength Rp0.2 [N/mm²]
Elongation A [%] Structure
Brinell hardness HB
EN-GJV-300 5.2100 300 210 2Predo-minantly ferritic
140 - 210
EN-GJV-350 5.2200 350 245 1,5 Ferritic / pearlitic 160 - 220
EN-GJV-400 5.2201 400 280 1 Ferritic / pearlitic 180 - 240
EN-GJV-450 5.2300 450 315 1Predo-minantly pearlitic
200 - 250
EN-GJV-500 5.2301 500 350 0,5 Pearlitic 220 - 260
Ductile cast iron› according to DIN EN 1563 – excerpt
Material code Material no.
Tensile strength Rm [N/mm²]
0.2% yield strength Rp0.2 [N/mm²]
Elongation A [%] Structure
Brinell hardness HB
EN-GJS-400-18-LT 5.3103 400 240 18 Ferritic 130 - 175
EN-GJS-400-15 5.3106 400 250 15Predo-minantly ferritic
135 -180
EN-GJS-500-7 5.3200 500 320 7 Ferritic / pearlitic 170 - 230
EN-GJS-600-3 5.3201 600 370 3 Pearlitic / ferritic 190 - 270
EN-GJS-700-2 5.3300 700 420 2Predo-minantly pearlitic
225 - 305
Material code Material no.
Tensile strength Rm [N/mm²]
0.2% yield strength Rp0.2 [N/mm²]
Elongation A [%] Structure
Brinell hardness HB
EN-GJS-450-18 5.3108 450 350 18 Ferritic 170 - 200
EN-GJS-500-14 5.3109 500 400 14 Ferritic 185 - 215
EN-GJS-600-10 5.3110 600 470 10 Ferritic 190 - 220
Properties of ductile cast iron Castability Strength (similar to steel) Toughness (similar to steel)
Machinability Cost / performance ratio as compared to steel
Resource-conserving
Mechanical properties on cast-on samples*
Solid-solution strengthened nodular cast iron
Properties of lamellar graphite cast iron
Castability Vibration dampening Resistant to compressive stress
Machinability Thermal conductivity Dimensional stability
Lamellar graphite cast iron› According to DIN EN 1561 – excerpt
Material code Material no.Diameter of the tensile specimen [mm]
Tensile strength Rm [N/mm²]
Brinell hardness HB Structure
EN-GJL-200 5.1300 20 200-300 185 - 225 Pearlitic
EN-GJL-250 5.1301 20 250-350 205 - 250 Pearlitic
EN-GJL-300 5.1302 20 300-400 225 - 270 Pearlitic
Mechanical properties on cast-on samples*
* The tensile strength and Brinell hardness in the casting are strongly dependent on the wall thickness.
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Material designation FC-MK-300
FC-MK-350
FC-MK-400
FC-MK-450
FC-MK-470
FC-CW-40
FC-UN-20
Varia-ble Unit
Tensile strength Rm MPa min. 400 450 500 580 600 400 580
0.2% yield strength Rp0,2 MPa min. 300 350 400 450 470 240 450
Elongation at break A % min. 18 18 14 13 10 18 13
Brinell hardness - HB 135-180 170-200 185-215 195-225 200-230 130-175 195-225
Structure - - Ferritic
ISO V notched bar impact work (average from three specimens)At -40 +/-2°CAt -20 +/-2°CAt -23 +/-5°C
KV J n.s. n.s. n.s. n.s. n.s. >10 n.s.
Notched bar impact work (average from three specimens) un-notched speci-menAt -20 +/-2°C
- - n.s. n.s. n.s. n.s. n.s. n.s. >10
Density ρ g/cm³ 7,1 7,1 7 7 7 7,1 7
Shrinkage % 0,8-1,2 0,8-1,2 0,8-1,2 0,8-1,2 0,8-1,2 0,8-1,2 0,8-1,2
MEUSELWITZ GUSS FERROCAST
Technological and physical values
n.s. › not specified MK › solid-solution strengthened CW › ColdWind UN › un-notched (un-notched specimen) Guaranteescompliancewithspecifiedproductproperties
asearlyasinthedesignphase.
Providesbestconditionsfortheconceptionofnewproducts.
Enhancesthepresentutilizationvalueofexistingstructural components.
Onewaytoimplementlightweightdesign.
FERROCAST
Experience related materials advice
Meuselwitz Guss company profile20
Meuselwitz Guss Eisengießerei GmbH Industriepark Nord 04610 Meuselwitz
Phone +49 3448 82 0 Fax +49 3448 82 202
Web www.meuselwitz-guss.de E-mail [email protected]
CONTACT
SAXONY-ANHALT
THURINGIA
SAXONY
Meuselwitz
Leipzig
Gera
Chemnitz
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