344 bloor street w, suite 607, toronto, on canada m5s 3a7 · 8 quality control - pattern &...

344 Bloor Street W, Suite 607, Toronto, ON Canada M5S 3A7www.lprglobal.com | www.uskoreahotlink.comTel.: +1 416-423-5590E-Mail: [email protected]

Contents Page

Industrial Steel Casting Foundry 3

Steel Casting Material & Product Capability 4

Steel Casting Capacity 5

Steel Casting Manufacturing Processes• Shell Mold Castings• Sand Mold Castings

6-7

Quality ControlPattern & Molding ProcessMelting ProcessHeat Treatment & NDESteel Casting Testing Equipment

8-12

Steel Casting Client List & Recent Projects 13

Headquarters & Foundry (Cheonan, Korea)

http://www.uskoreahotlink.com/products/manufacturing/shell-molding-sand-castings-foundry/

http://www.uskoreahotlink.com/products/manufacturing/shell-molding-sand-castings-foundry/ 3

Industrial Steel Casting Foundry

Core Business AreasLPR Global specializes in industrial steel casted components with heat-resistant and wear-resistant characteristics for valves, pumps, and equipment for the oil & gas industry, power generation, steel industries, and commercial vehicles. Some of the steel casting materials we cast most frequently include carbon steel, heat-resistant steel, corrosion-resistant steel, wear-resistant steel, Ni based alloy steel, and duplex stainless steels.

Our industrial steel castings have been supplied to various EPC projects and clients in the past. Notable clients include companies such as Kurimoto, Fuji Car Manufacturing, Hyundai, WEIR, Doosan Heavy Industries, and Advanced Valve Solutions.

Globe-Valve Body Wafer Butterfly Body Elbow

Grate Bar TrimTrain Parts Pump

Lug Butterfly Body

Hollow BallCavity BallMixer Parts Disc

http://www.uskoreahotlink.com/products/manufacturing/shell-molding-sand-castings-foundry/ 4

Steel Casting Material & Product Capability

Industrial Steel Casting Material Capability

Item Standard Number Typical Grade

Carbon Steel

ASTM 216 WCB, WCA, WCC

ASTM 352 LCB, LCA, LCC

JIS G5101 SC42, SC46, SC49

JIS G5151 SCPH1, SCPH2

Low-alloy SteelASTM A217 JIS G5111

WC1, WC4, WC5, WC6, WC9, C12A

SCMnCr2, SCMnCr3

SCMnCr4, SCMn1, SCMn2, SCMn3, SCMn5

Heat-resistant Stainless Steel

ASTM 297 HC, HD, HH, HE, HK30, HP

JIS G5122 SCH2, SCH11, SCH13, SCH17, SCH21, SCH24

Corrosion-resistant Stainless

Steel

ASTM A217 JIS G5111

WC1, WC4, WC5, WC6, WC9, C12A, SCMnCr2, SCMnCr3, SCMnCr4, SCMn1, SCMn2, SCMn3, SCMn5

Wear Resistant Stainless Steel

ASTM A743ASTM A352JIS G5121

CA15, CA40, CA15M, CA6NM, SCS1, SCS2, SCS3

Ni Base Steel ASTM A494N-12MV(HASTELLOY B), CW-12MW(HASTELLOY C), CZ-100, CY40(INCONNEL), M35-1, M30C(MONEL), ALLOY 20(UNS N08020)

Others AS CUSTOMER REQUEST

Industrial Application Machinery Components Valves

• Tube Supports• Round Hammer• Crushers• Grate Bars• End Bells• Pump Casings• Pump Covers• Pump Impellers• Brackets• Rail Vehicle Components• Elevator Components

• Incinerator plant components

• Heavy Machinery Components

• Mining Equipment Components

• Construction Equipment Components

• Gate Valves• Check Valves• Globe Valves• V-Notch Valves• Butterfly Valves• On-Off Ball Valves• Plug Valves• Rotary Valves• Cage-Guided Valves• Turbine Bypass Control

Valve• Single-seated Valves

5

Steel Casting Capacity

Sand Casting FacilityCapacity: maximum 2,500kg / pcFlask Size: 3500 x 3500 x 500 mmMold Line: 5kg to 3,000kgPattern Type: Wood, Aluminum, etc. (loose pattern / mounted pattern)Main Products: Valve, pump, machinery, mining, and train components

Shell Mold Casting FacilityCapacity: ~50kgShell Mold Line: 1kg to 50kgPattern Type: Steel (mounted pattern)Pattern Size Limit: 600 x 500 x 250 mmMain Products: incinerator, valve, train, and mining components


CNC Machining Capability Post CastingCNC VM960 L (2600x 950mm) machine

De-Molding ProcessMelting Furnace Initial Pattern & Combination Pattern Line

Total Production CapacityCapacity: 300 Ton / monthValve Components: 2,200 kg / eachMachinery Components: 2,500 kg / each

6

Steel Casting Manufacturing Processes

Shell Mold Casting (up to 50kg castings)

1. Melting 2. Sample Analysis 3. Pouring

4. Cooldown 5. First Shot Blasting 6. Cutting

7. Micro Grinding8. Second Shot

Blasting9. Visual Inspection

10. Machining11. Final Dimensional

Check (10%)12. Anti-corrosion

Packing and Shipping


7

Steel Casting Manufacturing Processes

CO2 Sand Casting (up to 2,500kg castings)

1. Melting 2. Sample Analysis 3. Pouring

4. Shakeout 5. First Shot Blasting 6. Cutting

7. Grinding 8. NDT Testing9. Welding Repair (If

needed)

10. Heat Treatment11. Second Shot

Blasting12. Dimensional

Inspection


8

Quality Control - Pattern & Molding Process

Strict casting process and quality control is how we maintain competitive lead time, price and overall quality and maintain existing business against competitors in the steel casting market. Such control procedure allows us to save time, and materials, and enables us to re-use scrap materials with chemical compositions in check.


Joint work between casting technicians and advisory R&D centers on cracks, shrinks, internal porous prevention design

Wooden Pattern CNC machining - thickness up to 100µm / Pattern and Casting shrinkage rate calculation by section

Reverse Engineering & Drawing

Casting Plan & Wooden Design

Pattern Making

Mold Process – Ceramic Molding

9

Quality Control – Melting Process


Alloy Design (Din 1.4832 / GX25CrNiSi20-14)

Ferrous Material & Scrap (Certified)

Degassing : Ca-Si &/or Ti

Ladle Tem. Over 250℃ holding Mold & Scrap Baking

Ladle Preheating Mold/Scrap Baking Chamber

10

Quality Control – Melting Process


Chemical Composition Check

Pouring

Target Chemical Composition

Y Block Tensile Specimen

Sample Getting Polishing Spectroanalysis

C Si P S Mn Cr Ni Mo

Din

1.48320.15~0.35 0.5~2.5 0.04max 0.03 max 2.0 max 19.0 ~21.0 13.0 ~15.0 0.5max

Target 0.25 1.20 0.02 0.01 1.2 20.0 14.0 0.17

11

Quality Control – Heat Treatment & NDE


Heat Treatment

According to ASME B 16.34 Spec.For checking skin & inner side soundnessPT (Penetrant Testing : Skin inspection)RT (Radiographic Testing) : Insideinspection

NDE Test (RT, PT, MT, UT)

[RT Inspection Process]

Tensile Test (Temp. RT)

Hardness Test : N/A

Charpy Impact Test : N/A

Mechanical Properties

Tensile (MPa) Yield (MPa) El.(%)

Din 1.4832 450≤ 230≤ 10≤

Target 470≤ 250≤ 20≤

Actual 483 277 24

12

Steel Casting Testing Equipment

Radiographic Testing (RT)

Ultrasonic Testing (UT)

Equipment Brand Standard/Model #

X-Ray Generator RIGAKU, ICM, Toshiba 130KVP 5mA to 300KVP 5mA 9

γ-Ray Project (Ir-192) Amersham, I.N.C, Sentinel 660, 660B, 120Ci, 140Ci, IR-100, 880(Delta) 52

γ-Ray Project (Co-60) Amersham 741, 33Ci, 680B, 110Ci 6


UT Equipment K/K, GE, Sonatest, PanametricsUSK-7S, USK-8S, USN58L SW, USN60SW,

USM 35X DAC, SS 130, EPOCH4B, SS130L, SS140L, SS150L

33

Ultrasonic Thickness Meter TOKIMEC, Olympus UTM100, 26 MG 2

Magnetic Testing (MT)


Handy Magna(YOKE)Kyung-Do, Nawoo, Kang-sang,

Pacific Enterprises

USK-7S, USK-8S, USN58L SW, USN60SW, USM 35X DAC, SS 130, EPOCH4B, SS130L,

SS140L, SS150L33

UV Meter Spectronics DM-365XA 7

Prod Kyung-Do, Kangsung 1500K, KS-05-S-2500 2

Clamp Meter National, Hioki 1200K, 3285 2


Penetrant Testing (PT)

Other


PT Comparator Kyung-Do A 8

Surface ThermometerAsmart Sensor, Yokokawa,

R.K.C., TESAR530, AR852B, YW 2455, DP-100, TES

130010


Black LightKyung-Do, Kangsung, Nawoo,

Denshijiki, SpectronicsBD-100, BD-100A, GS-100S, UV-100, UV-100S, BS-200, UV-125, BD-70, EK-3000

29

Lux MeterTES Electrical Electronic Corp,

CEM, TESTO, SmartsensorLX-101, LX-102, DT-8808, TES-1332A,

AR81310

Eddy Current Systems Hocking Phasec 3.4 1

LT Equipment (BT) Kyung-Do ILP-A01, ILP-A02, ILP-A03 3

Steel Casting Client List & Recent Projects

Power Plant

13

Client Product Remarks

Advanced Valve Solution V-Notch Valves A216 WCB, 12”, Class 600 RF

Doosan Heavy I & C Control Valves – Globe Valves, BFVs(Butterfly Valves)

Materials: WCB, F91, WC6Size: 2”-10” / Class 150-4500 BW

Eraring Power Plant Control Globe Valves A217 WC6, 4”, Class 600 BW

Gunjang Energy Control Valve A182 F91, 16" X 34“, Class 2500 BW

Hyosung Corporation Control Valve A351 CF8M, 3”, Class 150 RF

Korea Hydro & Nuclear Power Diaphragm Actuator A216 WCB, 6”, Class 150 BF

Petrochemical


SK Energy Control Globe Valves, On-Off Ball Valves Incheon, Korea

Arabian Amines Company Pressure Regulating Valves Saudi Arabia

Pars Petrochemical Co. Control Globe Valves, On-Off Ball Valves Iran

Honam Petrochemical Corp (HPC) Control Valve Daesan, Korea

Audco Italiana Srl Control Globe Valves Italy

Cirebon Electric Power Control Globe Valves, Butterfly Valves Indonesia


Steel Mill


Hyundai Steel V-Notch Valves A216 WCB, 12”, Class 600 RF

Doosan Heavy I& C Control Valves – Globe Valves, BFVs(Butterfly Valves)

Materials: WCB, F91, WC6Size: 2”-10” / Class 150-4500 BW

Eraring Power Plant Control Globe Valves A217 WC6, 4”, Class 600 BW

Gunjang Energy Turbine Bypass Control Valve A182 F91, 16" X 34“, Class 2500 BW

Hyosung Corporation Control Valve A351 CF8M, 3”, Class 150 RF

Other Industrial PlantsClient Product Remarks

AUDCO Italiana S.R.L Globe Valves and Spare Parts DN200 ASME 150#, Al-bronze material

Hyundai Steel Globe Valves, Pressure Regulating Valves 10" JIS 10K

Dongwoo Fine-Chem Single-seated, Cage-guided Valves A216 WCB, A351 CF8, A351 CF3M, SCS14A, Size: ½” - 14” / JIS 10K – JIS 40K

OCI (SK Materials) Single-seated, Cage-guided Valves A216 WCB, A351 CF8, A351 CF3M, SCS14A, Size: ¾” - 6” JIS 10K, ANSI 150

Hankook Silicon BFV, Single, Cage, V-Notch, Ball Valves A216 WCB, A351 CF3, A216 WCB¾”-30”, Class 150-600

LPR Global, Inc.344 Bloor Street W, Suite #607 Toronto, ON M5S 3A7 Canada

www.lprglobal.com | www.uskoreahotlink.comTel: +1 416-423-5590

E-Mail: [email protected]

344 bloor street w, suite 607, toronto, on canada m5s 3a7 · 8 quality control - pattern &...

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