A story about centrifugal casting technology. An introductory film made by order of the USSR Ministry of Heavy, Power and Transport Machine Building, promoting new developments of the Central Research Institute of Machine Building Technology on the technology market.
Alternating shots of the interiors of modern power plants.
Pipelines at a power plant.
The walls of the pipes must withstand high pressure up to 25 megapascals at a superheated steam temperature of 545 degrees Celsius.
The Central Research Institute of Mechanical Engineering Technology is solving the problems of creating large-diameter pipes.
Scientists are conducting research at the experimental site of their institute.
Scientists have proposed, along with other methods of producing large-sized cylindrical blanks, to use the centrifugal casting method.
A model explaining the essence of the method.
Molten metal is poured into a mold rotating at the required frequency.
Under the influence of centrifugal forces, the metal spreads in an even layer over the entire cylindrical surface of the mold, crystallizing in the shape of a pipe.
The method allows for the production of pipes with a given wall thickness and to obtain them seamless, and therefore more reliable.
The introduction of the method into production gave a positive result.
Pouring steel into a mold.
Obtaining a finished pipe.
Pipe samples.
Many technical problems arose during the manufacture of such large-diameter pipes.
It turned out that increasing the diameter and thickness of pipes, using large masses of metal leads to the occurrence of numerous defects in the product.
Alternating frames with defects in the material.
A scientist studies material samples under a microscope.
Metal structure on a computer display.
A special technique developed by scientists, modern equipment and devices, as well as numerous experiments helped the Central Research Institute of Mechanical Engineering Technology find ways to combat each of the defects.
This made it possible to obtain a dense homogeneous metal structure characterized by high isotropy.
Production of large-diameter pipes at PO BUMMASH in Izhevsk.
Machine for the production of large-diameter centrifugal pipes.
A mold drive consisting of two DC motors is installed on a massive foundation.
The fixed position of the support rollers allows installing molds of different diameters.
The mold is installed on the drive support rollers.
Horizontal movement of the mold is prevented by a special device - a flange.
Then the machine casing is installed.
The mold is pressed from above by rollers.
After installing the end caps of the mold, the machine is ready for operation.
Different types of molds.
Heating the mold with gas burners.
Using a special device, heat-insulating and non-stick materials are poured into the mold.
A cartoon showing this process.
The metal is melted.
A metal sample is taken.
The plant laboratory analyzes the metal.
Steel that satisfies the technologists in chemical composition is poured into a ladle, which is fed to the pouring device of the centrifugal machine.
Simultaneously with the pouring of the metal, spray cooling of the outer surface of the rotating mold is turned on.
During the pouring process, the required portion of liquid steel is accurately weighed using a tensor scale.
When pouring metal, synthetic flux is fed into the mold.
Floating to the surface of the melt, the flux cleans the metal of harmful impurities and protects the casting from the undesirable cooling effect of air.
Thus, when using spray cooling and flux, conditions are created for a strictly directed process of metal crystallization.
Control panel for the casting process.
After crystallization and cooling to a certain temperature, the finished casting is removed from the installation.
The pipe is carried around the shop by crane.
Centrifugal casting
Moscow Izhevsk
CNIITMASH Izhevsk PO BUMMASH
The next operation in the technological process of manufacturing centrifugally cast pipes is heat treatment.
Loading the pipes into the furnace.
The worker reads the control devices.
After heating the pipes in the furnace, holding them and slowly cooling them, the metal structure is aligned.
Quality control operations.
The first of them is checking the physical and chemical properties of the metal.
A ring template is cut off from the blank for comprehensive testing in the plant's laboratory.
Testing the impact and strength properties of the metal.
Laboratory equipment.
Micro and macrostructures, content of non-metallic inclusions are examined.
Research process, equipment operation.
After a positive conclusion from the laboratory, the casting is sent for mechanical processing.
The exact geometric parameters of the centrifugally cast pipes are confirmed by small allowances for metalworking.
Careful ultrasonic testing.
A pipeline made of centrifugally cast pipes.
Use of centrifugally cast pipes at a power plant.
Loading blanks of centrifugally cast pipes onto a cargo platform.
Alternation of personnel from industries that use centrifugally cast pipes.
Finished pipes.
Unloading a pipe from a mold.
This method is used in the manufacture of shaped castings.
Product samples.
Diesel engine builders use technology and centrifugal machines to manufacture engine liners for heavy-duty dump trucks.
Samples.
The institute's technology is used to manufacture special-purpose bimetallic pipes.
Pipe samples.
Author's certificates and patents for the production of centrifugal casting of pipes of various formats.
Alternation of frames from the film.
Centrifugal casting, Centrifugally cast pipes, Shaped casting, Bimetallic pipes
Moscow Izhevsk
TsNIITMASH. Izhevsk PO BUMMASH.