FORGING THE FUTURE NOW

The origin of the metallurgical industry in Terni dates back to 1884, closely linked to the spread of steel making on an industrial scale in Italy. This large metallurgical plant, named "Terni" until 1989, was founded in response to a strategic need. The heavy demand for products on the part of the newly created Italian Navy imposed that this industry should be placed in a geographically strategic area, which would become later a key factor in its further development into an integrated and diversified structure. At the end of World War II the Italian metallurgical industry was thoroughly reorganized on a completely new basis: the manufacturing of special products for power generation and industry. Within this framework, the Terni plant was assigned the role which was most appropriate to its experience and to its facilities: the manufacture and transformation of high quality steels. Such activity placed the “Terni” as it was, Società delle Fucine nowadays, among the few worldwide leading manufacturers capable of producing heavy and medium forgings in a large variety and with advanced manufacturing techniques.

Società delle Fucine has carried forward the expertise and innovative will, characteristic of the century old manufacturer, the “Terni”. Società delle Fucine operational structure is made up of the company headquarters and factory, which are located in Terni (100 Km north-east of Rome), optimally linked by road and rail for domestic communication network and served by Rome and Perugia airports and Civitavecchia and Livorno ports for international communications.Società delle Fucine productive unit covers a 120.000 sq/m area, manufacturing a wide range of forgings from carbon, high-and medium-alloyed and stainless steels.Società delle Fucine products are destined to primary economy sectors, such as power generation and industry where absolute reliability is required to assure working safety and, at the same time, economic advantages in its management.All quality steels, the development of which stems from a century-old metallurgical experience and their manufacture comply with the latest steelmaking techniques.

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Forgings Stainless steel welded tubes

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ThyssenKrupp Acciai Speciali Terni S.p.A.

Products

Power generation

Power generation,

Industrial, Naval, Aerospace,

Chemical, Petrochemical & Nuclear

Rolling rolls

Tool steel

Società delle Fucine forgings are mainly destined to Power generation, Mechanical, Chemical, Petrochemical, Off-shore and Aerospace applications: all sectors where dependability of machinery and plant components is essential for safety and continuity of services. All such requirements are guaranteed by the rigid application of manufacturing process procedures and severe quality controls.

For this sector, which includes Hydroelectric, Thermoelectric, Gas or combined power plants and Nuclear power plants, Società delle Fucine produces:

• Monobloc LP rotor forgings• Monobloc HP-IP rotor forgings• Monobloc combined LP-IP rotor forgings• Monobloc generator rotor forgings• End shafts, spindles and discs for welded and shrunk-on

rotors• Hydroelectric rotor shafts• Hydroelectric rotor rings• Hub for pelton wheels• Shafts and discs for gas turbine• Windmill shafts

Chemical, petrochemical & nuclear

The Chemical, Petrochemical and Nuclear sector represents for Società delle Fucine a strategical business line, where the following components are produced:

• Tube plates• Shell courses for chemical, petrochemical and steam gene-

ration industry• Pumps and valves for nuclear and fossil power stations• Forged components for nuclear reactors, steam generators,

pressurizers, etc.• Flasks for nuclear fuel transportation and storage• Section for welding activities; welders qualified according to

ASME code section IX; welding processes: SMAW, SAW, MIG, MAG,TIG.

Rolling rolls

Società delle Fucine produces a wide range of Back-up Rolls and Hot working Rolls for flat and shaped products. Weight of shipped rolls ranges up to 240 t. The choice of carbon and alloy elements aims to achieve the required mix of different properties, such as hardenability, hardness, toughness, fatigue and thermal cracking resistance. All machining steps are performed by using modern Numerical Control Lathes. Rolls are shipped by Società delle Fucine machine finished, ready for service.

Tool steel

Società delle Fucine manufactures a range of die-block steels, suitable for molding of plastics, steel hot-pressing, die-casting and hot extrusion of light alloys and for ancillary components.To ensure suitability of die-blocks to their application, steel is selected based on its general characteristics as a whole, i.e. taking into account its physical, mechanical and technological features.Machinability, hardness, polishing, photo-etching, toughness, wear resistance, fire-crack resistance and corrosion resistance are the main characteristics required for the different applica-tions.

Industrial, naval and aerospace

These are other significant fields of application, on which Società delle Fucine focuses its attention producing components for:

• Shipbuilding• Aereospace projects• Off-shore platforms• Forging presses

Facilities

Società delle Fucine is equipped with the most up to date facilities for: • Steelmaking / Ingot Pouring• Heating for forging• Forging• Machining• Heat Treatment • Final Machining• Destructive and Non Destructive testing

SteelmakingSocietà delle Fucine steelmaking is equipped with:• Two Electric Arc Furnaces up 180 tons• One ASEA-SKF refining plant up to 180 tons ladle• Two 140 tons, fully automatized Argo-Oxygen-Decarburization

(AOD), converters• One VD/VOD plant up to 140 tons capacity• Stream Degassing vacuum tanks for pouring up to 530 tons

ingots • Bottom pouring pits for solid and hollow ingots up to 450 tons

Heating for forgingThe heating for forging shop of Società delle Fucine is set up with: • Four natural gas heating furnaces up to 1000 t capacity, with

centralized remote temperature control

ForgingThe forging workshop of Società delle Fucine is set up with: • One 12.600 tons capacity hydraulic press equipped with an

integrated 700 tons*meter manipulator • One 5.000 tons hydraulic press equipped with an integrated

manipulator• Oxygen cutting machine up to 3000 mm in diameter.

MachiningSocietà delle Fucine machining shop is equipped with: • Thirteen horizontal numerical control lathes up to 300 tons

capacity • Five vertical numerical control lathes up to 250 tons capacity• Four milling machines• Two grinding machines up to 300 tons capacity• Two boring and honing machines up to 300 tons capacity

Heat treatmentSdF heat treatment shop is equipped with: • Vertical and horizontal furnaces • Vertical and horizontal water quenching tanks• Two rotating furnaces with quenching machine• One vertical oil quenching tank

Final Machining • The final machining of SdF is performed on dedicated vertical

and horizontal lathes and two grinding machines up to 300 ton capacity

• UT examinations are performed according to standards and specific procedures using manual and automatic facilities

Research & DevelopmentThe forging production area has always been accorded particular consideration because of the magnitude and complexity of the metallurgical problems involved and the need to produce highly dependable materials meeting the most challenging and sophisticated requirements. At Società delle Fucine research work is steadly carried out for the enhancement and rationalization of consolidated technology such as the optimisation of forging and heat treating cycles or the study of solidification of heavy ingots by means of mathematical models. Yet another activity is for the application on industrial scale of new technology such as extruded nodes for off-shore platforms and monobloc channel heads with integral extruded nozzles, etc.In case where sophisticated equipment is required, Società delle Fucine is effectively supported by Centro Sviluppo Materiali (CSM) of Rome, which has a branch in Terni.This co-operation aims not only at a thorough investigation and faster problem solution but, furthermore, it pursues an exhaustive problem-analysis through basic research work.The high level of quality of Società delle Fucine products is obtained by its technologically advanced facilities, laboratories and equipment and by the presence of a specialized engineering team, fully qualified for the very complex and delicate job of analysing materials within the manufacturing process.

Quality controlPersonnel proficiency and equipment variety and reliability guarantee a complete high-level quality control for SdF products. Our non-destructive test laboratory includes:

• Automatic ultrasound test equipment for shafts up to 150 ton;• 12 portable US test units;• 8 units 6000-10000 A for coloured or fluorescent magnetic particle tests;• Endoscopes for axial hole testing;• Penetrant and visual test units;

All non-destructive test personnel is qualified and certified for Level II tests, according to ASNT SNT-TC-1A and EN-473. The correctness and completeness of test procedures and their conformity with the most important national and international standards (EN, ISO, ASME, RCCM, etc.) as well as with customer specifications are guaranteed by the long, proven experience of Level III test operators.Our destructive test laboratory is equipped with:

• Furnaces for Simulated Post Weld Heat Treatment of samples;• Machines for room temperature, cold and hot tensile testing;• Pendulums for room temperature, cold and hot impact testing;• Fixed and portable Brinell, Rockwell and Shore hardness meters;• Creep testing machines;• Fatigue testing machine;• Drop-weight testing machine;• Portable quantometer for PMI.

The quality control structure includes a Dimensional Inspection and Calibration Laboratory that is equipped with the most updated metering equipment to guarantee the reliability, repeatability and reproducibility of measurements and with Chemical and Metallographic Examination Laboratories that are located in our industrial site.

Quality AssuranceThe principle at the basis of the approach to quality of Società delle Fucine can be summarised as follows: to identify and meet the requirements of customers, both internal and external. Based on this philosophy, the company has for decades applied a strict Quality System according to which all product fabrication and inspection steps are performed.This system has been assessed and accepted by all our main customers as well as by important certification bodies such as: the italian IGQ – Istituto di Garanzia Qualità, a member of IQ-Net, the german TÜV SÜD and the british Lloyd’s Register.Actually, our quality system has been one of the first Italian QA systems to be accepted by ASME for the manufacture of forged products for nuclear applications, that are required to comply with Section III, NCA-3800. Our quality system is steadily updated to meet the ever stricter specifications of reference standards and customer requirements.

A Company of ThyssenKrupp Acciai Speciali Terni Group

Società delle Fucine - Viale B. Brin 218 - 05100 Terni (Italy) Ph +39 0744 4881 - F +39 0744 470912 info.sdf@thyssenkrupp.com

www.fucineterni.it