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 northeast 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 mediumalloyed 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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Società delle
Fucine
Tubificio di
Terni
Aspasiel
Forgings
Stainless steel
welded tubes
Information
Technology
Products
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.
Power generation
For this sector, which includes Hydroelectric, Thermoelectric,
Gas or combined power plants and Nuclear power plants,
Società delle Fucine produces:
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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
Power generation,
Industrial, Naval, Aerospace,
Chemical, Petrochemical & Nuclear
Rolling rolls
Tool steel
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.
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 generation 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.
Industrial, naval and aerospace
These are other significant fields of application, on which Società
delle Fucine focuses its attention producing components for:
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Shipbuilding
Aereospace projects
Off-shore platforms
Forging presses
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 applications.
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
Steelmaking
Società 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 forging
The 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
Forging
The 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.
Machining
Società 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 treatment
SdF 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 & Development
The 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 control
Personnel proficiency and equipment variety and reliability guarantee a complete highlevel 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 Assurance
The 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
[email protected]
www.fucineterni.it