Grumolo delle Abbadesse, Italy
Grumolo delle Abbadesse, Italy

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Carpinelli A.,Societa delle Fucine S.r.l. | Palomba R.,ThyssenKrupp | Mignone A.,Societa delle Fucine S.r.l.
ThyssenKrupp techforum | Year: 2011

Market demand for ever bigger and heavier forgings, such as for rotors and generator shafts for thermonuclear plants with outputs of up to 1,600 MW and back-up rolls for plate mills up to 6 m in width, has prompted ThyssenKrupp Acciai Speciali Terni (AST) to design and carry out all the plant engineering changes necessary to manufacture ingots of 500 t and more. With these ingots, currently the largest ever manufactured in Europe, AST and its subsidiary Societa delle Fucine (SdF) are able to supply the international market with rotor shafts and generators for nuclear or conventional plants, in addition to back-up rolls for rolling mills with a shipped weight of up to 2501.


De Angelis A.,University of Perugia | Moschitta A.,University of Perugia | Carbone P.,University of Perugia | Calderini M.,Societa Delle Fucine S.R.L. | And 3 more authors.
IEEE Transactions on Instrumentation and Measurement | Year: 2015

In this paper, an ultrasonic positioning system is presented and characterized, based on the usage of a portable grid of beacons and of a few fixed anchors. Since the beacon grid can be moved to guarantee line-of-sight transmissions, the proposed strategy is potentially suitable for accurate positioning of a mobile object in an environment with a complex geometry. The system was tested experimentally, exhibiting a subcentimeter positioning accuracy in a range up to 4 m. © 2015 IEEE.


Curbis F.,University of Perugia | Mengaroni S.,University of Perugia | Calderini M.,Societa delle Fucine S.r.l. | Neri S.,Societa delle Fucine S.r.l. | And 3 more authors.
Metallurgia Italiana | Year: 2013

To fulfill the industrial demand of differentially hardened back up rolls with increased service performances and reduced costs, research into new chemical compositions of traditional steels, based on 3%Cr and 5%Cr has been carried out, to optimize the combination between micro-structure and mechanical properties. The effect of alloying elements on hardenability and mechanical properties of both 3% and 5% Cr steel with low Mo content has been evaluated. The hardenability of different material variants is determined by both experimental tests and metallurgical models, thereby allowing a direct comparison between the considered materials. The effect of tempering conditions (time and temperatures) is analyzed and aimed at defining the proper process conditions, suitable for achieving the desired mechanical properties and reaching in-service performances comparable to those of standard products. Moreover, the ESBD analysis revealed that the content of residual austenite was lower that the critical value for roll reliability.


Curbis F.,University of Perugia | Mengaroni S.,University of Perugia | Cianetti F.,University of Perugia | Calderini M.,Societa Delle Fucine S.r.l. | Neri S.,Societa Delle Fucine S.r.l.
Metallurgia Italiana | Year: 2014

In this paper the austenitizing phase of differential quenching treatment for large steel forgings is presented. Time and temperature are the variables that could be industrially-controlled in each heat treatment; so it is working on them that makes possible to optimize the process and then to maximize the final product quality. The analyzed products are the forged back-up rolls: they are characterized by an accurate thermal cycle after plastic deformation. Actually, after a preliminary thermal cycle realized to facilitate the rough machining operations, they are differentially quenched in order to increase the working layer hardness, which thickness is function of customer's specifications. Numerical analysis and, more precisely, FEM simulation, is a useful forecast tool to improve a scientific approach in industrial criticality resolution, especially when product and laboratory samples dimensions ratio is very high like in this case. In this field the obtainable results from a FEM analysis are thermal field, phase distribution and thermal induced stress distribution after heat treatment. In this case of study the FEM software used is Forge 2011.


De Angelis A.,University of Perugia | Moschitta A.,University of Perugia | Carbone P.,University of Perugia | Calderini M.,Societa Delle Fucine S.r.L. | And 3 more authors.
Conference Record - IEEE Instrumentation and Measurement Technology Conference | Year: 2014

In this paper, an ultrasonic positioning system is presented and characterized, based on the usage of a portable grid of beacons and of a few fixed anchors. Since the beacon grid can be moved to guarantee line of sight transmissions, the proposed strategy is potentially suitable for accurate positioning of a mobile object in an environment with a complex geometry. © 2014 IEEE.


Ricci M.G.,Tecnocentro Engineering S.r.l | Santin G.,Tecnocentro Engineering S.r.l | Cascariglia F.,Tecnocentro Engineering S.r.l | Scimiterna E.,Tecnocentro Engineering S.r.l | And 2 more authors.
Metallurgia Italiana | Year: 2011

Heat treatments of steels consist in a modification, in hot conditions, of the initial crystal lattice of such alloys and represent one of the most delicate step in the industrial production of forgings. In this frame, one of the most critical stages is quenching, which consists in rapid cooling of steel pieces at high temperature, in water or oil or in a polymer water solution (aquaquench). It is a process which is intrinsically unstable, complex from a physical point of view, which can be hardly predicted without using suitable simulation software. If not carefully carried out, this heat treatment can be inefficient or even harmful, causing fracture triggering, or, worse, directly the breakage of the piece. Of course, the bigger the forging, the greater the importance of estimating the process dynamics and, consequently, designing the plant configuration to obtain the expected final results, in order to avoid heavy economical losses deriving from a bad treatment. In this work a study of the water quenching process of large industrial forgings, made of SA 508 steel and intended for nuclear applications is presented. This is carried out by means of transient thermo-fluidsimulations in CFD environment (Computational Fluid Dynamics). The models have been validated by comparing the numerical results with the ones obtained by experimental trials carried out on steel test samples, having suitable dimension and properly instrumented: the results have shown that the average error is below 3%, while the maximum error is below 10%. These results confirm that the chosen method suitably simulates the physical phenomenon and so it can be extended to study a wide range of cases, in order to provide a valid and reliable support for large forgings Manufacturers.

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