Marcegaglia, China Yangzhou plant€¦ · Marcegaglia China 714,000 ... (ERW) Min. thickness (mm)...

China Yangzhou plant

TM

Marcegaglia China

714,000 sqm total area

153,000 sqm first phase covered area

EN norms production quality standards

Precision tubes from carbon and stainless steel

Yangzhou

Beijing

Shanghai

Hong KongMacau

Taiwan

Marcegaglia China spreads over a land of 714,000 m² located in Guangling Economic Development Zone, Yangzhou (270 km from Shanghai). The first phase of plant development includes 153,000 m² of covered production area equipped with European manufacturing systems, plus a 4,200 m² office building.

Marcegaglia tube production is implemented in complete accordance with EN norms including raw materials procurement, production, quality control, on time delivery and after-sale service, in order to supply top level complete solutions to our customers.

Quality and environment

Marcegaglia China is currently certified according to the most advanced international standards:•ISO 9001:2000 for the Quality Management system •ISO 14000 for the Environmental Management System•OHSAS 18000 for the Occupational Health and Safety management system

The ISO/TS 16949 required by the Automotive customers for the Quality Management System is currently under development.

In addition we guarantee:•strictcompliancewithEN norms including raw materials procurement, production, quality control, delivery, after-sale-service;

•samelevelofenvironmental standards required in EU is currently implemented;

•allmajorcertificationsinthesectorare being applied for manufacturing, production equipment are compliant with the latest energy saving criteria;

•highestlevelofservice to comply with Marcegaglia worldwide standards.

Production areas

All main production lines in Marcegaglia China are imported from Europe, represent the latest technology in the field of tube production and are a perfect “replica” of the lines operating within Marcegaglia European plants.

All the processes employed by Marcegaglia China are the same used in Italy, so that the same qualityand efficiency of European-made products can be guaranteed.

1) Coil slitting

2) Carbon steel welded tube mills

3) Stainless steel welded tube mills

4) Cold-drawn precision tube mills

1

2

5

7

3

4

6

5) Refrigeration tube mills

6) Pickling

7) Heat treatment

Carbon steel welded tubes (ERW)

Min. thickness (mm) 1,50

Max. thickness (mm) 16,00

Min. diameter (mm) 20

Max. diameter (mm) 254

SUPPLY CONDITIONS

- Dimensional tolerances according to manufacturing standard

- Special tolerances upon request

- Control documents 2.1, 2.2, 3.1, 3.2 according to EN 10204 and specific norm requirements

Round carbon steel welded precision tubes

Square carbon steel welded precision tubes

Rectangular carbon steel welded tubes


Main manufacturing standards

MANUFACTURING STANDARD

PRODUCT DESIGNATION

TREATMENT GRADE*

+CR1 Welded and sized+A Annealed +N Normalized+CR2 Welded and sized

E190, E320, E220, E370, E260, E420E155, E195, E235, E275, E355

SURFACE CONDITIONS

EN 10305-3 Round and shaped precision tubes

S1 From hot-rolled strip, blackS2 From hot-rolled strip, pickled

EN 10305-5 Square and rectangular precision tubes

EN 10219 Cold formed welded structural tubes (CE homologation)

S235JRHS275J0HS275J2HS355J0HS355J2H

(*) Upon request: supply of grades not included in the above mentioned standards

Manufacturing process

COILS SLITTING Tube fOrmING aNd weLdING

NOrmaLIZaTION STraIGHTeNING aNd CuTTING

NON deSTruCTIVe

TeSTING

PaCKaGING

Testing

STANDARD AND OPTIONAL TESTING

STA

ND

AR

D T

EST

Chemical analysis

Tensile test

Visual and dimensional test 100%

Flattening test or drift expanding test (*)

Roughness measurement

Eddy current test 100% acc. to EN 10246-3

Ultrasonic test 100% acc. to EN 10246-7

OP

TIO

NA

L TE

ST NDT of the full tube circumference for longitudinal imperfections

(*) The test method is at the discretion of the manufacturer; this option only applies for tubes supplied in the annealed or normalized delivery condition.

Typical applications

Marcegaglia has developed a unique know-how in the manufacturing of precision tubes to meet the strict dimensional and surface specifications requirements by manufacturers in key sectors such as constructions and mechanical engineering.


Precision tubes for steel structural work

Precision tubes for piling

Precision tubes for lifting equipment (building hoists and tower cranes)

Roller conveyor tubes

Precision tubes for pressure purposes

Precision tubes for automotive applications

Precision tubes for the cycle and motorcycle industry

Precision tubes for other industrial applications

The production program of Marcegaglia carbon steel welded tubes covers a wide range of structural and precision mechanical applications, guaranteeing specific suitability for subsequent processing.

Cold-drawn precision tubes (DOM)

SUPPLY CONDITIONS

- Tubes are supplied in 5000/8000 mm lengths unless otherwise specified in order



- Control documents 2.1, 2.2, 3.1, 3.2 according to EN 10204 and other specific norm requirements

Min. thickness (mm) 2 2

Max. thickness (mm) 15 24

Min. diameter (mm) 24 24

Max. diameter (mm) 245 245

Product range Welded Seamless

MANUFACTURING STANDARD

PRODUCT DESIGNATION

GRADE* TREATMENT

EN 10305-2 Cold-drawn welded tubes

E195E235E275E355

+C Hard. No final treatment after final cold drawing.

+LC Soft. Final heat treatment is followed by a suitable drawing pass (limited reduction of area).

+SR Stress Relieved. After final cold drawing, the tubes are stress relieved in a controlled atmosphere.

+A Annealed. After final cold drawing, the tubes are annealed in a controlled atmosphere.

+N Normalized. After final cold drawing, the tubes are normalized in a controlled atmosphere.

EN 10305-1

Cold-drawn seamless tubes (CDS), only for high thickness tubes (please refer to dimensional table)

E195E235E275E355

(*) Upon request: supply of grades not included in the above mentioned standards


Testing

STANDARD AND OPTIONAL TESTING

STA

ND

AR

D T

EST

Chemical analysis

Tensile test

Visual and dimensional test 100%

Roughness measurement

Eddy current test 100% acc. to EN 10246-3

Ultrasonic test 100% acc. to EN 10246-7

Impact test

NDT on longitudinal imperfections

OP

TIO

NA

L TE

ST Flattening test or drift expanding test


Precision tubes for hydraulic applications

Precision tubes for mechanical and automotive applications

Mechanical properties, as well as strictlycontrolled dimensionaltolerances, give cold-drawn tubes significant advantages for several precision applications.

China

Italy

Dedicated manufacturing plants based in Europe and Asia regularly supply the world marketswith a specialized production program for the hydraulic cylinder industry and other automotive applications.

Product range

Cold-drawn tubes for automotive and mechanical applications

TECHNICAL CHARACTERISTICS

GRADE E195, E235, E275, E355

TREATMENT +C, +LC, +SR, +A, +N

SURFACE TREATMENTS

•Outsidediameterandinside diameter: smooth as drawn (EN 10305-2)

•Onrequest: roughness Ra < 0.4 m

DIMENSIONAL TOLERANCE

•Standard: according to EN 10305-2

•Special: on request

OPTIONAL PROCESSING

Drawing in reactive oil Dephosphating

Cold-drawn tubes for cardans


GRADE E195, E235, E275, E355

TREATMENT +C, +LC, +SR, +A, +N

Ready-to-use cylinder tubes


GRADE E355

TREATMENT +C

SURFACE TREATMENTS

•Outsidediameter: smooth as drawn (EN 10305-2)

•Insidediameter: roughness Ra < 0.80 m (average 0.50÷0.60 m)

DIMENSIONAL TOLERANCE

•Insidediameter: ISO H9 (ISO H10 for thickness < 4 mm)

DELIVERY CONDITIONS

- Standard packaging with plastic caps and strapped bundles, standard weight approx. 1500 kg - Commercial lengths 5000-8000 mm, custom lengths upon request

- Surface protection

- Marking: MM E355 OD x ID EN 10305-2 +C - Heath

Product range

Cylinder tubes suitable for honing, skiving and roller burnishing


GRADE E355

TREATMENT +SR

SURFACE TREATMENTS


•Insidediameter: with stock allowance (for honing or skiving and roller burnishing)

Product range

DELIVERY CONDITIONS

- Standard packaging with strapped bundles, standard weight approx. 1500 kg

- Commercial lengths 5000-8000 mm, custom lengths upon request

- Surface protection

- Marking: MM E355 OD x ID EN 10305-2 +C - Heath

Cold-drawn tubes for telescopic cylinders


GRADE E355

TREATMENT +SR

SURFACE TREATMENTS


•Insidediameter: roughness Ra < 1.6 m

Product range

Stainless steel welded tubes (SS)

Min. thickness (mm) 1

Max. thickness (mm) 5

Min. diameter (mm) 19

Max. diameter (mm) 88.9

SUPPLY CONDITIONS



- Control documents 2.2, 3.1, 3.2 according to EN 10204 and specific norm requirements

Product range

PRO

CE

SS P

IPE

S FO

R F

LUID

S

EN 10217-7, (ASTM A270), (DIN 11850) Process pipes for the food and dairy industry

EN 10217-7, (DVGW GW541) Process pipes for drinkable water and press fitting

EN 10217-7, EN 10312 Process pipes for water treatment

EN 10217-7

EN 10217-7, (AD 2000 W2/W10), (PED 97/23)

EN 10217-7, (DIN 11866)

EN 10217-7, (ASTM A312 / A778)

Process pipes for the pulp and paper sector

Process pipes for chemical applications

Process pipes for pharmaceutical applications

Process pipes for oil and gas applications


ME

CH

AN

ICA

L A

PPLI

CA

TIO

NS EN 10296

EN 10217-7Round tubes for pumps and cylinders

EN 10217-7 Round tubes for elbows and fittings

EN 10217-7 Round tubes for heat resistances

EN 10296, (ASTM A554) Round tubes for automotive, exhaust systems

EN 10296, (ASTM A554)Round tubes for automotive, hydroforming appliance

EN 10296, (ASTM A554) Round tubes and box sections for automotive frame construction

AU

TOM

OTI

VE


Precision tubes for for fluids

Precision tubes for mechanicaland automotive applications

Feedwater heater tubes for power plants

Marcegaglia stands out todayas the world’s top producerof stainless steel welded tubeswith top-level certified manufacturingactivities worldwide and an overall capacity of 400 thousand tons per year.

LASER weldingRound tubes EN 10217-7, EN 10296

Standard delivery program

HF weldingRound tubes EN 10217-7, EN 10296

Refrigeration tubes (TR)

diametermm

nominal weight

g/m

4,75 70

5 74

6 91

6,35 98

8 126

9,50 152

SUPPLY CONDITIONS

- Outside diameter tolerance: nominal ±0,1 mm

- Wall thickness tolerance +0,05 mm / -0,10 mm


Tubes for condensers and refrigeration components

Marcegaglia special range of refrigeration tubes is manufactured according to the specific sector norms and tolerances, and is thoroughly tested to allow use in applications such as condensers and evaporators for heating and cooling systems and household appliances.

Production process design and development

The quality of the products manufactured by Marcegaglia China is suitable for many applications but it perfectly fit for the high requirements of OEM (Original Equipment Manufactures) customers. In order to supply OEM customers with high quality and service, Marcegaglia China has developed an accurate Process Control system and a special organization with Supply Chain and Project Management.

The Quality System is also designed and implemented in order to meet the highest standards.

Design and sample preparation are fundamental steps for supply new products to OEM customers. Marcegaglia China technical team has developed high skill and experience in product development for many international and domestic OEM customers.


COLLeCT aNd aNaLyZe marKeTING INfOrmaTION

maSS PrOduCTION

PrOduCT PrOCeSS deSIGN

SamPLe PrOduCTION

SamPLe PrOduCTIONVaLIdaTION

maNufaCTurING PrOCeSS CONfIrmaTION

deLIVery SamPLe aPPrOVaL by CuSTOmer

GeT CuSTOmer requeST

New product development flow chart

Two are the main steps required to develop prototypes for new products:

•Analysisofthecustomerrequirementsbasedon: - Manufacturing requirement - Steel grade (or chemical component) - Mechanical properties - Dimensions - Delivery condition - Surface conditions - Inspection certificate - NDT test

•Developmentofthemanufacturingprocess, which is different for each type of product.



•Choosethepropersteelgradebased on the chemical, mechanical and roughness requirements, Marcegaglia recommends the proper raw material based not only on EN standard, but also JIS, ASTM and GB standard.

•Calculatetheproperwidthofthestripsthanks to many years of experience in tooling manufacturing, Marcegaglia has successfully developed rules to select the exact width range for different sizes.

•Choosethetooling,includingtheinnerscarfingtools type for different Finpass rolls, we employ different radius of the scarfing knife, adjusting its height by adjusting the tooling pressure to obtain smooth surface of the welding area.

•SetuptheweldingparametersMarcegaglia has a well-developed data storing system to record all the welding parameters which can be reference for further production.

•Setuptheacceptancelevelofdefectbyeddycurrent test the acceptance level is set up according to customer requirement or general norms.

•Processandproductionvalidationdimensional test to verify the strip width, tooling and inner scarfing process. Flattening/drift expanding test according to different steel grade and also different norms to check the quality of the welding.According to customer requirement, we can also perform specific test 3.1 according to EN 10204.


Cold-drawn tubes (DOM)

•Choosetheproperhollowsizethe hollow size should be chosen so that the reduction rate is located in the proper range.The reduction rate is calculated with the following formula: Reduction rate=(100-((W1 / W2)*100))*100%W1: kg per meter of finish sizeW2: kg per meter of hollowsW1: =(OD1-T1)*T1*0.02466W2: =(OD2-T2)*T2*0.02466

•Selectthepicklingmodebased on the surface requirement, a phosphating or saponification process is performed.

•Choosethedie/Mandrelthe shape of the die/mandrel is a critical controlled characteristic. For TTC (ready-to-use) products, special dies are required.

•SetuptheStressRelieving(SR)processparameters according to different customer requirement, a different heating time, cooling time and cooling speed is set up.

•Verifythedrawingstressduring cold drawing, the mechanical stress should comply with the following formula:P/F=K < δsP: hollows drawing force (kgf)F: finished size section area (mm²)K: stress of drawing (kgf/mm²)δs: yield strength of finished tube (kgf/mm²)

•Processandproductionvalidationtesting is performed before/after cold drawing to verify the reduction rate. Test before/after SR to verify the furnace setting parameters. Process and production validation though statistic evaluation of the parameters.


Comparisons between Cold-Drawn Welded (CDW) and Cold-Drawn Seamless (CDS) tubes

The advantages of cold-drawn welded tubes when compared to cold-drawn seamless tubes can be summarized as: •Bettergeometry(ODandIDroundness)• Improvedqualitysurface(lessdefectafterpaintingand improve fatigue life)•Tightereccentricityandwallthicknesstolerances(the eccentricity is 3% max instead of 8%-10% normally guaranteed from seamless tubes)•Highertubesafety(tubesarecontrolled100%byultrasonic test and eddy current test)•Bettertoughnessatlowtemperature

For these reasons Marcegaglia China always recommend to use CDW tubes when the thickness permits it; indeed in Europe and USA, most cylinders are produced with welded tubes.


Stainless steel products (SS)

•Choosethepropersteelgradebased on the chemical, mechanical and roughness requirement, Marcegaglia recommends the proper raw material based not only on EN standard, but also JIS, ASTM and GB standard.

•Calculatetheproperwidthofthestripsthanks to many years of experience in tooling manufacturing, Marcegaglia has successfully developed rules to select the exact width range for different sizes.

•Choosethetooling,includingtheinnerscarfingtools type for different Finpass rolls, we employ different radius of the scarfing knife, adjusting its height by adjusting the tooling pressure to obtain smooth surface of the welding area.

•SetuptheweldingparametersMarcegaglia has a well-developed data storing system to record all the welding parameters which can be the reference for further production.

•Setuptheacceptancelevelofdefectbyeddycurrent test acceptance level is set up according to customer requirement or general norms.

•Processandproductionvalidationdimensional test to verify the strip width, tooling and inner scarfing process;flattening/drift expanding test according to different steel grade and also different norms to check the quality of the welding.According to customer requirement, we can also perform specific test 3.1 according to EN 10204.

Service center

The highly specialized service center machinery is dedicated to the the most diverse treatments and finishings of Marcegaglia product range of carbon and stainless steel tubes. Tailor-made services include cutting, end-finishing, special packaging and on-time scheduled delivery, plus a series of additional processing according to customer defined special requirements.

In addition to standard supply conditions, additional processes or solutions can be provided according to customers’ requirements.

Optional processing

•Suitabilityforsubsequentgalvanizing•Completenormalization or weld area normalization•Additionalheattreatments•Weldseamremoving•Specialendfinishing•Cuttolength•Customerdefinedmarking•Restrictedtolerances•Weldingpositioncontrol•Surfaceroughnessmeasurement•Deliverywithoutcorrosionprotection (degreased)•Specificcorrosionprotection•Specificpackagingmethod•Selectionoftubesfromasinglecasting•Hotgalvanization•Drawinginreactiveoil•Dephosphating

Laboratory and testing

The tubes produced in Marcegaglia China are strictly controlled to ensure the quality requirements. Tests are done both on the production lines (as described before) and on the finished products before shipment.Operators are continuously trained to guarantee that tests are performed in the correct way.

All batches of finished tubes are tested according to control plans defined by the norms or according to the customers’ specific requirements, all batches are delivered with quality certificate to ensure the compliance.

Marcegaglia China laboratory is equipped with the full range of testing equipments suitable to characterize the tubes according all main international technical standards.

All main testing equipment are imported to guarantee the best accuracy and reliability of the measurements.


Optical Emission SpectrometerChemical analysis on raw material and final product

Hydraulic Universal Testing MachineMechanical analysis on raw material and final product

TECHNICAL STANDARD

GB/T 228.1

EN ISO 6892-1

ASTM E8M

•100%Rawmaterialverification•100%Semiproductverification•100%Finalproductverification

TECHNICAL STANDARD

GB/T 4336

ASTM E415

•100%Rawmaterialverification•100%Finalproductverification


Charpy Impact TesterMechanical analysis on raw material and final productt

TECHNICAL STANDARD

GB/T 229

EN ISO 148-1

•100%Rawmaterialverification•100%Semiproductverification•100%Finalproductverification


Hardness TesterHardness analysis on raw material and final product

TECHNICAL STANDARD

GB/T 230.1; GB/T 4340

EN ISO 6508-1; EN ISO 6507-1

ASTM E18; ASTM E92

Hardnessanalysisonrawmaterial,semiproductandfinalproduct.HRA,HRB,HRC,HV,HR30T,HR30N


Roughness TesterRoughness test on semi-product and final product

Metallographic AnalysisMetallographic examination on raw material and final product - Process verification

TECHNICAL STANDARD

GB/T 6394; GB/T10561: GB/T 224

EN ISO 643; EN ISO 4967

ASTM E112; ASTM E45

Grainsize,non-metallicinclusions,decarburization,etc.

TECHNICAL STANDARD

EN ISO 4287

Surfaceroughnessonsemiproductandfinalproduct.

TM

No.1 Marcegaglia RoadGuangling Economic Development Zone • Yangzhou 225006 - P.R. [email protected] • www.marcegaglia.cn

Marcegaglia, China Yangzhou plant€¦ · Marcegaglia China 714,000 ... (ERW) Min. thickness (mm)...

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