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Hollow Ingot Casting :: Total Materia Article
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Hollow ingot casting is a well-established casting technology which is used by many well-known manufacturers te world over to produce lighter good quality ingots for a range of applications.
Some key advantages of hollow ingot castings include shortened forging times and subsequent yield increase and obvious savings in materials and finished product weight.
Steel casting into ingots allows for te production of oversized components weighing up to several hundred tons. Te main precondition of te competitiveness of any steel plant is te production of consistently high quality finished product. Among all forged parts, te rings or te shells for pressure vessels are traditionally made by removing te center part of te conventional ingots.
A hollow ingot is a forged ingot of typically with a large cross section, with a through axial channel formed during casting. This form of ingot is achieved by setting te specially designed metal rod with a gas cooling system internally within te casting form before casting. This technology allows a directional solidification of metal ingots to be cast from outside, inside and from te axial channel. Te pouring of te metal into a casting form is performed via a simple siphon method.
Hollow ingots are used to produce forgings with an axial channel such as rings and have a number of advantages over ingots with traditional geometry: metal ingots produced by this technology, are chemically more consistent due to accelerated directional solidification. In addition, te axial channel can significantly reduce metal consumption.
Te use of hollow ingots as a semi-finished product for cylindrical forgings brings te following additional benefits. In summary: hollow ingots takes less time to raise to forging temperature, by virtue of their smaller effective cross section; they require fewer forging operations, because te upsetting and punching steps become redundant. This is shown schematically in Figure 1. It is stated that it is possible to achieve te following savings by te use of hollow ingot instead classic, conventional forging ingot for forging large shells:
Forging yield: up to 35 % reduction of weight
Manufacturing time: up to 3 times less forging sequences when considering large shells issued form heavy ingots requiring efficient blooming to consolidate properties
Environmental and energy costs: significant cut in CO2 gas emission (up to 50 %) due to te shortening of te forging program and te reduction in weight
Figure 1: Te conventional cylindrical forging route compared to that of te hollow ingot
Casting of hollow ingots has been an established process for a long time and with various producers of heavy forgings. Some notable European manufactures include Sheffield Forgemasters International Ltd. and AREVA Creusot Forge. Te great advantage of using hollow ingots as a semi-finished product for te production of forgings such as shells and rings is mainly te lower level of te segregations. Other advantages are a shortened forging time and production yield increase, no welded area compared to rolling-welded process, higher quality of te product etc.
Figure 2: Schematic view of Hollow ingot technology
1. P. Machovčák, A.Opler, Z.Carbol, M.Korbáš, M.Kováč, V.Krutiš: Te development of hollow ingot casting technology at Vítkovice heavy machinery A.S., METAL 2013, 15-17.5.2013, Brno, Czech Republic,
2. OMZ Special steels successufully explores casting of hollow ingots, OMZ-Special Steels, Accessed August 2016
3. P. Machovčák, A.Opler, Z.Carbol, M.Tkadleckova, K.Michalek,K.Gryc, V.Krutiš, M.Kováč: Te utilization of numerical modeling to optimize te production of heavy forging ingots in Vítkovice heavy Machinery a.s., 1st International Conference on Ingot Casting, Rolling and Forging, ICRF, 6 June, 2012, Brüssel-Saal
4. O.Jaouen: Numerical simulation of a shell forming, from hollow ingot to te final product with a powerful software tool, TRANSVALOR, ICRF 2014, Accessed August 2016
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