| Cast iron | ||||||||||||
| CHEMICAL COMPOSITION(mass%) | ||||||||||||
| C | SI | Mn | Ni | Cr | Mo | Cu | S | P | Sn | Ti | V | |
| % MIN | 3.65 | 1.6 | 0.4 | / | 0.15 | / | 0.3 | / | / | / | / | / |
| % MAX | 3.8 | 2.1 | 0.8 | 0.1 | 0.35 | 0.25 | 0.6 | 0.15 | 0.1 | 0.15 | 0.05 | 0.05 |
| MICROSTRUCTURE | ||||||||||||
| MATRIX | Type of matrix | Fine Lamellar | ||||||||||
| Permissible limit | 5% Max, well distributed | |||||||||||
| Ledebutite | Not permissible | |||||||||||
| GRAPHITE (To UNI EN ISO 945) | Shape | ∣ | ||||||||||
| Distribution | A: 70% MIN | |||||||||||
| D·E:<4% Disporsed | ||||||||||||
| B: Resto/Remainder | ||||||||||||
| Size | 3- 4 -5 : 70% MIN | |||||||||||
| 2: Traces | ||||||||||||
| 6:≤15% | ||||||||||||
| Cementite and free carbides | Traces up pt 1% MAX permissible | |||||||||||
| MECHANICAL PROPERTIES OF CASTING | ||||||||||||
| HARDNESS (HBW) | On machined braking surfaces | 170~210 | ||||||||||
| On braking surfaces as-cast (0.5 mm below surface) | 230MAX | |||||||||||
| TENSILE STRENGTH(Rm) (N/m²) | On braking surface | 170 MIN | ||||||||||
| On mounting flange | ||||||||||||
| WEDGE INDENTATION STRENGTH (Rmk)(N/m²) | On braking surface | 125 MIN | ||||||||||
| Young's MODULUS (E) (N/m²) | / | 95 | ||||||||||
| PHYSICAL PROPERITIES (Indicative values) | ||||||||||||
| Density (volumic mass) | 7.1 kg/dm³ | |||||||||||
| Coefficient of thermal expansion at 20 degree | 9.10 1/K | |||||||||||
| Thermal conductivity at 100 degree | 50 W/Mk | |||||||||||
2. Foundry :
The foundry - At the heart of production
The quality and productivity of our plants are what optimally ensure 20 million cast parts can leave our factory each year.
The set of procedures for manufacturing brake discs are characterised by specialised and coordinated processes. Short transport routes, carefully tailored production stage capacities and flexibility all underpin our high productivity.
Automatic core production
6 Cool-box core production centres with automated core handling
High-rack core depot with a capacity of 20,000 cores
Fully automatic core transport to moulding plants
Moulding material preparation
Computer-controlled processing of clay-bonded moulding material
3 automatic vacuum mixers
Smelting
4 medium-frequency crucible furnaces
1 unlined water-cooled hot-blast cupola furnace
1 mains frequency channel-type induction furnaces
4 mains frequency crucible furnaces
The smelting output is currently 260,000 tonnes of molten iron per year, which Buderus Guss makes exclusively using steel scrap and returns.
Moulding and casting
6 fully automated vertical moulding plants
6 induction-heated casting furnaces
Camera-controlled fully automatic casting stopper controls
Laser-controlled casting stopper control
Raw casting finishing
Blasting and grinding in a through-feed process with four countinous rocker Barrel
Automatic visual inspection of brake discs with 4 triangular laser camera systems
Automatic robot-driven packaging of brake discs
