Replacement of a welding structure with an Austempered Ductile Iron (ADI) one

1. Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
1
Replacement of a welding structure with an Austempered Ductile Iron (ADI) one
Your
Logo

2. Cometto
Industries
Activities
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
2
Cometto Industries s.p.a is leader in design, production and selling of trailers,
semi trailers and self propelled vehicles for heavy transportation.
Your
Logo

3. MSPE
vehicles
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
3
This type of vehicles, especially addressed to heavy lifting and
transportation companies and to big steel and manufacturing
industries, allows the realization of movable lifting transportation of
any dimension and load capacity until several thousands tons.
Electronic steering system that allows a very high handling in small
areas, makes this product line really adapted for the transportation
of very big and heavy loads for chemical plants, sea platforms and
wind turbine components.
MSPE
vehicles
are
self
prolpelled
modular
means
that
can
be
assembled
side
by
side
or
back
to
back.
In
this
way,
they
can
compose
a
transportation
mean
with
a
theorically
unlimited
number
of
axles.
Your
Logo

4. MSPE
vehicles
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
4
MSPE vehicles are equipped with «compass» hydraulic suspensions that allow to
change the height of loading deck of 700 mm.
In this way it is possible to lift the payload without the use of special cranes.
Launching of the frigate of Marina Militare Italiana “Carlo Bergamini”.
Tonnage: 7000 ton. Work done with 240 MSPE axle’s lines
Your
Logo

5. MSPE
vehicles:
improvement
required
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
5
MSPE 4/4/2.43 MSPE 6/4/2.43
Axle load 40 ton 40 ton
Dead weight 16.5 ton 24 ton
Gross weight 160 ton 240 ton
Payload 143.5 ton 216 ton
Technical data of MSPE
Objective
of
50 ton/axle line
Your
Logo

6. MSPE
vehicles:
initial
situation
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
6
Lower
part
of
suspension
was
electro
welded
structure
Material:
S690QL
+
S355JR
Load
capacity:
20
ton
Weight:
99
kg
S690QL
Rp0.2 Rm A %
700 MPa 780-930 MPa 14
S355JR
Rp0.2 Rm A %
315 MPa 470-630 MPa 20
Your
Logo

7. MSPE
vehicles:
analysis
of
possible
solutions
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
7
Initial
structure
did
not
allow
the
increasing
of
load
capacity.
Increasing
of
thickness
of
metal
plates
was
not
possible
because
of
the
constrains
due
to
cynematisms
.
1
-­‐
Possible
solution:
materials
with
higher
admittable
stress
as
S890QL
S890QL
Rp0.2 Rm A %
900 MPa 940-1100 MPa 12Stress distribution
with 40 ton/axle line
Weak
points:
• More
complex
welding
process(pre-­‐heating,
interpass
temperatures…)
• Stress
concentrations
due
to
geometry
(notch
effects)
that
can
generate
early
fatigue
phenomena.
Hard
points:
• Low
investments
in
production
and
assembly
tools
Your
Logo

8. MSPE
vehicles:
analysis
of
possible
solutions
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
8
2
-­‐
Possible
solution:
design
of
a
new
structure
produced
by
casting.
Weak
points:
• Tooling
Hard
points:
• Increase
of
load
capacity
of
25
%
with
an
increase
of
2
%
of
weight
• Part
more
accurateand
repeatable
• Increasing
of
fatigue
life
due
to
reduction
of
notch
effects
• Shape
with
less
constrains
• Reduction
of
components
Stress distribution
with 50 ton/axle
Your
Logo

9. MSPE
vehicles:
choice
of
material
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
9
Why using Austempered Ductile Iron JS/800-10?
Rp0.2 Rm A %
500 MPa1 800 MPa1 101
574 MPa2 847 MPa2 132
Rp0.2 Rm A %
700 MPa 780-930 MPa 14
rif. Weldox 700 by SSAB
1ref. ISO 17804
2ref. Infosheet Zandardi fonderie
Principal technical properties
JS/800-10
thickness < 30 mm
S690QL
thickness
<
30
mm
Your
Logo

10. MSPE
vehicles:
analysis
of
possible
solutions
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
10
Axle oscillating structure
New
cast
structure
Material:
JS/800-­‐10
Load
capacity:
25
ton
Weight:
101
kg
Old
electro
welding
structure
Material:
S690QL
+
S355JR
Load
capacity:
20
ton
Weight:
99
kg
Conclusions…
Comparable
production
costs
Your
Logo

11. Application
of
new
structure
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
11
Suspensions
with
the
structure
in
austempered
ductile
iron
are
used
on
AIT
250
self
propelled
vehicle.
This
vehicle
works
in
the
Centre
Spatial
Guyanais
to
transport
of
sectors
of
rocket
with
solid
fuel
for
vectors
Ariane
5
and
Vega.
Your
Logo

12. Application
of
new
structure
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
12
Cast
structure
Material:
GJS
450-­‐15
Load
capacity
:
20
ton
Weight
:
101
kg
Electro
welding
structure
Material:
S690QL
+
S355JR
Load
capacity:
20
ton
Weight:
99
kg
Reduction
of
production
costs:
20%
Your
Logo

13. Further
application
of
ADI
material
on
Cometto
vehicles
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
13
Reduction
of
production
costs:
35%
Existing
solution
Cast
structure
Material:
GJS
450-­‐15
Load
capacity
:
25
ton
Weight
:
80
kg
Electro
welding
structure
Material:
S690QL
+
S355JR
Load
capacity:
20
ton
Weight:
62kg
New
solution
Your
Logo

14. Application
of
ADI
material
in
Cometto
EMT
vehicle
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
14
The
Electrical
Modular
self
propelled
Transporter
(EMT)
is
a
vehicle
for
inside
a n d
o u t s i d e
t ra n s p o r tat i o n s ,
c o n f i g u r a b l e ,
u s i n g
L i F e P O 4
accumulators
with
all
electrical
functions
(lifting,
steering,
travelling).
The
axles
of
its
suspension
groups
are
produced
by
casting
in
JS800/10.
When
the
vehicle
must
comply
ATEX
requirements,
the
axle,
thanks
to
its
peculiar
shape,
in
addition
to
resist
to
standard
stresses
of
a
steering
and
driving
suspension,
must
contain
an
eventual
inner
explosion
that
increase
an
overpressure
27
times
the
nominal
value.
Your
Logo

15. Application
of
ADI
material
in
Cometto
EMT
vehicle
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
15
Your
Logo

16. EMT
in
steel
industry
Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
16
Your
Logo

17. Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
17
Your
Logo

18. Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
18
Your
Logo

19. Austempering,
A
Technology
for
Substitution
ADI
DAYS
2016
6th
–
7th
October
Minerbe
19
Thank you for attention
Your
Logo