Production area and processes
Base material Warehouse
All the steel is stored in special holds, divided by section and type. This allows Forge Nicromo operators to minimize the movement of the bars / ingots, drastically reducing the duration of the operations and the risk of injury. Each bar and/or segment is identified through a unique serial number which, in collaboration with our sophisticated computer system, guarantees its total traceability.
Cutting Area
The cutting machinery consists of 6 saws with cutting capacity up to 850 mm and the possibility of automatic series cutting. The area is equipped with a terminal connected to the computer system; this allows the personnel to have a real-time situation regarding the net stock of raw material in the warehouse.
Forging / Rolling Area (Rings)
The area is divided into two forging lines and two rolling lines set up with two hydraulic presses, two rolling mills and ten reheating furnaces.
The two forging lines have been divided by product type in a way to make the most of the expertise and experience of the operators, ensuring interchangeability in the event of forced machine stops. Next to the two forging stations there are two temperature-controlled cooling tanks for cooling after forging.
The rolling lines are characterized by a line consisting of a modern and refined Hydromac LAR 200/180 rolling plant capable of transforming rings with external diameter of 2700 mm max and a height of 800 mm max (3000 Kg max) and a new line put into operation in 2021 consisting of a Hydromac LAR 80/63 lamination plant with a capacity of Ø 1600 max H 400 mm (1000 kg max).
The layout for both forging and rolling lines has been designed to optimize processing times, thus reaching a maximum level of productivity.
Heat Treatment
Area
The heat treatment area of Forge Nicromo consists of two latest generation plants that have API and Norsok M650 certification (see certifications).
The Normalization/Reheating plant consists of two double element GFelti furnaces with a maximum total capacity of 30 Tons (The second furnace was put into operation in the first half of 2021).
The Quenching/Solubilization plant consists of one automated treatment center which includes
2 + 2 furnaces (GFelti) 15 tons max/each + 1 cooling tank 15.000×5.000×3.500mm (260 m3).
Both systems guarantee a very high quality standard which, along with the matured experience in the forging processes, allows Forge Nicromo products to reach a higher quality standard.
Treatments that can be performed:
Normalization | Tempering | Quenching | Solubilization | Annealing
Cooling methods:
Still air | Forced air | Water
For other types of treatments, not feasible internally (e.g. oil cooling), Forge Nicromo relies on qualified external suppliers that are monitored every six months. All the ovens used, including the external suppliers ones, are calibrated in accordance with the API 6A – API 6D standards.
Workshop
To meet the increasingly demanding requests of customers and in order to minimize transport and optimize delivery times, from 2021 Forge Nicromo has implemented an area dedicated to mechanical turning and milling that has two VT1100 lathes. (max capacity ø1100 mm H1000), one lathe VT900 (max capacity ø900 mm H900) and a milling machine.
This allowed Forge Nicromo to perform most of the production phases internally, increasing quality standards and improving delivery times.
For the processing of the material, Forge Nicromo also relies on several qualified workshops.
Tests and Inspections
Forge Nicromo is able to satisfy each specific customer request thanks to an intense collaboration with the most established laboratories in the sector (ISO 17025). It is possible to perform tests and inspections on any type of material in accordance with the ASTM-ASME-NACE-PED-EN standards and in accordance with the customer’s specifications. Forge Nicromo is able to meet all the technical specifications of its customers through the execution of the most varied laboratory tests: control and verification of chemical analysis, mechanical tests, metallographic tests, corrosion resistance tests, non-destructive tests (NDE). All Forge Nicromo products, by standard, have EN 10204 3.1 test certificate. Upon specific customer request, we have the possibility perform tests in accordance with EN 10204 3.2, thus entrusting the verification of the test results to an accredited third party organization.
Control and Shipping area
The control and shipping area is separated from the material reception area and the production area, this allows to minimize the waiting times of the transporters. All our forgings are prepared for shipment according to strict internal standards, arranged on pallets and carefully strapped or packed with heat-stable plastic and clearly labelled in order to guarantee the highest levels of safety and traceability. The semi-finished or finished workpieces are stored in a special covered space in such a way as to prevent the surfaces products from being damaged by atmospheric agents.
Offices
Offices are adjacent to the production area: this allows them to have direct contact with the various departments and the production in order to provide immediate responses to the requests of Forge Nicromo customers. The structure has six meeting rooms to accommodate and satisfy the needs of all external staff, from the customer to the supplier. Inside there are: the Reception, the Commercial Office, the Programming/Production Office, the Purchasing Office, the Management, the Technical Office, the Quality Assurance Office, the Administration Office and the Presidency. The arrangement of the various offices allows the staff to interact and reinforce the concept of team on which the company strongly relies.
Computer System
Forge Nicromo has an integrated software made ad hoc that implements all the company phases (commercial analysis, planning, production, certification).
All documents related to the process, the suppliers and the customers (e.g. chemical compositions, quality parameters, customer specifications) are processed using digital tools.
In addition, each production phase is promptly reported into the company database in order to always have a real-time situation regarding the progress of existing orders.
All order documents, once production is completed, are archived in digital format and kept on the cloud.
