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FWD STEEL CASTING

Casting · Machining · Inspection. One Roof, One Guarantee.

Three capabilities decide whether a heavy casting succeeds. All three live in our factory — no subcontractors, no divided responsibility.

01 · Casting

Heavy Steel Smelting, Pouring & Heat Treatment — up to 300T

Two large foundry bases with eight molding pits give us the physical room that ultra-heavy castings demand. Molds are produced with the sodium-silicate sand process for dimensional stability and surface quality on large sections.

Melting is powered by four electric arc furnaces — 25T, 30T, 50T and 80T, combined for large pours — plus a 120T LF ladle refining furnace that degasses and desulfurizes every heat before pouring. Thirty cranes with up to 300T lifting capacity move molds, ladles and castings safely.

After shakeout and our 150/300T rotary-table shot blasting, four computer-controlled natural-gas furnaces (largest 13×8×5m) perform annealing, normalizing, quenching and tempering with logged temperature curves archived against each casting's heat number.

Every new project starts with CAE solidification simulation: risers, chills and gating are optimized on screen, so shrinkage ends up in risers — not in your component.

Max single casting
300 tons
Annual capacity
80,000 tons
EAF furnaces
25T / 30T / 50T / 80T
LF refining
120 tons
Heat treatment
4 furnaces, up to 13×8×5m
Crane capacity
30 cranes, up to 300T
80 ton ultra-high power electric arc furnace
80T UHP electric arc furnace
120 ton dual-station LF ladle refining furnace
120T dual-station LF refining furnace
258 ton casting poured with dual overhead ladles
258T casting pouring site, dual ladles
30 ton electric arc furnace
30T electric arc furnace
EAF dust collection system with 30,000 square meter filtration area
EAF dust-collection system (30,000 m² filtration)
Sand mold preparation in molding pit
Mold assembly in one of 8 molding pits
13x8x5 meter natural gas heat treatment furnace
13×8×5m gas heat-treatment furnace
CNC controlled natural gas heat treatment furnace
CNC temperature-controlled furnace

02 · Machining

Heavy CNC Machining — 8m/10m Lathes, Hobbing & Boring Mills

Most foundries ship rough castings and leave you to find a machine shop with 8-meter swing capacity. We finish the job ourselves — one purchase order, one quality system, one responsible supplier from molten steel to finished tolerance.

Gear cutting runs on Wuhan Heavy Duty 5m and 8m CNC gear hobbing machines and a Russian 10m CNC gear hobbing machine. Turning capacity covers 4m, 5m, 6.3m and 8m CNC vertical lathes; a Škoda 160 CNC boring-milling machine, floor-type gantry centers and ZJ 80/100 drilling machines complete bores, faces and drilling patterns.

Finish tolerances reach IT8 — millimeter to sub-millimeter per drawing — with documented dimensional reports on every machined surface.

Gear hobbing
5m / 8m / 10m CNC
Vertical lathes
4m / 5m / 6.3m / 8m CNC
Boring-milling
Škoda 160 · 220 CNC
Gantry centers
2.5×6m · 4×10m
Finish tolerance
IT8, mm to sub-mm
8 meter CNC gear hobbing machine cutting girth gear
Wuhan Heavy Duty 8m CNC gear hobbing
8 meter CNC vertical lathe machining heavy casting
8m CNC vertical lathe
6.3 meter CNC vertical lathe
6.3m CNC vertical lathe
5 meter CNC vertical lathe
5m CNC vertical lathe
CNC 160 boring machine
CNC 160 boring-milling machine
4x10m floor type gantry machining center
4×10m floor-type gantry machining center

03 · Inspection

100% NDT Inspection Lab — UT / MT / PT, Level-I Standard

Quality is verified, not promised. Our in-house laboratory runs 20+ instruments: a German OBLF direct-reading spectrometer checks chemistry at raw material, molten steel and finished casting; hydraulic and impact testing machines verify mechanical properties; a metallographic analyzer confirms microstructure.

Critical castings receive 100% ultrasonic coverage to Level-I acceptance standards, plus magnetic particle and penetrant testing of surfaces — executed by certified Level II/III inspectors, with an internal defect detection rate above 99.9%.

Every shipment carries an EN 10204 3.1 documentation package tied to the casting's unique heat number, and third-party agencies (SGS, BV, TÜV, DNV) are welcome at any hold point.

Spectrometer
OBLF (Germany)
NDT methods
UT / MT / PT (+RT on request)
Acceptance
Level-I flaw detection
Detection rate
>99.9% internal defects
Certification
EN 10204 3.1 + heat number
Third party
SGS · BV · TÜV · DNV
German OBLF direct reading spectrometer
OBLF direct-reading spectrometer (Germany)
Ultrasonic flaw detection equipment
Ultrasonic flaw detection (100% UT)
Magnetic particle flaw detector
Magnetic particle testing
60 ton tensile testing machine
60T tensile testing machine
Charpy impact testing machine
Impact testing machine
Metallographic analyzer
Metallographic analysis
3D laser scanner for dimensional inspection
3D laser dimensional scanning

Put These Capabilities to Work on Your Project.

Send drawings and specifications — our engineering desk responds with a feasibility review and transparent quote within 24 hours.

  • Engineering reply within 24 hours
  • NDA before you send drawings, on request
  • ASTM · EN · DIN · JIS standards supported
Zeichnungen hochladenSTEP, IGES, DWG oder PDF — max. 20 MB

🔒 Your drawings are covered by NDA on request and never shared with third parties.