CCRB PARTS U3 FABRICATION

CCRB PARTS U3-FABRICATION
— A Custom Manufacturing Platform for Heavy Engineering Components Based on Continuous Cast Round Billets

Subtitle:
Large Dimensions · Integrated Multi-Process Capability · High-Precision Delivery | Engineered Component Solutions for Global Energy & Heavy Equipment Sectors

Service Overview

CCRB PARTS U3-FABRICATION is a full-scope custom manufacturing service that transforms Continuous Cast Round Billets (CCRB) into finished, precision-engineered components. Leveraging high-purity CCRB feedstock in diameters ranging from Φ310 mm to Φ1320 mm and Φ1600 mm, the platform integrates a complete suite of capabilities—including forging, piercing, ring rolling, heat treatment, machining, and non-destructive examination (NDE)—to deliver large and extra-large components weighing over 100 metric tons with diameters exceeding 4 meters.

Machining accuracy reaches IT7 grade on critical mating surfaces, with geometric tolerances controlled within ±0.1 mm/m, meeting the stringent demands of high-end energy equipment for structural integrity and in-service reliability.

This service has been successfully deployed in global projects across pumped-storage hydropower, offshore wind, oil & gas extraction, and heavy machinery, providing verifiable, traceable, and sustainable component supply assurance for critical infrastructure.

U3ARC globally endorses this service and provides integrated support in application engineering consultation, supply chain co-planning, and third-party testing coordination, enabling seamless collaboration from concept design through to volume delivery.

CCRB Component Application Case Summary

Note: All listed cases have undergone customer witness, physical/chemical testing, and NDE validation. Third-party test reports are available upon request.

Representative Customization Cases

1. World’s First Monolithic Magnetic Yoke Ring for Pumped-Storage Generators

• Directly formed from Φ1200 mm CCRB, replacing traditional laminated construction.
• Achieved a single-piece forged yoke ring weighing over 60 metric tons with an outer diameter exceeding 4 meters.
• Improved material utilization by 22% and reduced manufacturing lead time by 35%.

2. Large-Diameter Wellhead Flange Assembly for Deepwater Oil & Gas

• Single-piece diameter up to 2.8 meters, rated Class 1500.
• Certified to NACE standards for deployment in high-sulfur reservoirs.

3. Integrated Main Shaft Forging for 15MW+ Offshore Wind Turbines

• Length exceeding 12 meters, manufactured via axial piercing combined with radial consolidation.
• Designed for a 25-year fatigue life; now in serial production for European projects.

Prototyping Approach & Acceptance Criteria

1. Prototyping Workflow:
   Requirement Confirmation → Process Review → First Article Trial → Third-Party Inspection → Customer Witness → Volume Release
2. Core Acceptance Criteria:

• Chemical Composition: Compliant with specified standards (ASTM/EN/ISO/GB).
• Mechanical Properties: Room/low-temperature tensile, impact, and hardness tests.
• Internal Quality: 100% Ultrasonic Testing per ASTM A388 Level II or EN 10228 Class 3.
• Dimensional Accuracy: As per drawing tolerances or ISO 2768-mK.
• Special Requirements: SSC, HIC, fatigue tests, etc., conducted per NACE, API, or client-specific specifications.

Capacity, Lead Time & Customization Services

1. Annual Processing Capacity:

• Forging: ≥80,000 metric tons/year
• Large-Scale Machining: Max. swing diameter 5.5 m, length 18 m

2. Standard Lead Times:

• Standard Components: 10–14 weeks
• Highly Customized Items (incl. prototyping): 16–24 weeks

3. Customization Service Scope:

• Material selection advisory
• Joint development of process routes
• Digital Twin co-validation
• Pilot batch → Ramp-up → JIT delivery

Delivery Methods & Packaging Marking

1. Sea Freight:

• Bare parts secured on steel-wooden cradles, wrapped in moisture-barrier film with desiccants.
• Suitable for 20'/40' HC containers or breakbulk vessels.

2. Air Freight:

• Packed in wooden crates or metal containers, compliant with IATA regulations for non-hazardous cargo.

3. Marking (Marking Details):

• Uniformly labeled with “U3ARC” + Contract No. + Heat No. + Net/Gross Weight + Destination + International handling symbols (“FRAGILE”, “THIS SIDE UP”, “KEEP DRY”, etc.)

Value-Added Services

• Application Engineering Consultation: Material-process-service life compatibility analysis
• Test Program Coordination: Liaison with global labs (SGS, BV, TÜV, Intertek, etc.)
• Supply Planning Management: Rolling 12-month delivery forecasts; VMI options available
• General Trade Finance: LC, DP, OA trade credit facilities via partner banks
• ESG Compliance Documentation: EPD (Environmental Product Declaration), Certificate of Origin, Carbon Footprint Report, Conflict Minerals Declaration

Technical & Commercial Disclaimer

The technical parameters herein are based on standard test conditions. Actual in-service performance may vary depending on the customer’s final heat treatment, machining practices, and operating environment. U3ARC shall not be liable for delivery delays caused by force majeure events, including but not limited to war, natural disasters, or changes in export control policies. All commercial terms are subject to the signed formal contract between parties.

Summary

CCRB PARTS U3-FABRICATION builds a heavy-component manufacturing ecosystem spanning “Material → Forming → Finishing → Verification,” anchored on world-class continuous cast round billet technology. We are committed to delivering engineered component solutions characterized by high reliability, high efficiency, and high sustainability to support the global energy transition and advanced equipment upgrading.

Please contact the U3ARC professional team
for customized proposals, samples, or technical data packages.