Custom Steel Profiles
CALVI
Established by Otmar Calvi in 1950 as a company specialising in the manufacturing of special cold drawn profiles, Calvi SpA today is a highly qualified company in the forming of any type of steel. It is recognised internationally and is a key driver for the local area.
Network
Calvi SpA belongs to the Italian group Calvi Holding SpA, a global leader in the metallurgical industry.
Because of Calvi’s extensive experience in the cold drawing of special profiles – combined with the expertise of the other group companies, including extrusion and hot rolling –Calvi Network Special Steel Profiles has achieved unchallenged technological and market leadership in the design and production of special steel profiles according to customer specifications.
Manufacturing Processes
Hot Rolling
After the testing of incoming material and automatic bar peeling phases, the raw material in cast, rolled or forged steel round bars is hot-rolled: a mechanical processing technique for the plastic forming of steel, which is obtained by passing it through a pair of rigid counter-rotating rollers at very high temperatures.The recent replacement of induction furnaces with new generation furnaces, the increase in heating levels, the presence of rolling stands and the introduction of automatic coiling winders provide the highest levels of safety and productivity for Calvi SpA.
In order to reduce product delivery times and ensure utmost flexibility, there is also an in-house division for building rolling equipment to support the rollers.
Preparation
Material heat treatment, phosphating and chemical and mechanical pickling bring the steel’s surface and mechanical properties back to most advantageous levels, thus optimising subsequent operations. Preparation may therefore become necessary as pre-processing or as an intermediate step which is repeated during different stages of the manufacturing process.
Cold Drawing
Drawing is the main step of profile manufacturing. It involves the preparation of complex geometries with rigorous precision and provides the product with a final section according to the dimensions required by the customer.
The feasibility analyses of drawn profiles are processed using sophisticated calculation tools (FEM) that ensure optimisation of the drawing activities during the project study phase. All the equipment and the many drawing installations for bars and coils are designed in-house and have a 1000 kN drawing capacity.
Once the drawing phase has been completed, other heat, chemical or mechanical treatment or new cold drawing steps may follow; otherwise the profile cutting phase begins.
Finishing
Calvi SpA also applies its extensive experience in the production of an ever-increasing range of sizes of special profiles, to the finishing phase.
Finishing is carried out on straightening lines that have been specially designed to meet even the most challenging requests (max. 0.1 mm/m). Finished material is collected in strapped bundles, in crates or on pallets depending on the customer’s needs or on the need for protection, and ready to be shipped by land, sea or air.
Application Sectors
Calvi’s technical staff develops and manufactures a wide range of steel products for many fields of application, including those that are more challenging in terms of accuracy and product technical characteristics. It complies with exceedingly stringent quality and safety standards, meeting the most demanding requirements.
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Short Firearms
Special profiles for gun components, such as for example, slides, triggers and levers. Cr-Mo or Cr-Mo-Ni alloy steels are used, or other steels according to customer specifications.
Long Firearms
Special profiles for rifle components, such as for example, breeches, levers, monoblocks and gas cylinder extractors. Cr-Mo or Cr-Mo-Ni alloy steels are used, or other steels according to customer specifications.
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Vehicles
Components for high pressure injection pumps found in diesel engines, clutch hubs, hinges, pole shoes in starter motors, by using steels for automatic bearings or according to industry-specific requirements.
Motorcycles
Components for gearshifts, equalizers and valve controls.
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Monorails
The profiles are used for manufacturing both linear guide rails and carriages. They are generally produced in carbon steels or induction hardening alloy steels and in case hardening steels.
U-shaped Guides
U- shaped guides with very strict specifications, in carbon steels and alloy steels.
Telescopic
U-shaped profiles, profiles for cursors, with or without the housing for ball bearings, in carbon steels and CrMo alloy steels. Depending on their end use, these profiles are tempered and adjusted by the customer, or used in the condition they are supplied.
Roller Guides
The profiles are used for manufacturing both linear guide rails and carriages. They are generally produced in carbon steels or induction hardening alloy steels and in case hardening steels.
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Structures
Special components subject to high stress.
Engines
Profiles for the structure of compressor rings. Special steel for high temperature.
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Standard
Special profiles for splined shafts and universal joints, using quenched steels and carbon steels.
Special
Other profiles with customer-specific dimensions, in carbon and alloy steel.
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Systems
L-profiles, H-profiles in austenitic stainless steel.
Equipment
Special profiles in austenitic stainless steel.
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Armoured Vehicles
Seal components for guides or guides for battery extraction drawers or similar. Use of carbon or alloy steels.
Radar
Components for guides for battery extraction drawers or other uses. Use of carbon or alloy steel or austenitic stainless steel.
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Turbines
Special profiles for hydroelectric power stators, with use of steels and carbon steels, or stainless steels for particular applications in nuclear power plants.
Generator
Carbon steel prismatic profiles.
Nuclear
Profiles for special complex shapes in austenitic stainless steel.
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Industry
Small and medium-sized structural profiles in carbon steel.
Furniture
Dies with smooth surfaces and sharp edges, made of carbon or stainless steel, for furniture accessories, structural components and wall cladding.
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Chemical
Simple structural profiles in austenitic stainless steel.
Petrochemical
Special sophisticated profiles in alloy steel and stainless steel.
Pharmaceutical
Structural H/I/L- shaped profiles in austenitic stainless steel.
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High-pressure piping
Special inserts for fitting and pipe sealing. Structural profiles in carbon steel.
Stair Nosing
Special stainless steel profiles with step protection and anti-skid properties.
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Agricultural Machines
Profiles for transmissions: standard splined shafts and with rolling teeth in carbon steel and case hardening and quenched alloy steels.
Woodwork Machines
Special profiles for tool holders and stop blocks for blades, using carbon steels and case hardening steels.
Printing Machines
Special profiles used as tensioning guides, or for semi-finished products of more complex sections, using carbon steels.
Textile Machines
Complex dies for special profiles with accurate surfaces and very narrow tolerances using carbon steels.
Machine Tools
Special profiles used in the jaws of lathe headstock vices, T-shaped blocks for worktables and in various clamping systems, using carbon, case hardening and quenched steels.
Presses
Complex structural profiles in carbon steel.
Packaging
Special profiles used for manufacturing mechanical components for the automation industry.
Pumps
Special profiles for shafts on submersible pumps, using both austenitic and martensitic stainless steel.
Machines for the Food Industry
Simple structural profiles in austenitic stainless steel.
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Forklifts
Classic precision U/T/H-shaped profiles in carbon steel.
Transport Systems
Guides of varying shapes and simple profiles in carbon steel.
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Pulp & Paper
T/H/L- shaped profiles in austenitic stainless steel.
Manual Tools and Power Tools
Special profiles, used for example, for pinion hubs in power saw chains, drills, workbench tools, using case hardening steels.
Padlocks and Locking Systems
Special profiles for padlocks, mechanisms and automatic locking systems on doors, using case hardening and carbon steels.
Mechanics
Profiles of various shapes, even of significant size, used for subsequent processing and usually in carbon steel and alloy steels.
Semiconductors
Mini-guides, carriages and guides, in stainless and high-carbon steel.
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Nautical Industry
Profiles for structural currents, various components. Carbon or austenitic stainless steels.
Rail Systems
Special profiles in long bars up to 8 m for seat fastening systems, or profiles that are custom cut and used in braking systems. Generally made in carbon steel. Profiles for securing overhead lines in carbon steel.
Truck
Components for high pressure injection pumps found in diesel engines, clutch hubs, hinges, equalizers, pole shoes in starter motors, and braking systems by using steels for automatic bearings or according to industry-specific requirements.