Open-die forging

Forgiatura Marcora is a renowned open-die forging house, established in 1952. In 2016 Forgiatura Marcora became part of VIAR Group and it is today fully owned by VIAR.
Thanks to its forging presses up to 5000 tons, Forgiatura Marcora produces open die forgings in carbon, alloy and stainless steel as well as duplex and superduplex, up to the maximum weight of 30 tons.

Close-die forging

Our closed-die forging division is focused on the production of forged fittings and branch outlets in all grades. Its products have been used for decades in oil & gas, petrochemical, power generation and many other industries.
Our state–of–the-art infrastructure in Primaluna (Lecco) is equipped with latest and technologically advanced machines to deliver small or bulk orders with excellence.
We closed-die forge over 10000 types of fittings and outlets.

All items are subject to rigorous monitoring throughout the production process to ensure VIAR rigorous standards are maintained.
The dedicated and professional team at VIAR can guarantee the highest standards of quality, conducted in accordance with VIAR certified Quality Assurance System.
We have qualified NDT personnel according to ISO 9712, level II and level III.
All testing equipment is regularly calibrated and certified.
VIAR Quality Assurance Manual (in controlled or uncontrolled edition) along with information on operation procedures are available upon request.

In addition to the incoming material control, VIAR Quality department carries out regular controls during the manufacturing cycle.
VIAR S.p.a. makes in the in-house laboratory quantometric, destructive, non destructive and special tests.
As per our incoming material control procedure a spot quantity of each heat number is subject to quantometric analysis.
The quality department of VIAR S.p.a. carries out regular monitoring during all the manufacturing process.
When required by the client or the project, the tests are carried out by external/independent laboratories.

VIAR is equipped with various automatic welding machines for the Cladding of pipes and special components.
The TIGer bi-cathode weld overlay technology we mainly use has been developed by POLYSOUDE, a variant of TIG Hot Wire cladding. The basic principle involves the juxtaposition of two TIG arcs, organized and controlled to be combined into one single arc with the calorific value of the combination of both powers and low heat imput, but with characteristics which are unusual for such intensities.
The addition of the preheated wire, warmed up using the Joule effect via the energy of a third current source, supports the specific profile of formed the weld pool helps improve the efficiency of the entire procedure in a sustainable way.
Depending on the requirements, it is possible to optimize the thickness of the layers to within a range between 1 and 3.5 mm. This flexibility enables the quantity of weld metal to be adjusted to strict requirements and thus significant savings can be made, taking into account the costs of filler products (generally the noble alloys).
Complete control over dilution (Iron Content) is provided with a rate of around 12% on the first layer and below 5% in the second layer.
Welding procedures and Operators are qualified mainly in accordance with ASME Sect. IX and DNVGL-ST-F101. Specific qualification in accordance with other Codes could be offered upon request.
Here below a list of the cladding machines that are fully operational at our premises:

VIAR Group will be adding soon the bending process to its supply chain.
A brand new machine has been bought: it will be installed in June/July 2024 and should be operational in September/October 2024.
The COJAFEX induction pipe bending machine will be able to handle pipes from 2” to 20”, with a maximum wall thickness of 100mm.

All items are carefully protected in order to prevent the rust and/or any kind of damage during transportation and handling.
Usually, small items are individually tagged, packed in plastic bags and closed in carton boxes or wooden cases.
Big components are safely secured into wooden cases that are often customized in order to optimize the shipping volumes, weights and, consequently, costs.
VIAR S.p.A. is potentially able to adapt this procedure in function of the directives set out in the client’s Purchase Order.
VIAR S.P.A. aims to provide a packing service that ensures goods arrival in the best condition possible. In this regard, all goods are to be securely protected and packed so that throughout the process of transportation/handling the goods remain in the highest condition.

VIAR premises is equipped with Multi-Tasking Machining Center which is a complete fusion of CNC turning center and machining center, forming by far the most advanced Multi-Tasking machine in the industry. Complete all operations in a single setup – turning, milling, boring, drilling and more. The machine delivers precision and performance for heavy, largediameter, shaft-type workpieces for a wide range of industry applications.
The machine is equipped with a high-output integral spindle motor featuring two gear ranges for a wide scope of heavyduty machining applications. A drop-worm system with the same positioning accuracy as a machining center rotary table drives the C-axis (0.0001-degree increments).
The high performance milling spindle is a 50 taper, single spindle turret with automatic tool changer. A heavy-duty roller gear cam makes up the framework of the machine’s B-axis that provides milling spindle indexing or contouring and maximum tool point agility.
Fully programmable, servo driven, steady rest and tailstock ensure safe and accurate machining of long workpieces.

VIAR is equipped with various automatic, semiautomatic and manual machines to satisfy the Customer needs when specific welding activities are requested.
Welding processes available are GTAW (manual and automatic), GMAW, SMAW and SAW.
Workshop environmental and cleanliness condition are maintained to the highest standards, in order to allow welding of Stainless Steel, Ni base alloys and reactive metals like Titanium. Carbon Steel and Low Alloy steel can also be worked.
Welding Procedures, Welders and Welding Operators are qualified mainly in accordance with ASME Sect. IX. Specific qualification in accordance with other Codes could be offered upon request.
VIAR Organization is certified in accordance with ISO 29001 and ISO 3834.

Heat treatment is a controlled process used to alter the microstructure of materials such as metals and alloys to impart properties which benefit the working life of a component, for example increased surface hardness, temperature resistance, ductility and strength.
As a global provider of forging products, VIAR has developed, applied and implemented also an extensive range of heat treatment services. All forgings used in the manufacture of our products have to be heat treated in accordance with the specifications applicable to the material used.
Since 10 years, VIAR has developed, applied and implemented a wide range of competences and capabilities in providing heat treatment processes of forging products including case hardening, tempering, solution and ageing treatment, Specialty Stainless Steel Processes (S3P), annealing and normalizing.
Our facilities process a wide variety of component sizes, with a combined daily capacity of about 30 tons, to exacting standards with reliable, repeatable results. Our heat treatment operations are managed by some of the best engineers and technicians in the industry, with the experience and expertise to provide vital support and a real understanding of customer requirements.
Our inspection procedures exceed the industry standard and can be tailored to meet a customer’s requirement. VIAR team of on-staff metallurgists and fully operational Quality Assurance Department are ready to ensure the highest quality and level of safety in any job. In particular, the Quality Control Laboratory, very well structured and fully equipped, is our entity that certifies the heat treatment process.
The top quality heat treating services is also guaranteed with comprehensive periodical calibration of all furnaces and related equipment’s.
Finally, the quality, in the VIAR environmental policy, is also guaranteed and monitored through modern extraction systems for smoke removal, reuse water cooler in addition to reset the operating noise process.
All forgings used in the manufacture of our products have to be heat treated in accordance with the specifications applicable to the material used. No material can enter the “incoming material control area” missing the covering certificate for chemical and mechanical properties and related heat treatment diagram.

VIAR premises is equipped with an extensive range of modern machinery ensuring optimum quality of production in total conformity with the most stringent specifications.

The raw material is stictly sourced from Italian or west European qualified suppliers.
We buy the ingots with “tailored” chemical compositions, in order to meet the project requirements and achieve the requested mechanical properties.

Our Operations Unit is the nerve center of the Company, through which all necessary information for the planning and practical execution of a Project flow. It’s the department that the Client will interface for the duration of the Project.
Project Managers are the Team Leaders; they are in charge of managing the personnel and resources assigned to a Project to ensure the best and swift execution according to the Project requirements. They represent the focal point of contact between Clients and our Company. After years of work, they have developed the necessary skills to ensure a prompt and accurate management of the Project and any additional requests or changes to the scope of the Project.
Project Managers are also supported by the Document Controllers, who manage all documentation pertaining to a Project in accordance with the requirements set by the Client. They are responsible of upkeeping the full traceability of the documentation flow for the entirety of the Project’s lifespan.
Material specialists, Engineers, draftmen and inspection coordinators complete the team.

VIAR is able to design and verify special piping components by means of Fintite Element Analysis.
VIAR designs special piping components in accordance with ASME VIII div.2 Part 5 as well as in accordance with other international recognized standard.
The adequacy of the design of flanges, branch connection fittings, tees and other piping components is established by mathematical analysis contained in pressure vessel or piping code (ASME, DIN, EN and STOOMWEZEN rules).
Piping components not listed in international recognized standard like flanges not in accordance with ASME B16.5 or ASME B16.47 are commonly designed in accordance with ASME VIII div.1 and ASME VIII div.2 (Part 5).