Abstract:This article focuses on the research and development of high hardness roller teeth steel castings, which are core components of drum-type crushers. The study addresses technical challenges such as complex structure, high hardness requirements, and tight dimensional tolerances. Through innovative casting processes, alloy composition control, and heat treatment techniques, the production of roller teeth that… Read more: Research and Development of High Hardness Roller Teeth Steel Casting

In the production of high-strength steel wheels, casting defects such as cracks and porosity can significantly compromise structural integrity. This study proposes a pressure plugging method combined with optimized welding parameters to repair defects in 40CrMnMo steel castings. The approach integrates preheating, laser cleaning, and post-weld heat treatment to ensure defect-free repair while maintaining mechanical… Read more: Welding Repair and Pressure Plugging Methods for Steel Casting Defects in High-Strength Steel Wheels

AbstractThis study focuses on the defects of inclusion and shrinkage that appeared on the end face of a ductile iron reducer housing produced by lost foam casting. By increasing the allowance on the end face of the casting, the inclusion in the reducer housing was resolved. Furthermore, new heat dissipation technology and flexible chiller technology… Read more: Inclusion and Shrink Hole Elimination of Lost Foam Casting Ductile Iron Reducer Housing

Sand inclusion and gas hole defects remain persistent challenges in green sand casting processes. Through collaborative research with technical partners, systematic methodologies combining material characterization and process adjustments have been developed to improve the quality of sand casting parts. 1. Sand Inclusion Defect Analysis Typical sand inclusion defects in sand casting parts manifest as surface… Read more: Defect Analysis and Process Optimization in Green Sand Casting of Sand Casting Parts

This technical analysis examines the premature fracture of a QT800-3 ductile iron casting crankshaft during full-load bench testing. The study employs macroscopic observation, scanning electron microscopy (SEM), and metallurgical analysis to identify the root cause of failure and propose corrective measures. 1. Macroscopic Fracture Analysis The fracture initiates at the transition zone between the connecting… Read more: Failure Analysis and Process Optimization of Ductile Iron Crankshaft in Automotive Applications

As the core component of automotive power systems, the engine cylinder block directly impacts engine performance, fuel efficiency, and reliability. This article explores advanced methodologies for optimizing and innovating the manufacturing processes of 1.5L engine cylinder blocks, focusing on precision machining, material science, and sustainable practices. 1. Precision CNC Machining Technology Modern CNC machining enables… Read more: High-Quality Manufacturing: Optimization and Innovation of 1.5L Engine Cylinder Block Processing Technology

Traditional pattern-based casting methods often fail to meet the short-cycle and low-cost demands of small-batch production for tractor components like internal/external lift arms, transmission rods, and brake housings. This study develops a rapid sand casting methodology integrating digital design, simulation, and patternless manufacturing to address these challenges. 1. Rapid Casting Process Architecture The optimized process… Read more: Research on Rapid Casting Methods for Small Tractor Components

Grey cast iron remains indispensable in manufacturing due to its unique combination of mechanical properties, cost-effectiveness, and processability. This article systematically explores its material characteristics, compositional design, inoculation mechanisms, and industrial applications. 1. Fundamental Properties of Grey Cast Iron The performance matrix of grey cast iron can be quantified through these critical parameters: Property Typical… Read more: Production and Application of Grey Cast Iron in Modern Foundry Practices

The manufacturing level of engine blocks serves as a critical indicator of a nation’s industrial capabilities and automotive development. Continuous improvements in engine power output, fuel efficiency, and emission reduction remain essential for both technological advancement and environmental compliance. Lost foam casting (LFC), a near-net-shape precision forming process, enables cleaner production by utilizing expandable polystyrene… Read more: Research on Lost Foam Casting Process for Diesel Engine Block Castings

As an engineer specializing in casting technology, I embarked on designing an efficient shell casting process for a gear oil pump housing, focusing on overcoming common defects like shrinkage, cold cracks, and misruns. Shell casting is pivotal in industries requiring precision components, such as automotive and petroleum sectors, where gear oil pumps ensure reliable fluid… Read more: Shell Casting Process Design for Gear Oil Pump Housing

Abstract Investment casting is widely applied in industries such as aerospace and automotive due to its ability to produce complex structures with high dimensional accuracy and good surface roughness. However, traditional investment casting relies heavily on iterative trial-and-error experiments, leading to high costs. In this paper, we propose an optimized pouring system design for support… Read more: Design of Investment Casting Pouring System for Support Parts Based on ProCAST

This study investigates the precision investment casting process optimization of a 42CrMo4 steel fixed disk component for automotive air-conditioning compressors. Through numerical simulation and orthogonal experimental design, we establish optimal process parameters to minimize shrinkage defects while maintaining production efficiency. 1. Component Structure and Process Requirements The fixed disk exhibits complex geometry with maximum dimensions… Read more: Design and Optimization of Precision Investment Casting Process for Automotive Air-Conditioning Compressor Fixed Disk

Low-pressure casting has evolved significantly since its inception over a century ago, becoming a critical method for producing high-integrity aluminum alloy components. This paper systematically examines the technical principles, process characteristics, and defect formation mechanisms in low-pressure casting, supported by quantitative analysis through mathematical models and experimental data. Fundamental Principles and Process Parameters The governing… Read more: Characteristics and Process Optimization of Low-Pressure Casting for Aluminum Alloy Components

AbstractIn the simulation of the sand casting process, the numerical calculation of the casting temperature field is the core part. The interfacial heat transfer coefficient (IHTC) is a necessary parameter for accurate calculation of the casting temperature field. This study focuses on the IHTC between the casting and the sand mold/core during the sand casting process. 1.… Read more: Interfacial Heat Transfer Coefficients between Casting and Sand Mold or Core in Sand Casting Process

In our foundry operations specializing in large-scale valve components for nuclear and marine systems, we consistently confront the challenge of blow hole defects during the casting of super duplex stainless steel (SDSS) butterfly valve bodies, specifically those made from grade 00Cr25Ni7Mo4N (SAF 2507). These defects, particularly prevalent in large sections like DN1050 valve bodies with… Read more: Mitigation of Blow Hole Defects in Super Duplex Stainless Steel Butterfly Valve Bodies for Seawater Applications

In sand casting production, process parameters significantly influence casting quality while complex 3D geometries create inherent quality control challenges. This paper presents a novel framework integrating process data analytics and 3D structural characterization for defect prediction in complex sand castings. 1. Process Data Acquisition and Analysis Critical process parameters were systematically collected from foundry production… Read more: Multi-Source Heterogeneous Data-Driven Quality Prediction for Complex Sand Castings

Steel castings play a critical role in engineering applications requiring high strength and fatigue resistance, such as railway bogies and heavy machinery. Due to inherent challenges in casting processes—including shrinkage, gas entrapment, and complex geometries—welding repair remains indispensable. However, improper welding practices can introduce defects like porosity, incomplete fusion, and stress concentrations, ultimately compromising component… Read more: Analysis of Quality Control in Welding Repair Process for Steel Castings

This study presents a systematic approach to resolving persistent quality issues in 11L commercial vehicle engine cylinder block castings through gating system redesign. The original process exhibited 11% porosity defects in upper crankcase regions and suboptimal mechanical properties (195-220 MPa tensile strength) at bearing cap locations. 1. Fluid Dynamics Analysis of Original Gating System The… Read more: Innovative Gating System Design for Engine Cylinder Block Castings: Process Optimization and Performance Enhancement

In the production of large and medium-sized resin-bonded sand casting parts, burn-on defects remain a critical challenge. These defects primarily manifest as mechanical and chemical burn-on, both stemming from molten metal penetration into sand molds. This article systematically analyzes the mechanisms of burn-on and proposes practical solutions to enhance casting quality. 1. Mechanisms of Burn-on… Read more: Solving Burn-on Defects in Resin-Bonded Sand Casting Parts

Abstract:The stainless steel bracket of a weeding machine was numerically simulated by investment casting using ProCAST software. The shrinkage defect of the casting was predicted, and the pouring system was improved. The process parameters of castings were studied through an orthogonal experiment, and the optimum scheme of process parameters was obtained by analysis. Through numerical… Read more: Optimization of Investment Casting Process for Stainless Steel Bracket

This study systematically investigates the filling behavior of grey cast iron in expendable pattern casting (EPC) through orthogonal experiments and single-factor tests. A self-developed 64-channel data acquisition system was employed to record metal front progression using electrical contact sensors and thermocouples. 1. Orthogonal Experimental Analysis The L18(37) orthogonal array evaluated seven critical parameters: Factor Level… Read more: Investigation on the Filling Characteristics of Grey Cast Iron in Dry Sand EPC Process

Abstract:This paper analyzes the advantages and disadvantages of five casting processes for producing output shaft shells and concludes that the lost foam casting process is relatively suitable. The shell castings produced by the lost foam casting process exhibit a dense structure, are free from defects such as contraction cavities and shrinkage porosity, and have a… Read more: Development and Application of Lost Foam Casting Process for Ductile Iron Shell Casting

In practical casting production, numerous defects inevitably occur, making process design and optimization critical for quality assurance. The effectiveness of casting solutions directly determines product integrity, particularly for complex components where shrinkage cavity casting defects frequently compromise structural soundness. The ZG310-570 seat body, a large-scale component weighing 2600kg with dimensions 1160mm×1430mm×810mm, presents significant manufacturing challenges.… Read more: Casting Process Design and Simulation Optimization for Large ZG310 Seat Body

Abstract: This paper introduces the structural characteristics and quality requirements of the intercooler seat tube made of nodular cast iron. It focuses on the casting process through the rational selection of the parting surface, sand core segmentation, core support structure, chilled iron design, and pouring system. The anti-error technology is adopted to improve the dimensional… Read more: Research on Casting Process of Nodular Cast Iron Intercooler Seat Tube

Surface defects like pitting corrosion critically impact the performance of aluminum alloy casting parts in demanding applications. This study comprehensively investigates defect formation mechanisms in AlMg10 alloy components using metallography, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and chemical analysis. The research reveals that surface pitting and subsurface blowholes constitute primary failure modes, with… Read more: Analysis of Surface Defects in AlMg10 Alloy Casting Parts

In the production of rump pan assemblies for scraper conveyors, defects such as shrinkage porosity, misruns, and cold shuts frequently occur during lost foam casting. This study focuses on optimizing the casting process through numerical simulations to enhance product quality while reducing development cycles. 1. Structural Characteristics and Challenges The rump pan (Fig. 1) features… Read more: Numerical Simulation and Process Optimization of Lost Foam Casting for Rump Pan

Ductile iron castings play a critical role in automotive safety components like clutch pressure plates, where residual stress distribution significantly impacts dimensional accuracy and service life. This study employs ProCAST finite element analysis to investigate temperature fields, solidification behavior, and residual stress formation in GGV30 vermicular graphite iron castings, providing insights for optimizing ductile iron… Read more: Numerical Simulation-Based Investigation of Residual Stress in Ductile Iron Pressure Plate Castings for Automotive Applications

The engine cylinder block’s main oil channel plays a critical role in maintaining lubrication and cooling efficiency. Plug leakage in this system often leads to insufficient oil pressure, accelerated wear, and potential engine failure. This article systematically examines the root causes, diagnostic methodologies, and engineering solutions for this prevalent issue. 1. Fundamental Causes of Plug… Read more: Analysis and Diagnosis of Oil Leakage in the Main Oil Channel Plug of Gasoline Engine Cylinder Block

Steel castings for steam turbine components require exceptional mechanical properties due to extreme operational conditions. This article presents a systematic approach to designing the casting process for a medium-pressure inner cylinder with complex geometries, focusing on solving critical challenges in shrinkage control, sand adhesion prevention, and dimensional accuracy. 1. Material Specifications and Technical Requirements The… Read more: Optimized Casting Process Design for Steam Turbine Medium-Pressure Inner Cylinder Steel Castings

Phenolic urethane resin sand, also known as the Pep-set process, is widely used in sand casting parts due to its high production efficiency, excellent surface quality, and low crack sensitivity. However, dispersed pinhole defects often appear on cast surfaces, especially under low-temperature conditions. This article systematically analyzes the root causes and proposes practical solutions to… Read more: Effective Solutions to Eliminate Pinhole Defects in Phenolic Urethane Resin Sand Casting Parts

As castings manufacturers strive for higher quality thin-gauge aluminum foil, understanding defect formation mechanisms in continuous cast-rolling processes becomes paramount. My extensive research reveals that TiB2 particle agglomeration and Ti-V intermetallic precipitation within the casting nozzle critically influence foil perforation defects. These phenomena, inherent to grain-refined aluminum alloys, necessitate strategic interventions throughout the melt treatment… Read more: Enhancing Aluminum Foil Quality in Continuous Cast-Rolling: Mitigation of Defects Arising from TiB2Agglomeration and Intermetallic Precipitation

In the production of exhaust manifolds using silicon molybdenum ductile iron (QTRSiMo41/QTRSi4Mo1), addressing shrinkage porosity at isolated thermal junctions remains a critical challenge. This article details systematic process optimizations to eliminate micro-shrinkage defects in bolt boss regions through balanced solidification principles and thermal management strategies. 1. Casting Defect Characteristics The exhaust manifold contains 14 bolt… Read more: Solving Shrinkage Porosity in Silicon Molybdenum Ductile Iron Exhaust Manifold Castings

Abstract: Steel casting occupies an important position in the industrial field due to its excellent mechanical properties and wide range of applications. The final properties of steel castings largely depend on the microstructure formed during the solidification process. This paper delves into the control technology of the microstructure during the solidification of steel castings, exploring… Read more: Microstructure Control Technology During the Solidification Process of Steel Casting

The crankcase serves as the foundational component of diesel engines, enduring significant mechanical and thermal stresses during operation. Nuclear power applications impose stringent requirements, including rapid startup times (e.g., 10 seconds to rated speed), necessitating flawless manufacturing. This article details a targeted supervision methodology applied to the resin sand casting process for 18PA6B crankcases, integrating… Read more: Analysis and Control of Key Points on Supervision of 18PA6B Diesel Engine Crankcase Casting

This study focuses on optimizing the precision investment casting process for ductile iron protective components used in oil drilling machinery. These components, characterized by their hollow cylindrical geometry with asymmetric slots and threaded grooves, require defect-free surfaces and internal structures to ensure operational reliability. Through numerical simulations and experimental validation, we address critical challenges such… Read more: Optimization of Precision Investment Casting Process for Ductile Iron Drilling Machine Protective Components

Abstract: This article focuses on the defect analysis and solution strategies for high toughness ductile iron cylinder heads, aiming to enhance the internal structure compactness and product quality of ductile iron castings. Through detailed research on solidification characteristics and effective casting processes, the formation of casting defects such as shrinkage porosity and gas porosity is… Read more: Defect Analysis and Solution of High Toughness Ductile Iron Cylinder Head

As a sand casting engineer with two decades of experience, I’ve witnessed remarkable advancements in mold quality through collaborative efforts between foundries and tooling specialists. However, the industry still faces challenges in core competencies and innovative capacity. This article presents critical insights into mold design methodologies and process optimizations for sand casting applications. 1. Fundamental… Read more: Innovations in Sand Casting Mold Design and Process Optimization

In mineral processing circuits, the crushing and grinding system represents a significant capital investment and energy consumption. With the increasing complexity of ore characteristics and stringent energy efficiency requirements, high-pressure grinding rolls (HPGR) have emerged as a critical technology for achieving “more crushing and less grinding.” This innovation reduces ball mill feed size while enhancing… Read more: Selection Correction of Ball Mill in HPGR-BM Process

Grey cast iron, a Fe-C-Si alloy with graphite flakes, accounts for approximately 70% of global cast iron production due to its cost-effectiveness, excellent machinability, and damping capacity. To expand its industrial applications, this study investigates the synergistic effects of austempering and boroaustempering treatments on enhancing mechanical properties and wear resistance. The experimental material, with a… Read more: Austempering and Boroaustempering Treatments for Grey Cast Iron

Abstract The lifting arm, due to its complex structure, often encounters defects such as shrinkage and dispersed shrinkage during the investment casting process. This paper utilizes numerical simulation software, ProCAST, to analyze and optimize the casting process. Based on the simulation results of the initial process scheme, improvements are made to the gating system. Orthogonal… Read more: Design and Optimization of Investment Casting Process for Lifting Arm

In modern engine cylinder block production, machining defects such as tool marks on critical surfaces like the #399 cylinder head joint face significantly impact manufacturing efficiency and product quality. This study investigates root causes and implements optimization measures to reduce rework rates and tooling costs. Problem Analysis The engine cylinder block manufacturing process exhibited excessive… Read more: Optimization of Machining Defects in Engine Cylinder Block Manufacturing

As global vehicle ownership exceeds 217 million units, the quality of automotive components becomes critically important. Piston pins serve as crucial connectors between pistons and connecting rods, functioning as double-point support beams that endure asymmetric alternating loads. Surface wear constitutes their primary failure mode, though fractures occasionally occur. Implementing optimized heat treatment significantly enhances durability… Read more: Heat Treatment of Automotive Piston Pins and Defect Prevention Strategies

The production of large machine tool castings faces escalating demands for precision, structural integrity, and environmental compliance. Lost foam casting (LFC) with furan resin binders has emerged as a transformative solution, particularly for components exceeding 3-ton mass with dimensional tolerances below ±0.15%. This paper systematically examines the implementation challenges and optimization strategies for this advanced… Read more: Advancements in Lost Foam Casting for Large Machine Tool Components

This paper presents a systematic approach to developing coated sand casting technology for high-precision export sand casting parts, specifically addressing front suspension brackets. Through rigorous experimentation and production validation over three years, we established an optimized process flow that achieves surface roughness Ra 6.3-12.5 μm and dimensional accuracy CT6-9 grade. 1. Technical Requirements Analysis The… Read more: Innovative Coated Sand Casting Process for Export Front Suspension Brackets

China’s steel casting industry has achieved global recognition for its large-scale production and diverse product portfolio of wear-resistant materials. With an annual demand exceeding 5 million tons, wear-resistant steel castings play a vital role in heavy industries such as mining, cement production, and power generation. This article systematically examines the classification, manufacturing processes, standards, and… Read more: Wear-Resistant Steel Castings: Materials, Applications, and Development Trends

AbstractPump body is the core flow component of the dredging pump, and its casting quality directly impacts the service life and overall efficiency of the dredging pump. This paper focuses on the numerical simulation and process optimization of sand casting for a dredging pump body. By utilizing advanced simulation software, the casting process was thoroughly… Read more: Numerical Simulation and Process Optimization of Sand Casting for Dredging Pump Body

Producing heavy-section ductile iron castings for wind turbine components requires meticulous control of multiple metallurgical and processing parameters. Through extensive industrial experience and systematic experimentation, I’ve identified critical factors influencing the quality consistency of these castings, particularly regarding their low-temperature impact toughness and structural integrity. The carbon equivalent (CE) calculation remains fundamental for ductile iron… Read more: Key Technical Considerations for Stable Production of High-Performance Ductile Iron Castings

Our concentrator processes polymetallic ores, primarily zinc-tin, through three grinding systems. System A and B each utilize a primary Φ2700×3600 grid-type ball mill paired with a secondary Φ2400×3000 ball mill. System C employs a Φ4500×2400 semi-autogenous grinding (SAG) mill and a Φ3200×4000 ball mill. Persistent issues plagued the Φ2700×3600 ball mills, particularly concerning their lining… Read more: Optimization of Lining Plate Selection in Mineral Grinding Operations

In modern foundry practice, casting defects remain critical challenges affecting component integrity. This article presents a comprehensive analysis of gas hole and shrinkage defects observed in QT400-15 ductile iron tray castings, along with systematic solutions validated through industrial trials. 1. Fundamental Characteristics of Casting Defects The circular tray component exhibits two primary casting defects: Defect… Read more: Casting Defect Analysis and Optimization Strategies for Large Ductile Iron Components

Abstract:This paper focuses on the optimization of the investment casting process for a 304 stainless steel ball valve. Through simulation and defect analysis using ProCAST software, the causes of shrinkage porosity and shrinkage holes in the traditional process were identified. By redesigning the gating system and adjusting process parameters, an optimal set of parameters was… Read more: Investment Casting Process Optimization of a 304 Stainless Steel Ball Valve

AbstractThe interaction between foam patterns and molten metal leads to significant differences in the fluid flow, temperature field, and filling capability during the lost foam casting process compared to traditional casting methods, making it more challenging to control casting defects. Utilizing numerical simulation technology allows for a visual observation of the filling and solidification processes… Read more: Numerical Simulation of Lost Foam Casting Process for Ductile Iron Shell Casting

Die casting equipment relies heavily on high-performance clamping units to ensure precise mold closure, reliable locking force, and efficient ejection of castings. This study presents a multi-objective optimization framework integrating Coordination Curve and Tolerance Hierarchical Sequence methods to enhance the motion and mechanical characteristics of a 4,000 kN die casting machine’s double-toggle clamping mechanism. The… Read more: Multi-objective Optimization of Clamping Unit for 4,000 kN Die Casting Machine Using Coordination Curve and Hierarchical Sequence Methods

As a researcher deeply involved in advancing manufacturing technologies for aerospace components, I have witnessed firsthand the transformative potential of automation in precision investment casting. This article explores the design, implementation, and impact of a novel Automatic Wax Pattern Assembly System (AWPAS) tailored for high-precision applications. By integrating robotics, advanced control systems, and modular hardware, this system addresses… Read more: Automatic Wax Pattern Assembly Systems in Precision Investment Casting

The influence of molybdenum addition on carbide precipitation, microstructural evolution, and tensile strength in grey cast iron was systematically investigated. Experimental results demonstrate that molybdenum significantly modifies graphite morphology while refining pearlite structure through carbide formation mechanisms. 1. Graphite Characteristics Molybdenum addition effectively modifies graphite morphology in grey cast iron: Mo Content (%) Graphite >300… Read more: Effect of Molybdenum on Microstructure and Mechanical Properties of Grey Cast Iron

Precision investment casting, an advanced near-net-shape manufacturing technology, faces significant challenges in managing its primary byproduct – waste ceramic shells. Approximately 2–3 million tons of these shells are generated annually in China alone. This review systematically examines emerging reclamation technologies and their applications across industries. 1. Characterization of Waste Ceramic Shells Waste shells from precision… Read more: Advances in Reclamation Technologies for Waste Ceramic Shells from Precision Investment Casting

Abstract Surface gas explosion sand adhesion has long been a critical defect in flywheel housing sand casting parts produced via clay sand static pressure molding. Initial process improvements, such as reducing bentonite content, lowering moisture, and enhancing venting, yielded unstable results. By leveraging MAGMA simulation software, this study identifies gas entrapment and insufficient venting as… Read more: MAGMA Simulation Analysis and Process Optimization for Gas Explosion Sand Adhesion in Clay Sand Casting Parts

The influence of normalizing temperature (850–1000 °C) on the microstructure and mechanical properties of G18CrMo2-6 steel casting was systematically investigated. The results reveal that the microstructure primarily consists of granular bainite, composed of bainitic ferrite (BF) and martensite-austenite (M-A) islands, across all tested temperatures. The evolution of M-A island characteristics and grain refinement mechanisms critically… Read more: Effect of Normalizing Temperature on Microstructure and Mechanical Properties of G18CrMo2-6 Steel Casting

Excavator bucket teeth operate in extreme conditions requiring exceptional wear resistance and mechanical strength. Traditionally manufactured through high-strength casting, standard carbon materials exhibit inadequate weldability. Preheating via furnace or torch has been standard practice, yet limitations persist—particularly for edge teeth welding where large-scale furnace preheating is impractical. Torch methods suffer from inconsistent heating, low efficiency,… Read more: Research on Surfacing Process for Excavator Bucket Teeth

The manufacturing of engine cylinder blocks – critical components requiring complex internal geometries and high dimensional stability – has long faced challenges in traditional casting processes. This paper presents a revolutionary approach using binder jetting 3D printing technology to overcome limitations in conventional production methods. 1. Advanced 3D Printing Process for Engine Cylinder Blocks The… Read more: Innovative 3D Printing Casting Method for Engine Cylinder Block Production

Abstract:This paper focuses on the sand casting process design and simulation optimization of a rotary disc, a critical component in drill press spindles. By analyzing the structural characteristics of the rotary disc and utilizing numerical simulation, an optimized casting process was developed. The paper presents the design of the pouring system, mold parting surface, gating… Read more: Sand Casting Process Design and Simulation Optimization Analysis