Introduction In the manufacturing of large engine cylinder blocks, the removal of core sand is a critical step that significantly impacts the quality and efficiency of production. Traditional methods such as manual knocking and sand bed vibration have limitations in terms of labor intensity, production efficiency, and the risk of damaging the engine cylinder block. To address these challenges, our… Read more: Vibratory Decoring Process for Large Engine Cylinder Blocks

Abstract:Quality is the cornerstone of a company’s survival and development. In the increasingly competitive market environment, enterprises must focus on product quality to survive and thrive. Taking the quality management of steel castings in a casting workshop as an example, this paper analyzes the existing issues in quality management and proposes improvement suggestions to enhance the quality management level, thereby… Read more: An Exploration of Quality Management Methods in the Steel Casting Process

As a researcher at the forefront of additive manufacturing, I have witnessed the transformative potential of sand 3D printing in revolutionizing traditional casting processes. This article explores the application of this technology in the production of ​engine cylinder blocks, emphasizing its advantages over conventional methods through quantitative analysis, formulas, and comparative tables. 1. ​Principles of Sand 3D Printing Sand 3D… Read more: Sand 3D Printing Technology in Engine Cylinder Block Casting

Abstract The heat-resistant steel casting of a newly introduced heavy-duty gas turbine compressor support ring in enterprises as the research object. Compared with ordinary castings, this type of casting has a larger size, a more complex structure, a larger amount of molten metal, and thick walls, making it prone to various casting defects. By leveraging the ProCAST simulation software, this… Read more: Casting Defects Research and Process Optimization of Compressor Support Ring Steel Casting Based on ProCAST

Abstract: In the context of the production of traditional steel castings, the lack of a scientific and meticulous ladle management system has become a prominent issue. This paper introduces and discusses the common problems encountered in the use of ladles and their corresponding solutions. By selecting suitable refractory materials, strictly controlling ladle process management, monitoring internal ladle temperature, and optimizing… Read more: Ladle Management for High-Quality Steel Castings

Abstract: The typical defects encountered in the welding and repair process of steel castings, emphasizing the metallographic characteristics of welded porosity and weld non-fusion. By analyzing the selection of welding methods, welding process qualification, and welding process quality control, the key control items and requirements in the welding process are highlighted to obtain stable welding quality. This study aims to… Read more: Quality Control of the Welding and Repair Process of Steel Castings

Abstract: Considering the practical fettling operations of large steel castings, such as bolsters and side frames for railway freight cars, this paper introduces a comprehensive intelligent solution. Based on the integration of 3D vision, robotics, safety and environmental protection, system integration, and control technologies, this solution aims to enhance production efficiency, improve operational quality, and reduce manual workload. The paper… Read more: Cleaning of Large Steel Castings in Railway Freight Cars

Abstract In the steel casting manufacturing industry, flash polishing plays a crucial role in determining the surface quality and aesthetics of the workpiece. Traditional manual polishing methods pose issues of safety and low efficiency, prompting manufacturing plants to seek more intelligent and efficient polishing solutions. With the rapid development of industrial intelligence, the integration of vision detection technology and industrial… Read more: Flare Detection and Grinding Path Planning Technology for Steel Castings

Abstract:The impact of pouring position on the casting process for a specific type of housing steel casting. The original pouring position with the C-shaped welding groove facing upwards was not conducive to realizing sequential solidification, resulting in a low process yield and casting defects such as sand inclusion and porosity. By adopting an optimized pouring position and modifying the gating… Read more: The Influence of Pouring Position on Casting Process for Certain Type of Housing Steel Casting

Abstract:This article details the research and development process of high hardness roller teeth steel castings, addressing the technical challenges posed by their complex structure, high hardness requirements, and stringent dimensional tolerances. Through meticulous process planning, ProCAST simulation optimization, and precise control of alloy composition and heat treatment, we successfully produced roller teeth that met the customer’s demanding specifications. The successful… Read more: Research and Development of High Hardness Roller Teeth Steel Casting

Abstract: This article delves into the ultrasonic testing technology employed for detecting embedded defects in steel castings for large butterfly valves. By integrating the unique acoustic characteristics of steel castings into the detection process, suitable single/dual-crystal longitudinal wave straight probes are selected through comparative experiments. The key points of the detection process for both single-crystal and dual-crystal straight probes are elaborated.… Read more: Ultrasonic Testing Technology for Steel Castings of Large Butterfly Valves

Abstract The typical defects encountered in steel valve casing castings, particularly focusing on the issue of core floating. By analyzing the root causes of instability during the molding process and insufficient stiffness of the core bone, a novel design approach featuring a double-row core bone is introduced. Through the integration of various measures such as core head fixation, box closing… Read more: Anti-Floating Core Techniques for Steel Valve Casing

Abstract The process design and optimization of a steel casting with a streamline structure. This streamline structural casting is a product with an irregular shape and thin walls. The casting needs to ensure its external streamline shape. Combining the experience of foundry engineers and simulation software results, the process design for this new product casting was completed. Based on the… Read more: Process Design and Optimization of Steel Casting with Streamline Structure

Abstract The failure of the steel castings in the excavation chain of the ballast cleaning machine, focuses on the analysis of the fracture morphology, mechanical properties, and metallographic structure of the failed parts, determines the cause of the failure, investigates and analyzes the casting production process, and determines the specific cause of the failure. The process improvement plan was formulated,… Read more: Quality Improvement of Steel Castings for Ballast Cleaning Machine

Abstract The quality control of key steel castings for electric multiple unit (EMU) trains. It introduces the technical specifications, surface quality requirements, and internal quality standards of these castings. By examining the prevention and control processes of various defects, such as excessive magnetic mark defects, slag porosity, and invasive porosity, the paper elaborates on the process measures employed to ensure… Read more: Quality Control of Key Steel Castings

Abstract:The issues of low efficiency, high safety risks, and long construction cycles during the installation of steel casting brackets for tilted dual-shaft rudder systems in the ship assembly stage. Taking the segmented dual-shaft rudder system of a certain Ro-Ro ship as the research object, we analyzed its precision control standards and requirements. We proposed a precision quality control method for… Read more: Precision Control and Application of Pre-installation for Steel Castings of Tilted Dual-Shaft Rudder System

Abstract: In the production process of aluminum alloy investment castings, the incorporation of gas or hydrogen evolution reactions can lead to pore defects in the castings. This article analyzes the causes and preventive measures for three types of pores, explores the causes and processes of pore formation through practical production examples, and proposes effective preventive measures to avoid pore defects… Read more: Causes and Prevention of Pore Defects in Aluminum Alloy Investment Casting

Abstract The technical challenges encountered during the trial production of K6 swing bolster steel castings for railway freight cars. Specifically, we designed a one-piece splicing refractory material three-way gating system to solve issues such as surface sand inclusion and misrun. Additionally, a dedicated exhaust bracket was introduced on the side bearing box to improve venting and eliminate misrun defects. The… Read more: Casting Process for K6 Swing Bolster Steel Casting for Railway Freight Cars

Abstract:The structural characteristics and technological challenges of titanium alloy brush box castings. Based on the analysis of the causes of defects in titanium alloy brush box castings, a high-strength, low-stress titanium alloy brush box casting process is explored and studied. Through production verification, the casting process developed in this study is proven to be successful and effective, providing guidance for… Read more: Titanium Alloy Brush Box Casting Process Research

Abstract The structure and technical specifications of shell castings for pavement mechanical vibrators. Addressing issues such as slag inclusion, shrinkage porosity, low process yield, and high sand-to-iron ratio in the original top-pouring process, we propose enhancements and optimizations. By adopting a middle-bottom pouring riser process and integrating various systems, we have significantly improved casting quality, reduced production costs, and ensured… Read more: Optimization Design of Shell Casting Process for Pavement Mechanical Vibrator

With increasingly stringent global emission regulations, engine manufacturers face mounting pressure to upgrade technologies ensuring compliance with environmental standards. Central to this challenge is the engine cylinder block, a critical component whose cleanliness directly impacts operational efficiency and longevity. This study focuses on optimizing the manufacturing processes to enhance the cleanliness of lubricating and cooling oil passages within diesel engine cylinder blocks,… Read more: Enhancing the Cleanliness Capability of Diesel Engine Cylinder Blocks

Abstract: The lost foam casting process of ultra-high chromium alloy impellers, focusing on alloy composition optimization, casting system design, and fine-grain strengthening measures. By employing these techniques, the castings achieve sequential solidification, eliminating defects such as shrinkage holes and cracks while enhancing abrasion resistance. The final product quality meets the requirements of acid corrosion conditions in slurry pump equipment. 1.… Read more: Ultra-high Chromium Alloy Impeller Lost Foam Casting Technology

Abstract: In the production of grinding machines, disc-cover, flat-plate, square, and short cylindrical hydraulic components are commonly seen. Although these components have simple shapes and structures, they feature large cross-sectional thicknesses, high technical requirements, and high reject rates in casting (ranging from 30% to 40%). By applying a centrifugal slag-collecting ladle, adopting the “horizontal casting and vertical pouring” process, utilizing… Read more: The Foundry Technology of Common Hydraulic Components in Grinding Machine Production

Abstract: The comprehensive analysis and optimization of the casting process for a nodular cast iron tool stand. The original process, which utilized risers for feeding shrinkages, resulted in slight shrinkage porosities. Through various scheme analyses and numerical simulations, a riser-free casting process was adopted, leading to qualified castings with simplified molding and increased yield. This paper details the casting structure,… Read more: Casting Process for Nodular Cast Iron Tool Stand

Abstract:This study focuses on the optimization of casting process parameters for an aluminum alloy cylinder body (specifically ZL114A alloy). By employing the Taguchi design method for orthogonal testing and gray relational analysis, the optimal combination of pouring temperature, filling and pressurizing speed, holding pressure, and holding time was determined. The results indicate a significant improvement in porosity and solidification time… Read more: Casting Process Parameters for Aluminum Alloy Cylinder Body Based on Gray Relational Analysis

Abstract:This article comprehensively reviews the characteristics, classifications, and current application status of wear-resistant steel castings. It introduces typical wear-resistant steel castings and their production processes, elaborates on the main standards for wear-resistant steel castings, and discusses their development trends. By exploring the technical field and analyzing development trends, this article aims to provide beneficial insights and suggestions for the future… Read more: Wear-resistant Steel Casting and Its Development Trends

Abstract: Stand-rider electric pallet jacks, known for their compactness, agility, and efficiency, play a pivotal role in logistics and warehousing. With the escalating market demand and technological advancements, upgrades, modifications, and optimizations in stand-rider electric pallet jack technology are continually occurring. This paper comprehensively analyzes stand-rider electric pallet jacks used in logistics, warehousing, and handling, from their characteristics, application fields, advantages,… Read more: Difficulties and Technical Measures of Steel Castings Steering Bracket for Stand-Rider Electric Pallet Jacks

Abstract: The characteristics, classifications, and current application status of wear-resistant steel castings. It introduces typical wear-resistant steel castings and their production processes, elucidating the primary standards for wear-resistant steel. The aim is to contribute thoughtful insights and suggestions for the future development of the wear-resistant material industry in China. 1. Introduction China’s wear-resistant steel material industry is renowned worldwide for its… Read more: Wear-Resistant Steel Casting and Its Development Trends

Abstract: The laser cladding technology applied to repair casting defects in steel casting, specifically targeting traction pins made of 25-steel. The microstructure, hardness, and wear properties of the austenitic stainless steel cladding layer were comprehensively analyzed. The results reveal the effectiveness of laser cladding in enhancing the surface properties of steel casting with defects. Keywords: steel casting; casting defects; laser… Read more: Laser Cladding Repair of Casting Defects in Steel Casting for Traction Pins

Abstract:The shell molding process, technological flow, raw materials, sand formula, and technological properties of coated sand. It analyzes the factors influencing the quality of coated sand used in steel casting production and summarizes the economic benefits created by introducing the coated sand process. 1. Introduction Our company, a state-owned large enterprise with an annual production capacity of 10,000 tons of… Read more: Application of Coated Sand in Steel Casting Production

Abstract Orange peel defects are prevalent on the surfaces of large steel castings, primarily caused by chemical reactions between corundum powder coating on the sand mold and molten steel at high temperatures. To address this issue, an optimized casting process is proposed in this paper, utilizing a combination of silica sand, chromite sand, and zircon powder coating to prevent contact… Read more: Prevention of Orange Peel Defects on Steel Casting Surfaces

Abstract The typical defects encountered in the production of steel castings for valve housings, specifically addressing the issue of core floating. By analyzing the root causes of instability in the molding process and insufficient stiffness of the core bone, a novel design approach featuring a double-row core bone is introduced. Through the integration of various measures such as core head… Read more: Anti-Floating Core Techniques for Steel Castings of Valve Housings

Abstract: The challenges of low efficiency, high safety risks, and extended construction cycles associated with the installation of steel casting brackets for tilted dual-shaft rudder systems during the ship hull assembly stage. Taking a certain Ro-Ro ship as the research object, we analyze the precision control standards and requirements, propose a method for precision quality control of steel casting brackets… Read more: Precision Control and Application of Steel Casting Pre-installation for Tilted Dual-Shaft Rudder System

Abstract This paper presents a numerical simulation of the investment casting process for automotive turbine parts made of IN713C alloy. By analyzing the turbine structure, solidification sequence, and stress distribution, the hot tearing tendency of the turbine was predicted. Additionally, the influence of different pouring process parameters on the hot tearing tendency was examined. The results indicate that hot tearing… Read more: Numerical Simulation and Analysis of Hot Tearing in Turbine Casting of IN713C Alloy Using Investment Casting

Abstract: This article delves into the intricacies of the 3D printing casting process for cylinder head castings, highlighting its advantages, technical specifics, and transformative impact on traditional casting methods. Through detailed analysis and illustrative examples, the paper aims to demonstrate the potential of 3D printing in revolutionizing the casting industry. Introduction Cylinder heads are box-shaped components with complex internal structures,… Read more: Comprehensive Analysis of 3D Printing Casting Process for Cylinder Head Castings

Abstract:The structural optimization design of the sand spreader for sand casting 3D printing equipment. By addressing the varying printing requirements of different types of sand, the design aims to improve the sanding density, strength, efficiency, and quality of the 3D printing process. 1. Introduction Sand casting 3D printing technology represents a significant advancement in the foundry industry. It effectively shortens… Read more: Structural Optimization Design of Sand Spreader for Sand Casting 3D Printing Equipment

Abstract:Considering the practical fettling operations of large steel castings, such as bolsters and side frames for railway freight cars, this paper proposes an intelligent and generalized solution. Based on the integration of 3D vision, robotics, safety and environmental protection, system integration, and control, this solution aims to enhance production efficiency, reduce manual labor intensity, and ensure a favorable working environment.… Read more: Intelligent Solution for Cleaning Large Steel Castings of Railway Freight Cars

Abstract: This paper focuses on the simulation and optimization of the V-process casting technology for high chromium cast iron impellers, addressing issues such as shrinkage and porosity defects. Through a combination of numerical simulation and experimental research, the temperature field, solidification process, and defects during casting were analyzed. The relationship between shrinkage and porosity defects and casting structure and process… Read more: Simulation and Optimization of V-process Casting Technology for High Chromium Cast Iron Impeller

Abstract This article delves into the casting process optimization of a flywheel energy storage motor base, aiming to eliminate shrinkage defects in the hot spot areas of the casting. Through the application of computer simulations and riser feeding theory, the casting process was refined, involving strategic placement of hot risers and optimization of the solidification sequence. The results demonstrate significant… Read more: Flywheel Casting Process Optimization

Abstract: This article delves into the research and development process of high hardness roller teeth steel castings, addressing the technical challenges posed by their complex structure, high hardness requirements, and stringent dimensional tolerances. Through meticulous process planning, the application of advanced simulation software, strict composition control, and innovative heat treatment processes, we successfully produced roller teeth steel castings that met customer… Read more: Research and Development of High Hardness Roller Teeth Steel Castings

Abstract: This paper delves into the precision casting process of an exhaust manifold, leveraging advanced simulation software (ProCAST) to analyze the filling and solidification processes, predict defect distributions, and ultimately design an optimized casting process. The research aims to eliminate defects and ensure high-quality castings, meeting the stringent requirements of modern engine technology. 1. Introduction With advancements in engine technology,… Read more: Precision Casting Process of Exhaust Manifold

Abstract Cast steel anchorages, as one of the core components of self-anchored suspension bridges, integrate multiple functions such as main cable anchoring, ballast, and limiting displacement. They are characterized by numerous angles on the outer contour surface and complex relative positions of anchoring holes. Taking the cast steel anchorage of a suspension bridge in China as an example, this paper… Read more: Processing Technology of Cast Steel Anchorage for Self-Anchored Suspension Bridges

Abstract:The factors influencing the conformity accuracy between simulation tests of railroad wagon steel castings primarily encompass discrepancies between physical objects and designed models, test specifics, and simulation methodologies. Employing cause-and-effect analysis, process analysis, physical testing, experimental research, and simulation analysis, this paper proposes enhancements to model accuracy, test specifics, and simulation approaches for steel castings. These improvements were applied and… Read more: Conformity Accuracy of Railroad Wagon Steel Castings in Testing and Simulation

Abstract: The methods of regulating the microstructure of steel castings during the solidification stage, aiming to enhance their functionality and broaden their application fields. By examining heat transfer and mass migration phenomena in the solidification process based on thermodynamic principles, and exploring the dynamic mechanisms underlying microstructure formation, we discuss the effects of critical technologies such as cooling rate, alloy composition… Read more: Microstructure Control Techniques During the Solidification Process of Steel Castings

Abstract: This paper focuses on the process design and simulation analysis of complex steel castings for a hoisting box. Based on the casting precision and surface quality requirements, a sand casting process was determined, along with the molding materials and casting process parameters. CAD and 3D software were utilized to design the casting process diagram and generate a three-dimensional model.… Read more: Process Design and Detailed Simulation Analysis of Complex Steel Casting for Hoisting Box

Abstract:The development process of ductile iron beam castings for high-precision gantry machining centers. Through comprehensive analysis of the structural characteristics and potential quality defects of beam castings, casting numerical simulation technology was utilized to optimize various process parameters. Strict control over raw material ratios, melting temperatures, spheroidization, and inoculation processes ensured high nodular graphite quality. After the initial trial production… Read more: Ductile Iron Beam Castings for High-Precision Gantry Machining Centers

Abstract:Crown bubbles are the main casting defects of pistons with casted crowns, which are also one of the primary causes of engine piston failure. Through reproduction tests of crown bubbles, this study investigates the influence of aluminum liquid temperature, pouring speed, filter mesh structure, and filter position on these defects. The results indicate that the missing or misplaced filter is… Read more: Analysis and Optimization of Crown Bubble Casting Defects in Aluminum Piston Casting

Abstract In recent years, lost foam casting technology has rapidly developed in China due to its advantages such as low pollution, flexible processing, low labor intensity, and good repeatability. It demonstrates significant advantages over other casting processes, especially in the production of box and shell products. This paper focuses on the analysis of casting defects such as burning-on, porosity, and… Read more: Lost Foam Casting Defects of Flywheel Housing and Other Castings

With the aid of AnyCasting software, the filling and solidification simulation analysis of permanent mold low-pressure casting process of aluminum alloy cover plate for Gas Insulated Switchgear (GIS) was conducted to investigate the origin of casting defects in the cover plate’s sealing groove. Optimized measures were then proposed, followed by production validation. The results indicated that when the mold temperature… Read more: Simulation Analysis and Process Optimization of Low Pressure Casting Cover Plate for GIS

Abstract: This paper analyzes the causes of crack defects in cylinder block castings and proposes corresponding improvement measures. By focusing on the locations prone to cracking and implementing targeted solutions, the crack rate of low-grade cylinder block castings has been significantly reduced. However, the improvement effect on high-grade castings is not as pronounced, necessitating further research. The use of tables… Read more: Analysis and Improvement Measures for Crack Defects in Cylinder Block Castings

Abstract: In traditional pouring systems, molten steel flowing through a sand mold easily undergoes sand washing, leading to sand inclusions, surface water marks, and other defects when the liquid material is unstable. In traditional exhaust systems, floating sand easily forms in the airway after the air hole is drilled, resulting in sand inclusion in the casting. When cutting the air… Read more: Casting Technology of Knuckle Castings for Railway Freight Cars

Abstract:The challenges associated with the traditional manual grinding process of cylinder block and cylinder head castings and introduces the adoption of robotic grinding technology as a solution. By analyzing the key difficulties and highlighting the critical technical aspects, this study aims to elucidate the overall scheme, action flow, and system composition of a robot grinding workstation. Furthermore, it emphasizes the… Read more: The Key Technology and Application of Robot Grinding of Cylinder Block and Cylinder Head Castings

Abstract Based on the exhaust process design of the pouring system for cylinder block castings, this paper explores methods to effectively solve the issue of exhaust during the casting process and reduce defects such as blowholes in the castings. By employing techniques such as hollowing out thick and large sand cores to reduce their weight, and considering the exhaust and… Read more: The Application of Exhaust Process Design for Cylinder Block Castings

Abstract: This paper delves into the formation mechanism of micro-cracks in thick and complex high manganese steel castings, using a finished ZGMn13 high manganese steel casting from a factory as the research subject. By analyzing the segregation of alloy elements, phase diagrams, and utilizing metallographic microscopes and scanning electron microscopes (SEM), it was discovered that micro-cracks distribute along grain boundaries,… Read more: Causes of Cracks in Thick and Complex High Manganese Steel Casting

Abstract In view of the disadvantages of poor working conditions, labor shortages, high labor intensity, high risk coefficients, and low product quality assurance in the cylinder block casting cleaning process of engine casting enterprises, this paper introduces the latest process design concepts for the cleaning process. The transformation and upgrading of the cleaning process have been achieved through product casting… Read more: Overall Automation Cleaning Process Development of High-End Heavy-Duty Engine Cylinder Block Casting

Abstract: The numerical simulation and experimental verification of investment casting for thin-walled titanium alloy castings. The research aims to predict and analyze casting defects, optimize the casting process, and improve the quality of titanium alloy castings. By utilizing advanced numerical simulation techniques, the formation mechanisms of casting defects such as porosity, inclusions, and shrinkage are investigated. The results are presented… Read more: Numerical Simulation and Verification of Investment Casting for Thin-Walled Titanium Alloy Castings

Abstract In order to further enhance the quality of large diesel engine intermediates and fulfill the escalating technical requirements of products, a thorough analysis of the current quality status was conducted, followed by the optimization and design of the casting process for these intermediates. By refining the molding process, melting process, and coordinating with quality control measures during operations, the… Read more: Optimal Design of Casting Process for Diesel Engine Intermediates

Abstract This paper delves into the casting process of the cylinder block for steam turbines, focusing on the challenges posed by the material properties and complex structure of the ZG15Cr1Mo1 steel used in the turbine casting. By adopting innovative casting techniques, such as horizontal pouring, incorporating risers and chill blocks, and setting up slag-collecting gates, we were able to address… Read more: Turbine Casting Process of Cylinder Block for Steam Turbines

In a landmark achievement for the global manufacturing sector, ZHY Casting has successfully delivered China’s first-ever low-pressure inner casing constructed entirely through advanced steel casting processes, setting a new benchmark for efficiency, quality, and innovation in the production of large, high-end steel cast components. This breakthrough not only underscores the company’s expertise in steel casting but also heralds a transformative… Read more: Revolution in Steel Casting: ZHY Casting’s Pioneering Delivery of Low-Pressure Inner Casing

Abstract This article delves into the structure and technical specifications of ductile iron tray castings, focusing on the issues of porosity and shrinkage defects encountered during production. Through comprehensive analysis, the root causes of these defects are identified, and corresponding countermeasures are proposed. The implementation of these measures has proven effective in eliminating porosity and shrinkage defects in the same… Read more: Analysis and Countermeasures for the Occurrence of Gas Hole and Shrinkage in Ductile Iron Tray Castings