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

Abstract: The various casting defects encountered during the production of a gantry-style cylinder block on an automated assembly line. Through comprehensive analysis and verification of changes to the gating system, exhaust system, and process parameters, effective solutions to these casting defects are proposed, ensuring the cylinder block meets processing and assembly requirements. Keywords: Gantry cylinder block, casting defects, solution measures.… Read more: Gantry Cylinder Block Common Casting Defects and Corresponding Solution Measures

Abstract: This paper delves into the casting process of large-scale support plate titanium alloy castings, focusing on the intricacies involved in achieving high-quality castings. Through comprehensive analysis and experimental validation, this study aims to provide insights into the optimal casting parameters and techniques for titanium alloy plate castings. The article is structured to include detailed descriptions, tables summarizing key findings,… Read more: Casting Process of Large-Scale Support Plate Titanium Alloy Casting

Abstract: Block casting, due to its complex shape, has traditionally been produced using sand casting processes. However, defects often occur at the bottom of the casting blanks, primarily due to limitations in the design of the gating system. The introduction and application of 3D printing technology have addressed these limitations, enabling the simulation of the pouring process and potential defect locations… Read more: The Application of 3D Printing Technology in Block Casting

Abstract: Die casting production is a crucial process for manufacturing high-precision and high-quality components. However, the quality of die castings is susceptible to various external factors, including raw materials, equipment, process parameters, etc. This paper delves into the impact of external factors on die casting quality and proposes corresponding countermeasures. Practical experience has demonstrated that external factors significantly influence die casting… Read more: Die Castings in Die Casting Production and the Countermeasures

Abstract: Surface roughness is crucial indicator for assessing the quality of sand casting surfaces, impacting wear resistance, fatigue strength, and vibration noise. Traditional measurement methods, such as standard specimen comparison and stylus profilometry, have limitations in terms of accuracy, speed, and applicability. This study proposes a non-contact measurement method for sand casting surface roughness based on machine vision, combining image… Read more: Surface Roughness Detection of Sand Casting Based on Machine Vision

Abstract Aiming at the possible defects such as pores and cracks in the manufacturing process of steel castings, a defect detection and repair technology for steel castings based on laser remelting process is proposed in combination with intelligent manufacturing technology. Firstly, intelligent manufacturing technology and its application in steel casting manufacturing are introduced and analyzed. Secondly, the laser remelting process… Read more: Repair Technology of Steel Casting Defects Based on Intelligent Manufacturing

Abstract: The C95820 aluminum-bronze double-suction impeller, characterized by its large size, uneven wall thickness, and complex structure, faces challenges in traditional casting methods due to defects such as concentrated shrinkage porosity, oxide inclusions, and porosity. This research leverages the technical advantages of 3D printing sand molds, utilizing ProCAST software to optimize and design the gating and riser system. By integrating… Read more: Research on the Impeller Casting Process Based on 3D Printing Sand Mold

Abstract:The innovative practice course on gypsum precision casting, focusing on its application in undergraduate industrial training at Tsinghua University. By integrating traditional handmade clay modeling, advanced reverse scanning technology, and 3D gypsum precision casting, we aim to cultivate students’ innovative thinking and practical skills. This paper discusses the necessity of curriculum reform, the implementation of the teaching plan, and the… Read more: Innovative Exploration Based on Gypsum Precision Casting Practice Course

Abstract In order to comprehensively enhance the kinematic and mechanical performance of the clamping unit of squeeze casting equipment, a multi-objective optimization method combining the Coordination Curve Method and the Hierarchical Sequence Method is proposed. Firstly, the operational characteristics of the curved lever-type clamping unit of squeeze casting equipment are analyzed, and a mathematical optimization model is constructed. Secondly, the… Read more: 4000 kN Squeeze Casting Machine Based on the Coordination Curve Method and Hierarchical Sequence Method

Abstract: The application of digital silk feeding spheroidization stations in the production of QT800-5 bracket castings. By leveraging a digital operation platform that integrates feeding, thermal analysis, and molten iron transfer systems, we ensure high-quality raw materials and precise control of alloying elements. This approach guarantees high spheroidization rates, optimal alloy compositions, and refined matrix structures, thereby producing QT800-5 bracket… Read more: Research and Application of Digital Silk Feeding Spheroidization Station on QT800-5 Bracket Castings

Abstract:Due to the thickness of QT500-7 ductile iron hubs in lost foam casting, casting defects including shrinkages and cavities are prone to occur during the casting process. Through the analysis of the casting structure, targeted optimization was carried out at positions prone to shrinkages and cavities by adjusting the gating method and pouring process to ensure meeting customer requirements. Meanwhile,… Read more: Process Design of Ductile Iron Hub by Lost Foam Casting

Abstract: This paper analyzes the influence of white patterns and coatings in the lost foam casting process on large and medium-sized castings such as cooling walls. By adopting corresponding control and treatment measures at key points in the mold making, molding, and pouring processes, defects such as sand burning and mold collapse are effectively prevented. The production efficiency of blast… Read more: Lost Foam Casting in the Production of Cooling Walls

Abstract: This study focuses on addressing the wrinkling and shrinkage defects encountered in the production of ductile iron reducer housings using lost foam casting. By optimizing the pouring system from top pouring to bottom pouring, the turbulent flow of molten iron during pouring is effectively minimized, resolving the issue of surface wrinkling. Furthermore, a novel heat dissipation technology is explored… Read more: Wrinkling and Shrinkage Defects of Ductile Iron Reducer Housing in Lost Foam Casting

Abstract In large semi-autogenous grinding (SAG) mills, the lining plates are subjected to extreme impact loads due to the use of large-diameter steel balls and high linear velocities. This leads to increased cracking risks and reduced service life of the lining plates. This study focuses on the structural evolution and performance optimization of shell lining plates in an φ11 m… Read more: Comparative Study on Shell Lining Plate Structures for Large Semi-Autogenous Grinding Mills

Abstract: This paper explores the effective application of additive manufacturing in investment casting processes for agricultural machinery. Additive manufacturing, also known as 3D printing, offers significant advantages in enhancing manufacturing precision, reducing production time, and simplifying operational difficulty. By integrating this technology with investment casting, the overall production quality and efficiency of agricultural machinery components can be substantially improved. Section… Read more: Additive Manufacturing in Investment Casting for Agricultural Machinery

Abstract This thesis focuses on the design and optimization of the investment casting process for car door bodies. By combining low-pressure casting with investment casting, the manufacturing process of car door bodies can be simplified, production cycles shortened, and product quality improved. The castings produced have high dimensional accuracy, low surface roughness, retained surface dense layers, reduced stress concentrations, dense… Read more: Design and Optimization of Investment Casting Process for Car Door Body

Abstract: The intricacies of lost foam casting, a revolutionary casting technique, and examines the defects encountered during the process, particularly in the production of flywheel housings and other castings. By utilizing a combination of theoretical analysis and practical experimentation, this study aims to identify the root causes of these defects and propose effective countermeasures to enhance casting quality. 1. Introduction… Read more: Defects in Lost Foam Casting of Flywheel Housing and Other Castings

Abstract Aiming at the quality issues such as shrinkage porosity, misrun, and cold shut often occurring during the development of lost foam casting rump pan assembled on the middle trough of the scraper conveyor, numerical simulation and process optimization of cast steel rump pan produced by lost foam casting were carried out using the InteCAST software. The results indicate that… Read more: Numerical Simulation and Process Optimization of Lost Foam Casting

Abstract The wheel castings of mining flatbed trucks are structurally complex and prone to defects such as porosity and shrinkage during the investment casting process. This study aims to reduce the porosity rate of these castings by analyzing the pouring process using numerical simulation software and optimizing the process scheme. Additionally, three process parameters—pouring temperature, pouring speed, and mold shell… Read more: Optimization of Investment Casting Process for Wheel Castings of Mining Flatbed Trucks

AbstractThis paper introduces the common casting defects in producing frame castings using furan resin sand molding. The causes of these defects are analyzed, and improvement measures are proposed. These measures have significantly reduced the reject rate of frame castings in actual production. 1. IntroductionThe base is an important part of the 430 vertical milling machine of Ningxia Xiaojuren Machine Tool… Read more: Frame Casting Process Improvement

Sand Casting Industry Problems Problem Aspect Description Labor-Intensive and Poor Environment Traditional sand casting has high labor intensity and poor working conditions, leading to recruitment and retention difficulties. The emergence of 3D printing technology can improve this situation. Customized Production Demand The market trend is towards customized and personalized production, with a shift from large-scale unified production to single-item or… Read more: Application Prospect of 3D Printing Technology in Sand Casting Field

1. Introduction The crankshaft is a crucial part of the automobile engine, responsible for power output. This article focuses on the wet sand casting process of automotive crankshafts, analyzing the casting process, defects, and control methods to improve casting quality and efficiency. Main Points Details Significance of Crankshaft Key component for power output in automotive engines, affected by various factors… Read more: Wet Sand Casting Process and Defect Control of Automotive Crankshafts

1. Introduction Casting defect, especially shrinkage defect, is a common issue in casting production. The unreasonable design of casting structure is one of the main reasons. This article analyzes several types of casting defects caused by structural problems and proposes corresponding solutions. 2. Defects Caused by Inadequate Feeding 2.1 Case Introduction 2.2 Solution 3. Defects Caused by Small Local Distance… Read more: Casting Defect Prevention by Optimizing Casting Structure

1. Casting Analysis and Design 1.1 Casting Material and Structure Element Ti Al N Others Mass Fraction (%) Balance 5.5 – 6.8 3.5 – 4.5 0.15 (max), 0.3 (max), 0.1 (max), 0.015 (max), 0.05 (max), 0.2 (max) 1.2 Pouring System Design Pouring System Section Ratio Characteristics Top Pouring Type 1 : 1.25 : 1.75 Simple structure, easy to fill the… Read more: Investment Casting of Thin-walled Frame Titanium Alloy Castings

1. Introduction Investment casting, also known as lost-wax casting, is a precision casting process that has been widely used in the manufacturing industry for producing complex and high-quality metal components. In the context of the oil drilling industry, ductile iron protective parts play a crucial role in ensuring the safety and reliability of drilling operations. This article focuses on the… Read more: Optimization of Investment Casting Process for Ductile Iron Drilling Machine Protective Parts

1. Introduction Casting quality, as defined in GB/T5611 casting terms, refers to various defects on the surface and inside of the casting during the production process. This article focuses on analyzing the “shrinkage and leakage” defects on the machining surface of a casting and proposes targeted solutions to improve the casting pass rate and reduce waste loss. 1.1 Shrinkage Defects… Read more: Analysis and Solution of “Shrinkage Porosity” Defect in Castings

1. Casting Defect in Cylinder Head of Low Pressure Casting 1.1 Introduction With the development of the automotive engine industry and the requirement of vehicle lightweight, aluminum alloys are widely used in the automotive and engine industries. However, due to the complex structure and process of aluminum alloy cylinder heads, casting defects are prone to occur, such as pinhole defects… Read more: Prevention of Pinhole Casting Defects in Low Pressure Casting Cylinder Head 

Product Structure and Problem Description Product Name Material Blank Mass Structure Features Quality Requirements Initial Casting Defects Tie rod seat B+ grade steel 30kg Simple, with large wall thickness difference and rounded hot spots at connections High internal quality, compensate for welding deformation Shrinkage porosity and sand holes in the rod hole area, low ultrasonic flaw detection qualification rate, and… Read more: Casting Defect Analysis and Improvement of Pull Rod Seat

1. Introduction Investment casting is a precision casting process that has been widely used in the manufacturing of various components with complex geometries and high dimensional accuracy requirements. In the production of mining flatbed wheel castings, ensuring the quality of the castings is of utmost importance due to the critical role these wheels play in the mining industry. This article… Read more: Optimization of Investment Casting Process for Wheel Castings of Mining Flatbed Trucks

The advancement of numerical simulation technologies has revolutionized traditional casting processes, enabling precise prediction and mitigation of defects in steel castings. This article explores the application of ProCAST simulation software in identifying and resolving shrinkage-related defects in steel castings for tracked vehicle wheel hubs. Through systematic process optimization, the study demonstrates significant improvements in product quality and production efficiency. 1.… Read more: ProCAST Simulation in Defect Prediction and Process Optimization of Steel Castings

1. Introduction Lost foam casting is a modern casting process that has gained significant popularity due to its numerous advantages. It offers reduced machining allowances, precise forming, simplified production procedures, shortened process flows, increased production efficiency, and decreased labor intensity. In the case of oil pan production, this process has been adopted to replace traditional sand casting methods. However, like… Read more: Lost Foam Casting of Oil Pan: Analysis of Defects and Optimization Measures

Abstract During the operation of large excavators (electric shovels, hydraulic shovels), the phenomenon of bucket teeth falling off is prone to occur, which in turn triggers failures in the crushing system. To ensure that falling bucket teeth are promptly detected, an electric shovel bucket teeth positioning monitoring system is designed. Based on existing wireless positioning monitoring technology for bucket teeth,… Read more: Research on Positioning Monitoring System for Bucket Teeth of Large Excavators

In the development and testing of internal combustion engines, ensuring the integrity of the engine cylinder block’s main oil passage is critical to maintaining optimal performance and longevity. During a recent durability test, an oil leakage issue was observed at the threaded oil plug of the main oil passage in an engine cylinder block. This article details the root cause… Read more: Countermeasures for Oil Leakage in the Main Oil Passage of Engine Cylinder Block

Abstract In this study, we conducted a comprehensive optimization of the sand casting process for a QT500-7 fixed base using numerical simulation techniques. The fixed base, designed for industrial robotic applications, required high structural integrity and defect-free casting due to its critical role in load-bearing and stability. By leveraging SolidWorks for 3D modeling and ProCAST for simulation, we analyzed the… Read more: Optimization of Sand Casting Process for QT500-7 Fixed Base via Numerical Simulation

1. Introduction Sand casting remains a cornerstone of metal casting industries due to its versatility, cost-effectiveness, and adaptability to complex geometries. However, traditional trial-and-error methods for optimizing casting processes are time-consuming and resource-intensive. This study focuses on leveraging numerical simulation technologies to predict defects, optimize process parameters, and enhance the quality of sand-cast components. By integrating computational fluid dynamics (CFD),… Read more: Numerical Simulation and Application of Sand Casting Process

1. Introduction The automotive industry faces mounting pressure to reduce carbon emissions and improve fuel efficiency, driven by global initiatives such as China’s “Dual Carbon” strategy. A critical pathway to achieving these goals lies in vehicle lightweighting, which directly correlates with reduced fuel consumption and lower CO₂ emissions. Studies indicate that a 10% reduction in vehicle weight can decrease fuel consumption… Read more: Lightweight Analysis of Automotive Engine Cylinder Block

As a leading manufacturer in the engine casting industry, our company has consistently prioritized advancements in core technologies to meet the escalating demands of heavy-duty engine cylinder block production. Over recent years, we have achieved a market share exceeding 30%, with annual output surpassing 1 million units. These engine cylinder blocks are integral to heavy-duty trucks, buses, urban transit systems,… Read more: Innovations in Automated Cleaning Processes for High-Performance Engine Cylinder Blocks

As a researcher deeply engaged in the field of casting technology, I have witnessed remarkable advancements in both traditional and modern casting methodologies, particularly for large-scale components. Among these, sand casting remains a cornerstone due to its versatility, cost-effectiveness, and adaptability to complex geometries. This article synthesizes recent progress in casting processes, numerical simulation techniques, and future trends, with a focus on sand… Read more: Advances in Casting Processes and Numerical Simulation for Large-Scale Castings

Introduction Sand casting remains one of the most prevalent manufacturing methods for producing metal components, particularly in industries requiring complex geometries and cost-effective production. A critical step in sand casting involves applying coatings to the surfaces of sand molds and cores. These coatings serve as barriers between molten metal and sand, minimizing surface defects such as penetration, veining, and burn-on,… Read more: Sand Casting: Comprehensive Study on Brush Application of Alcohol-Based Coatings

Abstract: This study delves into the application of digital wire feeding spheroidization stations in the production of QT800-5 bracket castings. By integrating digital technology, thermal analyzers, and iron transfer systems, we have established a digital operation platform. By selecting high-quality, high-purity raw materials, controlling elements that affect graphitization and anti-spheroidization, ensuring high spheroidization rates and reasonable alloy element contents, and… Read more: Digital Wire Feeding Spheroidization Station on QT800-5 Bracket Castings

As modern industries rapidly evolve, the demand for high-precision, high-performance cast components has outpaced the capabilities of traditional casting methods. Lost foam casting (LFC), an innovative technique utilizing expandable foam patterns, has garnered significant attention due to its simplicity, cost-effectiveness, and suitability for complex geometries. This article synthesizes advancements in Lost foam casting sub-processes—vacuum and low-pressure Lost foam casting, vibration-assisted… Read more: Research Status and Future Prospects of Lost Foam Casting Technology

1. Introduction Semi-autogenous grinding (SAG) mills are pivotal in mineral processing, yet their high energy consumption remains a critical challenge. The lining plate, a core component of SAG mills, not only protects the mill shell but also transmits energy to grinding media and ore particles. However, wear of the lining plate significantly alters the motion dynamics of grinding media, impacting grinding efficiency and… Read more: Lining Plate Wear in Semi-Autogenous Mills on the Motion Characteristics

The steel casting process is a complex and critical manufacturing operation that demands meticulous quality assurance measures to ensure the production of defect-free, high-performance castings. In this comprehensive article, we will delve deep into the various aspects of quality assurance in the steel casting process. Introduction Quality assurance plays a pivotal role in the steel casting process, as it directly… Read more: Quality Assurance in the Steel Casting Process

Lost foam casting has emerged as a revolutionary technique in the manufacturing of heavy machinery components, offering numerous advantages and transforming the way these critical parts are produced. Introduction Heavy machinery plays a vital role in various industries, from construction and mining to agriculture and manufacturing. The quality and performance of the components used in these machines are of utmost… Read more: Lost Foam Casting: Breakthrough in Heavy Machinery Component Casting

Lost foam casting, an innovative and efficient manufacturing process, has gained considerable prominence in the industrial sector. However, like any manufacturing technology, it comes with its own set of environmental implications that need to be carefully examined and addressed. Introduction Lost foam casting, also known as evaporative pattern casting or foam pattern casting, involves the use of a foam pattern… Read more: The Environmental Implications of Lost Foam Casting Technology

Sand casting is a widely utilized manufacturing process for producing various components across different industries. Achieving cost-effective production of high-quality sand casting parts is a crucial objective for manufacturers to remain competitive and meet the demanding requirements of their customers. This article explores the strategies and techniques employed to attain this balance. Introduction Sand casting offers flexibility in design, allowing… Read more: Cost-Effective Production of High-Quality Sand Casting Parts

Abstract This extensive article explores the cutting-edge technologies that have emerged with the potential to significantly enhance the efficiency of the lost foam casting process. The lost foam casting process, despite its numerous advantages, faces challenges in terms of productivity and cost-effectiveness. The introduction of new and innovative technologies offers promising solutions to overcome these obstacles and unlock new possibilities… Read more: Emerging Technologies to Improve Efficiency in Lost Foam Casting Process

The steel casting process is a labyrinth of technicalities and precision, demanding a comprehensive understanding and meticulous execution to yield high-quality end products. In this in-depth exploration, we will embark on a journey to navigate the multifaceted complexity of the steel casting process. Introduction Steel casting is not merely a manufacturing method; it is an art that combines science, engineering,… Read more: Navigating the Complexity of Steel Casting Process

In the automotive industry, the reliability of engine components is paramount to ensuring optimal performance and safety. Among these components, the engine camshaft plays a critical role in coordinating valve timing, directly influencing combustion efficiency and power output. This article presents a comprehensive analysis of an engine camshaft fracture failure encountered during cold-testing at our facility, alongside actionable strategies to… Read more: Engine Camshaft Fracture Failure Analysis and Prevention

Introduction Wear-resistant bucket teeth are critical components in mining and construction machinery, operating under extreme abrasive conditions. Traditional materials such as high-manganese steel, carbon steel, low-alloy steel, and surface-hardened variants often fail to balance wear resistance with toughness, leading to premature failure. This study introduces a bimetal composite casting technique that synergizes the high wear resistance of chromium-rich alloys with… Read more: Wear-Resistant Bucket Teeth Through Bimetal Composite Casting

Our factory, ZHY Casting, has transitioned from traditional forging and sand casting to ​investment casting for critical components in excavators. This shift, initiated in 1970, has significantly improved production efficiency, material savings, and component quality. Below, we detail the methodologies, parameters, and outcomes of adopting ​investment casting, supported by empirical data and process optimizations. 1. ​Investment Casting vs. Conventional Methods Investment… Read more: Advancements in Investment Casting for Construction Machinery

As a researcher specializing in steel casting processes, I have dedicated my efforts to understanding the formability and defect mechanisms in ​box casting components. The increasing demand for high-performance railway components, such as locomotive diesel engine bearing housings and axle boxes, necessitates rigorous analysis of ​casting defects to ensure structural integrity and operational safety. This article synthesizes my findings on process optimization,… Read more: Formability and Defect Analysis in Box Casting

Lost foam casting has gained significant traction in the industrial production landscape due to its unique characteristics and capabilities. This casting process offers several distinct advantages while also presenting certain limitations that need to be considered for optimal utilization. Introduction Lost foam casting, also known as evaporative pattern casting or foam pattern casting, is a contemporary manufacturing method that has… Read more: Advantages and Limitations of Lost Foam Casting in Industrial Production

1. Introduction In the realm of modern manufacturing, titanium alloy components play a crucial and irreplaceable role in numerous industries. Among them, the titanium alloy brush box, a key part of generators, demands high – performance casting technology due to its specific structural features and working environment requirements. This paper delves deep into the research of the casting technology for… Read more: Research on Titanium Alloy Brush Box Casting Technology A Comprehensive Exploration

Sand casting is an age-old manufacturing process that continues to play a vital role in modern industrial applications. The quality and performance of sand casting parts depend significantly on the design techniques employed. This article explores the advanced design techniques for sand casting parts, aiming to enhance their functionality, quality, and production efficiency. Introduction to Sand Casting and Its Significance… Read more: Advanced Design Techniques for Sand Casting Parts

Steel casting is a crucial manufacturing process that plays a vital role in various industries, from automotive and aerospace to construction and machinery. Achieving high-quality steel castings requires a deep understanding of the process, precise control of parameters, and the use of advanced technologies and materials. In this extensive article, we will delve into the intricacies of the steel casting… Read more: Unveiling the Secrets of High-Quality Steel Casting Process