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

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