China’s casting industry has experienced unprecedented growth over the past two decades, positioning itself as a global leader in production volume while facing significant challenges in technological advancement and sustainability. As the world’s largest producer of castings, China casting contributes over 28% of global output, yet struggles with productivity gaps compared to industrialized nations. This… Read more: Development Status and Future of China Casting Industry

During durability testing of a 2.0T engine with aluminum alloy main bearing covers manufactured through high-pressure die casting (HPDC), catastrophic fractures occurred at multiple bearing cap locations after 567 hours of operation. This study investigates the root causes through multi-disciplinary analysis and proposes effective structural and process improvements. 1. Fracture Mechanism Analysis The fracture originated… Read more: Analysis and Optimization of Main Bearing Cover Fracture in High-Pressure Die Casting Engine Components

This study addresses the challenges in producing high-hardness steel castings for roller teeth used in roller crushers. The components require exceptional dimensional accuracy (CT12 per GB/T 6414-2017), hardness ≥400 HBW, and defect-free microstructure. Through systematic process optimization and computational modeling, our team achieved first-pass success in manufacturing these critical steel castings. 1. Technical Requirements and… Read more: Research and Development of High Hardness Roller Teeth Steel Castings

Sand casting parts made of duplex stainless steels, such as A995-5A, face significant challenges in avoiding crack defects due to the inherent formation of brittle σ-phase intermetallic compounds during slow cooling. This article systematically analyzes the root causes of cracking and proposes optimized cooling strategies to enhance the reliability of heavy-section sand casting parts. 1.… Read more: Optimizing Cooling Processes to Mitigate Crack Defects in A995-5A Duplex Stainless Steel Sand Casting Parts

Through systematic material testing and process optimization, this study establishes critical parameters for producing engine cylinder blocks using vermicular graphite iron (VGI) with enhanced mechanical properties. The research focuses on achieving optimal vermicular rates while meeting RT450 strength requirements through controlled alloy additions and innovative casting techniques. 1. Material Composition Design The chemical composition framework… Read more: Trial Production and Performance Optimization of High-Strength Vermicular Iron Engine Cylinder Blocks

Abstract The optimization of investment casting processes heavily relies on empirical trial-and-error methods, resulting in long optimization cycles, high labor costs, low operational efficiency, and a lack of algorithmic optimization. Therefore, an integrated computing platform for investment casting processes was developed based on the ProCAST finite element simulation software and multitasking batch processing technology. This… Read more: Integrated Computational Platform for Investment Casting Processes

This study investigates the critical role of titanium (Ti) in optimizing ductile iron casting processes for automotive brake discs. Through controlled experimentation with varying Ti content (0.01%-0.12%), we establish quantitative relationships between alloy composition and final product performance using advanced metallurgical analysis and statistical modeling. 1. Thermodynamic Foundations of Ti Interaction The interaction between Ti… Read more: Influence of Titanium on Microstructure and Mechanical Properties in Ductile Iron Casting for Brake Disc Applications

As the Steel Casting Branch of the China Foundry Association, I have witnessed the remarkable evolution of China’s steel casting sector. Since 2000, China has maintained its position as the world’s largest casting producer for seven consecutive years. By 2005, total casting output exceeded 24 million tons, with 2006 production estimated at 26.4 million tons… Read more: Reflections and Analysis on the Current Situation and Development of China’s Steel Casting Industry

AbstractFor a long time, pitting has been a major defect in the surface quality of precision castings. This issue is commonly observed on the surfaces of 200-series stainless steel, 400-series stainless steel, carbon steel, and low-alloy steel. After shot peening or sandblasting, gray-black spots, pits, and even dents appear on the casting surface. These defects… Read more: Analysis of Causes and Prevention Measures for Surface Pitting on Investment Casting Precision Castings

Manufacturing robust components through casting requires specialized coatings that withstand extreme thermal and mechanical stresses, particularly for large casting production. Waterborne spray coatings offer significant advantages over solvent-based alternatives, including reduced environmental impact, lower energy consumption during drying, and enhanced operator safety. For large casting applications, where manual brushing becomes impractical and efficiency is paramount,… Read more: Optimizing Waterborne Spray Coatings for Large Casting Applications

In this study, we present a comprehensive analysis of the temperature field distribution in an engine cylinder block and cylinder head using a bidirectional fluid-structure coupling (FSI) approach. By incorporating heat flux correction based on comparative statistical analysis, we aim to enhance the accuracy of simulation results and validate them against experimental measurements. The methodology,… Read more: Temperature Field Analysis and Validation of Engine Cylinder Block and Head Using Heat Flux Correction

This study investigates the development of grey cast iron materials with enhanced machinability and cost-effectiveness for engine cylinder block applications. By comparing multi-component alloy additives (containing RE, Cr, Mn, Si, Fe) with traditional copper alloying under identical inoculation conditions, we systematically analyze the mechanical properties and machining performance through tensile strength testing, hardness measurement, and… Read more: Research on Low-Cost Easily Machinable Grey Cast Iron Materials for Engine Cylinder Blocks

AbstractThe origin of the lost-wax method in China has always been a focus of attention for scholars both domestically and internationally, yet no consensus has been reached in existing research. This article reviews the technological and historical conditions surrounding the origin of the lost-wax method in ancient China, as well as the main arguments in… Read more: Verification of Lost-Wax Method through Investment Casting Process

ASME SA-217 C12A valve body casting material is a high-alloy heat-resistant steel developed in the United States. It exhibits exceptional high-temperature oxidation resistance, creep strength, and thermal stability while maintaining favorable plasticity and machinability. These properties enable significant weight reduction in valve body castings operating under extreme temperature/pressure conditions, such as critical power generation components… Read more: Research on Key Processes for C12A Valve Body Castings

In industrial applications requiring prolonged exposure to high temperatures, steel castings such as GX40CrSi17 ferritic heat-resistant alloys play a critical role due to their cost-effectiveness and superior thermal stability. This study systematically investigates the phase transformations and carbide evolution in GX40CrSi17 steel casting under different aging temperatures (850°C, 950°C, and 1050°C) through thermodynamic simulations and… Read more: Effect of Aging Temperature on Microstructure Evolution in GX40CrSi17 Ferritic Heat-Resistant Steel Casting

Lost foam casting (LFC) has undergone transformative advancements through the development of a novel shell mold baking and vacuum pouring technique. This paper details a refined process that eliminates carbon-related defects while retaining LFC’s core advantages, demonstrated through the production of high-integrity steel rope clips for bridge applications. 1. Process Fundamentals The shell mold LFC… Read more: Innovative Lost Foam Casting Shell Mold Process for Defect-Free Steel Castings

The V-process casting technique, characterized by vacuum-sealed molding with dry sand and plastic films, has demonstrated significant advantages in producing high-quality aluminum alloy sand casting parts. This article explores its applications in refrigerator inner mold production, artistic relief design, and novel mold material development through systematic experiments and industrial case studies. 1. V-Process Implementation for… Read more: Exploration and Practice of V-Process Casting for Aluminum Alloy Sand Casting Parts

Abstract: This paper focuses on the lost foam casting process of medium thin-walled circular parts. A step gating system is designed based on the structural characteristics of the castings. Numerical simulation analysis of the filling and solidification processes during lost foam casting is conducted using ProCAST software. The simulation results and trial production verify the… Read more: Lost Foam Casting Process of Medium Thin-walled Circular Parts

The integration of 3D printing with precision investment casting represents a groundbreaking advancement in modern manufacturing. This synergy enables the direct production of complex, high-precision castings through digital modeling while significantly reducing development costs and lead times. The following analysis explores this technological convergence through material comparisons, process optimization, and quantitative modeling. 1. Material Compatibility… Read more: Application of 3D Printing in Precision Investment Casting Technology

In modern foundry industries, traditional trial-and-error methods for designing casting processes face limitations due to empirical dependencies, cost constraints, and complex production controls. Computer-Aided Engineering (CAE) has become indispensable for predicting casting feasibility and optimizing processes. This study demonstrates how MAGMASOFT® simulations enhance the development of engine cylinder block and head castings compliant with China… Read more: Application of CAE in Engine Cylinder Block and Head Castings for China VI Emission Standards

In evaporative pattern casting of ductile iron components, the design of gating systems and prevention of shrinkage defects remain critical challenges. This study focuses on a 180kg QT400-15 casting with complex geometry featuring thick sections up to 59mm and oil passages exceeding 510mm in length. Through systematic process optimization and defect analysis, we developed effective… Read more: Process Design and Defect Prevention in Evaporative Pattern Casting of Ductile Iron Castings

This study presents a comprehensive optimization methodology for low-pressure casting process parameters of A356 aluminum alloy sleeves, integrating numerical simulation, response surface methodology (RSM), and genetic algorithms to enhance casting quality and mechanical properties. The research focuses on minimizing shrinkage porosity volume and secondary dendrite arm spacing (SDAS) through systematic parameter tuning. Experimental Design and… Read more: squeeze casting

As a materials engineer specializing in sand casting processes, I have witnessed the revolutionary impact of high-performance coated sand on complex mold manufacturing. The fundamental composition of coated sand can be expressed as: $$ C_s = Q_s + R_m + A_d $$ Where $C_s$ represents coated sand, $Q_s$ denotes quartz base sand (typically 85-92 wt%),… Read more: Application and Optimization of High-Performance Coated Sand in Complex Sand Casting

Abstract: This paper improves the investment casting process of centrifugal impellers by incorporating 3D printing and silicone rubber demolding technologies. Through extensive practice, a reasonable process flow has been studied and formulated, resulting in the production of qualified centrifugal impeller products. The results demonstrate that centrifugal impeller parts with qualified surface quality and dimensional accuracy… Read more: Exploration and Research of Centrifugal Impeller Manufacturing Process Based on Investment Casting Technology

In our extensive experience with manufacturing excavator casting parts, particularly bucket teeth, we’ve identified sand casting as a dominant method due to its cost-effectiveness despite persistent challenges like sticky sand defects. This phenomenon manifests as a sintered layer of metal or metal oxides fused with molding sand, resulting in rough surfaces that compromise part integrity… Read more: chemical

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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