Abstract According to the structural characteristics of wheel core casting, the lost foam casting solidification process is simulated and analyzed in this paper. The simulation results, obtained using the numerical simulation software ProCAST, focus on the placement of the large flange of the wheel core facing downward. The findings reveal the presence of severe shrinkage… Read more: Study on Lost Foam Casting Process of Wheel Core Parts

In recent years, the demand for high-performance stainless steel components with complex geometries has driven advancements in precision investment casting. This study investigates the development of magnesium-based ceramic cores enhanced with CaCO3 mineralizers and wood flour additives to optimize sintering behavior, mechanical strength, and dissolution characteristics. The experimental framework and results are summarized below. Experimental… Read more: Research on Magnesium-Based Ceramic Cores for Stainless Steel Precision Investment Casting

In modern industrial applications, steel casting remains a critical manufacturing process for producing heavy-duty components like hoisting boxes used in elevator transmission systems. This article presents a comprehensive methodology for optimizing the casting process of ZG25CrNiMo low-alloy steel hoisting boxes through advanced simulation techniques and empirical validations. 1. Material Characteristics and Structural Challenges The hoisting… Read more: Process Optimization and Numerical Simulation of Complex Steel Casting for Hoisting Box Components

Lost foam casting (LFC), also known as expendable pattern casting, has evolved significantly since its invention in 1956. While widely adopted for automotive components globally, its application in steel castings remains challenging due to unique material characteristics. This paper systematically analyzes five critical casting defects encountered in steel LFC processes and proposes scientifically validated countermeasures.… Read more: Common Casting Defects and Preventive Measures in Lost Foam Casting of Steel Castings

This study investigates the optimization of precision casting parameters for critical engine cylinder block components using numerical simulation and experimental validation. Through systematic analysis of process variables, we demonstrate significant improvements in defect reduction and production efficiency. 1. Material Characteristics and Thermal Analysis The engine cylinder block components utilize 4Cr9Si2 martensitic heat-resistant steel with the… Read more: Optimization of Precision Casting Process for Engine Cylinder Block Components

Analysis and Process Improvement of Shrinkage Defects in Main Reducer Shell Casting In automotive shell casting applications, the main reducer housing is a critical drivetrain component introduced to China’s heavy-duty truck industry from German Mercedes-Benz technology in the late 20th century. This shell casting maintains stable market demand across truck models with minimal dimensional variations.… Read more: Gating redesign

This study investigates the sand casting process optimization for high-pressure steam chamber steel castings (ZG15Cr2Mo1) using numerical simulation. The research focuses on addressing shrinkage defects through systematic process design and computational analysis, demonstrating the effectiveness of sand casting technology in producing complex industrial components. 1. Casting Characteristics and Process Requirements The steam chamber exhibits a… Read more: Numerical Simulation and Optimization of Sand Casting Process for High-Pressure Steel Castings

AbstractThe manufacturing level of engine blocks is one of the important indicators to measure a country’s manufacturing industry, representing the development level of its automobile industry. Continuously improving engine efficiency, reducing fuel consumption, and minimizing exhaust emissions are both intrinsic demands for the automotive industry’s self-development and objective requirements from the external environment. Lost foam… Read more: Lost Foam Casting Process Research on Engine Block Castings

Grey cast iron is widely used in automotive engine components, such as cylinder heads, due to its excellent thermal conductivity and damping capacity. Surface hardness control remains critical for balancing machining performance and service reliability. This article systematically analyzes key factors affecting surface hardness through metallurgical mechanisms and experimental verification. 1. Formation Mechanism of Surface… Read more: Factors Influencing Surface Hardness of Grey Cast Iron Cylinder Heads

In the production of six-cylinder engine blocks using the coated sand iron mold casting process, blow hole defects have been a persistent challenge affecting product quality and yield. These blow hole defects typically manifest as surface or subsurface voids in critical areas like the cylinder top or water jacket surfaces, leading to significant scrap rates.… Read more: Prevention Measures for Blow Hole Defects in Six-Cylinder Engine Block Castings

Abstract: The various defects encountered during the production of oil pans using the lost foam casting process, including deformation, metal penetration, dross inclusion, shrinkage porosity, and substandard metallographic structure. Through optimization measures targeting the oil pan’s structural design, gating system, smelting and compounding, as well as the casting process, we have achieved significant improvements. The… Read more: Discussion and Practice on Lost Foam Casting Process of Oil Pan

This paper presents a comprehensive improvement strategy for ductile iron casting processes applied to large-scale agricultural tractor driving wheels. The component, manufactured as per GGG60-DIN1693 specifications, requires exceptional mechanical properties and defect control. Key challenges included eliminating draft angles in gear teeth, resolving shrinkage defects, and mitigating surface porosity. 1. Material Characteristics and Design Constraints… Read more: Optimization of Ductile Iron Casting Process for Heavy-Duty Driving Wheels

1. Current Challenges in Ladle Applications The production of high-quality steel castings requires meticulous control of ladle systems, which serve as critical intermediaries between melting furnaces and casting molds. Common operational issues include: Issue Category Specific Problems Potential Consequences Material Selection Inconsistent refractory quality Erosion contamination in steel castings Thermal Management Improper preheating (300-600°C range)… Read more: Optimizing Ladle Management for High-Quality Steel Casting Production

In the context of automotive lightweighting and increasing demands for engine performance, the wall thickness of engine cylinder blocks has been progressively reduced to 3.5 mm, with material grades upgraded from HT250 to HT300. While meeting structural and cost requirements, these changes have amplified shrinkage porosity risks, leading to leakage failures during engine testing and… Read more: Defect Analysis and Improvement Measures for Engine Cylinder Blocks

Traditional sand casting methods for ductile iron water meter shells often involve complex procedures, high labor intensity, and environmental pollution. Lost foam casting (LFC) offers a sustainable alternative by simplifying production, reducing machining allowances, and enhancing yield rates. This study focuses on optimizing the LFC process for manufacturing large-diameter (150 mm) thin-walled (6.5 mm) water… Read more: Optimization of Lost Foam Casting Process for Large-Diameter Thin-Walled Ductile Iron Water Meter Shells

As foundry engineers specializing in heavy-truck axle components, we encountered persistent shrinkage cavity casting defects in the main reducing shell cover (dimensions: 554 mm × 350 mm × 138 mm, weight: 20 kg). This ductile iron (QT400-15) component features critical thick sections (37 mm) adjacent to thin walls (7 mm), creating inherent solidification challenges. Through… Read more: Analysis of Shrinkage Defect in Ductile Iron Main Reducing Shell Cover and Countermeasures

Deburring casting parts presents significant challenges due to variability in excess material geometry and harsh production environments. At Heidenreich & Harbeck, where precision casting parts weighing up to 16 tons are manufactured, manual deburring exposed workers to extreme temperatures, airborne particulates, and repetitive strain injuries. Our collaboration with Boll Automation yielded a breakthrough solution: integrating… Read more: Robotic Automation in Casting Parts Deburring

In our foundry’s production of a four-cylinder diesel engine cylinder head with complex geometry and compact layout (Figure 1), persistent shrinkage porosity defects accounted for 70% of total casting defects. This paper systematically analyzes the root causes and presents optimized solutions through three process iterations. 1. Process Characteristics and Defect Manifestation The HT250 cylinder head… Read more: Analysis and Optimization of Casting Defects in Diesel Engine Cylinder Head Production

As a manufacturing engineer specializing in automotive components, I have dedicated significant efforts to refining the machining processes for engine cylinder blocks, particularly focusing on the precision and efficiency of cylinder bore fabrication. The engine cylinder block serves as the backbone of internal combustion engines, and its cylinder bores demand exceptional dimensional accuracy, surface finish,… Read more: Optimizing Machining Processes for Engine Cylinder Block Cylinder Bores

The intermediate annealing process critically determines the microstructure and mechanical properties of aluminum-lithium alloys used in aerospace applications. A recent study examined 5A90 Al-Li alloy sheets processed through intermediate annealing in air furnaces, revealing that optimal parameters significantly enhance performance. Annealing at 450–460°C for 70 minutes followed by rapid air cooling yielded peak comprehensive mechanical… Read more: Optimizing Intermediate Annealing for Aluminum-Lithium Alloys and Industry Production Dynamics

Titanium alloys are widely recognized for their low density, high specific strength, excellent corrosion resistance, and biocompatibility. These properties make them indispensable in aerospace, marine, and chemical industries. However, high manufacturing costs hinder broader applications. Precision investment casting, a near-net-shape technology, addresses this challenge by minimizing material waste and machining requirements. This study demonstrates the… Read more: Precision Investment Casting of Titanium Alloy Impeller with Complex Curved Blades

Abstract Based on the analysis of the structure and lost foam casting (LFC) process of a tractor transmission box, this paper summarizes the development of an lost foam casting process for large-sized and thin-walled shell parts. Through systematic research and numerical simulation, the optimal casting process is determined, effectively controlling deformation and ensuring no other… Read more: Lost Foam Casting Technology for Large-Sized and Thin-Walled Shell Parts

1. Introduction As a senior engineer specializing in mining equipment manufacturing, I have dedicated years to optimizing the durability and performance of critical components in mineral processing systems. Among these, lining plates for large semi-autogenous grinding (SAG) mills stand out due to their pivotal role in maintaining operational efficiency. This article delves into the comprehensive optimization of lining… Read more: Production Process Optimization of Lining Plates in Large Semi-Autogenous Grinding Mills

In modern industrial manufacturing, sand casting remains a critical process for producing complex metal components with intricate geometries. This article presents a comprehensive analysis of mold design strategies for turbine cover castings, focusing on structural optimization, defect mitigation, and process reliability. 1. Component Structural Analysis The turbine cover features: Uniform wall thickness of 4mm Curved… Read more: Design and Application of Sand Casting Molds for Complex Turbine Cover Components

Steel casting plays a critical role in manufacturing heavy-duty components like shearer rocker arm housings, which require exceptional structural integrity under cyclic stresses. This study investigates the casting process optimization of ZG20SiMn steel for a complex rocker arm housing with variable wall thicknesses (10–80 mm) using numerical simulation. Two gating systems—top-injection and bottom-injection—were evaluated to… Read more: Numerical Simulation and Process Optimization of ZG20SiMn Steel Casting for Shearer Rocker Arm Housing

Engine main bearing covers are critical automotive components operating under complex loads, demanding defect-free castings with stringent mechanical properties. Traditional trial-and-error methods prolong development cycles and increase costs. This study integrates numerical simulation with orthogonal testing to optimize the casting process for a 5-unit joint bearing cover made of QT500-7 ductile iron, achieving zero internal… Read more: Optimization of Engine Main Bearing Cover Casting Process Based on Orthogonal Test

Automated grinding of large engine cylinder block castings faces persistent challenges due to structural complexity and multi-variety production. This paper systematically addresses quality issues through five critical aspects – human factors, machinery optimization, material control, process methodology, and measurement systems – supported by quantitative analysis and practical implementation data. 1. Current Challenges in Automated Grinding… Read more: Enhancing Automated Grinding Quality for Large Engine Cylinder Block Castings

This study systematically evaluates the tensile-compressive fatigue performance of three grades of grey cast iron (HT250, low-alloy HT250, and HT300) under room temperature conditions. Through metallographic analysis, mechanical testing, and fracture morphology characterization, the effects of alloying elements, surface roughness, and loading frequency on fatigue behavior are quantitatively assessed. 1. Material Composition and Microstructural Analysis… Read more: Investigation of Tensile-Compressive Fatigue Behavior in High-Strength Grey Cast Iron

Green mining drives modern mineral processing, where production safety and energy efficiency are critical. Ball mills, consuming ~50% of concentrator operational costs, are pivotal for grinding quality and energy conservation. However, traditional optimization methods struggle with massive mining datasets. This work proposes BLPNFP-growth—a parallel frequent itemset mining (FIM) algorithm on Spark—to optimize ball mill parameters… Read more: Optimization of Ball Mill Running State with Improved NFP-Growth Algorithm in Spark Framework

This paper presents an optimized lost foam casting (LFC) process for manufacturing medium-large Siemens motor shell castings with complex geometries. Through systematic parameter adjustments and material innovations, we achieved significant improvements in dimensional accuracy and production efficiency compared to traditional furan resin sand processes. 1. Mold Design Considerations For motor shells measuring 1,240 × 800… Read more: Lost Foam Casting Process Optimization for Motor Shell Production

Abstract Railway freight car coupler is the key component to connect vehicles, transfer traction, and ensure the safe operation of trains. This paper focuses on the numerical simulation and process optimization design of investment casting for large complex heavy haul freight coupler, aiming to improve the quality and yield of the coupler castings. 1. Introduction… Read more:  Investment Casting for Large Complex Heavy Haul Freight Coupler

This paper presents a comprehensive investigation of casting defects in thin-walled sections of complex nodular iron castings, focusing on shrinkage porosity in intake/exhaust ports and slag inclusion at spring seat surfaces of marine diesel cylinder heads. Through systematic process optimization, defect rates were reduced from 50% to 93% in actual production. 1. Material Characteristics and… Read more: Casting Defect Analysis and Optimization in Marine Diesel Engine Cylinder Head Production

Ductile iron castings are critical components in wind turbine systems, including hubs, main frames, and bearing housings. Their complex geometries and heavy sections (60–120 mm wall thickness) make them prone to shrinkage porosity, a defect that reduces mechanical properties by up to 60% in tensile strength. This article systematically analyzes the root causes and proposes… Read more: Analysis and Prevention of Shrinkage Porosity in Ductile Iron Castings for Wind Turbines

Heat treatment fundamentally transforms metallic components through controlled heating and cooling cycles, enabling tailored mechanical properties that maximize material potential, extend service life, and enhance operational efficiency. When heat treatment defects occur, components become non-conforming or scrap, causing significant economic losses. These defects are classified by nature: cracks, distortions, residual stresses, microstructural abnormalities, performance deficiencies,… Read more: Understanding and Mitigating Heat Treatment Defects in Metallic Components

In modern foundry practices, furan resin sand casting has become a cornerstone for producing high-integrity sand casting parts due to its superior dimensional accuracy, low scrap rates, and economic efficiency. This paper systematically examines critical process parameters and proposes technical improvements to address common defects in sand casting parts manufactured through furan resin sand molding.… Read more: Optimization and Technical Analysis of Furan Resin Sand Casting Processes for High-Quality Sand Casting Parts

Frequent maintenance and replacement of Semi-Autogenous Grinding (SAG) mill lining plates significantly impact operational efficiency and cost in mineral processing plants. While various materials like high-manganese steel and high-chromium cast iron are employed, medium-carbon chromium-molybdenum (Cr-Mo) steel offers a promising balance of wear resistance and toughness, particularly under low-stress conditions. Achieving optimal performance in these… Read more: Optimizing Heat Treatment for Enhanced Performance of SAG Mill Lining Plates

Surface defect detection in engine cylinder block manufacturing is critical for ensuring product quality. Traditional manual inspection methods suffer from inefficiency and high labor costs. This paper proposes a vision-based defect detection framework combining a pix2pix generative adversarial network (GAN) and YOLOv5 deep learning model to address challenges caused by limited defect datasets in industrial… Read more: An Engine Cylinder Block Surface Defect Detection Method Using Deep Learning and Generative Adversarial Networks

This study focuses on enhancing the efficiency and quality of railway steel castings produced via green moulding clay sand, addressing critical challenges such as gas porosity, sand inclusion, and cracking. Through systematic experimentation and numerical simulations, optimized sand formulations and casting processes are proposed to minimize defects while maintaining cost-effectiveness. 1. Sand Formulation and Performance… Read more: Optimization and Defect Prevention in Steel Casting with Green Moulding Clay Sand

Abstract: The manufacturing level of diesel and gasoline engine blocks reflects the development status of a country’s automotive industry. Continuously improving engine efficiency, reducing fuel consumption, and minimizing exhaust emissions are both internal demands of the automotive industry’s development and external environmental requirements. Lost foam casting is one of the advanced manufacturing processes featuring near-net-shape… Read more: Lost Foam Casting in the Production of Engine Block Castings

This article presents a comprehensive analysis of precision investment casting for a stainless steel shell characterized by intricate geometries, uneven wall thicknesses, and numerous thermal junctions. The casting structure combines bearing bores, mounting flanges, and radial ribs, creating significant challenges in maintaining directional solidification and preventing shrinkage defects. 1. Thermal Management in Precision Investment Casting… Read more: Precision Investment Casting of Large Complex Stainless Steel Shells: Process Design and Optimization

Our research focuses on enhancing the mechanical and thermal properties of vanadium-titanium (V-Ti) grey cast iron through systematic composition design, targeting optimized performance for automotive brake drum applications. The study reveals critical relationships between alloying elements, graphite morphology, and material characteristics through controlled casting experiments. 1. Composition Design and Experimental Methodology Four distinct compositions of… Read more: Microstructure and Performance Optimization of Vanadium-Titanium Grey Cast Iron for Automotive Brake Drums

AlSi7Mg alloy is extensively utilized in aerospace and automotive industries due to its exceptional formability, high corrosion resistance, and balanced mechanical properties. Its excellent strength-to-weight ratio makes it particularly suitable for automotive structural components. High-pressure die casting, as a rapid near-net-shape manufacturing process, offers significant advantages for producing such complex geometries. However, defects and inconsistent… Read more: Optimizing Die Casting Parameters for Enhanced Mechanical Properties in AlSi7Mg Automotive Components

Abstract The lost foam casting process of nodular iron vacuum pump housing through a comprehensive analysis. By employing 3D simulation for the casting method, a rational gating system was designed. Foam cutting technology was utilized to create the vacuum pump housing white pattern, ensuring smooth pattern assembly. The liquid iron was nodularized using a cored… Read more: Lost Foam Casting Process of Nodular Iron Vacuum Pump Housing

Excavators are indispensable in infrastructure projects, with China’s fleet exceeding 1.3 million units. Bucket teeth endure extreme wear as primary ground-engaging components, creating massive demand for high-performance solutions. While casting traditionally dominated production, inherent defects like shrinkage cavities and environmental concerns necessitated advanced forging alternatives. This research establishes an optimized forging process addressing the unique… Read more: Influence of Preform Shape on Final Forging for Excavator Bucket Teeth

Gearbox housings, as critical components in mechanical systems, require exceptional dimensional accuracy, surface quality, and structural integrity. Traditional casting methods often struggle to meet these demands due to inherent limitations. This paper explores the application of vacuum lost foam casting (VLFC) in gearbox housing production, emphasizing its advantages in defect reduction, efficiency improvement, and environmental… Read more: Optimization of Gearbox Housing Production Through Vacuum Lost Foam Casting

Sand casting remains a cornerstone in manufacturing due to its cost-effectiveness and adaptability for complex geometries. This study investigates the influence of antimony (Sb) on the microstructure evolution of hypoeutectic Al-7Si alloys under gravity sand casting conditions, focusing on primary α-Al grains and eutectic Si morphology. By analyzing thermal profiles, grain characteristics, and modification mechanisms,… Read more: Effects of Antimony on Grain Refinement and Eutectic Silicon Modification in Hypoeutectic Al-Si Alloys Under Sand Casting Conditions

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