Abstract
The brake system is a critical safety component in automobiles, with brake discs and drums being the primary security parts. This article delves into the application of casting elements in brake disc casting production, emphasizing their eco-friendly, low-emission, and high-performance attributes. Drawing from the latest research and industry practices, the paper outlines the benefits of casting elements over traditional materials like coal dust and bentonite. The use of casting elements in brake disc casting has led to significant improvements in emission reduction, solid waste management, and product quality, thereby providing a valuable alternative for casting enterprises worldwide.
1. Introduction
Automotive brake discs and drums are vital components of the braking system, ensuring the safety of passengers and the vehicle itself. These components are typically produced through sand casting processes, which require a mixture of sand, binders, and additives to form the mold. However, traditional materials like coal dust and bentonite have been associated with numerous drawbacks, including high emissions, solid waste generation, and environmental pollution. In recent years, casting elements have emerged as a promising alternative, offering superior performance and environmental benefits.
This article aims to comprehensively examine the application of casting elements in brake disc casting production. We will explore their chemical composition, technical specifications, and performance advantages over traditional materials. Additionally, we will present case studies and data tables to illustrate the practical benefits of casting elements in the automotive casting industry.
2. Overview of Casting Elements
Casting elements are a patented material developed by Shandong Xuguang Derui Advanced Materials Co., Ltd. This innovative material combines high-quality bentonite, high-carbon eco-friendly anti-scaling materials, α-starch, cellulose, and other additives to create a versatile binder system for sand casting. Unlike coal dust, casting elements do not generate harmful emissions or solid waste during the casting process.
Table 1: Technical Specifications of Casting Elements
| Model | Blue Absorption (g/100g) | Wet Compressive Strength (kPa) | Hot-Wet Tensile Strength (kPa) | Micro-Volatiles (%) | Volatiles (%) | Bright Carbon (%) | 140 Mesh Pass Rate (%) |
|---|---|---|---|---|---|---|---|
| XZ50 | ≥20 | ≥70 | 2.8~3.3 | 10~12 | 15~23 | 6~8 | ≥90 |
| XZ60 | ≥22 | ≥80 | 3.0~3.5 | 10~12 | 14~22 | 5~7 | ≥90 |
| XZ65 | ≥25 | ≥85 | 3.0~3.5 | 10~12 | 12~20 | 4~6 | ≥90 |
| XZ70 | ≥27 | ≥90 | 3.0~3.8 | 10~12 | 11~19 | 4~6 | ≥90 |
| XZ75 | ≥28 | ≥95 | 3.2~3.8 | 10~12 | 10~18 | 3~5 | ≥90 |
| XZ80 | ≥30 | ≥95 | 3.2~3.8 | 10~12 | 9~18 | 3~5 | ≥90 |
| XZ85 | ≥30 | ≥100 | 3.2~3.8 | 10~12 | 8~16 | 3~4 | ≥90 |
Note: The manufacturer recommends using XZ80 for brake disc and drum casting.
3. Benefits of Casting Elements in Brake Disc Casting
Casting elements have revolutionized the brake disc casting process by introducing a myriad of advantages that surpass traditional materials such as coal dust and bentonite. These benefits encompass environmental friendliness, efficiency improvements, and quality enhancements, making casting elements an indispensable addition to modern brake disc manufacturing.
3.1 Environmental Advantages
3.1.1 Reduced Harmful Gas Emissions
Casting elements significantly reduce harmful gas emissions during brake disc casting, making the production process more environmentally sustainable. Traditional methods rely heavily on coal dust as an anti-sticking agent, which leads to the emission of toxic gases and particulate matter during casting and sand treatment. In contrast, casting elements employ high-polymer materials and natural plant-based components that do not release harmful gases during processing.
Table 1 summarizes the comparison between harmful gas emissions from casting elements and coal dust/bentonite mixtures.
| Material | SO₂ Emission (mg/m³) | Naphthalene Emission (mg/m³) | Phenol Emission (mg/m³) | Toluene Emission (mg/m³) |
|---|---|---|---|---|
| Casting Elements | 0.009 – 0.015 | 0.0001 – 0.0002 | Not Detected | 0.008 – 0.013 |
| Coal Dust + Bentonite | 0.0596 – 0.060 | 0.014 – 0.016 | 0.010 – 0.017 | 0.016 – 0.026 |
The data clearly indicates that casting elements drastically decrease the emission of SO₂, naphthalene, phenol, and toluene, thereby mitigating air pollution and improving workplace safety.
3.1.2 Lowered Solid Waste and Dust Generation
Casting elements also contribute to a reduction in solid waste and dust generation during brake disc casting. Traditional sand mixtures containing coal dust and bentonite produce significant amounts of dust during mixing, pouring, and shakeout operations. This dust, along with discarded old sand, represents a significant environmental burden.
Casting elements, on the other hand, reduce dust generation due to their higher burnout rate and lower residual ash content. This not only improves air quality within the casting facility but also decreases the amount of solid waste requiring disposal. Table 2 illustrates the comparison between solid waste generation from casting elements and traditional materials.
| Material | Solid Waste Reduction (%) | Dust Emission Reduction (%) |
|---|---|---|
| Casting Elements | 80% | 50% – 70% |
| Coal Dust + Bentonite | Baseline (0%) | Baseline (100%) |
As shown in the table, casting elements achieve a substantial reduction in solid waste and dust generation, translating into significant environmental benefits.
3.2 Enhanced Production Efficiency
Casting elements significantly enhance production efficiency in brake disc casting operations by improving the overall performance of the molding sand.
3.2.1 Improved Molding Sand Properties
Casting elements impart superior mechanical and physical properties to the molding sand, including increased wet compressive strength, better collapsibility, and improved permeability. These attributes contribute to fewer defects during pouring and easier shakeout, resulting in higher casting yields and reduced scrap rates.
Table 3 highlights the improved properties of molding sand containing casting elements compared to those with coal dust and bentonite.
| Property | Casting Elements | Coal Dust + Bentonite |
|---|---|---|
| Wet Compressive Strength (kPa) | ≥70 – ≥100 | Varies |
| Collapsibility | Excellent | Good – Poor |
| Permeability | Improved | Average – Poor |
The improved properties of casting element-based molding sand lead to more reliable and efficient casting processes, reducing downtime and improving overall production throughput.
3.2.2 Reduced Maintenance and Cleaning Requirements
Casting elements also reduce maintenance and cleaning requirements in brake disc casting facilities. Traditional materials tend to adhere to molds and castings, requiring extensive cleaning and maintenance efforts. In contrast, casting elements produce more easily shakeout castings with minimal sand adhesion, thereby simplifying the cleaning process and reducing downtime.
3.3 Improved Casting Quality
The introduction of casting elements in brake disc casting production has significantly enhanced the quality of castings. By optimizing the properties of the molding sand, casting elements contribute to a reduction in various casting defects, such as porosity, sand inclusion, and sand burning.
Firstly, the improved wet compressive strength and permeability of the molding sand mixed with casting elements ensure better filling of the mold cavity, reducing the likelihood of porosity defects. The high-carbon and eco-friendly anti-scouring materials in casting elements effectively prevent the penetration of molten metal into the sand, minimizing sand inclusion defects.
Secondly, casting elements improve the collapsibility and shakeout properties of the moldings. This ensures that the castings can be easily separated from the sand mold without causing damage to the casting surface, further reducing the occurrence of sand burning and other surface defects.
Moreover, the reduced dust and solid waste emissions from the use of casting elements contribute to a cleaner casting environment, which in turn benefits the overall casting quality. The lower moisture content and improved sand reuse rate also stabilize the molding sand properties, ensuring consistent casting quality over time.
In summary, casting elements not only reduce the occurrence of various casting defects but also enhance the overall quality and surface finish of brake disc castings. This improvement in casting quality translates into higher product reliability and customer satisfaction, ultimately benefiting the manufacturers and end-users alike.