Die Casting's Blog

Sand casting

admin — Mon, 22 Sep 2008 02:13:38 +0000

Sand casting is utilized to make large components of iron, Bronze, Brass and Aluminum. Melted metal is poured into a mould cavity made out of sand. Patterns: The cavity in the sand is made by utilizing a pattern (a rough duplicate of original) which are generally made of wood and rarely of metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape put into the mould to produce the inner features of the component like holes or internal passages. Core is put in cavity to form holes of the desired shapes. Core print is the portion added to pattern core or mould which is utilized to find and support the core within the mould. A riser is an extra cavity made in mould to hold excess molten material. The reason of this is to feed the molten metal to the mould cavity and as metal solidifies and shrinks and therefore, prevents holes in the main casting. In a two part mould, the upper half is called cope and the lower half is called drag. The parting line separates cope and drag. The drag is filled with sand in part and the core print, the cores and the gating process are put close to the parting line. The cope is then joined to drag and sand is poured covering the pattern, core and the gating system. The sand is made compact by vibration and mechanical method. After that the cope is separated from drag and the pattern is removed carefully. The purpose is to remove the pattern without breaking the mould cavity. This is facilitated by designing a draft, a slight angular offset from the vertical to vertical surface of the pattern. This is generally of 1° or 1.5 mm (0.060 in) whichever is more. The rougher the surface of design, the more the draft to be given. Sprues and runners: The melted material is poured in the pouring cup, it is part of gating process that provides the melted metal to the mould cavity. The vertical part of gating process connected with pouring cup is called sprue and the horizontal part is called the runners and lastly to the multiple points where it connects to the mould cavity is called gates. Alongside there are extensions to the gating process called vents that give the way for built-up gases and the displaced air to vent to the atmosphere. The cavity is generally made oversize to allow for metal contraction as it cools down to normal temperature. These are linear factors and apply in each direction. These shrinkages for allowance are approximate because the exact allowance is decided by shape and size of casting. Besides different components of casting need separate shrinking allowances. Sand casting is a way of making rough metal castings utilizing a mould generally made of sand made around a duplicate of the part to be cast that is removed once the sand becomes compact. Castings made this way may be refined by hammer preening, shot preening, polishing forging, plating, rough grinding machining sand castings not refined further are easily recognizable by sand like texture given by the mould. Therefore, the accuracy of part has to be improved by polishing or grinding. And the mould is broken after every casting to take out the part, a fresh mould is to be made for every casting. Paths for metal pouring during pouring into mould casting are called the runner system and include sprue, various feeders which maintain a good metal ‘feed’ and ‘runners’ and ingates which attach the runner system to cavity. Gas and steam made during casting exit via the permeable sand and riser are added either in the pattern itself or a separate pieces.

Investment Casting Process

admin — Wed, 17 Sep 2008 10:18:19 +0000

The investment casting process begins by creating an injection die that meets the requirements of the specific project. Once made, the die inserts wax that forms the desired patterns; a mold is created when the pattern attaches to a central wax sprue. Molten metal is then dispensed into the sprue.After dipping the wax several times into ceramic slurry, sand is added to the surface. Once the desired thickness is achieved, the wax is removed using an autoclave, leaving the impression of the required casting. The chosen metal is poured into the impression after the shell is heated in a furnace.

After the shell is removed with water blasting, each individual part is removed. Because the cast metal parts are still connected to the sprue, they are removed through the process of cold-break. In most cases, some degree of post-casting machining is also necessary to complete the investment casting process

Die casting description

admin — Wed, 17 Sep 2008 10:09:00 +0000

Die castings are made from alloy tool steels. They have at least two sections to permit the removal of castings, the fixed die, or cover, half and the ejector die half. Some dies also have parts, such as removable slides and cores, to produce holes, threads and other desired shapes in the casting. Openings in the die allow the addition of coolant and lubricant. Dies are either air- or water-cooled. The cooling of the die provides for quick cycling and is one of the factors in the high rate of production. It also gives a fine grain structure and superior strength and finish to the metal castings. The molds used by die casting manufacturers will perform up to 5 million shots in its lifetime.

The services provided by die casting manufacturers have many advantages over other processes. Die casting is efficient and economical, offering a wide range of durable shapes and components. Little or no machining is required after die castings are made because the process provides very close tolerances for even complex part shapes. Metal castings can be easily plated or finished. Die castings are dimensionally stable and heat resistant. These lightweight parts, even while having thin walls, retain the strength of an alloy because they do not consist of separate parts welded together.

Die casting manufacturers utilize a number of materials, including zinc, aluminum, magnesium, copper, lead and tin. Zinc is the easiest alloy to cast, has a low melting point and is economical and easily palatable. Zinc also has high impact strength, offers high ductability and promotes long die life. Aluminum alloys possess high dimensional stability for complex shapes and thin walls. Aluminum die casts are of a lightweight alloy that has good corrosion resistance, mechanical properties, high thermal and electrical conductivity and strength at high temperatures. Along with being the easiest alloy to machine, magnesium is also the lightest typically die cast. Magnesium die casting also has excellent strength-to-weight ratio. Copper is one of the hardest alloys and offers the highest mechanical properties of any other alloy that is cast. A dimensionally stable alloy, copper has high corrosion and wear resistance and strength approaching that of steel parts. Lead and tin are used for special forms of corrosion resistance. Although they have high density, parts with extremely close dimensions are able to be formed from lead castings and tin castings.

Casting exhibition highlight progress in energy industry into the new emission reduction targets

admin — Sun, 06 Jul 2008 08:03:48 +0000

Although power from the casting there is still a considerable gap between us, but through this exhibition we can see that the foundry industry in China and strengthen the clues and exciting!” Recently held in Shanghai 2008 China International Expo on casting, China Machinery Industry Special Adviser to the Federation, honorary president of China Foundry Association of Deputy Lu Yansun, told reporters he has spoken the perception of the show.
According to reports, at the same time held the 9th China International casting, forging and industrial furnaces exhibitions, the 2008 China International Casting the 11th China International Fair and Exhibition metallurgical industry, nearly 30 countries and regions thousand exhibitors Exhibitors, the area of nearly 60,000 square meters, nearly 10,000 pieces of exhibits, attracted 62 countries and regions in the professional audiences and buyers. China Machinery Industry Federation executive vice president of China Foundry Association, chairman of JIA Cheng-ping said that the current scale of the exhibition, the exhibition record levels since the new record. It reflects the prosperity of China’s foundry market, also demonstrated the continuous progress of China foundry industry of the track.
Progress into the most obvious casting bright spot
According to show excellent casting named head of the Expert Group, China Foundry Association executive vice president and secretary-general Zhang Bo, the fair number of exhibitors of casting products several times more than previous sessions, Shen Ping declare the outstanding casting reached 200 Variety. 15 experts selected from the 56 outstanding items, many of them fill the gaps and reach a world-class level of casting, this session has become the largest exhibition of highlights.
Group share in the limited liability company’s pavilion, the fair’s two largest castings, weighing 43 tons and 37 tons of 1 million kilowatts of supercritical steam turbine pressure in the cylinder, super ductile iron castings to attract a large number of visitors Eyes. Peng, chairman of the company who told reporters that this is their self-made, and have reached the advanced level abroad.
This power station to casting, casting machine, engine castings, compressor castings products of the four major professional casting enterprises, casting this year’s production will reach 45,000 tons, of which 60 per cent of the exports. Mr Fan said that enterprises in the development process to deal with the fierce market competition, it is necessary to absorb the energy, materials, the rising cost pressures, we must develop, produce high value-added products. To that end, sharing always adhere to independent innovation, the annual investment in research and development costs accounted for sales income of 5% to 8%. The enterprise also has been the ultimate return: Many world-renowned machine tool enterprises in the share purchase castings; domestic enterprises in the Three Gorges hydropower generating units to the three turbine blades, have shared, and they cast iron gas turbine, Steel Castings Taoshu the annual delivery of more of the world’s market share of 55 percent to 60 percent. The next step is shared by three to five years to build a world-class R & D center, and further promote enterprises in technological innovation. In strive to casting output, sales revenue reached 1.2 billion to 1.5 billion yuan, while profit margins have remained at double-digit levels.
Deputy Lu Yansun, as reporters arrived in Shanghai honorary chairman of Acer Power Plant Equipment Co., Ltd. Zhuduan the booth, executive vice president of the company went up to Yu Liang Jun, proudly pointing to the front of high-pressure gas turbine Menfa Shell said: “You give us the task completed.” According to reports, in March 2007, Deputy Lu Yansun, during an inspection tour to Hong Gang: China’s 1 million kilowatts Ultra-supercritical steam turbine casting is still the bottleneck, the dependence on imports, not only for the highest bid and Difficult to protect cargo, constraining the development of China’s power station equipment that can be added Wang Gang test. Acer result of using its steel castings developed more than 50 years of experience in power plant, after one year of efforts, finally have been fruitful, and reached a world standard. Yu Liang-jun said that the import substitution, a set of such a large number of domestic savings casting Exchange. And the number of good economic balance, its significance is difficult to measure the number, the first to break the foreign monopoly, and the other is in the process of independent innovation fostered a contingent of technical personnel, this is the most valuable asset. Wang Gang will be the next step based on market demand and further increase production.
In addition to supporting the large-scale power station equipment casting a prominent progress, from the exhibition can also see that in the automotive industry driven by the rapid development of China’s automotive castings also achieved gratifying results. As demonstrated at the FAW Foundry’s next-generation engine block, cylinder head, a high-strength thin wall castings, its thickness only 2.5 ~ 3.0 mm, one-time recognition by Volkswagen, Shanghai Volkswagen supply 210,000 / year . Chongqing Qingling Casting Co., Ltd. demonstrated their common-rail-to medium-sized commercial vehicle engines independently developed the key block castings, cylinder head, to meet the EU Ⅳ, Europe Ⅴ emissions requirements. The company General Manager Wu Ji-Qing to the press, now Qingling annual overseas export market of the engine block, cylinder head castings reach tens of thousands of sets, but also through years of “quality climbing”, the casting of non-performing rate of increase lower than 1500ppm, their goal is to control the following in 500 ppm.
Casting around products, foundry casting equipment and materials business enterprises in the exhibition have also introduced the latest achievements. As many world-renowned casting equipment vendors not only display the advanced equipment, but also to provide users with the relevant software used in the system batteries, casting, casting processes, such as cleaning up the industrial robot in the show is also popular concern. One industry expert told reporters that the huge China market to attract, the number of foreign exhibitors casting equipment enterprises have been set up and build factories in China.
Casting has 39 production of domestic and foreign manufacturers on display a variety of Sand, sand core binder, the original sand, paint and liquid metal filter, various ferroalloy, riser material, Shotblast materials, the exhibition area of 1620m2, the Jinan-quan Group Co., Ltd. of which the size of the booth, product exhibitions as many as the most堪称the fair, showing the casting material production enterprises in China’s strength.
According to professor of Qinghua University, China Foundry Association and vice president of Tien-Yu Huang, the Jinan-quan is the world’s largest supplier of casting material. At present, the company’s products occupy casting material of similar products of domestic market share of more than one-third and exported to Europe, America, Southeast Asia, more than 50 countries and regions, which Furan Resin annual sales of nearly 100,000 tons, ranking first in the world 1.
Energy-saving emission reduction targets of the new foundry industry
The show left the deepest impression is that reporters, come to every booth, every interviewer will be referred to the “energy-saving emission reduction,” “green cast” of the topic. China Foundry Association, chairman of JIA Cheng-ping pointed out that casting equipment manufacturing industry is the basis of industry, revitalize the equipment manufacturing industry is an important guarantee for one, but also heavy pollution, high energy consumption of one of the industries. How to promote energy-saving industry-wide emission reduction and building a resource-saving, environment-friendly enterprises casting before us is important and urgent issue.
Grace Steel Power Plant Equipment Co., Ltd. Zhuduan the panels on Yinzhao enterprises large picture factory environment, tree-yin, beautiful and clean, completely changed the people of the traditional casting enterprises Zangluan Chai impression.
Yu Liang-jun told reporters that three years ago, the Acer steel or black smoke everywhere, You Zangyou chaos of a traditional casting business outlook. After rectification of Today, Acer has become a garden-like steel enterprises. Environmental protection equipment investment in fixed assets of enterprises accounted for 30 percent more than a year of environmental protection equipment maintenance costs are around 1.5 million. Smoke all the recovery, the noise dropped to below national standards, also part of sludge recycling. Enterprises not only through the ISO9000, ISO14000, also received ohsas18000 occupational health and safety certification. Enterprises in the energy-saving emission reduction on the achievements of the United Nations also attract industrial organizations and Brazil, India and other overseas counterparts to have visited. Yu Liang Jun clearly remember one engage in a cast of 60 Japanese enterprises to visit the elderly, sheds tears, he sighed with emotion casting enterprises can have such beautiful and clean environment. Yu Liang Jun proud to say that we factory environment is a world-class. This has also allowed the staff enhanced self-confidence, improve their quality. Clean and beautiful environment have become the best advertising business, orders to pour.
In addition to the production process of environmental protection, energy saving technology is more and more attention to the area of renewable energy has become a hot investment casting enterprises.
Jiangyin Jixin Machinery Co., Ltd. has set its sight on the beginning of construction of wind power castings, from the 2005 production with an annual output of 10,000 tons, to 2006’s 20,000 tons in 2007, the 40,000 tons this year will reach 100,000 Tons of output. The company chairman package with the company displayed at the huge wind turbine wheel group, told reporters that the largest companies can now do two-megawatt wind power unit of the wheel, but to achieve the mass production. Preparation is now 2.5 MW and 3 MW. If this production to 100,000 tons, we will be the world’s wind power industry casting well-deserved lead.
Regional construction industry focused on the development of the next step
Zhang Bo told reporters, according to incomplete statistics, at present, the foundry industry has hundreds of industrial clustering, the collective appearance at the show by including Shanghai, Tianjin, Shandong, Zhejiang, Henan, Liaoning, Botou, Anhui Ningguo, more than 10 local outreach mission, the number and scale over the past shows that the Chinese foundry industry’s regional construction boom. China has just received a plaque cast iron base of the 18 cast iron enterprises are also the first joint exhibition. They said that they will take this opportunity to focus on the needs of casting enterprises, enhance research and development capabilities, improve product quality, while the full implementation of national energy consumption and environmental emissions reduction policies, to serve for casting enterprises.
According to the Secretary-General Zhu Botou Casting Association, the Association for the lead in local organizations, Botou exhibitors have seven enterprises, businesses reflect the good effect, has reached more than 60 cooperation intention. In addition, Botou City vice mayor also led to the local Bureau, Bureau of Commerce and other relevant departments in charge of the 13 people, more than 100 local business representatives will visit to learn.
He said that Botou is the history of our country’s three major foundry town, has 1,300 years of history, there are currently more than 700 casting enterprises, is the local pillar industries. Botou the past to produce export-based art castings, is now being machine tools, automobile and other machinery castings transfer. I wish the Secretary-General said that the next step they will cast Concorde in China with the help of industry experts properly formulate medium and long-term development plan, adjust the product structure, increase the share of high-end products, companies will also integrate and eliminate backward and further enhance concentration , The leading backbone enterprises bigger and stronger. Hope that the near future Botou casting with a new look to show people.

Modeling is based on making core casting process

admin — Mon, 30 Jun 2008 14:34:34 +0000

Modeling is based on making core casting process requirements in determining a good method of modeling, ready to shape the material basis. Casting the accuracy of all of the production process and the economic effects will depend mainly on this procedure. In many modern casting workshop, modeling-made batteries have achieved a mechanized or automated. Sand commonly used form core-making equipment is high, medium and low pressure molding machine and threw sand machine, without me radio pressure molding machine, radio-core, cold and hot-box machines.

Since the casting mold in cooling pouring out after a gate, riser and metal spikes Phi slit, sand casting of the casting also adhesion of the sand, it must be clean-up process. Such devices are the work of the Blasting machine, gate riser cutting machines. Sand-casting sand clean-up is a poor working conditions processes, in the choice of modeling methods, should be taken into account for as much as possible with sand to create convenient conditions for clean-up. Casting a result of some special requirements, but also by casting post-processing, such as heat treatment, plastic surgery, anti-rust treatment, such as rough.

Casting is more economic methods of rough shape, the shape of more complex components demonstrated its economy. aluminum die casting Such as car engine block and cylinder head, ship propellers and exquisite works of art, and so on. Cutting some of the difficult parts, such as the combustion turbine parts do not have to nickel-based alloys casting method can not be forming.

In addition, the die casting of parts of the size and weight to a wide range of metal types of almost unlimited; parts in a general mechanical properties, it is also a wear and corrosion-resistant, shock-absorbing properties, and so is the other metal forming methods such as forging , Rolling, welding, salt, and so can not. Therefore, in casting machine manufacturing methods used in the production of rough parts, and the number is still on the tonnage is the largest.

Casting often use a variety of metal materials, coke, wood, plastic, gas and liquid fuels, such as modeling materials. Have the necessary equipment used in various metal smelting furnace, a Mixer with the various Mixer, a shape-made batteries used in various molding machine, machine-made batteries, cleaning up the castings used for loading sand, Shot Blasting Machine And so on. Casting is also available for special machinery and equipment, and many transportation and material handling equipment.

Casting and other technology have different characteristics, mainly wide adaptability, needed materials and equipment, pollution of the environment. Casting will have dust and harmful gases and noise pollution to the environment, compared to other machinery manufacturing processes to become more serious, need to take measures to control.

Casting product development requirements of the trend is casting a better overall performance, higher accuracy and less headroom and clean the surface. In addition, the requirements of energy-saving society and restore the natural environment of the call also getting higher and higher. To meet these requirements, the new cast alloy will be developed, the new smelting technology and new equipment will be corresponding.

Casting the mechanized production continuously improve the degree of automation in the same time, to be more flexible production development, to expand the volume and variety of different production adaptability. Conserve energy and raw materials of new technologies will be giving priority to the development, have little or no pollution of the new equipment, new technology will be the first attention. Quality control technology in all stages of testing and nondestructive testing, stress determination, there will be a new development

Internal Testing

admin — Wed, 25 Jun 2008 15:16:35 +0000

ruyi iron casting Foundry employees conduct quality control tests from the start of the production process to the completion of the casting process.

Sand Lab
Before we use green sand for mold development, we test it in our sand lab for strength characteristics and compactability from the start.

Metals Lab
We conduct a variety of tests in our Metals lab during production and the testing results are then reported to our Gray Iron Casting customers.

Metals lab testing services we provide include:

Evaluating the molecular structure of a casting section using a Unitron MEC 8484 stereomicroscope.
Evaluating the thickness of casting walls by measuring and verifying the thickness using a Kraut-Kramer DML-4 ultrasonic thickness gauge.
Verifying the tensile strength of the casting using a Detroit tensile strength test machine to perform mechanical performance tests.
Verify the chemical composition of the die casting using spectrometer.
Shop Floor
ruyi Foundry personnel conduct a number of tests on the shop floor during production and the testing results are then reported to our Gray Iron casting customers.

Shop floor testing services include:

Hardness testing using a Tinius Olsen Brinell variable load hardness test machine,
Pyrometric testing using an Ircon optical pyrometer located at the Disamatic molding machine to measure and verify the temperature of the molten Gray Iron being cast, and
Mold hardness testing using a Dietert Mold hardness tester to ensure the molds have hardened enough to accept the molten Gray Iron and not deform.

7 casting enterprises funded by the United Nations

admin — Thu, 19 Jun 2008 16:58:26 +0000

A few days ago, from a relevant department was informed that: Jinnan District Dazhan Valve Plant, and other seven companies were the Ministry of Agriculture, the Global Environment Facility, the United Nations Development Programme and United Nations Industrial Development Organization has granted "township enterprises in China energy-saving and greenhouse gas emission reduction projects" Show business title. Energy conservation and the implementation of emission reduction projects show, to effectively promote the work of local energy-saving technical transformation of emission reduction, promote the sustainable development of enterprises. The industrial outskirts of the city began a comprehensive energy-saving emission reduction battle.

It is understood that the Global Environment Fund, China’s Ministry of die casitng Agriculture, the United Nations Development Programme and United Nations Industrial Development Organization in China jointly organized the implementation of the "Chinese township enterprises in energy conservation and greenhouse gas emission reduction projects." Jinnan District 7 are casting processes of industrial enterprises included in the "Chinese township enterprises in energy conservation and greenhouse gas emission reduction projects" plan. 7 companies were received 10,000 U.S. dollars to support the project funds and the Central Government to give 50,000 yuan of funds energy-saving technological transformation, energy-saving technological transformation of the emission reduction achieved remarkable results. 7 Biaomei enterprises, saving 850 tons, more than 2,100 tons of carbon dioxide emission reduction, the average corporate rate of 16.7 percent energy saving, technological transformation before and after the rejection rate decreased 3.4 percent.

2008, the city will be more deeply implement the provisions relating to the work of energy conservation, energy-saving emission reduction as the promotion of scientific development of Kit, promote industrial development in rural areas and construction of the organic unity of ecological civilization, lay a good energy-saving emission reduction battle, protracted war, to speed up Formed to conserve energy resources and protect the ecological environment of the industrial structure and the mode of growth, consumption patterns.

Steel Grating die casting

admin — Tue, 17 Jun 2008 13:35:01 +0000

Bar grating is designed to for many applications. Bar grating casting is a strong choice for projects ranging from trenches to decking. Aluminum bar grating is a good choice when a lightweight, corrosion resistant material is desired. Choose from many options such as: flush top, rectangular bar, plank, and I-bar. Aluminum grating is available in the swage locked, pressure locked (dove tail) and riveted design. Carbon steel bar grating is a nice choice when your project requires a strong material and you are not going to expose the grating to an expressly corrosive environment. Choose from plain or serrated surfaces, galvanized or standard black, and light or heavy duty grating. Stainless steel bar grating provides a superior corrosive & oxidation resistant material in a material stronger than aluminum. Stair tread bar grating is typically offered in a welded construction and is made with a checkered plate nosing that is welded to the leading edge of the tread.

Gravity Cast Parts
1) Materials: aluminum, brass. 2) Applied software for specification drawings: Pro-E, Auto CAD 2000. 3) die casting Main equipment: vertical type casting machine, horizontal type casting machine, rock over. 4) Applications: auto parts, machine parts, plumbing products

About China Sand Casting

admin — Sun, 15 Jun 2008 02:12:37 +0000

Sand casting is one of the most popular and simplest types of casting that has been used for centuries. Sand casting allows for smaller batches to be made compared to permanent mold casting and at a very reasonable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very small size operations. From castings that fit in the palm of your hand to train beds (one casting can create the entire bed for one rail car). Sand casting also allows most metals to be cast depending on the type of sand used for the molds.

Sand casting requires a lead time of days for production at high output rates (1-20 pieces/hr-mold) and is unsurpassed for large-part production. Green (moist) sand has almost no part weight limit, whereas dry sand has a practical part mass limit of 2300-2700 kg. Minimum part weight ranges from 0.075-0.1 kg. The sand is bonded together using clays (as in green sand) or chemical binders, or polymerized oils (such as motor oil). Sand can be recycled many times in most operations and requires little additional input.

Steel Grating in china

admin — Thu, 12 Jun 2008 00:33:53 +0000

Bar grating is designed to for many applications. Bar grating is a strong choice for projects ranging from trenches to decking. Aluminum bar grating is a good choice when a lightweight, corrosion resistant material is desired. Choose from many options such as: flush top, rectangular bar, plank, and I-bar. Aluminum grating is available in the swage locked, pressure locked (dove tail) and riveted design. Carbon steel bar grating is a nice choice when your project requires a strong material and you are not going to expose the grating to an expressly corrosive environment. Choose from plain or serrated surfaces, galvanized or standard black, and light or heavy duty grating. Stainless steel bar grating provides a superior corrosive & oxidation resistant material in a material stronger than aluminum. Stair tread bar grating is typically offered in a welded construction and is made with a checkered plate nosing that is welded to the leading edge of the tread.

Gravity Cast Parts1) Materials: aluminum die casting brass. 2) Applied software for specification drawings: Pro-E, Auto CAD 2000. 3) Main equipment: vertical type die casting machine, horizontal type casting machine, rock over. 4) Applications: auto parts, machine parts, plumbing products