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1 Safe Melting Practices 安全熔融法 Published By: MODERN CASTING A publication of the american Foundry Society Casting Competence Across Three Continents

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4 31 MODERN CASTING / October 2006

5 FALL 2012 volume 2 number 4 P.45 P.38 P.51 features 专题文章 23 Dos and Don ts in Melt Deck Safety 23 确保熔炼平台上的安全做与不该做的 吉莉安 科诺尔 j. knuerr 30 Reviewing China s Diecasting Industry 30 回顾中国的压铸工业 陈金城 J. Cheng 38 Exploring Self-Healing Castings 38 德国压铸工业重振雄风 J. Martinez-Lucci, A. Ruzek, S. Misra, P. Rohatgi and R. Amano 45 Harvey Industries Revives Wabash J. Martinez-Lucci, A. Ruzek, S. Misra, P. Rohatgi and R. Aman 45 哈维实业公司使沃巴什铸造厂复兴 A. Spada A. Spada 51 New Angles Emerge in Matchplate Molding 51 双面模样造型出现新趋势 m. colditz m. colditz To receive future issues, go to 要获得这在未来的数字杂志 去 departments 部门 Editorial Industry News Product News Supplier s Perspective 3 社論 行業新聞 產品新聞 供应商观点 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

6 1 2 3 TOP TEN FOUNDRY MUST-HAVES! FURNACE 2. POWER SUPPLY 3. ARMS SYSTEM 4. HOLDING SYSTEM 5. PREHEATING SYSTEM 6. CHARGING SYSTEM 7. AUTOPOUR SYSTEM 8. COMPUTER CONTROL 9. EMISSIONS CONTROL 10. SAFETY TRAINING Inductotherm builds induction melting, holding, heating and pouring systems for virtually all metals, including gray and ductile iron, steel, copper and copper-based alloys, aluminum, zinc, reactive metals and precious metals. As the world s largest manufacturer of the induction equipment shown here, only Inductotherm can offer proven efficient, reliable and effective systems for all your melt shop needs. Call INDUCTO or scan the QR code for direct access to Need a QR code reader? For iphone - use inigma, Blackberry & Android - use BeeTagg. Inductotherm Corp. - USA 10 Indel Ave., PO Box 157 Rancocas, NJ Leading Manufacturers of Melting. Thermal Processing and Production Systems for the Metals and Materials Industry Worldwide. Important: Appropriate Personal Protective Equipment (PPE) must be worn by anyone in proximity to molten metal.

7 铸造厂的十大 必备条件 应达几乎可以对所有金属建立感应熔炼 保温 加热 浇注系统 包括灰铁 球墨铸铁 钢 铜及铜合金 铝 锌 活性金属和贵金属 4 1. 熔炉 2. 供电 3. ARMS 系统 4. 保温系统 5. 预热系统 6. 充电系统 7. 自动落纱系统 8. 电脑控制 9. 排放控制 10. 安全培训 作为世界上最大的感应设备制造商 只有应达可以为 满足您的熔炼车间提供经过验证的高效 可靠和有效 的系统 拨打1.888.INDUCTO或扫描以下QR码便可直接访问 需要一个QR码阅读器吗 对于 iphone - 使用iNigma 黑莓和Android - 请使用BeeTagg 应达公司 - 美国 10InDel大道 邮政信箱157 兰科卡斯 NJ 是为全球金属和材料行业提供熔炼 热处理过程和生产系统的领军制造商 重要提示 必须着适当的个人防护装备 PPE 方可靠近熔炼的金属

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9 staff/工作人員 staff/工作人員 MODERN CASTING Foundry-Planet.com Publisher/Editor ALFRED T. SPADA, Publisher/Editor THOMAS FRITSCH, Senior Editor denise kapel, Senior Editor International CHRISTOPH VON PLATEN, Senior Editor SHANNON WETZEL, Editor/ International Sales ADRIANA ORTEGA, Assistant Editor JILLIAN KNUERR, Senior Editor Germany, Austria, Switzerland ALEXANDER MAYERHOFER, Advertising Sales JIM BECKWITH, JOE MURPHY, MARK MCGOWAN, Advertising Sales Manager CHRISTOPH VON PLATEN, Art Director MICHAEL J. BERRAFATO, Advertising Sales ALEXANDER MAYERHOFER, OANH NGUYEN-SCHRÖCK, MODERN CASTING A publication of the american Foundry Society China Foundry Association 中国铸造协会 Publisher/Executive Vice President & Secretary General/ 出品人 Zhang Libo/ 张立波 Senior Editor/ 主编 Wen Ping/ 温平 Deputy Editor/ 副主编 huang tianyou/ 黄天佑 Fan qi/ 范琦, fanqi@foundry.com.cn Editor/ 编辑 tian shijiang/ 田世江 cui yanshen/ 崔言燊, cuiyanshen@foundry.com.cn Advertising Sales Manager/ 广告销售主管 gao wei/ 高巍, gaowei@foundry.com.cn Advertising Sales/ 广告销售 zhou haoran/ 周浩然 FALL 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 7

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11 video editorial/ 社論 Good Old Europe Is Calling Is There a Crisis? 昔日美好的老欧洲在召唤 是有危机吗? What have we not already heard or experienced about state policy and financial politics in the world within the course of the last three years? Advice, reprimand, a gradual series of changes, wounded vanity and the daily struggle for the right financial political instruments. And always at the center is Europe. Of course, Europe is aware of its own struggles. Although it is still very strong as a whole, Europe unfortunately suffers under a heterogeneous structure and is intertwined with various regional economic strengths. So, what s in store for the European metalcasting facilities and their suppliers? Europe has recovered well from 2009 and 2010, and it is remarkably stable after leaving difficult times behind. It produces the second largest amount of castings, after China, with the highest efficiency and technological standards. Apart from those affected by the European crises chatter, European machine manufacturers and metalcasting suppliers selling high-tech products have long been competitive in the world market. European exports increasingly benefit from a slightly weaker Euro, order books are adequately filled, yet we still have to ask the question: How long will this continue, or is everything independent of the Euro and European crises? Just as the whole world is captivated by the development in Europe, metalcasting facilities and suppliers have to keep on eye on advancements as well, particularly in southern Europe. While policy determines the framework, it is up to businesses themselves to take future action. Securing a technological edge with innovation and investments made in the upcoming generation of engineers seems to be independent of the fragile financial markets, which are the best instruments to face a crisis. It s from this that the metalcasting industry can benefit throughout the world. Glück Auf! Good Luck! 在过去的三年里, 世界各国国策和金融政治方面的哪些事情是我们未曾听过或经历过的? 忠告 谴责 循序渐进的一系列变化 受伤的虚荣心及为争取 正确的 金融政治工具而进行的每日争斗 所有这一切的中心都是欧洲 当然, 欧洲也意识到自己的争斗 欧洲尽管整体非常强大, 却因其结构的异质性而备受煎熬, 区域经济优势各不相同的地区交织在一起 那么, 等待着欧洲金属铸造厂和其供应商的又是什么呢? 2009 至 2010 年间欧洲经济复苏良好, 欧洲在摆脱困境之后非常稳定 其生产的铸件产量位居世界第二, 仅次于中国, 而其铸件的效益和技术标准则位居全球第一 除那些受欧洲危机说法影响的外, 欧洲机器制造厂家和出售高端产品的金属铸造供应商在世界市场上一直有很强的竞争力 欧洲出口日益得益于小幅走软的欧元, 订单应接不暇, 然而我们仍要问这个问题 : 这将持续多久, 或者一切都与欧元和欧洲危机无关吗? 正如全世界都被欧洲的发展所吸引, 金属铸造厂和供应商不得不密切关注欧洲, 特别是南欧的发展 尽管政策决定框架, 而是否采取未来行动则取决于企业自身 以创新及对未来一代工程师的投资来确保技术优势似乎不受脆弱的金融市场的影响, 因为这些是面对危机的最好方法 全球的金属铸造业都将得益于此 祝铸造业好运! Thomas Fritsch Publisher/Editor-in-Chief Foundry-Planet.com Alfred T. Spada Publisher/Editor-in-Chief MODERN CASTING 张立波出品人中国铸造协 To receive this digital magazine in the future or to make comments about Global Casting, visit 要获得这在未来的数字杂志, 去 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 9

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13 industry news/ 行業新聞 Ankiros Exhibition Connects Supply Chain Ankiros 展览聚集世界供应链 The Ankiros 11 th International Iron-Steel & Foundry Technology Exhibition held Sept in Istanbul, Turkey, drew leading international suppliers from the casting, iron and steel industry. The event focused on bringing together products and technology associated with the supply chain of metalcasting and ferrous manufacturing and processing. More than 800 exhibitors from 39 countries gathered to showcase the latest technology innovations to domestic and international audiences. Among the exhibitors, 319 were Turkish, including representation from the Turkish Foundry Association (TUDOKSAD). According to Messe Hannover, the Ankiros organizer, Turkey s iron and steel sector is a strong economic force with a bright outlook. Steel production in Turkey increased by 17% in 2011 to 34 million tons, making it the second largest steel producer in Europe and the 10th largest in the world. Online Resource Click here to watch a video of the event. Ankiros 第 11 届国际钢铁及铸造技术展览会于 9 月 日在土耳其伊斯坦布尔举办, 吸引了铸造 钢铁行业国际领先的产品供应商前来参展 该次展览主要汇集了与铸造 有色金属生产加工供应链相关的技术和产品 来自 39 个国家的 800 多名参展商齐聚一堂, 向国内和国际的观众展示了最新的技术创新 在参展商中, 有 319 家来自土耳其国内, 包括来自土耳其铸造协会 (TUDOKSAD) 的代表 据展览主办方汉诺威介绍, 土耳其的钢铁业是一个强大的经济力量, 有着光明的前景 土耳其的钢铁产量 2011 年增长了 17%, 达到 3400 万吨, 使土耳其成为欧洲第網上資源二 世界第十的钢铁生产大国 China Foundry Museum Opens in Shenyang 展志之举惊世之作 热烈祝贺 中国铸造博物馆 挂牌开馆 The China Industry Museum in the Tiexi District, Shenyang, China, hosted an opening ceremony on May 18, 2012, for its new casting hall, the China Foundry Museum. Leaders from the district and the China Foundry Association unveiled a cast tablet with China Foundry Museum inscribed on it, marking the end of a year s preparatory work. Chen Haibo, mayor of Shenyang and Guo Yucai, deputy director of the State Administration of Cultural Heritage, delivered opening remarks. Then visitors toured the museum, which is on the site of a former metalcasting facility and includes displays of casting technology and cultural relics. In May 2012, the CFA unveiled a cast tablet naming the new casting hall of the China Industry Museum, the China Foundry Museum 年 5 月 18 日 适逢第 36 个 世界博物馆日, 这一天上午, 丽日辉映之下, 在中国沈阳铁西区卫工街北一马路这个坐标点上, 旌旗招展 人头攒动 欢歌笑语, 人们从四面八方涌向这里, 为的是一睹中国工业博物馆 ( 一期 ) 开馆盛况和分享这一新兴博物馆之风采所带给每一位观众的启迪与快乐 上午十时许, 中国工业博物馆铸造馆, 即 中国铸造博物馆 隆重挂牌仪式在入口处举行 中国铸造博物馆 主办方 中国铸造协会的领导 中国铸造博物馆 承办方 沈阳市铁西区政府相关领导共同掀开了 中国铸造博物馆 牌匾的 红盖头, 这标志着历时近一年来, 举中国铸造全行业之力, 主办方 协办方和承办方倾心 倾 中國鑄造博物館 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 11

14 industry news/ 行業新聞 Visitors toured the new China Foundry Museum on its opening day. 中國鑄造博物館 China Foundry Association members assemble for the opening of the China Foundry Museum in Shenyang. 中国铸造协会名誉理事长陆燕荪 郭树言 贾成炳, 中国铸造协会常务副理事长兼秘书长张立波应邀在主席台就坐 沈阳市市长陈海波 国家文物局副局长顾玉才先后发布致辞和讲话 Pitti Castings Acquires Foundry Division of Vaksh Steel Pitti 铸件厂收购 Vaksh 钢厂的铸造业务 Mumbai-based DealCurry.com reports Pitti Laminations Ltd. s subsidiary Pitti Castings has acquired the Foundry division of Vaksh Steel Private Ltd. in Secunderabad, India, for R83 Cr ($15 million). The deal reportedly will help Pitti s laminations and machining business along with individual profitability of the unit. Pitti Laminations, based in Hyderabad, India, manufactures electrical steel laminations for rotating electrical machinery for a variety of products. 情 倾力合作, 快马加鞭 紧锣密鼓的铸造博物馆筹建工作至此可以画上了一个圆满的句号 上午十一时十五分, 中国工业博物馆 ( 一期 ) 开馆仪式隆重举行 中国铸造协会名誉理事长陆燕荪 郭树言 贾成炳, 中国铸造协会常务副理事长兼秘书长张立波应邀在主席台就坐 沈阳市市长陈海波 国家文物局副局长顾玉才先后发布致辞和讲话 开馆仪式结束后, 大家兴致盎然地进行了博物馆现场参观 人们纷纷在每一件展品前驻足观赏 仔细端详, 并不时发出慨然赞叹 可有谁能想到 : 是沈阳市铁西区决策层的鸿图大志 政府部门的大手笔决策 尤其是明智联手中国铸造协会, 并于一年之前, 慧眼选址沈阳铸造厂原址破土动工 ; 您可知晓, 那些为博物馆勾勒蓝图 撰写展示大纲 逐句逐字推敲展览文本 一图一物审核展品的专家学者所倾注的心血与智慧 ; 有谁知道筹建处的领导与现场施工者在那北国隆冬 朔风刺骨的除夕之夜一起在工地奋战 一起在工棚吃饺子 一起迎接正月初一的黎明 ; 还有谁了解中国铸造协会的领导 博物馆筹建处的领导和工作人员殚精竭虑 百折不挠, 为了征集馆藏文物而废寝忘食 不分昼夜地奔走在大江南北 长城内外 大河上下 那些熟悉铸造博物馆筹建历程的人士, 博物馆建设的历程见证了一个真理 众人捧柴火焰高 今后, 每一个真诚关注中国铸造博物馆健康 可持续发展的人们有责任呵护这个刚刚诞生的博物馆新星 万里长征一步 大家都知道中国铸造博物馆今后要做的工作还很多 很细 很深 而面对眼前铸造博物馆那催人联想 炫动人眼 雍容典雅的非凡景象, 人们无不情不自禁 由衷地表达各自的兴奋与感慨, 而将这些对中国铸造博物馆建设工作的赞叹加以概括, 似可谓 展志之举, 惊世之作! 总部位于孟买的 DealCurry.com 报道 Pitti Laminations 有限公司的子公司 Pitti 铸件厂花费 R83 铬 (1500 万美元 ) 收购在印度海德拉巴的 Vaksh 钢铁私人有限公司的铸造业务 据报道, 这笔交易既推动了 Pitti 的叠片和加工业务, 又提高了部门个人的盈利能力 总部设在印度海得拉巴的 Pitti 叠片厂, 为各种产品的旋转电机生产电动钢叠片 12 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

15 industry news/行業新聞 Bonds Expands To Meet Increased Export Demand Bonds扩大业务以满足不断增长的出口需求 Surrey, England-based The Northern Echo reports Bonds, a group of metalcasting facilities in the north of England, is expanding. The company sells more than half of its steel castings directly overseas to 23 countries, and while its top export markets are in Europe, in 2011 Bonds added Mexico, Brazil, Israel and Japan to its growing list, the source reports. The company, which won the Queen s Award for International Trade last year, has benefited from a range of U.K. Trade and Investment (UKTI) support services. Bonds reportedly is converting a derelict site that will boost its production capacity. Building work at the former Kenmore plant, in Crook, County Durham, is expected to be complete this fall. Bonds group director Jon Blackett told The Northern Echo, Exporting is the lifeblood of our business, with some 90% of our castings ultimately being used overseas. This year, we anticipate our export sales to rise by 35% and, with signs of growing demand particularly from the oil and gas sector, we have increased our workforce from 175 to 220 people and are investing in the north of England to expand our manufacturing capacity. We are proof that traditional engineering can survive and prosper in the North by being adaptive and responsive to the international market. 据Surrey 英格兰地区的The Northern Echo报 道 Bonds 位于英格兰北部的一组铸造厂正在扩大 规模 该公司将一半以上的钢铸件直接销往海外23个 国家 而其最大的出口市场在欧洲 据报道 在2011 年 墨西哥 巴西 以色列和日本也被列入其主要出口 国 该公司去年赢得了国际贸易皇后奖 得益于英国贸 易投资总署 UKTI 的一系列支持服务 据报道 Bonds正在废弃的土地上兴建工厂来提 高其产能 预计今年秋天在Durham郡Crook以前的 Kenmore 工厂上的建设工作将会完成 Bonds集团的主任Jon Blackett在The Northern Echo说 出口是我们企业的命脉 我们的铸件约90 最终出口海外 今年 我们预计出口销售将增长35 由于需求不断增长 尤其是来自石油和天然气行业 我们员工人数已从175增加到220人 并在英格兰北部 投资 扩大我们的生产能力 我们证明了只要能够适应 国际市场和并对其有很敏感的判断能力 传统的工业依 然可以在英国北方得以生存和繁荣 Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 13

16 industry news/行業新聞 CEOs Meet at 7th IFF 总裁们相聚第七届国际铸造论坛 The world s leading metalcasting facilities and suppliers had an opportunity to discuss future expectations, challenges and industry trends in end-use markets at the 7th International Foundry Forum (IFF) held Sept in Prague. Metalcasting-relevant economic perceptions set the prelude, beginning with the current raw material situation to investment philosophies and the gradual shift toward Asia. The latest trends and requirements of large casting buyers were touched on from well-known companies, along with presentations of worldwide metalcasting industry reports from India, Japan, the U.S., China, Russia, South America and Europe. Previous to the event, the European Foundry Equipment Suppliers Association (CEMAFON) together with Foundry-Planet.com held a roundtable discussion on European metalcasting equipment suppliers facing the Euro crisis and its impact on the industry. IFF was organized in conjunction with the European Foundry Association (CAEF) and CEMAFON. The next IFF will be held in 在9月21-22日在布拉格举行的第7届国际铸造论 坛 IFF 上 世界领先的铸造设备商和他们的供应 商有机会讨论未来的预期和挑战以及最终用户市场 的发展趋势 论坛由与铸造相关的经济观念拉开序幕 从当前 原材料市场到投资理念 以及逐步转向亚洲的潮流 通过知名的企业 以及来自印度 日本 韩国 美 国 中国 俄罗斯 南美和欧洲的全球铸造行业的报 告 可以感知到铸件大客户的最新趋势和需求 在论坛召开之前 欧洲铸造设备供应商协会 CEMAFON 与Foundry-Planet网站共同举行了 圆桌讨论 对欧洲铸造设备供应商如 何应对欧元危机及其该危机对行业的 Online Resource 影响进行了探讨 Is there a crisis or do we have to cope with new market conditions? View a discussion with Gabriele Galante, Oskar Goitia, Jürgen Lamparter, Peter Larsen and Andrew Turner at CAFE 和CEMAFON共同举办 下 14 国际铸造论坛由欧洲铸造协会 一届将于2014年召开 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012 網上資源

17 industry news/行業新聞 China Foundry Association Tours South Zhejiang Province 浙江省南部铸造企业调研报告 The China Foundry Association (CFA) has been conducting a comprehensive investigation of the South Zhejiang Province since July 2012 to become acquainted with the status quo of metalcasting facilities in the area. A group in charge of Yangtze river delta, including Shanghai, Zhejiang and Jiangsu, made seven metalcasting facility visits organized by Yang Chunfan, president of the Zhengjiang Foundry Association. The first stop, Wenzhou Kaicheng Foundry Co. Ltd. is a private enterprise and one of the corporate members of CFA dedicated to high-end steel castings up to 50 tons, with an annual production of 18,000 tons. Its 92% sand reclamation rate is ranked at the top nationwide. It casts primarily steam turbine, valve, mining and metallurgy machinery parts, in carbon steel, alloy and stainless steel. Zhejiang Shidai Casting Co. Ltd., another private enterprise and CFA corporate member, offered a tour of its steel casting operation. In 2010, it was named one of the top 100 metalcasting enterprises in China. 为了更好地服务铸造企业 了解铸造企业的诉求 同 时也为了最大限度地了解目前国内各铸造企业的现状 2012年度中国铸造协会对国内铸造企业的综合调研工作 于7月份正式启动 负责长三角 上海 浙江 江苏三 地 铸造企业调研任务的一组人员在温理事长带领下 在浙江省铸造协会杨春帆秘书长的积极策划下 率先走 访了浙江省南部7家铸造企业 一.简介 温州市开诚机械有限公司是一家专业生产和销售高档 铸钢件的民营股份制企业 是中国铸造协会的理事单位 年生产能力为20000吨 最大单件重量达50吨 开 诚 拥有省内第一条酯硬化水玻璃干法再生生产线和三 台连续式的混砂机设备 旧砂回用处于全国领先水平 达92%以上 能生产各种几何形状复杂的砂铸件 公司主要产品为汽轮机 特种阀门 矿山机械和冶金 机械等铸件 主要材质为碳钢 合金钢 不锈钢等 2011年铸件产量为18000吨 产值达2亿元 第二站 浙江时代铸造有限公司 浙江时代铸造有限公司是一家专业生产铸钢件的民营 Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 15

18 industry news/ 行業新聞 Among its main products are valve, engineering machinery and automobile auxiliary castings, which sell domestically and are exported to Europe, America, Japan, Korea and other countries. Its casting output reached 6,800 tons in 2011 in Hastelloy, Monel, Duplex steel, precipitation hardening stainless steel, and super austenitic stainless steel. It casts parts for petroleum, chemical industry, power, paper making, automobile and engineering machinery. Wenzhou Ruiming Industrial Co. Ltd. produces auxiliary parts for motorcycles and automobiles in Zhejiang province, Ruian. Its main products are aluminum alloy cylinder heads, cylinder blocks, intake manifolds, cylinder head covers and aluminum frames. Its profit increased by 30% in the first half of 2012, versus the same period in Yuhuan Shengda Industry Co. Ltd., located in the eastern part of the auto and motorcycle zone in Yuhaun, Zhengjiang province, is a CFA corporate member and specializes in permanent mold and low-pressure casting. Its products include automotive brake master cylinders, wheel cylinders, pump parts and brake caliper parts; steering, power steering pump and air-conditioning castings; motorcycle brake master cylinders, wheel cylinders, stents and other castings; electric multiple unit (EMU) and high-speed rail brake master cylinder housings; and the steering bracket used in the Maglev train. Its casting output in the first half of 2012 remained the same as Cixi Huili Machinery & Electric Co. Ltd is a medium private enterprise and CFA corporate member specializing in gray iron, ductile iron and aluminum parts. It has been named one of the top 100 metalcasting enterprises on a comprehensive level. The enterprise implements the ISO9001 international management system standard and employs 6 sigma and 6S to conduct on-site control over quality and operation. It has obtained the TS and IRIS standard system certification, and its casting output approached 29,000 tons in Production Wenzhou Kaicheng Foundry Co. Ltd. produces steel castings up to 50 tons. 企业 是中国铸造协会的理事单位,2010 年被评为 首届全国铸造行业综合百强企业 其产品主要有泵阀 工程机械及汽车配件, 产品遍布全国远销欧州 美州 日本 韩国等国家及台湾地区 2011 年铸件年产量为 6800 吨, 产值达 3 亿元 其产品材质有镍基合金 蒙乃尔合金 哈氏合金 双相钢 沉淀硬化不锈钢 超级奥氏体不锈钢等 其产品广泛应用于石油 化工 电力 造纸 汽车及工程机械行业和领域 第三站 : 温州瑞明工业股份有限公司温州瑞明工业股份有限公司成立于 1995 年, 总部坐落于中国汽摩配之都 浙江省瑞安市, 是目前国内汽车行业铝产品产销量最大的企业之一, 专业从事研发 生产 销售铝产品, 其主导产品有铝合金缸盖 气缸体 进气歧管 缸盖罩 铝支架等系列产品, 是国际和国内知名汽车公司的一级供应商, 产品涵盖国内 国际低 中 高档汽车行业 瑞明 凭借可靠的产品质量及广大的用户群, 在 2012 年全球经济下滑比较严重的大背景下, 上半年较 2011 年同期经济效益增加了 30%, 预计下半年经济效益增长将超过 40% 第四站 : 玉环盛大汽摩部件工业有限公司玉环盛大汽摩部件工业有限公司 1993 年成立, 公司座落在浙江省玉环县汽摩工业园区东区, 是中国铸造协会理事单位, 专业从事铝合金金属型重力铸造和低压铸造 产品主要有汽车制动总泵 分泵 水泵件 制动卡钳件 ; 转向器 转向助力泵及空调铸件 ; 摩托车制动总泵 分泵 支架等铸件 ; 动车 高铁的制动器主缸外壳 ; 磁悬浮列车的转向支架等壳体铸件 2011 年铸件产值达到了 1.2 亿元,2012 年上半年由于受厂区作业面积的制约, 产量基本与 2011 年上半年同期持平, 但由于受用工成本急剧增加的影响, 其利润较去年同期略有下降 第五站 : 浙江慈溪汇丽机电公司浙江慈溪汇丽机电公司创立于 1988 年, 是一家中型私营企业, 主要从事铸造和加工各类灰铸铁 球墨铸铁 铸铝零件及高效节能电动机 为中国铸造协会理事单位, 是 中国铸件出口龙头企业 和 首届全国铸造行业综合百强企业 公司始终遵循 我所做的一切都是为了使您满意 的质量方针, 以 六西格玛 溫州市凱成鑄造廠 16 FOUNDRY-PLANET.COM MODERN Casting CHINA FOUNDRY ASSOCIATION Fall 2012

19 industry news/ 行業新聞 Wenzhou Ruiming Industrial Co. Ltd. produces auxiliary parts for motorcycles and automobiles. in the first half of 2012 declined 10%. The sixth stop, Ningbo Wanguan Precision Casting Co. Ltd., specializes in steel, alloy steel and stainless steel castings for metallurgy, mine, petroleum, chemical, railway, automobile and other machinery manufacturing for China and abroad. It produces 10,000 tons and its 2012 production has shrunk by almost one-third. Ningbo Riyue Co. Ltd. is a large-scale metalcasting facility and a CFA corporate member. Riyue has adopted internationally advanced techniques such as the resin sand technique, external furnace desulphurization, refinement and a combination of cupola and electric furnace melt operations. Its products for large-scale plastic injection machines, diesel machines, winddriven generators and machine tools are exported to the U.S., Japan and many other countries. It has a production capacity of 200,000 tons, and its maximum casting weighs 160 tons, with a maximum ductile iron casting thickness of in. (1,222 mm). In 2011, it reported an output of 95,500 tons, a figure which declined by 20% in the first half of Based on the survey of the casting enterprises in the south of Zhejiang province, the research panel reached a consensus that economic conditions were favorable in the first half of They said the weak market was beneficial to the elimination, merger and acquisition, and reorganization of small metalcasting enterprises and paved the way for the implementation of entry permission regulation. Ningbo Wanguan Precision Casting Co. Ltd., specializes in steel, alloy steel and stainless steel castings. 寧波萬冠精密鑄造有限公司 溫州瑞明工業股份有限公司 和 6S 进行现场品质和生产管理, 贯彻实行 ISO9001 国际质量管理体系标准, 公司已通过 TS 和 IRIS 标准体系认证 2011 年铸件产量 2.9 万吨, 产值达 3.5 亿元 受欧债危机及国内制造业疲软的影响, 汇丽机电公司 今年上半年产量同比下降了 10% 左右, 由于用工成本的大幅增加, 上半年的利润率下降 20% 左右 第六站 : 宁波万冠熔模铸造有限公司宁波万冠熔模铸造有限公司是一家专业生产普通钢 合金钢 不锈钢精密铸造件, 其产品涵盖冶金 矿山 石油 化工 铁路 汽车等机械制造业, 铸件远销全国各地和美国 澳大利亚 加拿大 西班牙 日本等国家,2011 年年产铸件 吨, 产值 1.5 亿元 2012 年受欧债危机影响宁波万冠熔模铸造有限公司, 上半年产量下降了近三分之一 第七站 : 宁波日月集团有限公司宁波日月集团有限公司是一家大型铸造企业, 是中国铸造协会的副理事长单位, 日月 采用国际先进的树脂砂工艺 ; 采用先进的炉外脱硫, 冲天炉 电炉双联精炼工艺并配有先进的理化检测设备 其产品远销美国 日本等多个国家 2012 年 5 月被中国铸造协会授予 绿色铸造示范企业 其主要产品有大型注塑机系列 大型柴油机系列 风力发电机系列 机床产品铸件 产能 20 万吨, 最大单件可达 160 吨, 最大壁厚 1200mm 的球墨铸铁件处于行业领先水平 2011 年铸件产量 9.65 万吨, 产值 9.64 亿元 2012 年生产形势 宁波日月集团有限公司 受大气候影响, 其上半年产量较去年同期下降 20% 左右 2011 年下半年及 2012 年上半年一季度风电产品几乎没有订单, 主要原因是风电铸件采购企业一直在消化以前的库存, 二季度后库存消化完毕, 所以订单开始回升 通过对浙江省南部几家铸造企业的调研, 调研组认为各家企业领导层对今年上半年的经济形势还是比较乐观的, 同时认为市场疲软正好有利于微小铸造企业的淘汰 兼并与重组 ; 也有利于 准入 制度的顺利实施 Fall 2012 FOUNDRY-PLANET.COM MODERN Casting CHINA FOUNDRY ASSOCIATION 17

20 industry news/ 行業新聞 The American Foundry Society launched a new brand identity with the unveiling of its new logo on August 16. The new logo is strong, simple and modern. The sansserif typeface makes it clean and easy to read, yet conveys a strong image. The connected letters and choice of color show an evolution from the previous logo, and the circular shape signifies AFS s relationship with metalcasting around the world. A web page devoted to the new logo and its development can be found at We always try to stay at the forefront of our industry, said Leo Baran, AFS director of membership services. In this case, we had to look the part, too. The tagline Advocate. Educate. Innovate. replaces the words American Foundry Society to communicate the organization s ongoing mission to: Advocate for the industry, its products and our members. Educate our members, the general public and our legislators about our industry, the unique aspects of its technology, the latest practices and advancements, as well as the values and benefits to society. Innovate in our processes and management styles in order to be a globally competitive manufacturing choice, keeping our members on the cutting edge. Innovation comes from our research and development programs, our education and training, and our communication to the industry on leading ideas and practices from across the globe. The message our new AFS logo conveys is exactly where we sit right now, as a society, said Jerry Call, AFS executive vice president. Adding The Institute is reminder of our significance on the education side of the industry, as well. The new design incorporates, The Institute, which melds the Cast Metals Institute and AFS brand to convey one, unified front. The Society will continue to be a critical supplier of knowledge in the unique metalcasting learning arena. Since June, AFS also has launched redesigned websites and newsletter designs. Headquartered in Schaumburg, Ill., AFS is a not-for-profit technical and management society that has existed since 1896 to provide and promote knowledge and services to strengthen the metalcasting industry for the ultimate benefit of its customers and society. AFS Unveils a New Logo AFS 推出新标志 美国铸造协会 8 月 16 日推出了新的品牌标识同时揭幕其新的标志 新的标志是强大, 简单和现代的 新标志采用 sansserif 字体, 一目了然, 易于阅读, 同时还传达了一种很强的图像感 连写的字母和颜色的选择较以往有所改进, 圆形标志着 AFS 同世界各国铸造业的联系 专门为此设计了一个网址 介绍新的标志和其发展过程 我们总是尽量要求自己走在这个行业的最前沿, 美国铸造协会的会员服务总监 Leo Baran 说,, 在这种情况下, 大家也应该关注一下我们的标语 倡导 教育和创新 ---- 取代了 美国铸造学会, 相信能够更好地传达我们在以下方面不屑的努力 : 服务于整个行业, 产品和我们的会员 教育我们的会员, 广大民众和立法议员对我们的行业, 其技术方面的独特性, 最新的做法和取得的进步, 以及给社会带来的价值和益处 在生产过程和管理模式方面践行创新, 做到在世界范围内具有竞争力, 同时使我们的会员具有一定的优势 创新来自于我们的研究和发展计划, 我们的教育和培训, 以及将从世界各地借鉴来的想法和做法传达给整个铸造行业 我们新的 AFS 标志所要传达的就是我们作为协会此刻正在做的事情, 美国铸造协会执行副总裁 Jerry Call 说, 加入 研究院 的元素时刻提醒着我们在行业教育方面的的重要性 新设计将 研究院 同美国铸造协会整合在一起, 传达了二者密不可分的关系 美国铸造协会仍将在铸造学习领域继续为大家提供丰富的知识 自六月以来, 美国铸造协会也推出了重新设计的网站和时事通讯 总部设在伊利诺伊州的绍姆堡,AFS 是一个不以营利为目的技术和管理协会 自 1896 年以来一直致力于以会员和社会的最终利益为出发点, 为增强整个铸造行业的实力提供服务 普及知识的责任 18 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

21 industry news/ 行業新聞 Industrial Opportunity Partners Acquires Aarrowcast 产业机遇合作伙伴收购 Aarrowcast Aarrowcast is a provider of gray, ductile and austempered ductile iron castings that specializes in large, complex castings utilizing sophisticated metallurgy. According to the company, its facility features three separate molding lines, including the largest automated green sand flask in North America. The company casts products for equipment in the agriculture, off-highway heavy truck, military and construction markets. We are very excited to acquire Aarrowcast, a market leader with unique manufacturing capabilities and a solid history of providing complex products to a long list of market-leading customers, said Adam Gottlieb, Senior Managing Director, IOP. The Aarrowcast senior management team, led by Ben Grigg, president and CEO, will continue to manage the business. In addition, Andrew Weller, an IOP Operating Principal, will assume the newly-created position of chairman. Weller has direct experience in overseeing and operating iron casting facilities. IOP s board is comprised of executives who provide leadership to businesses in which IOP invests. Aarrowcast has built a reputation with its customers, suppliers, and employees based on unmatched manufacturing abilities, service levels and product breadth, Weller said. I look forward to working closely with Ben, his team, and all Aarrowcast employees in continuing to invest in the Company to achieve further growth. Aarrowcast represents IOP s first platform investment in Industrial Opportunity Partners II, L.P., IOP s recently raised $275 million committed fund. We are thrilled to be partnering with Industrial Opportunity Partners, whose operational experience and strategic support will enhance Aarrowcast s continuous effort to deliver high-quality products and extraordinary service levels to our customers, Gregg said. William Blair represented Aarrowcast and the selling shareholders in this transaction. PNC Bank and RBS provided the senior financing, while Yukon Partners provided the subordinated financing for the acquisition. Legal representation for IOP was provided by Schiff Hardin, while Morrison Cohen represented Aarrowcast and the selling shareholders. Aarrowcast 是一家使用先进的冶金技术生产灰铸铁, 球墨铸铁和等温淬火球铁大型复杂铸件的厂商 据该公司称, 其设施包括三条独立的造型线, 还有北美最大的自动湿砂箱 该公司为农业, 非公路重型卡车, 军事和建筑市场生产铸件设备 我们很高兴收购 Aarrowcast, 它拥有独一无二的制造能力, 并且在相当长一段时间为市场中高端客户提供复杂的铸件产品,IOP 的高级管理总经理 Adam Gottlieb 说 由 Aarrowcast 公司的总裁兼首席执行官 Ben Grigg 带领的高级管理团队将继续管理业务 此外,Andrew Weller, 作为该公司的营运负责人将承担新设立的董事长一职 Weller 在监督和运营铸造厂方面有很多经验 IOP 的董事会有若干名 CEO 组成, 并对 IOP 投资的企业直接领导 Aarrowcast 因其无与伦比的制造能力, 服务水平和产品广度在客户, 供应商和员工中树立了良好的声誉,Weller 说, 我期待着同 Ben 及其团队紧密合作和所有 Aarrowcast 的员工深度合作, 继续投资本公司, 实现进一步增长 Aarrowcast 是 IOP 在产业机遇合作伙伴 II 中的第一个投资平台,IOP 最近筹到 2 亿 7500 万美元的专项基金 我们很高兴能与产业机遇合作伙伴合作, 其运作经验和战略支持势必会使 Aarrowcast 不断努力, 为我们的客户提供高品质的产品和卓越的服务水平, Gregg 说 William Blair 在本次交易中代表 Aarrowcast 和售股股东 PNC 银行和苏格兰皇家银行提供高级金融服务, 而 Yukon 合作伙伴为此次收购提供次级融资 Schiff Hardin 作为 IOP 的法律代表, 而 Morrison Cohen 代表 Aarrowcast 及售股股东 New U.S. Metalcasting Facility Planned in Wisconsin 计划在威斯康星州设立新铸造厂 U.K.-based mining equipment manufacturer Weir Minerals plans to build a 90,000-sq.-ft. metalcasting facility at its U.S. headquarters in Madison, Wis., according to the Wisconsin State Journal. If permitted by the state Department of Natural Resources, the company will begin construction in March and is slated to begin casting mining pump parts in Weir Minerals has metalcasting facilities in the U.K., Brazil, Chile and Australia. Bringing casting operations to the U.S. would enable the company to meet domestic demand for parts without shipping products around the world. 据麦迪逊, 威斯康星州日报报道, 英国的采矿设备制造商 Weir 矿业计划在其总部美国威斯康星州建立一家 平方英尺的铸造厂 若得到美国国家自然资源部的批准, 该公司将于三月开始动工, 并计划在 2015 年开始铸造采矿泵配件 Weir 矿业在英国, 巴西, 智利和澳大利亚均设立铸造厂 在美国设立铸造厂也是为满足美国国内对铸件的需求, 进而减少从全球采购的成本 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 19

22 industry news/行業新聞 ME Elecmetal Expands to Meet Demand ME Elecmetal扩展业务以满足需求 ME Elecmetal, Duluth, Minn., recently cut the official ribbon on a $12.2 million expansion. The company is increasing production to meet rising demands for its steel and other metal castings. The facility now employs 175 workers, and the company reports the expansion will add 30 permanent jobs. Back in 2008, with the downturn of the economy, this foundry was impacted directly. And now, to see this investment, to see workers back on the job, seeing more hires yet to come, it warms our heart, Duluth Mayor Don Ness told Fox 21 news of Gary-New Duluth, Minn. ME Elecmetal is a global supplier of cast steel and iron replacement pieces for the mining industry in Chile, South America and North America. It also participates in the European, African, Asian and Oceanic markets. The company has five metalcasting facilities, two in Chile, two in the U.S. and a licensee in Mexico. It produces more than 75,000 tons per year of capacity, with sales offices on five continents. ME Elecmetal 美国明尼苏达州Duluth 最近为增 加12.2万美元的扩建举行官方剪彩仪式 公司正在增加 钢材及其他金属铸件产量 以满足日益增长的需求 现 在该工厂雇用175名工人 该公司报告扩建将增加30个 永久职位 早在2008年 由于经济低迷 铸造产业受到了直接的 影响 而现在 看到这项投资 看到工人重返工作岗位 看 到有更多的雇用加入 这一切温暖了我们的心 Duluth市 长Don Ness在接受Fox 21新闻采访时说道 MEElecmetal是一家为智利 南美和北美的采矿业提 供铸钢和铸铁备用件的全球供应商 它也渗透到欧洲 非洲 亚洲和大洋洲市场 公司拥有5个铸造厂 两家位于智利 两家在美国 还有一家在墨 西哥刚获得营 业执照 每年生 产超过75,000 吨 在五大洲均 设有销售办事 ME Global (Elecmetal) won MODERN CASTING magazine s Casting of the Year award in 2005 for this tread belt shoe used to transport a NASA shuttle to launch. ME全球 Elecmetal 在2005年赢得现代铸造杂志的 年度 铸造 奖 是由于其生产了一种胎底花纹带鞋 这种鞋可用 来运送美国航天局航天飞机直至其发射升空 20 处 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

23 industry news/ 行業新聞 TITAL to Produce Aluminum Investment Castings in China TITAL 将在中国生产铝合金熔模铸件 Titanium and aluminum investment casting specialist TITAL GmbH (Bestwig, Germany) will start production in a new plant in Nautong, China, in The German company signed an agreement with the Chinese authorities for the setup and operation of the plant, which will produce aluminum investment castings for the European and Chinese markets. China s importance for the production of civil aircraft will strongly increase. Strategic alliances between western aircraft and engine manufacturers show this trend. And we do not want to stand outside, said Philipp Schack, managing director, TITAL. TITAL will be the first international aluminum investment casting specialist for aircraft components to start producing castings in China. The Chinese company, TITAL (Nantong) Co. Ltd., has received its official business license, and the refurbishment of its production facility has started. A team of three TITAL engineers will coordinate the production setup, and the machinery and equipment are scheduled to be finished by end of We plan to start full production in the first quarter of 2013 and to deliver the first aluminum parts in the same year, Schack said. The company expects to benefit from good international economic conditions and will focus on a strategic improvement of its market position. TITAL also plans to expand production at its headquarters in Bestwig, Germany. TITAL supplies industry leading companies around the world in the field of aerospace, defense, motor sport and industrial systems with aluminum and titanium investment casting products. Founded in 1974, the company employs more than 500 people with 2011 revenue of approximately 66 million dollars. Intat Precision to Expand in Indiana Intat 精铸厂在印第安纳州建厂 Intat Precision Inc., a subsidiary of Japan-based Aisin Takaoka Co. Ltd., is planning a $26 million expansion of one of its two plants in Rushville, Ind. The company casts parts for automakers including Subaru, Toyota and Nissan. This is the result of the level of performance that has been achieved at the Rushville operation, said Brad Rist, vice president of Intat, according to a report from the Indianapolis Business Journal. Our operation has really stepped up to meet several challenges the last few years, and through this recovery, we have demonstrated a confidence internally that made the decision to expand here the best choice, he said 年钛和铝熔模铸造专家 TITAL 有限公司 ( 德 国 Bestwig 市 ) 将在中国南通开始生产 这家德国公 司与中国政府签署了一项协议, 建设和运行工厂, 将为欧洲和中国市场生产铝熔模铸件 TITAL 将是第一个国际铝熔模铸造专家开始在中国 生产飞机部件 该公司名为 TITAL( 南通 ) 有限公 司, 已经拿到了正式营业执照, 其生产设施的装修 工程已经开始 一个 3 人的 TITAL 工程师团队今年夏天将在南通开 始工作, 协调生产配置 机器设备预计将于 2012 年 底前到位 我们计划在 2013 年第一季度开始全面投产, 并 在同年推出首个铝零件 TITAL 总经理菲利普 沙 克说 该公司预计, 得益于良好的国际经济环境, 将专 注于改善其市场地位的战略 TITAL 还计划扩大在 德国 Bestwig 市总部的生产 TITAL 为全球航空航天 国防 赛车和工业系统领 域的顶尖公司提供铝合金和钛合金熔模铸造产品 该公司成立于 1974 年, 拥有员工 500 余人,2011 年 的收入约为 66 亿美元 Intat 精密公司是一家总部设在日本的 Aisin Takaoka 有限公司的附属公司, 正计划投入 2600 万美元扩大它在印第安纳州 Rushville 的两个工厂之一 该铸造厂为斯巴鲁, 丰田和日产汽车制造商提供铸件 据从印第安纳波利商业杂志的一份报道显示,Intat 的副总裁 Brad Rist 说 : 这是由于在 Rushville, 生产水平已完全满足要求 我们在过去的几年里加快生产进度以满足数项挑战, 在这次经济复苏中, 我们内部一致表现出信心, 决定在这里建厂, 这应该是一次最好的选择 他说 To receive this digital magazine in the future, go to 要获得这在未来的数字杂志, 去 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 21

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25 Dos and Don ts in Melt Deck Safety 确保熔炼平台上的安全做与不该做的 Here is a safety list of dos and don ts to protect you from hazardous situations when working on the melt deck. 这里有一个做与不该做的安全列表 保护你在熔炼平台上工作时 避免危险情况 jillian knuerr, assistant editor 吉莉安 科诺尔 助理编辑 A To some, handling and melting metal is a normal, everyday part of their job. It may even be easy to forget that the tasks performed present risks and hazards when not carried out using proper safety equipment. But, what safety equipment is required in what areas? For starters, it s important to know what areas are considered hazardous in and around the melt deck. Proper hazard identification needs to be in place to alert users that they have entered a zone where hazards, such as a molten metal, heat, sparks or splash can exist. Workers must be prepared for situations or hazards to look for when working on the melt deck. After working in that area for an extended time, the situations may seem less dangerous, but workers cannot overlook the potential for danger to arise. When working melt deck operations, certain personal protective equipment (PPE) is required. Employers must perform a hazard assessment to determine the correct PPE to wear for each operation. Workers must know the correct PPE to wear and how to properly wear it; the equipment is designed to be effective when worn properly. What Areas Around the Melt Deck Present a Hazard? The hazard zone in melting operations includes areas where there is a possibility of a molten metal splash. Metalcasters know this area as the melt deck. 对 一些人来讲 处理和熔化金属是一种正常 的 日常工作的一部分 他甚至有可能很容 易忘记 当不适当的使用安全设备时 执行 任务时的风险和危害 但是 什么安全设备是需要的 用在哪些方面呢 对于初学者来说 重要的是要知道在熔炼平台上和其 周围哪些区域被认为是危险的 特有的危险源标识必须 到位 以提醒使用者 他们已经进入了一个存在危险的 区域 如熔融金属 热 铁花飞溅 工人必须对熔炼平台上工作时发现的情况或危险有 准备 在这里工作较长一段时间后 情况似乎不那么危 险 但工人不能忽视潜在的危险出现 当在熔炼平台上操作时 需要一定的个人防护装备 PPE 雇主必须执行危险性评估 以确定合适的个 人防护装备 为每个操作者穿着 工人必须知道个人必 须穿防护装备及如何正确地穿上它; 正确佩戴时 设备 的设计才是有效的 熔炼平台周围哪些地方 存在危险 危险区即在熔化操作 时熔融金属可能飞溅的区 域 操作者应知道这个区 域在熔炼平台上的面积 Hazard zones can be identified with the following methods: 危险区 可以使用下列 方法确定 The employer shall identify the extent of 用人单位应当确定危险区 Certain PPE is required to protect the body from head to toe in melting operations. 在熔炼操作时需要个人防护设 备 从头部到脚趾保护身体 Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 23

26 Hazard zones must be properly identified, including yellow railing. 危险区 必须正确标识 包括 黄色的栏杆 the hazard zone and mark it with color coding or post signs warning of the hazard. Signs must be posted at each point of entrance identifying it as a hazardous area. The flooring in the hazardous area entrances must be marked with a yellow line spanning the entire entrance. Only authorized personnel (supervisors, lab technicians and approved visitors dressed in appropriate PPE) should be allowed within the hazard zone and only to perform authorized tasks and keep their time within the zone to a minimum. Seeing the above notifications should immediately alert you that PPE is required. 的范围并用彩色编码标记或 What Hazards Exist on the Melt Deck? Workers in the identified hazard zone or melt deck area are likely to be affected by the following types of hazards, which would again be considered during the PPE assessment: Burns from physical contact with molten metal splashes, run-out, spills, sparks, flames, hot surfaces, cold tools or liquid introduction into the metal (explosion hazard). When molten metal comes into contact with a liquid in such a way that it entraps the liquid/moisture, a violent explosion can occur by the rapid production of steam or vapor. Physical explosions occur through an initiation mechanism whereby hot particles of molten metal are finely dispersed in a small volume of water resulting in rapid heat transfer from the hot particles to the water. This initiating event may cause severe damage to property and life. Burns and heat stress from exposure to radiant heat. Airborne contaminants such as dust and fumes. There are two types of PPE: primary and secondary. The secondary or basic PPE refers to clothing or PPE designed as basic protection for continuous use in areas where exposure to hazards is possible. The following are all examples of appropriate Proper melting gear can include boots, coats, face masks and hard hats. 24 张贴警示符号 标志必须张贴在每个已确 定的危险区域入口 在危险区域入口处的地板 上必须标有一个黄色的线横 跨整个入口处 只有授权的人员 穿着适 当的个人防护装备的监事 实验室技术人员和经批准的 游客 应在允许危险区域 内 仅执行授权任务 并保持他们在区域内 最少的时间 看到上面的通知 应立即提醒你 需要个人防护装 备 熔炼平台上存在哪些危险 工人在确定的危险区或熔炼平台有可能受到以下几种 类型危险影响 这需要再次在评估PPE 通过物理接触燃烧 熔融金属液飞溅 跑火 泄漏 火花 火焰 热表面 冷的工具或吸入液体到金属 爆炸危险 当熔融金属接触到这样一种方式 陷入 其中的液体/湿气 快速产生雾汽或蒸汽引发剧烈的 爆炸 爆炸发生 通过启动机制 使熔融金属的热粒 子细分散在快速传热粒子的水造成的水的体积 这引 发事件可能会造成生命和 财产的严重损害 燃烧和热应力从接触 到的辐射热 空气中的污染物如灰 尘和烟雾 有两种类型的个人防护 装备 主要的和辅助的 辅助的或基本的个人防护 装备 是指以衣物或为可 能暴露于危险地方连续使 用的基本保障的个人防护 正常的熔炼防护服可以包括靴 子 大衣 口罩 安全帽 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

27 secondary protection: 100% cotton or wool socks. 100% cotton undergarments. 100% cotton or wool outer garments. Safety glasses with side protection. Leather safety shoes with toe protection and a smooth toe. Hearing and respiratory protection, depending on the degree of exposure. Workers performing melting operations and working inside the identified hazard zone or melt deck area require primary PPE. Primary PPE is clothing or PPE designed for activities where significant exposure to hazards such as molten metal splash, radiant heat, flame, noise or flying particles are likely to occur. Types of primary PPE include coats, jackets, aprons, cape, sleeve(s) and bib, leggings, chaps and spats. The appropriate PPE may vary from facility to facility as operations are set up and operate differently (i.e., type of metal poured, casting size, position of worker to the pour and the furnace, condition of charge materials, engineering controls, etc.). Appropriate PPE can be determined by a hazard assessment, required by the Occupational Safety and Health Administration (OSHA) standard (d). Now that the types of PPE have been properly identified, let s take a look at how to properly wear the required PPE. Dos and Don ts in Melting Basic Protection and PPE: Do: Wear pants or leggings. Wear spats or leggings that cover the lacings of boots (if wearing laced boots). Molten metal or sparks can lodge in the tongue area of the boot. Maintain all protective clothing to keep it in serviceable condition. Repair fabric in a way that maintains its flame resistant properties. Wear types of PPE in any combination as needed to protect exposed body parts to heat or metal splatter, as determined by the hazard assessment for each work activity. Consider aluminized PPE when exposed to high heat and spark producing operations such as lancing, tapping, slagging or activities where molten metal splash is possible. Don t: Tuck pant legs inside boots or spats. Wear Nomex, as molten metal tends to stick to the fabric. Wear polyester, nylon or other man-made materi- 装备 下列全部是辅助防护的例子 : 100% 棉或羊毛袜 100% 的棉内衣 100% 棉或羊毛外衣 含侧面保护的安全眼镜 保护脚趾和有光滑的鞋尖皮革安全鞋 听力和呼吸系统的保护, 依暴露程度而定 执行熔化操作和在确定的危险区域或熔炼平台区域内工作的工人需要主要的个人防护装备 主要个人防护装备是显着暴露在如熔融金属飞溅, 热辐射, 火焰, 噪音或飞行粒子的危害可能发生的活动设计的服装或个人防护装备 主要个人防护装备的类型包括大衣, 夹克衫, 围裙, 披肩, 套袖, 围兜, 绑腿, 护腿和鞋套 适当的个人防护设备可能会有所不同从设备设施, 操作设置和不同的操作 ( 例如, 金属型浇注, 铸件尺寸, 工人的地位, 倾炉, 负责材料的条件, 工程控制等 ) 职业安全及健康管理局 (OSHA) 标准 (d) 项所规定的危险评估, 才能确定适当的个人防护装备 现在已知类型确定的个人防护装备, 让我们来看看如何正确穿着所需的个人防护设备 在熔炼的基础保护和个人防护装备方面做与不该做的 : 做 : 穿长裤或紧身裤 穿护脚或绑腿, 覆盖住系带靴子 ( 如果穿着系带靴 ) 因为熔融的金属或火花, 能停留在系带靴子的鞋舌部位 保养所有的防护服, 以保持它在使用状态 修复的方式来维护其阻燃性能的面料 穿在任何组合的个人防护装备的类型为需要保护身体外露部分热或金属飞溅, 每个工作活动的危险性评估确定 考虑含铝的个人防护装备, 当暴露在高温和飞溅中生产操作, 如切割, 出铁, 扒渣或熔融金属可能飞溅处工作 These molten metal handlers are protected with full face shields, gloves, and coats. 这些熔炼操作者被全面罩, 手套和大衣保护 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 25

28 als that can melt and possibly ignite. Wear phosphorus-treated cotton (for nonferrous metals) because molten metal sticks the fabric. Many flame resistant (FR) cotton fabrics use a phosphorus-based treatment. Wear clothing that may trap molten metal or sparks, such as cuffs, open pockets, loose legging tops, etc. Wear any sort of metal jewelry. Eye and Face Protection in Pouring Operations PPE items are available to protect you from head to toe. Identify the type of equipment that is available and required. For protection of the face and eyes, potential hazards are eye and face injuries from foreign bodies, molten metal splash and chemicals and damage from infrared and/or ultraviolet radiation. Safety glasses with side shields are minimum type of secondary protection that should be used for all metalcasting operations, especially melting. The following types of additional PPE should be used for the eyes and face: Full face shield, thermal/infrared with a gold tint/wire mesh. Full face shield, polycarbonate or #40 steel wire mesh. Tinted glasses specific to the type of metal (Iron Shade #3 #5 green; Steel Shade #8 green or #6 cobalt blue; Brass/Bronze Shade #3 #5 green or Shade #3 green with #3 aluminized face shield or Shade #6 cobalt blue (half lenses); Aluminum and Magnesium Clear, No Tint. Dos and Don ts in Melting Face and Eye Protection Do: Use appropriate darker shades of glasses for intense radiant energy. Switch to a lower shade number of un-tinted lenses when leaving the molten metal area or during extended periods when no molten metal viewing is required. Choose a lower shade number for glasses when molten metal viewing is momentary or incidental. Use a full face shield (such as polycarbonate or #40 steel mesh) when exposed to a potential hazard of molten metal splash such as furnace charging, tapping or ladle pouring. Don t: Forget to wear safety glasses with side protection when face protection is worn. Choose eye protection that is too dark as it may reduce visibility and create hazards such as tripping. Protection in Pouring Operations for Head, Hands and Feet The hazard assessment should consider potential head, hand and foot hazards 不做 : 把裤腿裹入靴子或护脚 穿诺梅克斯纤维, 熔融金属往往粘在织物上 穿聚酯, 尼龙或其他人造材料, 可以熔化或点燃 穿用磷处理的棉 ( 为有色金属 ), 因为熔融金属粘贴面料 许多阻燃 (FR) 的棉织物用以磷为基础处理 穿可能捕获熔融金属或火花, 如袖口, 打开的口袋, 宽松的上衣等 佩戴任何金属饰品 在浇注操作中眼睛和面部的防护个人防护产品可从头到脚来保护你 确定设备类型是合适且需要的 对于脸和眼睛的保护, 潜在的危险是异物使眼睛和面部受伤, 熔融金属飞溅和化学品, 还有红外线和 / 或紫外线辐射的损害 有侧面防护的安全眼镜属于辅助保护, 应作为所有铸造生产, 特别是熔炼人员的基本配置 下列类型的辅助人防护设备保护眼睛和脸 : 全面罩, 热 / 红外配金色 / 丝网 全面罩, 聚碳酸酯或 40# 钢丝网 玻璃的颜色依据金属类型 ( 铁 - 玻璃罩 #3 - #5 绿色 ; 钢 - 玻璃罩 #8 绿色或 #6 钴蓝色 ; 黄铜 / 青铜 - 玻璃罩 #3-#5 绿色或 #3 绿色配 #3 铝面罩或 #6 钴蓝 ( 半透镜 ); 铝和镁 - 清晰, 无色 熔炼过程中保护面部和眼睛做与不该做的 : 做 : 使用适当的深色眼镜防护强烈的辐射能量 离开熔炼金属区域或长时间不需要观察熔融金属时, 切换到面罩的未着色镜片 短暂的或偶然的观察熔融金属时, 选择眼镜的较低的暗度数值 当接触到熔融金属飞溅的潜在危险, 如加料, 出铁或取样时, 使用全面罩 ( 如聚碳酸酯或 40# 钢丝网 ) 不做 : 面部防护磨损时, 忘记戴侧面保护安全眼镜 Metatarsal safety shoes or engineer boots offer protection. 跖骨安全鞋或工程师靴子提供保护 26 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

29 Protective footwear is important to keep molten metal and sparks from lodging in boots. found on the melt deck including head injuries from falling objects, moving equipment and/or overhead obstructions, burns from physical contact with molten metal splash, sparks, flames and/or hot surfaces, foot injuries from falling or rolling objects and scrapes, cuts and abrasions. When head protection is needed, workers should utilize a thermal rated hard hat, with a cotton or wool cap or an aluminized hood. For hand protection, workers should use the following materials for mitts, cover mitts, cover pads or gloves: leather, cotton, wool, Kevlar, Wool-lined Kevlar, aluminized fabric or other heat resistant materials. For primary protection of the feet, workers should use metatarsal safety shoes or shoes with heat resistant soles. Dos and Don ts in Head, Hand and Foot Protection: Do: Use a thermal rated hard hat with a cotton or wool cap to provide protection from minor metal splatter. Consider the need for dexterity and grip security while operating equipment when choosing safety gloves. Have sleeves that cover the end of gloves, unless reaching overhead. Wear smooth toe safety shoes such as metatarsal safety shoes or engineer boots. Wear spats or leggings that cover the lacings to prevent molten metal or sparks from lodging in the tongue area of the boot when wearing lace boots. Wear pants or leggings that cover the top of the boot to prevent molten metal and sparks from entering the boot. Don t: Use gauntlet-type gloves unless there is no chance of metal being spilled into the glove. Wear Nomex gloves, as molten metal tends to stick to the fabric. Wear phosphorus-treated cotton (for nonferrous metals) because molten metal sticks the fabric. 选择保护眼镜太暗, 因为它可能会降低能见度, 引起危险如绊倒 在浇注操作中头, 手和脚的防护 危险评估应考虑到头, 手和脚在熔炼平台上潜在的危险, 包括高空坠物, 移动设备和 / 或头顶的障碍物使头部受伤, 与熔融金属飞溅的火花接触, 火焰和 / 或热表面灼伤, 物体坠落或滚动和剐蹭, 割伤和擦伤使脚部受伤 头部保护是必须的, 工人使用热等级的安全帽, 配棉或羊毛帽或铝罩 手的保护, 工人应使用下列材料的手套 : 皮革, 棉花, 羊毛, 芳纶, 羊毛内衬芳纶, 镀铝织物或其他耐热材料 脚的主要保护, 工人应穿用耐热鞋底, 保护脚趾的安全鞋 头, 手和脚的防护中做与不该做的 : 重要的是要保持从靴子接触熔融金属火花的防护 做 : 使用棉或羊毛帽的热等级的安全帽, 保护轻微的金属飞溅 考虑在操作设备时灵巧性和抓力保证的需要, 选择安全手套 穿套袖盖到手套, 除非达到要求 穿鞋尖光滑的保护跖骨安全鞋或工程师靴 穿护脚或绑腿覆盖系带鞋的鞋舌, 以防止熔融金属或火花粘上 穿长裤或紧身裤, 包括从上到脚的覆盖, 以防止熔融金属火花 不做 : 使用长套型手套, 除非金属不可能被落入手套 穿诺梅克斯的手套, 熔融金属往往 In certain situations, a respiratory mask is required. 在某些情况下, 需要呼吸面罩 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 27

30 Many flame resistant (FR) cotton fabrics use a phosphorus-based treatment. Tuck pant legs inside the boot or spat. Use shoes with exposed zippers or elastic materials that can melt or ignite. Hearing Protection in Melting and Pouring Operations: Potential hazards involving hearing include hearing loss due to noise exposure and an inability to hear warnings. Consider primary protection for hearing including, ear plugs, ear muffs and ear caps. Dos and Don ts in Hearing Protection: Do: Select hearing protection that provides sufficient noise reduction for the exposure. Calculate noise reduction and the noise reduction rating or the hazard when selecting proper protection. Don t: Select hearing protection that does not properly fit. Select hearing protection that is not appropriate for the workplace noise level. Melt Deck Respiratory Protection: Workers in ferrous melting operations risk exposure to toxic metals such as lead, cadmium, arsenic, chromium (either as part of the alloy or as a contaminant of the scrap being melted) and toxic gases such as carbon monoxide. Crystalline silica may be present from handling refractory materials such as furnace and ladle tear-out, relining and from other metalcasting areas. For magnesium consider acid gases when sludging and for aluminum, chlorine or fluorides used for degassing. The following types of respiratory protection can be used when needed: Half mask respirator Full facepiece respirator Filtering or air purifying facepiece respirator Powered air-purifying respirator PAPR Air supplied helmet or hood Dos and Don ts in Respiratory Protection: Do: Choose a respirator that is part of an effective respiratory protection program. Don t: Ignore the results of industrial hygiene monitoring of noise, dusts, metal fumes, gases and vapors when performing your hazard assessment. To receive this digital magazine in the future, go to 粘在织物上 穿用磷处理的棉 ( 为有色金属 ), 因为熔融金属粘贴面料 许多阻燃 (FR) 的棉织物用以磷为基础处理 将裤腿裹入靴子或护脚 使用外露的拉链或弹性材料可熔化或点燃的鞋 熔炼和浇注操作中听力的保护涉及听力的潜在危险, 包括噪声引起的听力损失和无法听到警告 听力基本保护, 包括耳塞, 耳罩 听力保护做与不该做的 : 做 : 选择听力保护, 提供足够的降噪 当选择适当的保护时, 计算降噪, 降噪等级 不做 : 选择不适合的听力保护 选择听力保护不适合工作场所的噪音水平 熔炼平台上呼吸系统的保护 : 工人熔炼金属操作风险指有毒金属, 如铅, 镉, 砷, 铬 ( 无论是作为合金的一部分或作为一个熔化的废钢夹杂物 ) 和有毒气体, 如一氧化碳的 二氧化硅材料, 如修炉, 钢包耐火材料大修和从其他铸造领域 熔炼镁产生的酸性气体和炼铝时脱气使氯或氟化物 需要时, 可以使用以下类型的呼吸保护 : 半面罩呼吸器 全面罩呼吸器 过滤或空气净化面罩呼吸器 电动空气净化呼吸器 PAPR 供气的头盔或头罩 呼吸系统保护做与不该做的 : 做 : 选择一个呼吸器, 是一个有效保护呼吸系统的一部分 不做 : 忽视执行危险评估时的噪声, 粉尘, 金属烟雾, 气体和蒸汽的工业卫生监测结果 如果您想订阅我们的数字杂志, 请登陆 28 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

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32 Reviewing China s Diecasting Industry 回顾中国的压铸工业 The development of China s high pressure die casting industry spans 60 years. 中国压铸业发展回顾与展望 jincheng cheng, beijing ratio tool-equipment factory 陈 金 城, 北京无线电工具设备厂 T he Beginning Period: s The yearly 1950s were a high tide of the economic development in China, with many factories built. As a result, many industries needed diecasting facilities to produce castings. At that time, factories in Changchun and Heilongjiang designed and produced small horizontal cold chamber diecasting machines, with a ton locking force. Later, factories in Shanghai, Nanjing and Beijing made small diecasting machines for their own use. In the mid-1950s, many diecasting machines were imported, mainly Polak, vertical cold chamber die machines from Czechoslovakia with four specifications and 200-ton locking force and horizontal cold chamber die machines from Russia with three specifications and a 530-ton locking force. In 1960s, the demand for diecastings proliferated, and the number of diecasting factories increased greatly; however, most were workshops affiliated to plants. Few standalone diecasting factories were built in Shanghai and Shenyang. At the same time, the first Chinese diecasting machine maker, Shanghai Die Casting Machine Co., was established. Several more diecasting machine makers appeared, producing both vertical and horizontal cold chamber die casting machines. At that time, the diecasting alloy was mainly aluminum alloy and zinc alloy, less copper alloy, and even no magnesium alloy. Most of these alloys were according to USSR s standard. During this period, some dies were designed and produced domestically, some were produced domestically based imported design from Russia and East Germany; few were directly imported. The material of die was mainly made of 3Cr2W8V steel, while 5CrMnMo steel was also used for zinc alloy. The heat treatment of dies was mainly quenching, while their surface treatment was mainly nitriding, and rarely cyanide treatment. For the aspect of the diecasting technology, in the early 1960s, there was no detection device for shooting process. At that time, vacuum die-casting technology was widely studied overseas, some domestic institutes 30 创 业岁月:二十世纪50年代至60年代 20世纪50年代初 正值我国国民经济建 设的高潮 一大批大型企业 工厂相继建 立 许多重要工业部门急需压铸设备生产压铸零件 当 时有长春 黑龙江等地曾自行设计制造小型卧式冷室 压铸机 锁模力为50吨级与100吨级 其后 上海 南 京 北京等地 也有工厂自制小型压铸机供自用 50年代中[1] 进口了一大批压铸机 主要有 捷克 斯洛伐克 的Polak型的立式冷室压铸机 有4种规 格 最大的为锁模力220 t级 前苏联的卧式冷室压铸 机 3种规格 最大的为锁模力530 t级 少量为东德 进口 进入60年代 压铸件的需求量激增 生产单位徒然 增加 多数工厂以附属车间为主 专业压铸厂也已在上 海 沈阳建成 同时 国内建立了第一家专业生产压铸 机的厂家 上海压铸机厂 不久 又有几家专业压铸 机厂建成 制造立式冷室压铸机和卧式冷室压铸机 当时 压铸合金大多数以铝合金和锌合金为主 有少 量铜合金 而镁合金更少 各种合金的牌号主要是沿用 前苏联的 这个时期 压铸模的设计与制造方面 有由国内自 行设计与制造的 也有引进前苏联和东德的模具设计图 纸 由国内制造 还有少量直接引进模具 关于模具的 加工方法 不同的工厂则是参差不齐 压铸模成型零件 所用的材料 对于所有合金 以3 Cr2W8V钢为主 锌 合金的模具也有用5CrMnMo钢 模具的热处理以淬火 为主 模具的表面处理技术多采用氮化处理 少量用氰 化处理 在压铸工艺技术方面 60年代初 压铸机尚未有配 置压射过程的检测装置 当时 真空压铸技术正在国外 广泛开展 国内不少单位紧跟其后 有一定的成效 充 氧压铸的工艺 曾有个别单位进行了试验 有关黑色金 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

33 made efforts, too and they made some progress. Some factories tested oxygen filling technique. And some factories and research institutes carried out research on die casting of ferrous alloys. The Development Period: s During the s, the diecasting industry witnessed a big improvement. Many big factories established diecasting workshops. Besides of Shanghai and Shenyang, professional die-casting factories were built in Beijing, Chongqing, and Dalian and so on. Automobile industry had been the biggest customer in the die-casting market. From the 1970s, for the purpose of Energy saving and low carbon, weight reduction became an important issue of vehicles, which complied with the characteristic of diecasting. Then this industry closely linked to the automobile industry. With these demands and those from other industries, the development of the diecasting industry accelerated. During this time, diecasting alloys included aluminum, zinc, copper, and magnesium alloys, among which the amount of aluminum alloy increased rapidly. In 1970s, the national diecasting alloy standards were set and implemented. By the early 1970s, domestic small diecasting machines could be produced quantitatively, but heavy machines were still not available. A sample heavy diecasting machine with locking force 4,000t was made but not put into use. At that time, imported machines increased rapidly, including those from Italy, Switzerland, Japan, and Czechoslovakia. Domestic manufacturers made hot chamber diecasting and vertical diecasting machines for zinc. Jinan Foundry and Metalforming Research Institute made the first domestic automatic diecasting machine with a 630- ton locking force. With the demand for diecasting increasing, die design improved through experience, and the Gate Design Sliding Rule, among other related books, was published. Machining of the dies was by machine tool with digital display and numerically controlled lathe. Professional diecasting factories were built in Guangdong, Shanghai, etc. Tooling, which had been produced solely in 3Cr2W8V steel also began to be built using AISI-H13 steel. During this period, international communication became active. In 1974, a Chinese delegation participated in the International Die Casting Congress & Expo held in Europe. In 1975, a European diecasting delegation visited China, and a technical exchange meeting was held in Beijing. In 1981, a delegation from the Japan Die Casting Association visited China. In 1983, a Chinese delegation took part in the 12th American International Die-casting Conference and Exhibition, and visited the headquarters of the Society of Die Casting Engineers (SDCE). In 1984, 属压铸, 东北 上海及北京等地, 都有工厂及研究机构进行过研究试验工作 稳步渐进 : 二十世纪 70 年代至 80 年代 20 世纪 70 年代和 80 年代期间, 压铸业在前一个时期的基础上, 有了较大的发展 许多大型企业都有下属的压铸车间 专业压铸厂除了上海 沈阳以外, 北京 重庆 沈阳 大连 青岛等大中城市中相继建立起来 从压铸市场来看, 汽车工业在当时已经是最大的用户,20 世纪 70 年代起, 世界各工业国家出于 节能 低碳 的要求, 汽车减轻质量成为重要课题, 更加凸显出压铸业的特点, 从而与汽车工业的依存关系更为紧密 加上其他各个工业门类都对压铸件的需求不断增加, 加快了压铸业发展的步伐 压铸合金, 仍然依次为铝 锌 铜 镁等合金, 其中铝合金用量增加最快 70 年代, 逐步建立和贯彻国家压铸合金标准, 当时制定的标准牌号较少 70 年代初 [1], 国产的中小型压铸机能够批量生产, 但缺乏大型机 国内曾试制了 1 台锁模力 4000 t 级的大型压铸机, 但未能投入实际使用 当时, 进口压铸机的数量大为增加 有意大利 瑞士 日本 捷克 ( 斯洛伐克 ) 德国等国家的机器 其时, 进口的大型机有 :WOTAN 公司的锁模力 1600 吨级 东芝 宇部 VIHORLAT 等公司的 1000 吨级, 共约 6 ~7 台 自动化程度较高 国产锌合金热室压铸机和全立式压铸机在当时已形成了系列化产品 还有, 济南铸锻研究所试制了我国第 1 台自动压铸机组, 锁模力为 630 t 级 其时, 国内也有企业进行铝合金热室机的试验, 后因故停顿 随着压铸件的要求不断提高, 国内的压铸模设计的经验逐渐成熟, 压射参数能够正确的选用, 浇口技术的理论知识有了较大的提高, 有国内自行设计制造的 浇口计算尺 随出版书籍供应 模具的加工技术方面, 采用数字显示 ( 座标 ) 的机床和初期的数控加工机床 专业的压铸模工厂相继建立, 如广东 上海 东北等地区和城市 压铸模材料已经不再局限于用 3Cr2W8V 钢这一钢种, 扩展选用国际广泛采用的美国牌号为 AISI-H13 钢 国产与之近似的牌号为 4Cr5MoV1Si, 1976 年列入国家标准 模具热处理已有采用真空热处理 模具的表面处理仍以氮化处理为主 当时, 有的单位 ( 长春一汽 ) 在进口压铸机的同时也引进全套压铸工艺技术 这个时期, 加强了与国外交流,1974 年, 我国组团参加欧洲国际压铸会议暨展览会 1975 年, 接待了欧洲压铸代表团对我国的回访, 在北京举行了交流座谈 ;1981 年, 日本压铸协会代表团来华参观访问, 在杭州举行了 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 31

34 a huge delegation organized by SDCE came to China and visited the factories in Beijing, Shanghai and Guangzhou. In the mid-1980s, a project to improve casting technology in developing countries funded by the United Nations was conducted. In this project, Jinan Foundry, the Metalforming Research Institute and Shanghai Die Casting Machine Co. were designated to import measurement devices and diecasting process monitoring parameters from the U.S. and then manufacture similar equipment domestically. As for diecasting technology, the industry began to focus on the automation of pouring equipment, spraying and grasping, detection and display of diecasting parameters, and automatic die temperature control. Advanced detection equipment was imported. Vacuum diecasting technology was selectively used, though still limited. The Flourishing Period: 1990s The diecasting industry in China entered a fast development period in the 1990s. In 1991, 752 factories produced die castings with 3,434 diecasting machines, among which 2,880 were domestically made and 554 were imported. Diecasting production volume increased 13.18% on average from 1991 to 2000 (Fig. 1). The automobile industry took the biggest share of the diecasting production, accounting for more than 65%. Other industries, including lifts, heating equipment, large lamps, home appliances, toys, tools, small hardware, etc. adopted more diecastings, as well. In the 1990s, the design standards, mechanical structure, technical parameters, performance and quality of die machines were improved. The automatic units gradually became suited for the assembly line. Jinan Foundry and Metalforming Research Institute successfully made the first flexible die-casting unit with locking force of 400 tons in LK Group participated in GIFA 99 in 交流会 ;1983 年, 我国组团首次参加美国第 12 届国际压铸会议暨展览会, 并专程访问 SDCE 总部, 建立了联系 1984 年, 美国压铸学会组织庞大代表团访华, 参观了北京 上海及广州的工厂并进行交流 80 年代中, 联合国组织的对发展中国家的援助项目之一 提高铸造技术, 我国指定济南铸锻机械研究所与上海压铸机厂组合, 从美国引进压铸过程压射参数检测技术及装置, 并进行国产化的准备工作 关于压铸工艺技术方面, 压射过程的工艺参数的选用从理论上提高认识 对于压铸机配置了浇料 喷涂及取件等自动化装置 压射参数的检测及显示 模具温度自动控制等技术逐渐受到重视 对压铸合金 压铸件的质量检测工作受到了重视, 采用进口先进的检测装备 对真空压铸技术能够有选择地加以应用, 但仍有局限性 蓬勃发展 : 二十世纪 90 年代 20 世纪 90 年代, 中国压铸业进入快速发展时期 根据 1991 年的统计, 我国当时压铸件生产的厂点 752 家, 压铸机的拥有量为 3434 台, 其中国产机 2880 台, 占 84%, 进口机 554 台, 占 16% 对于压铸件产量而言, 从图 1 [2] 可见,1991 年至 2000 年, 连续 10 年持续增长, 平均每年达到 % 其中, 汽车工业在压铸件产量中所占份额已属独占鳌头, 达到 65 % 以上 其他工业门类也都大量扩展采用压铸零件, 如梯级踏板 升降机 取暖器材和大型灯具等大型零件, 还有 3C 产品 家用电器, 玩具 小五金 等等 在 90 年代, 从机器的设计水平 技术参数 性能指标 机械结构 制造质量等方面, 都有所提高 自动化 Fig.1. Shown is the production volume of die castings in China during 1991 to 图 年 2000 年压铸件产量 32 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

35 Germany and a diecasting equipment exhibition in the U.S. Both were the first time Chinese-made diecasting machines were on display at the two famous international exhibitions. During that period, magnesium diecasting technology developed rapidly abroad. In China, LK Corp. launched the first domestic magnesium alloy diecasting machine and horizontal cold chamber diecasting machine for magnesium alloy in While aluminum was still the dominant diecasting alloy in China, it became more diversified. Zinc alloy diecasting was concentrated in Guangdong and Zhejiang provinces. Magnesium alloy diecastings were being used in forestry machinery, electric and pneumatic tools, as well as the aviation and marine industries. Later, the material came to be a popular choice in the automobile industry. Although domestic die manufacturing was greatly improved in the 1990s, some large and complex dies with high precision and special requirements, especially those for the parts for automobile industry, failed to meet requirements. CAD/CAM/CAE in die manufacturing started early, and mold filling simulation software was upgraded by domestic colleges and universities. CNC machining of the tooling was popular, and die cooling systems were improved. Fruitful study of hot work die steel was carried out, and a new series of steel was developed. Vacuum quenching and high-pressure gas quenching technology were adopted into the heat treatment of the die. Automated diecasting units, cells, complete production lines and other affiliated technologies were adopted by more facilities. However, PQ2 mapping technology was rarely applied because the majority of diecasting machine configuration did not satisfy the requirement. Slow injection techniques were introduced but remained in initial stages of development. 机组也逐渐具备了配套供应的能力 1990 年济南铸锻研究所试制成功国内第一台柔性压铸单元, 锁模力 400 t 级 1999 年 6 月和 9 月, 力劲集团公司以机器实物先后参加德国 GIFA 99 博览会和美国 NADCA 展览会 这是中国压铸机第一次参加这两个大型国际性展览会 这一期间, 国外镁合金压铸发展很快 在国内, 力劲集团公司于 90 年代末进行了充分的准备,2000 年初, 首先推出国产镁合金热室压铸机和适合压铸镁合金的卧式冷室压铸机 压铸合金中铝合金依然占主要地位 合金牌号出现多元化的局面, 并多数与国际接轨 锌合金压铸则较为集中在广东和浙江地区 镁合金在林业机械 电动与风动工具以及航空 航海等方面也都加以应用, 到了后期, 汽车工业上的应用已经成为热点 这个时期, 国内模具制造水平有了较大的提高, 但少数大型 复杂 高精度以及特殊要求的模具, 特别是汽车工业方面的零件, 还未能满足要求 模具 CAD / CAM / CAE 起步也较早, 填充型腔的模拟软件有了升级版, 国内部分高等学校对这方面进行自行开发并取得进展 在模具加工的装备方面, 立足于采用数控加工, 重视大型的数控加工机床 模具的冷却系统有所发展, 包括管路冷却 点冷却的方式, 对模温自动控制技术的认识有所提高 关于模具钢, 国内对热作模具钢的研究颇有成果, 自行开发 Y 系列新钢种 模具热处理工艺在真空淬火及高压气淬等技术的应用都有了进一步的扩展 压铸工艺技术方面, 采用自动化压铸机组 压铸单元 成套生产线的企业有所增加, 而且其他的相关配置的需求也不断增多 对于 PQ2 图技术, 由于当时国内多数压铸机上配置尚不具备条件, 实际应用较少 Fig. 2. Shown is the annual production of die castings in China during 图 年 2010 年压铸件产量 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 33

36 Vacuum die casting, local pressure technology and semi-solid casting technology were improved, and filling-type indirect squeeze casting technology began to enter the market. During the 1990s, China s die casting industry strengthened its communication with overseas industries. In 1991, the China Foundry Association sent a delegation to the 16th International Die Casting Congress, and in 1997, the Foundry Institution of Chinese Mechanical Engineering Society (FICMES) participated in the 19th International Die Casting Congress. The Big Leap Decade: The First 10 Years in the 21st Century Into the 21st century, with the rapid development of China s national economy and increased business from abroad, the domestic diecasting market continued to boom. Annual production increased by about 3.3 times during this 10-year span (Fig. 2). Up to the 21st century, industrial clusters appeared in the Yangtze River Delta, the Pearl River Delta, the three northeastern provinces and the southwest area. Subsequently, the diecasting industry emerged in the Northwest and Middle South Beijing-Tianjin-Hebei region. Meanwhile, Gaoyao in Guangdong, Ninghai in Zhejiang province, and Chongqing also established diecasting bases. The production of aluminum and zinc die castings increased. Magnesium diecasting gradually came into a period of development. The Diecasting of motor rotors in copper was successfully achieved, which was an important energy effiency breakthrough in the motor industry. Mass production of iron die castings was realized in some foundries. The rapid increase of requirements for large and sophisticated high-end die castings drove the progress of Chinese-made diecasting equipment, and its performance gradually increased in terms of scale, automation and unitization. Die casting machine makers began providing support facilities and integrated services. In recent years, the first 4,500-ton-class diecasting machine was made in China. The export of Chinese-made diecasting machines increased, of which some large-scale diecasting machine were exported to the U.S. and Japan. Generally speaking, great progress had been made in die design and manufacturing, but still lagged behind developed countries for the manufacture of large, sophisticated parts for the automobile industry. CAD/CAM/CAE were widely used in die design. Numerical simulation software gained attention. Domestic software owned part of market share, while foreign software took the leading position. Gate design technology, die temperature control and the overall structure were improved. CNC machining centers were widely used in machining of dies, but the lack of large and sophisticated CNC centers were still 至于慢压射技术, 当时国内曾于进行了介绍和宣传 [3], 也因各种原因, 只是停留在初始的认识阶段 真空压铸工艺不断改进 局部加压技术的应用有所扩展 半固态铸造技术取得进展 填充式间接挤压铸造技术开始进入压铸市场 这个时期, 我国压铸行业对外交往逐渐增多 1991 年, 中国铸造协会组团参加第 16 届美国国际压铸会议 ;1997 年, 中国铸造学会组团参加第 19 届美国国际压铸会议, 并且参与当时由 NADCA 组织的全球性的统计工作, 向其提供中国压铸业的相关资料, 其后, 各国 ( 列出了 9 个国家 ) 的数据统一登载在期刊 Die Casting Engineer 上[4], 从而掀开了我国压铸业进入国际行列的一页 其他的出国考察 座谈交流 境外参展等多种交流形式十分踊跃 突飞猛进 :21 世纪初的 10 年进入 21 世纪, 随着中国国民经济的高速发展, 国内压铸市场持续旺盛, 而且国外转移到中国采购逐渐增多, 反映了国内外市场的需求形势, 促使中国的压铸业加快提高生产技术的步伐, 压铸件产量持续保持着较高的增长,10 年间, 增长了约 3.3 倍, 见图 2 [5] 起初, 部分地域由于汽车产业 玩具及小五金产业的集中度铰高, 个别的产业集群在 90 年代就初具雏形 到了 21 世纪, 其他地域的产业集群相继崛起 [6], 其中有长江三角洲区域 珠江三角洲区域 东北三省及西南地区三省一市等 随后, 西北地区 中南地区 京津冀地区也都随着该地区的经济跃升而带动了压铸产业的发展 还有, 广东高要 浙江宁海以及重庆等地也建立了压铸基地 为了适应压铸业的发展, 压铸合金方面, 铝合金 锌合金有所增加, 镁合金逐步进入较为理性的发展阶段 铜合金压铸在电动机铜转子的压铸上取得成功, 这是电机工业的革新与节能战略意义上的重要突破 还有的单位对铸铁的压铸成功地进行了批量生产 在压铸设备方面, 由于大型 精密 高端的压铸件的快速增加, 推动了中国国产压铸机性能逐步提高, 在大型化 自动化 单元化等方面, 能够达到或接近国外先进水平, 并且已经有能力提供配套设施 集成服务等项目 近年来, 国产第一台最大的 4500 t 级压铸机问世, 还有两板机在国内已经进行了研制 中国制造的压铸机向海外的出口量有所增加, 其中还有成批的大型压铸机出口至美国 (3000 t 级 ) 和日本 (1250 t 级以上 ), 充分展现了中国压铸机制造的实力 关于压铸模的设计与制造, 总体而言有了很大的进 34 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

37 an obstacle to further development. A series of technical issues needed to be resolved, such as material, heat treatment, service life, and the rapid mantling and dismantling of dies. Thanks to the theoretical work (such as the filling process, etc.) carried out by some colleges and universities, diecasting technology continued to improve. Many domestic-made die casting machines became equipped with a display panel of the injection parameters. A few even provided the PQ2 map, which gave conditions for the application of related technology projects. High density diecasting technology was further developed. The vacuum device for vacuum diecasting began to be produced in China although still accounted for less market share. Local pressure technology was expanded. Horizontal HH squeeze casting machine adopting indirect squeeze casting technology used in squeeze casting was made, and HV-type squeeze casting machine was successfully tested. Universities and research institutes began the active study of semi-solid casting technology and proposed a variety of related methods (including semi-liquid). The first production line of semi-solid billet of aluminum alloy was established and put into application. During this decade, big diecasting companies owning dozens or even 100-plus large-scale diecasting machines emerged. A few diecasting companies and equipment suppliers acquired businesses abroad. This trend greatly promoted the development of the diecasting industry in China in scale, competitiveness and brand. Prospect of China s Diecasting Market With China s rapid economic growth, its diecasting industry faces a bright future. Chinese diecasting companies have greatly improved in management, culture, brand and competitiveness. They have come to realize the importance of qualified international certification, and take it as an important symbol of meeting international standards and management upgrades. Over the past decade, the diecasting industry of some industrial countries underwent great change, such as combination, merging and reorganization of diecasting enterprises and even bankruptcy. However, the demand for auto parts in the automotive industry of these countries didn t decrease. Therefore, part of diecasting production and sourcing was moved overseas. Most diecast parts were components for the automotive industry. This situation creates a large international market, which is encouraging for China s further diecasting industry development. The Industrial Structure of China s Diecasting Industry Due to the impact of domestic and international 步 但汽车工业的大型 精密 复杂零件的模具, 还有一定差距 模具设计工作方面,CAD/CAM/CAE 的使用日益普及, 模拟分析软件的应用受到重视, 国产软件已有一席之地, 而进口品牌较多 浇口技术 模具温控以及模具总体结构等的设计水平正在提高 数控加工中心成为主要设备, 但大型精密的仍感不足, 制约压铸模的发展进程 压铸模具用钢 模具热处理 模具寿命 模具快速装卸等许多技术问题都需要逐一解决 尤其是自动化生产过程的要求, 模具的可靠性和稳定性显得格外重要 压铸工艺技术不断提高, 在理论工作 ( 如充型过程等 ) 方面, 部分高校进行了研究与试验 近年来, 国产压铸机较多都能配备压射参数显示装置, 有的提供 PQ2 图等, 为有关的技术项目的应用提供了条件 近十年来, 高密实压铸的技术有了进一步的发展, 真空压铸技术的真空装置已有国产产品供应, 而多数是进口的 局部加压技术的应用有所扩展 挤压铸造 ( 简称挤铸 ) 中的填充式间接挤铸技术, 已经有国产的全卧式 HH 型挤铸机的产品供应,HV 型挤铸机国内也已试制成功 半固态铸造技术, 以高校和研究单位为主体, 多种与此相关的铸造方法 ( 包括半液态 ), 国内对此的研究试验十分活跃 国产第一条制备铝合金半固态坯料生产线已经建立, 进入工业应用阶段 这个时期内, 国内逐渐出现一些生产规模拥有压铸机达数十台乃至 100 台以上的大型压铸企业, 甚至有的并购国外的压铸企业 ; 也有压铸机企业兼并外国的压铸机企业的 这种局面, 极大地推动了我国压铸业扩大规模, 提高竞争力, 树立品牌, 加强纵向和横向的发展, 凸显出中国的压铸业在国际上的地位 中国压铸业的市场前景在中国国民经济快速增长的形势下, 压铸工业的发展道路更加宽广 在激烈的市场竞争中, 我国的压铸企业在企业管理 企业文化 企业品牌以及企业竞争力等方面有了较大的提升 认识到获得各种资质的国际认证的工作不但十分重要, 也是我国压铸企业在管理上升级, 与国际接轨的重要标志, 为赢得国际市场的份额创造了较为有利的环境和条件 近十余年来, 一些工业国家的压铸生产的工业结构发生了根本性变化, 有的压铸企业进行联合 兼并 改组, 有的倒闭 然而, 这些国家的汽车工业所需求的汽车零部件并没有减少, 因而有一些将压铸生产移到海外另设生产基地, 或向海外采购, 其中也以汽车工业配套件的居多, 这就留有很大的国际市场的空间, 这种现象 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 35

38 markets, the industrial structure of China s die casting industry is undergoing significant changes: More professional diecasting plants with larger average scales are appearing. Some are extending their business to further processing to deliver finished parts to its customers. Parts suppliers are beginning to set up diecasting factories to achieve virtuous circle and an optimized management model within the enterprise. The trend of combination or merging is strengthening. Manufacturers are changing to service providers. Regional diecasting industry clusters are expanding in size and industrial chain. The industry is taking advantage of overseas outsourcing of diecasting production, capital, technology, management and marketing by building more diecasting enterprises of foreign investment, joint venture, joint operation and partnership. Trends of Diecasting Technology Many research projects in diecasting technology have made significant progress, but, compared with foreign countries, there is still a gap, and for some projects the gap is bigger. The Chinese diecasting industry must selectively promote the research and development of cutting-edge innovation and make efforts to launch more technologies of self-owned intellectual property rights. Priority should be given to the following: Research of mold filling theory and its application. Diecasting material performance through the development of new alloys and composite materials. Design and processing technologies for thinwalled die castings, design of integrating castings into a single die casting, and joint design of diecast products. Development of large, complex, precision dies and process technology and improving die material, service life and surface treatment technology. Application of advanced diecasting technologies such as process parameter measurement, PQ2 technology, slow injection technology, and high density diecasting technology. Promotion of computer aided technologies, such as, computer-aided die design, selection and optimization of diecasting process parameters and numerical simulation. Improvement of equipment performance, reliability and stability and supporting facilities for energy efficiency and emission reduction. To receive this digital magazine in the future, go to 对中国而言, 加快了压铸业发展的步伐 中国的压铸业的产业结构在国内外市场的大环境 大形势下, 压铸业的产业结构正在发生重大的变化 : 专业压铸厂的数量增多, 规模逐步加大, 有的还延伸后续各种工序, 直至向用户交付成品零件 零部件供应商设立压铸厂, 实现企业内良性循环和优化的管理模式 合并 联合的趋势有所加强, 具有或联合 或兼并 或依附等多种形式 制造业正在大力推行制造商向服务商转型, 以新的面貌面向社会 地域性的压铸产业集群在规模以及产业链的延伸等方面继续扩展 以国外压铸生产移师海外为契机, 引进资金 技术 管理 市场和信息, 构筑更多的外资 合资 合营 合股等形式的压铸企业 中国压铸业的工艺技术趋向压铸工艺技术呈现日新月异的局面, 许多研究项目取得重大的进展, 但与国外相比, 还有一定的差距, 有的项目可能差距更大些 中国压铸业应根据国情, 有选择性地对有关项目或课题加以推广应用, 或二次开发, 或进行前沿创新等工作 争取有更多的自主知识产权的项目推出问世 为此, 从技术趋向的角度, 提出一些近期应优先考虑的课题与项目, 以供参考 : 压铸填充理论的基础研究及其应用 压铸材料的性能提高, 开发新的合金品种及其复合材料 各种合金的薄壁压铸件的设计与压铸工艺技术 ; 组装整合成单一压铸零件的设计 : 推行压铸产品联合设计 加快大型 复杂 精密压铸模及压铸工艺技术的开发制造 ; 提高模具加工技术 ; 开发与改进模具材料 ; 延长模具寿命 ; 模具的表面处理技术的研究 推广压铸工艺及先进技术, 如 : 普及压铸工艺参数的检测装置 PQ2 技术和慢压射技术等 扩展高密实压铸的相关技术的应用 推广电子计算机应用技术, 如 : 模具辅助设计 压铸工艺参数的优化及选用 模拟分析, 提高压铸设备性能 自动化生产过程的可靠性与稳定性 完善节能 减排与绿色压铸的配套设施 如果您想订阅我们的数字杂志, 请登陆 36 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

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40 Exploring Self-Healing Castings The capacity of bones to heal their own cracks has inspired researchers to turn their attention to cast metals. jose martinez-lucci, andrew ruzek, shobhit misra, pradeep rohatgi and ryo amano, univ. of wisconsin-milwaukee, milwaukee, wisconsin, usa. 探索自我修复铸件 骨骼修复自身裂纹的能力启发研究人员研究金属的自修复性 Jose Martinez-Lucci, Andrew Ruzek, Shobhit Misra, Pradeep Rohatgi and Ryo Amano 威斯康星大学 美国威斯康星州密尔沃基市 T hree methods of creating metal castings that can heal cracks in themselves are currently being developed at the University of Wisconsin-Milwaukee (UWM), Milwaukee, USA. While the technology is in its infancy, the main strategies in the development of self-healing metallic systems have incorporated shape memory alloy (SMA) reinforcements in cast metals and induced the formation of precipitates in an oversaturated but under-aged alloy. To put it simply, a material must have three things to heal itself: a structure that maintains functionality, parts that move to close voids and a trigger to activate this healing action. The three strategies being pursued at UWM are: incorporating SMA wires in castings; using molten interdendritic eutectic to seal surface cracks; embedding micro-balloons and micro-tubes containing a low melting point alloy in the matrix of a high melting point casting. Once the potential directions for developing self-healing metal castings were identified, computational simulation was performed to aid in predicting the types of cracks that could be healed using the third system being explored. While the precise microstructure of self-healing metal castings has not been determined, the examination of the systems at UWM was intended to help drive the development of casting methods in the future. Fig. 1. Shown is an optical microscopy of randomly orientated NiTi fibers in a Sn-20% Bi matrix synthesized at UWM. 38 美 国威斯康星大学密尔沃基分校 UWM 正 在开发三种铸件裂纹自我修复的方法 虽然这项技术还处于初级阶段 但是金属自愈系统发 展的主要战略已经将形状记忆合金 SMA 强化物用 于铸造 并在过饱和但失效不足的合金中诱导形成了 沉淀相 简单地说 这种材料必须有三样东西才能自愈 保持 功能的结构 能够移动并填补空洞以及激活愈合行动的 触发 UWM追求的三个策略是 使用铸件形状记忆合金 SMA 丝; 使用熔融枝晶间共晶弥合表面裂纹; 在高熔点铸造基体中嵌入含低熔点合金的微球和微管 一旦确定了铸件自我修复某个潜在的发展方向 就采 用已有软件进行计算机模拟帮助预测能够弥合的裂纹类 型 虽然尚未确定自我修复铸件的精确的微观组织 但 是UWM评估系统就用来帮助推动该铸造方法的进一步 发展 用于焊料和镁铸件的技术 图1 威斯康星大学合成的Sn-20% Bi基体上随机取向的NiTi纤维在 光学显微镜下的组织 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

41 Fig. 2. This scanning electron microscope image shows the crack surface of the NiTi short fiber reinforced Sn-20% Bi matrix. 图 2 扫描电子显微镜图像显示 NiTi 短纤维增强的 Sn-20% Bi 基体的裂纹表面 The techniques and concepts developed for solder and Mg-based castings can be extended to aluminum castings. In the case of SMA-reinforced systems, a metalcaster or designer would need to identify a suitable aluminum alloy matrix and an interfacing material that will liquefy and become sealed under the clamping force needed to heal the crack. For systems involving a low melting pointencapsulated healing agent, the healing agent must be selected based on its flow and solidification characteristics. Other off-eutectic systems also can be identified based on the thermodynamic phase diagrams of aluminum alloys, leading to self-healing in the selected system. Self-repairing metal castings would be ideal for use in applications such as high temperature turbine blades, automotive engines, fatigue and failure prone structures and aircraft castings. The success of self-healing concepts when used with polymers, ceramics, solders and magnesiumbased alloys could pave the way for the success of production castings in the future. The Three Methods Following is an exploration of the three self-healing systems under consideration at UWM. SMA Inserts When a casting with embedded SMA wires or particles is cracked, the reinforcements deform. Upon heating the composite to the austenite transformation temperature of SMA, the wires or particles recover their original shape. This shape change provides a clamping force that shuts the cracks. This, in combination with a matrix that is partially molten at healing tempera- 和概念可以扩展到铝铸件 在 SMA 增强系统中, 铸造者或设计师需要确定一个合适的铝合金基体材料和界面材料, 该材料能够液化, 从而在所需的夹紧力下愈合裂纹 对于涉及含低熔点合金愈合剂胶囊的系统, 根据流动和凝固特征选择愈合剂 其它非共晶系统可以根据铝合金热力学相图确定自我修复性 自我修复铸件的理想应用领域是高温涡轮叶片 汽车发动机 容易疲劳和失效的结构和飞机铸件 当在聚合物 陶瓷 焊料和镁基合金中使用时, 自修复的概念将为未来铸件的成功生产铺平道路 三种方法以下是 UWM 正在研究的三种自修复系统的探索 形状记忆合金 (SMA) 嵌入体当嵌入 SMA 丝或颗粒的铸件出现了裂纹, 增强物就会变形 将该复合材料加热到 SMA 的奥氏体转变温度,SMA 丝或颗粒就会恢复原来的形状 这种形状变化提供了闭合裂纹的夹紧力 这和在高温部分熔融的基体一起使裂纹焊合 该方法正在 Sn-20% Bi 合金中添加 NiTi 微粒和短 NiTi 纤维强化物进行尝试 UWM 在铸造锡铋合 Fig. 3. When this alumina microballoon is cracked in a self-healing matrix, Sn-Bi eutectic fills the balloon. 图 3 在自修复基体中当此氧化铝微球破裂时, 共晶锡铋熔体填充了微球 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 39

42 图4 裂纹内外的液体愈合剂的体积 1 =100 愈合剂 a 与重力 方向相反 没有液体流入裂纹; b 与重力方向一致 充填了裂纹 Fig. 4. The volume of the liquid agent inside and outside the crack is represented (1=100% healing agent). Oriented against gravity (a), no liquid flowed to the crack; toward gravity (b), the crack was filled. tures, can lead the cracks to become welded upon cooling. A study of the SMA method is being performed on composites with NiTi particulate and short NiTi fiber reinforcements in a Sn-20% Bi matrix. The cast Sn-Bi alloy with reinforcements of Nitinol short fibers is being synthesized with a typical microstructure at UWM (Figs. 1 and 2). Interdendritic Eutectic The basis of the off-eutectic healing system is the use of a standard microstructure found in cast metals to provide the needed components. In addition to a heat trigger, an off-eutectic system provides the other two components needed for healing dendrites as a structural component and the liquid eutectic phase as a mobile healing agent. An off-eutectic system is a hypoeutectic or hypereutectic system in which the composition allows for the formation of liquid and solid phases in equilibrium. In this work, two off-eutectic alloys are being investigated, both from the Sn-Bi system. The system has been chosen because it is a simple, purely eutectic, binary system used in solder applications. The compositions Sn-20% Bi and Bi-10% Sn were chosen because they exhibit approximately the same percentage of liquid phase at the healing temperature of 338F (170C), allowing the study of the two systems simultaneously. The optimal liquid to solid ratio for self-healing was identified to be around 20-30% of the liquid phase. This percentage allows for the interdendritic liquid to flow freely while maintaining structural stability. The challenge is to ensure the interdendritic liquid preferentially enters cracks near the surface. Embedding Hollow Reinforcements In a high melting point casting embedded with micro-balloons and micro-tubes containing low melting point alloys, an advancing crack Fig. 5. Simulation for a 0.25-mm crack oriented against gravity showed the liquid healing agent could partially fill the crack (a) or solidify and partially seal the crack (b). 40 金中添加Nitinol短纤维增强物得到了典型的微观组织 图1和2 枝晶间共晶 非共晶愈合系统的基础是在铸造合金中发现的标准 的微观组织为此提供了一种条件 除了热触发 过共 晶系统提供了其它两个条件 枝晶-组织条件和液态共 晶相-移动的愈合剂 非共晶是亚共晶或过共晶 该成 分下允许存在液相和固相的平衡 在这项工作中正在研究两个非共晶合金 都是基于 锡铋系统 选择该系统是因为它是一个用于焊料的简 单的纯粹二元系共晶 选择了Sn-20 Bi和Bi-10%Sn 是由于它们在愈合温度 下具有相同比 例的液相 这允许同时开展该两个系统的研究 用于 自修复的最佳液固比约为20-30 的液相 这个百分 比允许枝晶间液体在保持组织稳定情况下 液态金属 自由流动 所面临的挑战是要确保枝晶间液相优先流 入表面上的裂纹 嵌入空心增强物 在高熔点铸件中嵌入含有低熔点合金的微球和微 管 在裂纹扩展时就会破坏这些 微胶囊 然后 该材料可以加热 到低熔点合金的熔点以上 使其 图5 为与重力方向相反的0.25mm 裂纹的模拟结果 液体愈合剂可以 部分填充裂纹 a 或凝固并部分愈 合裂纹 b FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

43 Fig. 6. Simulation for 0.25-mm crack oriented at 30 degrees against gravity showed the liquid healing agent could partially fill the crack (a) or solidify and partially seal the crack. ruptures the microcapsules. The system then can be heated to above the melting point of the low melting alloy, allowing it to liquefy and flow into the crack. When the system is cooled, the low melting alloy solidifies in the crack, welding it shut (Fig. 3). Judging Hollow Reinforcements Computational fluid dynamic (CFD) modeling was applied to aid in predicting the temperature necessary to induce healing and the types of cracks that could be healed in castings with liquid healing agents. The analysis has shown that cracks of certain sizes and orientation can be filled from a reservoir of healing liquid within castings. For the hollow micro-tube system, two different metalcasting alloys were used: a matrix solder of 99.3% Sn-0.7% Cu with a melting point of 439F (226C) and a healing agent of 58% Bi-42% Sn (eutectic) with a melting point of 280F (138C). To investigate the types of cracks that can be healed, different crack diameters (1 mm, 0.25 mm and 10µm) were placed on the center of the matrix at different angles (30 degrees and 60 degrees). The effect of gravity in the liquid healing agent also was investigated by orienting the crack in the direction of gravity and against it. CFD was used to simulate the distribution of liquid flow into and out of the reinforcements and the crack. The simulation showed that a 1-mm crack oriented towards gravity could be completely filled using this mechanism (Fig. 4). The healing liquid was not able to fill the crack when the gravity was oriented in the opposite direction. The contact angle between the healing agent and matrix was Fig. 7. The simulation for the 0.25-mm crack at 60 degrees showed the liquid healing agent could flow to crack (a) and partially seal the crack (b). 图6为与重力方向成30度角的 0.25mm裂纹的模拟结果 液体愈 合剂可以部分填充裂纹 a 或凝固 并部分愈合裂纹 b 熔化并流入裂纹 当裂纹中的 低熔点合金冷却时 发生凝固 就焊合了裂纹 图3 评估空心增强物 应用了计算流体动力学 CFD 模拟来帮助预测 诱导裂纹愈合的温度和可以愈合的裂纹类型 分析表 明熔化的愈合剂可以填充铸件中一定大小和取向的裂 纹 对于中空的微管系统使用两种铸造合金 基体焊料 99.3 Sn-0.7 熔点 和愈合剂58 Bi-42 Sn 共晶 熔点 为 了研究哪些裂纹可以愈合 在基体中心布置了不同角 度 30度和60度 和不同直径 1mm 0.25mm和 10µm 的裂纹 通过改变愈合剂的重力方向和裂纹 的取向研究了重力的影响 采用了计算流体力学的方 法模拟了愈合剂在增强物和裂纹处的流入和流出 模拟结果表明 1mm的裂纹取向对应重力方向时可 以完全充满 填充机制如图4所示 当裂纹取向和愈合 剂熔体重力方向相反时愈合剂熔体就无法填补裂纹 当愈合剂和基体之间的接触角 大于90度时 毛细作用不足够 将愈合剂熔体拉入裂纹中 图7为与重力方向成60度角的 0.25mm裂纹的模拟结果 液体愈合 剂可以填充裂纹 a 并且并部分愈 合裂纹 b Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 41

44 Fig. 8. The simulation for the 10-µm crack oriented against gravity showed the agent would almost fill the entire crack (a) or solidify and seal it (b). 图 8 为与重力方相反的 10µm 裂纹的模拟结果, 愈合剂几乎填充了整个裂纹 (a) 或凝固并愈合裂纹 (b) higher than 90 degrees, and the effect of capillarity was not enough to pull the liquid from the container. For a 0.25-mm crack placed against gravity, the liquid flowed from the tube to the crack by capillary effect to a certain height (Fig. 5). When oriented against gravity at angles of 30 and 60 degrees, complete filling of the crack could not be achieved (Fig. 6 and Fig. 7), but changing the crack orientation affected the ability of the liquid to flow under capillary action. The results of the simulation for the 10-μm crack oriented against gravity are shown in Fig. 8. When any of the three cracks were oriented with gravity at angles of 30 degrees, they were completely filled by the healing agent (Fig. 9). Self-healing has been incorporated in polymers using hollow micro-balloons and tubes where certain healing agents polymerize upon contact with the catalyst flowing into the crack and sealing it. In ceramics, hollow reinforcements rupture to release healing agents that expand upon oxidation, filling small cracks. The same concept can be extended to cast metals. 对于取向和愈合剂重力相反的 0.25mm 裂纹, 熔体通过毛细作用从微管流入裂纹 ( 图 5) 当裂纹和重力成 30 或 60 度角时, 就不能实现完全填充裂纹 ( 图 6 和图 7), 但是改变裂纹取向影响液体在毛细作用下的流动 对于和重力方向相反的 10μm 的裂纹的充填模拟结果如图 8 所示 当该三个裂纹中任何一个和重力成 30 度角时, 愈合剂熔体都可完全充填 ( 图 9) 采用微球和微管的自修复已经应用到高分子材料中, 其中一定的愈合剂和流入到裂纹中的催化剂接触后就高分子化, 从而愈合裂纹 在陶瓷中, 中空的强化物断裂释放出愈合剂, 其在氧化后膨胀从而充填小裂纹 相同的概念可以扩展到铸造中 To receive this digital magazine in the future, go to 如果您想订阅我们的数字杂志, 请登陆 Fig. 9.The simulation for the 10-µm (a), 0.25-mm (b)and 1-mm (c) cracks at 30 degrees toward gravity are shown. 图 9 为与重力方向成 30 度角的 10µm(a) 0.25mm(b) 和 1mm(c) 裂纹的模拟结果 42 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

45 Inspiration for Self-Healing The interest in developing synthetic self-healing in metal castings primarily has been inspired by existing biological systems with auto-repair capabilities. Natural self-healing is seen in many organic systems, such as bones. Certain advances in fabricating self-healing systems have been made in the past few decades. The healing process can be autonomous (without human intervention) or nonautonomous. The latter requires external intervention, such as heating the material to trigger the repair process. Following is a look at eight healing mechanisms that have been explored in fields other than metalcasting. 1. Researchers at the Univ. of Illinois have developed autonomous healing in polymers by embedding microcapsules filled with a monomer healing agent and a catalyst in a polymeric epoxy matrix. When the healing agent contacts the catalyst, it is converted into a solid polymer, sealing cracks as they develop. 2. At the Univ. of Bristol, researchers used previous work to develop fiber reinforced polymer composites. By adding hollow fibers containing healing resin and hardener among the reinforcement fibers, they were able to demonstrate recovery from damage caused by impact. When damaged, the filled hollow fibers fracture locally, releasing resin and hardener. 3. A single, localized healing event has been achieved through the development of an interconnected micro-vascular network of encapsulations of healing agent, imitating the circulatory system present in biological organisms. The network delivers the healing agent continuously and repeatedly to damaged sites. 4. Groups at the Univ. of California Los Angeles and the Univ. of Southern California have developed a polymer in which about 30% of the cross-links disconnect at 248F (120C) and reconnect upon cooling. This allows the unlinked polymer chains to flow into the crack or void caused by damage, and upon cooling, the chains link the crack closed. 5. Self-healing concrete composites are being developed with glass fibers containing an air curing sealant embedded in the concrete matrix. This composite exhibits self-healing behavior but it suffers from a significant (10%-40%) loss of stiffness compared with standard concrete due to fibers. 6. Researchers have studied the crack-healing behavior and mechanical properties of a mullite composite toughened by the inclusion of 15% (by volume) SiC whiskers. 7. Self-healing ceramic materials can be produced where an oxidative reaction causes the volume of oxide to exceed the volume of the original material, allowing products of these reactions to fill small cracks. 8. Scientists at the Dalian Univ. of Technology in China have developed self-healing concrete using shape memory alloy wires to close cracks and hollow fibers containing adhesive to bind crack faces back together. 自我修复的启示 开发铸件的自我修复的兴趣主要是受现有生物系 统的自动修复功能的启发 在许多有机系统中, 如骨骼, 可以看到自然的自我修复 在过去的几十年中在制造自愈系统方面已经取得了一定的进展 愈合过程可以是自主的, 无需人工干预, 或者非自主的 后者则需要外部的干预, 如加热材料以触发修复过程 以下是在铸造领域外发现的八种愈合机制 1. 伊利诺伊大学的研究人员开发出通过在高分子材料中嵌入含单体愈合剂的微胶囊并在聚合环氧基体中加入催化剂的方法实现了自愈合 当愈合剂接触到催化剂时, 就转换成固体聚合物, 随着其进一步发展就弥合了裂纹 2. 布里斯托尔大学的研究人员在以前的工作基础上开发纤维增强聚合物复合材料 在增强纤维间加入含愈合树脂和固化剂的中空纤维, 他们能够证明冲击造成的损伤可以恢复 损坏时, 中空纤维局部断裂, 释放出树脂和固化剂 3. 模仿生物的循环系统, 通过相互联系的网状的封装愈合剂的微细管路, 实现了单独的局部的修复 愈合剂通过网络连续地 反复地向损伤部位提供 4. 加州大学洛杉矶分校和南加州大学的研究组已经开发出一种聚合物, 其中约 30% 的交叉链接在 248 (120 ) 断开, 并在冷却中重新连接上 这使得无关联的高分子链流入因损伤造成的裂纹或孔洞, 并在冷却中连接, 使裂纹闭合 5. 正在开发在混凝土基体加入空气固化密封胶与玻璃纤维的自修复混凝土复合材料 这种复合材料具有自修复行为, 但是由于加入了纤维, 刚度和标准混凝土相比损失显著 (10%-40%) 6. 研究人员研究了加入 15%( 体积分数 )SiC 晶须增韧的莫来石复合材料的裂纹愈合行为和机械性能 7. 可以生产自修复陶瓷材料, 其中产生的氧化反应导致氧化物量超过原材料的体积, 反应产物填补小裂纹 8. 中国大连理工大学的科学家开发出了自修复混凝土, 采用形状记忆合金丝修复裂纹, 采用含粘结剂的中空纤维粘合裂纹 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 43

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47 Harvey Industries Revives Wabash As an emerging force in North American metalcasting, Harvey Industries used the acquisition of its Wabash, Ind., operations as a launching pad for its corporate strategy alfred t. spada, editor/publisher 哈维实业公司使沃巴什铸造厂复兴 作为北美铸造业的一股新兴力量 哈维实业公司将收购的印第安纳州沃巴什铸造 厂作为公司战略的起点 Alfred T. Spada 编辑出版商 J erome Harvey s parents made him work in a casting operation growing up so he would learn never to make a career out of it. Born in Albion, Mich., Harvey was an only child whose parents both worked at the now-closed Hayes Albion iron casting facility. His father was a molder, and his mother managed the cafeteria. Harvey was a melt man, working summers during college on the arc furnace deck The lesson backfired. Metalcasting gets in your blood, Harvey said. I worked in the foundry, and it never left me. As CEO of Harvey Industries LLC, Livonia, Mich., Harvey is the face of an emerging powerhouse in today s metalcasting industry. Since 2007, his firm has acquired casting facilities in Aiken, S.C., Nuevo Laredo, Mexico, and Wabash, Ind., to complement its existing machining business in Westland, Mich. Jerome Harvey, CEO, Harvey Industries, LLC Harvey Industries Wabash Operations Wabash, Indiana Metals: Molding Processes: Value-Added: End Markets: Casting Size: 2010 Production: Employees: Plant Size: 319 and 356 aluminum. Green sand and permanent mold. Machining and assembly. Automotive and commercial vehicle. Less than 1 lb. to 30 lbs. 3,818 tons ,000 sq ft. (45,000 for machining) 杰 罗姆哈维的父母让他在铸造厂中成长和工 作 这让他学会永远不要去做其它的事情 哈维生于密西根州的阿尔比恩 童年时 哈维的父母 曾在现已关闭的哈耶斯阿尔比恩铸铁厂 工作 他的父亲是一个造型工 母亲经营着工厂的餐 厅 哈维是一个 熔炼人 大学暑假 期间他都在电弧炉台上工作 铸造在我的血液里流淌 哈维说 到 我曾在铸造厂里工作 而铸造也 不曾离开过我 作为密西根州哈维实业有限责任公司 的首席执行官 哈维是如今铸造行业新 兴经济体的代表 从2007年开始 他 的公司已经收购了南卡莱罗纳州艾肯 墨西哥Nuevo Laredo和印第安纳州沃 杰羅姆 哈維 哈維工業有限責任公司 CEO 哈维实业沃巴什工厂 沃巴什 印第安纳州 金属 造型工艺 附加值 终端市场 铸件尺寸 2010年产量 工人 工厂规模 铝319和356 潮模砂 金属型铸造 机加工和装配 汽车和商务车 不高于1-30磅 3818吨 155人 平方英尺 机加工占地 45000平方英尺 Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 45

48 According to Harvey, the goal is for the firm to become the one-stop shop OEMs desire. Metalcasting gives us the opportunity to control manufacturing from its [origin] all the way through the final product, Harvey said. We know we are more attractive to a customer if we are able to control the process from beginning to end. A Return to Past Glory In the early months of 2008, the Wabash casting facility, controlled by global automotive supplier Hayes-Lemmerz International Inc., Northville, Mich., had seen better days. Wabash was an aluminum green sand facility that catered to the automotive market with a strong focus on intake manifolds and cylinder heads. Once a prominent member of the growing, technology-driven CMI International group, this facility (which was established in 1978), was rumored to be closing as its parent company was looking to focus on its core competencies in the wheel business. Instead, on July 3, 2007, the Wabash facility became the first metalcasting acquisition by Harvey Industries. There was an immediate change in the employees attitude when the acquisition took place, said Janet Betzner, plant controller. Employees were enthusiastic and optimistic. There was a renewed energy. We purchased Wabash because it was the perfect target for four reasons, Harvey said. First, the plant pours aluminum and molds the part. Second, it has machining. Third, it has assembly. And last, the people in the facility are second to none. That combination made Wabash a winner. Harvey said that his firm was looking for a metalcasting opportunity since 2001 so it could pursue a vertically integrated position. While it had been successful as a machinist only, the firm believes metalcasting could take it to a new level. 巴什的铸造厂, 来补充密西根 Westland 已有的机加工业务 据哈维说, 公司的目标是成为一站式原始设备制造商 铸造给我们提供了控制从原材料一直到最终产品的整个制造过程的机会, 哈维说到, 如果我们能控制从开始到结束整个过程, 我们对消费者会更有吸引力 重回过往的辉煌? 2008 年的前几个月, 沃巴什铸造厂过的日子很好, 当时该工厂属于位于密歇根州 Northville 的全球汽车零部件供应商 Hayes-Lemmerz 沃巴什是一家受汽车零部件市场欢迎的铸造企业, 采用潮模砂专注于生产进气歧管和汽缸盖 该工厂曾经是成长型 技术驱动型的 CMI 国际集团的一名杰出成员, 由于其母公司要着重于提高在车轮业务上的核心能力, 传言这家建立于 1978 年的工厂将要关闭 然而该工厂没有被关闭, 在 2007 年 7 月 3 日, 沃巴什铸造厂成为第一家被哈维实业公司收购的铸造企业 在收购的时候, 雇员的态度立即发生了变化, 工厂管理者 Janet Betzner 说到, 工人积极又乐观, 有了新的生机 我们购买沃巴什因为以下四个原因让它成为了完美的目标, 哈维说到, 首先, 工厂浇注铝铸件, 第二, 它有机加工, 第三, 有组装线, 最后, 企业的人员独一无二 这些因素综合在一起让沃巴什铸造厂成为了赢家 哈维说他的企业自从年开始就已经在寻找铸造的机 46 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

49 The one-stop shop became very fashionable for automotive suppliers in the 2000s and it still remains a very prudent business decision for efficiency, Harvey said. Initially, the Wabash plant served as the corporate headquarters for Harvey Industries. This gave the employees at the plant an opportunity to learn about their new owners face-to-face. We started to see a return to the CMI days in the closeness of the plant to the ownership, Betzner said. It was more of a family atmosphere. The politics of a large global corporation were gone. With Harvey Industries, we are a smaller company with less overhead and more flexibility, said John Ballinger, plant manager, who came to run Wabash after the acquisition by Harvey Industries. We can work with customers on the plant level at a much faster pace, rather than running everything through corporate. During the recession, Wabash bottomed out with production at 30% of capacity and 80 employees. Today, the firm is running at 45% of capacity with 155 employees. It also is expanding with the recent addition of permanent and semi-permanent mold casting to its green sand molding capability. Advancing Operations Since the days when it was owned by CMI International and its iconic leader Ray Witt, the Wabash operation always has had a strong base in casting technology. The plant grew up around its unique cope and drag green sand line. With dual-ladle automated pouring of aluminum into 30 x 34 x 13/13-in. green sand molds, the line achieved speeds of 200 molds/hour. But we always need to become more competitive, Ballinger said. The world is flat, and we have to continue to be more competitive from our quality, costing and production standpoint. This necessity lead to an upgrade on the mold line. When we acquired Wabash, one of our goals was to improve the mold line change time, Harvey said. While we were producing 200 molds/hour, the challenge was to see how nimble we could be to go from part to part. The market volumes have gone smaller, so there is a need for quicker tool changes. 会, 进而寻求一个垂直整合点 作为一家成功的机械公司, 哈维实业相信铸造可以把它带到一个新的高度 一站式厂商在 2000 年左右在汽车零部件供应商界很流行, 而且这仍然是一个精明有效率的商业决定, 哈维说到 开始, 沃巴什铸造厂作为哈维实业的公司总部 这为工厂的员工提供了一个与他们的老板面对面学习了解的机会 我们开始感觉在 CMI 的日子回来了,Betzer 说到, 这更像一个家庭, 大型跨国企业的氛围一去不复返了 和哈维实业在一起, 我们是一家有着更少领导和更大灵活性的小企业, 收购后的沃巴什铸造厂经理 John Ballinger 说到, 我们可以和顾客在同一水平上以更快的节拍工作, 而不是通过公司来决定所有的事情 在不景气的时候, 沃巴什只有额定产量的 30 和 80 名员工 今天, 企业生产达到了能力的 45,155 名员工 近期企业还在扩大, 将增加金属型和半金属型铸造, 和潮模砂型铸造互补 先进的经营自从被 CMI 国际以及它的强有力的领导 Ray Witt 拥有后, 沃巴什铸造厂一直在铸造技术上拥有很强的基础 工厂有独特的上下箱潮模砂生产线 双浇包铝液自动浇注机 30 x 34 x 13/13 英寸砂箱, 造型线生产速度 200 型 / 小时 但是我们永远需要变得更有竞争力, Ballinger 说, 世界是平的, 我们必须继续从我们的质量 成本和生产上保持竞争力 这个需要促成了造型线的升级 当我们获得了沃巴什铸造厂时, 我们的目标之一就是提高造型线模板更换的时间, 哈维说, 当我们以每小时 200 型的速度生产时, 挑战取决 Harvey Industries Wabash, Ind., facility is built around its green sand molding line with automatic dual ladle pouring of aluminum. 哈维实业的沃巴什铸造厂是围绕双浇包自动铝液浇注机和潮模砂造型线建立的 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 47

50 The Wabash facility always has been known for its ability to cast intake manifolds and cylinder heads (top). In addition, Wabash has a strong foothold in value-added services (bottom), with more than 45,000 sq. ft. of the plant dedicated to machining and assembly operations. 沃巴什以其铸造进气歧管以及汽缸盖而闻名 此外, 沃巴什在附加值服务上有很强的优势, 工厂有 平方英尺是用于机加工和装配的 The team at Wabash has worked to improve this. The result is that the mold line now produces 240 molds/hour with a cycle time shortened to 15 seconds. The lower volumes at Wabash were a driving point for adding permanent mold casting to the facility. The tooling cost for the green sand line always has been too high to justify on lower volume components. According to Ballinger, the permanent mold operation will open the plant s doors to new work because of the flexibility it provides. Wabash also has invested $100,000 in its cleaning room and is using existing robots to build a flexible cell for casting gate removal. The new cell serves 12 different part numbers, with a 20-second tooling change time between parts. For an upper and lower intake manifold component with a volume of 220,000/year, the required number of workers for casting cleaning went from 20 to 12 with the new flexible cell. The feeling of the plant from the days of Ray Witt remains, Betzner said. Acquisition Assimilation In the Harvey Industries model, customer interaction occurs at the plant level as every facility is self-sustaining and entirely responsible for its own operations. If there are quality issues, the customer will contact the plant directly, rather than reach out to corporate, Ballinger said. Harvey Industries wants to avoid becoming a top-heavy 于我们可以从铸件到铸件之间可以切换灵敏程度 市场上单一产品产量越来越小, 所以需要更快地更换模具 沃巴什团队为此已经做了很多工作 结果是造型线现在可以每小时生产 240 型, 周期缩短为 15 秒 单一产品批量更小也是工厂增加金属型铸造的原因 对于小批量生产, 潮模砂的模具费用显得很高 根据 Ballinger 的说法, 金属型铸造具有灵活性, 这将为工厂打开一扇新的大门 沃巴什铸造厂也投资了 10 万美元用于清理车间, 使用现有的机器人组成了切割浇注系统的柔性单元 该单元可以处理 12 个不同的铸件, 工具切换时间为 20 秒 有了该单元后, 铸件清理需要的工人数从 20 降低为 12 现在仍然感觉到像当年 Ray Witt 先生在工厂, Betzner 说到 收购的消化在哈维实业的模式里, 在工厂里也有与客户的互动, 每一个工厂都是自主的, 并且为自己的经营负责 如果有质量问题, 顾客可以直接联系工厂, 而不是找集团公司, Ballinger 说到 哈维实业想要避免成为一个上重下轻的组织, 这个问 48 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

51 organization, a problem that plagued several metalcasting groups of the last 20 years. We are trying to stay with the fundamentals, Harvey said. As the corporate parent, we could grow our overhead too much, strain the business and not contribute to the bottom line. We need to keep our overhead lean, mean and trim and keep the bottom line strong. The firm relies on each of its plants to remain individually solvent. 题在过去的 20 年困扰了几个铸造集团 我们正在竭力保持这一基本原则, 哈维说, 作为母公司, 我们本可以增加普通管理成本, 着重于业务, 而不关注底层 但是, 正确的做法是减少管理费用 加强底层 公司依赖每一个工厂来保持经营的独立性和解决问题的能力 Harvey Industries growth in the metalcasting industry has been focused in two areas increasing its claim as a onestop shop and diversifying its business. In June 2010, the firm took its second step into metalcasting when it acquired another former subsidiary of Hayes Lemmerz International the aluminum and polymer component plant in Nuevo Laredo, Mexico. The facility employs 350 and is focused on the automotive and commercial vehicle industry. We are seeing similarities in all of our acquisitions to date, Harvey Industries CEO Jerome Harvey said. We are taking over firms that the previous owner believed wasn t in their core strategy. We have been willing suitors and are a company with one vision and one goal. The employees in these companies are receptive to our singular drive because they often have been dealing with changing models. In February 2011, in a move aimed at diversifying its casting business, Harvey Industries acquired the assets of R.E. Phelon Co., Inc., Aiken, S.C., through its wholly-owned subsidiary Harvey Industries Die-Casting LLC. The 130-employee aluminum diecaster is focused in the lawn and garden, power generation, commercial lighting, appliance and industrial markets. Like most human tendencies, we lean toward our strong suits. I grew up in the automotive industry and my best education was at General Motors, Harvey said. But we are making a concerted effort to diversify our business. The diecasting acquisition was 80% nonautomotive. While we are not turning our back on automotive by any stretch of the imagination, we do want to diversify. According to Harvey, the goal for the firm is to reach 40% automotive and 60% nonautomotive sales. Growth Beyond Wabash 沃巴什之外的发展 哈维实业在铸造行业的发展着重于两个领域 : 强化其作为一站式厂商以及业务的多元化在 2010 年 6 月, 公司进行了进入铸造领域的第二步, 收购了另一家原本为 HayesLemmerz 国际的工厂 墨西哥州 Nuevo Laredo 的铝和聚合物工厂 该公司雇佣了 350 人, 专注于汽车和商业车辆行业 在所有的收购中我们都可以看到相似的地方, 哈维实业的首席执行官哈维说到, 我们接管那些不被前老板认为是核心战略的工厂 我们的观点和目标一致 工厂里的员工接受我们简单明了的驱动力, 因为他们以前经常要疲于应付各种不同的模式 在 2011 年 2 月, 在一个旨在铸造业务多元化的行动中, 哈维实业通过它的全资子公司哈维压铸有限责任公司收购了南卡莱罗纳州艾肯的 R.E.Phelon 公司的资产 该公司有 130 名工人, 专注于草地花园 发电机 商业照明 家电和工业市场的铝压铸件生产 同大多数人类趋势一样, 我们向我们的强项倾斜 我在汽车行业长大, 我受到的最好的教育是在通用汽车, 哈维说到, 但是, 我们正在努力实现业务的多元化 收购的压铸厂 80 和汽车行业无关 我们不想将其改到汽车行业, 我们希望业务多元化 根据哈维的说法, 公司的目标是销售额中汽车行业占 40%, 其它占 60% This addition was intended to help the firm diversify its business away from automotive. 这段附加是用来介绍公司在汽车业务之外开展多元化的业务 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 49

52 When Harvey Industries acquired Wabash, one of the first initiatives was to increase mold production and flexibility. The line has grown from producing 200 molds/hour to 240. 當哈維行業收購沃巴什, 第当哈维实业收购沃巴什时, 动机之一就是增加造型效率和灵活性 生产线的产量从 200 型 / 小时增加到 240 型 / 小时 When companies are purchased by investment firms, profitability and political situations often can win out, Ballinger said. Jerome Harvey is a different leader. He wants us to run the business. Instead of setting out an edict to new acquisitions on day one, we tell them that we are going to work hard for them. We are responsible to you as an employer, Harvey said. In response, we ask that you are responsible to us as an employee. It is simple, straight to the point. While Harvey went on to point out that the firm has a strong set of metrics that are rolled out to the plant, it isn t all in the numbers. We have aggressively made acquisitions, so we have always had a changing seafront, Harvey said. Our competition is in other parts of the globe. There are certain things we can t be, but we must continue to challenge ourselves to be competitive in the marketplace. You can lose your shirt today by simply taking your eye off the ball for a short period of time. You have to stay focused on the point of sale today and tomorrow. For Ballinger and the rest of the team at Wabash, this corporate support is invigorating. As the first casting acquisition, Wabash has served as the big brother to the two more recent casting facility acquisitions. As Harvey Industries works to harmonize the various management systems across plants, the Wabash facility is a key stabilizer. We entered the casting market at a reasonably good time, Harvey said. We started on an upswing. The economy has not been the best to metalcasting, but this is the sort of job or career that you have to enjoy what you are doing or you are in trouble. I enjoy what I am doing. To receive this digital magazine in the future, go to 当公司被投资公司收购时, 通常可以得到盈利和政策形势, Ballinger 说, 但是, 杰罗姆 哈维是一个不同的领导, 他希望我们自己来经营业务 收购后的第一天不是向他们发布指令, 而是告诉他们我们将为他们努力工作 作为雇主, 我们对你们负有责任 哈维说到, 相应地, 我们要求你们作为雇员需要对我们负责任 就应该这样简单明了 然而, 哈维继续指出, 公司还有为工厂制定的一系列规章 我们已经强势地做了收购, 所以我们已经有了一个变化中的海岸, 哈维说到, 我们的竞争是在世界的其他地方 有些事我们做不到, 但是我们必须继续在市场中挑战自己 今天, 在眨眼的瞬间你就可能丢掉你的 T 恤, 因此你必须紧盯今天和以后的销售 对于沃巴什铸造厂的 Ballinger 以及团队里其他的人, 这个合作是爽快的 作为第一次收购的工厂, 沃巴什已经成为两个最近铸造铸造厂的 大哥哥 哈维实业尽力要平衡工厂之间不同的管理系统, 沃巴什显得非常重要 我们在一个合适的时机进入了铸造行业, 哈维说, 我们始于业界的上升期 目前对铸造来讲经济还不是最好, 但是这是那种需要你不得不去享受你所做的以及你遇到的困难的事业 我喜欢我在做的一切 如果您想订阅我们的数字杂志, 请登陆 50 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

53 New Angles Emerge in Matchplate Molding 双面模样造型出现新趋势 Steps for measuring mold hardness and machine mismatch are shared in this article. 通常 下列参数可能引起机器相关的失配. michael colditz, engineer, disa industries a/s, herlev, denmark Michael Colditz 工程师 迪砂工业公司 丹麦海莱乌市 H orizontally-parted, flaskless molding systems based on matchplate technology have been around for many years. Outside Europe, they are one of the most popular molding processes. The matchplate process employs pattern plates with patterns mounted on both sides. The dimensions, such as 28 x 32-in. (711 x 813-mm) indicate the dimensions of the pattern plate in the parting line of the mold. The molding machine works with the mold push out principle, meaning in the area of minimum mold thickness of 225 mm in each case, both molds have a conicity of 4 degrees in order to facilitate an error-free edge of the mold out of both chamber flasks. The flexible areas of the mold heights from 225 to 300mm (cope) and 225 to 350mm (drag) work in parallel in order to enable free height adjustment of the squeeze plate. The available top surface of the mold is reduced correspondingly, so placement of the pouring cup (downsprue position) and ventilation holes is possible in an area of 688 x 788 mm. After bringing together both mold chambers together with the pattern plate, the system is turned 90 degrees to face the sand hopper. The position of both sand shot slots is designed to give optimal distribution of sand during the sand shot and avoid undue wear of the pattern. The depth of 基 于双面模样技术的水平分型无箱造型系统 已经有很多年的历史了 在欧洲以外 这 是最常用的造型工艺之一 双面模样工艺用到每侧都安装模样的型板 例如 28 x 32 (711 x 813 mm)这样的大小 表示的 是分型面处型板的尺寸 造型机按照 推出砂型 的原则工作 意味着在砂型最小厚度225mm的区域 里 每个砂型都有4度的锥度 砂型的高度变化范围为 225mm~300mm 上型 和225~300mm 下型 上型和下型并行工作来保证挤压板高度的调整 砂型的 上表面相应减小 因此浇口杯 直浇道位置 和通风孔 可以安排在688 x788mm的区域里 将两个砂型和型板连接后 系统旋转90度 以对准 砂斗 射砂孔的设计是为了实现砂子的均匀分布 并且 避免模样的过度磨损 通过计算得到的在最大压缩25 的情况下的砂型内腔的深度 无箱造型工艺总是和低的型板利用率和大的边缘距 Fig. 1. Mold harndess measurement points are shown. Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 图1 砂型测量点 51

54 Fig The matchplate castings from Benton Foundry exhibit clean parting lines. 图 2-3 本顿铸造的双面模样铸件显示出非常清洁的分型面 the mold chamber is calculated to achieve maximum mold thickness after 25% compressibility. Flaskless molding processes are constantly associated with low pattern plate utilization and larger edge distances (compared to flask line technology). The main thing is to ensure a stable mold surface to prevent mold collapse and a comfortable distance to avoid mold breakage. Assuming a total pattern height of 200 mm with a casting module of 0.6 mm, a tight-fitting jacket would enable a distance-to- Mold Edge A of around 61 mm and to Mold Edge B of around 80 mm. Iron casting facilities also must consider the sand to iron ratio. A ratio of 5:1 or greater is needed to avoid undue impact on mold quality. Consistent metal/sand ratio can be facilitated by the possibility of height adjustment of the cope and drag mold. Benton Foundry, Benton, Pa., conducted a mold hardness test using an active pattern in its matchplate molding production process in September Rather than perform a scientific series of experiments, Benton simply collected values from practice in a representative test. A mold was measured at 15 points in the upper and lower blocks. In the subsequent molding process, measurements were repeated in a random check manner in the same position. The test revealed mold hardness remained extremely constant, varying only at one point in 80% of measurements. The measurement points were situated about 2 to 3 cm from the mold edge (Fig. 1). As in most patterns sand shot pressure of 2.0 kp/ cm 2 and a squeeze pressure of between 4.0 to 4.5 kp/ mm 2 was used. A Ridsdal-Dielrt Green Hardness B Scale was used 离 ( 相对于有箱造型 ) 联系在一起 最主要的是要确保稳定的砂型表面以防止砂型崩溃, 以及确保合适的距离以避免砂型断裂 假设某模样总高度为 200mm, 铸件模数为 0.6mm 的模样, 密封套要保证到砂型 A 边缘要有 61mm, 到 B 边缘 80mm 铸铁厂还必须考虑砂铁比 比值至少为 5:1, 以避免对砂型质量造成不必要的影响 一致的金属 / 砂子比, 可以通过调整上型和下型的高度来实现 宾夕法尼亚州的本顿铸造厂在 2011 年 9 月测量了砂型硬度, 在它的双面模样造型生产过程中使用了主动模样 本顿工厂只是简单地收集了实践具有代表性的测试值, 而不是进行科学的系列实验 在同一个砂型的上 下型上测量了 15 个点 在随后的造型过程中, 用随机检查的方式对这些位置进行重复测量 测试表明, 砂型的硬度非常一致, 仅仅有一个点的波动为 80% 测量点在砂型边缘 2-3mm 的位置 ( 见图 1) 和大部分模样一样, 使用的射砂压力为 2.0kp/cm2, 挤压压力在 Kp/mm2 之间 采用 Ridsdal-Dielrt 潮模砂 B 型硬度计测量砂型的硬度 该硬度计是美国开发的, 在美国, 砂型通常在振实造型和双面模样造型情况下更软一些 这台 DISA Fig Mold hardness measurement points were taken. 图 4-5 砂型的硬度测量点 52 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

55 Table 1. Summary of Mold Hardness Test Results in Copenhagen 表 1 哥本哈根的砂型硬度测试结果概括 Test Mold thickness Shot squeeze pressure Squeeze pressure Average hardness Difference 测试 砂型厚度 射挤压力 挤压压力 平均硬度 差异 In flask 砂型内 Outside 砂型外 ,1 18,9-0,2 softer 较软的 ,0 21,6 0,4 softer 较软的 ,8 20,2-0,6 softer 较软的 ,3 20,5-0,8 softer 较软的 ,6 20,2 0,6 harder 较硬的 to test the mold hardness. This mold hardness scale was developed in the U.S., where molds are generally softer in jolt-squeeze and matchplate machines. The squeeze pressure of DISA MATCH can be continuously adjusted between 3.0 and 10.0 kp/cm 2, and shot pressure continuously adjusted between 0 and 4.5 kp/cm 2. Thus, the pressures used by the casting facility lie in the lower region of recommended settings. Figures 2 and 3 show castings after shot blasting, without further finishing. The extremely clean parting lines are worthy of particular note. As a result of the practical tests conducted at Benton Foundry, a series of mold hardness tests was performed at the DISA facility in Copenhagen, Denmark, using a DISA MATCH 24/28. The aim was to test mold hardness with a shot pressure of 3.0 kp/cm 2 and a squeeze pressure of 8.0 and 10.0 kp/cm 2 and determine the effect on mold hardness outside the chamber flasks. The test was conducted using an even pattern plate and mold thickness of 190 and 255 mm in order to test the effect of variable mold heights as well. Starting 40 mm from the mold edge, 25 measurement points were distributed evenly over the mould surface using a template that was placed on the molds in order to ensure a constant measurement position (Figs.4 and 5). After mold hardness had been measured in the chamber flask, the mold was removed and destroyed. The next mold was produced, pushed out and taken apart again outside the machine. This was repeated three times with a shot pressure of 3.0 kp/cm 2 and a squeeze pressure of 8.0 kp/cm 2 with a mold thickness of 190 mm. The process was repeated again three times with a shot pressure MATCH 的挤压压力能在 Kp/mm2 之间连续调整, 射砂压力在 0-4.5Kp/mm2 之间 因此, 铸造厂使用的压力处在推荐值的下部区域 图 2 和 3 显示的是喷丸后的铸件, 尚未精加工 请注意分型线很干净 受本顿铸造实际测量的影响, 在丹麦哥本哈根,DISA 公司使用 DISA MATCH24/28 进行了一系列的砂型硬度测试 其目的是测试射砂压力 3.0 kp/cm2 挤压压力 8.0 和 10.0 kp/cm2 下砂型的硬度, 并确定其对砂型硬度的影响 为了同时测试不同砂型高度的影响, 也测试了一个平模样, 厚度分别为 190mm 和 225mm 从砂型边缘 40mm 处开始,25 个测量点在砂型表面平均分布, 并用在砂型上放置模样来保证测量点固定 测量砂型内腔硬度之后, 移走砂型并毁掉 制造下一个砂型, 压出, 并再次在造型机外分开 接下来重复三次, 压射压力为 3.0 kp/cm2, 挤压压力为 8.0Kp/mm2, 砂型的厚度为 190mm 之后再在注射压力 3.0 kp/ cm2, 挤压压力 10.0 kp/cm2 和砂型厚度 190mm 下重复三次这个过程 最后, 进行同样的测试, 注射压力 3.0 kp/cm2, 挤压压力为 10.0 kp/cm2, 和 255 毫米的砂型厚度 ( 见表 1) 不同于美国的铸造厂, 一般用的挤压力都比较高, Fig Iron and aluminum metalcasting facilities may insert chills and risers into the mold to aid solidification. 图 6-8 铁和铝的铸造厂通过向砂型中添加冷铁和冒口来促进凝固 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 53

56 Table 2. Mismatch Measurement Results 表 2 不匹配的测量结果 A B A B Number of molds 砂型数 (3) (9) (3) (9) (6) (12) (6) (12) Mismatch 不匹配 (3-9):2 or (6-12): Average 平均 Region 区域 of 3.0 kp/cm 2, a squeeze pressure of 10.0 kp/cm 2 and a mold thickness of 190 mm. Finally, the same test was conducted with a shot pressure of 3.0 kp/cm 2, a squeeze pressure of 10.0 kp/cm 2, and a mold thickness of 255 mm (Table 1). A considerably higher squeeze pressure was used in contrast to production at the American metalcasting facility, obviously resulting in a correspondingly greater hardness. Whether this mold hardness is necessary for the production of high-quality castings is a question to be answered from case to case. The terms softer and harder should pertain to the condition of the mold after it has been pushed out. The difference in mold hardness inside and outside the molding machine falls within the tolerance of the measurement. Stability remains stable after leaving the molding machine. In order to achieve further stabilization, the molds are mounted with a jacket in the parting line area prior to pouring. The jacket stays mounted on the mold during solidification. In iron casting facilities in particular, 形成相应更高的硬度 对于生产高质量的铸件, 这样的砂型硬度是否有必要依然是一个需要回答的问题 较软 和 较硬 应该涉及到砂型已被压出后的条件状况 砂型在机器内 外的硬度差在测量能够容忍的范围内, 离开造型机后平稳性依然保持很好 为了获得更好的平稳性, 砂型分型线区域在浇注前安装了一个保护套 凝固过程中保护套仍旧安装在砂型上 特别地, 在铸铁厂以及大部分铝工厂里, 砂型的重量是最重要的, 这保证了和其它任何自动砂型成形一样的近净成形过程 铸造人员也可以在砂型中加入冷铁和冒口 ( 见图 6-8) 造型机相关的失配虽然各种造型机的尺寸和速度各不相同, 有一点是总 Fig. 9. Mismatch is shown here as steps in the parting line. 图 9 分型线中的失配 54 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

57 as well as in most aluminium plants, a mold weight is placed on top of the mold. This ensures a near net shape casting in the same way as in any other automatic moulding processes. Metalcasters may also insert chills and risers into the mold (Figs. 6-8). Machine-Related Mismatch While dimensions and speeds of various molding machines vary, one thing is always the same machinerelated mismatch. But what does this mismatch actually mean? Defects in finished castings can arise from an imprecise fit between parted patterns, molds and core boxes. This gives rise to steps, or a mismatch in the mold parting line (Fig. 9). In general, the following parameters may cause machine-related mismatch: Malformed pattern plates. Wear and tear of pins and sockets. Imprecise alignment of the molding machine with the pouring and cooling line. Heating plates that are not parallel. Imprecise alignment of bottom wearplate and mold transport. Worn or badly adjusted swing plate movement. Worn guidance columns and bearings. Wrongly aligned guide rails. Wrongly aligned squeeze plate guide blocks. Test ring pattern plates have been used to measure machine-related mismatch. Two rings are molded and poured with the relevant gating. The ring thickness in at the 3 o clock, 6 o clock, 9 o clock, and 12 o clock positions is measured, and the difference between both sides determined. The mismatch measurement takes place in the following steps: Cleaning of the surfaces prior to mounting. Mounting of the ring pattern plate(s) in compliance with markings. Adjustment of chamber depth to the corresponding depth of ± 5 mm. Production of three molds and normal pouring. Marking of the three poured molds. Changeover to normal production and usual molding and pouring of necessary production. New changeover to the ring pattern plates and production and marking of three additional poured molds. Removal of test rings prior to shakeout. Numbering of the six sets in order of production and subsequent cleaning as in production. The rings are measured in the 3 o clock, 6 o clock, 9 o clock, and 12 o clock marking regions. The results are presented in a table (Table 2). The difference divided by two gives the horizontal and vertical mismatch. To receive this digital magazine in the future, go to 是相同的 机器相关的失配 但是这种不匹配究竟是什么意思? 铸件成品的缺陷是拆开的模样 砂型和芯盒的匹配不好造成的 这是由台阶或砂型的分型面 ( 图 9 ) 的不匹配造成的 通常, 下列参数可能引起机器相关的失配 : 模样有问题 定位销和套的磨损和撕裂 造型机和浇注和冷却线不对中 加热板不平行 底部抗磨板和砂型的搬运不匹配 摆动板的磨损 导柱和轴承磨损 导轨没有对准 挤压板定位块排列错误用环形测试模样测量机器相关的失配 造型, 并浇注两个环来测定失配 图 展示了一套 DISAMATIC 模板的测试位置在 点钟方向 然后测量 点钟位置环的厚度, 确定两边的差别 失配的测量发生在以下步骤 : 1. 安装前的表面清洁 2. 对照标记安装环的模样 (S) 3. 型腔深度调整到相应尺寸, 偏差 ±5mm 4. 造 3 个砂型, 然后浇注 5. 标记三个浇注的砂型 6. 切换到正常生产和通常造型和浇注过程 7. 转换回环形模样和造型和标记三个件 8. 落砂前移走测试环 9. 按照生产顺序对 6 个环进行编号, 以及生产过程后的清洗 10. 在标记的环 3 点钟 6 点钟 9 点钟和 12 点钟位置测试 11. 结果如表 2 所示差异显示出了水平和垂直的失配情况 如果您想订阅我们的数字杂志, 请登陆 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 55

58 product news/ 產品新聞 MetalTek Division Improves Crucible Performance, Service Life MetalTek 公司分部提高坩埚性能和使用寿命 Southern Centrifugal, a division of MetalTek International, Chattanooga, Tenn., was experiencing poor crucible performance and abbreviated operational life. Combining centrifugal, investment, sand and continuous casting operations, MetalTek operates eight international facilities serving customers in more than 25 countries. The company could not afford the continued operational downtime and lack of quality it was experiencing with its existing crucibles. Southern Centrifugal melts 30 different alloys aluminum bronze, red brass, manganese bronze and monels, as well as high-leaded, proprietary alloys in its manufacturing process. Side wall erosion often took its crucibles out of service, sometimes after as few as 17 days. Depending on the alloy, the average service life was less than 40 days. Melting and holding or melting and tapping applications were eroding the walls even faster. This led to excessive downtime for crucible replacement, as well as a lack of consistent quality in melting and casting operations. As the Southern Centrifugal team investigated maximizing its melting profitability, it realized crucibles were only a fraction of the overall cost. Backing material, top cap, grout, freight, labor and downtime made finding a longer lasting crucible vital to maintaining competitiveness. The solution came from MorganMMS and its Z2 Syncarb crucible. The Z2 Syncarb crucible is a high pressure, isostatically pressed, hybrid SiC/clay-graphite crucible that achieves optimal life when melting copper and copper alloys in induction and gas fired furnace applications. Metaltek found the Z2 offered significant advantages in energy efficiency, higher thermal conductivity and prolonged service 南方离心铸造, 是位于田纳西州查塔努加市 MetalTek 公司的一个分部, 一直经历糟糕的坩埚性能和缩减的运行寿命 MetalTek 公司兼有离心铸造 熔模铸造 砂铸和连续铸造, 运营 8 个国际化的工厂, 服务超过 25 个国家的客户 这家公司再不能承受持续的停机和所经历的劣质坩埚 南方离心铸造熔炼 30 种不同的合金 -- 铝青铜, 红色黄铜, 锰青铜和蒙乃尔合金等, 以及高铅和根据工艺定制的特种合金 侧向浸蚀经常令坩埚报废, 有时只有 17 天 根据合金, 平均使用寿命不到 40 天 熔炼和保温或熔炼和除渣的交替使坩埚被侵蚀的甚至更快 这导致了过多坩埚更换和铸造业务的停机时间, 熔炼和铸造缺乏稳定的质量 经过南方离心铸造团队调查, 使其熔炼部门盈利最大化, 发现坩埚只占整体成本的一小部分 而炉衬材料, 顶盖, 灌浆, 运费, 劳动力和停机产生的成本, 使得找到一个较持久的坩埚, 以保持竞争力至关重要 解决方案来自摩根熔炼系统公司的 Z2Syncarb 坩埚 Z2Syncarb 坩埚是一个高压力, 等静压, 混合碳化硅 / 粘土的石墨坩埚, 达到最佳使用寿命的熔化铜及铜合金, 可在感应和气体燃炉中应用 MetalTek 公司发现 Z2 在能源效率, 更高的热传导和延长使用寿命方面提供了显着的优势 凭借其广泛的质 MorganMMS Z2 Syncarb crucibles are isostatically pressed hybrid SiC/clay graphite crucibles for melting copper-base alloys. 摩根熔炼系统公司的 Z2Syncarb 坩埚是等静压, 混合碳化硅 / 粘土的石墨坩埚, 适用于熔炼铜合金 56 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

59 product news/產品新聞 图1 在其三个2,000磅感应 炉 熔炼铅青铜合金 炉1 铝和锰青铜 炉2和3 摩根熔炼系统公司的Z2Syncarb坩埚优于MetalTek公 司以前使用的坩埚 数据由 MetalTek公司提供 Fig. 1. The MorganMMS Z2 crucibles outperformed MetalTek s previous crucibles in its three 2,000lb. induction furnaces for leaded bronze alloys (furnace 1) and aluminum and manganese bronzes (furnace 2 and 3). Data provided by MetalTek International. life. Using its extensive quality control process, MetalTek gathered significant amounts of data related to the campaign life of its crucibles with various alloys (Fig. 1). We ve experienced a very dramatic improvement in average crucible life with Z2 crucibles versus other products used in the past two times the life, in fact, said Carl Bednark, metallurgical engineer for MetalTek. We expect the Z2 Syncarb to have a major impact on our operations. Visit for more information. 量控制过程 MetalTek公司收集各种合金的坩埚使用 寿命的相关数据 图1 其实 我们已经经历了一个非常引人注目的改 善 两次使用Z2坩埚的平均使用寿命与其他产品坩埚 比较 MetalTek公司的冶金工程师卡尔 贝德纳尔 克说 我们预计Z2Syncarb坩埚对我们的业务有重 大影响 更多信息请访问 Increase Casting Quality and Reduce Finishing Room Costs 提高铸件质量 降低加工车间成本 Fluctuating raw material prices, increasing labor wages, and the ever-changing growth rates of specific casting buyer target markets present what can best be described as a moving target that requires managers to have good aim as well as the ability to change weapons at a moment s notice. Many of these profit-driving variables are beyond the control of a metalcasting facility, but inward-looking metalcasters who successfully discover ways to reduce internal costs can reap immediate benefits through enhanced competitiveness. One of the more time and energy consuming areas for any metalcasting facility is the finishing room, which often can comprise upwards of 40% of the total production cost of a casting. Regardless of the type of alloy, metalcasting process, or size, the feeding and gating must be removed from the casting in some way. Some smaller, but competitive casting producers (along with a surprising number of some of the largest) have embraced the use of a variety of high temperature capable filter mesh fabrics to serve the dual-role of molten metal filter and casting de-gating aid. Filter mesh material is particularly 波动的原材料价格 不断提高的人工薪酬 以及 特定铸件采购目标市场瞬息万变的成长率 都只能 说明 作为一个不断移动的目标 不仅需要经理人们 有一个准确的目标 同样需要具备马上更换设备的能 力 这些可变的利益以及超出铸造厂的控制 但是内 向的铸造人 成功的发现了通过增强竞争力 获得直 接利益来降低内在成本的方法 对任何铸造厂来说 加工车间是占有更多时间和 能源的区域之一 通常占铸件生产总成本的40%以 上 无论何种金属类型 工艺 或尺寸 浇冒口一定 要从铸件上去除 一些规模较小 但有竞争力的铸件 生产商 以及与一些数量惊人最大规模的 已经接受 了各种耐高温过滤网的使用 即过滤熔融金属 和铸 件的浇注援助的双重作用 过滤网材料在具有成本意 Fall 2012 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION 57

60 product news/ 產品新聞 Traditional foundry finishing room techniques can constitute up to 40% of a casting s cost. 对任何铸造厂来说, 加工车间是占有更多时间和能源的区域之一, 通常占铸件生产总成本的 40% 以上 attractive among costconscious metalcasters because it does not require significant up-front capital investment in manual cutting equipment and additional personnel. However, casting professionals are required to learn the technology and develop practical application knowledge of the filter mesh materials in filtering and de-gating roles. Existing Material Solutions Many sand casting facilities use flat cut pieces of either silica mesh or fiberglass mesh material by placing them in various sections of their gating network (base of the downsprue, mid-way in runners, and particularly at end casting in-gates) to capture slag and inclusions, reduce feed turbulence and create break points where desired. These break-points or cleavage planes are typically the same areas formerly targeted for manual cutting, but are more easily separated with less impact. The use of fiberglass mesh is limited to aluminum casting due to its relatively low temperature capability. Metalcasters pouring higher temperature alloys and cast metals such as iron may employ resin-stiffened silica mesh material that can withstand average pouring temperatures of approximately 1,565C. Other application parameters include overall pouring weight, filter meshto-alloy contact area dimensions, and pouring time. As a general rule, the larger the alloy flow-through or contact areas of the filter mesh, the less the overall pouring weight and exposure time should be. Otherwise, the risk of the filter mesh breaking through or deflecting too far in the direction of molten metal 识的铸造者之间特别受欢迎, 因为它不需要手动切割设备和额外的人员的前期资本投资 然而, 铸造专业人士需要学习滤网材料的技术和开发实际应用知识在过滤和浇注中的作用 现有材料的解决方案 许多砂型铸造厂使用薄片式的二氧化硅滤网或玻璃纤维滤网, 通过把他们放置浇注系统各个部分 ( 直浇口, 中间浇道, 尤其是浇注系统末端 ) 来除去渣和夹杂物, 降低浇注波动, 在需要的地方创造断点 这些断点或裂开面与以前通常的手工切割有针对性的同一区域, 但冲击较小, 更容易分离 玻纤网格布的使用仅限于铝铸件, 由于其相对较低的耐高温能力 浇注工浇注温度较高的金属和高温合金, 如铁, 可以使用合成树脂加强的二氧化硅网状材料, 可承受平均浇注温度约为 1565 其他应用程序的参数包括整体浇注重量, 滤网合金接触面积尺寸和浇注时间 作为一般规则, 合金流过或过滤网的接触面积越大, 整体浇注重量和接触时间应该越短 否则, 滤网断裂或在熔融金属的流动方向偏转太远的风险大幅度增长 CerraFlex used in a ductile iron application, showing a flat cleavage-plane (breakoff point) that separated with only the impact of a shop hammer. Later cross-section examination of the incoming flow side of the CerraFlex filter showed a small amount of captured slag as well. CerraFlex 为大部分铸造合金和金属开发, 包括钢, 铸铁, 铝, 铜合金和其它合金 58 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

61 product news/ 產品新聞 Custom cut shapes of CerraFlex (aka CerraBreakers ) are fitted to the ingates of a core prior to casting. To the right is a standard (control) core for the same casting. 具有更广泛的过滤熔融金属滤网材料, 更加紧密地匹配铸造的具体应用参数, 可以减少清理车间的成本和提高铸件质量 flow grows considerably. Once staff gains experience in using a filter mesh material with their own specific application variables, the benefits of additional metal filtration, reduced in-mold turbulence and far easier degating become evident and measurable. Both fiberglass and silica mesh filter material are limited in their ability to handle significant molten metal throughput, and when that limit is pushed, deflection or bulging in the direction of molten alloy flow can occur, resulting in a non-flat cleavage plane requiring additional machining to correct. As a consequence, metalcasting facilities with demanding applications that fall outside the capabilities of either material have had to rely on standard finishing room practices and other molten metal filter types until recently. Emerging Developments Two new filter mesh technologies have been developed by Comanche Technologies, Downington, Pa., that effectively extend these de-gating and filtration techniques to metalcasting applications previously beyond the capabilities of standard fiberglass and silica mesh. CerraGlas is a proprietary ceramic-compounded fiberglass mesh specifically designed for advanced aluminum casting applications that is significantly stronger (reduced chance of break-through or deflection of material, resulting in a flat cleavage-plane when de-gated) and provides an average 20% increase in pouring temperature capability. CerraFlex was developed for use with most cast alloys and metals, including steels, cast iron, aluminum, copper-based alloys and more. Capable of withstanding pouring temperatures of up to 1,871C, CerraFlex provides the highest rigidity and strength cur- 一旦员工获得用自己的特定应用滤网材料的经验, 金属过滤额外的好处, 降低了模具的更换和容易得多的去除浇注系统成为明显的, 可衡量的 玻璃纤维和二氧化硅滤网材料在他们的处理能力显着的熔融金属生产量有限, 限制推时, 在合金熔体流动的方向, 偏转或胀箱可能发生, 导致非平面的断裂面, 需要额外加工纠正 因此, 铸造厂不得不依靠标准的做法要求苛刻的应用以外, 任何材料的能力范围和其他熔融金属过滤器类型, 直到最近 事态发展两个新的过滤网技术被位于宾夕法尼亚州唐宁镇的 Comanche Technologies 公司成功开发, 功能超出以前的标准玻璃纤维和和二氧化硅滤网, 有效地扩展这些去浇口和过滤技术在铸造应用 CerraGlas 是陶瓷复合的玻纤滤网, 专为先进的铝铸造使用, 显著增强 ( 降低材料断裂或偏移的几率, 在去除浇注系统时获得一个平面 ), 并能平均提高 20% 的浇注温度 CerraFlex 为大部分铸造合金和金属开发, 包括钢, 铸铁, 铝, 铜合金和其它合金 CerraFlex 浇注温度高达 1871, 在目前熔融金属滤网材料中承受能力, 刚性和强度是最高的 铸造厂, 这些改进 The flat cleavage-planes or break-off points provided by the CerraBreakers are easily visible as highlighted on the end casting. The feeder-gating actually fell off on its own while the casting was being transported to the shakeout area. CerraFlex 浇注温度高达 1871, 在目前熔融金属滤网材料中承受能力, 刚性和强度是最高的 铸造厂, 这些改进转化为更大的过滤材料的接触面积, 较重的浇注重量, 金属和合金的范围更广, 可以过滤和更容易的去除浇注系统 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 59

62 product news/ 產品新聞 rently available among molten metal filter mesh materials. For metalcasting facilities, these improvements translate into larger filter material contact areas, heavier pouring weights, and a much wider range of alloys and cast metals that can be filtered and more easily de-gated. Having a wider variety of molten metal filter mesh materials available to more closely match a metalcaster s specific application parameters can greatly improve its chances of reducing cleaning room costs and improving casting quality. However, such internal efforts must receive strong management support, and testing of new de-gating techniques and filter mesh materials should be conducted and tracked to ensure they are meeting the cost reduction and performance expectations of everyone involved. Metalcasters should expect and receive strong technical product and application support from their suppliers in these initiatives. Experienced metalcasting procurement managers usually pose a bona-fide technical application question when screening a potential new supplier that goes beyond simple recitation of marketing literature or website bullet points and requires the supplier to show a basic familiarity with metallurgical processes related to filtration and de-gating. The quality and thoroughness of the answer will reveal far more about what the foundry can expect from that supplier in the future, aside from low-priced filter mesh. Visit for more information. 转化为更大的过滤材料的接触面积, 较重的浇注重量, 金属和合金的范围更广, 可以过滤和更容易的去除浇注系统 具有更广泛的过滤熔融金属滤网材料, 更加紧密地匹配铸造的具体应用参数, 可以减少清理车间的成本和提高铸件质量 然而, 这种内部的努力必须得到强有力的管理支持, 并测试新的浇注技术和滤网材料, 进行跟踪, 以确保它们满足降低成本和涉及每个人的业绩预期 铸造从业者应该期望和接收雄厚的技术产品和应用, 从他们的供应商在这些举措的支持 资深铸造采购经理筛选潜在的新的供应商, 超出了简单的背诵营销文献或网站的要点, 并要求供应商显示基本熟悉冶金工艺与过滤和反门时, 通常构成了真正的技术应用问题 答案的质量和完整性, 就会发现远远铸造可以从该供应商期望在未来, 除了低价滤网 更多信息请访问 : Heat Protection Clothing Meets Highest Safety Standards 热防护服达到了最高安全标准 JUTEC GmbH Heat Protection GmbH, Oldenburg, Germany, specialist for heat and work protection, has worked closely together with the aluminum industry to develop an aluminized heat protection fabric for clothing when exposed to hot, higher radiation heat or light aluminum sparks. The basic material is very light and gives the clothing, even when aluminized, a soft textile character. Hours of high wear comfort along with work security are the results. Jutec is one of the first companies in the heat protection sector to have its fabrics certified with the new DIN EN ISO standard that has replaced the old DIN EN 531. JUTEC GmbH s aim is to give metalcasters an optimal solution for their extremely difficult work area. During tapping or measuring of temperatures, workers should wear aluminized clothing Typical damage of some protective clothing includes aluminum foil peeling away, leaving the employee with no protection. 德国奥尔登堡的 JUTEC 热防护有限公司是热防护专家, 一直与铝行业密切合作, 开发了一种铝热防护服面料, 用以在直接暴露热源 高热辐射以及铝液飞溅情况下的防护 使用的主体材料很轻, 因此, 即使镀铝, 衣服仍然很柔软, 长时间穿着舒适并且保证工作安全 JUTEC 是首批面料获得热防护部门推行的新 DIN ENISO 标准认证的公司之一, 取代了旧的 ENISO11612 JUTEC 公司的目标是为铸造工人解决在极端艰苦的环境下工作的问题 在出钢液或者测量温度的时候, 工人需要从头到脚穿上镀铝的衣服来避免烧伤或灼伤 然而, 这些衣服笨重 呆板 僵硬 防护服的一些典型损害包括铝箔, 剥离, 留下的员工没有保护 60 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

63 product news/ 產品新聞 from head to toe to protect against temperature and contact heat. But, during their work, metalcasters have to cope with clothing that is heavy, inflexible, stiff and constrictive. JUTEC has analyzed these situations in many metalcasting facilities and tested several materials in order to make light, flexible heat protection clothing available to workers in the industry. Priority is employee safety and the best possible comfort fort the wearer. For instance, a worker in an iron casting facility may during his normal function, walk over blistering waste. The waste is so hot, even wearing special shoes with special heat protective soles could have lead to harm and even burns on the feet. Workers have tried various types of shoes for many different work situations. All of these shoes proved to be defective and in some cases lead to foot injuries. Working together with JUTEC, a new special gaiter for the covering of the feet and shoes has been developed. The gaiters protect the complete shoe, and the sensitive sole is protected by an extremely cut and heat resistant material. The gaiters are made of a combination of very flexible aluminum fabric and a cut resistant material. Following certification in November 2008, Jutec s new, innovative and flexible material for heat protection clothing has the following values according to safety standard DIN EN ISO 11612:2009: A1 for limited flame spread. B1 for convective heat. C3 for radiation heat (highest value). D3 for aluminum/zinc splash (highest value). E3 for iron/steel splash (second highest value). Visit for more information. JUTEC 分析了许多铸造厂中出现的这种情况, 测试了 多种材料来制作轻质 舒适 适用于工人的热防护服 他们最优先考虑的是员工的安全和最佳的舒适度 例如, 铸造厂里的工人通常都需要从热的废料边走过 由于废料非常热, 以至于即使穿着有特殊热防护功能的鞋底的鞋子, 也依然避免不了烫伤甚至烧伤 工人已经在各种工作环境下尝试了各种鞋子 但是, 所有这些鞋子都被证明有缺陷, 并且在某些情况下会导致脚部受伤 通过和 JUTEC 一起努力, 已经成功研制了一种新的防护脚部和鞋子的鞋罩 鞋罩保护起整个鞋子, 敏感的脚底部分通过一个特别的耐割 耐热的材料保护 鞋罩由非常灵活舒适的铝合金织物和一种防切割的材料制成 根据 2008 年 11 月进行的 DIN EN ISO11612:2009 认证,JUTEC 公司开发的创新性的 灵活舒适的热防护服装材料符合以下安全标准 : A1 防止一定程度的火焰蔓延 B1 防对流传热 C3 防辐射热 ( 最高值 ) D3 防铝 / 锌的飞溅 ( 最高值 ) E3 防铁 / 钢铁飞溅 ( 第二高值 ) 更多信息请访问 : Optimal material is needed in heat protection gloves to avoid burning the workers hands. 最佳的材料, 需要热保护手套, 以避免燃烧的工人的手 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 61

64 product news/ 產品新聞 Applications for 3D Printing Go Beyond Automotive 3D 快速成型机的应用不仅限于汽车 Numerous industrial segments, beyond automotive manufacturers and suppliers, now require small quantities of cast metal assemblies and components for testing and prototype manufacture, and 3D printing offers a solution by producing the required sand cores and molds without requiring tooling. In contrast to conventional mold making, in which the production of model plates or core boxes alone can take several weeks, 3D printing makes it possible to print smaller sand molds in as little as a few hours. The molds are created without cumbersome and expensive mold set-ups and are produced in a fully automated process based on CAD data using the layer building method, which consists of the repeated application of 300 micrometre-thick quartz sand layers selectively glued together with a binder. After printing, the mold is unpacked and cleaned of excess sand. At the service center of voxeljet technology GmbH, state-of-the-art 3D printing systems create high-quality sand molds and cores for metal casting exactly in accordance with customer specifications. Never before have we printed such a broad spectrum of molds and assisted so many customers from different industries, said Dr. Ingo Ederer, CEO of voxeljet technology GmbH. 3D print technology significantly reduces the production time for prototypes and small series and places fewer restrictions on the designer s freedom of scope. Designs can be made true to their structure without having to watch for draft angles or undercuts. Even molds that have been modified during the testing phase can be printed immediately in accordance with the new CAD data, without requiring tool modifications. 3D printing also can be significantly cheaper than conventional methods due to the lack of tool costs up to a certain batch size. The smaller the batch size, the greater the cost advantage offered by our voxeljet technology, Ederer said. And depending on the complexity and size of the molds, 3D printing can still be the preferred choice for batch sizes of several hundred parts. Voxeljet operates one 除汽车制造商和供应商之外, 还有许多工业领域需要少量的铸造部件和组件进行测试和原型制造, 三维快速成型为此提供了一个解决方案, 无需模具就能生产所需的砂芯和砂型 传统的造型过程可能需要几个星期的时间生产模板或芯盒, 然而, 三维快速成型技术使人们有可能在短短几个小时 烧制 出所需砂型 在该过程中, 砂型不再经过繁琐和昂贵的造型模具, 并且在 CAD 数据基础上通过层层堆积烧结法完全自动化实现, 其中将重复铺放的 300 微米层厚的石英砂层选择性地用烧结在一起 最后, 取出砂型, 清理掉多余的砂子 在 voxeljet 技术有限公司服务中心, 采用最先进的三维快速成型系统完全按照客户的要求生产高品质的砂型和砂芯 Voxeljet 技术公司的首席执行官 Ingo Ederer 博士说 : 以前我们从未如此烧制过如此大范围的砂型, 也没有并协助过这么多来自不同行业的客户 3D 快速成型技术大大降低了原型和小批量生产的时间, 给设计师的约束更少 更加忠实于设计的结构, 不需要考虑拔模斜度和凸起分模面 即使在测试阶段修改砂型, 也可以按照新的 CAD 数据立即成型, 无需模具修改 由于省去了模具的成本 ( 大到一定尺寸的模具 ), 三维快速成型技术也可以比传统方法更便宜 批次越小, 我们的 Voxeljet 技术的成本优势越大, 埃德雷尔说 取决于砂型的复杂性和尺寸, 有时对于批量为几百 Fig. 1. Voxeljet s 3D printer VX4000 can produce large molds up to 8 cu.m in volume. 图 1 Voxeljet VX4000 3D 快速成型机可以生产体积可达 8 立方米的大型砂型 62 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

65 product news/ 產品新聞 Fig. 3. This cast aluminum designer chair was produced with voxeljet 3D printing technology. 图 采用 voxeljet 三维打印技术生产的铸铝设计师椅 of Europe s largest service centers for the on-demand production of molds and has made a name for itself around the world as a manufacturer of innovative 3D printing systems. The past few years have seen veritable quantum leaps with respect to printing quality as well as printing speed, Ederer said. The high-performance print heads of the new machines achieve excellent resolutions and printing speeds that are five times higher than even just a few years ago. In addition, with our VX4000 we are now able to generate molds of the size of a sports car something that would have been unthinkable not long ago. The VX4000 machine can produce 4 x 2 x 1-m sand molds with a volume of 8 cu.m, which provide sufficient room for the rapid production of extremely large individual molds or can be used for the efficient production of smaller parts (Fig. 1). The machine operates at more than three times the build speed of voxeljet s standard printers, but with the same resolution and precision. This performance is made possible with the use of a particularly wide print head, resulting in time and cost savings for users. Building platforms are alternately inserted into the process station to allow for continuous building in three-shift operations. (Fig. 2). This 3D print technology recently was used to produce the Batoidea chair, created by Belgian designer Peter Donders (Fig. 3). Its design conjures up the image of an elegantly gliding stingray. The chair, made of cast aluminum, would have been too expensive to make without the use of 3D print technology. Donders was able to turn his unconventional 件的产品三维快速成型技术仍然是首选的 Voxeljet 经营着欧洲最大的服务中心, 提供砂型生产, 并因创新的三维快速成型系统制造商而闻名世界 在过去的几年里, 我们看到了快速成型质量和速度的飞跃, 埃德雷尔说, 新型打印机的高性能烧结系统实现了出色的分辨率, 成型速度是几年前的 5 倍 此外, 我们的 VX4000 现在能够生产跑车大小的砂型 - 这在不久前是想都不敢想的 VX4000 机可以产生 米体积为 8 立方米的砂型, 这为特大型单件砂型的快速生产提供了足够的空间, 或者可用于稍小件的高效生产 ( 图 1) 本机工作速度是 Voxeljet 标准机型的三倍以上, 而且具有相同的分辨率和精度 该性能是通过一个特别宽的成型机实现的, 为用户节省时间和成本 要交替地将工作台插入工作站以允许其连续工作, 三班倒 ( 图 2) 这种 3D 快速成型技术最近被用于生产 Batoidea 椅子, 该椅子由比利时设计师彼得 德尔斯 ( 图 3) 设计 它的设计让人联想到优雅的滑翔黄貂鱼的形象 该椅子由铝做成, 如果没有三维快速成型技术, 由传统方法制造太昂贵, 该椅 Fig. 2. Building platforms are alternately inserted into the process station to allow for continuous building in threeshift operations. 图 2 工作台被交替地插入工作站以允许连续打印, 三班倒 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 63

66 product news/ 產品新聞 ideas into reality on the computer, using the Rhino3D modeling program. The CAD data set required for 3D printing was automatically available on the computer following completion of the work. Five sand molds were needed to produce the large chair at voxeljet s service center in Augsburg, with the largest individual mold measuring x 713 x 382 mm. The final design consisted of a thin-walled aluminum cast structure, which underwent further processing until the application of the finishing varnish. Visit for more information. 子是不可能生产出来的 德尔斯能够使用 Rhino3D 建模程序把他的新奇的想法在计算机上变成现实 三维快速成型所需的 CAD 数据在电脑上的设计工作完成后就自动生成了 该大椅子的铸造需要五块砂型, 最大单个为 X 713 X 382 毫米 最终的设计包括一个薄壁铝合金铸造结构, 其需要采用罩面清漆进行进一步处理 ( 图 5) 更多信息请访问 : Biostable Die Lubes 生物稳定型模具润滑剂 Petrofer has developed water miscible release agents for die casting with wide-reaching resistance against microbial attack. This provides good stability against bacteria growth and the growing of yeast and fungi. The latter is especially important when the die lubricant is applied in a centralized system. Fungi fibres in such a system can block filters, sieves and nozzles. In the worst case, it can jam the whole production. The prevention or halt in the growth of microbes has been attempted by adding conventional biocides to the die lube concentrates or feeding them to the dilutions. The biocides often contain formaldehyde or depository substances. Recently, formaldehyde has been increasingly criticised. In France, for instance, the use of formaldehyde in metal cutting fluids has been strictly forbidden for a number of years. New bio-stable die lubes do not contain formaldehydes and have not to be labelled as dangerous. For their identification, the bio-stable qualities carry the letters BS in their brand names. Currently, the most commonly used types are DIE-LUBRIC 1060 BS and 1060 BS-2. Versions for other dilution ratios also are available. Visit for more information. 德润宝公司 (Petrofer) 研发成功一种能够抵抗微生物腐蚀的水溶性压铸脱模剂 这种脱模剂能够稳定抵抗细菌 酵母以及真菌的增长 当将润滑剂用在集中的系统时, 后者显得尤其重要 在这样的系统中, 真菌可以阻塞过滤器 筛和喷嘴 在最坏的情况下, 可能堵坏整个机器 有人尝试向润滑剂中添加常规的杀菌剂来预防和阻止真菌的生长 生物杀菌剂往往含有甲醛等, 而最近, 甲醛受到越来越多的批评 例如, 在法国, 金属切削液中甲醛的使用已经被禁止多年了 新的生物稳定型模具润滑剂不含甲醛, 因此被认为不具有危险性 为了方便识别, 生物稳定型的润滑剂在品牌中含有 BS 字样 目前, 最常用的型号是 DIE-LU- BRIC 1060 BS 和 1060 BS-2, 也可提供其它稀释比的润滑剂 更多信息请访问 : 64 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

67 product news/ 產品新聞 Measuring Remaining Furnace Lining Thickness 测量炉衬剩余厚度 Up to now, identification of wear at electric melting, holding and pouring furnaces has mainly been the business of the melter, who operates the equipment and makes decisions based on experience. Power input, current, voltage and frequency information are available to the operating staff. In cold conditions, the crucible can be measured and inspected for potential defects of the furnace lining, which helps to avoid failures and furnace breakthroughs. In sintered furnace lining, cracks evolve during the cooling process and typically close as the furnace is heated. Unfortunately, these cracks also drive wear deeper into the lining. Metal fins are dangerous, especially in coreless induction furnaces, as they infiltrate into the furnace lining cracks. This causes expensive production loss and provokes extensive damage to the melting equipment or, in the worst case, explosions. The SAVEWAY system measures the remaining lining thickness during furnace operation. The original lining thickness is divided into 16 increments and shown separately in each sensor segment. Large and small wash outs, metal infiltration, cracks and even the smallest metal fins are reliably indicated. The detection of coolant leakages at the coil and the monitoring of the dry-out progress of the refractory during sintering is made possible through this technology. For 20 years, the SAVEWAY system has been monitoring refractory lining of coreless induction furnaces and other melting and holding equipment. The system is installed worldwide in more than 900 furnaces of different manufacturers and linings. In addition to increasing safety for operating staff and equipment, refractory service life is typically increased 30%. Visit for more information. 到目前为止, 对熔化电炉 保温电炉 浇注炉的炉衬磨损的鉴定一直都是熔炼工的工作, 他们操作设备, 并根据经验来做出决定 他们可以获得输入功率 电流 电压 频率等信息 在冷下来的状态下, 他们可以测量和检查坩埚炉衬是否存在潜在缺陷以避免故障 防止泄露 在烧结的炉衬中, 裂纹在冷的状态下中扩展, 而在加热的时候愈合 不幸的是, 这些裂纹也诱发磨损深入到炉衬深处 金属飞边非常危险, 尤其对无芯感应炉, 因为它们会渗入炉衬的裂纹里 这导致很高的生产损失, 引发熔炼设备的损坏, 甚至在严重的情况下会发生爆炸 SAVEWAY 系统测量熔炼过程中的炉衬厚度 初始的炉衬厚度被划分为 16 个等级, 每个等级用传感器单独显示 大大小小的冲蚀 金属的渗透 裂纹, 甚至是最小的金属飞边都能被可靠地检测出来 该技术使得监测线圈中冷却剂泄露以及耐火材料的烧结蒸干过程成为可能 20 年来,SAVEWAY 系统一直在监测无芯感应炉以及其它熔炼和保温设备的耐火炉衬 系统应用于全世界超过 900 家炉子制造商和炉衬制造商 除了提高了操作人员和设备的安全, 耐火材料的寿命也显著提高了 30% 更多信息请访问 : Shown is a display of the SAVEWAY system. 所示是显示的 SAVE- WAY 系统 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 65

68 product news/ 產品新聞 Spalek Produces Vibratory Devices Spalek 生产振动机械 Spaleck Oberflächentechnik GmbH & Co. KG, Bocholt, Germany, is a full-service provider for the surface treatment of metal, synthetic or wooden parts with numerous partners. The company s entire know-how in vibratory grinding is bundled at its plant site, with a demonstration center area for customers. There, customers can obtain an overview of the range of machines, and new device concepts and process materials are tested under real conditions. As a rule, customers come to us with a workpiece that is to be processed, said Ingo Löken, Spalek sales engineer. The typical areas of use for vibratory grinding devices are the deburring, polishing, edge diffraction, smoothing and cleaning of metal, synthetic or wooden parts. Principally speaking, three basic concepts exist for this: rotation, vibration and centrifugal force. All machines from Spaleck Oberflächentechnik draw on these basic concepts in differing manners, explains Löken. Rotation devices (Fig. 2) constitute the simplest and most cost-effective device variant for vibratory grinding. The workpieces are placed in a drum together with the process materials. The drum then rotates, and the rotation ensures the correct vibratory grinding result after a certain time. In contrast to the other concepts, this variant is the slowest and mainly found in smaller companies without high throughput of parts. Vibration devices suitable for larger workpieces are faster by a factor of 5 (Fig. 3). The machine is vibrated by an unbalance motor. In the trough, the workpieces are set in horizontal worm-shaped movement together with the grinding wheels, thus triggering the grinding process. The 德国 Bocholt 市的 Spaleck Oberflächen technik 公司是一家提供金属 合成材料或木制部件表面处理的厂家, 有众多的合作伙伴 该公司在振动研磨的全部诀窍一并展示在其厂区的产品展示中心 在那里, 客户可以看到公司生产机器全貌, 还可以看到新的设备概念和材料在真实条件下进行的测试 作为一项规则, 客户都带一件要处理的工件到我们这里来 Spalek 销售工程师 Ingo Löken 说 振动研磨装置的典型使用领域是金属 合成材料或木制部件的去毛刺 抛光 倒角 磨光和清洁 概括地说, 其中存在三个基本概念 : 旋转 振动和离心力 Löken 解释说 : 所有 Spaleck 制造的机器都是这些基本概念的不同应用 旋转装置 ( 图 2) 是振动研磨中最简单 最经济的器件 工件和被处理的材料一起放置在旋转盘上 然后, 盘旋转时, 确保了经过一定时间后的振动研磨结果 与其他概念相比, 这种情况是最慢的, 主要用于小公司 适合大工件的振动设备要快 5 倍 ( 图 3) 机器的振动由不平衡马达产生 在振动槽中, 工件在水平和砂轮 Fig. 1. The process materials are subdivided into chips (grinding wheels) and compounds (liquid additives). 图 1 处理材料细分为碎屑 ( 砂轮 ) 和化合物 ( 液体添加剂 ) 66 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

69 product news/ 產品新聞 Fig. 2. Rotation devices are particularly suitable for small batches. 图 2 旋转装置特别适合于小批量 process materials and the time factor can then be used to set the desired grinding result. Round trough vibrators are designed solely for the batch processing of workpieces, i.e. the devices must be loaded and unloaded with bulk material by an employee; complete automation is possible to a limited extent only. The last type of device works on the basis of centrifugal force and is ten times faster than the vibration devices. A rotating plate is located in a fixed upper part (Fig. 4). During the vibratory grinding process, this is accelerated up to a high speed. Adding process materials also sets the workpieces in rotating worm-shaped movement within the grinding wheels. As this vibratory grinding process is only suitable for small workpieces, this type of device is found, for example, in the production of coins. In some industrial applications there was a desire to integrate vibratory grinding into the manufacturing process as an automated solution, Löken said. This idea resulted in the development of the throughfeed devices of the DL series. With this 一起向前蠕动, 由此而进行磨削 要处理的材料和处理时间是决定磨削效果的因素 圆形槽振动器是专门为批量处理工件设计的, 即设备要有工人装载和卸载大型金属材料, 只能在一定程度上实现自动化 最后一类设备采用离心力的原理工作, 比振动设备快十倍 在上部固定部分安装一块旋转板 ( 图 4) 在振动研磨过程期间, 该板被加速到高速 被处理材料也是在砂轮内蠕动前进 由于这个振动研磨过程是只适用于小工件, 例如, 在生产的硬币中能找到这种类型的设备 Löken 说 : 在一些工业应用中有一个愿望, 将振动研磨整合到制造过程中以实现自动化 这种想法导致 DL 系列直通供料装置的发展 有了这种类型的装置, 可以连 Fig. 3. A horizontal worm-shaped movement is generated in the round trough vibrator and triggers the grinding process. 图 3 圆形槽振动器中的水平蠕动运动中发生研磨 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 67

70 product news/ 產品新聞 Fig. 4. Centrifugal force devices are ten times quicker than vibration devices. 图 4 离心设备比振动装置快 10 倍 type of device, the workpieces are continuously processed and separated in contrast to the batch processing in the classical round trough vibrator. The DL devices use the vibration technology to generate the relative movement Following repeated requests by customers, Spalek has developed a smaller variant of the DL the DL 600 (Fig. 5). This machine enables throughfeed processing in the smallest of spaces and is ideally suited to the diecasting industry. The diameter of the work container is 1,600 mm and ensures perfect all-round running of the workpieces despite the compact form. The stretched length of the work container is 9 m and enables flexible throughfeed times of 8 minutes with a greatly reduced space requirement of less than 4 sq.m. Thanks to the small dimensions, the DL600 can be optimally coupled to an existing diecasting machine. Process interlinking makes it possible for the workpieces to pass directly to the vibratory grinding process following casting, before passing through a drying process. This eliminates the transport of the workpieces from the diecasting machine to the vibratory grinding device, thus saving time and storage capacity. Visit for more information. 续处理和分离工件, 而这在传统的圆槽形振动器的批处理中是做不到的 该 DL 设备使用振动技术产生相对运动 经过客户反复请求,Spalek 已开发 DL DL600 设备的较小的变体 ( 图 5) 本机在最小的空间内实现直通供料, 非常适合压铸行业 工作容器的直径为 1,600 mm, 尽管布局紧凑, 仍确保工件全面运动 工作容器长 9 米, 并且可以灵活实现直通供料, 时间为 8 分钟, 空间大为降低, 小于 4 平方米 由于尺寸小,DL600 可以很好地安到现有压铸机上 工序集成使工件在铸造后直接传送给振动研磨工序, 而后通过干燥工序 这消除了工件从压铸机到振动研磨装置的运输, 从而节省了时间和存储空间 更多信息请访问 : Fig. 5. Thanks to its compact size, the DL 600 is perfectly suited for use in the diecasting industry. 图 5 由于设计紧凑,DL600 非常适合用于在压铸行业 68 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

71 product news/ 產品新聞 Additive Controls Veining, Eliminates Refractory Coatings 无须耐火涂料, 添加剂控制裂纹 Sand additives are used to control veining defects on cored surfaces, most often in conjunction with refractory coatings, which improve surface finish and control metal penetration. A new product has been developed that combines the positive effects of additives and coatings into a single material. The new additive from ASK Chemicals is based on low-density alumina silicate ceramic (LDASC) with a small addition of fluxing material. Testing has shown this material has unique expansion and contraction properties that eliminate veining and provide superior casting surface finish. A 5% addition level is sufficient for most applications. A variety of automotive castings including disc brake rotors, brake calipers and steering knuckles have been produced with good results without the need for coatings. Various materials have been used as anti-veining sand additives. An LDASC-based additive than could be successfully used below 10% was needed. Initially, tests were conducted to characterize the chemical and thermal properties of a number of different LDASC raw materials. Once the different LDASC options were defined, their chemical compositions were analyzed. Large variations in both the alumina content and the amount of impurities were found. The thermal testing was carried out in a Misura heating microscope, which allows visual recording of a sample during a heating cycle. The silhouette of the sample is recorded on a computer during the fusion test. using image analysis equipment, the evolution of the contraction of the sample can be determined as a function of the temperature. Each sample was formed by pressing a cylindrical button 3 mm in diameter and 3 mm in height, which was placed on a stand. This stayed in the instrument sample holder of the heating microscope where it underwent heating at a rate of 77F/min. (25C/min.) to the maximum temperature of 2,822F (1,550C). From the recorded images, the contraction temperature curve was plotted and several characteristic temperatures were determined. From here ASK compared the chemical properties of the LDASC materials with the Initial Contraction Temperatures. Veining tests also were performed on 2x2 test pieces (2-in. diameter by 砂型添加剂用于控制重要表面的裂纹缺陷, 经常和耐火材料一起使用, 后者可以提高表面光洁度 控制金属的渗入 已经开发了一种材料, 可以结合耐火材料和添加剂二者优点 ASK 化学品公司的这种新型添加剂是通过低密度硅酸铝陶瓷 (LDASC) 添加少量溶剂材料制成的 测试表明, 这种材料具有优异的膨胀和收缩性能, 能够消除裂纹, 提供良好的铸造表面光洁度 加入 5% 就可以满足大多数场合的应用 大量的汽车零部件, 例如盘式制动器转子 制动卡钳和转向节已经成功采用了这种添加剂, 质量良好, 并且而不需要耐火涂料 很多种材料被用做抗裂纹的添加剂 亟需一种添加量 10% 以下就可以达到很好效果的 LDASC 添加剂 起初, 通过一系列的实验测量了不同 LDASC 材料的化学和热力学性能 一旦确定选择不同的 LDASC, 它们的化学成分就可以被分析出来 可以发现, 它们的氧化铝和杂质的含量差别佷大 热力学性能是在一台 Misura 加热显微镜中测量的, 这台显微镜可以将试样在加热周期内的变化的影像记录下来 熔化测试期间, 样品的录像记录在计算机中 利用图像处理软件, 可以得到样品的收缩是温度的函数 每个样品是挤压成形的圆柱, 高 3mm, 直径 3mm, 放置在支架上 样品在加热显微镜的样品保持器中, 按照 77F/min(22 /min) 的速度加热, 直到最高温度 2822F(1550 ) 从记录的影像中, 可以作出收缩 - 温度曲线, 并且得到几个特征点 通过这条曲线,ASK 比较了 LDASC 的最初收缩温度 裂纹测试也采用 2mm 高 2mm 直径的样品来测 Fig. 1. This photo shows a mixture of LDASC and silica sand. 图 1: 该图显示了不同 LDASC 样品的收缩曲线 Table 1. Thermal Analysis of the LDASC Samples LDASC 样本的热分析结果 ( 表同图 1) Typical Temperature 各样品的特征温度 Sample 73 Sample 74 Sample 75 Sample 76 Sample 77 ( 依次为样品 73 样品 74 样品 75 样品 76 77): 样品 Initial Contraction Temperature r 初始收缩温度 1,045C 935C 1,025C 990C 1,155C Final Contraction Temperature 最终收缩温度 1,295C 1,160C 1,270C 1,235C 1,550C Softening Temperature 软化温度 1,340C 1,250C 1,445C 1,355C Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 69

72 product news/ 產品新聞 Fig. 2: This graph shows the Initial Contraction Temperature versus LDASC chemistry. 图 2: 该图显示初始收缩温度以及 LDASC 的化学性质 2-in. height) to determine if a relationship existed between veining and the thermal characteristics. Each core sample contained 5% LDASC and 95% silica sand. Next, ASK s research turned to the influence of different types of fluxes on the samples. After several trials with different types of fluxes, it was determined that 6% Li2CO3 in Sample 77 gave similar initial contraction temperatures. However, the final contraction temperature was lowered by 230C (446F), so the contraction would be much faster during casting. Lithium carbonate also was added to LDASC 73 for comparison. Similarly, Misura thermal analysis was used to develop curves for sub-angular and round sand, and for other mineral additives in sand, for comparison. Observing the behavior of sample 77 with 6% Li2CO3 came closest to the curves with other sand additives effective against veining, samples to evaluate the veining and penetration were prepared for the new additive (now designated ISOSEAL 2011 or ESA 2011). Cores were prepared using 94% sub-angular sand C-70, 1.5% phenolic urethane binder 418/618, and 5% of the ESA 2011 additive (94% of sample 77 LDASC + 6% Li2CO3). It was noted that 6% lithium carbonate as a component of the anti-veining additive produced no veining, regardless of the LDASC sample used. The castings all exhibited an excellent surface finish. By contrast, the samples from cores without additives (100% sand) and the samples with LDASC alone as the additive produced significant veining defects of 10 and 7 respectively (on a scale of 0-10 for veining, 0 being the best and 10 the worst). Subsequently, the effects of lithium carbonate levels in a LDASC-based additive of sample 77 and the amount of additive in the composition of the molding sand were tested. Once the results were deemed satisfactory, ASK began industrial testing in casting facilities that use 70 AFS GFN sand, the common practice for vertical molding. Further testing was conducted with other, coarser sands. Testing showed the additive worked satisfactorily. 试, 以试图确定裂纹和热力学性质之间是否存在关系 每一个样品含 5% 的 LDASC 材料, 剩下的 95% 为硅砂 接下来,ASK 的研究不同类型的溶剂对样品的影响 通过测试多种不同的溶剂后发现,77 号样品中添加 6% 的 Li2CO3 能够达到相近的初始收缩温度 然而, 最终收缩温度却下降了 230 因此在铸造过程中, 收缩速度增加 为作对比, 在 LDASC 73 中添加了一定量的碳酸铝 同样的,MIsura 热力学分析也被用于棱角状砂 圆形砂以及用作对比的含有其它矿物添加剂砂的曲线测量中 观察到, 对于裂纹控制, 含有 6% 的 Li2CO3 样品 77 表现了和其它添加剂一样最为接近的曲线 用 94% 的次棱角砂 C % 酚醛尿烷黏合剂 418/618 以及 5% 的 ESA2011 添加剂制成砂芯 试验注意到, 含有 6% 的碳酸锂添加剂不造成裂纹缺陷, 所有的铸件都显示了很好的表面质量 作为对比, 没有添加剂的砂芯 (100% 型砂 ) 以及单独添加 LDASC 的样品都造成了明显的裂纹缺陷, 分别为 10 和 7 级 ( 将裂纹等级划分为 0-10,0 为最好,10 最差 ) 接着, 对以 LDASC 为基础的 77 号添加剂中添加碳酸锂的效果以及型砂组成中添加剂的量都进行了测试 测试结果令人满意,ASK 开始在铸造厂中进行工业测试, 测试的砂型为垂直分型的常用砂 70AFS GFN 在其它比较粗糙的型砂中进行进一步测试 测试表明, 添加剂效果良好 使用 AFS GFN55 的制动盘有一些裂纹和渗漏, 但是一旦砂子换为 AFS Fig. 3. This graph shows the contraction behavior of different sand additive mixes with silica sand. 图 3: 该图显示不同添加剂与型砂混合后的收缩特性 70 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

73 product news/ 產品新聞 Fig. 4. This shows the casting results for two commercial sand additives compared to silica sand. 图 4: 该图显示两种砂型添加剂对比得到的铸件质量 Brake disks using AFS GFN 55 exhibited some veining and penetration, but once the sand was changed to AFS GFN 65, the problems were corrected. At higher temperatures, the additive increases the acid demand value (ADV) of the mixed sand, which decreases the bench life. This can be addressed using binder 419/619, a coldbox binder with a greater shelf life. The ESA 2011 additive does not produce additional gas evolution compared to sand alone. Additions of 5% of ESA 2011 additive decrease the weight of the core by about 10%. This means more cores can be produced from the same weight of mixed sand, and the cores are lighter and easier to handle. A laboratory study was conducted simulating the effects of burning the core and charring the additive and adding it to the molding sand at a rate of 2.5%. No effect was observed. Visit for more information. The Nissan metalcasting facility in Cantabria, Spain, has manufactured a complex ductile iron housing for John Deere for several years. This casting is a critical component of the hydrostatic drive trains used to power crawler tracks used in civil engineering machinery. The T casting is part of a transmission system assembled in John Deere s Getafe plant, close to Madrid. This is a core product of the plant and one of five critical castings Nissan Cantabria produces for this project. The casting (T ) also known as the tear, for its shape, was infamous within the facility, primarily because of previous problems related to porosity. Even with an approval concession, many castings were rejected due to porosity revealed during machining, reducing productivity and efficiency for both the metalcasting facility and the customer. Attempts to address the porosity issues with changes in the gating and feeding systems generally were unsuccessful, and the casting began to live up to its nickname. In basic terms, the problems with the casting were due to geometry, relatively high weight and the material specification (GJS 500-7). The casting geometry (Figures 1 and 2) consists of significant changes in the section thickness, generating two different cooling and solidification volumes. This leaves the inner ring completely isolated and difficult to feed, resulting in gross porosity defects. Trials were conducted with several process parameters to eliminate the problem: Chemical analysis. Pouring temperature. Adjusting the metallurgy. Feeder system modification. GFN65, 这种情况就消除了 在高温下, 添加剂提高了混合砂的酸性需求值 (ADV), 降低可使用寿命 这个问题可以通过使用具有更大寿命的冷芯盒粘合剂 419/619 解决 ESA2011 添加剂并不比型砂产生更多的气体 ESA2011 5% 的添加量可以降低砂芯 10% 的重量 这说明, 同样的混砂量可以制成更多的砂芯, 并且砂芯更轻 便于处理 在实验室里进行了砂芯的燃烧 添加剂碳化以及向砂型中添加 2.5% 的添加剂的模拟, 没有发现副作用 更多信息请访问 : Nissan Improves Casting Quality Using Feedex 日产利用 Feedex 提高铸件质量 西班牙坎塔布里亚的日产铸造工厂已经有好几年为约翰迪尔 (John Deere) 生产复杂的球墨铸铁缸体件 这个铸件是一个民用工程机械上的履带静压传动系统的关键部件 T 铸件是约翰迪尔公司附近马德里的赫塔菲工厂组装的传动系统的一个部分 这个铸件是工厂的核心产品之一, 也是坎塔布里亚日产公司为这个项目生产的 5 个关键零件之一 这个铸件 (T239237) 因为其形状, 也被称为 眼泪, 因为其缩孔缩松问题, 在工厂里臭名昭著 尽管有批准特权, 许多铸件还是由于缩孔缩松相关的问题, 降低了机加工和用户的质量和效率而被拒收 旨在解决这个问题而进行的浇注系统方面的改进都没有成功, 这个铸件就逐渐拥有了这个绰号 本质上来说, 这个铸件的问题主要是由于几何形状 相对较大的质量以及材料的特性 (GLS 500-7) 造成的 铸件的几何形状 ( 包括图 1 和图 2) 在部分厚度上存在明显的变化, 形成两个不同的冷却和凝固区 这导致铸件内圈完全孤立, 难以充型, 造成缩孔缩松缺陷 尝试从以下几个工艺参数方面进行尝试来解决这个问题 : 化学分析 浇注温度 调整冶金成分 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 71

74 product news/ 產品新聞 The casting geometry consists of significant changes in the section thickness, generating two different cooling and solidification volumes. This leaves the inner ring completely isolated and difficult to feed, resulting in gross porosity defects. When none of the above completely resolved the problem, the metalcaster decided to use a chill on the inner profile of the casting to move the defect to a more acceptable location. Different methoding designs were studied with the objective of placing chills in the inner and outer parts of the casting to investigate the effect on cooling. The porosity defects were always located in the central part of the casting. Even with the use of chills, the required quality standard could not be achieved consistently, with scrap levels after final machining reaching nearly 2.5%. Further, manual removal of the inner chill was costly, difficult and unsafe. A hydraulic press improved safety but ran the risk of marking the casting surface to a depth beneath the machining allowance. Even after applying a coating on the chills, small defects occurred in the machined areas of the casting. Chill production was a problem, as these had to be cast in-house and in many cases were not reusable. In 2009, John Deere proposed a small change in the design of the casting. The time required for the reapproval process presented Foseco International Limited, Tamworth, Staffordshire, England, with an opportunity to develop a new methoding proposal for Nissan. Work started with a solidification and mold filling study using MagmaSoft. The two clear objectives were to eliminate the use of chills and evaluate the use of highly exothermic Feedex spot feeders (which could now be applied due to the casting design modifications). The chosen option was to feed the external profile of the casting with a Kalminex 2000ZP 9/12 K sleeve; while using a Feedex VSK 770 / 33 MH sleeve (modulus 4.2cm) to feed the internal part of the casting. This combination of feeders gave the metalcasting facility several advantages high yield, improved molding properties and an extremely small contact area with the casting. In addition to the improved feeding system design, the cores were manufactured with 30% chromite sand in the core sand mix to improve the temperature gradient during the solidification process. As a result, the central core acted as a weak chill, reducing the superheating effect in the central part of the casting. The results of tests were promising, and the castings were completely sound and clear of internal defects. Visit for more information. 铸件的几何形状在部分厚度上存在明显的变化, 形成两个不同的冷却和凝固区 浇注系统改进当上述方法没有哪一个能彻底解决这个问题, 铸造工程师就决定在铸件内腔用一个冷铁来将缺陷转移到一个更为接受的地方 冷铁的放置位置及其对冷却过程的影响也经过了很多的研究 然而, 缩孔缩松缺陷却始终位于中心位置 即使使用冷铁, 铸件质量标准仍然没法达到, 机加工后的废品水平接近 2.5% 此外, 手工清除内部的冷铁成本高 困难并且不安全 液压机提高了安全性, 但是要面临对铸件表面造成超过机加工余量的划痕的风险 即使对冷铁施加涂层后, 依然在铸件机加工后的区域出现小缺陷 冷铁的生产是一个问题, 因为这些很难在内部铸造, 并且多数场合下不能回收利用 2009 年, 约翰迪尔公司对铸件提出了一个小的设计上的改动, 需要对工艺进行重新设计, 这给了英国斯塔福德郡的福士科公司一个机会, 为日产公司带来新的思路 工作始于一次利用 Magma 模拟凝固和充型过程 两个明确的目标是减小冷铁的使用以及评价高放热的 Feedex 点状冒口 ( 由于铸件设计的改变而变得可以使用了 ) 的作用 选择该冒口是为了适应铸件的外轮廓, 采用 Kalminex 2000ZP 9/12 K 保温冒口套 ; 采用 Feedex VSK 770 / 33 MH( 模数为 4.2cm) 冒口套以补缩铸件内部 该设计有几大优势 : 高工艺出品率 更好的造型性能以及和铸件非常小的接触面积 除了改进浇注系统设计, 在砂芯的制作中还使用了 30% 的铬铁矿砂, 提高了凝固过程中的温度梯度 因而, 中间区域就像一个冷铁, 减小了铸件中部的过热效果 测试的结果非常理想, 铸件完全清除了缩孔缩松缺陷 铸件的几何形状在部分厚度上存在明显的变化, 形成两个不同的冷却和凝固区 这导致内圈完全孤立, 难以充型, 造成缩孔缩松缺陷 更多信息请访问 : 72 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

75 product news/ 產品新聞 GE Software Automates Failure Analysis Process Chain GE 软件使失效分析过程链自动化 The phoenix datos x 2.2 computed tomography (CT) software from the Inspection Technologies Business of GE Measurement & Control, Wunstorf, Germany, features fully automated data acquisition and volume processing to allow high-resolution precision metrology and failure analysis tasks to be performed significantly faster, with minimal operator training. Users of GE s phoenix x-ray high-resolution CT systems in a wide variety of industries and academic institutions can benefit from a combination of time and cost effectiveness, as well as improved reproducibility of 3D measurement and failure analysis results because of the minimization of operator influence. With phoenix datos x 2.2, the whole scan and reconstruction process runs without any operator interaction and 3D failure analysis or metrology tasks performed with third party programs can be executed automatically, explained Oliver Brunke, CT product manager, GE. The click & measure CT functionality allows display and analysis of the 3D results on the screen in just three steps, so that operator skill requirements are dramatically reduced, while CT analysis time is up to five times faster compared with the previous datos x 1 software version. The intuitive graphical user interface of the new software ensures easy usage and a fast learning curve, including auto- 来自德国 GE 测量与控制公司检测技术业务部门的 计算机断层扫描软件 (CT) 凤凰 datos 2.2, 让高精度的精密测量和失效分析任务进行地更加快速, 并且需要很少的人工培训 由于人工影响的减小, 各个行业和学术机构的 GE 凤凰 X 射线 CT 系统的用户都可以从时间和经费上的减小获益, 并且得到更好的 3D 测量质量以及失效分析结果 有了凤凰 datos2.2, 整个扫描和重构过程不需要任何操作干预,3D 失效分析可以通过第三方程序自动执行,GE 公司 CT 产品经理 Oliver Brunke 说到 : 点击测量 CT 可以 3 步内实现 3D 结果在屏幕上的显示和分析, 对操作者技术要求大幅降低, 同时 CT 分析比原先 datos x1 版本快 5 倍 直观的用户界面 自动校正系统以及对检测器 功能管等的监视功能保证了使用方便 学习快捷 一个处理流程导向功能的工具栏可以进行一步一步 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 73

76 product news/ 產品新聞 mated system calibration and monitoring functions for tube, detector, etc. A process flow oriented function tool bar allows step-by-step workflow setup, and the CT results display has been significantly improved as the 3D volume is shown not only in 2D axis views but also in a 3D render mode. As the entire process of the CT data acquisition through volume reconstruction to implementation of the measurement runs completely automatically, it is possible to conduct the first sampling of a complex component in less than 60 minutes. This makes dimensional measurement with CT an effective tool for metal castings and precision components. Particularly complex part geometries with inaccessible or hidden features can be measured with CT in many cases faster than with conventional CMM. Compared with the current datos x version, the new velo CT module offers up to nine times faster CT volume reconstruction. Depending on the volume size, the CT results are now available in seconds or minutes. Another effective tool for accelerated high throughput laboratory and production oriented CT tasks is the new batch CT module. Due to preprogrammed multi-object scans with no further interaction, it allows the degree of system usage to be enlarged by up to % by performing various automatic CT scans and evaluations outside of the operator working time. Visit for more information. 的工作流程设置,CT 结果的显示得到了显著提升, 不仅仅是二维的坐标显示, 而是 3D 渲染模式 由于通过体积重建进行的数据采集以及执行测量的整个过程完全自动化, 可以在不超过 60 分钟的时间内完成一个复杂件的初步造型 这使得 CT 三维测量成为铸造和精密成型的有效工具 尤其是带有隐藏或够不着的特征的复杂零件时,CT 测量在许多情况下要比传统的 CMM 更快 和现在 datos 版本相比, 新的 velo CT 模块提供了快 9 倍的 CT 立体重建速度 根据体积大小, 可以在几秒到几分钟内得到 CT 结果 新 Batch CT 模块对高产出实验室以及生产导向的 CT 任务非常有效的 由于编程控制的多对象扫描没有进一步的交互, 可以在操作者工作时间之外进行各种自动的 CT 扫描和评价, 将使用率提高了 20%-30% 更多信息请访问 : Coreless Vacuum Induction Furnaces for Refining, Recycling 无芯真空感应炉, 用于精炼 回收重熔 Vacuum-type induction furnaces are becoming increasingly widespread for removing undesirable alloying elements, as well as for the production of high-purity, low-gas alloys and for melting special materials. Typical applications include: Deoxidation of high-grade steel melts. Carbon reduction of molten steel. Melt degassing. Distillation of zinc and other low-melting alloys. The design of Simmerath, Germany-based Otto Junker s vacuum type coreless induction furnaces provides operating safety and reliability as only the actual melting chamber is evacuated, whereas the induction coil with its power and water inputs remains outside the vacuum. A cooling air system arranged between coil and crucible lining protects the furnace shell from overheating while also permitting continuous temperature monitoring of 真空感应炉也日趋广泛用于除去不想要的合金元素, 以及用于生产高纯度 低气体含量的合金和用于熔化特殊材料 典型的应用包括 : 高级钢熔化脱氧 钢水的碳还原 熔体除气 锌和其它的低熔点合金的净化 德国奥托容克 (Otto Junker) 的真空无芯感应炉的设计操作安全 可靠, 这是因为只有实际熔化室是真空的, 而它的电源的感应线圈和水输入在真空外 线圈和坩埚衬里之间的冷却空气系统, 配置 The zinc distillation plant s vacuum furnace is at right, with the zinc condenser on the left. 在锌蒸馏工厂, 真空炉在右侧, 冷凝器在左边 74 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

77 product news/ 產品新聞 the refractory lining via the cooling air ducts distributed along the circumference of the crucible. This design prevents electric glow discharge and any hazardous contact between cooling water and molten metal in the case of a breakdown. Overall, the plant essentially comprises a vacuum-type coreless induction furnace with the necessary ancillary equipment including a frequency converter and switchgear system, zinc condenser, filter unit and vacuum pump. The charge material is melted in the furnace under atmospheric pressure. Once it is molten, the furnace is sealed off with a hood and connected in vacuum-tight manner to the zinc condenser and filter unit arranged beside the furnace. An appropriate vacuum is generated by the vacuum pump, and the melt temperature is raised to approximately 1, F (1,000-1,050C), causing the zinc to evaporate intensely. The resulting zinc vapors are passed into the unheated condenser and condense there. The condenser design ensures the temperature exceeds the melting point of zinc at all times but will never rise too high. Accurate temperature management and partial cooling of the vessel make for an optimum process. When the condensation step is completed, the condenser is disconnected from the furnace and the molten zinc is drained into a ladle. The alloy left in the melting furnace is removed in the same manner. This complex process calls for accurate monitoring and control of all operating parameters, especially temperatures, pressure and electric power. These functions are performed by a furnace control system designed specifically for this application. Such vacuum-based zinc distillation systems are being built for customers in Germany, India and Canada. Visit for more information. 过热保护炉壳, 同时也能通过分布在坩埚外周的冷却空气管道, 实现对耐火衬里的温度的连续监测 这个设计可以防止放电击穿时冷却水和熔融金属的接触 总之, 工厂很有必要一台带有必要辅助设备的真空无芯感应电炉, 包括一个频率转换器 开关装置系统 锌冷凝器 过滤单元以及真空泵 炉料在炉内大气压下熔炼 一旦熔化, 炉就被密封罩罩住, 并以真空密封的方式连接到锌冷凝器和炉旁配置的过滤器单元 由真空泵产生适当的真空, 熔体温度提高到约 F( ), 使锌激烈蒸发 由此产生的锌蒸汽被传递到未加热的冷凝器并凝结 冷凝器的设计确保温度会超过锌的熔点, 但永远不会升得太高 精确的温度控制和局部冷却形成使工艺达到最佳 当冷凝完成后, 断开冷凝器和炉子的连接, 熔融状态的锌排到浇包 留在熔化炉中的合金用相同的方式除去 这个复杂的过程需要准确的监测, 控制好所有操作参数, 尤其是温度 压力和电功率 这样的真空的锌蒸馏净化系统正在为德国 印度和加拿大的客户制造 更多信息请访问 : Seiatsu Airflow Squeeze Technology Increases Production 静压气流挤压技术提高生产效率 Iron metalcaster Eisengiesserei Baumgarte GmbH, Brackwede, Bielefeld, Germany, deployed the Seiatsu airflow squeeze technology developed by Heinrich Wagner Sinto Maschinenfabrik GmbH (HWS). Within only one year, it had increased production by 30% while reducing rejects by 35% and downtime by 25%. This was achieved without purchasing an entirely new plant. The plant was fully operational after a break in production of only four weeks. The task was to remove the previous molding machine and replace it with a modern HWS Seiatsu molding machine. In addition, the mold box capacity was enlarged by adding 88 new mold boxes and installing a semi-automatic pattern-changing station. Our objective was to improve the quality of the casting parts and in turn reduce the amount of subsequent work required, said Eckhard Winter, CEO of Baumgarte. AIRPRESSplus technology was originally employed for mold compaction. This was certainly the way to go 15 years ago, but today 德国比勒费尔德金属铸造公司 (Eisengiesserei Baumgarte), 应用了由海因里希 瓦格纳新东机械制造有限公司 (HWS) 开发的静压气流挤压技术 在短短一年间, 产量增加了 30%, 废品率降低 35%, 停机时间降低了 25% 完全变成成了一个全新的工厂 该工厂在停产短短四个星期后全面投入生产 期间的任务是要移走以前的造型机, 取而代之的是一个现代化的 HWS 静压造型机 此外, 通过添加 88 个新的砂箱以及安装一个半自动模样更换站 我们的目标是提高铸件的质量, 反过来, 减小后续工作量, Baumgarte 公司总裁 Eckhard Winter 说到 静压气流挤压技术最初时用于砂型的压实 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 75

78 product news/ 產品新聞 the system displays weaknesses in the shape of corners and edges, Winter said. The Seiatsu airflow squeeze technology system comprises a two-stage compacting process. The sand is first weighed into a dosing hopper and then uniformly distributed through vents in the mold. A hydraulically controlled disc valve opens a transverse section in a fraction of a second, which allows it to generate airflow for precompaction. In the next stage, the sand is further compacted by a hydraulic multi-ram press. The semi-automatic pattern changing station enables an entire pattern assembly to be changed within the cycle time, meaning plant operations can continue unhindered. The machine s semi-automatic design also means the workplace can be laid out more ergonomically. It requires less manual intervention and less effort than before, Winter said. This represents a further increase in the system s productivity. The incorporation of a pouring funnel drilling jig and an air-hole punching machine means many manual work processes are now performed automatically. Because halting and refitting the plant is no longer necessary when changing production over to a new mold series, a series comprising as little as 20 units is also possible. This increases our product range, Winter said. However, Baumgarte s expanded range was, above all, due to the enlargement of the mold box. We have raised the height of the mold box by 50mm to increase the range of parts that are possible, Winter said. The plant is now able to cast large-area and elongated parts with unit weights of kg. HWS machines can be integrated with third-party systems. Visit for more information. 这确实是 15 年前走的老路, 但是今天, 在砂型边角上出现了弱点 Winter 说到 静压气流挤压技术包含两阶段的压缩过程 首先称量砂子放到计量料斗中, 然后均匀地通过通风口分布到砂箱中 液压控制的碟阀在几分之一秒的时间内打开一个口, 产生预紧实所需的气流 在下一阶段中, 砂子进一步由液压多柱塞压实 半自动模板更换台使得模板可以在一个完整的周期内更换安装, 这意味着操作可以连续进行 本机的半自动设计也意味着工作场所可以更符合人体工程学 现在比以前需要更少的人工参与和劳动, Winter 说 这表示系统的生产效率进一步增加 将浇口杯钻孔夹具和空气打孔机组合起来, 意味着许多手工工作现在都自动化了 由于生产改变到一个全新的砂型系列, 不用停止生产进行改造, 所以具有至少 20 个单元的造型也是可能的 这扩大了我们的产品范围,Winter 说到 然而,Baumgarte 公司的生产范围扩大了, 最主要的还是由于砂箱的扩大 我们将砂箱的高度增加了 50mm, 以扩大铸件生产范围, Winter 说 工厂现在可以铸造 35.8t 重的大面积和很长的铸件 HSW 机器还可以和第三方系统集成 更多信息请访问 : Bruker s Carbon and Sulfur Analyzer Now Features Auto Cleaning Bruker 公司生产的碳硫分析仪现拥有自动清洁功能 Bruker AXS, Billerica, Mass., has added an auto cleaning feature to its G4 ICARUS CS HF carbon and sulfur analyzer, which is used by metalcasting facilities to assess and control the carbon and sulfur content in metal. Over time and after many sample analyses, byproducts such as metal oxide dust accumulate in the combustion furnace area of the analyzer, resulting in erratic results or even component failure. Prior to this upgrade, cleaning the instrument required disassembly and cumbersome manual cleaning that ate up lab time. While other self-cleaning analyzers require abrasive cleaning of the quartz tube by brushes and a vacuum cleaner, Bruker designed a pneumatically assisted cleaning assembly to scrub and dispose of the interfering combustion proper- Bruker AXS 公司 ( 位于美国马萨诸塞州比尔里卡 ) 如今将其生产的 G4 ICARUS CS HF 碳硫分析仪中增加了自动清洁功能, 此产品广泛应用于铸造企业在产品中评估和控制金属中碳硫含量 经过多次的样品分析, 对燃烧炉进行金属元素分析的仪器中会有大量杂物堆积, 例如, 金属氧化物 这样会导致分析结果偏差或是仪器故障 在产品升级之前, 仪器的清洁需要繁琐的拆卸工序及手工清洁过程, 也会浪费大量时间 其他带有自清功能的分析仪需要采用对石英管的 76 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

79 product news/ 產品新聞 A combustion viewing port on the front of the analyzer allows users to monitor the process in real-time. 从燃烧分析仪前观看端口, 使用户能够实时监控过程 ties automatically in the G4 ICARUS. A pneumatically-driven piston with integrated components cleans the furnace area, including a metal dust filter and the extraction nozzle with a downward stroke after each analysis. Dust is wiped from the metallic filter, and various blades on the cleaning mechanism s plunger remove splattering particles from the inner rim of the extraction nozzle. A small pulse of oxygen flow transports the liberated particulates into the spent crucible, to be disposed along with the combusted sample material. According to Bruker, this new auto cleaning feature allows the user to perform hundreds of analyses, depending on the application, before disassembly and manual cleaning is required. Using a high frequency induction furnace, the G4 ICA- RUS converts solid samples into gaseous components, which are measured by infrared detectors and processed into tangible carbon and sulfur concentrations. By providing a high pressure, oxygen-rich environment in the furnace, the sample material and accelerator combust, reaching temperatures above 1,500C, while liberated carbon and sulfur compounds are oxidized to form carbon dioxide and sulfur dioxide. The G4 ICARUS features a viewing port on the front of the furnace to allow users to monitor the combustion process in real-time. The extraction nozzle directly above the furnace removes the gaseous components from the furnace to be transported downstream for eventual detection. Destructive byproducts that can splatter against the surrounding quartz combustion tube also are extracted by the nozzle. According to Bruker, users benefit from limited dust contamination with improved analytical results and extended quartz tube lifetimes. The combusted gas stream exiting the furnace area is directed through a drying reagent to remove any moisture that may have been produced or released during combustion. Pressure and flow regulating components ensure consistent combustion, transport and detection from one analysis to the next. The purified gas stream is quantified using selective and stable non-dispersive infrared detectors, which respond exclusively to the amount of carbon dioxide and sulfur dioxide in the stream. After sulfur is detected, the gas stream flows through a heated oxidation furnace 打磨清刷方法或是使用真空清洁器 Bruker 公司设计生产的 G4 ICARUS 产品带有气动功能以辅助仪器在干预燃烧的性能的同时自动清理和处理废物 每一次的实验分析中, 一组气动活塞部件用于清洁炉区, 包括金属粉尘过滤器 粉尘被带离金属过滤器, 大量的废物通过大尺寸出气孔流出 在载气的作用下, 粉尘被自动带离炉头位置, 随着燃烧的样品材料加以处置 Bruker 公司称, 根据实际应用得出, 具有自动清洁功能的产品在彻底拆卸手工清洁前, 可以完成数百次分析检测工作 在高频感应炉中,G4 ICARUS 将固体样本转化为气体成分, 通过红外探测仪测量分析碳硫气体溶度 通过提高空气压力, 炉内氧气充足, 样品材料加速燃烧, 炉温达到 1500 C, 分离出来的碳硫物质被氧化为二氧化硫和二氧化碳 G4 ICARUS 红外碳硫分析仪在炉前还装有观察屏, 使用者可以实时监控炉内燃烧过程 炉体上的抽气口将气体从炉内抽出直接检测 有害物质也通过抽气孔排出, 避免废气在燃烧石英管周围堆积 Bruker 公司表示, 粉尘污染得到限制后, 使用者得到更准确的分析结果并且可延长石英电子管的使用寿命 从炉体中排出的可燃气体流直接加入干燥试剂, This block diagram depicts the primary components of the G4 ICARUS CS HF and the analytical flow path. 这个框图描述 G4 ICARUS CS HF 的主要组成部分和分析流路 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 77

80 product news/ 產品新聞 The Bruker G4 ICARUS CS HF carbon and sulfur analyzer features automatic cleaning. Bruker 公司的 G4 ICARUS CS HF 碳硫分析仪有自动清洗功能. to catalytically oxidize carbon monoxide to carbon dioxide and convert some of the sulfur dioxide to sulfur trioxide. Sulfur compounds, which are no longer needed, are removed by passing the gas stream through cellulose. The gas stream comprised of oxygen, carbon dioxide and possibly a small amount of nonoxidized sulfur dioxide, flows through a selective carbon dioxide cell to measure the carbon content before exiting through the exhaust. The analysis time for a single analysis with the Bruker GH ICARUS is nominally 40 seconds, depending on the sample application, sample mass and carbon/sulfur concentration. Visit for more information. 以消除在燃烧过程中产生的水分 压力与空气流动调节部件确保炉内持续燃烧, 以及不断输送气体进行检测 经过净化的气体使用选择定的高稳定性的非色散性红外探测仪检测, 得出的二氧化碳与二氧化硫的量较为准确 硫检测过后, 气体流经过加热氧化炉后, 一氧化碳被催化为二氧化碳, 二氧化硫被催化为三氧化硫 更多信息请登录 : Clean Water Glycol Reduces Maintenance Costs 清洁的水乙二醇可降低保养费用 Leakage, defective valves or pumps and frequent exchange of seals are, for many, a maintenance responsibility in pressure die-casting and a well-known part of daily routines. Less known is the fact that 80% of all failures in hydraulic systems are caused by contamination in the operating fluid. Removing particles from the fluid can prolong the lifetime of valves and pumps by a factor of 7 and result in significantly less downtime and maintenance costs. CJC Fine Filter units operate in an offline circuit with integrated circulating pumps. As the central part of these filters, the depth filter insert retains particles down to 1 µm with a dirt holding capacity of up to 4 kg per filter element. Even in rough surroundings such as pressure die-casting facilities, fluid systems can permanently be kept clean. Applications at German car manufacturers show that by increasing the cleanliness of water glycol from 19/18/14 to 14/12/9 (factor 32), the lifetime of hydraulic components is prolonged and precision of the process is enhanced. There also is a decrease in blowholes which reduces the amount of scrap. For further information and contact details, see 渗漏现象经常出现在有缺陷密封泵体 阀体中 众多情况下, 保养工作在这类高压压铸件中成为熟知日常工序 很少有人知道,80% 导致液压系统缺陷的因素来自于流动液体中的污染物 去除液体中的杂质可延长泵阀产品 7% 的使用寿命, 并且可以大大降低停工时间和保养费用 CJC 精滤器是带有一体化循环泵的离线过滤装置 作为过滤器的核心部件, 每个滤芯在滤液中每下降 1 微米, 纳污量可提高 4 千克 ( 见图 1) 即使在粗糙的表面环境下, 例如高压压铸件中, 液压系统可持久保持清洁 德国汽车生产商利用此产品将水乙二醇的清洁度从 19/18/14 提高至 14/12/9( 因素 32), 液压部件的使用寿命得到了提高, 工艺精密度得到了加强 同时, 此产品还降低了气孔的产生, 降低了废品数量 更多信息及细节请登录 : As the central part of CJC Fine Filters, the depth filter insert retains particles down to 1 µm with a dirt holding capacity of up to 4 kg per filter element. 作为 CJC 精细过滤器的中央部, 深度过滤器的插入保留最多至 4 公斤每过滤元件的污物保持能力下降到 1 微米的颗粒 78 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION Fall 2012

81 Supplier s Perspective/ 供应商观点 Cleaner Air in Asia KMA s Parisa Javadian shares insights on air purification for metalcasters in the Far East. 亚洲工厂空气的清洁 KMA 公司 Parisa Javadian 对远东铸造厂空气净化的见解 Parisa Javadian, global marketing and business development leader for KMA, Königswinter, Germany, discusses growth in Far Eastern markets with Global Casting Magazine. KMA provides air filtration and heat recovery systems to industrial facilities. The German and European markets are characterized by strict regulations in conjunction with product quality, quality in work and acquiring certifications. What is the situation in China and the Far Eastern market? Javadian: The Chinese market is distinguished by an increasing sense of responsibility. Even if no strict mandatory limits and values for emission outputs are in place, there is an increasing awareness of air quality at the top management level. Many Chinese managers and decision makers have realized the importance and the benefits of clean air in the workplace, and they are implementing this knowledge. Air filtration not only saves the environment, but offers substantial advantages for the plant, leading to decreased costs and increased productivity. How can benefits through air filtration be explained? Air purification costs money, and an exhaust air filtration system requires an additional investment. Javadian: Die casting machines generate greasy, oily and paste-like smoke and aerosols. Some managers think the easiest and cheapest method of exhaust air treatment is no treatment at all. Allowing exhaust air to disperse into the production hall without being purified is not a cost-saving method. People often fail to consider the greasy aerosols that will deposit on newly made products and the entire manufacturing plant. Oily 德国 Königswinter 市 KMA 公司的全球市场营销和业务发展经理 Parisa Javadian 和世界铸造 (Global Casting ) 杂志社讨论了远东市场的增长 KMA 为工业装备提供空气过滤和热回收系统 德国和欧洲市场的特点是除产品质量 工作质量和获得认证之外严格的空气质量规定 在中国和远东市场的情况是什么呢? Javadian: 中国市场的特点是责任感与日俱增 即使现在排放方面还没有严格的强制性限制和指标, 高层管理人员开始意识到空气质量问题 许多中国的管理者和决策者已经认识到工作场所的清洁空气的重要性和好处, 他们正在强化这方面的认识 空气过滤不仅保护了环境, 还为工厂提供了巨大的优势, 即降低成本和提高生产率 空气过滤能带来好处该如何解释呢? 空气净化费钱, 废气过滤系统需要额外的投资 Javadian: 压铸机产生油腻和糊状的烟雾和气溶胶 有些管理者认为, 处理废气的最简单和最便宜的方法是不用管 允许废气排入没有净化设备的生产车间并不是一种节约成本的方法 人们往往没有考虑到油腻的气溶胶将沉积在新产品和整个生产厂 Parisa Javadian Parisa Javadian Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 79

82 KMA Ultravent KMA Ultravent deposits affect product quality and increase the need for maintenance. In addition, the casting machines, peripheral devices, as well as the building, itself, accumulate dirt on their surfaces. Air pollution has a negative effect on metalcasting facility employees, which can result in illness and decreased productivity. A company might save the cost of an air filtration system but incur extra costs in other sectors. If the metalcasting facility made a one-time investment in an exhaust air filtration system, the company would achieve significant cost savings over the years and return the initial investment in a short payback period. When considering the investment needed to build up a new metalcasting plant, including casting machines, peripheral devices and the facility itself, the additional expenditure for an exhaust air filter system is relatively low. KMA exhaust air filter systems work in a recirculating air mode. Especially on cold winter days, which are very common in the north of China, companies can save up to 80% of their annual operating costs. An 80% savings is a fairly large amount. How is that possible and how does it work? Javadian: With the exhaust air mode, waste air is led outside, either with or without air purification. This method ensures clean air in the workplace but creates high followup costs, especially during cold winter periods. The same amount of air that is led outside has to be replaced by 80 油性的沉积影响产品质量和增加维修 此外 铸造机 和外围设备以及建筑物本身 在其油渍表面上会沉积 灰尘 空气污染对铸造工厂的员工有不良影响 这可 能会导致疾病和生产力的下降 公司或许节约了空气 过滤系统的成本 但在其它方面产生了额外的费用 如果铸造厂一次性投资废气过滤系统 该公司几年 后就能显著节约 并在很短的投资回收期回收初始投 资 如果考虑新铸造厂的投资 包括铸造机 外围设 备和空气净化设施本身 用于废气过滤系统的额外开 支是比较低的 KMA废气过滤系统在循环空气模式 下工作 特别是在寒冷的冬日里 这在中国北方是很 常见的 公司可节省高达80 的年运营成本 节省80 是一个相当大的量 这怎么可能 它是如何 工作的 > Javadian 在排气情况下 无论有或没有空气 净化 废气都被排到室外 此方法可确保工作场所 空气的清洁 但后续成本高 尤其是在寒冷的冬天期 间 相同量的空气被引到室外 进来的新鲜空气来自 FOUNDRY-PLANET.COM Modern Cast ing CHINA FOUNDRY ASSOCIATION Fall 2012

83 KMA filter systems (yellow) clean the air in a metalcasting facility. KMA 过滤系统 ( 黄色 ) 净化铸造厂的空气 incoming fresh air from outdoors, which has to be heated up before it is led inside. Heating the cold fresh air to room temperature causes high operation costs. At the same time, the environment becomes polluted by high CO2 emissions from the heating process. In a recirculating air mode, the exhaust air will be cleaned effectively with highly efficient KMA electrostatic filter units. After filtration, the purified air will be led back into the production hall, allowing air to circulate in the hall without heat loss. The total energy consumption of the metalcasting facility decreases up to 80%, and high amounts of carbon dioxide emissions are avoided. KMA filter systems help metalcasting facilities achieve ISO 9000 and ISO certifications. While filter units in a recirculating air mode must purify the air permanently in a highly efficient way, the filter system s maintenance must be kept as low as possible and its durability must be kept as high as possible. What can customers from eastern countries expect from KMA Umwelttechnik, which is located in Germany, as well as from KMA products? Javadian: KMA exhaust air filter systems are characterized by a robust design as well as high quality and low-wear materials, which lead to long-term durability of the filter device. Aerosols leave greasy or encrusted deposits on the filter surface. Unsuitable filter types can quickly plug and become ineffective, leading to excessive costs associated with filter replacement and disposal. KMA filter systems are equipped with electrostatic precipitators, which never obstruct the air flow through the exhaust system. The filter cells do not need to be changed. KMA filter systems can be optionally equipped by an automatic filter cleaning device with an intelligent control system to minimize maintenance. As a general rule, all of our products are designed to be cost-effective and energy efficient. The increasing awareness and responsibility in China toward energy efficiency and clean air quality is increasing the demand for KMA exhaust air filter systems in Far Eastern countries. Beginning in October 2012, our customers from Far Eastern countries will be able to contact KMA in our new branch in Shanghai. In addition, KMA has had a close commercial partnership with Ultraseal India for quite a while. Ultraseal provides thermo curing methacrylate sealant and porosity sealing equipment, as well as industrial washing systems. With the new office in Shanghai and the collaboration with Ultraseal, we can meet our customers individual needs by offering a lot of flexibility. To receive this digital magazine in the future, go to 室外, 需要加热 将寒冷的新鲜空气加热到室温, 导致经营成本高 在同一时间, 环境被加热过程中所造成的高的二氧化碳排放量所污染 在循环空气模式中, 废气将被高效 KMA 的静电过滤器单元有效清洗 经过过滤, 净化后的空气将被引回到生产大厅, 让空气流通, 这个过程没有热损失 铸造厂总能量消耗可降低高达 80%, 并避免了大量二氧化碳的排放 KMA 过滤系统可以帮助铸造厂实现 ISO9000 和 ISO14000 认证 虽然过滤器单元中的再循环空气模式必须永久净化空气, 在高效率的方式, 过滤器系统的维护必须保持尽可能的低, 其耐用性必须尽可能高 来自东方国家的客户可以期望从设在德国的 KMA 公司以及 KMA 产品中得到什么好处? > Javadian:KMA 废气过滤器系统的特征在于强壮的设计 高品质和低磨损材料, 这些都使得过滤器装置经久耐用 气溶胶留下油腻或碳酸盐会沉积在过滤器表面上 不合适的过滤器类型可能很快会被堵塞, 过滤功能失效, 导致过滤器更换和处置的高费用 KMA 过滤器系统都配备了静电除尘器, 从不阻碍空气流通过排气系统 该过滤器的过滤单元不需要更换 KMA 过滤系统可选配自动清洗过滤器设备和智能控制系统以减少维护 通常, 我们设计的产品都具有成本效益和能源效率 在中国等远东国家能源利用效率和清洁空气的质量认识和责任的提升加快了对 KMA 废气过滤系统的需求 从 2012 年 10 月开始, 我们远东国家的客户将可以联系 KMA 在上海的分部 此外,KMA 和印度 Ultraseal 公司一段时间以来有着紧密的商业合作伙伴关系 Ultraseal 提供热固化丙烯酸酯密封胶和孔隙度密封设备以及工业清洗系统 随着上海新办事处和 Ultraseal 的合作, 我们能够满足客户的个性化需求, 提供了很大的灵活性 要获得这在未来的数字杂志, 去 Fall 2012 FOUNDRY-PLANET.COM Modern Casting CHINA FOUNDRY ASSOCIATION 81

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