Global Casting Magazine 2020 Issue 2

Published By:

MODERN

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CASTING

| FOUNDRY-PLANET.COM | MODER A PUBLICATION OF THE AMERICAN SOCIETY N CASTI NG | FOUNDRY CHINA FOUNDRY ASSOCIATION August 2020

Casting Competence Across Three Continents

WWW.GLOBALCASTINGMAGAZINE.COM

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AUGUST 2020

volume 10 number 2

P.26

FEATURES

专题文章

25 Lethbridge Iron Works, BRP-US Win Castings Of The Year

25 LETHBRIDGE公司、BRP-US公司赢 得年度铸件奖

30 Newcomer of the Year

30 年度新秀奖

31 Best Casting Conversion

31 铸造最佳转换奖

38 A System For The Thermal Analysis Of Steels

38 钢的热分析系统

DEPARTMENTS

专栏

6 Industry News 45 Product News

6 行业新闻 45 产品新闻

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STAFF/工作人員

STAFF/工作人员 MODERN CASTING

FOUNDRY-PLANET.COM

Managing Editor SHANNON WETZEL, swetzel@afsinc.org

Publisher/Editor THOMAS FRITSCH, tf@foundry-planet.com

Advertising Sales JOE MURPHY, AdSales25@aol.com FABIO CAVALIERI, fabio@afsinc.org

Senior Editor/ International Sales ADRIANA WEISENBACH, aw@foundry-planet.com Advertising Sales OANH LARSEN, ons@foundry-planet.com THERESA NEUMANN, tn@foundry-planet.com

Art Director MICHAEL J. BERRAFATO, mberrafato@afsinc.org

MODERN

CASTING 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 GAO WEI/高巍, gaowei@foundry.com.cn Li Mengmeng/李 蒙蒙, limengmeng@foundry.com.cn Advertising Sales Manager/ 广告销售主管 GAO WEI/ 高巍, gaowei@foundry.com.cn

张立波 出品人 中国铸造协会

Shannon Wetzel Managing Editor MODERN CASTING

Thomas Fritsch Publisher/Editor-in-Chief Foundry-Planet.com

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INDUSTRY NEWS/行业新闻

Industry News Contents 行业新闻目录

Industrial 3d Printing Accelerates Electric Car Industry 16 工业3D打印加速电动汽车发展 Covid-19 Global Industry Analysis 19 COVID-19病毒对全球行业影响分析 Resumption Of The Casting Production In China 21 中国铸造业复产 The international foundry festival at Targi Kielce 22 凯尔采国际铸造节将于今年举办

Foseco: Right Now, Research And Development Is Even More Important 16 福士科：现在，研发更重要 Sf&E Pours Largest Nuclear Impeller In Its History 18 SF＆E公司浇注最大的核叶轮 Ha Group And Si Group To Continue Long Term Partnership In Brazil And South Africa 24 HA集团和SI集团将在巴西和南非继续长期合作

50 Years Rump Strahlanlagen 7 RUMP抛丸设备公司成立50周年 German Cast Production 2019 And Outlook 2020. 10 德国铸造业2019年情况和2020年展望 Zanardi Fonderie – A Diary Of Shut Down To Restart 18 ZANARDI铸造公司 –关闭和复产的记录 Discover Turkey - New horizons, new markets, and new technologies for the die casting world. 23 发现土耳其-压铸世界的新视野、新市场和新技术。 ANKIROS/ANNOFER/TURKCAST 2020 – Prominent gathering of the foundry world. 23 2020年土耳其铸造、冶金暨钢铁工业展-全球铸 造业最重要的聚会 Enlarging Space for Die-Casting 24 扩大压铸的展区 ANKIROS/ANNOFER/TURKCAST 2020 Supporters 24 2020年土耳其铸造、冶金暨钢铁工业展的支持单位

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INDUSTRY NEWS/行业新闻

50 Years Rump Strahlanlagen RUMP抛丸设备公司成立50周年

On March 1, 1969, the company was founded by Konrad Rump as Konrad Rump KG with location in the East Westphalian Salzkotten. What began in a small private household at that time developed quickly thanks to Konrad Rump’s great expertise and entrepreneurial skills that it took only three years until it was necessary to relocate the offices to a larger residential building. Seven years later, with further growth, sales, construction and warehousing were moved to the commercial area “Breite Werl”. There also their own electrical planning department was set up Another 16 years later it went to the current location “Berglar.” The mechanical production was added.

Company founder Konrad Rump attached great importance to the fact that the company is run by the family.

Therefore, in 2010, he ordered is son-in-law Marcel Adriano to become another managing director. He helped him with advice and support until he withdrew more and more from daily business life. In June 2013, Konrad Rump died suddenly and unexpectedly.

RUMP develops customer-specific machines and system solutions with turbines and pneumatic blasting technologies.

They accompany the customers during the entire cycle of the project, from the initial idea, the service during operation, the possible adjustments to changing requirements to the dismantling of the plant. The competent employees not only keep an eye on the reliability, environmental friendliness and cost-effectiveness of the workpiece-oriented surface treatment, they also look at the system interfaces, such as conveyor technology, feeding, networking and Industry 4.0 For five decades, the company has been producing blasting systems in a wide variety of designs for a wide range of applications. Starting with small compact systems, such as the CUBESTA® and CAPSOR® models, short delivery times can be achieved through batch production on stock. These machines have been redesigned in terms of technology, form and color. The company also supplies customized blasting equipment for e.g. 100 tons workpiece weight. Solutions from RUMP can be found in all production areas, such as foundries, wagon and vehicle construction, automotive industry, welded assemblies, forgings, bulk solids and much more.

Each machine is individually tailored to the needs of the customer. The production of the machine components is fast and flexible - from planning to production exclusively at the plant in Salzkotten. This underlines the high quality of the RUMP shot blasting machines - just like the production according to the quality management DIN EN ISO 9001: 2015.

The highly efficient blasting turbines of the current R generation, developed by RUMP, provide optimal blasting media flow, durability and the simplest maintenance. Depending on the field of application or customer request, they are available in a wide variety of lining variants in order to achieve maximum service life. These turbines can also replace older blasting systems to operate inventory machines again more economically. Here, too, RUMP is continuously developing or redeveloping to increase its efficiency in blasting.

1969年3月1日，Konrad Rump先生创立了公司并以 他的名字命名，Konrad Rump KG公司位于东威斯特伐 利亚州萨尔茨科滕。得益于Konrad Rump先生丰富的专 业知识和创业技能，当时这个非常小的私人家庭作坊发展 得很快，花用了3年时间，就不得不将办公室搬迁到更大 的办公楼内。7年后，随着进一步的增长，销售、设计和 备件部门搬迁到商业区域“布雷特·韦尔”。还在那里设 立了自己的电气规划部。 又经过16年，公司搬到现在的位置“伯格拉”，并增 加了机械生产。 公司创始人Konrad Rump先生非常重视公司由家族 传承。因此，在2010年任命女婿马塞尔·阿德里诺成为 另一位董事总经理，帮助他提供建议和支持。随后他逐 步地退出日常商务活动。2013年6月，Konrad Rump 先生突然意外死亡。 RUMP公司用涡轮和气动喷丸技术开发客户专用的机 器和系统解决方案。他们在项目的全部周期中陪伴客户， 从最初的想法、运营期间的服务、对改变需求的可能调 整到设备的拆除。合格的员工不仅关注工件表面处理的 可靠性、环境友好性和成本效益，还关注系统接口，如 输送技术、进料、网络和工业4.0 50年来，公司一直在设计、生产各种应用广泛的 抛丸系统。从小的紧凑型系统开始，如CUBESTA®和 CAPSOR®型，可以通过批量生产库存来实现缩短交货 时间。这些机器在技术、外形和颜色方面进行了重新设 计。该公司还为客户提供定制的抛丸设备，如重达100 吨工件的专用设备。从RUMP公司的解决方案可以应用 在所有生产领域，如铸造厂、货车和车辆结构、汽车工 业、焊接组件、锻件、散状物料等等。 每台设备都是根据客户的需要量身定制的。机器零部 件的生产快速且灵活，从计划到生产完全在萨尔茨科滕 的工厂完成。这突出了RUMP公司抛丸机的高质量，就 像按照质量管理体系DIN EN ISO 9001: 2015生产一样。 目前R代的高效抛丸涡轮机由RUMP公司开发，提供最 佳的抛丸介质流、耐久性和最简单的维护。根据应用程序 或客户应用的领域，它们可以在不同的衬板变体中使用， 以达到最大的使用寿命。这些涡轮机也可以取代旧的抛丸 系统，以更经济地操作现存的机器。与此同时，RUMP公 司也在不断发展或重新发展，以提高其抛丸效率。 现有的喷丸机可由RUMP公司服务团队根据要求进 行检查和参数调整。登记要更换的磨损部件以及维修工

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

“We knew we were sending money out with every load, just unsure how much. Initially we estimated a one year payback. In reality we were blown away with a payback in less than 3 months.

Reliability…check.

Performance…check.

Payback…check.

Obviously we are thrilled!”

Steve Starks, Olin Brass

HIGHER CONCENTRATES, CLEANER MELTS.

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行业新闻 Existing shot blasting machines are checked and parameterized by the RUMP service team upon request. Wear parts to be replaced are registered and repair as well as maintenance works performed. If preferred, this work can also be carried out together with the customer's maintenance staff.

Required spare and wearing parts are often available at short notice due to their proximity to their own production. All this gives RUMP users the security they need to minimize potential downtime of the blasting system. ■

作。如果感兴趣，这项工作也可以与客户的维护人员 一起进行。所需的备件和磨损部件通常可以在很短的 时间内获得，因为它们大部分由自己生产。所有这些 都给了RUMP公司用户所需的安全性，以尽量减少抛 丸系统的潜在停机时间。 ■

German Cast Production 2019 And Outlook 2020 德国铸造业2019年情况和2020年展望 After the year 2019 was already characterized by a wide range of uncertainties and unstable economic policy conditions and German industry had been in recession since the fourth quarter of 2018, it still looked like a trend reversal for 2020 with subsequently more stable business. Since the outbreak of the coronavirus in China and the global spread of the new pathogen, the tide has turned and will keep the economy in suspense in the coming months. At this point, a note: In addition to the corona pandemic, other important economic and political issues are currently disappearing in the general public and media landscape. The many factors of uncertainty that affect companies' propensity to invest include: Brexit, existing trade conflicts between the economic powers and conflicts in the Middle East (Saudi Arabia and Russia) with uncertainty signals regarding oil and gas prices. The extent of the pandemic is not yet foreseeable.

The consequences for the economy can hardly be predicted and depend heavily on the length and depth of the health protection measures. Economic research institutes therefore view different scenarios as likely. If protective measures are gradually loosened from summer onwards, a gradual recovery in the second half of 2020 may be expected. By 2021 at the latest, catch-up effects should stimulate the German economy. Now looking back at 2019:

German cast production 2019: total figures The German foundry industry shrank last year by 8.9% to a total production (Fe and NE) of 4,950 million t. Their sales also fell - by 8.5% to EUR 12.430 billion. As in previous years, there was a heterogeneous development in the individual material groups: with 3.805 million tonnes, the iron and steel foundries produced 10.6% less than in 2018.

The production of non-ferrous metal founders shrank more moderately. 1.146 million t means a minus of 2.6%.

To put it in a nutshell: The decline compared to the extraordinarily high 2018 level is clear, but the production still corresponds to the level of 2010. Also in 2019, vehicle construction was by far the most important customer branch of the foundry industry with around 60%, followed by the machine - and plant construction with 20% of the total cast components. In the area of other cast components, which also accounted for 20 percent, there are many parts for mechanical engineering, as a clear demarcation e.g. between mechanical engineering and electrical engineering is no longer possible.

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在2019年，经济政策和条件已经具有广泛的不确定 性和不稳定性，尽管德国工业自2018年第四季度以来一 直处于衰退状态，但是预测2020年会趋势逆转，随后业 务更加稳定。自从新冠病毒在中国爆发并在全球传播以 来，潮流已经转向，并将在未来几个月使经济陷入悬念。 在这一点上，需要注意：除了新冠疫情，其他重要的经济 和政治问题目前正在一般公众和媒体中消失。影响公司投 资倾向的许多不确定性因素包括：英国脱欧、经济大国 之间现有的贸易冲突和中东（沙特阿拉伯和俄罗斯）的 冲突，以及石油和天然气价格的不确定性信号。目前， 新冠疫情的影响程度尚不可预见。对经济的后果很难预 测，在很大程度上取决于卫生保护措施的长度和深度。 因此，经济研究机构认为有可能出现不同的情况。如果 从夏季开始逐渐放松防护要求，预计2020年下半年将逐 步恢复。最迟在2021年，追赶效应将刺激德国经济。现 在回顾2019年：

德国2019年铸件产量： 德国铸造业去年萎缩了8.9%，总产量(黑色和有色)为 495万吨，销售也下降了8.5%，约为124.30亿欧元。与 往年一样，不同材质铸件的情况也不一样：铸铁和铸钢企 业的产量比2018年下降10.6%，约为380.5万吨，有色铸 造企业产量的收缩较缓，下降了2.6%，约为114.6万吨。 简而言之，与2018年的较高水平相比，下降是显而易 见的，但产量仍然与2010年的水平相当。同样在2019 年，汽车工业是铸造行业最重要的客户行业，约占60% ，其次是机械和市政建设，占铸件总产量的20%。其他 铸件应用领域，也占20%，有许多铸件应用于工程机 械，作为明确的界限，例如工程机械和电气工程之间， 已经不可能了。

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INDUSTRY NEWS/行业新闻 Three factors reduced the number of orders The customer industries in the foundry industry can look back on a challenging year due to weaker international demand. In particular, three factors led to lower orders: a slowing global economy, structural change in the automotive industry and numerous politically motivated upheavals - such as Brexit and ongoing trade disputes between the USA and China and the EU. All of this led to high uncertainties and had a braking effect on the propensity to invest. For the foundry industry, this meant a noticeable decline in order intake regardless of the material. For vehicle construction, the iron and steel foundries produced 2.087 million tons in 2019, 10.5% fewer components than in the previous year.

This shows the increasing influence of the factory conversions of leading OEMs on e-mobility. There was also a 2.3% decline on the non-ferrous metals side to 0.919 million t. Declining orders from German mechanical and plant engineering led to a decline in production of iron and steel founders by 15.5% to 0.933 million tons. The German non-ferrous metal founders even had to accept a decrease of 16.6%. Because of the high export intensity, many branches of mechanical engineering suffer from global uncertainties. The minus rate was very different in the casting-intensive divisions.

三个因素减少了订单数量 铸造行业的客户行业可以回顾，这个因为国际需求较 弱而非常具有挑战性的一年。特别是，有三个因素导致 订单下降：全球经济放缓、汽车行业的结构性变化和许 多出于政治动机的动荡-如英国脱欧，美国与中国和欧 盟之间持续的贸易争端。所有这些都导致了很大的不确 定性，并对投资倾向产生了遏制效应。对于铸造行业来 说，这意味着无论何种材质，订单获取量都明显下降。 在汽车铸件方面，2019年铸铁和铸钢的工厂生产208.7 万吨铸件，比上年减少10.5%。 这表明，领先的OEM制造商受到电动汽车转型的影 响越来越大。有色铸件的产量也下降了2.3%，约为91.9 万吨。德国机械设备和工程机械订单的下降导致铸铁、 铸钢件的产量下降15.5%，约为93.3万吨。德国有色铸 造企业甚至不得不接受16.6%的下降。由于出口依赖性 高，工程机械的许多分支受到全球不确定性的影响。在 铸件大量应用的行业，下降程度有很大的不同。

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行业新闻

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For more information do not hesitate to ask your Elkem representative or visit elkem.com/foundry 12

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INDUSTRY NEWS/行业新闻 Outlook 2020 - how it could have happened At the beginning of 2020, it looked as if the German foundries still had a good chance of maintaining the 2019 production level in the final balance of the year. A bottoming out in the course of the first half of the year and a slow recovery in the second half of the year were considered to be quite realistic. With the additional factor "corona virus", the situation changes fundamentally for the rest of the year.

Outlook 2020 - status quo with coronavirus Due to the spread of the coronavirus, the outlook for 2020 set out at the beginning of the year is now waste. The exogenous shock will hit Germany and the global economy to an unknown extent. Because what is special about the new virus for the economy is that there is a simultaneous supply and demand shock. In addition, the effects are already clearly noticeable on the financial markets.

The stock exchanges around the world reacted in March with individual daily record losses. The most important indices, including the German Dax, are several thousand points below their highs, reflecting the clearly negative expectations of investors.

But what does the virus outbreak mean for the German foundry industry? For a more precise classification, a look at the core sales markets of vehicle and mechanical engineering follows.

Vehicle construction - situation at the OEMs At the beginning of the corona pandemic, the Chinese city of Wuhan in the Hubei region was primarily affected.

After curfews were put in place to curb the spread, the automotive hub also saw production stops by European OEMs. As a result, - with a time lag - disruptions in the global supply chains were expected, as many companies procure primary products from China. In addition, the demand for cars collapsed. After sales figures were already 10% lower in 2018 than in 2018, the drop in registrations in January increased to minus 20%. In February, the Corona crisis hit hard: the passenger car market volume collapsed by 82%.

This development is now also to be feared for other countries. The number of infected people is increasing globally every day. Northern Italy and Spain in particular are particularly hard hit and are currently fighting the virus. Car manufacturers are currently examining the extent to which they can produce medical technology and protective equipment, such as masks, in their plants. Due to Covid 19 cases in German automotive plants, these also had to be closed in rows, while in China production slowly started up again in 1-shift operation. For the time being, compliance with the European CO2 emissions standards for passenger cars is taking a back seat (95% of new registrations may not exceed CO2 emissions of 95 grams per kilometer on average).

Vehicle manufacturing - worldwide decline in demand for cars In general, demand for passenger cars is expected to plummet worldwide in the first half of 2020. Independent forecasting institutions such as LMC Automotive already assumed in their Corona Pandemic scenario in February that a 10% decline in production for 2020 should be expected for the

展望2020年-将发生什么 在2020年初，德国的铸造厂似乎仍然有很好的机会， 在今年最终盘点时保持2019年的生产水平。上半年的触 底和下半年的缓慢复苏被认为是相当现实的。随着意外 的因素“新冠病毒”，形势在今年剩余时间里发生了根 本的变化。

展望2020-冠状病毒的现状 由于冠状病毒的传播，年初制定的2020年展望现在 无法实现。外部冲击将在一个未知的程度上打击德国和 全球经济。因为新冠病毒对经济的特殊之处在于同时存 在供求冲击。此外，对金融市场的影响已经显而易见。 世界各地的证券交易所在3月份的反应中出现了个人 每日创纪录的亏损。最重要的指数，包括德国DAX， 都低于其高点数千点，反映了投资者明显的负面预期。 但病毒的爆发对德国铸造业意味着什么？为了获得更精 确的分类，请看以下汽车和工程机械的核心销售市场。

汽车制造业- OEM企业现状 在新冠病毒大流行开始时，中国湖北的武汉市受到最 主要的影响。在实施居家隔离以遏制蔓延之后，汽车行 业的枢纽，欧洲OEM制造商的生产停止了。因此，随着 时间的推移，全球供应链预计会出现中断，因为许多公司 从中国采购初级产品。此外，对汽车的需求也崩溃了。在 2018年的销售数字已经比2018年低10%之后，1月份的 注册人数下降到了20%。今年2月，新冠危机重创乘用车 市场，成交量暴跌82%。 这一发展现在也是其他国家所担心的。全球感染人 数每天都在增加。特别是意大利北部和西班牙受到特别 严重的打击，目前正在新冠病毒作斗争。汽车制造商目 前正在研究他们在工厂生产医疗技术和防护设备（如口 罩）的可行性。由于德国汽车厂出现新冠病例，这些工 厂也不得不成排关闭，而在中国，生产再次缓慢启动， 以一班倒运行。目前，遵守欧洲乘用车CO2排放标准的 情况正处于次要地位（95%的新登记汽车遵守不超过平 均每公里95g的CO2排放量）。

汽车制造-全球汽车需求下降 总体上，2020年上半年全球对乘用车的需求预计将大 幅下降。LMC汽车等独立的预测机构已经在2月份的新冠 大流行情景中预测，中国乘用车市场预计2020年的产量 将下降10%。欧洲市场在2020年也可能面临相当大的压

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INDUSTRY NEWS/行业新闻 Chinese passenger car market. The European market is also likely to be under considerable pressure in 2020. The VDA has so far not issued an officially adjusted forecast for the German and European automotive market. Industry analyst Ferdinand Dudenhöffer expects sales in Western Europe to decline by 11%, however, depending on the further course of the pandemic in Europe, the figures could be even lower. For 2020, he anticipates a corona-related decline in sales of one million.

Dudenhöffer also expects the Western European automotive market to take a decade to return to 2019 levels.

Mechanical engineering In addition to the German foundries, the machine builders are also concerned about the car industry's production stops.

The VDMA temporarily lowered its production forecast from minus 2% to minus 5%. In a flash survey by the VDMA, 60% of the companies indicated that the supply chains were affected, particularly by Italy and China. German foundries were occasionally able to take advantage of the opportunity and take on orders to ensure the production of important components. This shows that in such times it is necessary not to close foundries in general. Because they often produce key components that are required to keep a machine running, which in turn is required for the production of essential goods.

Corona virus - also positive outlook?

First, on the aspect of the companies' immediate economic management of the situation: foundries will report liquidity shortages. The concrete political options for action by the European Union as well as the federal and state governments to support German SMEs in this crisis are currently being discussed. It is essential that the help reaches the companies on site.

Nothing should be glossed over at this point: The effect of the corona pandemic is clear, predominantly negative and thus also a major risk factor for the German foundry industry. At the same time, there are occasional opportunities. Because now is the right time to convince customers to increasingly order castings again in Germany. Since production ceased in China, global supply chains have been increasingly evaluated and reconsidered. The establishment of a second supplier and thus the concept of dual sourcing could be an option for many foundry customers in the future to ensure the delivery of preliminary products.

Now one should not expect that purchasing leaves the price-controlled approach and is no longer globally oriented, first examples from the industry prove this, but there are many advantages to ordering from domestic companies - such as short transport routes, prompt delivery, reliability and high quality On the hand. However, in times of functioning global supply chains, they are not the decisive factor for an order. In times of crisis, however, these aspects become all the more important. However, there is a chance that orders will at least partially remain with German companies in the long term. Knowing that many foundries initially struggle with the immediate, operational management of the new situation, these positive aspects are only hinted at here. In retrospect, the Corona crisis can be analyzed retrospectively from an economic perspective and the lessons outlined here can be discussed in depth. www.bdguss.de ■

力。德国汽车工业协会迄今尚未发布德国和欧洲汽车市场 的正式调整预测。行业分析师费迪南德·杜登霍夫预计， 西欧的销售额将下降11%，但根据欧洲疫情的进一步发 展，这一数字可能会更低。在2020年，他预计与新冠相 关的销售将下降100万辆。杜登霍夫还预计，西欧汽车市 场需要10年才能恢复到2019年的水平。

工程机械 除了德国的铸造厂，机器制造商也关心汽车工业的停 产情况。德国机械工业联合会暂时将其生产预测从下降 2%调整至下降5%。在德国机械工业联合会的一项快速 调查中，60%的公司表示供应链受到影响，特别是涉及 意大利和中国。德国铸造厂也许能够利用这一机会并获 得订单，以确保重要部件的生产。这表明，在这种情况 下，有必要保证部分铸造厂运行。因为它们通常生产保 持机器运行所需的关键部件，而这反过来又是生产基本 货物所必需的。

新冠病毒-是否有积极的前景？ 首先，在公司直接经济管理方面的情况：铸造厂将报 告流动性短缺。目前正在讨论欧盟以及联邦和州政府在 这场危机中支持德国中小企业的具体政治选择。重要的 是，援助可以直接到达公司。在这一点上，什么都不应 该掩盖：新冠流行病的影响是明确的，主要是负面的， 因此也是德国铸造业的主要危险因素。同时，也有偶尔 的机会。因为现在是说服客户在德国再次订购铸件的正 确时机。自中国因疫情停止供应，全球供应链越来越多 的被评价和重新考虑。建立第二个供应商，因此双重采 购的概念可能是许多铸造客户未来确保交付初步产品的 一种选择。 现在，人们不再期望采购总是关注价格控制的方法， 不再以全球为导向，行业第一次例证了这一点，从国内 公司订购有许多优点-例如运输路线短、交货及时、可 靠性和高质量。但是，在全球供应链协作的时代，它们 不是订单的决定性因素。然而，在危机时期，这些方面 变得更加重要。然而，从长远来看，至少有部分订单可 能保留在德国公司。据了解许多铸造厂在最开始就针对 新形势进行直接、有效改变，这些积极的方面在这里不 详述。回顾过去，可以从经济的角度对新冠危机进行回 顾性分析，并可以深入讨论这里概述的教训。 www.bdguss.de ■

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Foseco: Right Now, Research And Development Is Even More Important 福士科：现在，研发更重要 Before the corona shutdown, we visited the on-site research and development center for foundries, located near the Technical University of Enschede in the Netherlands, which has been researching and working for the international foundry industry for about 5 years. There, we met Dr. Fabian Sander, Global R&D Head at the Vesuvius Foundry Division, who enthusiastically showed us the facilites, including ultra-modern laboratories and test foundry, all fitted with the latest technology and equipment from well-known suppliers.

The R&D center in Enschede naturally works closely with the production facilities of Vesuvius GmbH in Borken and can therefore offer customers the cutting-edge technology that foundries need. As Dr. Sander emphasized, the goal is to achieve the best solutions.

On the one hand, it is about concrete research projects according to customer requirements. On the other, it is coming up with solutions before the problem arises in anticipation of customer needs. This is a result of close cooperation.

Modernly designed work environments and flat structures form the ideal framework for a relaxed, yet dense research atmosphere, with highly motivated employees and high-tech facilities focusing on melt treatment, feeder and filtration technology, binders, and coatings.

It can be expected that the global corona pandemic will intensify competition and lead to changes and even higher demands, and cast buyers could rethink their supply chains.

Curse and blessing, it is essential to be ahead in research and development. ■

在新冠疫情之前，我们参观了位于荷兰恩斯赫德技术 大学附近的铸造研发中心，该中心为全球铸造行业研究和 工作了大约5年。在那里，我们见到了维苏威公司铸造分 公司的全球研发负责人法比安·桑德博士，他热情地向我 们展示了工厂设施，包括超现代实验室和测试铸造厂， 所有这些都配备了来自知名供应商的最新技术和设备。 恩斯赫德的研发中心与维苏威铸造公司在博肯的生产 厂密切合作，因此可以为客户提供发现所需要的尖端技 术。正如桑德博士所强调的，目标是实现最佳的解决方 案。 一方面是根据客户要求进行具体的研究项目。另一方 面，在预期客户需求出现问题之前，研发中心正在提出 解决方案。这是密切合作的结果。 现代设计的工作环境和扁平的工作架构，构成了轻松 而富集的研究氛围的理想框架，员工积极性很高，高科技 产品专注于熔炼处理、冒口和过滤技术、粘合剂和涂料。 可以预期，全球新冠大流行将加剧竞争，导致变化， 甚至更高的需求，铸造买家可能将重新考虑他们的供应 链。福祸相依，在研发中领先是至关重要的。

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Industrial 3d Printing Accelerates Electric Car Industry 工业3D打印加速电动汽车发展 As key suppliers of the car industry, many foundries are under threat due to the current growth in e-mobility. The reason is, that the demand for castings for an electrically powered vehicle is significantly lower than for a conventional combustion engine. But voxeljet, the experts in industrial 3D printing, researched the application of 3D printed sand molds and metal casting for an electric vehicle in China.

With this case study, the innovative Research and Development department of the Asia-Pacific Division, led by Jin Tianshi, Managing Director voxeljet China, has gathered important information from major clients regarding their experiences in the field of industrial 3D printing for sand molds and the production of cast parts for electric mobility.

To improve the performance of their electric engines, the customer of the Chinese foundry MeiMai Fastcast Suzhou Co. Ltd turned to voxeljet. The mission: The first generation of their electrical engine did not meet 16

由于目前电动汽车的发展，作为汽车行业的关键供 应商，许多铸造厂的订单受到影响。原因是，电动汽 车对铸件的需求明显低于传统内燃机汽车。但是维捷公 司，工业3D打印专家，研究了3D打印砂型和金属铸造 在中国电动汽车中的应用。通过这个案例研究，亚太事 业部的创新研发部门，由维捷中国董事总经理金天拾领 导，从主要客户那里收集了重要的信息，了解他们在砂 型工业3D打印和电动汽车铸造零件生产领域的经验。 为了提高他们的电动发动机的性能，维捷公司的中 国客户，美迈快铸苏州有限公司找到他们。任务来源： 他们的第一代电动发动机不能满足各种客车的需求。 来自苏州美迈的一位开发工程师说：“我们必须

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INDUSTRY NEWS/行业新闻 the demands of various passenger cars.

A research engineer from MeiMai Suzhou said: “We had to make major improvements very quickly and therefore had to test numerous variants of the e-motor housing. Using conventional molding methods, the development of the new housing would have been extremely time-consuming.

Thankfully we came across voxeljet’s 3D printing process for the tool less production of casting molds.”

“Increasing design flexibility and saving time were the critical factors, that made MeiMai Suzhou approach us,” said Tianshi from voxeljet. “Because the conventional process for manufacturing housing parts for prototypes of electric car motors simply took too long.”

By utilizing 3D printing, MeiMai Suzhou was able to complete the project before the set deadline. The whole project involved the manufacture and testing of various design iterations, the complete collection of data on the different components. Using conventional molding processes, the project would have taken up to two months. With additive manufacturing, the team of MeiMai Suzhou was able to complete the project within just three weeks.

Another advantage of the 3D printing process, besides the rapid production of the molds, was the cost efficiency for small batches. Since the 3D printing process doesn’t require any tools, small batches can be produced with a dramatic cost-benefit. In addition to this, voxeljet’s high-precision industrial 3D printing systems ensure very low waste or scrapping rates, because when using conventional methods and a tool for molding, any changes on the prototype would require a hands-on revision of the tool or a completely new one. With 3D printing, any changes can be carried out digitally and a new test mold can be printed and casted.

“The post-production of various types of motors can be carried out much quicker and therefore shortens the product development cycle dramatically,” Tianshi said. “For example, both type A and type B can be installed and tested at the same time, and then the higher performance or more efficient version can be selected for mass production.”

However, industrial 3D printing does not have to be used just for electrical engine housings. The Chinese foundry MeiMai Suzhou is already experimenting with the production of sand molds for retarder and controller housings, various brackets, support frames and several other components that play a key role in emobility.

“The whole process makes it just so much easier to build prototypes,” Jin Tianshi said. voxeljet 3D printing allows for part optimization: from topology optimization to durability and performance, as well as weight savings In addition to the rapid realization of the engine parts, MeiMai Suzhou was able to improve its motor performance by intelligently optimizing the designs.

“The durability of the components can also be influenced.

As a next step in the housing development, we will also tackle weight reduction through topology adjustments such as the position and height of the outer reinforcing ribs," Tianshi said. "Thanks to 3D printing, emobility is a real opportunity for foundries!" ■

迅速做出重大改进，因此必须测试大量的电动马达 外壳。使用传统的成型方法，开发新的壳体将极其耗 时。非常幸运，我们遇到了维捷公司的3D打印工艺， 节省了生产铸造模具的环节。” 维捷公司的金天拾表示：“增加设计灵活性和节省 时间是关键因素，使苏州美迈公司接受我们。因为生 产电动汽车发动机外壳部件，传统工艺耗时太长。” 通过使用3D打印，苏州美迈能够在设定的截止日 期前完成该项目。整个项目涉及各种设计迭代的制造 和测试，以及对不同组件的数据的完整收集。使用传 统的成型工艺，该项目将需要两个月的时间。在增材 制造方面，苏州美迈的团队能够在短短3周内完成该 项目。 除了快速生产铸型外，3D打印工艺的另一个优点 是，小批量的成本效率。由于3D打印工艺不需要任 何模具，小批量可以生产戏剧性的成本效益。此外， 维捷公司的高精度工业3D打印系统确保了非常低的损 耗或报废率，因为当使用传统的方法和成型工具时， 原型上的任何更改都需要对模具进行完全的修改。有 了3D打印，任何变化都可以通过修改数据，新的测试 铸型可以打印和铸造。 “各种类型电机的后期生产可以更快地进行，因此 大大缩短了产品开发周期，”金天拾说，“例如，A型 和B型都可以同时安装和测试，然后可以选择性能更高 或效率更高的版本进行大规模生产。” 然而，工业3D打印不一定只用于电动发动机壳体。 中国铸造厂苏州美迈已经在试验生产缓速器和控制器 外壳、各种支架、支撑架和其他几个在电动汽车中起 关键作用部件的砂型。 金天拾说：“整个过程使制造原型变得更加容 易。” 维捷公司3D打印可以优化零件：从拓扑优化到耐 久性和整体性能优化，以及减少重量，除了快速实现 发动机部件生产，美迈苏州能够通过智能优化设计来 提高其电机性能。 “零部件的耐久性也会受到影响。作为壳体开发的 下一步，我们还将通过拓扑调整，如外部加强肋的位 置和高度，来解决减重问题。”金天拾说，“多亏了 3D打印，使电动汽车成为铸造厂真正的机会！”

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SF&E Pours Largest Nuclear Impeller in Its History SF＆E公司浇注最大的核叶轮 Stainless Foundry & Engineering, Inc. poured the largest impeller in the history of its company. Utilizing AOD ingot, they melted and cast 6,000 pounds of Ca6Nm martensitic stainless steel.

The reputation of Stainless Foundry & Engineering (SF&E) was built on being an industry leader in manufacturing all styles of impellers. Historically the Pump & Valve industry has had a great need for high quality Impellers, relying on SF&E for high spec work like the one shared below.

SF&E specializes in: • Open Impellers • Multi Staged Impellers • Double Suction Impellers • Closed impellers SF&E works to exacting industry standards. Recently, a customer was in dire need of a series of nuclear impellers commanding the foundry's biggest challenge yet. Not only that, but this all unfolded during the global COVID-19 pandemic and local Stay at Home order.

This customer was originally scheduled to be on site for the majority of the process. The Stay at Home order may have prevented this from happening, but it did not delay the push to deliver this project on an expedited schedule. Positive and proactive measures were taken to communicate with the customer. Conference calls about the project's status took place every Tuesday and Thursday, on top of sharing various e-mails and photos detailing the progress on these first article castings.

Even through extenuating circumstances, the entire process was a success. SF&E cast, machined, and performed various non-destructive tests, including 120 radiographic exposures, on these large class 1 nuclear impellers to fulfill an 11-week lead time while maintaining a collaborative relationship with the customer. ■

SF＆E公司浇注出公司历史上最大的叶轮。熔化了 6000磅Ca6Nm马氏体不锈钢，AOD炉精炼。 SF＆E公司的声誉建立在能够制造各种样式叶轮，是行 业领导者。从历史上看，泵、阀行业对高质量叶轮的需求 很大，依靠SF＆E公司要求严格的工作，共享以下内容。 SF&E specializes in: SF＆E公司专业生产： • 开放式叶轮 • 多级叶轮 • 双吸叶轮 • 封闭式叶轮 SF＆E致力于严格的行业标准。最近，客户迫切需要 一系列核叶轮，成为迄今为止铸造厂最大的挑战。不仅 如此，在全球COVID-19大流行和本地“居家隔离”期 间，这一切都得到了体现。 该客户原定在大部分过程中都在现场，居家隔离，在 线办公的禁令阻止了这种情况的发生，但是它并没有延 迟推动按计划进度交付该项目的努力。公司采取了积极 主动的措施与客户沟通。关于项目状态的电话会议在每 个星期二和星期四举行，此外还分享了各种电子邮件和 照片，详细介绍了这些首件铸件的进展。 即使情况恶化，整个过程还是成功的。SF＆E公司对这 些大型1级核叶轮进行铸造，加工和执行各种无损检测， 包括120次射线照相曝光，以期达到11周的交付周期，同 时保持与客户的合作关系。 ■

Zanardi Fonderie – A Diary of Shut Down to Restart ZANARDI铸造公司 –关闭和复产的记录 On Saturday, February 22, Zanardi Foundry had the first confirmed news and began to realize what was happening. Between February 24 and March 12, production kept working regularly, but business trips, meeting with visitors, and trainings were immediately cancelled, and restrictions and new rules in the offices were put into effect. March 13 until March 20, in accordance with the Unions, the foundry was closed using layoffs, though work in fettling, machining, and heat treatment departments continued. Deliveries were regularly carried out.

March 23 until April 27, every production and logistic activity was stopped, according to Government Decree “Chiudi Italia.”

Since the beginning of the emergency, a broadcast SMS communication tool was activated to share urgent informa18

2月22日星期六， ZANARDI铸造公司得到了第一个 确认的消息，并开始意识到发生了什么。 在2月24日至 3月12日之间，生产正常进行，但商务旅行，与访客见 面和培训被立即取消，并且办公室的限制和新规定也已 生效。3月13日至3月20日，根据工会联合会的规定， 铸造车间因裁员而关闭，机加工和热处理部门的工作继 续，定期交货。 根据政府法令“Chiudi Italia”，从3月23日至4月27 日，所有生产和物流活动均已停止。 从紧急情况开始，ZANARDI铸造公司就激活了广播

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INDUSTRY NEWS/行业新闻 tion with Zanardi employees 24/7, and smart working management was promptly for employees. Around 60 employees were enabled to work from home, to be able to give any time continuity to Zanardi's business relationships, and to be 100% ready for when production may be restarted and make deliveries to customers.

On May 4, according to the latest decree by the Italian Prime Minister, Zanardi Fonderie restarted its production activities and implemented the regulations laid down by a strict health and hygiene protocol drafted in cooperation with all the representatives of workers and employers and trade unions.

To allow all workers to return to normality whilst respecting the necessary rules to protect their own health and that of their colleagues, Zanardi Fonderie adopted key measures by the Health and Safety Committee (HSC).

They are sanitization of all the company’s premises, smart working, body temperature checked with a thermal camera and scanner at all entrances, mandatory distance, and supply masks for employees and visitors.

Have a look at this link to know more about all the important safety measures the foundry has implemented: https://zanardifonderie.com/en/reopening-safely-to-tacklethe-covid-19-emergency-together/.

Over 30 work-related instructions and procedures have been drafted to clarify and remind all workers of the importance and obligation to conduct themselves appropriately at all times. These have been represented in graphic form and displayed in all the company production departments, offices and communal entrance and exit areas.

C19 impact in the upcoming months At Zanardi Fonderie, reactiveness and adaptability will be the key words to be successful in the “post-Covid” era. Since the beginning of the emergency, Zanardi has been training to be ready to restart at its best, possibly even better than before.

Like in any big changes, there will be products suffering a big crisis in demand, and others selling more than before.

Therefore, the absence of a clear perspective doesn’t mean necessarily pessimism, there will be new opportunities in the world coming after. ■

SMS通讯工具，与员工24/7共享紧急信息，并迅速为 员工提供了智能工作管理。大约有60名员工可以在家工 作，可以随时保持ZANARDI铸造公司业务关系的连续 性，并可以100％准备好重启生产并交付给客户。 根据意大利首相的最新法令，5月4日，ZANARDI铸 造公司重新开始了生产活动，并实施了严格的健康和卫 生规程，与所有工人，雇主和工会代表共同起草了规章。 为了使所有工人恢复正常状态，同时遵守保护自己和 同事健康的必要规则，ZANARDI铸造公司采用了健康 与安全委员会（HSC）的关键措施。他们对公司的所有 场所进行消毒，智能工作，在所有入口使用热像仪和扫 描仪检查体温，强制距离以及为员工和访客提供口罩。 查看此链接可了解有关铸造厂已实施的所有重要安全 措施的更多信息：https://zanardifonderie.com/en/ reopening-safely-to-tackle-the-covid-19-emergency-together/。 起草了30多项与工作有关的指示和程序，以澄清和提 醒所有工人在任何时候都应适当举止的重要性和义务。 这些以图形形式表示，并显示在公司的所有生产部门， 办公室以及公共出入口区域。

未来几个月新冠病毒的影响 在ZANARDI铸造公司，反应性和适应性将是在“ 后疫情”时代成功的关键词。

从紧急情况开始以

来，ZANARDI铸造公司一直在进行培训，以准备在最 佳状态下重启，甚至可能比以前更好。 就像任何大的变化一样，产品将遭受巨大的需求危 机，而其他产品的销量将比以往更高。因此，缺乏明确 的观点并不一定意味着悲观情绪，随之而来的世界将有 新的机遇。 ■

Covid-19 Global Industry Analysis COVID-19病毒对全球行业影响分析 The WFO surveyed its membership associations from around the world on the effects that the COVID-19 pandemic is having on the general economy and industry. It has received responses from 10 countries including, China, U.S., Germany, and Japan, along with a number of other Asian and European countries.

The overriding effect is on the automotive sector and those foundries supplying this industry, with many reporting a reduction of up to 50% since the closing down of the major car makers. The impact has been particularly felt in U.S., Japan and Germany, but also in other countries where the foundry industry is embedded in the automotive sector, such as Slovenia, Poland,

COVID-19大流行以来，WFO调查了来自世界各地的 会员协会，对经济和工业产生的影响进行了调查。收到 了来自中国，美国，德国和日本等10个国家以及许多其 他亚洲和欧洲国家的回应。 压倒一切的影响是汽车行业和为该行业提供产品的铸 造工厂，自主要汽车制造商倒闭以来，许多铸造厂的产 量下降多达50％。在美国，日本和德国，尤其是在铸造 行业嵌入汽车行业的其他国家（例如斯洛文尼亚，波兰，

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INDUSTRY NEWS/行业新闻 Turkey and Mexico. The hardest hit country from our survey seems to be Korea, with a 50% decline in all orders, whilst in Indonesia, the effects are expected to be only a 10% reduction and the recovery to be within three months.

土耳其和墨西哥），这种影响尤其明显。在我们的调查 中，受打击最严重的国家似乎是韩国，所有订单均下降 了50％，而在印度尼西亚，预计影响仅减少了10％，复

Workforce

苏将在3个月内完成。

Virtually every respondent reports significant reductions in workforce, partially to assist with social distancing rules but mostly due to the reduction in orders and current demand. On average this has been around 20%. Initially a number of foundries took extended vacation leave around the Easter period in April, to accommodate a reduction in orders, government ‘social distancing’ and lockdown’ guidelines, and to enable facilities to prepare for increased COVID-19 safety procedures. The latter involved altering production facilities to enable social distance working with new working practices, additional washing and cleaning facilities etc. New homeworking procedures have also been adopted in most countries for non-production staff.

Most countries have experienced some form of Governmental support, either through business tax reliefs, loans, grants, wage support for furloughed employees or support with energy. It is anticipated that this will ease the shortterm issues associated with low order books and adopting new working practices to minimize the number of employees working together at the same time.

员工队伍

Ability to conduct business

开展业务的能力

Whilst preparation of facilities to enable further “safe working” conditions has been ongoing, WFO member associations report that one of the most significant concerns for the foundry sector has been the inability to travel, both within borders and internationally. Foundries and the supply industries have cited visiting existing and potential customers as an important part of their business. Thus, the travel restrictions have adversely affected their ability to market, sell and offer ‘hands-on’ technical support.

There is concern that, with travel restrictions still in place, this could affect future growth potential.

This has also impacted delivery of goods and receipt of raw materials and supplies. A number of European countries reported issues with cross border deliveries and, where foundries had significant export commitments, this is causing additional concerns and complications.

The supply sector has expressed concern over the ability to access raw materials in the volumes required once foundry production starts to pick up. Some countries have indicated a need to modify global supply chains in the future to protect against shortages and extended delivery times.

Essential Industries It has been interesting to see the variation in governmental identification of foundries as an essential part of the supply chain. Those working in the medical sector have witnessed significant and rapid increases in orders and have had to manage the need to accommodate this with increased capacity. Other essential goods industries have also seen increases in demand, these sectors include: those supplying paper products, energy production, agriculture, food produc20

几乎每个受访对象都报告了劳动力的大幅减少，部分 原因是为了满足社会安全社交距离的规则，但主要是由 于订单和当前需求的减少。平均而言，这一比例约为20 ％。最初，一些铸造厂在4月的复活节休了长假，以适应 订单减少，政府的“社会安全距离”和“封锁”准则， 并使工厂能够为增加的COVID-19安全程序做准备。后 者涉及改变生产设备，以实现新工作方式的社会距离要 求，额外的洗涤和清洁设施等。在大多数国家，非生产 人员也采用了新的家庭作业程序。 大多数国家都获得了某种形式的政府支持，包括通过 营业税减免，贷款，捐款，对休假员工的工资支持或能 源支持。预计这将缓解与低订单有关的短期问题，并采 用新的工作方法以最大程度地减少同时工作的员工数量。

尽管企业正在准备，以确保进一步的“安全工作”条 件，但WFO成员协会报告说，铸造行业最重要的担忧之 一是无法在国内和国际范围内旅行。铸造厂和供应商将拜 访现有和潜在客户视为其业务的重要组成部分。因此，旅 行限制对他们的营销，销售和提供“实际动手”技术支持 的能力产生了不利影响。令人担忧的是，由于仍然存在旅 行限制，这可能会影响未来的增长潜力。 这也影响了货物的交付以及原材料和供应品的接收。 许多欧洲国家报告了跨境交付问题，并且在铸造厂有重 大出口承诺的情况下，这引起了更多的担忧和麻烦。 供应部门对铸造厂生产开始回升后能否以获取所需数 量原材料表示担忧。一些国家表示将来需要调整全球供 应链，以防止短缺和延长交货时间。

基础产业 有趣的是，政府对铸造厂的身份识别的变化是供应 链的重要组成部分。在医疗领域工作的人员目睹了订单 的迅速显着增长，并且不得不应对增加产能以适应这种 需求。其他必需品行业的需求也有所增加，这些行业包 括：纸产品供应，能源生产，农业，食品生产和分配， 清洁和废水处理。这与为汽车行业（已停止交易一段时

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INDUSTRY NEWS/行业新闻 tion and distribution, cleaning and wastewater treatment.

This has been in marked contrast to those supplying the automotive industry (which ceased trading for a period) and the oil and gas sector, the latter of which has been impacted by the dramatic drop in oil prices.

Conclusion and Future Outlook Those foundries offering a wider range of castings have been able to spread the risk and have been less impacted than others. However, in general all in non-essential markets have been adversely affected with reductions in order books.

Many countries reported that investment plans and capital expenditure projects have been cancelled or delayed with medium term concerns about the post-COVID economy being the major reason.

The general consensus is that the recovery will be slow and prolonged, with many foundries citing six to nine months as the best estimate of recovery and then with potential reductions in the demand as recession hit economies influence the purchasing capacity of the population.

The other common response has been the uncertainty of the future related to the control of the virus, with no vaccine or cure yet to be found and the signs of some countries seeing a second spike in infection rates, despite the draconian and disruptive lockdowns. This means a general level of unease and uncertainty over when and how the overall markets will recover, leading to a pessimistic view of the short- and medium-term recovery.

There is a feeling that there will be closures and redundancies in some countries, whilst others may be better equipped to manage the reduction and new working practices. ■

间）和石油和天然气行业的供应形成鲜明对比，后者受 到石油价格急剧下跌的影响。

结论与未来展望 那些提供更多种类铸件的铸造厂能够分散风险，并且 所受的影响也要比其他铸造厂小。但是，总的来说，所 有非必需市场都受到订单减少的不利影响。 许多国家报告说，投资计划和资本支出项目已被取消 或推迟，其主要原因是对新冠疫情后经济的中期担忧。 普遍的共识是，复苏将是缓慢而漫长的，许多铸造厂 认为最好的估计是6-9个月，然后随着经济衰退对经济的 影响及人们购买力的影响，需求可能会减少。 另一个常见的应对措施是，与新冠病毒控制有关的 未来的不确定性，尚无疫苗或治疗方法的征兆，尽管严 酷和破坏性的封锁，一些国家的感染率再次出现上升的 迹象。这意味着对于整体市场何时以及如何复苏的总体 不安和不确定性，导致对短期和中期复苏持悲观态度。 感觉有些国家将实行裁员，而另一些国家则可能有更 好的能力来管理裁员和新的工作规定。 ■

Resumption of the Casting Production in China 中国铸造业复产 Mr. Zhang Libo, president of the China Foundry Association, led a team of experts from CFA to research the startup of work and production in Jize County. The chairman of the Jize County Party Committee and County Government accompanied the project, which took place from May 11-12.

Jize County is located in the south of the Hebei Province of China. In recent years, local government has actively promoted industrial upgrading, increased investment in environmental protection, and led enterprises into foundry parks to sustainable development. After upgrading, there are 58 foundry enterprises in Jize County, with municipal castings as the main products, with more than 200 automatic vertical and horizontal molding lines, more than 8200 employees, and 550,000 tons of castings in 2019 and an annual output value of 4.85 billion yuan. Has a number of well-known foundry enterprises, such as Handan Qunshan Foundry Co., Ltd, Hongguang Handan Cast Foundry Co., Ltd., and Baote casting. Awarded by China Foundry Association "Municipal Casting Base in China".

Now, active assistance from local governments, local foundry enterprises have all realized the resumption of production. Domestic market has returned to normal, affected by the epidemic, foreign market demand deficiency, the later market situation is not clear. ■

2020年5月11～12日，中国铸造协会张立波会长率专 家团队对鸡泽县“中国市政铸件产业基地”进行复工复产 调研，鸡泽县委县政府主要领导陪同调研。 鸡泽县位于河北南部，近年来积极推进产业提升，在 环保方面增加投资，同时引导企业进入铸造园区，聚集 发展。目前改造提升后，鸡泽县现有铸造企业58家，市 政类铸件产品为主要产品，拥有200余条自动化垂直及 水平造型线，从业人员8200余人，2019年铸件产量55 万吨，年产值48.5亿元。拥有群山铸造、虹光铸造、宝 特铸造等一批知名铸造企业。被中国铸造协会授予“中 国市政铸件基地”称号。 在地方政府积极协助下，目前当地铸造企业已全部实 现复工复产，国内订单需求已恢复正常，受疫情影响， 国外订单需求减弱，后期市场情况尚不明朗。 ■

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INDUSTRY NEWS/行业新闻

The international foundry festival at Targi Kielce 凯尔采国际铸造节将于今年举办

The events cluster is held in the Kielce exhibition and congress centre under the banner of the 'Industrial Autumn'. For years the Industrial Autumn has brought together representatives of the foundry business sector, components and modern technologies suppliers, foundries business insiders from all around the world. The expo is much more than over 300 companies from 37 countries putting their products and services on show, there are also workshops and industry focused seminars. The upcoming Industrial Autumn trade shows are held from 29 September to 1 October 2020.

The event is held in alternate years, each expo brings together an extensive groups of exhibitors and business-insider visitors from all corners of the world. The next METAL and its accompanying trade shows: ALUMINUM&NONFERMET, RECYCLING, CONTROL-TECH and HEAT TREATMENT offer a unique opportunity to establish business contacts with global partners, fond new leads and strengthen companies’ position on world’s markets. The previous Kielce event hosted industry representatives from Ukraine, Belarus, Russia, South Korea, Hong Kong, China, Turkey, Georgia and Serbia. The cooperation established with China Foundry Association has advanced Poland to become an important communication node and logistics liaison point for whole Eurasia. Asian companies are more and more active participants of the "Industrial Autumn" under the China Foundry Association’s umbrella.

There were also participants of the 73rd World Foundry Congress among the several thousand world experts who visited the trade fair. The expo hosted professionals, representatives of various industries and business-sectors such as foundry, machine and electromechanical, rail, shipbuilding, armaments, robotics and automation, automotive and aviation. They came to Targi Kielce from the most distant corners of the world, including Austria, Belgium, Estonia, France, Lithuania, the Netherlands, Sweden, Switzerland, Uzbekistan, Germany, the Czech Republic, Italy, Ukraine, Hungary, Belarus, Slovakia, Spain, Great Britain, the United States, Slovenia, Russia, Turkey, India, China and Japan.

The expos’ excellent standing is closely connected with positive forecasts for the whole industry. Polish foundry business facts and figures - over 460 foundries with the output of over 1.1 million tonnes of castings per year make Poland fifth place in Europe’s casting production ranking, right after Germany, France and Italy.

The expo - a knowledge packed platform For years, Targi Kielce has enjoyed the support of foundry organizations and important media. China Foundry Association (CFA), Belarusian Association of Foundrymen and Metallurgists , Italian Foundry Suppliers' Association Amafond and the Polish STOP - Technical Association of Polish Foundrymen. The Kielce casting expos have been held under the honorary patronage of the Ministry of Enterprise and Technology. The patronage granted by the Ministry is a true appreciation for the organisers of this important event, a very significant point on the global foundry business map.

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凯尔采铸造会展活动将作为“秋季工业展”在波兰 凯尔采会展中心举办。经过多年的发展，秋季工业展 吸引了全球的铸造行业企业、零部件和现代技术供应 商等企业参加。届时，来自37个国家和地区的300多 家企业将携带最新的产品和技术参展，期间，还将举 办多场讲座和论坛。本届秋季工业展将于2020年9月 29日-10月1日举办。 展会两年一届。本届展会同期举办铝合金及有色 金属展、金属回收利用展、控制技术展及热处理展， 将为参展企业提供与全球同行建立联系、洽谈业务、 提高企业全球知名度的机会。上届展会的展商主要来 自乌克兰、白俄罗斯、俄罗斯、韩国、中国、中国香 港、土耳其、格鲁吉亚和塞尔维亚等国家和地区。此 外，主办方与中国铸造协会的合作使波兰成为欧亚大 陆一个重要的交流中心。 同时，来自第73届世界铸造大会的代表参观了展 会。观众包括来自奥地利、比利时、爱沙尼亚、法 国、立陶宛、荷兰、瑞典、瑞士、乌兹别克斯坦、德 国、捷克、意大利、乌克兰、匈牙利、白俄罗斯、斯 洛伐克、西班牙、英国、美国、斯洛文尼亚、俄罗 斯、土耳其、印度、中国和 日本等国家和地区的铸 造、设备、机电、铁路、造船、军工、机器人技术和 自动化、汽车和航空等领域的专家和代表。 展会的成功举办与整个行业的积极发展预期密切相 关。波兰有超过460家铸造厂，铸件年产量超过110 万吨。波兰是欧洲第5大铸件生产国，前三名是德国、 法国和意大利。

知识汇集的平台 多年来，凯尔采展览中心得到很多铸造行业组织 和媒体的支持，其中包括中国铸造协会、白俄罗斯铸 造冶金协会、意大利铸造设备供应商协会以及波兰铸 造协会。凯尔采铸造展还得到波兰企业及科技部的荣 誉赞助，这是对凯尔采展览中心举办该展会的大力支 持。

讲座及论坛 行业研讨会、讲座及培训课程是本届“秋季工业 展”的组成部分。上一届展会期间，举办了“使用火

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INDUSTRY NEWS/行业新闻 Workshops and seminars

花光谱仪/光学发射光谱仪OES进行材料识别”，“

Industry seminars, workshops and training sessions are an inherent part of the 'Industrial Autumn' trade show series. The previous expo included the meeting on "Materials identification with the use of spark spectrometry/Optical Emission Spectroscopy OES," the “Foundry 4.0: the best solutions from Italy" and the seminar focused upon "Metal Printing". The CONTROL-TECH - Fair of Industrial Measuring Technology and Non-Destructive Testing includes the DMIUT Diagnostics of Materials and Industrial Components congress; the meeting is held in Gdańsk. The session brings together participants from Japan and Canada et.al. The conference’s objective is to promote and disseminate the knowledge on the latest trends and solutions in non-destructive materials and steel elements testing, with particular emphasis on techniques based on steel magnetic properties. The issues discussed within the scope of the May conference find an excellent continuation at the September trade fair.

Presence of the whole array of top-class companies, businessinsider customers, well-targeted expo audience, B2B and matchmaking meetings, conferences, seminars, numerous foreign guests including top-class experts and a whole array of important accompanying and fringe events - this is what contributes to the expo success!

■

铸造4.0：意大利的最佳解决方案”以及以“金属打 印”为主题的研讨会。CONTROL-TECH，工业测量 技术和无损检测展览会包括材料和工业组件诊断大会 DMIUT，会议在格但斯克举办。会议汇集了来自日 本和加拿大等国家的参与者。此次会议的目的是促进 和宣传有关无损材料和钢元素测试的最新趋势和解决 方案的知识，尤其强调基于钢磁性能的技术。这次会 议使五月举办论坛的议题得到了很好的延续。 展会期间将有众多知名企业、行业客户、专业邀请 观众的参与，将举办多场B2B和对接会、论坛、研讨 会。众多的国际顶级嘉宾的参与以及一系列配套活动 的举办，这是展会成功的关键！ ■

Discover Turkey - New horizons, new markets, and new technologies for the die casting world. 发现土耳其-压铸世界的新视野、新市场和新技术。 Turkey ranks second in iron, steel and malleable iron castings and third in non-ferrous metal castings in Europe.

With already 90 % capacity in the die casting sector, Turkish foundries are keen to invest on enhancing their production capacities. Higher demand creates lots of opportunities for machinery, material and technology suppliers to the die casting industry. ■

在欧洲，土耳其铸铁、铸钢和可锻铸铁的铸件产量排 名第二，有色金属铸件的产量排名第三。在压铸的产能 已达90%的情况下，土耳其铸造厂仍热衷于投资提高产 能。更多的需求为压铸行业的设备、材料和技术供应商 创造了许多机会。 ■

ANKIROS/ANNOFER/TURKCAST 2020 – Prominent gathering of the foundry world.

2020年土耳其铸造、冶金暨钢铁工业展-全球铸造业最重要的聚会 The next edition of the trade fair trio ANKIROS/ANNOFER/TURKCAST trio will take place from 12 to 14 November 2020 in Istanbul, organized by Hannover-Messe ANKIROS Fuarcilik.

Two well established international congresses, the 11th International Foundry Congress by Turkish Foundry Association, and the 20th International Metallurgy and Materials Congress by Turkish Chamber of Metallurgy and Materials Engineers will take place simultaneously.

These shows have become the largest and most prestigious foundry event for Eurasia, bringing together all sections and stakeholders of the foundry industry under one roof. Taking place every two years since 1992, the fairs have established a

由汉诺威展览公司主办，即将到来的展会三重奏，土 耳其铸造、冶金暨钢铁工业展将于2020年11月12日至 14日在伊斯坦布尔举行。同时还将举行，土耳其铸造协 会主办的第十一届国际铸造大会，土耳其冶金和材料工 程师商会组织的第二十届国际冶金和材料大会。 历届展会已成为欧亚大陆最大和最负盛名的铸造活 动，将铸造行业的所有领域和利益相关者聚集在一起。 自1992年以来，展会每两年举行一次，已成为全球铸 造业的主要展会之一。 2018年展会，共有1,020家展商参展，其中有自45个

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行业新闻 reputation as one of the major shows for global foundry industry.

In 2018, the event hosted 1,020 exhibitors, of which 621 were international companies from 45 countries. 17,200 industry professionals from all around the world visited the event. Stand reservations of the leading suppliers to the foundry industry are progressing fast for the 2020 event. ■

国家的621家国际展商。来自世界各地的17200名行 业专业人士参观了展会。领先的供应商预定了展位， 希望2020年的展会对铸造行业取得快速进展。

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Enlarging Space for Die-Casting 扩大压铸的展区 Die-Casting will be a special focus topic in 2020. The high demand in the sector will offer great opportunities for exhibitors. ■

压铸将是2020年的特别关注的话题，压铸行业的大量 需求将为参展商提供巨大的机会。

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ANKIROS/ANNOFER/TURKCAST 2020 Supporters 2020年土耳其铸造、冶金暨钢铁工业展的支持单位 The fairs are fully supported by all related national associations, Turkish Foundry Association, as well as international associations.

■ Follow us at www.ankiros.com @hmankirosfairs

展会得到所有相关国家协会、土耳其铸造协会以及国 际协会的全力支持。

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相关资讯请访问网站：www.ankiros.com

Ha Group And Si Group To Continue Long Term Partnership In Brazil And South Africa HA集团和SI集团将在巴西和南非继续长期合作 Hüttenes-Albertus (HA), the world’s leading manufacturer of chemical products for the foundry industry, has announced that the company will continue its partnerships with the US-American specialty chemicals company SI Group in both Brazil and South Africa - following the termination of the agreement between ASK Chemicals and SI Group in terms of the intended disposal of SI Group´s Industrial Resin business to ASK Chemicals.

“Brazil and South Africa are important growth markets for HA. We have been successfully serving our customers in these two countries for many decades via our joint ventures and are looking forward to continue our long-standing and fruitful regional partnership. As a stakeholder in SI Group’s Industrial Resins business, we will continue to bring our expertise and experience to bear and provide value-adding products and services to our customers in both countries,” said Franz Friedrich Butz and Christoph Koch, Managing Directors of Hüttenes-Albertus.

With the combination of HA’s cutting-edge product technology and SI Group’s modern production facilities in Rio Claro, Brazil and Johannesburg and Durban, South Africa, the two partners are well positioned to meet the needs of foundries in these important growth markets. ■ 24

HA集团是世界领先的铸造行业化工产品制造商， 宣布该公司将继续保持与美国专业化工产品公司SI集 团在巴西和南非的伙伴关系。由于ASK化工和SI集团 之间的协议终止，原协议SI集团意向将其工业树脂业 务处置给ASK化工。 “巴西和南非是HA集团重要的增长市场。几十年 来，我们通过合资企业成功地为这两个国家的客户服 务，并期待着继续我们长期和富有成效的区域伙伴关 系。作为SI集团工业树脂业务的利益相关者，我们将 继续提供我们的专业知识和经验，并为我们在这两个 国家的客户提供增值产品和服务。”HA集团董事总经 理弗朗茨•弗里德里希•布茨和克里斯托夫•库克说。 随着HA集团先进的产品技术和SI集团在巴西里约 热内卢、南非约翰内斯堡和德班的现代生产设施的结 合，这两个合作伙伴完全有能力满足这些重要的增长 市场的铸造厂的需求。

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION August 2020

Lethbridge Iron Works, BRP-US Win Castings Of The Year LETHBRIDGE公司、BRP-US公司赢得年度铸件奖

A

t first, the senior process engineer at AFS Corporate Member BRP-US Inc. (Spruce Pine, North Carolina) didn’t really want anything to do with the 300-HP V6 engine block for a marine outboard engine. The block was so large and complex, featring a water jacket which sequences cooling water through nine separate targeted passageways within the block, cylinder bores, and exhaust. It was not a simple tube within a tube water jacket design.

最

初，美国铸造协会会员单位，北卡罗莱纳州 云杉松市BRP-US公司的高级工艺师真的不 想与船用舷外发动机300-HP V6发动机缸体

的订单有任何联系。缸体如此巨大且复杂，独特的水套 将冷却水顺序的送入9条独立的目标通道，通向缸体、 气缸孔和排气管。这不是简单的管道内的水套设计。 “当我们看到这个产品时，我知道这将是个困难的

GS-Snipe 300HP V-6 Aluminum Block BRP-US Inc. August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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“When we looked at this part, I knew it would be a difficult part, and I didn’t really want to sign off on it,” said Willie Anglin, senior process engineer. “But now, five years later, it is running better than many of our other blocks. The truth is, I never thought we would see it run as well as we do.”

The two-stroke 300HP V-6 marine engine block called the G2 Snipe is cast in aluminum via the lost foam method. Nine foam tools are required to produce 15 individual foam patterns and the runner. The cast walls are as thin as 4mm for weight savings. Plus, rather than bolt a welded exhaust to the block, the engine

项目，我真不想签字。”高级工艺工程师威利•安格林 说，“但是，五年后的今天，它比我们的许多其他发动 机运行得更好。事实上，我从未想到我们会看到它运行 的像我们设计的一样好。” 两冲程300-HP V6船用发动机缸体也被称为G2 Snipe，采用消失模铸铝工艺制造。需要9个消失模模具 生产出15个单独的消失模模型和浇道。为了减少重量， 铸件的壁厚只有4毫米。另外，发动机设计师不想用螺 栓固定焊接排气管到缸体上，而是想把这些功能融入单 一的铝铸件中。

Opener Main Body Lethbridge Iron Works Co. Ltd.

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION August 2020

designers wanted to incorporate those features into the single aluminum casting.

The one-piece design eliminated the need for multiple castings, weldments, and their assembly.

“The internal passages in this part are too delicate or too small to be made with sand cores,” said Curtis Taylor, plant manager. “Lost foam internal passages, complicated internal passages is our claim to fame. We hold tight tolerances, and we make parts where people need a lot of cooling passages or oil passages.”

This type of marine engine block is not so off base for BRP, which poured the first V-block two-stroke engine in production using lost foam. But succeeding at casting this part depended on process improvements at BRP that ultimately benefitted many other parts in production.

The first step in making the G2 Snipe is to make subassemblies of both the cylinder banks and the exhausts. Next, the cylinder banks are mated to the exhausts. However, before they can be joined, any glue squeeze or potential misalignment of the individual foam sections on the two mating surfaces must be dealt with.

一体化设计避免了需要多个铸件、焊接件及其装 配。 工厂经理柯蒂斯•泰勒介绍：“这款产品的内部流 道太细而且太小，无法用砂芯制造。消失模工艺的内 部流道、复杂的内部流道是我们的强项。我们有严格 的公差，我们制造的零件大量用于冷却流道或油路流 道。” 首次浇注这款两冲程船用发动机V型缸体铸件，对 于BRP公司来说并不简单。但成功铸造这一产品取决 于BRP公司的工艺改进，并最终使许多其他零件在生 产中获益。 生产G2 Snipe的第一步是制作气缸组和排气管的 白模。接下来，将气缸组与排气管白模粘在一起。然 而，粘接之前，必须处理两个组件中白模部分所用胶 水的挤出部分或潜在的错位。 BRP uses a robot to smooth the mating sur-

The cast version of the opener main body (left) reduced the part count of the fabrication (right) from 12 to one.

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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BRP uses a robot to smooth the mating surfaces and remove all obstacles to a robust glue joint between the cylinder bank and the exhaust.

“This part caused us to revisit our processes,” Taylor said. “The tolerances for everything that touches this part are tighter than everything else we produce at this plant. Everything is tighter because the product demands it.”

One of the improvements stemming from the G2 Snipe is BRP’s drying process.

“Historically, we used only heat to dry the parts, and the biggest improvement we saw was through dehumidifying the makeup air,” Anglin said. “We were able to decrease the relative humidity by roughly 90% for more effective drying.”

Dry foam patterns are important, because moisture takes energy out of the metal as it is poured, creating cold-metal type defects. Moisture can also turn to steam, which can cause voids. Achieving more efficient drying helped BRP improve its scrap rate by 40%.

For the G2 engine block, BRP also faced a challenge specific to larger lost foam cast parts.

“In a larger part like this, you are moving metal 25 inches through the part from a gate, and it just makes it so much more difficult to get the metal back and the liquid to stay liquid in those internal passages,” Anglin said.

BRP has been successfully casting the G2 block for five years, but Taylor admits the first three years were challenging. Through continuous process developments, like improved drying, the foundry has been efficiently manufacturing the block for two years now.

Casting such a complicated part may seem like more trouble than it’s worth, but the cost savings from eliminating individual parts are considerable. Incorporating features into a single casting also helps achieve certain property and quality requirements.

“You also reduce the number of gas leaks you could potentially have in a part. That can be an issue when screws holding pieces together come apart,” Anglin pointed out. “You are going to save money, time, tooling costs, and will require fewer tools, fasteners, nuts and bolts—everything that goes into making multiple parts.”

faces and remove all obstacles to a robust glue

Casting Conversion Frees Up Customer’s Internal Resources

出，“你将节省金钱、时间、工具成本，并且需要更

Lethbridge castingThe opener main body casting

by Lethbridge Iron Works Co. was a textbook case for a casting conversion from a steel fabrication. The cast design reduced the part count from 12 to 1, reduced labor and equipment time for the customer, decreased overall cost, and improved the performance through increased strength and tighter tolerances.

“For the customer, what makes a good candidate for conversion is the ability to save both time and money,” said Mark Mundell, director of sales, Lethbridge Iron Works. “Everything written about conversion is true.

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joint between the cylinder bank and the exhaust.

BRP公司使用机器人来磨平粘接表面，并去除气缸 组和排气管之间坚固的胶水接头。 泰勒说：“这款产品让我们重新审视了我们的工 艺，这款产品所需要的公差都比我们在这家工厂生产 过的所有产品都要严格。 一切都更严格，因为产品 需要。” 来自G2 Snipe生产的改进之一是BRP公司的干燥 工艺。 “原本，我们只通过加热来干燥零件，现在最大改 进是通过除湿改变空气湿度，”安格林说， “为了更 有效地干燥，我们能够将相对湿度降低大约90%。” 白模的干燥非常重要，因为浇注过程中水分会从液 态金属中吸收热量，可能出现温度低产生的缺陷。水 分也会变成蒸汽从而导致气孔。实现更有效的干燥有 助于BRP公司减少40%的废品率。 对于G2发动机缸体，BRP公司也面临着生产如此 大尺寸消失模铸件的挑战。 “如此大的铸件，金属液从浇口开始需要流动25 英寸，而且金属液充型和在流道内保持金属液的稳定 更困难。”安格林说。 BRP公司成功地铸造出G2缸体已有5年，但泰勒承 认，最初3年不断面临挑战。通过不断的工艺发展， 如改进干燥工艺，两年来铸造厂已经可以高效地生产 缸体。 铸造如此复杂的零件，似乎需要解决的困难比铸件 价值更多，但避免了需要装配多个零件而节省的成本 相当可观。将多种功能集成到单个铸件中也有助于实 现某些性能和质量要求。 “单个铸件还可以减少部分潜在的气体泄漏。这 将是件好事，不需要连接更多零部件，”安格林指 少的工具、紧固件、螺母和螺栓—所有用于制造多个 部件的东西。”

铸件释放客户的内部资源 将钢结构件转换为铸件，莱斯布里奇铸铁公司生产 的开槽器主体铸件是个教科书式的案例。设计的铸件 将零件数量从原来的12个减少到1个，为客户减少人 工和设备的使用，降低了整体成本，并通过提升强度

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION August 2020

If you can make a casting out of a multiple piece component, it is going to provide for a cheaper, more consistent and repeatable part, and it will lean out the manufacturing process.”

Some casting conversions are more challenging than others. In the case of the opener main body for a coulter seeding drill, the design included varying section thicknesses and several functioning features located on different planes. A zipper-shaped depth adjustment feature is cast perpendicular to the mold parting plane, with other features being located on the horizontal parting plane.

“The success of a conversion comes down to being able to work with the engineer to create a casting that is both castable and still meets their design needs,” Mundell said.

Incorporating the numerous adjustment features into the casting was critical to making the conversion a reality. Through the use of multiple cores, parting design, and draft allowances, all features were castable and achieved the necessary results.

After casting, Lethbridge Iron Works uses robotic grinding to finish each part. As this casting is the main component in the assembly, with multiple parts connecting to it, consistent surface finish and dimensional stability is critical.

“We grind almost everything with a robot now,” Mundell said. “It provides repeatability, consistent finish, and increased productivity.

The cast version will save the customer considerable time and money.

“There’s a tremendous savings because there are a lot of units on one seeding drill,” Mundell said.

“As companies struggle to hire people, leaning their processes out by reducing the waste associated with fabrications and focusing on assembling saves both time, money and frees up resource for use elsewhere.”

All told, the main body casting incorporates multiple adjustment features, such as the height of the scraper and depths of the opener, integrated shielding, and clear, legible, cast-on identification markers.

The conversion to casting resulted in a cosmetically superior appearance to the fabrication and an overall part cost savings of more than 30%. The consistent, repeatable, and dimensionally stable casting significantly exceeds that of the original weldment.

“The biggest wins in a conversion are the cost savings and the ability to reduce pressure on a company’s internal resources to not have to have people and equipment available to otherwise fabricate the part,” Mundell said. “These are the fun jobs, where you really get to make a difference to a company’s bottom line.” ■

和更严格的公差来提高性能。 莱斯布里奇铸铁公司销售总监马克•蒙代尔表示：“ 对于客户来说，如何让转换成为好选择，是既省时又 省钱的能力。关于转换的一切描述都是真的。如果能 把多个零部件变为单个铸件，将其变为更便宜、更一 致和可重复的零部件，将简化制造过程。” 某些铸件的转换比其他改变更具挑战性，犁沟播种 机的开沟主体结构就是这种情况，设计包括不同的截 面厚度和位于不同平面上的几个特殊功能件。拉链形 深度调整特殊结构垂直于铸型分型平面，其他特征结 构位于水平分型平面上。 蒙代尔说：“转换的成功要归功于能够与工程师合 作，创造出既可铸造又能满足设计需要的铸件。 将许多调整特性整合到铸件是使转换成为现实的关 键。通过多种芯子的使用、分型设计和余量考虑，所 有的功能都是可以通过铸件实现的，并取得了必要的 效果。 铸件生产出来，莱斯布里奇铸铁厂使用机器人磨削 完成每个铸件。由于该铸件是装配中的主要部件，有 多个部件连接在一起，因此一致的表面光洁度和尺寸 稳定性至关重要。 “我们现在几乎所有的产品都用机器人来磨，” 蒙代尔说，“它可以保证重复性、一致性和提高生产 率。 铸件将为客户节省大量的时间和金钱。 蒙代尔说：“由于把播种机上多个零部件转换为单 个铸件，所以节省了大量的资金。随着把公司从努力 招聘员工、培训、集中精力组装的流程中剥离出来， 通过减少与制造相关的浪费，既节省了时间，也节省 了金钱，并腾出了资源供其他地方使用。” 总之，主体铸件包含多种调整功能，如刮刀的高度 和开沟器的深度，集成屏蔽，以及清晰、可读的铸造 识别标记。转换为铸造导致了一个美容优越的外观， 以制造和整体零件成本节省超过30%。铸件的一致 性、可重复性和尺寸稳定性明显超过了原来的焊件。 蒙代尔说：“转换过程中最大的好处是节省了成 本，降低了公司内部资源的压力，无需不必要的人员 和设备来制造零件。这些都是有趣的工作，你可以真 正改变公司的底线。” ■

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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Newcomer of the Year

年度新秀奖

Grapple arm

抓斗臂

Wabi Iron and Steel Corp. (New Liskeard, Ontario, Canada)

Material: 8630 alloy steel [ASTM A148 GR115-95 (8630)] Process: Phenolic urethane nobake Weight: 204 lbs.

Dimensions: 45 x 18 in.

Application: Forestry. Grabs and holds trees in situ during the cutting of a tree base.

Customer: Quadco Inc. • Originally an 8-piece weldment, this grapple arm for tree-harvesting was converted to a single-piece, waterquenched and tempered 8630 alloy steel casting. It was made in collaboration between Wabi Iron and Steel and its customer, Quadco.

• The conversion from a weldment to a casting saved the customer 8 hours of production time, reduced field complaint issues by over 70%, improved safety for workers in the field and eliminated half the total cost of a fully machined grapple arm.

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瓦比钢铁公司（加拿大安大略省新莱斯克市） 材质：8630合金钢 [ASTMA148GR115-95（8630）] 工艺：酚醛氨基甲酸乙酯 重量：204磅 尺寸：45 x 18英寸 应用：林业，在砍伐树基期间，就地抓取和持有树木。 客户：Quadco公司。 • 最初是由8个零部件焊接成，这个抓取树木的抓斗臂 被转换成单一铸件，水淬调质8630合金钢铸件。由 Wabi钢铁公司及其客户Quadco合作制造。 • 从焊接件到铸件的转换为客户节省了8小时的生产时 间，减少了70%以上的现场投诉，提升了现场工人的 安全保障，并降低了抓斗臂设备总成本的一半。

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION August 2020

Best Casting Conversion

铸造最佳转换奖

Rear suspension trailing arm

后悬挂拖曳臂

Waupaca Foundry Inc. (Waupaca, Wisconsin)

Material: Ductile iron Process: Green sand vertical molding Weight: 25.69 lbs.

Dimensions: 21.5 x 8.5 in.

Application: Turf care. Used on a zero-turn commercial lawn mower.

Customer: Bad Boy Mowers • This conversion from an 8-piece steel weldment to a single ductile iron casting improved the quality and durability of the rear suspension trailing arm on a commercial lawn mower, which previously had been prone to bend and twist upon impact.

• While the original weldment never reached production due to high failure rates, this collaboration between Bad Boy Mower’s Tier 1 Diamond Precision and Waupaca Foundry has had zero warranty claims since launching in December 2018.

瓦帕卡铸造公司（威斯康星州瓦帕卡市） 材料：球墨铸铁 工艺：粘土砂垂直造型 重量：25.69磅 尺寸：21.5x8.5英寸 应用：草皮护理，用于零转商业割草机。 客户：Bad Boy割草机公司 • 由8个零部件焊接成的钢焊接件，改为单个球墨铸铁 件，这个转换提高了商业割草机后悬挂拖曳臂的质量和 耐久性，原来的割草机很容易在撞击时弯曲和扭曲。 • 由于故障率高，原来焊接的产品从未达到产量，但 Bad Boy割草机公司的Tier 1 Diamond Precision公 司和瓦帕卡铸造厂之间的合作自2018年12月启动以 来一直没有接到保修要求。

August 2020 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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Best Prototype or Innovation

最好的原型或创新奖

Duplex fuel nozzle

双联式喷油嘴

Aristo-Cast Inc. (Almont, Michigan)

Material: Stainless steel [17-4 ph] Process: Printed investment shell Weight: 115 grams Dimensions: 2.5 x 1.5 x 1.5 in.

Application: Aircraft jet engine and land-based turbines.

Customer: Internal design/proof of concept • This fuel nozzle from Aristo-Cast creates a fuel spray pattern for complete combustion in an engine.

• Created as a proof of concept, this casting successfully replaces a direct metal laser sintering (DMLS) component, cutting costs by an average of 50%.

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Aristo铸造公司（密歇根州阿尔蒙特） 材质：不锈钢[17-4ph] 工艺：3D打印熔模外壳 重量：115克 尺寸：2.5x1.5x1.5英寸 应用：飞机喷气发动机和陆基涡轮机 客户：内部设计/概念证明 • Aristo铸造公司的燃料喷嘴为发动机的完全燃烧创造 了燃料喷雾模式。 • 作为概念的证明，铸件成功地取代了直接用金属激光 烧结(DMLS)的部件，平均降低成本约50%。

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Achievement by a Small Foundry

小铸造厂成就奖

Lift wrench

升降扳手

LA Aluminum Casting Co. (Hayden, Idaho)

Material: 356 aluminum T6 Process: Semi-permanent mold Weight: 6.42 lbs.

Dimensions: 11.7 x 10.9 x 2.75 in.

Application: Oil and gas. Hammer union wrench and pipelifter.

Customer: Mountain Valley Supply • The lift wrench replaces the oil and gas industry’s traditional tool of choice, the sledgehammer. It combines leverage, strength and pipe-lifting capabilities and is safer to use than a sledgehammer.

• LA Aluminum helped customer Mountain Valley Supply change a weaker weldment into this lightweight aluminum casting pull-tested to break at 6,600 lbs. of force. It provides a savings of thousands of dollars a year.

LA铸铝公司（爱达荷州海登） 材质：356铝合金T6 工艺：半永久模具 重量：6.42磅 尺寸：11.7x10.9x2.75英寸 用途：石油和天然气行业的锤子扳手和管道升降器。 客户：山谷供应公司 • 升降扳手取代了石油和天然气行业的传统工具，大 锤。 它结合杠杆，力量和管道提升能力，比使用 大锤更安全。 • LA铸铝公司帮助客户山谷供应公司将不耐用的焊 接件变为轻量化的铸铝件，拉力试验表明打击力可 达6600磅。每年可节省数千美元。

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Outstanding Achievement

出色成就奖

Pump housing

泵壳

O’Fallon Casting (O’Fallon, Missouri)

Material: C355-T6 aluminum Process: Investment Weight: 8.12 lbs.

Dimensions: 9.5 x 9.5 x 4 in.

Application: Aerospace. Pump housing for a commercial aircraft engine.

Customer: Undisclosed • The number and complexity of the internal core passages allow O’Fallon’s customer to decrease the overall size and number of pieces in the engine pump. Instead of multiple pieces with less-complex geometries being assembled together, this one-piece investment casting saves weight and eliminates future failure points at the assembly location.

• The original design had as many as 13 openings that needed to be welded shut prior to delivering the casting.

Through the investment casting process and design optimizations, O’Fallon was able to help the customer reduce the number of weld openings to four. This saved money for the customer and provided a more robust product.

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奥法伦铸造厂（密苏里州奥法伦市） 材质：C355-T6铝合金 工艺：熔模铸造 重量：8.12磅。 尺寸：9.5x9.5x4英寸。 应用：航空航天，商用飞机发动机的泵壳。 客户：未披露 • 由于能够满足内部砂芯通道的数量和复杂性，奥法伦 铸造厂的客户可以减少发动机泵的整体尺寸和数量。 而不是把几何形状简单的多个零件组装在一起，这种 单件熔模铸件减少了重量，并消除了后面装配位置时 的故障点。 • 最初的设计有多达13个开口，在铸件交付之前需要焊 接封闭。通过铸造工艺和设计优化，奥法伦铸造厂能 够帮助客户将焊缝开口的数量减少到4个。这为客户 节省了资金，并提供了更耐用的产品。

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Outstanding Achievement

出色成就奖

Trip arm

松放杆

Dotson Iron Casting (Mankato, Minnesota)

Material: Ductile iron 80-55-06 Process: Horizontal green sand Weight: 23 lbs.

Dimensions: 12 x 12 x 3 in.

Application: Agriculture. Used in tillage tools.

Customer: Summers Manufacturing • This ductile iron casting from Dotson was converted from a five-piece fabrication for use in a tillage tool. The trip arm absorbs shock as discs hit obstructions in fields.

• Converting to a casting allowed engineers at Summers Manufacturing to add material to high-stress areas and remove material from less critical areas. A feature was added for retaining the pin and roll pin, eliminating a bushing in the fabricated part. It also improved fit-up during assembly and enhanced the overall appearance of the machine.

• Dotson’s customer saved nearly $100,000 and more than 3,000 employee hours annually.

多特森铸铁厂（明尼苏达州曼卡托市） 材质：球墨铸铁80-55-06 工艺：黏土砂水平铸造 重量：23磅。 尺寸：12x12x3英寸。 应用：农业，用于耕作工具 客户：萨默斯制造公司 • 这款多特森铸铁厂的球墨铸铁件是将5个零部件整合 转换而来，用于耕作工具。行程臂吸收因破碎盘击碎 田野中障碍物的冲击。 • 转换为铸件后，萨默斯制造公司的工程师可以在高应 力位置增加材料，并在较不关键的地区减少材料。明 显改善是增加了保持销和滚销，消除了衬套。 还改 善了装配过程中的装配，美化了机器的整体外观。 • 多特森铸铁厂的客户每年节省了近10万美元和3000 多个工时。

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Outstanding Achievement

出色成就奖

Snowmobile front bumper

雪地摩托前保险杠

Powercast Manufacturing Inc. (St.-Eustache, Quebec, Canada)

Material: A357 aluminum Process: Permanent mold Weight: 4 lbs.

Dimensions: 22 x 15 x 7 in.

Application: Outdoor recreation. Front bumper for a snowmobile.

Customer: BRP (Ski-Doo) • This casting is a premium product, an upgrade to the welded tubing bumper that comes standard on the SkiDoo snowmobile.

• Powercast Manufacturing, the only foundry to accept the challenge to cast this component, had to tackle many issues in order to create a successful part: designing a cast bumper that would add a premium look while performing well and safely, building a foundry tool for the awkward shape, heat treating a part with such a shape without warping it, and handling complicated machining. Each set of drilled holes has a different reference point, and the size of the part makes it difficult to fit into most CNC machining centers.

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PowerCast制造公司(加拿大魁北克省圣厄斯塔什) 材质：铝合金A357 工艺：金属型模具 重量：4磅 尺寸：22×15×7英寸 应用：户外娱乐，雪地车的前保险杠 客户：庞巴迪（Doo滑雪） • 这款铸件是优秀的产品，是Ski-Doo滑雪车标准管状 焊接保险杠升级版。 • PowerCast制造公司是唯一接受铸造这款产品挑战的 铸造厂，为了创造出成功的零件，必须解决许多问 题：设计出保险杠铸件，在保证性能良好和安全的情 况下美化外观，为形状复杂的铸件开发铸造工具，在 保证不变形的情况下对零件进行热处理，并处理复杂 的加工。每组钻孔都有不同的参考点，零件的尺寸使 得很难适应大多数数控加工中心。

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Outstanding Achievement

出色成就奖

Magnesium strut tower brace

镁合金结构件支撑塔

Meridian Lightweight Technologies Inc. (Strathroy, Ontario, Canada)/Ford Motor Co. (Dearborn, Michigan)

Material: AE44 magnesium alloy Process: Cold chamber high-pressure die-casting Weight: 3.6kg Dimensions: 1075mm x 432mm x 137mm Application: Automotive. 2020 Ford Mustang Shelby GT500 strut tower brace.

Customer: Ford Motor Co. • This magnesium strut tower brace, a collaboration between Ford and Meridian Lightweight Technologies, is the first usage of AE44 magnesium die-casting alloy for a visual application in the automotive industry. The magnesium casting is converted from a steel stamping and aluminum extrusion. It replaces two main structural components from the previous generation design to accomplish a weight reduction of nearly 50%.

• The design of the strut-tower brace was optimized for die-casting technology and specifically for magnesium diecasting, allowing for a complex shape with the front surface moved 95mm rearward from the previous generation to visually highlight the intercooled supercharger manifold, while meeting all stiffness and durability requirements. ■

子午线轻量化技术公司（加拿大安大略省斯特拉斯罗 伊)/福特汽车公司(戴伯恩，密歇根州） 材质：AE44镁合金 工艺：冷室高压压铸 重量：3.6 kg 尺寸：1075mm x 432mm x 137mm 应用：汽车，2020年福特野马谢尔比GT500支撑塔。 客户：福特汽车公司。 • 这款镁合金支撑塔结构件是福特公司和子午线轻量化 技术公司间的合作，是第一次将AE44镁合金压铸使 用在汽车工业的可视化系统。镁合金铸件由原来的钢 冲压件和铝合金挤压件转化而成。替代了前一代设计 中的两个主要结构部件，使重量减少了近50%。 • 支撑塔结构的设计根据压铸技术而优化，特别是镁合 金压铸技术，允许复杂的形状，前表面比上一代的 设计向后移动95 mm，以直观地突出中冷增压器歧 管，同时满足所有的刚度和耐久性要求。 ■

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A System For The Thermal Analysis Of Steels het kapadia and robert tuttle

钢的热分析系统 作者：赫特·卡帕迪亚、罗伯特·图特尔

T

here has been growing interest in steel grain refinement research. This interest stems from the relentless drive for improved mechanical properties, specifically strength and ductility.

Grain refinement research has been focusing on determining which compounds can heterogeneously nucleate steel. Depending on the alloy, the candidate phase must match with δ-ferrite or austenite. Rare earth phases have been found particularly suitable for austenitic steels. There is also some evidence that they are effective in assisting ferritic steels. Titanium nitrides and carbides have been effective for ferritic steels, and methods for stabilizing them in liquid steel are being examined. Thus, there appears to be several different routes for the grain refinement of steels.

Industrial adoption will eventually require a method for assessing grain refinement additions as part of process control. Production foundries must be able to verify a certain level of refinement will occur. Errors in the production process should be detected and corrected prior to pouring.

A method for this verification will require rapid testing time and ruggedness for melt deck use in addition to the normal requirements for industrial process control. To date, researchers have primarily examined the final microstructure, which is

当

前，对钢的晶粒细化的研究越来越引起人们 的兴趣，这种兴趣源于对改善力学性能的不 懈努力，特别是强度和韧性。钢的晶粒细化

研究一直集中在确定哪些化合物可以异质成核。根据合 金的不同，候选相必须与δ-铁素体或奥氏体相匹配。稀 土相已被发现特别适合奥氏体钢。还有一些证据表明， 它们在协助铁素体钢成核方面是有效的。钛的氮化物和 碳化物已成为铁素体钢的有效材料，目前正在研究在液 态钢中稳定它们的方法。因此，钢的晶粒细化似乎有几 种不同的途径。 作为过程控制的一部分，工业应用最终需要评估添 加成核化合物细化晶粒的方法。铸造厂生产时必须能够 验证细化将会发生。在浇注前，应检测和纠正生产过 程中的错误。除了正常的工业过程控制的要求，这种验 证的方法还需要测试时间快速和在环境恶劣的熔炼工部 使用。到目前为止，研究人员主要在研究最终的微观结 构，这很耗时。它还只提供了铸件浇注后的细化信息。

Fig 1. The cooling curve comparison for normal cups is shown.

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Fig 2. This is the cooling rate comparison between the second and sixth cups.

time consuming. It also only provides information on refinement after castings are poured. Additionally, this method has limitations on interpretation of the grain refinement process.

The slow speed and after casting basis of this technique is unacceptable in industry. Therefore, a method must be developed to support research and industrial adoption.

Looking at other metallurgical areas using additions for promoting heterogeneous nucleation provides a possible suitable method. Thermal analysis has been successfully employed in aluminum and iron foundries. Aluminum foundries utilize the technique for assessing the effectiveness of grain refining and eutectic modification additions.

Cast iron foundries use the same technique to determine the success of inoculation additions for promoting graphite. These methods employ a single thermocouple in a shell core cup. A sample is poured into the cup and the cooling curve recorded. This curve is then analyzed to determine the effect additions have had on the melt. This technique has proven very effective for measuring heterogenous nucleation on the foundry floor.

Research examined incorporating the single thermocouple technique on steels, with a system used in aluminum and cast irons, to develop a more detailed understanding of solidification. 4130 steel was selected because of its broad application.

This system utilizes an existing commercial DAQ system specializing in the thermal analysis of metals and includes advanced analysis techniques and algorithms. The data obtained then was compared to thermodynamic predictions and the Jenkortoret reference data for this alloy.

此外，该方法对晶粒细化过程的解释也有局限性。

Procedure

石墨和铝丸。持续加热到3150℉(1730℃)，然后被

A 50-lb. (23 kg.) heat of 4130 steel was melted in a 3kHz induction furnace with an Al2O3 crucible in air. An initial charge of 1010, FeCr, and FeMo was added. At 1700C (3100F), additions of FeSi, FeMn, graphite, and aluminum shot were added. Heating continued to 3,150F (1,730C) where it was then tapped into a preheated 2.3kg capacity hand ladle. To maintain deoxidization, a

这种技术的慢速和在铸造之后验证，工业上是不可接 受的。因此，必须开发一种方法来支持研究和工业 应用。 借鉴其他冶金领域使用添加化合物促进非均质成 核，提供可能合适的方法。热分析已成功地应用于铸 铝和铸铁。铸铝利用该技术评估晶粒细化和共晶改性 添加的有效性。铸铁厂使用同样的技术来确定孕育促 进石墨增碳的成功。这些方法是将样品倒入壳芯杯， 使用单个热电偶，并记录冷却曲线。然后对这条曲线 进行分析，以确定添加物对熔融金属的影响。该技术 在铸造厂已被证明是非常有效的测量异种成核方法。 实验研究了在铝和铸铁中使用系统，将单一热电 偶技术结合在钢上，以发展对凝固理论更详细的理 解。根据应用广泛性，选用4130钢。使用专业从事 金属热分析的商用DAQ系统，包括先进的分析技术 和算法。然后将所得数据与热力学预测和该合金的 Jenkortoret参考数据进行比较。

步骤 将50磅（23公斤）4130钢放入3kHz感应炉中熔 化，使用Al2O3坩埚。在1010℃时，先加入FeCr和 FeMo。在1700℃(3100℉)时，加入FeSi、FeMn、 倒入预热的，容量为2.3kg的手持浇包中。为了避免 氧化，在倒出前，将1g铝丸放入手持浇包中。 然后将钢液倒入安装在支架上的热分析杯中。合 金浇注后，数据采集系统(DAQ)记录并分析钢液凝固 的冷却曲线。为了确定所使用的单热电偶方法的正确

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Fig 3. Here is the cooling curve comparison for covered cups.

1g piece of aluminum shot was put in the hand ladle prior to tapping.

Liquid steel then was poured into the thermal analysis (TA) cup which is mounted on a stand. Once the alloy was poured, the data acquisition system (DAQ) recorded and analyzed the cooling curve of the solidifying steel. To determine the correct cooling rate for the single thermocouple method being used, the TA cups were uncovered, covered, and wrapped and covered. A ceramic fiber blanket with a density of 128kg/m3 was used as the covering material. The top cover had a thickness of 50 mm and a length and width of 150 mm. The run order was randomized. Two TA cups were analyzed for each condition, and a total of six cups were poured per heat. After filling the first cup, the remaining

冷却速率，对热分析杯进行无盖、加盖、包裹并加盖 3种操作。以密度为128kg/m3的陶瓷纤维毯为覆盖 材料。盖的厚度为50mm，长度和宽度为150mm。 运行顺序是随机的。对每种情况下的两个热分析杯进 行分析，每批钢液总共倒6杯。在浇注完第一个杯子 后，将剩余的金属倒入靶中，然后做光谱，分析化学 成分。

结果和讨论 图1所示为正常杯的冷却曲线。曲线相似，表明所

Fig 4. Cooling curve comparison for wrapped and covered cups are depicted here.

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Fig 5. This is a cooling rate comparison for normal cups.

metal was poured into a bar cavity from which a chemical sample was then extracted for optical emission spectroscopy.

获得数据的重复性是可接受的。曲线中唯一注意到的

Results and Discussion

异；黑线的过热度为64℉(17.8℃)，而红线的过热度

Figure 1 depicts the cooling curves of the normal cups.

The curves are similar, which indicates the data obtained had acceptable reproducibility. The only difference noticed in the curves are in the form of a slight time difference. This variance is due to the difference in superheat; the black line had a superheat of 64F (17.8C) while the red line had a super heat of 50.4F (10.2C).

In the original experiment, six cups were poured. While the cooling curves appeared similar to each other, examination of the cooling rate found a significant issue (Figure 2). The cooling rate signatures were very different for the

为50.4℉(10.2℃)。

差异是轻微的时间差。这一差异是由于过热度的差

在原来的实验中，总共浇注6个杯。虽然冷却曲线 彼此相似，但对冷却速率的检查发现了一个重要的问 题（图2）。第一次和第二次包裹并加盖样品的冷却 速率特征差异很大，这是实验期间倒入的第二和第六 杯。似乎在炉子中保温超过4个热分析杯会导致显著 的合金化损失。这是通过在第五和第六杯上进行光

Fig 6. Depicted here is the cooling rate comparison for covered cups.

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Fig 7. Cooling rate comparisons for wrapped and covered cups are shown.

first and second wrapped and covered samples, which were the second and sixth cups poured during the experiment.

It appears that holding steel in the furnace for more than four TA cups resulted in significant alloying loss. This was confirmed by conducting spectroscopy on the fifth and sixth cups. These cups had much lower contents of the oxidizable elements of C, Si, Mn, Cr, and Al compared to the heat chemistry. Thus, the last two cups poured had a drastically different composition than the first four. This was likely because the initial heat had been held for over an hour due to the freezing times of these cups. A second heat was poured to ensure the covered and wrapped and covered conditions were done with steel of a similar composition. The uncovered cups were close enough to each other to be considered the composition, so they did not require repeating.

Figure 3 illustrates the cooling curves for the second run of covered cups. Figure 4 displays the results obtained from wrapped and covered TA cups.

The DAQ system currently does not have an algorithm for automatically detecting the peritectic reaction temperature. For the peritectic temperature, the authors examined the cooling curves for a peak just prior to the solidus. Then, the corresponding time stamp for that peak were taken. The time was then used to read thetemperature from the cooling curve. Figures 5, 6, and 7 illustrate the cooling rates for the normal, covered, and wrapped and covered cups. The curves plotted display the cooling rate of each cup over a period of five minutes.

Several thermal arrests are identifiable on the cool rate curves. The first is the initial heating of the thermocouple followed by the liquidus arrest. Afterwards, there is a small peak that corresponds to the peritectic transformation (Figure 5).

The largest peaks are associated with reaching the solidus.

Overall, very little noise is present in the normal cup curves.

Figures 6 and 7 depict cooling rate curves that are far noisier than the normal cup. Since these cups were covered to reduce their cooling rate, the strength of the solidification reactions were less, which created a lower signal-tonoise ratio. This lower signal-to-noise ratio would make 42

谱证实的。与热化学相比，这些杯中C、Si、Mn、Cr 和Al的可氧化元素含量要低得多。因此，最后两杯倒 出的成分与前四杯截然不同。这很可能是因为由于这 些杯子的冷冻时间，最初的热量已经保持了一个多小 时。第二次加热，以确保覆盖和包裹和覆盖条件是用 类似成分的钢。未加盖的杯子彼此足够接近，被认为 是一组，所以他们不需要重复。 图3显示了加盖杯第二次实验的冷却曲线。图4显示 了从包裹和加盖的TA杯中获得的结果。 目前，DAQ系统没有自动检测包晶反应温度的算 法。对于包晶温度，实验人员研究了凝固前一个峰的 冷却曲线。然后，取该峰的相应时间点。然后用时 间从冷却曲线上读取温度。图5、图6和图7说明了正 常、加盖、包裹和加盖杯的冷却速率。绘制的曲线显 示了每个杯子在五分钟内的冷却速度。 在冷速率曲线上可以识别几个热阻聚物。首先是热 电偶的初始加热，然后是液相线暂留。然后，有一个 小峰对应着包晶转变（图5）。最大的峰与到达固相有 关。总的来说，在正常的杯子曲线中几乎没有干扰。 图6和图7所示冷却速率曲线，这些曲线比普通杯 的干扰要大得多。由于这些杯子加了盖以降低其冷却 速率，凝固反应的强度较小，从而产生了较低的信噪 比。这种较低的信噪比将使分析，特别是自动化，更 加困难。因此，它们似乎不适于过程控制甚至研究。 在加盖和包裹并加覆盖的条件下，第二个杯子的峰值 要小得多。对于包裹和加盖，冷却曲线形状的差异似 乎与样品之间过热度的大变化有关。因此，正常杯由

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analysis, especially automated, more difficult. Thus, it would appear they are not as appropriate for process control or even research. In both the covered and wrapped and covered conditions, the second cup had a much smaller peak. For the wrapped and covered, it appears that the difference in cooling curve shape is related to the large variation in superheat between the samples. Therefore, normal cups were considered for further analyses due to their higher signal-to-noise ratio.

Table 1 provides the liquidus temperatures from the thermodynamic predictions, Jenkortoret data, and these experiments. The Jenkortoret data includes phase reaction temperatures at 0.1, 0.5, and 2C/s. The 2C/s data has been selected for comparison since it is close to the 1.8C/s average cooling rate of the normal cup samples.

Table 2 lists the solidus temperatures from the thermodynamic predictions, Jenkortoret data, and this work. There is significantly less agreement in the temperature of the solidus.

The thermodynamic predictions indicate a very low temperature while the Jenkortoret data and this work find the solidus at a higher temperature. Considering the 68F (20C) difference between the thermodynamic conditions and the Jenkortoret data, it appears the disparity is related to technique.

Thermodynamic software are based on the CALPHAD method and frequently use data from DSC experiments for their dataset. Sample sizes for DSC methods are often in the milligram range. The samples for the reference data were approximately 35 g, while these experiments use a sample that is approximately 280 g. As solidification occurs, the latent heat of fusion is released. Assuming the only heat generated during solidification occurs from this, then Equation 1 holds true: Q=mHf Where, Q is the energy released during a phase change ( J), m is the mass of the substance (kg), and Hf is the latent heat of fusion ( J/kg). Computing the energy evolved in each sample indicates a large variation in the total energy emitted during solidification. The energy released increased with sample size and matches the increase of the solidus temperature with sample size. It appears that the measured solidus may be affected by the sample size in addition to the documented effect of cooling rate. This would make sense since the smaller samples might evolve less heat during

于其较高的信噪比而被考虑进行进一步的分析。 表1提供了热力学预测、Jenkortoret数据和这些实 验中的液相线温度。 Jenkortoret数据包括0.1、0.5和 2C/s的相反应温度。选择2C/s数据进行比较，因为它 接近正常杯样品的平均冷却速率1.8C/s。 表2列出了热力学预测、Jenkortoret数据和这项工 作中的凝固温度。凝固温度的一致性明显较小。热力 学预测表明温度很低，而Jenkortoret数据和这项工作 发现凝固温度较高。考虑到热力学条件与Jenkortoret 数据之间的68℉(20℃)差异，这种差异似乎与技术有 关。热力学软件是基于相图计算方法，经常使用DSC 实验数据作为数据集。DSC方法的样品尺寸通常在毫 克范围内。 参考数据的样品约为35g，而这些实验使 用的样品约为280g，当凝固发生时，熔合潜热被释 放。假设凝固过程中产生的唯一热量是由此产生的， 则方程1成立：Q=mHf 其中，Q是相变中释放的能量(J)，m是物质的质量 (kg)，Hf是熔炼的潜热(J/kg)。计算每个样品中演化的 能量表明凝固过程中发射的总能量有很大的变化。释 放的能量随样品尺寸的增加而增加，并与固体温度的 增加与样品尺寸相匹配。 看来，除了记录的冷却速率 的影响外，测量的固体可能会受到样品大小的影响。 这将是有意义的，因为较小的样品可能在凝固过程中 演化较少的热量，从而导致可检测到的温度差异。因 此，在较小的样品中，峰的高度可能显得较低，因为 必须释放足够的热量才能形成可检测的峰。较小的峰 更难检测，这可能是观察到的差异的来源。这也将解 释系统测量的高固体，尽管与Jenkortoret数据具有相 似的冷却速率。

Table 1. Liquidus Comparison Liquidus from Thermodynamic Predictions (°C)

Liquidus from Jenkortoret @ 2°C/s (°C)

1500

1501

Liquidus from DAQ (°C) 1499 1506 1500

Condition

Normal Covered Wrapped & Covered

Table 2. Solidus Comparison Solidus from Thermodynamic Predictions (°C)

Solidus from Jenkortoret @ 2°C/s (°C)

1402

1420

Solidus from DAQ (°C) 1431 1424 1423

Condition Normal Covered Wrapped & Covered

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solidification to cause a detectable difference in temperature.

Thus in smaller samples, the peak might appear lower since sufficient heat must be released to cause the formation of a detectable peak. Smaller peaks are harder to detect and could be the source of the differences observed. This would also explain the high solidus measured by the system despite having a similar cooling rate to the Jenkortoret data.

Another factor that might contribute to the differences in the measured solidus temperatures stems from the location of the thermocouple in each technique. In DSC, the thermocouple is located within the holder and the pan and sample rest on top. The Jenkortoret experiments had a thermocouple within an alumina protection tube inserted into the sample.

The current work also had a thermocouple directly inserted into the sample, but in a quartz tube. The insertions of a thermocouple within the sample should result in less lag between the thermocouple reading and the sample.

另一个可能导致测量的凝固温度差异的因素来自 热电偶在每种技术中的位置。在DSC中，热电偶位 于支架内，坩锅和样品位于顶部。在Jenkortoret实 验中，在插入样品的氧化铝保护管中有一个热电偶。 目前的工作也有一个热电偶直接插入样品。热电偶在 样品中的插入应导致热电偶读数与样品之间的较小滞 后。

结论 结果证明了单热电偶热分析的适用性。冷却速率曲 线为液相线、包晶和固相反应显示出明显的峰。正常 杯子条件下产生的曲线，与加盖和包裹的杯子相比， 噪音最少。因此，使用没有任何覆盖的杯子似乎是最

Conclusions

适合钢。过多的保温时间导致热成分发生显著变化。

The results demonstrate the applicability of single thermocouple thermal analysis. The cooling rate curves provided distinct peaks for the liquidus, peritectic, and solidus reactions. The normal cup condition produced curves with the least amount of noise when compared to the covered and wrapped and covered cups. Thus, using cups without any covering appears to be the most appropriate for steels. Excessive holding times were found to cause the heat composition to change significantly. Future work should attempt to keep the number of thermal analysis cup measurements to a minimum to prevent this effect.

The measured reaction temperatures were compared to reference data and thermodynamic predictions. The liquidus temperatures of all three had good agreement. There was more variation with the solidus temperatures among the data sources.

The difference in the solidus may be attributed to the size of the samples, which are much bigger in this work than either the reference data or the DSC data that forms the basis of the thermodynamic predictions. It was also determined that the values for the peritectic temperature were different from each other. These deviations may be attributed to a number of factors such the low height of the peritectic peak, differences in sample size, cooling rate differences, and scarce DSC data, which makes it harder for the thermodynamic prediction software to predict an accurate value for the peritectic. The lack of overall data on the peritectic likely reflects that it is a more difficult reaction to characterize. Further work is required to understand the reason for the difference. It was concluded the disagreement between techniques may reflect experimental difficulties with characterizing the peritectic and solidus and not the experimental system.

The single thermocouple thermal analysis system employed in this work provided consistent data that can be used for the analysis of steels. The robustness of the system indicates it could be incorporated in assessing individual steel heats for process control in an industrial setting. It also provides an additional technique for characterizing the solidification characteristics of steels. ■

今后的工作应尽量减少热分析杯的测量次数，以防止

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这种影响。 将测量的反应温度与参考数据和热力学预测进行了 比较。三者的液相线温度有很好的一致性。数据源之 间的凝固温度变化较大。 凝固的差异可以归因于样品的大小，在这项工作 中，它们比构成热力学预测基础的参考数据或DSC数 据要大得多。还确定了包晶温度的值是不同的。这些 偏差可归因于包晶峰的高度低、样本量差异、冷却速 率差异和DSC数据稀缺等诸多因素，这使得热力学预 测软件更难预测包晶温度的准确值。 缺乏关于包晶的 总体数据可能反映出这是一个更难描述的反应。 需 要进一步的工作来了解差异的原因。结果表明，技术 之间的分歧可能反映了表征包晶和凝固实验的困难， 而不是实验系统。 本工作采用的单热电偶热分析系统提供了一致的数 据，可用于钢的分析。该系统的鲁棒性表明，它可以 结合在评估个别钢炉的过程控制在工业环境中。它还 为表征钢的凝固特性提供了一种额外的技术。 ■

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product news/产品新闻

Product News Table of Contents 产品新闻目录 MOLD, CORE & SAND PREPARATION

MELTING, POURING & HEAT TREATMENT

Increased Profitability Through Innovative Foundry Equipment 以创新提升铸造设备盈利能力

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Brownfield Project: a time and space challenge 棕色地块项目：时间与空间的挑战

49

Foseco’s Latest Coating Innovation: Semco Fd – The New Fast Dry Waterbased Coating 福士科公司涂料创新： SEMCO FD –新型快干水性涂料

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Innovative Synergized Technology 创新协同技术

48

Redefining core competencies 重新定义制芯能力

49

Kurtz: Cylinder Head In Low Pressure? 库尔茨公司：低压铸造气缸盖？

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product news/产品新闻

Kurtz: Cylinder Head In Low Pressure? 库尔茨公司：低压铸造气缸盖？ Nemak is a leading provider of innovative lightweight solutions for the global automotive industry, specializing in the development and manufacturing of aluminum components for powertrain and body structure applications. Headquartered in Monterrey, Mexico, the company employs more than 22,000 people at 38 facilities worldwide generating revenues of USD 4.7 billion in 2018. Nemak is a Tier 1 supplier to major OEMs and is among the world´s 60 largest automotive suppliers. The plant in Izmir, Turkey, produces oil sumps and brackets for leading automotive manufacturers in high pressure die casting as well as cylinder heads in gravity and now also in low pressure, supported by Kurtz foundry equipment.

Nemak, a world-renowned manufacturer of engine blocks and especially cylinder heads, has decided to further expand its production of cylinder heads. Due to a special design of the cylinder head, the ideal process in this case was not gravity as before, but low-pressure. Since greenfield construction was not possible at the Nemak Turkey production site, the capacity expansion was carried out as a brownfield project – this means existing halls were converted accordingly. The integration of the low-pressure process for cylinder heads took place quasi at the “open heart”: During ongoing production, the foundry was rebuilt and the new casting line prepared. Even for the assembly and commissioning of the first part in low pressure as a prelude to series production, ongoing production was not interrupted for a second.

尼玛克是全球汽车行业轻量化创新解决方案的领 先供应商，专业开发和制造用于动力总成和车身结 构应用的铝合金零部件。公司总部位于墨西哥蒙特 雷，在全球38家工厂有员工22000多人，2018年营 业收入为47亿美元。尼玛克是OEM主要的一级供应 商，是全球60家最大汽车零部件供应商之一。尼玛 克在土耳其伊兹密尔市的工厂，用压铸工艺为知名 汽车制造商生产油底壳和托架，用重力铸造生产气 缸盖，现在，在库尔茨铸造设备公司的支持下用低 压工艺生产气缸盖。 尼玛克，世界知名的发动机缸体，特别是气缸盖 制造商，决定进一步扩大其气缸盖的生产。由于气 缸盖的特殊设计，在这种情况下，理想的工艺不是 重力铸造，而是低压铸造。由于尼玛克在土耳其工 厂生产现场没有待开发的建设土地，因此扩充产能 是以棕地投资项目进行的-这意味着现有的厂房要 相应地进行转换。气缸盖低压工艺的集成几乎发生 在“敞开的心脏”：在持续生产过程中，铸造厂被 重建，新的铸造线安装就位。即使是在低压线组装 和调试第一部分作为系列生产的前奏，正在进行的 生产也没有中断一秒钟。

Brownfield Project: a time and space challenge This project was anything but standard for both Nemak and Kurtz. In addition to the extreme time pressure, the limited space available presented us with major challenges, which is typical for brownfield installations. Together, we ultimately came up with ideal solutions – a small excerpt from the implemented measures: Height reduction and adaptation of the cooling installation to the casting machines as well as adaptation of the overall layout of the FSC casting line.

The highest commandment was the adherence to the schedule. “We only had seven months from the award of the contract to the first shot, which is absolutely unusual for such complex projects. Such a goal can only be achieved if both sides are passionate and give their all. The cooperation during the project and planning phase, the assembly time on site, where everything ran hand in hand, up to commissioning, was simply super,” says Lothar Hartmann, General 46

棕色地块项目：时间与空间的挑战 这个项目对尼玛克公司和库尔茨公司来说都是标 准的。除了极端的时间压力，有限的空间带来的重 大的挑战，这是典型的棕地投资置换。总之，我们 最终找到了理想的解决方案-一个小的摘录，从实施 的措施：降低高度和适应冷却安装到铸造设备，以 及适应FSC铸造线的总体布局。 最高的命令是遵守时间表。“从合同签署到开始 动工，我们只有七个月的时间，这对于如此复杂的 项目来说是绝对不寻常的。 只有双方都充满激情并 全力以赴，这样的目标才能实现。 在项目和计划阶 段的合作，现场的装配时间，所有的东西都是携手

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product news/产品新闻

Manager Business Unit Foundry Machines Kurtz GmbH, looking back on the extremely ambitious project. This was the only possible way to meet the time schedule despite the one or other small hurdle.

On technology: Nemak opted for a Kurtz casting line AL18-16FSC. The highlight of the line is the cooling technology with 48 regulated water circuits, which can later be extended to 96 circuits if required. Cooling is controlled by temperature and time. Thanks to the large low-pressure casting furnace with 2,800 kg aluminium capacity and the additional machine equipment, Nemak can produce frames and structural parts as well as cylinder heads in two cavities. In the final stage, the casting line will consist of a total of four machines and will be completely installed by June 2020. “With the Kurtz AL18-16FSC, Nemak is well equipped for future castings – both for light-weight construction and e-mobility. We would like to take this opportunity to express our sincere thanks for this extraordinary cooperation – a cooperation you can only wish for. All the best for Nemak and good luck for the future,” stated Kurtz Managing Director Uwe Rothaug. ■

完成的，直到调试，简直是超级棒，”库尔茨公司铸 造设备业务总经理洛萨·哈特曼说，“回顾这个非常 雄心勃勃的项目。这是唯一的可能来满足时间表的方 式，尽管有一个或多个小障碍。” 关于工艺：尼玛克公司选择了库尔茨公司Al1816FSC铸造线。这条线的亮点在于是冷却技术，有48 条调控冷却水循环，的如果需要的话，它以后可以扩 展到96条。冷却由温度和时间控制。由于大型低压铝 合金铸造机配备2800 kg的保温炉和其他辅助设备， 尼玛克公司可以在两个工位生产框架铸件、结构件以 及气缸盖。在最后阶段，铸造线将由总共4台机器组 成，并将在2020年6月前完全安装。“随着库尔茨公 司Al18-16FSC铸造线的问世，尼玛克公司为未来的 铸件配备了充足的设备——既可用于轻量化结构，也 可用于电动汽车。我们愿借此机会对这一非凡的合作 表示真诚的感谢，期待尼玛克公司有最好的好运和未 来。”库尔茨公司总经理乌韦•罗索格说。 ■

Foseco’s Latest Coating Innovation: Semco Fd – The New Fast Dry Waterbased Coating 福士科公司涂料创新：SEMCO FD –新型快干水性涂料 Almost all foundries supplying the automotive industry have now switched to the use of water-based coatings. This is state of the art.

However, when larger castings are produced in small batches or even single parts, the use of water-based coating is not really popular.

The reasons for this include the following: • The lack of drying and storage capacity.

• The loss of time due to longer drying times.

• The lower productivity.

On the other hand, the demand for safe, less VOCreleasing and more cost-effective products has never been greater, especially in the jobbing casting segment.

Added to this is the current shortage of ethanol and isopropanol solvents due to the corona crisis.

Many foundries are currently paying many times more for solvent coatings in order to maintain production. In addition, the quality is often inferior and there is still uncertainty about availability.

Therefore, the ultimate solution for use in steel and iron customer foundries in this case is a coating that is harmless to health and dries independently in a short time, a coating that provides the same or better casting surface finish and also is not subject to hazardous mate-

几乎所有为汽车工业配套的铸造厂现在都转向使 用水性涂料，这是最先进的工艺 然而，当生产小批量甚至单个较大的铸件时，水 性涂层的使用并不是很受欢迎。 其原因包括： • 缺乏干燥和储存能力。 • 由于干燥时间较长而浪费时间。 • 生产效率较低。 另一方面，对安全、减少VOC的排放和更具成本 效益的产品方面的需求越来越多，特别是在铸造部 门。 此外，由于新冠危机，目前乙醇和异丙醇溶剂 短缺。 现在，许多铸造厂为了保持生产，已经为溶剂 涂料支付了许多倍的费用。此外，质量也不令人满 意，在可用性方面仍然存在不确定性。 因此，在这种情况下，对于铸铁和铸钢的铸造 厂，最终解决方案是健康无害的，在短时间内独立 干燥，提供相同或更好的铸造表面光洁度的涂料，

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product news/产品新闻 rial storage regulations.

The range of our new SEMCO FD waterbased fast dry coatings includes: • Pure zircon based filler formulations for the heaviest iron and steel applications.

• Aluminum silicate types for iron and smaller steel castings.

• A range of other silicate fillers to optimize cost and application.

To address these needs, Foseco has developed a new fast drying water-based coating called SEMCO FD. The concept of SEMCO FD is unique in that it allows foundries to use coatings with significantly higher solids content, which provides greater protection against casting defects.

The result is an accelerated drying process, lower energy consumption, an enormous improvement in the quality of the working environment, as well as improved profitability of the foundry. ■

也不受危险材料储存条例的约束。 新的SEMCOFD水性快干涂料的范围包括： • 对大型铸铁、铸钢件，用纯锆基填料配方。 • 较小的铸铁、铸钢件，用硅酸铝类填料。 • 其他类型铸件用硅酸盐填料，以优化成本和应 用。 为了满足这些需求，福士科公司开发了一种新 的快速干燥水基涂层，称为SEMCO FD。 SEMCO FD的概念是独特的，因为它使铸造厂 使用的涂料固体含量显著提高，提供了更大的保 护，以防止铸件缺陷。 其结果是干燥过程加快，能耗降低，工作环境 改善，铸造利润提高。 ■

Increased Profitability Through Innovative Foundry Equipment 以创新提升铸造设备盈利能力 Founded in 1966 in Fukuoka, southern Japan, Hirado has been supplying the foundry industry for over 50 years. Since the 1970’s Hirado has been working with the major Japanese foundries in creating innovative equipment to reduce worker fatigue, increase production process and lower costs. This relationship has allowed Hirado to become renowned throughout Asia. Since its release thousands of its equipment have been installed and are currently being used in foundries in over 20 countries.

A new factory in the Fukuoka prefecture was constructed to respond to the increased demand for Hirado equipment. Even now, all equipment is 100% developed and manufactured in house in Japan according to the highest quality standards. ■

Hirado公司成立于1966年，位于日本南部的福冈， 已为铸造行业服务了50多年。自20世纪70年代以 来，Hirado公司一直与日本的主要的铸造厂合作， 制造创新的设备，以减少工人的疲劳，增加产量和 降低成本。这种关系使Hirado公司在整个亚洲享有 盛誉。自上市以来，已安装了数千台设备，目前正 在20多个国家的铸造厂使用。 为了应对市场对Hirado公司设备日益增长的需求， 公司在福冈县建造了新工厂。即使是现在，所有的 设备都是100%按照最高质量标准在日本国内开发和 制造的。 ■

Innovative Synergized Technology 创新协同技术 Hirado has developed an innovative hydraulic system through decades of experience and research. This technology allows Hirado to develop light weight, fast, safe & flexible equipment such as its EP Casting Splitter Wedge series for degating castings and SBH Snap Breaker series for breaking runners.

By implementing this equipment in the degating and finishing process, foundries can massively reduce labor costs, work fatigue and consumable costs while speeding up the degating process leading to increase profitability.

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Hirado公司通过几十年的经验和研究开发出创新的 液压系统。该技术使Hirado公司能够制造重量轻、速 度快、安全、灵活的设备，如其EP铸件浇、冒口分类 器系列用于铸件去除浇、冒口，SBH破碎器系列用于浇 道的破碎。 在去冒口、浇道和铸件清理过程使用该设备，铸造 厂可以在加快去冒口的同时，减少人工的使用，同时加 快去冒口速度，提高盈利能力。

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product news/产品新闻 An effective and personal solution for every foundry

为每个铸造厂提供有效且定制化的解决方案

Hirado knows through decades of experience that every foundry is different. By having a state of the art manufacturing facility and a dedicated, experienced and skilled team of engineers, Hirado is able to develop customized enhancements to its equipment and even offer brand new concepts as a personalized and effective solution for every foundry.

凭借几十年的经验，Hirado公司知道每个铸造厂都 是不同的。通过拥有最先进的制造设施和一支专注、经 验丰富和熟练的工程师团队，Hirado公司能够为客户开 发其专属的定制设备，甚至为每个铸造厂提供全新的概 念，作为个性化和有效的解决方案。

Experience Hirado

Hirado经验

Hirado continues to expand its worldwide presence by having partnerships with equally dedicated and experienced local partners. In recent years Hirado has established a network of partners in Europe, currently serving 15 countries and including major markets such as Germany, France, Italy, Spain & Poland.

Hirado and its partners pride themselves in not only supplying high quality equipment, but also in establishing a long lasting relationship with foundries. To experience Hirado, their equipment and the advantages it can offer, local partners are able to demonstrate the equipment on site and consult with foundries on the best possible solution. ■ To find out more about Hirado, their innovative equipment and its network of partners, please visit the official website at www.hirado.co.jp/en

Hirado公司继续扩大其在世界各地的市场，与 同样专注和有经验的当地企业建立伙伴关系。近年 来，Hirado公司在欧洲建立了合作伙伴网络，目前服务 于15个国家，包括德国、法国、意大利、西班牙和波兰 等主要市场。 Hirado公司及其合作伙伴不仅为提供高质量的设 备而自豪，而且也为与铸造厂建立长期的关系而自 豪。Hirado公司的经验，他们优质设备和它可以提供的 经验，当地的合作伙伴能够在现场演示设备，并就最好 的解决方案与铸造厂协商。 ■ 欲了解更多关于Hirado公司的创新设备及其合作伙 伴的信息，请访问官方网站www.hirado.co.jp/en

Redefining core competencies 重新定义制芯能力 Even today, experts have to solve many problems in core production based on their experience or by trial and error. In an interactive MAGMAacademy workshop carried out by MAGMA Inc., USA, and Laempe-Reich, attendees had the opportunity to discuss various technical challenges in the core shop related to core shooting, gassing, and binder hardening.

The typical degrees of freedom available to the core maker such as tool design, modification of vent types and locations, using different nozzle/blow tube strategies and cavity layout were examined. The enriching environment spanning both hands-on real core production and core simulation provided a unique experience for the attendees to assess the impact of the most common variables on core making in real time.

All proposed vent and nozzle combinations for the investigated core summed up to a theoretical total of 262,144 possible designs. Finding the best combination with a trial-and-error approach was simply not possible – neither with real trials nor with the help of traditional simulation tools. With the use of Autonomous Engineering in MAGMA C+M (Core + Mold), a total of 160 designs were automatically created and simulated. Today, this technology can evaluate these 160 different design scenarios in less time than it would take to make 2 real physical trials.

即使在今天，专家们仍必须根据他们的经验或通过 反复试验来解决砂芯生产中的许多问题。在由美国迈 格码公司和Laempe-Reich公司举办的迈格码学院讲 习班上，与会人员讨论了制芯车间中与射芯、通气和 粘结剂硬化有关的各种技术挑战。 试验研究了制芯厂商拥有的典型自由度，例如模具 设计、排气类型和排气位置的改变、使用不同的射嘴/ 吹气管设计和腔体布局。砂芯的实际生产和制芯模拟 为与会者提供了独特的体验，可以让他们实时评估最 常见变量对制芯的影响。 研究中的排气和射嘴组合的理论设计方案共计有 262,144种。因此，无论是通过实际试验还是借助传统 的模拟工具，根本不可能通过反复试验法找到最佳的 组合。而通过采用MAGMA C + M（砂芯+模具）的 自主优化，160个设计方案得以自动创建和模拟。如 今，这项技术可以在比进行两次真正的试验所需更少 的时间内评估这160个不同的设计方案。 MAGMA C + M中的平行坐标图使您可以轻松评估 不同变量对确定的主要目标的影响，即具有最高密度 砂芯（图1）。图中的每条线对应于一个模拟设计，并

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product news/产品新闻 图1：平行坐标图 显示了优化工艺 设计对砂芯密度 的影响。

Fig. 1: The parallel coordinates plot shows the impact of process design modifications on core density

A parallel coordinates plot in MAGMA C+M made it easy to assess the effects of the different variables on the defined main objective: a core with the highest possible density (Fig. 1). Each line in the plot corresponds to one of the simulated designs, and a different color is assigned to each design/line depending on its quality. Blue lines lead to a poor or low density, whereas bright yellow ones lead to better compaction and higher density in the core.

A positive relationship was determined between the total shooting area of the blow tubes and the core quality at the end of the shooting process. As the number of nozzles increased, along with the appropriate venting conditions, the core density increased.

Shooting a sand-binder mixture into a cavity and achieving its maximum compaction is half of the battle in obtaining a defect-free core. For coldbox cores, after this phase the gassing manifold introduces amine into the core box cavity through the nozzles and sometimes through the top vents.

Typically the operator will start with an initial amount

Fig. 2: Increasing the cycle time reduces the amount of non-hardened core areas (left). Defect assessment of non-hardened areas in produced cores (right)

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且根据其质量为每个设计/每条线分配不同的颜色。 蓝色线条表明较差或较低的密度，而亮黄色线条表明 砂芯有更好的压实度及较高的密度。 吹气管的总射芯面积与射芯结束时的砂芯质量之 间呈正相关关系。随着射嘴数量的增加，加上适当的 排气条件，砂芯密度增加。 将砂粘结剂的混合物射入型腔并实现最大压实度 使获得无缺陷型芯成功了一半。对于冷芯盒砂芯，在 此阶段之后，充气歧管通过射嘴（有时通过顶部排气 口）将胺通入到芯盒腔中。 通常，操作员会从初始量的胺开始加入，然后逐 渐增加直至生产出可接受的砂芯。同样，操作员可以 延长生产周期来重复此方法，使胺有更多时间来固化 砂芯。 通过工艺设计生产砂芯，在虚拟实验设计

图2：延长生产周 期会减少未硬化砂 芯区域（左）。对 已生产砂芯中未硬 化区域的缺陷评估 （右）

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product news/产品新闻 Fig. 3: Final result after optimizing the venting configuration

of amine and increase it until an acceptable core is made.

Similarly, the operator may repeat this approach with an extended cycle time to allow more time for the amine to cure the core.

The real-life cores produced using the process set-up which led to a dense core after shooting in the simulated Design of Experiments (DoE) proved: the core quality increased with an increasing amine amount. However, the workshop teams also found that even with a 63% increase in amine content, a good quality core was not possible (Fig. 2).

In a second iteration, the gassing time was increased, which is also a common practice to reduce defects in core making, even if it lengthens the cycle time and leads to lower productivity. However, after 45 seconds of curing time, the core still showed un-cured areas (Fig. 2, (right)).

To provide the attendees with further understanding of defect resolution for an uncured core, an alternative venting layout was presented with the original starting conditions (cycle time 15 seconds, 19cc of amine). This combination was simulated and produced, and the modified venting layout turned out to be the key element to success. All previous un-cured areas had been fully cured and the core had achieved all objectives for shooting and gassing (Fig. 3).

MAGMA C+M had provided critical information for the cost-effective manufacture of a quality core in the early stages of tooling design. ■

图3：优化排气布局后的最 终结果。

（DoE）中射芯后产生了高密度的砂芯，这表明： 砂芯质量随胺含量的增加而提高。但是，研讨小组 还发现，即使胺含量增加63％，也无法获得高质量 的芯子（图2）。 在第二次试验中，通气时间增加了，这也是减少 芯子缺陷的一种常见做法，尽管这延长了生产周期 并导致生产率降低。但是，在固化45秒后，砂芯仍 显示有未固化区域（图2右）。 为了使与会者进一步了解未固化砂芯缺陷的解决 方案，研究人员提出了初始生产条件（生产周期为 15秒，胺的添加量为19cc）的排气布局方案，模拟 了这种组合并进行生产，结果表明，修改后的排气 布局方案是取得成功的关键要素。之前所有未固化 的区域均已完全固化，并且砂芯已达到射芯和通气 的所有目标（图3）。 MAGMA C + M为在模具设计的早期阶段以更为 经济的方式生产优质砂芯提供了关键信息。 ■

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