Global Casting Magazine Volume 8 Number 2

Green Sand Properties 湿型砂性能

Also 还请关注: Industry News p. 11 行业新闻 p.11

MODERN

CASTING A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY

Casting Competence Across Three Continents

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HOT SAND INTAKE

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APRIL 27-30, 2019

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Expect to see: • 400 + full-scale exhibitor booths with live demonstrations, realworld equipment, and exciting announcements • High-profile keynote speakers talking about current metalcasting issues and events • The latest technical research, practical panel discussions, and management advice from leading industry experts Plan now to attend this energetic event April 27-30, 2019, in Atlanta, Georgia!

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WWW.GLOBALCASTINGMAGAZINE.COM

JULY 2018

volume 8 number 2

P.17

P.22

P.33 FEATURES

专题文章

22 Development and Casting of High Cerium Content Aluminum Alloys

22 高铈铝合金的研制与铸造

D. WEISS

28 Does Water Quality Affect Green Sand Properties?

B. WALLACE, S. RAVI AND J. THIEL

33 The Middle Frame Design for an Electric Car Y. SAISAI AND Z, YIDA

38 Status of the Vietnam Foundry Industry

戴维·韦斯

28 水质对湿型砂性能有何影响？ B. WALLACE, S. RAVI AND J. THIEL

33 新能源车中部车架设计 玉赛赛, 张宜达

38 越南铸造业现状 GCM STAFF REPORT

GCM STAFF REPORT

DEPARTMENTS

专栏

9 Editorial 11 Industry News 40 Product News

9 编者的话 11 行业新闻 40 产品新闻

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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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

Associate Editor BRIAN SANDALOW, bsandalow@afsinc.org

Senior Editor/ International Sales ADRIANA WEISENBACH, aw@foundry-planet.com

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

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

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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Hawkeye Borescopes ®

Hawkeye管道探視器

沙子

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無效

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閃光

Flash as seen with a Hawkeye V2 Video Borescope

我們提供嚴格，靈活和視頻管道探視器80個設計。 Manufacturers of complex castings now have a fast, affordable way to improve quality control in their visual inspection process with Hawkeye® Pro Borescopes.

We stock over 80 models of rigid, flexible and video borescopes, and accessories, at prices far less than comparable instruments. Hawkeye Pro Borescopes provide detailed images of sand, voids, flash, surface-finish irregularities, and numerous other defects that can affect the quality of a wide range of mission-critical castings used in automotive, aviation, power generation, and more.

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editorial/编者的话

Meet Challenges With Joint Efforts 共同应对挑战

T

he world foundrymen gathered together and participated in the “2nd Global Foundry Forum” during Metal China 2018, May 15-17, 2018, in Beijing, focusing on the hot topic of challenges and opportunities brought about by “Belt and Road” initiative. In Sep. 23-27, foundry elites from all over the world will meet in Krakow, Poland for the 73rd World Foundry Congress themed with “Creative Foundry.”

The world foundry industry faces many challenges in common: green development and weak casting growth require joint efforts, new technology revolution requires cooperation and joint development, and there is need of complementary and flow for human resources. All these challenges call for an exchange platform which is built by the world foundrymen, and which will lead the sustainable, healthy and orderly development of the world foundry industry.

Global Casting Magazine is willing to contribute to the development of the global foundry industry. ■ Zhang Libo Publisher/President China Foundry Association

张立波 出品人 中国铸造协会

2018

年5 月15-17 日的Metal

China 2018期间，全球铸造业精英相聚北京参加“第 二届全球铸造论坛”，热议“一带一路”倡议为铸造业 的发展带来的机遇与挑战；9月23-27日，全球铸造人 将汇聚波兰克拉科夫“第73届世界铸造大会”，共赏“ 创意铸造”之美。 世界铸造业面临着许多共同的挑战——绿色发展的 挑战需要共同应对、铸件市场增长乏力的挑战需要共同 应对、新技术革命带来的挑战需要合作开发、人力资源 的挑战需要互补流动，这些挑战促使着全球铸造人共同 搭建交流的平台，去引领世界铸造行业的持续、健康、 有序发展。 《世界铸造》杂志愿为全球铸造业的发展贡献力量。

张立波 出品人/会长 中国铸造协会

Shannon Wetzel Managing Editor MODERN CASTING

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

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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Kraków 2018

73 WFC

The 73rd World Foundry INDUSTRY NEWS/行业新闻

Congress ’Creative Foundry’

23–27 September 2018 Krakow, Congress Center, POLAND Organisers: Polish Foundrymen’s Association

World Foundry Organization

Registration until 31st August 2018 • Materials • Technologies • Digitalisation • Management • Ecology •

www.73wfc.com More than...

• 200 scientific and technical presentations • • 150 technical and scientific posters • • 80 participants of Young Researchers’ Seminar • • 40 exhibitors of Creative Foundry Exhibition • • 8 different technical excursion • …all dedicated to world foundry industry…

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

INDUSTRY NEWS/行业新闻

Industry News Contents 行业新闻目录

Fellow Pan Fusheng Academician Workstation Established in Ka Shui Technology Park in Daya Bay 13 潘复生院士工作站落户惠州大亚湾嘉瑞科技工业园区 Total Casting Production in China Grew 4.7% in 2017 2017 年中国铸件产量增长4.7%

14

2nd GFF and 3rd Belt & Road Forum Held in Beijing 第二届全球铸造论坛暨第三届“一带一路” 铸造产业合作发展论坛在京举办

14

FCRI Group Promoted New Products at Metal China 2018 金刚集团携新品亮相2018第十六届中国国际 铸造博览会 Xinxing Ductile Iron Pipes Makes Contribution to the Construction of Recycled Water Reuse Pipelines in Linhe District 新兴铸管助力临河区再生水回用管网建设

16

17

Shiloh completes acquisition of Brabant Alucast Italy and Brabant Alucast Netherlands Shiloh公司收购Brabant Alucast在意大 利和荷兰的公司

19

McWane Inc. Acquires Waterman Industries McWane收购Waterman工业公司

18

GIS Launches Draxton Brand GIS集团成立 Draxton分公司

18

Hitchiner announces expansion Hitchiner公司宣布扩建计划

19

TEI, Voxeljet Announce Agreement TEI, Voxeljet宣布签订合作协议

20

Magellan announces agreement with aeroengine customer.

Magellan宣布与航空发动机客户合作

21

Mercury Marine begins latest expansion Mercury Marine启动新扩建项目

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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11

INDUSTRY NEWS/行业新闻

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

INDUSTRY NEWS/行业新闻

Fellow Pan Fusheng Academician Workstation Established in Ka Shui Technology Park in Daya Bay 潘复生院士工作站落户惠州大亚湾嘉瑞科技工业园区 With the rapid development of the national economy, innovation has become the core driving force to accelerate the enterprise development. Through the close cooperation between the industry and research institutes, it will inject powerful impetus into the enterprise innovation and development. On May 25, 2018, Fellow Pan Fusheng team signed the cooperation agreement with Ka Shui Group and Intelligent Foundry Industry Light Alloy Innovation Center to jointly set up an academician workstation in Daya Bay. Mr. Lee Yuen Fat, Chairman of Ka Shui Group, Fellow Pan Fusheng of Chongqing University and Mr. Yang Jun, the General Manager of The Intelligent Foundry Industry Light Alloy Innovation Center attended the signing ceremony and Professor Jiang Bin signed on behalf of Fellow Pan Fusheng. This has marked the formal establishment of Fellow Pan Fusheng academician workstation in Ka Shui Technology Park in Daya Bay. By virtue of the strong R&D strength of Fellow Pan and his team in the field of magnesium alloy research and the rich experience accumulated by Ka Shui Group in the field of magnesium alloy products, the academician workstation will be the leading platform for the development of advanced magnesium alloy materials and processing technology with the platform advantages of Intelligent Foundry Industry Light Alloy Innovation Center. In addition, we should strengthen cooperation in production, teaching and research, and contribute to the development of light alloy manufacturing industry, lead the technology direction and industrialization promotion of lightweight magnesium alloy, and create large-scale industrial technology research and development and transformation application ecosystem. ■

随着国家经济高速发展，企业创新能力已成为加 快产业发展的核心驱动力，通过产学研紧密合作， 为企业创新发展注入强大动力。2018年5月25日上 午，潘复生院士团队与嘉瑞集团暨智能铸造产业轻 合金创新中心签订合作协议，在大亚湾携手建设院 士工作站。 嘉瑞集团主席李远发先生、重庆大学潘复生院 士、智能铸造产业轻合金创新中心总经理杨军先 生，一同出席签约仪式，潘复生院士团队成员蒋斌 教授代表潘复生院士上台签约，这标志着潘复生院 士工作站正式落户大亚湾嘉瑞科技工业园区。 院士工作站的建立，凭借潘院士团队在镁合金领 域的强大研发实力和嘉瑞集团在镁合金产品的深厚 积淀，借助智能铸造产业轻合金创新中心的平台优 势，共同打造先进镁合金材料研发及加工工艺研发 的国内领先平台，进一步整合资源，深化产学研合 作，为推动轻合金制造行业创新发展做出贡献。引 领轻量化镁合金技术方向及产业化推广，打造大型 的产业化技术研发和转化应用生态圈。 ■

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行业新闻

Total Casting Production in China Grew 4.7% in 2017 2017 年中国铸件产量增长4.7% The statistics of Chinese foundry industry in 2017 was released by the Executive Vice President and Secretary-general Mr. Zhang Zhiyong of China Foundry Association during the 14th China Foundry Association Annual Congress.

执行副会长兼秘书长张志勇首次向社会发布了中国铸造

The whole industry grows 4.7%

全行业增速4.7%

According to the data, the total output of all types of castings in China in 2017 reached 49.4 million tons, an increase of 4.7% from 2016. From the perspective of different materials, the output of gray cast iron reached 21.15 million tons in 2017 while it was 20.35 million tons in 2016, an increase of 3.9%; ductile iron (including vermicular) increased from 13.2 million tons to 13.75 million tons, an increase of 4.2%. Driven by rail transit, mining, metallurgical, heavy machinery, construction machinery and other industries, the output of steel castings grew rapidly, reaching 8.8%; due to the demand for “lightweight”, aluminum (magnesium) alloy castings increased by 5.8%, reaching 7.3 million tons; malleable cast iron, copper alloys and other castings were almost the same as last year.

From the perspective of the proportion of various types of casting material, the output of steel castings resumed growth in 2017, accounting for 11.3% of the total (10.8% in 2016); aluminum (magnesium) alloy castings production increased to 14.8% (14.6% in 2016); the proportion of ductile iron castings was 27.8%, with a slightly decline (28.0% in 2016).

According to changing demand structures in downstream industries, the automobile, construction machinery and rail transit contributed a lot to castings in 2017, which increased by 7.1%, 15.2% and 14.3% respectively. Among them, automobile industry directly increased one million tons of castings; the internal combustion engine and agricultural machinery contributed an increase of 0.8%; the mining, metallurgical and heavy machinery brought another 2.3% increase.

The demand proportion for various types of castings of the downstream industry in 2017 was: the proportion of automobile castings rose to 30.6% (29.9% in 2016), and in particular the production of trucks increased significantly. ■

在第十四届中国铸造协会年会期间，中国铸造协会 行业2017 年统计数据。

数据显示，2017 年中国各类铸件总产量4,940 万 吨， 较2016 年增长4.7%。从不同材质铸件产量来 看，灰铸铁2016 年产量2035 万吨，17 年达到2115 万吨，增幅3.9%；球墨铸铁（包括蠕墨铸铁）从1320 万吨增长到1375 万吨，增幅4.2%；受轨道交通、矿冶 重机、工程机械等行业的带动，铸钢件产量增速较快， 达到8.8%；因“轻量化”的需求，铝（镁）合金铸件 增长5.8%，2017 年达到730 万吨；可锻铸铁、铜合金 及其他类铸件变化不大。 从各类材质铸件占比来看，2017 年，铸钢件产量恢复 增长，占比上升至11.3%（2016 年为10.8%）；铝（镁） 合金铸件产量占比上升至14.8%（2016 为14.6%)，球墨 铸铁件占比为27.8%，略有回调（2016 为28.0%）。 从下游行业铸件需求结构变化来看，2017年汽车、 工程机械和轨道交通对铸造的拉动较大，分别增长 7.1%、15.2% 和14.3%；其中汽车行业直接带动铸件 100 万吨产量的增加；内燃机及农机拉动增幅0.8%； 矿冶重机拉动增幅2.3%。 2017 年下游行业各类铸件需求比例为：汽车铸件占 比上升至30.6%（2016 年为29.9%），尤其是货车产 量大幅增长。 ■

2nd GFF and 3rd Belt & Road Forum Held in Beijing 第二届全球铸造论坛暨第三届“一带一路”铸造产业合作发展论坛在京举办 On May 16, 2018, the global foundry elites gathered in Beijing to participate in the 2nd Global Foundry Forum and the 3rd “Belt & Road” Foundry Industry Cooperation and Development Forum. More than 60 international representatives from BRICS countries, Asian Foundry Forum members, countries along the Belt and Road, and developed foundry nations of Germany, the United States, France, Japan, Norway, Denmark and Spain, as well as another 100 more well-known Chinese foundry entrepreneurs attended the forum, discussing how to make good use of the global foundry market, creating opportunities for the global foundry industry with “Belt and Road” initiative, and calling 14

2018 年5 月16 日，全球铸造业精英汇聚北京共 同参加第二届全球铸造论坛暨第三届“一带一路”铸 造产业合作发展论坛。金砖国家、亚洲铸造论坛、“ 一带一路”沿线国家、德国、美国、法国、日本、挪 威、丹麦、西班牙等铸造发达国家的60 余位国际代 表，近100 位国内知名铸造企业家参会，共同研讨如 何有效利用全球铸造市场，依托“一带一路”倡议为 铸造业的发展带来机遇，共同推动全球铸造业高质量 合作，共赢发展。

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

INDUSTRY NEWS/行业新闻 on all members to jointly promote high-quality cooperation and achieve win-win development.

“Belt and Road” initiative has brought new opportunities for the development of the world and provided new modes of cooperation and development. The wave of globalization has expanded the field of mutual exchange and cooperation between the foundry industries of various countries. The Global Foundry Forum is to integrate global foundry resources, achieve mutual benefits and information sharing, build a convenient dialogue platform and create a solid and comprehensive communication mechanism. Mr. Zhang Libo, president of China Foundry Association, proposed in his speech: “In the face of the new trend of global economic and technological development with ‘Belt and Road’ Initiative, we need to plan mechanisms and strategies for in-depth cooperation and enhance the quality of international cooperation to achieve the sustainable development of the global foundry industry."

Mr. Zhu Jianxun, vice president of SQ Group, put forward with the initiative to create a "world foundry alliance."

He believes that the world foundry industry faces many common challenges: green development requires joint response, weak growth in the casting market requires joint response, the challenge posed by new technology revolution requires cooperation, and human resources challenge needs complementary flows. These challenges have motivated global foundry industry to seek an organization such as the “alliance of the foundry organizations” to lead the continuous, healthy and orderly development of the foundry industry in the world. At the same time, different countries have different market potentials for casting, different levels in areas of demand, industry support, resources and disadvantages, human resources, funding requirements, industrial policies and environmental protection...If these differences cannot be timely, well-analyzed, and dealt with, the world foundry alliance can assist and promote the better development of the foundry industry throughout the world.

With the theme of "promote the sustainable development of foundry industry with innovation", Dr. Carsten Kuhlgatz from Germany introduced HA; the president of Institute of Indian Foundrymen Mr. Amish Panchal introduced the development of the foundry industry in India and also introduced BRICS foundry industry on behalf of BRICS Foundry Association. Russian Association of Foundrymen President Mr. Dibrov introduced the status and prospects of Russian foundry industry and analyzed possible cooperation areas.

After the keynote reports, the forum also held a “Belt and Road” foundry market dialogue session. Participants shared their remarkable achievements and valuable experiences, worked together for the scientific and better development of the global foundry industry. ■

“一带一路”倡议给世界的发展带来了新的机遇， 提供了新的合作发展模式，全球化的浪潮，使各国铸造 业彼此间交流合作的领域不断扩大，全球铸造论坛就是 为了整合全球铸造资源，实现互惠互利，信息共享，搭 建便捷的对话平台，铸就稳固的全方位交流机制。中 国铸造协会会长张立波在致辞中倡议：“面对‘一带一 路’世界经济技术发展的新趋势，我们需要谋划深度合 作的机制和策略，‘提升国际合作质量，实现全球铸造 业可持续发展’。” 圣泉集团股份有限公司副总裁祝建勋在报告中提出 了创建“世界铸协联盟”的倡议。 他认为，世界铸造业面临着许多共同的挑战——绿 色发展的挑战需要共同应对、铸件市场增长乏力的挑 战需要共同应对、新技术革命带来的挑战需要合作开 发、人力资源的挑战需要互补流动……这些挑战促使 着全球铸造人寻求一个如“世界铸协联盟”一样的组 织去引领世界铸造行业的持续、健康、有序发展。同 时，各个国家铸造业市场潜力不同、需求水平和行业 水平不同、市场需求面不同、行业配套程度不同、生 产资源优劣势不同、人力资源多不相同、资金需求不 同、产业政策与环保力度不同……这些差异的存在若 不能及时、良好地面对、分析、处理，“世界铸协联 盟”可以协助并推进整个世界的铸造业更好地发展。 来自德国的Dr.Carsten Kuhlgatz 以“创新推动铸 造业可持续发展”为题，介绍了欧区爱公司的概况； 印度铸造协会会长Mr. Amish Panchal 介绍了印度铸 造业与金砖国家铸造业的发展情况、俄罗斯铸造协会 会长Dibrov 介绍了俄罗斯铸造业的发展现状和发展前 景，并分析了可能的合作领域。 主旨报告后，论坛还举行了“一带一路”铸造 市场对话环节，参会代表们一起分享全球铸造业 所取得的不菲成就和宝贵经验，一起谋划全球铸 造业科学发展的良策，一起憧憬全球铸造业携手 发展的美好明天。

■

July 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行业新闻

FCRI Group Promoted New Products at Metal China 2018 金刚集团携新品亮相2018第十六届中国国际铸造博览会

FCRI Group attended the 16th China International Foundry Expo (Metal China 2018) in Beijing with ceramic foam filters. FCRI mainly promoted ceramic filters and refractory powder, especially for twisting ceramic filter , zirconia ceramic foam filter which using o temperature is above 1600 C. FCRI ceramic foam filters can remove impurities effectively and improve the purities of molten metal which increase the surface quality and strength of pouring castings, ensure the quality rate of the products and reduce the production consumption and increase the economic benefits.

FCRI Group is the leader in advanced ceramic industry with production and sales experience in ceramic foam filters over 10 years. In 2017, FCRI moved the advanced ceramics plant to FCRI (Gaoming) industrial zone and rebuilt multi-production lines of ceramic foam filter with high automation equipments and advanced technology. The annual production capacity of ceramic foam filter is 5000 m3 now and FCRI is planning to increase the capacity in the second half of this year. ■

金刚集团携拳头产品泡沫陶瓷过滤器系列参加由 中国铸造协会主办的第十六届中国国际铸造博览会 （Metal China 2018）。本次参展产品包括陶瓷过 滤器全系列产品及耐火材料粉体，尤其主推缠绕型 陶瓷过滤器以及使用温度在1600度以上的氧化锆泡 沫陶瓷过滤器。 金刚牌泡沫陶瓷过滤器，可以有效地去除金属 溶液中的夹杂物，大大提高金属溶液的纯净度， 使浇注出来的金属铸件表面光滑，强度增加，保证 产品合格率，从而降低企业生产能耗，增加经济 效益。 金刚集团是国内特陶行业的领先者，具备十余年 生产和销售泡沫陶瓷过滤器的经验。2017年，集团 将特种陶瓷生产基地整体搬迁至高明（金刚）工业 园，组建多条泡沫陶瓷过滤器生产线，设备自动化 水平高，工艺技术先进，现具备年产泡沫陶瓷过滤 器5000立方的产能并计划在下半年扩大产能。 ■

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

INDUSTRY NEWS/行业新闻

Xinxing Ductile Iron Pipes Makes Contribution to the Construction of Recycled Water Reuse Pipelines in Linhe District 新兴铸管助力临河区再生水回用管网建设 Recently, the construction of a recycled water reuse pipelines in Linhe District, Bayannur City, Inner Mongolia was started. Xinxing’s centrifugal ductile iron pipes provide safety protection for local recycled water supply!

For sewage and recycled water transportation, compared with conventional pipes such as steel pipes and PCCP pipes, Ductile Iron pipes have big advantages such as better performance on corrosion resistance, long service life, high hoop rigidity, etc. Moreover, the comprehensive cost is lower than other pipes. These advantages make ductile iron pipes the best choice for sewage transportation.

For the purpose of consuming the recycled water of sewage treatment plants rationally, increasing the utilization rate of water resources, as well as achieving zero discharge of recycled water, the government of Linhe District organized this construction project for the reuse of recycled water pipelines.

Based on the new Water supply emergency engineering plan, the proprietor, Linhe District Construction Bureau, has carefully considered the advantages of different pipes. After visited Xinxing’s factories and comprehensively considered factors like product quality, supply capacity and after-sales service, the proprietor finally chose Xinxing as the pipe supplier. When the project started, Xinxing rapidly produced and delivered ductile iron pipes. During pipes installing process, after-sales technical staffs of Xinxing offered assistance and guide to the proprietor, laying the foundation for following pressure tests.

In recent years, Xinxing ductile iron pipes have been increasingly used in sewage and recycled water transportation projects. DN2400 ductile iron pipes for sewage, which is the largest pipe’s diameter in China, were used in Zhenjiang sponge city renewal project and played a key role in solving urban flooding issue. Linhe District Recycled Water Reuse Pipelines Project played an exemplary role in using ductile iron pipes for sewage and recycled water transportation projects in northern part of China.

With the economic and social development, there will be more and more Xinxing ductile iron pipes used in water supply and drainage projects. Xinxing will make greater contributions to the safety of water transportation and rational use of water resources in the future! ■

近日，内蒙古巴彦淖尔市临河区再生水回用管网建设 工程开工建设。新兴离心球墨铸铁管为当地再生水输送 提供安全保障！ 相较于钢管、PCCP管等传统管材，中污水用球墨铸 铁管具有耐腐蚀、寿命长、环刚度高等优点，综合使用 成本低于其他管材，是中污水输送的理想管材。 巴彦淖尔市临河区为了合理消纳、处理城市污水处理 厂再生水，提升水资源利用率，实现再生水零排放，组 织实施再生水回用管网建设工程。根据新制定的供水应 急工程方案，业主临河区建设局对管材进行了认真的比 选。最终，业主方经过实地考察，从产品质量、供货能 力和售后服务等综合因素考虑，他们最终选择新兴铸管 为管材供应商。项目开工后，新兴铸管迅速组织供货。 随着管材陆续安装到位，公司安排了售后技术人员全程 跟踪指导，为后续的打压试水做好铺垫。 近年来，新兴球墨铸铁管在排水工程、中水回用等 项目中得到日益广泛的应用。江苏镇江，国内最大口 径DN2400球墨铸铁污水管应用于当地海绵城市改造工 程，为解决城市内涝起到了 积极作用。 临河区再生水回 用管网工程的实施，为北方 城市中污水工程应用球管起 到了示范作用。随着经济社 会的发展，将有越来越多的 新兴中污水用球墨铸铁管应 用于给排水工程中，为输水 安全和水资源有序利用做出 更大贡献！ ■

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INDUSTRY NEWS/行业新闻

McWane Inc. Acquires Waterman Industries McWane收购Waterman工业公司

AFS Corporate Member McWane Inc. has purchased Waterman Industries (Exeter, California). Waterman manufactures water control products for water treatment, wastewater, agriculture, rural water delivery, hydro-power and flood control management.

Waterman is a manufacturer of both cast iron and fabricated stainless-steel water control gates. The company was founded by W.A. Waterman in 1912 and initially manufactured agricultural irrigation equipment for Central Valley farms. In 1953, the company expanded into water control infrastructure products including large and complex cast iron sluice gates, fabricated slide gates and radial gates.

“We are excited to add Waterman to the McWane family of companies,” McWane president and CEO Ruffner Page said.“Waterman’s high-quality products and veteran industry experts are an excellent complement to McWane’s Valve and Hydrant Group.”

McWane will invest in Waterman’s production facility in Exeter to modernize operations with new equipment and manufacturing processes to improve productivity, product delivery times, and team member safety.

In a news release, the company said it will also focus on improving communication and strengthening relationships with its customers, channel partners, and suppliers.

“McWane is excited to join the Exeter community with our purchase of Waterman, a recognized local leader for more than 100 years,” said Olivier Marietta, Waterman’s new general manager. “We will strengthen Waterman’s commitment to be a cornerstone of the local community, a respected and leading employer, and a loyal long-term partner to our customers and channel partners.” ■

美国铸造协会企业会员McWane有限公司已收 购Waterman工业公司（加利福尼亚州 埃克塞特 市。Waterman工业公司生产用于水处理、废水处理、 农业和农村供水、水力发电和防洪控制的产品。 Waterman公司主要生产铸铁和焊接不锈钢水控制 闸。该公司由W.A. Waterman于1912年创立，最初为 中央山谷农场生产农业灌溉设备。1953年，公司扩展到 水利基础设施产品，包括大型复杂的铸铁闸门、焊接滑 动闸门和弧形闸门。 McWane公司总裁兼首席执行官Ruffner Page 说：“我们很高兴Waterman加入McWane大家 庭。Waterman的高品质产品和资深行业专家是McWane阀门和水龙头集团的最佳补充。” McWane将投资Waterman在埃克塞特的生产厂，通 过新设备、新制造工艺实现运营现代化，从而提高生产 力、缩短产品交付时间、提升团队成员安全性。 据报道，该公司表示还将重点关注改善沟通，加强与 客户、渠道合作伙伴和供应商的关系。 Waterman新任总经理Olivier Marietta表示：“ 我们收购了当地超过100年历史的公认的领军企业 Waterman，McWane很高兴能加入埃克塞特社区。我 们将加强Waterman致力于成为当地社区发展基石的承 诺，这是一家备受尊敬的领先企业，也是我们的客户和 渠道合作伙伴的忠实长期合作伙伴。” ■

GIS Launches Draxton Brand GIS集团成立 Draxton分公司 Grupo Industrial Saltillo, S.A.B. de C.V., a Mexican multinational industrial conglomerate serving the automotive market, with a presence in the construction and housewares sectors, announced the consolidation of the three auto parts businesses – CIFUNSA, ACE and INFUN – into one unit named Draxton.

Draxton will be the name of the new consolidated unit and the brand name for all of the unit’s products. Draxton, along with the company’s joint ventures,will serve more than 50 customers in the automotive industry in six countries that represent the main markets for the sector. The capacity of the GIS auto parts sector will exceed 550,000 tons of iron casting, 10,000 tons of aluminum casting and 15,000,000 machined parts to supply global platforms.

“The formation of Draxton marks the culmination of a key stage in our globalization strategy. By unifying our original auto parts business, CIFUNSA, with two recent 18

萨尔提略工业集团公司是一家服务于汽车市场的墨 西哥跨国工业集团，业务还分布于建筑和家用品领域。 公司宣布将CIFUNSA、ACE和INFUN三个汽车零部件 业务合并为一个名为Draxton的公司。 Draxton将作为合并后的公司名称和新成立公司所有 产品的品牌名称。 合并后的Draxton公司将为6个国家 的汽车行业主要市场的50多家客户提供服务。GIS集团 汽车零部件产能将超过55万吨铸铁件，1万吨铝合金铸 件和1500万件机加工件，供应全球市场。 “Draxton的成立标志着我们全球化战略的关键阶 段达到了最高水平。通过统一原有的汽车零部件业务 CIFUNSA和最近的两项收购ACE和INFUN，我们扩大 了在欧洲和亚洲的业务范围，”GIS集团首席执行官

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INDUSTRY NEWS/行业新闻 acquisitions ACE and INFUN, we expanded our presence to Europe and Asia,” GIS CEO Jose Manuel Arana said.

“In Draxton, we are capitalizing on synergies, implementing shared best practices, and creating a new global brand in the automotive industry. For GIS, this will be our core business that today generates 70% of the group’s revenues.”

Draxton and GIS JVs will continue to be led by Jorge Rada, global director since 2016, who has more than 25 years of experience in the automotive industry. This division consists of more than 4,000 employees, 14 plants and three world-class R&D centers known globally as Draxton 4 Competitiveness (DC4). ■

Jose Manuel Arana说，“Draxton将利用协同效应、 实施共享的最佳实践方案，在汽车行业开创一个全新的 全球品牌。对于GIS集团而言，这将是集团产生70％收 入的核心业务。” Draxton公司和GIS集团合资公司将继续由2016年就 担任全球总监的Jorge Rada领导，他在汽车行业拥有超 过25年的经验。该业务部门拥有超过4,000名员工，14 个工厂和3个被称为DC4的世界级研发中心。 ■

Hitchiner announces expansion Hitchiner公司宣布扩建计划 Hitchiner Manufacturing Co. Inc. announced plans to expand its New Hampshire operations with the construction of a new, 85,000-square-foot facility on the company’s Elm Street Campus.

The building represents a multi-phased $50 million capital investment and will house operations to support new growth in markets Hitchiner currently serves. The investment is contingent on securing financing and permits from the town and state.

Hitchiner expects the investment will also eventually create an estimated 85 local jobs. The expansion will help ensure the future of Hitchiner’s current operations in the state.

“Expanding in New Hampshire would not have been possible without the support of state and local government.

Businesses planning to start-up or expand in the state today face important challenges. The high cost of energy in New Hampshire can be an especially high hurdle, particularly for manufacturing companies,” said Hitchiner chairman and CEO John H. Morison. “Fortunately, Hitchiner was able to work through these challenges with the governor’s office and the Town of Milford.”

The expansion is scheduled to begin in the middle of 2018. ■

Hitchiner公司宣布将扩大其在新罕布什尔州的业务 规模，在该公司的榆树街厂区建设一座面积达85,000 平方英尺（约7897平方米）的新工厂。 新厂的建设投资额达5000万美元，将分期完成，新 增的设备将可以满足Hitchiner公司的发展要求。项目 还取决于是否获得融资以及州、镇政府的许可。 Hitchiner公司预计该扩建项目将为当地增加约85个 就业岗位，助力Hitchiner在该州的未来发展。 Hitchiner董事长兼首席执行官John H. Morison表 示，“如果没有州和地方政府的支持，在新罕布什尔州 的扩张将不可能实现。目前，公司计划在该州启动的扩 张业务面临着重大挑战。新罕布什尔州的能源成本高昂 是一个特别大的障碍，尤其对于制造企业而言。幸运的 是，Hitchiner能够通过在州和米尔福德镇的支持和帮 助下应对这些挑战。” 工厂扩建项目预计将于2018年中启动。 ■

Shiloh completes acquisition of Brabant Alucast Italy and Brabant Alucast Netherlands Shiloh公司收购Brabant Alucast在意大利和荷兰的公司 Shiloh Industries Inc., a global supplier of lightweighting, noise and vibration solutions, completed its acquisition of its Brabant Alucast Italy and Brabant Alucast Netherlands.

The company will double production capacity for magnesium castings with this addition and says it will "become one of the leading global manufacturers of magnesium cross car beams as well as one of the largest automotive magnesium suppliers worldwide."

“The acquisition is significant both strategically and oper-

全球轻量化、噪音与振动解决方案供应商Shiloh工 业公司完成了对Brabant Alucast（意大利）和Brabant Alucast（荷兰）两家公司的收购。 收购后，公司的镁合金铸件生产能力将翻倍，而且 将“成为全球领先的镁合金交叉梁横梁制造商之一，同 时也是全球最大的汽车镁合金铸件供应商之一。”

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INDUSTRY NEWS/行业新闻 ationally redefining our position in the industry by expanding our technology portfolio and enhancing our manufacturing capabilities”, said David Jaeger, senior vice president and managing director, CastLight. “The new operations also bring aluminum casting capabilities, closing a gap in Shiloh’s European production needs.”

“Our growth in Europe is a result of the increasing demand for our innovative technologies and lightweighting solutions in both automotive and commercial vehicle applications,” said Ramzi Hermiz, president and CEO. “We remain committed to providing world-class service and meeting the performance and safety needs of our customers in the region and around the world,” Hermiz continued. “Shiloh’s unique multi-material capabilities in aluminum, magnesium and steel allow maximum weight savings without compromising safety, strength, performance or the environment.”

Shiloh’s global footprint now includes 33 manufacturing facilities and technical centers spanning three continents with over 4,200 employees. ■

“本次收购通过扩大技术组合和提高生产能力重新定 义了公司在行业中的地位，因此，从战略和业务上都具 有重要意义，”CastLight部门的高级副总裁兼董事总经 理David Jaeger说，“新的业务还增加了铝合金铸造能 力，缩小了Shiloh公司在欧洲生产需求方面的差距。” “公司在欧洲的不断发展是汽车和商用车市场对 我们创新技术和轻量化解决方案的需求不断增长的结 果，”公司总裁兼首席执行官Ramzi Hermiz说，“ 我们将一如既往地致力于提供世界一流的服务， 并满足该地区乃至全球客户对产品性能及安全的需 求，”Hermiz表示，“Shiloh在铝、镁合金和铸钢件 方面独特的多种材料解决方案可以在不影响安全性、强 度、性能或环境的前提下最大限度地减轻产品重量。” Shiloh公司在全球的三大洲拥有33个制造工厂和技 术中心，以及超过4200名员工。 ■

TEI, Voxeljet Announce Agreement TEI, Voxeljet宣布签订合作协议 AFS Corporate Member Tooling and Equipment International (Livonia, Michigan) has signed a three-year volume contract with fellow Corporate Member voxeljet America Inc. (Canton, Michigan) for 3-D printed sand molds and cores.

TEI has committed to purchase more than 500,000 liters of 3-D printed sand from voxeljet over an expected three-year period. In connection with the contract, voxeljet will install additional printing capacity in TEI’s Livonia facility as well as using its existing machines in its Canton, Michigan facility.

TEI has a comprehensive low-pressure aluminum casting facility together with heat treatment and a state-ofthe-art machine shop with over 50 CNC machines. TEI supplies machined-prototype and low-volume components in aluminum, iron and steel to automotive, aerospace and defense customers. With the help of voxeljet’s high productivity 3-D printing systems, geared towards industrial production, TEI will offer all phases of manufacturing from one source: design, 3-D sand printing, casting, heat treatment, machining, and inspection.

“This is an outstanding opportunity for both companies to further capitalize on the benefits of large scale 3-D sand printing for engineered aluminum castings,” said Oliver Johnson, president, TEI. “With voxeljet working alongside us to supply molds and cores, we will be able to compress lead times even further for our customers while also setting new records in terms of the size and weight of parts we can cast.”

“The 3-D printing industry is at an inflection point, and this marks another milestone in our mission to push 3-D printing into industrial production,” said David Tait, managing director, voxeljet America. “We are very proud to support TEI’s growth strategy with our unique 3-D printing technology.” ■ 20

美国铸造协会会员企业Tooling and Equipment 国际公司（简称TEI）（密歇根州利沃尼亚）与会员 企业voxeljet（密歇根州坎顿）签署了一份为期三年 的批量合同，用于生产3D打印砂型和砂芯。 TEI承诺在约定的3年时间内从voxeljet购买超过50 万公升3D打印砂。 根据合同，voxeljet将在TEI公司 利沃尼亚工厂安装额外的打印设备，并在其位于密歇 根州坎顿的工厂使用现有的生产设备。 TEI拥有完备的低压铝合金铸造设备以及热处理 设备和拥有超过50台数控机床的最先进的机加工 车间。TEI向汽车、航空航天和国防客户提供铝合 金、铸铁和铸钢等机加工原型和小批量部件。借助 voxeljet的高效3D打印系统，TEI将为工业生产提供 一站式的全制造过程：设计、3D砂型打印、铸造、 热处理、加工和检测。 TEI总裁Oliver Johnson表示：“这是两家公司进 一步发挥大型3D砂型打印设备生产铝合金铸件优势 的绝佳机会。voxeljet为我们提供砂型和砂芯，我们 将能够进一步压缩交付时间，同时还能在铸件尺寸和 重量方面创造新的记录。” “3D打印行业正处于一个转折点，这标志着 我们推动3D打印技术进入工业生产的另一个里程 碑，”voxeljet美国公司董事总经理David Tait 说，“voxeljet为能够利用独特的3D打印技术支持 TEI公司的发展战略感到非常自豪。”

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

INDUSTRY NEWS/行业新闻

Magellan announces agreement with aeroengine customer Magellan宣布与航空发动机客户合作 Magellan Aerospace (Toronto) announced the signing of a five-year agreement with a commercial aeroengine customer to manufacture complex magnesium and aluminium castings and finished, machined engine shafts for gas turbine engines.

The castings will be produced by Magellan facilities in Haley, Ontario, and Glendale, Arizona, and Magellan’s facility in Haverhill, Massachusetts will manufacture the engine shafts.

The new agreement is expected to generate approximately CDN $53 million in revenue for Magellan through 2023.

“This new long-term agreement is with an established Magellan customer and provides the framework for a new level of strategic alignment, the company said in a news release.

“In addition to legacy casting programs for current engine platforms, the agreement also encompasses the production of shafts at Magellan Aerospace, Haverhill, Inc. to support additional commercial engine programs.”

Magellan Aerospace is a global aerospace company that provides complex assemblies and systems solutions to aircraft and engine manufacturers, and defense and space agencies worldwide. Magellan designs and manufactures aeroengine and aerostructure assemblies and components for aerospace markets, advanced proprietary products for military and space markets, and provides engine and component repair and overhaul services worldwide. ■

多伦多的Magellan航空航天公司宣布与商用航空发动 机客户签订了为期5年的合作协议，生产复杂镁合金及铝 合金铸件以及燃气涡轮发动机用机加工发动机轴。 这些铸件将由位于安大略省哈利和亚利桑那州格伦代 尔的Magellan工厂生产，Magellan在马萨诸塞州黑弗里 尔的工厂将生产发动机轴。预计到2023年，该合作协议 将为Magellan带来约5300万加元的收入。 “这个新的长期协议是Magellan与一个现有客户签订 的，为双方提供了战略联盟合作新水平的框架，”公司 在报道中表示，“除了用于当前发动机平台的传统铸造 程序外，该协议还包括在Magellan航空航天公司生产发 动机轴以支持更多的商用发动机项目。” Magellan航空航天公司是一家全球航空航天公司，为 飞机和发动机制造商以及全球防务和航天机构提供复杂 的装配和系统解决方案。Magellan为航空航天市场设计 和制造航空发动机、航空结构组件及部件，为军事和航 空航天市场提供先进的专利产品，并在全球范围内提供 发动机和部件修理及大修服务。 ■

Mercury Marine begins latest expansion Mercury Marine启动新扩建项目

Mercury Marine has broken ground on a new expansion at its global headquarters in Fond du Lac, Wisconsin.

The first chamber and office space of the two-story NVH (Noise, Vibration, Harshness) facility is scheduled to be completed by October 2018, while the second chamber is targeted to be completed by the end of the year.

The new facility will be Mercury’s third major expansion in the last 18 months. In early 2017, Mercury officially opened its new $24 million EDP paint plant and in April 2017, Mercury commissioned a 4,500-ton high-pressure die-cast machine, the largest in North America.

The $10 million investment will add close to 20,000 additional sq. ft. to the more than 2.5 million square-foot campus.

With this latest expansion, Mercury has now invested more than $800 million since 2009 in expansion and R&D. The groundbreaking event was attended by Mercury employers, community leaders and many of the partners who are working on the project.

NVH is the engineering practice of studying noise, vibration and harshness characteristics.

The new technical center will contain two marine-specific hemi-anechoic chambers, structural dynamic testing bays, listening rooms, offices and workspaces. ■

Mercury Marine在其公司全球总部所在地威斯康辛 州丰迪拉克举办了新项目的奠基仪式。 两层楼高的NVH（噪声、振动、声振粗糙度）工厂 的第一层办公空间计划在2018年10月前竣工，第二层 办公空间计划将于年底前竣工。 新工厂将是Mercury Marine在过去18个月中的第三 次重大扩建。2017年初，Mercury正式开设了新的价 值2400万美元的EDP喷涂工厂，并于2017年4月完成 北美最大的4500吨高压压铸机的调试。 1000万美元的投资将在超过250万平方英尺（约 23.2平方米）的厂区基础上扩大20,000平方英尺（约 1858平方米）。 加上这次扩建，自2009年以来，Mercury已经在扩 建和研发方面投资了8亿多美元。Mercury雇主、社区 领导和参与该项目的很多合作伙伴参加了奠基仪式。 NVH是研究噪声、振动和声振粗糙度特性的工程实 践。 新的技术中心将包含两个海洋专用半电波室、结构 动态测试台、测听室、办公室和工作区。 ■

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Development and Casting of High Cerium Content Aluminum Alloys A pilot casting study looked at the promising aluminum-cerium alloy system that exhibits good mechanical properties at high temperatures.

David Weiss

高铈铝合金的研制与铸造 一项铸件试验研究了前景广阔的铝-铈合金系统在高温下具有良好的力学性能。 戴维·韦斯

E

utectic aluminum-cerium (Al-Ce) alloy systems have good mechanical properties at high temperatures and are very castable. Their castability is as good or better than the aluminum-silicon system with some deterioration as additional alloying elements are added. In alloy systems that use cerium in combination with common aluminum alloying elements such as silicon, magnesium and/or copper, the casting characteristics are generally better than the aluminum-copper system.

Additional alloying elements are used in aluminum casting, primarily to assist in the development of roomtemperature mechanical properties. Cerium stabilizes those properties at high temperatures (392-752F [200-400C]). The primary intermetallic formed in the aluminum-rich region of the Al-Ce system is Al11Ce3.3 Microstructures typical of a eutectic aluminum-cerium

共

晶铝铈（Al-Ce）合金在高温下具有良好的 力学性能而且铸造性能非常好。其铸造性能 和铝硅系一样，甚至更好，但随着合金元

素的加入，它们的性能也有所恶化。在使用铈与硅、镁 和/或铜等常用铝合金元素相结合的合金体系中，铸造 性能一般优于铝-铜体系。 其他用于铝铸件的合金添加元素，主要为了帮助提升 室温下的力学性能。铈在高温（392-752F [200-400C] ）下性能保持了稳定。在铝-铈合金系的富铝区域形成 的初级金属间化合物是Al11Ce3. 3 典型的共晶铝铈合金系统的微观结构如图1和图2所 示。铸态显微组织显出良好的互连共晶微观结构和纯铝

Figs. 1-2. The left image shows the as-cast microstructure of Al6Ce alloy, and the right is as-cast microstructure of Al-12Ce alloy.

Table 1. Composition of Base Alloy For Al-Ce Development P1520

22

Si

Fe

Total Others

Aluminum

0.11

0.17

0.09

Remainder

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Fig. 3. Shown is the binary aluminum-cerium phase diagram.

alloy system are shown in Figures 1 and 2. The as-cast microstructures show a fine interconnected eutectic microstructure and the pure aluminum phase. The scale of the laths can be as small as 100nm and do not exhibit preferential direction at standard cooling rates. These structures are stable at higher temperatures. The intermetallics are trapped by the zero solubility of cerium in the aluminum matrix. This trapping prevents the system from minimizing surface energy through diffusion, which blocks the alloys from traditional coarsening interactions.

The idea of using cerium as a primary alloying element in aluminum casings at near eutectic compositions is not completely new. The element has been studied for the effect of its additions of up to 4 wt% on the solidification range, solidification volume change and cast microstructure in an Al-4.5Cu alloy. The microstructure and mechanical properties of Al-Ce-Ni alloys containing up to 16 wt% Ce and 8 wt% Ni have also been studied.

This study aimed to determine the suitability of using standard foundry processing parameters on metal quality and mechanical properties for the casting of an Al-10Mg-8Ce alloy. The study found production systems for melting, degassing and other processing of aluminum-silicon or aluminum-copper alloys can be used without modification for conventional casting of aluminum-cerium

相。枝晶的尺寸可以小至100nm，并且在标准冷却速 率下不显示优先方向。这些结构在较高温度下保持稳 定。金属间化合物被铈在铝基体中的零溶解度所阻碍。 这种阻碍防止了系统通过扩散来最小化表面能，阻止了 合金发生常见的粗化相互作用。 在铝铸件中加入铈作为一种基本合金元素，在近共晶 成分下进行合金化并不是什么新鲜事。目前，已经研究 了在Al-4.5Cu合金中添加铈最高到4wt％的情况下，对 合金的固化范围、凝固体积变化趋势以及铸态显微组织 的影响。还研究了铈含量最大到16wt％和镍含量最大 到8wt％的铝铈镍（Al-Ce-Ni）合金的微观结构和力学 性能。 该研究旨在确定在Al-10Mg-8Ce合金的铸造中，标 准工艺参数对材料质量和力学性能的 适用性。研究发现，用于铝-硅或铝铜合金的熔化、脱气和其他工艺系统 无需修改就可用于常规铸造铝-铈合金 件。研究期间，金属铈的价格在4-5美 元/磅，使用铈作为合金元素对于大批 量生产在经济上是可行的。

铸件试验

Fig. 4. At 16% cerium, the test bar mold did not completely fill.

Table 2. As Cast Mechanical Properties (MPa) of Binary Compositions in the Al-Ce System Tensile, As Cast

Yield, As Cast

% E, As Cast

Al-16Ce

144

68

2.5

Al-12Ce

163

58

13.5

Al-10 Ce

152

Test Error

8

Al-8 Ce

148

Test Error

19

Al-6 Ce

103

30

25

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Fig. 5. This x-ray image shows hot tear castings produced in Al-8Ce alloy.

Fig. 6. Radiographic images were taken of step castings produced in Al-8Ce alloy. The image on the right is from a casting using a copper chill.

alloys. With the price of metallic cerium in the $4-5/lb. range during the study, the use of cerium as an alloying element is economically feasible for high-volume production.

合金系进行初始分析，结果表明，该合金在高达

Casting Trials

这些合金特性是未知的。相图显示的是铈含量约为

Initial analysis performed on an Al-Ce system produced via powder metallurgy followed by hot forging showed promising strengths at temperatures up to 650F (343C). However, the casting characteristics of these alloys were unknown. A review of the phase diagram showed a promising eutectic composition at approximately 10 wt% cerium that suggested the alloy could be cast. Figure 3 depicts the calculated binary phase diagram of Al-Ce system.

To test the casting of the Al-Ce alloys, preliminary trials were performed using a permanent mold containing the standard ASTM B108 test bar geometry. The casting alloys were prepared in 55-lb.

(25-kg) batches using P1520

对使用粉末冶金工艺生产并进行热锻处理的铝-铈 650°F（343℃）的高温下具有明显的优势。然而， 10 wt％时出现了共晶成分，这表明该合金可以用于 铸造。图3描述了铝-铈合金的计算二元相图。 为了测试铝-铈合金的铸造效果，初步试验是使用 包含标准ASTM b 108测试杆的几何形状的金属型模 具进行。使用含有表1中 成分的P1520铸锭制备 55磅（25kg）的批量合 金。合金未进行脱气处 理，在752°F（400℃） 的金属型中进行浇注，

Fig. 7. A complicated cylinder head was successfully cast using an 8% Ce binary alloy.

Fig.8. These cylinder heads were produced in green sand molds with an Al-Ce-Mg alloy.

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Fig.9. Experimental rotary engines were produced in chemicallybonded sand molds with an Al-CeMg alloy.

ingot with the composition shown in Table 1. The alloy was not degassed and was poured into the mold heated to 752F (400C) using a casting temperature of 1,382F (750C).

When casting Al-Si alloys such as 356 or 355 containing 5% silicon or more at a mold temperature of 752F and a metal temperature of 1,382F, the test bar set easily fills and good test bars are produced. To fill consistently, alloys containing less silicon require additional superheat to either the mold or the metal.

In the casting trial, compositions of up to 10% cerium filled the mold completely and the production of sound bars was consistent with those produced with alloys containing 5% Si. At 12% cerium, mold-filling capability declined and the metal temperature was adjusted upwards to 1,427F (775C) to achieve complete fill.

Figure 4 shows that at 16% cerium, the mold did not fill completely at a mold temperature of 797F (425C) and a casting temperature of 1,427F. The arrow shows the extent of the fill on the riser which is usually filled to the top of the mold, in-line with the top of the sprue. This is a result of the rapidly increasing melting temperature above the eutectic point for the alloy. None of the test bars showed evidence of hot tearing.

A second trial was conducted using the same materials and processing parameters but using a step plate mold and a hot tearing mold to estimate feeding characteristics and susceptibility to hot tearing (Figs. 5-6). Overall castability of the studied compositions appears to be in line with currently available commercial alloys. As a comparison, hot-tear molds and step plates also were cast from A206. In comparing the A206 castings versus the identical Al-Ce castings, the A206 castings appeared to have larger and more pronounced macroscopic defects present than did the castings of Al-Ce alloys.

Since the casting characteristics of the binary system were acceptable, a complicated cylinder head was cast using an 8% Ce binary alloy (Fig. 7). The casting was poured successfully

浇注温度达1382°F（750℃）。 当金属型温度为752°F，金属液温度1382°F时， 浇注含有5％或含硅量更高的铝-硅合金（例如356 或355）时，测试棒组容易填充并能得到良好的测试 棒。为了填充一致，含硅量较少的合金需要使铸型或 金属液温度更高。 在铸件试验中，含铈量最高到10％的合金可以完 全填充模具，合金棒的制作与含硅量5％的合金生产 一致。在铈含量为12％时，铸型的填充能力下降， 金属液温度需升至1427°F（775℃），以实现完全填 充。 图4显示，铈含量为16％时，铸型温度为 797°F（425℃）及浇注温度为1427°F时未完全填 充。箭头表明，通常填充到铸型顶部的冒口的填充范 围，与浇道的顶部一致。这是快速上升的合金熔炼温 度高于合金共晶点的结果。没有一个测试棒显示出热 裂的迹象。 使用相同的材料和工艺参数进行了第二次试验，但 使用了阶梯式铸型和热裂铸型来预测物料的特性和对 热裂的敏感性（图5-6）。测试合金成分的总体可铸 性似乎与目前可用的工业合金一致。为了便于比较， 热裂铸型和阶梯式铸型由A206铸造而成。在比较 A206铸件和相同的铝-铈铸件时，A206铸件似乎具 有比铝-铈合金铸件更大、更明显的宏观缺陷。 由于二元系统的铸件特性是可以接受的，使用含 铈8％的二元合金生产出复杂的汽缸盖（图7）。铸 件成功浇注并检查了其热裂纹或其他缺陷。由于熔体

Table 3. As Cast Mechanical Properties(MPa) of Ternary Compositions in the Al-Ce-Mg System Tensile

Yield

%E

Tensile 260ºC

Yield 260ºC

%E 260ºC

Al-8Ce-4Mg

189

107

3

No Test

No Test

No Test

Al-8Ce-7Mg

195

151

2

134

121

4

Al-8Ce-10Mg

227

186

1

137

130

4

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Table 4. Starting composition of alloy 535 before magnesium and cerium additions.

535

Si

Fe

Cu

Mn

Mg

Ti

0.098

0.091

0.041

0.159

6.85

0.016

and inspected for hot tears or other defects. Besides a few minor misruns attributable to a lower melt superheat than currently is used to produce this head, the casting passed all inspection criteria.

In general, Al-Ce alloys near the eutectic composition exhibited good to excellent casting characteristics. However, the room temperature mechanical properties were not high enough for many commercial applications nor did the alloys have a positive response to heat treatment. Generally, the tensile strength increases with increasing Ce content up to the eutectic composition. The yield strength increased with increasing cerium content in all compositions studied. The extensometer slipped when measuring the 8% and 10% compositions, giving erroneous measurements (Table 2).

An additional 20 alloys were produced using Al-8Ce as a base composition with additives of silicon, magnesium, copper, zinc, nickel, titanium, manganese or iron. The 8Ce base composition was chosen for economic reasons, even though higher levels of Ce develop better mechanical properties. Except for magnesium, the addition of these alloying elements in excess of 1% reduced die filling capability even though many of the alloys had improved mechanical properties. For ternary Al-Ce-Mg alloys, yield strength increased with increasing magnesium levels without a noticeable reduction in castability up to the tested level of 10% magnesium.

Mechanical properties for three of these alloys are shown in Table 3. The 500F (260C) properties were measured after stabilizing the samples at that temperature for 30 minutes.

The data shown in Tables 2 and 3 is the result of the average of six test bars. The maximum recorded standard deviation for tensile and yield strength was 4.4 MPa. The elongation values were rounded to the nearest percent but no values were outside of +/-.4% of the reported data.

Preliminary work has been completed to develop mechanical properties after long-term high temperature exposure.

After exposure at 500F (260C) for 336 hours and measured

过热度比目前用于生产该汽缸盖铸件的低，引起了 一些微小误差，除此以外，该铸件通过了所有检验 标准。 一般而言，接近共晶成分的铝-铈合金表现出优 良的铸造特性。然而，室温力学性能对于许多商 用铸件来说不够高，而且合金对热处理也没有积极 反应。通常，抗拉强度随着铈含量增加直至共晶组 成而增加。在研究的所有组合中，随着铈含量的增 加，屈服强度增加。测量8％和10％比例的成分组合 时，延伸率下降，给出了错误的测量结果（表2）。 使用Al-8Ce为基础成分并以硅、镁、铜、锌、 镍、钛、锰或铁作为添加剂生产出另外20种合金。 虽然更高含量的Ce具有更好的力学性能，出于经济 原因选择了8Ce作为基础成分。除镁之外，尽管很 多合金具有更好的力学性能，添加超过1％的这些合 金元素会降低铸型的填充能力。对于三元Al-Ce-Mg 合金，屈服强度随着镁含量的增加而增加，而可铸 性在镁含量增至10％时明显下降。 在这些合金中，其中3种合金的力学性能如表3所 示。将样品在温度为500°F（260℃）稳定30分钟并 测量其性能。表2和表3中所示的数据是6个测试棒 的平均结果。拉伸强度和屈服强度的最大标准偏差 记录值为4.4MPa。延伸率四舍五入到最接近的百分 比，但没有超出报告数据的+/- 4％之外。 经长期高温暴露后，力学性能研究的初步工作 基本完成。在500°F（260℃）的高温下暴露336 小时并在室温下测试，Al-8Ce-10Mg-F合金的屈

Fig 10. The as-alloyed cost of Al-Ce material is competitive with other high-performance aluminum alloys systems, as shown in this graphical comparison.

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at room temperature, the Al-8Ce-10Mg-F alloy had a yield strength of 144 MPa, 33% higher than 354.0-T61 after 100 hours of exposure. This yield strength is higher than shown with 30-minute exposure in Table 3, indicating some positive effect from long-term thermal exposure.

服强度为144MPa，比经过100小时暴露的354.0-

Pilot Production

试生产

Since the Al-Ce-Mg alloys have both good castability and good mechanical properties, a pilot study was made using a 705-lb. (320-kg) heat of an Al-10Mg-8Ce alloy. Aluminum 535 was used as the base material with a chemistry as shown in Table 4.

Many commercial castings were poured using patterns and permanent molds that were gated for 200 and 300 series alloys (Figures 8 and 9). The gating was not modified to pour the Al-Ce. The casting quality was acceptable and equivalent to that produced in the production alloys. Test bars were produced from the production batch of material and tested to determine if the properties met those of the smaller batches of experimental material. The tensile strength of the material was 3.5% higher than the early experimental heats which were melted under argon and cover flux but had no degassing. Optical examination of test bars at 50X revealed that they had lower oxide levels than the early experimental heats.

A total of 20 tensile bars from the pilot production lot have been tested at room temperature with average properties of 235 MPa tensile, 192 MPa yield and 1% elongation.

Next, 551 lbs. (250 kg) of the alloy was held for 17 hours at 1,384F (750C). The magnesium chemistry was checked at 9.78% or a 3.1% loss over that interval. This is a smaller than expected magnesium loss given the holding time and the lack of a protective atmosphere. The reasons for this unusual magnesium stability is being investigated.

Economic Considerations Cerium is the most abundant rare earth element. With the price of metallic cerium in the $4-5 per lb. range at the time of the study, the use of cerium as an alloying element is economically feasible for high-volume production. The as-alloyed cost of Al-Ce material is competitive with other high-performance aluminum alloy systems. A graphical comparison is given in Figure 10.

Several test pieces and complicated castings have been produced in the Al-Ce alloy systems. The data and experience to date indicate Al-Ce or Al-Ce-Mg have castability equivalent to 300 series alloys. Other alloy additions have generally diminished castability but show promise with additional work. The use of production processing equipment resulted in better mechanical properties than the earlier development heats because of the more effective removal of oxides and hydrogen. Unexpected results that require further study include the apparent reduced solubility of hydrogen in alloys containing cerium and the role of cerium on the stabilization of magnesium in Al-Mg-Ce alloys. ■ This article is based on a paper (17-013) originally presented at the 2017 Metalcasting Congress.

T61的屈服强度高33％。该屈服强度比表3中暴露 30分钟时的屈服强度更高，表明长期热暴露会产生 一些积极影响。

由于铝-铈-镁合金具有良好的可铸性和良好 的力学性能，因此在试验性研究中使用了705磅 （320kg）的Al-10Mg-8Ce合金。535铝合金作为 基础材料的化学反应过程如表4所示。 很多商用铸件使用的铸型或金属型是200和300系 合金（图8和图9）浇注而成。铝-铈合金的浇道没有 改变。铸件质是可以接受，并且与生产合金的质量 相当。测试棒使用批量生产的材料生产并进行测试 以确定其特性是否适用于小批量试验材料。试验材 料的拉伸强度比在氩气下熔化并覆盖熔剂且没有脱 气处理的早期试验金属高3.5％。测试棒经50倍光学 镜检查，结果表明它们的氧化物含量比早期试验的 材料要低。试生产批次的总共20根拉伸试棒在室温 下进行试验，平均拉伸强度为235MPa，平均屈服强 度为192MPa，平均伸长率为1％。 接下来，551磅（250kg）的合金在 1384°F（75℃）温度下保持17小时。在此间隔期 间，镁成分的损失为9.78％或3.1％。由于持续时间 长且缺乏保护气体，镁的损失比预期要小。这种不 常见的镁稳定性的产生原因正在进行调查。

经济因素 铈是含量最丰富的稀土元素。研究中，金属铈的 价格在每磅4-5美元的范围内，使用铈作为合金元素 在批量生产中是经济可行的。Al-Ce合金的成本与其 他高性能铝合金系统相比具有竞争力。图解对比如 图10所示。 采用Al-Ce合金系统已生产了多个测试件和复杂铸 件。截至目前的数据和经验表明Al-Ce或Al-Ce-Mg 具有相当于300系铝合金的可铸性。其他合金的加 入一般都会降低铸件的铸造性能，但通过其他方式 还是有很大的潜力。由于更有效地去除氧化物和氢 气，生产加工设备的使用导致合金件比早期试验产 品具有更好的力学性能。需要进一步加以研究的意 外结果包括氢在含铈合金中的溶解度明显降低以及 铈在Al-Mg-Ce合金中稳定镁元素的作用。 本文基于最初发布于2017年美国铸造大会中的 （17-013）号论文。

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■

Does Water Quality Affect Green Sand Properties?

Research was conducted to evaluate the effect of contaminants commonly found in tap and well water in the U.S. on green sand properties.

Bo Wallace, American Foundry Society (Schaumburg, Illinois) and Sairam Ravi and Jerry Thiel, University of Northern Iowa (Cedar falls, Iowa)

水质对湿型砂性能有何影响？ 本文研究和评估了美国自来水和井水中常见的污染物对湿型砂性能的影响。 作者：博伊•华莱士，美国铸造协会（伊利诺伊州绍姆堡）；萨里兰•拉维、杰里•瑟尔， 北爱荷华大学（爱荷华州 锡达福尔斯）

W

ater-soluble salts or electrolytes are just some of the mineral contaminants found in everyday tap water used by foundries across the U.S for their green sand systems. Bentonite is the main bonding compound of green sand systems, and for it to have quality bonding, it first must be activated with the use of an agent. A good activating agent must fulfill three requirements:

Fig. 1. Contaminants detected in the water samples are sorted according to region.

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水

溶性盐或电解盐，仅仅是美国各地铸造厂湿 型砂铸造工艺日常使用的自来水中发现的部 分矿物污染物。膨润土是湿型砂铸造的主要

粘结化合物，要使其具有良好的粘结性能，首先要用助 剂进行活化。好的活化剂必须满足3个要求：

图1：水样中检测到 的污染物按地区进行 分类。 | FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

图2：9个样品的湿抗 拉强度检测结果。

Fig. 2. Wet tensile strength results were measured for nine samples.

• Be distinctly soluble in water, having a solubility of at least 1 g/100 g of water.

• Be composed of anions, which react with cations (Na+) to give insoluble compounds.

• Supply small, univalent cations for ion exchange.

Previous research studied the effect of these electrolytic salts on the physical characteristics of green sand, in particular wet tensile strength. Wet tensile strength testing helps determine the tensile strength of the green sand’s condensation zone after the mold has been poured. Previous research has shown that an increase in the electrolytic salts, found in well water, led to a decrease in wet tensile strength when compared to samples of green sand containing distilled water, where the wet tensile was not affected.

Past research led to the question of whether these electrolytes are causing the decreasing strength within the clay-water relationship. This possibly could be due to the

Fig. 3. Green shear strength results were measured for nine samples.

• 明显溶于水，溶解度至少为1g试剂/100g水。

• 由阴离子组成，与阳离子（Na+）反应生成不溶性化 合物。

• 为离子交换提供小的一价阳离子。

电解盐对湿型砂的物理特性的影响在之前的研究中

做了分析，特别是湿拉强度。湿拉强度测试有助于确定 铸型在浇注后湿型砂凝结区的抗拉强度。之前的研究 表明，加入蒸馏水的湿型砂样品湿拉强度不受影响，与 其相比，随着井水中所含的电解盐的增加，湿拉强度降 低。 过去的研究需要解决的问题是，水中的电解盐是否在 粘土-水结合后引起拉伸强度下降。这可能是由于钠基 膨润土的阴离子（带负电荷的离子）性质及其在水中电

图3：9个样品的 湿剪切强度检测结 果。

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Fig. 4. AFS permeability results for nine samples are shown.

图4：美国铸造协会 检测的9个样品的渗 透性。

anionic (positively charged ions) nature of sodium bentonite clay and its necessary cationic (negatively charged ions) exchange between the electrolytic salts within the water. Anions and cations react together to form neutralized compounds. An example of this reaction is that of Sodium (Na+) and Chlorine (Cl-) where the two react together forming your basic table salt (NaCl).

Past research conducted on the effect of individual electrolytic salts on the wet tensile strength of green sand showed salts had an immediate effect on the wet tensile strength, with the wet tensile strength decreasing initially.

However, as time went on, the wet tensile strength was determined to increase. This was determined to be due to the presence of the particular electrolytes within the system and not the actual concentration.

Recently, trials were conducted at the University of Northern Iowa Metal Casting Center (Cedar Falls, Iowa) to evaluate the effect of contaminants commonly found in tap and well water in the U.S. on green sand properties.

Fig. 5. Loss on ignition results for nine samples are shown.

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解盐必需的阳离子（正电荷离子）发生了交换。阴 离子和阳离子反应形成中和的化合物。这种反应的 例子是钠（Na+）和氯（Cl-）化学反应形成最基本 的食盐（NaCl）。 过去进行的个别的电解盐对湿型砂湿拉强度影响 的研究表明，盐对湿拉强度产生即时影响效应，湿 拉强度在一开始下降。然而，随着时间的推移，湿 拉强度逐渐增加。这是由于系统内存在特定的电解 盐而不是受实际的浓度影响。 最近，在北爱荷华州金属铸造中心（爱荷华州 锡 达福尔斯）进行了试验，以评估美国自来水和井水 中常见的污染物对湿型砂性能的影响。从国内不同 地区采集了16个水样，并设计了一系列实验来评估

图5：9个样品的烧失 量检测结果。 | FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

Sixteen water samples were obtained from different regions of the country and a series of experiments were designed to evaluate the effect of the measured contaminants.

The water samples received were sent to an external lab to test for contaminants using an Inductively Coupled Plasma Mass Spectrometer (ICP-MS).

The lab determined sodium, chlorine, magnesium and calcium were the major contaminants detected above the method detection limit (MDL). Figure 1 shows the average contaminants detected in the water samples, sorted by region. From the results, the southwest region was observed to have higher concentrations of sodium, chlorine and calcium, when compared to the other regions. The magnesium concentrations detected were lower when compared to the other three contaminants, though still over the MDL. Other contaminants, such as phosphorous and potassium were detected below MDL and hence, were not significant.

Low and high levels of the four contaminants were selected from the results shown in Figure 2. Nine experiments were conducted, including one with distilled water, which served as the control sample. The water samples were created by doping distilled water with the contaminants.

For each experiment, a new batch of green sand was prepared using 7% Western Bentonite, based on sand weight, and 20% seacoal, based on clay weight. A three-screen 55 GFN Silica sand was used as the base aggregate.

Class 30 iron plate castings were poured to evaluate and compare the performance properties of the nine green sand mixtures. The casting design offered a sand:metal ratio of 5:1.

pH of Doped Water Samples The pH of the doped water samples was measured.

Adding the elements at their low levels slightly increases the pH, when compared to the control sample. From the pH of samples 2, 3 and 4, it can be seen adding higher levels of Mg, Ca and Cl2 considerably increases the pH.

Fig. 6. Bulk density results for nine samples are shown.

实测污染物对湿型砂的影响。 接收到的水样被送到外部实验室，用电感耦合等离 子体质谱仪（ICP-MS）检测污染物。 实验室测定的钠、氯、镁和钙是在方法检测极限 （MDL）以上检测到的主要污染物。图1所示是按区 域分类的水样中检测到的平均污染物浓度。从结果 看，与其他地区相比，美国西南地区的水质中的钠、 氯和钙浓度较高。与其他三种污染物相比，检测到的 镁浓度较低，但仍高于MDL水平。其他污染物如磷和 钾在MDL水平以下才检测到，因此影响不大。 从图2所示的结果中选出了高、低含量的4种污染 物，并进行了9个实验，其中1个使用蒸馏水作为参照 样品。水样是通过在蒸馏水中掺入污染物制成的。 在每个实验中，使用基于砂重的7％西部膨润土和 基于粘土重量的20％的石英砂制备新批次的湿型砂。 使用三孔筛55GFN细度的硅砂作为基础骨料。 浇注30级厚板铸件以评估和比较9种湿型砂混合物 的性能。铸件设计的砂铁比为5：1。

掺杂水样的pH值 实验检测了掺杂污染物水样的pH值。与参照样 品相比，污染物掺杂量处于低水平时，pH值轻微上 升。从水样2、3和4的pH值检测发现，添加较多的 镁、钙和氯气使pH值显著上升。然而，与其他污染 物相比，添加钠对pH值有更大的影响。实验发现， 所有含钠较高的水样的pH值约为11.65-11.89。

图6：9个样品的容 积密度检测结果。

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However, the addition of sodium can be observed to have a larger effect on the pH, when compared to the other contaminants. All water samples with high sodium levels were observed to have pH values of approximately 11.65-11.89.

湿型砂的特性

Green Sand Properties

湿抗压强度为17psi（磅/平方英寸）。可以观察

The green compression strength results are shown in Figure 2. Similar strengths were measured for all samples, with the exception of sample 3. Sample 3 was recorded to have an average green strength of 17 psi. Sample 3 can be observed to have a high chlorine level and the other contaminants at low levels.

The wet tensile strength results are shown in Figure 3. A trend similar to green compression strength can be observed. Wet tensile strength results were measured to be similar for all samples, except samples 3 and 4. Samples 3 and 4 were observed to have wet tensile strengths of 0.303 N/cm2 and 0.330 N/cm2. The other samples were measured to have wet tensile strengths in the range of 0.380-0.410 N/cm2.

Figure 4 shows the green shear strength results measured for all samples. The control sample was measured to have higher green shear strength when compared to the other samples, at 6.33 psi. Similar to the trend seen in green compression and wet tensile strength results, sample 3 was measured to have comparatively lower green shear strengths, at 3.817 psi. Samples 4, 7 and 8 were also observed to have lower shear strengths, when compared to the control sample, ranging from 4.5-4.7 psi.

The permeability results are shown in Figure 5. The control sample can be observed to have significantly higher permeability, at 206.3, when compared to the other samples. Samples 2 and 3 were measured to have AFS permeability of ~125 while the other samples were measured to have permeability in the range of 138-150.

Figure 6 shows the loss on ignition (LOI) results for all samples. With the exception of sample 3, the other samples can be observed to have similar LOI, ranging from 1.071.14%. Sample 3 was measured to have a slightly higher LOI of 1.37%.

The bulk density results for all samples are shown in Figure 8. Similar results were observed for all samples, ranging from 93.4 lbs./ft3 to 94.6 lbs./ft3.

While the research indicated there were some detrimental effects of the contaminants on green sand properties, especially in green compression, wet tensile and green shear strength, little to no differences were observed in the test castings.

Some contaminants also might have positive side effects, such as sodium or calcium on improving green sand properties. However, further research with a larger number of replicates will be required to conclusively prove the preliminary results. ■

到，样品3具有较高的氯含量，其他污染物含量较

湿型砂的抗压强度结果如图2所示。除样品3 外，所有样品呈现相似的抗压强度。样品3的平均

低。 如图3所示，湿拉强度的检测结果与湿压强度类 似。除样品3和样品4外，所有样品的湿拉伸强度结 果相似。样品3和4的湿拉伸强度为0.303N/cm2和 0.330N/cm2。其他样品的湿抗拉强度在0.3800.410N/cm2范围内。 图4显示了所有样品的湿剪切强度检测结果。与 其他样品相比，参照样品在6.33psi下具有更高的 湿剪切强度。与在湿抗压强度和湿拉伸强度结果中 看到的趋势类似，样品3在3.817psi下具有相对较 低的湿剪切强度。与参照样品相比，样品4、7和8 也检测到较低的剪切强度，范围从4.5-4.7psi。 渗透性检测结果如图5所示。与其他样品相比， 可以观察到参照样品具有非常高的渗透性，为 206.3。而样品2和3的AFS渗透性为约125，而其 他样品测得的渗透性在138-150范围内。 图6所示为所有样品的烧失量（LOI）实验结 果。除样品3外，其他样品具有相似的烧失量，范 围从1.07-1.14％。样品3的烧失量稍高，为1.37 ％。 所有样品的容积密度检测结果如图8所示。所 有样品具有类似的结果，范围从93.4磅/立方英 尺-94.6磅/立方英尺。 虽然研究表明污染物对湿型砂性能有一些不利影 响，特别是在湿压强度、湿拉强度和湿剪切强度方 面，但对测试铸件的性能几乎没有影响。 一些污染物也可能具有积极的作用，如钠或钙可 以改善湿型砂的性能。但是，还需进行大量的重复 性研究才能验证初步的科研结果。 ■ 本文基于第122届美国铸造大会上发表的（18-009）号 论文“水质对湿型砂性能有何影响”。这项研究得到美 国铸造协会资助。

This article is based on the paper “Effect of Water Quality on Green Sand Properties” (18-009) presented at the 122nd Metalcasting Congress. The study was an AFS-funded research project.

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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION July 2018

The Middle Frame Design for an Electric Car yu saisai and zhang yida, anyang qiang ji precision manufacturing base co. ltd.

新能源车中部车架设计 安阳强基精密制造产业园股份有限公司 编写：玉赛赛 校对：张宜达

L

arge, thin wall and complex precision casting technology of investment casting that has been developed in the automotive field has won a new expansion application. For new energy vehicles, also known as electric or partially-electric cars, the advantages of lightweight component parts are obvious. In this application, the design and manufacturing process were integrated to create a first-class design.

In the original design, there is no big circular angle around the model, and the inner cavity is only 22mm.

Because the inner frame of the middle frame is too narrow, it is easy to bleed from parting. It is not easy to make shells on account of the narrow inner cavity. It is an unacceptable structure for investment casting. The design resulted in many casting defects and serious deformation.

In order to compare the influence of a circular angle, analysis and comparison were made. On the basis of the original scheme, only the four corners were rounded, and the rest of the design was unchanged. The weight increased by 0.3 kg.

By comparing the free mode results, it was found that the first 6 order mode frequency of the big circular angle

失

蜡熔模铸造技术的大型、薄壁、复杂精密铸 造技术，其技术已在汽车领域进行了全新的 拓展应用。对于新能源汽车结构轻量化、部

件零件化优势明显。将设计和工艺融为一体，从而设计 制造出的一流的产品，这在国内是独一无二的，是中国 唯一的设计和工艺联合的典范。而将结构设计与先进的 制造工艺绑定，是我们独特的设计形式。 模型四周没有大的圆角，并且内腔只有22mm，由 于中部车架的内腔太窄，容易跑火，不好制壳，是失蜡 熔模铸造不能接受的结构，铸件缺陷较多，变形严重。 为比较圆角有无的影响，进行分析对比：原方案为富 晟汽车中部车架。在原方案基础上，仅在四个边角上层 增加圆角，其余不做改动，称为加圆角方案。质量增加 0.3kg。 对比自由模态结果可以发现，加圆角方案的前6阶模 态所对应的频率均比原方案大，提高幅度3%-12%。车 身扭转刚度是白车身的重要指标之一，因此这里特别关

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Original Scheme/Mass: 24.98kg

Big Circular Angle Scheme/Mass: 25.28kg

2.2.1、自由模态

scheme was larger than the original scheme, with an increase of 3-12%. The torsional stiffness of the car body is one of the important indicators of body-in-white templates, so the torsional stiffness is paid special attention to, and the first order torsional frequency of the big circular angle scheme was raised by 1.3Hz, up by 3.4%.

The deformation of each condition is more than 60% less than the original scheme, indicating the increase of the circular angle structure can effectively improve the stiffness of the structure, and the stress of the two schemes is basically equal.

The simulation results show that compared with the structure without the circular angle, the increase of the circular angle can advance the structural stiffness of the middle frame significantly. The middle frame material is ZL114A, with an

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注车扭的扭转刚度，加圆角方案的一阶扭转频率提高 1.3Hz，提高了3.4%。 加圆角方案的各工况变形均比原方案小60%以上， 说明圆角结构的增加会有效提高了结构的刚度，两个方 案的应力基本持平。 仿真对比发现，与不加圆角结构相比，增加圆角能 够使车架的结构刚度明显提高。中部车架材料使用的是 ZL114A，延伸率为3%，加圆角变形减少60%以上，原 方案相对于加圆角方案就是一种破坏模式。由于设计内 腔太窄，容易跑火，铸件变形严重。我们只是改变设计 的很小一步分，效果特别明显。

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2.2.2. Strength Analysis

elongation rate of 3%. The deformation of the increase of the 由中部车架增加圆角联想到我们做的下箱体、油底壳 circular angle structure is reduced by more than 60%. Com等重新进行的结构设计，使用我们的设计、生产方式对 pared with the big circular angle scheme, the original scheme 结构的模态、强度、变形带来的巨大的影响。 is a failure mode. Because the cavity is too narrow and easy to bleed from parting, and the deformation of the casting is 在整车状态下约束模态，考察在整车状态下的振动频 serious. By just changing the design of a small step, the effect 率，考虑电池质量进行加载。 is particularly obvious. 相比于没有加强筋的优化方案，有加强筋方案一阶 2. The Leading Design Ideas Have Significantly Improved 模态频率提升了3Hz，提高幅度为21%。与中部车架类 the Performance of the Structure The the same design approach was taken for the battery 似，只是增加了一个加强筋，但是模态提高特别明显。 case and oil pan of the car. This has made a huge impact in 对油底壳进行结构改进，油底壳外侧增加了环筋和横 manufacture of structure mode, strength and deformation. 筋，在中间凹槽U形改为改为H形，左右三角筋向中间 Under the constraint mode of the vehicle, the vibration frequency of the vehicle under the condition of the vehicle is 靠拢等一系列方法，使油底壳结构性能明显提升。 investigated, and electricity quality is considered. 油底壳的模态分析显示改进模型的前10阶频率均 Compared with the scheme without a reinforcing bar, 大于原始模型的相应频率，第一阶频率提高135%， the first order mode frequency of strengthening bars increase 3Hz, rising up 21%. Similar to the central frame, only a 提高明显，表明改进模型的刚度有明显改善。发动 stiffener is added, but the mode frequency enhancement is 机为6缸四冲程，怠速转速为600r/min，额定转速为 particularly obvious.

1900r/min，最大扭矩转 A series of methods have been used for improving the 速为1100~1450r/min， structure of the oil pan, such as 其相对应的频率分别为 adding ring bars and transverse 30Hz，95Hz，55~72Hz。 bars in the outer side of the oil pan, changing the groove U 再设计模型的频率可有效地避 shape to an H shape, and draw开发动机的振动频率。 ing right and left triangle bars to 油底壳的静力分析显示改 the middle. 进后比改进前变形减小81%， The mode analysis of the oil pan shows that the first 10 应力减小19%，刚度和强度较 order frequency of the improved 之前有较为明显的提升。 model is higher than the original 无加强筋 从某新能源车的中部车 model. The frequency of the first order is increased by 135%, 架，我们开发的下箱体、油底 and the increase indicates the 壳的对比过程我们可以发现， stiffness of the improved model 我们可以设计制造出的一流的 has a significant improvement.

The car’s engine is a six-cylinder 产品，这是在国内独有的，在 four-stroke, with idling speed of 国际上也领先一步。安阳强基 600r/min, rated rotation speed 设计与工艺的联合，设计只是 of 1900r/min, maximum torque speed of 1100~1450r/min, and 通过改变很小的一部分就能带 the corresponding frequencies 来强有力的效果。基于先进的 of 30Hz, 95Hz, 55~72Hz. The 有加强筋

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frequency of the improved model can avoid the vibration frequency of the engine effectively.

Static analysis of the oil pan shows that the deformation decreases 81%, the stress decreases 19%, and the stiffness and strength are significantly improved compared with the original one.

The case of the middle frame, battery case and oil pan of a new energy vehicle, making small changes to a design can have a powerful effect on manufacturability. Based on advanced precision casting technology, the material can be transferred according to the load in the process of structural design, which can not only reduce the waste of material and reduce the weight, but also optimize the layout of the structure, which is no longer limited by the original process. This design method can play an important role in the design of cars and the weight loss of new energy vehicles. ■

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失蜡熔模精密铸造技术，在结构设计过程中可以根据 载荷传递路线针对性的布置材料，既避免了材料浪费 减轻了重量，也优化了结构布置，不再被原本的工艺 所局限。结构设计与先进的制造工艺绑定，是我们独 特的设计形式，运用这种独特的设计手法对于汽车的 设计、对于新能源汽车的减重能够发挥最大作用，这 项技术必将改变传统汽车的设计生产方式，使汽车设 计制造变得更加灵活。■

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TENBLOC® INOCULANT + ELKEM PROCESS KNOW-HOW = COSTEFFICIENCY

Elkem has taken over the production of the well-known Tenbloc® inserts and these are now part of our extensive foundry alloy portfolio. Tenbloc® is an in the mould inoculant block manufactured by a unique powder metallurgical method.

It provides your foundry with consistent, reliable and costeffective inoculation for ductile and grey irons.

For more information do not hesitate to ask your Elkem representative or contact us directly at foundry@elkem.com

The Status of the Vietnam Foundry Industry global casting staff report

越南铸造业现状

T

he Vietnam Foundry Industry produces approximately 500,000 ton/year and employs around 100,000 directly and 300,000 indirectly. The growth of the industry is important inclusive growth for other engineering sectors and overall Vietnam economics.

The foundry industry in Vietnam is serving to the following sectors: • Automotive and Auto Component • Power • Tractor • Construction Machinery • Pump, Compressor, Pipe Valve, Pipe Fitting • Electrical, Textile, Cement, Agro Machinery • Machining Tool & Engineering Industry

Application Share • 20% output of the foundry industry goes into the automotive industry.

越

南铸造业每年生产约50万吨铸件，直接雇员 约10万人，间接雇员约30万人。铸造业的 发展是其他工程制造部门和越南整体经济的

重要组成部分。 铸造业的重要性 铸造业服务于以下行业 • 汽车及汽车零部件 • 电力

• 拖拉机

• 工程机械

• 泵阀、压缩机、管件及配件

• 电气、纺织、水泥、农业机械 • 机加工及机械工业

各种材质铸件占比

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• 20% output of the foundry industry goes into electrical, textile, as Veam Foundry produces 20,000 tons/year of cast parts for Toshiba Industrial Motor and Juki sewing machines.

• 10% output of the foundry industry goes into construction machinery. IKI Cast produces 6,000 tons/year for Komatsu and the new plant will produce 10,000 tons/year.

• 20% output of the foundry industry goes into machining tool, as Citizen Machinery Vietnam produces 10,000 tons/year and VJE produces 10,000 tons/year.

Casting Share • The most popular molding technology is green sand at 70% usage, followed by nobake furan system (15%), metal mold (10%), permanent mold (5%).

• Foundry factories are investment more in upgrading automatic molding system and high technology energy saving.

• More and more investment is going toward the improvement of health and safety environment.

• There is increasing investment in foundry industry and FDI. Japan, Korea, Taiwan companies are leading investors. ■

造型线类型比例

应用比例 • 20％的铸件产量进入汽车行业。

• 20％的铸件产量进入电气、纺织机械行业。例

如，Veam铸造厂每年为东芝工业电机提供2万吨零 部件，用于Juki缝纫机。

• 10％的铸件产量进入工程机械行业，例如，IKI铸造

公司每年为小松及新工厂提供6000吨和1万吨铸件。

• 20％的铸件产量进入机床行业。

各种材质铸件占比 • 最受欢迎的是湿型砂技术，占比70％；其次是自硬砂 呋喃系统，占比15％，金属铸模10％，金属型5％。

• 铸造厂在升级自动成型系统和节能高科技方面投入更 多。

• 对职业健康、安全和环保的投入越来越多。

• 外国直接投资增加。日本、韩国和中国台湾的铸造企 业是主要投资者。 ■

企业所有权类型比例

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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 Fusion-Diamond Ultrahard Grinding Tools & Equipment Specialized in Cast Ironto Create a New World of Grinding for the Foundry Industry 铸铁件磨削专用金刚石熔合超硬磨具 及磨削设备

ExOne and SGL partner on 3D printed carbon for cores and molds ExOne公司与SGL集团合作开发3D打 印碳芯和铸型 41

Elkem Adds Inoculant Block to Portfolio 42 埃肯公司系列产品新增块状孕育剂

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product news/产品新闻

Fusion-Diamond Ultrahard Grinding Tools & Equipment Specialized in Cast Ironto Create a New World of Grinding for the Foundry Industry 铸铁件磨削专用金刚石熔合超硬磨具及磨削设备 开创铸造行业磨削新天地 Nanjing Guhua Electromechanical Technology Co., Ltd. which is located in Xiongzhou Industrial Park, Luhe District, Nanjing, China is a new technology company with a professional technical team specializing in R&D, manufacturing, sales and services in terms of grinding tools & equipment specialized in foundry industry.

Guhua’s fusion-diamond ultrahard grinding tools and equipment series products were developed for the grinding of cast iron and aims to solve existing problems of traditional grinding tools. The product’s characteristics are: 1. Higher Efficiency, Better Durability and Cost Performance The wheels offer high exposure of diamonds and highstrength bonding with steel substrate. When equipped with special grinding facilities, compared with traditional grinding tools, the grinding efficiency of cast iron will increase after one use and the life span will be over 60 times.

2. Safe and environmentally-friendly The products consist of premium steels and diamonds, eliminating problems of traditional grinding tools, namely poor water and alkali resistance, short storage time, easily broken, large sparks and serious dust pollution.

3. Works well with automatic grinding equipment Compared with traditional grinding tools, this durable and environmentally-friendly product makes itself the perfect choice of automatic grinding equipment.

Relying on strong capabilities in product development,

Fusion-Diamond Ultrahard Grinding Tools Series

南京固华机电科技有限公司地处江苏省南京市六合 区雄州工业园区，致力于铸造行业专用磨具及磨削设备 的研发、生产、销售及服务的国际化高新技术企业。 固华牌铸铁件磨削专用金刚石熔合超硬磨具及磨削 设备系列产品针对铸造行业的特点及传统磨削工具存在 的问题而研发。该系列产品具备以下特点： 1、 高效 耐用 经济——磨具的金刚石出露高，与钢 基体结合强度高；配合专用磨削设备，磨削铸铁件的效 率较传统磨具可增加1倍以上,工具平均使用寿命可达传 统磨具的60倍以上!

2、 安全 环保——磨具基体采用优质钢材、磨料采 用金刚石，彻底消除了传统磨具的耐水性及耐碱性差、 保存期短、易断裂、火花大、粉尘污染严重的问题！ 3、 自动化磨削设备的最优选择——磨具外廓尺寸变 化小且使用寿命长，确保自动化设备连续运转工作；较 自动化打磨传统磨具电镀法金刚石磨具更环保，寿命更 长久，是自动化磨削设备的最优选择！ 凭借强大的产品研发、设计及生产加工能力，固华

图1金刚石熔合超硬磨具系列

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product news/产品新闻 图2高速磨轮机

High-Speed Vertical Grinding Machine

design and mechanical processing, Nanjing Guhua is devoted to provide customized products design and manufacturing for domestic and international clients. Continuous research and development of high and new technology products, creating a new world of grinding in foundry industry. ■ For more information, please visit: www.njguhua-et.com

公司向国内外客户提供“量身定制式”产品设计 及生产加工。不断开发高新技术产品，开创铸造 行业磨削新天地！ ■ 更多信息，请登录网站了解www.njguhua-et.com

Elkem Adds Inoculant Block to Portfolio 埃肯公司系列产品新增块状孕育剂 Elkem has announced the addition of Tenbloc to its portfolio. Tenbloc is a unique, in-the-mold inoculant block providing consistent, reliable and cost-effective inoculation for ductile and gray irons. This helps foundries produce castings with improved metallurgical structures and mechanical properties.

埃肯公司宣布其系列产品中增加Tenbloc。Tenbloc 是一种独特的型内孕育块，为球墨铸铁和灰铸铁提供一 致、可靠和经济的孕育，有助于铸造厂生产出冶金性能 和力学性能更好的铸件。

The main benefits are:

主要优势包括：

• Inoculating at the latest possible stage in the casting process eliminates inoculant fade.

• Accurate weight control gives a consistent level of inoculation into every mould.

• Close dimensional tolerances ensure a good fit into the mould print.

• Tenbloc is 100% inoculant and does not contain a binder or any other additive.

• Tenbloc is available in several different analytical grades, specifically formulated for both ductile and gray iron.

Tenbloc is manufactured by a unique powder metallurgical method, giving accurate dimensions and weights. Blocks are produced in either cylindrical or taper shape, in the weight range from 5g to 1,000g.

Production by this method results in Tenbloc having low thermal conductivity. This means Tenbloc starts to dissolve immediately and continuously throughout the pour time,

• 在浇注的最后阶段进行孕育，不会造成孕育的消退。 • 精确的重量控制可以使每个铸型的孕育水平保持一 致。 • 精确的尺寸公差确保符合铸型的尺寸。 • Tenbloc是100％的纯孕育剂，不含粘结剂或任何其 他添加剂。 • Tenbloc有多种细分等级可供选择，特别适用于球墨 铸铁和灰铸铁。

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Tenbloc采用独特的粉末冶金方法生产，具有精确的 尺寸和重量。块状的孕育剂的形状有圆柱形或锥形，重 量范围5g到1,000g。 通过这种方式生产的Tenbloc导热性低。这意味着 Tenbloc在浇注开始时就溶解，并持续到浇注完成。确

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product news/产品新闻 ensuring all metal, particularly the first metal poured, is inoculated.

The use of Tenbloc in the mold is the latest possible stage at which inoculant can be added. This means the amount of inoculant to be used can be reduced to a minimum as there is no inoculant fade and as such, it is a cost effective and efficient use of inoculant. Typical addition rates are 0.1%, but these can be adjusted to suit specific customer requirements.

Close control of all stages of production gives Tenbloc several advantages: • It is free from impurities, eliminating the introduction of undesirable elements in the iron.

• There are no slag inclusions, gas holes or porosity.

• The unique metallurgical bond formed during production is important for immediate and controlled dissolution. ■

保所有金属液，特别是初始浇注的金属液持续孕育。 在铸型中使用Tenbloc，是孕育剂可以添加的最晚阶 段。这意味着孕育剂的使用量可以减到最少，由于没有 孕育衰退，因此，这是经济有效的孕育剂使用方法。这 种孕育剂的添加率为0.1％，但可以根据特定的客户要 求进行调整。 Tenbloc的生产全程严密控制，使Tenbloc具有以下 优点： • 不含杂质，使铁液中不含有其他不需要的成分。 • 不产生夹渣、气孔或孔隙。 • 生产过程中形成的独特的冶金键对快速溶解和溶解控 制非常重要。 ■

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product news/产品新闻

ExOne and SGL partner on 3D printed carbon for cores and molds ExOne公司与SGL集团合作开发3D打印碳芯和铸型 The ExOne Company, a global provider of three-dimensional 3D printing machines and 3D printed products to industrial customers, announced that SGL Group is bringing carbon and graphite components created using ExOne’s 3D binder jet printing technology to the market under the brand name Carboprint.

“ExOne has formed a unique collaborative relationship with SGL Group who has developed a material that is ideally suited for our binder jetting technology,” said Rick Lucas, ExOne’s Chief Technology Officer. “Each party brings their expertise: SGL Group offers extensive knowledge on raw material and powder preparation, as well as versatile technologies for postprocessing carbon components. As the leading supplier for industrial binder jetting technology, ExOne contributes its competencies in 3D printing. This technology enables not only the production of small prototypes, but also efficient serial production and fast development of customer-specific solutions.”

As the carbon body is initially porous after printing, SGL Group post-processing, such as polymer impregnation or silicon or metal infiltration, play a major role. These additional processes allow the adjustment of versatile material properties to the specific application.

Now that the initial material development study is complete, SGL is engineering components and transforming the extreme degree of design freedom in 3D printing into real benefits for customers. Thanks to the basic properties of carbon, such as high chemical stability and good electrical and thermal conductivity, first trial components are being developed for testing in applications in the areas of chemical apparatus construction and environmental technology.

Specific examples include heat exchangers and components for distillation columns, as well as pump components made of siliconized 3D-printed carbon. ■ For more information: www.

为工业客户提供3D打印设备和3D打印产品的全球供 应商ExOne公司宣布，SGL集团采用ExOne公司3D打印 技术生产出碳和石墨部件，以Carboprint为品牌推向市 场。 ExOne公司首席技术官Rick Lucas说：“ExOne与 SGL集团形成了独特的合作关系，SGL集团开发了一种 非常适用于我们的粘结剂喷射技术的材料。双方都有各 自的专业技能：SGL集团提供原材料和粉末制备的全面 支持，以及碳零部件后处理的多种技术。作为工业粘结 剂喷射技术的领先供应商，ExOne为3D打印提供了强 大的技术支持。这项技术不仅能够用于生产小型原型， 还能进行高效的连续生产，为客户快速提供具体的解决 方案。” 最初打印的碳基体是多孔的，因此，SGL集团的后处 理工艺起着主要作用，如聚合物浸渍或硅、金属浸渗。 这些附加工艺使各种材料的属性调整到最佳以适应不同 的应用。 最初的材料研发工作已经完成，SGL正在设计组件、 并将3D打印的设计自由度转化为客户的实际利益。由于 碳的基本性质，如高的 化学稳定性，良好的导 电性和导热性，用于化 学仪器结构和环境技术 领域的试验组件已在研 发中，例如，蒸馏塔的 热交换器和组件，以及 硅浸渗的3D打印碳的泵 零部件。 ■ 更多信息，请访问网站：www. sglgroup.com

sglgroup.com.

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product news/产品新闻

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