Global Casting Magazine Volume 8 Number 3

Page 1

Foundry Improvements 改进铸造工艺

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








WWW.GLOBALCASTINGMAGAZINE.COM

SEPTEMBER 2018

volume 8 number 3

P.11

P.36

P.31 FEATURES

专题文章

31 5 Steps to Identify Casting Defects

31 5步识别铸件缺陷

S. KANNAN, A. PATHAK AND T. COBETT

36 Solving the Problems in Your Foundry A MODERN CASTING STAFF AND AFS INSTITUTE REPORT

S. KANNAN, A. PATHAK AND T. COBETT

36 解决铸造企业的难题 A MODERN CASTING STAFF AND AFS INSTITUTE REPORT

DEPARTMENTS

专栏

9 Editorial 11 Industry News 42 Product News

9 编者的话 11 行业新闻 42 产品新闻

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

5



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

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

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

7


Hawkeye Borescopes ®

Hawkeye管道探視器

沙子

Sand visible with a Hawkeye Pro Slim 12” Rigid Borescope

無效

Void in casting, after machining, seen with a Hawkeye Pro Hardy 7”

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. Made in USA

gradientlens.com

1-585-235-2620

info@gradientlens.com


editorial/编者的话

Foundry Leadership Conference Insights 来自铸造总裁研讨会的行业思考

M

etalcasters around the world face many of the same challenges. That point, which has been expressed before in Global Casting Magazine, was articulated again by speakers at the recent Foundry Leadership Conference in Amelia Island, Florida, presented by the American Foundry Society. Moderated by AFS Vice President Peter Reich, LaempeReich, a panel on the Condition of the Global Foundry Industry also included Brad Muller, Charlotte Pipe and Foundry; Atsushi Nagai, SintoKogio; Carsten Kuhlgatz, HA International; and Denny Dotson, representing the World Foundry Organization. In Japan, foundry output reached its peak in 2008, and today is at 80 percent of that peak level. The number of foundries has consolidated from 4,200 in 1990 to about 1,800 today. Japan’s foundries face skilled worker shortages, aggravated by slow population growth. Profit margins are at 2% or less. Other challenges include rising costs of materials and electricity, plus environmental issues. Foundries there are countering these trends through product differentiation, defect reduction and IOT systems. In Germany, the main challenges are rising energy and material costs, government over-regulation, challenges in recruiting young talent, and effects of trade tariffs. The move to replace diesel vehicle engines with electric-only vehicles also poses implications for castings. German foundries are countering these trends through programs to interest highschool students in foundry careers, as well the adoption of Industry 4.0 and additive manufacturing initiatives. China, the world’s largest producer of castings, is adopting a government policy aimed at reducing the number of foundries from 20,000 to 10,000. India is benefitting from a major commitment to training foundry workers, coupled with a decline in oppressive interest rates. That country’s casting exports are shipped heavily to U.S. markets. Thailand is considered Asia’s version of Detroit, and produces and consumes large quantities of auto-related castings. In North America, casting sales are on the rise thanks to a strong economy since the 2016 elections. For the first time since 2006 during the Bush administration, U.S. GDP is higher than the unemployment rate. Shortages of reliable labor is one of the foremost challenges for U.S. foundries, coupled with overly broad regulations, particularly at OSHA. As Dotson noted, knowledge in the metalcasting industry knows no national boundaries. Great ideas introduced in one country are quickly replicated elsewhere. Many suppliers already operate on an international basis. Dotson encourages all foundries to be aware of international trends and technical breakthroughs, as well as to engage in global metalcasting organizations where appropriate. ■ Doug Kurkul CEO American Foundry Society

界各地的铸造企业都面临着很多相同的挑 战,上一期的《世界铸造》杂志已表达了 这一观点。最近,由美国铸造协会在佛罗 里达州阿米莉亚岛举办的铸造总裁研讨会上对此做了 再次分析。以“全球铸造行业现状”为主题的研讨会 由美国铸造协会副会长、LaempeReich公司的 Peter Reich主持,参加讨论的还包括Charlotte Pipe and Foundry公司的Brad Muller,SintoKogio公司的 Atsushi Nagai,欧区爱公司的Carsten Kuhlgatz, 以及代表世界铸造组织的Denny Dotson。 日本的铸件产量在2008年达到顶峰,目前保持在 峰值的80%。铸件企业的数量从1990年的4,200个整 合为现在的大约1,800个。由于人口增长缓慢,日本 的铸造企业面临技术工人短缺的困境。利润率仅为2 %或更低。其他挑战包括原材料和电力成本上升以及 环保问题。日本的铸件厂通过产品差异化、减少产品 缺陷和物联网系统来应对这些挑战。 在德国,主要的挑战来自能源和材料成本上升、政 府过度监管、年轻人才短缺以及贸易关税的影响。用 纯电动汽车取代柴油车发动机的举措也对铸造行业产 生影响。德国的铸造企业正在通过各种方案来应对这 些挑战,包括吸引高中生对铸造行业产生兴趣、工业 4.0和增材制造计划。 作为世界上最大的铸件生产国,中国正在通过政策 调控将铸件厂数量从2万个减少到1万个。印度铸造业 受益于做出了针对铸造工人的培训的承诺,以及利率 的下降。印度铸件主要出口美国。泰国被认为是亚洲 的底特律,生产和消费大量与汽车相关的铸件。 在北美,由于2016年总统选举以来的经济强劲势 头,铸件销售呈上升趋势。而且自2006年布什政府 以来,美国国内生产总值增速首次高于失业率。可 靠劳动力的短缺是美国铸造厂面临的最重要的挑战 之一,此外还有过于宽松的法规、特别是职业健康 和安全法规方面的影响。 正如Dotson所指出的,铸造行业的知识技术不分 国界。一个国家的好的发展思路很快就会在其他国 家和地区得到复制。很多企业已经实现了国际化运 营。Dotson鼓励所有铸件企业了解国际发展趋势和新 技术,并在适当的时机加入全球性的铸造组织。 ■ Doug Kurkul CEO 美国铸造协会

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

9


INDUSTRY NEWS/行业新闻

10

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


INDUSTRY NEWS/行业新闻

Industry News Contents 行业新闻目录

CHINA DIECASTING 2018 展后报告

13

“Belt and Road” Project Launched in Mongolia “一带一路”铸造项目再次落户蒙古国

28

KOCEL Group Won GE POWER 2017 Innovation Supplier of the Year Award 共享集团荣获GE POWER 2017年度创新供应商奖

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

30

Simpson Technologies Gmbh Acquires German Foundry Industry Solutions Provider 24 辛普森(德国)科技公司收购德国铸造技术咨询公司

AUSTRALIA

Austrilian Foundry Industry Observations 澳大利亚铸造行业简况

29

Betz Industries Expanding BETZ工业公司扩建

25

Waupaca Foundry Honored By Toyota 沃帕卡铸造公司荣获丰田公司奖

25

Consolidated Precision Products Acquiring Selmet CONSOLIDATED公司收购SELMET公司

25

Ryobi Die Casting Inc. Receives Award From Honda 利优比压铸有限公司荣获本田公司质量卓越奖

26

Atek Expanding Iowa Plant, Technical Capabilities ATEK爱荷华州工厂扩建

27

Unimin, Fairmount Santrol Complete Merger; New Company Called Covia 尤尼明公司和费尔芒特山拓公司完成兼并

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

27

11


INDUSTRY NEWS/行业新闻

12

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


INDUSTRY NEWS/行业新闻

CHINA DIECASTING 2018 2018展后数据 CHINA DIECASTING 2018 - The 13th China International Diecasting Congress & Exhibition (CID) & 2018 China Nonferrous Alloys & Special Casting Exhibition (CNF) were held from 18th to 20th of July, 2018 at Shanghai New International Exhibition Center (SNIEC) in China. Organized by Foundry Institution of Chinese Mechanical Engineering Society (FICMES) and NürnbergMesse China, the exhibition expanded its show space to 3 halls, and has achieved great success of all time. As the leading trade fair in die casting industry, CHINA DIECASTING had a total net space of 14,124 sqm (10,032 sqm in 2017), gathered 409 exhibitors (323 for 2017) from 15 countries and regions, including: Denmark, France, Germany, Italy, Japan, Korea, Spain, Sweden, Switzerland, Thailand, UK, U.S, and of course, China (mainland, Hong Kong and Taiwan), among which 23% are overseas exhibitors. The exhibitor has also attracted 16,236 trade visitors (14,256 in 2017) during three days. Both exhibitors and visitors were impressed by the quality and services of the show, CHINA DIECASTING now has become Asia’s No.1 exhibition in die casting industry.

Continuous New Record of International Trade Visitors: 16,236 trade visitors were mainly experts of manufacturing, developers and merchandisers from automotive including its peripheral industry and other sectors – travelled to Shanghai more than 41 countries and regions. The proportion of overseas visitors was another marked increase. The strongest countries of origin were in Asia, and then Europe: after China, the majority came from India, Japan, Korea, USA, Germany, Thailand, Singapore, Malaysia, Indonesia and Mexico. Advanced technologies announced on “The 13th China International Diecasting Congress” and “The 4th International Symposium on Nonferrous Alloys and Special Casting Technologies” “The 13th China International Diecasting Congress” and “The 4th International Symposium on Nonferrous Alloys and Special Casting Technologies” was held from July 15th to 17th, 2018 in Novotel Shanghai Clover. 28 im-

展后报告 一、2018展后数据 ● 展出面积36000平方米,同比增长56%; ● 展商数量414家,同比增长28%,国际展商比例达23%; ● 服务16236名来自全球41个国家和地区的专业人士, 同比增长14%; ● 7大主题日活动; ● 3大特色展示区; ● 10余场同期会议。 二、开幕式 2018年7月18日上午9:30,第十三届中国国际压铸 会议暨展览会、2018中国有色合金及特种铸造展览会 开幕式隆重举行,获得了行业领袖、学界泰斗、合作伙 伴、政商要员鼎力支持!他们是: ● 中国机械工程学会铸造分会理事长、中国工程院院士 丁文江先生; ● 中国机械工程学会铸造分会理事长、铸造行业生产力 促进中心主任、沈阳铸造研究所有限公司董事长娄延 春先生; ● 中国工程院院士、国家镁合金材料工程技术研究中心 主任潘复生先生; ● 纽伦堡国际博览集团董事会成员Rolf Keller先生; ● 中国航天科技集团有限公司科技委副主任师宏耕先生; ● 日本压铸协会会长杉本润先生; ● 株式会社轻金属通信AL社社长上岛孝一先生; ● 欧洲铸造设备供应商协会秘书长Timo Wurz先生; ● 国际锌协会技术及市场发展经理Martin van Leeuwen先生; ● 德国驻上海总领事馆领事郎素安女士; ● 越南铸造协会国际合作部主任Mike Luu先生; ● 宁波模具行业协会秘书长张小岩先生。 三、展商分析 本届展会参展单位达到414家,同比增长来自全球15 个国家和地区,名企云集、星光熠熠。众多新产品、新 技术及应用属首次亮相。 海外展商比重23%。 来自15个国家和地区的展 商:中国、德国、美国、日本、 英国、丹麦、法国、意大利、 韩国、西班牙、瑞典、瑞士、泰 国、中国香港、中国台湾。

展商感言 中国压铸展-CHINA DIECASTING与中国有色展-CHINA NON-

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

13


INDUSTRY NEWS/行业新闻

14

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


INDUSTRY NEWS/行业新闻

portant speeches with latest foundry and casting technologies were given during the 2-day congress, delivered great value to the audience.

Voice from exhibitor: Mr. Wei Baohua, Senior VP of Asia Pacific at Norican Group, sums up:” CHINA DIECASTING 2018 is a professional, high-valued trade fair in die casting industry. Innovations and advanced technologies show up at right marketplace in every edition, which attract the major players in the specific industry. Much more importantly, the quality of trade visitors could not have been better.”

FERROUS以其高度专业化、国际化, 参展企业具有典型性和代表性而著称 业内,并得到各方认可与支持。 德国富来公司CEO葛玉江先生: 展会效果不错,业内专业人士到 场,欢迎明年有更多专业人士到 来!感谢主办方,2019年再相聚! 诺瑞肯集团亚太区高级副总裁魏 宝华先生:我觉得2018上海压铸展的专业性很强,现场每 年都可以看到压铸行业本身的技术发展和设备革新,展会 比较精,行业上主要的player也都来 了,说明了大家对这个活动的关注 和认可。 上海东芝机械有限公司李文博先 生:7月份上海展会在主办方不懈 努力下圆满完成,展会效果很好。 希望今后展会一年比一年更加精

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

15


INDUSTRY NEWS/行业新闻

16

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


INDUSTRY NEWS/行业新闻

On-site Events: CHINA DIECASTING 2018 and CHINA NONFERROUS 2018 offer a high-end platform for leading die casting and special casting enterprises to display latest technologies, products and process, all the participants can be benefit from on-site event besides showcasing:

- Innovation Day Focusing on topics of “Die Casting Industry Digital Plant” and “Die Casting Innovation Solution”, “Innovation Day”, the 2-day technical seminar, warmed up by online voting aroused 100,000+ attentions before

彩。期待下一届展会与大家 再相聚。 阿尔克森(苏州)铸造 技术有限公司总经理余永吉 先生:首先,祝贺CHINA DIECASTING2018圆满落 幕。AGS作为此次压铸展参 展商和“创新技术日”协办 方之一,着实感受到此次展 会带给我们的新产品、新技 术以及新的发展方向。现场 活动精彩纷呈,确实让我体验了一场“压铸盛宴”。

四、观众分析 国内观众Top10排 名:上海(53.96%) 、江苏(19.91%)、 浙江(11.55%)、广 东(3.50%)、山东

FCRI Ceramic Fliter

No. 18, Liuyuan Road, Shiwan, Foshan, Guangdong, China, 528031

FCRI GROUP CO.,LTD.

+86-757-82780713

www.fcri.com.cn

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

17


INDUSTRY NEWS/行业新闻

APRIL 27-30, 2019

ATLANTA, GEORGIA

& METALCASTING CONGRESS connecting SUPPLIERS | METALCASTERS | CASTING BUYERS

Metalcasting Success Starts Here CastExpo 2019, held once every three years, will be here before you know it. 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! Exhibitor registration is now open. For more information, visit

www.castexpo.com

18

#castexpo

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


INDUSTRY NEWS/行业新闻

the event. It shared the latest technologies in relevant topics. Speakers on behalf of their companies has won good opportunities of exposure through the event.

- Best Die Casting Competition & Display The brand event “Best Die Casting Competition & Display” of CHINA DIECASTING has been upgraded on last year’s basis. The competition has been divided, according the materials of the die casting parts, into 3 separate categories: Aluminum, Magnesium and Zinc, which has attracted 134 runners for the GOLD awards and EXCELLENCE awards. There are 90 aluminum die castings, 12 magnesium die castings and 32 zinc die castings among them.

(2.14%)、北京(1.67% )、河北(1.10%)、安徽 (0.95%)、辽宁(0.86%) 、福建(0.64%)。 海外观众Top10排名:印 度(22.5%)、日本(16.1% )、台湾(15.2%)、韩国 (11.8%)、美国(3.9% )、德国(2.5%)、泰国 (2.5%)、新加坡(2.5%) 、马来西亚(2.3%)、印度 尼西亚(2.3%)。 观众行业分析:汽, 摩配件(37.76%)、电子, 电 器(16.31%)、机电仪表(13.95%)、电动工具 (9.44%)、灯具饰品(9.23%)、日常五金(6.01% )、建筑五金(5.58%)、玩具行业(1.72%)、其它 (0.00%) 观众感兴趣的产品:压铸机(11.15%)、压铸 周边设备(8.77%)、压铸件(11.35%)、压铸模 具(10.86%)、熔炼设备(8.70%)、压铸机配件

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

19


INDUSTRY NEWS/行业新闻

- Auto-Tech Day Follows the leading trend of “lightweight, new-energy, and intelligence” in the global automotive industry, “Auto-Tech Day” discussed revolutionary challenges and opportunities, in form of development forum and displaying. The forum, “2018 Automotive Lightweight Development Forum” has invited 7 experts from GF Casting Solutions, GM, DF Motor, DGS, BYD, AluMag Automotive, N-CE Neuwirth Consulting & Engineering, discussed the latest progress and solution of lightweight automotive parts, as well as the opportunities. 8 die casters showed the 24 top die casting automotive parts in the “Innovative Die Casting Auto Parts Display” area. In Japan Die Casting Parts Display area, 6 leading

20

(8.01%)、压铸原材 料(5.92%)、辅料耗 材(6.20%)、压铸软 件(5.08%)、低压 铸造件(4.53%)、 后加工和表面处理(6.82%)、检测/环保/安全设备 (4.60%)、机械加工设备(5.50)、行业服务(2.51 )、其它(0.00%) 观众职务范围:行政管理(12.55%)、采购 (16.35%)、生产/制造(22.81%)、技术/研发工程 师(22.81%)、市场(10.27%)、销售(15.21%) 、其它(0.00%) 五、第十三届中国国际压铸会议/第4届有色合金及 特种铸造技术国际研讨会 7月16-17日,为期两天的会议有28位来自高等院 校、国家重点实验室、国内外知名企业的专家学者和业 界精英带来了精彩的报告与业界分享, 与会代表反响

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


INDUSTRY NEWS/行业新闻 Japanese die casting companies also brought die casting parts representing their latest forming & casting technologies this year.

热烈,新朋老友相聚共谋发展。

- Mould Manufacturing Day 2018

创新技术日

Mould Manufacturing Day 2018 contains 2 parts: “The Summit Mould Manufacturing” and “International Match-making for Moulds & Die Casting Parts”. Chinese die casting manufacturers are proposing higher requirement towards the dies and moulds, since they are also facing strict procurement standards from global buyers. “The Summit Mould Manufacturing Forum 2018” invited 7 experts, engineers and technicians from associations and relevant downstream and upstream industries shared current market trend and government policies, and also explored innovative development solutions. The match-making provides high-efficient opportunities for 17 buyers vs. 52 suppliers to negotiate face to face.

- Technologies in nonferrous alloys and applications Besides the workmanship, sometimes materials are also critical to improve the manufacturing. By the time 3 seminar themes announced, there are already quite a number of audience expecting the sharing from the forum.

六、同期活动 “创新技术日”活动,包括“压铸行业数字化工 厂”专场、“压铸创新技术解决方案”专场。现场发布 通过筛选的30多项新产品及新技术,呈现当前压铸界 关注的创新技术和产品信息,洞悉压铸领域最新发展动 向,给予业内人士全方位的压铸创新技术体验。

汽车技术日 “汽车技术日”探讨和展示“未来汽车发展趋势 之轻量化和新能源”进程中的热门话题,演讲嘉宾来 自东风汽车、通用汽车、比亚迪汽车、GF乔治费歇 尔、DGS等业内知名企业。高品质的演讲吸引了众多业 内人士参与,场场爆满。

铸造有色合金专题 1. 先进有色金属铸造技术交流会 由中国航天科技集团有限公司铸造工艺技术中心、

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

21


INDUSTRY NEWS/行业新闻 “Seminar on Casting Technology of Advanced Nonferrous Alloys” invited 12 speakers from top colleges and universities, research institutes, and leading enterprises in the field of the national defense and related industries, presented valuable reports focused on academic exchanges of new nonferrous material and technology development. “Magnesium Alloys Casting Technologies Session” focused on discussion of the application status and future prospects of magnesium alloy in aerospace, automobile, 3C and other fields. 8 speakers from leading association, manufacturers and universities had joined this session. “Semi-Solid Metal Casting Technologies Development Seminar and Products Display” had 4 industry experts and representatives of enterprises to discuss the sustainable development of this process by making technical presentations and displaying high quality casting products.

- Other Programs 6 well-known universities and enterprises from China presented 8 scientific and technological achievements on “The 5th China Foundry Science and Technology Achievements Trade Fair”, setting up a bridge between

22

上海金属材料近净成形工程技术研究中心、中国机械工 程学会铸造分会、上海航天技术研究院主办,上海航天 精密机械研究所承办的先进有色金属铸造技术交流会, 是本届展会重点打造的现场活动之一。 会议邀请国防领域及相关行业的高校、研究院所、 企事业单位的多位专家、学者,组织了多个极具含金量 的专题报告,其中中国工程院丁文江院士作了《镁基功 能材料研究进展》的报告,中国工程院潘复生院士作了 《铸造镁合金材料与工艺新技术》的报告。 权威专家及精彩报告,使260余名与会代表获益良多。

2. 镁合金铸造技术专场 本专场汇集行业领先企业及知名专家学者,共同探 讨镁合金在航空航天、汽车、3C等领域应用现状和发 展前景,全新的视角、热点话题,引爆全场。

模具专题日 1. 压铸模具制造高峰论坛 压铸模具行业企业家、专家学者、工程技术人员齐 聚,通过案例分享的方式,立足解决实际问题,探讨新 的设计思路和方式,引领压铸模具制造行业向着高端、

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


INDUSTRY NEWS/行业新闻 academic institutes and companies. CHINA DIECASTING has also introduce "Southeast Asia Investment Forum” to trade visitors, which will attract enterprises to new dynamic die casting markets overseas. The next event for the EUROGUSS product family will be ALUCAST, from 6 to 8 December 2018, ALUCAST will be held in Greater Noida, Delhi/NCR, India, with around 150 exhibitors and more than 3,500 trade visitors.

SAVE THE DATE ! The next CHINA DIECASTING will take place at Shanghai New International Exhibition Center (SNIEC) in Shanghai, China, from 17 to 19 July, 2019. ■

More information at: www.diecastexpo.cn/en/ www.cnf-ex.com/en/

智能化方向发展。

2. 模具及压铸件跨国采配会 本项活动为压铸件及压铸模具供求双方提供面对面 交流平台,众多采购商和供应商积极响应和参与,得到 与会者的好评。 第5届中国铸造科技成果交易洽谈会 会议专注于压铸及相关领域科研成果的市场推广与 在行科研项目的合作研发,充分发挥产学研相结合的优 势,立足为企业解决实际问题并建立长期合作关系,得 到业界肯定。

海外市场专题 东南亚投资说明会 本次活动邀请到了泰国投资委员会、罗勇工业园及 东南亚压铸行业协会负责人介绍市场及投资相关政策, 助力压铸企业进军东南亚市场,得到业界关注,现场气 氛热烈。

七、三大特色展示区 中国优质压铸件评选及展示区 现场有69家业界知名企业携135件铸件参加评选并 集中展示,如精诚工科汽车系统有限公司精工压铸分 公司、比亚迪汽车工业有限公司第十七事业部 精铸工 厂、中信戴卡股份有限公司、GF乔治费歇尔等。铸件 展示区内人潮涌动,观众络绎不绝,对于这种形式的展 示观众表示出极大的兴趣。 7月18日经主办方特邀业界权威专家现场评审,最终 评选出8个“金奖铸件及模具”及21个“优质铸件及模 具”奖项,获奖产品在现场进行了集中展示。在当日晚 上举行的“盛典之约”招待晚宴上举行了隆重的颁奖典 礼,为获奖单位颁发了奖杯及获奖证书,并现场展示“ 金奖铸件”。

前沿汽车铸造工艺展示区 主办单位选择相关优质企业重点打造“汽车日活 动”,并配有“前沿汽车铸造工艺展示区”。来自欧美 以及国内的精品汽车铸件在展区展示,吸引了众多观众 驻足参观。

日本优质压铸件展示区 本届CHINA DIECASTING中国压铸展,日本展团携 手亮相,展示当今日本先进的压铸技术、设备和产品。 展会现场特设的“日本优质压铸件展示区”,重点展示 代表日本高端制造水准的压铸产品。 八、“盛典之约”招待晚宴—行业精英聚会 “盛典之约”,精英聚会,注定是CHINA DIECASTING 2018一道亮丽的风景线。7月18日晚,嘉 宾及展商代表相聚在,参加了主办方精心准备的欢迎晚 宴。主办单位现场对获奖铸件、创新产品及技术予以表 奖;对给予展会鼎力支持的各方合作伙伴及行业专家表 示感谢。 ■ September 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

23


INDUSTRY NEWS/行业新闻

Simpson Technologies Gmbh Acquires German Foundry Industry Solutions Provider 辛普森(德国)科技公司收购德国铸造技术咨询公司 Simpson Technologies (Deutschland) GmbH (Alfeld, Germany), a subsidiary of AFS Corporate Member Simpson Technologies Corporation (Aurora, Illinois) specializing in process solutions for the metal casting and chemical process industries, announced the acquisition of Webac Gesellschaft für Maschinenbau GmbH (Euskirchen, Germany) together with its subsidiaries Webac Maskin AB (Stockholm, Sweden) and Webac s.r.o (Pribram, Czech Republic). Webac has 56 years of experience in Germany providing advanced process technology and customized plants for the foundry and oil and gas industries. “Simpson and Webac share a commitment to deliver to customers innovative technologies with excellent service levels and support,” said André Klimm, managing director, Simpson Technologies (Deutschland) GmbH. “Acquiring Webac and their talented team will strengthen our ability to service customers in Europe while offering Webac customers access to Simpson’s industry- leading products, including the largest portfolio of sand preparation and control technologies in the world.” In a news release, Simpson said Webac will strengthen and expand Simpson’s product line to include thermal sand reclamation technology and plants, core sand preparation technology and plants, fully engineered sand preparation systems and projects and frac sand processing technology for the oil and gas industry. Webac, the release said, “also adds key infrastructure and capacity in manufacturing, warehousing and logistics. “ “The acquisition of Webac is our sixth acquisition in the last 20 years and the second in Europe since acquiring the former Georg Fischer sand laboratory equipment business from DISA Industrie AG in 2008. This shows our commitment to the European market and to the growth of our European business,” said Bruce Dienst, CEO, Simpson Technologies. “Our global growth strategy is focused on acquiring or developing innovative technologies, new capabilities and expanding our reach to better serve our global customers with efficient and effective technology and outstanding customer service. The facility in Euskirchen, and the talented team there, will serve as an important and expanding hub for our business in Europe.” Webac brings more than 85 years of experience in the foundry industry dating back to 1931 with the founding of the AB Westin & Backlund company in Stockholm, Sweden. The growing demand for machines and complete plants led to the founding in 1962 of a German subsidiary, Webac Gesellschaft für Maschinenbau GmbH. It quickly grew to become a major supplier of foundry technology and plants. Heinrich Richard Kairies, Managing Director, Webac Gesellschaft für Maschinenbau GmbH said his company was excited to join with Simpson. “The collaboration of both companies will benefit each of our customer bases worldwide, and ultimately help drive new industry innovation through our design and development strengths,” he said. ■ 24

美国铸造协会会员、专注于金属铸造和化工工艺解决 方案的辛普森科技集团公司(伊利诺伊州奥罗拉)的德 国阿尔菲尔德子公司辛普森科技公司,宣布收购Webac 机械工程公司(德国奥伊斯基兴)及其子公司Webac Maskin AB(瑞典斯德哥尔摩)和Webac s.r.o(捷克普 里布拉姆)。Webac公司在德国已有56年的历史,为铸 造和石油天然气行业提供先进的工艺技术和定制设备。 “辛普森和Webac共同致力于为客户提供创新技术 以及卓越的服务和支持,”辛普森(德国)科技公司董 事总经理André Klimm说,“收购Webac公司及其优秀 的团队将增强我们为欧洲客户提供服务的能力,同时为 Webac公司的客户提供辛普森公司行业领先的产品,包 括世界上最大的砂处理和控制技术的产品组合。” 辛普森公司在新闻发布会上表示,Webac公司的加 入将增强和扩大辛普森的产品范围,包括用于石油和天 然气行业的热法砂再生技术和设备、砂芯制备技术和设 备、完整的砂处理系统和工程以及压裂砂处理技术。报 道称,Webac“还增强了制造业、仓储和物流方面的关 键基础设施和产能。” “收购Webac公司是我们在过去20年中的第6次收 购,也是自2008年从迪砂公司收购前乔治费歇尔制砂实 验室设备业务以来的第2次收购。本次收购表明我们对欧 洲市场的重视以及我们致力于欧洲业务发展的承诺,” 辛普森科技公司首席执行官布鲁斯丁斯特说。“我们的 全球发展战略专注于获取或开发创新技术、具备新的生 产能力并扩大我们的业务范围,以更高效的技术和出色 的客户服务为全球客户提供更好的服务。位于奥伊斯基 兴的工厂和那里的优秀团队将成为公司在欧洲业务的重 要增长中心。 自AB Westin& Backlund公司于1931年在瑞典斯德 哥尔摩成立,Webac公司服务铸造行业超过85年的历 史。随着机器和成套设备的需求不断增长,德国子公司 Webac 机械工程公司于1962年成立,并迅速发展成为铸 造技术和设备的主要供应商。 Webac机械工程公司董事总经理海因西里表示,公司 很高兴加入辛普森科技集团。他说,“两家公司的合并 将使双方的全球客户群受益,并最终通过我们的设计和 开发优势推动新的行业创新。”

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


INDUSTRY NEWS/行业新闻

Betz Industries Expanding BETZ工业公司扩建

AFS Corporate Member Betz Industries (Grand Rapids, Michigan) is planning to invest $3.5 million to add a new 41,280 sq. ft. facility in Walker, Michigan, that would offer machining services. The gray and ductile iron caster produces castings for multiple industries. According to a report from MiBiz.com, the addition could add 15 new jobs and will allow the company to machine products instead of sub-contracting to other facilities. “We’ve always had our customers ask us to do machining, or for us to find outside machining sources for them,” co-owner Gregg Betz told MiBiz. “We’ve had a number of our customers that have asked us to do some of the 2D type machining, especially at the bottoms of the castings.” The company has reportedly purchased 52 acres of land in the area, which is next to Betz Industries’ campus. Construction should be complete by the end of 2019. Walker city manager Darrel Schmalzel said the addition is good news for the area. “They continue and always have been a wonderful asset to the community,” Schmalzel said, according to the report. ■

美国铸造协会会员Betz工业公司(密歇根州大急流 城),主要产品为工业用灰铁件和球墨铸铁件,计划 投资350万美元在密歇根州沃克市新建约3835m2的厂 房,作为机加工车间。 据MiBiz.com报道,新建的车间将增加15个就业岗位, 使公司具备直接加工产品的能力,而不用转包给其他工厂。 企业共有人Gregg Betz对MiBiz说,“我们的客户经常 向我们提出加工的需求,或者让我们帮助寻找加工厂。很多 客户要求我们进行2D加工,特别是在铸件的底部。” 据报道,BETZ公司购买了Betz工业园附近的52英亩 的土地。施工预计将于2019年底完成。 沃克市长Darrel Schmalzel表示,Betz公司的扩 建对该地区的发展来说是个好消息。他在报道中表 示,“Betz公司将继续并且一直是沃克的一个很好的资 产。” ■

Waupaca Foundry Honored By Toyota 沃帕卡铸造公司荣获丰田公司奖

AFS Corporate Member Waupaca Foundry (Waupaca, Wisconsin) was honored by Toyota Industrial Equipment Manufacturing with one of five available professional excellence awards. Waupaca is the first Tier II supplier to be honored with one of these awards. Waupaca has supplied iron castings to TIEM since 2002. In 2017, Waupaca was contracted to produce 21 parts at its gray and ductile iron foundries in Waupaca and Marinette, Wisconsin, and Tell City, Indiana. “We were able to flawlessly launch new parts for TIEM because at all levels within our organization our culture is focused on partnering with our customers to meet their goals,” said John Wiesbrock, executive vice president of sales, marketing and supply chain management, Waupaca Foundry. ■

美国铸造协会会员沃帕卡铸造公司(威斯康辛州沃 帕卡)获得丰田工业设备制造公司的“专业卓越奖”, 是五个获奖企业之一。沃帕卡铸造公司是首个获此奖项 的二级供应商。 自2002年以来,沃帕卡铸造公司开始向丰田工业设 备制造公司供应铸铁件。2017年,沃帕卡铸造公司获 得21种零部件的生产订单,这些铸件由其位于威斯康 辛州沃帕卡、马里内特以及位于印第安纳州特尔市的灰 铁和球墨铸铁厂生产。 沃帕卡铸造公司负责销售、市场和供应链管理的执行 副总裁John Wiesbrock说:“我们可以为丰田工业设备 制造公司研发完美的新产品,因为无论在哪个级别,我 们的公司文化就是与客户合作并满足客户需求。” ■

Consolidated Precision Products Acquiring Selmet CONSOLIDATED公司收购SELMET公司

Consolidated Precision Products Corp. (Cleveland), a manufacturer of components and sub-assemblies primarily for the commercial aerospace and defense markets, announced it has reached an agreement to acquire Selmet Inc. (Albany, Oregon).

Consolidated精密铸件公司(克利夫兰)是一家为 商用航空航天和国防业提供零部件和装配件的制造商, 宣布与Selmet公司(俄勒冈州奥尔巴尼)达成收购协 议。

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

25


INDUSTRY NEWS/行业新闻 Selmet is a manufacturer of titanium castings and machined components for the aerospace and defense industries. Founded in 1983, Selmet operates an investment casting foundry. With the acquisition of Selmet, CPP will expand its offering to include titanium castings. "Paired with CPP's existing product set, the transaction will enable CPP to provide the most comprehensive casting capabilities in the industry," CPP said in a news release. Selmet's current management team will remain upon closing of the transaction to help drive continued growth. "We have long admired Selmet's world-class technical capabilities, longstanding customer relationships, strong management team and track record of growth," said James Stewart, CEO, CPP. "This highly complementary acquisition will round out our product offering to include titanium castings, enabling us to meet the strong demand from customers seeking advanced titanium content for next-generation platforms. We are pleased to welcome the talented Selmet team to the CPP family." "We believe the combination of CPP and Selmet's products creates a highly attractive and comprehensive platform for CPP's customers in the aerospace and defense industries," said Dan Zamlong, managing director, global private equity firm Warburg Pincus. "We look forward to continuing to support CPP and its future growth." ■

Selmet是为航空航天和国防工业提供钛合金铸件 和机加工零部件的制造商,成立于1983年,采用熔 模精密铸造工艺。 收购Selmet公司之后,Consolidated精密铸件公 司(CPP)将扩大产品范围,增加钛合金铸件。 CPP在报道中称,“与CPP现有的产品组合一 起,本次收购将使CPP具备最全面的铸件生产能 力。” 收购结束之后,Selmet将继续保持目前的管理团 队,以推动持续的增长。 “我们长期以来一直钦佩Selme公司世界级的技 术能力、长期客户关系、强有力的管理团队以及良 好的增长业绩,”CPP首席执行官詹姆斯•斯图尔特 说,“两家公司的产品高度互补,将使我们的产品 系列扩展到钛合金铸件,从而使公司能够满足客户 对未来发展所需的先进钛合金产品的需求。我们很 高兴Selmet的优秀团队加入CPP大家庭。” “我们相信CPP和Selmet产品的结合将为CPP在 航空航天和国防工业的客户创造全面的极具吸引力 的平台,”全球私募股权公司华平投资集团董事总 经理Dan Zamlong表示:“我们期待继续为CPP及 其未来的增长提供支持。” ■

Ryobi Die Casting Inc. Receives Award From Honda 利优比压铸有限公司荣获本田公司质量卓越奖 Ryobi Die Casting (Shelbyville, Indiana), a supplier of aluminum diecastings was recognized with an Excellence in Quality Award from Honda at its Annual Supplier Conference. Honda has more than 700 (OEM) suppliers that provide parts to 16 Honda plants in North America that produce Honda and Acura automobiles and light trucks and the engines and transmissions that power them. Ryobi Die Casting was one of only 45 out of 736 OEM parts suppliers serving Honda with parts and components for mass production recognized with an award. “We are known in the industry to have highquality dies that produce very high-quality parts,” said Tom Johnson, USA president, Ryobi Die Casting. “We are proud to have been able to bring our high-quality systems and know-how and have been able to partner with Honda. We are also proud to be a significant supplier on the 2018 Honda Accord, 2018 North American Car of the Year.” ■

26

铝合金压铸件生产企业利优比压铸公司(印第 安纳州谢尔比维尔)在本田公司年度供应商大会上 荣获质量卓越奖。 本田拥有700多家(OEM)为北美的16家本田 工厂提供零部件的供应商,这些企业生产本田汽 车、讴歌汽车和轻型卡车以及为其提供动力的发 动机和变速箱。利优比压铸公司是本田公司736家 OEM零件供应商中生产大批量零部件产品的45家 获奖企业之一。 “我们以生产高质量的模具以及压铸产品而 业内闻名,”利优比美国公司总裁汤姆•约翰逊 说,“我们很自豪能够呈现高品质的生产系统和 专业知识,并能够与本田公司合作。我们也很自豪 能成为2018北美年度汽车的2018款本田雅阁的重 要供应商。” ■

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


INDUSTRY NEWS/行业新闻

Atek Expanding Iowa Plant, Technical Capabilities ATEK爱荷华州工厂扩建 AFS Corporate Member ATEK Metal Technologies (New Hampton, Iowa) is expanding its plant and technical capabilities to keep up with demand. The company has recently completed a significant expansion of its metal casting, heat treatment and finished machining capabilities. “We added 40% to our low pressure permanent mold casting capacity to keep up with our accelerating growth,” said Tom Christie, president, ATEK Metal Technologies. “We also have added state-of-the-art precision machining capabilities to be able to provide our customers with cast and machined finished components.” ATEK has also invested in robotic de-gating and deburring of castings. This system will be operational in July. “We are applying automation where it makes sense for the safety of our people and to provide the best value possible for our customers,” Christie said. The company is also planning a building expansion that's scheduled to be completed in December. “We need additional plant space to support growth,” Christie said. “The new building will allow us to consolidate our warehousing and shipping areas and make room on the plant floor for ongoing expansion of operations.” The entire plant expansion is scheduled to be complete by the end of 2018. ■

美国铸造协会会员ATEK金属科技公司(爱荷华州 新汉普顿)正在扩建工厂、提升技术能力,以满足需 求。该公司近期完成了铸造、热处理和机加工产能的 扩展项目。 “为了与增长速度保持一致,我们在低压金属型铸 造产能方面增加了40%,”ATEK 金属科技公司总裁 汤姆•克里斯蒂说,“我们还增加了最先进的精密加 工能力,以便为我们的客户提供铸造和机加工成品部 件。” ATEK还投资于使用机器人去除浇口和去毛刺。该系 统于7月投入使用。克里斯蒂说:“我们正在将自动化 应用于有助于提高安全生产的方面,并为客户提供最 大的价值。” 公司还将计划于12月底完成厂房的扩建。 “我们需要更大的工厂规模以支持公司的发展,” 克里斯蒂说,“新的厂房将使我们可以扩大仓储和运 货区,并有足够的扩展空间。” 工厂扩建项目预计将于2018年年底竣工。 ■

Unimin, Fairmount Santrol Complete Merger; New Company Called Covia 尤尼明公司和费尔芒特山拓公司完成兼并 The merger between AFS Corporate Members Unimin Corporation and Fairmount Santrol is complete, and the new name of the company is Covia Holdings Corporation (Chesterland, Ohio). “Today is a historic day for Covia and we would like to thank our stockholders, employees, customers and partners for their support in completing this significant achievement,” said Jenniffer Deckard, President and CEO, Covia. “As we make our debut as Covia, the strong foundation built by our two highly complementary legacy organizations underpins an industry leader, strongly positioned to serve customers’ needs through our broad array of high-quality products, distinctive technical capabilities, and the industry’s most comprehensive production and distribution network. "We look forward to utilizing these unique competitive advantages to achieve our near-term synergy goals and to create significant long-term value for all of our stakeholders." Covia will commence trading today on the New York Stock Exchange under the ticker symbol CVIA. Fairmount Santrol common stock ceased trading prior to the market opening today and will be delisted from the NYSE. ■

美国铸造协会会员尤尼明集团和费尔芒特山拓公司 完成兼并,重组成立新公司卡维亚控股集团公司(俄 亥俄州切斯特兰德)。 “今天是卡维亚历史性的一天,我们要感谢我们 的股东、员工、客户和合作伙伴对取得这一重大成就 给予的支持,”卡维亚总裁兼首席执行官Jenniffer Deckard说,“这是卡维亚公司的首次亮相,由两个 高度互补的优势企业以及强大基础奠定了卡维亚作为 行业领导者的基础,通过一系列高质量产品、独特的 技术能力及其最全面的生产和销售网络,将可以完全 满足客户的需求。 我们希望通过公司独有的竞争优势来获得近期的协 同发展目标,并为我们的利益相关者创造长期的巨大 价值。 卡维亚将于今天在纽约证券交易所上市,股票代号 为CVIA。费尔芒特山拓普通股在开市前停止交易,从 纽交所退市。 ■

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

27


INDUSTRY NEWS/行业新闻

“Belt and Road” Project Launched in Mongolia “一带一路”铸造项目再次落户蒙古国 As the chairman unit of the Foundry Working Committee of “Belt and Road” Industry and Commerce Association initiated by nearly 30 countries and regions, China Foundry Association has been committed to international cooperation in the foundry industry and has gradually established mutual exchanges with foundry organizations along “Belt and Road” and built a platform to actively promote overseas matchmaking for Chinese high-quality production capacity. On September 8, Mr. Zhang Zhiyong, executive vice president and secretary general of China Foundry Association, Mr. Yan Qidong, secretary general of the Austempering Casting Branch, Mr. Chen Quanxin, general manager of NingGuo HuaFeng Wear-resistant Material Co. Ltd. and chief engineer Mr. Yao Yongmao, went to Mongolia to attend the opening ceremony of Fuyou Huafeng Wear-resistant Materials Co. Ltd. The president of the Mongolian Foundry and Metallurgy Association and the president of the Inner Mongolia Chamber of Commerce attended the ceremony. Fuyou Huafeng Wear-resistant Material Co., Ltd. is located in Govisumber, Mongolia. It is a joint venture between Ningguo Huafeng Wear-resistant Material Co., Ltd. and Mongolian Fuyou Wear-resistant Material Factory, with a total investment of about 50 million yuan. The company occupies 146 acres, owns a 8000kw substation, is equipped with six sets of one-ton intermediate frequency furnaces, one set of automatic grinding-ball production line with iron-mold coated sand and heat treatment line, and one coated sand production line and sand reclamation line, with an annual production capacity of 20,000 tons of grinding balls. It also has direct-reading spectrometer, metallographic examination and mechanical testing equipment. Mr. Zhang Zhiyong pointed out the foundry industry in China and Mongolia was highly complementary. With the "Belt and Road" initiative, cooperation between the China and Mongolia foundry industries have been promoted and deepened further. The opening of Mongolian Fuyou Huafeng Wear-resistant Materials Co., Ltd. was another achievement for cooperation between China and Mongolia after the ChinaMongolia Foundry Industrial Park. ■

28

作为由近30个国家和地区发起的“一带一路工商 协会联盟”的铸造工作委员会主任委员单位,中国铸 造协会一直致力于铸造业国际合作,并逐步与沿线国 家的铸造业组织搭建起了相互交流的平台,积极推进 中国铸造业优质产能的海外对接。 2018年9月8日,中国铸造协会执行副会长兼秘 书长张志勇、等温淬火铸件分会秘书长闫启栋、安徽 宁国华丰耐磨材料有限公司总经理陈全心及总工程师 姚永茂,共同赴蒙古乔伊尔市出席富友华丰耐磨材料 有限公司的开业庆典。蒙古铸造协会会长,内蒙古商 会会长等相关领导参加了仪式。 蒙古富友华丰耐磨材料有限公司位于蒙古国苏 木贝尔省乔伊尔市,是安徽宁国华丰耐磨材料有限 公司和蒙古国富友耐磨材料厂合资组建,总投资约 5000万元。公司占地146亩,自有8000kw变电站, 配置6台1吨中频炉、1套全自动铁模覆砂磨球生产线 及热处理线、1条覆膜砂生产线及旧砂再生线,拥有 直读光谱仪、金相检验及力学检测设备,具备年产磨 球2万吨的生产能力。 张志勇指出,中蒙两国铸造业有很强的互补 性,在“一带一路”倡议下,在中国铸造协会和蒙古 铸造协会有力的推动下,中蒙铸造业合作逐渐深入, 蒙古富友华丰耐磨材料有限公司开业投产,是继中蒙 铸造工业园之后,中蒙铸造业合作的又一硕果。 ■

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


INDUSTRY NEWS/行业新闻

Austrilian Foundry Industry Observations 澳大利亚铸造行业简况 Mr. Alper Dayioglu, member of the Foundry Working Committee of “Belt and Road” Industry and Commerce Association, general manager of Qingdao Ideal Engineering Technology, had a meeting with the president of Australia Foundry Institute, Mr. Alan Cooke on June 12 at Melbourne. At the beginning of the meeting, China and Turkey Foundry Industry 2017 reports were given to Cooke, who then shared general information about Australian foundry industry’s situation. Cooke had worked at Ford’s foundry for 23 years in different departments such as foundry production, casting quality control etc. The foundry industry in Australia is developed mostly in the east states of the country: Victoria, New South Wales and Queensland. However, the number of foundries have been decreasing year by year, which are already small in number. Ford’s production activites were stopped completely in 2016; the local automative brand Holden and other foreign investment automative companies were also all shut down in 2017. Now, the Austalian automative industry depends on outside sources; all the car brands are imported from other countries. According to Cooke, the main reasons are high production cost, the local market is too small to support a lcoal industry, the extra costs caused by the fact that the manufacturing capacity is much higher than the demand on the market etc. Australian foundries produce mostly iron, ductile iron, steel, aluminum castings, and to a lesser extent copper and alloy castings. The main sectors served by the present casting industry are agriculture, mining and defense industries. AWBell and Bradken are two examples of Australian-based foundries supplying the U.S. defense industry. AWBell’s expertise in high strength, thin wall, precision aluminium castings is world-class. Bradken has been supplying ferrous castings to OEMs in the North Amercian market for many years. White Industries, Northern Iron and Brass, and Weir are examples of foundries supplying castings to the agricultural industry, either through pump housings and impellers, ground engaging components or valve componentry. Keech is an outstanding example of an Australia-based foundry supplying to the global mining industry. Note that due to the size of the Australian market, most foundries in Australia have a very diverse customer base across many industries including defense, agriculture and mining as well as rail, automotive and industrial castings. Regarding the foundry machinery, equipment, materials and refractories’ production and importation, Cooke says most of the world brands have their local representatives or own

在访问澳大利亚期间,受中国铸造协会委托,中国铸 造协会一带一路工作委员会委员、青岛爱迪亚工程技术 有限公司总经理安伯士先生(Alper Dayioglu,土耳其 人)于2018年6月12日在墨尔本拜访了澳大利亚铸造协 会总会长艾伦·库克(Alan Cooke)先生。 会谈期间,安伯士向库克会长介绍了中国和土耳其铸 造行业2017年情况,随后交流了关于澳大利亚铸造行业 信息,了解了行业发展情况。 库克先生在澳大利亚的福特汽车厂的铸造厂生产部, 质量管理部等不同部门工作了23年。他说澳洲铸造行 业所在的主要区域是澳洲东部,包括:维多利亚州、新 南威尔士州和昆士兰。近几年本来不多的铸造厂数量又 减少了,库克先生工作过的福特厂2016年关闭了。在 2017年,澳洲当地汽车品牌霍顿和其他在澳大利亚生 产汽车的工厂陆续停工。目前澳洲的汽车品牌都是国外 的,完全依赖进口。库克先生认为生产成本高,本地市 场太小,无法支持本地产业的产能是造成这钟现象的主 要原因,市场需求量远远小于生产量导致额外的制造成 本。 澳大利亚铸造厂生产的铸件材质为灰铁、球铁、钢 和铝合金,以及较少量的铜合金。主要应用于农业、矿 业、国防工业。下面有关于这三个行业中从事生产的重 要公司简要信息: AWBell和Bradken是为美国国防工业提供铸件的两个 工厂。AWBell公司在高强、薄壁精密铝铸件方面的专业 技术是世界一流的。Bradken多年来一直向北美市场供 应铸铁件。 White Industries,Northern Iron and Brass和 Weir公司主要生产农业用铸件如泵壳体,叶轮,驱动零 部件或阀门部件。 Keech公司是向全球矿业供应铸 件的杰出的澳大利亚铸造厂代表。 由于澳大利亚市场的规模有限, 澳大利亚大多数铸造厂在许多行业 都拥有非常多元化的客户群,包括 上述的国防,农业和矿业,还生产 铁路,汽车和工业铸件。 安伯士向库克先生问到澳大利亚 的铸造机械设备、铸造材料和耐火

澳大利亚铸造协会总会长艾伦·库克 (Alan Cooke)先生及夫人 September 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

29


INDUSTRY NEWS/行业新闻 companies in Australia, and they are the main suppliers for the foundry needs. Cooke informed that Australia National Foundry Congrees will take place in Queensland this year, October 12-14. After the communication about the Australia foundry industry, Mr. Dayioglu gave general information about the Turkish and Chinese foundry industries. In addition, he gave brief information about his own company Qingdao Ideal and Turkish company Ideal Model’s activities, productions and services for the foundries and steel mills. The exhibitions being held in Beijing, Shanghai and Istanbul were announced and Cooke and the other members of Australian Foundry Institute were invited. The meeting with Mr. Cooke was quite positive. Despite the fact that the Australian casting market is small in size, it consists of some well-known foundries operating continously for many years. The distance of Australia from the other regions of the world causes disadvantages, as does the size of the markets that Australian foundries service. This disadvantage drive the need for a stringent approach to casting quality and innovation so that Australian foundries can compete on a global market. Also this disadvantage might be considered as an opportunity for the companies in China and Turkey, which are capable of supporting supply of high-quality casting parts, foundry machines, and materials. ■ You can visit the institute's web site to find out more about foundries and suppliers in Australia. www.australianfoundryinstitute.com.au.

材料市场供应情况。 库克先生说澳洲铸造设备和铸造原 辅材料都是经过欧美大品牌公司的当地代理商进口后在 市场销售。 另外还了解到2018年10月12-14日在昆士兰举办澳 大利亚国家铸造会议,库克先生诚挚邀请中国铸造协会 参加。 交流了澳洲铸造情况后,安伯士介绍了土耳其和中 国铸造行业的大概情况。并且告知青岛爱迪亚工程技 术,在土耳其经营的IDEAL MODEL公司在全球业务情 况,生产的产品和提供的服务介绍。邀请了库克先生和 其他澳洲铸造协会会员参观中国铸造协会举办的上海 和北京国际铸造展,以及每两年一次在土耳其举行的 ANKIROS/TURKCAST国际铸造展会。 会谈相当积极友好。虽然澳大利亚铸造市场不大,但 仍保留有比较稳定的,经营多年的知名铸造厂。澳大利 亚与世界其他地区的距离使澳大利亚铸造厂为全球市场 提供服务是不利的,但这种劣势推动了对铸造质量和创 新的严格要求,以便澳大利亚铸造厂可以在全球市场上 竞争。此外,对于中国和土耳其的公司来说,这一劣势 也可能被视为一种机遇,因为它们能够支持高质量的铸 件、铸造机械和材料的供应。。 关于澳洲铸造厂和供应商的详细信息可以在澳大利亚 铸造协会官网上了解。 ■ www.australianfoundryinstitute.com.au

KOCEL Group Won GE POWER 2017 Innovation Supplier of the Year Award 共享集团荣获GE POWER 2017年度创新供应商奖 On May 30, GE Power held a supplier conference in Shanghai. KOCEL Group was invited as the main supplier of GE Power to participate in the conference. General manager of KOCEL Equipment vice president Xu Guoqiang, deputy general manager of KOCEL Cast Steel Li Yongxin, and deputy general manager of customer success center Sun Baoqing, attended the meeting. During the conference, KOCEL Equipment was awarded the Innovation Award of the year 2017. KOCEL was highly recognized by GE with its achievements in technological innovation. Mr. Xu delivered a speech and shared experience. KOCEL pioneered the use of innovative technologies such as 3D printing and intelligent factories in foundry industry. In 2017, KOCEL used these innovative technologies to produce highly complex castings for GE, such as turbine blades, engine cylinder heads, cooler housings and exhaust manifolds. It not only saves mold and R&D costs for GE, but it also significantly shortens the lead time, which lay the foundation for KOCEL and GE for future cooperation in many fields. ■ 30

5月30日,GE Power 在上海召开供应商会议。共 享装备作为GE Power主要供应商受邀参加本次会议, 共享装备副总裁徐国强、共享铸钢副总经理李永新、 顾客成功中心副总经理孙宝庆出席此次会议。 此次供应商会议上,共享装备被授予2017年度“ 创新”奖。GE在会上高度肯定了共享在技术创新方面 取得的成就。徐总代表共享作演讲和获奖感言。Kocel 在铸造行业率先使用3D打印、智能化工厂等创新技 术,在2017年,使用该创新技术为GE生产了汽轮机叶 片、发动机缸头、冷却器壳体、排气歧管等高难度复 杂铸件,不仅为GE节省了模具费用和研发费用,同时 还大幅缩短了交货周期。这为共享与GE未来在多领域 合作奠定了基础。 ■

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


5 Steps to Identify Casting Defects A comprehensive checklist can help troubleshoot and eliminate certain issues. sudesh kannan, university of phoenix, co power llc (schaumburg, illinois); abhishek pathak,

cwc textron foundry (muskegon, michigan); tom cobett, t. cobett and associates (strongsville, ohio)

5步识别铸件缺陷 一份全面的检查清单可以帮助排除故障并消除某些问题。 Sudesh Kannan, Abhishek Pathak, Tom Cobett

T

he procedure of identifying, diagnosing and minimizing or eliminating crucial casting defects is important for a foundry to run in a low-cost, and high-efficiency mode. It can disprove incorrect conventional wisdom and show that unexpected methods are actually the best way to move forward. To do this, there are three keys to remember: 1. Focus on identifying a casting defect on the basis of its appearance. 2. Be aware of the interactive nature of foundry processes and variables. 3. Use rigorous experimental design methods to study complex causes of defects. Foundry personnel can be quick to label a defect cause based on a cursory examination. Terms such as slag defect and cold shut are part of the defect process. The International Casting Defect Atlas gives a specific code/category to defects based on appearance. It also suggests foundry personnel be aware that most casting defects are due to the interaction of several process variables rather than one factor, such as temperature or gating system design. This allows the foundry engineer to design experiments to capture the complexity of the defect cause. AFS Corporate Member CWC Textron Foundry (Muskegon, Michigan) used this process of casting defect categorization, identification, cause determination and defect reduction to address an issue with camshaft castings. The defects began occurring after an upgrade from manual pouring of molds to automatic pouring of molds. Auto pouring systems are considered to be safer reliable and efficient compared to manual systems. However, in the early tests comparing castings from manually poured molds to castings from automatically poured molds, the casting scrap rate was always significantly higher for the automatically poured molds. Other variables, such as pouring temperature and transfer time impacted the scrap rate. This gray and ductile iron foundry has been producing alloy and ductile camshafts for many decades. All molds are produced

件缺陷的识别、诊断、最小化或消除是铸 造企业在低成本、高效率模式下运行的重要 环节。

这个过程可以反证传统经验是不正确的,并且证明意

想不到的新方法才是解决问题的最佳方式。 为了达到目标,要记住3个要点: 1.重视根据外观识别铸造缺陷。 2.注意铸造工艺和变量的交互性。 3.使用严格的实验方法来研究铸件缺陷的复杂原因。 检验员可以在粗略检查的基础上快速标注缺陷原因。 要用夹渣和冷隔等术语标定缺陷。国际铸件缺陷图谱根 据外观制定了缺陷的特定代码/类别。这也表明铸造工 人应该意识到,大多数铸件缺陷是由多个工艺变量的相 互作用引起的,而不是温度或浇注系统设计等某一个因 素造成。这就允许铸造工程师设计出挖掘复杂的缺陷原 因的实验。美国铸造协会会员企业CWC Textron铸造 公司(密歇根州马斯基根)通过对铸造缺陷的分类、识 别、原因确定和减少缺陷的过程来解决凸轮轴铸件的缺 陷问题。 铸件缺陷从铸型由人工浇注升级到自动浇注后开始出 现。与人工浇注系统相比,自动浇注系统被认为是更安 全、更可靠和更高效的。 然而,在早期测试中,将人工浇注的铸件与自动浇 注的铸件进行比较,自动浇注的铸件废品率始终处于更 高水平。而其他变量,如浇注温度和取件时间会影响废 品率。 几十年来,这家铸铁厂一直生产合金和球墨铸铁凸轮 轴。所有铸型均采用高压、水平分型有箱线湿型砂工艺 生产。造型线上的砂箱通过传送带送到浇注区。

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

31


Fig 1. After analysis, defects were identified as dross and pinholes (see box region). Cold shut (misruns) were also found associated with these defects.

图1:经过分析,铸件缺陷 被确定为浮渣和针孔(见图 中框内区域)。还发现冷隔 (充型不足)与这些缺陷有 关。

Fig 2. After analysis, defects were identified pinholes (inset shows casting defect region). Cold shut (misruns) were also found associated with these defects.

图2:经过分析,铸件缺陷 确定为针孔(插图显示了铸 件缺陷区域)。还发现了冷 隔(充型不足)与这些缺陷 有关。

Fig 3. After analysis, defects were identified as dross and pinholes (see box region). Cold shut (misruns) were also found associated with these defects.

图3:经过分析,铸件缺陷 确定为浮渣和针孔(见框内 区域)。还发现了冷隔(充 型不足)与这些缺陷有关。

on a horizontally parted, high pressure, tight flask, green sand, automatic molding line. Flasks on this molding line move on a conveyor to the pouring area. Primary melting is done with a cupola. The base iron is held in a channel induction furnace. MgFeSi is added to a large tundish ladle as it is filled from the induction furnace. In manual pouring, the ladles were filled from the tundish ladle and inmold inoculation was used. The main sources of casting scrap are were simply listed as “dirt” or “slag.” Now, an automatic pouring system has replaced the manual pouring ladles. The equipment was acquired and installed to make mold pouring safer and more consistent from mold to mold. The automatic pouring system ladle holds significantly more iron than the manual pouring ladles. During the transition to automatic pouring, the manual pouring area was kept intact. Whenever molds were poured using the automatic pouring system, the camshaft castings exhibited a high frequency of cope-side inclusion defects. These defects were small, but deep enough to cause the castings to be scrapped. 32

采用冲天炉熔炼,铁液在有芯感应电炉中保温。然后 从感应电炉倒入大的中间包并加入了MgFeSi。在人工 浇注作业中,铁液从中间包倒入浇包,采用铸型内孕育 方式。铸件缺陷的主要原因被简单地归为“灰尘”或“ 夹渣”。 现在,自动浇注系统取代了人工浇注。为了使浇注更 安全、更稳定,采购和安装了设备。自动浇注系统的浇 包比人工浇注的浇包能够容纳更多的铁液。在从人工浇 注到自动浇注的过渡期间,人工浇注区仍保持作业。 每当使用自动浇注系统浇注时,凸轮轴出现夹杂物 缺陷的频率很高。这些缺陷很小,但足以使铸件成为废 品。 为了解决夹渣、针孔和浮渣缺陷,CWC Textron公 司采用了经过验证的分步方法。

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


Table 1. Key Factors and Variables Considered for Experimental Design 表1:实验设计的关键要素和变量 Factor Manual Ladle 要素 人工浇包 Iron Capacity 1,000 lbs 容量 Iron Temperature Control Range +/- 40F 铁液温度控制区间 Time in Ladle 2-3 minutes 浇包内的时间 Ladle Lining Type ProCast 80 浇包耐火材料类型 Slag Dam Refractory Type ProCast 80 挡渣口耐火材料类型 Spout Refractory BluRAM 60 浇口耐火材料 FeSi Inoculation Method In mold 铁硅孕育 型内 Metal Temperature Measurement Immersion probe 金属液温度测量方式 浸入式

Autopour Ladle 自动浇注浇包 3600 lbs +/- 100F 12-15 minutes (expected to be 7-8 minutes in auto transfer mode) ProCast 80 KRICON 70 PHLOCAST SiC 60 Powder in metal stream 金属液随流孕育 I-R pyrometer camera I-R高温摄像机

Key factors considered in this study were related to the time for metal transfer and insulation issues in the AP ladle, that lead to lower pouring temperatures 本研究中考虑的关键因素与自动浇注系统中的转运和保温的时间有关,这些因素导致浇注温度的降低。

To solve the slag, pinhole, and dross defects, CWC Textron worked through a proven step-by-step approach.

5个步骤

FIVE-STEP PROCESS

业,方法和工具可能会有所变化。

以下是每个步骤需遵循的细节。针对不同的铸造企

Details of each of the steps followed are shared below. There may be changes in the methods and tools specific to an individual foundry.

第1步:确定缺陷

Step 1 – Identify the Defect

然这是一种可接受的方法,但在检验完成后,根据国际

Foundry personnel have a tendency to identify a defect based on cause like slag defect or sand inclusions. While this is an acceptable method, after the diagnosis is done, the International Atlas of Casting Defects recommends that unknown defects be classified based on appearance rather than cause. Using the photos and descriptions given in the atlas, the foundry decided these defects appear to be G121 (inclusions) or B123 (pinholes) (Figures 2 and 3). The key advantage of this classification system is that foundries are allowed to have multiple labels for the defect and leaves it more open to investigate different causes for the defect. Detailed optical micrography confirmed the defects were dross and pinholes related to magnesium vapors. It is essential to verify the casting defects through such detailed analysis, prior to exploring cause and remediation steps. In addition to optical microscopy, SEM (scanning electron microscopy) along with spectroscopy was used.

铸件缺陷图谱的建议,即根据缺陷外观而不是原因对未

Step 2 – Experimental Design When the castings were poured with the manual ladles, the frequency of inclusion defects was very low. When the castings were poured with the automatic pouring system, the frequency of inclusion defects was very high. Also, it was observed that on a same day at the same time, under similar sets of green sand parameters, frequency of the inclusion defects was still higher with the automatic pouring system compared to manual pour. This would suggest that metal and

铸造工人倾向于根据夹渣或夹砂等原因识别缺陷。虽

知缺陷进行分类。根据图谱中的照片和描述,铸造厂判 断这些缺陷似乎属于G121(夹杂物缺陷)或B123(针 孔缺陷)(图2和图3)。 这种分类方法的优点主要是允许铸造厂选多个缺陷标 签,并且使调查不同的缺陷原因有更多空间。 详细的光学显微照片证实了这些缺陷是与镁蒸气有关 的浮渣和针孔。在调查原因和补救步骤之前,必须通过 详细的分析来验证铸件缺陷。除光学显微镜外,还可使 用SEM(扫描电子显微镜)和光谱分析仪。

第2步:实验设计 人工浇注铸件时,夹杂物缺陷的发生频率非常低。 当使用自动浇注系统时,夹杂物缺陷的发生频率却非常 高。此外,观察发现,在同一天的同一时间、湿砂参数 类似的情况下,与人工浇注相比,使用自动浇注系统的 夹杂物缺陷发生频率仍然更高。这表明金属液和型砂不 是缺陷产生的主要原因。因此,没有进行调整铁液成分 或改善砂型性能的试验。 然而,CWC公司专注于研究浇注温度、浇注时间和 工艺、镁的处理和孕育方法(在人工浇注中是块状,自

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

33


Table 2. Experimental Design for Initial Trials 表2:初步试验的实验设计 Trial No Trial Description 试验号 试验描述 Trial #1 Reduced mass gating with reduced choke area (1.33 sq in.), no frag bar and add 4 bismuth pills 试验1 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #2 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验2 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #3 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验3 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #4 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验4 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #5 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验5 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #6 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验6 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #7 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验7 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸 Trial #8 Reduced mass gating with reduced choke area (1.33 sq in.), no drag bar and add 4 bismuth pills 试验8 通过减小阻流截面(1.33平方英寸)降低浇道金属液流速,无拉杆、添加4个铋丸

Ladle 钢包 Regular ladle 常规浇包 Regular Ladle 常规浇包 Insulated Ladle 保温浇包 Insulated ladle 保温浇包 Insulated Ladle 保温浇包 Insulated ladle 保温浇包 Regular Ladle 常规浇包 Regular Ladle 常规浇包

Tap Temp Pour Cup 出炉温度 浇杯 2,750F D cup 2,750F

Offset

2,750F

Offset

2,750F

D cup

2,850F

Offset cup

2,850F

D cup

2,850F

D cup

2,850F

Offset cup

molding sand were not primary causes of defect. For this reason, no trials were run with modified base iron metallurgy or modified molding sand properties. Instead, CWC focused on studying the pouring temperature, pouring time and method, Mg-treatment and inoculation method (tablet in manual pour, in-stream in automatic pouring unit). Table 1 summarizes the key variables and factors considered. Detailed fractional factorial design experiments were designed based on well-known statistical methods. Most foundry casting defects are caused by interacting variables (for example, low pouring temperature + specific chemistry). Factorial design is a tool that allows experimentation on many factors simultaneously. In this case study, researchers ran 2 level factorial design with three factors requiring a total of eight runs. Three factors considered in the experiment were: ladle type (regular ladle and insulated ladle), temperature (lower pouring temperature and higher pouring temperature) and pour cup (D-shaped cup: conical cup with one side flatand offset-basin cup). Detailed factorial design/experimental design is provided in Table 2.

动浇注装置中是随流孕育)。表1概括了所需考虑的

Step 3 – Gating Design and Filtration Review

中为数不多的常数之一。由于这种浇注系统在人工浇

Often, foundry personnel jump to modifying the gating system when they observe slag/dross defects. While turbulence in the gating system may be an important factor, the gating system is one of the few constants in the multivariable production environment of the foundry. Since this gating system worked well in the manual pouring system, no major modifications were proposed. It was noticed that the cross-sectional area of the sprue base and runner was very large and the pouring time was controlled by manual pouring operation. It is strongly recommended that computer simulations of solidification and flow are conducted to review the performance of the gating system. Oxidation of iron and formation of inclusions will likely increase as the velocity of the metal increases. Slowing down the flow and keeping the 34

关键变量和因素。基于众所周知的统计方法设计了 详细的分数因子设计实验。大多数铸件缺陷是由相互 作用的变量引起的(例如,低浇注温度+特定化学成 分)。 因子设计是一种允许同时对许多因素进行实验的 工具。在本案例中,研究人员采用了2级因子设计方 法,其中有3个影响因素需要进行8次实验。实验中 需考虑的3个因素是:浇包类型(常规浇包和隔热浇 包)、温度(较低的浇注温度和较高的浇注温度)和 浇杯(D形杯:一侧扁平的锥形杯,以及曲线盆杯) 。表2中提供了详细的因子设计/实验设计信息。

第3步:浇道设计和过滤检查 通常,铸造人员在发现夹渣/浮渣缺陷时,会仓促 进行浇注系统的调整。虽然浇注系统中的紊流可能是 一个重要因素,但浇注系统是铸造厂多变量生产环境 注中运行良好,因此铸造厂未提出任何大的改进。 在实验中,还注意到浇道底座和浇道的横截面积非常 大,浇注时间由人工浇注的操作来控制;而且强烈建 议进行凝固和流动的计算机模拟,以检查浇注系统的 性能。随着金属液的流动速度加快,铁的氧化和夹杂 物的形成可能会增加。减慢流速并保持浇注系统充满 状态可能会减少铸件表面的夹杂物。 过滤片应被视为“保险”措施,而不是为了去除外 部炉渣和浮渣。低效的除渣操作会导致过滤器堵塞, 从而很快导致滞流和浇注减慢。过滤片通常被认为

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


gating system full may show a reduction in surface inclusions. Filters should be considered an “insurance” policy rather than the main function of keeping external slag and dross away. Inefficient dross removal practice can lead to filter blockages, quickly leading to misruns and slow pours. Filters are often considered “flow modifiers” as significant dross in castings are related to turbulence in the runner and ingate system. There are two aspects of filter sizing: the primary sizing is related to ensuring that the filter does not act as the choke. The standard rule of thumb is the cross-sectional area of the filter should be at least 4-6 times that of the choke. The secondary sizing requirement is related to filter capacity, or the volume of ductile iron that can be passed through the filter prior to blockage. Typically, this capacity is around 20-40 lb./square inch of filter. Filter pore size can be classified as fine, medium and large. In most applications, medium or large openings are preferred. The filter supplier can provide appropriate sizing sheets for particular castings and filter types. In the case of this project, the filter was considered adequate for the specific application. Excellent guidelines are available for sizing and placing filters in gating system.

Step 4 – Preliminary Trials It is important that trials be conducted with just a handful of variables. Proper experimental designs are required to ensure interaction effects are captured (effect of pouring time, temperature and chemistry together, for example). Pours were grouped by heat, and at least 10-20 molds were poured per heat. It is important to measure and document all variables related to the casting.

Step 5 – Production Trials Production trial volumes and details are important in a quality assurance program. Production trials for automotive applications typically require thousands of castings. Some foundries might review data for a whole shift or for several heats to ensure repeatability and reliability of quality. Data tracking includes pouring temperatures, pouring times, microstructure, chemistry, lab tests related to mechanical properties, and other information. During the preliminary and production trials, the pouring was done automatically but the metal transfer was manual (by forklift) and, therefore, took more time, resulting in a higher than normal temperature loss. Following the five-step process, key recommendations to reduce the defect included: • Increase the pouring temperatures. • Control pouring temperatures (by improving ladle insulation). • Reduce magnesium additions. • Increase the bismuth addition after MgFeSi treatment. • Improve the automatic pouring ability to pour in the center of the cup. • Reduce velocity and turbulence of the metal in the mold. Operate the automatic pouring system with fully automatic ladle filling. ■

是“流动改良器”,因为铸件中的夹渣主要与浇道 和浇口系统中的紊流有关。 确定过滤片的尺寸有两方面因素:首先,尺寸与 确保过滤片阻流截面不堵塞有关。标准的经验做法 是过滤片的横截面积应至少是阻流截面的4-6倍。 其次,尺寸的要求与过滤金属液的能力、或在堵 塞之前通过过滤片的球墨铸铁铁液的容量有关。通 常情况下,过滤片的金属过滤能力约为20-40磅/平 方英寸。 过滤片孔径可分为细孔、中孔和大孔。在大多数 应用中,优选中型或大型孔径。过滤片供应商可以 为特定的铸件和过滤类型提供合适的尺寸对照表。 在本实验项目中,过滤片足以满足特别应用,在 浇注系统中确定过滤片的尺寸和放置过滤片都有非 常好的指导。

第4步:初步试验 重要的是,只需很少的变量就可以进行试验。还 需要有适当的实验设计以确保获得相互作用效果( 例如,浇注时间、温度和化学作用的综合效果)。 浇注按炉次分组、每个炉次至少浇铸10-20个铸型。 测量和记录与铸件相关的所有变量非常重要。

第5步:生产试验 生产试验的数量和细节在质量保证计划中非常 重要。汽车领域的生产试验通常需要生产数千个铸 件。一些铸造厂可能要检查整个班次或多个炉次的 数据,以确保质量的可重复性和可靠性。数据跟 踪包括浇注温度、浇注时间、微观结构、化学反 应过程、与力学性能相关的实验室检测结果及其他 信息。 在初步和生产试验期间,采用自动浇注,但是金 属液的运送采用了人工方式(通过叉车),因此花 费了更多时间,导致温度的损失高于正常水平。5个 步骤分析之后,得出下列减少铸件缺陷的方法: •提高浇注温度。 •控制浇注温度(提高浇包隔热性能)。 •减少镁的添加量。 •球化处理后增加铋的添加量。 •提高自动浇注能力,倒入浇口中心。 •降低铸型中金属液的流速,减少紊流。 •使用全自动浇包充型操作方式的自动浇注系统。■

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

35


Solving the Problems in Your Foundry A systematic approach to identifying problems and achieving solutions can help metalcasters meet customer expectations and avoid unnecessary costs of quality. a modern casting staff and afs institute report

解决铸造企业的难题 采用识别和解决问题的系统方法,可以帮助铸造企业满足客户期望,并且避免不 必要的质量成本。 美国铸造协会研究院、Modern Casting报道

P

roblem-solving in life and in business can seem like a complex and intimidating effort causing many to fall back to a hands-off approach. But problems must be solved in a metalcasting operation or they eventually lead to additional costs to your business and loss of profitability. Using structured problem solving, metalcasters take a systematic approach to identifying problems and finding a solution that addresses the problem’s root cause. This general strategy includes a focus on process metrics and customer needs. Structured problem solving includes defining, describing and establishing possible causes; testing the most probable cause; verifying the true cause; and implementing well-tested countermeasures. When integrated with existing records, such as shop floor incident reports, scrap reports, and customer feedback, quality

Fig. 1. The total cost of quality is more than the visible costs of rework, inspection and warranty payments. Hidden costs, like lost customer loyalty, are less obvious but can have a high penalty.

36

理生活和商业活动中的难题似乎是一项复杂 且令人生畏的工作,使很多人放纵不管。但 是,铸造生产中的问题必须解决,否则,它

们最终会导致业务产生额外成本、盈利能力下降。 通过结构化解决方案,铸造企业采用系统方法来确定 问题并找到解决问题根本原因的方法。这样的总体战略 包括关注流程指标和客户需求。 结构化问题解决方案包括:定义、描述和确定可能的 原因、试验最可能的原因、验证真正的原因并实施经过 充分验证的对策。 当与现有记录(例如车间事故报告、报废报告和客 户反馈)综合考虑时,质保人员可以利用适当的提问技 能、关键和创造性的思维技能、知识捕获技能和诊断技

图1:质量的总成本 高于返工、检查和保 修费用的可见成本。 隐藏成本是不太明显 的,例如失去客户忠 诚度,但可能会受到 高额的罚款。

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


Table 1. Sample Problem Definitions 表1:示例问题定义 Typical 一般定义 Our plant has been seeing a big increase in porosity rejects lately. 我们工厂的孔隙率废品铸件最近大幅增加。 A customer complained about our cast housings breaking in the field. 一位客户抱怨,我们铸造的壳体在现场破裂。 A malfunction in our heat treat furnace is causing finished parts to be out of spec. 我们的热处理炉故障导致成品零件超出了规格要求。 Table 2. Key Points in Corrective Action Flow 表2:纠正措施流程要点 Key points: 要点 Communication strategy starts at the top: 从沟通策略开始 Work from paper and electronic records 从书面和电子文件记录着手 Confirm facts 确认信息 Determine requirements 决定需求 Centralize monitoring in QA 质保的集中监控 Pass down good information 传递积极信息 Isolate and contain: 隔离和控制

Better 改进后 Starting in February, porosity rejects for the R40 rotor increased to 5.4% from the normal 0.6%, increasing annual costs by $230,000. 从2月份起,孔隙率废品铸件R40转子从平时的0.6%上升到5.4%,成本每年增 加23万美元。 In the last month, we’ve had 4 complaints of the 12” JK95 fracturing at the connecting flange during installation; there were no prior occurrences. 在上一个月里,在安装过程中对连接法兰上出现的12” JK95破裂事件遭遇了 4次投诉;以前没有发生过类似事件。 On June 20, in-process tests showed the average hardness of our steel castings to be Rc36, below the specified range of Rc 40 – 43. 6月20日,在线测试显示,铸钢件的平均硬度为Rc36,低于指定的Rc 40-43。

Key points: 要点 Identify and define the problem: 确定和定义问题 Examine the actual product defect where possible 尽可能检测真正的产品缺陷 Verify proper defect identification 确认缺陷特征 Confirm understanding of corrective action requirements and timing 确认对于纠正措施需求和时间的理解

Gather and analyze data: 收集和分析数据

Limit the damage and isolate the customer from the problem 减小损坏并使客户与问题隔离

Collect information about the problem based on C & E diagrams or other root cause techniques 根据C&E图表或其他根本原因查找技术收集有关信息

Quit sending defective parts 停止交付有缺陷的部件

Test assumptions 测试假设 Rule out contributors 排除诱因 Evaluate relationships 评估相互关系 Confirm the chain of cause and effect until systematic, root cause is identified 系统地找到根本原因后,再确认因果关系 Monitor and document change: 监控和变更记录 Check effectiveness and adjust (act) where necessary to ensure the problem goes away. 检查有效性并在必要时调整措施、以确保问题消失。 Use in-house documents to help manage the process 使用内部文档来帮助管理流程

Reduce or eliminate: 减少或消除 Identify a countermeasure that addresses the root cause 确定解决根本原因的对策 Implement the countermeasure(s) across all applicable lines, stations, mold, etc. 在所有适用的生产线、工位、模具等实施对策。 Anticipate cultural resistance to change 预见文化因素对变革的抵制 Communicate and train 沟通和培训

Don’t make changes that are not documented and reviewed by all affected parties 未经所有受影响方的记录和审核,不要进行更改

assurance personnel can leverage proper questioning skills, critical and creative thinking skills, knowledge capturing skills, and diagnostic skills to solve incidents and problems efficiently and accurately. Structured problem solving is effective because it provides focus in problem definition and consistency of direction in

能来有效准确地解决事故和问题。 结构化问题解决方案是有效的,原因是它关注问题的 定义和调查问题方向的一致性。它协调数据的收集和分 析、促进团队成员与管理层及客户之间的沟通,并促进

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

37


investigating the problem. It coordinates collection and analysis of data, facilitates communication between team members, management, and the customer, and promotes countermeasures that address the root cause and not its symptoms.

Costs of Quality Quality is conforming to requirements at a cost the customer perceives as value. Four types of costs go into the total cost of quality: prevention costs, appraisal costs, internal failure costs, and external failure costs. Prevention costs includes activities specifically designed to prevent poor quality, such as quality planning, internal system audits, training and supplier quality work. Appraisal costs are associated with measuring, evaluating, auditing products to ensure conformance to quality standards. Internal and external failure costs result from products not conforming to customer requirements, either occurring prior to or after shipment to the customer. Most costs, especially those associated with external failures, are not obvious and can be difficult to quantify, such as lost customer loyalty, increased inventory, expediting costs, and late deliveries (Figure 1). Problems cost more the further they occur from the process where they were made. This is because added

Fig. 2. A good corrective action flow will start with problem communication and move through a loop of defining the problem, isolating and containment, data analysis, problem reduction, monitoring and further communication.

38

解决问题的根本原因而不是其表面现象。

质量成本 质量需要满足客户认同的价值成本。质量成本包 含四种类型:预防成本、评估成本、内部故障成本 和外部故障成本。 预防成本包括专门用于防止质量不合格采取的行 动,例如质量计划、内部系统审核、培训和供应商 质量评估工作。评估成本与测量、评估和审核产品 相关,以确保产品符合质量标准。内部和外部故障 成本来自不符合客户要求的产品,无论是在给客户 发货之前还是之后。 大多数成本并不明显且难以量化,尤其是与外部 故障相关的成本,例如客户忠诚度下降、库存增加、 成本快速增加和交付延迟(图1)。 如果问题发生在生产过程中,那么成本会更高。 这是因为随着对产品加工处理的深入,其附加值增 加。客户可能受到直接影响,且客户受到的影响是 供应商的责任。与之相关的成本,例如运输、设备 赔偿金或劳动力成本也会增加。

图2:良好的纠正措施流 程将从问题的沟通开始, 形成定义问题、隔离和控 制、数据分析、减少问 题、监控和进一步沟通的 循环。

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


value increases as more processing has been done on the product. The customer may be directly affected, and customer impacts are the responsibility of the supplier. Attendant costs, such as shipping, damage to equipment the casting was in, or labor costs, go up, as well. Short-term corrective actions or poor solutions can sometimes add costs greater than the problem itself. Like a band-aid on a bad cut, it only lasts so long before the wound becomes worse and you have to pay for professional care. Poor quality always has some cost. At a minimum, some level of prevention and appraisal is necessary, but those costs will be far less than failure. The minimum cost is a significant dose of prevention, some appraisal costs and a minimal amount of internal failure. The implementation of preventive measures to control quality often takes a great deal of time and process knowledge. Appraisal measures are initially undertaken that cause internal failures to increase but external failures to decrease. Quality maturity sees prevention costs increase and failure costs decrease. As problems are identified closer to the source of failure, fewer variables are at play, cause-and-effect relationships are better understood, and costs associated with correcting these failures decreases. Prevention activities, especially quality planning, auditing, error proofing, and training, can yield a 10 to 1 return on investment according to the American Society for Quality’s Quality Cost Committee.

然而,短期纠正措施或不良的解决方案有时会增加 成本,超过问题本身的成本。就像伤口上的创可贴一 样,经过很长时间它才会使伤口加重,但是你需要支 付额外的专业护理费用。 质量不好总是有代价的。因此,至少需要给予一定 的预防和评估,但这些成本远低于失败。 最低成本包含重要的预防、评估和最小的内部故障 成本。保证质量的预防措施往往需要大量的时间和工 艺知识。最先采取的评估措施会导致内部故障增加但 外部故障减少。 质量成熟可以提高预防成本、降低故障成本。由 于问题越接近故障源,可以使变量更少、更好地理解 因果关系,而且,与纠正这些故障相关的成本也会减 少。 据美国质量协会质量成本委员会表示,预防策略, 特别是质量计划、审计、错误预防和培训,可以产生 10比1的投资回报。

纠正措施 良好的纠正措施流程将从问题沟通开始,然后是 识别和定义问题(图2)。一旦出现问题,负责解决 问题的人需要编写清晰有效的问题定义,从而做出需 要改进问题的详细说明,其中包含主要指标;如果需

Corrective Action

要,还可以通过第二个指标来说明问题的严重程度(

A good corrective action flow will start with problem communication and move to identifying and defining the problem (Figure 2). Once a problem arises, the personnel charged with solving it needs to write a clear and effective problem definition that details the issue the team wants to improve. It gives the primary metric, and if needed, a second metric, outlines the magnitude of the problem (usually with a financial impact) and sets the time frame. The problem definition should include a detailed, narrative description, be neutral to avoid jumping to solutions, and include a reference to a baseline measure. Table 1 lists sample problem definitions. Every metalcasting facility has its own way of dealing with quality issues. Smaller facilities might only have a coordinator rather than a formal problemsolving team. But the coordinator and/or the team should involve quality assurance personnel for technical problem solving help, engineering/supervision for process help and implementation, maintenance for practical solutions, and operators for shop knowledge. After defining the problem, the coordinator should move the team through isolation and containment, data collection and analysis, problem elimination or

通常包含财务影响)并设置时间范围。问题定义应包 括详细的叙述性描述、保持中立态度以避免仓促做出 解决方案的决定,还应包含基本解决方案的参考。表 1列出了示例问题的定义。 每个铸造企业都有自己处理质量问题的方法。小企 业可能只有协调员而不是正式的解决问题的团队。但 是协调员和/或团队应该让质保人员帮忙解决技术问 题、让工程和监督人员参与工艺过程和实施、让保障 人员参与实际解决方案的确定,并让操作员讲解车间 知识。 在定义问题之后,协调员应该通过隔离和控制、数 据收集和分析、问题消除或减少、监控和记录,以及 结果沟通来推动团队的合作。有关每个步骤的信息, 请参阅表2中的说明。 为了帮助识别、定义问题以及信息收集,可以使用 简单的表格与客户进行沟通。故障报告是“倾听”客 户投诉的一种方式。它可能无法提供您需要的所有信

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

39


reduction, monitoring and documentation, and communication of the results of action. See the chart in Table 2 for information on each step. To help in the problem identification, definition and information collecting process, simple forms can be used to communicate with the customer. A trouble report is a means of “listening” to a customer’s complaint. It may not give all the information you need, but the report can ask some simple questions to help you understand the problem and the customer describe the problem in meaningful terms. Sample questions can ask for specific descriptions of the problem, conditions under which it occurred, and the quantity affected. The form can also include information about customer expectations for correcting the problem. Another useful form is a corrective action request for internal follow-up by quality, engineering, maintenance and operations personnel. These departments document what short-term actions they have taken to document and stop the problem from recurring, and give directions to others about the next steps required. This document also asks the problem be categorized so any further action, such as long-term measures or a root cause analysis, can be taken. Quality alerts are documents issued to communicate the necessary short-term actions required by employees. It identifies the problem and shows key facts and should be posted where employees can access the information. Short-term and long-term measures can be used to solve a problem. Short-term actions may include: • Containment • Quarantine of suspect parts. • Go/no-go gauges. • Extra sampling and testing. • Extra inspection, including lot control for scrap or rework. • Training. • Establishing acceptable (temporary) rework or salvage procedures, if possible. A critical element in short-term action is communication with the customer so they know they are protected. Customers are key stakeholders, and they hate being in the dark when there’s an issue, whether quality or delivery. It’s important to make the distinction between acute and chronic problems. Chronic problems exist when performance is below standard but relatively stable over a long period of time. It is often related to the basic capability of the process, and fixing it requires fundamental process improvement. An example of a chronic problem is overall equipment efficiency of 65% over the past two years, which is below a target of 75%. An acute problem exists when performance worsens significantly from the normal level. This can be over a very short period of time or be sporadic and is 40

息,但可以提出一些简单的问题来帮助您理解问题、 客户也可以用易于理解的词来描述问题。示例问题包 含问题的具体描述、发生的条件以及受影响的数量。 表格还可以包括客户对纠正问题的期望的相关信息。 另一个有用的表格是纠正措施需求表,便于质量、 工程、维护和操作人员的内部跟进。表格记录了他们 采取哪些短期行动来记录并阻止问题再次发生,并向 其他人提供有关所需后续步骤的指示。该文件还要求 对问题进行分类,以便可以针对长期措施或根本原因 的分析开展进一步行动。 质量预警是为了员工沟通所需采取的必要短期措施 的记录文件。它可以识别问题并显示关键信息,应发 布在员工易于获取信息的地方。 短期和长期措施都可以用来解决问题。短期措施 包含: • 遏制

• 隔离可疑部件

• 通过/不通过量规 • 样本分析和测试

• 额外的检测,包括废品的分批控制或返工 • 培训

• 如果可能的话,建立合理的(临时的)返工或抢修 作业机制。

短期措施的关键因素是与客户的沟通,让他们知道 自己的权益将受到保护。客户是关键的利益相关者, 在出现质量或交付方面的问题时,他们不愿意一无所 知。 区分问题的轻重缓急非常重要。当产品性能低于标 准但长期相对稳定时,这种问题属于长期慢性问题。 这通常与基本的生产能力有关,纠正措施即改进根本 的生产工艺。长期慢性问题的一个例子是,整体设备 效率在过去两年为65%,低于75%的目标。 当产品质量比正常水平显著下降时,这种情况属 于紧急严重问题。这可能是在很短的时间内或是偶尔 发生,并且通常与生产过程中的一些无记录的偏差有 关。紧急问题的一个例子是,经过5年的零故障后, 却在最后3个月发生了3次现场故障。 如果根本原因是系统问题,完全应用像六西格玛这 样的程序可能不适合紧急问题的处理。如果系统层面 存在缺陷,那么,除了对管理层面做出改变外,不一

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


often related to some undocumented deviation in the process. An example of an acute problem is three field failures in the last three months after five years with zero failures. The full application of a program like Six Sigma is probably not appropriate for acute problems even when the root cause is a system issue. If there is a flaw at the system level, it doesn’t necessarily involve a fundamental change to the process except at a management level. While short-term measures only address the immediate problem, to keep customers happy, sometimes these measures are necessary to do what’s right for them and to meet contractual obligations. If short-term measures are required repetitively, however, you haven’t addressed the root cause or “real problem.” Long-term countermeasures are not necessarily complex or facility-wide, but they permanently alter the system of doing things. They address the root cause. Typically, long-term measures will involve a documented alteration of the process. • Tips for success in long-term measures include: • Take control of the problem-solving process and get management’s buy-in. • Have a standard response format in place for external customer complaints. • Get started on the corrective action as soon as you have a reasonable idea of the problem. Don’t wait for perfect information. • Too frequent corrective action cycling overwhelms management systems. Don’t issue unneeded CAR’s. • Tailor your effort to the true impact of the problem. • Don’t leave problem solving to the quality department. Practical input from the plant floor, supported by data, is essential in developing effective countermeasures. • During the problem-solving process, have a communication plan to keep team members, customers, and management informed: • Appropriate information and level of detail (edit carefully!) • Preferred medium (e.g. emails, phone calls, meetings, one-on-ones, reports) for each stakeholder. • Appropriate frequency of communication. • Be pro-active! Ask stakeholders how they want to be kept in the loop. • After a problem is solved, ask, “What have we learned?” Correlating data and positive customer feedback and positive feedback from those internally working to solve the problem will be indicators your corrective action measures are working. ■

定需要生产工艺的根本性改变。 虽然短期措施只能解决当前的问题,为了让客户 满意,这些措施有时对于他们采取正确的行动和履 行合同义务也是必要的。但是,如果需要重复采取 短期措施,说明根本原因或“真正的问题”没有得 到解决。 长期措施不一定是复杂的或针对全厂范围的,但 它们解决了根本问题,因此可以产生永久地改变。 通常,长期措施包括对生产工艺记录的变更。 采取长期措施的成功秘诀: • 控制解决问题的过程并获得管理层的支持。 • 针对外部客户投诉制定标准响应模式。

• 一旦有了合理的解决方案,请立即采取纠正措 施。不要等到信息完善。

• 太频繁的纠正措施将使管理系统不堪重负。不要 发布不必要的纠正措施需求表。

• 根据问题的真正影响调整方案。

• 不要将问题留给质量部门。在数据的支持下,工 厂的实际投入对于制定有效的对策至关重要。

• 在解决问题的过程中制定沟通计划,让团队成 员、客户和管理层了解情况。

• 适当的信息和详细程度(请认真编辑!)

• 每个利益相关方的首选沟通方式(例如电子邮 件、电话、会议、一对一或报告)。

• 适当的沟通频率。

• 积极主动!询问利益相关者希望如何更好地沟 通。

• 在一个问题得到解决后,请进行总结。

关联数据、积极的客户反馈以及与解决问题有关

的内部工作的积极反馈,将成为纠正措施正在发挥 作用的指标。 ■ 本文是美国铸造协会研究院课程“铸造工艺改进”的一 小部分。

This article is based on a small portion of the AFS Institute classroom course, Foundry Process Improvement. September 2018 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

41


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

Better breaker maintenance leads to increased uptime 更好维护可延长破碎机使用时间

43

Robotics make difficult casting sustainable 机器人使复杂铸件的生产具有可持续性

45

Improved Casting Machine Design Promotes Better, Lighter Cast Parts 48 改进设计,生产更好、更轻的铸件

Ceramic media improves casting quality, reduces production time 提高铸件质量、缩短生产时间的陶粒砂

Conditioner improves performance and quality of nodularization process 49 改善球化效果和质量的球化剂 Conmet-Xin Witness FMF Speed Again 康迈信再次见证国机铸锻新速度

42

50

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

46


product news/产品新闻

Better breaker maintenance leads to increased uptime 更好维护可延长破碎机使用时间 The hydraulic breaker attachment, one of the most common attachments for a remote-controlled demolition machine, generates as much as 1,500 ft.-lbs. of force at its tip. Typical wear and tear is expected, which is why keeping up on breaker maintenance is vital to ensure optimum performance on the jobsite. “Operators often overlook breakers, so they might not receive the proper time and attention they deserve in a maintenance regimen,” said Keith Becker, managing member of Becker Equipment Company LLC. “To get the most out of their investment, operators should consider the breaker as another piece of equipment with its own service schedule rather than a simple attachment, such as a bucket scoop. While the breaker requires the machine’s hydraulic system to provide the pressure to run, it is just as important as the machine itself and requires regular servicing.”

A Brokk machine breaks refractory. Solid maintenance of breakers can lead to many advantages.

液压破碎锤头是遥控拆卸机最常见的附件之一,可在 顶端产生高达1500 ft.-lbs的力。磨损是最常见的,这 就是为什么破碎锤头的维护对确保其在使用时发挥最佳 性能至关重要。 贝克尔设备公司管理者凯斯•贝克尔说:“操作员经常 会忽视破碎锤头,因此,它们可能无法在维护方案中分到 应有的时间和重视。为了最大限度地利用投资,操作者应 该把破碎锤头看作是有单独维护计划的设备,而不是简单 的附件,比如铲斗。虽然破碎锤头需要液压系统提供运行 压力,但它与机器本身一样重要,需要定期维修。”

第一步:选择正确的润滑膏 并非所有的润滑膏都是一样的。我们需要寻找可以承

Brokk设备破碎耐火材料。增强对破碎锤的维护具有很多优势。

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

43


product news/产品新闻 Step One: Choose the Right Grease

受232°C的锤头润滑膏。请记住,如果润滑膏在工具上

Not all grease is the same. Look for a chisel paste that can withstand temperatures as high as 450F. Keep in mind, if grease is running down the tool, it’s most likely not correct. Proper greasing minimizes metal-on-metal contact to prevent the tool from overheating, which can prematurely wear tool steel, damage bushings and ruin hydraulic seals. Using standard grease may save you nickels and dimes now, but could eventually cost you time and money by requiring more frequent greasing. And if the tool steel isn’t properly lubricated, you’ll see added costs in tool steel replacements. Some companies offer a durable, molybdenum-based chisel paste. This paste contains small copper and graphite particles that roll up like ball bearings between the tool steel and working bushing. The paste is also more viscous than standard lubricants, which allows it to remain between the steel and bushings and provide better lubrication for longer periods than using grease alone.

流动,那么很可能是不对的。适当的润滑可最大限度地 减少金属与金属的接触,防止工具过热,避免过早的磨 损工具钢、损坏衬套和破坏液压密封。 使用标准润滑膏可以为您节省一点成本,但最终可能 需要更频繁地进行润滑,从而花费更多的时间和金钱。 如果工具钢没有得到适当的润滑,你会发现工具钢更换 的成本会增加。 一些公司提供耐用的钼基锤头润滑膏。这种粘合材料 含有小的铜和石墨颗粒,它们像工具钢和衬套之间的滚 珠轴承一样卷起。润滑膏也比标准润滑剂更具有粘性, 使其能够保持在工具钢和衬套之间,并且比单独使用润 滑脂的润滑时间更长。

Step Two: Lubricate Appropriately

第二步:适当润滑

Once you have the right grease, be sure you are using it correctly. Greasing before and during operation also is part of proper breaker maintenance that reduces equipment wear. To lubricate a breaker, apply pressure on the tool steel to verify that it is pushed all the way into the breaker. Inject grease into the breaker’s lubrication points using a grease gun, until it exits the bottom of the breaker. This ensures the void between the bushings and the tool steel is filled and new grease displaces any remaining grease that might contain dust or debris. Some manufacturers recommend adding grease every two hours when a breaker requires manual greasing or if the operator sees shiny slivers of metal on the tool steel. Some breakers have automatic lubrication systems that keep tool steel properly lubricated, but those systems still need daily inspections to ensure there is adequate grease in their vessels.

一旦找到了合适的润滑膏,需正确使用。在运行前和 运行期间进行润滑也是破碎锤正确维护的一部分,可减 少设备磨损。要润滑破碎锤,请在工具钢上施加压力, 以确保它被完全推入破碎锤。使用注油枪将润滑膏注入 破碎锤的润滑点,直至其离开破碎锤底部。这样可以确 保衬套和工具钢之间的空隙被填满,新的润滑膏可以替 换任何可能含有灰尘或碎屑的残留润滑膏。一些制造商 建议,当破碎锤需要手动润滑或操作员看到工具钢上出 现磨损的金属裂片时,则需每两小时添加一次润滑膏。 一些破碎锤具有自动润滑系统,可以保持工具钢的正 确润滑,但这些系统仍需每日检查,确保容器中有足够 的润滑膏。

Step Three: Check the Bushing

第三步:检查衬套

Even with the best lubrication, replacing the wear bushings is inevitable. Measuring the wear of your bushing is essential to maintaining a reliable breaker, and you don’t always need to take apart your machine to do so. Instead, use a 3/16-inch drill bit and try to slide it between the tool and bushing. Typically, about 1/4 inch of space is the wear limit for a bushing. A good way to estimate is if the drill bit fits between the tool and the bushing it may need replacing. However, having a mechanic evaluate the bushing is the most accurate way of assessing wear bushings.

即使使用最好的润滑膏,也不可避免地需要更换磨损 的衬套。检测衬套的磨损程度对于破碎锤的可靠维护至 关重要,而且,并不总是需要拆开机器进行检修。只需 使用3/16英寸的钻头并尽量在工具钢和衬套之间滑动。 通常,约1/4英寸的空间是衬套的磨损极限。估算磨 损的好方法是看钻头是否适合安装在工具钢和衬套之 间,否则,它就可能需要更换。当然,让机修工来检查 是评估衬套磨损的最准确方法。

Step Four: Monitor Nitrogen Levels

第四步:监测氮水平

Many breakers feature nitrogen gas in the back-head as a cushion and for increased power. This minimizes the power demand on the carrier’s hydraulic system and ensures consistent, high-impact energy. It’s important to maintain and fill the nitrogen reservoir as needed for consistent power output. Be sure to conduct a visual inspection of the breaker before every use, and a thorough examination weekly to ensure everything is working properly —this results in increased uptime and extended breaker life. ■

许多破碎锤在后端配备氮气作为缓冲并提高功率。这 最大限度地减少了对运输设备液压系统的动力需求,并 确保一致的高冲击能量。为保证稳定的功率输出,按需 保持和填充氮气储备是非常重要的。 务必在每次使用前对破碎锤进行目视检查,每周进行 一次彻底检查,以确保一切运行正常,从而延长设备的 正常运行时间并延长破碎锤的使用寿命。 ■

Visit www.brokkinc.com for more information.

44

更多信息,请访问www.brokkinc.com

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


product news/产品新闻

Ceramic media improves casting quality, reduces production time 提高铸件质量、缩短生产时间的陶粒砂 Eagle Foundry (Eagle Creek, Oregon) is a jobbing foundry that produces over 13,000 different parts. Using a sodium silicate nobake process, Eagle pours high-chrome white iron, chrome moly, heat-resistant stainless steel, tool steel, manganese and low alloy steels at temperatures ranging from 2,550-3,000F in castings up to 2,000 lbs. The foundry operation needed to achieve compliance with OSHA silica dust permissible exposure limits (PEL) without compromising product quality, process efficiency or economic performance. Eagle replaced its entire silica sand system with Carbo Ceramics’ Accucast ID (intermediate density) 70 ceramic casting media. The Accucast ceramic casting media is a manufactured product that is chemically inert and compatible with the various resin systems. It is engineered to provide increased thermal stability and pellet strength for greater casting quality and precision, increased media recycle life, and reduced media consumption. Extensive testing has proven that Accucast ceramic casting media produces no respirable silica dust, so it complies with OSHA’s PEL regulation. After several product cycles to optimize operations for the new casting media, Eagle reported improved casting surface finish, with castings meeting dimensional tolerance targets. The foundry experienced reduced resin requirements and eliminated the requirement for additional mold reinforcement and the use of a mold and core wash. Cleaning times were reduced, in one instance from 50 minutes with sand to 10 minutes with Accucast.

The Accucast ceramic casting media, used by Eagle Foundry, is a manufactured product that is chemically inert and compatible with the various resin systems.

Eagle铸造厂(俄勒冈州Eagle Creek)是一家单件 小批量铸件工厂,可生产超过13,000种不同的零部件。 采用水玻璃自硬砂工艺,Eagle公司生产高铬白口铁、 铬钼合金、耐热不锈钢、工具钢、锰和低合金钢铸件, 浇注温度为1400-1650℃ ,最大铸件重量约907Kg。 在不影响产品质量、工艺效率或经济性的同时,铸造厂 还需达到OSHA(职业安全和健康署)对于SiO粉尘允 许排放限值(PEL)的要求。 Eagle公司用Carbo Ceramics公司的Accucast ID( 中密度)70的陶粒砂替换了整个硅砂系统。Accucast 陶粒砂是一种化学惰性且与各种树脂系统兼容的产品。 经过精心设计,它具有更好的热稳定性和颗粒强度,从 而提高铸件质量和尺寸精度,延长型砂循环使用寿命, 减少型砂的消耗。 大量的测试证明,Accucast陶粒砂不会产生可吸入 的SiO2粉尘,符合职业安全和健康署对于SiO粉尘允许 排放限值要求。 更换新的陶粒砂系统后,经过几轮优化生产作 业,Eagle公司已改进了铸件的表面光洁度、并且铸件 符合尺寸公差要求。 在铸造过程中,树脂加入量降低,并且取消了额外 的铸型加固、铸型和芯子刷涂料的需求。与使用硅砂相 比,有一款铸件使用Accucast陶粒砂所需的清理时间从 50分钟减少到10分钟。 取消铸型和芯子刷涂料,以及铸型加固这两个工序,

Eagle铸造厂使用的 Accucast陶粒砂是一 种惰性且与各种树脂 系统兼容的产品。

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

45


product news/产品新闻 Core and mold wash and physical mold packing were eliminated, cutting full shift man hours for both processes, plus wash drying time. Chemical costs were reduced by around $110,000 per year, and resin requirements were reduced from 3.75-5.0% with silica sand to 2.5-2.75% with Accucast. Surface cleaning time was reduced by 87.5%, and this eliminated overtime on grinding and welding, which reduced the wear on grinding wheels and piping. Media reclamation was significantly improved. Overall media consumption was reduced, which also resulted in reduced disposal volumes and replacement costs. ■

也减少了两个工序的全部工时和涂料的干燥时间。化工 原材料的成本每年减少约11万美元,对于树脂的加入 量,也从使用硅砂的3.75-5.0%降低到使用Accucast陶 粒砂的2.5-2.75%。 表面清理时间减少了87.5%,这就避免了因磨削和焊 接而导致的延迟交货的情况,从而减轻了砂轮和管道的 磨损。型砂的回用率显著提升。 由于型砂总消耗量减少,降低了处理总量和更换成 本。 ■ 更多信息,请访问carboindustrial.com

Visit carboindustrial.com for more information.

Robotics make difficult casting sustainable 机器人使复杂铸件的生产具有可持续性 The disc AFS Corporate Member Washburn Iron Works (Washburn, Wisconsin) casts for an agricultural client isn’t a new product for the company. The gray iron component used for grain/seed separation is one they’ve manufactured for years, but the method needed to be transformed. Instead of producing the cope and drag via manual hand-ramming like they had for decades, Washburn changed to a custom molding station with robotics. The manual process was so challenging physically that employees at Washburn would asked to be transferred to another department, just to avoid working on this disc. “We decided that’s not sustainable. It’s not good for any of our employees. It’s not good for our customers,” said Taylor Pearson, vice president of sales and operations. “We embarked on a thought process and a design to automate the whole thing.” In 2013, Taylor and his brother Cole Pearson, the vice president of manufacturing & processes, designed their own robotic grinding cell. The work was done in-house, and Cole Pearson taught himself how to program the robot. With that in mind, Washburn was able to see what else robots could do for them, and that’s what led them to the custom molding for the discs. “That’s when we started putting pen to paper and coming up with ideas and bouncing designs off one another,” Cole Pearson said. “We share an office, which is really nice because we’d turn to each other and go ‘What about this?’ and someone says ‘Well, that’s a good idea, but what about that?’ It just grows from there.” The Pearsons have a whiteboard in their office and they would just swap ideas and drawings. There might be a hang-up, but a few days later one would come up with a solution and move on to the next issue. The process of designing the robot took around 10 months, with six spent on planning and four months on building and implementation. 46

美国铸造协会会员企业沃什伯恩铸铁厂(威斯康星州 沃什伯恩)为农业机械客户生产的铸件并不是公司的新 产品。这个用于分离谷物/种子的灰铸铁件公司已生产很 多年了,但生产工艺需要改进。 沃什伯恩铸造厂不再采用几十年以来的手动夯实方式 生产上、下铸型,而是改为使用机器人技术的铸型生产 工作站。手工工艺极具挑战性,以至于沃什伯恩铸造厂 的员工希望申请调换到另一个部门,就是为了避免在手 工车间工作。 “但是我们认为这是不可持续的发展方式。对我们的 任何一个员工来说都是不合理的,对我们的客户来说也 不好,”销售和运营副总裁泰勒•皮尔森说,“我们开始 转变思维,并计划实现整个生产工艺的自动化。” 早在2013年,泰勒和他的兄弟生产和加工副总裁科 尔皮尔森就自主设计了机器人磨削单元。这项工作是 在公司内部完成的,科尔•皮尔森还自学了机器人编程。 由此,沃什伯恩公司看到了机器人的更多可能性,这也 是他们定制分离盘造型线的原因。 “从那时起,我们开始着手启动新工作并提出新想 法、不断讨论设计方案,”科尔•皮尔森说,“我们共 用一个办公室,这真是太好了,因为我们可以随时沟通 想法;有人提出一个好的方案,还可以有更多其他的方 案。我们就是这样慢慢开始了转变。” 皮尔森兄弟的办公室里有一块白板,他们可以交流想 法和设计图。中间可能会有障碍,但过几天后,他们就 会想出解决方案,然后继续讨论下一个问题。机器人的 设计过程大约需要10个月,其中6个月用于规划、4个月 用于建造和安装。

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


product news/产品新闻 And somewhat to their pleasant surprise, things went smoothly once the robot was put to use last year. The robotic molding station utilizes two types of sand, fills the sand mold, can ram the mold both clockwise and counter-clockwise depending on the cope and drag, and then strikes off the mold. “We were pretty lucky or smart, probably pretty lucky, that our design worked right away,” Taylor Pearson said. “We haven’t had tweaks. We haven’t had a breakdown on it yet, knock on wood.”

The benefits to the robot are obvious. “It’s kind of unique because not many people use the robot to make the mold,” Cole Pearson said. “They use robots to handle things. We’re using the robot to fill the cavities, ram them, strike them and do that over and over, and keeping the guys closing the molds over. It’s a pretty neat thing to see.” The disc, which is produced in around 150 different formations, is now one of Washburn’s easier molding positions. Production is more repeatable and scrap rate has been reduced by 50%. Mold hardness has moved from 50-60 in the human manual process to 75-80, and the robotic molds are more uniform. “Without the robot we wouldn’t have been able to maintain the pace, or we would have had to give a price increase,” Taylor Pearson said. “We try to provide solutions for customers, so rather than turn around to them and say we’ve got to double the price of this casting, we said how can we make this work and how can we keep making this casting for them? That’s what leads us down the path.” ■

Washburn Iron Works found a new way to produce the agricultural disc.

令人惊喜的是,从去年机器人投入使用后一切进展 顺利。机器人造型工作台使用两种类型的型砂来填充铸 型,可以根据上下型来顺时针和逆时针冲压铸型,然后 推出。 “我们非常幸运或聪明,更多的是幸运,我们的设计 方案立竿见影,”泰勒•皮尔森说,“我们没有进行过修 整,目前还没有出现过故障,真是太幸运了。” 机器人的好处显而易见。 “这是很特别的,因为很少有人使用机器人制造铸 型,”科尔•皮尔森说,“别人用机器人来运输传送部 件。但我们用机器人来填充铸型、冲压、取出铸型,重 复这些操作,并让工人远离铸型。这是一件非常了不起 的事。” 分离盘有大约150种不同的形状,现在是沃什伯恩铸 造厂铸型制造较容易的产品之一。生产过程更具可重复 性,废品率降低了50%。铸型的强度从手动生产方式的 50-60提高到75-80,而且机器人生产的铸型更一致。 “如果没有机器人的帮助,我们就无法保持发展的步 伐,或者我们就不得不提高价格,”泰勒•皮尔森说,“ 我们努力为客户提供解决方案,因此,我们并没有向客 户提高价格,我们考虑的是想办法解决问题,继续为他 们提供这种铸件。这就是我们努力的方向。” ■

沃什伯恩铸铁厂为生产农用机械分离盘 创新思路。

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

47


product news/产品新闻

Improved Casting Machine Design Promotes Better, Lighter Cast Parts 改进设计,生产更好、更轻的铸件 Every automobile manufacturer has made it clear to their metal casting suppliers: reducing vehicle weight is increasingly important. Besides solid castings, hollow casting, a variation on the permanent mold process, is an

Kurtz Low-Pressure Die Casting Machines can achieve a yieldstrength of more than 260 MPa; ultimate tensile strength of more than 340 MPa; and an elongation of more than 12%.

48

所有的汽车制造商都向他们的铸件供应商明确表示: 减轻车辆重量已经变得越来越重要了。除了实心铸造、 空心铸造外,对金属型铸造工艺进行改良是生产复杂轻

库尔特低压压铸机生产的产品屈服强度可达260MPa以上,极限 抗拉强度超过340MPa,伸长率超过12%。

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


product news/产品新闻

option for producing complex lightweight structures. It can produce individual components that replace an assembly of metal parts, saving weight and handling costs. Weight reductions of up to 40% are possible. Moreover, parts cast using Kurtz low-pressure casting technology can achieve significant mechanical values. Depending on the part design and casting recipe, lowpressure die cast parts can achieve a yield-strength of more than 260 MPa; ultimate tensile strength of more than 340 MPa; and an elongation of more than 12%. With these values, safety-critical automotive parts such as knuckles, control arms, or subframes can be redesigned to reduce material. Along with the additional possibility of using sand cores, they can be made even lighter by hollow casting. In order to make this process economical for the highvolume automotive industry it became faster. Kurtz realized this among other measures by increasing the size of the low-pressure die casting machine to make multiple parts casting possible. Furnaces between 2,000- and 3,300-kg capacity have become standard for Kurtz. Large furnaces make it possible to use multiple feed tubes at large distances and casting boxes are avoided. Direct gating improves yield, increases quality and saves operational costs. Additionally, the casting process had to become quicker. By means of sophisticated cooling units the casting cycle will be reduced and at the same time quality of the finished parts be improved. Larger machines are designed from 48 cooling circuits, and often may have more than 100 circuits. In cooling, besides air and mix, the trend is clearly going toward water. The overall result: the foundry customers are able to successfully cast with Kurtz eight knuckles at once in less than three minutes. ■ For more information visit www.foundrymachines.com.

质结构件的选择。通过改良工艺,可以生产单个铸件, 以替代金属部件的组装,从而减轻铸件重量、降低运输 成本,减重可高达40%。 此外,采用库尔特公司的低压铸造技术生产的零部 件具备很好的力学性能。根据零件设计和铸造工艺,低 压压铸件的屈服强度可以达到260MPa以上,极限抗拉 强度超过340MPa,伸长率超过12%。有了这些性能优 势,为了减少材料的使用,可以重新设计关键性的汽车 安全零部件,如转向节、控制杆或副车架。除了可以使 用砂芯生产这些零部件外,还可以通过空心铸造工艺使 它们变得更轻。 为了使这种生产工艺在大批量生产需求的汽车工业中 的应用更具经济性,它要变得更有效率。为了实现这一 目标,库尔特公司通过增大低压压铸机的尺寸使多铸件 的铸造成为可能。容量为2000至3300公斤之间的炉子 已成为库尔特公司的标准配置。使用大容量熔炉,可以 在较远的距离内使用多个进料管,避免了使用砂箱。直 接浇注可提高产量、提升质量并节省运营成本。 此外,铸造生产过程必须变得更快。采用复杂精细 的冷却单元,可以缩短生产周期、同时提高成品部件的 质量。 较大的机器设计有48个冷却回路,通常可能有100多 个回路。在冷却方面,除通过空气和混合气体外,水是 一个显著趋势。 综合结论:客户能够在不到3分钟的时间内使用库尔 特公司的8转向节设备一次性成功浇注。 ■ 更多信息,请访问www.foundrymachines.com。

Conditioner improves performance and quality of nodularization process 改善球化效果和质量的球化剂 The demand for more precise and repetitive processes is constantly increasing to satisfy the growing qualitative demands of end user industries. Further, both for high volume and large castings production, increasing consideration is being given to metal cleanliness and longevity of treatment vessels, both leading to the reduction of slag/dross defects and increased productivity. In response to these growing demands, Elkem has developed the Topseed conditioner range of products designed to enhance the MgFeSi nodularisation process.

为了满足最终用户日益增长的质量要求,他们对更精 确和可重复的工艺过程的需求不断增长。 此外,对于高产量和大型铸件的生产,需要对铸件的 清洁度和处理设备的寿命给予越来越多的重视,两者都 会减少夹渣/浮渣缺陷的产生、并提高生产率。 为满足这些不断增长的需求,埃肯公司开发了Topseed球化剂系列产品,目的是为了增强MgFeSi的球 化。Topseed产品致力于达到以下目标: •优化镁的回收率

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

49


product news/产品新闻 The Topseed products work to achieve the following: • Optimize the magnesium recovery. • Reduce magnesium reactivity and fumes emission. • Provide a higher and repetitive nucleation level in the treated iron. • Reduce fade of nodularity. • Change slag characteristics to an easily removable form. The Topseed conditioner range is based on a high density FeSi containing a balanced amount of active elements, calcium, barium and aluminium. These act as a deoxidant when added on top of the MgFeSi and add nuclei to counter the negative effect of magnesium on nucleation. Even a small addition of Topseed will delay the onset of the reaction and provide measurable consistent improvements in the magnesium recovery and metallurgical quality of the iron. Elkem’s technical engineers are able to advise on the best ladle shape and pocket design and together with a selected MgFeSi from its extensive range and one of the Topseed conditioner grades, they can help optimize and produce consistency in the nodularization process. ■

•减弱镁反应、减少烟雾排放 •为处理过的铸件提供更高和可重复的成核水平 •减少球化退化 •使炉渣更易于清除 Topseed球化剂系列是基于高密度且包含适量活性元 素钙、钡和铝的硅铁合金。当添加到镁表面时,这些物 质起到脱氧作用,并加入原子核来抵消镁对成核的负面 影响。即使少量添加Topseed也会延迟反应的开始,并 为镁的还原和铸件的冶金质量提供可观且一致的改进。 埃肯公司的技术工程师能够就最佳的浇包形状和口袋 设计提供建议,并且结合从广泛的MgFeSi和不同等级 的Topseed球化剂的精选产品,它们可以帮助优化球化 过程并保证一致性。 ■ 更多信息,请访问:www.ekem.com/foundry。

For more information, visit www.elkem.com/foundry.

Reaction with steel coins 添加钢包的反应效果

Reaction with Topseed® Conditioner 添加Topseed®的反应效果

The thermal analysis curves shown above demonstrate the benefits of Topseed ® conditioner. On the left series of curves, the grey line shows the cooling curve of nodularised iron which has been covered by steel coins. The coloured curve shows the effect of using Topseed. On the right hand side curves, the same iron is shown after inoculation with 0.1% Alinoc ® inoculant as an in-stream addition. In both cases, the increase in the (green) graphitisation phase of the curve indicates better nodule number and distribution; reduced tendency to shrink and carbide.

50

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


product news/产品新闻

Conmet-Xin Witness FMF Speed Again 康迈信再次见证国机铸锻新速度 On June 30, 2018, the first castings were successfully poured in the workshop of CMX automatic air-flow highpressure squeeze molding equipment. The warm applause and hot molten iron on the scene witnessed this exciting moment. This is the third automatic air-flow high-pressure squeeze molding equipment in the CMX workshop, designed and manufactured by FMF. Due to the overwhelming supply of orders and heavy production tasks, the rush

to schedule and speed up has been the top priority of this project. From the start of installation to the full-line linkage production, FMF made it happened in 60 days through installation and commissioning work in second shifts and 24-hour shift rotations. On July 11, CMX on-site news broke again: the XZ4412 automatic air-flow high-pressure squeeze molding equipment with the highest single-host productivity 240 molds/hour was refreshed by 270 molds/ hour. Facing customers’ ardent expectations, FMF thinks what customers want and meet their urgency: 45 days to complete the entire line of mechanical, hydraulic, electrical system installation, 15 days to complete the entire line commissioning, and 12 hours to complete the gating machine linkage commissioning. ConMet, which owns 90% of the heavy-duty truck parts market in North America, funded the establishment of Shandong Conmet-Xin Machinery Co., Ltd. in 2013. The international, high-end positioning prompted it to invest in the world’s leading modern foundry equipment, such as the German HWS horizontal parting hydrostatic molding line cooperated with FMF, American Yingda medium frequency induction furnace, German Eirich sand mixer, etc. Relying on the advanced management experience, as well as more than 60 years of professional technology accumulation and advantages in the field of casting and forging, the three hydrostatic molding production lines have successfully realized the continuous improvement of the actual production efficiency. ■

2018年6月30日,康迈信静压造型生产线车间浇注第 一箱铸件圆满完成,现场热烈的掌声、滚烫的铁水都见 证了这一激动的时刻。 这是美资企业康迈信公司委托国机铸锻设计制造的第 三条静压造型生产线。由于康迈信订单应接不暇、生产 任务非常繁重,抢工期、提进度成了本次装调工作的重

中之重。从开始安装到全线联动生产,国际同行需要180 天,而国机铸锻安装调试两班倒、24小时连轴转,仅用 60天就完工! 7月11日,康迈信现场再传捷报:单主机生产率最 高为240型/小时的XZ4412静压造型线再次被刷新,达到 了270型/小时,为设计生产率的114%。 面对客户的殷切期盼,国机铸锻想客户之所想,急 客户之所急:45天完成全线机械、液压、电气系统安 装,15天完成整线调试,12小时完成浇注机联动调试。 拥有北美90%重卡零部件市场的美国ConMet公 司,2013年出资组建了山东康迈信机械有限公司。“工 欲善其事,必先利其器”,国际化高端定位促使其投资 引进了德国HWS与国机铸锻合作的水平分型静压造型 线、美国应达中频感应电炉、德国爱立许混砂机等世界 领先的现代化铸造设备;而与国机铸锻的一次次合作, 则是惊艳于国机铸锻依托中汽工程在工程规划设计、工 程总承包等方面的丰富资源和先进管理经验,及铸锻行 业六十余载的专业技术积淀和信息化、智能化法曼福品 牌优势,成功实现了三条静压造型生产线实际生产效率 的不断提高! ■

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

51


product news/产品新闻

China Drives Rising Demand for Matchplate Molding Lines 双面模板造型线的需求不断增加 DISA has seen a surge in demand for molding lines using matchplate technology, driven by enquiries from Chinese customers for large DISA MATCH lines. The trend mainly comes from foundries producing larger castings initially looking for horizontal moulding machines and then switching to matchplate technology during the enquiry process. The growing brake drum market in China is another driver. Jerry Ma, VP Sales OEM Foundry for DISA in China, explains: “What we’re seeing in China is that a successful sale of a DISA MATCH to one foundry then leads to many foundries in the same area or region to follow. For example, we have sold a number of DISA MATCH 32/32 for delivery in 2018. These current orders are for the production of big castings, mainly brake discs and other agricultural/general industrial machinery components. The brake drum market is expanding in China, but many customers will still go with a flask line for these types of castings.

Real-life benefits “We have been working hard to convince them of the benefits of DISA MATCH technology, but the most powerful case is made by other foundries close by choosing a DISA MATCH and demonstrating its advantages in real life - better than we could ever do in conversation,” Ma said. “We’re confident—and delighted—that matchplate technology will continue its march through the large castings market in China.” A similar rise in demand for matchplate technology from DISA has been seen in Turkey, where—unlike in China— smaller DISA MATCH lines are also sought after. In China, customers looking for a molding line for smaller castings tend to move straight to vertical moulding technology. The new DISAMATIC C3 was developed in direct response to this market demand.

52

中国客户不断咨询大型 DISA MATCH 双面模板造型 线,受此推动,迪砂意识到对使用双面模板造型技术的 造型线需求在增加。 这一趋势主要来自生产较大铸件的铸造厂,它们最 初寻找水平有箱造型机,然后在询问过程中切换到双面 模板技术。中国不断增长的制动鼓市场是另一个推动因 素。 迪砂的中国 OEM 销售副总裁马建立解释道:“我 们在中国看到的情况是,在我们成功地向一家铸造厂出 售 DISA MATCH 后,导致同一地区或区域的许多铸造 厂纷纷效仿。因此,在2018年我们在中国售出了好多条 DISA MATCH 32/32造型线。这些订单与生产大型铸件 有关,主要是制动盘和其他农业/一般工业机械部件。 制动鼓在中国市场正在不断扩大,但许多客户仍将采用 水平有箱造型线生产这些类型的铸件。

真实的好处 我们一直在努力使他们相信 DISA MATCH 技术的好 处,但最具说服力的是事实,其他铸造厂选择了 DISA MATCH,并展示了它在实际生产中的优势,这真是事 实胜于雄辩。我们有信心,并且很高兴看到,双面模板 造型技术将继续在中国的大型铸件市场上发展。“ 与中国类似,在土耳其,对迪砂双面模板技术的 需求也出现增长,但与中国不同的是,较小的 DISA MATCH 系列也受到追捧。 在中国,寻求小型铸件造型线的客户倾向于直接采用 垂直造型技术。新的 DISAMATIC C3 正是针对这一市 场需求而开发的 。

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


Turn static files into dynamic content formats.

Create a flipbook
Issuu converts static files into: digital portfolios, online yearbooks, online catalogs, digital photo albums and more. Sign up and create your flipbook.