WWW.GLOBALCASTINGMAGAZINE.COM
OCTOBER 2019
volume 9 number 3
P.28
P.9
P.52 FEATURES
专题文章
22 Evaluating Steel
22 评估并改善钢的冲击磨损性能
28 Diecasting at Toyota
28 丰田汽车压铸件的研发
32 Q&A With Patrick Andre of Vesuvius 35 Getting to Know Anders Wilhjelm, the New Norican Group President and CEO 37 Application Exploration and Analysis of Zhuyuansu in Casting Production
32 与维苏威集团帕特里克·安德烈的采访 35 诺瑞肯集团新任总裁兼首席执行官安 德斯·威廉访谈 37 铸元素在铸造生产中的应用探析
DEPARTMENTS
专栏
6 Editorial 8 Industry News 48 Product News
6 编者的话 8 行业新闻 48 产品新闻
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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
Hawkeye Borescopes ®
Hawkeye管道探視器
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Void in casting, after machining, seen with a Hawkeye Pro Hardy 7”
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Flash as seen with a Hawkeye V2 Video Borescope
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editorial/编者的话 editorial/社論
Asia Foundry Association Established 亚洲铸造业联合会在曼谷正式成立
O
n Sep. 18, 2019, the first day of Metal+Metallurgy Thailand, 12 foundry organizations of Asian countries and regions were getting together in the City of Angels-Bangkok to attend the founding conference of Asia Foundry Association, signing the Constitution of Asia Foundry Association and witnessing this important moment which was a milestone for the Asian foundry industry. From this moment on, the Asia Foundry Association has announced its formal establishment. Asia has a vast territory, a large population and abundant resources. The development prospect of the foundry industry is broad. This is our advantage. However, we also have disadvantages because of the different cultural backgrounds and language barriers among Asian countries and regions. In Asia, there are large foundry nations, such as China, India, Japan, and South Korea, but there are also countries and regions with few foundry industries, such as Laos and Myanmar. Of course, there are more countries like Vietnam, Thailand, Indonesia, and Malaysia where the foundry industry is booming. The development level of the foundry industry varies from country to country, and the demand is very different. Building a common communication platform has become an urgent need for the development of the foundry industry in Asia. In 2010, Asia Foundry Forum was successfully held under the active preparations of foundry organizations of seven countries and regions in Asia. It has been held for five consecutive years and has become an important platform for the communication of the Asian foundry industry. Today, Asia Foundry Association has been established on the basis of Asia Foundry Forum. The founding numbers has reached 12, and their casting production account for 65% of the world total. In the future, with the sustainable development of the Asian foundry industry, our members will grow large and be prosperous. Thank you for all your support. As the first president of the Asia Foundry Association, I am honored and also aware of the great responsibility. Thank you for your trust in setting up the Secretariat at China Foundry Association. Hereby, on behalf of China Foundry Association, I will lead the team of Asia Foundry Association’s Secretariat to serve the development of the Asian foundry industry, promote exchanges and cooperation, and strengthen talent education and training to improve the overall level of foundry technology, management, safety and environmental protection, and promote the sustainable development of the Asian foundry industry. Thank you! ■
Zhang Libo Publisher/President China Foundry Association 6
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019年9月18日，在METAL+METALLURGY Thailand开幕首日，12个亚洲国家和地区铸造组织的 代表相聚”天使之城”曼谷，出席亚洲铸造业联
合会成立大会，签署了亚洲铸造业联合会章程，共同见 证亚洲铸造业这一具有里程碑意义的重要时刻。从此， 亚洲铸造业联合会正式宣告成立。亚洲幅员辽阔，人口 众多，资源 丰富，铸造业的发展前景广阔，这是我们的优势； 然而我们国家众多，文化背景各异，语言不通，彼此间 的交流难度较大。我们既有像中国、印度、日本、韩 国这样位居世界前十的铸造大国，也有像老挝、缅甸等 几乎没有铸造行业的国家。当然，更多的是像越南、泰 国、印尼、马来西亚这样铸造业处于蓬勃发展的国家。 各国铸造业的发展水平不一，需求更是千差万别，搭 建我们共同的交流平台已成为亚洲铸造业发展的迫切需 要。2010年，在亚洲7个国家和地区铸造行业组织的积 极筹备下，亚洲铸造论坛成功举办，至今已经连续举办 了5届，成为亚洲铸造业沟通交流的重要平台。今天，我 们又在亚洲铸造论坛的基础上，成立起亚洲铸造业联合 会，创始成员达到12家，其铸件产量约为全球铸件总产 量的65%左右。未来，随着亚洲铸造业的可持续发展， 我们的成员会越来越发展壮大。 感谢大家的拥戴，由我担任亚洲铸造业联合会首任会 长，我即荣幸，又深感责任重大。也感谢大家的信任， 把亚洲铸造业联合会秘书处设立在中国铸造协会。在 此，我代表中国铸造协会承诺，我将带领亚洲铸造业联 合会秘书处这一工作团队，努力服务于亚洲铸造业各领 域的发展，大力促进亚洲铸造业的交流与合作、加强人 才教育和培训，提高铸造技术、管理、安全和环保整体 水平，推动亚洲铸造业的可持续发展。 谢谢大家！■
张立波 出品人/会长 中国铸造协会
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STAFF/工作人員
STAFF/工作人员 MODERN CASTING
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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
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October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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INDUSTRY NEWS/行业新闻
Industry News Contents 行业新闻目录
Taiyuan Heavy Machinery casts world's largest high-end steel part 世界最大高端铸钢件在太重诞生
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Construction of river-crossing immersed pipes construction completed 10 新兴铸管：首例过河沉管作业顺利完成 World's longest stempost casting produced 世界最长船艏柱铸件铸造完成
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Diecaster 2A expanding Alabama facility 11 压铸企业2A扩展阿拉巴马工厂 Victaulic acquires Globe Fire Sprinkler 12 唯特利公司收购灭火器生产企业 Waupaca opens two facilities 13 沃帕卡建新厂 Boeing again honors G&H Tool 14 波音公司授予G&H模具公司卓越表现奖 Skuld wins thin-walled ductile iron grant 15 Skuld公司获薄壁球墨铸铁科研基金 MacLean expanding Alabama operations 15 MacLean阿拉巴马州工厂扩建 Speyside purchases Weatherly, Hazleton companies 15 Speyside铸造公司收购两家铸造厂 Consolidated Precision Products purchases titanium investment casting business from ATI 16 Consolidated精密铸件公司收购ATI公司的钛 合金精密铸造业务 IBC begins commercial production of Beralcast 363 17 IBC公司开始Beralcast 363合金商业生产
Silbitz Group Beteiligungs GmbH has acquired a stake in Meuselwitz Guss Eisengiesserei GmbH 18 西尔比兹集团收购马瑟威茨铸造有限公司的股份
AMERICAN announces plans for valve and hydrant research center 17 美国铸造企业宣布成立阀门及消防栓研发中心 Mercury Marine breaks ground on expansion 18 水星海事公司扩建项目启动 Barron Industries increasing capacity 19 巴伦工业提高产能 Latrobe Foundry establishes new location 20 拉特罗布铸造公司建新厂 MHI and Primetals Technologies to acquire ABP Induction Systems 21 三菱重工和普锐特冶金技术收购ABP感应系统集团
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| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
INDUSTRY NEWS/行业新闻
Taiyuan heavy machinery casts world's largest high-end steel part 世界最大高端铸钢件在太重诞生 The 35,000-ton multi-directional composite extruder manufactured by Taiyuan Heavy Machinery for Nanjing Develop is the largest pressing machine in the world. The main components are produced in Tianjin Binhai Lin’gang Base of Taiyuan Heavy Machinery, and four supporting castings are produced in Taiyuan. They are the largest castings in the world. On December 10, the lower beam of Nanjing Develop’s 350MN press was transported to Tianjin. The remaining three pieces were also transported in mid-March, mid-May and mid-June. Four giant steel castings delivered by Taiyuan Heavy Machinery will be used in the multi-directional composite extrusion hydraulic die forging equipment for the contract signed between Taiyuan Heavy Machinery Binhai Forging Company and Nanjing Develop Advanced Manufacturing Co., Ltd. The main parts of the press are manufactured, machined and assembled by the Binhai Forging Company. Four parts of the upper and lower beams and double columns of the press machine are produced by the foundry company of Taiyuan Heavy Machinery. The column has a weight of 565 tons and an upper beam of 537 tons. The total weight of the four components is over 2,000 tons. The production of the column and upper beam has exceeded the design limit of Taiyuan Heavy Machinery, especially the largesize column outline, complex structure, different wall thickness, poor manufacturability, are all challenges and brings safety risks toward the capabilities of steel melting, lifting, heat treatment, rough machining equipment and casting transportation. To ensure the quality of the product, the material selection is the first step. The materials of the four large pieces of giant castings are selected in accordance with European standards: the yield strength and tensile strength performance values are much higher than the standard, the key parts of the castings require ultrasonic flaw detection to reach the third level of European standard. The weld sealing level for sand hole is required to reach the first-level of flaw detection, which is also a great challenge to the staff. There are several major innovations in the product: continuous optimizing and establishing new processes and process parameters using software to make simulations of all kinds of casting, solidification, heat treatment and other processes; strictly controlling the chemical composition and gas content of materials, optimizing the refining process of molten steel, optimizing the normalizing heat treatment process, ensuring that the mechanical properties of the test parts meet the requirements of the drawings; the first scientifically safe crossover runner pouring and five hanging bags furnace pouring. The casting of these complex structural parts of columns and upper beams is the first in China and has reached the leading level in the world foundry industry. ■
太重为南京迪威尔生产制造的350MN多向复合挤压 机是目前世界上最大的压机。其中，主件在太重天津滨 海临港基地生产，与其配套的四大铸件在太原生产，是 目前世界上最大的铸件。2018年12月10日，第1条“巨 龙”——南京迪威尔350MN压机下横梁运输车平安抵 达天津。其余3件也分别于今年3月中旬、5月中旬和6月 中旬完成运输。 太重此次发运的“四大件”巨无霸铸钢件，用于太重 滨海锻压分公司与南京迪威尔高端制造有限公司签订的 350MN（即35000吨）多向复合挤压液压模锻设备，由 滨海分公司对350MN压机主机部分进行制造、加工、装 配。设备的上、下横梁和双立柱等四大件由太重冶铸分 公司生产，该立柱单重565吨、上横梁为537吨，四大 件总重量逾2000吨。其中立柱和上横梁的铸件生产已经 超过了太重集团万吨国产化铸造项目的设计极限，尤其 立柱的轮廓尺寸超大，结构复杂，壁厚悬殊，铸造工艺 性极差，制造难度很大，对新系统钢水熔炼、起重、热 处理、粗加工等设备能力以及铸件运输都存在很大的考 验和安全风险。 要保证产品过硬的质量，选材是头一关。需要指出 的是，四大件巨无霸铸件的材质是选用欧洲标准，且对 屈服强度和抗拉强度性能值有远远超出标准数据的极高 要求；铸件关键部位要求超声波探伤达到欧标三级，而 对出砂孔封焊焊缝要求达到同标准一级探伤要求，这对 工人的焊接水平也是很大的挑战。 据介绍，该产品在工艺技术上至少有以下重大创新： 通过MAGMA等进口软件对各件浇注、凝固、热处理等 工序全方位仿真模拟，不断优化并确立新的工艺方案及 工艺参数；严格控制材质化学成份及气体含量，优化钢 水精炼工艺，优化正火热处理工艺，确保试块机械性能达 到图纸要求；国内首创 科学安全的浇道过跨、 五包吊包碰炉浇注组织 方案；经查询，复杂结 构件立柱、上横梁的铸 造，在国内同行业中没 有先例，已经达到世界 铸造业领先水平。 ■
October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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INDUSTRY NEWS/行业新闻
Construction of river-crossing immersed pipes construction completed 新兴铸管：首例过河沉管作业顺利完成 Recently, on the Xipi River of Anhui Province, the first case of a river-crossing immersed pipe construction of Lu'an Dushan Town Water Plant project was successfully completed with the active participation of Xinxing’s after-sales service team. Before construction started, Shi Qiang, Xinxing’s sales manager, and Lu Chuanqing, Xinxing’s after-sales technician, arrived at the site in advance to check the topography of the site. They did preparations like constructing river bottom cofferdam and excavating the trench. The condition of on-site construction is very difficult, and some local people said it is impossible for the county. Continuous rainy days and turbulent water flow, coupled with the soft soil of the river bottom trench, posed great difficulties for the construction of the project, because the use of conventional tractor technology may lead to river collapse. It seemed like the Xipi River had turned into an insurmountable obstacle that had stopped Xinxing people. Mountains multiply and streams double back. However, there is a way out. Limited by the on-site construction conditions, the after-sales technician Lu Chuanqing and others figured out a solution. After DI pipes were sealed, the resulting enclosed space helped the pipes floating on the surface of the river. The tech plan using this feature to construct the river-
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近日，在美丽的安徽省西淠河上，六安独山镇水厂配 套管网项目在新兴铸管售后服务团队的积极参与下，顺 利完成新兴铸管首例过河沉管作业。 近日，新兴铸管业务经理史强、售后技术工程师吕 传庆等人提前到达现场，查看现场地势地貌，做河底 围堰，开挖沟槽。现场施工可谓“难于上青天”：连 日阴雨不断、湍急的水流，加上河底沟槽土质松软， 采用常规拖拉管技术可能导致河底塌方，为项目的实 施造成很大的困难。西淠河变成了一道难以逾越的障 碍，拦住了新兴人。 “山重水复疑无路，柳暗花明又一村”。受现场施工 条件的限制，售后人员吕传庆等人想到球墨铸铁管盘承 封堵后，产生的密闭空间可以在水面漂浮的特性来制定 沉管技术方案，迅速得到施工方的认同。 客户利益无小事，施工进度不能停。按照沉管技术方
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
INDUSTRY NEWS/行业新闻 crossing immersed pipes was accepted by the construction team. The customer's requirements were very important to Xinxing, and the construction progress could not be stopped. According to the tech plan, the sales service team of the Xinxing did their best to help the construction team on installing the pipes one by one. More than a 100-meter pipeline was placed along the Xipi riverbank. Thirty meters from the riverbank, the rushing water flow adds difficulty to the construction, but the team wasn’t deterred. The after-sales technician and the construction team calculated the distance of the traction, and successfully connected the pipeline to the other side of the river. Then the construction team members began to inject water from the end of the pipeline, draining the air in the pipeline, and using external force to ensure the pipeline was straight. The pipeline began to sink by the gravity of the water inside, and finally sank into the channel at the bottom of the river, and river-crossing immersed pipe construction was successfully completed. The successful completion of the river-crossing immersed pipe construction reduced construction costs and saved time for the project. A company without on-site standing will be abandoned by the market. Xinxing’s after-sales service team with full responsibility and construction experience helped their clients solve problems. ■
案，新兴铸管的销售服务团队迅速投入到项目中，配 合施工方逐根安装管材，牵引推进。一条100多米长 的铸管长龙，蜿蜒穿梭在西淠河面上。 在离岸30米处，湍急的水流给施工增加了难度， 售后人员与施工方计算出牵引的距离，一次性牵引管 线到达河对岸。紧接着，施工人员从管线端部开始注 水，排净管线内的空气，利用外力确保管线平直。管 线受到水的重力开始依次下沉，最后顺利沉入河底沟 槽，沉管作业顺利完成。 过河沉管作业的顺利完成降低了施工成本，为项 目节约了时间。“没有现场的出彩，就会有市场的出 局”，新兴铸管的销售服务团队用高度的责任心和丰 富的施工经验帮助客户破解管道过河的难题，获得业 主及施工方的高度赞扬。 ■
Diecaster 2A expanding Alabama facility 压铸企业2A扩展阿拉巴马工厂
Italian diecaster 2A S.p.A. is planning to invest $15 million to expand its foundry in Auburn, Alabama, where it serves as a Tier 1 supplier to major producers of automobiles and heavy trucks. As part of the expansion announced, 2A will install new equipment capable of exerting pressures on dies of between 1,000 and 2,700 tons, as well as 4,500 tons. The first of these
2a supplies diecastings to major automotive customers, including Porsche for its Panamera models.
意大利压铸企业2A S.p.A.计划投资1500万美元扩建 其阿拉巴马州奥本的铸造厂，该铸造厂是汽车和重型卡 车主要零部件的一级供应商。 作为扩建计划的一部分，2A公司将安装1000t、2700t 及4500t的3台压铸机。1000t压铸机预计将于2020年3 月投入使用。
2A公司为主要汽车客户生产压铸件，其中包括保时捷的帕纳梅拉。
October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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INDUSTRY NEWS/行业新闻 machines is scheduled to be operational in March 2020. The expansion project at 2A USA in Auburn will create more than 50 jobs and double the Auburn facility’s current diecasting area. 2A’s parent company, headquartered in Santena, Italy, specializes in the diecasting of large, complex aluminum components that are coated, machined, assembled and painted to meet customer requests. In Europe, 2A produces parts for major automotive and truck manufacturers including Porsche, AlfaRomeo, Maserati and Volvo Trucks. “My father Carlo founded 2A with a clear vision of a technology and customer-driven diecasting company,” president Vincenzo Ilotte said. “We are very proud of our location in Auburn and plan to further grow our operation to serve our customers in the U.S.” 2A USA entered Alabama in 2014, when it acquired a plant operated by Aluminum Technology Schmid North America in Auburn Technology Park West. The company invested in state-of-the-art die casting and machining equipment at the facility, retaining 95 jobs. ■
位于奥本的2A美国公司扩建项目将新增50个就业岗 位，厂房面积将扩大为现有的2倍。 2A的母公司总部位于意大利桑泰纳，专注于大型复 杂铝合金零部件的生产，为客户提供覆膜、机加工、组 装和喷涂等服务。在欧洲，2A公司为保时捷、阿尔法罗 密欧、玛莎拉蒂及沃尔沃等汽车及卡车制造商生产零 部件。 “我的父亲卡洛创办2A公司的初衷是成立一家科技 型及客户导向型的压铸企业，”2A公司董事长文森佐— 伊洛特说：“我们为在奥本设厂感到非常骄傲，我们计 划扩大生产、更好地服务美国的客户。” 2014年，2A公司在美国阿拉巴马州成立，收购了铝合 金科技公司施密特北美（奥本）科技园西区。公司采购了 最先进的压铸机和机加工设备，保留了95个工作岗位。 ■
Victaulic acquires Globe Fire Sprinkler 唯特利公司收购灭火器生产企业 AFS Corporate Member Victaulic (Easton, Pennsylvania) has purchased Globe Fire Sprinkler (Standish, Michigan). Victaulic is a manufacturer of mechanical pipe joining of pipe union products. It has 13 manufacturing facilities worldwide, including five foundries. “The addition of Globe’s fire protection sprinkler volume and engineering capabilities will provide the scale and skills necessary to be a true leader in all aspects of the fire protection industry,” Victaulic CEO John F. Malloy said. Steven Worthington, who will serve as president of Globe Fire Protection, echoed that excitement. “Victaulic brings additional financial resources to Globe, enabling added focus on innovation to support our customers and the industry,” he said. ■
As part of Victaulic’s business strategy, the company operates foundries at five locations, including in the U.S. and a new plant built in 2012 in Mexico, shown here. Victaulic has seen rapid growth in commercial, industrial (such as sprinkler systems) and mining construction, and the new casting operation was built to help support that growth.
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美国铸造协会会员企业Victaulic（宾夕法尼亚州伊 斯顿）公司收购位于密歇根州斯坦迪士的Globe Fire Sprinkler公司。 唯特利公司是一家生产管件接头的企业，在全球拥有 13个工厂，其中包含5个铸造厂。 唯特利公司CEO约翰·F·马洛伊表示：“Globe Fire Sprinkler公司的加入，提高了公司消防器材的产能和加 工能力，使唯特利具备必要的生产规模和能力，成为消 防行业全方位的真正领导者。” 史蒂文•沃辛顿将担任Globe Fire Protection公司董事 长，他非常高兴地说：“唯特利为Globe公司带来更多的 金融资源，使公司有能力专注于为客户和行业提供创新的 产品。” ■
作为唯特利公司发展 战略的一部分，公司 在美国和墨西哥有5个 铸造厂，其中图中所 示为建于2012年的墨 西哥铸造厂。唯特利 在商用、工业用灭火 器行业及采矿机械方 面取得了快速增长， 新的铸造厂有助于支 持快速的发展。
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
INDUSTRY NEWS/行业新闻
Waupaca opens two facilities 沃帕卡建新厂 AFS Corporate Member Waupaca Foundry, a Hitachi Metals company, opened its manufacturing plant in Ironwood, Michigan. The facility will process castings produced in Waupaca, Wisconsin. The facility is expected to create 61 new jobs and an investment of $4.3 million and covers 50,000 sq. ft. Opening a facility to handle cleaning and finishing of cast parts will allow us to meet customers’ expectations in quality and delivery of their parts,” Waupaca executive vice president John Wiesbrock said. Waupaca expanded to Ironwood to find more workers. “Like many employers across the nation Waupaca Foundry is finding ways to overcome low unemployment and a shortage of skilled workers,” Waupaca president, COO & CEO Mike Nikolai said. The company also announced it is opening a machining operation adjacent to its gray iron foundry located on the east side of Waupaca, Wisconsin. The new machining plant will machine brake components for the commercial vehicle market produced at Waupaca Foundry. The facility has 50,000 sq. ft. of manufacturing space and will initially employ 15 skilled workers. The decision to expand operations beyond raw castings was to support customer demand. “Our global markets are changing and customers want a higher level of value-added services,” Wiesbrock said. “A vertically integrated model such as this takes the waste out of the supply chain for customers.” Wiesbrock added opening this facility fulfills corporate objectives established in 2016 to vertically integrate services. Braking components machined in the new facility will be used by heavy duty truck manufacturers. These components are cast and machined on site in Waupaca rather than shipped to Tier 1 suppliers. However, Wiesbrock adds that opening the machining operation will not eliminate the need for other supply chain partners providing machining services. ■
美国铸造协会会员企业、日立金属集团子公司沃帕卡 铸造厂在密歇根艾恩伍德开建新厂，将为威斯康辛州沃 帕卡的工厂提供铸件加工服务。新工厂预计将提供61个 就业岗位，项目投资额为430万美元，占地50,000 sq. ft.（约4645平方米）。 沃帕卡铸造公司执行副总裁约翰•维斯布鲁克说：“新 建一个铸件清理和加工的工厂，使公司能够满足客户对于 产品质量和交货周期的要求。” 沃帕卡公司将在艾恩伍德招聘更多的工人。 沃帕卡公司总裁兼首席运营官、首席执行官迈克•尼古 拉表示：“像其他很多企业一样，沃帕卡铸造厂也在通过 各种方式克服低失业率和人才短缺的问题。” 公司还宣布将在位于威斯康辛州沃帕卡的灰铸铁厂附 近新建一个机加工厂，为沃帕卡铸造厂生产的商用车刹 车盘零部件提供机加工服务。 工厂的生产区域占地50,000
sq.
ft.
（约4645平方米），起初将雇佣15名技术工人。这个新 工厂是为了支持和满足客户的需求。 “我们的全球市场在不断变化，客户也需要高水平的 增值服务，”维斯布鲁克说，“垂直一体化的经营模式 可以简化客户供应链。”维斯布鲁克补充道，新工厂的 建设正是对公司2016年确立的垂直一体化服务模式的发 展目标的承诺。 新工厂主要为重型卡车制造商加工刹车组件。这些组件 在沃帕卡的铸造厂进行铸造和加工，而不是直接发给一级
Waupaca Foundry’s new machining center features highly automated systems and automated guided vehicles. October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
供应商。维斯 布鲁克表示， 但是，新工厂 将不会取代其 他提供机加工 服务的供应链 合作伙伴。 ■
沃帕卡铸造公司 新的机加工中心 配备了高度自动 化系统和自动导 引车。
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INDUSTRY NEWS/行业新闻
Boeing again honors G&H Tool 波音公司授予G&H模具公司卓越表现奖 G.H. Tool & Mold, a Tooling Tech Group company and a supplier of diecast dies and aerospace tooling, announced it has earned recognition as a Boeing Performance Excellence Award recipient for 2018. To achieve this, G.H. Tool maintained a gold composite performance rating for each month of the performance period from October 2017-September 2018. The company has been supplying assembly and support tooling to Boeing for 11 years, receiving the Performance Excellence Award in either the gold or silver category for eight of the last nine years. Boeing evaluates its suppliers on key elements such as quality, delivery, cost competitiveness and service. To achieve gold status, companies must meet delivery and quality targets 100% of the time. This year, Boeing awarded 380 suppliers with the Boeing Performance Excellence Award, of which 82 achieved gold status. “We’re extremely proud of our entire team and their dedication to producing and delivering work of the utmost quality,” said Dave Graves, G.H. Tool & Mold president. ■
G&H模具公司是一家模具科技集团公司，也是压 铸模具及航空航天用模具的供应商，日前宣布已获得 波音公司授予的2018年卓越表现奖。 为了获得这一奖项，G&H模具公司在2017年10 月—2018年9月期间，每个月都保持了金色等级的卓 越表现。公司为波音公司提供模具组装和支持服务已 经长达11年，并且在过去的9年中获得了8次金色等级 或银色等级的卓越表现奖。 波音根据产品质量、交付周期、成本竞争力和服务 水平等关键因素来评价供应商。为了达到金色等级， 供应商必须100%满足质量和交货周期的目标要求。 今年，波音向380家供应商授予卓越表现奖，其中82 家获得金色等级。 G&H模具公司总裁戴夫•格雷夫斯表示：“我们的 团队为客户生产和交付最优质的产品，为此我们感到 非常自豪。” ■
FCRI Ceramic Fliter
No. 18, Liuyuan Road, Shiwan, Foshan, Guangdong, China, 528031
FCRI GROUP CO.,LTD.
14
+86-757-82780713
www.fcri.com.cn
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INDUSTRY NEWS/行业新闻
Skuld wins thin-walled ductile iron grant Skuld公司获薄壁球墨铸铁科研基金
Skuld LLC (Columbus, Ohio) received a Small Business Innovative Research grant from the Department of Energy (DOE). The grant will be used to show going to 0.060-in. thick ductile iron can be done without negatively impacting automobile properties. Skuld’s most recent trials reduced the weight of designs by 70% and material costs by 40%. This is of interest to the DOE due to increasing fuel efficiency standards. By 2025, the corporate average fuel efficiency standards are supposed to rise to 54.5 mpg, up from 35. “The average vehicle has 600 pounds of castings,” Skuld co-owner Sarah Jordan said. “Over half the castings are made of iron or steel. To have an affordable solution, the ability to go thinner in iron-based alloys is essential.” ■
位于美国俄亥俄州哥伦布市的Skuld有限责任公司获 得能源部授予的小型企业创新研发基金。这笔基金将用 于壁厚仅为0.06英寸（约1.5mm）的球墨铸铁且不影响 汽车性能的研究。 为了满足能源部日趋严格的能效标准，Skuld公司最近的 试验将球墨铸铁件的重量减少了70%、材料成本降低40%。 到2025年，企业的平均能效标准预计将从35 mpg提高 到54.5 mpg。 Skuld公司的共同所有人萨拉• 乔丹说：“汽车中铸 件所占的重量平均为600磅（约0.27t），超过一半为铸 铁件或铸钢件。为了找到比较经济的解决方案，是否能 够生产更薄的铁基合金是关键。” ■
MacLean expanding Alabama operations MacLean阿拉巴马州工厂扩建
MacLean Power Systems announced a $5.3 million investment to upgrade equipment and the 67,000 sq. ft. foundry in Alabaster, Alabama. The current foundry employs 90 and sits on 22 acres. In a news release, the company said the investment will “bring advanced aluminum mold making and mold handling operations to the foundry, which now offers aluminum casting and fiberglass products finishing and assembly.” Development will begin in the middle of 2019, and production is expected in the first quarter of next year. “Our vision for the modern foundry is to provide a state-of-the-art, clean, safe and world-class sand-casting operation. There is a growing demand for aluminum casting to support grid hardening and power infrastructure repairs,” president Jim Tanner said. “Our new foundry will help us increase output to meet the demand for products produced in Alabama. The MPS goal is to provide meaningful and rewarding careers for all employees. We’re confident that our investments in advanced technologies will help us attract and keep the best employees.” ■
MacLean电力系统公司宣布，将投资530万美元用 于阿拉巴马州阿拉巴斯特铸造厂的设备升级及67000 sq. ft.（约6225平方米）的扩建。现有工厂雇佣90名 员工、占地22英亩（约89030平方米）。 据报道，公司称投资将“为铸造厂引入先进铝合金模 具制造和维护，目前车间生产铝合金铸件和玻璃纤维制 品的精整和组装。”项目将于2019年年中启动，预计将 于2020年第一季度投产。 MacLean公司总裁吉姆•坦纳表示：“公司的铸造现 代化目标是具备最先进、清洁、安全和世界一流的砂型 铸造工艺。电网强化及电力基础设施维修方面对于铝合 金铸件的需求不断增长，新建的铸造厂将提高产量，以 满足阿拉巴马州工厂的产量要求。MacLean公司的愿 景是为所有员工提供有意义和有回报的职业。我们相 信，公司在高科技方面的投资将有助于吸引和留住优 秀员工。” ■
Speyside purchases Weatherly, Hazleton companies Speyside铸造公司收购两家铸造厂
Speyside Foundry Holdings (Ann Arbor, Michigan), a portfolio company of Speyside Equity Fund I LP, announced the acquisition of Weatherly Casting and Machine Company (Weatherly, Pennsylvania) and Hazleton Casting Company (Hazleton, Pennsylvania). Both transactions were completed June 12. Weatherly Casting and Machine Company, a sister company to Hazleton Casting Company, is an iron foundry, providing machining services and other value-add services such as laboratory and non-destructive testing. Hazleton Casting Company is a steel foundry specializing in alloy steel casting. ■
美国密歇根州安阿伯市的Speyside铸造控股公司是 Speyside股票基金公司的投资组合公司，宣布收购美国 铸造协会会员企业韦瑟利铸造机械厂（宾夕法尼亚州韦 瑟利）及黑泽尔顿铸造厂（宾夕法尼亚州黑泽尔顿）。 交易已于6月12日完成。 韦瑟利铸造机械厂是黑泽尔顿铸造厂的姐妹公司，作 为一家铸铁企业，还提供机加工和其他增值服务，例如 实验室检测和无损检测等。黑泽尔顿铸造厂成立于20世 纪初。 ■
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INDUSTRY NEWS/行业新闻
Consolidated Precision Products purchases titanium investment casting business from ATI Consolidated精密铸件公司收购ATI公司的钛合金精密铸造业务
Allegheny Technologies Incorporated announced it has reached a definitive agreement to sell its cast products business to Consolidated Precision Products Corp. (Cleveland). CPP operates 16 global facilities manufacturing products primarily for the aerospace, defense and industrial industries and is a portfolio company of Warburg Pincus, a global private equity firm. The transaction is expected to close in the early part of the third quarter 2019. The ATI cast products business unit is part of the High Performance Materials & Components (HPMC) segment. It produces titanium investment castings that are primarily used by aerospace and defense OEMs in the production of commercial jet airframes and engines. A post-casting machining facility in Salem, Oregon, will remain with ATI and provide services to CPP and others. “We continue to actively evaluate our business portfolio to ensure that we are focused on the businesses that offer ATI the best combination of growth, profitability, and corporate synergies,” said Robert S. Wetherbee, president and CEO, Allegheny Technologies.
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阿勒格尼技术公司（ATI）宣布与位于克利夫兰的 Consolidated精密铸件公司（CPP）就出售铸造业务达 成最终协议。 CPP在全球有16个工厂，主要为航空航天、国防、工 业等领域供应铸件，也是私募华平投资公司的投资组合 公司。本次交易预计将于2019年第三季度初完成。 ATI的铸造业务部是高性能材料及组件部门（HPMC） 的一部分，生产的钛合金精密铸件主要供航空航天和国 防领域OEM企业用于商用飞机的机身及发动机。位于俄 勒冈州塞勒姆的机械加工厂将保留在ATI内，为CPP和其 他部门提供服务。 ATI公司总裁兼首席执行官罗伯特•韦瑟比说：“我们 将继续积极的评估公司业务组合，确保公司所专注的业 务可以支持ATI的利润增长和企业协同发展。”
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INDUSTRY NEWS/行业新闻 “ATI’s HPMC segment is at its best when we couple our materials science expertise and extensive forging experience to produce critical jet engine components in our worldclass production facilities,” said John Sims, Executive Vice President, HPMC Segment, Allegheny Technologies. “ATI’s Cast Products business is a good fit for CPP’s aerospace and industrial focused business portfolio.” ■
“我们将材料技术和大量的锻造生产经验相结 合，ATI的高性能材料及组件部门（HPMC）将可以发 挥最大优势，在世界一流的工厂生产飞机发动机的关键 组件，”HPMC执行副总裁约翰•西姆斯表示，“ATI的铸 造业务与CPP航空航天和工业领域的需求相契合。” ■
IBC begins commercial production of Beralcast 363 IBC公司开始Beralcast 363合金商业生产 IBC Advanced Alloys (Franklin, Indiana) has begun commercial production of Beralcast 363, a series of beryllium-alloy castings for a producer of commercial satellite systems. “This is a very important step toward commercial-scale production of precision beryllium alloy parts for the satellite industry,” said IBC chairman Mark Smith. “IBC looks forward to ramping up production of these and other units to meet the unique needs of this customer, and to expanding our reach into the global satellite industry for IBC’s investment cast beryllium-aluminum alloy components.” Beralcast satellite parts will be finish machined and will undergo final testing before assembly into a subsystem for integration into satellites for first launch. Initial production is expected to ramp up over time. Multiple units manufactured by IBC may be used in a single satellite. “These components presented an exciting engineering challenge, because competing processes and materials were not able to cost-effectively meet the performance characteristics needed in these very demanding applications,” said Ben Rampulla, president of IBC’s engineered materials division. “The material properties of Beralcast 363, combined with IBC’s ability to cast complex geometries, offers tremendous potential to IBC and to the satellite industry.” ■
美国印第安纳州富兰克林的IBC先进合金公司已开始 Beralcast363合金的商业生产，为商业卫星系统供应商 提供系列铍合金铸件。 “这是使用于卫星工业的铍合金零部件达到商业生产 规模的非常重要的一步，”IBC公司董事长马克•史密斯 表示，“IBC希望提高这些及其他生产单元的产量，以满 足客户的特殊要求，同时将IBC的铍铝精密铸件业务扩大 到全球卫星市场。” 所生产的铍铝合金铸件将是最终加工产品，并且在组 装到卫星之前将进行最后的测试。今后，产量将不断增 加。 IBC生产的多个组件可能将用于一颗卫星。 “这些组件的生产对我们提出了很大的挑战，因为有 竞争力的工艺和材料不具备成本优势，其性能特点不能 满足这些要求严格的应用，”IBC公司工程材料部的总裁 本•兰普拉表示，“铍铝363合金的材料性能以及IBC的复 杂几何形状铸件的生产能力，使IBC和卫星行业具备了巨 大的发展潜力。” ■
AMERICAN announces plans for valve and hydrant research center 美国铸造企业宣布成立阀门及消防栓研发中心 AMERICAN Flow Control, the valve and hydrant division of AFS Corporate Member AMERICAN Cast Iron Pipe Company (Birmingham, Alabama), has announced the formation of AMERICAN Innovation LLC. According to a news release, the company is dedicated to research and development and intends to construct a facility, the AMERICAN Flow Control Center for Innovative Excellence, in Crawfordsville, Indiana, this summer. The 30,000 sq. ft. facility will cost $9-12 million to build. Once completed, it will employ approximately eight research and development personnel. The facility will include the latest equipment and technologies for enhancing existing valve and hydrant products, as well as developing new infrastructurerelated products. “It will expand our research and design functions, allowing us to fast track innovations to get products to market more quickly,” said John Hagelskamp, division sales manager for AMERICAN Flow Control. ■
AMERICAN Flow Control，美国铸造协会会员企业 美国铸铁管公司（阿拉巴马州伯明翰）的阀门及消防栓 业务部门，宣布成立创新中心。据报道，公司将致力于 研发工作并计划今年夏天在印第安纳州克劳福兹维尔组 建AMERICAN Flow Control创新中心。 创新中心占地30,000sq. ft.（约2787平方米），投资 额达900-1200万美元，将雇佣大约8名研发人员。工厂将 采用最新的设备和技术，提升现有的阀门和消防产品、开 发市政建设相关的新产品。 AMERICAN Flow Control的销售经理约翰•哈格尔斯 坎普说：“创新中心将增强公司的研发和设计能力，使我 们对市场所需的创新产品做出快速反应。” ■
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INDUSTRY NEWS/行业新闻
Mercury Marine breaks ground on expansion 水星海事公司扩建项目启动
Mercury Marine (Fond du Lac, Wisconsin) broke ground on a 30,000 sq. ft. addition to its propeller casting facility. When complete, Mercury’s propeller facilities total footprint will encompass 90,000 sq. ft. The expansion, which was officially announced during an event in May, will be at Mercury’s global headquarters in Fond du Lac, and will allow the company to almost double its current output for stainless steel propellers. In total, Mercury will invest $17 million to expand the propeller facility which increases the company’s overall investment to more than $1.1 billion since 2008. “The market growth in high-horsepower four-stroke outboards, plus the market reception to Mercury’s new V6 and V8 outboards, has driven an unprecedented increase in demand for stainless steel propellers,” said Dirk Bjornstad, Mercury Marine Propellers general manager. “This capital expansion will align the propeller business with our increased growth as well as position the business to gain additional market share with new best-inclass propeller designs.” ■
美国水星海事公司（威斯康辛州丰迪拉克） 在现有的螺旋桨铸造厂基础上扩建30000 sq. f t. （约2787平方米）。项目竣工后，水星螺旋桨工厂的总 面积将扩大到90000 sq. ft.（约8361平方米）。该扩建 计划于今年5月正式宣布，建成后，水星公司不锈钢螺旋 桨的产能将翻番。 本次扩建项目投资额达1700万美元，将使水星公司自 2008年开始至今的总投资超过11亿美元。 “随着大马力四驱舷外发动机的需求增长，以及市场 对水星新产品V6和V8舷外发动机的接受，不锈钢螺旋 桨市场迎来了前所未有的需求增长，”水星海事螺旋桨 公司总经理德克•毕卓斯坦说，“这次的投资将使公司 的螺旋桨业务满足不断增长的市场需求，此外，最先进 的螺旋桨设计也为公司赢得了额外的市场份额。”
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Silbitz Group Beteiligungs GmbH has acquired a stake in Meuselwitz Guss Eisengiesserei GmbH 西尔比兹集团收购马瑟威茨铸造有限公司的股份 The Silbitz Group, headquartered in Silbitz, Thuringia, has three foundries in Silbitz, Zeitz and in Košice, Slovakia, as well as a mechanical processor in Stassfurt. The Silbitz Group, a company from the portfolio of Deutsche Beteiligungs AG (DBAG), is joining Meuselwitz Guss with immediate effect. "We are very pleased to be able to give the company a long-term perspective as a new co-shareholder of Meuselwitz Guss Eisengiesserei GmbH. We are convinced of the performance of the company and its employees," said Dr. Torsten Tiefel, Managing Director of Silbitz Group GmbH. The group entered the Meuselwitz Guss Eisengiesserei GmbH by acquiring the shares of the former executive director, Herbert Werner. His merit is to have decisively developed and advanced the foundry. "After 48 years with Meuselwitz Guss and my many years as managing director and consultant in the company, the foundry is very important to me. The technical equipment of Meuselwitz Guss Eisengiesserei GmbH offers an excellent starting point for the further development of the company, so that I have decided to sell my company shares to Silbitz Group Beteiligungs GmbH,” explained Werner. "I am sure that with the Silbitz Group, my life's work can continue not only in my own interests, but also in the interests of the motivated workforce and can be developed further on.” 18
西尔比兹集团总部位于德国图林根州西尔比兹，公司 在西尔比兹、蔡茨和斯洛伐克的科希策拥有3家铸造厂， 并在斯塔斯福特设有机械加工厂。西尔比兹集团是德国 Beteiligungs（DBAG）的成员之一，即将入股马瑟威 茨铸造有限公司。 “作为马瑟威茨铸造有限公司新的共同股东，我们非 常高兴能够给公司提供一个长远的发展视角。我们相信 马瑟威茨公司及其员工的表现。”西尔比兹集团总经理 托尔斯滕•蒂费尔博士说。 西尔比兹集团通过收购前执行董事赫伯特•维尔纳的 股份加入马瑟威茨铸造有限公司。赫伯特•维尔纳的贡 献是果断地推进了铸造厂的发展。 “在马瑟威茨公司工作了48年，并担任公司总经理 和顾问多年，对我来说铸造厂非常重要。马瑟威茨铸 造公司的技术设备为公司的进一步发展提供了良好的起 点，所以，我已经决定将我在公司股份出售给西尔比兹 集团，”维尔纳解释到，“我相信，对于西尔比兹集团 来说，我的工作不仅符合我自己的利益，也有利于调动
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INDUSTRY NEWS/行业新闻 "As the Silbitz Group, we are aware of the long-standing commitment of Mr. Werner and we will be responsible for shaping the technically well-aligned company in his spirit," Tiefel said. The Silbitz Group is one of the leading foundry groups in Europe. It employs 1,230 people and 67 apprentices at four company locations. For the current year, a turnover of 192 million euros is planned. The foundry group has a casting capacity of more than 75,000 tonnes per year and is a reliable partner for casting in precision in nine business areas, including wind power, engine technology, mechanical engineering, drive technology, mining and utility and rail engineering. Meuselwitz Guss Eisengiesserei GmbH, which belongs to the DIHAG Group, generates annual sales of 65 million euros and has a production volume of 30,000 tons. Meuselwitz employs around 320 people and 27 apprentices. With the help of modern manual and large forming plants, large parts up to 80 tons of piece weight, high reproducibility of the workpiece quality and inductive melting operation in the material quality up to "solid solution hardened nodular cast iron" are the specialty for the machine tools, injection molding, measuring plates, press construction and wind energy sectors. ■
劳动力，并且可以获得进一步发展。” 作为西尔比兹集团，我们意识到维尔纳先生的长期承 诺，我们将秉承以他的精神，塑造技术一致的公司，” 蒂费尔说。 西尔比兹集团是欧洲领先的铸造集团之一。它的4家 公司拥有1,230名员工和67名学徒。本年度的营业额预 计为1.92亿欧元。集团的铸造产能每年超过75,000吨， 是包括风力发电、发动机技术、机械工程、驱动技术、 采矿和公用事业以及铁路工程等9大行业可信赖的精密 铸件供应商。 马瑟威茨公司隶属于DIHAG集团，年销售额为6500 万欧元，年产量为30,000吨。公司拥有约320名员工和 27名学徒。在现代手工和大型成型设备的帮助下，最大 铸件重达80吨，工件质量的高度一致性及材料质量在感 应熔炼作业下达到“固溶强化球墨铸铁”的效果，达到 在机床、注塑、测量工具、冲压和风能领域应用的特殊 要求。 ■
Barron Industries increasing capacity 巴伦工业提高产能
Barron Industries (Oxford, Michigan) is increasing capacity to meet demand from its defense customers for aluminum, stainless and carbon steel precision castings. The company is growing its workforce by more than 30% and investing in new equipment to bring on a second and third shift at its 65,000 sq. ft. manufacturing facility in southeast Michigan. Barron has new orders from General Dynamics Land Systems, BAE Systems, and Oshkosh Defense. Serving General Dynamics for more than 35 years, Barron will manufacture cast components for the upgrades of the Stryker and Abrams tank programs recently announced by the U.S. Army. Barron Industries has been awarded a $3 million renewable one-year contract to supply parts for the upgrade of M1A1 Abrams Main Battle Tanks to the state-of-the-art M1A2 System Enhancement Package Version 3 (SEPv3) configuration. In 2018, the Army ordered more than three brigades of the upgraded tanks from General Dynamics. “Based on forecast domestic and international sales through 2029, Barron anticipates our (General Dynamics) contract to renew annually with the total value of work to exceed $40 million through 2029,” company president Bruce Barron said. In addition, General Dynamics has awarded Barron a $4 million renewable one-year contract to supply parts for the upgrade of its Stryker flat-bottom vehicles to the Stryker A1 configuration. ■
为了满足国防领域的客户需求，巴伦工业公司（密歇 根州牛津市）不断提高铝合金、不锈钢和碳钢精密铸件 的产量。公司已增加了30%的工人并购买新的设备，进 行二班及三班倒的生产模式。 巴伦公司从通用动力陆地系统公司、英国宇航系统公 司、奥什科什防务部获得新的订单。 巴伦公司与通用动力公司合作已超过35年，还将为其 生产美国陆军最近宣布的斯特瑞克及艾布拉姆斯坦克项 目用铸件。 巴伦工业公司获得300万美元的资金，用于支持M1A1 艾布拉姆斯主战坦克升级到最先进的M1A2增强系统版本 3（SEPv3）。2018年，美国陆军与通用动力公司签订了 不止3个旅的坦克升级订单。 巴伦公司董事长布鲁斯•巴伦表示：“根据2029年国内 和国际销售预测，巴伦公司与通用动力的订单额在2029 年前将超过4000万美元。” 此外，通用动力与巴伦公司还签订了为期一年价值400 万美元的订单，为斯特瑞克平底坦克升级为斯特瑞克A1 配置供应部件。 ■
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INDUSTRY NEWS/行业新闻
Latrobe Foundry establishes new location 拉特罗布铸造公司建新厂
AFS Corporate Member Latrobe Foundry Machine & Supply Co. (Latrobe, Pennsylvania) announced the opening of a second machining location in Pasco, Washington. The site will machine items from aluminum bar and tube stock and will increase capacity to better serve customers across the country. The manufacturing facility in Whitney, Pennsylvania, will continue to cast and machine aluminum products. The new facility is led by Michael Steiner, a fourth-generation owner. Steiner joined the company in 2014 after several years with Ferguson Enterprises (Oaks, Pennsylvania). “Because the Western United States and Western Canada account for more than 20% of our annual sales, we felt that it was important to have a family member and owner on-site,” president Ted Steiner said. “I couldn’t be happier about leading this expansion of Latrobe Foundry in Washington,” Michael Steiner said. “This facility represents not only our commitment to our customers, but our dedication to continuing the legacy started by my great-grandfather 86 years ago. We will continue to provide the quality, American-made products we are known for while expanding our reach into new business sectors.” The company manufactures, machines, and distributes aluminum pipe fittings and flanges available in numerous stock sizes and styles, including standard, reducing, and butt weld. ■
美国铸造协会会员企业拉特罗布铸造机械公司（宾夕 法尼亚州拉特罗布）宣布将在华盛顿州帕斯科建第二个 机加工厂。新厂将加工铝合金棒和管材，并将提高产能 以更好地服务全美范围内的客户。位于宾夕法尼亚州惠 特尼的工厂将继续铸造和加工铝合金产品。 新厂将由公司第四代接班人迈克尔•斯坦纳管理。 斯坦纳于2014年加入公司，之前曾就职于位于宾夕法尼 亚州奥克斯的弗格森企业管理有限公司。 公司董事长泰德•斯坦纳说：“美国西部和加拿 大西部的市场份额占全年销售额超过20%，因此由一位 家族成员和接班人来管理新公司是非常重要的。” “能够负责此次拉特罗布铸造厂的扩建项目我感到十 分高兴，”迈克尔•斯坦纳说，“工厂的扩建不仅表明 我们对客户的承诺，还有对我的曾祖父86年前创办公司 的传承。我们在扩大新的业务的同时，也将继续保持生 产高质量、美国造的知名产品。” 公司主要生产、加工和销售不同尺寸和类型的铝合金 管件和法兰制品，包括标准件、异型件和对接焊件。 ■
World's longest stempost casting produced 世界最长船艏柱铸件铸造完成 On June 13, Ansteel Cast Steel Co. Ltd announced that the stempost parts produced for the world's largest container ship of 22,000 containers have been cast and welded at the Jiangnan Shipyard in Shanghai. The stempost also has set a world record: 15 meters long, 2.9 meters wide, and with a curved arc of 3 meters. The stempost is the front-end component of the hull. Because it is located at the bow of the ship, it plays the role of cleaving through the waves and navigating, which is required to have sufficient rigidity and strength, as well as a good configuration. The design and manufacturing team of the stempost castings calculated the reasonable anti-deformation by computer simulation of the stress shrinkage before casting, so the size of each rough part was accurate. During heat treatment, the infrared ray level is used to correct the level of the casting. Multi anti-deformation support points are designed based on simulating of the deformation trend to ensure the levelness of the casting. CNC is used to ensure that the curved surface arc conforms to the hull, and the three-dimensional scribed line is to ensure the position of the inner ribs. In the post grinding, the casting is leveled by using special supporting iron, and the partial deformation adopts cold orthopedic modification to ensure the straightness during the subsequent heating air-gouging grinding. ■ 20
6月13日，鞍钢铸钢有限公司宣布该公司为世界最大 22000 箱集装箱船铸造的船艏柱铸件已于近日完工，并 在位于上海的江南造船厂焊接完成。船艏柱创下了世界 纪录——长15 米，宽2.9米，弧度弯曲3 米。 船艏柱是船体最前端的构件。由于位于船头，起着劈 波斩浪、破冰航行等作用，要求艏柱必须具备足够的刚 度和强度，以及良好的外形。 鞍钢铸钢有限公司该项目负责人表示，在铸造前，船 艏柱铸件设计制造团队通过计算机模拟铸件应力收缩， 计算出合理的反变形量，从而使艏柱各个毛坯尺寸准确。 在热处理过程中，采取红外线水平仪校正铸件水平度， 根据模拟变形趋势，科学设计多个防变形支撑点，保证 了铸件毛坯的水平度。使用数控机床加工，保证变曲面 圆弧符合船体型线，同时立体刻线定位所有筋板，确保 内筋位置。后期打磨时，通过使用专用支撑铁来校平铸 件，局部变形采用冷矫形修型，保证了铸件在后续加热 气刨打磨时的平直度。 ■
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INDUSTRY NEWS/行业新闻
MHI and Primetals Technologies to acquire ABP Induction Systems 三菱重工和普锐特冶金技术收购ABP感应系统集团
Mitsubishi Heavy Industries (MHI) and Primetals Technologies (PT) acquire ABP Induction Systems (ABP), a global manufacturer and servicer of induction furnaces and heating systems from CM Acquisitions, a Chicago based private equity firm. ABP offers a variety of best-in-class products and comprehensive services to blue-chip customers, including leading automotive OEMs and suppliers, industrial manufacturers, independent foundries as well as steel plant manufacturers and steel producers. MHI and Primetals Technologies will jointly take ABP's shares. Future business activities will be conducted in close cooperation with and under the leadership of Primetals Technologies. ABP provides state-of-the-art equipment for ferrous and non-ferrous metal casting, forging and steel making. Its main products are induction melting, holding and pouring furnaces as well as induction heaters. ABP's business is built upon a large and global customer base with more than 1,600 active units worldwide. ABP also has a core competence in the service business and provides comprehensive aftermarket solutions to customers though the entire product lifecycle. Service centers are strategically located close to the major industrial areas in Germany, the United States, China, India, Mexico, Russia, South Africa, Sweden and Thailand. ABP also exclusively provides special induction heaters to Primetals Technologies for endless strip production, which helps provide a competitive edge. "ABP's induction heaters are one of the most crucial elements for endless strip production, a flagship process for Primetals Technologies. With ABP becoming one of MHI's group companies and the further close ties that will bring, we can develop and provide customers with even more advanced technologies. Also, with the acquisition of ABP, we combine its competence in induction heating and related activities with our know-how as a worldwide engineering, plant-building, lifecycle services and digitalization partner for the metals industry," said Satoru Iijima, Chairman of the Board and CEO of Primetals Technologies. "ABP´s well-experienced portfolio and its know-how will certainly complement our wide range of customer plants, namely mini mills and long rolling plants, especially in emerging markets, as well as in endless strip production." Till Schreiter, CEO of ABP, added: "ABP's state-of-art induction products and technology-driven culture will fit well with both shareholders. Through a closer tie-up with MHI and Primetals Technologies, ABP can pursue further growth potentials, which will also lead to the contribution to them." With MHI and Primetals Technologies, ABP has access to their resources worldwide, which will improve ABP´s global market presence, provide opportunities to develop new business sectors, and drive digitalization. "This will assure longterm stability for our facilities, employees and customers." ABP will be a group company of MHI under the ownership of Mitsubishi Heavy Industries America, Inc., headquartered in Houston, Texas, and Primetals Technologies USA LLC, Alpharetta, Georgia. ■
三菱重工(MHI)和普锐特冶金技术从位于芝加哥的私募 股权公司CM Acquisitions手中收购ABP感应系统(ABP) ，一家感应炉和加热系统跨国制造商和服务商。ABP面 向汽车制造商和供应商、工业制造商、独立铸造企业、 钢铁设备制造商和钢铁企业等高端客户提供众多一流产 品和综合性服务。三菱重工和普锐特冶金技术将联合持 有ABP公司的股份。将来的业务工作将在与普锐特冶金 技术的密切合作和指导下开展。 ABP面向黑色和有色金属铸造、锻造和钢铁冶金行业 提供先进的设备，主要产品有感应熔炼、保温和浇注炉 及感应加热器。ABP的业务建立在一个庞大的全球客户群 基础之上，在世界各地拥有超过1,600个活跃用户。ABP 的核心业务还包括服务，为客户提供涵盖产品整个寿命 周期的综合性售后服务方案。出于战略考虑，公司在德 国、美国、中国、印度、墨西哥、俄罗斯、南非、瑞典 和泰国的主要工业地区附近设立了服务中心。 ABP还为普锐特冶金技术无头带钢生产线独家提供特 种感应加热器，为该技术赢得竞争优势提供了有力保障。 “ABP的感应加热器是堪称普锐特冶金技术旗舰工艺 的无头带钢生产线中最关键的设备之一。ABP变成三菱重 工所属的一家公司后，我们之间的联系得到进一步加强， 这使我们能够为客户开发和提供更先进的技术。而且，通 过收购ABP，我们把它在感应加热和相关领域的雄厚实力 同我们作为冶金行业国际领先设计、制造、全周期服务和 数字化合作伙伴的丰富诀窍结合在了一起，”普锐特冶金 技术董事会主席兼首席执行官Satoru Iijima说。“ABP的 方案、经验和诀窍肯定会成为我们为客户提供的许多设备 的强有力补充，包括短流程钢厂和长材轧制设备，尤其是 在新兴市场，当然还有无头带钢生产设备。” ABP首席执行官Till Schreiter补充说：“ABP的先进感 应产品和追求技术的公司文化同两家股东非常契合。通过 与三菱重工和普锐特冶金技术建立更加密切的联系，ABP 能够获得更大的发展空间，而这也将对两家股东做出贡 献。”ABP将会获得三菱重工和普锐特冶金技术的国际 资源，从而扩大ABP在国际市场的影响，为新业务领域 的开发和数字化发展创造条件。“这将为我们的企业、 员工和客户的长期稳定性提供保障。” ABP作为三菱重工的旗下公司之一，其股份将由总部 位于德克萨斯州休斯顿的三菱重工美国有限公司和佐治 亚州Alpharetta的普锐特冶金技术美国有限责任公司持 有。 ■
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Evaluating & Improving a Steel for Impact Wear Resistance Adding nickel enhanced the tensile ductility and toughness of a steel that was formulated to be strong and impact-resistant. Viraj Athavale and David C. Van Aken, Missouri University of Science and Technology (Rolla, Missouri); Tom Yaniak, Caterpillar Inc. (Mossville, Illinois); Mingzhi Xi, Georgia Southern University (Statesboro, Georgia)
评估并改善钢的冲击磨损性能 添加镍可提高钢的拉伸塑性和韧性，使其具有良好的抗冲击性。 Viraj Athavale、David C. Van Aken，密苏里科技大学（密苏里州罗拉）；Tom Yaniak， 卡特彼勒公司（伊利诺伊州莫斯维尔）；Mingzhi Xi，佐治亚南方大学（佐治亚州斯泰茨伯勒）。
E
arth-moving equipment and associated tools are subject to a variety of wear mechanisms, and this proves to be a challenge with respect to qualifying the best material for general application. Preference for quenched and tempered steels for ground engaging tools is often related to other performance criteria, e.g. fatigue, and notch or fracture toughness. Even in a loosesoil work site, occasional buried and unmovable obstacles produce impact-loading; quenched and tempered steels provide better fracture resistance. In a study, a Mn-Si-Mo-V steel was formulated to minimize solidification shrinkage porosity with the goal of obtaining a high-strength and impact-resistant steel. Three chemistries, baseline, baseline plus 2 wt. % nickel (Ni) and baseline with 1.5 wt. % Ni but no vanadium (V), were produced keeping a manganese to carbon ratio of 5-1 (Table 1). Steels were heat treated to produce an average prior austenite grain size of 50-70 µm, a lath martensitic microstructure, and a Stage I tempered hardness of 525-560 HBW (53-55 HRC). Yield strength and ultimate tensile strength averaged 1482 MPa (215 ksi) and 1930 MPa (280 ksi). Nickel additions proved effective in enhancing both tensile ductility and impact toughness. The alloy without
Fig 1. Optical images are shown of the heat-treated baseline +Ni-V steel as a function of distance from the steel chill. All specimens were etched with 2% nital. Fig. 1a is the grip section of tensile bar one, Fig. 1b depicts the grip section of tensile bar three, and 1c is the representative structure from a Charpy V-notch bar.
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由
于土方作业设备和相关工具受到各种磨损机 制的影响，因此一般应用中，确定适用的最 佳材料是个挑战。
与地面接触的工具的淬火和回火钢性能的选择通常与 其他性能标准相关，例如疲劳度、缺口或断裂韧性。 即使在松散的土壤施工，偶尔出现埋藏物或不可移除 的障碍物时，也会产生冲击力; 淬火和回火钢的抗断裂 性更好。 在一项研究中，为了获得高强度和抗冲击的钢， 定制Mn-Si-Mo-V合金钢，以最小化凝固收缩孔隙度。 研究3种化学成份：基础成份、基础成份+2 wt％镍 （Ni）、基础成份+1.5wt％镍（Ni）但不含钒（V） ，保持锰碳比为5-1（表1）。对钢进行热处理，平均 的原始奥氏体晶粒尺寸为50-70μm，呈现条状马氏体 微观结构，第一阶段的回火硬度为525-560HBW（5355HRC）。屈服强度和极限拉伸强度平均为 1482MPa（215ksi）和1930MPa（280ksi）。
图1所示为热处理基线+Ni-V钢作为钢冷却距离的函数的光学图 像。所有样品均使用2％硝酸盐蚀刻。图1a是拉伸杆1的握把部 分，图1b显示了拉杆3的握把部分，图1c是来自夏比V型缺口杆 的代表性结构。
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图2所示的误差线显示 了双样本测试的平均 最大值和最小值。基 线钢显示出与冷却距 离的差异最大。
Fig 2. Error bars represent the maximum and minimum values of the two-sample test average. The baseline heat showed the greatest variation with respect to distance from the chill.
vanadium showed the least dependence of tensile ductility with distance from the chill and varied between 11% to 7%. Impact wear was simulated using a gouging abrasion test, and the alloys demonstrated a 27% to 46% reduction in wear relative to steels currently employed. All three alloys produced the expected Stage I tempered martensitic microstructure, but the measured hardness was lower than expected for these steels. Most notably in Table 2 was a greater difference between calculated and measured hardness for the Ni-containing alloys. The addition of Ni lowers both the martensite start temperature and the rate of martensite transformation. Plate martensites are more common when formed below 392F (200C), and as much as 20% plate martensite may be expected for the baseline +Ni steel. Metallographic results appear to corroborate the calculated kinetics. Measurement of prior austenite grain size was in reasonable agreement of the size calculated for the time and temperature that the steel was held prior to quenching (Table 2). The smaller measured grain size observed in the baseline heat is likely due to grain pinning by AlN or VN. In general, the tensile properties decreased with distance from the chill. In a study for cast Cr-Ni-Mo alloys using the same casting configuration, the tensile ductility was shown to
镍的添加可有效提高拉伸塑性和冲击韧性。不含钒 的合金表现出拉伸塑性与冷却间隔的依赖程度最低， 并且在11％-7％之间变化。通过气刨磨损试验模拟冲 击磨损，与目前使用的钢相比，合金钢的磨损降低27 ％-46％。 3种成份的合金都呈现了预期的第一阶段的回火马 氏体微观结构，但测量的硬度低于预期。最明显的 是，如表2所示，含镍（Ni）合金的试验硬度和实际 测量值之间存在较大差异。Ni的添加降低了马氏体的 初始温度和转化速率。 当低于392F（200℃）时，板状马氏体更易形成， 并且对于基础成份+ Ni合金钢，预期可以产生多达 20％的板状马氏体。金相结果似乎证实了计算的动力 学。原始奥氏体晶粒尺寸的测量值与在淬火之前根据 保温的时间和温度计算所得的尺寸一致（表2）。在 对基础成份合金钢热处理时观察到的较小的晶粒尺寸 可能是由于AlN或VN的晶粒钉扎导致。
Table 1. Chemistry of Experimental Castings
表1：试验铸件的化学成份 Alloy
N, ppm
Al
S, ppm
P, ppm
P+Sb+ Sn+As
C
Mn
Si
Cr
Ni
Mo
V
Aim Baseline Baseline+Ni
0.38 0.37 0.37
1.90 1.77 1.83
1.20 1.19 1.2
0.05 0.03
0.03 1.99
0.50 0.53 0.47
0.20 0.22 0.2
<100 56 65
0.02 max 0.016 0.018
<100 80 ppm 60 ppm
<100 70 ppm 90 ppm
<0.035 0.015 0.0145
0.02 0.02
0.003 0.004
Baseline+NiV
0.37
1.72
1.12
0.02
1.5
0.46
0.007
72
0.015
40 ppm
70 ppm
0.011
0.01
0.001
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Cu
23
Ti
图3所示为夏比V型缺口冲 击能量，显示了在室温（图 3a）和-40°F（-40℃）吸收 能量的一般趋势（图3b）。 仅在距离冷却4英寸（100毫 米）处测量到基线特性。结 果报告为两个距离为1英寸 和2英寸的平均值，以及三 个或四个距离更远的测试的 平均值。
Fig 3. This is the Charpy Vnotch impact energy showing a general trend of energy absorbed for room temperature (Fig. 3a) and -40F (-40C) (Fig. 3b). Baseline properties were measured only at the 4 in. (100 mm) distance from the chill. Results are reported as the average of two for distances of one and two inches and average of three or four tests for greater distances.
be related to the maximum pore length measured on the fracture surface. Measurements of pore lengths on tensile fracture surfaces for the alloys reported here are being conducted and will be reported later. A significant decrease in ultimate tensile strength also was observed when the elongation to failure was less than 4%. At present there is no method to relate quantitative measurements of porosity as collected on random metallographic cross sections to the maximum shrinkage pore size that might exist in the gage section of a tensile bar. However, it is reasonable to assume that material with a higher porosity coverage would exhibit lower tensile ductility. A comparison of the porosity coverage between the baseline and the baseline +Ni would support this claim. To obtain a tensile elongation greater than 9% in the baseline +Ni steel would require the area coverage of porosity to be less than 0.024% with a secondary dendrite arm spacing of less than 100µm. A more stringent requirement of lower area coverage would be necessary for the same steel with a greater secondary dendrite arm spacing since the pores would be
通常情况下，拉伸性 能随着与冷铁的距离而下 降。一项使用相同铸件结 构铸造Cr-Ni-Mo合金的 研究显示，拉伸塑性与在 断裂表面上测量的最大 孔隙长度相关。研究中合 金的拉伸断裂表面上的孔 隙长度的测量工作正在进 行，并将在稍后报告。当 断裂伸长率小于4％时， 可以观察到极限拉伸强度 显著降低。 目前，尚无法证明在 金相截面上随机收集的孔 隙率的定量测量值与拉伸 杆的测量截面上可能存在 的最大缩松相关。然而， 可以合理地假设，具有较 高孔隙覆盖率的材料将表现出较低的拉伸塑性。基础成 份与基础成份+Ni之间的孔隙覆盖率的比较支持这一观 点。为了在基础成份+Ni的合金钢中获得大于9％的延 伸率，要求孔隙面积的覆盖率小于0.024％、二次枝晶 臂间距小于100μm。由于孔隙较大，对于具有较大二次
Table 2. Summary of Measured Hardness and Prior Austenite Grain Sizes With Predicted Values and Calculated Martensite Start Temperatures
表2：使用预测值和计算的马氏体起始温度测量的硬度和先前奥氏体晶粒尺寸 Baseline Calculated temper hardness, 400F (204C) 1 hour23 Measured temper hardness, 400F (204C) 2 hours Calculated PAGS31 Measured PAGS34 Ms34
24
Baseline+Ni
Baseline+Ni-V
55.9 HRC
56.2 HRC
55.1 HRC
54.3 ± 0.3 HRC
53.3 ± 0.2 HRC 37 µm 47.3 ± 10 µm 273C
53.5 ± 0.4 HRC
79 µm 55.6 ± 12.3 µm 305C
48 µm 35.6 ± 9.8 µm 286C
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larger. This is observed for the baseline +Ni alloy where the same area coverage of 0.024% produced 6.5% elongation to failure with a secondary dendrite arm spacing of 375µm. The variation in tensile properties with distance from the chill is more significant for the baseline alloy, and other mitigating factors might be contributing to the lower properties than just greater porosity. First, Type II (eutectic) MnS inclusions will lower tensile ductility and notch toughness. Second, the tensile fracture transitioned from a predominately ductile, microvoid coalescence to a brittle cleavage fracture. Brittle fracture was also observed in the baseline +Ni heat but only in association with porosity, and the pore size was generally smaller in comparison to the baseline chemistry. In recent work, the cleavage fracture observed close to shrinkage pores in cast HY80 and HY100 steel was associated with M7C3 carbide precipitates with plate-like morphologies. The higher alloy content in these last regions to solidify could encourage coarse plate-like carbides. However, this fracture feature also was observed for both Charpy V-notch specimen and tensile specimen. In the study presented here, the cleavage like fracture was only observed during tensile testing. Furthermore, the carbide stability study conducted based upon the last 15% liquid does not predict M7C3 formation. A “fish-eye” fracture feature was noted, and this would be indicative of hydrogen damage if the fracture was intergranular. It’s been reported the occurrence of hydrogen induced intergranular or transgranular quasi-cleavage fracture largely depends on tramp element (P, Sb, Sn, As) segregation to grain boundaries and the subsequent loss of
In Fig. 4a, the wear data for various wrought and cast steel are plotted with respect to microstructure and hardness. Fig. 4b is the same data as in Fig. 4a but identified with appropriate ratio of YS/UTS. Data in Fig. 4b shown in red are all cast and Stage I tempered steels.
枝晶臂间距的相同钢材，对低面积覆盖提出了更严格 的要求。在基础成份+Ni合金中观察到，对于相同的 0.024％的面积覆盖率，断裂伸长率为6.5％、二次枝 晶臂间距为375μm。 对于基础成份合金，其拉伸塑性随冷却间隔的变 化更为显著，而其他削弱因素不仅会产生较大的孔隙 率，还可能导致较差的拉伸延展性。首先，II型（共 晶）MnS夹杂物将降低拉伸塑性和缺口韧性。其次， 拉伸断裂从易延展的微孔集聚型转变为脆性解理断 裂。在基础成份+Ni金属液中也能观察到脆性断裂， 但仅与孔隙度相关；与 基线化合物相比，孔隙 通常较小。 在最近的研究中， 在HY80和HY100钢中 观察到收缩孔处的解理 断裂与具有板状形态的 M7C3碳化物沉淀物相 关。这些最后凝固的区 域中合金含量较高，可 能会助长粗大的片状碳 化物形成。。然而，在 夏比V型缺口试样和拉 伸试样中也观察到这种 断裂特征。在本研究 中，仅在拉伸测试时观 察到解理断裂。此外， 基于最后的15％液相 中进行的碳化物稳定性 研究不能预测M7C3的 形成。 观察到“鱼眼”断 裂特征，如果断裂是 晶粒间的，这表明是
在图4a中，根据微观结构和 硬度显示了各种锻造钢和铸 钢的磨损数据。图4b与图4a 中的数据相同，但YS/UTS比 更为恰当。图4b中红色显示 的数据均为铸造和第一阶段 的回火钢。
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grain boundary cohesive strength. Hydrogen embrittlement is typically studied in Ni-Cr-Mo type steels used in energy production. These steels are usually tempered above 572F (300C), which lowers the soluble carbon in ferrite to that being in equilibrium with cementite (Stage III tempering) or with the alloy carbide formed during secondary hardening. These elevated tempering temperatures also promote tramp element segregation to grain boundaries. Intergranular fracture is also a common fracture mode observed for both tempered martensite embrittlement in plain carbon steels and temper embrittlement in alloy steels in the presence of phosphorus. Hydrogen induced quasi-cleavage fracture has been reported for the HY-class of steels when the effects of tramp element segregation are mitigated. Quasi-cleavage fracture also has been reported in Stage I tempered steels for a SAE 10B22 steel tempered at 302F (150C). Both boron and carbon increase the cohesive strength of grain boundaries. This lesson was learned during the development of interstitial free steels where intergranular fracture was characteristic of cold work embrittlement. The benefits of Stage I tempering now can be recognized as contributing to grain boundary cohesive strength as a result of the higher carbon content in solution. The role of shrinkage porosity is similar to blister formation where hydrogen gas accumulates and builds up pressure within a cavity. The pore also can act as an irreversible trap, which is an activation energy greater than 50 kJ/mol. If the hydrogen is not fully removed by baking, then upon austenitization the thermal energy will be sufficient to release the hydrogen back into solution near the pore with austenite having a higher solubility for hydrogen. The pores also may act as stress risers and enhance the sensitivity of the steel to hydrogen as has been shown for martensitic advanced high strength steel. Hydrogen damage in steels show a strain rate dependence with more damage occurring at slower strain rates. Charpy impact testing is not immune to hydrogen damage, as has been shown for line pipe steels. Hydrogen damage is manifested as a shift in the ductile to brittle transition temperature to higher temperatures. This shift in temperature is concentration dependent and the magnitude of the shift increases with hydrogen content. Thus, hydrogen induced cracking may be observed. It is thus reasonable to conclude air-melted steels with ultimate tensile strengths in excess 1,860 MPa (270 ksi) may be subject to hydrogen embrittlement and shrinkage porosity may require longer baking times to remove the hydrogen. Thus, the cleavage fracture associated with porosity in these ultra-high strength steels may be an indication of hydrogen damage. The main difference between the baseline and the Ni-containing alloys can be described by the mode of solidification. In two calculated phase diagrams using the baseline chemistry with manganese being the independent variable, and then using 1.77 wt.% Mn with the baseline chemistry to plot the phase diagram with Ni as the independent variable, only the baseline composition goes through the peritectic reaction. Notch toughness as measured by absorbed energy during Charpy impact testing also shows a dependence upon dis26
含有氢元素引起的。据已发表的论文，因为氢残留引 起的晶间或穿晶的解理断裂很大程度上取决于有害元 素（P、Sb、Sn、As）偏析到晶界和随后的晶界凝 聚强度的下降。通常情况下，在发电设备中使用的 Ni-Cr-Mo型铸钢中研究氢脆化。这种钢材通常在高于 572°F（300℃）的温度回火，将铁素体中的可溶性碳 降低到与渗碳体（第3阶段回火）或二次硬化期间形 成的合金碳化物处于平衡状态。升高的回火温度也促 使杂质元素偏析到晶界。对于普通碳钢中的回火马氏 体脆化和在磷存在下合金钢中的回火脆化，沿晶断裂 也是常见的断裂模式。 本文研究了氢导致准解理断裂对H级钢的影响，并 在此基础上减轻了有害元素偏析的影响。。对于在 302°F（150℃）回火的SAE 10B22钢，在第一阶段的 回火钢中也有准解理断裂的报道。硼和碳都增强了晶 界的内聚强度。这些是在无间隙原子钢的研发过程中 总结出来的，其中沿晶断裂是冷加工脆化的特征。由 于溶液中碳含量较高，现在可以认为第一阶段的回火 有助于增强晶界凝聚强度。 缩孔的作用与气泡的形成类似，其中氢气在型腔内 积聚并形成压力。收缩孔也可以视为不可逆的陷阱， 其活化能量大于50kJ/mol。如果通过热处理没有完全 除去氢气，则在奥氏体化时，热能足以将氢释放回缩 孔附近的溶液中，奥氏体具有较高的氢溶解度。如马 氏体高级高强度钢所表现出来的，缩松孔也可以起到 压力冒口的作用并增强钢对氢的敏感性。 钢的氢损伤表现出应变率依赖性，在较慢的应变 速率下发生更多的损伤。夏比冲击试验不能免受氢 损伤，通过管线钢材已得到证实。氢损伤表现为韧性 转变为脆性过程中的温度升到较高。温度的这种变化 取决于浓度，并且偏移的幅度随着氢含量的增加而增 加。从而，可以观察到由于氢诱导产生的断裂。可以 合理地得出结论，具有超过1,860MPa（270ksi）的 极限拉伸强度的空气熔炼钢可能会发生氢脆化，并且 缩松可能需要更长的烘干时间来除去氢。因此，与这 些超高强钢中的孔隙相关的解理断裂可能是发生氢损 坏的迹象。 基础成份和含Ni合金的主要差异可以通过凝固模 式来表述。在两个计算的相图中，首先使用基础化 学反应，其中锰是独立变量，然后使用1.77wt.%的 Mn和基础化学反应来绘制相图，其中Ni作为独立变
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tance relative to the chill. Impact energies greater than 20 J (15 ft-lb) were obtained only from steel closest to the chill. Notch toughness increased with Ni content and overall the baseline +Ni alloy performed the best. Prior austenite grain size did not seem to be a factor, since the measured values for the three alloys were within the error of the measurement (±10%). The role of eutectic solidification of the MnS has not been accounted for, but the sulfur content of 80 ppm is relatively low and the Baseline tensile specimen closest to the chill had elongations to failure of 8% which is reasonable for a cast steel with an ultimate tensile strength of 1986 MPa (288 ksi). The gouging wear data has been plotted with respect to hardness in Figure 4. The role of microstructure is depicted in Figure 4a and the best performers are the baseline +Ni and the austenitic steel. The same data is plotted in Figure 4b and the results are sorted by YS/UTS ratio. The tensile properties from the second row (away from the chill) were used to represent the steel produced in this study, since the wear test coupons were taken furthest from the chill. The most gouging wear resistant alloys tend to be those with low YS/UTS ratios. Thus, the major conclusion drawn from this study is that both high hardness for wear resistance in loose soil or sand can be combined with a low YS/UTS to produce good gouging wear resistance. The mechanism of this improvement is the rapid rate of work hardening, which is expected to decrease the depth of cutting in the wear scar and thus produce a smaller volume of material removal during each abrasive cut. The role of Ni in the improved wear properties of the materials tested appears to be in lowering the yield strength to produce a lower YS/UTS ratio, i.e. greater work hardening as Ni is increased. The hardness of the counterbody was less than all three alloys tested from this study. As previously noted, a softer counterbody may produce more aggressive wear as a result of the rock sticking and rolling across the counterbody exposing fresh rock face to the steel being tested. The contribution of Mn-C solid solution defect pair to the work hardening of these Stage I tempered martensitic steels is still speculative, but the results obtained are better than quench and tempered steels with similar Ni contents. The higher wear rates for the baseline steel may be related to porosity and the presence of Type II sulfides. Gouging wear resistance of quenched and tempered steel is improved by increasing the rate of work hardening as characterized by a low ratio (<0.8) of yield strength to ultimate tensile strength. The alloys formulated in this study would provide an excellent choice for a general application ground engaging tool providing both high hardness for resistance to 2-body wear as encountered in loose or sandy soils and resistance to gouging impact wear associated with rock breaking and crushing. The alloys studied have not been optimized, but provide a good starting point for formulating new steels with improved performance. ■ This article is an adaptation of paper 19-045 presented at the 2019 Metalcasting Congress in Atlanta.
量，只有基础成份可以通过包晶反应。 在夏比冲击试验中，通过吸收的能量测试的缺口韧 性也显示出对于冷却间隔的依赖性。仅从最接近冷却 的钢中获得大于20J（15ft-lb）的冲击能量。随着Ni 含量的增加，缺口韧性增加，总体而言，基础成份+ Ni合金表现最佳。之前的奥氏体晶粒尺寸似乎不是影 响因素，因为三种合金的测量值都在测量误差范围内 （±10％）。MnS共晶凝固的作用尚未得到解释，但 80ppm的硫含量相对较低，最接近冷却的基础成份的 拉伸试样的断裂伸长率为8％，这对于具有极限抗拉 强度为1986 MPa（288 ksi）的铸钢来说是合理的。 图4所示为气刨磨损数据与硬度的关系。图4a表明 了微观结构的作用，并且可以看出最佳性能是基线+ Ni和奥氏体钢。图4b中是相同的数据，但结果按YS/ UTS比率进行排序。第二行（远离冷却）的拉伸性能 适用于本研究中的钢，因为磨损试样来自距离冷却 最远的地方。气刨耐磨合金倾向于具有低YS/UTS比 率。因此，从这项研究中得出的主要结论是，松散土 质或砂子中的高硬度耐磨性可以与低YS/UTS结合以 产生良好的气刨耐磨性。这种改进作用原理是快速的 加工硬化速度可能会减少磨痕的切削深度，从而在每 次磨削过程中，需要去除的材料量较小。 Ni在改善所测试材料的磨损性能中的作用似乎是降 低屈服强度，使YS/UTS比较小，即当Ni的含量增加 时，加工硬度更大。实验体的硬度低于本研究测试的 三种合金。如前所述，较软的实验体可能会产生更显 著的磨损，这是由于砂石在实验体上粘附并滚动，增 加了测试钢材对砂石的接触和摩擦。Mn-C固溶体的 缺陷对第一阶段回火马氏体钢的加工硬化的影响仍然 是推测性的，但所得结果优于具有相似Ni含量的淬火 和回火钢。基础成份钢的较高磨损率可能与孔隙率和 II型硫化物的存在有关。 通过提高加工硬化速率改善淬火和回火钢的刨削耐 磨性，其特点是屈服强度与极限拉伸强度呈现低比率 （<0.8）。本研究中生产的合金是普遍适用的土方作 业设备的极好的选择，使松散或沙质土壤中的双体耐 磨硬度和对破碎和与破碎相关的抗刨磨冲击力的硬度 较强。本研究中的合金材料尚未经过优化，但对于生 产具有改进性能的新型钢材是一个好的开始。 ■ 本文根据美国铸造协会在亚特兰大举办的2019美国铸造大 会上发表的10-045论文改编。
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Optimizing the Design Process Saves Precious Time in Mass Production Toyota Motor Corporation uses software to better diecast parts.
设计过程的优化帮助节省宝贵的批量生产时间
T
oday’s challenges of the automotive industry are short product development cycles along with resource efficiency and profitability. At the same time, desired or necessary design changes to products and components should still be feasible as late as possible in the development process to keep the required flexibility. Especially for the mass production process of aluminum diecasting, used at Toyota Motor Corporation for various highly complex components, these changes lead to timeconsuming and cost-intensive modifications of the valuable production tools and process layout. To overcome this conflict, the engineers of Toyota Motor Corporation strive to move from a sequential to a concurrent development cycle of product and process design as well as production planning. The objective is to meet the partly contrary requirements at the earliest stage possible to minimize costly changes and prototyping efforts.
Examples for aluminum diecast parts at Toyota include engine blocks and suspension towers.
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如
今的汽车行业普遍面临着产品开发周期明 显缩短、资源效率和盈利能力较低的严峻挑 战。与此同时，即使是到了开发过程的很晚
期，汽车制造商仍可能会对产品或零部件进行必要的更 改，以维持一定的灵活性。 在丰田汽车公司，在他们针对各种高度复杂的零部件 采用的铝压铸件批量生产工艺中，这一点体现得尤为明 显。某些更改将会导致需要修改各种生产工具和工艺布 置，而这种修改不仅耗时，而且成本高昂。 为了解决这种矛盾，丰田汽车公司的工程师通过努 力，将原来按顺序进行的产品、工艺设计和生产计划开 发流程改为了同步开发周期。这样做的目的就是希望在 尽量早期阶段满足部分相悖的要求，从而最大程度地减
来自丰田的铝压铸件样图
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The transition from a sequential conventional development process to a highly efficient concurrent development cycle is illustrated.
从按顺序执行的传统开发流程转向高效的同步开发周期
The application of virtual methods, such as casting process simulation, is key to assessing feasibility and potential manufacturing restrictions in the very beginning of and along the whole development and design process. The aim is to realize a robust and cost-efficient casting process that incorporates the different demands of Design, Process Engineering, and Production at the same time. Therefore, the Toyota engineers successfully integrated the methodology of autonomous engineering with MAGMASOFT into their design process. The efficient identification of significant influencing variables on casting quality and profitability is only possible through methodical process analysis and systematic test planning. To evaluate an optimal work-flow and assess the potential benefits, the methodology of MAGMASOFT® autonomous engineering was applied to a representative housing geometry.
少成本高昂的后期更改和原型设计工作。
Simultaneous optimization of wall thickness and ingate design is used to meet both design and process engineering requirements
在开发和设计过程的最开始以及整个过程中，诸如铸 造工艺模拟这类虚拟方法的应用，对于评估可行性及潜 在的制造限制发挥了关键的作用。 目标是要实现一个强大稳健且极具成本效益的铸 造工艺，确保能够同时整合对产品设计、工程设计 和制造工艺的不同需求。为此，丰田工程师成功将 MAGMASOFT® 的自主设计集成到了自己的设计过 程中。他们相信，只有通过高科技的工艺分析和系统 的测试规划，才能有效识别出影响铸件质量和盈利能 力的重要变量。 为了评估合适的工作流并估算出潜在效益，丰田
同步优化壁厚和内浇口设计，确保同时 满足设计和工艺工程要求
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Objective functions and design variables are shown.
目标函数和设计变量
The objective was to find the best com- promise between the requirements of the design department regarding a minimum wall thickness of the component and the process engineering aiming for a robustness and early stage economic efficiency of the casting process. The engineers of Toyota Motor Corporation wanted to guarantee that both objectives were met, resulting in a thin walled housing that can be produced robustly from the first sampling on. As design variables of the virtual DoE in MAGMASOFT®, two cast part geometries of different wall thicknesses were combined with parametric square sections and positions of the ingates. In a second step, the objectives and critical quality criteria for the optimization process were defined in MAG-
汽车公司的工程师针对典型的外壳铸件应用了 MAG-
Merged scatter charts help find the best results for the defined gate design and wall thickness.
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MASOFT® 自主设计。 目标是在设计部门所期望的“壁厚最薄的零部件”和 工艺工程部门所期望的铸造工艺的“稳健性和早期阶段 经济效率”之间找到合适的平衡点。丰田汽车公司的工 程师希望能够实现上述两个目标，并确保首批试样就能 稳健生产出薄壁外壳。 在 MAGMASOFT® 中进行的虚拟试验设计 (DoE) 中，将壁厚不同的两个铸件几何以及不同参数的内浇口 截面和位置作为变量，进行模拟分析。 在第二步，他们在 MAGMASOFT® 中定义了优化
借助合并散点图找到已定义浇口设计和壁厚 的最佳结果
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Optimization saves precious working hours.
通过优化节省极其宝贵的工作时间
MASOFT. In this case, avoiding misruns for a robust castability and reducing air entrapment for quality reasons were the most important objectives. In order to reduce the time for preparation and calculation, a simplified simulation model was used according to the MAGMA APPROACH. A systematic assessment and comparison of the virtual trials using MAGMASOFT scatter charts clearly revealed the best solutions for the de- fined wall thicknesses and ingate designs. The quantitative comparison of all variants using statistical methods provides reliable results without subjective influences. In this way misruns could be completely avoided upfront, as the optimized results could easily be found in the areas of a better range for filling and a better range for quality. The application of MAGMASOFT autonomous engineering saved precious time in comparison to the conventional simulation process, as many manual tasks like 3-D geometry model- ling and meshing could be avoided completely. With the reference of this example, Toyota engineers proved that in addition to identifying a robust design and manufacturing solution, the required investment in working hours during design could be reduced by 50%. This helped to significantly reduce lead time in the development process as a whole. For Toyota, the methodology of MAGMASOFT autonomous engineering today supports a more comprehensive understanding of processes, providing quantitative information at early stages of product and process development securing reliable decision making. ■
过程的评估目标和关键质量标准。在丰田汽车公司 的这个案例中，从产品质量方面来说，最重要的目 标就是要避免出现浇不足并减少铸造卷气现象。为 了缩短准备时间和计算时间，他们根据 迈格码六步 法简化了模拟模型。 通过使用 MAGMASOFT® 散点图对虚拟试验进 行系统评估和比较之后，我们可以 清楚地看出能够实现定义的壁厚和内浇口设计的合 适解决方案。通过使用统计方法对所有变量进行定量 比较，可以得出不受主观影响的可靠结果。 通过这种方式，可以在前期就完全避免出现浇不足 问题，而且通过优化结果评估，能够轻松的找到更好 的充型方案以及更好的质量方案，。 与传统模拟过程相比，通过应用 MAGMASOFT® 自主设计，像 3D 几何建模和网格化等 大量的手工任务都可以完全避免掉，因此可以节省 非常多的时间。通过这个案例，丰田的工程师们证 实，除了识别稳健设计和制造解决方案以外，设计 期间所需的工作时间投入可减少 50%。这显著缩短 了整个开发过程中的前置期。 对于丰田而言，MAGMASOFT® 自主设计现在不 仅能够帮助他们更全面地了解工艺，而且在产品和工 艺开发早期阶段就能提供大量有用的信息以帮助他们 做出安全可靠的决策。 ■
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Q&A With Patrick Andre of Vesuvius Patrick André, CEO of Vesuvius discusses GIFA, new technology, and reducing greenhouse gas emissions
与维苏威集团帕特里克•安德烈的采访 以下是Foundry Planet在2019年GIFA展期间与维苏威集团首席执行官帕特 里克•安德烈就展会、新技术及减少温室气体排放等问题的讨论。
What sets GIFA (GMTN) apart from the other major industry events in the world? GMTN is considered the most important trade show for the businesses Vesuvius operates in, with a wide range of international congresses, symposia, forums and special events. Vesuvius participates in three of the exhibitions – THERMPROCESS (Fused Silica), METEC (Flow Control, Advanced Refractories and Sensors & Probes) and, of course, GIFA (for Foundry and Sensors & Probes). We use this unique opportunity to communicate to and exchange with our customers and suppliers on our latest technological solutions, new products and service offerings. Our core competitive strengths are our market and technology leadership as well as our strong customer relationships. GMTN allows us, in a single location, to meet our customers, address their technological challenges and foster our partnerships. 32
GIFA (GMTN)与世界上其他主要行业展会的区别是 什么？ GMTN是维苏威集团最重要的专业展会，该展包含 各种各样的国际会议、专题讨论会、论坛和专题活动。 维苏威参加了三个主题展览-THERMPROCESS（热处理 展），METEC（冶金展），当然还有GIFA（铸造展）。 我们利用这一独特机会与客户和供应商就最新技术及解 决方案、新产品和服务进行沟通和交流。 我们的核心竞争优势是我们的市场和技术领先地位以 及强大的客户关系。GMTN使我们能够在一个地点与客 户会面，解决他们所面临的技术挑战并加强我们的合作 伙伴关系。
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Vesuvius is one of the really big global players. What are your highlights for the foundries at this show? Vesuvius is proud to be a leading supplier of technology solutions for foundries through our brand FOSECO. We continuously invest into Research & Development to develop ever more advanced solutions that allow our customers to improve their products or processes. We showcase 14 new technologies at GIFA 2019 which is evidence of our strong commitment to Research & Development and of our close customer relationships in developing new applications and solutions. To name just a few examples: • In feeding systems, we will feature the new, patented range of FEEDEX K feeders alongside SCK (sleeve construction kit) modular feeders for large castings. • The new HOLLOTEX Shroud filtration system application for large, high value steel castings offers unparalleled levels of inclusion removal and reoxidation reduction. • Automotive coatings offering the highest levels of internal casting cavity cleanliness will be featured together with our Intelligent Coating Unit coating control system. • Finally, for aluminum foundries, FOSECO will be promoting the latest generation of SMARTT Melt Treatment Stations and ENERTEK ISO crucibles that offer enhanced insulation and reduced power consumption. Customers that are visiting our booth will be able to find about these and many other advanced technologies in our portfolio.
Foundries are facing major challenges and the global economy seems to be weakening. How do you see the current situation and which markets have the best development potential? Foundries face cyclicality from their end-markets and international competition has intensified. However, the past year has been positive for many foundries (ferrous and nonferrous) given the strong economic development globally. But yes, the global economy is currently softening, particularly in automotive. This of course presents a challenge to foundries, but we do not yet consider this situation worrying. For example, some geographies as well as some segments, such as mining and agriculture – which drive high casting volumes – continue to grow. Nonetheless, there is uncertainty how the economy will evolve in light of the ongoing global trade conflicts. However, in such environments, casting innovation becomes even more important to help sustain the business and increase competitiveness. Our latest innovations provide differentiating solutions that bring value to our customers and help them withstand potential headwinds.
Additive manufacturing is also becoming an increasingly important topic at GIFA. To what extent have foundries already embraced and integrated 3D printing equipment, and what contribution does your company make in this context?
维苏威集团是全球知名企业，在此次铸造展的展示亮 点是什么？ 维苏威很荣幸能够通过我们的品牌福士科而成为铸 造企业技术解决方案的领先供应商。我们不断投入研 发，开发更先进的解决方案，使我们的客户能够改进他 们的产品或工艺。 我们在GIFA 2019展示了14项新技术，这证明了我们 对研发的坚定承诺以及我们在开发新应用和解决方案方 面的密切客户关系。 举几个例子： • 在补缩系统中，对于大型铸件，我们将采用新的 专利系列FEEDEX K冒口和SCK（套管结构套件） 模块化冒口。 • 新型HOLLOTEX护罩过滤系统适用于大型高价值 铸钢件，具备无与伦比的夹杂物去除和再氧化降 低能力。 • 我们的智能涂层单元涂层控制系统将提供具有最 高内部铸腔清洁度的汽车涂层。 • 最后，对于铝铸造厂，福士科将推出最新一代的 SMARTT熔液处理站和ENERTEK ISO坩埚，以增 强绝缘性、降低功耗。 铸造厂面临重大挑战，全球经济似乎正在走弱。您如 何看待当前的情况以及您认为哪些市场具有最佳的发 展潜力？ 铸造企业的终端市场面临周期性，而且国际竞争加 剧。然而，鉴于全球经济的强劲发展，过去一年对许多 铸造厂（黑色和有色金属）都是积极的。 但是确实，全球经济目前正在走弱，特别是汽车行 业。这当然对铸造厂提出了挑战，但我们不认为目前的 情况是令人担忧的。例如，一些地区以及一些行业，如 采矿和农业正在推动铸件产量的增长。尽管如此，鉴于 持续的全球贸易冲突，全球经济走向仍存在不确定性。 然而，在这样的环境中，铸造创新对于帮助维持企 业业务和提高竞争力变得更加重要。我们最新的创新技 术提供了差异化解决方案，为客户创造价值，帮助他们 抵御潜在的风险。 增材制造也成为GIFA越来越重要的主题。目前，铸造 厂已经在多大程度上接受并采用了3D打印设备，贵公 司在这方面做出了哪些贡献？ 我们密切关注增材制造技术的不断进步。事实上， 增材制造技术已经广泛应用于铸件生产中：尽管不适用
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We are monitoring the continuous advancements in additive manufacturing. In fact, additive manufacturing is already widely used in casting production: while not for high volume castings it is used to create moulds and cores and also for rapid prototyping. Foundries are evaluating the benefits of 3D printing versus traditional manufacturing. In our view, both production routes will coexist alongside each but for high-volume castings, traditional castings will likely remain the most cost competitive route in the near future. In Vesuvius, we monitor the needs of this segment and drive projects that use 3D printing in the development of new casting consumable technologies.
In Europe, climate change and the right approach to addressing it are a hot topic. How does Vesuvius view the problem? Climate change is a global phenomenon that affects all businesses and every individual. We at Vesuvius consider climate change as a real and very serious issue. The metals industry is energy intensive which drives CO2 emissions and, as a result, there is increasing pressure to improve this CO2 footprint. Most importantly, Vesuvius’ contribution to reducing emissions and achieving the goals set by the Paris agreement will come from our products and services. Our products help improve the sustainability footprint of our customers’ production processes by increasing yields, reducing scrap, lowering energy consumption and improving the quality of their end products. At the same time internally, Vesuvius has been working to reduce our emissions of greenhouse gases and energy consumption for many years. In the last 5 years, we reached our goals of 10 percent improvement. We are in the process of defining our targets for the next 5 years and continue to optimize our operations, focusing on maximizing the utilization of raw materials and recycling. For example, FOSECO’s new ENERTEK ISO crucible is designed to save energy in induction furnaces. However, given the global nature climate change, we must tackle it at a global level. All measures taken have to ensure that foundries in Europe can continue to compete with non-European suppliers, which potentially have lower environmental standards in their respective region. ■
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于大批量铸件生产，但可用于生产模具和型芯，还可 用于快速成型。 铸造厂正在评估3D打印与传统制造技术相比的优 势。我们认为，这两种生产方式将并存，但对于大批 量铸件，传统工艺在近期仍是最具成本竞争力的生产 方式。 维苏威集团关注着这一细分市场的需求，并推动在 新的铸造耗材技术开发中使用3D打印的项目。 在欧洲，气候变化问题已成为热点话题。维苏威集 团如何看待这个问题呢？ 气候变化是一个全球化问题，影响所有的企业和个 人。维苏威集团认为气候变化是一个非常严峻的现实 问题。 金属行业是能源密集型行业，增加CO2的排放，因 此，减少CO2排放的压力越来越大。 最重要的是，维苏威集团对减排和实现《巴黎协 定》设定的目标的贡献将来自于我们的产品和服务。 我们的产品可提高产量、减少废品，降低能耗并提高 最终产品的质量，从而有助于提高客户生产过程的可 持续性。 同时，在公司内部，维苏威集团多年来一直在努力 减少温室气体排放量和能源消耗。在过去的五年中， 我们达到了10％的减排目标。我们正在确定未来五年 的目标，并将继续优化我们的运营，重点是最大限度 地利用原材料和回收利用原材料。例如，福士科的新 型ENERTEK ISO坩埚旨在节省感应电炉的能源消耗。 但是，鉴于全球的气候变化问题，我们必须在全球 范围内应对。采取的所有措施必须确保欧洲的铸造厂 可以继续与非欧洲供应商竞争，因为欧洲以外的供应 商在各自地区的环保标准可能较低。 ■
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
Getting to Know Anders Wilhjelm, the New Norican Group President and CEO Norican group has a new, highly experienced and technically accomplished president and CEO, Anders Wilhjelm. To provide the customers and the wider industry with some insights into the man who will be at the helm of the group which includes DISA, Italpresse Gauss, Strikowestofen and Wheelabrator.
诺瑞肯集团新任总裁兼首席执行官安德 斯•威廉访谈 诺瑞肯集团新任总裁兼首席执行官安德斯•威廉拥有丰富的经验和深厚的技术背 景。为了帮助客户及更广泛的行业了解诺瑞肯集团（旗下拥有迪砂、意特佩雷斯 高斯、史杰克西和维尔贝莱特等企业）的新掌舵人，Foundry Planet请安德斯•威 廉给大家介绍一下他的经营之道、对于技术的热情以及个人履历。
Anders, what is your business background and why did you decide to take the reins at Norican? I have spent most of my career in international leadership and board-level roles at B2B companies, latterly as Group CEO of Solar A/S and prior to that, President
安德斯，请向我们介绍一下您的工作经历以及为什 么决定加入诺瑞肯集团？ 我的大部分职业生涯是在 B2B 公司担任国际领导 和董事会职位，最近一次是担任 Solar A/S 集团的首
October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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and CEO of GEA Process Engineering. However my business focus and career passion has always been the combination of technology and global business development, which is what brought me to Norican Group. Norican is a strong combination of knowledgeable people, a global network and an owner team I already enjoy working with. Combine this with the exciting developments that are taking hold across the group from digital connected technologies to simple engineering innovations – ideas truly are currency at Norican, which is why I didn’t need much time to think when the Norican opportunity was presented to me.
席执行官，再之前是 GEA Process Engineering 的总
What excites you about joining Norican Group?
对于加入诺瑞肯集团，哪些地方让您感到兴奋？
The pure potential. As a company that comprises the four technologies of DISA, Italpresse Gauss, StrikoWestofen and Wheelabrator, Norican has the breadth and depth to solve industry challenges. Our equipment offer combines to cover everything from melting and casting to part preparation and finishing everything focused in metal. Adding to this, each of the technologies is an industry leader in its own right, so the opportunity to inspire customers with the potential performance gains offered by equipment from across the group, is truly exciting. I was also impressed by the groupwide approach to innovation and data usage, exemplified by the creation of Norican Digital. As such I believe the company’s future is even more exciting than its past. Finally for me, the key ingredient to success is people, and here the teams across Norican wear their passion for innovation with pride and are genuinely committed to customers. Group success is about teamwork, shared values and speed. With these qualities in abundance I believe we have what it takes to succeed for ourselves and for our customers.
What approach will you bring to the business to ensure we continue improving and delivering leading equipment and excellent services to customers? I am a big believer in empowerment and avoiding bureaucracy to maximize business speed. Speed is a culture. You cannot buy more time – it’s the ultimate scarce resource. In a company the size of Norican, you need structure and process to manage operations, so my focus will be devoted on ensuring all of these processes are as effective, connected and seamless as possible for the benefit of customers. In business I also pride myself on being competitively paranoid and never taking a customer or a market position for granted. That’s why I am determined this business will extend its reputation as a leader in innovation, to continue fueling customer growth. Lastly, I think it’s very important to be professionally humble and constructively dissatisfied – and to use these traits to improve… always. ■
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裁兼首席执行官。我的业务重点和职业激情始终在技 术整合与全球业务扩展方面，这也是促使我选择诺瑞 肯集团的原因。 诺瑞肯拥有知识渊博的人才、全球化网络和易于共 事的所有者团队。除此以外，诺瑞肯集团十分注重创 新，从数字互联技术到简单的工程改良，处处洋溢着 朝气蓬勃的发展气息。因此，当加入诺瑞肯集团的机 会摆在我面前时，我毫不犹豫就答应了。 纯粹的潜力。作为一家由迪砂、意特佩雷斯高斯、 史杰克西和维尔贝莱特四大技术领导者组成的公司， 诺瑞肯拥有解决行业挑战的广度和深度。我们提供的 设备能够满足从熔炼和铸造到零件表面处理和精加工 的一切需求，一切都围绕着金属加工。除此以外，这 四家公司都是各自行业的技术领导者，因此，通过集 团内部协作，可为客户提供潜在性能提升机会，这一 点非常令人兴奋。 整个组织的创新和数据使用方式也给我留下了深 刻的印象，Norican Digital 的创建就是一个良好的示 例。因此，我坚信公司将创造远超以往的辉煌。 最后，我个人认为，成功的关键因素是人才。在诺 瑞肯，各个团队对创新满怀激情和无比的自豪，并且 真正地将客户利益摆在第一位。团队协作、共同价值 观和速度是团队取得成功的关键。凭借上述品质，我 坚信我们拥有帮助自己及客户取得成功所需的一切。 您的经营理念是什么？您打算如何确保公司继续发 展并为客户提供领先的设备和优质的服务？ 我是“放权和消除官僚主义，以最大限度提高业 务速度”的坚定拥护者。速度是一种文化。你买不到 时间-它是一种极其稀缺的资源。在诺瑞肯这样规模的 公司里，结构和流程对于管理运营是不可或缺的，因 此我将专注于确保所有这些流程尽可能有效、互联和 无缝协作，最终令客户受益。 在商业领域，我十分看重竞争，我从不认为哪家公 司能够坐拥客户或较高的市场地位。因此，我将继续 扩大公司的创新影响力，持续推动客户增长。 最后，我认为在专业领域保持谦虚和在制度方面保 持不满足至关重要-这将促使我们不断改进、发展。 ■
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
Application Exploration and Analysis of Zhuyuansu in Casting Production pang chaomin, li xishi, li xinfeng, ren baozi, zhao xinwu
铸元素在铸造生产中的应用探析
B
庞超敏, 李熙石, 李新峰, 任豹子, 赵新武
entonite and pulverized coal are always used as greensand moulding bonding agent and anti-sticking sand material in greensand moulding, and Zhuyuansu [1] is a kind of moulding material which can replace bentonite and pulverized coal; it is a patent technology. It has the advantages of small addition amount, stable process performance, good appearance quality of castings under the same process conditions, obvious reduction of sand dropping and sticking defects, yield-improving and cost-saving. In particular, it is worth mentioning that there is no pulverized coal in moulding sand, in the process of casting molten iron, no air pollution brought by combustion of pulverized coal, no MgO brought by combustion of pulverized coal, or no MgS generated by the combination of S and Mg in pulverized coal. In terms of nodular cast iron, magnesium compounds are reduced, which plays a key role in improving the surface decaying graphite of nodular cast iron. For the exhaust manifold used at high and low temperature, the risk of cracks in the exhaust manifold is reduced due to the reduction of graphite layer in the surface layer.
Raising of the question Since the use of wet sand moulding, Hengtong Casting had been using pulverized coal as anti-sticking material for wet sand moulding.Under the conditions at that time, pulverized coal has played a proper role in anti-sticking sand of castings. Taking Hengtong Casting’s production of 3613 as an example, in 2017, 322,211 pieces of 3,613 castings were produced and 3,033 sand-dropping wastes were produced, which ranked the firs in waste analysis of the sand-dropping wastes of castings. In order to reduce the waste rate of castings and improve product quality, it was imperative to reduce the waste of sand dropping and sticking. The market has more stringent requirements for the appearance quality of castings, and also has higher requirements for our casting production units. In addition, sand mixing process is the Company’s largest source of pollution, pulverized coal is light and black; bentonite is light and white, in the process of storage, handling, adding and sand mixing, dust is flying fuill of the whole workshop, which is obvious to all in our company. With the increasingly stringent environmental requirements of the country, it is difficult for pulverized coal and bentonite to meet the requirements of casting production. Practical production shows that, instead of adding new sand, collapsible resin coated sand is used to replace new sand. Because the residual inert resin film on the surface of
湿
湿型砂造型一直使用膨润土和煤粉作为湿型 砂造型粘结剂和防粘砂材料，铸元素［1］ 是一种可替代膨润土和煤粉的造型材料；是
一项专利技术。它的加入量少，工艺性能稳定，在工艺 相同的条件下铸件外观质量好，掉砂、粘砂缺陷明显减 少，提高了成品率，节约了成本。特别值得一提的是型 砂中没有煤粉，铁液在浇注过程中，没有煤粉的燃烧而 带来的空气污染，也没有煤粉的燃烧而带来的MgO， 也没有煤粉中的S与Mg结合而产生的MgS。对于球墨 铸铁而言，镁的化合物减少了，对改善球墨铸铁表层衰 退石墨起到了关键的作用。对高低温状态下使用的排气 歧管，由于表层片墨层的减少，降低了排气歧管裂纹产 生的风险。
一 问题的提出 亨通铸造使用湿砂型造型以来，一直使用煤粉作为 湿砂型防粘砂材料。在当时的条件下，煤粉对铸件防粘 砂起到了应有的作用,以亨通铸造生产3613为例，2017 年全年共生产3613铸件322211支，掉砂废品3033支， 在废品分析中铸件掉砂废品排名第一，为降低铸件废品 率，提升产品质量，降低掉砂、粘砂废品势在必行。 市场对铸件外观质量的要求更为严格，也对我们生产 铸件单位提出更高的要求。另外混砂工序是公司最大的 污染源，煤粉质轻色黑；膨润土质轻白色，在存储、搬 运、添加及型砂混制过程中灰尘飞扬，充斥整个车间， 这在我们公司有目共睹，随着国家对环境的要求越来越 严，煤粉和膨润土很难适应现在铸造生产的要求。 实际生产表明：不加入新砂，用溃散覆膜砂代替新 砂，由于溃散覆膜砂表层残留的惰性树脂膜具有憎水性 消弱了与水化膜的结合强度，影响到了型砂的性能， 随着旧砂中覆膜砂数量的增加，型砂的热湿拉强度和表 面耐磨性降低；导致废品率上升；如加入新砂，势必要
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collapsible resin coated sand has hydrophobicity, it weakens the bonding strength with hydration film and affects the properties of moulded sand. With the increase of the number of resin coated sand in used sand, the hot-wet tensile strength and surface wear resistance of moulding sand decrease, which leads to the increase of waste rate; if new sand is added, it is necessary to increase the amount of bentonite and pulverized coal, a part of used sand should be discharged regularly to keep the sand balance in the sand treatment system, which increases the production cost, and increases the amount of solid waste discharged in the casting process and pollutes the environment. Therefore, after the new moulding material is added, the toughness and moulding property of the moulding sand should be improved, the hot and wet tensile strength of the moulding sand, the sand-entrainment resistance and the surface wear resistance and the fluidity of the moulding sand should be improved; and on the premise of not reducing the wet compressive strength of the moulding sand; and on the premise of not reducing the wet compressive strength of moulding sand, the adverse effects of the addition of resin coated sand core on the properties of clay sand are eliminated, and the anti-sticking properties of moulding sand are enhanced
增加膨润土和煤粉的加入量，还需定期排放一部分
Influence of the characteristics, technical indexes and application methods of Zhuyuansual powder on the properties of moulding sand containing a large amount of resin coated sand
元素粉，已投入市场应用。铸元素粉是以优质钠基
Enterprises need a new kind of moulding material to improve the toughness and moulding ability of moulding sand, increase the hot-wet tensile strength, sand-entrainment resistance and surface abrasion resistance of moulding sand, and the fluidity of moulding sand after addition; and on the premise of not reducing the wet compressive strength of moulding sand, the adverse effect of adding resin coated sand core on the properties of clay sand is eliminated, and the anti-sticking property of moulding sand is enhanced. Benefiting from the introduction of experts from casting association, a new kind of moulding material — Zhuyuansu powder, has been put into market application. The Zhuyuansual powder is a Zhuyuansual clay green sand mixture additives which is developed on the basis of high quality sodium bentonite, high carbon sand-sticking-proof material, alpha starch and other organic materials. Table 1 Zhuyuansu model and technical indexes
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旧砂以保持砂处理系统的砂量平衡，提高了生产成 本，同时还增加了铸造过程固体废弃物的排放量， 污染了环境。因此新的铸型材料加入后要改善型砂 的韧性和起模性，提高型砂的热湿拉强度，抗夹砂 能力和表面耐磨性和型砂的流动性；在不降低型砂 湿压强度的前提下，消除覆膜砂砂芯加入对粘土砂 性能的不利影响，并增强型砂的抗粘砂性能。 二．铸元素粉特点、技术指标及使用方法对含大 量覆膜砂的型砂性能的影响 企业需要一种新的铸型材料，在加入后要改善型 砂的韧性和起模性，提高型砂的热湿拉强度，抗夹 砂能力和表面耐磨性和型砂的流动性；在不降低型 砂湿压强度的前提下，消除覆膜砂砂芯加入对粘土 砂性能的不利影响，并增强型砂的抗粘砂性能。 得益与铸协专家的介绍，一种新的造型材料---铸 膨润土、高碳防粘砂材料、α淀粉及其他有机物质为 基础开发出了铸元素粘土湿型砂混合添加料。
铸元素粉特点： 1. 加入量比一般膨润土、煤粉总和减少一半左右。 2. 型砂韧性好，提高起模强度。 3. 流动性好，便于充型紧实。 4. 保存性好，防止风干失去强度，特别是热砂。 5. 水分加入量减少15-20%，可防止气孔的产生。 6. 旧砂含泥量减少，降低新砂加入量。新砂加入量 减少60%，含10%以下的芯砂可完全不加，保持 用砂量的平衡。 7. 有效的解决了大量使用覆膜砂、三乙胺砂给型砂 造成的脆性。
表1 铸元素型号及技术指标
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
Characteristics of Zhuyuansual powder: 1. The addition of bentonite and pulverized coal is reduced by about half as much as that of ordinary bentonite and pulverized coal. 2. Molding sand has good toughness and improves the starting strength. 3. Good liquidity, easy to fill and compact. 4. Good preservation to prevent air-drying loss of strength, especially hot sand. 5. The addition of moisture content is reduced by 15-20%, which can prevent formation of pores. 6. The mud content of old sand is decreased and the addition of new sand is lowered. The addition of new sand can be reduced by 60% and core sand with less than 10% can be totally eliminated, thus maintaining the balance of the amount of sand used. 7. It effectively solves the brittleness of moulding sand caused by the extensive use of resin coated sand and triethylamine sand. 8. The surface finish of the castings is improved, and the defects of sand washing and scarring are eliminated. 9. It has good reusability and can keep low addition for a long time. 10. Dust and flue gas pollution during casting is reduced. 11. The discharging device of sand mixer can be reduced by one. 12. The open-box sand after casting is easy to disperse, which can simplify the crushing equipment. 13. No spontaneous combustion of pulverized coal, which eliminates potential safety hazards. 14. The overall cost is decreased by 10-15%.
Model and technical indexes Zhuyuansu model and technical indexes are shown in Table 1.
Use method 1. The existing sand treatment bentonite silo is used to store the Zhuyuansual powder; the original pulverized coal silo is used to store the bentonite, and the bentonite is used as a standby to solve the fluctuation caused by the strength of the moulding sand of different products and to adjust the strength fluctuation. 2. The original sand mixing process remains unchanged.
8. 铸件表面光洁度提高，消除了铸件冲砂、结疤缺 陷。 9. 复用性好，可长时间保持低加入量。 10.减少粉尘和浇注时烟气的污染。 11.混砂机卸料装置可减少一个。 12.浇注后开箱的砂块显著容易散落，可简化破碎设 备。 13.不产生煤粉的自燃现象，消除了安全隐患。 14.综合成本下降10-15%。 三 型号及技术指标
铸元素型号及技术指标 见表1。
四 使用方法 1. 使用现有的砂处理膨润土仓存放铸元素粉；原来的 煤粉仓存放膨润土，膨润土作为备用，以解决不同 产品铸件，对型砂强度引起的波动，用来调剂强度 的波动。 2. 原混砂工艺不变。 铸元素粉在型砂浇注过程中的作用如下： 1）铁液的高温作用，铸元素粉的有机纤维质产生 大量还原性气体，防止铁液被氧化并可使铁液表面的 氧化铁还原，减少金属氧化物和型砂进行化学反应的 可能性。型腔中还原性气体主要来自铸元素粉热解生 成的挥发分。 2）铸元素粉受热后的矿物质等开始软化，具有可 塑性。如果由开始软化至固化之间温度范围比较宽和 时间比较长，则可缓冲石英颗粒在改变温度区间受热 而形成的膨胀应力，从而可以减少用砂型受热膨胀而 产生的铸件夹砂缺陷。
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The role of Zhuyuansual powder in the casting process of moulding sand is as follows: 1) To the high temperature effect of molten iron, the organic fibre of Zhuyuansual powder produces a large amount of reducing gas, which prevents the molten iron from being oxidized and can reduce the iron oxide on the surface of molten iron, thus reducing the possibility of chemical reaction between metal oxides and moulding sand. The reducing gas in the mould cavity mainly comes from the volatile matter produced by the pyrolysis of the Zhuyuansual powder. 2) After heating, the minerals of Zhuyuansual powder begin to soften and have plasticity. If the temperature range from softening to solidification is wide and the time is long, the expansion stress of quartz particles caused by heating in the changing temperature range can be buffered, thus the sand inclusion defect of castings caused by thermal expansion of sand moulds can be reduced. 3) The Zhuyuansu powder produces colloid after heating, and the volume expansion part of the colloid plugs the pore between the sand grains on the surface of the sand mould, which makes the molten iron difficult to penetrate.
Performance comparison of moulding sand before and after test In order to prevent the fluctuation of moulding sand quality and the increase of casting waste, the original sand mixing process remains unchanged, as shown in Table 2 and Table 3. Sand mixing process remains unchanged as shown in Table 2. The properties of moulding sand before and after using Zhuyuansus are shown in Table 4. From Table 1, Table 2 and Table 3, it can be seen that bentonite and pulverized coal in moulding sand can be replaced by Zhuyuansus, under the situation without adding new sand (our Company’s original sand mixing process did not add new sand), comparing the moulding sand mixed by clay used sand containing a large amount of resin coated sand core with the moulding sand mixed with used sand, bentonite and pulverized coal under the same technological conditions, the wet compressive strength, air permeability and compactness are similar, and the hot-wet tensile strength is obviously improved, and it can be seen that the adoption of Zhuyuansus and clay moulding sand mixed by clay sand and used sand with a large amount of resin coated sand core can eliminate the adverse effects of a large number of resin coated sand core on the properties of the sand. Based on the above test results, Zhuyuansus is gradu40
3）铸元素粉受热后产生胶质体，胶质体的体积膨 胀部分堵塞砂型表面沙粒间的孔隙，使铁液不易渗 入。
五 试验前后型砂性能对比 为防止型砂质量波动大，造成铸造废品的增加，原 有的混砂工艺不变。见表2、表3。 将膨润土和煤粉由铸元素粉进行替换。 混砂工艺不变 见表2。 采用铸元素前后型砂性能 见表4。 由表1、表2、表3可以看出采用铸元素取代型砂中 的膨润土和煤粉，在不加新砂（本公司原混砂工艺不 添加新砂）的情况下，用含大量覆膜砂芯砂的粘土旧 砂混制的型砂和采用旧砂、膨润土和煤粉在相同工艺 条件下混制的型砂相比，湿压强度、透气性、紧实率 相近，热湿拉强度明显提高，由此可见采用铸元素和 含大量覆膜砂芯砂的粘土砂旧砂混制粘土型砂，可以 消除大量覆膜砂芯砂混入对型砂性能的不利影响。 基于上述试验结果，在型砂系统实施铸元素逐渐取 代膨润土和煤粉。为保证生产的正常进行，以免型砂 性能产生大的波动，造成批量废品，我们采用在原有 膨润土、煤粉湿型黏土旧砂的基础上添加铸元素，在 工作过程中采取逐渐由铸元素替代旧砂中膨润土和煤 粉，经过一段时间的循环，旧砂中的膨润土和煤粉就 完全由铸元素所代替。 过渡期间型砂的配比及性能 如表4和表5所示。 在使用铸元素粉期间，调整铸元素粉的加入量的 前提以型砂检测结果不出现大的波动为前提，根据生 产铸件大小和起模的不同，及时调整铸元素粉和膨润 土的加入量，并对生产的铸件及时进行检验，查看铸 件的外观及废品，防止批量问题的出现，造成成本的 浪费。
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ally implemented to replace bentonite and pulverized coal in moulding sand system. In order to ensure the normal production and avoid the large fluctuation of moulding sand performance to lead to the generaton of batches of waste, we adopt the method that adding Zhuyuansus on the basis of the original bentonite and pulverized coal green moulding clay used sand, in the working process, gradually replacing bentonite and pulverized coal in used sand by Zhuyuansus, and after a period of circulation, bentonite and pulverized coal in used sand are completely replaced by Zhuyuansus. The blending ratio and properties of moulding sand during the transition period are shown in Tables 4 and 5. During the use of Zhuyuansual powder, the precondition of adjusting the addition of Zhuyuansual powder is that there is no big fluctuation in the test results of sand. According to the size of casting and the difference of drawing, the addition of Zhuyuansual powder and bentonite can be adjusted in time, and the produced castings shall be inspected in time, the appearance of casting and the waste products shall be inspected, so as to prevent the emergence of batch problems, resulting in waste of cost. The properties of moulding sand in transition period is shown in Table 6.
过渡期间型砂性能 见表6 。
八 铸元素黏土砂对球铁表层片墨的影响 铸元素粉是以优质钠基膨润土、高碳防粘砂材 料、α淀粉及其他有机物质为基础所组成，传统潮模 砂中加入了煤粉，煤粉中的含硫量基本在0.5%左右， 用铸元素粉代替煤粉和膨润土，由于铸元素粉中硫含 量在0.2%左右，经过一定时间的循环，整个砂处理中 型砂的硫含量进一步降低，为解决表层片墨层厚度超 标问题提供了依据。同一铸件在不同部位使用钠基膨 润土、煤粉和使用铸元素片墨层检测。图7取样部位 产生片墨层的机理：球化后的铁液在浇注过程中由 于Mg与空气中O接触，一部分Mg要氧化成MgO， 铁液在与型壁接触时，煤粉要燃烧，煤粉的燃烧过程 也就是Mg的氧化过程，再者煤粉中S也要与Mg化合 形成MgS，当铁液表层的残留镁量低到一定程度，不
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六 铸件外观质量对比 Comparison of appearance quality of castings
Effect of Zhuyuansual clay sand on surface graphite of ductile iron Zhuyuansual powder is composed of high-quality sodiumbased bentonite, high-carbon sand-sticking-proof material, alpha-starch and other organic substances, Pulverized coal is added to traditional tidal sand, and the sulfur content of pulverized coal is about 0.5%, the Zhuyuansual powder is used to replace pulverized coal and bentonite, as the sulfur content of Zhuyuansu powder is about 0.2%, the sulfur content of moulding sand in the whole sand treatment is further reduced 42
足以保证球化，就产生了衰退石墨和片墨，统称片 墨层。理论上说片墨层是不可避免的，但过厚的片 墨层对产品质量有一定的影响，特别是在高低温冷 热交变状态下使用的排气歧管，片墨层是热裂源。 图14是壁厚4mm处的片墨层，图15是霍尼韦尔高 镍材质允许的片墨层。因此各个发动机企业对排
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七 铸件废品率对比 Contrast of casting waste rate 1 原型砂工艺废品率折线图 见图5 1 Line chart of waste rate of prototype sand process is shown in Figure 5
after a certain period of circulation, which provides a basis for solving the problem of excessive graphite layer thickness of surface layer. Sodium bentonite and pulverized coal, and Zhuyuansual graphite layer are used to test the different parts for the same casting. Figure 7 sampling site. Mechanisms of producing graphite layer: because of the contact between Mg and O in the air during the casting process of spheroidized molten iron, part of Mg will be oxidized to MgO. When molten iron is in contact with the mould wall, pulverized coal will burn. The combustion process of pulverized coal is also the oxidation process of Mg. Furthermore, S in pulverized coal will combine with Mg to form MgS, when the residual magnesium in the surface layer of molten iron is low enough not to ensure spheroidization, decaying graphite and graphite are produced, which is collectively called graphite layer. In theory, graphite layer is unavoidable, but too thick graphite layer has a certain impact on product quality, especially in the exhaust manifold used under the alternating state of high and low temperature, cold and hot, graphite layer is the source of hot cracking. Figure14 is agraphite layer with a wall thickness of 4mm, and Figure 15 is a graphite layer allowed by Honeywell’s high nickel material. Therefore, each engine enterprise has certain regulations on the surface graphite of the exhaust manifold and turbine box. Generally, it is allowed to be between 0.2mm and 0.3mm, or even less than 0.15mm. It is very difficult to meet this requirement in technology. The oxidation
气歧管，涡轮箱的表层片墨都有一定的规定，一般 允许在0.2～0.3mm之间，甚至要求小于0.15mm。 达到这个要求工艺上是有很大难度的。在《汽车排 气系统用耐热材料的抗氧化性能研究》［2］一文中 对耐热材料的抗氧化性能做了详尽的研究，那么铸 造过程产生的表层氧化层（即片墨层）是高低温下 使用的排气歧管和涡轮箱的热裂源。使用铸元素后 有效的减少了片墨层的厚度，这是一个了不起的成 果。图14已经明显的能观察到片墨的存在，图15的 表层已经完全是氧化层而几乎看不到石墨。在使用 铸元素的金相图片中（图8、图10、图12）铸件表 层没有片墨，甚至看不到衰退石墨。表7检测结果
九．成本的节约，环境的改善，固体废弃物排 放的减少，存储空间合理利用。 1.所加辅料数量减少，带来成本节约 以亨通铸造混砂线为例，每天混制型砂480吨， 需加煤粉量为480*0.6%=2.88吨，膨润土加入量
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resistance of heat-resistant materials for automotive exhausting system is studied in detail in the paper of An Investigation on the Anti-oxidation Property of Heat-resisting Materials Used for Automotive Exhausting System [2], and then the surface oxide layer (i.e. graphite layer) produced during casting process is the hot crack source of exhaust manifold and turbine box used at high and low temperature. After use of Zhuyuansus, the thickness of the graphite layer is effectively reduced, which is a remarkable achievement. The presence of graphite has been clearly observed in Figure14, while the surface in Figure 15 is
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为480*0.7%=3.36吨。使用铸元素粉后加入量为 480*0.7%=3.36吨 使用铸元素粉替代煤粉和膨润土成本效益如表8 所示。 从上表得出，用铸元素粉替代煤粉和膨润土在成
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completely oxidized and graphite is barely visible. In the metallographic pictures of Zhuyuansus (Figsure 8, 10 and 12), there is no graphite on the surface of the castings, and even no decaying graphite can be seen. The test results are shown in Table 7.
Cost saving, environmental improvement, reduction of solid waste discharge and rational utilization of storage space 1. The quantity reducing of added supplementary materials brought cost savings. Taking Hengtong Casting sand mixing line as an example, 480 tons of moulding sand are mixed every day, the amount of pulverized coal that needs to be added is
本上效益显著，降低型砂成本。
2.废品的减少，带来效益的提高 使用铸元素粉前掉砂、多肉废品1.01%；使用铸 元素粉后掉砂、多肉废品为0.57%，提高了0.44% 带来效益的提高。按照年生产纲领100000支计算， 相当于减少4400支废品，每只扣除残值，可节约20 元，4400支可节约88000元。见表9。
3.降低了工人的劳动强度
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480*0.6%=2.88 tons, and the amount of bentonite that needs to be added is 480*0.7%=3.36 tons. After Zhuyuansual powder is used, the addition is 480*0.7%=3.36 tons. The cost-effectiveness of using Zhuyuansual powder to replace pulverized coal and bentonite is shown in table 8. From the above table, it can be concluded that the replacement of pulverized coal and bentonite with Zhuyuansual powder has significant cost-effectiveness and reduces the cost of moulding sand.
2. Reduction of waste brought the improvement of benefit. Before using Zhuyuansu powder, the sand dropping and fleshy Waste accounted for 1.01%; and after using Zhuyuansu powder the sand dropping and fleshy Waste accounted for 0.57%, improved by 0.44%, which brought the improvement of benefit. According to the annual production program of 100,000 units, it was equivalent to reducing 4,400 pieces of waste products, each deducting residual value, saving 20 yuan, and 4400
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砂处理添加的辅料煤粉和膨润土在使用铸元素粉前 每天需添加6.2吨左右，在使用铸元素后每天只需添加 3.36吨左右的铸元素粉，1个月左右可减少2.88*25天 =72吨的加入量。
4.降低了固体废弃物的排放量，节约能源 使用铸元素粉前每天排放固体废弃物4吨，使用铸元 素粉后，砂处理整体粉尘减小，每天排放的固体废弃物 减少为2.4吨; 全月可减少1.6*25=40吨，降低了固体废 弃物的处理难度。 铸件外观粘砂少，清理过程产生的黑砂相应的减少， 可适当减少产品的抛丸时间，节约了部分动力消耗。
5.环境的改善
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units can save 88,000 yuan. It is shown in Table 9.
铸元素粉与煤粉外观对比 （图16）：
3. Reduce the labor intensity of workers
铸元素粉外观为灰色，对环境的污染相对较小；
Before using Zhuyuansual powder, pulverized coal and bentonite as supplementary materials for sand treatment needed to be added about 6.2 tons per day, after using Zhuyuansual powder, it only needed to add about 3.36 tons of Zhuyuansual powder, and the addition amount can be reduced by 2.88*25 days = 72 tons per month or so.
煤粉外观为黑色，对环境的污染较大，高温下与
4. Reduce the discharge of solid waste and save energy Before using Zhuyuansual powder, four tons of solid waste are discharged every day , after using Zhuyuansual powder, the overall dust in sand treatment decreased, and the solid waste discharged per day decreased to 2.4 tons; and for the whole month, it can be reduced by 1.6*25=40 tons, which reduces the difficulty of solid waste treatment. The castings appearance have less sticking sands, and the black sand produced in the cleaning process is reduced correspondingly, which can appropriately reduce the shot blasting time of the product and save part of the power consumption.
5. Improvement of the environment Appearance comparison between Zhuyuansual powder and pulverized coal (Figure 16): The appearance of Zhuyuansual powder is grey, and the pollution to environment is relatively small; The appearance of pulverized coal is black, which pollutes the environment greatly. The gas produced by the combination of pulverized coal and bentonite at high temperature is harmful to human body.
6. Reasonable utilization of storage space The original use of bentonite and pulverized coal requires a lot of space to store bentonite and pulverized coal respectively. After the use of cast elemental powder, it is only need half of the original storage space.
膨润土结合产生的气体对人体有害。
6.存储空间得到合理利用 原来使用膨润土和煤粉需要很大的空间分别存放 膨润土和煤粉，使用铸元素粉后，只需原有一半的 存储空间即可。
十.结论 综上所述，我公司作为生产铸铁的专业企业，湿 型造型为主要造型方式，旬阳日用型砂量达480余 吨，年产铸件100余万支，使用铸元素粉替代煤粉 和膨润土，从改善型砂性能、提高铸件质量、降低 生产成本、减少铸件废品率、净化工作环境等方面 都有显著效果。特别是使用大量溃散的覆膜砂，不 添加新砂的情况下，使用铸元素粉替代煤粉和膨润 土可有效改善型砂性能。片墨层的消除对于高低温 下使用的铸件更显意义重大。当然影响片墨层的因 素很多，需要方方面面都要有效的控制，才能生产 出优质的铸件。 需要说明一点，使用铸元素和膨润土+煤粉的可 行性比较，只能对同一产品，同样工艺使用前后做 对比试验，不同产品，不同工艺没有可比性。
Conclusion In summary, our Company, as a professional enterprise producing cast iron, takes green moulding as the main moulding method. The daily moulding sand volume in Xunyang is up to 480 tons, and the annual production of castings is more than 1 million pieces, With the use of castal element powder to replace pulverized coal and bentonite, significant results have been achieved in improving the properties of moulding sand, improving the quality of castings, reducing the production cost, reducing the waste rate of castings and purifying the working environment. Especially when a large amount of collapsible resin coated sand is used and no new sand is added, the performance of moulding sand can be effectively improved by using Zhuyuansual powder to replace pulverized coal and bentonite. The elimination of graphite layer is of great significance to castings used at high and low temperatures. Of course, there are many factors affecting the graphite layer, which need effective control in all aspects to produce high quality castings. ■
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product news/产品新闻
Product News Table of Contents 产品新闻目录 MOLD, CORE & SAND PREPARATION
MELTING, POURING & HEAT TREATMENT
DISA India transforms Nelcast’s molding line performance 49 迪砂印度公司改善Nelcast工厂造型线性能
Bürkert presents gas controls customized for a variety of casting plants 49 Bürkert为不同的铸造厂定制气体控制系统
ExOne and Siemens partner to bring Industry 4.0 to industrial 3D printing ExOne与西门子合作将工业4.0引入工业 3D打印
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Personalized rapid customization integration solution provider for equipment complex parts 53 装备复杂零部件个性化快速定制一体化解决 方案提供商 Huicheng Foundry ordered 3 large die casting machines from Norican 济南慧成采购3台Italpresse大型压铸机 Fusion-Diamond ultrahard grinding tools create new grinding 铸铁件磨削专用金刚石熔合超硬磨具及 磨削设备开创铸造行业磨削新天地
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Mingzhi Technology presents a new coremaking experience 56 明志科技：打破常规 重新定义——MiCC制 芯生产新体验
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product news/产品新闻
Bürkert presents gas controls customized for a variety of casting plants Bürkert为不同的铸造厂定制气体控制系统 Industrial plants for producing steel for casting or for thermal processing technology place different requirements on their gas supply and rely on different automation concepts. Therefore, communication between components must always be tailored to the specific needs of the plant. Bürkert Fluid Control Systems is presenting a range of automation concepts for gas control based on its proven mass flow controllers (MFC). Possibilities range from data exchange through to “conventional” analogue standardized interfaces and digital networking using all common fieldbus protocols all the way to plug-and-play MFC assemblies, not to mention complete control cabinets including all components for gas control. For smaller or simpler plants where only small amounts of data need to be transferred, the conventional analogue interface is the ideal choice. Start-up and maintenance are straightforward, and signals can be checked with the help of simple aids. These vendor-neutral devices operate independently of the controller and are extremely easy to replace. If diagnostic data, device state etc. are to be transmitted in addition to set-point and actual values, the mass flow controllers can communicate via digital interfaces, e.g. PROFINET, EtherNet/IP, PROFIBUS DP, Modbus TCP, EtherCAT, CANopen or RS485. Gateways and Bürkert’s proprietary büS network also allow the integration of other protocols - for gas-control functions that are fully compatible with Industry 4.0. Plug-and-play complete solutions, which can easily be connected to the higher-level controller for precise dosing and logging of gas volumes, can be realized with digital as well as analogue interfaces. The MFC assemblies and complete control cabinets are tailored to the application requirements. The entire fluid control layout is factory-tested, ensuring that installation and start-up can be completed easily and quickly on site. In all automated gas-control solutions, the “Communicator” software simplifies the configuration, parameterization and diagnostics tasks. This practical EDIP tool (Efficient Device Integration Platform) is suitable for analogue and digital devices. It gives the user a complete overview of all cyclical process values as well as all acyclic diagnostic data. Device configurations can be backed up and restored and the integrated, graphical programming environment makes it possible to create control functions for decentralized subsystems. Connections to a PC can also be established on the fly using a USB-CAN adapter. ■
在钢铁、铸造和热处理的生产过程中，根据要求不 同，使用不同的气体输送以及使用不同的自动控制系 统。因此，组件之间的通信必须始终根据工厂的特定需 求进行定制。Bürkert流体控制系统基于其成熟的质量 流量控制器（MFC），展示了一系列用于气体控制的 自动化概念。范围从数据交换到“传统”模拟标准化接 口和使用所有通用现场总线协议的数字网络，一直到即 插即用的MFC组件，还包括所有气体控制组件的总控 制柜。 对于只需要传输少量数据的小型或工艺简单的工 厂，传统的模拟接口是理想的选择。启动和维护非常 简单，可以借助简单的辅助工具检查信号。这些独立 于供应商的设备独立于控制器运行，非常容易更换。 如果除了设定点和实际值之外还要传输诊断数据，设 备状态等，则质量流量控制器可以通过数字接口进行 通信，例如，PROFINET，EtherNet/IP，PROFIBUS DP，Modbus TCP，EtherCAT，CANopen或RS485。 网关和Bürkert专有的büS网络还允许集成其他协议-用 于与工业4.0完全兼容的气体控制功能。即插即用的完 整解决方案可以通过数字和模拟接口实现，可以轻松连 接到更高级别的控制器，以实现精确计量和记录气体容 量。MFC组件和完整的控制柜根据应用要求量身定制。 整个流体控制布局经过工厂测试，确保可以在现场轻松 快速地完成安装和启动。 在所有自动化气体控制解决方案 中，“Communicator”软件简化了配置，参数设置 和诊断任务。这种实用的EDIP工具（高效设备集成平 台）适用于模拟和数字设备。它为用户提供了所有循环 过程值以及所有非循环诊断数据的完整概述。可以备份 和恢复设备配置，并且集成的图形编程环境可以为分散 的子系统创建控制功能。也可以使用USB-CAN适配器 即时建立与PC的连接。 ■
DISA India transforms Nelcast’s molding line performance 迪砂印度公司改善Nelcast工厂造型线性能 Producing 118,000 tons of ductile and gray iron castings annually, Nelcast is the largest jobbing foundry in India. It exports its products worldwide to clients in the automotive, construction, mining and
Nelcast公司每年生产11.8万吨球铁和灰铸铁铸 件，是印度最大的铸造厂，产品出口到全世界的汽 车、建筑、采矿和铁路部门的客户。Nelcast在Gudur
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product news/产品新闻 railways sectors. Equipped with two DISA FLEX horizontal flask green sand molding lines and several DISA ARPA Jolt Squeeze molding machines, Nelcast’s flagship plant in Gudur produces 60,000 tons of ductile iron castings every year. Nelcast was looking to find a better solution for managing the maintenance of its DISA FLEX 70 molding line with a goal to achieve best-in-class uptime and quality through an improved preventative and predictive maintenance. Rather than dedicate additional in-house resources, it wanted to partner with an expert to completely outsource regular servicing and spare parts support. Nelcast runs 24X6 and was looking for a partner who could not just commit resources but also take ownership of the task and approached DISA who they believed was uniquely qualified and committed. DISA India proposed a service contract that would meet all of Nelcast’s needs. DISA would take complete ownership of the FLEX 70 molding line, from the sand plant and molding machine to the conveyer and dust collecting equipment. It would schedule and deliver all maintenance and make sure parts were changed at the right time as well as supporting in-house training, safety and process optimization. Nelcast agreed and the new Service Contract – unique in the Indian market – was signed in November 2017. DISA dedicated an experienced engineer to work full time in the Gudur plant to enhance equipment performance and availability and reduce downtime and lead time. Free of maintenance concerns, Nelcast could focus on managing its production. Within a year, the DISA-managed line’s reliability increased sharply, and downtime dropped due to expert, regular maintenance and timely replacement of all necessary wear parts. With an objective measurement of performance and an incentive structure in the contract, the interests of Nelcast and DISA were perfectly aligned. From improving mold hardness to reducing cycle time, DISA’s Service Contract enhanced every part of Nelcast’s process. Sand mixing and other delays were reduced or eliminated. With every part of the line and process working in harmony, maximum production increased from 84 to 93 molds per hour, quality improved and scrap dropped significantly. With on-the-job DISA training, foundry staff learned optimum machine settings and efficient safe operation. A single point of contact and consistent monthly invoicing reduced administration for Nelcast and made maintenance costs predictable. With better casting consistency, Nelcast rated DISA’s initiative as a “World Class” service offering and agreed a further Service Contract to manage its DISA FLEX 90 molding line in 2018. With growing demand from other clients, Service Contracts are now a standard part of DISA India’s Aftermarket offering. ■
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的旗舰工厂配备了两条迪砂FLEX水平有箱湿型砂造 型生产线和几台迪砂ARPA Jolt挤压成型机，每年生 产6万吨球墨铸铁件。 Nelcast希望找到更好的解决方案来改善迪砂 FLEX 70造型线的维护，目标是通过改进预防性和 预测性维护来实现最佳的正常运行时间和质量。方 案不是投资增加内部的维护和管理，而是希望与专 家合作，完全外包常规服务和备件支持。Nelcast 实行24小时6办制生产，正在寻找不仅可以提供资 源、还可以承担任务的合作伙伴，了解DISA产品并 具有独特资格和承诺。 迪砂印度公司提供了服务合同，可以满足 Nelcast的所有需求。迪砂将全权管理FLEX 70造 型线，从砂处理和成型，到输送设备和集尘设备。 迪砂印度公司将安排并提供所有维护，确保在适当 的时间更换零件，并支持内部培训，安全和流程优 化。Nelcast表示赞同在印度市场独一无二的新服务 合同，于2017年11月签署合同。迪砂聘请了一名经 验丰富的工程师在Gudur工厂全职工作，以提高设 备性能和生产能力，减少停机和交付周期。Nelcast 没有维护的烦恼，可以专注于生产。 在一年之内，迪砂管理下的生产线的可靠性显著 提高，由于专家指导、定期维护和及时更换所有必 要的磨损部件，停机时间下降。通过客观衡量合同 中的绩效和激励结构，Nelcast和迪砂的利益完全 一致。 从提高型板硬度到缩短运行周期，迪砂的服务合 同增强了Nelcast工艺的每个部分，减少或消除了混 砂和其他延误。随着生产线和工艺的每个部分协调 工作，最大生产速率从每小时84型增加到93型，质 量得到改善，废品率显著下降。 通过迪砂公司的在岗培训，铸造作业人员学到最 佳的参数设置和高效的安全操作。单点联系和一致 的月度采购减少了Nelcast的管理，并使维护成本可 预测。 凭借更好的铸造生产一致性，Nelcast将迪砂的 举措评为“世界级”服务，并在2018年同意进一步 管理其迪砂FLEX 90造型线。随着其他客户的需求 不断增长，服务合同现已成为迪砂印度售后市场的 标准组成。 ■
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
product news/产品新闻
ExOne and Siemens partner to bring Industry 4.0 to industrial 3D printing ExOne与西门子合作将工业4.0引入工业3D打印 The ExOne Company, a global business in industrial sand and metal 3D printers using binder jetting technology, announced a partnership with Siemens, a global company in automation and digitalization, that will benefit industrial customers in the foundry, aerospace, automotive, energy and other markets. Siemens’ Digital Enterprise Portfolio of software and automation technology including MindSphere are fully implemented on the new S-MAX Pro sand printer, that can achieve print speeds of up to 135 l/h (18 s/layer). The S-MAX Pro was launched at the 2019 GIFA International Foundry Trade Fair. “With this expanded partnership, ExOne will deliver even more value to our foundry and manufacturing customers who rely on our industrial 3D printers,” said CEO John Hartner. “We are proud to be the first industrial 3D printer
采用粘合剂喷射技术的工业砂3D打印和金属3D打印 技术公司ExOne宣布，与全球自动化和数字化知名公司 西门子开展合作，双方将为铸造、航空航天、汽车、能 源等行业的客户提供服务。 西门子的软件和自动化技术数字企业产品组合,包括 MindSphere将通过新型砂打印机S-MAX Pro得到完全 体现，最高打印速度可实现135升/小时（18秒/层）。 S-MAX Pro在2019年德国国际铸造展GIFA上推出。 “通过扩大合作伙伴关系，ExOne将为使用我们的 3D打印技术的铸造厂和制造企业提供更多的价值，” 首席执行官约翰•哈特纳说，“我们非常自豪成为第一家 完全集成西门子最新的控制、传感运动技术以及和新的
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product news/产品新闻 to fully integrate the latest of Siemens control, sensing and motion technologies and this new MindSphere technology, which will give our customers a new level of control and plant integration.” Dr. Karsten Heuser, Vice President of Additive Manufacturing at Siemens Digital Industries said: “We are proud to further strengthen our partnership with ExOne and to further advance the industrialization of Additive Manufacturing. Siemens brings in new digital technologies and its profound industrial domain knowhow to help ExOne in generating real values. The new S-MAX Pro 3D printer again proves that seamlessly integrated software and automation solutions result in shorter time to market, higher performance and maximum availability.” The Digital Enterprise portfolio from Siemens comprises integrated hardware, software and services supporting ExOne to leverage the benefits of Industry 4.0. In the center of this holistic approach stands the “Digital Twin” using a shared data model alongside the entire value chain: From the machine concept over machine simulation, engineering and commissioning to operations and services. Machine operators secure their investments with shorter lead times, increased machine performance and smarter service decisions. The ExOne app “3D Live” runs on MindSphere–the open and cloud-based IoT operating system from Siemens to analyze machine data and other relevant information in real-time, providing the basis for automated or timely decision-making and by that turns data into value. As an example, ExOne machines enable the operator to identify anomalies for improving maintenance and repair activities so that unplanned downtimes can be avoided. “We look forward to working with Siemens to further our capabilities in delivering production solutions for industrial 3D printing. Together we will help our customers integrate our systems into new smart factories and integrate with those already deploying Siemens’ technology,” Hartner said. ■
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MindSphere（开放物联网操作系统）的3D打印技术公 司，将使客户的控制和工厂集成达到新的水平。” 西门子数字工业增材制造副总裁卡斯滕•霍伊泽尔博 士表示：“我们很自豪能够进一步加强与ExOne的合作 关系，并进一步推进增材制造的产业化。西门子引入了 新的数字技术及其深厚的工业领域知识，帮助ExOne创 造真正的价值。新的S-MAX Pro 3D打印机再次证明无 缝集成的软件和自动化解决方案可缩短产品上市时间， 提高产品性能并实现最大可用性。“ 与ExOne3D打印系统连接 西门子的数字企业产品组合包括集成硬件、软件和 服务，以支持ExOne能够充分利用工业4.0的优势。这 种整体工艺的核心是“双重数字化”，即在整个价值链 使用共享数据模型：从机器的概念到机器的模拟、生产 和调试，包括运营和服务。机器操作员通过缩短交货时 间，提高机器性能和做出更智能的决策来保障投资。 ExOne APP“3D Live”运行在MindSphere上-西门 子的开放式和基于云的物联网操作系统，可实时分析机 器数据和其他相关信息，为自动或及时做出决策提供基 础，从而将数据转换为价值。例如，ExOne的设备使操 作员能够识别异常情况，改善维护和维修操作，从而避 免意外停机。 哈特纳补充说：“我们期待与西门子合作，进一步提 升我们为工业3D打印提供生产解决方案的能力。我们 将共同帮助客户把我们的系统集成到新的智能工厂中， 并与已经采用的西门子技术进行集成。” ■
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
product news/产品新闻
Personalized rapid customization integration solution provider for equipment complex parts 装备复杂零部件个性化快速定制一体化解决方案提供商 China Academy of Machinery Science & Technology Group (CAM) was founded in 1956, the goal of CAM is to improve the equipment manufacturing level of China. CAM has 16 subsidiaries including the holding companies with the operation system of the group management of parentsubsidiary type. CAM has built 39 key laboratories and an engineering research center, and all have been certified by government as national, provincial and industrial level innovation platform. CAM is engaged in the basic common technology research for manufacturing industry. With the development in these 60 years, CAM has gained more than 7,000 achievements which have been applied in the main domestic economical industries such as machinery manufacturing, automobile, aeronautic and aerospace, environmental protection, energy, transportation, information, metallurgy chemical engineering, construction and etc. Complicated casting patternless composite manufacturing technology and equipment which is developed by CAM won the second prize of National Technological Invention. The key patternless casting technology of high-efficiency, high-performance, and high-precision has been breakthrough and great achievements have been made in technology, composite casting and Seria equipments. Complex curved sand/core flexible extrusion near-forming technology, cutting net-forming technology and composite forming process developed by CAM make the patternless, high-precision, high-efficiency manufacturing of complicate castings realized, shortening more than 50% of the manufacturing cycle and reducing more than 30% of the cost. Invented a multi-material composite casting mold matching with the casting and its assembly method, realized the active regulation of the casting performance, solved the problem of shape and performance precisely control, casting scrap rate reduced from 5%-10% to 2%-4%, weight reduced about 10%-20%. It developed the digitally controlled flexible array contacts and high wear-resistant large aspect ratio cutting tools, proposed an integrated tool cooling and cutting sand removal method, developed a sand/core flexible extrusion molding machines, patternless casting precision forming machines and 15 other
机械科学研究总院集团始建于1956年，提升中国装 备制造水平是机械总院的神圣使命。拥有16 家全资及 控股子企业（公司），实行母子公司式集团管理体制。 建有39个国家级及省市级重点实验室和工程（技术） 研究中心。主要从事装备制造业制造技术（基础共性技 术）研究开发的研究院和现代制造服务业企业，自成 立五十余年来，累计取得科研成果及专利7000 多项， 广泛应用于机械制造、汽车、航空航天、环保、能源、 交通运输、信息产业、冶金、化工、建筑等重要产业 领域。 由机械科学研究总院集团自主研发的“复杂铸件无模 复合成形制造方法与装备”荣获国家技术发明二等奖。 该成果突破了复杂铸件高效率、高性能、高精度无模成 形关键技术，在工艺方法、复合铸型、系统装备等方面 取得重大成果。开发出复杂砂型/芯曲面柔性挤压近成形 技术、切削净成形技术及其复合成形工艺，实现了复杂 铸件无模化、高精度、高效率制造，制造周期缩短50% 以上，成本降低30%以上；发明了一种与铸件相匹配的 多材质复合铸型及其坎合组装方法，实现了铸件性能主 动调控，解决了形性精确控制难题，铸件废品率从5% ～10%降至2%～4%，减重10%～20%；开发出数字化 控制的柔性阵列触头、高耐磨大长径比切削刀具，提出 了刀具冷却与切削排砂一体化方法，研制出砂型/芯柔性 挤压成形机、无模铸造精密成形机等7类15种装备，解 决了复杂铸件高精度成形制造装备难题，铸件精度提高 了2～3个等级，可达CT8。无模铸造精密成形机可用于
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product news/产品新闻 kinds of equipment in seven categories, solved the problems of complicated castings high-precision forming manufacturing equipment. Casting accuracy has increased by 2 to 3 levels and can reach up to CT8.The patternless casting precision forming machine can be used to manufacture resin sand, water glass sand, coated sand, ceramics, etc. The maximum forming size is 5,000 × 3,000 × 1,000 mm. The achievements were granted 47 invention patents (19 in the United States, Japan, and Europe) and 12 software copyrights. They won the second prize of National Technological Invention in year 2017, the China Machinery Industry Science and Technology Award (technical invention) in 2016, China Patent Gold Award in 2016, Beijing Science and Technology Award (technical invention) in 2012, First Prize of Beijing Invention Patent in 2011 and three national key new products. The technology has been promoted and applied in more than 100 companies including Shanghai Academy of Space Technology, AECC Harbin Dongan Engine, Guangxi Yuchai Machinery Group, FAW Foundry and Yto Group Corporation. The equipment has been exported to Spain. Fourteen application demonstration bases have been established in China, realizing the manufacturing of steel/iron, aluminum/magnesium alloy castings. This technology is of great significance for promoting the innovation of high-end equipment technology, safeguarding national defense security, and promoting green development. ■
树脂砂、水玻璃砂、覆膜砂、陶瓷等多种铸型制造， 最大成形尺寸为5000mm×3000mm×1000mm。 该成果获授权发明专利47件（美、日、欧等19 件），软件著作权12项。获2017年度国家技术发 明二等奖、2016年中国机械工业科学技术特等奖 （技术发明）、2016年中国专利金奖、2012年北 京市科学技术一等奖（技术发明）、2011年北京 市发明专利一等奖和3项国家重点新产品等。该技 术已在航天八院、东安发动机、广西玉柴、一汽铸 造、中国一拖等100多家企业推广应用，设备出口 西班牙，并在国内建立14个应用示范基地，实现了 铸钢/铁、铝/镁合金等铸件制造。该技术对促进高 端装备技术创新，维护国防安全，推动绿色发展具 有重大意义。 ■ 更多内容，请访问www.cimpe.cn
For more information, please visit: www.cimpe.cn
Huicheng Foundry ordered 3 large die casting machines from Norican 济南慧成采购3台Italpresse大型压铸机 Jinan Huicheng Foundry Co., Ltd. ( Jinan, Shandong), a member company of China Foundry Association, signed an agreement to order three high-pressure die-casting machines from Italpresse Gauss, a Norican Technology Company, on June 26, at Norican’s stand at this year’s GIFA. All three purchases are firsts in the Chinese market. They are: the first TF4400 Italpresse Toggle Free die casting machine in China for a Chinese customer, the first IPr3700 Italpresse die casting machine in China for a Chinese customer, the first TF1850 Italpresse die casting machine in China for a Chinese customer and the first Italpresse machine to be manufactured locally in China. Ms. Liu Yanling, the Vice President and General Manager of Jinan Huicheng Foundry Co., Ltd., and Wei Baohua, Senior VP of Norican Group Asia Pacific, President of Norican Group’s Metal Forming and CEO of Norican Group attended the signing ceremony. Jinan Huicheng Foundry Co., Ltd. is an aluminum alloy die-casting manufacturer with a plant area of 100,000 square meters. It is a specialized technology company which can provide high-pressure casting, low-pressure casting, gravity casting, machining, stamping and mold design and manufacturing services. In the beginning, the company mainly produced powertrain castings including motor engine boxes and gearboxes. To meet market demand, the company now 54
6月26日，2019德国GIFA铸造展诺瑞肯集团展台 上，中国铸造协会理事单位济南慧成铸造有限公司与 诺瑞肯集团成功签订3台高压压铸机设备购买协议。包 括中国首台进口4400吨高压压铸机、3700吨高压压 铸机以及国产首台1850吨高压压铸机各一台。济南慧 成铸造有限公司副董事长、总经理刘燕岭、诺瑞肯集 团亚太区高级副总裁魏宝华、诺瑞肯集团金属成型总 裁Peter和诺瑞肯集团CEO Anders作为双方代表正式 签署战略合作协议。 济南慧成铸造有限公司是一家中国老牌的铝合金压 铸企业，拥有十万平方米的厂房，是集高压铸造、低 压铸造、重力铸造、机械加工、冲压及模具设计与制 造为一体的专业化高科技企业。公司前身主要做摩托 发动机箱体、变速箱等动力总成铝合金铸件，随着市 场的变化，后期逐渐介入汽车、船舶、轨道交通等交 通工具的动力总成行业，工程机械行业、通讯行业的 精密铝合金、铝镁合金属铸件配套，属于难度较大的
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
product news/产品新闻 has invested in the powertrain industry of vehicles, ships, rail transit; aluminum investment castings and alu-mag castings for engineering machinery and communication industry are sophisticated high-end die castings. Liu Yanling said, “Italpresse always devotes itself to the research and development of die casting technology. Italpresse was the first company to introduce forged platens, and this is the core technology which we can see in other companies now. From the design of the platens right through to the excellent machine controls, Italpresse technology will give us an accuracy and flexibility that is a real competitive advantage.” With the strategic cooperation between Jinan Huicheng and Norican Group, the foundry will provide the market with high quality aluminum alloy die castings that meet the new requirements the market. Liu concludes: “Local service here in China is incredibly important to us. We’re delighted to cooperate with Norican Group and proud to be the first company in China to purchase these machines.” ■
高端压铸件。 刘燕岭女士表示：“在压铸领域，意特佩雷斯是 比较安静地沉淀于研发，为压铸机行业贡献研发的企 业，其中它的自动化模桥、快速锁模装置是非常特殊 的，还有最核心的模板，现在其他的企业也有模板焊 接钢材技术，但是最初我们是在意特佩雷斯看见的， 也就是说在压铸机领域里面，它是热衷于研发而不止 是卖压铸机。” 济南慧成与诺瑞肯集团结成战略合作伙伴，为市场 提供优质的符合新市场需要的铝合金压铸件。 刘燕岭总结说：“提供中国本土服务对我们来说非 常重要，我们很高兴与诺瑞肯集团合作，并且为成为 中国首家购买这些设备的公司感到自豪。” ■
Fusion-diamond ultrahard grinding tools create new grinding 铸铁件磨削专用金刚石熔合超硬磨具及磨削设备开创铸造行业磨削新天地 Guhua brand fusion-diamond ultrahard grinding tools and equipment are the new products which are specially researched and developed by Nanjing Guhua Electromechanical Technology Co., Ltd. for the characteristics of foundry industry and problems of traditional grinding tools. They can be widely used in manual and automatic grinding. They are the latest invention in the field of international ultrahard abrasives and are the upgrade and update of traditional diamond ultrahard grinding tools, resin silicon carbide and corundum grinding tools. Moreover, all products are internationally certified. The product quality management system has passed ISO9001:2015 standard certification. For safety standard, they have MPA and CE certification certificates. The characteristics are as follows: • High-efficient durable & economical—Advanced international fusion-diamond technology ensures high diamonds exposure and high-strength bonding between diamonds and steel substrate. Compared with traditional grinding tools, the grinding efficiency of cast iron will increase over 1 time and the life span will be over 60 times. • Safe & environmental-friendly—The product consists of premium steel and diamonds has thoroughly eliminated many problems of traditional grinding tools, such as poor water & alkali resistance, short storage time, easily broken, large sparks and serious dust pollution. • Perfect choice for automatic grinding equipment—Compared with traditional diamond ultrahard grinding tools, higher efficiency and longer life span of our products ensure more continuous operation of the automatic equipment, plus better economy thus being the perfect choice for automatic grinding equipment. ■
“固华牌”金刚石熔合超硬磨具及磨削设备，是 南京固华机电科技有限公司针对铸造行业特点及传统 磨削工具中存在的问题而研发及生产的新型产品，可 广泛应用于手工与自动化磨削中。它是国际超硬磨具 领域的最新发明，是传统金刚石超硬磨具、树脂碳化 硅及刚玉磨具的升级换代产品。产品质量管理体系通 过ISO9001:2015标准认证，产品具备国际安全认证 MPA、CE证书。优势如下： 1. 高效 耐用 经济——领先国际的金刚石熔合技术，确 保金刚石出露高、金刚石与钢基体结合强度高。打磨 铸铁件的效率较传统磨具可增加1倍以上，使用寿命 可达传统磨具的60倍以上！ 2. 安全 环保——磨具基体采用优质钢材、磨料采用金 刚石，彻底消除了传统磨具的耐水性及耐碱性差、保 存期短、易断裂、火花大、粉尘污染严重的问题！ 3. 自动化磨削设备的最优选择——较传统金刚石超硬磨 具，磨削效率更高、使用寿命更长，确保自动化设备 更加连续地运转工作，配合良好的经济性，是自动化 磨削设备的最优选择！ ■ 更多信息，请登录我公司官方网站进行了解： http://www.njguhua-et.com/ 或者，您也可以邮件联系我们： charlie.chen@njguhua.com; katrina.cui@njguhua.com
October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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product news/产品新闻
Mingzhi Technology presents a new coremaking experience 明志科技：打破常规 重新定义——MiCC制芯生产新体验 In the first half of 2019, following three years of development, Mingzhi pioneered a new generation of core centers: the intelligent integrated core center (MiCC 300) with a new control system (MiCL 1.0) which meets the requirements of intelligent casting production. It is developed based on a “Green Foundry” philosophy and our in-house foundry experiences with considerations of safety, efficiency, environmental-friendliness, intelligence, convenience and aesthetic design. This new product was uniquely developed by Mingzhi with an original design which promises to refresh the coremaking experiences of foundries. The traditional core unit consists of a sand handling system, mixing system and coremaking system including a core shooter, steel platform, mixer and daily hopper. The overall height of the unit is over 9m. It occupies a considerable space and is challenging to install. MiCC is comprised of an integrated core sand preparation machine, a core shooter, auxiliary equipment and scrubber, all of which combined create a complete integrated core center. MiCC’s key features include it’s compact structure, easy maintenance and installation. With a convenient layout to satisfy core production requirements, it shortens the core making process and saves on raw material use and energy consumption. The complete core unit consists of five modules: • The raw material module stores sand, powder, binder and has an auto-temp control on the daily hopper to meet the process and environmental requirements. • The sand mixing module achieves real-time mixing of sand, powder, binder using a pre-mixing and final-mixing patented technology for better core sand mixing efficiency and utilization. • The core making module includes functions of
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2019年上半年明志科技在国内外成功推出的“打 破常规、重新定义”的智能化集成式制芯单元（MiCC 300）配以适应铸造生产智能化要求的全新MiCL1.0 智能控制系统，是明志科技历经3年多的探索开发，基 于“绿色和智能铸造”理念，并结合明志科技多年铸造 生产的体验和经验，以绿色环保、安全高效、集成美 观、智能便捷为设计理念，自主创新、全球首创为客户 的制芯生产提供全新体验的新产品。
传统制芯单元： 包括原砂处理系统、混砂系统、制芯系统；如图1， 包括制芯机，制芯机上方的钢构平台、钢构平台上的混 砂机、混砂机上方的日耗斗平台及日耗斗，以及连接各 个系统装置的管路。为此，整个制芯单元组成一般都在 9米以上，占地面积大，安装难度高，现场安装工作量 大，安装工期。
MiCC集成式制芯单元（如图2）： MiCC按照制芯工艺流程将制芯生产所需的芯砂准 备、砂芯成型以及配套的工艺装备、环保装置集成为一 体，组成一个完整的集成式制芯单元，降低了厂房高度 要求，缩短了安装工期，非常方便客户根据铸造生产需 求的灵活设置，而且实现了制芯过程的短流程运行，极 大地节约生产过程中的各种材料和能源的损耗，降低运 行成本并实现最大程度的节能与环保。 整个单元划分为以下5大模块： 五大模块功能及亮点： 100. 原料模块：实现原砂、辅料、粘结剂存储及温
| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION October 2019
product news/产品新闻 core box closing, shooting, curing, core ejecting, shooting head and upper core box cleaning. An all-electric servo control makes movement more rapid and positioning more accurate. Combined with multi-pressure shooting and curing patented technology, it diversifies the shooting process, solidifies faster and uses less catalyst and thus core making efficiency is improved. • The auxiliary module includes functions of noise deadening, lubrication, amine dosing (cold box process), scrubber (cold box process), water cooling (inorganic) and moisturizing device (inorganic). Shortens exhaust gas path to save energy, collects exhaust at minimum loss and neutralizes emission directly, saving costs. • The electrical control module integrates industrial PC+PLC and sensors which collect in-time key data to enhance systematic control and process capabilities. MiCC also distinguishes operation controls, process controls, maintenance controls, and supervisory controls for stable production and management. The one-click function simplifies operation. Its maintenance management and remote diagnosis greatly guarantee timely maintenance for the stability of process and core quality. An added convenience for managers is provided in knowing production information as needed and integrating with MES systems. ■
控；日耗斗集成调温技术保证了工艺要求并实现最 大程度的节能高效环保。 200. 混砂模块：实现原砂、辅料、粘结剂定量及混 合；其预混+终混的两级专利混砂技术实现了砂芯的 现混现用，既提升了芯砂混制的效率又改善了砂芯 利用率。 300. 制芯模块：含锁模、射砂、固化、顶芯、射头及 上芯盒清理等功能；其高精度的伺服控制技术实现 主要运动件的快速移动和精准定位，并结合多级压 力射砂及集成固化专利技术，增加了射砂过程的多 样性选择、提升了吹气固化效率、降低了催化剂用 量，实现了砂芯生产效率的最大化。 400. 辅助模块：含消音、自动润滑，以及与制芯工艺 密切相关的催化剂定量、尾气处理（冷芯）、水冷 和保湿（无机）等功能；其尾气处理装置采用最短 距离集成，以最小管路损失实现尾气高效处理，满 足节能环保的要求；同时完成对制芯机排出废气进 行中和处理实现直排，最大程度地节约成本。 500. 电控模块：硬件采用工控机IPC+PLC+传感器集成 控制技术，提升了系统的控制及处理能力，通过各 传感器收集反馈各种关键生产环境及参数信息。软 件配以自主开发的MiCL智能制芯控制系统，通过身 份识别将操作、工艺调整、设备维护及管理权限实 现了有效的区分管理，保障了生产稳定性和管理的 要求。其一键式操作极大地降低操作难度；备配件 维护管理及远程故障诊断极大地便利了设备的及时 维护；工艺参数的智能调用并结合环境变化及时调 整，确保工艺和制芯质量的稳定性；各种管理者所 需的报表提供，方便各级管理人员了解生产信息并 便利与MES系统集成。
携手共享制芯生产新体验 MiCC明志集成式制芯单元帮助您实现灵活便利、安 全高效、绿色智能的制芯生产新体验，帮助您降低投资 成本和运行成本。 欢迎您莅临明志科技体验“快乐制芯”，我们将为 您提供最佳的制芯解决方案，为您创造最大价值！ ■
October 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |
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