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Hawkeye Borescopes ®

Hawkeye管道探視器

沙子

Sand visible with a Hawkeye Pro Slim 12” Rigid Borescope

無效

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

閃光

Flash as seen with a Hawkeye V2 Video Borescope

我們提供嚴格,靈活和視頻管道探視器80個設計。 Manufacturers of complex castings now have a fast, affordable way to improve quality control in their visual inspection process with Hawkeye® Pro Borescopes. We stock over 80 models of rigid, flexible and video borescopes, and accessories, at prices far less than comparable instruments. Hawkeye Pro Borescopes provide detailed images of sand, voids, flash, surface-finish irregularities, and numerous other defects that can affect the quality of a wide range of mission-critical castings used in automotive, aviation, power generation, and more. Made in USA

gradientlens.com

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info@gradientlens.com


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ExOne industrial-strength sand cores and mold packages and functional metal parts: cost-effective & precise.

exone.com


WWW.GLOBALCASTINGMAGAZINE.COM

DECEMBER 2017

volume 7 number 4

P.44

P.31

P.9 FEATURES

专题文章

31 Searching for the Low-Cost, Power-Dense, Aluminum Engine

31 低成本、动力强的铝合金发动机的研究

J. BLACKBURN, J. THRASHER

38 Critical Characteristics Affecting the Surface Finish of Castings

J. BLACKBURN, J. THRASHER

38 影响铸件表面质量的关键因素 N. BRYANT, J. THIEL

N. BRYANT, J. THIEL

DEPARTMENTS

专栏

9 Editorial 11 Industry News 44 Product News

9 编者的话 11 行业新闻 44 产品新闻

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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STAFF/工作人員

STAFF/工作人員 MODERN CASTING

FOUNDRY-PLANET.COM

Managing Editor SHANNON WETZEL, swetzel@afsinc.org

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

Associate Editor BRIAN SANDALOW, bsandalow@afsinc.org

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

Advertising Sales JIM BECKWITH, jbeckwith@afsinc.org JOE MURPHY, AdSales25@aol.com MARK MCGOWAN, mmcgowan@afsinc.org

Advertising Sales OANH LARSEN, ons@foundry-planet.com THERESA NEUMANN, tn@foundry-planet.com

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

MODERN

CASTING CHINA FOUNDRY ASSOCIATION 中国铸造协会 Publisher/Executive Vice President & Secretary General/ 出品人 ZHANG LIBO/ 张立波 Senior Editor/ 主编 WEN PING/ 温平 Deputy Editor/ 副主编 HUANG TIANYOU/ 黄天佑 FAN QI/ 范琦, fanqi@foundry.com.cn Editor/编辑 GAO WEI/高巍, gaowei@foundry.com.cn Li Mengmeng/李 蒙蒙, limengmeng@foundry.com.cn Advertising Sales Manager/ 广告销售主管 GAO WEI/ 高巍, gaowei@foundry.com.cn

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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editorial/编者的话

Casting Conversions Mean Growth 铸造工艺的转变意味着发展

I

n the metalcasting industry, casting conversions represent a real target for growth. These are engineered components originally produced with another manufacturing method that are redesigned for the metalcasting process. Typically, the cases involved a multiple part weldment or fabrication re-engineered as a single-piece casting. The casting process offers many benefits to the designer that centers around the freedom of shape, making it a good choice for intriate parts. The designer can manipulate a component to meet multiple functions, place material and strength where needed, and remove material where it is not for lower weight and cost. Still, metalcasting is not always the first manufacturing method considered for a new part and it might not be until after production and some time has passed that the case for metalcasting starts to surface. Cost reductions might be sought, or better repeatability is needed. Metalcasters can be pretty good at spotting potential conversions to metalcasting and often work with customers to do a cost benefit analysis, pinpointing which pieces would decrease costs and improve value the most. Even after considering the benefits to converting to metalcasting, designers and purchasers have another hurdle: tooling cost. Investing up front on the patterns to make the castings for a component already in production? It is not an easy pill to swallow, and traditional tooling can be expensive. However, metalcasters are making inroads in reducing those costs. Rapid manufacturing has been building steam and includes CNC machining patterns, 3-D printing sand and wax molds, and now, 3-D printing plastic patterns. In recent years, 3-D printing equipment and material has become more widespread and less expensive, so the barrier to entry is lowering. Printing patterns is quicker and cheaper than producing them the traditional way, particularly when going through the design and development phases. Often this method is used for very low volumes, such as between one or two pieces, but that is changing. Some reports have shown 3-D printed plastic patterns working for up to 500 molds. Now is the time to further explore 3-D printing tooling. It can lower your costs and time to market, as well as remove a little bit of the hurdle for redeveloping a part to take advantage of the casting process’ design freedoms.—Shannon Wetzel, Modern Casting managing editor. ■

张立波 出品人 中国铸造协会

铸造行业而言,向铸造工艺转变是行业真 正的增长目标。有些零部件最初采用其他 工艺生产,而现在改为采用铸造工艺重新 设计。通常情况下,这样的改变可以是多部件的焊接 件或多个铸件重新设计为单件铸件。 铸造工艺为设计师自由设计产品形状提供了很多便 利,使其成为复杂零件的最佳选择。设计师可以设计一 个部件以满足多种功能,根据需要在相应的位置添加材 料、提升强度,也可以为了降低重量和成本,减少某些 位置的材料。 尽管如此,铸造并不总是新零件的制造方法的首 选,可能在生产完成后才会想到,或者经过一段时间后 才开始采用铸造工艺。可能需要降低成本,或者需要更 好的可重复性生产。 铸造企业能够非常巧妙地找到潜在的转变点,并且 可以与客户合作进行成本效益分析,指出哪些部位能 够降低成本并最大限度地提升价值。 即使是考虑到改用铸造工艺的种种优势后,设计 师和采购商还存在其他的困扰:模具成本。是否要从 已投产铸件的模具投资开始?这是不容易接受的,传 统的模具制造方法是非常昂贵的。 然而,铸造企业在降低这些成本方面取得了巨大 进步。快速制造工艺已经有了很大发展,包括CNC机 械加工成型、3D打印砂型和蜡模,现在还有3D打印 塑料模具。 近年来,3D打印设备和材料已经得到越来越广泛 的应用,价格也越来越低,因此进入的门槛在逐渐降 低。打印模、型比传统制造工艺不仅快而且便宜,尤 其是在设计和研发阶段。这种工艺通常用于小批量生 产,例如一两件产品的生产,但是情况已经发生了改 变。一些报道表明,3D打印的塑料模具可以生产出 500个铸型。 现在正处于进一步开发3D打印模具的时期。它可 以降低成本和投放市场的时间,此外,利用铸造工艺 的设计自由优势,为铸件的重新研发扫除障碍—Shan-

non Wetzel, Modern Casting managing editor. ■

Shannon Wetzel Managing Editor MODERN CASTING

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

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行業新聞

PRECISE ALLOYS + DYNAMIC DOSING = OPTIMUM IRON QUALITY Read more about better iron foundry results in this magazine

Improving your casting quality and efficiency starts with Elkem. Our custom made dynamic dosing systems assist you in precisely calculating, dosing and positioning of the foundry alloys in your ladle. The Elkem dynamic dosing system reduces the risk of human error, calculates the optimal addition rates, improves your iron quality and allows full traceability and documentation of the treatment process. If you want more information, please, talk to your Elkem representative or contact at foundry@elkem.com | FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION 10 us

December 2017


INDUSTRY NEWS/行業新聞

Movable Bracket of a Forage Harvester 草料收割机的可移动支架

EDS Casting redesigned a welded construction into a ductile iron (EN-GJS-450-10) sand casting with an ExOne 3-D printed sand mold package. This project was commenced for a client in the agricultural industry. This console is a repeating element from an agricultural machine. The old construction had many problems with fatigue failure and warping due to welding. The goal was twofold. The first was to convert the welded construction into a cost-efficient casting while increasing the performance. The second goal was to engineer a working solution and deliver the part within a next to impossible deadline: 10 weeks. The results were a 54% weight reduction, from 18 kg in S355MC to 8.2 kg in En-GJS-450-10 (5.31-7) and a 40% cost reduction. The problems were successfully eliminated during the engineering of a new, optimized sand casting. The product was built into the machine within the deadline of 10 weeks. ■

EDS铸造公司使用ExOne 3D设备打印砂型,将原 来的焊接结构件改为球墨铸铁(EN-GJS-450-10)砂 型铸件。 这个项目开始于与一个农业客户的合作。这个控制 台是农业机械经常更换的部件。原来的结构有由于焊 接引起疲劳失效和翘曲问题。工作目标是双重的,首 先是将焊接结构件转换成具有成本效益的铸件,同时 提高性能; 第二个目标是设计解决方案,并在接近不 可能的生产周期内交付铸件:10周。 最终的结果是控制台重量减轻了54%,从原来的 S355MC的18 kg减少到En-GJS-450-10(5.31-7) 的8.2kg,成本降低了40%。通过设计新的优化的砂 型铸件,这些问题成功解决。该铸件在10周内完成并 安装于设备。 ■

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行業新聞

VISIT US IN HALL 7A - STAND 412 Schmeltzmetall Jürgen Barz info@schmelzmetall.com

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Comexale Emmanuel Bach info@comexale.com

T.E.L. Nordic ApS Lars Skogstad skogstad@telnordic.dk

N.T.K. Plants Management Tuvia Kornfeld elgad@netvision.net.il

BCM Kimya Cenk Sonmez cenk@bcmkim.com

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION December 2017

CTS-EurogussAD 11-2017.indd 1

2017-11-13 3:18 PM


INDUSTRY NEWS/行業新聞

Ground-breaking for Bühler Innovation Campus 布勒创新中心举办奠基仪式 Bühler celebrated the ground breaking for its Innovation Campus in Uzwil, Switzerland. Completion of the building is expected for the first quarter of 2019. This significant investment of over CHF 50 million, spent over three years, demonstrates Bühler’s commitment to innovation and technology, and to the workplace Switzerland. “This innovation campus will reinforce our innovation power and market leadership. It will help us bring together the smartest minds of the industry to create innovations for a better world”, said Stefan Scheiber, CEO of Bühler, at the ground-breaking. The innovation campus consists of two key elements: the upgraded technology labs and the new innovation building. The new building will build a bridge between the engineering and business world in the existing towers and the upgraded application labs. “This building is focused on collaborative innovation,” says Ian Roberts, Chief Technology Officer at Bühler. “We are creating a collaborative space for all functions, all ages, and all knowledge holders. It will allow us to live and foster our innovation culture and test future work practices.” The new building will bring together Bühler’s network of partners, be they customers, start-ups, academics, or suppliers, and create a link to the technology labs. Bühler’s existing technology labs, such as the Die Casting technology center will be upgraded during the building

布勒集团在瑞士乌茨维尔举办了创新中心奠基仪 式,项目预计2019年第一季度竣工。工程投资额超过 5000万瑞士法郎,建设周期为3年,该项目表明了布勒 集团致力于技术创新的决心以及瑞士工厂的建设。“创 新中心将增强我们的创新能力和市场领导地位,有助于 我们汇集行业智慧,更好的为未来创造新技术,”布勒 集团CEO斯蒂芬·塞贝尔在奠基仪式上说。 创新中心由2个关键部分组成:升级后的技术实验室和 新的创新大楼。新建筑将把现有的工程和业务大楼与升级 改造后的应用实验室连接起来。“新的办公大楼将应用于 协同创新,”布勒集团首席技术官伊恩·罗伯茨说,“我们 希望为所有功能、各个年龄段的员工以及各类知识技能拥 有者创造一个协同创新的空间。它将有利于创新文化的培 育和发展,以及未来工作的实践。”新大楼将与布勒合作 伙伴的网络链接起来,包括客户、初创公司、学者或供应 商等,把他们与技术实验室联系起来。 布勒集团现有的实验室是新科研中心的组成部分,

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行業新聞

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INDUSTRY NEWS/行業新聞 process, and are an integral part of the new campus, as they are closely interlinked with the new building. The training and application areas for Die Casting will be completed in 2018. Equipped with complete die casting cells, they provide the perfect setting to test and improve products and processes together with customers and partners and to train die casting experts on the latest equipment. To be able to connect the global die casting industry, a new training and application center was inaugurated in Wuxi, China, in October. Together with the third Bühler Die Casting hub in Holland, US, it enables Bühler to offer training and exchange of know-how around the globe. ■

如现有的压铸技术中心在新项目建设过程中将进行升 级,它们与新建筑是紧密相连的。压铸培训和应用中心 将于2018年建成。该中心配备了全压铸单元,将为客 户和合作伙伴提供完善 的设备来检测和提高产 品和工艺,并且可以使 压铸专家了解最先进的 设备。为了能够与全球 压铸行业联系起来,一 个新的培训和应用中心 已经于10月在中国无锡 成立。随着第3家布勒压 铸技术中心在美国荷兰 镇成立,布勒集团将具 备在全球范围内为客户 提供培训和技术交流的 能力。 ■

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行業新聞

GET IN TOUCH! INDUSTRY 4.0 DIE CASTING LOW PRESSURE CASTING GRAVITY CASTING

The universal measurement system for machines of all manufacturers CQC Cast Quality Control This universal measurement and monitoring system offers comprehensive analysis possibilities and maximum flexibility, regardless of the make or age of the machine. User-friendly software and state-of-the-art hardware components make it possible for our customers to meet the ever-increasing demands of the die-casting industry. Sensors The accuracy of the process data measuring system is one aspect. The other aspect is that sensors have to deliver the corresponding data to the measuring system. The more precise they are, the more accurately they can be evaluated by the system. Our sensors represent our own tried-andtested developments and are subject to continuous further refinement in collaboration with leading producers. They are therefore ideally suited for use in the die casting process.

Measuring 16

Controlling

Monitoring

ELECTRONICS GmbH Kirchstraße 53 D-73765 Neuhausen/F. Phone +49 7158 60465 E-Mail: info@electronics-gmbh.de www.electronics-gmbh.de Analysing

Recording

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION December 2017


INDUSTRY NEWS/行業新聞

EUROGUSS 2018 fully booked EUROGUSS 2018展位售罄 EUROGUSS will take place at the Exhibition Centre Nuremberg from 16 to 18 January 2018. With around 600 exhibitors and more than 12,000 visitors expected, it's the leading trade fair for the entire die casting supply chain, from raw materials through technologies and processes to finished products. An attractive supporting programme featuring the International German Die Casting Congress, a finishing technology pavilion, practical workshops and awards ceremonies for die-casting competitions for aluminium, zinc, and for the first time, magnesium, make EUROGUSS the No. 1 gathering for the European die casting industry. The Nuremberg trade fair experts are also involved in other die casting events worldwide in 2018: at CHINA DIECASTING from 18 to 20 July in in Shanghai (China), at Fundiexpo in Guadalajara, Mexico for the first time from 24 to 26 October, and at ALUCAST in Delhi, India from 6 to 8 December. "The preparations for EUROGUSS are going really well,'' says a delighted Christopher Boss, Exhibition Director at NürnbergMesse.” More than 600 exhibitors - more than ever before - have registered for the event. Many exhibitors have chosen to have larger stands than they did at the last event. Naturally, all the market leaders will be out in force again, but we also have new exhibitors on board. Every last square metre of the three exhibition halls has been booked, so we are absolutely full. This shows just how important die casting is for lightweight construction." Products on display cover the entire die casting supply chain. More than half of EUROGUSS exhibitors are international. After Germany, the biggest exhibiting nation is Italy, followed by Turkey, Switzerland, Austria and Spain. Around 38 percent of the exhibitors are diecasting foundries. The remaining exhibitors will be showcasing die casting technology like machines, peripheral equipment, furnaces, moulds, metals, alloys, release agents and operating materials. There will also be displays covering the after-treatment of castings, hardening and surface technology, quality management, control and drive technology, rapid prototyping and software.

International German Die Casting Congress in NCC Ost for first time In 2018, the International German Die Casting Congress, which is very popular with trade fair visitors, will take place in the directly adjacent and easily accessible NCC Ost Congress Center. Presentations on the latest industry issues and developments will be the focus at the established three day event. The presentations will be simultaneously translated into English for the benefit of all international visitors.

EUROGUSS将于2018年1月16-18日在德国纽伦 堡会展中心举办,预计将有600多家展商和12000 多名专业观众参加。该展会是包括原材料、技术、 工艺以及产品的整个压铸行业产业链的知名行业展 会。同期重要的活动有德国国际压铸会议、表面处 理技术展、实操体验区,还有铝合金、锌合金以及 首次涉及的镁合金铸件颁奖活动,使EUROGUSS成 为欧洲第一大压铸行业盛会。2018年,纽伦堡展览 公司还将参与世界其他地区的压铸行业展会:7月 18-20日在中国上海举办的中国压铸展CHINA DIECASTING,首次参加10月24-26日在墨西哥瓜达拉 哈拉举办的墨西哥铸造展Fundiexpo以及12月6-8日 在印度德里举办的铝工业展ALUCAST。 “EUROGUSS的筹备工作进展一切顺利。”纽伦 堡展览公司展览总监克里斯多夫·博斯高兴地说。“ 目前参展商已达600多家,超过了前几届的展商数。 很多展商都申请了更大的展位面积。当然,压铸行 业的领军企业将悉数参展,此外,还有很多新的参 展商。3个展馆的展位已全部售罄。这些都表明压铸 行业对轻量化技术发展的重要性。” 展品涵盖了压铸行业全产业链。EUROGUSS半 数以上展商为国际展商。除德国外,参展商数量最 多的依次来自意大利、土耳其、瑞士、奥地利和西 班牙。38%的展商是压铸件生产企业,其余展商将 展示压铸机、周边设备、工业炉、模具、金属及合 金、脱模剂和材料等。此外,还有用于铸件的后处 理、硬化和表面处理技术、质量管理、控制和驱动 技术,快速成型和软件。

德国国际压铸会议首次在NCC Ost举办 2018年,深受观众欢迎的德国国际压铸会议将 在NCC Ost会议中心举办。最新的行业动态和发展 趋势的演讲将成为3天展会的焦点,为方便国际代 表参会,展会报告将进行英文同声传译。从11月 起,会议日程可以从网站下载www.euroguss.de/

December 2017 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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INDUSTRY NEWS/行業新聞

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INDUSTRY NEWS/行業新聞 As of November, the congress programme can be downloaded from: www.euroguss.de/programme. The congress is hosted by the Association of German Die Casting Foundries (VDD) within the German Foundry Association (BDG). Participation in the congress is included in the trade fair admission price.

Finishing technology pavilion in Hall 6 The separate pavilion for the key topic of finishing technology, which successfully premiered two years ago, will be featured once again in 2018. The after-treatment and coating of functional and heavy duty castings is an important issue for casting foundries. Appropriate machines and processing technologies help give the surfaces of cast products a high-quality appearance and may involve treatments like deburring, grinding, polishing, coating or finishing. The finishing pavilion in Hall 6, Stand 6-333 will showcase companies that offer machining and surface finishing of lightweight metals.

First-hand experience of die casting events worldwide NürnbergMesse Group is reinforcing the position of its successful events at its home location of Nuremberg by developing worldwide product families. The company sees itself as paving the way for German and other European die casting foundries aiming to break into the international market or wanting to strengthen their global business relationships. The next event in the EUROGUSS product family is CHINA DIECASTING in Shanghai from 18 to 20 July 2018, which expects to welcome around 350 exhibitors and 15,000 trade visitors. For the first time, NürnbergMesse Group will have a pavilion at the leading foundry exhibition Fundiexpo in Guadalajara, Mexico from 24 to 26 October 2018. Around 170 exhibitors and 5,000 trade visitors are expected to attend. The next event after that will be from 6 to 8 December 2018, when ALUCAST in Greater Noida, Delhi/NCR, India, will open its doors to around 150 exhibitors and more than 3,500 trade visitors. Various companies will report on their personal experiences in China, Mexico and India during EUROGUSS, within the scope of the China, Mexico and India Days event in NCC Ost. Surveys and market forecasts will also be presented. In the entrance area to Hall 7A interested parties can get detailed information about these overseas events. ■

programme。本次会议由德国铸造协会(BDG)的 德国压铸协会(VDD)主办。展会参观费包含会议 费。

表面处理技术展位于6号展馆 上届成功举办的表面处理技术展将于2018年再 次举办。后处理技术、功能涂料以及重型铸件是铸 件企业的重要话题。适宜的设备和工艺技术将使铸 件呈现高质量的表面效果,可能涉及到的后处理工 艺有修边、打磨、抛光、喷涂及精整。表面处理技 术展位于6号展馆,提供轻金属的机加工和表面处 理技术的展商将在6-333展台展示。

全世界压铸行业盛会的第一手信息 纽伦堡展览集团旗下展会的成功举办,增强了其 在德国本土的地位,同时还不断拓展集团在世界其 他地区的合作关系。纽伦堡展览公司为德国和欧洲 范围内希望进入国际市场或强化全球业务关系的压 铸企业开辟了道路。下一个EUROGUSS系列展会是 将于2018年7月18-20日在中国上海举办的CHINA DIECASTING,预计将有约350家展商和15000名 专业观众参加。纽伦堡展览公司还将首次参加10月 24-26日在墨西哥瓜达拉哈拉举办的墨西哥铸造展 Fundiexpo,预计将有170家展商和5000名专业观 众参加。之后,还将参加12月6-8日在印度德里举 办的铝工业展ALUCAST,预计将有150家展商和 3500多名专业观众参加。 来自中国、墨西哥和印度的企业将分别在EUROGUSS期间,在NCC Ost会议中心举办的中国日、 墨西哥日和印度日活动中分享经验,还将分享研究 和市场预测报告。如对以上活动感兴趣,您可在7A 号馆的入口处获取相关活动的详细信息。 您也可通过网站获得更多信息: www.euroguss.de/international。 ■

For further information please visit: www.euroguss.de/international.

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ANKIROS/ANNOFER/TURKCAST 2018 – An Ideal Platform For the Foundry Industry 2018土耳其国际铸造冶金展——铸造行业的理想平台 Turkey is ranked second in iron, steel and malleable iron castings and third in nonferrous metal castings in Europe. Capacity utilization rate is 65% in iron and steel Casting, but 90% in diecasting. Being aware of this fact, Turkish metalcasters are keen on investing in diecasting while keeping their existing market shares in their already established production range. This creates a lot of opportunities for machinery, material and technology suppliers to the diecasting industry. The next edition of ANKIROS/ANNOFER/ TURKCAST 2018 exhibition trio will be organized by Hannover-Messe Ankiros A.S. between October 25-27, 2018, in Istanbul, Turkey, in conjunction with two well established international congresses, namely the 10th International Foundry Congress by Turkish Foundrymen Association and the 19th International Metallurgy and Materials Congress by Turkish Chamber of Metallurgy and Materials Engineers. This trade fair trio has become the largest and most prestigious foundry event of Eurasia aiming to bring together all elements of the Eurasian Foundry Industry under one roof. Taking place every two years since 1992,

土耳其的铸钢、铸铁和可锻铸铁产量在欧洲排名 第二,有色金属铸件排名第三。铸钢铸铁的产能利 用率为65%,但是压铸产能利用率为90%。意识 到这个问题后,土耳其铸造企业在保持现有生产的 市场份额外,开始关注压铸业务,为压铸行业的设 备、材料和技术供应商创造了机会。 下一届土耳其铸造冶金展(ANKIROS / ANNOFER / TURKCAST 2018)的三个主题展会将 由汉诺威展览公司(Hannover-Messe Ankiros A.S.)主办,将于2018年10月25日-27日在土耳其 伊斯坦布尔举办。同期举办的有土耳其铸造协会主 办的第10届土耳其国际铸造大会,土耳其冶金与材 料工程师协会主办的第19届国际冶金与材料大会。 该三合一展已成为欧亚大陆规模最大且最知名 的铸造展会,旨在全面展示欧亚大陆铸造行业的发 展。自1992年,该展会每两年举办一次,已逐渐

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INDUSTRY NEWS/行業新聞 the fairs are establishing a reputation as one of the major shows for the global foundry industry. The 2016 edition of this exhibition trio was a great success as 985 exhibitors from 45 countries, around 15,000 industry professionals from all around the world, gathered on the 22.072m² net stand area. Stand reservations of the leading suppliers to foundries are progressing faster than ever for ANKIROS/ANNOFER/ TURKCAST 2018 fairs, which are gaining more and more corporate attention. These trade fairs will play an important role in the metallurgy industry and bring great business opportunities again. Due to the facts given earlier, there is a rapidly growing section for diecasting in ANKIROS and leading suppliers to the foundry industry have already secured their stand spaces. ■

发展成为全球 主要铸造行业 展会之一。 土耳其铸造 展于2016年 取得了巨大的 成功,共有来 自45个国家的 985家参展商 和来自世界各 地的约15,000 名专业观众参 加,展览净面 积达22072平 米。2018土 耳其铸造冶金 展得到了越来越多企业的关注,主要铸造企业都提前 预订了展位面积。三合一展会将再次在铸造冶金行业 发挥重要的作用并带来巨大的商机。 正如本文开始所述,压铸领域将在本届土耳其国际 冶金展上有快速增长。铸造行业的领先供应商已经预 定了展位。 ■

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Guangxi’s First Chassis Smart Manufacturing Plant Founded 广西首个底盘智能制造工厂落地广西汽车集团 On Sep. 25, 2017, Guangxi’s first wholly demonstration chassis smart manufacturing plant was founded in Liudong Passenger Vehicle Chassis Plant of Liuzhou Wuling Automobile Industry Co. Ltd., which is affiliated to Guangxi Automobile Group. The plant covers an area of 33 acres and is expected to produce 1 million sets of components for chassis per year. The first phase investment is 436 million yuan with an annual production capacity of 200,000 sets of main retarders and 200,000 key components for automatic gearboxes. The project is planned to be put into production in the second quarter of 2018. Applying smart manufacturing technology into the auto parts production is an effective method for Wuling Industry to promote its transformation and upgrade in recent years. The smart manufacturing plant fills the gap of the localization of key equipment for rear axle and independent suspension assembling line, forms key technology’s industry standard and patent, not only improving the quality and efficiency in key components manufacturing and also becoming the pacesetter in building a high-level smart chassis components production mode. Wuling Industry takes the opportunity of product transformation and industry upgrading, and devotes to build the self-owned brand of auto parts with international competitiveness. By upgrading from “manufacturing” to “smart manufacturing”, and following closely with the new type industry development trend of Guangxi, Wuling Industry is growing toward “Made in China 2025.” ■

2017年9月25日,广西汽车集团所属柳州五菱汽车 工业有限公司柳东乘用车底盘工厂,在其位于柳东新区 花岭片区的柳东乘用车零部件基地3期破土动工——广 西首个底盘智能制造全示范性工厂正式落地。该项目 占地200亩,目标产品为乘用车底盘系列产品,规划 为年产100万台套底盘核心零部件产品。项目一期总投 资4.36亿元,将具备20万台乘用车独立主减速器年产 能,20万台自动变速箱关键零部件年产能,计划2018 年二季度达产。 将智能制造应用到汽车零部件制造当中,是五菱工 业公司近几年推动企业更好转型升级的有力抓手。据 悉,该智能工厂项目突破了我国后桥/独立悬架装配生 产线关键短板装备国产化空白,形成关键技术的行业标 准与专利,不仅全面为企业在关键零部件制造上提质增 效,更将成为广西在打造高水准汽车底盘零部件智能 化生产模式标杆。五菱工业以产品转型、产业升级为契 机,着手打造具有国际竞争力的汽车零部件自主品牌, 通过由“制造”向“智造”升级,紧跟广西新型工业化 步伐,向“中国制造2025”迈进。 ■

Dalian Yaming Received National Special Fund 大连亚明汽车部件股份有限公司智能制造新模式项目获得国家 专项扶持资金 Recently, Dalian Yaming Automobile Parts Co. Ltd. received a national supporting fund of 20 million RMB for its new model of intelligent manufacturing in applying for 2017 special fund of industry transform and upgrade program. Began in June 2015, the project is expected to complete in August 2019 with a total investment of 204 million RMB. It includes the construction of digital plant for key intelligent equipment, internet of things data collection and sensing system, execution system of shopfloor manufacturing, visualized control center, involving 12 key equipment manufacturing, such as industry robots and high-end equipment, smart sensing and control equipment, intelligent detection and assembling equipment, intelligent logistics and storage equipment. It will allow the company to be able to produce large complex die mold in a more effective and flexible way and produce complex aluminum castings fully automatically. The company’s revenue will increase 150 million yuan and the profit will increase 12 million yuan. ■

日前,大连亚明汽车部件股份有限公司申报2017年 工业转型升级专项资金的智能制造新模式项目获得国 家2000万元的资金扶持。 该项目从2015年6月开始建设,预计2019年8月竣 工,计划总投资2.04亿元,主要包括建立智能化核心 设备的数字化车间、物联网的数据采集与传感系统、 车间制造执行系统、制造过程可视化的控制中心等内 容,涉及工业机器人及高端装备、智能传感与控制装 备、智能检测与装配装备、智能物流与仓储装备等12 种智能制造核心装备。 项目建成后,将使企业实现大型复杂压铸模具高效 柔性生产的智能制造及复杂铝合金压铸件全自动化生 产,每年可增加销售收入1.5亿元,增加利润1200万 元。 ■

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Sinolion Industrial Park Aluminum Wheel Put Into Production 中秦兴龙铝合金车轮项目正式投产 On Oct. 11, the high-strength and light-weight aluminum wheel project of Sinolion Industrial Park has been completed in Qinhuangdao, Hebei province, which means the annual output of 20,000 tons of light-weight chassis project has been officially put into production. Sinolion Industrial Park, which is a joint venture of 5 billion RMB by Sinolion Investment Holding and CITIC DICASTAL, started construction on Feb. 19, 2017. It includes seven projects, such as an annual output of 3 million highperformance light-weight aluminum wheels project, 20,000 tons of light-weight chassis components and new energy electric motor housing. The industrial park is expected to be completed in the end of 2017. The total investment for the first phase of the aluminum wheel project reaches 2.5 billion RMB and the annual production value is expected to reach 800 million RMB and increase 500 job positions. ■

10月11日,中秦兴龙产业园高强度、轻量化铝合金车 轮项目在河北秦皇岛开发区全线贯通,同时,年产2万吨 轻量化汽车底盘零部件项目顺利投产。 中秦兴龙产业园项目由中秦兴龙投资控股有限公司与 中信戴卡股份有限公司共同投资建设,项目总投资50亿 元,于2017年2月19日开工建设。主要建设年产300万 支高性能轻量化铝合金汽车车轮项目、年产2万吨汽车轻 量化底盘零部件项目、新能源汽车电机壳体项目等7个项 目,预计2017年年底完工。 中秦兴龙铝合金车轮项目总投资25亿元,项目投产 后,预计可实现年产值8亿元,新增就业岗位500个。 ■

Introduction of Anyang Qiang Ji and Its Technology 安阳强基技术介绍 Anyang Qiang Ji Precision Manufacturing Base Co.,Ltd is a leading high tech company in providing foundry product design and development, precision casting products and development of precision casting equipment. Based on a systematic integrated investment casting technology, Anyang Qiang Ji develops the oversized or super small sized, thin walled, complex precision castings and various castings. Anyang Qiang Ji has provided hundreds kinds of nearly impossible products in the fields of aviation, aerospace, weapon, automobile, energy, hydropower, ship, equipment and other civil and military fields successfully.The systematic integrated investment casting process of Anyang Qiang Ji is developed through a series of systematic integrated innovations in traditional investment casting. There are nearly 200 micro-innovations on the key process equipment and tools, every manufacturing process and materials and their preparation techniques, which make the technology reach the most advanced level of precision casting home and abroad at present. Based on the technology manufacturers have the abilities of making the products that are oversized or super small sized, thin walled, and with very complex and compact structure, which cannot be or hardly can be processed by traditional manufacturing such as turning, milling, planning and forging. Such processes can also help the manufacturers avoid worthless efforts. Thus during the product design, no matter how complex, how compact, how difficult the material is to process or cannot be process, the technology can provide for the security realization, it can liberate designers` ideas, and support and direct for a variety of optimized de-

安阳强基精密制造产业园股份有限公司是一家以精 密铸造技术为基础,从事铸造产品设计开发、精密铸造 生产、精密铸造装备研制一体化的高新技术企业。产 业园公司依托集成精密成型技术体系,开发制造各类大 型、薄壁、复杂精密铸件以及一体化设计成形组件,成 功的为航空、航天、兵器、汽车、能源、水电、轮船、 装备等军民领域填补多项产品、装备、制造技术空白, 为多款世界一流技术装备研制提供实现工艺保障,已有 数百种产品在军民各领域应用,得到各军民企业和国际 知名公司的高度关注,在国内精密铸造领域成为技术领 军企业。 集成精密成型技术体系是在传统失蜡熔模精密铸造 工艺基础上,在关键工艺装备、各个工艺流程的实现方 法、材料及其制备技术等多方面进行创新,是对全工艺 流程近200多项微创新而研发成功的,实现了精密铸造 领域的“系统集成创新”,是目前国内外技术水平最先 进的精密铸造工艺。 集成精密成型技术体系能独创性地制造传统车、 铣、刨、磨、锻等冷加工手段和常规成型手段无法加 工、难以加工以及依照价值工程不值得加工的各种极限 尺寸的(超大的和极小的)、薄壁的、具有极其复杂 的、紧凑结构的零件。由于这种特点,集成精密成型技 术体系彻底解放了制造工艺的限制对产品设计带来的制 约,使得在产品研发设计过程中,工程师只需关注产品

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INDUSTRY NEWS/行業新聞 sign. Based on the systematic integrated investment casting process, Anyang Qiang Ji has provided hundreds of “impossible” products such as the first aluminum integrated casting frame in the country and the hollow stator blade for nuclear power turbine-generator unit. Besides, based on the understanding and improvements of the essence of the traditional process and process equipment, Anyang Qiang Ji developed a series of main equipment. It has a range of unique patented devices such as wax injector, wax test system, wax resistance to deformation logistics system, curtaining coating machine, shell mould dry system, de-waxing stove, wax recovery system, pouring furnace, solidification control furnace, heat treatment furnace and so on, which improves the current art situation of investment casting. The systematic integrated investment casting technology can be applied to all industrial sectors that need metal part. In order to apply the technology to the national economic departments and industry, Anyang QiangJi develops industrialize practice through construction and operation of precision manufacturing base. Its intelligent investment casting production line in the park is the first set at home and aboard, it will break the bottleneck that the precision casting cannot be automated and mass produced. Besides, it is in line with the requirements of energy-saving and emission reduction. The product line realized mass production of oversized and complex products and is advanced in the world. ■

功能的最佳实现而无需顾忌后续的制造工艺约束,极大 的拓展了设计人员的自由设计空间,能最大限度地发挥 创新性设计的潜能,从而可以实现各种领域各种产品的 大幅度的轻量化设计、正向设计、再设计、优化设计。 依托此技术,公司在各军民领域实现了数百种“不可 能”的产品。如:国内首件全铝整体铸造车架、核电汽 轮机组末级空心静叶片。 此外,通过对工艺及传统工艺装备本质的把握及改 造,安阳强基克服了大部分传统产业的局限,研制了一 系列核心装备,拥有包括压蜡机、蜡件检测系统、蜡 件抗变形物流系统、淋浆淋砂机、模壳风干系统、脱蜡 釜、蜡回收调质系统、浇铸釜、凝固控制炉、热处理炉 等一系列专利装备,大大改善了精密铸造的工艺现状。 集成精密成型技术适用所有需要金属结构零件的工业 领域。为将该技术应用于国家经济各部门和产业,安阳 强基以建设和运营精密制造产业基地(园)的方式进行 产业化实践。其“超大型薄壁精密制造成套智能化生产 线”不仅使我国成为世界上首个拥有首台套大型精密铸 造成套技术装备的国家,同时还体现了产品全生命周期 的绿色铸造。该生产线解决了大型、复杂结构产品工业 化的落地,并达到目前国内国际的顶尖水平。 ■

Visit us at EUROGUSS 2018 16.01. – 18.01.18 Hall: 7 Booth: 618

we buy we sell

we repair we modernize

we dismantle we reassemble

Worldwide sale of various used foundry plants.

First class service for second hand foundry plants.

Relocation of foundries partially or completely.

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Searching for the Low-Cost, Power-Dense, Aluminum Engine jeff blackburn and jeff thrasher, exco engineering, newmarket, ontario, canada

低成本、动力强的铝合金发动机的研究 加拿大安大略省纽马克特 Exco工程公司,Jeff Blackburn和Jeff Thrasher

A

luminum alloys play a significant role in the vehicle light-weighting movement, with applications ranging from aluminum sheet body panels to cast aluminum powertrain and structural components. While most industry experts agree aluminum content will continue to increase in the cars and trucks of tomorrow, the competition for market share among materials and manufacturing methods is intense in an industry driven by innovation but constrained by very high cost sensitivity. A new approach to forming closed deck aluminum engine blocks could substantially lower cost compared to what has been previously achieved. Vehicle light weighting is a key contributor to OEM efforts to comply with future CAFE (Corporate Average Fuel Economy) requirements, but it is not the only one. Producing smaller displacement engines could offer improved fuel economy without sacrificing performance, often through the introduction of turbo charging. This increase in power per unit of engine displacement (specific output) means greater demands on the system as a whole, and a particular challenge lies in achieving sufficient strength and rigidity in the engine block head deck area. Historically, engine designers have had to choose between the robust closed head deck engine design formed via relatively expensive low pressure casting processes and an open head deck design formed via the more economical high pressure diecasting (HPDC) process. While attractive from a cost perspective, HPDC historically has been capable of producing only the open head deck design, which lacks the lateral cylinder wall support and rigidity of the closed deck option. As a result, when highly specific output is mandated, the engine designer often has had little choice but to develop a closed head

Fig. 1. Shown is an open deck aluminum engine design.

合金在汽车轻量化进程中起着重要作用,其 应用范围从车身铝板材到铸铝的动力总成和 结构件。虽然大多数行业专家认为未来汽车

和卡车的铝材料用量将继续增长,但是在创新驱动的行 业中,材料和制造方法之间的市场份额竞争激烈,受到 成本敏感度较高的制约。与之前的成果相比,一种制造 封闭式发动机的新方法可以大大降低成本。 汽车轻量化是OEM符合未来CAFE(公司平均燃油 经济性)要求的关键因素,但并非唯一因素。通常通过 引入涡轮增压技术,生产更小排量的发动机可以在不牺 牲车辆性能的情况下提高燃油经济性。单位发动机排量 (单位功率)的功率增加意味着对整车系统提出更高要 求,而且,特别的挑战在于发动机缸盖部分要有足够的 强度和刚度。过去,发动机设计者必须在相对昂贵的低 压铸造工艺生产的高强度的封闭式发动机设计方案和更 经济的压铸(HPDC)工艺生产的开放式设计方案之间 进行选择。压铸工艺更具成本吸引力,但是目前压铸工 艺仅能够生产开放式发动机缸盖,缺乏横向气缸壁的支 撑和刚性封闭选项。因此,当强制要求较高的单位输出 时,发动机设计人员往往别无选择,只能选择通过低压 铸造方法生产封闭式缸盖设计方案,并且每件产品将比

图1:铝合金发动机 设计图

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图2:当在发动机 汽缸壁顶部有桥接 时,发动机被认为 是封闭的设计。

Fig. 2. When bridging is present in the top of the engine cylinder walls, the engine is considered to be a closed deck design.

deck design formed via the low pressure method and face a premium over HPDC that can exceed $80 per part produced.

Aluminum Engine Block Forming Methods For years, aluminum has been a popular choice in engine block material in both mass market and niche applications. The material’s potential to deliver substantial weight savings over conventional iron blocks has seen it evolve into the material of choice for small and mid-sized engines. The fundamental difference between HPDC and low-pressure casting is that in HPDC, the steel forming tool can be used repeatedly (generally producing 80,000 parts or more before replacement) whereas the low pressure method usually sacrifices all or part of the tool (made of compressed sand mixed with binding agents) with each part produced. Inherent in the reuse of the HPDC mold is the requirement that all casting geometry be open in one direction so the forming tool can be pulled out of the casting after the aluminum solidifies. Casting geometry that is not open in one direction is considered undercut or closed geometry. The key advantage of low-pressure casting is this ability to cast “closed” geometry, offering greater design flexibility than HPDC. However, the required sacrifice of the tool with every casting made, coupled with a substantially longer cycle time and greater floor space requirements drives a tremendous cost penalty: with an $80/casting premium over HPDC, a low-pressure manufacturing strategy can mean $100 million or more in incremental annual cost on a highvolume engine program. Additionally, the low-pressure process generally cannot produce the very thin walls achievable in HPDC and thus

Fig. 3. The high pressure diecasting tool shown above is the inverse image of the engine block itself. By creating gaps in the water jacket geometry indicated above with red arrows, an engine block could be produced that provides a strengthening bridge between the head deck and the cylinder bores, as shown in Figure 4.

高压压铸工艺高出80美元。

铝合金发动机缸体生产方法 多年来,在大众市场和小众应用领域,铝合金一直是 发动机缸体材料的热门选择。与传统铸铁缸体相比,这 种材料可以大大减轻重量,因此它已成为中小型发动机 的首选材料。 压铸与低压铸造的根本区别在于,压铸 工艺,钢制模具可以反复使用(更换前通常生产80,000 个或更多压铸件),而低压铸造方法在生产铸件时通常 需要消耗全部或部分铸型(由型砂与粘合剂混合制备) 。压铸模具再利用的内在要求是,所有的铸件几何形状 朝一个方向开放,以便在铝合金凝固后可以将成形铸件 取出,与模具分离。 开口不在同一方向的铸件几何形 状被认为是凸出的或闭合几何形状。 低压铸造的关键优势在于其铸造“封闭”几何形状的 能力,比压铸具有更高的设计灵活性。但是,每个铸件 生产过程中铸型的消耗、更长的生产周期和更大的占地 空间要求,将导致巨大的成本支出:与压铸相比,每件 铸件成本增加80美元。低压铸造发展战略可能意味着大 批量发动机生产中将额外增加1亿美元或更高的成本。 另外,低压铸造工艺通常不能生产在压铸中可实现的 壁厚非常薄的铸件。因此,通常生产出让汽车轻量化工 程师感到失望的较重产品。

图3:以上所示的 高压压铸是发动机 缸体本身的反转图 像。如图4所示, 通过在图中红色箭 头上面所示的水套 几何结构中形成间 隙,可以生产这样 一个发动机缸体, 在缸盖和缸孔之间 安装加强桥。

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图4:图中红色箭头 指示为加强桥。

Fig. 4. Strengthening bridges are indicated here with red arrows.

typically produces a heavier product, to the chagrin of vehicle light weighting engineers.

开放和封闭式发动机

Open and Closed Deck Engines

材料将气缸壁的顶部桥接到发动机缸体周边。如果

The terms open deck and closed deck refer to the absence or presence of material bridging the top of the cylinder walls to the peripheral body of the engine block. If this bridging material is not present the engine is considered an open deck design. If this bridging is present, it is considered a closed or semi-closed deck design. One can imagine how the closed deck design presents a fundamental problem for a casting process requiring removal of the steel forming tool. A new method of creating the desired undercut closed deck geometry while using conventional HPDC tooling (no loose or lost cores) relies on casting dams the full depth of the water jacket channel. These dams form the necessary strengthening bridges between the cylinder bores and the peripheral body. If left as formed, these dams would block the flow path of the coolant along the length of the engine in the water jacket channel. It is a subsequent machining step that transforms the dams into bridges, providing closed deck-style cylinder support while allowing the coolant to flow unobstructed below the bridges and along the cylinder walls.

Fig. 5. The remaining need for a successful HPDC engine design is opening a flow path to let water move around all cylinder bores. This is done by gaining machining access via frost plug openings (shown above) and using orbital movement of a woodruff cutter below the plane of the head deck to connect the water jacket channel segments, as shown in Fig. 6.

术语“开放式”和“封闭式”区别在于是否有 这种桥接材料不存在,发动机被认为是开放式设 计。如果这种桥接存在,则认为是封闭或半封闭的 设计。人们可以想象,封闭式发动机铸件对铸造工 艺根本要求是需要把铸件从钢质模具中取出。 使用传统的压铸模具(无滑块或可溶芯)生产 所需的凸出或封闭几何结构的铸件的创新方法,取 决于铸件加强梁即气缸水套通道的最大深度。 这些加强梁是气缸和发动机本体之间必要的连 接。 如果保持原状,这些加强梁会深入发动机的水 套通道中,阻塞冷却剂的流动路径。 随后的加工步骤,将加强梁加工成连接梁,为 封闭式气缸提供支撑,同时允许冷却剂在连接梁下 以及沿气缸壁畅通无阻地流动。

图5:成功的高压压铸发动机 设计的其他需求是打开流动 通道使水在所有气缸孔周围 流动。这是通过经由防冻塞 开口(如上所示)获得机加 工通道以及使用在缸盖下方 的半圆铣刀的运动轨道来连 接水套通道来完成的,如图 6所示。

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图6:缸盖平面以下的半圆铣刀的运动轨 道连接水套通道。

Fig. 6. The orbital movement of a woodruff cutter below the plane of the head deck connects the water jacket segments.

The machining to remove the coolant-blocking portion of the aluminum dams is done through openings in the side faces of the engine block. To minimize the diameter of the holes, a woodruff style “T” cutter geometry is used. This preserves the valuable surface area on the sides of the block for mounting bosses and cast-in features while stiffening the area of connection to the cylinder wall, all while maintaining the desired water jacket cross sectional size. This additional woodruff machining introduces incremental cost, but would consume just a small fraction of the original $80 per piece savings, while producing similar geometry. The machined holes in the sides of the block are then plugged using core plugs. These plugs (sometimes referred to as frost plugs) have been used as a low cost, reliable method of sealing such low pressure passages in engine blocks for more than 50 years. An added benefit of this new semi-closed deck HPDC forming method is that the dams introduced provide a marked improvement of the flow path for the molten aluminum during the casting phase. CAE simulation indicates this considerably improved flow pattern will improve cast material properties in the entire head deck face, especially the problematic fire ring area; simulation also points toward significant quality improvements in cylinder wall porosity, potentially easing implementation of spray bore technology where it is sought.

The Challenges and Potential Payoff Other challenges remain in the diecasting of engine blocks with increased specific power, among them a need for greater strength in the bulkhead/bearing cap area. However, innovation and technology are attacking this problem, as well, with additive manufacturing methods now greatly increasing the cooling capability in today’s HPDC tooling, in turn delivering improved mechanical properties in these critical cast areas. Today’s engine designer needs to consider many factors. However, in a world where savings of even a few dollars in piece price represent a notable victory, the possibility of removing $80 from the price of an engine block could provide a strong incentive to explore this new solution. ■

Fig. 7. Frost plugs are inserted into the openings, sealing the water jacket.

铝加强梁对冷却剂阻塞部分是通过发动机缸体侧 面的开口去除的。为了使开口的直径最小,可以使用 半圆形的“T”形几何形状。这就保留了缸体侧面有 价值的表面区域,用于安装凸台并满足浇铸特点,同 时加强与气缸壁的连接面积,保持期望的水套横截面 尺寸。 这种额外的半圆形加工方法产生了增量成本,但是 只需原来每件80美元的一小部分且能生产出相似的几 何形状。 然后,使用芯塞将缸体侧面的加工孔堵塞。这些塞 子(有时被称为防冻塞)作为发动机缸体中密封低压 通道的低成本可靠的方法已有50多年的历史。 这种新型半封闭压铸造成形法的另一个好处是,引 入的加强梁在压铸过程中可以显著改善铝液的流动路 径。CAE模拟表明,显著改进的流动型态将改善整个 气缸盖表面的材料性能,特别是有问题的补充区域; 仿真模拟也表明气缸壁孔隙度的质量显著提升,可能 会减少喷吹技术的实施

挑战和潜在收益 其他挑战是,发动机缸体压铸的功率系数提高,在 气缸壁/轴承盖区域需要更大的强度。然而,创新技 术也在解决这个问题,以及现在使用的增材制造方法 大大提高了目前压铸模具的冷却能力,从而在这些关 键铸造领域改进了机械性能。 目前,发动机设计师需要考虑很多因素。然而,当 今,每件铸件价格降低几美元都说明了显著的胜利, 那么,从发动机价格中减少80 美元的可能性为探索新的解决 方案提供了强大的动力。 ■

图7:将防冻塞插入开口 中,密封水套。

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Critical Characteristics Affecting the Surface Finish of Castings n. bryant and j. thiel, university of northern iowa (cedar falls, iowa)

影响铸件表面质量的关键因素 布赖恩特(N. Bryant)和J. Thiel,北爱荷华大学(Cedar Falls,爱荷华州)

T

he dimensional accuracy at which sand castings can now be produced has approached that of investment castings. 3-D sand printing technologies have greatly improved the dimensional accuracy of molds and cores but have failed to match the surface smoothness of conventional sand castings, let alone investment castings. Investment casting provides very smooth parts with excellent feature resolution and dimensional accuracy. 3-D printed sand molds and cores may provide a cost-effective alternative to investment casting if the process can meet both dimensional and surface requirements.  Although many changes and improvements have been made in the area of foundry consumables, sand is the one material that has stayed somewhat constant. After mining and washing, if required, foundry sands are classified into individual or two-mesh groupings and stored. They are combined into normal distributions for shipping to the foundry customer. Although there are many different mine distributions, sand of similar AFS-grain fineness number is supplied in similar distributions. Surface finish is an integral part of casting quality specifications.  Rough internal surface finishes on castings can cause the loss of efficiency for both fluids and high velocity gasses. Such is the case for turbocharger and

Fig. 1. The relationship between AFS-GFN and sand core AFS permeability is shown.

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在砂型铸件的尺寸精度已经可以接近精密铸 件的尺寸精度。3-D打印技术极大提高了模 具和型、芯的尺寸精度,但是却无法与传统

砂型铸件的表面光洁度相比,更不用说精密铸件了。 熔模铸造工艺生产的零部件表面非常光滑,具有出色 的表面光洁度和尺寸精度。如果3-D打印的砂型和砂芯 可以同时满足零部件尺寸和表面光洁度的要求,那么相 比熔模铸造工艺其性价比更高。 虽然在铸造材料方面已经有了很多的变化和改进, 但砂子是不变的材料。在采选和洗涤后,如果需要,铸 造用砂分为单独或双网格包装并储存。它们被归入正常 的物流配送中,以便运送给铸造客户。虽然有许多不同 的矿井分布,但类似的AFS细度的砂子以相似的分布供 应。 表面清理是铸件质量规范的组成部分。如果清理后铸 件的内表面粗糙,可能会导致流体和高速气体的效率损 失。涡轮增压器和进气歧管就是这种情况。北爱荷华大

图1:AFS-GFN与 砂芯AFS渗透率之间 的关系。

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图2:表面积与砂芯 AFS渗透率之间的 关系。

Fig. 2. This is the relationship between surface area and sand core AFS permeability.

intake manifold components. The University of Northern Iowa has been investigating mold material characteristics that affect surface smoothness for castings.  The research was conducted on aluminum castings but has applications and relevance in ferrous alloys that don’t exhibit defects such as penetration or fused sand defects. The study investigates the influence of molding media characteristics such as sand fineness, material type and refractory coating selection. The goal of the project was to accomplish investment casting surface finishes in sand cast parts.

Permeability and Surface Area Results AFS permeability is defined as the amount of time it takes for a known volume of air to pass through a standard sample at a head of 10 cm of water. Simply, the AFS permeability represents the amount of open spaces between the aggregate grains that allows air to pass. The GFN of a material significantly changes the permeability until 80 GFN, where the trend appears to level out. The data shows that the same surface roughness can be achieved with any particle shape at different rates.  The spherical and round grain materials improve casting smoothness at an accelerated rate in comparison to angular and sub-angular aggregates.

Fig. 3. The relationship between surface area and surface roughness with various grain shapes is depicted.

学一直在研究影响铸件表面粗糙度的造型材料的特性。 该研究是在铝铸件上进行的,但黑色金属同样适用和相 关,不会存在渗透或粘砂等缺陷。研究包括造型材料的 特性,如砂的细度,材料类型和耐火涂层的选择。该项 目的目标是使砂型铸件表面达到熔模铸造水平。

渗透性和表面积 AFS渗透率定义为已知体积的空气通过10厘米水柱 头的标准样品所花费的时间。 简而言之,AFS渗透率代 表允许空气通过的材料颗粒之间的开放空间量。材料的 GFN显著地改变渗透率,直到80GFN,这个趋势似乎 已经趋于平稳。 数据显示,不同粒度下的任何颗粒形状都可以获得 相同的表面粗糙度。与角形和次棱角形的砂粒相比,球 形和圆形的颗粒材料以更快的速度提升铸件表面的光洁 度。

液体镓接触角测量结果 通过液体镓测试方法来测量出接触角,是为了测量结

图3:具有不同颗粒 形状的表面积和铸件 表面粗糙度之间的 关系。

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图4:砂型和液态 镓接触角之间的 关系。

Fig. 4. This shows the relationship between the sand type and contact angle of liquid gallium.

Gallium Contact Angle Results

合造型材料的相对润湿性。陶粒砂具有最高的接触角,

Contact angle measurements were conducted to measure the relative wettability of the bonded molding aggregates with liquid metal using a liquid gallium test. Ceramic sands had the highest contact angle while zircon and olivine shared a similar lower contact angle. The gallium exhibited hydrophobic behavior on all sand surfaces.  A similar AFS-GFN was used for all of the samples.  The results indicate the contact angle for the sand types depended heavily on the aggregate grain shape as shown on the secondary axis, rather than base material.  The ceramic sands had the roundest shape and olivine sands exhibited a highly angular shape.  While surface wettability of the base aggregate may play a role in casting surface finish, the range of contact angle measurements in the test series was subordinate to grain shape. 

而锆石和橄榄石具有相似的较低的接触角。 镓在所有的

Surface Roughness Results from Test Castings Surface roughness results were measured using a contact profilometer. There was a significant improvement in surface smoothness from the three-screen 44 GFN silica to the four-screen 67 GFN silica. Changes beyond 67 GFN did not show an impact on surface roughness despite variation in dis-

Fig. 5. Here is the comparison between gallium and gray iron contact angles.

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砂粒表面都表现出疏水性。 所有样品都使用了类似的 AFS-GFN。结果表明,各类型砂的接触角主要取决于 次生轴上所示的材料颗粒形状,而不是基体材料。 陶粒 砂具有最光滑的形状,橄榄石砂呈现出高角度的形状。 虽然材料基体的表面润湿性可能对铸件表面光洁度起作 用,但系列测试中,接触角测量范围从属于颗粒形状。

铸件表面粗糙度测试结果 表面粗糙度的结果用接触表面光度仪进行测量。从 三筛44 GFN硅砂到四筛67 GFN砂硅,表面光滑度有显 著改善。尽管分布宽度有所变化,但超过67 GFN之后 的变化并未显示出对表面粗糙度的影响。观察到阈值是 185 RMS。 材料在101到106 GFN之间可以观察到光洁度有大 幅改善。在粒度分布中,106 GFN砂200目以上粒度

图5:镓和灰铁接 触角之间的比较。

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图6:从铬铁矿芯获得 的A356铝合金的表面 光度仪测量结果。

Fig. 6. Profilometer results for A356 aluminum obtained from chromite cores are depicted.

tribution width. The threshold value of 185 RMS is observed. A large improvement in smoothness can be observed between the 101 and 106 GFN materials. The 106 GFN sand has over 17% more 200 mesh material in the screen distribution. The two-screen 115 and 118 GFN materials resulted in a decrease in smoothness. The 143 GFN sand resulted in similar readings to the 106 GFN zircon. The threshold value is 200 RMS. A steady improvement in surface smoothness was observed from the four-screen 49 GFN chromite to the three-screen 73 GFN chromite despite the particle distribution becoming narrower. A 19% increase in retention of the 140-mesh screen was seen in the 73 GFN chromite in comparison to the 49 GFN.  A significant increase in casting smoothness was shown from the three-screen 73 GFN to the four-screen 77 GFN chromite sands regardless of their similar grain fineness numbers.  No change in smoothness was observed between the 77 GFN and 99 GFN chromite materials.  Interestingly, the two sands shared a very similar retention in the 200-mesh screen. The threshold value is 250 RMS. There is a significant improvement in casting smoothness from the 78 GFN olivine to the 84 GFN olivine despite the narrower distribution.  An increase of 15% retention in the 140-mesh screen was visible in the 84 GFN olivine.  There is significance between the 84 and 85 GFN olivine.  The 85 GFN

Fig. 7. Here is the surface roughness of a3-D printed sands uncoated.

含量超过17%。双筛115和118 GFN砂导致光洁度降 低。143 GFN硅砂得到与106 GFN锆石砂类似的读 数。阈值是200 RMS。 尽管粒度分布变窄,但从四筛49 GFN铬铁矿砂到三 筛73 GFN铬铁矿砂,表面光滑度稳定提高。与49 GFN 相比,73 GFN铬铁矿砂增加19%140目砂。尽管它们 有着相似的细度数量,从三筛73 GFN到四筛77 GFN铬 铁矿砂的铸造平滑度显著增加。在77 GFN和99 GFN铬 铁矿材料之间没有观察到光滑度的变化。有趣的是,这 两个砂子在200目的筛网上保留了非常相似的结果。阈 值是250 RMS。 尽管分布较窄,但从78 GFN橄榄石砂到84 GFN橄 榄石砂的铸件表面光洁度有显著改善。在84 GFN橄榄 石砂中,增加15%140目筛。84和85 GFN橄榄石砂之 间有很大的变化。85 GFN橄榄石将光滑度提高了50 倍。85 GFN橄榄石是一种三筛砂子,在200目筛网中保 留几乎10%,而84 GFN橄榄石只是一种双筛材料。从 85 GFN橄榄石到98 GFN橄榄石可以观察到光滑度的稳

图7:未经涂覆的 3D打印砂的表面粗 糙度。

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Fig. 8. Profilometer results for A356 aluminum obtained from refractory coated silica cores are shown here.

olivine improved the smoothness by 50. The 85 GFN olivine is a three-screen sand with almost 10% retention in the 200-mesh screen while the 84 GFN olivine is simply a two-screen material. A steady improvement in smoothness can be observed from the 85 GFN olivine to the 98 GFN olivine.  The screen distribution shows an increase of 5% retention in the 200-mesh screen. No change was seen from the 98 GFN to the 114 GFN olivine despite an increase in 200 mesh retention of nearly 7%.  A threshold value of 244 RMS can be observed. The surface roughness results for the castings obtained from ceramic cores show slight improvement between the 32 GFN and 41 GFN materials.  There was an increase in retention of the 70-mesh screen by 34% in the 41 GFN sand.  A significant increase in smoothness was observed between the 41 GFN and 54 GFN ceramics.  The 54 GFN material had over 19% greater retention in the 100-mesh screen in comparison to the 41 GFN material.  This improvement occurred despite the distribution narrowing in the 54 GFN material.  The largest impact in the ceramic results was seen between the 54 GFN and 68 GFN sands.  The 68 GFN sand had 15% higher retention in the 140-mesh screen which widened the distribution.  Despite an increase of over 40% retention in the 140-mesh screen, little improvement was observed between the 68 GFN and 92 GFN materials.  The threshold value is 236 RMS. The surfaces generated by the 3-D printed sands are significantly rougher than a rammed sand surface using the same aggregate.  The samples printed in the XY orientation provided the smoothest test casting surface while those printed in the XZ and YZ orientation resulted in the roughest. The rammed silica uncoated 83 GFN silica sand resulted in a roughness value of 185 RMS.  Although the castings appeared smoother, the refractory coatings increased the surface roughness as measured by the profilometer. The alcohol-based alumina coating exhibited the best performance while the alcohol based zircon coating resulted in the highest roughness.  The 83 GFN 3-D printed samples showed the opposite effect.  While the uncoated sample printed in the most favorable orientation of XY, the uncoated sample exhibited a casting roughness of 943 RMS.  The coatings smoothed the surface substantially from the uncoated surface finish from a low of 339 to a high of 488 RMS.  It appears the surface finish of the coated sands is somewhat independent of the 42

图8:从耐火涂 层硅砂芯获得的 A356铝合金的 表面光度仪测量 结果。

定提高。筛目分布显示在200目的筛子中有5%的增 加。从98 GFN到114 GFN橄榄石没有发现变化,尽 管200目的保留率增加了近7%。可以观察到244RMS 的阈值。 使用陶粒砂制芯改善铸件表面粗糙度的结果,在 32 GFN 到41 GFN之间有轻微改善。在41GFN砂 中,70目筛保留率提高了34%。陶粒砂在41GFN到 54GFN之间显著改善铸件光洁度。与41GFN材料相 比,54GFN材料在100目筛网中的保留量增加了19 %以上。尽管54GFN材料的分布有所缩小,但仍然 有所改善。在54GFN到68GFN之间,对陶粒砂结果 的影响最大。68 GFN砂在140目的筛中保留了15% ,扩大了分布。尽管在140目筛网上保留了超过40% 的保留率,但是在68GFN至92GFN材料之间没有观 察到什么改进。阈值是236 RMS。 3D打印用砂产生的表面比使用相同的骨料夯实的 砂子表面粗糙得多。在XY方向上打印的样品提供了 最光滑的测试铸件表面,而在XZ和YZ方向上打印的 样品具有最粗糙的表面。 冲压未涂覆的83 GFN硅砂的粗糙度值为185 RMS。虽然铸件看起来比较光滑,但耐火涂层增加 了由表面光度测量仪测得的表面粗糙度。醇基氧化 铝涂层表现出最好的性能,而醇基锆石涂层表现出 最高的粗糙度。83GFN 3D打印样品显示出相反的 效果。当未涂层的样品以最有利的XY方向打印时, 未涂层的样品表现出的铸件粗糙度为943RMS。 涂层使铸件表面的光洁度大大提升,从未涂覆的的 339RMS的最低值提高到高达488RMS。看起来 涂覆的砂子的表面光洁度与基底砂的粗糙度关系不

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roughness of the substrate sand and depends heavily on the formulation of the refractory coating. 3-D printed sand, although starting with a much rougher surface finish, can be improved significantly with the use of refractory coatings.

大,而很大程度上取决于耐火涂层的配方。3D打印

Conclusions

结论

Currently available molding aggregates have the ability to achieve surface roughness values of less than 200 RMS microinches. These values are slightly within the values associated with investment castings.  For the materials tested, each exhibited a decrease in casting roughness with increasing aggregate AFS grain fineness.  This was true with all materials up to a threshold value, at which time no further decrease in casting roughness was seen with increasing AFSGFN.  This was supported by previously conducted research.  Within all material groups, the effect of AFS-GFN was secondary to both calculated surface area and aggregate permeability.  While permeability can be thought to describe the open areas of the compacted sand, the surface area better describes the screen distribution of the sand and corresponding amount of fine particles.  Both permeability and surface area were directly related to casting surface smoothness. It should be noted that this was true for aggregates within a shape group.  Although angular and sub-angular aggregates had high surface areas, their permeability was high and indicated an open surface.  Spherical and rounded aggregates exhibited the smoothest surfaces combining low permeability with high surface area.  It was originally believed surface wettability as measured by contact angle between liquid metal and the bonded aggregate was a critical factor in the resulting casting surface finish.  While it was shown that contact angle on various materials at similar AFS-GFN was not proportional to the casting roughness, it was confirmed that grain shape was a major factor.  The absence of a relationship between contact angle and casting surface roughness might be explained by the fact that grain shape was seen as a major influence in surface roughness.  There is a significant possibility that the contact angle of various materials was affected more by the grain shape and resulting surface smoothness than that of the wettability of the material alone.  As with all measuring instruments, artifacts of the test method may influence the results to some degree.  The increase in casting roughness, although visually the castings looked smoother with the application of refractory coating, may be due to the shape of the peaks and valleys created with the coatings.  By definition and measurement, the refractory coatings only increased the surface roughness over non-coated samples.  All of the refractory coatings were very successful in improving the surface roughness of the 3-D printed sands. It appeared that the surface finish of the test castings from coated samples was somewhat independent of the starting substrate sand.  The coatings had a major effect on the surface finish but further work is required to revise the coatings to improve casting finishes.   ■ This article is based on paper 17-094 that was presented at the 2017 Metalcasting Congress.

的砂子虽然最初的表面光洁度粗糙,但可以通过使 用耐火涂料得到显著改善。

目前可用的造型材料具有实现小于200RMS微英 寸的表面粗糙度的能力。这些数值略低于精密铸件相 关的数值。对于所测试的材料,随着聚集的AFS晶粒 细度的增加,每种材料均表现出使铸件表面粗糙度降 低。在所有材料达到阈值的情况下都是如此,此时随 着AFS-GFN的增加,没有看到铸件表面粗糙度的进 一步降低。之前进行的研究支持了这一结果。 在所有材料实验中,AFS-GFN的效果对于计算的 表面积和总渗透率都是次要的。 虽然渗透率可以被 认为是描述压实砂的开放区域,但是表面区域更好 地描述了砂的筛分布和相应的细颗粒量。渗透性和 表面积均与铸件表面光滑度直接相关。应该指出的 是,对于形状组中的造型材料来说也是适用的。尽 管角形和次棱角形的颗粒材料具有较大的表面积, 但它们的渗透性很高并且表现出开放的表面。球形 和圆形的颗粒材料表现出平滑的表面,以及低渗透 性和大表面积。 最初,液态金属和粘结材料之间的接触角测量的 表面润湿性被认为是所得铸件表面光洁度的关键因 素。结果表明,相似AFS-GFN的各种材料上的接触 角与铸件表面粗糙度不成正比,颗粒形状已证实是主 要因素。接触角和铸件表面粗糙度之间没有关系可以 用颗粒形状被认为是表面粗糙度的主要影响来解释。 与材料本身的润湿性相比,各种材料的接触角受颗粒 形状和铸件表面光滑度的影响更大。 与所有测量仪器一样,测试方法的人工环境可 能会在一定程度上影响结果。尽管经过耐火涂料涂 层后铸件表面在视觉上看起来较平滑,但是铸件粗 糙度的增加可能是由于涂层产生的高峰和低谷造成 的。根据定义和测量,耐火涂层仅增加未涂覆样品 的表面粗糙度。所有的耐火涂层在改善3-D打印砂 的表面粗糙度方面非常成功。涂覆样品的测试铸件 的表面光洁度似乎与基底砂关系不大。涂层对表面 光洁度有重要影响,但需要进一步改变涂层材料来 改善铸件光洁度。 ■ 本文基于2017年美国铸造大会上的的17-094号论文。

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product news/產品新聞

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

MELTING, POURING & HEAT TREATMENT

25 Years of Tribo-Chemie Tribo-Chemie公司25年的发展历程

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Blasting of Aluminum – Business as Usual? 48 铝铸件的抛丸清理—常规方式能否适用?

German Know-How and Quality - TRENNEX 德国技术和质量—TRENNEX

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Dynamic Dosing System Automates Ductile Iron Treatment 50 铝动态定量系统使球墨铸铁生产实现自动化

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FCRI Ceramic Filter 佛山金刚企业集团陶瓷过滤器产品

New Materials in Mold Making to Meet New Challenges in Diecasting 压铸模具新材料应对新挑战

Jet Cooling Optimizes Casting Quality, Cycle Time 喷射冷却技术优化铸件质量和生产周期

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PLANT ENGINEERING Italpresse Introduces New App for Live Remote Maintenance 45 意特佩雷斯引进新的实时远程维修应用软件 A Brand-New Procurement Experience Of Non-Standard Industrial Products 非标工业品电商之路探索

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Precise Measurement Results In Visual Endoscopic Inspection 精密测量用于可视化内窥镜检查

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SOFTWARE CQC Cast Quality Control by Electronics 51 Electronics公司的CQC铸件质量控制技术

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product news/產品新聞

25 Years of Tribo-Chemie Tribo-Chemie公司25年的发展历程 Tribo-Chemie was founded in 1992 with the aim of manufacturing “Made in Germany” release agents that provide solutions for companies looking for suitable products for pressure diecasting and forging. The Isolat Enviro 1011 and Isolat TT 77 have become well established in the market, and Tribo-Chemie is proud to announce the company is the one supplier among all international suppliers of release agents with an approved product for gluing automotive structural parts. Isolat TT 77 has made it to be the release agent for the production of these special parts of a world famous, German car producer. Product groups like Graphitex ® and Isolat ® prove themselves worldwide, under difficult conditions as well. Tribo-Chemie is particularly proud of its intensive customer support, as the ultimate aim is that the supplied products work perfectly in the production process at the customer’s. Production processes at individual customers are never identical and this has to be taken into account when developing and using highly-efficient release agents. Tribo-Chemie mainly has the expertise and commitment of their mostly long-standing employees to thank for its success. The company, managed by the Bastian family has greatly developed over the last few years as a result and is optimistically looking toward the future. ■

Tribo-Chemie公司于1992年成立,目标是成为“德 国制造”的脱模剂生产商,为压铸和锻造企业提供适合 的产品。 Isolat Enviro 1011和Isolat TT 77在市场上已非常 成熟,Tribo-Chemie公司非常自豪地宣布已跻身适用 于汽车结构件的国际脱模剂供应商。Isolat TT 77使公 司成为这种特殊零部件的脱模剂供应商,这些零件用于 世界著名的德国汽车生产企业。 即使应用在恶劣条件下,公司的产品系列,如 Graphitex ® 和Isolat ® 已在全球证明了自己。 Tribo-Chemie公司尤其以能够为客户提供持续不断 的支持感到自豪,最终目标是公司提供的产品能够与客 户的生产工艺完美契合。每个客户的生产工艺不是完全 相同的,因此,公司在研发和使用高效的脱模剂时必须 考虑这些因素。 Tribo-Chemie公司得到了长 期服务的工作人员的专业技术和 承诺,使公司获得成功。 公司由巴斯蒂安家族经营, 在过去的几年已获得了巨大的发 展,并且对未来充满希望。 ■

CEO Barbara Bastian and Felix Bastian (Authorised Officer) are thrilled to be presented with the Chamber of Industry and Commerce Certificate of Honour by Dr. Sascha Genders from the WürzburgSchweinfurt Chamber of Industry and Commerce (right).

Italpresse Introduces New App for Live Remote Maintenance 意特佩雷斯引进新的实时远程维修应用软件 Italpresse Gauss has teamed up with industrial software expert Wonderware (Schneider Electric Group) to develop a powerful app for live remote maintenance and service assistance for users of its high-performance light metal casting solutions. The AMe interactive assistant, first shown at Metef 2017 in Verona, boosts maintenance efficiency and speed of trouble-shooting by enabling maintenance workers to establish a live video connection with an Italpresse Gauss expert, access drawings and machine documentation, and follow maintenance guides on screen - all via a tablet. Making this technology available on a mobile device means workers can use it directly at the machine. Shared video allows both Italpresse Gauss experts and the maintenance workers to then look at the machine together and identify faults faster.

意特佩雷斯高斯公司与工业软件专家Wonderware( 施耐德电气集团)合作,为需要高性能轻金属铸件解决方 案的用户开发一款用于实时远程维修和服务支持的功能强 大的软件。 AMe交互助理软件,首次在意大利维罗纳的Metef 2017展会上展示,可以通过平板电脑建立起维修工人与 意特佩雷斯高斯公司专家的实时视频联系,获得图纸和设 备记录、按屏幕上的维修指南进行操作,提高了维修效率 和解决问题的速度。 通过移动设备实现这项技术,意味着工人能够根据软 件提示直接在设备上进行操作。通过视频共享,意特佩雷 斯高斯公司的专家和维修工人可以共同检查设备并更快地

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product news/產品新聞

Augmented and virtual reality enable staff in-situ to access guided maintenance protocols that show the whole machine in 3D, along with step-by-step instructions and detailed parts inventory. Pointing the camera at a specific machine part will automatically call up all relevant maintenance documentation and detailed guides, saving time and ensuring flawless and effective maintenance. The AMe interactive maintenance assistant taps into Italpresse Gauss’s HMe machine monitoring and control system, which was also developed in partnership with Wonderware and enables powerful diagnostics and advanced process control. Both AMe and HMe were designed to provide actionable information quickly and in a user-friendly format ultimately to cut down non-productive time and keep vital machines running at optimum performance levels. The developments are part of a wider effort at Norican Group to connect man and machine, equipment and processes in the spirit of Industry 4.0. Italpresse Gauss will be showcasing their AMe Interactive Assistant at Euroguss 2018, the International Trade Fair for Die Casting. Visitors of the Europe’s most important die casting event will have an opportunity to experience the new AMe remote assistant at stand 514, Hall 7, from 16th - 18th January 2018 in Nuremberg (Germany). ■

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确定问题所在。 增强和虚拟现实技术使现场操作的员工可方便获得指 导性的维修操作办法,通过3D全景展示整个设备,还可 看到逐步的指导操作和详细的零件目录。 将摄像机指向一个特定的设备部件,将自动获得所有 相关的维修记录和详细的操作指南,节省了维修时间并 且确保维修操作无误且有效。 AMe的交互维修软件接入意特佩雷斯高斯的HMe设备 监控系统,实现超强诊断和先进的工艺控制。HMe设备 监控系统也是意特佩雷斯高斯与Wonderware公司合作 开发的。 AMe和HMe的目的都是使用户更加方便且快速地采取 措施,最终减少非生产性时间、使关键设备以最佳性能 运行。 这些新技术是诺瑞肯集团在工业4.0的发展趋势下,将 人和设备、设备和工艺紧密联系起来采取的措施。 意特佩雷斯高斯公司将在2018年1月16-18日在德国 纽伦堡举办的Euroguss 2018展示AMe交互辅助软件技 术。参观观众将有机会在7号馆514展台体验最新的AMe 远程辅助软件技术。 ■

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product news/產品新聞

German Know-How and Quality - TRENNEX 德国技术和质量—TRENNEX In over 100 years that began as a lubricant-dealer, Geiger + Co. Schmierstoff-Chemie GmbH has developed into a leading producer of high-quality release agents and lubricants for die casting. Located since the beginning in Heilbronn, our headquarters have always been adapted and modernized to current needs. “To stay on the ball” and the constant determination to produce a better product has been our recipe of success for years. Release agents and lubricants are essential in die casting foundries and play a key role in the production of highquality cast parts. With the perfect release agent and lubricating effect of our TRENNEX®-Products we have achieved a clear prerequisite for an error-free casting cycle and provide impeccable casting surfaces and clean molds. The positive sales performance from the previous years was continued in 2017. This steady sales growth over the past few years reflects the successful direction that the company is heading in. We were able to invest in multiple areas, for example in our manufacturing facility and in our logistics department. Trennex already has over 10 years of experience in the field of Minimum Quantity Spraying for die casting. Through continuous and customer-oriented development activities we have built up a large portfolio of lubricants for Minimum Quantity Spraying that can fulfill many different requirements. With these products, we’ve already helped many customers implement Minimum Quantity Spraying into their production facilities’ series production. Structural die casting will continue to gain importance in the future. Trennex products already have a solid footing in this area and can help in the realization of completely new die cast products. With zinc die casting, Trennex can help replace solventbased products with water-based lubricants. This is where exhaust-air quality in the production facility or product flammability comes into focus. China is the most important automotive market in the world and thanks to competent partners this opportunity could be developed further over the past few years. This is why being at the 2017 China Die Casting trade show was so important to us. German Know-How and Quality – Made in India. Our newly established die lubricant production in India with our partner HETPAN Die Lubricants is expected to accommodate all the needs of the Indian market. Lightweight design, electromobility and increased environmental protection are factors that will lead to great changes but also new opportunities in the die casting industry in the coming years. With our decades of experience and our global presence, we stand at the ready to assist you with our colleagues onsite as competent and highly effective partners. ■

作为一家有100多年历史,起步于润滑油的经销 商,Geiger + Co. Schmierstoff-Chemie GmbH公司 已发展成为高品质压铸件脱模剂和润滑油的主要生产 企业。 自成立起,公司总部一直位于德国海尔布隆并且不 断适应和满足市场的需求。 生产更高质量的产品的“专注力”和信念是公司成 功的秘诀。 脱模剂和润滑油对压铸企业是必不可少的,在生产 高质量铸件中起着关键作用。 TRENNEX®产品有出色的脱模和润滑效果,是企业 获得无误差的压铸生产循环以及无可挑剔的铸件表面和 清洁铸型的先决条件。 2017年,公司继续保持了良好的销售业绩。 过去几年,公司稳定的销售增长趋势反映了公司正 确的发展方向。 我们已在多个方面追加投资,例如我们的生产设备 和物流部门。 Trennex产品在压铸件微量喷涂应用领域已有10多 年的经验。 以持续的和客户为中心的发展战略,公司已经建立 起庞大的满足多种需求的微量喷涂润滑剂产品系列。通 过这些产品,公司已经帮助很多客户将微量喷涂技术应 用到他们的批量生产中。 未来,结构压铸件将继续占有重要地位。Trennex产 品已经在该领域占有一席之地,并有助于全新的压铸件 产品的生产。 对于锌合金压铸件,Trennex能够用水基润滑剂代替 溶剂型产品。 这款产品适用于那些关注生产中废气排放或可燃性 的企业。 中国是世界上最重要的汽车市场,由于有竞争力的 合作伙伴,公司在中国的业务在过去的几年得到了快 速发展。这也是2017年中国压铸展对我们非常重要的 原因。 德国技术和质量——印度制造 公司在印度新建的压铸件润滑剂生产基地与公司的 合作伙伴HETPAN润滑剂公司预计将能够满足印度市场 的所有需求。 轻量化设计、电动汽车和不断增强的环保要求是改 革创新的主要方面,也是未来压铸行业新的发展机遇。 有数十年的发展经验和全球布局,公司以及所有员 工已经做好准备,将成为有竞争力和高效率的合作伙 伴。 ■

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product news/產品新聞

Blasting of Aluminum – Business as Usual? 铝铸件的抛丸清理—常规方式能否适用? The engineers and technicians at AGTOS have intensively dealt with the topic of aluminum. Numerous tests have been conducted in cooperation with customers. Even machines specially constructed for this material have been developed. Many experiences were gained in the AGTOS test center as well as in practice with well-known customers. Consequently, sophisticated solutions for the blasting of and with aluminum are offered. Increasingly, aluminum workpieces are also treated with blasting abrasive of the same material. This can provide advantages, but has an impact on the construction of the machine. Due to the physical properties, such as, e.g. the specific weight which is lower in comparison to steel abrasive, special considerations have to be taken into account when constructing shot blast machines. This starts with the repose angle, which affects some components of the shot blast machine, e.g. hopper and bunker. The volume of certain components have to be adjusted as well. The optimization of the turbines must be considered in this case. The special flow behavior of aluminum blasting abrasive must be taken into account. Therefore, the turbines are constructed to work optimally with various aluminum grains. Aluminum blasting abrasive must be handled gently. Increased heat generation within the turbines is avoided because it destroys the aluminum abrasive. This is the only way to achieve a good blasting result within economical operations. In the case of shot blast machines from AGTOS, the destruction of this valuable “tool” within the shot blast machine is avoided as far as possible without having any effect on the workpiece surface. Abrasive loss is also prevented. This saves valuable material and also helps to reduce operating costs. After the blasting process, a highly efficient blow-off device cleans the workpieces and discharge of the abrasive is prevented. The above-described measures are directed to the economic operation of the shot blast machine with comparably low operating costs. The blasting technology should at best always adapt to the internal material flow. Therefore, wire mesh conveyor blast machines are a machine type frequently requested by automated operators. The main advantage of this type of shot blast machines is that the wire mesh belt enables the blasting from below and above, without having to turn or hang the workpieces manually. The workpieces which are going to be blasted are placed on a wire mesh belt, via automatic transfer or by a manipulator (in exceptional cases manually), which transports them through the machine. They first pass through the inlet sluice. This seals the adjoining blasting chamber to the outside. In the blasting chamber, high performance turbines throw the blasting abrasive onto the workpieces at a high speed. The wire mesh belt is constructed in such a way that the workpieces 48

AGTOS公司的工程师和技术人员对铝进行了大量 的研究,并与客户合作进行了大量的实验。甚至专门 为这种材料设计的设备也已经研发完成。在AGTOS 公司测试中心以及知名客户的应用中获得了很多经验 数据,因此,得出用于铝合金零部件的先进的抛丸清 理解决方案。 如今,铝合金零部件也越来越多地使用相同材质 的抛丸磨料进行清理。这种处理方式有优点,但是对 设备的结构产生影响。 基于铝合金的物理特性,例如,比重轻于钢制磨 料,在设计抛丸机时必须考虑这些特殊的因素。从休 止角开始,将影响抛丸机部分部件的设计,例如,料 斗和料仓。某些零部件的装入量也必须调整。 在这种情况下,必须考虑抛丸涡轮的优化,也必 须考虑铝质喷丸磨料的流动特性。因此,涡轮的结构 应该能够与各种铝颗粒完美协同工作。铝质喷丸磨料 的处理必须仔细,需要避免在涡轮内热量上升,因为 它会破坏铝磨料。这是用较为经济的操作方式获得良 好抛丸效果的唯一办法。 对于AGTOS公司的抛丸机,尽可能避免破坏抛丸 机内这种有价值的“工具”,而不对铸件表面产生任 何影响。同时也避免磨料损失。这不仅节省了宝贵的 材料,也有助于降低运营成本。在喷丸处理之后,高 效的吹除装置会吹去铸件上残留的磨料,防止磨料带 出。上述措施针对运营成本相对较低的抛丸机的经济 运行。 抛丸技术最好能始终适应内部材料流动。因此, 网带式传输抛丸机可以按操作者要求自动化工作。这 种抛丸机的主要优点是能够从网带下方和上方进行抛 丸清理,而不必手动转动或悬挂工件。 将要被喷丸的零部件通过自动传送或机械手(在 特殊情况下采取手动方式)被放置在网带上进行传 送。 工件首先通过入口闸门,闸门密封将相邻的抛丸 室与外部隔开。在抛丸室内,高性能的涡轮将磨料高 速喷射到工件上。网带的结构使得工件可以从顶部和 底部同时被喷射。喷丸清理后,吹走残留的磨料和灰

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product news/產品新聞 can be blasted at the same time from the top and bottom. After the blasting process, the workpieces are cleaned due to blowing off the remaining abrasive and dust. The dust will be separated due to the supplied filter unit and the blasting abrasive will return to the circuit of the machine. The AGTOS wire mesh conveyor blast machines are constructed for the heaviest strain. Due to the installed high performance turbines, an optimal covering of the surface is achieved. This is the guarantee for short blasting times and high quality results. The automatic blasting device installed directly above the turbines ensures that it is only blasted when workpieces are in the blasting area. This minimizes the wear on the shot blast machine. A blow-off device removes the abrasive remaining on the workpieces. Many companies work with a hanging workpiece transportation within the plant. For this case of operation, AGTOS has developed the continuous overhead rail shot blast machine for the blasting of and with aluminum. Conventional hanger-type blast machines are also available for bag-railway operation. The blasting process starts with the entry of the hangers loaded with the workpieces into the blasting machine. An inlet sluice seals the blasting chamber to the surrounding. The hangers pass through the blasting chamber, while the turbines impinge them. After the blasting process, an outlet sluice follows. A blow-off device helps to recover the blasting abrasive. The hangers can now be fed to further processing steps or to the dispatch. Rubber belt tumble blast machines with a rubber belt or steel mill tumble blast machines with a belt made of steel plates are the solution of processing workpieces, which are moved in containers such as boxes or pallet cages. However, due to the fact that the workpieces always touch each other during the blasting, loading and unloading, these machine types are not used or rarely used for processing (usually thin-walled) aluminum workpieces. ■

Test center DHT for aluminum: AGTOS Continuous overhead rail shot blast machine for processing aluminum workpieces.

尘,工件得到了清理。由于配备了过滤设备,灰尘 将被分离,残留的磨料将返回到机器的回路中。 AGTOS网带式传输抛丸机的构造可以承受最重 的力。由于安装了高性能涡轮,可以实现最佳的表 面覆盖。这些保证了短时间的抛丸和高质量的结 果。 直接安装在涡轮上方的自动抛丸装置确保了只 有工件在抛丸区域时才被喷丸处理,最大限度地减 少了抛丸机的磨损。送风装置去除残留在工件上的 磨料。 很多公司使用工厂内的悬挂工件运输设施。在这 种情况下,AGTOS公司开发了用于铝或含有铝金属 的吊链连续抛丸机。传统的吊挂式抛丸机也可用于 袋式运输。 抛丸过程从悬挂有工件的吊钩进入抛丸机开始。 入口闸门密封将抛丸室与周围环境分隔。吊钩在涡 轮机撞击时穿过抛丸室。 抛丸过程之后,随之到达出口闸门。送风装置有 助于回收喷砂磨料。吊钩则可以用于下一步的处理 过程或运输。 橡胶带式翻滚抛丸机或钢板型材滚筒抛丸机也是 清理工件的解决方案,这些工件被装入料箱或网箱 等容器中。但是,由于工件在抛丸、装卸过程中经 常互相触碰,在清理(通常是薄壁)铝工件时不使 用或很少使用这种机型。

铝件的测试中心 DHT:AGTOS公司用于 处理铝工件的吊链连续 式抛丸机。

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product news/產品新聞

Dynamic Dosing System Automates Ductile Iron Treatment 动态定量系统使球墨铸铁生产实现自动化 ELKEM, the leading supplier of alloys dedicated to the iron foundry industry and their equipment partner, a proven source for foundry automation equipment, have joined forces to develop and supply a Dynamic Dosing System to the global foundry industry. The Dynamic Dosing System enables foundries to precisely and automatically calculate, dose and position the treatment alloys into a dedicated pocket in the treatment ladle for high quality ductile iron production. This robust equipment is custom made to suit the specific requirements and premises of each individual foundry. The quantity, dimensions and positioning of the alloy hoppers and associated transport systems corresponds exactly to the foundry’s requirements. Based on spectrometer analysis, thermal analysis and other relevant process parameters, the dedicated software enables precise calculation of all treatment additions. The precision weighing and transportation system doses the right quantity of the required materials in the correct sequence and places it precisely in the pocket of the treatment ladle. The dynamic software directs and registers every process parameter and material addition, reducing the risk of human error and enabling complete traceability of the iron treatment process. Furthermore, the Dynamic Dosing Software is based on the vast experience of ELKEM and their equipment partner, minimizing process variation and progressively optimizing addition rates. ELKEM’s Dynamic Dosing System will improve the iron treatment process consistency, reduce treatment time and improve iron quality while reducing cost and emissions. This Dynamic Dosing System is more flexible and less costly than other alloy addition methods and it is technically supported by ELKEM’s foundry experts and EUROMAC’s equipment specialists. ■

Elkem Dynamic Dosing system with 12 hoppers feeding 1 exit

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包含12个料斗和1个出口 的埃肯动态定量系统

铸铁领域领先的合金供应商埃肯及其设备合作伙 伴——铸造自动化设备富有经验的供应商,联手合作 为全球铸造行业研发并提供动态定量系统。 动态定量系统使铸造厂能够精确地自动计算、添加 和定位合金的量和位置,并将其放置在处理浇包的专用 口袋中,以便生产高质量的球墨铸铁。 这个功能强大的设备可以满足每个铸造厂的具体要 求和前提定制。合金料斗和相关运输系统的数量、尺寸 和位置完全符合铸造厂的要求。 在光谱仪分析、热分析和其他相关工艺参数的基础 上,该专用软件能够精确计算所有添加物。 精确称量和运输系统按照正确的顺序添加适量的材 料,并将其准确放入处理浇包的口袋中。 动态软件指导和记录每个工艺参数和材料添加的过 程,减少人为错误的风险,并使铁液处理过程具备完整 可追溯性。 此外,动态定量软件基于埃肯及其设备合作伙伴的 丰富经验,最大限度地减少工艺变化并逐步优化加料 速率。 埃肯的动态定量系统将提高铸铁处理工艺的一致 性、减少处理时间并提高铁液质量,同时降低生产成 本,减少排放。 这种动态定量系统比其他合金添加方法更灵活、成 本更低,并由埃肯公司的铸造专家和合作伙伴的设备专 家提供技术支持。

Elkem Dynamic Dosing System with fve hoppers feeding two exits.

包含5个料斗和2个出口 的埃肯动态定量系统

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product news/產品新聞

CQC Cast Quality Control by Electronics Electronics公司的CQC铸件质量控制技术 Electronics-GmbH is a family business founded in 1979 and is market leader for measurement technology for quality control in die-casting in Europe. Measurement technology of Electronics-GmbH is used all over the world. Main customers are car manufactures and their suppliers, manufacturers of fittings, electric engines, garden and forestry equipment as well as other producers of non-ferrous die-casting parts. CQC consists of two components: hardware and software. Due to improved hardware components the data acquisition system allows direct interaction with the die-casting process. Using a modular design 8, 16, 24 and 32 channel versions are possible. In terms of resolution and modularity the CQC outperforms displays build into the die-casting equipment. Therefore it is being used not only to visualize the shot curve but additionally to monitor sensors mounted into the die as incavity- temperature or pressure sensors. The new software is specifically adapted to the hardware design and facilitates handling measurement technology within the die-casting sector. It is mostly handled by symbols and standard functions can be operated intuitively. CQC comprises innovative future orientated functions. In detail the following advantages are to be noted: The measuring sensors are freely selectable in the channel assignment. It is possible to generate a datamatrix code for component tracking directly from the measurement software. Statistics data and trend analysis can be displayed in one screen. Columns for the process describing variables can be arranged in any order using variable widths. The assignment of the digital input and output signals is freely selectable. In addition long-term detection of temperature and flow measurement is installed. As outstanding benefits are to be mentioned the comfortable operation via touchscreen, the user-friendly interface, self explaining icons and symbols and a powerful OPC-UA interface. ■

1979年成立的家族企业Electronics公司是欧洲压铸 件质量检测的领导者。 Electronics公司的测量技术在世界各地得到应用,主 要客户为汽车制造商及其供应商、配件制造商、电动发 动机,花园和林业设备以及有色金属压铸件生产商。 CQC由硬件和软件两部分组成。由于硬件的改进,数 据采集系统可以直接与压铸工艺相互接入。可以使用8 、16、24和32通道版本的模块化设计。在分辨率和模块 性方面,CQC的性能优于压铸设备的显示器。因此,它 不仅用于压铸曲线可视化,而且还用于监测安装在模具 中作为内腔温度或压力传感器的传感器。 新软件特别适用于硬件设计,并有助于压铸行业的测 量技术。它主要由符号处理,其标准功能可以直观地进 行操作。 CQC包含创新的未来定位功能。以下将详细介绍其优 点: 测量传感器可在通道分配中自由选择。可以直接从测 量软件生成用于部件跟踪的数据矩阵代码。统计数据和 趋势分析可以在一个屏幕上显示。描述变量的过程列可 以使用可变宽度以任意顺序排列。数字输入和输出信号 的分配可自由选择。另外,还安装了温度和流量测量的 长期检测设备。 因此,其突出优点包括舒适的触屏操作方式、用户友 好的界面设计、自我解释的图标和一个强大的OPC-UA 接口。

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product news/產品新聞

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product news/產品新聞

A Brand-New Procurement Experience Of Non-Standard Industrial Products 非标工业品电商之路探索 The traditional procurement of non-standard industrial products has a lot of disadvantages such as the long-time span, complicated affecting factors, etc. Some factors in the purchasing process, including the selection of the right suppliers, the discussion of price, prototype manufacturing and evaluation, the order confirmation, the coordination and communication with suppliers, will directly affect the quality of the whole procurement. Facing the procurement difficulties such as limited time, heavy tasks and high standard, purchasing in traditional ways will not only take a lot of time and effort but also have quality risk. However, relying only on online procurement is lack of practical experiences, such as on-the-spot investigation, face-to-face negotiation and comparison of samples, the actual purchasing requirements can’t be met no matter which way you choose. The unique online and physical B2B service model, first created by China Foundry E-Commerce, solves the abovementioned problems effectively. On the China Foundry ECommerce platform, the buyers can pick out better suppliers with the supplier screening system and watch their online digital exhibition hall, getting an initial understanding of supplier. After forming a preliminary intent, the buyers may go to the physical exhibition center which was designed based on the glasses-free 3D technology, virtual reality and front-projected holographic display technology to watch the supplier’s factory, the core equipment and inspect their workshop conditions, etc. to get a deep understanding of the enterprise’ s production and manufacturing capacity. Then the buyers could set up the proportion of each rating-item according to the actual needs, get a comprehensive evaluation. At the same time, the buyers will release the enquiry and get feedback from suppliers quickly. In addition, at the physical trading center, there is a private meeting room for buyers and suppliers to discuss business details face to face and sign the contract. The integration of the advanced technology and traditional foundry industry helps China Foundry E-Commerce to build a business platform which provides a series of service, including advanced intelligent knowledge consulting, the digital exhibition form “industrial display”, “onestop” buying and trading experience with low cost and high efficiency, industrial big data customized service and intelligent manufacturing technology. By connecting and integrating the industry chain of upstream and downstream enterprises, the company strives to realize “space sharing and information sharing” for all industrial chains, become the Alibaba of foundry industry, and build the most vital foundry industry service sharing ecosystem and create a new “Internet+casting” era. ■

在产业互联网的浪潮下,B2B正迎来历史性的发展 机遇,工业品电商发展异常迅猛,中铸云商在做好标 准工业品线上交易之外探索出一条针对非标工业品的 电商之路。 一直以来,非标工业品的传统采购途径存在诸多 时间跨度漫长、影响因素复杂的采购环节。比如海量 供应商选择,询价比价议价,评估索样,决定请购订 购,协调与沟通等,采购时间紧、任务重、标准高, 仅依靠传统途径耗时费力有时不能按时按质完成任 务,仅依靠网络途径缺乏实地考察、面对面商谈、 货比三家看样试用等手段途径,无法达到实际采购 要求。 而“中铸云商”的线上线下融合的切入思路正好 找到了非标工业品电商的有效抓手,即采购商通过 中铸云商线上交易平台进行供应商筛选,在线观看企 业数字展厅初步了解供应商情况。经过筛选形成初 步意向后,可前往中铸云商的线下展厅观看基于裸眼 3D、虚拟现实、全息影像等技术的企业厂区、生产 情况、核心设备等展示内容,考察真实完整的企业车 间生产情况,按设立的权重对参观过的供应商进行打 分评价,同时现场发布询盘,获得供应商报价反馈。 供应商前往线下展厅,与采购商面对面交流,讨论商 务细节,签订合同。高效、轻松的采购体验让采购人 员无需四处奔波,降低采购风险,提高工作效率。 中铸云商平台作为基于互联网的综合交易平台, 天生就具备“在线化、数据化”的特征和优势。大大 削减了产销之间的信息不对称,加速了生产端与市场 需求端的紧密连接,使非标工业品的需求直接链接生 产制造。从订单出发,打通了一条采购—订单—生 产的需求链。形成了一种需求拉动型生产方式,使需 求数据、信息得以迅捷地传达给供应商。供应商根 据市场的需求变化组织物料采购、生产制造和物流配 送,最终形成柔性化的供应链系统。并将进一步推动 整条供应链乃至优化整个产业的发展,着力实现铸造 全产业链 “空间共享+信息共享”,打造铸造行业的 阿里巴巴,构建最具生命力的行业服务共享生态圈, 开创一个全新的“互联网+铸造”时代。 ■

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product news/產品新聞

FCRI Ceramic Filter 佛山金刚企业集团陶瓷过滤器产品 FCRI Group was established in 1958 with the headquarter in Foshan, Guangdong. Based on the technological innovation, FCRI continuous adopting the modern management concept, persisting diversity, collectivity and globalization in the development. Now FCRI has become a comprehensive hi-tech enterprise in technology research, technical service, production and sales, economical trading and journal publishing. With more than ten years of research and development, FCRI ceramic Filter has high refractoriness, good filtration effect and high filtration efficiency with unique three dimensional structures and 80-90 % open cell rate. Besides for melting metal filtration at high temperature, it can also be applied in gas treatment at high temperature, carrier of catalyzer, solid thermal exchange and special filling for chemical industry. With the foundation for FCRI (Gaoming) Industrial Park in 2017, the annual output for ceramic filter is 5000 m3. ■

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佛山金刚企业集团源自一九五八年成立的佛山 市陶瓷研究所。在五十多年的发展历程中,以科技 创新为发展之本,不断引进现代化管理理念,坚持 多元化、集团化、国际化发展,成为一家集科研开 发、技术服务、生产营销、经济贸易及科技期刊出 版为一体的综合型高新技术企业。 金刚牌陶瓷过滤器经过10多年不断发展与改进, 其耐火度高、过滤效果好、过滤效率高,具有独特 的三维连通曲孔网状骨架结构和80-90%开口通孔 率。该产品除了用于高温熔融金属过滤外,还适用 于高温烟气处理、催化剂载体、固体热交换器和特 种填料等领域。随着今年金刚(高明)工业园的落 成,泡沫陶瓷年产达5000立方米。 ■

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product news/產品新聞

Jet Cooling Optimizes Casting Quality, Cycle Time 喷射冷却技术优化铸件质量和生产周期 As a technological leader in the design and development of thermal solutions, Lethiguel can offer its know-how and expertise in the fields of cooling systems. Lethiguel research and development department closely works with our clients to develop the right product, for the right application. We have been offering turnkey solutions for over thirty years, for non-ferrous alloys processes improvement. Today, Lethiguel is working more than ever on continuous improvement of its own cooling systems, and is also subcontracting its knowledge for any type of problematic. We have a strong expertise, experience and on-site available techniques. Our engineering team is dedicated to the research of new solutions, products and processes. Therefore we can provide a collaborative work with our clients’ technical teams. Jet Cooling will optimize your casting quality and cycle time, meaning performance and quality for innovative companies. The thermal fatigue of non-ferrous metal die-

作为热处理解决方案设计和研发的技术领导 者,Lethiguel能够为冷却系统提供技术和专业知识。 Lethiguel公司的研发部门与客户密切合作,研发出 适宜的产品和正确的应用。在过去的30多年,我们已 经为有色金属工艺的改进提供了“交钥匙”的整体解决 方案。 现在,Lethiguel公司正不遗余力地改进其冷却系 统,并且把技术应用于任何类型的问题。我们拥有强大 的专业技术和经验以及在线的技术解决方案。我们的工 程团队致力于创新解决方案、新产品和新工艺的研发。 因此,我们能够与客户的技术团队开展合作。 喷射冷却技术将提升铸件质量、优化生产周期,也就 是创新型企业关注的运营和产品质量。有色压铸件热疲 劳性能的要求,在较高的操作温度时变得更加严格,高

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product news/產品新聞

THE 73rd

WORLD FOUNDRY CONGRESS ”Creative Foundry”

Scientific and Technical Sessions Exhibition ’Creative Foundry’, Krakow International Fair of Technologies for Foundry, Kielce Work Visits Post Congress Tours

City Tours Social Events

Visit us:

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www.73wfc.com

Organizers:

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product news/產品新聞 casting dies becomes more severe at higher operating service temperatures, reducing die life significantly. Consequently, to extend die life, die design has to address efficient cooling methods. Jet Cooling is the most successful solution so far. Our R&D department will answer any consultation regarding a global thermal quality problematic. Each project is individually evaluated, and we will bring all our attention to your request. We also make thermal studies for any metal and liquid. Nowadays, as a heating and cooling solutions manufacturer and with our growing experience and knowledge of the industry, we are today proudly taking a step to another level, as a global integrator and partner for the die-casting industry. We can deliver turnkey solutions such as Immersion Heating Furnaces, Heating Stations and Transport Ladles. In 2017, Lethiguel supplies clients in 35 countries, thanks to an efficient and reliable supply-chain. ■

温将显著降低压铸模具的使用寿命。因此,为了延长模 具寿命,模具设计必须有效解决冷却问题。喷射冷却技 术是目前最成功的解决方案。 公司的研发部门将解答全球任何关于热性能相关的质 量问题。每个项目都是单独评估的,我们将完全关注您 的需求。我们也将进行任何一种金属或金属液的热分析 研究。 现在,作为加热和冷却技术的解决方案提供商,公 司具备丰富的经验和技术,作为压铸行业的全球集成商 和合作伙伴,公司已经非常自豪地进入到另一个发展阶 段。我们能够为客户提供“交钥匙”的整体解决方案, 例如浸没式加热炉、加热站和转运包。 2017年,由于高效和可靠的供应链,Lethiguel公司 为35个国家的客户提供了服务。 ■

New Materials in Mold Making to Meet New Challenges in Diecasting 压铸模具新材料应对新挑战 Modern light metal diecasting is facing increasing challenges regarding efficiency, costs and quality of the casts. Higher cooling rates reduce cycle times which leads to reduced production costs and increased capacities. Faster cooling also reduces dendrite arm spacing with positive effects regarding mechanical properties and smaller wall thicknesses of the casts. Anviloy Tungsten Heavy Alloy products replace or add on to tool steel solutions. They demonstrate outstanding properties of tungsten combined with some other unique effects. The properties of Anviloy products consists of excellent thermal conductivity, very high melting point and high strength and hardness at casting temperatures. The Anviloy products also have a good chemical and solution resistance and exceptional machinability. Typical applications for Anviloy products are used in gate components, distributors, core pins, sprue bushes, sprue posts, runners, cooling inserts and wear resistance inserts. Additionally, Anviloy Weld Rod and Wire, a TIG-welding filler metal, is available to repair or armour both tool steel and Anviloy Tungsten Alloys. Anviloy Products are made of tungsten based heavy alloys. They are used in diecasting processes to increase the performance of molds in regards to thermal conductivity and wear resistance. To replace the commonly used

现在,轻金属压铸在生产效率、铸件成本和质量方面 面临着越来越大的挑战。更快的冷却速度缩短了生产周 期,从而降低了生产成本、提高了产能。更快的冷却速 度也减小了枝晶间距,对铸件的机械性能和更少的壁厚 产生积极的影响。 Anviloy公司的高钨含量的合金钢取代或作为模具钢 解决方案的补充。它们能够展示出钨的优异性能以及其 他一些独特效果。 Anviloy公司的产品性能包括:优越的热导性、非常 高的熔点、高强度、高硬度。产品还具有良好的耐化学 腐蚀和耐溶性以及卓越的机加工性能。 Anviloy公司产品主要用于浇口组件、分配器、芯 棒、浇口套、浇口柱、浇道、冷却衬套和耐磨镶块。 此外,Anviloy焊接棒材和焊丝作为钨极惰性气体 保护电弧焊填充金属,可用于修复或保护模具钢和 Anviloy钨合金。 Anviloy产品由钨基重合金制成,用于压铸工艺可以提 高模具在导热性和耐磨 性方面的性能。为了取 代压铸模具中常用的工

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product news/產品新聞 tool steel in diecasting molds, Anviloy Products can be used as inserts or core-pins. Recently more and more diecasting molds are equipped with Anviloy Products in areas such as gates, distributors, core pins, sprue bushes, sprue posts, runners and cooling or wear resistance inserts. In addition, much success has been seen by manufacturing the entire die casting mould completely out of Tucomet. Additionally, Anviloy Weld Rod, a TIG-welding filler metal, is available to repair or armor both tool steel and Anviloy Tungsten Alloys. Anviloy Tungsten Heavy Alloy products demonstrate outstanding properties of tungsten combined with some other unique effects. These properties meet the requirements for mold materials in the diecasting process. The service life in various casting applications is several times higher than it would be with hot work tool steels such as H13 / 1.2343. In many applications, the life of the Anviloy components last 25 times longer than the traditional hot work tool steels. Consequently, contamination of the aluminum with iron is almost completely eliminated. Similarly, due to the high thermal conductivity and low thermal expansion, heat checks can be prevented. Anviloy 1150 has a very low tendency to stick, or solder, to the cast product. This eliminates the need for coating and thus the hydrogen formation due to the coating. One of the biggest advantages is the up to four times higher thermal conductivity compared to hot work tool steel. This feature not only enables shorter cycle times but also improves the finished product’s material properties and drastically reduces the formation of bubbles. This allows reducing wall thicknesses and material savings. Only with higher casting temperatures, which usually are beyond the permitted temperature range of hot work tool steels, a complete mould filling can be achieved. Anviloy is able to withstand this loading. Its advantages even increase with increasing temperature. In contrast to hot work tool steels (H13), Anviloy 1150 does not require any heat treatment prior to use. This then adds another level of cost savings during the die manufacturing process. The latest development is Anviloy 3D, which is an additive manufacturing style Anviloy product. Conformal cooling is one of the major topics in mould making. Complex cooling channels can be realized by additive manufacturing and 3D printing which works with steel pretty good. Weldstone has developed a process which allows them to produce solid Anviloy parts with asymmetrical closed cooling channels inside to cool the part best where it is really needed. ■

具钢,Anviloy产品可以用作镶块或芯棒。 最近,越来越多的压铸模具配备了Anviloy产品,如浇 口、分配器、芯棒、浇口套、浇口柱、浇道以及冷却或耐 磨镶块。此外,完全通过Tucomet工艺将压铸模具制造出 来已经取得了很大的成功。 此外,Anviloy焊接棒作为钨极惰性气体保护电弧 焊填充金属,可用于修复或保护工具钢和Anviloy钨合 金。Anviloy钨高比重合金产品具有钨的优越性能以及其 他一些特殊效果。 这些性能满足了压铸工艺对模具材料的要求。在各种铸 造应用中的使用寿命比使用H13/1.2343等热加工工具钢要 高几倍。在很多应用中,Anviloy组件的使用寿命比传统 的热加工工具钢长25倍。因此,几乎完全消除了铝合金污 染。类似的,其高导热性和低热膨胀性可以防止热裂纹的 产生。Anviloy1150产品具有非常低的粘附或焊接倾向,不 需要使用涂层,因此不会产生由于涂层而形成的氢气。 与热加工模具钢相比,Anviloy产品的最大优点之一是 导热率高出4倍。这一特点不仅缩短了生产周期,而且改 善了成品的材料性能,大大减少了气孔的形成。这样可以 更进一步减少壁厚、节省材料。只有在较高的温度下,通 常超过了热加工工具钢允许的温度范围,才能实现完整 的模具填充。Anviloy能够承受这种高温。随着温度的升 高,其优势更加明显。 与热加工工具钢(H13)相比,Anviloy 1150在使用 前不需要任何热处理,在模具制造过程中节省了另一方面 的成本。 最新的研发成果是Anviloy 3D,这是一种增材制造工 艺的Anviloy产品。 异型冷却是模具制造的一个重点。复合冷却水路可以 通过增材制造和3D打印技术来实现,这些技术用于钢材 效果相当好。威尔斯通公司已经开发出一种生产坚固的 Anviloy部件的生产工艺,部件内部的非对称封闭式冷却 水路用以在需要的位置起到最佳的冷却效果。 ■

Precise Measurement Results In Visual Endoscopic Inspection 精密测量用于可视化内窥镜检查 Historically, the emphasis in RVI was placed upon being able to visualise a defect in a remote area. However, as this sector has developed, it has now placed much greater emphasis on the ability to see and measure the defect. This has been driven primarily by the Aviation market sector mainly due to the fact that what is seen as indisputable by all stakeholders within the aviation industry is the prime goal of airworthiness and operational 58

过去,精密可视化检查的重点放在了能够远程发现 缺陷。但是,随着技术的发展,现在更强调检查和测 量缺陷的能力。这主要是由航空市场驱动的,主要是因 为航空业内所有利益相关方认为无可争议的首要目标是 适航和运行安全。然而,其他行业现在已经认识到这项

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product news/產品新聞 safety. However, other industries have now come to recognize the overarching cost saving that this technology can offer. In this context borescope/videoscope inspection solutions are increasingly becoming a key enabler to support safety, performance and quality control of any kind of equipment or machinery as it can allow the user to detect and evaluate defects or imperfections without costly disassembly or removal. For the inspection process to be effective, the system must provide outstanding optical performance and clear, sharp images. The videoscope must allow precise tip control and feature a high-quality image sensor as well as adjustable light intensity in order to allow precise error detection and assessment. The screen size and the scale of the live image have a major impact on user ergonomics and visual fatigue and thus on the quality and effectiveness of the inspection. For more than ten years now, KARL STORZ’s patented MULTIPOINT laser measurement technology has been winning customers over with the speed, precision and measurement accuracy it provides in endoscopic inspection. At a size of only 4.4mm, the KARL SOTRZ MULTIPOINT “See & Measure” videoscope is the smallest on the market. The “See and Measure” concept provides quick measurement results and full-scale visual images and models (not split screen), thus significantly improving the work process by eliminating the need to switch to a separate measuring adapter. KARL STORZ also provides one of the thinnest distal ends available in the field of “See and Measure” videoscopes. MULTIPOINT technology uses a 49-Point 3D laser system that, in conjunction with the software, enables the sensor to analyse the surface structure of the object. The laser-based MULTIPOINT measurement technology provides extremely precise, certified, calibrated measurement results in any position and on a variety of surfaces. Measurement accuracy remains consistently high at distances of up to 80 mm. With the newly optimized MULTIPOINT 3.0 measurement software, KARL STORZ now offers an enhanced threedimensional depth measurement processes. Automatic 3D plane detection supports users in operating the system to allow easy and rapid measurement. The new MULTIPOINT software can perform up to eight different types of measurement: Besides its existing depth, height, lengthe area and line-to-point measurement functions, it now also offers 3D surface, tip curl and blade clearance measurements to allow optimal measurement of gap and angle dimensions. Since the position of the measuring videoscope within the object cannot always be precisely determined, it is crucial to ensure that measurements are unambiguous. The MULTIPOINT 3.0 measurement software guarantees absolute measurement precision for areas within the maximum measuring distance, including with videoscope tilted to extreme angles of up to 30°. It can even deliver exact measurement results despite strong vibration and in heavily soiled environments. This simplifies users’ work processes and provides a higher degree of process confidence. ■

技术可以带来的总体成本的节约。在这种情况下,内窥 镜/视频内窥镜检查解决方案越来越成为支持任何类型 的设备或机器的安全性、性能和质量控制的关键促成因 素,因为它允许用户检测和评估缺陷,而不需要进行代 价昂贵的拆卸或移除。 为使检验过程有效,系统必须具有出色的光学性能 和非常清晰的图像。视频内窥镜必须允许实现精确的尖 端控制,并具有高质量的图像传感器以及可调节的光强 度,以便实现精确的错误检测和评定。实时图像的大小 和屏幕尺寸对用户人体工程学和视觉疲劳以及检查的质 量和有效性有重大影响。 十多年来,KARL STORZ的专利产品MULTIPOINT 多点激光测量技术以其为内窥镜检查所提供的速度、精 确度和测量精度获得了客户的一致好评。KARL SOTRZ MULTIPOINT的“查看和测量”(“See&Measure” )视频显示器尺寸仅为4.4毫米,是市场上最小的。“ 查看和测量”的概念提供了快速的测量结果和全面的 视觉图像和模型(不分屏),从而显著改善了工作过 程,无需切换到单独的测量适配器。KARL STORZ还提 供“See and Measure”视频内窥镜领域中最薄的远端 之一。 MULTIPOINT技术采用49点三维激光系统,结合软 件,使传感器能够分析物体的表面结构。 基于激光的 MULTIPOINT测量技术可在任何位置和各种表面上提供 极其精确、经过认证的校准测量结果。测量精度始终保 持在高达80毫米的距离。 通过最新优化的MULTIPOINT 3.0测量软件,KARL STORZ现在提供了增强的三维深度测量过程。 自动三 维平面检测功能支持用户操作系统,以实现简单快速的 测量。新的MULTIPOINT软件可以执行多达8种不同 类型的测量:除了现有的深度、高度、长度和线对点 测量功能之外,现在还提供三维表面、尖端卷曲和叶 片间隙测量,获得最佳的间隙和角度测量结果。 由于测量视频内窥镜在物体内的位置不能总是精确 确定,所以确保精确的测量是至关重要的。 MULTIPOINT 3.0测量软件保证了最大测量距离范围内的绝 对测量精度,包括视频镜倾 斜至最大角度30°。即使在 强烈振动和严重污染的环境 中,它甚至可以提供精确的测 量结果。这简化了用户的工 作流程,并确保更高的流程 可靠。 ■

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Global Casting Magazine Vol. 7 Issue 4  
Global Casting Magazine Vol. 7 Issue 4