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Different Strategies, Same Goals p. 29

策略不同,目标一致 p. 29

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CASTING A PUBLICATION OF THE AMERICAN FOUNDRY SOCIETY

Casting Competence Across Three Continents


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WWW.GLOBALCASTINGMAGAZINE.COM

DECEMBER 2019

volume 9 number 4

P.29

P.34 FEATURES

专题文章

29 Different Strategies, Same Goals

29 策略不同,目标一致

34 Pouring Multiple Metals? Here’s 7 Things to Remember

34 浇注不同材质铸件?请记住7个要点

38 Census of World Casting Production Total Casting Tons Hits 112 Million

38 2018全球铸件产量数据发布 全球铸件产量达1.12亿吨

DEPARTMENTS

专栏

6 Editorial 9 Industry News 42 Product News

6 编者的话 9 行业新闻 42 产品新闻

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editorial/编者的话

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Trends to Watch in the Metalcasting Industry 铸造行业中应关注的几个趋势

etalcasting is a great industry. It is the foundation of most forms of manufacturing, and it combines ancient historical roots with the most modern of technologies. Metalcasters are found in almost every country, pouring a broad variety of alloys. Now, with the arrival of the year 2020, it is a perfect time to reflect on some of the trends in the metalcasting industry that can be seen in many parts of the world.

Worker Shortages In the United States, the unemployment rate is just 3.5 percent, the lowest such mark in more than 50 years. Many other nations also see strong employment trends for the year ahead. In much of North America, foundries and other types of manufacturers are finding it difficult to find and retain enough reliable workers. In a tight labor market, it’s easy for a worker to move from one job to another for even the smallest of pay increases. Foundries in North America are countering this trend in a variety of ways. One is by approaching alternative sources of employees, including recently laid-off workers, returning military veterans, immigrants, or even recovering addicts. Some foundries are also using non-traditional approaches to enhanced recruitment. This can include bonuses for current employees who refer a new employee; and bonuses for new employees who successfully stay on the job for an agreedupon number of months. A second approach is redouble the effort to attract younger people to our industry. In a number of parts of the world, well-organized apprentice programs are an entrée to metalcasting careers. In Norther America, metalcasters and other manufacturers open their facilities to student tours on the first Friday of October for Manufacturing Day tours. In 2019, AFS also produced a Metalcasting Careers Video which can be found on YouTube. It’s a fast-paced video with testimonials from young people, explaining why they love their careers in metalcasting.

Foundry Automation Another response to the worker shortage challenge is to reduce the number of employees needed for key job functions. This is accomplished by investing in automation for certain plant operations. Often, the highest priority area for automation is the function that the foundry is finding the most difficulty in keeping staffed. The American Foundry Society expects that even as the unemployment rate rises, the challenge in finding and retaining workers will remain. Investments in automation can make a foundry more 6

属铸造业是一个伟大的行业。它是大多数装 备制造业的基础,并将古老的历史传承与最 先进的现代技术结合在一起。几乎每个国

家都可以找到金属铸造企业,它们浇铸了各种各样的合 金。2020年即将到来,现在正是了解世界上许多国家都 有的金属铸造行业某些趋势的最佳时机。

工人短缺 美国的失业率仅为3.5%,是50多年来的最低水平。其 他很多国家也预测近几年将实现较高的就业率。在北美大 部分地区,铸造厂和其他制造业企业都面临着雇佣和保留 足够的有能力工人的难题。在劳动力紧缺的情况下,员工 很容易因为工资的小幅度上涨而调换工作。 北美的铸造厂正在通过各种办法应对这一趋势。其中 一种办法是,通过接触其他领域的雇员,包括最近下岗 的工人、退伍军人、移民等。一些铸造厂也正在通过非 传统的方法来取得良好的招聘效果,包括向介绍新员工 入职的现有员工发放奖金,以及为新入职且工作时间满 合同规定的几个月的员工提供奖金。 另一种方法是,下大力气来吸引年轻人加入铸造行 业。在世界许多地方,组织完善的学徒计划是进入铸造 业的一个渠道。在北美,铸造厂和其他制造企业将10月的 第一个星期五作为开放日,允许学生参观其工厂。2019 年,美国铸造协会还制作了一个关于铸造职业的视频, 可以在YouTube上找到。这是一个快节奏的视频,有很 多年轻人的推荐和介绍,解释了为什么他们热爱他们所 处的金属铸造行业。

铸造自动化 应对工人短缺挑战的另一种方法是减少关键工作岗位 所需的雇员数量,这要通过车间的自动化来实现。通常 情况下,实现自动化的优先领域是铸造厂在保持人员配 备方面遇到最大困难的工作岗位。美国铸造协会预测, 即使失业率上升,寻找和留住工人的挑战仍然存在。自 动化方面的投资可以使铸造厂在未来的发展中更具可持 续性。可喜的是,近年来,已经出现了不同价位的很多

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editorial/编者的话

sustainable for the future. Happily, many varieties of new equipment have been introduced in recent years at a variety of price points for foundry leaders to consider. The Internet of Things presents another opportunity for foundries to put big data, sensors, and electronics to work in improving foundry decision-making. On June 9-10, 2020, AFS will hold its first ever Foundry Industry 2.0 Conference just outside Chicago, Illinois. Metalcasters from around the world are invited to attend this conference and hear two days of expert presentations. Details can be found at www.afsinc.org.

新设备,可以供铸造企业的管理者考虑购买。 物联网为铸造企业提供了另一个可能性,将大数 据、传感器和电子设备用于改善铸造厂的决策。2020 年6月9-10日,美国铸造协会将在伊利诺伊州芝加哥 市郊举办首次铸造业2.0会议。届时,将邀请来自世界 各地的金属铸造厂参加此次会议,聆听为期两天的专 家演讲。会议详细信息可以通过www.afsinc.org查看。

市场趋势 电动汽车的发展比许多观察家的预测更快,尤其是

Marketplace Trends The electrification of the auto industry is advancing faster than many observers expected, especially in parts of Europe and Asia. The move to electrification is being driven in part by consumer demand, but even more so by government mandates aimed at curbing emissions. This is just one of the marketplace trends with enormous implications for metalcasters. Light-weighting, additive manufacturing, conversions from other forms of production to castings, and other marketplace trends bear close observation by the leaders of metalcasting operations.

Leadership Succession In the end, it all comes back to the quality of the people involved in any business operation. Metalcasting companies whose leaders are approaching retirement should start planning many years in advance to identify and train the next generation of leaders. With seasoning and experience, these younger leaders will develop the judgment and perspectives needed to be great metalcasting leaders. One cannot start too early in these efforts. All of these trends in the metalcasting industry will help to make our industry a fascinating place to operate and work for decades to come! ■

在欧洲和亚洲部分地区。电动汽车的发展受到消费者 需求的推动,更重要的是受到政府减排要求的驱使。 这只是对铸造业有很大影响的市场趋势之一。此外, 轻量化、增材制造、从其他生产方式向铸造转换及其 他趋势都受到铸造企业管理者的密切关注。

培养下一代领导者 但是,最后,这一切都将归结于参与任何业务操作 的人员的素质。铸造企业的领导者应在退休前的很多 年就做出培养接班人的计划。凭借锻炼和经验积累, 铸造企业的年轻人将具备优秀领导者所需的知识和远 见。在这方面,开始得越早越好。 所有这些趋势将有助于使我们的铸造行业成为未来 数十年的一个具有吸引力的行业和职业!■

Doug Kurkul CEO AMERICAN FOUNDRY SOCIETY

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INDUSTRY NEWS/行业新闻

Industry News Contents 行业新闻目录

Leaders And Technicians From Russia, China And Brazil Brought Together At 9Th Brics International Foundry Forum 11 俄罗斯、中国和巴西铸造协会及专家学者参加第9届金 砖国家铸造业论坛

ABP Induction to supply 2 IFM-S induction furnaces to Shandong in China ABP向山东一家企业交付2台IFM-S感应电炉

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Wencan Group Signed Acquisition Agreement with Le Bélier S.A. 文灿股份与法国百炼集团签署并购协议

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Xinxing Ductile Iron Pipes Acquires Hubei Quanli Machinery 新兴铸管成功收购湖北全力机械

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Brazilian Foundry Market Grows 16% In Three Years, Performance Improving Since 2015 11 巴西铸造市场近3年增长16%,自2015年起得到不断 改善 

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Mueller Breaks Ground on New Illinois Facility Mueller公司新工厂开建 

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METAL+METALLURGY THAILAND 2019 a Success 2019泰国国际铸造冶金展览会成功举办

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Sigma Acquires Avalon Precision Casting 西格玛公司收购阿瓦隆精密铸件公司

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LK’s 6000t Intelligent Die Casting Unit Export to the US 世界首台6000T智能压铸单元将出口美国

Grede Sold by AAM AAM公司出售格里德铸铁厂

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Shanxi Jianbang and Primetals Sign Framework Cooperation Agreement 建邦集团与普锐特冶金技术公司签订框架合作协议

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CIDC 2020 Lights the New Future of Die Casting Industry Chain 新时代大趋势 CIDC 2020点亮压铸产业链新未来

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Asia Foundry Association Delegates Attend ISIC 2019 23 亚洲铸造业联合会代表参加2019国际精密铸造会议 Ceramsite Project Put into Production 洛阳凯林铸材有限公司渑池工厂年产4.5万 吨宝珠砂项目投产 Iron-based New Material Summit Forum Held in Longfengshan 铁基新材料高峰论坛在龙凤山举办

Impro Holds Groundbreaking for New Facility in San Luis Potosi 鹰普公司在圣路易斯波托西新工厂举行开工仪式

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Allison Transmission Purchases Walker Die Casting, C&R Tool 26 艾里森变速箱公司收购沃克压铸公司及C&R工具公司

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

Leaders and technicians from Russia, China and Brazil brought together at 9th BRICS International Foundry Forum 俄罗斯、中国和巴西铸造协会及专家学者参加第9届金砖国家 铸造业论坛 Bringing together the main players of the national and international foundry, the 18th FENAF (Latin American Foundry Fair) attracted a highly qualified audience (42% presidents / managers of companies) and a significant amount of business of R$50 millions. During the four days of the event, it was possible to follow the CONAF (ABIFA Foundry Congress) and the 9th BRICS International Foundry Forum that brought together in Brazil leaders and technicians from Russia, China and Brazil who discussed the directions of the foundry sector and new technologies that are being developed in related industries. This year, the event was held in the Pro Mango Event Center in São Paulo, on 9,650 square meters with one hundred exhibitors. Luis Filipe Villas-Boas, President of the CAEF Executive Committee, represented CAEF The European Foundry Association at the International BRICS Foundry Forum, which took place on 18 September 2019 in São Paulo City, Brazil. At the same time ABIFA, the Brazilian Foundry Association, celebrated their 50th anniversary and organised FENAF 2019 – the Latin American Foundry Fair. During the forum information on the foundry industry´s situation, such as the economic scenario, industry sustainability pollution control, new technologies and implementation of industry 4.0, and other trends were shared among the BRICS nations (delegations from China, Russia and Brazil were present). This year, Mr Villas-Boas was invited to give the opening lecture of the 9th Foundry Forum. He presented the current status and perspectives of the European foundry industry. In addition, he explained the economic situation in Europe and reported on the latest figures. Finally, Luis Filipe Villas-Boas presented the foundries’ expectations based on the Foundry Industry Sentiment (FISI) and pointed out future challenges as well as political fields of action. Concurrently with the fair, CONAF gathered around 170 participants who, during the four days of the event, attended the panels and lectures where relevant industry topics such as “New steels for the automotive sector” and “Process automation for production” were discussed. The next BRICS Foundry Forum is scheduled for 2020 in Moscow, Russia. ■

第18届拉美铸造展吸引了巴西国内和国际展商以及高 质量观众的参与,其中42%的观众为公司董事长、经理, 交易额达5000万雷亚尔(约8383万元人民币)。 在4天展期中,来自俄罗斯、中国和巴西的铸造协会 领导和技术人员汇聚巴西铸造大会(CONAF)和第9届 金砖国家铸造论坛,讨论了铸造行业的发展方向及新技 术。本届展会在巴西圣保罗Pro Mango会展中心举办, 展览面积为9,650平方米,展商数量100家。 欧洲铸造协会(CAEF)执委会主席Luis Filipe VillasBoas在9月18日举办的第9届金砖国家铸造论坛上代表 CAEF参加了会议。同时,巴西铸造协会(ABIFA)还举 办了成立50周年庆祝活动,并组织了拉丁美洲铸造博览 会(FENAF 2019)。论坛期间,金砖国家代表分享了 各国铸造业的发展形势,如经济发展情况、行业可持续 性、环保、新技术和工业4.0等方面的政策和落实情况。 Villas-Boas先生应邀参加了第9届金砖国家铸造论坛 并在开幕式上演讲。他介绍了欧洲铸造业的现状和发展 趋势。此外,他还介绍了欧洲的经济状况并做了最新发 展数据的报告。最后, Villas-Boas先生根据铸造业信心 (FISI)提出了铸造厂的展望,并指出了未来将面临的挑 战以及政策领域应采取的措施。 约170人参加了展会同期举办的巴西铸造大会 (CONAF),在为期4天的论坛和研讨会中讨论了一系 列与铸造行业相关的话题,如“汽车行业使用的新型铸 钢件”、“铸造生产的自动化”等。 下一届金砖国家铸造论坛将于2020年在俄罗斯莫斯 科举办。 ■

Brazilian foundry market grows 16% in three years, performance improving since 2015 巴西铸造市场近3年增长16%,自2015年起得到不断改善 After a long and difficult period, the Brazilian industry is growing again. The third quarter started better than expected, and consultants are predicting a gradual recovery in the coming months. Proof of this is the constant growth presented in the last three years, in which the sector grew 16% between 2016 and

经过一段较长的困难时期,巴西铸造业再次呈现上 升趋势。第三季度的表现好于预期,咨询公司预测在近 几个月内将实现缓慢复苏。从过去3年的持续增长中可

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INDUSTRY NEWS/行业新闻 2019. The market of castings, according to the Brazilian Foundry Association (ABIFA), is driven in large part by the demand of the automotive industry, which in the first semester expanded production of vehicles by 2.8% compared to the same period in the previous year, as the National Association of Automobile Manufacturers (Anfavea) points out. The sustainable growth that is observed is felt by the most recent market figures. In the accumulated from January to June 2019, it produced 1,161,165 tons of castings, 4.2% more than the same period of 2018, when it registered 1,115,134 tons. Brazil has the capacity to produce 4 million tons annually. If the estimated production of 2.44 million tons is maintained this year, the country remains among the ten largest foundry markets in the world, which is headed by China which produced in 2017 (49.4 million tons, followed by India (12,060,000), United States ( 9,670,000), Germany (5,480,000), Japan (5.4 million) Russia (4.2 million), Mexico (2,910,000), Korea (2,540,000), Italy (2,240,000) and Brazil (2,220,000). Of what the country produces annually, about 16.5% is destined for exports. The foundry sector is the foundation of the entire industry and one of the main thermometers of the economy. According to ABIFA, Brazil has 1,170 foundry companies, where 40% of these working in iron Foundry, 21% aluminum and 14%, with steel. Another 25% of the companies work with non-ferrous metals, copper, zinc and magnesium.

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见一斑,巴西铸造业在2016-2019年间增长16%。据巴 西铸造协会报道,巴西铸件市场主要受到汽车业需求的 驱动。巴西汽车制造商协会指出,今年上半年,巴西汽 车产量比2018年同期增长2.8%。 持续增长趋势也可从近期的很多行业数据中观测到。 2019年1-6月,巴西铸件产量达到116万吨,比2018 年同期的112吨增长4.2%;实际上巴西的铸件产能可达到 每年400万吨。如果可以实现预期的244万吨目标产量, 巴西今年将继续位居世界十大铸件产量国家行列。2017 年世界十大铸件产量的排名是:中国(4940万吨)、 印度(1206万吨)、美国(967万吨)、德国(548万 吨)、日本(540万吨)、俄罗斯(420万吨)、墨西 哥(291万吨)、韩国(254万吨)、意大利(224万 吨)、巴西(222万吨)。其中,巴西的铸件出口大约 占总产量的16.5%。 铸造业是工业的基础,是经济发展的晴雨表。根据巴 西铸造协会的数据,巴西有1170家铸造厂,其中40% 为铸铁企业、21%为铝合金铸造企业、14%为铸钢厂, 另有25%为有色金属企业(包含铜、锌和镁),所有材 质铸件产值2018年为80亿美元。

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INDUSTRY NEWS/行业新闻 Together, they were responsible for generating a revenue of close to US $8 billion in 2018. In 2019, a turnover of around $9 billion is likely. "And we are very confident in achieving the goal, because the automotive industry, which represents more than 54% of the demands of our industry, has an optimistic prediction. According to Anfavea is expected growth of 9% in production, with a high of 11.4% in sales in the domestic market ", explains Roberto João de Deus, executive director of ABIFA. The 6.9% growth rate projected for this year may even seem small, but it is very celebrated by ABIFA for the gradual remoteness of a period that will not miss. Generation of jobs-another index that demonstrates the resumption of the sector is the generation of jobs that from 2016 to over here grew 11.6% in the sector. Today, the foundry Market employs about 56000 people. Minas Gerais leads the ranking with 16,794 jobs, followed by Santa Catarina with 16,393 and São Paulo comes in third place with 12,239. ■

预计2019年的产值很可能达到90亿美元。 巴西铸造协会执行会长Roberto João de Deus 表 示:“我们非常有信心实现这个目标,因为巴西汽车铸 件的需求量超过54%,我们对此保持乐观的预测。据巴 西汽车制造商协会透露,汽车铸件产量预计增长9%,国 内市场销售量占11.4%。” 虽然今年6.9%的增速预测看起来不是很高,但是巴 西铸造协会表示,在目前这个时期获得这样的增长率还 是值得庆贺的。 就业人数是另一个体现铸造行业复苏的指标。从2016 年到现在,铸造行业的就业增长11.6%。目前,巴西铸造 业从业人员约为5.6万人。米纳斯吉拉斯州以16794人领 先于全国,圣卡塔琳娜州及圣保罗州紧随其后,分别为 16,393人和12,239人。 ■

ABP Induction to supply 2 IFM-S induction furnaces to Shandong in China ABP向山东一家企业交付2台IFM-S感应电炉 ABP Induction has delivered and commissioned two IFM-S type induction furnaces to China. The Dortmundbased company has thus once again prevailed over the customer's established market partners. The decisive factors for placing the order were the high safety performance and the intelligent technology installed in the ABP systems, combined with more environmentally friendly operation. The two induction furnace plants with TWIN-POWER® energy supply were delivered to Shandong Himile Mechanical Science and Technology Co.,Ltd. in Gaomi in Eastern China from March 2019. The complete system was commissioned within 60 days of the arrival of the equipment and systems. An important factor for ABP: to be present in the market. The customer already operates furnaces from other market players. Nevertheless, we were able to convince him of the benefits of the ABP systems. Such benefits include the operational safety features and the advanced technology, especially with regard to the TWIN-POWER® technology. This makes is possible for customers to carry out melting with one furnace, while at the same time sintering or holding with the other furnace. The customer benefits from a higher degree of converter utilization, lower maintenance and investment costs, and ultimately also protects the environment. This is ensured by the ABP PRODAPT® melt processor, which calculates the energy requirement on the basis of the furnace content and enables effective control of the energy supply for melting and holding operation. "We see that we can generate economic benefits for our customers through our innovative ABP technologies – the market recognizes this," explains Andy Jiang, responsible for ABP in the Chinese market.

ABP感应系统公司已向中国一家企业交付并调试了两 台IFM-S型感应炉。总部位于多特蒙德的ABP公司再次 赢得了客户的信任。获得该订单的决定性因素是ABP系 统的高安全性能和智能技术,以及更环保的操作系统。 这两台配备双动力能源TWIN-POWER®的感应电炉 于2019年3月交付给位于山东省高密市的豪迈集团。全 套系统在设备到位的60天内完成调试安装。 ABP的成功因素:占有市场。客户已经在使用其他厂 商的熔炼炉。但是,ABP公司通过自身优势能够说服客 户。这样的优势包括操作安全和先进的技术,特别是在 TWIN-POWER®技术方面。这使得客户可以在用一个炉 子进行熔炼的同时,使用另一个炉子进行烧结或保温。客 户将从转炉利用率很高、更低的维护和投资成本中受益, 并且最终还能够保护环境。ABP PRODAPT®熔炼处理器 可以确保这些优势,该处理器根据熔炉内的容量计算能 量需求,并能够有效控制熔炼和保温操作的能量供应。 “我们知道,ABP的创新感应系统技术可以为客户带 来经济效益,并已得到市场的认可,”ABP中国区总经 理姜兴华说到。

关于ABP感应系统公司 ABP感应系统公司是一家为金属及金属加工行业专业

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INDUSTRY NEWS/行业新闻 About ABP Induction

制造熔炼和保温的感应电炉及系统的全球领先企业。公

ABP is a leading manufacturer of induction furnaces and systems for inductive melting and holding for the metal and metalworking industries. ABP is an expert in melting, casting, holding and heating iron, steel and non-ferrous metals with design, production, assembly and services for foundries, forges and steelworks. The ABP Induction Group with more than 400 employees operates companies in the USA, Mexico, Sweden, Germany, South Africa, Russia, India, Thailand and China. It is represented by service and sales partners in most of the world's industrialized nations. ■

司是熔炼、浇注、保温、加热领域的专业厂家,为铸造、 锻造和钢铁企业提供设计、生产、组装和售后服务。ABP 感应系统集团在美国、墨西哥、瑞典、德国、南非、俄罗 斯、印度、泰国和中国等地设有工厂,员工有400多人; 在世界各地设有销售及服务代表处。

Wencan Group signs acquisition agreement with Le Bélier S.A. 文灿股份与法国百炼集团签署并购协议

On December 8, Chinese diecasting giant Wencan Group and three major shareholders of the French company Le Bélier SA signed an agreement in Paris to acquire 61.96% of the shares of Le Bélier held by these shareholders at a price of 38.18 Euros per share, and finally make a comprehensive tender offer for the remaining equity. Le Bélier’s history can be traced back to 1961. It currently has 12 manufacturing bases around the world, including France, Hungary, Serbia, China, and Mexico. Le Bélier is a world leader in the field of precision aluminum castings for automotive brake systems. It also enjoys a high market share in the field of

12月8日,文灿股份与法国Le Bélier S.A.(百炼集团) 的3名主要股东于巴黎签署协议,拟以每股38.18欧元的 价格收购该等股东持有的百炼集团61.96%股权,并最终 对剩余股权进行全面要约收购。 百炼集团历史可以追溯至1961年,目前在全球拥有12 处制造基地,分别位于法国、匈牙利、塞尔维亚、中国和 墨西哥等地,百炼集团在汽车制动系统的精密铝合金铸件

FCRI Ceramic Fliter

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

FCRI GROUP CO.,LTD.

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+86-757-82780713

www.fcri.com.cn

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INDUSTRY NEWS/行业新闻 aluminum alloy castings for air intake systems, chassis and body structure parts. Its customers include world-renowned tier-one auto parts suppliers, such as ZF TRW, Germany Continental, Valeo, Bosch, Bentler as well as well-known vehicle manufacturers BMW, Daimler, Peugeot Citroen, Renault Nissan, etc.. Wencan Group was established in 1998 with its headquarters in Foshan, Guangdong Province, and has wholly-owned subsidiaries in Nantong, Jiangsu and Tianjin. The company and its subsidiaries efficiently and quickly serve the automobile and tier-one customers in China and around the world. The company is mainly engaged in the R&D, production and sales of automotive aluminum precision diecasting parts. Its products are mainly used in engine systems, transmission systems, chassis systems, braking systems, body structure parts and other automotive parts of middle and high-end automobiles. Its customers include world-renowned first-class auto parts suppliers ZF TRW, WABCO, VALEO, HALDEX, GETRAG, BOSCH, MAHLE, JATCO as well as vehicle manufacturers, such as General Motors, Mercedes-Benz, Great Wall Motor, Volkswagen, Tesla, Geely and Shanghai NIO. Through this merger, Wencan's advanced high-pressure casting process will be integrated with Le Bélier’s leading gravity casting process to form a comprehensive casting process chain. At the same time, both sides will coordinately advance the comprehensive development of low-pressure casting technology and processes to meet the diversified needs of customers. After the completion of the merger and acquisition, Wencan will establish a manufacturing and R & D base covering the world's major automotive markets, achieve a significant increase in the market share and product range of precision aluminum alloy products in the automotive parts field, and realize a globalized layout, international management mode and talent structure. ■

领域居于世界领导者的位置,同时在进气系统铝合金铸 件以及底盘及车身结构件领域也享有较高的市场份额, 其服务的客户包括采埃孚天合、德国大陆、法雷奥、博 世、本特勒等全球知名汽车零部件一级供应商,以及宝 马、戴姆勒、标致雪铁龙、雷诺日产等知名整车厂商。 文灿股份于1998年在广东省佛山市设总部,并在江 苏南通和天津设有全资子公司。高效快捷地服务于中国 乃至世界各地的汽车整车和一级零部件客户。公司主要 从事汽车铝合金精密压铸件的研发、生产和销售,产品 主要用于中高档汽车的发动机系统、变速箱系统、底盘 系统、制动系统、车身结构件及其他汽车零部件。公司 客户包括采埃孚天合、威伯科、法雷奥、瀚德、格特拉 克、博世、马勒、加特可等全球知名一级汽车零部件供 应商,以及通用汽车、奔驰、长城汽车、大众、特斯拉、 吉利、上海蔚来等整车厂商。 通过本次并购,文灿股份领先的高压铸造工艺将与百 炼集团领先的重力铸造工艺整合形成完整的铸造工艺链, 同时双方将协同推进低压铸造技术工艺的全面发展,以满 足客户多元化的产品工艺需求。本次并购完成后,文灿股 份将形成覆盖全球主要汽车市场的制造及研发基地,并 实现公司精密铝合金铸件产品于汽车零部件领域的市场 份额和产品范围的大幅提升,实现全球化的产业布局, 国际化的管理模式和人才格局。

Xinxing Ductile Iron Pipes acquires Hubei Quanli Machinery 新兴铸管成功收购湖北全力机械

In July 2019, Xinxing Ductile Iron Pipes successfully acquired Hubei Quanli Machinery. Hubei Xinxing Quanli Machinery Co., Ltd. was established, which announced that Hubei Quanli and the large state-owned Xinxing Pipe were successfully reorganized. Xinxing Quanli Co., Ltd. is a professional auto parts manufacturing company established after Hubei Quanli was acquired by Xinxing Ductile Iron Pipes Co., Ltd. with a lawful bid. The registered fund reached 300 million yuan. Xinxing Ductile Iron Pipes Co., Ltd. is under the supervision of the State-owned Assets Supervision and Administration Commission of the State Council. It is the world’s largest centrifugal ductile iron pipes supplier with a production capacity of 3 million tons of ductile iron pipes. It now has a number of production bases in Handan, Hebei and Wuhu, Anhui. The company has won "Top 10 Listed Companies," "Outstanding Contribution Award for Chinese Foundry Industry," and "China's Top 500 Most Valuable and Famous Brands," among other honors. According to Xinxing Ductile Iron Pipes, the establishment of Hubei Xinxing Quanli Machinery is an important investment achievement of Xinxing, marking a big step forward for the company to develop its foundry business. ■

2019年7月,新兴铸管股份有限公司成功收购湖北 全力机械,宣告湖北全力与大型央企新兴铸管股份有 限公司成功重组。新兴全力公司是大型央企新兴铸管 股份有限公司依法竞买原全力公司拍卖资产,注册3 亿元成立的专业化汽车零部件制造企业。 新兴铸管股份有限公司隶属于国务院国资委监管, 现拥有河北邯郸、安徽芜湖等多个生产基地,具有年 产300万吨球墨铸铁管的生产能力,是全球离心球墨 铸铁管最大的供应商。先后荣获“十佳上市公司”“ 中国铸造行业突出贡献奖”“中国最具价值著名诚信 品牌500强”等荣誉。 新兴铸管股份有限公司负责人表示,湖北新兴全 力机械有限公司的成立,是公司产业投资取得的重 要成果,标志着公司在铸造产业发展道路上迈出了 可喜的一步。 ■

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INDUSTRY NEWS/行业新闻

METAL+METALLURGY THAILAND 2019 a success 2019泰国国际铸造冶金展览会成功举办 METAL+METALLURGY THAILAND 2019 was held Sept. 18-20 at the Bangkok International Trade and Exhibition Center. More than 200 exhibitors from 20 countries and regions participated in the exhibition, and visitors from 32 countries and regions attended, including China, Thailand, U.S., U.K., Germany, France, Japan, Korea, Canada, Spain, Malaysia, Philippine, Indonesia, India, Vietnam, and Singapore. According to a survey of participators, 95% of exhibitors were satisfied with the event, 94% would continue to exhibit in the next year and 91% exhibitors would recommend this exhibition to their partners and customers. It all indicates that the first overseas exhibition sponsored by China Foundry Association was a success. Sponsored by China Foundry Association, Metal+Metallurgy Thailand 2019 has won the support of Thai Foundry Association, Thailand Convention and Exhibition Bureau, Thai-China Cultural Relations Committee,

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2019年9月18-20日,2019泰国国际铸造冶金展览会 在曼谷国际贸易展览中心成功举办!来自20个国家和地 区的200余家展商汇聚一堂,三天展期共吸引来自中国、 泰国、美国、英国、德国、法国、日本、韩国、加拿大、 西班牙、马来西亚、菲律宾、印度尼西亚、印度、越南、 新加坡等32个国家和地区的专业观众到会参观。根据 展商调研表数据显示,95%的参展商对本届展会表示满 意,94%的展商表示明年将继续参展,91% 的展商表示 会推荐展会给业界同行、客户与合作商。 本届展会由中国 铸造协会主办,得到 泰国铸造协会、泰国 会展局、泰中文化关 系委员会、中国贸发 局、中国驻泰国大使 馆,中国机械工业联

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INDUSTRY NEWS/行业新闻 Trade Development Bureau of China, Chinese Embassy in Thailand, China Machinery Industry Federation, Thailand-China Industrial Cooperation Institute, the Eastern Thai Economic Corridor, China General Machinery Association, Thai Iron and Steel Institute, Thai Subcontracting Promotion Association, Thai Tool and Die Industry Association, as well as great support and active participation from other Asian foundry industry organizations, including the Institute of Indian Foundrymen, Japan Foundry Society, Vietnam Foundry Metallurgy Science Technology Association, Indonesian Foundry Industries Association, Mongolian Metallurgical Association, Korea Foundry Society, Federation of Malaysian Foundry & Engineering Industries Association, Hong Kong Foundry Association, Pakistan Foundry Association, and Taiwan Casting Industry Association. The opening ceremony of Metal+Metallurgy Thailand was held in morning of Sep. 18. Pini, with former Deputy Prime Minister of Thailand and the chairman of Thai-China Cultural Relations Committee, Mr. Su Guangling, deputy director of promotion department, the Trade Development Bureau of China, Mr. Huang Kai, the first Secretary of Chinese Embassy in Thailand, Mr. Chiruit Isarangun Na Ayuthaya, Chairman of Thailand Convention and Exhibition Bureau, Mrs Achana Limpaitoon, the committee member of Thailand-China Industrial Cooperation Institute, Mr. Verapong Chaipern, chief expert of the Eastern Thai Economic Corridor, and Mr. Zhang Libo, vice president of China Machinery Industry Federation and president of China Foundry Association delivered speeches at the opening ceremony. China is Thailand’s largest export and import market and Thailand is China’s third largest trading partner among ASEAN countries. Chinese foundry equipment and raw and auxiliary materials have been warmly welcomed in Thailand and bilateral cooperation in the metal industry is very active. “Metal+Metallurgy Thailand” has established a platform for the exchange and cooperation of foundry industry between China and Southeast Asian countries. It is also an exploration and practice on international capacity cooperation with “Belt and Road” Initiative. In line with the needs of the metal industry market in Thailand and Southeast Asia, the exhibits cover the entire industrial chain of technology, material, equipment and intelligent solution in industries of foundry, metallurgy, diecasting, industrial furnace, heat treatment, robot, tube & wire, and cables, etc. In order to facilitate the precise match of supply and demand during the exhibition days, except for product displays, sandboxes, and posters, there were also a series of diversified events held at the same time, such as seminars, conferences, and plant visits. They were to promote effective interaction between Chinese and foreign foundry industry organizations and enterprises, and

合会、泰国工业联合会 泰中企业合作委员会、 泰国东部经济走廊、中国 通用机械协会、泰国钢铁 协会、泰国分销协会、泰 国模具协会等中泰双方国 家政府,东南亚各行业以 及泰国本地行业组织的大 力支持,同时获得来自印 度铸造协会、日本铸造学 会、越南铸造和冶金科学 技术协会、印度尼西亚铸造协会、蒙古冶金协会、韩国 铸造学会、马来西亚机器厂商总会等亚洲其他国家和地 区以及中国各地方行业组织的积极参与。 9月18日,首届泰国国际铸造冶金展在曼谷国际贸易展 览中心成功开幕。泰中文化关系委员会主席、泰国前总理 披尼,中国贸发局促进处副处长苏广领,中国驻泰国大 使馆第一秘书黄凯,泰国会展局主席Chiruit Isarangun Na Ayuthaya先生,泰国工业联合会泰中企业合作委员 会委员Achana Limpaitoon女士,泰国东部经济走廊首 席专家、前任泰国工业管理局董事Verapong Chaipern 先生,中国机械工业联合会副会长、中国铸造协会会长 张立波等领导出席开幕式并先后致开幕词。 中国是泰国第一大出口市场和第一大进口来源地,其 铸造装备及原辅材料受到泰国市场热烈欢迎;泰国是中 国在东盟国家中的第三大贸易伙伴,双边在金属制造业 领域合作密切。由中国铸造协会倾全行业之力精心打造 的“2019泰国国际铸造冶金展”为中国与东南亚国家的 铸造业交流与合作搭建了平台,也是“一带一路”国际铸 造产能合作的探索与实践。 紧贴泰国及东南亚金属工业市场需求,展品涵盖铸 造、冶金、压铸、工业炉、热处理、机器人、管线管材、 线材线缆等行业上下游全产业链技术、材料、设备与智能 化解决方案等内容。 为了在有限的时间和空间内助力供需双方精准对接, 展览现场不仅通过实物、宣传片、沙盘、海报等方式进 行产品展示,同时将经贸活动与产学研有机融合,通过 一系列高质量、专业化的创新论坛、高端会议以及馆外 实地考察活动等,促进中外铸造行业组织之间、企业之 间实现有效互动,搭建起一个立足东南亚、辐射整个亚

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INDUSTRY NEWS/行业新闻 build a display and exchange, business and innovation platform that was based in Southeast Asia, radiated the entire Asia-Pacific region, and affected the global metal industry.

太地区进而影响全球金属工业的展示交流、商贸洽谈与

Industry insights reveal the trend

行业洞悉 遇见趋势

The “Efficient and Intelligent Foundry Equipment and Technology Development Forum,” “Green and Environmentally Friendly Foundry Materials and Technology Development Forum,” and DISA Technology Seminar highlighting intelligence, green and brand, provided insights into industry’s forefront, wrote the results of transformation and upgrading, and promoted the industry-university-research combination. Suzhou Mingzhi Technology, DISA, Nanjing Guhua, Jinpu Materials, SQ Group and Kaitai Group brought the latest research achievements to the exhibition. At the same time, the representatives of these exhibitors attended the forum, discussed and shared the sintered ceramic foundry sand process, efficient and environmentally friendly cleaning solutions, intelligent and efficient grinding and cleaning technology. At the forum, the companies focused on introducing the foundry equipment and materials that matched the needs of Thailand market, which has been well received by the participants.

Quality products gain orders The first edition of Metal+Metallurgy Thailand achieved a double harvest of brand promotion and industry benefits. Environmentally friendly raw and auxiliary materials, high-end castings, die-castings, molds, intelligent equipment and innovative technologies with excellent quality and good reputation have greatly impressed the visitors. The exhibition not only enhanced China foundry brand, but also promoted the precise matching of high-quality resources and markets between China and Thailand. The next Metal+Metallurgy is scheduled to be held Sep. 1618, 2020, in BITEC Hall 105, Bangkok, Thailand. ■ For more information, visit: www.metalthailand.cn/2019/en-en/.

融合创新的平台。

凸显智能化、绿色化与品牌化的“高效智能铸造装备 与技术发展论坛”、“绿色环保铸造材料与技术发展论 坛”与DISA技术研讨会洞悉产业前沿,写下转型升级成 果,促进产学研相结合。 苏州明志科技、DISA、南京固华、金璞、圣泉与开 泰集团携最新研究成果助阵展会,同时派代表出席论坛 并就烧结陶瓷铸造砂工艺,高效、环保铸造清洁解决方 案,智能、高效铸件打磨、清理技术等对铸造生产的一 系列改进为现场观众做了精彩分享。论坛上,各企业重 点向与会人员介绍了同泰国需求相匹配的铸造设备,环 保绿色铸造原辅材料与最新、最完整铸造解决方案,受 到现场参会人士一致好评。

人气火爆 订单满满 首届展会实现了品牌推广与产业效益的双丰收,环保 绿色的铸造用原辅材料,高端铸件、压铸件、模具,智 能化设备以及创新型技术等以卓越的品质、良好的口碑 俘获了无数国内外参会朋友的“芳心”,不仅提升了“ 中国铸造名片”的品牌影响力,同时推动了中泰优质资 源和优质市场的精准对接。 第二届泰国国际铸造冶金展览会将于2020年9月16-18 日在泰国国际贸易展览中心105展馆举办!

LK’s 6000t intelligent die casting unit exported to the U.S. 世界首台6000T智能压铸单元出口美国

On Nov. 27, LK Group signed an agreement with its American customer for 6 sets of 6000t and 4 sets of 5500t intelligent die casting units. It’s an exciting news from the LK Group 40th Anniversary Open Day and Die Casting Technology Conference. The 6000t die casting unit is the largest machine in this field in the world. It’s mainly applied in producing new energy vehicle structural parts. The export to the US is a new record in Chinese die casting industry, which is a symbol that Chinese die casting industry is heading for strong. The executive member of Asia Foundry Association, founder of LK Group Mr. Siong Song Liu delivered a speech at the conference, “LK Group will further promote the research and application of intelligent, automated, networking and energy-saving equipments in new energy vehicles, communication and other related areas. LK will give 18

11月27日,力劲集团与美国客商签订6台6000T与4 台5500T的智能压铸单元,来自力劲集团40周年工厂 开放日暨新时代创新发展论坛上的重磅报道真是砥砺 人心,令人振奋! 该6000T压铸机单元迄今为止全球最大,主要应用于 新能源汽车结构件领域。出口美国将为新能源汽车工业 发展插上腾飞的双翼,这是压铸业界的新纪录,标志着 中国压铸正在由大向强,在中国压铸业发展史上具有里 程碑式的意义。 力劲集团创始人刘相尚先生在论坛致辞中表示,力劲 集团未来将在更深层次推进智能化、自动化、网络化及 节能环保装备在新能源汽车、通讯以及其它领域的研发 与应用,充分发挥生产优势,助推全行业提质增效,为

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INDUSTRY NEWS/行业新闻 full play to its production advantages and improve the quality and efficiency of the whole industry, making more contributions to the die casting industry. The President of Asia Foundry Association and President of China Foundry Association Mr. Zhang Libo, Executive Vice President of China Foundry Association Ms. Fan Qi were invited to attend the conference and witness this glorious moment. In Mr. Zhang Libo’s speech, he said: “LK Group is not only an excellent company in the die casting equipment industry in China, but also outstands in the world die casting sector.” He wished LK Group become better and better and make more contributions to the revitalization of Chinese national industry. LK will bring its latest equipment and share the cuttingedge technology at the upcoming 14th Chine International Die Casting Industry Exhibition, May 13-16, 2020 in Shanghai. ■

中外铸造实现互惠共赢 贡献自己的一份力量。 中铸协会长张立波先 生、执行副会长范琦女 士应邀出席本次论坛并 与各方企业代表见证这 一荣耀时刻。中国铸造 协会会长张立波热情致 辞,他表示,力劲集团 不仅是中国压铸装备制 造业的优秀企业,同时 也在世界压铸装备制造 业中独树一帜,是中国 铸造业值得骄傲与自豪 的一面旗帜。最后他祝愿力劲集团在国际铸造业中越来 越好,为中国的民族工业振兴不懈努力。 2020年5月13-16日,第十四届中国国际压铸工业展览 会现场,力劲科技将携顶级设备亮相展会,与来自世界 80多个国家和地区的参会人士面对面交流,现场分享最 前沿技术与成果,助力行业迈向高质量可持续发展! ■

Shanxi Jianbang and Primetals sign framework cooperation agreement

建邦集团与普锐特冶金技术公司签订框架合作协议 During the second China International Import Expo held in Shanghai, Mr. Chang Chongbin, Shanxi Jianbang Group's financial director and multi-operations director, represented the company to participate in the expo. After a series of onsite considerations and communications, the company reached a preliminary cooperation intention with Primetals and signed a framework cooperation agreement. Mr. Chang Chongbin of Shanxi Jianbang Group, Primetals (China) CEO Ogawa Hiroshi, Sales Vice President Moser Christoph, attended the signing ceremony. The agreement mainly focuses on cooperation in steel mill process, converter equipment optimization and the extension of the steel industry chain to intelligent manufacturing, covering comprehensive technologies, products and services of the whole steel industry chain, from raw materials to finished products. After the signing ceremony, Primetals (China) CEO Ogawa Hiroshi said that he believed the signing of this agreement would become a new starting point for good cooperation between both sides. Primetals will do its best to ensure that the cooperation progresses smoothly. Mr. Chang Chongbin also stated that Jianbang Group adheres to the development concept of “safe development, green development, low-carbon development and circular development” and will actively integrate into the process of globalization, carrying out pragmatic cooperation with the industry-leading company in various areas. ■

在第二届中国国际进口博览会上,建邦集团公司财 务部长兼多种经营部长常崇斌代表公司参展。经过一 系列现场考量和业务沟通交流后,公司与普锐特冶金 达成初步合作意向,并现场签订框架合作协议。常崇 斌部长、普锐特中国CEO Ogawa Hiroshi、销售副总 裁 Moser Christoph等出席签约仪式。 本次签约主要围绕包括钢厂流程、转炉设备优化、 钢铁产业链条向智能制造业延伸等方面展开合作,涵盖 钢铁产业链从原材料到成品的每一项环节全面的技术、 产品和服务。 签约仪式后,普瑞特中国CEO Ogawa Hiroshi表 示,相信本次签约将成为双方良好合作的新起点,普 锐特会尽最大努力,保证合作项目稳步推进。常崇斌 部长也表示,建邦集团秉持“安全发展 绿色发展 低碳 发展 循环发展”的发展理念,将积极融入经济全球化 进程,致力于与行业领军企业开展多领域务实合作。 ■

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INDUSTRY NEWS/行业新闻

CIDC 2020 lights the new future of die casting industry chain 新时代大趋势 CIDC 2020点亮压铸产业链新未来 On May 13-16, 2020, the National Exhibition and Convention Center (Shanghai) will once again become the focus of the global foundry. Sponsored by China Foundry Association, the 14th China International Die Casting Industry Exhibition and the 14th International Nonferrous and Special Casting Exhibition (hereinafter referred to as CIDC) will open in Shanghai to lead traditional die casting towards a new era characterized by "digitalization, network and intelligence." Starting in 2020, CIDC will be held once a year and settle in Shanghai. The scale of the exhibition has been upgraded on the basis of previous sessions. The 230,000 square meters exhibition area will bring together the entire industrial chain of metal industries, including foundry, die casting, metallurgy, industrial furnace, bearing and robot. In total, the six concurrent exhibitions will attract 2,600 exhibitors on the same stage, and 220,000 visitors from more than 80 countries and regions are expected to participate in the exhibition for purchasing, learning and sharing.

Upgrade industry chain, discover the new trend Automation, intelligence, and digitization have become the industry's development trend. The higher requirements for equipment structural components, end products, new energy vehicles, and electronic communications will drive the diecasting industry to upgrade. At this exhibition, the four themed pavilions will start from internal and external core factors that affect the development of the industry and enterprises, such as user demands, market space, technological evolution and trend prediction. They will intuitively and systematically show the automation, intelligent and digital products and technologies which has been and will be adopted in the diecasting industry. Participators will discuss with the exhibitors and friends from all over the world the new opportunities for industry development and new ecosystems for corporate survival. By now, more than 1,000 exhibitors have applied to take part in the exhibition, covering the top 50 Chinese diecasting manu-

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2020年5月13-16日,上海国家会展中心将再次成为全 球铸造人瞩目的焦点。第十四届中国国际压铸工业展览会 暨第十四届国际有色及特种铸造展览会(以下简称“压铸 展”)将于开放的上海引领传统压铸迈向以“数字化、网 络化、智能化”为特征的高质量发展新时代。 自2020年起,中国国际压铸工业展览会将由“两年一 届”提升为“一年一届”,展会举办地坐标锁定中国上海。 本届展会规模在历届基础上实现全新升级,23万平米 的超大展出面积将汇聚铸造、压铸、冶金、工业炉、轴 承、机器人等金属工业全产业链展示主题,5方联合,6展 同台,2600余家展商同台展示,预计将吸引来自全球80 多个国家和地区的220000人次专业观众到会采购洽谈。

产业链升级 探索铸造新风向 向自动化、智能化、数字化方向过渡已成为行业发展 趋势,设备类结构件、终端类产品、新能源汽车、电子 通信等领域对压铸工艺提出的更高要求将带动压铸产业 升级蜕变。本届展会,4大主题展馆将从用户需求、市 场空间、技术演进以及趋势预判等影响行业及企业发展 的内外部核心要素着手,直观、系统地展示铸造业已经 采用和未来即将采用的自动化、智能化与数字化产品与 技术,与来自世界各地的展商观众朋友共同探讨行业发 展新机遇和企业生存新生态。 展会目前已吸引来自世界各国和各地区的1012家核 心展商强势入驻,其中有以广东文灿压铸、苏州亚德 林、重庆大江美利信、广东鸿图、上海晋拓、嘉瑞集 团、力劲集团、意特佩雷斯、帕盛博(FLOW-3D)、 上海爱仕达、浙江万丰、布勒、广州德珐麟、爱司凯、 瑞立集团、日立金属等为代表的“中国压铸件企业50

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INDUSTRY NEWS/行业新闻 facturers and top 20 mold making companies, such as WENCAN, YADELIN, MILLISON, HONGTU, Jintuo, KaShui, LK, Norican, PSB FLOW-3D CAST, ASD, WANFENG, BUHLER, DEFAQI, AMSKY, SORL, HITACHI, etc. Famous brands DISA, ABP, FONDARC, Calderys, Eirich, OTTO Junker, Pyrotek, VULCAN, EVOLUT, ASK, HA, Inductotherm, MAGMA, Elkem, Vesuvius,Kurtz, Clariant, SFR, GK, Hunter, IMF, AMCOL, Cocan, Fuji, Heraeus, HYSIM, CACLCO, and Loramendi & Aurrenak will display the most advanced technologies and the strong development momentum of the industry.

Yangtze River Delta enterprises show The Yangtze River Delta area with Shanghai as its economic center is one of the most important advanced manufacturing bases in the world and one of the most developed foundry industry areas in China. It is also an important base for high-end equipment manufacturing in China. The demand for mid-tohigh-end nonferrous casting products, vermicular graphite cast iron, high-performance ductile cast iron and high-strength steel castings has continued to grow, leading high-end enterprises of the upstream and downstream industries to settle here. The foundry industry clusters and parks have begun to take shape. The exhibition specially set up a "Yangtze River Delta Enterprise Show Area" to display the new style, new ideas, and new achievements of high-quality diecasting companies in the Yangtze River Delta to the world.

Safe production and environmental protection show Safe production and environmental protection are related to the survival and development of a company. This exhibition has set up a special area for safety and environmental protection. Many world-renowned manufacturers and suppliers will display the latest achievements and applications of lightweight and intelligent technologies of magnesium alloy, semi-solid, extrusion casting and mold manufacturing, as well as diecasting machines in various industries such as automotive, aerospace, machine tools, medical, electronics, electromechanical, etc. A series of leading and cutting-edge equipments and materials will be launched, such as the used sand reclamation equipment, ventilation and dust removal devices, various environmentally-friendly binders, and the advanced workshop dust removal systems, explosion protection systems,

强”与“中国压铸模具企业20强” 等压铸件、压铸 模具骨干企业向来自世界80多个国家和地区的参展 参会人士展示中国压铸转型升级的理念与成果;更 有DISA、ABP、FONDARC、凯得力耐火材料(中 国)有限公司、爱立许集团(中国)有限公司、奥托 容克冶金设备(上海)有限公司、派罗特克(深圳) 高温材料有限公司、美国福康工程有限公司北京代表 处、埃华路(芜湖)机器人工程有限公司、亚世科 (镇江)新材料科技有限公司、上海欧区爱国际贸易 有限公司、应达工业(上海)有限公司、迈格码(苏 州)软件科技有限公司、埃肯国际贸易(上海)有限 公司、维苏威铸造科技(江苏)有限公司、库尔特机 电设备(上海)有限公司、科莱恩化工(中国)有 限公司、中铸新材工业(江苏)有限公司、美国GK 公司、亨特自动化机械(上海)有限公司、埃姆福( 无锡)智控科技有限公司、建平唯科东明矿业有限公 司、聚能石墨、富士电机(珠海)有限公司、上海贺 利氏电测骑士有限公司、天津浩宇天仿科技有限公 司、天津凯星科技有限公司、洛拉门迪 & Aurrenak (Fundigex)等国际知名企业,荟萃世界先进技术,彰 显行业发展最新动向。

长三角名企展示园 以上海为经济中心的长三角地区是全球重要的先进 制造业基地和我国铸造业最发达的地区之一,同时也 是中国高端装备及战略新兴产业重要的生产基地,对 有色合金铸件、蠕墨铸铁件、高性能球墨铸铁件和高 强度铸钢件等中高端铸件产品的需求持续增长使行业 上下游高精尖企业在这里扎堆落户,铸造产业集群和 园区也已初具规模。本届展会专设“长三角名企展示 园”,向来自世界各地的行业同仁展示长三角地区优 质压铸企业的新风貌、新理念和新成果。

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INDUSTRY NEWS/行业新闻 noise reduction systems, and wastewater treatment systems.

安全环保展区

Semi-solid technology show

安全、环保工作事关企业生存发展,顺应安全、环保 新形势,本届展会特设安全环保展区,众多世界知名设 备、材料、铸件厂商在争先展示镁合金、半固态、挤压 铸造、模具制造等轻量化与智能化技术以及高智能化压 铸机、浇注机等设备和材料在汽车、航空航天、机床、 医疗、电子、机电等各社会领域的最新应用成果的同时, 争先推出具有国际领先水平的铸造设备、原辅材料,包括 旧砂再生装置和通风除尘装置及各种环保型粘结剂,集 中展示先进的车间除尘系统、防爆系统、降噪系统、废 水处理系统等,帮助铸造企业做好环保和安全防护工作。

The development of lightweight vehicles has brought new requirements for diecasting technology. The introduction of semisolid die-casting technology has met automotive manufacturers' requirements for high quality and lightweight parts. Compared with thermal deformation forming processes, semi-solid forming has many unique advantages such as net forming, high quality, high performance, low energy consumption and low cost. This show area will highlight the application achievements of semi-solid diecasting technology in automotive structural parts, connecting fittings, brackets, brake calipers, as well as motors, engines and automotive air-conditioning compressors that have strict requirements on air tightness.

Gathering talents During the four exhibition days, a lot of industry talents from major universities in China will gather in the exhibition center. At the time, a series of supporting activities such as precision matchmaking and talent exchange meetings will focus on the status of high-end foundry talent training in China, vocational education and corporate personnel strategy adjustments, which will be discussed deeply among the participants. The demand system for enterprise talent will be introduced into the college personnel training system, further deepening the integration of production, teaching and research. It will build a friendly bridge for communication and cooperation between enterprises and talents, and promote the linking up of education chain and talents of the foundry industry.

Supporting activities highlight innovation and cooperation A high-profile China Diecasting Innovation and Development Forum will kick off during the exhibition. It will focus on industry development trend analysis, cutting-edge technology exchange, industry insiders sharing, government and enterprise dialogue. The forum meets the development requirements of the times and the development trend of the die-casting industry, it will gather academicians, well-known domestic and foreign experts, scholars and industry leaders to release policies, innovative products and technologies, which aim for promoting independent innovation. Leaders of relevant national government departments will make an in-depth interpretation of the industrial policies and development opportunities; enterprises representatives will share their experiences and ideas in the process of structural adjustment and industrial transformation. More than 100 supporting activities will be organized during the exhibition, such as the 4th China Foundry Festival, the 16th China Foundry Association Annual Congress, China Foundry Sourcing Alliance Conference, the Gold Award Diecasting Selection and Ceremony, China International Die Casting Procurement Conference, and the “Belt and Road” International Capacity Cooperation and Development Forum, which will convey comprehensive information on policy guidance, development trends in upstream and downstream industries, changes in the international landscape, cutting-edge technologies and the world market. ■ For more information, visit www.expochina.cn.

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半固态展区 汽车轻量化发展对压铸技术提出了新需求,半固态压 铸成形技术的推出满足了汽车制造商对零部件高质轻量 的要求。相对锻造等热变形成形工艺,半固态成形具有 净成形、高质量、高性能、低能耗、低成本等诸多独特 的优点。本展区将重点展示半固态压铸成形技术开发应 用在汽车结构件、连接件、支架、刹车卡钳,以及对气 密性有严格要求的电机、发动机、车用空调压缩机等领 域的应用成果。

汇聚天下铸造英才 为期四天的行业盛会,来自全国各大高校的前端行业 人才将齐聚上海国家会展中心,届时举办的多场人才精 准对接会与专业人才交流会等配套活动将围绕中国高端 铸造人才培养现状、职业教育与企业人事战略调整等与 参展参会人士进行深入探讨,将企业人才需求体系导入 院校人才培养体系,进一步深化产学研融合,为企业与 人才之间架设起沟通合作的友好桥梁,促进铸造业教育 链、人才链与产业链、创新链的有机衔接。

群英携手 压铸辉煌 中国压铸创新与发展论坛,集行业发展态势分析,前 沿压铸技术交流,行业大咖观点分享,政府与企业对话 于一体,契合时代发展需求和压铸行业发展趋势,聚集 中国工程院院士、国内外知名专家学者与行业翘楚,发 布创新产品与技术,鼓励推动自主创新。届时国家相关 部门领导将为参会人士深度解读国家政策及发展机遇, 与会代表将分享压铸企业在结构调整、产业转型过程中 的经验和思路。 同期还将举办第四届中国铸造节、第十六届中国铸造 协会年会、中国铸造采购商联盟大会、优质压铸件金奖 评选及颁奖典礼、中国国际压铸件采购洽谈会、“一带 一路”国际铸造产能合作发展论坛等百余项活动,向业 界充分传递政策导向、上下游行业发展动态、国际竞争 格局变化以及铸造科技前沿和市场信息等。 ■

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INDUSTRY NEWS/行业新闻

Asia Foundry Association delegates attend ISIC 2019 亚洲铸造业联合会代表参加2019国际精密铸造会议

Organized by Taiwan Foundry Society, the International Seminar of Investment Casting (ISIC 2019) was held Nov. 1315 in Taichung, Taiwan. The President of Asia Foundry Association (AFA) and President of China Foundry Association (CFA) Mr. Zhang Libo, the Executive Vice President Mr. Gao Wei and the Secretary General of Investment Casting branch of CFA Mr. Zhang Yun attended the seminar and its opening ceremony. Mr. Zhang Yun, on behalf of CFA, made a presentation on the topic of the investment casting market in the Chinese mainland. Mr. Zhang Libo, the president of AFA, also awarded the executive members certificates to Mr. Liao Kuan Chen, Chairman of Taiwan Casting Industry Association. These AFA executive members are recommended by Taiwan Casting Industry Association. In addition, the delegates from China Foundry Association, Investment Casting Institute, European Investment Casters’ Federation, Japan Foundry Society and Taiwan Foundry Society discussed the organization of the next ISIC, scheduled to be held October 2020 in the U.S. ■

11月13-15日,2019国际精密铸造会议ISIC在台湾 台中举办,本届会议由台湾铸造学会承办。亚洲铸造业 联合会会长、中国铸造协会会长张立波,专务高巍,中 国铸造协会精密铸造分会秘书长张耘等作为大陆代表参 加大会开幕式,张耘秘书长代表中铸协做题为《中国精 密铸造市场》的报告。期间,张立波会长还将台湾铸造 品工业同业公会推荐的台湾地区亚洲铸造业联合会执委 委员证书颁给台湾铸造品工业同业公会廖坤成理事长。 此外,中国铸造协会参会代表与北美精密铸造协会、 欧洲精密铸造协会、日本铸造协会、台湾铸造学会代表 讨论2020年10月将在美国举办的国际精密铸造会议的 组织工作。 ■

Ceramsite project put into production 洛阳凯林铸材有限公司渑池工厂年产4.5万吨宝珠砂项目投产 On Oct. 16, Sanmenxia Mianchi Zhikai New Materials Co., Ltd, a plant of Luoyang Kailin Foundry Material Company in Henan Province announced that its 45,000 tons of ceramsite project was put into production. Ceramsite is an artificial foundry sand that can substitute for chromite and zircon sand. The project is funded by Luoyang Kailin, a leading company in the industry with 20 years of experience in R&D, production, and sales of ceramsite. It relies on the brand and market advantages of Luoyang Kailin and the rich bauxite and electric power advantages in Mianchi. The project has a total investment of 165 million yuan and is designed for two phases of construction. The investment in the first phase is 45 million yuan, and the planned land for construction is 20 acres, with an annual output of 15,000 tons of ceramsite. After production, it can achieve annual sales of 50 million yuan. The investment for the second phase is 120 million yuan, and the planned construction area is 50 acres with an annual output of 30,000 tons, which can achieve annual sales of 150 million yuan when put into production. ■

10月16日,河南洛阳凯林铸材有限公司渑池工 厂——三门峡渑池县智凯新材料有限公司年产4.5万吨 宝珠砂项目在三门峡市渑池县举行隆重的投产仪式。 该项目是有着20年宝珠砂研发生产销售经验的业内 龙头企业——洛阳凯林铸材有限公司投资的,依托洛 阳凯林铸材有限公司“宝珠砂”的品牌商标以及市场 优势,利用渑池县丰富的铝矾土资源以及电力优势, 打造渑池县“宝珠砂”企业生产基地的项目。该项目 总投资1.65亿元,设计为二期建设。其中一期投资额 4500万元,建设规划用地20亩,年产1.5万吨宝珠砂, 投产后可实现年销售额5000万元;二期投资1.2亿元, 建设规划用地50亩,年产3万吨宝珠砂,投产后可实现 年销售额1.5亿元。 ■

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INDUSTRY NEWS/行业新闻

Mueller breaks ground on new Illinois facility Mueller公司新工厂开建

AFS Corporate Member Mueller Water Products (Atlanta) broke ground on its new, state-of-the-art foundry in Decatur, Illinois. “We started Mueller here in Decatur in 1857 and have been lucky enough to be in business here for over 160 years, and we are very excited about this groundbreaking and putting this brand new foundry here in Decatur,” said senior vice president of sales and marketing Chad Mize, according to the Herald & Review. “We believe this investment will allow our organization, as well as the city, to thrive for the next 160 years. This foundry is going to be the most modern, state of the art, most capable, efficient brass foundry in the world.” The foundry will be located at 2700 N. Jasper Street and manufacture finished brass goods for water and gas transmission. Up to 250 employees will work at the foundry when it is completed. The first parts are expected to be poured in about 18 months. “This foundry is being built for us to grow. So yes, there's new technology and we are going to employ that technology, but we also have a commitment from the state and the city to support the training of our employees on this new equipment,” Mize said, according to the report. “So our employees are still going to be here. They are still going to be making brass parts for us, they are going to be doing it a little bit differently, so it is going to give us the ability to bring more into our foundry than we've had in the past.” Currently, Mueller has a metalcasting facility on Garfield Avenue in Decatur, as well as another manufacturing facility on Eldorado Street. Eventually all casting production will be moved to the new foundry once construction is complete. Mueller Water Products’ portfolio includes engineered valves, fire hydrants, pipe connection and repair products, metering products, leak detection, and pipe condition assessment. Last year, Mueller also announced a three-year expansion project at its foundry in Chattanooga, Tennessee. ■

美国铸造协会会员企业Mueller水管制品公司(亚特兰 大)在伊利诺伊州迪凯特新建最先进的工厂。 “Mueller公司的迪凯特工厂从1857年开始营业,并 且有幸已经经营了160多年,我们为新工厂的开建以及 即将投产的全新工厂感到非常激动,”销售与市场高级 副总裁查德•迈兹在《先驱评论》的采访中表示,“我 们相信这项投资将使我们的公司以及整个城市在下一个 160年蓬勃发展。新铸造厂将成为世界上最现代、最先 进、功能更全面、效率更高的铜铸造厂。” 新铸造厂将生产黄铜水管及输气管道制品。建成后预 计将有250名员工在此工作。 预计将于18个月后投产并生产出第一批铸件。 “新厂将助力公司的发展壮大。为此,我们将采用新 的技术。但是我们要履行对州和市政府作出的承诺,对 员工进行新设备的操作培训。”迈兹说,“因此,我们 的员工仍将留在这里,他们将继续生产黄铜铸件产品, 但是他们使用的生产方式将有所不同,因此这将带给公 司更多的可能性。” 目前,Mueller已在迪凯特市的加菲尔德大道及埃尔 多拉多街设有铸造厂。新厂建成后,所有铸件生产将转 移至新的铸造厂。 Mueller水管制品公司的产品组合包括工程阀、消火 栓、管道连接件和备件、计量产品、泄漏检测和管道状 况评估。 去年,Mueller公司还宣布在田纳西州查塔努加的铸 造厂进行为期三年的扩建改造。 ■

Sigma acquires Avalon Precision Casting 西格玛公司收购阿瓦隆精密铸件公司 AFS Corporate Member Sigma Electric Manufacturing Corporation (Garner, North Carolina), a manufacturer of ferrous and non-ferrous castings, announced the acquisition of Avalon Precision Casting (Cleveland). Avalon manufactures investment castings for customers in the aerospace, defense, HVAC, power, agriculture, and oil and gas end markets. In a news release, Avalon said the “combination of Avalon’s investment castings capabilities and Sigma’s global, market-leading casting and precision machining capabilities brings significant product sourcing, supply chain management, and scale opportunities to each company’s customer base.” “We are excited about the addition of the Avalon facilities, and warmly welcome Avalon as a part of the Sigma team,” Sigma 24

美国铸造协会会员企业西格玛电气制造公司(北卡罗 来纳州加纳)是一家生产黑色和有色金属铸件的制造商, 宣布收购阿瓦隆精密铸件公司(克利夫兰)。阿瓦隆公司 主要为航空航天、国防、暖通空调、电力、农业机械、油 气开采等行业生产精密铸件。 阿瓦隆公司在报道中表示:“阿瓦隆的精密铸造能力 与西格玛全球领先的铸造和精密加工能力的结合为各自 公司的客户群带来了巨大的产品采购、供应链管理和市 场扩展机会。” “我们对阿瓦隆公司的加入感到非常高兴,并热烈欢 迎阿瓦隆公司成为西格玛团队的一员。”西格玛公司总裁

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INDUSTRY NEWS/行业新闻 president and CEO Viren Joshi said. “This acquisition combines the excellent investment casting capabilities of Avalon with the global presence and strengths of Sigma. The combination of both companies will add value for our combined customer base, as together we create a more comprehensive product and service offering leveraging the strengths of both companies.” In the news release, Sigma touted how the acquisition of Avalon means “the combined business is well placed to be a valuable strategic partner as customers increasingly look to manage and streamline complex global supply chains and work with worldclass casting suppliers with comprehensive product offerings across metal types and process capabilities.” “We are proud of Avalon’s long history as a valued supply partner for our investment casting customers,” Avalon president and CEO David Palivec said. “Our new partnership with Sigma will enhance our capabilities to help us better serve our markets and expand our product offering. We look forward to our next phase of growth as a part of Sigma’s global platform.” Along with its portfolio of metalcasting facilities, Sigma also has a 180,000 sq. ft. warehouse/distribution and technical center near Raleigh, North Carolina. In 2003, the company shifted to lean manufacturing. Per its website, Sigma “offers customers a wide range of services including engineering and design, secondary finishing, assembly, packaging and global supply chain management.” ■

兼首席执行官维伦•乔希说,“此次收购将阿瓦隆公司出 色的精密铸造能力与西格玛的全球业务和实力相结合。两 家公司的合并将为共同的客户群提供更大的价值,同时我 们将利用两家公司的优势提供更全面的产品和服务。” 据报道,西格玛公司宣称收购阿瓦隆公司意味着“随 着客户越来越多地寻求管理和简化复杂的全球供应链, 并与能够提供全面产品组合、具备多种工艺的世界一流 的供应商合作,合并后的公司将成为客户有价值的战略 合作伙伴。” “阿瓦隆作为精密铸造客户重要的合作伙伴已有很长 的历史,我们为此感到自豪。”阿瓦隆公司总裁兼首席 执行官大卫•帕力维表示:“我们与西格玛公司建立的 新合作关系将增强我们的生产能力,帮助我们更好地服 务于市场并扩大产品范围。我们期待公司作为西格玛全 球事业的一部分,进入到下一阶段的增长。” 除了金属铸造外,西格玛公司还在北卡罗来纳州罗 利市附近建有一个18万平方英尺(约16722平方米)的 仓库/分销和技术中心。2003年,公司转向精益生产。 通过西格玛公司网站了解到,西格玛“为客户提供了 广泛的服务,包括工程设计、二次加工、组装、包装和 全球供应链管理。” ■

Grede sold by AAM AAM公司出售格里德铸铁厂 AFS Corporate Member American Axle & Manufacturing Holdings (Detroit) announced it has entered into a definitive agreement to sell Grede, its U.S. iron casting operations, to funds managed by Gamut Capital Management for $245 million. The sale is the latest change for Grede, which was acquired by AAM in 2017 when it purchased Metaldyne Performance Group for $3.3 billion. Across 10 manufacturing facilities, Grede develops, manufactures, assembles and supplies ductile, gray, and specialty iron castings and machined components for automotive, commercial vehicle and industrial markets. In 2018, Grede generated $781 million in sales. “The sale of Grede will enable us to streamline our business, accelerate our debt reduction initiatives and enhance our margin profile,” AAM chairman and CEO David C. Dauch said. “We will continue to optimize and invest in our highly-engineered product portfolio, focus on profitable growth opportunities including electrification, and further strengthen AAM’s value proposition to all key stakeholders.” AAM will retain its El Carmen, Mexico, iron casting operations. In a release, AAM said “the El Carmen manufacturing facility will continue to provide significant vertical integration benefits to AAM, while also continuing to serve external customers in Mexico and other global markets.” The $245 million sale price will consist of $185 mil-

美国铸造协会会员企业美国轮轴生产企业AAM公司 ( 底特律)宣布已经与Gamut资本管理公司为出售其格里德 铸铁厂进入到最终协议阶段,出售价格为2.45亿美元。 这是格里德公司自2017年被麦特达因公司以33亿美元 出售给AAM公司以来发生的最大变化。 格里德公司的10个工厂为汽车、商用车和工业市场 开发、制造、组装和供应球墨铸铁、灰铸铁和特种铸铁 以及机械零部件。2018年,格里德公司的销售额为7.81 亿美元。 “出售格里德将使我们能够简化业务、加快债务削减 计划并提高利润率。”AAM董事长兼首席执行官大卫• 多奇说:“我们将继续优化并投资我们的产品组合,关注 包括电气化在内的可盈利增长机会,并进一步加强AAM 对所有主要利益相关者的价值主张。” AAM将保留其在墨西哥埃尔卡门的铸铁业务。AAM 在一则报道中称:“埃尔卡门工厂将继续体现AAM公司 巨大的垂直整合优势,同时还将继续为墨西哥和全球其 他市场的客户提供服务。” 2.45亿美元的出售价格将包括1.85亿美元的现金和

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INDUSTRY NEWS/行业新闻 lion in cash and a $60 million deferred payment obligation. The transaction is expected to close in the fourth quarter of 2019. “Grede is a market-leading supplier of high-performance, mission-critical castings with national scale, a blue-chip customer base and significant opportunities for growth,” said Jordan Zaken, founding partner, Gamut. “We are excited to partner with Grede and its dedicated employee base in its next chapter as an independent company focused on operational excellence and best-inclass delivery for its customers.” ■

6000万美元的延期付款。该交易预计将于2019年第四 季度完成。 “格里德公司是高性能、关键铸件的市场领先供应 商,拥有全国范围的、一流的客户群和巨大的增长机 会。”Gamut创始合伙人乔丹•扎克表示:“我们很高 兴能与格里德及其专业的员工合作,接下来格里德将成 为一家专注于具备卓越运营能力以及一流交付能力的独 立公司。” ■

Impro holds groundbreaking for new facility in San Luis Potosi 鹰普公司在圣路易斯波托西新工厂举行开工仪式 Impro Group held a groundbreaking ceremony for the Impro Mexico SLP Campus in San Luis Potosí, Mexico. The campus will cover almost 2.5 million sq. ft. and have five plants, including precision machining, sand casting, investment casting, aerospace components and surface treatment. Impro plans to invest over $100 million into the campus over the next 3-5 years, which will generate up to 1,500 new jobs locally. ■

鹰普集团为其墨西哥圣路易斯波托西州的新园区举行 了开工仪式。 园区占地近250万平方英尺(约232258平方米),有 5个工厂,包括精密加工、砂型铸造、精密铸造、航空航 天零部件生产及表面处理。 鹰普公司计划在未来的3-5年向园区投资1亿美元,该 项目将为当地新增1500个就业岗位。 ■

Allison Transmission purchases Walker Die Casting, C&R Tool 艾里森变速箱公司收购沃克压铸公司及C&R工具公司 Allison Transmission (Indianapolis), the world’s largest manufacturer of fully automatic transmissions for medium- and heavy-duty vehicles, made a strong move into metalcasting with its purchase of Walker Die Casting (Lewisburg, Tennessee) and C&R Tool and Engineering (Muscle Shoals, Alabama). Allison, which purchases thousands of tons of castings per year, paid approximately $103 million in cash for Walker Die Casting and C&R Tool and Engineering. “We are delighted to announce the acquisitions of Walker Die Casting and C&R Tool and Engineering,” said Allison Transmission president and CEO David S. Graziosi. “Walker’s products are a critical component in the manufacture and quality of our on-highway transmissions. We plan to grow the business and continue the heritage established by Robert Walker in 1958.” Walker produces aluminum castings and has been a supplier to Allison for 20 years. The Walker family sought a buyer for the business, allowing Allison to purchase the assets of the company that supplies essential components for its core on-highway transmission products. C&R Tool and Engineering is a leading supplier of metal working tools for use at Walker and 26

艾里森变速箱公司(印第安纳波利斯)是全球最大的 中型和重型车辆全自动变速箱制造商,通过收购沃克压 铸公司(田纳西州路易斯堡)和C&R工具与工程公司( 阿拉巴马州马斯尔肖尔斯)。 每年购买数千吨铸件的艾里森公司斥资约1.03亿美元 现金收购了沃克压铸公司和C&R工具与工程公司。 “我们很高兴宣布完成对沃克压铸公司和C&R工具 与工程公司的收购,”艾里森公司总裁兼首席执行官大 卫•格拉齐奥西说,“沃克的产品是我们生产公路变速 器的关键质量组成部分。我们计划扩展此项业务,并且 使罗伯特•沃克于1958年创立的沃克公司得以传承。” 沃克公司主要生产铝铸件,作为艾里森的供应商已有 20年。沃克家族想要寻找买家,从而使艾里森公司能够 购买沃克公司的资产,为其核心公路变速箱产品提供必 要的组件。C&R工具与工程公司是用于沃克和其他公司 的金属加工工具的领先供应商。

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INDUSTRY NEWS/行业新闻 other companies. “While it is always hard to let go of the business you built, we are proud that it will remain in good hands with Allison Transmission,” said John Walker, Walker Die Casting president and son of the founder. Walker Die Casting and C&R Tool and Engineering will be run as Allison Transmission plants and continue to operate in their respective locations. Walker Die Casting is the second-largest employer in Lewisburg, employing several hundred people. Allison is a growing business, and this has created challenges in finding casting capacity for the increasing demand for parts. The Allison development teams work with their casting suppliers to find ways to improve output by using R&R studies and tooling design changes to streamline the process, reduce scrap, remove bottlenecks, and maximize production. “The foundry base is strapped, the availability has gone down,” James Bohlen, senior advanced development supplier, quality engineer for ferrous and nonferrous castings at Allison, told Modern Casting earlier this year. “We understand, we have capability studies we review, and we have methods of understanding our foundry’s capabilities and outputs and whether there is a bottleneck or a problem child, like scrap.” ■

“虽然放弃已建立的公司业务是一项艰难的决定,但 我们为能与艾里森变速箱公司保持良好的关系而感到骄 傲,”沃克压铸公司总裁兼创始人之子约翰•沃克表示。 沃克压铸公司及C&R工具与工程公司将作为艾里森的 生产厂并将继续在各自原来的地址进行生产。沃克压铸公 司是路易斯堡的第二大雇主,有数百名员工。 艾里森公司是一个不断发展的企业,日益增长的零部 件需求对其铸造产能提出了挑战。艾里森的开发团队与 他们的铸件供应商合作,通过使用R&R研究和改变工具 设计来找到提高产量的方法,简化生产流程、减少废品、 消除生产瓶颈并使产量最大化。 “公司的铸造生产已受限,效率下降了,”艾里森公 司黑色和有色金属铸件生产部的质量工程师、高级供应 商开发詹姆斯•博伦在今年早些时候对Modern Casting 表示,“我们认识到这个问题并进行了产能研究,我们 也拥有了解铸造厂的产能和产出以及是否存在瓶颈或问 题(例如废品)的方法。” ■

Iron-based New Material Summit Forum held in Longfengshan 铁基新材料高峰论坛在龙凤山举办

Wu'an City, Hebei Province is rich in iron ore, and its high quality is rare in China and even the world. Located in Wu'an, Longfengshan Casting Industry Co., Ltd. (hereinafter referred to as Longfengshan) is a high-tech enterprise specializing in the development and production of ultra-high purity pig iron, high-purity pig iron and hypoeutectic pig iron. On Nov. 2, the Iron-based New Material Summit Forum organized by World Foundry Organization, China Foundry Association and Longfengshan was held in Longfengshan company to discuss industry and enterprise development. Mr. Andrew Turner, the Secretary General of the World Foundry Organization, Mr. Zhang Libo, Vice President of China Machinery Industry Federation and

河北省武安市铁矿资源丰富,其较高品质在全国乃至 世界实属罕见。坐落于武安的河北龙凤山铸业有限公司 (以下简称龙凤山)是一家专业研制生产铸造用超高纯 生铁、高纯生铁、亚共晶生铁的国家高新技术企业。11 月2日,龙凤山承办了世界铸造组织·中国铸造协会·龙凤 山铁基新材料高峰论坛,探讨行业及企业发展。 世界铸造组织秘书长Andrew Turner,中国机械工业 联合会副会长、中国铸造协会会长张立波,中国铸造协 会专家委员会主任张伯明,中国铸造协会资深专家刘金

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INDUSTRY NEWS/行业新闻 President of China Foundry Association, Mr. Zhang Boming, Director of Expert Committee of China Foundry Association, Mr. Liu Jincheng, Senior Expert of China Foundry Association, Mr. Gao Wei, Executive vice president of China Foundry Association, as well as the leaders of Longfengshan, including Chairman Mr. Bai Jubing, Vice Chairman Mr. Liu Wucheng, General Manager Ms. Bai Jiaxin attended the forum. The participants discussed the situation of the foundry industry at home and abroad, the development trend of iron-based new materials, and the prospects of Longfengshan’s high-end iron-based new materials. Mr. Zhang Libo chaired the forum and delivered a speech. He said that Chinese foundry industry has been developing at a high speed for many years and gradually progressed towards the goal of becoming stronger and stronger. In particular, the successful research of ultra-high purity pig iron for casting in Longfengshan has had further accelerated the ironbased materials development and the whole foundry industry in China. At the meeting, experts Mr. Zhang Boming and Mr. Liu Jincheng gave speeches on the development trends of the domestic and world foundry industry. Mr. Liu Wucheng and Ms. Bai Jiaxin from Longfengshan made a report on the basic situation and development status of Longfengshan, and they also invited the participants to visit No. 1 furnace open stove, inspection and testing center, ultra-high purity workshop. During the visit, Mr. Turner inquired about Longfengshan's process, inspection equipment and methods in detail. He said: "Everyone say that China is a miracle country. It really impressed me that China can catch up and surpass the international level in just over a decade. I believe that the globalization pace of foundry industry is further accelerating, and China foundry connects with the most advanced in the world will no longer be far away. " ■

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城,中国铸造协会专务高巍,龙凤山董事长白居秉, 副董事长刘武成,总经理白佳鑫等人参加了本次论 坛。与会代表就国内外铸造行业形势、铁基新材料发 展态势,以及龙凤山高端铁基新材料未来前景等问题 展开了深入探讨。 张立波主持本次论坛,并发表致辞。他表示,多年 来,中国铸造行业一直以高速发展的态势,逐渐向由 大变强的目标持续推进,尤其铸造用超高纯生铁等铁 基新材料在龙凤山的研制成功,进一步加速推进了中 国铸造业与世界先进的接轨。 会上,中国铸造协会专家委员会主任张伯明,中国 铸造协会资深专家刘金城分别就国内外铸造行业发展 趋势发表了讲话。龙凤山副董事长刘武成,总经理白 佳鑫就龙凤山的基本情况和发展现状作了汇报,并邀 请与会人员参观了1#炉开放炉台、检验中心、超高 纯车间。参观过程中,Turner详细询问了龙凤山工艺 技术和检化验设备及手段。Turner说:“都说中国是 产生奇迹的国家,中国能在短短十几年在铸造原材料 比赶超国际水平,让我感到震撼,此次一行,我认为 铸造全球化的步伐正在进一步加快,而中国铸造与世 界先进的接轨也将不再遥远。”

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Different Strategies, Same Goals Whether it’s week-long shutdowns or intermittent breaks, metalcasters are using planned maintenance to keep their facilities and equipment working properly. brian sandalow, associate editor

策略不同,目标一致 无论是为期一周的停产还是间歇性暂停,铸造厂都在按计划维护保养设备,以保 证设备正常运行。 Modern Casting副主编Brian Sandalow

Blackhawk’s December shutdown is used for major projects and installations.

Blackhawk公司12月份的停产用于主要设备的检修及安装。

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J

ust by the nature of what they do, metalcasting facilities are not easy places to maintain. They deal with tons of molten metal and use complicated equipment to form crucial and dependable components. Keeping it humming takes work and planning. Metalcasters might not all share the same strategies, but they have the same goal: keep their plant running as safely and smoothly as possible.

Blackhawk de Mexico (Santa Catarina, Nuevo Leon, Mexico) Rodrigo Calderon, the plant manager for AFS Corporate Member Blackhawk de Mexico, did not mince words when asked about the importance of scheduled-maintenance shutdowns. “It’s completely crucial,” he said. “It’s a very good time to make sure everything is working properly.” Blackhawk is a gray and ductile iron foundry, and one of its biggest priorities is the energy it uses for melting. The transformers and the rest of the equipment that makes melting possible doesn’t need to be in good shape. Calderon said it needs to be in “perfect” condition. The downtime with scheduled shutdowns makes that possible. “It’s also a safety issue,” Calderon said. “You can have a really big issue with safety, like a fire or other hazards.” Blackhawk usually has two shutdowns per year. The first is in the middle of the year, which lasts for only a few days and is not for full maintenance. Instead, it is a review of the plant and its needs, and includes predictive maintenance for the transformers and energy stations. The second shutdown comes in December and can last as long as 10 days, depending on how much work is needed. Sometimes, that means installing new equipment or replacing old machines, and work on the transformers.

A gray and ductile iron foundry, one of Blackhawk’s biggest priorities is the energy it uses for melting.

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lackhawk公司12月份的停产用于主要设备的 检修及安装 就其所处的环境和所执行的作业而言,铸造

厂的设备并不易于维护。大量熔融金属液倒入形状复杂 的型腔,形成关键而可靠的零部件。 保持设备稳定运行需要按计划维护保养。铸造厂家可 能并不执行相同的策略,但是他们的目标是相同的:使 设备尽可能安全、平稳地运行。

墨西哥Blackhawk公司 (墨西哥新莱昂州圣卡塔琳娜市) 罗德里戈•卡尔德隆是美国铸造协会会员企业墨西哥 Blackhawk公司的工厂经理,当问到定期停机维护的重 要性时,他直言不讳的说:“这至关重要,定期维护是 确保所有设备正常运转的前提条件。” Blackhawk公司主要生产灰铸铁件和球墨铸铁件,其 最重要的优先事项之一是熔炼所使用的能源。变压器和 其他熔炼所需的设备处于良好的状态是不够的。卡尔德 隆强调,它必须处于“完美”状态。按计划停机并进行 维护使之成为可能。 “这同时也是安全问题,”卡尔德隆说,“而且是真 正的关乎安全的大问题,比如火灾或其他危险。” 通常Blackhawk公司每年进行两次停产维护。第一 次是在年中,只持续几天,不是全面维护。相反,是 对工厂及其需求的检视,包括变压器和能源站的预见

作为灰铸铁和球墨铸铁厂,Blackhawk公司需优先考虑的问题之 一是其熔炼所需的能源。

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Blackhawk usually has two shutdowns per year. The first is in the middle of the year, which lasts for only a few days and is not for full maintenance.

通常Blackhawk公司每年进行两次停产维护。第一次是在年中, 只持续几天,不是全面维护

“Normally, we use an external company for the maintenance of the transformers,” Calderon said. “For all the energy supply equipment, we use an expert. They have all the equipment, all the measuring devices and thermographic cameras with better resolution.” Plans for this shutdown start in October with meetings every 10 days, and in November the meetings become weekly and involve production staff, maintenance and the plant’s management. At times, Calderon said, it’s important to involve the purchasing department if outside contractors or suppliers need to perform the maintenance. As he said, it’s better to know too early than too late that something is needed. “Because you are going to shut down the power, you have to empty all the furnaces due the cooling system,” Calderon said. “You have to empty all the furnaces, empty the holding furnace, which is a 60-ton furnace. Normally, we use that time to make the inductor change to the holding furnace. That is the importance of the December shutdown.” Planning is key. “Make sure you see all the details, because once people are outside the plant, to bring extra people in or to bring people back from vacation is going to be difficult,” Calderon said. “You need to plan it as early as possible.” The December shutdown is used by Blackhawk for major projects. Last year, the company installed robotic cells for the grinding area. Every project has a timeline, and Blackhawk uses software so everybody can access a timeline on mobile devices. There is a project manager who follows the different activities during different days, and there are more meetings between Calderon and other managers for progress reports. “Sometimes, you have a little bit of a delay,” Calderon said. “But if you follow the plans with discipline, you will get results. Make sure that everyone that needs to be

性维护。 第二次停产通常在12月,约持续10天,具体取决于 所需的工作量。有时,也在这一期间安装新设备或更换 旧设备,并对变压器进行维护。 “通常,我们聘请外面的公司来维护变压器,”卡尔 德隆说,“对于所有的供应能源的设备,我们都聘请专 业公司维护。他们有专业的设备,所有的检测设备和具 有更好分辨率的热像相机。” 停产的计划从10月份开始制定,每隔10天召开一次 会议,到11月时会议间隔变成每周一次,涉及生产、 维修和工厂的管理人员。卡尔德隆说,有时,如果需要 外部承包商或供应商进行维护,请采购部门参与非常必 要。正如他所说,早一些知道需要什么比晚知道要好。 卡尔德隆说:“因为需要关闭电源,考虑到冷却系 统,所以必须清空所有的炉子。清空所有的熔炼炉包括 60吨的保温炉。通常,我们利用这段时间更换保温炉感 应线圈。这就是12月份停产的重要性。” 计划是关键。 卡尔德隆说:“要确保考虑到所有的细节,因为一旦 员工离开工厂,让他们从假期中返回非常困难。因此需 要尽早计划。” Blackhawk公司12月份的停产维护期也用于重大项 目的执行。去年,公司为清理打磨工部安装了机器人。 每个项目都有时间表,Blackhawk公司使用管理软件, 这样每个人都可以在移动设备上登录了解时间进度。项 目经理可以在不同的时间跟踪不同的项目,卡尔德隆和

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involved is involved.” As Calderon alluded to, the planning for a scheduledmaintenance shutdown is not a light issue. It requires time, calculations and a coordinated effort between all departments. One key is to make sure the foundry’s customers are still being served, and Calderon said Blackhawk takes that into consideration. For Blackhawk, those customers might be undergoing their own planned maintenance. “Normally, our customers also have a shutdown. Some of them have shutdowns twice a year if they are in construction or agriculture. They have a one-week shutdown in the summer, and a two-week shutdown in December around Christmas,” he said. “We have monthly meetings with them to hear their scheduling and production forecasts. We plan the shutdowns together in December. “We use the same time they are going to be stopping. Sometimes we need a couple days more. We plan to make sure they have enough castings to get their work done.” As for the foundry workers who might not be directly involved in the maintenance shutdowns, Calderon said the company tries to give them breaks “as much as possible.” However, if an area needs new equipment, the workers need to be familiar with the change and be ready to produce when the shutdown is complete, usually around the first week of January. “It depends on the area. If the finishing area is involved, you want to bring the team leaders back a couple days before to make sure everything is going to work normally,” Calderon said. “You have to make sure

其他经理之间会有更多的会议沟通进度报告。

Aarrowcast, which specializes in large-cored iron castings, performs scheduled maintenance in shorter group blocks that are staggered over long weekends.

Aarrowcast公司专业生产大芯铸铁件,在周末进行分组的定期 维护。

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卡尔德隆说:“有时候,会有一点延迟。但如果你有 纪律地执行计划,你就会得到结果。要确保每个需要参 与的人都参与进来。” 正如卡尔德隆所说的,维修停产计划并不是一个轻 松的问题。这需要时间、计算和所有部门之间的协调努 力。最关键是要确保铸造厂的客户仍然能够得到服务, 卡尔德隆说Blackhawk公司考虑到了这一点。 与Blackhawk公司一样,这些客户可能正在进行自己 的维护计划。 “通常情况,我们的客户也会停产维护。如果他们从 事建筑业或农业,他们每年会停产维护两次。他们夏季 停工一周,圣诞节前后停工两周。”他说,“我们每月 与他们举行会议,了解他们的时间表及产量需求。我们 通常计划在12月一起停产。” “我们与客户计划停产的时间保持一致,有时候我们 需要多几天的时间。我们计划并确保客户有足够的铸件 来完成他们的工作。” 对于铸造厂内部无需直接参与停机维护的工人,卡尔 德隆介绍到,公司试图给他们“尽可能多”的休息,但 是,如果哪个工部需要安装新设备,通常是在1月份的第 一周,工人需要熟悉设备并在停产结束时做好生产准备。

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the equipment is going to work properly.”

Aarrowcast (Shawano, Wisconsin) A producer of more than 50,000 tons of gray and ductile iron castings annually, AFS Corporate Member Aarrowcast does not carry out long planned-maintenance shutdowns. Instead, they are performed in shorter group blocks that are staggered over long weekends. “We’ve learned that if we don’t do that maintenance shutdown, and do these timely preventive maintenance and predictive maintenance activities and repairs, we will pay for it in the long run with excess downtime,” Aarrowcast president and COO Randy Brull said. Aarrowcast has a detailed preventive maintenance system, predictive maintenance system, and work-order system. The predictive and preventive maintenance is generally performed in normal down times during the week or every day. And when the shutdowns occur—usually once per quarter—the focus is most likely equipment. “It’s really fixing it before it’s broken,” Brull said. “It’s an attempt to fix just before it breaks. During our maintenance shutdowns, we’ll spend time repairing things we know are worn, but also things we have predicted that will fail in the near future.” As far as timing, Aarrowcast tries to do as much of the work as it can around holiday weekends because they will already be down. But that isn’t the case all the time. “In some cases, it is planned just on periodic need,” Brull said. Maintenance is a big job, and Aarrowcast does use outside services to help. They do it for a pair of reasons. “We have our normal maintenance crew we are supporting, and in a shutdown we are trying to get so much work done, we bring outside people in to help and just to support them. We’re trying to maximize the amount of work done in that shutdown period,” he said. “And in some cases, it’s just a technical skillset that we may not have. It may be something specific to a piece of equipment that the manufacturer would have that we don’t have. We may not have the technical skills to do everything.” Clearly, Aarrowcast has plenty of skills and is experienced planning their maintenance. If the shutdowns occur during non-holiday periods, they will inform customers and make sure they have enough castings to fill needs. In general, a successful maintenance schedule comes back to planning. “There’s an extensive maintenance plan that says, here’s what work has to be done, here’s what we can do during that time period and the maintenance team holds that responsibility to make sure they are doing the right things to be most effective,” Brull said. “They are evaluating downtime records, they are evaluating predictive maintenance reports. They are just looking for noise vibration and planning what they have to do based around those results. “It becomes a challenge because there is quite a bit of planning that has to be done and coordination because you have many people with many different activities taking place in a short period of time,” Brull said. “It’s critical that the plan is established, that the parts needed are staged and ready to go, and there is a solid plan.” ■

“这取决于是哪个工部,如果涉及到最后的清理工 部,需要提前几天让班组长们回来,以确保一切都能正常 进行。“卡尔德隆说:“你必须确保设备能正常工作。”

Aarrowcast公司(威斯康星州沙瓦诺) 美国铸造协会会员企业Aarrowcast公司,每年生产 超过5万吨的灰铸铁件和球墨铸铁件,他们不做长时间 的停产维护计划。相反,他们在较短的时间段进行维护 保养作业,通常在周末交错安排。 “我们已经了解到,如果我们不安排停机维护,不定 期进行预防性维护和维修,我们将不得不付出长时间停 产或计划外停产的代价。”Aarrowcast公司董事长兼首 席运营官兰迪·布鲁尔说。 Aarrowcast公司有详细的预防性维护系统、预测维 护系统和工单系统。预测和预防性维护通常在每周或每 天的正常停机时间内进行。当停产发生时(通常每季度 有一次),维护的焦点是最可能出问题的设备。 “在设备故障之前,真正的修好它。”布鲁尔说,“ 这是一种在故障之前修复的尝试。在我们停产维修期 间,我们将花时间维修已确定出现磨损的零部件,但也 有一些是我们预测在不久的将来会出现故障的部分。” 至于时间安排,Aarrowcast公司尝试尽可能安排在 假日周末,因为设备此时已经在停机状态了。 但并不是所有的维护都这样安排。 布鲁尔表示:“在某些情况下,维护计划必须根据周 期性的需要。” 维修保养的工作量巨大,因此Aarrowcast公司引入外 部服务来解决。之所以这样做是考虑到两方面的因素。 “我们有自己的日常维修人员,在停工期间,我们尽 量完成很多的工作,必须要引进外部人员来帮助和支持他 们。”他说,“我们正努力使停产期间的工作量最大化。” “而在某些情况下,我们可能没有相关的技术和技 能,或者制造商拥有的设备是特制的,是我们所不具备 的。也就是说,我们不可能具备做任何事情的技能。” 显然,Aarrowcast公司凭借优秀的技能和丰富的经验 制定维护计划。如果停产发生在非假日期间,他们将通 知客户,并确保他们有足够的铸件,以满足生产需求。 总体来说,成功的维护作业来自于完善计划。 “一个详尽的维护计划说明哪些工作是必须做的,哪 些工作在哪个时间段内可以做,维护团队负责确保他们 正在做的事情是正确的和最有效的,”布鲁尔说,“他 们正在评估停机记录,做出预测性维护报告;并在寻找 噪音振动,根据这些结果规划他们必须做的工作。” “这是个挑战,因为有很多计划需要执行和协调, 有很多人在短时间内进行了许多不同的工作,”布鲁尔 说,“重要的是,制定计划,准备好所需的零件,这就 是一个好的计划。” ■

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Pouring Multiple Metals? Here’s 7 Things to Remember

From training to marking alloys, there are many ways for metalcasters to succeed when working with different alloys and metals. brian sandalow, associate editor

浇注不同材质铸件?请记住7个要点 从培训到标记合金,铸造企业在浇注不同的合金和金属时有许多成功的方法。 副主编Brian Sandalow

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o metalcasting business is simple. Every facility has its challenges to overcome while striving to produce quality components for customers. Some of them pour multiple metals under the same roof, which presents its own unique hurdles. Modern Casting spoke with two experienced metalcasting professionals to find out how facilities can succeed when working with different materials. David Laude is the foundry administration manager at AFS Corporate Member Manufacturer’s Brass & Aluminum Foundry (Blue Island, Illinois). MBAF pours 300 and 500 series aluminum, along with tin bronzes, aluminum bronzes, manganese bronzes, silicon bronzes and high conductivity copper; and grain refined 700x nickel-zinc-aluminum bronze for the glass mold industry. Also consulted was Tom Doré, the AFS Technical Director. Doré was formerly a vice president at AFS Corporate Member Alu-Bra Foundry (Bensenville, Illinois), where he worked from 1993-2017.

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个铸造企业都不简单。他们在努力为客户生 产优质铸件的同时,还需要克服很多挑战。 其中一些企业要同时生产多种材质的铸件

这就是他们面对的特殊挑战。 为了了解如何成功浇注不同材质的铸件,Modern Casting采访了两名经验丰富的金属铸造专家。 大卫•劳德是美国铸造协会会员企业铜&铝制品铸 造厂(MBAF)(伊利诺伊州蓝岛)的铸造行政经 理。MBAF浇注300和500系列的铝合金,锡铜合金、 铝铜合金、锰铜合金、硅铜合金和高导电铜,以及用于 玻璃模具行业的700x镍锌铝铜再结晶合金 。 另一位受访的是美国铸造协会技术总监汤姆•多雷。 多雷曾担任美国铸造协会会员企业Alu-Bra铸造厂(伊 利诺伊州本森维尔)的副总裁,他于1993-2017年就职

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Manufacturer’s Brass & Aluminum Foundry pours 300 and 500 series aluminum, along with tin bronzes, aluminum bronzes, manganese bronzes, silicon bronzes and high conductivity copper.

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Identifying Alloys And Parts Is Crucial

“We have labeled carts for each alloy we pour that we use for each alloy for returns. For ingot, we keep the brass in its identified shipping box until we put it in the crucible to melt. For aluminum, we color coordinate the ingot and the returns carts for each of the aluminums we pour.” —Laude “Crucibles have metal tags that travel with them (on them) identified by the alloy they are dedicated for. Any lids or physical covers are cleaned to not have contaminants that can drop in the melt. Ingot skids and containers are identified by alloy at all times. Foundry re-melt container/carts are identified by alloy. All skimming tools, lances or other products that may touch or enter the melt are dedicated or cleaned and identified by alloy type. Barriers may be placed to prevent spills from being comingled between adjacent lines with differing alloys. “Spills are collected in pans identified by alloy until deposited in the specific re-melt dedicated container. Containers and carts are covered at critical areas like cutoff to avoid incorrect inadvertent additions. Final inspection containers are separated by dedicated barrels. Sample chemistry is checked and matched to customer, part, order and melt lot.” —Doré

2

Production Planning Can Be Optimized

“Each morning the production schedule is communicated to each department so they have an idea of what alloys will be poured that day. We try to plan it so the molding changeover happens around the same time as the furnace changeover so the molds aren’t waiting for metal.  What helps is the induction furnaces we use have a capacity of 100-200 lbs. of aluminum, so changing to a new alloy isn’t

MBAF浇注300和500系列的铝合金,锡铜合金、铝铜合金、锰 铜合金、硅铜合金和高导电铜。

1 于该公司。

识别合金及部件是关键 “对于重新熔化的回炉料合金,我们为

每种合金的手推车贴了标签。对于铸锭, 我们将黄铜放在指定的运输箱中,直到将 其放入坩埚中熔化。对于铝合金,我们对

浇注的每种铝锭和回炉料进行颜色分类。”——劳德 坩埚有随其一起的金属标签(在其上),对合金进

行标识。清洁盖子或物理覆盖表面,以免污染物进入熔 体中。铸锭板和容器始终有合金标识。铸造厂的重熔容 器/小车配有合金标识。所有可能接触或进入熔体的扒 渣工具或其他产品都是专用的或清洁过的,并根据合金 类型进行标识。可以通过放置隔离物,防止浇注不同合 金的相邻生产线之间的溢出合金混合在一起。 “溢出合金被收集在有合金标识的料斗中,直到其 放入特定的重熔专用收集容器中。收集箱和手推车在关 键区域(例如边界处)被覆盖起来,以免因疏忽加入 不恰当的添加物。最终检测容器由专用桶隔开。检查 样品的化学成分,并与客户、零件、订单和熔体批次匹

2

配。”——多雷

优化生产计划 “每天早上都会将生产计划传达给各部

门,这样他们就可以知道当天将浇注什么 合金。我们尝试制定计划,使模具的更换 与炉子转换几乎同步进行,从而使模具不

December 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

35


too much longer than staying on the same alloy.” —Laude “Production is planned based upon the product mix, demand, due dates, alloys, molding rates, melt rate, and time impact to prepare crucibles and melt staging for alloy changeovers. It is a complicated plan to optimize properly. Sand requirements are planned and the molten metal heat impact on overall sand system quality is considered. When a pattern is used for multiple alloys the pattern dimension needs to consider the effects of pattern shrinkage relative to dimensional requirements. The gating and rigging design needs to accommodate all alloys that may be run through the gating system, including differing venting and chilling requirements, and the impact different metal temperatures may have on core gas evolution. The accommodations to pour multiple alloys from the same tool frequently have an effect on cost optimization.” —Doré

3

The Melt Room Is A High-Risk Location

“It’s going to catch the sum of how well you’ve controlled your contamination efforts throughout the foundry. In many foundries, the different alloys are running concurrently, so there may even be multiple plates producing the same part in two different but similar-looking alloys. But there would be severe consequences with a mistake. “If you’ve controlled everything all the way through, and at final inspection somebody finds a defect and the casting is rejected and it’s tossed into the wrong barrel to be returned

Manufacturer’s Brass & Aluminum Foundry provides castings for many industries, and stresses the importance of training to make sure the metal avoids contamination.

36

再等待金属液。有利的是,我们使用的感应炉的熔炼能 力为100-200磅的铝,因此更换新合金的时间不会比停 留在相同合金上的时间长太多。”——劳德 “生产计划根据产品组合、需求、交货日期、合金、 成型速率、熔炼速率和时间等来制定,为合金转换所需 的坩埚和熔炼步骤做准备。合理的优化生产是一个复杂 的计划。需考虑用砂要求,并考虑熔炼金属热量对砂系 统整体质量的影响。当铸模用于多种合金时,需要考虑 与模具尺寸要求相关的缩松的影响。浇口和冒口的设计 需要适合可能通过浇口系统的所有合金,包括不同的排 气和冷却要求,以及不同的金属温度可能对砂芯气体逸 出的影响。从同一模具浇注多种合金的调节经常会影响

3

成本优化。”——多雷

熔炼车间是高风险区域 “这将概括你在整个铸造厂对污染工作

的控制程度。在许多铸造厂,不同的合金 同时浇注,因此甚至可能有多个模具生产 两种不同但外观相似的合金铸件。但是,

一个错误会带来严重后果。” “如果整个过程都得到了很好的控制,但在最终检查

中,有人发现了缺陷并将铸件归为次品,然后将其丢入

MBAF公司为许多行业提供铸件,并强调必须进行培训以确保避 免金属污染。

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION December 2019


for re-melt, multiple heats can be contaminated. The melt room is the key.” —Doré

4

Training Must Take Place Throughout The Facility

“It starts with leadership ensuring all carts used for returns are always labeled. This is critical when we have a low yield job and run out of identified carts for that given alloy–we must stay on top of any temporary usage carts. From there, we must train all employees on the importance of segregation of alloys. We follow our ISO 9001 quality procedures and make sure we do what we say and say what we do, and keep all of our operators trained on any and all changes that are made.” —Laude

5 6

Molds Are Also Affected

“Let’s say you’re a predominantly aluminum foundry and you’re going to run some brass castings, which are three times more dense than aluminum and have a higher pouring temperature. Your mold-to-metal ratio may matter more now, and the properties of the green sand will have to be monitored.” —Doré

Preheats Can Help

“At the end of the day, we usually know what we’ll be pouring first thing the next morning, so we’ll get that alloy near the furnace area and get it so the furnace is ready to turn on. When changing over, we try to get the next alloy crucible ready and turn the furnace on so it is heating up as we are pouring the last pot of the previous alloy.” —Laude “Generally, I like to preheat early before the production lines are filling to avoid bottlenecking once molding has begun. I prefer to try to keep each alloy running all day or until it may be completed and a currently running alloy can be expanded over to the furnace to continue pouring.” —Doré

7

Avoid Contamination

“For anyone who’s running multiple alloys, the biggest consideration is to avoid crosscontamination. To do that, foundries may need to choose a dedicated crucible for each alloy. But if a facility is not set up in the kind of environment to be able to do that, extreme care and consideration needs to be taken on how the crucibles are cleaned, because that can be a source of contamination. “Every employee needs to understand the consequence of contamination to be on alert for potential mistakes and mistake opportunities. In case of doubt, the metal must go into the identified scrap barrel that can be sent for separate recovery operations.” —Doré ■

错误的料筒中进行重新熔化,那么可能会污染多炉金

4

属液。因此,熔炼车间是关键。”——多雷

培训必须贯穿于整个工厂 “从领导层开始,就要确保装有回

炉料的所有手推车始终贴有标签。当我 们的场地有限并且对于给定的合金来说 没有足够的可用推车时,这一点至关重

要。我们必须熟练掌握可临时使用的推车。在此,我 们必须对所有员工培训有关合金分离的重要性。我们 要遵循ISO 9001质量程序,并确保做我们所说的、 说我们所做的,并使所有操作员接受任何及所有相关

5 6

更改程序的培训。”——劳德

铸型也有影响 “假设一家企业主要从事铝铸造,当

要浇注一些铜铸件,铜的密度是铝的3 倍,浇注温度更高。那么,铸型与金属 的比例可能会变得更加重要,并且必须

监控湿型砂的特性。”——多雷

预热起作用 “在一天的作业结束后,我们通常都

知道第二天早上的浇注合金类型,我们 将把这种合金放在炉子附近,然后把它 拿出来,这样就可以启动炉子了。转换

炉子时,我们将准备好下一个合金坩埚并打开炉子, 以便在我们浇注前一批合金的最后一炉时对其进行加 热。”——劳德 “总的来说,我喜欢在生产线作业完成之前提早 预热,以避免一旦成型作业开始而出现瓶颈问题。 我宁愿选择使每种合金整天或直到其完成浇注,并且 可以将当前浇注的合金扩展到熔炉中以继续浇注作

7

业。”——多雷

避免污染 “对于浇注多种合金的企业,应重视

避免交叉污染。为此,铸造厂可能需要 为每种合金选择专用的坩埚。但是,在 这种情况下,如果没有设备可以采用,

则必须格外注意并考虑如何清洁坩埚,否则将可能成 为污染源。” “每个员工都需要了解污染的后果,警惕潜在的 错误和错误发生的机会。如有疑虑,金属液必须进入 到指定的废料桶,然后可以将其运输到单独的回收操 作中。”——多雷

December 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

37


CENSUS OF WORLD CASTING PRODUCTION

Total Casting Tons Hits 112 Million

Worldwide casting production growth slowed but still reported a 2.6% increase in 2018. a modern casting staff report

2018全球铸件产量数据发布 全球铸件产量达1.12亿吨

虽然预测全球铸件产量增长放缓,但是2018年仍实现了2.6%的增长。 Modern Casting报道

I

n 2018, global production increased to more than 112.7 million metric tons, an increase of 2.6% when compared to the previous year, according to this year’s Modern Casting Census of World Casting Production. The nearly 113 million metric tons of metal castings produced in 2018 represent an increase of 2.5 million tons, but the world’s largest producer of castings, China, reported a 0.1% decrease in production. Of the 28 countries that provided data for the past two years, 19 reported an expansion in annual volumes when comparing 2018 to 2017. The top 10 casting producing nations are listed on page 25. Once again, China, India, and the U.S. hold the top three spots. A total of 45,954 foundries were reported worldwide, with the largest share of foundries pouring iron, then aluminum, followed by steel. The data reported in the Census of World Casting Production is supplied by each nation’s metalcasting association or similar representatives, as well as the World Foundry Organization and CAEF-The European Foundry Association. ■ 38

据美国铸造协会Modern Casting杂志所做的 全球铸件产量普查,2018年,全球铸件总产 量超过1.127亿吨,比2017年增长了2.6%( 约250万吨)。 在过去两年(2017-2018)均参与普查并提供铸件 产量数据的国家或地区中,有19个国家或地区的产量实 现了增长。2018年的十大铸件生产国排名基本稳定,其 中,中国以4935万吨的产量保持全球第一大铸件生产 国的地位,约占全球铸件产量近44%,但比2017年减 少了0.1%;紧随其后的印度铸件产量达到1339万吨, 比2017年增长133万吨(增幅为11.1%);位居第三的 美国铸件产量也有较大增长,产量达1076万吨。随后是 日本(558万吨)、德国(543万吨)、俄罗斯(420万 吨)、墨西哥(291万吨)、韩国(252万吨)、巴西 (228万吨)、意大利(226万吨)。 此外,据统计,2018年,全球铸造企业共有45954 家。按铸件材质统计,占比最多的是铸铁企业,其次是 有色金属企业(铝合金),随后是铸钢企业。 本次全球铸件产量普查数据由各国或地区的铸造协会 以及世界铸造组织、欧洲铸造协会等提供。 ■

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION December 2019


2018 Casting Production (metric tons) Country

Gray Iron

Ductile Iron

Malleable Iron

Steel

Copper Base

Aluminum

Magnesium

Zinc

Other Nonferrous

Total

Austria

43,000

109,700

-

11,400

-

144,695

-

-

-

308,795

Belarus

-

-

-

-

-

-

-

-

-

247,000

Belgium

69,900

7,800

-

7,500

-

2,200

-

-

-

87,400

17,500

9,100

-

1,350

-

10,500

-

-

-

38,450

Brazil

1,305,036

535,116

-

244,008

20,945

172,076

5,040

1,158

-

2,283,379

BulgariaB

30,300

9,200C

-

10,400

292

5,540

-

42

-

CanadaD

330,841

-

-

90,091

14,237

211,374

-

-

China

20,650,000

14,150,000

600,000

5,750,000

800,000

7,150,000

-

-

250,000

49,350,000

Croatia

31,100

11,800

-

50

221

25,174

-

25

15

68,385

Czech Republic

176,500

57,000

-

62,000

20,500

101,000

300

1,200

-

418,500

Denmark

29,600

61,900

-

-

1,285

-

-

-

89

92,874

EgyptB

-

-

-

-

-

-

-

-

-

200,000

Finland

18,400

36,200

-

10,100

3,031

2,395

-

100

-

70,226

France

597,400

682,100

-

60,400

19,307

394,727

-

24,854

2,424

1,781,212

Germany

2,435,600

1,636,000

-

184,700

79,278

1,020,013

18,198

59,205

5

5,432,999

Hungary

22,000

63,400

-

2,800

705

136,518

273

1,610

93

227,399

India

9,413,164

1,313,104

50,000

1,215,636

-

1,396,778

-

-

-

13,388,682

Italy

767,600

428,600

-

56,900

69,729

856,016

8,065

73,303

983

2,261,196

Bosnia & HerzegovinaA

A

E

55,774 646,543

Japan

2,070,301

1,689,391

39,940

171,860

74,559

1,505,499

-

19,085

4,782

5,575,417

Korea (Republic of)

989,200

700,200

1,000

158,300

25,100

630,000

13,000F

-

-

2,516,800

MexicoB

892,188

526,897

-

373,965

217,200

817,911

-

81,300

-

2,909,461

Norway

8,800

22,300

-

-

-

6,525

-

-

Pakistan

181,000

24,540

-

48,750

14,200

21,200

-

-

2,730

292,420

Poland

480,000

160,000

-

50,000

6,100

330,000

-

7,500

2,900

1,036,500

Portugal

43,400

96,800

-

5,300

16,496

37,612

-

2,440

Romania

19,500

2,000

20

9,000

2,900

66,000

5,000

400

116

104,936

Russia

2,184,000G

-

-

1,134,000

117,600

588,000

75,600

-

100,800

4,200,000

37,625

202,048

Serbia

26,300

3,100

-

18,150

3,100

10,120

1

30

-

60,801

Slovenia

62,501

43,538

3,100

27,801

755

52,050

-

8,510

-

198,255

South AfricaB

140,000

157,000

-

93,500

14,000

38,000

-

500

-

443,000

Spain

357,600

711,600

-

66,600

14,400

127,159

-

9,020

2,516

1,288,895

Sweden

161,700

64,000

-

22,900

8,792

48,000

-

-

-

305,392

Switzerland

36,700

22,100

-

2,300

2,086

13,790

-

1,118

-

78,094

Taiwan

641,178

215,796

-

68,577

31,202

421,283

-

-

-

1,378,036

Turkey

603,000

912,900

-

192,400

30,709

475,003

1,250

40,025

-

2,255,287

UkraineD

400,000

120,000

30,000

580,000

60,000

280,000

15,000

25,000

50,000

1,560,000

U.K.

144,900

219,500

-

49,200

8,670

146,900

2,640

8,085

-

579,895

U.S. Metric

4,062,373

3,325,740

37,195

931,679

288,485

1,609,346

140,614

313,886

47,174

10,756,492

WORLD TOTAL

49,442,582

28,128,422

761,255

11,711,617

1,965,884

18,853,404

284,981

678,396

464,627

112,738,168

A) 2016 Data B) 2017 Data C) Included with ductile iron D) 2015 Data E) All nonferrous F) Includes zinc G) Includes all iron December 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

39


TOP 10 CASTING PRODUCERS 1. China

2. India

3. U.S.

13,388,682 metric tons

Percent change: 11.1%

10,756,492 metric tons

Percent change: 10.6%

4. Japan

5. Germany

6. Russia

7. Mexico

8. Korea

9. Brazil

10. Italy

40

49,350,00 metric tons

Percent change: -0.1%

5,575,417 metric tons

Percent change: 2.2%

5,432,999 metric tons

10大铸件生产国产量数据 1.中国: 4935万吨 减少0.1% 2.印度:1338.8682万吨 增长11.1% 3.美国: 1075.6492万吨 增长10.6% 4.日本: 557.5417万吨 增长2.2% 5.德国: 543.2999万吨 减少0.9%

Percent change: -0.9%

6.俄罗斯:420万吨 减少0.6%

4,200,000 metric tons

7.墨西哥:290.9461万吨(2017年数据)

2,909,461 metric tons

8.韩国: 251.6800万吨 减少0.8%

Percent change: -0.6%

2017 data

2,516,800 metric tons

Percent change: -0.8%

2,283,379 metric tons

9.巴西: 228.3379万吨 增长3.1% 10.意大利:226.1196万吨 增长0.8%

Percent change: 3.1%

2,261,196 metric tons

Percent change: 0.8%

| FOUNDRY-PLANET.COM | MODER N CASTI NG | CHINA FOUNDRY ASSOCIATION December 2019


Metalcasting Plants by Nation Country Austria Belarus Belgium Bosnia & HerzegovinaA Brazil BulgariaB CanadaC ChinaA CroatiaA Czech Republic Denmark Finland France Germany Hungary India Italy JapanC Korea MexicoB Norway Pakistan Poland Portugal Romania RussiaA SerbiaA Slovenia South AfricaB Spain Sweden Switzerland Taiwan Turkey Ukraine U.K.A U.S. TOTAL A) 2016 data

B) 2017 data

Iron

Steel

12 5 5 396 80 14,000 26 56 8 11 150 27 147 670 518 5 1,610 180 23 46 26 15 -

3 8 2 134 4,000 5 28 7 40 38 66 139 65 35 8 5 29 12 2 -

441 270 216 617 C) 2015 data D) Includes diecasting facilities

Nonferrous

2018 Total

23 6 4 494 18 8,000 37 7 14 337 31 859 1,033D 232 3 205 240 57 46 51 61 40 -

38 19 11 1,024 98 175 26,000 31 121 15 32 380 527 58 4,600 1,044 1,769 889 800 8 1,880 455 88 85 1,140 36 51 167 126 99 57 -

105

390

936

280 341 -

290 204 977 -

840 420 1,935 45,954

December 2019 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

41


product news/产品新闻

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

MELTING, POURING & HEAT TREATMENT

Personalized Rapid Customization Integration Solution Provider for Equipment Complex Parts 47 装备复杂零部件个性化快速定制一体化解决 方案提供商

Seamless Pouring: Efficient Automation for Data-driven Foundries 43 浇注自适应系统:数据驱动铸造厂的高效自 动化 Avoiding Micro Porosity Defects In Iron Castings: A Case Study 案例分析:避免铸铁件中的微孔缺陷

47

SOFTWARE Magma Introduces Its New Release Magmasoft® 5.4.1 49 迈格码公司发布新版本MAGMASOFT® 5.4.1

42

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product news/产品新闻

Seamless Pouring: Efficient Automation for Data-driven Foundries PER LARSEN, PRODUCT PORTFOLIO AND INNOVATION MANAGER, DISA

浇注自适应系统:数据驱动铸造厂的高效自动化 迪砂产品组合及创新经理PER LARSEN Foundries are increasingly implementing data-driven process automation to reach longstanding goals like higher quality, lower scrap, maximum uptime and minimum costs. Fully integrated digital synchronization of pouring and molding—seamless pouring—is particularly valuable for foundries challenged by just-in-time production’s shorter runs and more frequent pattern changes. With the automated systems handling molding and pouring seamlessly interfaced to each other, the casting process becomes faster while producing higher quality components more consistently. The automated pouring process includes pouring temperature control along with inoculation feeding and verification for each mold. This increases the quality of each casting and reduces the scrap rate. This comprehensive automation also reduces the need for operators with many years of specialist experience. With fewer workers involved overall, operations become safer too.

越来越多的铸造厂通过数据驱动工艺的自动化,以实 现长期目标,例如更高的产品质量、更低的废品率、最长 的正常运行时间和最低的成本。浇注自适应系统实现浇注 和造型的完全集成和数字化同步,对面临周期短的零库存 生产和频繁更换型板挑战的铸造厂来说尤其有价值。 借助浇注自适应系统自动处理铸型和浇注系统的无 缝连接,浇注过程变得更快,同时生产出的铸件质量更 高且更具一致性。自动化浇注工艺包括浇注温度控制和 孕育剂的添加以及每个铸型的充型确认。这样可以提高 每个铸件的质量并降低废品率。这种全面的自动化工艺 还减少了对拥有多年专业经验的作业人员的需求。总体 上减少了工人的参与,生产操作也变得更加安全。

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product news/产品新闻 Customers with DISAMATIC® molding lines often need to change patterns frequently between short runs due to the trend towards just-in-time production. Using equipment like DISA’s Automatic Pattern Changer (APC) or Quick Pattern Changer (QPC), pattern plates can be changed in as little as one minute. With high-speed pattern changes in place, the process bottleneck tends to shift to pouring—the time needed to manually reposition the pouring device for the pours following a pattern change. Though pouring is often already partly automated, full automation requires seamless integration of the molding line and pouring equipment control systems so that they work completely in synchronization in all possible operational situations. For that to happen reliably, the pouring unit must “know” exactly where to securely pour the next mold and adjust the position of the pouring device if required. During steady production of identical molds, efficient automatic pouring is not too difficult to achieve. The mold string moves by the same distance—the mold thickness—each time a new mold is produced. So, the pouring device can stay in the same position, ready to fill the next empty mold once the line stops. Only small adjustments to the pouring position are needed to compensate for any variation in mold thickness caused by changes in sand compressibility. It’s during pattern changes where mold thickness can change that sophisticated automation is required. Unlike horizontal flask processes where the flask height is fixed, the vertical DISAMATIC® process can adjust mold thickness to exactly what is needed for each set of patterns to keep the sand-to-iron ratio constant and take pattern heights into account. Following a pattern change, the DISAMATIC® machine starts to produce the next batch of molds with one thickness but the pouring unit further down the line is still pouring molds from the previous pattern which might be of a different mold thickness. To cope with this, molding line and pouring unit have to work seamlessly as a combined, synchronized system, producing one mold thickness while securely pouring another.

Seamless Pouring after Pattern Changes After a pattern change, the thickness of the remaining molds between the molding machine and the pouring unit made by the previous pattern remains as before but, because the new molds appearing from the molding machine can be thicker or thinner, the whole string can step forward by a different distance each cycle—the thickness of the new molds. With each stroke of the molding machine, the seamless pouring system has to readjust the pouring position to make it ready for the next pour. Once the previous batch of molds has been poured, mold thickness becomes consistent again and steady state production resumes.

Integrating Moulding and Pouring Systems DISA’s Monitizer®|CIM (Computer Integrated Modules) system logs every mold produced and then tracks it as it moves down the line. Acting as the process timekeeper, it produces a stream of time-stamped data that, second by 44

使用DISAMATIC®造型生产线的客户经常需要在短 时间内频繁地更换型板,这是由于他们倾向于零库存的 生产方式。使用DISA的自动型板更换器(APC)或快速 型板更换器(QPC)等设备,型板可在短短的一分钟内 完成更换。 保证了型板的快速更换,生产过程瓶颈开始转移到浇 注环节,也就是在型板更换后手动重新定位浇注设备所 需的时间。尽管浇注通常已部分自动化,全自动化还需 要造型线和浇注设备控制系统的无缝结合,以便它们可 以在所有可能的操作情况下完全同步运行。 为了使此过程更加可靠,浇注单元必须准确“知道” 安全浇注下一个铸型的位置,并在需要时调整浇注设备 的位置。在稳定生产相同铸型时,实现有效的自动浇注 并不难。每生产一个新铸型时,铸型串就会移动相同的 距离(铸型厚度)。因此,浇注设备可以保持在相同的 位置,一旦造型线停止运行,就可以浇注下一个铸型。 只需对浇注位置做很小的调整即可补偿因型砂压缩比变 化而引起的铸型厚度的变化。 在型板更换后,铸型厚度可能会发生变化,因此需 要先进的自动化技术。与水平造型线的砂箱高度固定不 同,垂直造型线DISAMATIC®工艺可以将铸型厚度调 整到每组铸型所需的精确厚度,以保持砂铁比恒定并考 虑铸型的高度。 型板更换后,DISAMATIC®设备开始生产具有同一 厚度的下一批铸型,但浇注设备仍在按上一组型板浇 注,而铸型厚度可能不同了。为了解决这个问题,造型 线和浇注设备必须作为组合系统同步无缝地工作,即生 产同一厚度铸型时,同时按更改后铸型安全浇注。

铸型更换后实现自适应浇注 型板更换后,在造型机和浇注设备之间剩余铸型的厚 度,与之前型板生产的铸型厚度相同,而新的铸型厚度 可能略厚或者略薄一些,那么整个铸型串在每个循环中 可以向前移动不同的距离,即新铸型的厚度。随着造型 机的每个造型工位,自适应浇注系统必须重新调整浇注 位置,为下一次浇注做好准备。当前一批铸型浇注完成 后,铸型厚度将再次保持一致,并恢复稳定生产。

集成造型和浇注系统 迪砂公司的Monitizer®|CIM(计算机集成模块)系 统记录生产的每个铸型,然后在整个生产线上对其进行 跟踪。作为生产过程计时器,生成带有时间标记的数据

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product news/产品新闻 second, allows the position of each mold on the line and its pouring cup to be calculated. It exchanges this real-time data with the pouring unit’s control system and other systems as required to allow exact synchronization. The DISA system extracts important data for each mold from the CIM database, like mold thickness and “ok/not ok to pour,” and sends this to the pouring unit’s control system. Using this precise data (generated after the mold has been squeezed), the pouring unit can move the pouring device to the right position before the mold arrives, then time the opening of the stopper rod to begin while the mold is still moving. The mold arrives just in time to receive the iron coming out of the pouring unit. The DISA molding system also passes across to the Monitizer®|CIM relevant data from the molding machine like the current mold size and shot pressure, as well as wider process data like sand compressibility. In turn, Monitizer®|CIM receives and stores quality-critical parameters for each mold from the pouring unit like pouring temperature, pouring time and whether the pouring and inoculation processes have occurred successfully. That makes it possible to mark individual molds as bad and separate them later before they are mixed up in the shake out system.

Ortrander’s Experience of Seamless Pouring Ortrander Eisenhütte is a family-owned foundry in Germany, specializing in medium-sized batches of high-quality iron castings for automotive components, woodburning stoves and heavy infrastructure as well as general machine parts. The foundry pours gray, ductile and vermicular iron, producing around 27,000 tons of good castings annually, and runs two shifts, five days a week. Operating four 6-ton induction melting furnaces and three DISA molding lines, Ortrander produces around 100 tons of castings every day. This total is made up of short production runs of one hour or sometimes even less for important customers, so patterns must be changed frequently. To optimize quality and efficiency, CEO Bernd H. Williams-Boock has directed significant resources into adopting automation and analytics. The first step was to automate the iron melting and dosing process, with the three existing pouring furnaces upgraded with the latest pourTECH systems featuring 3D laser technology, inoculation and temperature control. Now furnaces, molding line and pouring are all digitally controlled and synchronized, running almost completely automatically. While the molding machine changes the pattern, the pourTECH pouring controller asks DISA’s Monitizer®|CIM system for the new mold dimensions. Based on the DISA data feed, the pouring controller calculates where to position the pouring device for each pour. It knows exactly when the first new mold reaches the pouring device and automatically changes to the new pouring sequence. If the pouring device reaches the end of its travel at any time, the DISAMATIC® machine pauses and the pouring device moves back automatically. For the first new mold out of the machine, the operator is alerted by an alarm so he can visually check that its position is correct.

流,该数据流以秒为单位计算每个铸型在生产线上的位 置及其浇口杯的位置。它会根据需要与浇注设备的控制 系统和其他系统交换实时数据,以实现精确同步。 迪砂系统从CIM数据库中提取每个铸型的重要数据, 例如铸型厚度和“可以浇注/不可以浇注”,然后将其 发送到浇注设备的控制系统。利用这个精确的数据(在 铸型挤压后生成),浇注可以在铸型到达之前将浇注装 置移动到正确的位置,然后在铸型仍在移动的同时确定 塞杆的开启时间。因此,铸型可以及时到达浇注位置, 以接收从浇注单元出来的铁液。 迪砂造型系统还会将来自造型机的相关数据传 递给Monitizer®|CIM,例如当前的铸型尺寸和射 砂压力,以及更多的工艺数据例如型砂压缩比。然 后,Monitizer®|CIM从浇注单元接收并存储每个铸型 的关键质量参数,如浇注温度、浇注时间以及浇注和孕 育是否成功进行。这样就可以将某个铸型单独标记为不 合格,并在进入落砂系统之前将它们分离出来。

Ortrander公司自适应浇注的经验 Ortrander Eisenhütte公司是德国的家族铸造企业, 专业生产中等批量、高质量的汽车零部件、燃木火炉铸 件、重型基础设施以及通用零部件铸铁件。该铸造厂生 产灰铸铁、球墨铸铁和蠕墨铸铁,每年生产约2.7万吨 优质铸件,实行两班制,每周工作五天。 Ortrander工厂有4台6吨感应熔炼炉和3条迪砂造型 线,每天可生产约100吨铸件。这些产量值由每小时的 短周期生产构成,对于重要的客户,时间甚至可能更 短,因此必须频繁更换型板。 为了优化质量和效率,首席执行官Bernd H. Williams-Boock投入了大量资源采用自动化和分析技术。 第一步是使铁的熔化和浇注过程自动化,现有的3台浇 注炉都升级为最新的带有3D激光技术、孕育和温度控制 的pourTECH系统。现在,熔炉、造型线和浇注都实现 了数字控制和同步运行,几乎可以完全自动运行。 在造型机更换型板的同时,pourTECH浇注控制器 要求迪砂的Monitizer®|CIM系统提供新的铸型尺寸。 根据迪砂的数据反馈,浇注控制器计算出每次浇注的位 置。准确获得第一个新铸型何时到达浇注设备并自动调 整新的浇注顺序。 如果浇注设备在任何时候都移动到其行程的终点,则 DISAMATIC®造型线会暂停、浇注设备会自动移回。 当造型机生产出第一个新铸型时,操作员会收到提示,

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product news/产品新闻 Seamless integration between molding and pouring makes for a faster, more consistent and higher quality process with less scrap and lower downtime. At Ortrander, automated pouring dispenses with the three minutes it previously took to adjust the position of the pouring device during pattern changes. According to Williams-Boock, the whole changeover used to take 4 1/2 minutes. Today, it’s under two minutes. With between eight and 12 pattern changes per shift, Ortrander’s staff now spends around 30 minutes per shift changing patterns—less than half what it used to take. With more consistency and the ability to constantly optimize the process, quality has improved. Ortrander has cut scrap by about 20% by implementing seamless pouring. In addition to less downtime during pattern changes, only two people are required for the whole molding and pouring line instead of the previous three. During some shifts, three people can operate two complete lines.

The Data Dividend from Seamless Pouring When trying to improve a process, foundry workers often say, “we are doing the same thing in the same way, but the result is different.” So, they pour for 10 seconds at the same temperature and to the same level, but some castings are good and some are bad. By adding automated sensors, collecting time-stamped data for every process parameter, and monitoring results, the integrated systems behind seamless pouring produce a stream of linked process data that makes it far easier to spot the root cause when quality starts to go in the wrong direction. Managers can quickly check for out-of-tolerance parameters if, for example, unexpected slag inclusions appear in a batch of brake discs. Because the controllers for the molding machine, pouring unit and other functions like furnaces and sand mixers work in harmony, the data they generate could be analyzed to find correlations across the whole process, from sand properties through to final casting surface quality. How pouring level and temperature affect mold filling for each individual pattern is one possible example. The resulting database also provides the foundation for the future use of automated analytics techniques like Machine Learning and Artificial Intelligence (AI) for process optimization. Ortrander gathers process data in real time via machine interfaces, sensor measurements and test samples. For every mold poured, around a thousand parameters are collected. Previously it only recorded the time taken for each pour but now it knows exactly what the pouring cup level was at each fraction of a second, letting experienced staff investigate how that parameter influences other metrics as well as final casting quality. Was the pouring cup draining during mold filling or was the cup filled to an almost constant level during the filling sequence? With between three and five million molds produced each year, Ortrander has already gathered a huge amount of data. Ortrander also stores multiple images of every pour in the pourTECH database in case it needs to investigate any quality issues. Finding a way to evaluate these images automatically is a future goal. ■ 46

从而可以目视检查其位置是否正确。 造型和浇注之间的自适应集成可实现更快、更一 致和更高质量的生产,从而减少废品和停机时间。在 Ortrander公司,自动浇注省去了之前在型板更换期间 调整浇注设备位置所需的三分钟时间。 据威廉姆斯-布克先生说,过去,整个更换过程需 要4.5分钟,而现在只需不到两分钟。每个班次要进行 8-12个型板的更换,现在,Ortrander公司的员工每个 班次更换板型需要约30分钟,不到之前的一半。 借助更高的产品一致性和不断优化工艺的能力,产品 质量得到了提高。Ortrander公司通过采取自适应浇注已 将废品率减少了约20%。除了减少型板更换期间的停机 时间外,整个造型和浇注线只需要两个人,以前则需要三 人。在某些班次中,三个人可以操作两条完整的生产线。

自适应浇注的数据优势 铸造厂的工作人员在尝试改进工艺时经常说:“我 们以相同的方式做相同的事情,但是结果却不同。”因 此,他们在相同的温度浇注10秒达到相同的金属液面, 但是结果是,有些为合格件、有些为不合格品。通过添 加自动传感器,为每个过程参数收集带有时间标记的数 据并监视结果,自适应浇注背后的集成系统产生了一系 列链接的工艺数据,当质量开始出现问题时,更容易找 出根本原因。例如,当一批制动盘中出现预期外的夹渣 时,管理人员可以快速检查超出公差范围的参数。 由于造型机、浇注单元和其他设备(如熔化炉和混砂 机)的控制器可以协同工作,可以通过分析它们生成的 数据来找到从型砂性能到最终铸件表面质量的整个过程 的相关性。一个可能的情况是用浇注液面和温度来分析 它们如何影响每个单独铸型的填充。最终的数据库还为 将来通过诸如机器学习和人工智能(AI)之类的自动化 分析技术进行工艺优化奠定了基础。 Ortrander通过机器界面、传感器测量和测试样品实 时收集过程数据。对于每个浇注的铸型,大约收集了上 千个参数。以前,它只记录每次浇注用的时间,但现 在,它确切地知道每秒钟的浇注量是多少,让有经验的 工作人员来研究该参数如何影响其他指标以及最终的铸 件质量。浇口杯在铸型填充过程中是空的还是在填充过 程中几乎保持恒定的液位? 每年生产三到五百万个铸型,Ortrander已经收集了 大量数据。如果需要研究任何质量问题,Ortrander还 将每次浇注的多个图像存储在pourTECH数据库中。寻 找一种自动评估这些图像的方法是未来的目标。 ■

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product news/产品新闻

Avoiding Micro Porosity Defects In Iron Castings: A Case Study 案例分析:避免铸铁件中的微孔缺陷 A leading gray and ductile iron foundry experienced some defects and machining issues with their cast products. This defect did not only cause high production costs, but also was a major risk to the foundry’s reputation with their customer. The foundry specializes in producing automotive, agricultural, earthmoving, and engineering castings for the global market. At one time, it was experiencing issues with machining its cast products. Together with its customer, they contacted Elkem and asked for support. The problem was a microporosity defect causing leakage. The defect was only found after expensive machining. They had to use chills to minimize the defect which required extra time and manpower for the setting and maintaining the chill material. Due to the chill application and variation in microstructure, there was a poor machinability and the total rejection rate was as high as 6 % of the entire production. This defect did not only cause high production costs, but was also a major risk to the foundry’s reputation with their customer. Elkem technicians spent six days with the foundry staff conducting a thorough process audit in order to evaluate the problem. After an in-depth analysis of the metallurgical issue in the plant, further work was conducted in one of Elkem’s regional research labs. The results indicated a necessary change of alloying materials. Elkem technical staff performed a trial with Lamet® as nodulariser and Ultraseed® Ce as instream inoculant. After changing to the recommended use of Lamet® and Ultraseed® Ce MSI, the foundry saw significant quality improvements: • Leakage and porosity defect were eliminated • Rejection rate went down from 6 % to 2 % • Hardness variation could be minimized • Machinability and microstructure were improved • Over 30.000 € per year could be saved. ■

一家高水平的生产灰铁和球墨铸铁的铸造厂在生产 中遇到铸件缺陷和机加工方面的问题。这种缺陷不仅会 造成生产成本上升,而且对铸造厂在客户中的声誉构成 重大威胁。 该铸造厂专门为全球市场生产汽车、农机、土方和 工程设备方面的铸件。 公司曾在生产铸件时遇到了问题。他们与客户一起 向埃肯公司寻求技术支持。 主要问题是微孔缺陷导致渗漏,但是这种缺陷只能 在机加工之后才能发现,极大的增加生产成本。因此, 他们必须使用冷铁以最大程度地减少缺陷,但是这需要 额外的时间和人力来设置和维护冷铁。由于冷铁的使用 和微观结构的变化,使铸件的加工性能变差,总废品率 高达6%。 这种缺陷不仅导致高昂的生产成本,而且对铸造厂 在客户中的声誉构成重大威胁。 埃肯公司的技术人员与铸造厂的员工一起对生产工 艺进行了为期6天的彻底审核,以评估存在的问题。在 对该铸造厂的冶炼工艺进行了深入分析之后,进一步的 研究工作在埃肯公司的研究实验室中开展。 结果表明必须改变合金材料。埃肯公司的技术人员 使用球化剂Lamet®和内部孕育剂Ultraseed®Ce进行 了试验。 改用推荐方案Lamet®和Ultraseed®Ce MSI之后, 铸造厂的产品质量有了显著改善: •消除了渗漏和气孔缺陷; •废品率从6%降至2%; •硬度变化可以最小化; •加工性能和微观结构得到改善; •每年可节省超过30000欧元。 ■

Personalized Rapid Customization Integration Solution Provider for Equipment Complex Parts 装备复杂零部件个性化快速定制一体化解决方案提供商 China Academy of Machinery Science & Technology Group (CAM) was founded in 1956. The goal of CAM is to improve the equipment manufacturing level of China. CAM has 16 subsidiaries including holding companies with the operation system of the group management of parent-subsidiary type. CAM has built 39 key laboratories and engineering research center, and all these have been certified by government as national, provincial, and industrial level innovation platform. CAM is engaged in the basic common technology research for manufacturing industry. With the development in these 60 years, CAM has gained more than 7,000 achievements which have been applied in the main domestic economical industries such as machinery manufacturing, automobile, aeronautic and aerospace, environmental protec-

机械科学研究总院集团始建于1956年,提升中国 装备制造水平是机械总院的神圣使命。拥有16 家全 资及控股子企业(公司),实行母子公司式集团管理 体制。建有39个国家级及省市级重点实验室和工程 (技术)研究中心。主要从事装备制造业制造技术( 基础共性技术)研究开发的研究院和现代制造服务业 企业,自成立五十余年来,累计取得科研成果及专利 7000 多项,广泛应用于机械制造、汽车、航空航天、

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product news/产品新闻 tion, energy, transportation, information, metallurgy chemical engineering, construction, and etc. Complicated casting patternless composite manufacturing technology and equipment which is developed by CAM won the second prize of National Technological Invention. The key patternless casting technology of high-efficiency, high-performance, and high-precision has been breakthrough and great achievements have been made in technology, composite casting and Seria equipments. Complex curved sand/core flexible extrusion near forming technology, cutting net forming technology and composite forming process developed by CAM make the patternless, high-precision, high-efficiency manufacturing of complicate castings realized, shortening more than 50% of the manufacturing cycle and reducing more than 30% of the cost. The technology includes a multi-material composite casting mold matching with the casting and its assembly method, which realized the active regulation of the casting performance, solved the problem of shape and performance precisely control, reduced casting scrap rate from 5%-10% to 2%-4%, and weight by about 10%-20%. It developed the digitally controlled flexible array contacts and high wear-resistant large aspect ratio cutting tools, proposed an integrated tool cooling and cutting sand removal method, developed a sand/core flexible extrusion molding machines, patternless casting precision forming machines and other 15 kinds of equipment in seven categories, solved the problems of complicate castings high-precision forming manufacturing equipment, casting accuracy has increased by 2 to 3 levels and can reach up to CT8. The patternless casting precision forming machine can be used to manufacture resin sand, water glass sand, coated sand, ceramics, etc. The maximum forming size is 5000mm×3000mm×1000mm. The achievements were granted 47 invention patents (19 in the United States, Japan, and Europe) and 12 software copyrights. It won the second prize of National Technological Invention in 2017, the China Machinery Industry Science and Technology Award (technical invention) in 2016, China Patent Gold Award in 2016, Beijing Science and Technology Award (technical invention) in 2012, First Prize of Beijing Invention Patent in 2011 and three national key new products. The technology has been promoted and applied in more than 100 companies including Shanghai Academy of Space Technology, AECC Harbin Dongan Engine, Guangxi Yuchai Machinery Group, FAW Foundry and Yto Group Corporation. The equipment has been exported to Spain. Fourteen application demonstration bases have been established in China for the manufacture of steel/iron, aluminum/magnesium alloy castings. This technology is of great significance for promoting the innovation of high-end equipment technology, safeguarding national defense security, and promoting green development. ■

环保、能源、交通运输、信息产业、冶金、化工、建 筑等重要产业领域。 由机械科学研究总院集团自主研发的“复杂铸件无 模复合成形制造方法与装备”荣获国家技术发明二等 奖。该成果突破了复杂铸件高效率、高性能、高精度 无模成形关键技术,在工艺方法、复合铸型、系统装 备等方面取得重大成果。开发出复杂砂型/芯曲面柔 性挤压近成形技术、切削净成形技术及其复合成形工 艺,实现了复杂铸件无模化、高精度、高效率制造, 制造周期缩短50%以上,成本降低30%以上;发明了 一种与铸件相匹配的多材质复合铸型及其坎合组装方 法,实现了铸件性能主动调控,解决了形性精确控制 难题,铸件废品率从5%~10%降至2%~4%,减重 10%~20%;开发出数字化控制的柔性阵列触头、高 耐磨大长径比切削刀具,提出了刀具冷却与切削排砂 一体化方法,研制出砂型/芯柔性挤压成形机、无模铸 造精密成形机等7类15种装备,解决了复杂铸件高精 度成形制造装备难题,铸件精度提高了2~3个等级, 可达CT8。无模铸造精密成形机可用于树脂砂、水玻 璃砂、覆膜砂、陶瓷等多种铸型制造,最大成形尺寸 为5000mm×3000mm×1000mm。 该成果获授权发明专利47件(美、日、欧等19 件),软件著作权12项。获2017年度国家技术发明二 等奖、2016年中国机械工业科学技术特等奖(技术发 明)、2016年中国专利金奖、2012年北京市科学技 术一等奖(技术发明)、2011年北京市发明专利一等 奖和3项国家重点新产品等。该技术已在航天八院、东 安发动机、广西玉柴、一汽铸造、中国一拖等100多 家企业推广应用,设备出口西班牙,并在国内建立14 个应用示范基地,实现了铸钢/铁、铝/镁合金等铸件 制造。该技术对促进高端装备技术创新,维护国防安 全,推动绿色发展具有重大意义。 ■ 更多内容,请访问www.cimpe.cn.

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product news/产品新闻

Magma Introduces Its New Release Magmasoft 5.4.1 迈格码公司发布新版本MAGMASOFT 5.4.1 MAGMAinteract® is a new and innovative software for the visualization of MAGMASOFT® results. The free 3D viewer allows the intuitive visualization of information exported from MAGMASOFT® 5.4.1. The fast and easy presentation promotes communication between interested parties within a company as well as between suppliers and customers. MAGMAinteract® offers the following key functionality: interactive display of all MAGMASOFT® 3D results, animations of mold filling (also with tracer particles) and the solidification process, visualization of all results and criteria including distortion for previously defined cross-sections, and the interactive evaluation of virtual designs of experiments in a parallel coordinate diagram. All results can be rotated, zoomed and panned by the user. With the current release, MAGMASOFT® users can export results selected by them and make these results available to third parties in the compressed MAGMAinteract® format. MAGMAinteract® can be downloaded free of charge by anyone interested in viewing exported MAGMASOFT® results from the MAGMA website (www.magmasoft.com/interact) for use on computers running Microsoft Windows 7 or higher. For diecasting, temperature, velocity and pressure results as well as the gate from which the melt originated can be displayed and animated directly on virtual particles (tracer particles). This simplifies the judgment of complex, flow-relevant questions. For the design of the shot profile, various options are now available for evaluating curves for plunger speeds and the pressure curve reduced by the PQ² function. MAGMA C+M users can now also use the new possibilities for evaluating the flow with virtual particles for the design and optimization of core production. Typical application examples include the assessment of different flow velocities of gas and sand flow or the investigation of the cooling behavior of air for drying inorganically bound cores. In cooperation with DISA, the database for the MAGMAdisa module was updated for all current molding lines. Together with FOSECO, new datasets for SCK risers were added to the geometry database. For users of MAGMA C+M, there is now the possibility to interactively place nozzles from the parametric database onto the surface of the core geometry in a few simple steps. In the Result Perspective, numerous improvements have been implemented for fast display and evaluation of project results. The picking function can now be used to display different results at defined locations. New optimization objectives are available for users of stress simulations. For example, distortion predictions can be evaluated and optimized with regard to their deviations from defined points, lines or angles. For heat treatment simulations, significant improvements have been realized for the automatic determination of contact between the component and the heat treatment rack. All contact pairings are automatically detected and continuously updated based on the part and rack distortion. In this way, the realistic contact situation is modelled and it is ensured that the predicted distortion corresponds to reality at all times. MAGMA CC, the program for simulation and optimization of the continuous casting process, has been extended by various thermal criteria. At the same time, a new, independent mode for modelling the horizontal continuous casting process simplifies the modelling of this process for the user. ■

MAGMAinteract®是一款新推出的创新软件,用 于显示MAGMASOFT®的结果。通过免费的3D浏览器 可以直观地看到从MAGMASOFT® 5.4.1.导出的结果 信息。这种快速方便的演示方式促进了公司内相关部门 之间以及供应商和客户之间的沟通。 MAGMAinteract®具有以下关键功能:所有 MAGMASOFT® 3D结果的交互显示,充型动画(也包 括粒子追踪)和凝固过程所有结果和判据的可视化(包括 预定义的横截面的变形),以及在平行坐标图中对虚拟 实验设计的交互评估。所有结果都可以由用户旋转、缩 放和平移。 当前版本,MAGMASOFT®用户可以导出由他们 选择的结果,并将这些结果以MAGMAinteract®格式 压缩,提供给第三方。MAGMAinteract®软件可以免 费下载,可以在运行MicrosoftWindows7或更高版本 的计算机上查看导出的MAGMASOFT®结果。 对于压铸生产,温度、速度和压力以及熔融金属 液的浇口可以直接以虚拟粒子(追踪粒子)显示和设置 动画。这简化了复杂、流动相关问题的判断。对于压射 剖面的设计,现在可以使用各种选项来评估冲头速度曲 线和由PQ²函数减小的压力曲线。 MAGMA C+M的用户现在也可以使用新的可行性 来评价虚拟粒子的流动,进行砂芯生产的设计和优化。 典型的应用实例包括评估气体和砂流的不同流速或干燥 无机粘结剂砂芯的空气冷却性能研究。 与迪砂公司合作,更新了MAGMAdisa模块的数 据库,用于所有正在使用的造型线。与福士科公司一 起,添加SCK冒口的新数据包到几何数据库中。对于迈 格码公司的MAGMA C+M用户来说,现在有可能通过 几个简单的步骤将参数数据库中的射嘴交互地放置到砂 芯几何图形的表面上。在结果方面,为快速显示和评价 项目成果,已实施了许多改进。取值功能现在可以用于 在定义的位置显示不同的结果。 新的优化目标可用于应力模拟。例如,变形预测 可以评估和优化它们偏离定义的点、线或角度。对于热 处理模拟,在自动确定铸件与热处理支架之间的接触方 面实现了显著的改进。所有接触配对都会根据零件和支 架的变形自动检测和不断更新。这样,真实的接触情况 被建模,并确保预测的变形在任何时候都符合现实。 MAGMA CC,用于模拟和优化连铸过程的程序已 经根据各种热准则进行了扩展。同时,新的用于建模的 水平连铸工艺的独特模型简化了用户的建模过程。 ■

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Profile for Global Casting Magazine

December 2019  

December 2019