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CASTING

| FOUNDRY-PLANET.COM | MODER | CHINA A PUBLICATION OF THENG AMERICAN FOUNDRY SOCIETY N CASTI FOUNDRY ASSOCIATION December 2020

Casting Competence Across Three Continents


WWW.GLOBALCASTINGMAGAZINE.COM

APRIL 2021

volume 11 number 1

P.53

P.47

FEATURES

专题文章

33 The Impact of COVID-19 and the Trend of Indonesian Foundry Industry

33 印尼铸造业发展现状及趋势

38 Fuji Electric invites you to participate in METAL CHINA 2021 and exchange environmental protection technologies

环保新技术

42 Working Together to Solve Today’s Foundry Industry Challenges

38 富士电机邀您参加第十九届铸博会 交流 42 共同解决当今铸造业的挑战 47 600MW汽轮机高中压外缸钢水质 量提升

47 The Quality Improvement of Molten Steel on HP-IP Outer Casting of a 600MW Steam Turbine DEPARTMENTS

专栏

6 Editorial 8 Industry News 53 Product News

6 编者的话 8 行业新闻 53 产品新闻

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STAFF/工作人員 STAFF/工作人員

STAFF/工作人员 STAFF/工作人员 FOUNDRY-PLANET.COM FOUNDRY-PLANET.COM

MODERN CASTING MODERN CASTING

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

Managing Editor Managing Editor SHANNON WETZEL, swetzel@afsinc.org SHANNON WETZEL, swetzel@afsinc.org Advertising Sales Associate Editor Associate Editor JOE MURPHY, AdSales25@aol.com BRIAN SANDALOW, bsandalow@afsinc.org BRIAN SANDALOW, bsandalow@afsinc.org FABIO CAVALIERI, fabio@afsinc.org Advertising Sales Advertising Sales Art Director MURPHY, AdSales25@aol.com JOEJOE MURPHY, AdSales25@aol.com MICHAEL J. BERRAFATO, mberrafato@afsinc.org FABIO CAVALIERI, fabio@afsinc.org FABIO CAVALIERI, fabio@afsinc.org

Senior Editor/ International Sales Content/Website Management Senior Editor/ International Sales ADRIANA WEISENBACH, aw@foundry-planet.com Maximilian Schröck,aw@foundry-planet.com ms@foundry-planet.com ADRIANA WEISENBACH, Advertising Sales Advertising Sales OANH LARSEN, ons@foundry-planet.com OANH LARSEN, ons@foundry-planet.com THERESA NEUMANN, tn@foundry-planet.com MATTHIAS AMANN, ma@foundry-planet.com THERESA NEUMANN, tn@foundry-planet.com

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

MODERN MODERN

CASTING CASTING CHINA FOUNDRY ASSOCIATION 中国铸造协会 CHINA FOUNDRY ASSOCIATION 中国铸造协会 Publisher/Executive President & Secretary General/ 出品人 Publisher/President/ 出品人/会长 Publisher/Executive ViceVice President & Secretary General/ 出品人 ZHANG LIBO/ 张立波 ZHANG LIBO/ 张立波 Senior Editor/ 主编 Senior Editor/ 主编 WEN PING/ 温平 GAO WEI/高巍 gaowei@foundry.com.cn WEN PING/ 温平 Deputy Editor/ 副主编 Editor/编辑 Deputy Editor/ 副主编 HUANG TIANYOU/ 黄天佑 HUANG TIANYOU/ 黄天佑 LI MENGMENG/李蒙蒙, limengmeng@foundry.com.cn QI/ 范琦, fanqi@foundry.com.cn FANFAN QI/ 范琦, fanqi@foundry.com.cn Advertising Sales Manager/ 广告销售主管 Editor/编辑 Editor/编辑 CHEN XING/陈星 chenxing@foundry.com.cn GAO WEI/高巍, gaowei@foundry.com.cn GAO WEI/高巍, gaowei@foundry.com.cn Sales/广告销售 Li Mengmeng/李 蒙蒙, limengmeng@foundry.com.cn Li Mengmeng/李 蒙蒙, limengmeng@foundry.com.cn WANG CHUANG/王闯 wangchuang@foundry.com.cn Advertising Sales Manager/ 广告销售主管 CHEN HAIKUO/陈海阔 chenhaikuo@foundry.com.cn Advertising Sales Manager/ 广告销售主管 WEI/ 高巍, gaowei@foundry.com.cn GAOGAO WEI/ 高巍, gaowei@foundry.com.cn

张立波 张立波 出品人 出品人 中国铸造协会 中国铸造协会

Shannon Wetzel Shannon Wetzel Managing Editor Managing Editor MODERN CASTING MODERN CASTING

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

March 2019 FOUNDRY-PLANET.COM MODERN CASTI NG CHINA FOUNDRY ASSOCIATION || MODERN || CHINA || 57 April 2021 FOUNDRY-PLANET.COM CASTI NG FOUNDRY ASSOCIATION | MODERN | CHINA | 7 March 2019 FOUNDRY-PLANET.COM CASTI NG FOUNDRY ASSOCIATION


editorial/编者的话

10 years’ Cultivation, Innovation and Dedication

--Congratulation on the 10th Anniversary of Global Casting Magazine

十载耕耘创新 矢志服务行业 ——庆祝《世界铸造》杂志创刊10周年

H

ello, readers of the Global Casting Magazine (GCM). The first issue of 2021 is published. This year marks the 10th anniversary of GCM. As the world’s only Chinese-English bilingual journal dedicated to the foundry industry, it has gone through 10 years, and it will continue to grow with the time. Through the cooperation and continuous innovation by China Foundry Association, American Foundry Society and Foundry Planet, GCM has provided the latest and excellent news to the global foundrymen, and is serving the sustainable development of the global foundry industry. In this year, three publishers will jointly hold a series of activities to celebrate the 10th anniversary of the magazine with dear readers and friends, to retrospect and look into the future! In the past 2020, the sudden Covid-19 pandemic has had a profound impact on the lives and production activities of people all over the world, and it has also had a huge impact on the global foundry industry. However, it has been proved that our foundry industry is an industry with strong resilience. At present, the global foundry industry is recovering and stabilizing; moreover, with the test of the pandemic, more and more companies are paying more attention to transformation and upgrading, environmental protection and sustainable development, providing a guarantee for the safety and stability of the industrial chain and supply chain of the manufacturing industry. As one of the vanes of the global foundry industry, the 19th China International Foundry Expo (METAL CHINA) and the 15th China International Die Casting Industry Exhibition (DIECASTING CHINA) will be held at the National Exhibition and Convention Center (Shanghai) from May 26 to 28, 2021, which will display the latest development, show the resilience of the global foundry industry and explore the development direction of the foundry industry in the post-pandemic era. Taking this opportunity, Global Casting Magazine will report on the events for our worldwide readers, allowing you access to further understanding new technologies, new products and new trends of the global foundry industry. Thank you for your support and attention! ■

Zhang Libo Publisher/President China Foundry Association 6

《世

界铸造》杂志的读者朋友们,大家好! 新年首期杂志与大家见面了,2021年是 《世界铸造》杂志创刊10周年,作为铸

造行业全球唯一的中英双语期刊,历经10年,历久弥新。 中国铸造协会、美国铸造协会和铸造星球三方鼎力合作、 开拓创新,为全球铸造人提供最新、最棒的资讯,服务 于全球铸造业的持续发展。今年,我们三方将会共同举 办系列活动,与亲爱的读者朋友们共同庆祝杂志创刊10 周年,总结过去,继往开来! 2020年,突如其来的新冠疫情对全世界范围内人们的 生活和生产活动都产生了深远影响,对全球铸造业也产 生了巨大影响。但是,事实证明,我们的铸造业是具有 强大韧性的行业,目前全球铸造业已在复苏中并趋于稳 定;而且,经过疫情的考验,越来越多的企业更加重视 转型和升级、环保和可持续发展,为制造业产业链和供 应链的安全稳定提供了保障。 作为全球铸造行业的风向标之一,第十九届中国国际 铸造博览会、第十五届中国国际压铸工业展览会即将于 今年5月26-28日在国家会展中心(上海)举办,将展示 中国铸造业的发展成果,展现全球铸造业的发展韧性, 探索后疫情时代铸造业的发展方向。 借此机会,《世界铸造》杂志将为全球读者报道展会 盛况,让您进一步了解全球铸造业新技术、新产品、新 趋势。 感谢您的支持和关注! ■

张立波 出品人/会长 中国铸造协会

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

Industry News Contents 行业新闻目录

METAL CHINA+DIECASTING 2021 will Grandly Open in May 18 5月开启!邀您见证2021铸造行业大事!

Missouri, U.S. foundry seeks to grow, build jobs 10 美国密苏里州铸造厂寻求发展,创造就业机会 

Weifang Platform of China Academy of Machinery Science & Technology- Quick Customized Solution Provider for Complex Parts of High-end Equipment 22 机械科学研究总院潍坊平台-高端装备复杂零部件个性化快速 定制解决方案提供商

Victaulic acquires Waupaca facility in Pennsylvania 12 唯特利收购宾夕法尼亚州沃帕卡工厂

LK’s 6000-ton Die Casting Machine Put into Production at Customer Factory 24 力劲6000吨智能压铸单元在韩国GLOVITECH越南工厂正式上线生产

Franklin Bronze adds 3D printer 14 富兰克林铸铜厂使用3D打印设备

Kimura installs 4th furnace––with 1-ton capacity 12 木村铸造公司安装第4台1吨的熔炉

ABN--to be the Leader of Green Melting of Aluminum Alloy 24 安保能——做铝合金绿色熔炼的领跑者

TRM Equity acquires all assets of Elyria Foundry and Hodge Foundry 14 TRM Equity收购Elyria和Hodge铸造厂的所有资产

New Melting Equipment of TAA Put into Production 25 大亚新设备顺利投产

Lawton welcomes Penn-Mar to iron foundry group 14 劳顿公司欢迎Penn-Mar加入其铸铁集团

Wanfeng Technology Provides Automated Solutions for AECC 25 万丰科技为中国航发集团提供自动化解决方案

Dotson expansion in the works 16 Dotson扩建工程

Hengli Hydraulics Will Bring its Star Products to METAL CHINA 2021 26 恒立液压将携明星产品亮相第十九届中国国际铸造博览会

General Kinematics to supply material handling system at Charlotte Pipe and Foundry Co.’s greenfield site 16 General Kinematics将为夏洛特管道铸造公司的 新厂提供物料处理系统

Your Digital Expert-Qinhuangdao Xinyue invites you to visit the METAL CHINA 2021 26 数字化工厂解决方案专家——秦皇岛信越诚邀您莅临参观十九届铸博会 ASD will bring Lightweight Aluminum Casting Solutions to METAL CHINA 2021 27 艾斯迪将携轻量化铝合金铸造解决方案亮相第十九届铸博会 Core Components of Magnesium Alloy Semi-solid Equipment will Show at Diecasting China 2021 28 镁合金半固态设备核心部件即将闪亮登场Diecasting China 2021 The Navigator of Intelligent Manufacturing and High-end Equipment Industry 28 智能制造与高端装备业的“领航员” Morikawa Targets 40% Scrap Reduction: Japanese Foundry Chooses Disa’s Monitizer® For Ai-Driven Process Enhancement 30 森川公司的目标是减少40%的废品:日本铸造企业选择迪砂MONITIZER®来实现AI驱动的工艺提升 8

75 Years Of Innovation In Vacuum Technology 18 致力于真空技术创新75年 Dynacast Germany: New Magnesium Die-Cast Part Needs Its Own Deburring Press 28 德国奈那卡斯:新型镁合金压铸件需要适合的去毛刺设备 HA Group Intensifies Activities In Southeast Asia 29 欧区爱集团增强东南亚市场业务 Omega - Happy Customers, Successful Foundry Projects 30 OMEGA公司为客户提供成功的项目

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

Missouri, U.S. foundry seeks to grow, build jobs 美国密苏里州铸造厂寻求发展,创造就业机会 Lakeside Casting in Monroe City, Missouri, has announced plans to buy out the remaining $600,000 of its real estate lease with the city and expand this year, according to area’s local The Herald-Whig newspaper. “My focus has always been on growing jobs,” Controlling Owner Chuck Mudd told reporter Forrest Gossett. “That’s the reason that we started this.” His company plans to build a new warehouse that will allow for manufacturing growth. Lakeside Casting was started in 2002 with assistance of an economic development boost from Monroe County and the state of Missouri, including a public-private partnership with a federal Block Development Grant and the real estate lease with Monroe City. Founded by four partners with over 150 years of combined experience in the die-casting business, Lakeside markets itself as “Your Global Link to Zinc,” and makes component parts such as ignition assemblies for trucks, natural gas meters, key casting for the automotive industry and many other OEM parts. ■

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密苏里州门罗市的湖滨铸造公司已宣布今年收购市政 府剩余60万美元的房地产租赁权的计划,并将扩大规模。 “我一直把重点放在增加就业岗位上,”控股所有人 查克·穆德告诉记者福雷斯特·戈塞特:“这就是我们这 样做的原因。”他的公司计划建一个新仓库,以促进制 造业的增长。 湖滨铸造公司于2002年在门罗县和密苏里州的经济发 展推动下成立,包括与联邦区域发展补助(Block Development Grant)的公私合作伙伴关系以及与门罗市的房 地产租赁合作。湖滨铸造公司由4个在压铸领域拥有超过 150年综合经验的合作伙伴创立,公司的市场定位是“ 为您建立与锌的全球联系”,并生产卡车的点火总成、 天然气表、汽车关键零部件和很多其他OEM零件。 ■

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

Victaulic acquires Waupaca facility in Pennsylvania 唯特利收购宾夕法尼亚州沃帕卡工厂

Victaulic (Easton, Pennsylvania), a global manufacturer of mechanical pipe joining, fire protection and flow control solutions has purchased a 220,000-sq.-ft Waupaca manufacturing plant in Lawrenceville, Pennsylvania. When operating at full capacity, the facility will increase Victaulic’s foundry production capacity by 70 percent in the U.S. and allow for future growth as Victaulic’s business demands increase. The facility, including two foundry molding lines, will also enable Victaulic to produce larger scale products. “The addition of Waupaca’s Lawrenceville foundry will provide the scale and capacity necessary to continue our growth plans, and most importantly, service our valued North American customers,” said John F. Malloy, Chairman of Victaulic. “Additionally, Victaulic is doing its part to add vital manufacturing jobs within Pennsylvania. A major aspect of our business strategy has always been to manufacture products in close proximity to our customers.” Victaulic anticipates adding new jobs to Tioga County in the near future, with many expected to be filled by local talent from the area’s skilled workforce. New hires will join the current Victaulic team of more than 1,600 Pennsylvania employees and approximately 4,500 people globally. “Victaulic greatly appreciates the support of Develop Tioga, Tioga County, the Tioga County Commissioners, and its local elected officials, particularly Senator Cris Dush and State Representative Clint Owlett,” said Rick Bucher, Victaulic president and CEO. “We are dedicated to building a long-term, mutually beneficial partnership with the region and its hardworking residents.” The company is also nearing completion of an additional 400,000-sq.-ft. light assembly facility in Lower Nazareth, which is expected to be fully operational in 2021. ■

机械管道连接、消防和流量控制解决方案的全球制造 商唯特利(宾夕法尼亚州伊斯顿)已购买了位于宾夕法 尼亚州劳伦斯维尔的沃帕卡铸造厂。该工厂有220,000 平方英尺(约20439平方米),满负荷生产时,将使唯 特利在美国的铸造产能提高70%,随着唯特利业务需求 的增长,未来还将继续增长。该工厂包括两条造型线, 将使唯特利能够生产更多的铸件。 唯特利公司董事长约翰·F·马洛伊表示:“沃帕卡公司 劳伦斯维尔铸造厂的加入,将为公司的持续发展提供所 需的规模和产能。最重要的是,为我们的北美客户提供 服务。此外,唯特利正在为宾夕法尼亚州新增重要的制 造业领域的工作岗位而做出自己的努力。公司发展战略 的一个重要方面一直是就近为客户生产产品。” 唯特利公司预计在不久的将来将为泰奥加县增加新的 工作岗位,其中很多岗位将提供给技术工人。新员工将 加入目前的唯特利团队,该团队目前由1,600多名宾夕 法尼亚州员工和约4,500名全球员工组成。 “唯特利对开发泰奥加、泰奥加县、泰奥加县委员及 本地当选官员,尤其是参议员克里斯以及州代表克林特 等的支持表示赞赏,”唯特利公司总裁兼首席执行官里 克•布赫尔说:“我们致力于与该地区以及勤奋的居民建 立长期互利的伙伴关系。” 另外一个位于下拿撒勒400,000平方英尺(约37161 平方米)的轻量化产品装配厂也即将竣工,工厂预计将 于2021年投入全面运营。 ■

Kimura installs 4th furnace––with 1-ton capacity 木村铸造公司安装第4台1吨的熔炉

A new Pillar Induction furnace with 1-ton melting capacity has been installed at AFS Corporate Member Kimura Foundry America, Inc. (Shelbyville, Indiana). The addition enables Kimura to meet customer demand for heavier casting parts, particularly in the construction, agricultural machinery, power generation, oil & gas, pump and compressor industries. The foundry also expects to improve pouring efficiency and casting turnaround thanks to the high-capacity furnace’s ability to pour multiple parts simultaneously. The company began operating in November 2018 with three furnaces: two with 300-lbs. melting capacity and one with 500 lbs. Today, with four furnaces, Kimura can produce castings weighing a few pounds to 1700 lbs. The foundry is using its new Pillar to melt popular grades of gray and ductile irons, as well as steel, stainless steel, heat resistant steel and compact graphite iron. All its furnaces are connected to a furnace monitoring system for safety and stabilized operation. ■. 12

美国铸造协会会员企业木村铸造(美国)公司(印第

安纳州谢尔比维尔)已安装了彼乐公司的1吨感应电炉, 使木村铸造厂能够满足客户对较大铸件的需求,特别是在 建筑机械、农业机械、发电设备、石油和天然气设备、泵 和压缩机行业的客户需求。该铸造厂还希望借助高产能熔 炉同时浇注多个零件的能力来提高浇注效率和周转率。 2018年11月,该公司3台熔化炉开始投产:其中两台 熔炼能力为300磅,一台为500磅。现在,木村公司共有 4台熔化炉,可以生产重达几磅至1700磅的铸件。铸造厂 正在使用新的彼乐公司熔炼设备熔炼常用规格的灰铁和球 墨铸铁,以及钢、不锈钢、耐热钢和蠕墨铸铁件。所有 熔化炉都与监控系统连接,以确保运行安全和稳定。 ■

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INDUSTRY NEWS/行业新闻

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INDUSTRY NEWS/行业新闻

Franklin Bronze adds 3D printer 富兰克林铸铜厂使用3D打印设备

Franklin Bronze Precision Components (Franklin, Indiana) has invested in a Peopoly Moai 130 Laser SLA 3D Printer to produce rapid prototype parts and short runs of investment castings. The Laser SLA 3D Printer is able to construct parts quickly and accurately with high precision and resolution. “The addition of this 3D printer to our facility allows us to quickly prove out design changes without needing to alter the tooling each time,” said Neil Kruse, senior IC process engineer. “For instance, making a gating change can be proved before cutting into the tool. “We are looking forward to working on trials and iterations for new and existing parts with our customers in a more efficient manner. Additionally, working with customers that have an intricately designed part.” ■

富兰克林铸铜精密零部件公司(印第安纳州富兰克 林)购买了Peopoly的 Moai 130激光SLA 3D打印机, 以生产快速原型零件和小批量的精密铸件。激光SLA 3D 打印机能够以高精度和高分辨率快速而准确地生产零件。 高级集成电路工艺工程师尼尔•克鲁斯表示:“我们的 工厂增加了这种3D打印机,使我们能够迅速验证更新后 的设计方案,而无需每次都改动模具。例如,可以在切 割模具之前改变浇口的设计并进行验证。” “我们期待与客户以更有效的方式进行新铸件和现有 铸件的试验和更新。此外,我们期待与生产复杂铸件的 客户合作。” ■

TRM Equity acquires all assets of Elyria Foundry and Hodge Foundry TRM Equity收购Elyria和Hodge铸造厂的所有资产

TRM Equity has acquired Elyria Foundry and Hodge Foundry (Elyria, Ohio), a company specializing in ductile iron castings up to 200,000 pounds and serving many markets including defense, oil and gas, construction equipment and mining. Elyria Foundry has operated since the early 1900s and has developed a strong technical and metallurgical team that drives its success. “The foundry industry has been under considerable pressure over the last few decades, and we have focused on the companies with unique positions and capabilities in their space,” said Jeffrey Stone, managing director for TRM Equity. “Elyria Foundry has range to produce very large castings and the depth of technical talent to solve problems for its customers. We look forward to partnering with the Elyria Foundry team to navigate through a challenging environment and continue to be a valued resource to its customers far into the future.” ■

TRM股权公司收购了位于俄亥俄州伊利里亚的伊利里 亚铸造厂和霍奇铸造厂,该铸造厂专业生产重量为20万 磅以下的球墨铸铁,并为国防、石油和天然气、建筑设备 和采矿等行业提供服务。伊利里亚铸造厂成立于20世纪 初,并发展了强大的技术和冶金团队,促进公司的成功。 TRM 股权公司董事总经理杰弗里·斯通表示:“在过 去的几十年中,铸造行业一直承受着巨大的压力,我们 一直专注于在各自领域具有独特地位和能力的公司。伊 利里亚铸造厂可以生产非常大的铸件,并拥有丰富的技 术人才可以为客户解决问题。我们期待与伊利里亚铸造 团队合作,在充满挑战的环境中引领发展,并在将来继

AFS Corporate Member The C.A. Lawton Co. (DePere, Wisconsin) has acquired Penn-Mar, a gray-and-ductile iron foundry in Hanover, Pennsylvania. Penn-Mar manufactures multicored, gray and ductile iron castings ranging from 150 to 5,000 lbs. Using an air-set, nobake molding process, it serves the refrigeration/air conditioning, pump/compressor, and motor/generator industries. “The addition of Penn-Mar Castings to our platform and especially the Iron Group creates a truly next-level offering,” said Alex Lawton, CEO of the now five-site specialty metals platform. “The combination with The C.A. Lawton Co. and its De Pere, Wisconsin, and Minster, Ohio, operations provides a combination of scope and reliability that will be valued by many.” Announced by Oakland Standard Co., the deal enhances the private equity firm’s iron foundry group. “I’m very excited to see our specialty metals group continue to build a uniquely integrated multisite, multi-offering company,” said Dan Bickersteth, a co-founder and managing director of

美国铸造协会会员企业C.A.劳顿公司(威斯康星州德

续成为客户的宝贵资源。” ■

Lawton welcomes Penn-Mar to iron foundry group 劳顿公司欢迎Penn-Mar加入其铸铁集团

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佩尔)收购了位于宾夕法尼亚州汉诺威的灰铸铁生产厂 Penn-Mar。 Penn-Mar公司生产150-5,000磅不等的多芯的灰铸铁 和球墨铸铁件。公司使用自硬砂成型工艺,服务于制冷/ 空调、泵/压缩机和电机/发电机行业。 “将Penn-Mar公司生产的铸件纳入到我们的产品系列 中,尤其是铸铁系列,这是真正的服务于客户的产品,” 现已拥有5家工厂的特种铸件生产企业劳顿公司的首席执 行官亚历克斯•劳顿说:“与劳顿公司及其在威斯康星州 德佩尔和俄亥俄州Minster工厂的整合提供了更广的产品 范围和更强的可靠性,这将被更多人所重视。” 奥克兰标准公司(Oakland Standard Co.)宣布,这

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INDUSTRY NEWS/行业新闻 Oakland Standard Co. “Alex Lawton and his leadership team, especially Barry Adamski as COO and Tim Flannery as CFO, will do a great job onboarding Penn-Mar Castings.” Lakeside Casting in Monroe City, Missouri, has announced plans to buy out the remaining $600,000 of its real estate lease with the city and expand this year, according to area’s local The Herald-Whig newspaper. “My focus has always been on growing jobs,” Controlling Owner Chuck Mudd told reporter Forrest Gossett. “That’s the reason that we started this.” His company plans to build a new warehouse that will allow for manufacturing growth. ■

项交易将增强这家私募股权公司的铸铁业务。 奥克兰标准公司(Oakland Standard Co)的联合创 始人兼董事总经理丹·比克斯特斯说:“看到我们的特种 金属集团继续发展为一个多点生产的多样化产品公司, 我感到非常高兴。亚历克斯•劳顿和他的领导团队, 特 别是担任首席运营官的巴里·亚当斯基和担任首席财务官 的蒂姆·弗兰纳里,将在加入Penn-Mar铸件公司后做得 很好。” ■

Dotson expansion in the works Dotson扩建工程

AFS Corporate Member Dotson Iron Castings, which supplies precision parts for farm machinery, heavy trucks, industrial equipment and the construction industry and more, is planning a major expansion of its Mankato, Minnesota plant, adding new meeting rooms, break areas, locker rooms and a rooftop patio. Recently featured in the city’s local newspaper, The Free Press, the company says its 7,800-square-foot addition will also offer a fresh, modern look to the public with a new glass front, decorative, multicolored metal panels and updated landscaping. In the summertime, thousands pass by the foundry, which is located near the city’s Riverfront Park and new amphitheater. Despite the current economic downturn, Dotson is hiring––and the new space, the company says, will add to its collection of recruiting tools. ■

美国铸造协会会员企业多森铸铁厂为农业机械、重型卡 车、工业设备和建筑机械及其他行业提供精密零部件。公 司正计划对其明尼苏达州曼卡托工厂进行大规模扩建,增 加新的会议室、休息区、更衣室和一个屋顶露台。 最近,公司在当地报纸《自由报》上刊登报道,其新 增的7800平方英尺(约725平方米)的面积将安装新的玻 璃面板、装饰性彩色金属板,通过美化环境使公司更具现 代感。铸造厂位于城市河滨公园和新的圆形剧场附近,夏 季,将有成千上万的民众路过这里。 尽管当前经济并不景气,但多森公司仍在招聘。公司 表示,新的工厂将增加招聘机会。 ■

General Kinematics to supply material handling system at Charlotte Pipe and Foundry Co.’s greenfield site

General Kinematics将为夏洛特管道铸造公司的新厂提供物料处理系统 AFS Corporate Member Charlotte Pipe and Foundry Company (Charlotte, North Carolina) has selected AFS Corporate Member General Kinematics to provide the material handling system for its new state-of-the-art facility on 428 acres in Oakboro, North Carolina. Inside the new cast iron foundry, GK will have responsibility for the furnace charge system, as well as the equipment from the end of the molding line through the cleaning room. General Kinematics, a vibratory equipment manufacturer and system integrator located in Crystal Lake, Illinois, has worked with Charlotte Pipe and Foundry Company for many years. "Everyone at General Kinematics is excited for Charlotte Pipe as they begin the huge undertaking of relocating their foundry operations,” said Tom Musschoot, president of General Kinematics. “I am appreciative of the trust that the team at Charlotte Pipe has put in our company and am proud that General Kinematics gets to be part of this historic move." Jim Egan, vice president of North America Sales for General Kinematics, added, “The Charlotte Pipe team is an experienced group of foundry experts with high standards. For them to recognize our foundry team’s efforts through this extensive planning process is validation that we are meeting our customers’ needs. Now we can begin to deliver on their trust.” The facility’s completion is projected for the third quarter of 2023. ■ 16

美国铸造协会会员企业夏洛特管道铸造公司(北卡罗 莱纳州夏洛特)已选择美国铸造协会会员企业General Kinematics为其位于北卡罗来纳州奥克伯勒的428英亩 的新厂提供物料处理系统。在这个新的铸铁厂,General Kinematics公司将负责熔炉装料系统以及从造型线末端 到清洁室的设备。 位于伊利诺伊州水晶湖的振动设备制造和系统集成商 General Kinematics已与夏洛特管道铸造公司合作了多年。 General Kinematics公司董事长汤姆·穆斯乔特表 示:“General Kinematics公司的所有人都对夏洛特管 道铸造公司感到兴奋,他们已开始着手铸造厂搬迁的艰 巨任务。我对夏洛特团队给予我们的信任表示赞赏,并 为General Kinematics将成为这一历史性举措的一部分 感到自豪。” General Kinematics北美销售副总裁吉姆·伊根补充 说:“夏洛特公司团队是一支经验丰富的高水准铸造专 家团队。通过广泛的规划过程,使我们铸造团队所做的 努力得到认可,验证了我们能够满足客户的需求。现在, 我们即将开始兑现承诺。” 新厂预计将于2023年第三季度竣工。 ■

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75 years of innovation in vacuum technology Since 1946, Fondarex Contributed To The Successful Implementation Of Thousands Of Projects In Vacuum Die Casting. A MESSAGE FROM DOMINIK BAUMGARTNER, FONDAREX CEO

致力于真空技术创新75年 自1946年以来,方达瑞为数千个真空压铸项目的成功做出了贡献。 方达瑞首席执行官 多米尼克·鲍姆加特纳

Initially established as a HPDC foundry in Montreux, Switzerland in 1946, for over 30 years the company produced high-quality castings for the automotive and household appliances industries with half a dozen die casting machines. In 1952, the first vacuum system was developed in-house for its foundry, aiming at optimizing the quality of the parts. During the last 45 years, the company has continuously expanded – not only in connection with its customers, nowadays numbering above 1,000, but constantly focusing on product development, with a forward-thinking reliability. Fondarex has developed and manufactured over 80 dedicated vacuum systems and more than 30 different vacuum valve and chill block models. Fondarex differentiates itself by offering its customers complete advice and technological support for each individual project, based on the long know-how and experience acquired. Our goal is for foundries to be able to produce in the most efficient and cost-effective way possible with the best part quality. Currently, Fondarex, in combination with a wider range of newly developed vacuum systems, valves and chill blocks, is pleased to take part in the new era of vacuum die casting. Above and beyond, Fondarex is active on the GIGA castings projects which are taking place already on three continents. This is an incredible story that is being written and the company is proud to leave its mark and expertise to shape the industry. ■

最初,公司于1946年在瑞士蒙特勒建立高压压铸厂,在 30多年间使用6台压铸机生产用于汽车和家用电器行业的高 质量铸件。1952年,第一个真空系统在其铸造厂内研发成 功,用于优化铸件质量。在过去的45年中,公司不断发展 壮大——不仅在客户的数量上(如今已超过1000),而且 还不断致力于具有前瞻性可靠性产品的开发。方达瑞已经 研发和制造了80多个专用真空系统以及30多种不同的真空 阀和冷却块。方达瑞凭借长期积累的专业知识和经验,通 过为每个项目的客户提供全面的建议和技术支持,使自己 与众不同。公司的目标是使铸造厂能够以最有效和最具成 本效益的方式生产高质量的铸件。 目前,方达瑞凭借各种新开发的真空系统、阀门和冷却 块相结合,积极投入到真空压铸的新时代。除此以外,方 达瑞积极参与已经在三大洲进行的GIGA铸件项目。这是 让人难以置信的项目,而且正在进行中,我们很荣幸能留 下自己的印记,用我们的技术来塑造行业。作为从模拟到 全球现场支持的整体真空解决方案供应商,方达瑞是您寻 找各种真空辅助成型零件的合作伙伴。所有这些只有通过 方达瑞员工以及客户的奉献精神和专业知识才能实现,因 此,感谢75年以来大家的努力和付出。 ■

METAL CHINA+DIECASTING 2021 will grandly open in May 5月开启!邀您见证2021铸造行业大事! On May 26-28, the 19th China International Foundry Expo (METAL CHINA) and the 15th China International Die Casting Industry Exhibition (DIECASTING CHINA) will link the upstream and downstream industries together that sixth exhibitions will be held in the same place at the same time, with a total exhibition area of 120,000 sq.m. Over 1300 exhibitors from more than 30 countries and regions will present the vitality of the industry at the National Exhibition and Convention Center (Shanghai), with a rich industry connotation, an international brand lineup, and a diversified form of exhibiting.

A Strong Lineup of the Entire Industry Chain This exhibition will cover multiple subsectors and focus on exhibiting foundry equipment, materials, high-quality castings, moulds, computer-aided software, specialized robots, 3D printing technologies, environmental protection equipments, refractory materials, industrial furnaces and raw material production equip18

2021年5月26-28日,第十九届中国国际铸造博览会、 第十五届中国国际压铸工业展览会将联动上下游,六展同 期同地,120000平米展出面积,30多个国家和地区的 1300多家行业知名展商,以更丰富的产业内涵、更国际 化的品牌阵容、更多元化的表现形式,于国家会展中心 (上海)呈现行业的蓬勃生机。

全产业链强大阵容 本届展会将集中展出铸造设备、铸造材料、优质铸 件、铸造用模具、铸造计算机辅助软件、铸造专用机器 人、3D打印、环保设备、耐火材料、工业炉以及原材料 生产设备等,涵盖多个行业细分领域。不仅有硬件产品, 也有软件产品,将成为行业企业风采展示并获得定向采购 资源的专属商贸平台。

同期展会:

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INDUSTRY NEWS/行业新闻 ments. With hardware products and also software products, it will become an exclusive business platform for enterprises to showcase their brands and obtain targeted procurement resources.

Concurrent Exhibitions: The 20th China International Metallurgical Industry Exhibition The 16th China International Refractory and Industrial Ceramics Exhibition The 19th China International Industrial Furnace and Thermal Technology Exhibition 2021 China International Fluid Machinery Exhibition

Diversified Exhibition Areas and Industrial Clusters The increased demand and purchasing power of Chinese market is creating a new development space. During the exhibitions, some specialty exhibition areas are set up, including intelligent manufacturing and robot, testing instrument, safety and environmental protection, castings for pipe network system, industrial clusters, the Yangtze River Delta famous enterprises, colleges and institutes, and the foundry culture demonstration, etc. Industrial clusters represented by Jiahe, Liyang, and Zhangwu, as well as various local pavilions, will show the rich industrial resources and competitive advantages of different places, leading the high-quality development of the industry.

100+ Events Provide Insight Into the Future of the Industry

第二十届中国国际冶金工业展览会 第十六届中国国际耐火材料及工业陶瓷展览会 第十九届中国国际工业炉及热工技术展览会 2021中国国际流体机械展览会

多元化展区、产业集群打破边界 中国市场强大的需求力和购买力正在缔造出全新的发 展空间,届时智能制造与机器人展区、检测仪器展区、 安全与环保展区、管网系统铸件展区、产业集群展区、 长三角名企展示园、大专院校与科研院所展区、铸造文 化展区等专题展区亮相展会。以嘉禾、溧阳、彰武为代 表的各产业集群以及各地方展团将展现各地方丰富的产 业资源和竞争优势,引领行业高质量发展。

100+活动登场 洞见行业未来 第十七届中国铸造协会年会、产业集群交流会、优质 铸件金奖、优质压铸件金奖、全国铸造材料金鼎奖、全 国铸造装备创新奖、“四新”技术、艺术铸品金奖颁奖 仪式以及权威行业专家现场咨询等百余场活动接连登场; 此外数十场主题论坛、采配对接、现场发布等多元配套 活动,为行业同仁搭建互动交流的平台,为企业打通供 需渠道提供保障。 2021年5月26-28日,我们在上海期 待您的到来。2022年5月,我们相约上海再相见! ■

www.expochina.cn

More than a hundred supporting events, including the 17th China Foundry Association Annual Congress, Industrial Cluster Development Exchange, Gold Award for High Quality Castings, Gold Award for High Quality Die Castings, Golden Tripod Award for Foundry Material, Foundry Equipment Innovation Award, New Technologies Award in four areas, Gold Award for Art Castings, and onsite consultation with experts, will be presented during the exhibition days. In addition, dozens of forums with different themes, matchmaking programs, new product releases and other diversified activities will together build a communication platform for industry insiders and provide guarantee for enterprises to open up supply and demand channels. Looking forward to meeting you on May 26-28, 2021, NECC, Shanghai. Let’s make our next appointment in May, 2022, Shanghai again! For more information, please contact Maggie, Tel:+86 18911227983 or email to limengmeng@foundry.com.cn ■ Website: www.expochina.cn

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Weifang platform of China Academy of Machinery Science & Technologyquick customized solution provider for complex parts of high-end equipment 机械科学研究总院潍坊平台 -高端装备复杂零部件个性化快速定制解决方案提供商 Weifang Platform is subordinate to Beijing National Innovation Institute of Lightweight Ltd., which is the second level unit of the large-scale science and technology state-owned enterprise China Academy of Machinery Science and Technology Group Co., Ltd. It is a part of National Innovation Center of Lightweight Material Forming Technology and Equipment and State Key Laboratory of Advanced Forming Technology & Equipment. In 2014, Shandong 3D Printing & Advanced Manufacturing Innovation Service Platform was built in Weifang High-tech Zone, and in 2018, Shandong Innovation Service Platform of Digital Green-Casting Technology & Equipment was built in Fangzi District of Weifang. It realized a fixed asset investment of 80 million yuan in Weifang, with a production site of 15,000 square meters. Relying on the Second Prize of National Technology Invention Award of the team of Academician Shan Zhongde-Complicated Casting Patternless Composite Manufacturing Technology and Equipment for regional industrialization promotion. It mainly focuses on the development of customized products for aerospace power machinery and engineering machinery complex parts, the development and sales of personalized mold flexible forming equipment and production line, the development and system integration of central control system of casting production line, Shandong Cloud Service Platform of Casting Industry www.cimpe.cn and other directions to provide full-process technical services and product promotion. It provides long-term and stable technical support for Weichai Power Co., Ltd., Weichai Lovol, Shengrui Transmission and other local enterprises, and carries out extensive and long-term military civilian integration technical cooperation with China FAW, YTO Group, Yuchai Machinery Group Co.,Ltd., Dongfeng Trucks, CNHTC in the direction of civil products, and with CASC, CASIC, NORINCO Group, CSSC in the direction of military products. Product and Service Capabilities 1: Personalized Rapid Customization Service for Complex Parts Weifang Platform has built an automatic, intelligent and network service base in Weifang, which focuses on the whole process of large complex metal parts, patternless composite forming and small advanced parts investment casting forming, from raw material preparation, composite casting process of increasing and decreasing materials, professional molding equipment development and application to the implementation of smelting integration process, product machining, parts materials and accuracy detection, etc. It can carry out fast, low-cost personalized customization and small batch production for different types of complex metal parts such as high-end alloy engines, automatic transmissions, turbochargers and so on. The largest forming size of the base can reach 5 meters, and the annual output of sand molds is 5,000 tons, and various advanced alloy parts are 2,000 tons. At the same time, the platform has built the largest non-me22

潍坊平台隶属于国资委监管的大型科技型央企机械科 学研究总院集团的二级单位-北京机科国创轻量化科学 研究院有限公司,是国家轻量化材料成形技术及装备创 新中心及先进成形技术与装备国家重点实验室的组成部 分,2014年在潍坊高新区建设了山东省3D打印暨先进 制造创新服务平台,2018年在潍坊坊子区建设了山东省 数字化绿色铸造技术与装备创新服务平台,在潍实现固 定资产投资8000万元,拥有生产场地15000平方米,依 托单忠德院士团队的国家技术发明二等奖-复杂铸件无模 复合成形制造方法与装备进行区域产业化推广,主要围 绕航空航天、动力机械、工程机械等复杂零部件个性化 快速定制产品开发、个性化铸型柔性成形设备与生产线 开发及销售、铸造生产线中央控制系统开发及系统集成、 山东省铸装工业云服务平台(www.cimpe.cn)等方向提 供全流程技术服务及产品推广。为潍柴动力、潍柴雷沃、 盛瑞传动等当地企业提供长期稳定的技术支持,并与中国 一汽、中国一拖、玉柴机器、东风商用车、中国重汽等在 民品方向,与航天科技、航天科工、中国兵器、中国船舶 等在军品方向,开展广泛且长期的军民融合技术合作。

产品及服务能力一:复杂零部件个性化快速定制服务 平台在潍坊建设了围绕大型复杂金属件无模复合成 形、小型高端零部件熔模铸造成形的从原材料制备、增 减材复合铸型工艺、专业化造型装备开发及应用到熔炼 一体化工艺实施、产品机加工、零部件材料及精度检测 等全流程的自动化、智能化、网络化服务基地,可针对 高端合金发动机、自动变速器、涡轮增压器等不同类型的 复杂金属零部件进行快速、低成本个性化定制及小批量生 产工作。基地单次最大成形尺寸可达5米,年产砂型模具 5000余吨,各类高端合金零部件2000余吨。 同时,平台针对以树脂、尼龙、橡胶、复合材料等 非金属材料建设了华北最大的非金属增材制造中心,为智 能可穿戴装备原型开发、医疗影视等精美道具开发进行产 品设计、生产、优化分析及装备开发工作。中心拥有各类 3D打印设备15台,可满足全部非金属零部件材料及工艺

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INDUSTRY NEWS/行业新闻 tallic additive manufacturing center in North China for non-metallic materials such as resin, nylon, rubber and composite materials, and carried out product design, production, optimization analysis and equipment development for prototype development of intelligent wearable equipment and development of exquisite props such as medical, film and television. The center has 15 sets of all kinds of 3D printing equipment, which can meet the external service of all non-metallic parts materials and processes, with an annual output of more than 4000 non-metallic products. Product and Service Capabilities 2: Personalized Cast Flexible Forming Equipment R&D of Production and Sales On the basis of personalized and rapid customized product development services around complex parts, the platform relies on the National Innovation Center and the State Key laboratory to establish a professional equipment R&D team of 30 people in Weifang, who are engaged in the R&D and sales of high-efficiency digital patternless casting precision forming machine, highefficiency sand mold 3D printing forming machine, personalized mold flexible production line and other equipment and production lines, and providing the whole process service for the construction of enterprise level rapid manufacturing center. At present, the company has built a 5,000-ton rapid manufacturing center for Guangxi Yuchai Machinery Group Co.,Ltd., a 1,000-ton rapid manufacturing center for Weichai Power Co.,Ltd., a 2,000-ton rapid manufacturing center for China YTO, three 500-ton and 2000-ton rapid manufacturing centers for a military plant under the CASC, accumulatively sold more than 200 sets of serialized patternless composite forming equipment in China. Product and Service Capabilities 3: Digital Transformation of Production Line and Industrial Interconnection With more than 10 years of service accumulation in the foundry industry, starting from the foundry process, combined with industrial interconnection development ability, the company provides foundry enterprises with digital acquisition, lightweight MES system development, central control system development and other services. Shandong Cloud Service Platform of Casting Industry (www.cimpe.cn) jointly built by CAM and the Shandong Provincial Department of Industry and Information Technology, is based on the transformation demand of new and old kinetic energy in Shandong foundry industry, focusing on foundry materials, equipment and service companies in the province to integrate resources from industries such as industrial chain collaboration, online customization of complex parts and sharing of large-scale equipment, and online diagnosis by experts. It provides foundry companies with digital transformation services for production lines. At present, it has provided the whole process R&D and technical support for the central control system of Yuchai Rapid Manufacturing Center, the digital control system of Weichai Core-making Workshop, Shanghai Wanze Green Casting Process Expert System, Linhai Power Agricultural Machinery Network Collaboration System, and SANY Machine Construction Machinery Virtual Reality Platform. National Innovation Center of Lightweight Materials Forming Technology & Equipment State Key Laboratory of Advanced Forming Technology & Equipment For more information, please contact: Mr. HONG Haichun, Tel: 18811228132, Email: honghc025@163.com Website: www.camtc.cc/www.cimpe.cn ■

对外服务工作,年产非金属产品4000余件。

产品及服务能力二:个性化铸型柔性成形设备 及生产线研发及销售 在围绕汽车结构件个性化快速定制产品开发服务基 础上,平台依托国创中心和国重实验室,在潍坊建立 了30人的专业化设备研发团队,从事高效数字化无模 铸造精密成形机、高效数字化砂型打印精密成形机、 个性化铸型柔性成形生产线等设备、生产线的研发及 销售,同时为提供企业级快速制造中心建设全流程 服务,目前已为广西玉柴建设了5000吨级发动机快 速制造中心,为潍柴动力建设了1000吨级发动机快 速制造中心,为中国一拖建设了2000吨级结构件快 速制造中心,为航天科技集团下属某军工厂分别建 设了三处500吨级、2000吨级军品快速制造中心, 累计在国内销售系列化无模复合成形装备200余台。

产品及服务能力三:铸造行业生产线数字化改 造及工业互联 以10余年铸造行业的服务积淀,从铸造工艺出发, 结合工业互联开发能力,为铸造类企业提供数字化采 集,轻量化MES系统及中央管控系统开发等服务;同 时依托与机械总院集团、山东省工信厅一同建设的山 东省铸装工业云服务平台(www.cimpe.cn),立足 山东省铸造行业新旧动能转换需求,围绕省内铸造材 料、装备及服务企业进行从产业链协同、复杂零部件 在线定制、大型仪器设备共享、专家在线诊断等行业 进行资源整合。目前已为玉柴快速制造中心中央管控 系统、潍柴制芯车间数字化管控系统、上海万泽绿色 铸造工艺专家系统、江苏林海高端农机零部件网络协 同制造系统、三一工程机械AR/VR展示系统提供全流 程研发及技术支持。 国家轻量化材料成形技术及装备创新中心 先进成形技术与装备国家重点实验室潍坊基地 更多公司信息及解决方案,请联系:洪海春,联 系电话:18811228132, Email: honghc025@163. com,网址:www.camtc.cc/www.cimpe.cn ■

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INDUSTRY NEWS/行业新闻

LK’s 6000-ton Die Casting Machine Put into Production at Customer Factory 力劲6000吨智能压铸单元在韩国GLOVITECH越南工厂正式上线生产 In order to meet the rapidly increasing demand for 5G ultralarge communication components from large Korean telecommunications companies. In mid-2020, the GLOVITECH Vietnam factory ordered 1 set of 4,000-ton and 1 set of 6,000-ton large intelligent cold-chamber die-casting units from LK Group. Glovitech is headquartered in Ansan, Gyeonggi-do, South Korea. It mainly produces telecommunications equipment parts, medical equipment parts, and LED parts. The company has mold design and manufacturing, die-casting molding, metal processing, painting and other production processes and platforms. LK Group sent a technical team to Vietnam to fully support the customer production to ensure the smooth progress and overcome the risks and difficulties of the COVID-19 epidemic. During the Chinese Lunar New Year, the customer’s factory was still stationed for installation. The commissioning of machine that all systems and components of a building are designed, installed, tested, operated, and maintained according to the operational requirements to ensure the entire project. In March 2021, the GLOVITECH Vietnam factory 5G RF unit housing was successfully produced. "GLOVITECH is the first to implement the technology to produce this ever housing for 5G tele communication industry.” Quan Junzhe, CEO of GLOVITECH said, “The 5G RF unit production has a more complex structure than ordinary products. It is difficult to produce, and has high requirements for the performance of die-casting units. The 4000-ton, 6000-ton large-scale intelligent cold-chamber die-casting units have high production efficiency, fast production capacity and stable performance, which satisfy the scale production of 5G ultra-large and thin-walled parts." Due to the high thermal conductivity of 5G products, the 5G RF unit shell produced by GLOVITECH uses raw materials with low silicon content. In order to manufacture difficult radiators, GLOVITECH has given full play to the advantages and strength of mold development and high-end die-casting production technology. In 2021, China's new energy vehicle and lightweight manufacturing industry will accelerate, and the Chinese market will still be the most important market for LK Group. LK’s ultra-large intelligent die-casting unit is expected to lead LK Group to achieve high-speed growth goals. On May 26-28, 2021, at the 19th China International Foundry Expo (METAL CHINA 2021) and the 15th China International Die Casting Industry Exhibition (DIECASTING CHINA 2021), LK Group will show its development and innovation achievements. Welcome to booth 2B04 to witness its quality and strength. ■

为满足三星电子等大型电信企业对5G超大型通讯组件急 剧增长的需求,2020年年中,GLOVITECH越南工厂向力 劲集团订购了1套4000吨、1套6000吨大型智能冷室压铸 单元。GLOVITECH总部位于韩国京畿道,拥有模具设计与 制造、压铸成型、金属加工、喷漆等生产工艺与平台,主 要生产通信设备组件、医疗器械零件、LED零件等产品。 为保障GLOVITECH越南工厂生产计划的顺利进行, 力劲集团派出技术团队远赴越南,全面支持客户生产工 作,克服COVID-19疫情风险与各种困难,在中国农历 春节期间依然驻守客户工厂,进行装机、测试、调试等 一系列工作,确保了两套大型智能压铸单元如期上线, 力争达到最佳生产周期与产品合格率。 2021年3月,GLOVITECH越南工厂5G RF单元外壳顺 利生产,进入规模量产和商业化应用阶段“GLOVITECH 是全球首家采用大型压铸单元实现超大型5G RF单元外壳 批量化、智能化生产的公司。”GLOVITECH公司首席执 行官权俊哲表示,“5G RF单元散热片结构复杂,比一般 的产品长而且薄,生产难度大,对压铸单元的性能有较 高要求。力劲4000吨、6000吨大型智能冷室压铸单元 生产效率高、产能快、性能稳定,很好地满足了5G超大 型薄壁件的规模化生产要求。” 2021年,中国新能源汽车轻量化制造产业将加速前 进,中国市场仍旧是力劲集团全球布局的最重要市场, 力劲超大型智能压铸单元有望成为引领力劲集团实现新 一年高速增长目标的重磅引擎。2021年5月26-28日, 第十九届中国国际铸造博览会、第十五届中国国际压铸 工业展览会&第十五届国际有色及特种铸造展览会的现 场,力劲集团又将呈现出怎样的变革与创新?欢迎莅临 展台2B04,见证品质与实力。 ■

ABN--to be the Leader of Green Melting of Aluminum Alloy 安保能——做铝合金绿色熔炼的领跑者

Baoding ABN Melting Facility Co., Ltd. (ABN) is specialized in research and manufacturing of aluminum melting and treatment equipment. Since its establishment, ABN is devoted to the innovation of energy-saving, eco-friendly and low-loss melting furnaces. ABN will hold a new product launch conference during METAL CHINA 2021. Visitors are welcome to visit and attend the conference at ABN’s booth. Booth number: HALL 2.1, 2B07. ABN is a subsidiary of Hebei Lizhong Group. It has more than 30 years of experience in casting production, casting equipment manufacturing and process technology development. ABN has continued to grow in recent years. Except for mastering 24

保定安保能冶金设备有限公司(以下简称安保能)作 为专业研发、制造铝合金熔炼设备的生产厂家,自成立 以来,扎根熔铝炉市场,在追求“安全、环保、节能” 的道路上创下一个个新的高度。 为大力推广公司的产品与技术,2021年第十九届铸博 会期间,安保能将举办新品发布会,欢迎各位观众莅临本 公司展位参观交流,展位号:HALL 2.1 2B07。 保定安保能冶金设备有限公司是河北立中集团的子公

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INDUSTRY NEWS/行业新闻 the core technology of aluminum alloy smelting equipment, it has developed an advanced and more widely applicable Highefficiency Constant-rate Uniform Aluminum Melting Furnace, which is mainly used for melting aluminum ingots, as well as all sorts of aluminum scraps. With this furnace, the working environment is smokeless and odorless. It has low metal loss, low energy consumption, and no composition segregation. Using the Secondary Aluminum Melting Furnace with Automatic Al-Fe Separation System, no preliminary breaking or selecting step is needed, neither the addition of salt flux. With this furnace, the melting process can avoid an increase of iron content in the aluminum, although the scraps contain high-level iron parts, and have an efficient Al-Fe separation as well as low metal loss. Furthermore, the combustion of various combustible matters in the scrap results in lower energy consumption. ABN Inline liquid aluminum purification system can reduce the melting temperature, improve the purifying effect, lower energy consumption, and save refining time. No filter is needed, and the cost is reduced. We have pioneered new equipment in China and their applications for the long-distance transport of molten aluminum with excellent thermal insulation, erosion and impact resistance, and safety control. ■

司,有三十多年的熔铸生产实践及管理经验和熔铸装备 制造及工艺技术沉淀。安保能在近些年的发展中不断壮 大,在掌握铝合金熔炼设备核心技术的同时,研制出了 先进的、适应更广泛的高效等速等温熔解炉、再生铝自动 熔化铝铁分离、铝液在线净化装备、铝液远距离运输装备 等产品。高效等速等温熔解炉组采用熔池熔解技术、废烟 气净化技术、有机可燃物“补给燃烧”技术,解决了熔铸 行业环境污染、金属损耗高、能耗高等难题;ABN再生 铝自动熔化铝铁分离炉节省了拆解、破碎、磁选等多种 生产工序,含铁件的废铝熔解过程中铝铁不产生互熔, 铝铁实现充分分离,消除了铝渣高温自燃,降低了金属 烧损,自动除镁除锌;ABN铝液在线净化系统具有铝液 除气除渣、静置沉降等功能,提高了净化效率,节省了 作业时间,充分降低了能耗和成本等问题。 ■

New Melting Equipment of TAA Put into Production 大亚新设备顺利投产

On Jan. 16, a new electric melting furnace of Zibo TAA Metal Technology Co., Ltd., which is a large metal abrasives supplier in China, was put into operation. The melting capacity will increase by more than 60,000 tons per year after it is put into operation. In order to better serve customers, increase production capacity and promote product structure upgrades, the company launched this new electric furnace production line project in October 2020. It took only 100 days for the new line put into production. The commissioning of the new electric furnace has increased the production capacity of various abrasives and casting products, and shortened the product delivery period; better melting performance has also laid the foundation for the improvement of abrasive performance and the development of new products. TAA uses self-developed low-carbon steel shots, bainite steel shots and special mixed abrasives and other series of new products and overall technical solutions to continuously meet the multilateral needs of high-end customers for surface treatment effects, improving operating efficiency, and reducing costs. Not only has it been highly recognized by the industry and the market, it has also won many industry awards at METAL CHINA. Welcome to visit our booth 3A01, Hall 3 at the 19th China International Foundry Expo and the 15th China International Die Casting Industry Exhibition from May 26-28, 2021 in National Exhibition and Convention Center, Shanghai. ■

1月16日,大亚金属又一台新的熔炼电炉正式投产, 投产后熔炼产能将增加6万吨/年以上。 为更好地服务客户、提高产能、促进产品结构升级, 公司于2020年10月启动新电炉生产线项目,自项目开工 建设到正式投产仅用时100天,展现了大亚速度。 新电炉的投产使用,提高了公司各类磨料及铸件产品 的生产能力,缩短了产品交付期;更好的熔炼性能也为 磨料的性能提升和新产品的研发奠定了基础。 公司用自主研发的低碳钢丸、贝氏体钢丸及专用混合 磨料等系列新产品以及整体技术解决方案,不断满足着 高端客户对产品表面处理效果及提高作业效率、降低成 本的多边需求,不仅得到行业与市场的高度认可,并在 历届展会上揽获多项行业大奖。公司已参加将于2021年 5月26-28日在国家会展中心(上海)举办的第十九届中 国国际铸造博览会、第十五届中国国际压铸工业展览会, 欢迎到公司展台洽谈合作,展位号:3A01。 ■

Wanfeng Technology Provides Automated Solutions for AECC 万丰科技为中国航发集团提供自动化解决方案

On February 18th, the evaluation of automated production line for aluminum alloy casting cleaning organized by Aero Engine Corporation of China (AECC) was held. After careful selection and review by the expert group, Wanfeng Technology received recognition and won the bid, relying on its excellent comprehensive strength, technical level, industry experience and brand recognition, which means that Wanfeng Smart manufacturing will provide supporting services for the upgrade of Chinese top aero engine products.

2月18日,由中国航发集团组织的铝合金铸件清理自动 化生产线评标工作完成,经专家组的认真评选和审核,万 丰科技凭借优秀的综合实力、技术水平、行业经验以及 良好的品牌口碑获得认可、成功中标,这意味着万丰“ 智”造将配套服务于中国顶尖的航空发动机产品升级。 此次,万丰科技提供的生产线项目主要用于航空零部 件产品后处理多道工序的全自动化生产。项目针对客户

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INDUSTRY NEWS/行业新闻 The project provided by Wanfeng Technology is mainly used for the fully automated production of multiple processes in the post-processing of aviation parts and components. The project provides innovative designs in accordance with customer requirements and product characteristics. The production layout realizes the optimization of space utilization and the automation of the production process, so that all equipment is highly integrated, and the characteristics of intelligence, safety, efficiency, energy saving, and noise reduction are realized. Through 3D vision+flexible production line technology, unmanned, flexible and digitalization of the whole process of multi-variety and mass production are realized. As the industry leading provider of nonferrous casting production equipment and solutions, Wanfeng Technology enjoys international leading technology and a high market share. Its R&D and innovative brands are widely praised in the industry. Welcome to visit our booth 2B03 at the 15th China International Die Casting Industry Exhibition from May 26-28, 2021 in National Exhibition and Convention Center, Shanghai. ■

要求和产品特点提供了创新性设计,生产布局实现空间 利用的最优化,生产流程的自动化,做到所有设备高度 集成,实现智能、安全、高效、节能、降噪等特点,同 时通过3D视觉+柔性化生产线技术,实现多品种、批量 生产全流程无人化、柔性化、数字化。 作为行业领先的有色铸造整套生产装备和解决方案的 提供商,万丰科技在业务相关领域,拥有国际领先的技 术和较高的市场占有率,由其研发与创新的品牌在业界 广受赞誉。公司已参加将于2021年5月26-28日在国家会 展中心(上海)举办的第十九届中国国际铸造博览会、第 十五届中国国际压铸工业展览会,欢迎到公司展台洽谈合 作,展位号:2B03。 ■

Hengli Hydraulics Will Bring its Star Products to METAL CHINA 2021 恒立液压将携明星产品亮相第十九届中国国际铸造博览会

On March 25, 2021, Chinese Premier Li Keqiang went to Hengli Hydraulic Co., Ltd. during his inspection trip in Jiangsu, where he inquired about the company's products, its technologies and input into research and development. The Premier expressed high recognition and appreciation for the development results. Headquartered in Changzhou, Jiangsu, Hengli has established four international advanced manufacturing bases for high-pressure cylinders, hydraulic pump valves, precision castings, and pneumatic components. It has successfully entered the market of global highend hydraulic components through the acquisition of Shanghai Lixin Hydraulics, Berlin InLine Hydraulics, and Japan Hattori Seiko. In order to continuously improve the service response speed and brand image, and promote the rapid growth of overseas business, Hengli has established branches in Japan, the United States, and India to improve the overseas regional marketing service network. Changzhou Casting Plant of Hengli Hydraulic is a council member of China Foundry Association. Hengli Hydraulics has been listed in the third batch of Single Champion Manufacturing Enterprises by the Ministry of Industry and Information Technology, and has also been awarded the "China Green Foundry Demonstration Enterprise" by China Foundry Association. From May 26-28, 2021, Hengli Hydraulics will bring its star products to the 19th China International Foundry Expo and the 15th China International Die Casting Industry Exhibition hosted by China Foundry Association, at the National Exhibition and Convention Center (Shanghai). Visit us at booth 1C07, Hall1.1. ■

2021年3月25日,国家总理李克强赴江苏常州考察, 首站来到江苏恒立液压股份有限公司,了解了企业近年 来的运作情况和发展前景,对企业取得的发展成果表示 了高度肯定与赞赏。 恒立液压总部位于中国常州,建有高压油缸、液压 泵阀、精密铸造、气动元件四个国际先进的液压产品制 造基地,并通过并购上海立新液压、德国柏林InLine液 压、日本服部精工,成功进军全球高端液压元件领域。 为不断提升地区服务响应速度和品牌形象,推动海外业 务快速增长,先后建立日本、美国、印度分公司,完善 海外地区营销服务网络。 江苏恒立液压股份有限公司常州铸造分公司是中国铸 造协会理事单位。恒立液压还曾获评工信部第三批制造 业单项冠军企业、中国铸造协会评定的“中国绿色铸造 示范企业”。今年5月26~28日,恒立液压将继续携明星 产品亮相由中国铸造协会主办的第十九届中国国际铸造 博览会、第十五届中国国际压铸工业展览会,展位位于 国家会展中心(上海)1.1H馆C07,届时欢迎业界同仁莅 临参观、交流。 ■

Your Digital Expert-Qinhuangdao Xinyue invites you to visit the METAL CHINA 2021 数字化工厂解决方案专家——秦皇岛信越诚邀您莅临参观十九届铸博会

Qinhuangdao Xinyue Intelligent Equipment Co., Ltd. (Xinyue Company) is a wholly-owned subsidiary of CITIC Dicastal Co., Ltd. It was founded in April 2015 and formerly operated as CITIC Dicastal Equipment Development Center. Xinyue Company is specialized in the development, production and sales of special equipment for the production of non-ferrous metal castings parts by using gravity, low pressure, counter pressure, forging, spinning and other process technologies, and the design and implementation of aluminum wheel production line and whole plant automation, informatization and intelligence. It also provides automatic equipment that integrates production, process, technol26

秦皇岛信越智能装备有限公司(以下简称为信越公 司)为中信戴卡股份有限公司的全资子公司,其前身为 中信戴卡股份有限公司-装备研制中心。信越公司成立于 2015年4月,是一家专业从事利用重力、低压、差压、锻 造、旋压、高压等工艺技术,专门开发、制作、销售有色 金属铸件生产专用设备,铝合金轮毂生产线、整厂自动 化、信息化、智能化的解决方案设计、实施,及提供有 色金属铸件生产、工艺、技术、管理、咨询、服务于一 体的自动化装备及工厂信息化、智能化系统集成服务商。

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INDUSTRY NEWS/行业新闻 ogy, management, consulting and service for non-ferrous metal casting part, and integrated intelligent informatization system. Product profile: A new low-pressure casting machine unit for producing wheel with automation, informationization, intelligence, safety, energy saving, environmental protection and high efficiency. • Low-pressure casting machine & automation equipment • Differential pressure casting machine • Visual identification system • Automatic deburring equipment • Coating production line On May 26-28, 2021, Xinyue will launch its self-developed differential pressure casting machine with fully automated production equipment to the market at the 19th China International Foundry Expo at the National Exhibition and Convention Center (Shanghai). Welcome to visit the booth: 2D02, Hall 2. ■

产品介绍:自动化、信息化、智能化,安全、节能、环 保、高效的新一代轮毂低压铸造机单元。 • 低压铸造机&自动化的配套设备 • 差压铸造机 • 视觉识别系统 • 铸件机加工后自动铣毛刺 • 涂装生产线 2021年5月26-28日,在国家会展中心(上海)即将 举办的第十九届中国国际铸造博览会上,秦皇岛信越将 面向市场推出其自主研发的——差压铸造机全自动化生 产配套设备,向来自世界各地的行业同仁展示其国际一 流水平的差压铸造全自动化生产模式。欢迎大家莅临展 位参观指导。展位号:2D02 ■

ASD will bring Lightweight Aluminum Casting Solutions to METAL CHINA 2021 艾斯迪将携轻量化铝合金铸造解决方案亮相第十九届铸博会 Founded in 1998, ASD Automotive Components (Tianjin) Co.,Ltd.(formerly known as ASIMCO Automotive Components (Tianjin) Co., Ltd.) renamed in July 2020. For more than 20 years, the company has been committed to the production of aluminum alloy casting products, mainly engaged in the R&D, production, and sales of key automotive components. It has gradually formed a product system with automotive power system component, transmission system component, chassis system component and new energy auto part as its core. It has developed into a high-tech enterprise integrating independent R&D, design, mold manufacturing, casting, machining and assembly, with an annual production capacity of 25,000 tons of aluminum alloy castings. And its business covers Asia, Europe, North America, etc. ASD Automotive Components, which is committed to the lightweight design and manufacturing of automobiles, has continuously provided lightweight aluminum alloy casting and machining products to global customers through CAE finite element analysis and mold flow analysis. It has two factories which are located in Tianjin and Wuhu. The company is providing services to its world customers with advanced technology and high-quality products. On January 16, 2021, the new plant of ASD (Wuhu) Material Technology Co., Ltd., a wholly-owned subsidiary of ASD Automotive Components (Tianjin) Co., Ltd., was put into trial production. The project started in 2019, with a land area of about 80 acres and a construction area of 30,000 square meters. It is planned and designed in accordance with Industry 4.0 standards. The total investment is 450 million yuan. It mainly produces aluminum alloy automotive parts. The main construction of the new plant includes die-casting workshop, machining workshop, stocking area workshop, auxiliary material warehouse, etc., manufacturing intake manifold, oil pan, differential case, elbow, bearing seat, timing cover, camshaft cover, pedals, engine pipe fittings, front end covers, air compressor housings, etc.. Equipped with automatic die-casting production line, gravity automatic production line, lowpressure automatic production line, and high-precision machining equipment, automatic cleaning equipment, professional technology research and development laboratories, it will have an annual production capacity of 13,000 tons of aluminum castings after the completion of the factory. May 26-28, 2021, the 19th China International Foundry Expo and the 15th China International Die Casting Industry Exhibition will be held at the National Exhibition and Convention Center (Shanghai). ASD will bring its high-tech products to the exhibition. Welcome to visit our booth at 2D16, Hall 2. ■

成立于1998年的艾斯迪远东(天津)科技有限公司 前身为亚新科(天津)汽车零部件有限公司,于2020 年7月初正式更名。二十多年来,公司专注于生产铝合 金铸造产品,主要从事汽车关键零部件的研发、生产、 销售,逐步形成了以汽车动力系统零部件、传动系统零 部件、底盘系统零部件以及新能源汽车零部件为核心的 产品体系,已发展成为集自主研发、设计、模具制造、 铸造生产、机加工、装配为一体的高新技术企业,具有 年产2.5万吨铝合金铸件的生产能力,业务遍布亚洲、 欧洲、北美等多个国家和地区。 致力于汽车轻量化设计与制造的艾斯迪,通过CAE有 限元分析和模流分析,为全球客户源源不断地提供着轻 量化铝合金铸造及机加产品,旗下设立的天津和芜湖两 家工厂,南北呼应,携手并进,用先进的技术和高质量 的产品服务于世界各地的汽车整车和一级零部件客户。 2021年1月16日,艾斯迪远东(天津)科技有限公司 全资子公司——艾斯迪(芜湖)材料技术有限公司新工 厂正式点火试产。该项目于2019年开工,用地面积约80 亩,建筑面积30000平方米,坐拥优质的长江港口和多 元化的运输方式,按照工业4.0标准进行规划设计,总投 资4.5亿元,主要生产汽车铝合金压铸零部件产品。新工 厂主体工程建设包括压铸车间、机加工车间、备货区车 间、辅料库等,生产进气歧管、油底壳、差速器壳、弯 水管、轴承座、正时罩盖、凸轮轴盖、踏板、发动机管 件、前端盖、空压机壳体等各类车用铝合金壳体和支架 产品等,拥有自动压铸生产线、重力自动生产线、低压 自动生产线,并配备高精度机加工设备、自动清洗线设 备、专业的技术研发实验室等,工厂建成后将具备年产 1.3万吨铝铸件的生产能力。 2021年5月26-28日,第十九届中国国际铸造博览 会、第十五届中国国际压铸工业展览会将于国家会展中 心(上海)举行,艾斯迪将携最新高科技产品亮相展 会。公司展位号:2D16。 ■

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INDUSTRY NEWS/行业新闻

Core Components of Magnesium Alloy Semi-solid Equipment will Show at Diecasting China 2021 镁合金半固态设备核心部件即将闪亮登场Diecasting China 2021

Kunshan Shengshida Machinery Co., Ltd (Kunshan Shengshida) is an overall solution provider for the magnesium alloy industry integrating R&D, production and service. It is a professional team that has mastered the world's advanced magnesium alloy semi-solid forming technology earlier in China. As a leading brand in this industry in China, the company has been committed to the field of magnesium alloy semi-solid for 18 years. Now it has more than 20 core intellectual property rights (including 6 invention patents). After the scale upgrade in 2018, the plant has been expanded to an area of more than 6000 square meters and is the largest domestic supplier of magnesium alloy semi-solid forming equipment, consumables and parts. In order to meet more friends, discuss cooperation and business opportunities, and jointly promote the application of magnesium alloy semi-solid in more fields, Kunshan Shengshida will display various magnesium alloy semi-solid equipment and products at the 19th China International Foundry Expo and the 15th China International Die Casting Industry Exhibition, May 26-28, 2021 in Shanghai. Looking forward to your visit at our booth: 2D39, Hall 2. ■

昆山盛事达专注于镁合金行业,是一家集研发、生 产、服务为一体的镁合金整体方案供应商、是国内较早 掌握世界先进镁合金半固态成型技术的专业团队。作为 国内镁合金半固态的领导品牌,昆山盛事达机械设备有 限公司18年来不断深耕镁合金半固态领域,现已拥有20 多项核心知识产权(包括6项发明专利),2018年规模 升级后,新厂房使用面积扩大到6000多平方米,是国内 最大的集镁合金半固态成型设备制造、耗材、零部件生 产的供应商。 为结识更多业内外朋友、洽谈合作商机互通有无、 共同推动镁合金半固态在更多领域的应用,2021年5月 26-28日,第十九届中国国际铸造博览会暨第十五届中 国国际压铸工业展览会举办期间,昆山盛事达将现场展 示公司各类镁合金半固态技术设备产品,期待与您共同 探索新环境下的更多可能。 ■

The Navigator of Intelligent Manufacturing and High-end Equipment Industry 智能制造与高端装备业的“领航员”

As a national leader in high-end intelligent equipment, SINOMACH Casting and Forging Machinery Co., Ltd. is a subsidiary of SINOMACH which is among the world top 500. It has ranked No. 1 in China's top 100 machinery industry for 11 consecutive years. The sales volume of its static pressure line has ranked first for 4 consecutive years in 2017, 2018, 2019, and 2020 in China. The new flaskless vertical moulding line is faster, more stable and smarter! The world's first intelligent flexible flask line will become the global flask moulding center. Covering an area of 150,000 square meters, SINOMACH focuses on three major business development areas: clean, efficient and green intelligent casting equipment, high-end uncoiling intelligent CNC equipment, and high-end intelligent automotive equipment. It has the ability to provide complete solutions for casting, forging and automotive equipment, as well as providing EPC services. The company attaches great importance to product promotion, and recognizes the broad platform of METAL CHINA and DIECASTING CHINA hosted by China Foundry Association. It has benefitted from the exhibitions by obtaining orders, market information, and meeting customers. On May 26-28, 2021, at the 19th China International Foundry Expo and the 15th China International Die Casting Industry Exhibition, SINOMACH will hold new product launch conference for its new model of vertical line and the flexible sand flask moulding line, as well as the on-site signing ceremony. Welcome to visit our booth 3B01-6. ■

作为全国高端智能装备领军企业,国机铸锻机械有限 公司隶属于世界500强国机集团,连续11年蝉联中国机 械工业百强榜首,静压线2017、2018、2019、2020 连续4年全国销量第1。新型无箱垂直造型线更快、更 稳、更智能!全球首条智能柔性砂箱加工线将成为全球 砂箱加工中心。 国机铸锻占地15万平方米,聚焦清洁高效绿色智能铸 造成套装备、高档数控开卷智能成套装备和高端汽车智能 装备三大业务发展方向,具备为铸造、锻压和汽车装备领 域提供完整解决方案和EPC工程总承包的能力。 公司十分注重产品推广,更是认可由中铸协主办的铸 博会和压铸展这一广阔平台,每次参展都有很多收获, 现场签单、获得市场潜在价值信息、见到老客户、结识 新客户。2021年5月26-28日,第十九届中国国际铸造博 览会、第十五届中国国际压铸工业展览会&第十五届国际 有色及特种铸造展览会上,国机铸锻将现场举办新型垂直 线、柔性砂箱加工线新产品发布会,还有现场签约仪式等 您来围观。欢迎新老客户莅临展位3B01-6参观洽谈。 ■

Dynacast Germany: New Magnesium Die-Cast Part Needs Its Own Deburring Press 德国奈那卡斯:新型镁合金压铸件需要适合的去毛刺设备

"There are die-cast parts that must not be broken for further use during deburring, but rather require a clean full cut with the help of a specially manufactured deburring press," explains DYNACST Germany boss Armin Beck in an interview. The current challenge concerns a magnesium die-cast part that will later be used as the rear lock for a luxury Bavarian vehicle. The 28

德国奈那卡斯公司老板阿明•贝克在接受采访时说 到:“压铸件在去毛刺过程中不能被损坏,这就需要在 专门设计制造的去毛刺压机的帮助下进行完整的切割。” 当前的挑战涉及镁合金压铸件,该铸件随后将用作巴 伐利亚豪华车的后置锁紧装置。铸件表面不得有任何断

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INDUSTRY NEWS/行业新闻 cast part must not have any fracture surfaces, because an injectionmolded part is attached during further processing, and the necessary tightness is only guaranteed with a full cut using a corresponding deburring press. Investment-intensive project with a dynamic solution Overall, Beck speaks of an extraordinarily exciting project, as the production of the new cast part involved a so-called "hard start", that is, a part is replaced by a new part during the current series. This required a high degree of flexibility and speed in the foundry, as well as in the requirements for mechanical engineering. The new rear lock is cast as a magnesium casting on a specially manufactured DYNACAST hot chamber machine with multislide technology. One works with a tool with two-slide technology and injection in the mold half. After the casting, the cast part is transported on a conveyor belt through a cooling tunnel, is then picked up by the Aulbach deburring press and cut cleanly. Abk PRESSENBAU UND AUTOMATION very quickly turned out to be the ideal supplier for the provision of the absolutely necessary deburring automation, because the specialists from Mömlingen had a suitable deburring robot on hand and, with their competence and expertise in deburring automation, were able to tailor the hydraulics and electrics precisely to the requirements of DYNACAST Germany. Armin Beck also praises the good communication with Ms. Aulbach and Mr. Kohlmann, and the quick and precise implementation as a good companion for the demanding project. About DYNACAST: DYNACAST produces in 26 plants in 16 countries worldwide. DYNACAST Deutschland GmbH produces complex precision parts made of magnesium, zinc and aluminum in Bräunlingen in Baden with around 250 employees, using multi-slide die casting machines. The DYNACAST Germany portfolio includes thousands of items, which are usually no larger than the size of your hand. The most important customers include automobile manufacturers, electrical engineering, medical technology, leisure and sports. About abk PRESSENBAU UND AUTOMATION: Partner for all areas of deburring automation Tailor-made answers for integrated casting cells, optimized use of robots in the machining process and individual solutions for challenges in foundries ■

裂,因为在进一步加工过程中会连接注塑件,并且只有 在使用相应的去毛刺压机进行全切割时,才能保证必需 的密封性。 具有动态解决方案的投资密集型项目 总的来说,贝克谈到了一个非常激动人心的项目,因 为新铸件的生产涉及所谓的“硬启动”,即在当前系列 中,一个零件被新零件替代。这要求铸造厂具有高度的 灵活性和速度,以及满足机械工程方面的要求。 新型后置锁紧装置采用镁合金、在专门的具有多滑模 技术的奈那卡斯热室机上铸造。也就是使用具有两滑模 技术并在半模中进行注塑。铸造后,铸件经冷却通道运 输到传送带,然后由Aulbach去毛刺压机拾取并进行完 整地切割。 很快,Abk PRESSENBAU UND AUTOMATION就 成为提供绝对必要的自动化去毛刺设备的理想供应商。 以前,来自Mömlingen的专家们都有合适的去毛刺机 器人,凭借其在去毛刺自动化方面的能力和专业知识, 他们能够量身定制液压和电气系统,完全符合德国奈那 卡斯公司的要求。 阿明•贝克对与Aulbach女士和Kohlmann先生的良好 沟通表示赞许,他们快速准确地实施这项要求严格的项 目,是良好的合作伙伴。 关于奈那卡斯: 奈那卡斯在全球16个国家/地区有26家工厂。 德国奈那卡斯公司使用多滑模压铸机在巴登州的布劳 林根生产由镁、锌和铝制成的复杂精密零件,公司约有 250名员工。 德国奈那卡斯公司的产品组合包括数千种,产品尺寸 通常不超过手掌大小。最重要的客户包括汽车制造商、 电气工程、医疗技术、休闲和体育。 关于Abk PRESSENBAU UND AUTOMATION: 去毛刺自动化所有领域的合作伙伴 为集成铸造单元提供量身定制的解决方案,在加工过 程中优化机器人的使用以及针对铸造厂的挑战提供个性 化解决方案。 ■

HA Group Intensifies Activities In Southeast Asia 欧区爱集团增强东南亚市场业务

Hüttenes-Albertus (HA), the world's leading manufacturer of chemical products for the foundry industry, announces the acquisition of the majority stake in Centre West Foundry Supplies Sdn. Bhd. From 4 January 2021, the company becomes part of the global network of the HA Group as HA ASEAN Sdn. Bhd. Centre West Foundry Supplies had previously been HA’s long-term distribution partner in Malaysia since 2014. Ken CHEW Kean Woei, Centre West’s previous managing director, remains a strong minority shareholder and becomes CEO of the new company HA ASEAN. "After many years of successful partnership with HA in Malaysia and Singapore, I am now looking forward to becoming part of the HA Group and supporting our customers and partners in all of ASEAN with high-quality products and competent service," says Chew Kean Woei. In the future, the Hüttenes-Albertus Group (HA Group) will drive the development of its business in Southeast Asia

全球领先的铸造化学品生产商欧区爱(HA)宣布收 购Center West 铸造品公司的多数股权。从2021年1月 4日起,Center West公司以欧区爱东盟公司的身份加 入欧区爱集团的全球网络。 自2014年以来,Center West公司一直是欧区爱在 马来西亚的长期经销合作伙伴。Center West的前董事 总经理Ken CHEW Kean Woei仍然是少数股东,并成 为新公司欧区爱东盟公司的首席执行官。 “我们已经与欧区爱公司在马来西亚和新加坡市场 建立了多年成功的合作关系,现在公司期待成为欧区 爱集团的一员,并以高质量的产品和优质的服务为整 个东盟的客户和合作伙伴提供支持。” 将来,欧区爱集团将以吉隆坡为基点推动其东南亚

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INDUSTRY NEWS/行业新闻 from Kuala Lumpur. The distribution partners AB Thai Foundry Supplies Co, Ltd., PT Haltraco Sarana Mulia and Mahachem Sdn. Bhd. will continue to operate as HA's local partners in Thailand, Indonesia and Northern Malaysia, respectively. “With the foundation of HA ASEAN, the HA Group is taking an vital strategic step to expand its activities in the important Southeast Asian growth market. Many years of successful cooperation have shown that Centre West is the right partner for the fast-growing Southeast Asian foundry market” concludes Bernhard Müller, Regional Vice President Asia & Pacific. ■

业务的发展。经销合作伙伴AB泰国铸造品公司、霍尔特 拉科·萨拉纳·穆里亚公司和Mahachem公司将继续分别 作为欧区爱在泰国、印度尼西亚和马来西亚北部的本地 合作伙伴。 欧区爱亚太地区副总裁伯恩哈德•穆勒总结说:“在欧 区爱东盟公司的基础上,欧区爱集团正在采取重要的战略 步骤,以扩大其在不断增长的重要的东南亚市场业务。多 年的成功合作表明,Center West是快速发展的东南亚铸 造市场正确的合作伙伴。” ■

Omega - Happy Customers, Successful Foundry Projects OMEGA公司为客户提供成功的项目 Despite the challenges of the pandemic, AIA Engineering based in Ahmedabad/Gujarat in India continues with their latest expansion and greenfield site development of a new foundry. A “Pooja” ceremony was held after the Omega Sinto shakeout was placed in position. Once complete the foundry will consist of a fully integrated box-less moulding line, capable of producing 4 moulds per hour with a maximum size of 3.2m long x 1.8m wide and 1.8m high. Included in the project will be automated pouring cooling lines, shakeout, mechanical reclamation, chromite separation and thermal reclamtion. The new foundry, producing 30,000 tons per year, is expected to be operational by mid-2021, congratulations to all involved at AIA Engineering. ISO 45001 - We are proud of our latest achievement! For organisations that are serious about improving employee safety, reducing workplace risks and creating better, safer working conditions, there’s ISO 45001. According to the International Labour Organisation, more than 7 600 people die from work-related accidents or diseases every single day. That’s why an ISO committee of occupational health & safety experts set to work to develop an International Standard with the potential to save almost three million lives each year. Omega Sinto Foundry Machinery has succesfully secured this acreditation! Health & safety is of paramount importance to our company and we take the safety of our empoyees very seriously. Our commitment and dedication to secure a safe environment has been acknowledged with ISO 40051. ■

尽管面对新冠疫情大流行的影响,但总部位于印度古 吉拉特邦艾哈迈达巴德的AIA Engineering公司仍在进 行继续扩建和新建铸造厂。在Omega Sinto的落砂设备 就位后,举行了“Pooja”仪式。铸造厂建成后,该项 目包括完全集成每小时可生产最大尺寸为3.2m(长) x1.8m(宽)x1.8m(高)的4个铸型的无箱造型线、 自动浇注冷却线、落砂设备、机械回收设备、铬铁矿分 离和热回收设备。每年铸件产量为30,000吨,预计将在 2021年中期投产。 ISO 45001-为我们的最新成就感到自豪! 对于那些认真考虑提高员工安全性,降低工作场所 风险并创造更好、更安全的工作条件的企业,可以应用 ISO 45001。 根据国际劳工组织的统计,每天有7600多人死于与工作有 关的事故或疾病。因此,ISO职业健康与安全专家委员会着 手制定了一项国际标准,有望每年挽救近300万人的生命。 Omega Sinto铸造机械公司已成功获得了认可。员工 的健康与安全对公司至关重要,我们非常重视员工的安 全。公司对确保安全生产环境的承诺和努力已通过ISO 40051认证。 ■

Morikawa Targets 40% Scrap Reduction: Japanese Foundry Chooses Disa’s Monitizer® For Ai-Driven Process Enhancement 森川公司的目标是减少40%的废品:日本铸造企业选择迪砂 MONITIZER®来实现AI驱动的工艺提升 A longstanding DISA customer, Morikawa has relied on high-speed, vertical DISAMATIC® moulding machines since 1979. The foundry now expects DISA’s state-of-the-art Industry 4.0 tools to provide significant competitive advantage and transform it into a digital leader. “Operating the Monitizer solutions will improve our productivity and quality, and that will increase 30

森川公司是迪砂公司的长期客户,自1979年以来就一 直使用高速垂直DISAMATIC®造型机。森川公司现在希 望迪砂最新的工业4.0技术能够提供显著的竞争优势,并 使其转型成为数字化领导者。 森川公司总裁兼首席执行官森川润一(Junichi Morikawa)说:“使用Monitizer解决方案将提高

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INDUSTRY NEWS/行业新闻 the profitability of our business,” says President & CEO Junichi Morikawa. “DISA presented a case study of a DISAMATIC user who is operating Monitizer|PRESCRIBE successfully, By using AI, they expect us to see a reduction of more than 40% in the cost of defective castings.”

我们的生产率和产品质量,这将提升我们的盈利

Boosting performance – and the bottom line

提升性能——底线

Morikawa produces small iron and steel automotive components such as hub carriers and bearing housings. Green sand moulding with complex cores lies at the heart of its casting process. “Digital tools are useful for collecting and analysing manufacturing parameters and process data to improve production efficiency and produce high quality castings,” explains Mr Morikawa.“AI will help us find the optimal manufacturing conditions for each individual casting and we will use it as a quality improvement tool to reduce defective casting costs.” “More consistent quality will ensure stable delivery times and greater trust from customers,” continues the CEO. “With greater profitability and customer trust, we can expect to increase our sales further by becoming more competitive in both price and quality.” “We’re very excited to welcome Morikawa as our first Japanese customer for the Monitizer Suite. Worldwide adoption of Monitizer is rising fast and that’s partly because we can demonstrate proven, realworld examples of scrap reduction with our AI system. Monitizer is quick and straightforward to deploy and we support the customer throughout their entire digital journey, right from the start."

Collect process data and put it to work Monitizer’s modular approach lets foundries start by collecting data, then move quickly to more sophisticated digital applications – gaining value at each step. By implementing the full Monitizer suite, Morikawa will be able to switch quickly from manual, paperbased processes to digital data collection, visualisation and analysis. The first step in the project will be to upgrade the foundry’s existing installation of DISA’s Monitizer | CIM, which handles tasks like recipe management, process overview and performance reporting, to the latest version. CIM will collect, timestamp, and centrally store data from Morikawa’s DISA equipment, and enable machine-to-machine communication that allows sub-processes like moulding and pouring to be automated and synchronised. “Monitizer|CIM ensures the proper operation of the DISAMATIC moulding line and its ancillary functions by synchronising each other precisely,” notes Mr Morikawa. “We regard it as an infrastructure tool to get the best performance from our DISA equipment such as the Automatic Pattern Changer, Shuttle Conveyor and DISACOOL cooling drum, in addition to our DISAMATIC moulding machines. All in all,

能力。迪砂展示了一个DISAMATIC用户成功运行 Monitizer|PRESCRIBE的案例,该用户通过使用AI技 术预计能够将缺陷铸件减少40%以上。”

森川公司生产较小尺寸的铸铁、铸钢的汽车零部 件,例如轮毂支架和轴承座。使用具有复杂砂芯的湿 砂造型是其铸造工艺的核心。森川先生解释说:“数 字化手段可用于收集和分析制造参数和工艺数据,以 提高生产效率并生产高质量的铸件。AI将帮助我们为 每个铸件找到最佳的制造条件,并将其作为质量改进 的手段,从而减少次品。” 首席执行官继续说道:“更一致的产品质量将确保 稳定的交货时间和客户更大的信任。凭借更高的盈利 能力和客户信任度,我们期望在价格和质量上更具竞 争力来进一步提高销售量。” “我们非常高兴森川公司成为Monitizer Suite的 第一个日本客户。Monitizer在全球范围内的使用正 在迅速增加,部分原因是我们可以使用AI系统演示经 过实践检验的减少废品的案例。Monitizer的应用迅 速而直接,我们从一开始就在客户的整个数字化过程 中为其提供支持。”

收集过程数据并将其用于工作 Monitizer的模块化方法使铸造厂可以从收集数据 开始,然后迅速转移到更复杂的数字应用程序中,并 且在每个步骤中获得价值。通过应用完整的Monitizer 套件,森川公司能够快速地从纸面的手动过程转换为 数字化的数据收集、可视化操作和分析。 该项目的第一步是升级铸造厂现有的迪砂 Monitizer|CIM,安装后,CIM可处理最新版本的任 务,例如配方管理、过程概述和性能报告。CIM将从 森川公司的迪砂设备收集、标记时间戳并集中存储数 据,实现机器对机器的通信,从而使造型和浇注等过 程实现自动化和同步。 “Monitizer|CIM通过精确同步来确保DISAMATIC 造型线的正常运行及其辅助功能。”森川先生指 出,“除了我们的DISAMATIC造型机外,我们将迪 砂设备视为一种基础设施工具并从中获得最佳性能, 例如自动模板更换器、穿梭输送机和DISACOOL冷却

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INDUSTRY NEWS/行业新闻 we consider Monitizer|CIM to be essential to operate efficiently.”

Connect any foundry equipment with Monitizer|GLOBAL Deploying Monitizer|GLOBAL will be the next step, digitally connecting the complete casting process, from melting and sand mixing to inoculation and quality control. GLOBAL’s cloud infrastructure centralises all data, making it easily available, offering a complete real-time digital picture of the whole process and supporting remote monitoring and alerting across both Morikawa’s lines. With universally compatible Norigate IIoT gateways, Monitizer|GLOBAL can acquire data from any foundry equipment or sensor. It then presents live data in easy-to-understand, userspecific browser-based dashboards with customised KPIs that speed up fault-finding and make performance reporting instantly accessible. “With GLOBAL, what's happening on the manufacturing floor becomes digitally visible,” explains the CEO. “This insight will enable us to improve productivity by identifying operational issues and solving them. We look forward to enjoying the advantage of matching DISAMATIC and the rest of the equipment with Monitizer|GLOBAL for comprehensive visualisation of the entire manufacturing process.”

AI optimises your process – in real time With a real-time digital view of all its key equipment and sub-processes, Morikawa can then start to optimise its whole process with Monitizer|PRESCRIBE’s AI-driven predictive modelling. During live production, PRESCRIBE’s Expert Execution System (EES) supports dynamic, real-time optimisation by predicting the correct machine settings for every pattern before defects occur – not after. “Experience and intuition alone can no longer provide the quality improvements we need to eliminate casting defects,” says Mr Morikawa. “The casting industry has a wide range of machines and processes, and it is difficult to monitor and control each process in an integrated manner. By using AI technology to analyse the huge amounts of complex, intertwined data without human intervention and deriving "prescriptions" from that analysis, we believe that quality can be improved further, and that defect costs can be significantly reduced. We cannot wait to get the Monitizer solutions installed and benefit from them.” ■

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鼓)。总之,我们认为Monitizer|CIM对于高效运营 至关重要。”

使用Monitizer|GLOBAL连接任何铸造设备 下一步将使用Monitizer|GLOBAL,以数字化方式 连接从熔化、混砂、孕育到质量控制的整个铸造过 程。Monitizer|GLOBAL的云基础设施集中了所有数 据,使其易于使用,提供了整个过程的完整实时图片, 并支持森川公司两条生产线的远程监控和警报。通过通 用兼容的Norigate IIoT网关,Monitizer|GLOBAL可以 从任何铸造设备或传感器获取数据。然后,它使用自定 义的KPI在易于理解的、用户定制的基于浏览器的仪表 板中显示实时数据,这些KPI可以加快故障查找速度并 即时查看性能报告。 首席执行官解释说:“有了GLOBAL,生产现场 发生的实时情况就变得数字化可见。这种具有远见的 技术将使我们能够通过识别和解决运营问题来提高 生产力。我们期待获得将DISAMATIC及其它设备与 Monitizer|GLOBAL相连接匹配的优势,从而使整个 生产过程实现全面可视化。”

AI技术实时优化您的工艺流程 通过其所有关键设备和子过程的实时数字视图, 森川公司随后可以开始使用Monitizer|PRESCRIBE 的AI驱动预测造型来优化整个过程。在现场生产期 间,PRESCRIBE的专家执行系统(EES)通过在出现 缺陷之前而不是之后预测每种模型的正确机器设置, 来支持动态实时的优化。 森川先生说:“仅凭经验和直觉已不再可以为消除 铸件缺陷提供所需的质量改进。铸造行业拥有广泛的 设备和工艺,很难以集成的方式监视和控制每个过程。 通过使用AI技术无需人工干预即可分析大量复杂且交织 的数据,并从该分析中得出方案,我们相信可以进一步 提高质量,并且可以显著降低缺陷成本。我们迫不及待 想要安装Monitizer并从中受益。” ■

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The Impact of COVID-19 and the Trend of Indonesian Foundry Industry Mr. Gao Wei: Secretary General of Asia Foundry Association, Deputy President of China Foundry Association Mr. A.Safiun: President of Indonesian Foundry Industries Association (APLINDO)

印尼铸造业发展现状及趋势 高巍:亚洲铸造业联合会秘书长,中国铸造协会专务 A.Safiun:印度尼西亚铸造工业协会会长

I

ndonesian Foundry Industries Association (APLINDO), established on December 9, 1981, is an organization that is used as a tool of struggle to create a healthy industrial climate in Indonesia, striving for the industry to grow and develop towards self-reliance, producing arts that can compete strongly in the global market. • In February 1984, the association became a member of

度尼西亚铸造工业协会(APLINDO)成立 于1981年12月9日,旨在为印尼创造健康的 铸造工业环境,致力于铸造业的发展并使之

变得强大且高效,从而使其产品具有全球竞争力。

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GAMMA (Federation of Associations of Indonesian Metalworks and Machinery Industries). • In January 1998, it joined the Indonesian Chamber of Commerce and Industry. • In September 2019, it became a member of Asia Foundry Association. Currently APLINDO consists of 49 companies, i.e. 20 ferrous casting, five investment casting, 10 nonferrous casting, three lead recycling, three alloy aluminum, and eight foundry material and equipment companies.

• 1984年2月,加入印尼金属加工和机械工业协会

Vision

材料及设备企业。

The assoication’s vision is to place the Indonesian foundry – a strategic up-stream industry – in a strong and firm position and to become the foundation for developing machinery and metal industry, so that it will be able to help accelerate the national economic growth.

Mission The mission is to assemble companies which are working on foundry and those involved with foundry. To strengthen relationship, to initiate cooperation and to harmonize common steps among foundry industries. To realize a self- supporting machinery and foundry industry. To apply valuable and appropriate technology, so that the products are able to compete on the global market. Mr. Gao Wei: How was the industry influenced by the pandemic in 2020, what has happened to the foundry industry? Mr. A.Safiun: The emergence of the COVID-19 outbreak that spread throughout the world, including

联合会(GAMMA)。 • 1998年1月,加入印度尼西亚工商会。 • 2019年9月,加入亚洲铸造业联合会。 目前,印度尼西亚铸造工业协会(APLINDO) 有49个会员企业,其中,有20家黑色金属铸造企 业、5家精密铸造企业、10家有色金属铸造企业(铝 合金)、3家铅回收企业、3家铝合金企业和8家铸造

远景目标 使印尼铸造业(战略性的上游产业)的地位强大 且牢固,使之发展成为机械和金属工业的基础,进 而有助于加速国民经济的增长。

使命 汇集从事铸造及其相关行业的企业。加强与铸造 业企业的联系,提出合作倡议并协调发展步伐。实 现机械和铸造行业的自给自足。应用有价值的适用 技术,使铸造产品能够在全球市场上具有竞争力。 高巍:2020年的新冠疫情对印尼铸造行业有怎样 的影响? A.Safiun:新冠疫情在全世界大流行,对印度尼 西亚及其铸造业的发展也产生了深远的影响。

Table 1. Industrial Production of APLINDO Members. APLINDO成员铸件产量 Production (MT/year) No

Description

2018

2019

2020

1

Gray Iron casting 灰铸铁

155.726

147.331

77.783

2

Ductile Iron casting 球墨铸铁

86.568

85.104

42.060

3

Malleable Iron casting 可锻铸铁

179.436

75.848

86.940

4

Steel casting 铸钢件

22.360

32.128

25.664

5

Aluminum Casting 铝合金铸件 Investment Casting 精密铸件

80.484

91.332

46.08

6.078

6.120

3.060

Lead Recycle Industries 铅回收工业 Alloy Aluminum Industries 铝合金工业

64.800

56.400

25.600

273.000

73.000

36.500

36.000

36.000

18.000

6 7 8 9

Recycle Foundry Sand 铸造砂回收

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in Indonesia, had a profound impact on the growth and development of the foundry industry. In 2020, when Indonesia was hit by the Covid-19 pandemic, the foundry industry worked around 30-50% of its production capacity. The Indonesian government has implemented social distancing to the industry to continue operating with a workforce limitation of up to 50%. The casting industry production of APLINDO members in 2019 for iron casting (ductile, gray) amounted to 232,435 tons, down 48.4% in 2020 to 119,843 tons, as well as for steel casting and aluminum casting (Table 1). Mr. Gao Wei: What activities will be held during 2021? Mr. A.Safiun: a. Host an international Exhibition: • International Metal Technology Indonesia Online Preview, 24-25 March 2021 • International Metal Technology Indonesia Offline Preview, 13-15 October 2021 b. Webinars c. Training Program d. Board Meeting Mr. Gao Wei: What are the development trends and features of the foundry industry of your country? Mr. A.Safiun: Various economic indicators show opportunities for economic recovery in Indonesia. To maintain this, the government has issued various policies for economic recovery, among others: a. Providing PPnBM Relaxation Incentives for Motor Vehicles (KB), as well as for the Property sector in the form of Government Borne VAT (DTP) for Landed Houses and Flats. b. Providing income tax (PPh) 21 incentives for individuals until June 2021. This policy is felt to have a positive impact on the growth of the metal casting industry in Indonesia which is engaged in the automotive sector and the infrastructure development that the government continues to promote. In addition, with the issuance of the Job Creation Law No.11 of 2020 and Government Regulation No.22 of 2021 concerning the implementation of environmental protection and management which removes foundry sand from the list of hazardous and toxic waste (B3), it has a positive impact on the development and growth of the industry. foundry in Indonesia. ■

2020年,受新冠疫情的冲击,印度尼西亚铸造行 业的实际产能达到30%-50%。印尼政府实施了社交 隔离政策,企业员工错峰上班,到岗率不超过50%。 下表所示为近几年印尼铸造协会(APLINDO)成 员所生产的各种材质铸件产量。其中2019年的铸铁 件(包括球墨铸铁和灰铸铁)为232,435吨,2020年 的产量为119,843吨,下降48.4%。 高巍:2021年,印尼铸造业将举办哪些活动? A.Safiun: a.举办国际展览会: • 2021年3月24日至25日,印度尼西亚国际金属技 术展览会(虚拟展) • 2021年10月13日至15日,印度尼西亚国际金属技 术展览会(线下展) b.网络研讨会 c.培训活动 d.董事会会议 高巍:印尼铸造行业的发展趋势及特点? A.Safiun:各项经济指标显示出印尼经济复苏的 迹象。为此,政府发布了一系列经济复苏政策,其中 包括a. 推出机动车奢侈品消费税(PPnBM)免税激 励措施;在房地产行业,为带有土地房屋和公寓实施 政府负担增值税政策;b.在2021年6月之前为个人提 供所得税(PPh)方面的21项激励措施。 据悉,这项政策将对印度尼西亚的金属铸造业,尤 其是政府持续推动的汽车业和基础设施业的增长产生 积极影响。 此外,随着2020年创造就业法的第11条和2021年 关于环保和管理的法规中将铸造砂从危险和有毒废物 (B3)清单中删除的实施,这些政策将对印尼铸造行 业的发展产生积极影响。■

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Fuji Electric invites you to participate in METAL CHINA 2021 and exchange environmental protection technologies mr. gao wei: secretary general of asia foundry association deputy president of china foundry association

ms. du hui, general manager, systems sales division, power electronics systems sales headquarters, fuji electric (china) co., ltd.

富士电机邀您参加第十九届铸博会 交 流环保新技术 高巍:亚洲铸造业联合会秘书长、中国铸造协会专务 杜晖:富士电机(中国)有限公司系统营业统括部统括部长

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ince its foundation in 1923, Fuji Electric has continued to innovate energy and environmental technologies, which have been widely used in the industrial infrastructure to support the economic and social sustainable development. In the history of nearly one hundred years, Fuji Electric has designed and produced nearly 400,000 different products, making great contributions to energy conservation and environmental protection. It is mainly divided into four major business sectors: power electronics systems, semiconductors, power generation, food and beverage distribution. Each business sector has its own representative products. For example, the intermediate frequency furnace belongs to the power electronics system business sector, and the IGBT semiconductor belongs to the electronic component sector. In order to provide customers with a better experience and provide reliable guarantees, Fuji Electric is committed to establishing production bases in China. Responding to customer’s requirements in the first time ensures the customer’s needs. Fuji Electric (Zhuhai) Co., Ltd. is the production base of intermediate frequency furnaces, providing strong support for the domestic and Southeast Asian market. Mr. Gao Wei: What is the impact of the pandemic on Japanese foundry industry? Ms. DU Hui: The unexpected Covid19 has had a great impact on the production and life of people all over the world, including China and Japan. Regarding the impact on the Japanese foundry market, 1) According to the statistics of Japan Foundry Association, as of May 2020, the production capacity of the Japanese 38

1923年成立以来,富士电机集团不断创新 能源与环境技术,广泛应用于产业基础设 施建设,助力经济社会可持续发展。近百

年的历史中,富士电机共设计和生产了近40万种不同产 品,在节能和环保活动中做出了巨大贡献。主要分为四 大事业板块:电力电子系统、电子元件、发电与食品流 通。各个事业板块都有各自的代表产品。如中频感应电 炉属于电力电子系统事业板块,IGBT半导体属于电子元 件板块。 为给客户带来更好的体验,提供可靠保障,富士电 机集团致力于在中国各地建立生产基地。对客户的要 求第一时间进行响应,保障了客户的需求。富士电机 (珠海)有限公司是中频炉的生产基地,为面向中国 国内及东南亚中频炉市场提供了强有力的支持。 高巍:2020年的疫情对日本铸造市场产生了怎样的 影响? 杜晖:2020年突如其来的疫情对包括 中国、日本在内的全世界人民的生产生 活都造成了很大的影响。其中关于对日 本铸造市场的影响,1)根据日本铸造协 会的统计数据,截止到2020年05月,日 本铸造行业产能几乎减半;其后,逐步恢 复产能,从2020全年度数据来看,相对

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foundry industry has almost halved; since then, the production capacity has been gradually restored. From the data of 2020, compared with 2019, the output of cast iron, cast steel, copper alloy and cast aluminum decreased by 18.1%, 15.8%, 18.2% and 22.7% respectively. From the industry perspective, the automotive industry was hit harder in the beginning of the pandemic, and it is currently recovering; in shipbuilding and machine tool industries, the global sluggish demand caused by the pandemic is still continuing. 2) Japanese foundry companies, mainly private companies and mostly century-old companies, are actively transforming and adjusting their product lines, relatively speaking, they can withstand various tests (including pandemic, financial crisis, etc.). 3) Fuji Electric, as a foundry equipment manufacturer, performed basically the same as 2019 in terms of orders for intermediate frequency furnaces in the Japanese market, and overall it is relatively stable. What is more affected is that some new projects that were scheduled to be launched in the first half of 2020 have been slightly delayed, and the delayed projects have been restarted in the second half of 2020. It can be seen that the Japanese foundry market is basically similar to the domestic foundry market in China. The industry was greatly impacted in the first half and recovered, stabilized in the second half of 2020. The order trend is consistent with the production capacity of the entire Japanese foundry industry.

于2019年度,铸铁减产18.1%、铸钢减产15.8%,

Mr. Gao Wei: What important measures or development strategies will your company take in 2021 or in recent years?

年的综合机电类厂家,拥有438,690种产品之多;

Ms. DU Hui: Fuji Electric Co., Ltd. is a comprehensive electromechanical manufacturer established in 1923, with 438,690 products. Among them, the power semiconductor IGBT, which has affected the nerves of the world in recent years, is the core device of industrial transformation, energy conservation and environmental protection, even more, it is ranked top three in the world. First, we will strengthen marketing. As we all know, Fuji Electric is one of the few companies in the medium frequency induction heating furnace industry that uses IGBT power supplies. In 2021, we will increase the market promotion of IGBT power supply technology, so that the majority of foundry companies can fully understand and accept this technology. At present, the mainstream SCR technology on the market is a product that appeared in 1960. Industrial control products such as high-speed rail, wind power, new energy vehicles, and inverters have basically been replaced by IGBT. The introduction of new technologies in the foundry industry is also an imperative trend. In terms of the form of marketing, we will adopt communication and interaction both virtually and physically. Second, we will strengthen cooperation with foundry associations. By cooperating with China Foundry Association, we can have a deeper understanding of the 40

铜合金减产18.2%、铸铝减产22.7%。从行业的角 度来讲,汽车行业在疫情初期受到冲击比较大, 目前已在恢复中;造船和机床等行业,受疫情影响 导致的全世界需求不振还在持续中。2)日本铸造 企业,以私企为主、百年企业居多,在疫情期间积 极转型、调整产品线等,相对来说经得起各种考验 (包括:疫情、金融危机等)。3)富士电机作为 一家铸造设备生产企业,从日本市场中频炉订单来 看,基本与2019年持平,总体上来说还是比较稳 定的。受影响较大的是原定前半年启动的一些新建 项目发生了小幅度延期,延期项目后半年也都陆续 启动了,可以看到日本铸造市场基本和中国国内铸 造市场情况差不多,前半年受较大影响,后半年有 所恢复,回稳。订单趋势基本和整个日本铸造行业 的产能情况匹配。 高巍:2021年或者最近几年贵司有哪些重要举 措,或者发展战略? 杜晖:富士电机株式会社,是一家成立于1923 其中,近几年牵动全世界神经的,作为产业转型、 节能环保的核心器件—功率半导体IGBT,更是排名 世界前三。 首先,是加强市场宣传。众所周知,富士电机是 一家在中频感应加热电炉业内为数不多的使用IGBT 电源的企业。在2021年中,我们要加大IGBT电源 技术的市场宣传及推广,使广大铸造企业能够充分 了解并接受这个技术。目前市场上主流的可控硅技 术已经是1960年出现的产物,在如高铁,风电, 新能源汽车,变频器等工控产品,现在基本上都已 经被IGBT所取代。铸造行业的新技术导入,也是一 个必行的趋势。宣传形式上来说我们会以线下交流 学习,线上交流互动等多种模式结合。 其次,是加强与各铸造协会的合作。通过与铸 造协会合作,我们能更深客的了解中国及各地区铸 造企业的具体发展方针,更全面的了解铸造企业的 需求,今后的发展中,我司会进一步保持与铸造协 会的沟通,更精准的为各地区铸造企业提供优质服 务。

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specific development policies and comprehensive needs of Chinese foundry industry and companies. In the future, the company will further maintain communication with China Foundry Association and provide more precise and high-quality services for foundry enterprises in various regions. Finally, we will continue to improve the level of aftersales service. In recent years, our intermediate frequency furnace sales have made great progress in the Chinese market. With the expansion of the market and the increase in the number of customers, the building of a timely and reliable after-sale team has become more and more important. At present, the technical service of Fuji intermediate frequency furnace has been adjusted from the previous single factory response method to a national after-sales service network covering a total of 15 sales networks and offices, which can provide customers with timely and reliable after-sale service and on-site support. Mr. Gao Wei: How does your company contribute to the energy saving and environmental protection cause of Chinese foundry industry? Ms. DU Hui: The energy conservation and environmental protection of Japanese technology is at the leading level in various industries. Environment protection is one of the development concepts of Fuji Electric. The company is not only an intermediate frequency furnace company, is also a company that can manufacture small products such as semiconductor components and also power station equipment. Therefore, relying on our company’s core device technology and rich software and hardware application experience, we can provide foundry companies with a full range of energy-saving and environmental protection solutions and help them to carry out transformation. Secondly, as for the medium frequency induction furnace, Fuji Electric adopts advanced IGBT technology and unique coil design, which can contribute to the environmental protection of foundry enterprises in terms of energy saving, electricity saving and improving the service life of the furnace lining.

最后,是提高售后服务水平。近几年我司中频 炉在中国市场销售取得了长足进步,随着市场的扩 大,客户数量的提升,及时可靠的售后及技术队伍 的建立越来越重要。目前,富士中频炉技术服务从 以前的单一工厂应对方式,调整为充分利用富士电 机(中国)有限公司各营业网点及事务所为基础的 总计涵盖15个网点的全国性售后服务网络。为客户 提供及时,可靠的售后服务及现场支持。 高巍:贵司如何助力中国铸造业的节能环保事 业? 杜晖:日本技术在各个行业中,节能和环保都是 处于领先水平的,对于环境的保护是富士电机集团 的发展理念之一。富士电机不仅仅是一家中频炉企 业,我们公司是一家小到半导体元器件,大到发电 站设备都可以制造的企业。因此,依托我司的核心 器件技术、丰富的软硬件应用经验,可以为铸造企 业提供全方位的节能环保改造方案,助力环保企业 进行节能环保改造。 其次,富士电机从中频感应电炉的产品来说,富 士采用先进的IGBT技术,特有的线圈设计,无论从 节能省电,还是提高炉衬使用寿命,都可以为铸造 企业环保做出贡献。 高巍:贵司参加2021年铸博会(METAL CHINA)的主要展品介绍 杜晖:我司对铸博会一直是非常重视的,几乎历 届铸博会大家都可以看到富士电机的身影。本次我 们的主要展出技术,除中频感应电炉以外,还囊括

Mr. Gao Wei: Introduction of your company’s main exhibits at METAL CHINA 2021

了IH感应加热、IOT远程监控技术,以及IGBT、变

Ms. DU Hui: Our company has always attached great importance to METAL CHINA, and we have participated in almost every session. In 2021, except for medium frequency induction furnace, we will also display IH induction heating, IOT remote monitoring technology, as well as IGBT, inverter, servo, flowmeter and other core components, and bring more experience to customers. We are sincerely welcoming you to visit our booth which is located at 3C11 at METAL CHINA 2021. ■

展出,争取给客户带来更多的体验。

频器、伺服、流量计等核心器件,届时也会有实物 我司2021年铸博会(METAL CHINA)的展位 号:3C11,诚挚邀请大家拨冗莅临观摩指导。 ■

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Working Together to Solve Today’s Foundry Industry Challenges Following strategic realignment, Imerys and its subsidiary Calderys are joining their expertise in the foundry industry under a One Stop Shop offering, from refractory to moulding sand. mike yang, kun xu

共同解决当今铸造业的挑战 经过战略调整后,益瑞石集团(Imerys)及其子公司凯得力(Calderys)将其专 业技术结合起来,为铸造行业提供从耐火材料到型砂的一站式服务。 作者:Mike Yang, Kun Xu

C

hina continues to dominate global casting production in terms of volume. The challenges facing the country’s metal casting industry, however, remain common to foundries around the world: how to safely ensure the highest quality of casting with the lowest cost and environmental impact. This is particularly true as demand for high-end and more complex castings increase – for example, with the rapid expansion of the Chinese automobile industry. At the same time, the need for the foundry industry to reduce its environmental footprint through greater energy and resource efficiency will only increase under the 14th Five Year Plan (FYP). Under the plan, China’s energy consumption per unit of GDP will fall by 13.5% and carbon dioxide (CO2) emissions per unit of GDP will fall by 18% between 2021 and 2025, as the country aims to meet targets to peak CO2 emissions by 2030 and achieve carbon neutrality by 2060. Of course, these challenges are not new. The 13th Five Year Strategic Plan for the Chinese Foundry Industry included targets on quality and energy consumption. Meanwhile, both the need for quality and sustainability must continue to be balanced with the need to control costs and remain competitive in a crowded marketplace. The demands placed on Chinese foundrymen and women are therefore complex and require state-of-theart solutions from the suppliers that serve the industry. There is also no one-size-fits-all approach: each foundry is unique and will require solutions that can be tailored to its specific business and application requirements. Imerys and its subsidiary Calderys offer a one-stop shop to foundries for their refractory and moulding sand needs, combining refractory and bentonite production facilities, alongside a global network of expertise. In doing so, the company supports foundries in tackling the challenges ahead safely and cost-effectively, while also reducing the impact on the environment. Calderys and Imerys Innovation teams are continuously working on developing new generations of solutions to better serve foundries, from new product formulations to digital services. 42

铸件产量而言,中国继续在全球占领先地 位。但是,中国金属铸造行业所面临全球共 同的挑战,即如何以最低成本和最少污染生

产最高品质的铸件。尤其是随着中国汽车工业的迅速发 展,对高端和更复杂铸件的需求增加。 同时,在“十四五”时期,对铸造行业通过提高能源 和资源效率来减少环境污染的要求会继续提高。 根据“十四五规划”,中国将在2030年实现二氧化 碳排放达标,到2060年实现碳中和。因此,在20212025年,中国单位GDP的能源消耗将下降13.5%,二 氧化碳排放量将下降18%。 当然,这些挑战并不是最新出现的。中国铸造业的“ 十三五规划”包括质量和能耗目标。同时,对质量和可 持续性的需求必须与控制成本的需求保持平衡,并在激 烈的市场中保持竞争力。 因此,中国铸造业所肩负的责任是非常复杂的,要求 为铸造行业服务的供应商提供最新的解决方案。也没有 千篇一律的方法:每个铸造厂都有其特殊性,需要可量 身定制的解决方案来满足其特定的业务和应用要求。 益瑞石集团(Imerys)及其子公司凯得力(Calderys)通过结合耐火材料和膨润土生产设施以及全球网 络,为铸造企业提供了一站式服务,以满足其耐火材料 和型砂的需求。因此,该公司可以支持铸造企业安全且 经济地应对未来的挑战,同时减少对环境的影响。 从新产品生产到数字化服务,Calderys和Imerys的创新团队 一直在努力开发新一代解决方案,以更好地服务于铸造企业。

铸造耐火材料的全球领导者 凯得力(Calderys)的经验和知识可以追溯到1908 年,当时发明了第一批具有耐火性能的铝酸盐水泥,这 是现代不定型耐火材料的前身。自2008年以来,该公司 在中国江苏张家港工厂生产耐火材料,并于2012年通过

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More than a hundred years of foundry experience 拥有一百多年的铸造经验 • 1934: S&B bentonite activities begin

1934年:S&B的膨润土业务启动。

• 1974: Imetal is born. It became Imerys in 1999. The company focuses on mineral-based specialties.

1974年:Imetal公司成立,于1999年更名为益瑞石(Imerys)。该公司专注于矿物类的特色产品。

• 2005: Calderys is born from the merger of Plibrico International and Lafarge Refractories. 2005年:派力固欧洲国际和拉法基耐火材料公司合并成立凯得力公司 。

• Under the Imerys Group, it is a global provider for refractory solutions.

在益瑞石集团(Imerys),它是耐火材料解决方案的全球供应商。

• 2013: S&B acquires a 50% stake in Chaoyang GoldCommon Mining Co Ltd, a leading bentonite producer in China. 2013年:S&B收购了中国领先的膨润土生产商朝阳永同昌矿业有限公司50%的股份。

• 2015: Imerys Group acquires S&B and the IKO brand becomes Imerys Metalcasting Solutions. 2015年:益瑞石集团收购S&B,IKO品牌成为益瑞石铸造解决方案。 • The Group operates under Calderys for refractory products and services, and Imerys for bentonite solutions, providing foundries with a complete portfolio of solutions. 凯得力公司隶属于该集团,从事耐火材料产品生产和服务。同时,益瑞石集团从事膨润土解决方案的运营, 为铸造厂提供完整的解决方案组合。

A Global Leader in Foundry Refractories Calderys’ experience and knowledge go back to the invention of the first aluminous cement with refractory qualities in 1908, the precursor to modern monolithic refractories. Since 2008, the company has produced refractories in China at the Zhangjiagang Plant in Jiangsu, becoming ISO 9001 certified in 2012 and ISO 14001 certified in 2013. The site now employs 93 people and produces 30,000 tonnes annually, supplying about 500 customers.

A Complete Control Over Our Silica-based Refractories A key element within Calderys offering is the SILICA MIX range of silica-based refractories for coreless induction furnaces (CIF) and channel furnace applications. These refractories are produced using our Swedish microcrystalline quartzite. Due to the exceptional conditions of its formation, this unique rock is the highest grade of raw material in the world and provides SILICA MIX products with a range of exceptional qualities. These qualities include excellent thermal stability and resistance to chemical attack, both of which help to increase operating life compared with other furnace refractory solutions, and therefore reduce maintenance costs and downtime. Meanwhile, its low porosity when sintered reduces the risk of coil damage by vapour condensation, by preventing vapour ingress through the lining. The SILICA MIX range is also low density, which helps to lower heat losses and improve the thermal and energy efficiency of the melting process. Compatible with most slags when melting iron, it is also available in a boron-free version for the highest level of health and safety compliance

ISO 9001认证,于2013年通过ISO 14001认证。 该厂现有93名员工,年产量30,000吨,为大约500 个客户提供服务。

全流程控制的二氧化硅基耐火材料 凯得力SILICA MIX系列硅基耐火材料,用于无芯中 频感应炉(CIF)和有芯感应炉。这是使用凯得力自有 的瑞典微晶石英岩生产的。由于其特殊的形成条件,这 种独特的岩石是世界上最高等级的原材料,可为SILICA MIX产品提供一系列卓越的品质。 这些品质包括出色的热稳定性和抗化学侵蚀性,与其 他熔炉耐火材料解决方案相比,这两项都有助于延长使 用寿命,并因此降低了维护成本和停机时间。同时,其 低孔隙率在烧结时可防止蒸气通过衬里进入,从而降低 了因蒸气凝结而损坏线圈的风险。 SILICA MIX系列产品的密度也很低,有助于降低热 量损失并提高熔化过程的热效率和能效。兼容熔化铁水 时的大多数炉渣,也可实现无硼,以达到最高水平的健 康和安全合规性。

适用于铸钢铸铁厂的专用浇注耐火材料 凯得力用于钢铁铸造的全系列耐火材料还包括适用于 所有设备的CALDE®系列浇注耐火材料。 CALDE®系列还包括CALDE®SHIELD炉衬,通过在 烧结过程中形成不渗透层来防止蒸气进入,可确保形成 承受熔体条件所需的陶瓷烧结相。大大提高热面衬里的

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Table 1 Calderys product line for foundries include 凯得力铸造产品线包括 Ladles, cupola, pouring and holding furnaces 钢包、冲天炉、浇注和保温炉

CALDE® CAST and CALDE® FLOW

Cupola and ladles 冲天炉和钢包

CALDE® RAM and CALDE® GUN

Coreless induction furnaces for steel, pouring and holding furnaces and ladles 铸钢用无芯感应炉、浇注、保温炉和钢包

CALDE® MIX

Repairs 维修设备

CALDE® PATCH, CALDE® TROWEL, CALDE® STIX and CALDE® PLAST

A Dry Vibrating Material Solution for Coreless Induction Furnace: 用于无芯感应炉的干式振动材料解决方案 The CALDE® range was the basis for the successful implementation of a dry vibrating material refractory solution for the five-tonne capacity coreless induction pressure pouring furnace at Kehua Holdings in Jiansu, a manufacturer of automobile turbocharger components. CALDE®系列是成功实施干式振动材料耐火材料解决方案,该解决方案是为汽车涡轮增压器组件制造商江苏省 科华控股的5吨容量无芯感应压力浇注炉实施的。 The 550kW furnace processes high-temperature resistant steel with pouring temperatures of 1500°C-1550°C. 550kW的炉子熔炼浇注温度为1500°C-1550°C的耐高温钢。

Calderys designed the refractory solution and supervised installation and sintering, including: 凯得力设计了耐火材料解决方案,并监督安装和烧结,包括: • CALDE® MIX SC 80MD on the upper case •CALDE®MIX SC 80MD上炉体 • CALDE® MIX SC 80MD with 0.5% BO for the top cap •CALDE®MIX SC 80MD上炉体 • CALDE® CAST UB 85 and PB 82 UH for the launder system •CALDE®CAST UB 85和PB 82 UH用于流槽 • TAICAST KN 1600 for the cover. •炉盖为TAICAST KN 1600 The solution successfully provided a lining life of three months. 该解决方案使衬里使用寿命可以达到三个月。

A Dedicated Castables Range for Iron and Steel foundries The CALDE® range also includes the CALDE® SHIELD furnace lining, which ensures the formation of the ceramic bond required to withstand melt conditions by forming an impervious layer during sintering to prevent vapour ingress. This increases the durability of the hot face lining from the first charge, reducing coil damage due to condensate, and improves the reliability and predictability of the lining performance when melting zinc-plated scrap.

Serving the Bentonite Needs of Chinese Foundries Imerys offers bentonite binders for moulding sands via its joint venture employing 120 people and with annual production of 250,000 tonnes. This business supplies about 44

耐用性,减少因冷凝水引起的线圈损坏,并提高熔化镀 锌废料时衬里性能的可靠性和可预测性。 Alkon系列:专为铝铸造厂设计 对于铝铸造厂,专门研发了ALKON®系列整体材 料,以抵抗熔铝对熔炉和其他设备的影响,例如减少刚 玉的形成和机械损伤。该系列涵盖所有类型的熔炉,包 括罐式熔炉和保温炉、双室竖炉熔炼炉。 作为产品线的支持,凯得力的服务还包括设计和工程 服务以及安装监督。

满足中国铸造企业的膨润土需求 益瑞石集团(Imerys)通过其拥有120名员工,年产

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中国 建平 工厂

Jianping Site, China

300 customers in China from the Jianping mine and factory site in Liaoning, which was recently expanded in line with growing sales. Imerys has access to high-grade bentonite reserves with high thermal durability, green compression strength and wet tensile strength. The company’s products offer foundries the opportunity to improve the longevity and reliability of their castings, improving process efficiency, product quality and reducing the scrap rate. This helps improve both energy and resource efficiency. The product can also be flexibly tailored to meet customer requirements and activation can be precisely controlled to make sure it remains stable. Beyond the bentonite itself, Imerys offers a range of services that support foundries to improve their operations, including: • moulding sand analysis and assessments • onsite casting and mould failure analysis • training courses • troubleshooting casting defects With the improvements at the Jianping site, the company is well positioned to supply the increasing demand for its products with increased warehouse capacity and an upgraded dryer. Work on the expansion began in 2019 with the final plan completed in 2021. Expansion of the warehouse was completed in 2020, followed by a doubling of capacity of the dryer and a new milling capacity. Improvements are ongoing with the acquisition of a new mine to secure future resources to supply customers’ needs. “These changes have allowed us to be more productive and efficient, especially with the dryer improvements,” explains Fiona Yang, China Country Leader at Imerys. “This is all important for customer-centricity. We need to be proactive to interact with our customers’ requirements in lead time and stable quality.”

量25万吨的合资企业生产用于型砂的膨润土粘结剂。该 业务通过辽宁建平矿山和工厂为中国约300个客户提供 服务,该工厂最近随着销售的增长在不断扩大规模。 益瑞石集团(Imerys)拥有具有高耐热性、湿压强 度和热湿拉强度的高级膨润土资源。该公司的产品为铸 造厂提供了改善铸件寿命和可靠性、提高工艺效率、产 品质量并降低废品率的可能性,这将有助于提高能源和 资源效率。 该产品还可以为满足客户需求而灵活定制,活化作 用可以通过精确地控制以确保其保持稳定。除了膨润 土,益瑞石还提供一系列服务以支持铸造企业改善其运 营,包括: • 型砂分析和评估 • 铸件和模具现场故障分析 • 培训课程 • 铸件缺陷检测 通过建平工厂的改进,扩充仓库容量和升级烘干 线,该公司可以很好地满足不断增长的产品需求。 扩建工作于2019年开始,计划于2021年完成。仓库 的扩建已于2020年完成,干燥和研磨能力随之增加了 一倍。新矿山的收购工作正在进行中,以确保将来有足 够的资源来满足客户的需求。 “这些变化使我们能够提高生产力和效率,尤其是 在干燥技术方面进行了改进,”益瑞石集团中方负责人 Fiona Yang解释说,“对以客户为中心的公司是非常 重要的,我们需要积极主动地与客户进行沟通,以缩短 交货时间并保持产品的质量稳定。”

Imerys and Calderys at Metal China and Diecasting 2021

益瑞石和凯得力参加Metal China和Diecasting 2021

When it comes to meeting the challenges facing the Chinese foundry industry, high-quality refractory and bentonite products will play an important role, helping foundrymen and women to put the pieces of the sustainability jigsaw together. This means reducing the environmental impact through reduced energy and raw material consumption; improving the health and safety of workers; and supporting the bottom line in a highly competitive marketplace. Imerys and Calderys’ refractory and bentonite products and services are able to do this. By improving the thermal efficiency of the furnace, for example, melt times are reduced

为应对中国铸造业面临的挑战,高质量的耐火材料 和膨润土产品将发挥重要作用,将助力铸造企业实现可 持续发展。这意味着通过减少能源和原材料消耗来减少 对环境的影响,提升员工的健康和安全水平,并在竞争 激烈的市场中继续发展。 益瑞石和凯得力的耐火材料和膨润土产品以及服务 能够满足这些要求。例如,提高熔炉的热效率,可以缩 短熔化时间并减少能量消耗,从而将金属保持在熔融

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and less energy is consumed to keep the metal in a molten state; by increasing the longevity of consumables, maintenance requirements are minimised, both reducing costs and improving worker safety; and by improving the quality of the casts, less is wasted and the demands of China’s high-tech industries can be met by domestically produced parts. These are just three ways that Imerys and Calderys bring the advantages of their global experience and technical knowledge to the foundry sector. Visitors to Metal China & Diecasting 2021 can find out more at booth 1F07. ■

状态。通过延长易损件的使用寿命,将维护要求降至最 低,既降低了成本又提高了员工的安全性;通过提高铸 件质量,可以减少浪费,国产铸件也可以满足中国高科 技产业的需求。 以上是益瑞石和凯得力向铸造行业提供其全球经验和技 术优势的三种方式。获得更多信息,欢迎参观我司在Metal China & Diecasting 2021的展位,展位号1F07。 ■

Reference

1. Wei Gao, The 13th Five-year Strategic Plan of the Chinese Foundry Industry, presentation of the China Foundry Association, 15 March 2017: https:// www.foundry-planet.com/fileadmin/redakteur/pdfdateien/8-Wei-Gao.pdf

1. Wei Gao, The 13th Five-year Strategic Plan of the Chinese Foundry Industry, presentation of the China Foundry Association, 15 March 2017: https://www.foundry-planet.com/fileadmin/redakteur/pdf-dateien/8-Wei-Gao.pdf Safeguarding the Environment at the Zhangjiagang Plant The Zhangjiagang Plant has been recognised by the provincial government in Jiangsu as a leader in environmental protection, following years of hard work by the plant to improve its environmental performance and surpass national requirements. Key to this process was the sourcing of raw materials. “In 2016, the plant improved the quality of its raw materials,” said Ricken Ren, Environmental, Health and Safety Manager at the plant. “With major work no longer required to reduce the water content of the materials, we were able to reduce the use of the drying kiln, which uses natural gases, in turn greatly reducing the plant’s energy consumption.” The plant has also improved its dust control measures with dust-seal partitioning and dust collection pipes to minimise the amount of dust that workers and equipment are exposed to. As a result of these measures, the plant’s natural gas usage has been reduced by 23,000m3 per year and, according to dust emission detection results, its average airborne dust concentration is 4.3mg/m3 – far lower than the national standard requirement of 120mg/m3. “Keeping the plant’s environmental impact as low as possible is a never-ending job,” concludes Ricken. “We perform daily checks to ensure devices such as our dust collectors are working effectively, and we continuously monitor our emissions during operations according to national laws. Every department works together – it’s a great team effort.”

Zhangjiagang Site, China

46

Reference

张家港工厂的环境保护 经过多年的努力,张家港工厂提高其环保水平并 超过了国家要求,已被江苏省政府认定为环境保护领 导者,取得此成绩的关键是原材料的采购。 “2016年,工厂提升了原材料的质量,”工厂 的环境、健康和安全经理Ricken Ren说,“由于不 再需要大量减少材料中水分的工作,我们能够减少 天然气烘干炉的使用,从而大大减少了工厂的能源 消耗。” 该工厂还通过粉尘密封隔板和粉尘收集管道改善 了粉尘控制措施,以最大程度地减少工人和设备所接 触的粉尘量。 由于采取了这些措施,该厂的天然气使用量每年 减少了23,000m3。根据粉尘排放检测结果,空气中 粉尘的平均浓度为4.3mg/m3–远低于国家标准要求 的120mg/m3。 Ricken总结说:“将工厂对环境的影响保持在尽 可能低的水平是一项永无止境的工作。我们进行日常 检查,以确保诸如除尘器之类的设备有效运行,并且 我们会根据国家法律在运营过程中持续监控排放。每 个部门协同工作——这是一项伟大的团队工作。”

中国 张家港工厂

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The Quality Improvement of Molten Steel on HP-IP Outer Casting of a 600MW Steam Turbine song jian, wang qing, wu yanrong, kang qiang, dongfang turbine co., ltd. (de yang, sichuan, china)

600MW汽轮机高中压外缸钢水质量提升 宋健,王庆,武彦荣,康强(东方汽轮机有限公司,四川德阳 618000)

T

he HP-IP outer casting is an important component of a 600MW steam turbine. These castings have large tonnage and high-quality requirements. The quality of molten steel is the key factor to determine the quality of casting. At present now, the HP-IP outer casting needs 100 tons of molten steel. According to the company’s existing equipment, a ladle of molten steel is not sufficient for production; it takes several furnaces to smelt together, two ladles of molten steel poured together, the process quality control is difficult. In this paper, slag treatment, VD time adjustment, weight of molten steel in ladle, optimization of pouring process, and so on are studied. The purpose is to improve the quality of molten steel by studying the technological measures and management system.

1.1 The production situation The material of the HP-IP outer casting (as shown in Figure 1) is ZG15Cr1Mo1V; this material is used for cylinder stator, steam cabinet and the main steam valve shell under 570C working conditions, and other high temperature components of steam turbine. It is a kind of alloy steel with high mechanical properties (as shown in Table 1) and strong heat resistance. (The chemical composition is shown in Table 2.) The HP-IP outer casting needs about 100 tons of molten steel, and adopting the EAF+LF+VD mode (as shown in

要:高中压外缸作为600MW型汽轮机重要 静子部件,该类铸件吨位大、质量要求高。 钢水质量是决定铸钢件质量的关键因素。

目前,我公司自产大吨位高中压外缸铸件所需钢水100 吨左右,根据公司现有冶炼设备,一包钢水无法满足生 产要求,需多炉联合熔炼,两包钢水合浇,过程质量控 制难度较大。本文主要通过精炼炉调渣改进、真空处理 (VD)时间调整、钢包钢水量吨位配置、浇注过程控 制优化等措施,在工艺方法和管理制度方面进行研究, 以达到提升钢水质量的目的。 关键词:600MW汽轮机高中压外缸;双包合浇;首 次补焊率;钢水质量 1 引言

1.1 生产概况 我公司自产的600MW机组高中压外缸(见图1)材 质为ZG15Cr1Mo1V,该材质用于570℃以下工作条件 的汽缸、蒸汽室、主汽阀壳等汽轮机高温部分铸件。它 是一种力学性能(见表1)要求高、耐热性较强的合金 钢材质(化学成分标准见表2)。

Fig. 1. Three-dimensional figure April 2021 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

图1 高中压外缸 三维图

47


Table 1. The mechanical properties of ZG15Cr1Mo1V. 表1 ZG15Cr1Mo1V力学性能 Rm N/mm2 ≥550

Rp0.02 N/mm2 ≥410

A %(L0=4D) ≥15

Figure 2), it takes several furnaces to smelt together, two ladles of molten steel are poured together, various processes, large alloy addition and long smelting time. Due to EAF, LF and VD are used together. If the plan is not careful, the smelting and pouring links cannot be effectively connected, and there are safety risks such as leakage of ladle, molten steel solidification and the argon is blocked. It will cause a large amount of energy consumption, and even lead to the failure of smelting and pouring. The production is difficult to organize.

1.2 HP-IP outer casting quality status In the production process, the molten steel is injected from two EAFs (electric arc furnace) to one LF (ladle furnace), as shown in Figure 2. It takes a long time, the molten steel is easy to cool down, the slag is thick, and the smelting quality is not easy to control during the refining period. It is easy to appear unqualified chemical composition, uneven temperature, poor slag quality, secondary pollution of molten steel and other quality problems. Thus, the casting defects such as blowhole and inclusion defects, shrinkage porosity and mechanical characteristic abnormal are produced, which bring great pressure to the cleaning work of the casting.

1.2.1 NCR status According to the NCR statistical analysis of the company quality database, as shown in Table 3. There are many casting defects in this kind of HP-IP outer casting, resulting in great quality loss. From February 2018 to May 2019, a total of 86 NCRs related to HP-IP outer casting of 600MW steam turbine were counted. In Table 3, the percentages of NCR of various types are compared, blowhole and inclusion defects accounted for more than 52.3% of the total NCR, the quality of molten steel is one of the main influencing factors, so it is very necessary to improve the quality of molten steel in this kind of castings.

1.2.2 First repair welding rate Defects here refer to inherent defects, such as UT, MT, RT defects, etc. First repair welding rate is a key index to reflect the quality of molten steel. According to the statistical analysis of the first welding repair rate (internal defect) of the HP-IP outer casting from February 2018 to May 2019, the average value is 1.56%. Compared with other castings, the

Z % ≥50

HB 170-220

该产品需求钢水100吨左右,并且采用EAF+LF+VD 生产模式(见图2),多炉联动,双包合浇,工序繁 多,合金添加量大,冶炼时间长。由于EAF、LF、VD多 炉共同使用,如果计划不缜密,冶炼、浇注环节不能有 效衔接,存在着漏包、冻包、氩气不通等安全风险。会 造成能源的大量消耗,甚至导致熔炼、浇注失败,生产 组织难度较大。

1.2 高中压外缸质量状况 生产过程中,钢水分别从两个EAF(电弧炉)注入一 个LF(钢包精炼炉),见图2。耗时长,钢水易降温, 钢渣粘稠且多,精炼期熔炼质量不易控制。易出现化学 成分超差、温度不均匀、炉渣质量差、钢水二次污染等 质量问题,从而产生气孔、夹杂、缩松缩孔、性能不合 格等铸造缺陷,给铸件尾部清整工作带来较大压力。

1.2.1 NCR发生情况 根据公司质量数据库NCR统计分析(见表3),该类 高中压外缸铸造缺陷多,造成较大的质量损失。2018 年2月至2019年5月,共统计出600MW机组高中压外缸 相关的NCR合计86条。 表3中,对比各种类型NCR占比,气孔及夹杂物缺陷 占整个NCR总数的52.3%以上,大多数为铸件内在缺 陷,钢水质量问题是主要影响因子之一,所以提升该类 铸件的钢水质量非常必要。

1.2.2 首次缺陷补焊率情况 这里的缺陷是指铸件内在缺陷,如UT、MT、RT缺陷 等。铸件首次补焊率是反映钢水质量的关键指标。通过 对质量数据库2018年2月至2019年5月高中压外缸首次补 焊率(内在缺陷)统计分析可得,其平均值为1.56%。相 对其他类型铸件,首次补焊率较高。

2 优化方案 2.1 合理判断精炼炉渣,优化调渣方式

Table 2. The chemical composition of ZG15Cr1Mo1V wt%. 表2 ZG15Cr1Mo1V化学成分控制目标,wt% C

Si

Mn

0.10 ~ 0.20

0.20 ~ 0.60

0.50 ~ 0.90

48

P ≤

S ≤

0.025

0.015

Cr

Mo

V

1.20 ~ 1.50

0.90 ~ 1.20

0.15 ~ 0.25

Ti ≤

Ni ≤

Cu ≤

Al ≤

0.050

0.50

0.35

0.01

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图2 高中压外缸生产 流程图

Fig. 2. HP-IP outer casting production process

2.1.1 精炼炉炉渣判断

first repair welding rate is higher.

根据表4中炉渣颜色及形貌,通过5M1E法分析调渣

2. Optimization scheme

问题,制定相关优化措施。

2.1 Reasonably judge the slag of refining furnace and optimize the method of slag control

2.1.2 调渣方式改进

2.1.1 Judge the slag of refining furnace

1、通过加入碳粉、碳化硅等粉料,精炼过程中造泡

According to the color and morphology of slag in Table 4, the slag treatment problem was analyzed by 5M1E, and relevant optimization measures were formulated.

沫渣,保证炉内气氛,保证电弧埋弧加热,防止弧光伤 及包衬。 2、推广“给渣线穿一层衣服”理念,有效防止渣线

2.1.2 Optimize the method of slag control (1) By adding carbon powder, silicon carbide and other powder materials, foam slag is made in the refining process to ensure normal production, ensure arc heating, and prevent arc light from hurting the ladle. (2) Popularize the concept of “wear a layer of clothes on slag line” to effectively prevent the damage of slag line position. (3) According to the dry and wet condition of slag, adjust with lime and fluorite respectively. (4) Adopt strong reducing agent deoxidization, such as ferrotitanium, silico-calcium, compound refining agent, etc. (5) The target slag is white slag, and the evidence is collected by photographing.

2.2 Enhance VD processing effect

位置损伤。 3、根据炉渣干湿情况,用石灰、萤石分别调整。 4、采用强还原剂脱氧,如钛铁、硅钙块、复合精炼 剂等。 5、保证目标渣为白渣,并通过拍照取证。

2.2 加强VD真空处理效果 2.2.1 延长VD处理时间 由于主包钢水量多,按通用规范要求的VD时间,真 空处理效果不佳。适当延长VD处理时间,要求VD处理 时间≥25min,有效去除钢液内气体、夹杂物含量。

2.2.1 Prolong VD processing time Due to the large amount of molten steel in the main ladle,

2.2.2 增加VD深抽方式

Table 3. NCR status of HP-IP outer casting 表3 600MW机组高中压外缸NCR发生情况 defect types

blowhole and inclusion defects

processing problem

crack

shape and weight deviation

Mechanical Characteristic abnormal

other

Surface defects

缺陷类型

气孔及夹杂物缺陷

加工问题

裂纹

形状及重量偏差

性能不合格

其他

外观缺陷

NCR number

45

12

3

19

2

3

2

数量

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Table 4. The slag condition is judged by the color and morphology of slag 表4 通过炉渣颜色及形貌判断渣况 Color 炉渣颜色

Characteristics 特征

Morphology of slag 炉渣形貌

Characteristics 特征

black 黑色

The oxidation is very strong, and the erosion of the ladle is strong 氧化性很强,对钢包的侵蚀力度大

the slag surface smooth 渣面平滑

target slag 目标渣

gray, brown 灰色、褐色

The oxidation property is strong, and the erosion of ladle is great 氧化性较强,对钢包的侵蚀力度较大

scratchy slag 渣面粗糙

large amount of lime or dry slag 石灰量较大或渣较干

yellow 黄色

The desulfurization reaction has been carried out 已进行了脱硫反应

thin slag 蘸渣渣皮薄

slag dilute 炉渣稀

green 绿色

more Chromium oxide 铬的氧化物较多

foaming slag 泡沫渣

high gas content in slag 渣中含气量大

white 白色

reduction slag, target slag 还原渣,目标渣

tight slag 紧实渣

the vacuum treatment effect is not good according to the VD time required by the general specification. Proper extension of VD treatment time, VD treatment time is required to be greater than or equal to 25min, effectively remove gas and inclusions in molten steel.

2.2.2 Added VD strong handling Looking at the vacuum tank with a peephole, under the premise of ensuring safety, the VD processing time can be extended, and the holding time of high vacuum degree below 100Pa is greater than or equal to 3min., in order to obtain better vacuum treatment effect.

2.3 Optimize the molten steel content of large and small ladles (1) Calculate the molten steel demand of HP-IP outer casting body by process. When large ladle is poured, the molten steel level rises to 100mm above the casting height. (2) Make clear the weight of the molten steel of large ladle and small ladle on duty instruction, and strictly implement it. (3) Before the end of casting, ensure enough water (2-3t) of the remaining steel in the large ladle to prevent the ladle bottom slag mixing roll from pouring into the cavity and reduce the secondary pollution of molten steel.

low gas content in slag, the slag after VD 渣中含气量小,VD后渣

通过窥视孔观察VD罐内情况,在保证安全的前提 下,延长高真空度处理时间,高真空度在100Pa以下 保持时间≥3min,通过深抽的方式取得更好的真空处 理效果。

2.3 优化大钢包、小钢包的钢水量 1、工艺测算高中压外缸铸件本体需求钢水量, 要求大钢包浇注时,钢液面上升至型腔中分面以上 100mm。 2、在当班浇注指令上明确大钢包、小钢包的钢水 量,并严格执行。 3、浇注结束前,保证大钢包内余钢量足够 (2-3t),防止钢包底部钢渣混卷浇入型腔,减少了 钢液二次污染。

2.4 优化大电弧炉、小电弧炉出钢时间 大钢包中的钢水来自大电炉和小电炉,见图2。小 电炉根据大电炉的出钢时间择机出钢,保证两炉钢水 同时进入精炼包进行精炼,保证钢水均匀性,以提高

2.4 Optimize the completion time of large and small EAF

钢水质量。

The molten steel in the large ladle comes from the large EAF and the small EAF, as shown in Figure 2. Small EAF according to the completion time of the big EAF, ensure that both furnaces of molten steel are refined together, ensure the uniformity of molten steel to improve the quality of molten steel.

2.5 浇注方案优化

Fig. 3. Slag adjustment, slag judgment site

先用大钢包通过底返式浇注,经观察待钢液上型腔

图3 调渣、判渣 现场

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图4 VD处理现场

Fig. 4. The scene of the VD

2.5 Optimization of pouring process

中分面100mm以上后,再用小钢包在冒口上方浇注,

The large ladle is used for the bottom back casting at first. It was observed that after the molten steel level rises to 100mm above the casting height, a small ladle was used to pour above the riser, and the pouring was stopped after completion, as shown in Figure 5.

上浇高线后停止浇注,见图5。

3. Economic benefits According to the analysis of the company quality database, from June 2019 to August 2020, the first repair welding rate of the HP-IP outer casting of 600MW decreased to 1.13%. If the casting is calculated at 50 tons, the material E5515-1CMV can be saved by 5,000 yuan per piece of the HP-IP outer casting. At the same time, it reduces the cost of repair welding, heat treatment, processing, flaw detection and other processes.

4. Conclusions According to the quality requirements and manufacturing characteristics of the HP-IP outer casting of 600MW, combined with the existing equipment performance of the company, the optimization is carried out from the aspects of slag adjustment in refining furnace, VD, ladle molten steel configuration and optimization of pouring process. Through the implementation of measures and statistical analysis, the purpose of improving the quality of molten steel has been achieved, the quality of this kind of casting is improved, which plays a key role for the company to improve the efficiency, quality and smooth output of the unit. ■

Reference [1]Li Kuisheng,Casting process and principle, China Machine Press,1989. [2]Wen Yongdu,Li Dongqi,Zhu chengxing, Foundry inspection technique, China Machine Press,1989. [3]Chen Jiaxiang, Siderology, Metallurgical Industry Press,1990. [4]Lu Jiajian,Liu Jianyong,Chen Kun, Research on Casting Technology of Nozzle box of Ultra-supercritical 660MW Turbine,Dongfang Steam Turbine,2009.

Fig. 5. Pouring scene

3 经济效益 通过质量数据库统计分析,2019年6月至2020年8 月的600MW机组高中压外缸首次缺陷补焊率下降至 1.13%。如果外缸铸件按50吨计算,每件高中压外缸 节约焊材E5515-1CMV 5000元。与此同时,减少了补 焊、热处理、加工、探伤等工序成本。

4 结语 根据600MW型汽轮机高中压外缸铸件的质量要求 及制造特点,结合公司现有设备性能,从精炼炉调 渣、VD处理、钢包钢水配置、浇注过程控制等方面进 行优化,经过措施实施及统计分析,达到了提高钢水质 量的目的,提升了该类铸件的质量,为公司将本增效、 质量提升及机组顺利产出起了关键作用。 ■

参考文献 [1] 李魁盛,铸造工艺及原理,机械工业出版 社,1989. [2] 温永都、李冬琪、朱承兴,铸造检验技术,机械 工业出版社,1989. [3] 陈家祥,钢铁冶金学,冶金工业出版社,1990. [4] 陆加见,刘建勇,陈昆,超超临界660MW汽轮 机喷嘴室铸造工艺技术研究,东方汽轮机,2009

图5 浇注现场

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product news/产品新闻

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

MELTING, POURING & HEAT TREATMENT

Innovations in Binder Jetting Increase Sustainability and Promote Serial Production 49 粘结剂喷射技术的创新提高可持续性并促 进批量生产

How to improve slag condition during nodularisation 球化过程中如何改善炉渣状况

47

50

Automotive Parts Production Line – Ready for the Future 汽车零件生产线——为未来做好准备

51

57

SOFTWARE

Sand Reclaimer Measures Up to a High Standard 符合高标准的砂再生设备 Smarter Than Oil - Water-Based Hydraulic Fluids From Fluid Experts 比油更神奇 – 源自德国的绿色环保水 基液压液

Benefits for users and decision makers - MAGMASOFT 5.5 53 MAGMASOFT 5.5 为用户和决策者助力 Time for a new inspection experience 亟需新的检测体验

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product news/产品新闻

How to improve slag condition during nodularisation 球化过程中如何改善炉渣状况 Among the major challenges facing cast iron foundries today are how to get the best value from costly nodularising alloys and how to stop slag particles entering the mould cavity. Elkem has developed a range of barium based ferrosilicon alloys, known as Topseed ® conditioner, which have been designed to overcome these issues. Significantly, the use of the calculated and controlled amounts of the alloy in the ladle changes the slag characteristics to give an easily removable slag. Whereas very often the slag in the treatment ladle after the nodularisation process is quite liquid or viscous, Topseed ® will change the slag form to that of dry granules. These can easily be skimmed from the ladle without the use of environmentally unfriendly slag coagulants, such as unexpanded perlite. Not only does this reduce the volume of material to be removed from the ladle and disposed of, by the slag not sticking to the ladle refractory, some increases in ladle life can also be seen. Figure 1 shows a typical ladle surface with a viscous slag and Figure 2 shows the effect of Topseed ® with a dry and easily removable slag. By precipitating the slag in the treatment ladle, the chances of inclusions in the final casting are significantly reduced. However, it must be noted that slag has to precipitate somewhere. By coming out early in the process, it is sometimes observed that the volume of slag in the ladle is increased – true, but it is far better and cheaper to bring out the slag here than in the casting.

铸铁企业现在面临的主要挑战包括:如何从添加球化 合金中获得最大价值,以及如何防止炉渣进入型腔。 为此,埃肯开发了一系列钡基硅铁合金,也就是 Topseed®系列孕育剂,为克服这些缺陷设计。 显然,通过计算并控制合金在钢包中的添加量,改变 了炉渣的特性,使炉渣易于去除。经球化处理后,钢包 中的炉渣通常是液态或粘稠状态,而Topseed®会将炉 渣的形态变为干燥颗粒。无需使用污染环境的造渣剂( 例如未膨胀的珍珠岩),就可以轻松地将它们从钢包中 撇去。这不仅减少了要从钢包中去除并丢弃的材料的体 积,而且炉渣不粘在钢包的耐火包衬上,因此,钢包的 使用寿命也有所增加。 图1显示了粘性炉渣的典型钢包表面,图2显示了应 用Topseed®后干燥且易于去除的炉渣效果。 在处理包中沉淀炉渣,可显著减少最终铸件中的夹杂 物。但是,要注意的是,炉渣必须进行沉淀。沉淀炉渣 要尽早进行,有时会发现钢包中的炉渣量增加了,确实 是这样的,但是尽早将炉渣去除比在铸件中去除要好得 多,也要便宜得多。 高品质、干燥且不含油的废钢材的短缺,意味着有 些铸造厂已经 转向使用更便 宜但又充满问 题的材料,因 此,覆盖材

图1:传统的粘 性炉渣。

Figure 1. Typical viscous slag April 2021 FOUNDRY-PLANET.COM | MODERN CASTI NG | CHINA FOUNDRY ASSOCIATION |

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product news/产品新闻

图2:易于清除 的干渣。

Figure 2. Easy to remove dry slag

The shortage of good quality, dry and oil-free steel chips has meant that some foundries have moved to cheaper, yet more problematic, cover materials, machine chips being seen more frequently. These have low density, can have harmful residues from wet machining, contain inclusions and overall are not effective. Use of a dense controlled composition alloy will slow down the onset of the reaction, thus allowing a greater ferrostatic head to build in the ladle and give a better magnesium/metal contact. In some cases, this has enabled the use of a lower Mg nodulariser, thus reducing reactivity and giving safer working conditions. Figure 3 shows the difference in reaction with steel coins (left) and Topseed ® Conditioner (right). ■

料、机加工碎屑等的出现更为频繁。这些材料密度 低,可能会在机加工冷却过程中产生包含着夹杂物的 有害残留物,造成总体上无效。使用致密且成分受控 的合金将减慢反应的开始,从而允许在钢包中建立 更大的铁水静压头,并获得效果更好的镁/金属接触 反应。在某些情况下,这使得可以使用镁含量较低的 球化剂,从而降低了反应性并提供了更安全的工作环 境。图3显示了钢币使用镁合金(左)和Topseed®调 节剂(右)的不同反应。 ■

Figure 3. Reaction with steel coins covering MgFeSi (left) and Topseed® Conditioner (right)

图3:对钢币 使用镁硅铁合 金(左)和 Topseed®孕育 剂(右)的不 同反应。

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product news/产品新闻

Innovations in Binder Jetting Increase Sustainability and Promote Serial Production 粘结剂喷射技术的创新提高可持续性并促进批量生产 ExOne 3D printer S-Max® Pro Furan with two job boxes and numerous features

Advances to sand binder jetting are allowing manufacturers to tailor the technology to meet the needs of their specific application and scale use to series production with increasing automation options. Binder jetting technology prints complex designs by selectively applying binder to foundry-grade sand layer by layer to build up a geometry. By printing directly from CAD files, this additive manufacturing technology eliminates the need for physical patterns, saving space for storage and reducing the production time of molds and cores to days. A variety of binders, organic and inorganic, are available to customize parts to the requirement of the casting. Furan is the most common binder system for sand 3D printing because of its ease of use and production speed. Since it does not require thermal curing, solvent-based furan binder systems create molds and cores in a single-step process. These can be used directly after printing and desanding, saving production time as well as labor and costs associated with curing in an oven or microwave as required by other binders. Furan is also flexible in its application and can be used for high-temperature casting applications. Initial automation steps are being integrated into the furan production process to half the time needed to desand a job box after a print. Companies looking to implement a more sustainable manufacturing strategy are transitioning to inorganic binder to produce nearly emission-free sand cores that improve the air quality during both printing and pouring. Traditional binder systems contain organic material that produces fumes during the casting process. Without any organic content to burn, inorganic cores release essentially no emissions into the foundry. Inorganic binder is at the beginning of its potential producing cores for non-ferrous and light metal applications today with exciting potential for future expansion into high-temperature applications. The increased sustainability of inorganic systems is also beneficial to the bottom line. Without emissions to vent, foundries require less air treatment and manufacturers benefit from decreased scrap rates due to significantly reduced gas pressure during casting. The minimal adhesion of unused sand to the final part makes it easy to remove and enables increased levels of automation since sand can easily flow through holes perforated plates in the floor of the job box. This advanced desanding automation can save operators nearly 95% of the time spent manually removing sand after a print is complete and allows up to four S-Max® Pro sand 3d printers to be connected to one desanding station in a manufacturing cell. Today, additive manufacturing users produce intricate sand molds and cores, but ever-increasing automation and processes

具有两个作业箱和众多 功能的ExOne 3D打印机 S-Max®Pro Furan。

砂粘结剂喷射系统的进 步使制造商可以定制技术满 足特定应用的需求,并通过 增加自动化功能来进行批量 生产。粘结剂喷射技术是通 过将粘结剂有选择地逐层铺 设在铸造用砂上以建立几何形状,从而打印出复杂的形 状。通过直接打印CAD文件,这种增材制造技术消除了 对实际模型的需求,节省了存储空间,并将模具和型芯 的生产时间缩短至几天。可以根据铸件要求,使用多种 有机和无机粘结剂来定制生产零件。 呋喃因其易用性和生产速度成为3D打印最常见的粘 结剂系统。由于不需要热固化,基于溶剂的呋喃粘结剂 系统只需一步即可制造模具和型芯。它们可在打印和除 砂后直接使用,从而节省了生产时间以及其他粘结剂在 烤箱或微波炉中固化的相关人工和成本。呋喃在应用方 面也很灵活,适用于高温铸造。最初的自动化操作已被 整合到呋喃生产过程中,所需时间仅为打印后除砂工作 的一半时间。 希望实施更可持续的生产策略的公司正在向无机粘 结剂过渡,生产出几乎无排放的砂芯,改善打印和浇注 过程中的空气质量。传统的粘结剂系统包含在铸造过程 中会产生废气的有机材料。无机砂芯不燃烧任何有机成 分,基本上不释放任何废气。现在,无机粘结剂是为有 色金属和轻金属应用领域生产砂芯的开始,而且还将有 潜力进一步扩展到高温应用领域。 无机粘结剂系统可持续性的提高也是最重要的好处。 没有废气排放,铸造厂需要较少的大气污染处理,并且 由于铸造过程中的气压大大降低,企业的废品率降低。 未使用的砂子与最终部件之间的附着力极小,因此易于 清除;砂子可以轻松地流过作业箱地板上打孔板的孔, 有助于提高自动化水平。相比手动清除砂子,这种先进 的自动化除砂工艺可为操作人员节省近95%的时间,并 且最多可将4台S-Max®Pro 3D砂型打印机连接到制造单 元中的一个除砂站。 现在,增材制造用户可以生产复杂的砂模和型芯, 但是为生产高价值铸件量身定制的不断提高的自动化水 平和工艺将为面向未来的铸造厂引领方向。可互换的工

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product news/产品新闻 tailored to high-value casting applications lead the way towards the foundry of the future. Interchangeable job boxes and automated desanding processes increase OEE and drive adoption of binder jetting for serial production. Forward-looking connections for additional robotics are already taken into consideration to allow foundries to invest with confidence. To increase sustainability, production with inorganic binder enables manufacturers to cast aluminum in a more resource-friendly way as development continues on both inorganic binders for additional casting metals and furan chemistries with reduced LOI values to support the drive toward the green foundry. ■

作箱和自动除砂工艺提高了设备综合效率,推动了粘结 剂喷射技术在批量生产中的应用。此外,对其他机器人 技术的考虑是具有前瞻性的,使铸造厂能够充满信心地 进行投资。为了提高可持续性,使用无机粘结剂进行生 产使制造商能够以资源更加友好 的方式生产铝合金铸件,用于其 他铸件的无机粘结剂和降低烧失量 (LOI)的呋喃树脂的不断研发, 将支持绿色铸造的发展。 ■

The Automated Desanding Station for Inorganic Binder Jetting reduces desanding times by up to 95%.

用于无机粘结剂喷射的自动除砂站可减 少高达95%的除砂时间。

Sand Reclaimer Measures Up to a High Standard 符合高标准的砂再生设备 Late in 2017, AFS Corporate Member Quaker City Castings (QCC, Salem, Ohio), purchased a used Gudgeon Thermfire thermal sand reclaimer system, which the Canadian supplier refurbished to like-new condition. In the elaborate, two-anda-half-year process of preparing for its delivery and installation, surprises had a way of cropping up, but the biggest was a positive lesson about what the QCC team was really capable of. “This was not my area of expertise, but I have good maintenance folks,” said Dave Lordi, who became QCC president in 2018. “I surprised myself because I was able direct the project once I figured out how it all works. We would meet once a week to just go over some of the main parts of the project that we wanted to accomplish ... We knew we could do it from our prior experience [of setting up a previous unit]. But this was a different animal.” Indeed, the 18-foot-tall unit, adjacent 25-foot-high elevators, and necessary supporting infrastructure, which Lordi refers to as the system’s “veins and arteries,” required thoughtful planning and patience well before the unit’s delivery last year. But the first obstacle was determining where the reclaiming system would reside. Proximity to the molding area was key, however none of the eligible existing buildings could contain the reclaimer giant under their roofs. The logical solution: build a new building, which finished up as a 30- x 30-ft. prefabbed steel structure and took the better part of 2018’s summer to complete.

How It Works The rationale for the investment was clear enough––consuming over 8,000 tons of sand in a year, QCC stood to gain substantially by reusing rather than wasting about 90% of its annual volume of sand. Lordi said he expects the system will pay for itself in three years. The refurbished Gudgeon is capable of processing 72 tons of sand per 24 hours. Initially, QCC plans to run the system two to three days per week, so it has plenty of room to grow as business increases in the future. As Modern Casting went to press 56

2017年底,位于俄亥俄州塞勒姆的美国铸造协会会 员企业Quaker City Castings(QCC)购买了加拿大 Gudgeon Thermfire的二手热法砂再生系统,这家加 拿大供应商对其进行了翻新,使其像新的一样。在为期 两年半的交付和安装过程中,发生了很多意想不到的事 情,但最大的收获是QCC团队从中学到了很多。 “这不是我们公司的专业领域,但是我们有很好的维 护人员,”自2018年起担任QCC公司董事长的戴夫·洛 迪说:“令我自己感到惊讶的是,一旦我弄清了所有的 工作流程,我就能指导该项目的开展。我们每周开一次 会,只讨论我们要完成的主要工作。我们知道可以根据 先前的经验(安装一个以前的单元)来完成。但这是一 个不同的设备。” 的确,这个18英尺高的机器,与25英尺高的电梯以 及必要的支撑基础设施(洛迪将其称为系统的“静脉和 动脉”)相邻,设备在去年交付之前就需要进行周密的 计划和耐心等待。但首当其冲是要确定回收系统安装在 哪里。靠近造型区域是关键,但是,所有符合条件的现 有建筑都不能容纳这个巨型设备。合理的解决方案是: 建造一幢高度为30 x 30英尺的预制钢结构建筑物,并在 2018年夏季竣工。

如何运行 投资新设备的理由很明确:QCC公司一年消耗8,000 吨砂子,这些砂子可以回收再利用而不是90%的砂子都 被浪费掉。洛迪说,他预计砂再生系统将在3年内收回 成本。 翻新后的Gudgeon砂再生设备每24小时可处理72吨 砂子。最初,QCC公司计划每周运行该系统两到三天,

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product news/产品新闻 in mid-December, the foundry was just about ready to flip the switch and begin its new journey into thermal sand reclamation. Somewhat reminiscent of the old “Dry Bones” children’s tune–– as in, “foot bone connected to the leg bone”––Lordi outlined the process of exactly what the system does and how it works. After molds are poured and castings are extracted, sand is put through a shakeout system to break it down as small as possible by mechanical means. Sand then travels via elevator to an intermediate silo, where it’s pumped to a second silo––here’s it’s in a holding pattern of sorts, waiting to go through the reclaimer. From Silo 2, sand is gravity fed into a separating system that magnetically removes metal and sieves out other material you don’t want in the reclaimer. Next, sand moves up in an elevator that’s positioned next to the reclaim unit––the elevator feeds sand into a hopper that takes it into the reclaimer. Mechanical processes accomplished, the thermal process–– actual baking of the sand––now takes over. By heating sand, the reclaimer burns off the chemical that was used to bind the sand. Its last function is to then cool the sand. Sand exits the reclaimer and moves into a second elevator that puts it into another hopper, which then feeds it into another transporter that sends it to its final silo where it’s ready to be used for new molds. With the exception of some specialty work such as building and main silo construction, as well as the pouring of some cement pads, QCC’s own maintenance crew handled all the installations, as well as the less visible infrastructure, including air lines, buried natural gas lines, electrical wiring, water lines and piping for dust collection. QCC worked closely with Gudgeon’s service team throughout the entire process, and the OEM sent service personnel to the foundry to review all the system’s connections to make sure everything was to their specifications. To his foundry peers who may consider installing or replacing a sand reclaimer, Lordi has one singular message: “Do it right. Don’t try to cut any corners,” he said. “There’s a lot of things about the unit that are very specific; a lot of computer-controlled aspects to it. The system itself is the heart, but there are many accessories––the feed systems and the parts that control them, and the electrical components. You have to do everything according to what the manufacturer recommends, because once it runs, it’s going to run continuously. So I would just say, do it right.” ■

随着业务的增长,它将有很大的增长空间。去年12月中 旬,QCC公司已准备启用新设备,并开始热法砂再生。 洛迪还介绍了该系统的工作过程以及工作原理,就 像以前的儿歌“Dry Bones”的曲调,“足骨连接到股 骨”。 铸型在浇注并取出铸件后,砂子通过筛分系统,使用 机械方法将其分解得尽可能小。 然后,砂子通过升降机到达中间的料仓,然后被泵送 到第二个料仓,这里的砂子处于各种等待状态,等待通 过回收系统。 砂子从料仓2被重力送入分离系统,该系统磁选去除 金属并筛分回收系统中不需要的其他材料。 接下来,砂子通过再生设备旁边的升降机向上移动, 进入料斗,然后进入到再生设备。 机械破碎完成后,加热过程——也就是实际的干燥 过程开始了,通过加热砂子,再生设备将砂子的粘结化 学物质燃烧掉。再生设备的最后功能是冷却砂子。 砂子离开再生设备,进入第二个升降机,升降机将其 送入另一个料斗,然后到达另一个运输机。运输机将其 送到最终的料仓,准备用于新的铸型。 除了一些特殊的工作,例如建筑物和主料仓结构,以 及浇注一些水泥板外,QCC公司自己的维修团队负责所 有的安装工作,以及基础设施,包括空气管线、地下天 然气管线 、电线、水管和用于收集灰尘的管道安装。 在整个过程中,QCC与Gudgeon的服务团队紧密合 作,OEM将服务人员派往铸造厂检查系统的所有连接, 以确保所有安装均符合要求。 对于可能考虑安装或更换砂再生设备的铸造业同行来 说,洛迪表示:“要按正确的方式做。不要试图偷工减 料。” “关于该设备的很多问题都是非常具体的,有很多计 算机控制方面的问题。系统本身就是心脏,但是有很多 附件——进料系统和控制它们的部件以及电气部件。您 必须按照制造商的建议进行所有操作,因为一旦开始运 行,它将运行下去。所以我只想说,一定要按正确的方 式安装。” ■

Automotive Parts Production Line – Ready for the Future 汽车零件生产线——为未来做好准备

Zhejiang VIE Science & Technology Co., Ltd. specifies in R&D work and became a leading supplier of automotive parts. Being a company with a future prospective, VIE decided to produce demanding aluminum cast parts for the automotive industry. Looking for the right partner, VIE got in contact with Kurtz Ersa. After numerous meetings and detailed technical discussions, the first contract and the joint project were fixed at Metal + Metallurgy China 2016. VIE started directly with “coreless frames” and was thus able to generate a commission for the local market for these demanding

浙江万安科技有限公司通过研发成为汽车零部件的 领先供应商。作为一家有远见的公司,万安决定为汽车 行业生产高要求的铝铸件。在寻找合作伙伴时,万安与 德国库尔特埃莎公司取得了联系。经过多次会议和详细 的技术讨论后,第一个合同和合作项目在2016年的中 国国际铸造博览会上签订。 万安直接从“无心框架铸件”开始,因此能够为这 些高要求的车身零件在当地市场产生效益。万安的目

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product news/产品新闻 body parts. The objectives and claims of VIE were challenging, as the frames ought to be cast directly coated twice – no standard for such large parts. Due to the requirements, only the FSC casting line with furnace shuttle could be considered, though directly with innovations. Up to then, size 18-16 with a clearance of 1,800 x 1,600 mm was standard for Kurtz machines. These dimensions were cutting it very close for the large double mould used for the production of frames. For this reason, a decision was made for the new size 22-17 with more clamping area for large moulds. Besides the vast closing unit of the casting machine with a wide clamping area, the large low pressure furnace and the use of multiple riser tubes were also a key to success. A 2,800 kg furnace is used with currently up to ten riser tubes. For maximum line effectiveness, furnaces are changed mostly during the casting machines’ off times by means of the proven furnace shuttle. To fulfil the high quality requirements, the cooling makes a decisive contribution – for which the system has 64 mixed cooling circuits. In cooperation with the customer, Kurtz has designed a high-capacity, extendable casting line, making it possible for the customer to expend further and thus to invest further in the future. This was a wise and foresighted decision: Entering the market with high-quality and light hollow cast frames, VIE could immediately convince the premium customers in the automotive branch. Soon, both delivered machines were producing at the capacity limit and an increase became necessary. End of 2020 VIE placed the follow-up order for two further machines that will be installed in this line. The first cast is planned for August 2021. Already equipped with two high-end machines, VIE decided for only two adjustments: First, the cooling circuits will be regulated instead of controlled – an important process factor for even higher quality and shorter cycle time. Second, the machines will be equipped with an exhaust system to extract the core gases. With these two add-ons VIE will certainly push the process even further to achieve the best quality at shortest cycle time. ■ Kurtz low pressure casting machine AL22-17FSC.

Challenging aluminum cast parts: light hollow cast frames.

Metallic 3D printing 金属3D打印

Kurtz低压铸造机 AL22-17FSC。

具有挑战性的铝 铸件:轻型空心 框架铸件。

Foundry machines 铸造设备

Kurtz casting line: installed (blue) and ordered (orange) machines, as well as further capacity expansion opportunity (white).

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标和要求颇具挑战性,这样的框架应直接在铸造中涂覆 两次,对于大型部件是没有标准的。根据要求,尽管直 接进行了创新,但仅有可自动更换炉体的FSC铸造生产 线可以考虑使用。当时,尺寸为18-16且间隙为1800 x 1600毫米的尺寸是库尔特设备的标准配置。这样的尺 寸非常接近用于生产框架铸件的大型双模具。 因此,决定采用新的22-17尺寸,并为大型模具提 供更大的锁模面积。有更大锁模面积的铸造机除了具有 宽阔的闭合装置外,大型低压炉和使用多个上升管也是 成功的关键。一个2800公斤的炉子目前最多可使用10 根上升管。为了最大程度地提高生产效率,大多数情况 下,在铸造机停工期间,通过已经受考验换炉系统更换 炉子。为了满足高质量的要求,冷却系统做出了决定性 的贡献,即冷却系统有64个混合冷却回路。 库尔特公司与客户合作设计了一条大容量、可扩展的 铸造生产线,使客户有可能进一步扩大产能。这是明智 而有远见的决定:凭借高品质和轻型无心框架铸件进入 市场的万安公司,可以立即获得优质汽车客户的信任。 于是很快,交付的两台设备都达到了 最大产能,因此有必要提高产能。 2020年年底,万安公司签下在该生 产线中安装另外两台机器的订单,并 计划于2021年8月投产。 万安公司已配备了两台高端设备, 并决定只进行两次调整:首先,将 对冷却回路进行调节而不是加以控 制——这是提高产品质量和缩短周期 的重要因素。其次,机器将配备排气 系统以排出芯子气体。有了这两个附 加组件,万安将能够进一步提升该生 产工艺,从而在最短的周期时间内达 到最佳的产品质量。 ■

Kurtz铸造线:已安装(蓝色)和已订购 (橙色)的机器,以及今后的安装计划 (白色)。

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product news/产品新闻

Benefits for users and decision makers - MAGMASOFT 5.5 MAGMASOFT 5.5 为用户和决策者助力 The wait is over! With the release of MAGMASOFT® 5.5 you can look forward to innovative new capabilities. Efficient casting development, reliable starts of production and robust process windows - numerous new options in the release 5.5 allow for creating even more value in casting design, in toolmaking and in the foundry. Particular emphasis has been placed on further simplified and efficient use of the software and its results.

Cast Iron in Motion Completely new capabilities are available to iron foundrymen to consider the effects of metallurgy and metal treatment on the solidification and feeding behavior. With the innovative SMAFEE feeding algorithm, you can take even better account of the influence of melt quality, inoculation practice, and local pressure distributions on porosity development. In addition, thermal convection during solidification is now calculated as a standard for iron castings. The influence of this flow on the temperature distribution has an influence on the feeding behavior both in large castings and in series production. The “heart” of the optimized MAGMA-iron module is the SMAFEE feeding algorithm. Pressure differences in the metal are created through the combination of metallostatic pressure, local austenite shrinkage and graphite precipitation, and the rigidity of the mold. The software calculates local metal transport in partially solidified regions of the casting and the resulting ability to feed the solidifying iron. Thus, both metal quality and inoculation state influence feeding and porosity formation in the casting. The new feeding model is available for all types of cast iron: ductile, grey and compacted graphite iron.

Quality Assessment in Die Casting In high pressure die casting, defects due to entrapped air together with shrinkage porosity are major causes for scrap. Tooling and process design are therefore very strongly focused on reducing porosity due to entrapped gases. The mass balance of air in the cavity and the transport of entrapped air can be reliably predicted using MAGMASOFT® 5.5. In the new “Air” result, the amount of air in the cavity and in the melt is visualized quantitatively and allows a complete assessment over the entire filling process. It’s possible to consistently evaluate the quality of the tooling design and the process conditions over the course of a project, even under changing situations.

无需再等,MAGMASOFT® 5.5现已发布!新版本 增加了令人期待的创新功能。高效的铸件开发、可靠的 启动生产和稳健的工艺窗口,5.5版本中的众多新选项 帮助您在铸造设计,模具制造和铸造生产中创造更多价 值。我们还特别对软件做了进一步的改善,带给您更加 简单和高效的使用体验。

铸铁的全新铸件求解器 铸铁厂可以使用全新的功能,衡量冶金和金属处理 对凝固和补缩行为的影响。 借助创新的SMAFEE补缩算 法,您可以更好地了解熔体质量,孕育效果以及局部压 力分布对缩孔的影响。 此外,凝固过程中的热对流,现在被当作是铸铁的 一项标准选项。热对流会影响温度的分布,从而影响到 大型铸件和批量生产中的补缩行为。 优化后的MAGMAiron模块的“核心”是SMAFEE补 缩算法。 金属液内部的压差是由金属液静压、局部奥氏体收 缩、石墨析出以及模具刚性相互作用产生的。软件可以 计算铸件局部凝固区域的金属流动,以及由此产生的补 缩凝固能力。因此,金属质量和孕育状态会影响铸件的 补缩和缩孔的形成。 新的补缩模型适用于所有类型的铸铁:球墨铸铁,灰 口铸铁和蠕墨墨铸铁。

砂芯在铸造过程中的变形 在高压压铸中,卷气和缩孔缺陷是造成废品的主要原 因。因此,模具和工艺设计非常注重降低因卷气引起的 气孔。使用MAGMASOFT®5.5 可以可靠地预测型腔内 空气的质量平衡和所卷气体的移动。 在新的“气体”结 果中,可以看到型腔内的气体和熔液的定量结果,并可 以在整个填充过程中进行全面评估。 即使在变化的情况 下,也可以在整个项目的过程中持续评估模具设计的质 量和工艺条件。

变形的砂芯 随着轻量化设计需求的增加, 以及由此造成的更薄的壁厚,由变 形或砂芯断裂而导致的与砂芯相关 的铸件缺陷越来越多。在新发布的 MAGMAstress中,首次可以预测填

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product news/产品新闻 Prediction of entrapped air

Visualization of all defects for comparison with CT (blue gas, red shrinkage porosity).

The Crooked Core With the progressive necessity for lightweight designs and the resulting thinner wall sections, core-related casting defects due to distortion or core breakage are increasing. For the first time, in the new release MAGMAstress can be used to predict stresses in cores during filling and solidification and to prevent result- ing casting defects due to core distortion or failure. During mold filling, the core heats up and is subjected to mechanical forces due to buoyancy. As core expands during solidification, it may be confined by the core marks, resulting in distortion or even breakage. In the analysis, the constantly changing material properties of the core are taken into account. The prediction of core distortion has been developed and validated with well-known industry and university partners. Extensive material data is available for various sand/binder combinations. In addition to cold-box cores, particular attention has been paid to predicting the distortion behavior of inorganic cores. These unique capabilities provide the user with increased security in avoiding core breakage, allows the prediction of

Detailed evaluation of the venting conditions during die filling

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裹入气体预测

所有缺陷的CT图像,以进行对比(蓝 色为气体,红色为缩孔)

充和凝固过程中砂芯的应力,并防止由于砂芯变形或失 效而导致的铸件缺陷。在充型过程中,砂芯会被加热并 受到浮力的作用;当砂芯在凝固过程中膨胀时,它可能 会受到砂芯腔体的限制,从而导致变形甚至断裂。分析 考虑到了砂芯随温度变化的材料性能。 使用计算出的曲线可以定量跟踪相应的空气质量以及 排气条件的有效性。 另外,增压阶段的补缩预测得到了改善。 因此,铸 件中的所有潜在缺陷(由卷气和缩孔引起)首次可以作 为单个结果进行评估,也可以直接与CT测量的结果进行 比较。 我们与知名的行业和大学合作伙伴一起开发和验证了 预测砂芯变形的功能,并可提供各种砂/粘结剂组合的 大量材料数据。 除了冷芯,我们还特别关注预测无机砂 芯的变形方式。 这些独特的功能避免芯断裂,允许预测局部尺寸偏 差,并通过改进芯盒设计实现砂芯变形的预补偿,为用

充型过程中排气条件的详细评估

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product news/产品新闻 Core distortion during filling of an electric motor housing

电动机壳体填充 期间的砂芯变形

local dimensional tolerances, and enables the precompensation of core distortion through modified core-box designs. Unnecessary costs can be avoided via a systematic tooling and process development.

户提供了更高的安全性。 有计划有步骤的开发模具 和工艺可以避免不必要的成本浪费。

Core Gases During Casting

在新版本中,扩展了预测铸造过程中砂芯发 气的功能。浇注过程中会自动产生气泡,这些具 有很高危险性的气体裹挟在熔体中。气泡根据其 大小和浮力,随熔体移动。 除气泡直径和压力 外,MAGMASOFT®5.5现在提供了一个新判据来评 估熔体中卷入的气体。 这是对铸件缺陷进行定量预 测的另一个重要组成部分。

With the new version, the capabilities for predicting core gases generated during casting have also been extended. Bubbles are automatically generated during pouring in those areas with a high risk of core gases escaping into the melt. These bubbles are transported by the melt dependent on their size and buoyancy. In addition to bubble diameter and pressure, MAGMASOFT® 5.5 offers a new criterion for evaluating gases trapped in the melt. This is another important building block for the quantitative prediction of casting defects.

Optimized Heat Treatment of Steel Castings MAGMASOFT® has long offered capabilities for the optimization of heat treatments. This allows you to check whether your defined process conditions will provide microstructure and mechanical properties in the component which meet customer requirements. The program now takes into account a significantly extended alloy range for low and high alloy steel grades. The prediction of the heat treated microstructure and properties includes consideration of austenite grain growth, and a new result for the cooling rate in the critical temperature region during quenching is available. A unique feature is the ability to transfer calculated local segregation-related composition information from the casting process to the heat treatment simulation. With the heat treatment results from MAGMASOFT® 5.5, you are now in an even better position to guarantee process conditions, which fulfill customer specifications and at the same

Optimization of process conditions in steel continuous casting

铸造中的砂芯发气

铸钢件热处理的优化 MAGMASOFT®长期以来一直提供优化热处理的 功能。您可以检查设定的热处理工艺条件是否能满足 客户对铸件的金相组织和机械性能的要求。现在,软 件显著的拓宽了适用的合金成分范围,包括低合金钢 和高合金钢种。对 热处理后金相组织和机械性能的 预测考虑了奥氏体晶粒的长大,并且提供一个新的淬 火过程中临界温度区域的冷却速度的结果。 新版本的一个独特功能是:将计算出的铸件区域 偏析的成分信息从铸造过程传递到热处理模拟中。借 助MAGMASOFT®5.5的热处理结果,您现在可以更 好地保证工艺条件,以满足客户对规格的要求;同时 更高效地利用您的资源,能源和生产能力。

MAGMA CC-现在可用于钢的连续铸造 新版的MAGMA CC可以更有效地应用于所有连续

钢的连续铸造工艺条件的优化

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product news/产品新闻 铸造过程(此处为碳含量)中由于 偏析而引起的局部合金浓度信息的 传递,导致热处理计算中淬火后的 马氏体分布的不同

The transfer of local alloy concentration informationdue to segregation during casting (here carbon) leads to different martensite distributions after quenching in the heat treatment calculation

time use your resources, energy and production capacity more efficiently.

MAGMA CC - Now also for steel MAGMA CC can now be used even more efficiently for all continuous casting processes and offers the capability to simulate steel continuous casting for all typical formats and machines – including bow-type casters. With the new version 5.5, numerous enhancements are available for the start-up process as well as for the thermal and mechanical simulation of the complete strand. In addition, you can assess the formation of center cracks.

Reach your goal faster with MAGMASOFT® The use of a software should support the user’s daily work routine simply and effectively. The time to solution must be as short as possible. This is exactly our goal: in MAGMASOFT® 5.5 there are many improvements in usability to get you to the required results faster. Save time when opening projects. You now get a detailed overview of your project with an interactive 3D geometry preview in the Project Perspective. The handling of geometries has been significantly improved and accelerated. The mea- surement perspective for determining calculated distortion has been updated. With the help of the new quality criteria “Roundness” and “Flatness”, you can automatically and quantitatively evaluate and minimize dimensional variations in your castings. With the new version you have the possibility to generate 4D results for our viewer MAGMAinteract® automatically during the simulation, to export geometries in MAGMAinteract® format for your current project versions and to discuss the results easily and interactively within your company or with suppliers and customers. Access to the software has also been accelerated. Starting with the new release, all customers with a valid maintenance status have access to their personal software version for download from the support area of our website. MAGMASOFT® 5.5 offers new potentials in many different areas for securing and increasing the efficiency of your casting designs, your tooling layouts and your production processes. ■ 62

铸造工艺,模拟所有典型规格和机器(包括弧形连铸 机)的钢的连续铸造。 新的5.5版本中,许多增强功 能可用于启动过程以及整个铸流的热流和机械方面的 模拟。 此外,还可以评估中心裂纹的形成。

MAGMASOFT®助您更快实现目标 软件的使用应该简单有效地支持用户的日常工 作,解决问题的时间必须尽可能短。这正是我们的目 标:MAGMASOFT®5.5在可用性方面进行了许多改 进,帮助您更快地获得所需的结果。从打开项目时 就可节省时间。现在,您可以在项目管理器中通过交 互式3D几何预览图获得项目的详细概述。对几何模 型的处理已得到显著的改善和加速。计算变形的测量 管理器已更新。借助新的质量标准“圆度”和“平整 度”,您可以自动地、定量地评估铸件的尺寸变化并 将其最小化。 您可以使用新版本,在模拟中通过 MAGMAinteract®查看自动生成的4D结果,并可以 将当前项目版本的结果以MAGMAinteract®的格式导 出,与同事、供应商和客户轻松进行讨论 。 从MAGMASOFT®5.5版本开始,所有处于有效维 护状态的用户都可以从我们网站的技术支持区域下载 有效许可的软件版本。 MAGMASOFT®5.5在许多不同领域提供了新潜力, 可确保并提高铸造设计,模具设计和生产工艺的效率。 ■

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product news/产品新闻

Smarter Than Oil - Water-Based Hydraulic Fluids From Fluid Experts 比油更神奇 – 源自德国的绿色环保水基液压液 Fluid-SKL (Tianjin) GreenTech is a cooperation between China and Germany. In Germany, it has supplied the entire German hard coal mining industry for the past 10 years, the only company able to meet the very high technical and environmental requirements and occupational safety regulations set by RAG AG. In 10 years, Fluid-SKL (Tianjin) GreenTech has proven with over 600 machines that it is possible to operate mineral oil and bio oil-free mining. Appropriate approvals are of course available. All products are TÜV and hygienic institute certified and of course have passed all tests.

Not based on a standard, rather on innovation! Fluid-SKL (Tianjin) GreenTech develops hydraulic fluids that are characterized by a profile that is unique in four ways. They are up to 100% biodegradable, which makes them extremely environmentally friendly. At the same time, by being neither toxic nor carcinogenic, they offer excellent flame retardancy and promote health protection. Thanks to a patented additive technology, they also prevent corrosion in the systems and have a high cleaning effect. The three product lines - CORSAVE, LUBESAVE and FREEZESAVE offer the potential to operate hydraulic systems worldwide in a more environmentally friendly and safer way, and with less wear than ever before. The products are even approved for use in food production!

Pretty smart, don’t you think? Imagine having hydraulic fluids in your machine / vehicle with the following properties:

Environment / sustainability

弗洛德克圣凯伦(天津)环保科技有限公司是一家 中德合作企业。在过去的数十年中,为德国全部煤矿供 应绿色环保液压液。产品完全满足鲁尔集团标准,该标 准对技术和环保要求极为严苛,且我公司是唯一一家可 以同时达到鲁尔集团标准中健康防护要求的企业。数十 年间,通过在600多台机械设备上的应用充分证明,水 基液压液可以完全替代矿物油或植物油制成的液压油。 诚然,产品也相应的获得了所需的各种许可。全部产品 均经过德国TUV以及卫生机构的检测和认证,实验过程 及结果符合所有标准要求。弗洛德克圣凯伦所研发的液 压液具有四重独特之处:产品的生物降解性最高可达 100%,因此极具环保性;同时具有极高的阻燃性,且 不含任何有毒或致癌物质,可有效促进健康防护;得益 于其独特的专利添加剂技术,可以有效防止对设备系统 的腐蚀,并在系统内部起到清洁的作用。绿色环保浓缩 液、绿色环保抗磨液压液和绿色环保防冻液三个产品线 旨在全球范围内打造更环保、更安全、更耐磨的液压系 统。此外,产品获得食品机械使用许可。

这不正是比油更神奇的体现吗? 使用弗洛德克圣凯伦研发的液压液,将赋予您的设 备 / 工程车辆以下特性:

环保性 / 可持续发展

• Does not cause any environmental damage! • Is up to 100% biodegradable! • Does not contain any substances from which food is made!

• 不会造成环境污染

Health & safety

• 不包含植物油或可产生植物油的物质

• 最高可100%生物降解

• Is very flame retardant! • Can be extinguished / cooled with water! • Does not contain any critical substances!

• 极不易燃

Technology / performance

• 可用水熄灭 / 冷却

• Meets the highest technical standards! • Corresponds to the performance level of high-performance hydraulic oils! • Has no problems with water contamination!

Profitability • Is significantly cheaper than previously available organic oils! • Shows practically no signs of aging! • Food approved • Maximum biodegradability - oil-free hydraulic fluids Companies are radically rethinking using innovation

健康 / 安全性

• 不含有害物质

技术性能 • 符合最高技术标准 • 满足高性能液压油的技术性能要求 • 不会造成水质污染

经济性

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product news/产品新闻 to lead to a better environment. The result of research and development work at Fluid-SKL (Tianjin) GreenTech is, for example, the provision of new solutions for operators of hydraulic devices. Performance and protection are now the top priorities for water-based hydraulic fluids. These products also perform better in terms of fire safety, environmental protection, and worker health and safety.

Initial Situation Mineral oil and bio-based hydraulic fluids are used in many hydraulic systems today. When the hydraulic cylinders are immersed in water or when the machine is operated in a certain environment, as is the case in mining and steel production, as well as in the chemical and paper industries, these fluids must meet certain requirements. Fire and explosion protection often play an important role. However, when planning to change the fluids in a hydraulic system, the actual performance of the new product generally takes precedence over all other considerations. Water-based hydraulics have seen such performance development in recent years that these new fluid products can now be seen as the right option for those looking to go oil-free. Equipment Protection and Performance Production engineers view hydraulic equipment as critical to the operation of their business. A standstill in this area can often bring the entire production line to a standstill, which is why wear regimes are in great demand today. The hydraulic products CORSAVE, LUBESAVE and FREEZESAVE from Fluid-SKL (Tianjin) GreenTech were developed with this in mind. They offer longer running times, improved corrosion protection and better prevention of sludge formation without sacrificing performance. We have 10 years of experience as users. Fire Protection - Since hydraulic fluids from FluidSKL (Tianjin) GreenTech were originally developed for use underground in leading machine manufacturers, they are inherently fireproof and also offer maximum explosion protection. As a result, they also offer other industrial sectors such as foundries, steel production and aluminum processing improved protection against fire and explosion. Environmental Protection - The operators of hydraulic devices are responsible for ensuring that neither persons nor the environment are harmed during normal operation or as a result of a malfunction. Using a water based hydraulic fluid system can improve safety not only when things are going normally, but also when things go wrong. Thanks to their high biodegradability, fluids from Fluid-SKL (Tianjin) GreenTech make a positive contribution to the environment. They are also suitable for use in construction machinery, in handling and conveyor systems, as well as in agricultural and forestry machines and in hydraulic engineering. Machines and vehicles of this type often operate on surfaces where hydraulic leaks are likely to allow fluids to penetrate the underground. Fluid-SKL (Tianjin) GreenTech health and safety protection products contain no unsafe additives and therefore meet the highest possible health and safety standards. The fire risk is also significantly reduced thanks to a high fire resistance class, while the excellent ecotoxicological properties are of considerable benefit in the event of leakage or leakage of liquid. 64

• 与植物油相比效益明显 • 几乎没有老化迹象 • 可用于食品机械 • 最强的生物降解性 – 无油液压液 现代企业都应认真思考,如何才能在技术发展创新的 过程中达到环境保护的要求,弗洛德克圣凯伦的研发成 果为液压设备提供了全新的解决方案。技术性能和安全 防护是水基液压液的主要优势,此外,其在阻燃、环保 和员工健康与安全方面更具有绝对优势。

当今现状 如今,许多液压系统都使用基于矿物油或植物油的 液压油。如果液压缸在水下应用,或者设备在特定的环 境中运行,无论采矿业、炼钢或者化学以及造纸业,则 这些液体必须满足一定的特殊要求,防火和防爆性能通 常更是重中之重。但是,当计划更换液压系统中的液体 时,应优先考虑新产品的实际性能,而非其他因素。近 年来,水基液压液的性能不断优化,使得此类新型产品 成为去油化的正确选择。 在负责设备维护和保障生产的工程师眼中,液压设备 对其公司的运营至关重要,因为液压设备停产通常会拖 累整条生产线,这也是低磨损液压液的需求居高不下的 原因。弗洛德克圣凯伦生产的绿色环保浓缩液,绿色环 保抗磨液压液和绿色环保防冻液系列产品在研发时就充 分考虑了这一点。它们在不降低技术性能的前提下保障 设备的运行时间更长,提供更强的抗腐蚀性能以及更好 的防止沉淀杂质堆积的功能。 在这一领域,我们积累了数十年的用户使用经验。 防火性能 - 弗洛德克圣凯伦公司研发液压液的初衷 是为满足井下机械设备的使用条件,因受其使用环境所 限,必须具有阻燃性,且能提供最强的防爆保护。因 此,也可为铸造业、钢铁和铝加工等工业领域,提供更 强的防火和防爆保护。 环境保护 - 液压设备的操作员有责任确保在正常操 作过程中或由于故障而产生泄露时,不会对人员或环境 造成损害。使用水基液压液,不仅在设备正常运行时, 更能在其出现故障时提高安全性。由于弗洛德克圣凯伦 的产品具有极高的生物降解性,因此也对环境保护做出 了积极的贡献。该液压液同样适用于建筑设备、物流运 输、输送设施、农林机械以及水利工程,因为这些设备 和工程车辆经常应用在环保要求更为严苛的领域,避免 因液压系统泄露而造成液压油渗入地下。 弗洛德克圣凯伦所研发的产品不含任何危险或有害的 添加剂,因此满足最高的健康和安全标准。极高的阻燃 性也大大降低了火灾风险,而其出色的生态毒理学特性 在发生液体溢出或泄漏时同样具有显着的优势。 如果中国和全球其他国家想停止使用油基液压产

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product news/产品新闻 If China and the world want to say goodbye to oil-based hydraulic applications in the long term, they now have a very good method that has been tried and tested in over 600 machines for 10 years. In Fluid-SKL (Tianjin) GreenTech’s experience, up to 70 percent of all hydraulic applications today can be operated without bio oil and without mineral oil.

Applications

品,我们可以提供极佳的解决方案,并已经在600多台 机械设备上进行了数十年的研究和测试。 根据我们的经验,如今多达70%的液压设备均可以在 不使用植物油和矿物油的情况下运行。

应用领域

• Opencast and underground mining (RAG AG, OKD, GHH, Tiefenbach, Marco, Caterpillar, EEP) • Foundries (Wieland, Westland, Barath Forge, Aurubis, Hauhinco,) • Steel production. (Thyssenkrupp, Hauhinco) • Chemical industry (Kluthe, TAG,) • Papermaking • Water industry • waste management • Agriculture and Forestry • Construction sector (Neuhäuser, Deilmann) • Logistics ( Jäschke, SMT Scharf, GTA,) ■

• 露天矿和井下综采工作面(鲁尔集团,蒂芬巴赫,马 可,卡特彼勒,OKD,GHH,EEP) • 铸造业(威琅电气,奥鲁比斯,Westland,Barath Forge,Hauhinco) • 炼钢(蒂森克虏伯,Hauhinco) • 化学工业(科路德,TAG) • 造纸 • 水工业 • 废弃物管理 • 农业和林业 • 建筑业(诺豪泽,戴尔曼)

Contact us for more information:

• 物流运输(沙尔夫,Jaeschke,GTA)

Fluid-SKL (Tianjin) GreenTech Co., Ltd. No. 5 Dongwang Road Dongmajuan city Wuqing District, Tianjin Contact: Ning An 18600727851 Wei Wei 13051312489

获取更多信息,请您与我们联系: 弗洛德克圣凯伦(天津)环保科技有限公司 天津市武清区东马圈镇东旺道5号 联系人:安宁 18600727851 魏为 13051312489

Time for a new inspection experience 亟需新的检测体验 With the new YXLON UX20 x-ray system, Yxlon has introduced a completely new operating concept. Besides quality and reliability, the main focus lies on the system’s ease of operation. Specific knowledge of x-ray technology is no longer necessary. 借助新的YXLON UX20 X射线系统,Yxlon引入了全新的操作理念。除了质量和可靠性外, 焦点问题还在于系统的易操作性,不再需要X射线技术方面的具体知识。 The UX20 with its compact design has been specially designed for use in the harsh environments of foundries. It is ideally suited for the inspection of castings of sizes up to 800mm in diameter and 1100mm in height. The system components such as the generator, cooler, and highvoltage cable are economically integrated into the cabin and at the same time easily accessible for maintenance work. The control desk mounted at the system is ergonomically Fig. 1: YXLON UX20 – compact radioscopy and CT system with clearly arranged and height-adjustable control desk

UX20设计紧凑,是专门为在恶劣的铸造环境中使用 而设计的。它非常适合检查直径最大为800mm,高度 最大为1100mm的铸件。发电 机、冷却器和高压电缆等系统 组件集成到一起,不仅具有经 济性、同时易于检修。 安装在系统上的控制台的 高度符合人体工程学。控制 台只有必需的功能设计:可 以使用操纵杆和按钮直观地 执行手动X射线检查。能够进 图1:YXLON UX20具有紧凑的 X射线检查和CT系统,控制台布 局清晰且高度可调。

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product news/产品新闻 Fig. 2: Large inspection envelope with multiple manipulation possibilities of part and x-ray components

图2:宽敞的测试室,为零件和X 射线组件提供了多种操作选择。

adjustable in height. It is reduced to the 行简便操作的基础是安装了屡获殊荣 essentials needed: Manual x-ray inspec的Geminy软件平台,该平台包含了 tion can be performed intuitively with 所有涉及的程序。图形元素以及各种 joysticks and buttons. The basis for the simple operation is the awarded Geminy 预设和向导能够支持经验不足的操作 software platform which combines all 员快速获得最佳的检查结果。单独的 programs involved. Graphic elements and 检查顺序包括过滤器和参考图像,而 a selection of pre-settings and wizards 且可通过菜单导航轻松创建用于小批 support the inexperienced operator to quickly achieve best inspection results. Individual inspection 量半自动检查并在需要时调用的标记。放射线检查和 sequences incl. filters, reference images, and markings for the 计算机断层扫描之间的直接转换加快了深入分析的速 semi-automatic inspection of small batches are easily created 度。测试报告将与所有图像和设置参数一起自动存储 via menu navigation and called up whenever needed. The direct changeover between radioscopy 在后台。 and computed tomography speeds up 为了节省时间和精力,零件机械 in-depth analyses. The test report is 手在关闭装料门时自动进入测试位 automatically stored in the background along with all images and setting pa置,并在检查后回到设备边缘的装料 rameters. 位置。 To save time and efforts, the parts 由于有了许多选件和升级功能,例 manipulator automatically moves into the test position when the loading door is 如检测器、独立CT分析站以及性能不 closed and after the inspection back into 同的重建PC,YXLON UX20可以随着 the loading position at the edge of the 用户需求的增长而发展。作为标准配 cabin. Thanks to many options and up置的基本系统,购买后,它可以变成 grades such as a selection of detectors 一个“多面手”或“专家”。 ■ and the separate CT analysis station YXLON (Beijing) X-Ray Equipand reconstruction PC in different perment Trading Co., Ltd. formance levels, YXLON UX20 grows C07, First Floor, Building 2 with the user’s needs. Purchased as a Zhongke Industrial Park Fig. 3: Separate workstation for CT evalubasic system in the standard configura103 Beiqing Road, Haidian ations tion, it can evolve into an all-rounder or District 图3:用于CT评估的独立工作站。 a specialist. ■ 100004 Beijing YXLON International GmbH China Essener Bogen 5 Phone: +86 10 88579581 22419 Hamburg www.yxlon.cn Germany Phone: +49 40 527290 yxlon@hbg.yxlon.com www.yxlon.com

Fig. 4: Low space requirements and easy maintenance thanks to integrated and at the same time easily accessible components such as cooler, generator, and high-voltage cable

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图4:由于集成了冷却器、发电机和 高压电缆等易于同时使用的组件,因 此空间需求小,设备维护特别方便。

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product news/产品新闻

Capacitor leading brand--Jiande Haihua Electric Co. 电容器领先品牌——建德海华电气有限公司 Established in 2002, Jiande Haihua Electric Co., Ltd. is a professional manufacturer of capacitors for induction heating systems. Our company set up a set of leading capacitor automatic professional production lines and complete testing equipment, which can monitor the quality of the whole process from raw materials to semi-finished and finished products to ensure high quality products. Haihua also set up the only line of capacitor operation test equipment in the industry, which can carry out destructive test and detection of products, which provides a strong guarantee for the research and development of new products and the application of new materials. Haihua has a strong production capacity, with an annual output of more than 100,000 capacitors. It mainly produces products such as resonance capacitors for induction heating devices, DC filter capacitors, protection capacitors, absorption capacitors and ultra-audio capacitors, with more than 800 models and specifications. The domestic market share is over 40%, and the products are also exported to Europe, America and Southeast Asia. Haihua continuously develops new products to meet customer needs in an all-round way, and can customize products for customers, so that customers’ products have more competitive advantages in the market. ■

成立于2002年的建德海华电气有限公司,是一家集 研发、设计、生产、销售和服务于一体的感应加热系统 电容器专业制造企业。公司拥有一套领先的电容器自动 化专业生产线和完整的检测试验设备,从产品的原材料 到半成品、成品的全过程进行质量跟踪监测,确保优质 的产品;还拥有行业内仅有的一套电容器运行型试验设 备,可以对产品进行破坏性试验检测,为新产品的研发 和新材料应用提供了有力的保障。 公司具有强大的生产能力,年产10万余台电容器,主 要生产感应加热装置用谐振电容器、直流滤波电容器、 保护电容器、吸收电容器以及超音频电容器等产品, 型号规格超过800多种。在国内的市场占有率达40%以 上,产品还出口到欧美、东南亚市场。 公司通过不断开发研制新产品,全方位满足客户需求, 可以为客户定制产品,使客户的产品更具市场竞争优 势。 ■ 更多产品信息,请联系:叶女士15168765707

For more product information, please contact: Ms. Ye 15168765707

Efficient curing process of the core machine 制芯机高效吹气固化技术 yang linlong, xu leilei, (suzhou mingzhi technology co., ltd.)

杨林龙1 徐磊磊1 (1苏州明志科技股份有限公司) (1)射砂筒总成,(2)吹气罩总 成,(3)加热器总成,(4)连接软 管总成,(5)连接小车总成;

(1) Sand shooting barrel assembly, (2) Gassing bell assembly, (3) Heater assembly, (4) Connecting hose assembly, (5) Connecting trolley assembly

图1 传统方案简图

Figure 1. Sketch of the traditional solution

Abstract: To introduce the development method, performance values and results newest generation of the integrated high-efficiency heater for the core machines, as well as a finite element analysis method to improve the performance of the heater, with an integrated design concept. The results show that significant results have been achieved in improving the curing efficiency of the core making machine, reducing energy consumption and creating catalyst material savings. Key words: Integration; Heater; Efficient; Energy saving; Material savings

1. Introduction The gas generator (including gas heater, abbreviated as

摘要:介绍制芯机新一代集成高效加热器的开发方 法、开发价值及成果,结合有限元分析手段,对加热器 进行性能提升,并采用集成结构的设计理念,结果表明 在提高制芯机固化效率、降低能耗及节省催化剂用量等 方面都获得了很大成果。 关键词:集成 加热器 高效 节能 节材

1 前言 铸造行业广泛使用的传统制芯机气体发生器(含气体 加热器,简称加热器)通常与设备分离式安装,通过软

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product news/产品新闻 Table 1. The relationship between core-making cycle time and efficiency using the traditional method

表1 传统方案制芯周期时间与效率的关系

表2 传统方案制芯机主要功能配电 功率与能耗的关系

Table 2. The relationship between power distribution and energy consumption of the main functions of the traditional core machine

(1)加热器体,(2)吹气流道,(3) 进气口,(4)出气口,(5)电热元件, (6)注胺口,(7)保温层,(8)吹气 罩,(9)芯盒,(10)砂芯;

(1) The heater body is integrated with the gassing channel and electric heating element, (2) Blowing air duct (3) Air inlet (4) Air outlet (5) Electric heating element (6) Amine injection port (7) Heat insulation (8) Gassing bell (9) Core box (10) Sand core

图2 集成方案示意图

Figure 2. Schematic diagram of the integration scheme

heater) of the traditional core making machine, widely used in the foundry industry, is usually installed separately from the equipment. Its main function is to send high-temperature gas or catalytic gas into the blowing plate through hoses, joints, the connecting plate and into the core box, resulting in the hardening of the sand core. Based upon research into the inorganic and organic core curing process, improving the heater’s ability to continuously provide high-temperature gas is a known challenge. Considering the status quo and inherent problems, the development of high-performance heaters can provide high-level efficiency and energy savings. With the current technology, the high-temperature gas has a lengthy transport distance, great temperature loss (up to 60% or more), high energy consumption, and poor stability. Especially among the conditions of the inorganic curing process, the temperature cannot be guaranteed, resulting in low curing efficiency and high energy consumption.

(1) Sand shooting barrel assembly (2) Blow hood assembly (3) Integrated heater assembly (4) Connecting trolley assembly

Figure 3 Schematic diagram of the integration scheme

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管、接头、连接板将高温气体或催化气体送入吹气 板后进入芯盒内部,实现砂芯固化。 通过对无机及有机制芯固化工艺的研究,提升加 热器持续提供高温气体能力是关键参数,结合目前 的现状及问题,开发高性能的加热器可以实现高效 与节能。 现有技术高温气体输送距离长,温度损失大(达 到60%以上),能耗高,稳定性差。尤其在无机固 化工艺条件下,温度无法保证,造成固化效率低, 能耗高。

2 现状分析 传统方案简图如图1所示,表示制芯机上部移动 机构的组合,由于在制芯过程上部每一周期往复一

1)射砂筒总成,(2)吹气罩 总成,(3)集成加热器总成, (4)连接小车总成;

图3 集成方案简图

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product news/产品新闻 Table 3 The relationship between cycle time and efficiency of integrated solution manufacturing sand core

表3 集成方案制芯周期时间与 效率的关系

Table 4 The relationship between power distribution and energy consumption of the main processes of the integrated core making machine

表4 集成方案制芯机主要功 能配电功率与能耗的关系

2. Status analysis

次,加热器固定在上机架上,通过软管总成将热空气

The schematic diagram of the traditional generator scheme is revealed in Figure 1, which shows the combination of the upper moving mechanism of the core making machine. Since the upper part of the core making process repeats once every cycle, the heater is fixed on the upper frame, and the hot air or the catalytic gas is delivered to the gassing bell under a specific pressure which results in the hardening of the sand core. For analysis of the cycle time of the core making process, we use the 40L core-making machine core cycle time as an example; see Table 1: T1-The time required for auxiliary equipment actions in core making (s). T2-The period of time for sand shooting and discharge of high-pressure gas after the mold closing equipment is locked (s). T3- The time required for core sand curing after filling the cavity (s) The core-making cycle time is T=T1+T2+T3, and the hardening of the sand core accounts for about 50%~60% of the core-making cycle. The traditional

或催化气体在一定压力下输送至吹气罩内实现砂芯固

Figure 4 Heater geometry model

Figure 5 Completed finalization plan of the integrated heater

化。 T1-为设备实现制芯的辅助动作总和(s); T2-在模具合型设备紧锁后实现射砂及排出高压气 体的周期(s); T3-为芯砂填满型腔后将芯砂固化成砂芯的 周期(s); 制芯周期时间T=T1+T2+T3,砂芯固化约占制芯 周期的50%~60%,传统方案制芯效率约为50~60 型/H(冷芯工艺),40~50型/H(无机工艺)。 通过制芯机主要功能配电功率组成分析,以40L制 芯机为例,参见图3: 制芯机主要功能配电功率由液 压、执行元件及加热器组成,其中 加热器占比达到25%~40左右,结

图4 加热器几何模型

图5 集成式加热器最终定型方案

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product news/产品新闻 Table 5 Blowing inlet temperature curve of the integrated solution

core-making efficiency is about 50-60 type/H (cold core process), 40-50 type/H (Inorganic technology). For analysis of the distribution power composition of the main functions of the core making machine, we use the 40L core making machine as an example, see Table 2: The main functional power distribution of the core making machine is divided across the hydraulic station (pressure), operating units, and heaters. Among these, heaters account for about 25%~40%. Combined with the previous evaluation data, the curing energy consumption of the traditional core making machine (Cold core process) is about 0.009Kwh/kg (Calculated based on the ratio of the measured curing energy consumption to the weight of the sand core during a specific blowing period).

3. Integrated solution 3.1 According to the above analysis of the operating cycle, the heater accounts for 60% of the total core-making cycle, and the energy consumption accounts for 40%. The question of how to integrate the design will be the starting point in a addressing the efficiency and consumption problem. The heater integration task includes primarily structural integration and functional integration. Structural integration: the heater is integrated with the blowing hood of the core making machine. Functional integration: heater and cold core process catalyst atomization accomplish a functional integration. The schematic diagram of the integration scheme is shown in Figure 2 The schematic diagram of the integrated scheme is shown in Figure 3. Compared to the traditional scheme, the other mechanisms are the same, but the heater is integrated on the blowing hood, eliminating the traditional connecting hose assembly. 3.2 According to the current structure of the key functional component of the heater, its physical shape and the geometric model of the fluid channel area are preprocessed, and the flow and heat exchange process of the heater are simulated and analyzed according to the operating conditions of the heater. 1) The three-dimensional flow trajectory diagram of the gas in the heater channel and the core area diagram of the air flow vortex are obtained through simulation, and the air inlet Reynolds number, obtained through simulation, is within the “strong turbulence” stage. 2) The heater is designed to simultaneously introduce gas into both sets of flow channels. Since the channel geometric 70

合前期测评数据,传 统制芯机(冷芯工 艺)固化能耗约为 0.009Kwh/kg(根据 一定吹气时间内的实 测固化能耗与砂芯重量的比值计算得出)。

3 集成方案 3.1根据上述动作周期分析,加热器占总制芯周期 的60%,能耗占40%,如何进行集成设计将是解决 问题的切入点。 加热器集成方案主要包括结构集成及功能集成。 结构集成:加热器与制芯机吹气罩集成; 功能集成:加热器与冷芯工艺催化剂雾化加入功 能集成; 集成方案示意图如图2所示。 集成方案简图如图3所示,和传统方案相比,其 他机构相同,但加热器集成在了吹气罩上,取消了 传统的连接软管总成。 3.2根据关键功能部件加热器的实际结构,对其实 体外形,流体流道区域几何模型进行预处理,根据 加热器运行工况,对其流动和换热过程进行有限元 仿真分析。 1) 通过仿真获取了加热器流道中气体的三维流动 迹线图及空气流动涡旋核心区域图,通过仿真得到 的空气进口雷诺数处于旺盛湍流阶段。 2) 本加热器设计两组流道同时通入气体。由于通 道几何结构对称相似,通过仿真,获取了两组流道 中的空气流动呈现出对称分布的流动规律。 3) 结合涡旋核心区域图仿真分析,在本加热器流 道中,绝大部分区域的气体流动状态处于湍流涡旋 流动,因此加热器的换热效率比较高。 4)本加热器不同层板中的蛇形弯曲流道通过流 道不同截面尺寸的不停缩放实现了对气体气流的加 速,一定程度上强化了换热效果。 5)从加热器顶端进口到底端出口,气体的温度

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product news/产品新闻 表6 集成方案 验证结果(以 40L制芯机为 例)

Table 6. Verification results of the integration scheme (take 40L core making machine as an example)

structure is symmetrically similar, the gas flow in the two sets of flow channels also exhibits a symmetrically distributed flow pattern. 3) It can be seen from the schematic diagram that within the heater flow channels, the gas flow state in most areas is a turbulent vortex flow, so the heating and heat exchange efficiency of the heater is relatively high. 4) The serpentine curved flow channels in the different layers of the heater are connected through the vertical tube. Due to the small size of the round tube, the acceleration of the gas flow is achieved by the constant scaling of the pipe size in the heater, which enhances the heat exchange effect to some extent. 5) From the top inlet of the heater to the bottom outlet, the temperature rise of the gas is relatively stable and continuous. This indicates that when the heating rod is working, the heater shell and the gas near the boundary layer near the wall of the flow channel are effectively heated, and the vortex in the elbow area makes the gas heat exchange stronger. The temperature rise of the mainstream in the smooth straight channel depends primarily upon the heat status of the molecules.

4 Production test and verification results 4.1 Through the application of the integrated solution, due to the increase of blowing temperature and continuous improvement, the blowing curing time is significantly shortened, thereby reducing the amount of sand core curing time and improving the core making efficiency. (See Table 3): The percentage of sand core hardening in the core-making cycle is reduced from 50%~60% to about 37%~44%, and the core-making efficiency of the integrated solution is increased to approximately 90-100 type/H (cold core process) and 80-90 type/H (inorganic process). 4.2 Due to the elimination of the high-temperature gas delivery pipeline, the blowing temperature heat loss is greatly reduced, while the same inlet temperature of the blowing hood is achieved. The set temperature of the heater integra-

升高是较为平稳和持续的。这说明,加热棒工作 时,把加热器壳体和靠近流道近壁面边界层处的气 体有效加热了,并且在弯头区域由于涡旋作用使得 气体换热加强,在光滑直通道中的主流温升主要依 靠分子导热。

4 生产测试及验证结果 4.1通过集成方案的应用,由于吹气温度的提升及 持续能力的提高,吹气固化时间将明显缩短,从而 降低了砂芯固化时间的占比,提高了制芯效率,参 见表3: 砂芯固化占制芯周期的百分比由50%~60%降 至约37%~44%,集成方案制芯效率约提高至90 ~100型/H(冷芯工艺),80~90型/H(无机工艺)。 4.2由于取消了高温气体输送管路,使吹气温度热 量损失大大降低,获取同样的吹气罩入口温度,加 热器集成方案的设定温度更低,响应时间也更短, 加热器的配电功率占比也由25%~40%降至18% ~30%,固化能耗预估可降低50%以上,参见表4: 另外,由于采用功能集成,对于冷芯工艺而言, 加热器与催化剂雾化加入功能集成,催化剂可通过 初步雾化后实现即吹即注,催化剂气化效率及利用 率提高,从而在降低催化剂消耗的情况下,获得更 高的催化效果,提升固化效率。 4.3图5为集成式加热器最终定型方案,已应用于 明志MiCC300集成智能制芯单元生产测试验证,已 累计制芯近20万模,无故障,可实现有机工艺吹气 入口温度150℃以上,无机工艺吹气入口温度200℃

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product news/产品新闻 tion scheme is lower, the response time is shorter, and the percentage of heating power is also reduced from 25%~40% to 18%~30%. In addition, the curing energy consumption is estimated to be reduced by more than 50%. (See Table 4): In addition, for the cold core process, as the heater and the catalyst atomization are functionally integrated, the catalyst can be blown and injected after the initial atomization, and the catalyst gasification efficiency and utilization rate are improved, thereby reducing the catalyst. In the case of consumption, a higher catalytic effect is obtained, and the curing efficiency is improved. 4.3 Figure 5 represents the finalized plan of the integrated heater, which has been applied to the production test verification of the Mingzhi MiCC300 integrated intelligent core-making unit. Almost 200,000 molds of sand core have been manufactured with no process failures. The blowing inlet temperature of the organic process can be above 150ºC. Inorganic process blowing inlet temperature is above 200ºC (blowing pressure is 3bar, blowing flow is about 1200L/min); 4.4 Table 5 shows the blowing inlet temperature curve of the integrated solution. During the entire high-efficiency curing period (within 30s), the blowing inlet temperature of the integrated heater shows improved capability to remain constant. The blowing inlet temperature over 30s shows a downward trend, with a decrease of about 5 %, which reflects that the heater’s heat capacity, heating power and other parameters are well designed and result in good performance. 4.5 See Table 6 for verification results The data obtained through the production test verification clearly shows: in the case of reducing the heat loss by 50%, the energy consumption can be effectively reduced by 50%, the curing efficiency increased by 30% to 50%, the amount of catalyst reduced by 30%, and the costs of exhaust gas purification treatment will decrease accordingly (the exhaust system processing air volume is reduced by 40% to 50%).

5. Conclusion

以上(吹气压力3bar,吹气流量约1200L/min条件 下); 4.4表5为集成方案吹气入口温度曲线,在整个高 效固化时间段(30s内),集成加热器吹气入口温度 恒定能力比较好,超过30s吹气入口温度呈现下降趋 势,下降幅度约为5%,体现了加热器热容量、加热 功率等参数设计富裕适中,性能较好。 4.5验证结果参见表6。 通过生产测试验证获得的数据清楚表明:在减少热 量损失50%的情况下,可以有效减少50%的能耗并提 升30%~50%固化效率,降低催化剂用量30%,以及 尾气净化处理的成本也随之降低(尾气系统处理风量 降低40%~50%)。

5 结论 本文针对制芯机高效吹气固化技术进行了研究, 综合热交换原理、固化工艺原理、先进的集成设计理 念,建立了加热器有限元数字分析模型,通过多维度 分析,确定了加热器的最终设计参数,同时对定型加 热器进行测试定量及生产验证达到了: (1)降低能耗大于30%; (2)有机工艺降低催化剂用量大于30%; (3)固化效率提升50%左右; (4)有机工艺条件下尾气处理风量降低50%以 上。 ■ 更多信息请访问: www.mingzhi-technology.com or www.mingzhitechnology.eu

This paper studies the high-efficiency blowing and curing technology of the core-making machine. It integrates heat exchange principles, curing process principles, and advanced integrated design concepts. A finite element digital analysis model of the heater is established. Through multidimensional analysis, the finalized heater is also established. Design parameters, and likewise, test quantification and production verification of the finalized heater yield the following results: (1) Reduced energy consumption by more than 30% (2) Reduction in the amount of catalyst by more than 30% under the organic process (3) Curing efficiency increase by about 50% (4) Exhaust gas treatment air volume reduction by more than 50% under the organic process conditions ■ For questions or information: www.mingzhi-technology.com or www.mingzhitechnology.eu

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