CN103506580A - Casting method for large thin-wall valve body steel casting - Google Patents

Casting method for large thin-wall valve body steel casting Download PDF

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Publication number
CN103506580A
CN103506580A CN201310521299.0A CN201310521299A CN103506580A CN 103506580 A CN103506580 A CN 103506580A CN 201310521299 A CN201310521299 A CN 201310521299A CN 103506580 A CN103506580 A CN 103506580A
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casting
valve
thin
steel
core
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CN201310521299.0A
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Chinese (zh)
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CN103506580B (en
Inventor
刘为作
於兴洲
吕万鹏
部显文
黄浩
王海建
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宜昌船舶柴油机有限公司
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Abstract

A casting method for a large thin-wall valve body steel casting comprises the following steps: 1, manufacturing a composite physical model: manufacturing an upper half valve body external mold, a lower half valve body external mold, the overall frame of a second core box, and an irregular-shaped section template; filling a mixed filler between the frame and the section template; tamping, smoothly trimming the filler; performing natural curing after the dimensional requirement is met; 2, sand mulling; 3, modeling and core manufacturing; 4, painting, mounting the core, and combining boxes; 5, smelting and casting; 6, performing post-treatment. The large thin-wall valve body steel casting is prepared through the steps. The casting method adopting the composite model can improve the model manufacturing efficiency, saves wood, and reduces the model manufacturing cost; through the adoption of stepped flat ingate system, as well as the manner that a chiller, a riser and compensation are combined, the thin-wall valve body steel casting is protected from fracture, insufficient casting, cold shut, wrinkling, and other casting defects, so as to realize the sequential solidification of the valve body steel casting, and meet the technical requirement of the valve body steel casting.

Description

The casting method of large thin-wall valve body steel-casting
Technical field
The present invention relates to a kind of casting method, particularly a kind of casting method of large thin-wall valve body steel-casting.
Background technology
Large thin-wall valve body steel-casting, it is the crucial foundry goods of hydraulic mechanical equipment, high 2050 mm * 1750mm * 1000 mm that is respectively of length and width, has the connecting water pipe flange of three directions in profile, inner chamber has 16 water guide arcs (14) to be connected column (15) with 16 upper and lower propeller boss, referring to Fig. 4, the most of region of water cavity and profile is irregular line style, main wall thickness 32 mm, quality 4100kg, require flange face magnetic powder inspection, ultrasonic examination II level, other black skin requires magnetic powder inspection III level.
Prior art condition drag is made, need first with timber, to make the contour structures of foundry goods full pattern and core box, adopt again the regular shapes such as wood craft machines processing flange, cylinder, for irregular linear regions, can only setting-out make model, adopt manual mode, the piecemeal removal redundance of contrast model.Analogue formation, not only needs to consume a large amount of timber like this, and need to spend a large amount of manpowers and longer duration.
Valve body steel casting surface is long-pending very large, and water cavity cross section wall thickness only has 32 mm, under prior art condition, adopt the circular ingate of rising pouring, 1550 ± 15 ℃ of pouring temperatures, end face arranges rising head mode, and away from ingate and rising head place, easily there is the defects such as misrun, cold shut, elephant skin in foundry goods water cavity surface, and in foundry goods ingate junction, because molten steel is overheated and crack defect does not freely easily appear in Feeding channel.If these defects, repairing within the scope of standard code, just need to take the modes such as polishing, magnetic powder inspection, carbon plane, soldering to process, and when defect is above standard, the quality accident that will cause foundry goods to be scrapped.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of casting method of large thin-wall valve body steel-casting, can make fast, economically complicated erose cast model, molten steel stable filling type from bottom to top while guaranteeing casting pouring, realize foundry goods consecutive solidification, thereby obtain the foundry goods that quality meets specification requirement.
For solving the problems of the technologies described above, the technical solution adopted in the present invention is: a kind of casting method of large thin-wall valve body steel-casting, comprises the following steps:
One, entity composite model is made;
With timber, make whole skeleton and the erose section template of first valve body, second valve body external mold and the second core box, at skeleton and model room filling mixed fillers, tamping, filler is repaired fairing, meets after dimensional requirement air-set;
The first core box and the 3rd core box adopt conventional method to make;
On propeller boss, lower flange, reinforcement gusset, water guide arc are connected column with propeller boss and do loose piece, and the first core box, the second core box and the 3rd core box are made location core print each other;
Two, mulling;
Three, moulding, coremaking;
At place, the horizontal maximum cross-section of foundry goods, i.e. first valve body and second valve body parting punishment type, the flange of second valve body arranges chill, on the flange of first valve body and cylindrical shell, rising head is set;
Four, swabbing, lower core, mould assembling;
Five, smelt, pour into a mould;
Six, post-processed;
By above-mentioned steps, obtain cast-in-block large thin-wall valve body steel-casting.
In step 1, upper and lower propeller boss is driven grade reduced scale by 1.0% making, and other reduced scale is made by 1.8%.
In step 1, model mixed fillers proportioning is magnesia and wood chip 1:1 by volume, magnesium chloride brine addition with hand-tight hold that compound can be extruded pulp-water and after loosing one's grip resilient be as the criterion.
In step 2, roughing sand is quartz sand and chromite sand, and binding agent is alkali phenolic resins, and curing agent is organic ester, and alkali phenolic resins addition accounts for 1.5~2.0% of sand addition in mass ratio, and organic ester addition accounts for 20.0~30.0% of alkali phenolic resins addition.
In step 2, for preventing foundry goods generation scab, at the thick high temperature resistant chromite sand of the fillet heat energy-saving position use 15mm ± 5mm of casting mold and core, deformability material is placed at the second core box middle part.
In step 3, adopt unchoked running system, with high temperature resistant flat earthen-ware pipe, do ingate, ingate is established three layers and be a plurality of along horizontal layout, and each constituent element sectional area ratio of running gate system is:
F directly: F horizontal: F in=1:1.2:1.4.
In mould assembling step, after mould assembling and closing, to die cavity blowing hot-air baking 4~6 hours, die cavity is hot lower cast within the scope of 100 ± 20 ℃;
In cast step, 1540~1570 ℃ of pouring temperatures, be 70~90 seconds the duration of pouring.
Described post-processed comprises: shaping, heat treatment, polishing, flaw detection, soldering repairing and destressing heat treatment;
In described shaping, heat treatment step, foundry goods is incubated above rear peeling in 72 hours in sandbox, with the subsidy of Ethylene Oxide lancing dead head, then carries out normalizing heat treatment, 880~920 ℃ of normalizing temperatures, temperature retention time 6 hours, the air cooling of coming out of the stove, crystal grain thinning.
In described soldering repairing, destressing treatment step, adopt the soldering of CO2 gas shielded arc welding, 100 ℃~150 ℃ of soldering region preheat temperatures, the heat treatment that eliminates stress of postwelding integral body, 550 ℃~600 ℃ of heat treatment temperatures, temperature retention time 4 hours.
The casting method of a kind of large thin-wall valve body steel-casting provided by the invention, by adopting composite model preparation method, be the whole skeleton of first analogue formation and erose section template, and then improved modelling efficiency in the mode of skeleton and model room filling mixed fillers, save timber, reduced modelling cost.The flat ingate system of ladder adopting, chill, rising head are combined with mode with subsidy, prevented that the casting flaws such as crackle, misrun, cold shut and elephant skin from appearring in thin-walled valve body steel-casting, realized the consecutive solidification of foundry goods, met the specification requirement of valve body moulding.
The valve body material of the present invention's casting is WCB (ASTM A216 standard), and censorship disjunctor sample physical and chemical index is as follows:
Casting C Si Mn P S CE
Require≤0.30≤0.60≤1.00≤0.04≤0.045≤0.5
Y301???0.26???0.41???0.96????0.01???0.011???0.42
Y302???0.28???0.37???0.87???0.011???0.015???0.43。
Mechanical performance:
Casting Rm (MPa) Re (MPa) A (%) Z (%)
Require 485-655 >=250 >=22 >=35
Y301??????535??????275?????????35??????63
Y302???????565??????290????????33?????55.5。
Flaw detection, dimension control result are: valve body moulding is carried out magnetic powder inspection, ultrasonic examination check by hydraulic cast steel inspection specification (CCH70-3), meets the requirement of II level.The dimensional tolerance of casting reaches CT12 level.
Accompanying drawing explanation
Below in conjunction with drawings and Examples, the invention will be further described.
Fig. 1 is the overall structure schematic diagram of medium casting of the present invention.
Fig. 2 is the cross-sectional schematic of the N-N of Fig. 1.
Fig. 3 is the schematic top plan view of Fig. 1.
Fig. 4 is the cross-sectional schematic of the M-M of Fig. 1.
Fig. 5 is the cross-sectional schematic of the P-P of Fig. 2.
Fig. 6 is the cross-sectional schematic of the Q-Q of Fig. 5.
In figure: the first core box 1, the second core box 2, the three core boxes 3, on propeller boss, lower flange 4, chill 5, foundry goods 6, rising head subsidy 7, running gate system 8, upper and lower propeller boss is opened shelves 9, second valve body 10, first valve body 11, rising head 12, strengthens gusset 13, water guide arc 14, and propeller boss connects column 15, flat earthen-ware pipe 16.
The specific embodiment
In Fig. 1 ~ 6, a kind of casting method of large thin-wall valve body steel-casting, comprises the following steps:
One, entity composite model is made
By 650 hydraulic mechanical equipment valve body drawing compilation casting techniques, process diagram as shown in Figure 1, Figure 2, Figure 3 shows.
With timber, make whole skeleton and the erose section template of first valve body 11, second valve body 10 external molds and the second core box 2, at skeleton and model room filling mixed fillers, tamping, filler is repaired fairing, meets after dimensional requirement air-set; Model mixed fillers proportioning is magnesia and wood chip 1:1 by volume, magnesium chloride brine addition with hand-tight hold that compound can be extruded pulp-water and after loosing one's grip resilient be as the criterion.
Upper and lower propeller boss is driven shelves 9 reduced scales by 1.0% making, and other reduced scale is made by 1.8%.
The first core box 1, the 3rd core box 3 adopt conventional method to make;
On propeller boss, lower flange 4, reinforcement gusset 13, water guide arc 14 are connected column 15 and do loose piece with propeller boss, and the first core box 1, the second core box 2 and the 3rd core box 3 are made location core print each other;
Two, mulling
In step 2, use flow mixer mulling, roughing sand is quartz sand and chromite sand, and binding agent is alkali phenolic resins, and curing agent is organic ester.Quartz sand size 30 order~70 orders, chromite sand granularity 70 orders, alkali phenolic resins addition accounts for 1.5~2.0% of roughing sand addition in mass ratio, and organic ester addition accounts for 20.0~30.0% of alkali phenolic resins addition.The placement of quartz sand and chromite sand is according to location positioning.For example, for preventing that foundry goods 6 from scab occurring, on the fillet heat energy-saving position surface of casting mold and core, use the thick high temperature resistant chromite sand of 15mm ± 5mm, quartz sand is used at all the other positions.Deformability material is placed at the second core box 2 middle parts, and deformability material adopts the materials such as straw rope, wood chip, and establishes nylon tube and give vent to anger to core print.
Three, moulding, coremaking
At place, the horizontal maximum cross-section of foundry goods 6, be first valve body 11 and second valve body 10 parting places position somatotype as shown in cross hairs in Fig. 2, the flange of second valve body 10 arranges a plurality of chills 5, and a plurality of rising heads 12 are set on the flange of first valve body 11 and cylindrical shell, and rising head arranges rising head subsidy 7 for 12 times.
The present invention adopts unchoked running system 8, referring to Fig. 1 ~ 3,5,6, with resistant to elevated temperatures flat earthen-ware pipe 16, do ingate, ingate is established three layers and be a plurality of along horizontal layout, flat earthen-ware pipe 16 is as shown in Figure 3 provided with a plurality of at every layer, as can be seen from Figure 5,, in described flat earthen-ware pipe 16, vertically the cross-sectional area of running channel is less than the cross-sectional area of branch's running channel.Structure, can guarantee that the molten steel flow speed in each passage progressively slows down thus, thereby can realize stable filling type from the bottom up, avoids occurring misrun, cold shut, elephant skin and in foundry goods and branch's running channel junction, because of the crack defect of the overheated appearance of molten steel.Zone circle numeral in Fig. 1 the sphere of action of each layer of ingate.
Being also advantageous in that of flat running channel: be that flat earthen-ware pipe 16 is made ingate by the flat running channel of multiple tracks, its single ingate sectional area that enters die cavity is less, can prevent that the junction of foundry goods and ingate is because of the crack defect of the overheated appearance of molten steel, and prevent that the defects such as cold shut, elephant skin from appearring in cast(ing) surface.
Each constituent element sectional area ratio of running gate system is:
F directly: F horizontal: F in=1:1.2:1.4.
F wherein directlyfor the cross-sectional area of vertical running channel, F horizontalfor the cross-sectional area summation of transverse branch running channel, F infor the branch's running channel being communicated with die cavity is the cross-sectional area summation of ingate.
Four, swabbing, lower core, mould assembling
The impermeable chromite powder coating of brushing alcohol radical, causes core nylon escape pipe outside casting mold while joining core;
In mould assembling step, after mould assembling and closing, to die cavity blowing hot-air baking 4~6 hours, die cavity is hot lower cast within the scope of 100 ± 20 ℃;
Five, smelt, pour into a mould
Adopt electric arc furnace smelting in conjunction with LF stove refined molten steel, 1540~1570 ℃ of valve body pouring temperatures, be 70~90 seconds the duration of pouring.
Six, post-processed
Described post-processed comprises: shaping, heat treatment, polishing, flaw detection, soldering repairing and destressing heat treatment;
Foundry goods in sand mold, be incubated 72 hours above after peeling, with the subsidy of Ethylene Oxide gas gas cutting dead head, carry out normalizing heat treatment, 880~920 ℃ of normalizing temperatures, temperature retention time 6 hours, the air cooling of coming out of the stove, crystal grain thinning, improves and improves the mechanical performance of material.
Polishing after foundry goods roughing, flaw detection, the defect that flaw detection is found should be removed totally, and is polished into the groove shape that is suitable for soldering, and before soldering, preheat temperature is 100 ℃~150 ℃, adopts CO 2gas shielded arc welding soldering, welding wire trade mark ER50-6(GB/T8110), the heat treatment that eliminates stress of postwelding foundry goods integral body, 550 ℃~600 ℃ of heat treatment temperatures, temperature retention time 4 hours.

Claims (10)

1. a casting method for large thin-wall valve body steel-casting, is characterized in that comprising the following steps:
One, entity composite model is made;
With timber, make whole skeleton and the erose section template of first valve body (11), second valve body (10) external mold and the second core box (2), at skeleton and model room filling mixed fillers, tamping, filler is repaired fairing, meet after dimensional requirement air-set;
The first core box (1) and the 3rd core box (3) adopt conventional method to make;
Lower flange on propeller boss (4), reinforcement gusset (13), water guide arc (14) are connected column (15) and do loose piece with propeller boss, the first core box (1), the second core box (2) and the 3rd core box (3) are made location core print each other;
Two, mulling;
Three, moulding, coremaking;
At place, the horizontal maximum cross-section of foundry goods (6), i.e. first valve body (11) and second valve body (10) parting punishment type, the flange of second valve body (10) arranges chill (5), and rising head (12) is set on the flange of first valve body (11) and cylindrical shell;
Four, swabbing, lower core, mould assembling;
Five, smelt, pour into a mould;
Six, post-processed;
By above-mentioned steps, obtain cast-in-block large thin-wall valve body steel-casting.
2. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, is characterized in that: in step 1, upper and lower propeller boss is driven shelves (9) reduced scale and made by 1.0%, and other reduced scale is made by 1.8%.
3. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, it is characterized in that: in step 1, model mixed fillers proportioning is magnesia and wood chip 1:1 by volume, magnesium chloride brine addition with hand-tight hold that compound can be extruded pulp-water and after loosing one's grip resilient be as the criterion.
4. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, it is characterized in that: in step 2, roughing sand is quartz sand and chromite sand, binding agent is alkali phenolic resins, curing agent is organic ester, alkali phenolic resins addition accounts for 1.5~2.0% of sand addition in mass ratio, and organic ester addition accounts for 20.0~30.0% of alkali phenolic resins addition.
5. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, it is characterized in that: in step 2, for preventing that foundry goods (6) from scab occurring, fillet heat energy-saving position at casting mold and core is used the thick high temperature resistant chromite sand of 15mm ± 5mm, and deformability material is placed at the second core box (2) middle part.
6. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, it is characterized in that: in step 3, adopt unchoked running system (8), with high temperature resistant flat earthen-ware pipe (16), do ingate, ingate is established three layers and be a plurality of along horizontal layout, and each constituent element sectional area ratio of running gate system is:
F directly: F horizontal: F in=1:1.2:1.4.
7. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, is characterized in that: in mould assembling step, after mould assembling and closing, to die cavity blowing hot-air baking 4~6 hours, die cavity is hot lower cast within the scope of 100 ± 20 ℃.
8. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, is characterized in that: in cast step, and 1540~1570 ℃ of pouring temperatures, be 70~90 seconds the duration of pouring.
9. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1, is characterized in that: described post-processed comprises: shaping, heat treatment, polishing, flaw detection, soldering repairing and destressing heat treatment;
In described shaping, heat treatment step, foundry goods is incubated above rear peeling in 72 hours in sandbox, with the subsidy of Ethylene Oxide lancing dead head, then carries out normalizing heat treatment, 880~920 ℃ of normalizing temperatures, temperature retention time 6 hours, the air cooling of coming out of the stove, crystal grain thinning.
10. the casting method of a kind of large thin-wall valve body steel-casting according to claim 1; it is characterized in that: in described soldering repairing, destressing treatment step; adopt the soldering of CO2 gas shielded arc welding; 100 ℃~150 ℃ of soldering region preheat temperatures; the heat treatment that eliminates stress of postwelding integral body; 550 ℃~600 ℃ of heat treatment temperatures, temperature retention time 4 hours.
CN201310521299.0A 2013-10-30 2013-10-30 The casting method of large-scale thin-wall valve body steel-casting CN103506580B (en)

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CN104043780A (en) * 2014-06-24 2014-09-17 南通华东油压科技有限公司 Vane pump casting mold and casting process thereof
CN104162635A (en) * 2014-08-05 2014-11-26 宁夏共享铸钢有限公司 Making method of steel casting mould of steam turbine
CN104399881A (en) * 2014-11-21 2015-03-11 宜昌船舶柴油机有限公司 Casting method for steel casting of bearing pedestal of low-speed diesel engine for large-cylinder-diameter ship
CN104550750A (en) * 2015-01-28 2015-04-29 安庆雅德帝伯活塞有限公司 Ultra-thin piston mold runner
CN104722718A (en) * 2015-03-13 2015-06-24 宝鸡石油机械有限责任公司 Casting method of mud pump air dome shell for bearing pressure
CN106180574A (en) * 2016-08-25 2016-12-07 共享装备股份有限公司 A kind of manufacture method of wheel hub core
CN106734950A (en) * 2016-11-30 2017-05-31 共享铸钢有限公司 A kind of casting technique of hollow valve body steel-casting
WO2017088332A1 (en) * 2015-11-26 2017-06-01 江苏科技大学 Casting apparatus and casting method for anchor fluke
CN107042279A (en) * 2016-11-30 2017-08-15 安徽应流集团霍山铸造有限公司 A kind of method for solving ultra-thin gap complicated inner cavity structural casting sand shim
WO2018039857A1 (en) * 2016-08-29 2018-03-08 丁洋 Casting technology for directional control valve
CN108705069A (en) * 2018-05-29 2018-10-26 辽宁福鞍重工股份有限公司 A kind of finishing process of monoblock cast heavy type combustion engine steering frame
CN109108221A (en) * 2018-09-27 2019-01-01 欧通集团青田万鑫阀门科技有限公司 The production technology of fast opening and closing power station exhaust check valve casting
CN109339129A (en) * 2018-09-29 2019-02-15 青岛连山铸造有限公司 A kind of excavator disjunctor axle bed and preparation method thereof
CN109909451A (en) * 2019-04-09 2019-06-21 安徽应流集团霍山铸造有限公司 A kind of steel-casting casting model and its pouring procedure
CN111421116A (en) * 2020-04-27 2020-07-17 中国船舶重工集团公司第七二五研究所 Preparation process of copper alloy filter shell for ship
CN111590015A (en) * 2020-04-12 2020-08-28 辽宁华圣模具有限公司 Casting mold material for numerical control machining and mold manufacturing method

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CN101920312A (en) * 2010-08-21 2010-12-22 宜昌船舶柴油机有限公司 Casting method and leveling tool for large multi-blade casting
CN102717031A (en) * 2012-07-02 2012-10-10 山西模范机械制造有限公司 Large-scale thin-wall valve body lost foam casting process

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GB812352A (en) * 1955-01-03 1959-04-22 Vickers Electrical Co Ltd Improvements in and relating to casting
CN101235912A (en) * 2008-03-03 2008-08-06 范志鹏 Countryside high school experimental laboratory water nozzles antifreeze gate valve
CN101920312A (en) * 2010-08-21 2010-12-22 宜昌船舶柴油机有限公司 Casting method and leveling tool for large multi-blade casting
CN102717031A (en) * 2012-07-02 2012-10-10 山西模范机械制造有限公司 Large-scale thin-wall valve body lost foam casting process

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CN104043780A (en) * 2014-06-24 2014-09-17 南通华东油压科技有限公司 Vane pump casting mold and casting process thereof
CN104162635A (en) * 2014-08-05 2014-11-26 宁夏共享铸钢有限公司 Making method of steel casting mould of steam turbine
CN104162635B (en) * 2014-08-05 2016-06-15 宁夏共享铸钢有限公司 A kind of manufacture method of steam turbine cast steel part mould
CN104399881A (en) * 2014-11-21 2015-03-11 宜昌船舶柴油机有限公司 Casting method for steel casting of bearing pedestal of low-speed diesel engine for large-cylinder-diameter ship
CN104399881B (en) * 2014-11-21 2017-03-29 宜昌船舶柴油机有限公司 The casting method of low-speed diesel for large-bore vessel bearing block steel-casting
CN104550750A (en) * 2015-01-28 2015-04-29 安庆雅德帝伯活塞有限公司 Ultra-thin piston mold runner
CN104722718A (en) * 2015-03-13 2015-06-24 宝鸡石油机械有限责任公司 Casting method of mud pump air dome shell for bearing pressure
WO2017088332A1 (en) * 2015-11-26 2017-06-01 江苏科技大学 Casting apparatus and casting method for anchor fluke
CN106180574A (en) * 2016-08-25 2016-12-07 共享装备股份有限公司 A kind of manufacture method of wheel hub core
WO2018039857A1 (en) * 2016-08-29 2018-03-08 丁洋 Casting technology for directional control valve
CN106734950A (en) * 2016-11-30 2017-05-31 共享铸钢有限公司 A kind of casting technique of hollow valve body steel-casting
CN107042279A (en) * 2016-11-30 2017-08-15 安徽应流集团霍山铸造有限公司 A kind of method for solving ultra-thin gap complicated inner cavity structural casting sand shim
CN108705069A (en) * 2018-05-29 2018-10-26 辽宁福鞍重工股份有限公司 A kind of finishing process of monoblock cast heavy type combustion engine steering frame
CN109108221A (en) * 2018-09-27 2019-01-01 欧通集团青田万鑫阀门科技有限公司 The production technology of fast opening and closing power station exhaust check valve casting
CN109339129A (en) * 2018-09-29 2019-02-15 青岛连山铸造有限公司 A kind of excavator disjunctor axle bed and preparation method thereof
CN109909451A (en) * 2019-04-09 2019-06-21 安徽应流集团霍山铸造有限公司 A kind of steel-casting casting model and its pouring procedure
CN111590015A (en) * 2020-04-12 2020-08-28 辽宁华圣模具有限公司 Casting mold material for numerical control machining and mold manufacturing method
CN111421116A (en) * 2020-04-27 2020-07-17 中国船舶重工集团公司第七二五研究所 Preparation process of copper alloy filter shell for ship

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