CN104014717B - A kind of casting method of ZL101 thin-walled aluminum alloys component - Google Patents

A kind of casting method of ZL101 thin-walled aluminum alloys component Download PDF

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CN104014717B
CN104014717B CN201410241851.5A CN201410241851A CN104014717B CN 104014717 B CN104014717 B CN 104014717B CN 201410241851 A CN201410241851 A CN 201410241851A CN 104014717 B CN104014717 B CN 104014717B
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朱小英
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Daye Hongtai Aluminum Co., Ltd.
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Abstract

The invention discloses a kind of casting method of ZL101 thin-walled aluminum alloys component, the method comprises the steps: 1) prepare molding sand raw material; 2) prepare binding agent slip, described binding agent is made up of following component by weight percentage: starch 36-40%, furane resins 6-8%, calcium-base bentonite 14-16% ,-100 order Bagasse-cellulose powder 3-5%, zinc stearate 1-2%, sodium phosphate trimer 2-3%, surplus is water; 3) molding sand is prepared; 4) casting mold and running gate system is made; 5) melting ZL101 alloy; Wherein adopt the Sr of interpolation 0.035% to carry out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 735-745 DEG C, after refining, leave standstill 10-12min; 6) pour into a mould: wherein controlling aluminium alloy pouring temperature is 720-730 DEG C, and poring rate controls as follows, and the precontract 2/5 of always watering fluence adopts the speed of 6-8kg/s, middle about 2/5 adopts 4-5kg/s, and last about 1/5 adopts 6-8kg/s; 7) with after type cooling, die sinking, clears up and heat-treats.

Description

A kind of casting method of ZL101 thin-walled aluminum alloys component
Technical field
The present invention relates to aluminium alloy casting technology field, be specifically related to a kind of casting method of thin-walled aluminium alloy castings.
Background technology
At present, increasing thin-walled aluminum alloys component adopts casting one-shot forming, as large-scale pedestal, spiral case, hatch door class foundry goods, this kind of casting dimension is larger, wall is thin, machined surface is not many, wall thickness place 40-100mm, the thin place 3-5mm of wall, wall thickness transition is uneven, casting technique difficulty is large, size difficulty controls, this kind of foundry goods adopts ZL101 alloy sand mold gravitational casting or metallicity die casting usually, although ZL101 alloy has good mobility, but liquid metal is at thin-walled, in long and narrow passage, cooling velocity is fast, the casting flaws such as easy generation cold shut, usually running channel design is adopted in prior art, arrange chill, Feeder Design etc. improve the method for pouring condition, but these methods are still not ideal, for this kind of cast product, report by improving to overcome this kind of defect to molding sand in prior art is rare.
The effect of molding sand in Foundry Production is very important, and the casting wasted product caused because of the poor quality of molding sand accounts for 30 ~ 50% of the total waste product of foundry goods.Usually to the requirement of molding sand be: 1, there is higher intensity and heat endurance, to bear the effect of various external force and high temperature.2, good mobility, i.e. the ability of molding sand mutual movement between sand grains under external force or Action of Gravity Field own.3, certain plasticity, namely molding sand is out of shape under external force, can keep the ability of the shape given after external force is removed.4, good gas permeability, namely molding sand hole is through the ability of gas.5, high collapsibility, whether, also known as knockability, namely after casting solidification, whether molding sand easily destroys, the easy performance removed from foundry goods.
Molding sand is different by binding agent used, can be divided into clay-bonded sand, water-glass sand, cement bonded sand, quartz sand etc., maximum with clay-bonded sand, water-glass sand and quartz sand.
Roughing sand in molding sand, types of binder etc. have material impact to the performance of foundry goods, particularly aluminium alloy is cast, the sand formulation Sand particle diameter of traditional used in aluminium alloy casting is too large or too little, molding sand material footpath is too large, although gas permeability is better, aloxite part surface ratio is more coarse, fineness is bad, molding sand material footpath is too little, causes mo ld void bad, and aluminium casting has pore to produce.Domestic and international widely used coal dust clay green-sand, generally formed with the water system of mixing by roughing sand, binding agent, coal dust additive etc., there is certain Sand sticking-resistant effect and the advantage that the cost of material is low, production efficiency is high, but its consumption is large, discharge seriously, at casting process coal dust firing decomposition generation toxic gas is polluted.And the ratio of defects such as scab, pore, crackle of traditional molding sand Birmasil product is more than 15%, the high very big increase causing casting cost of percent defective.
Therefore, the present invention puts forth effort from the improvement of casting sand to improve the casting flaw of ZL101 thin-walled aluminum alloys component.
Summary of the invention
For the deficiencies in the prior art, an object of the present invention is the casting method providing a kind of ZL101 thin-walled aluminum alloys component, the method adopts brand-new molding sand as making casting mold, adopt gravity-assist pouring method, coordinate the improvement of alloy smelting and pouring technology, overcome the casting flaw of ZL101 thin-walled aluminum alloys component.
For achieving the above object, the technical scheme of the application's employing is as follows:
A casting method for ZL101 thin-walled aluminum alloys component, the method comprises the steps:
1) molding sand raw material is prepared: the casting sand adopted forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 60-64 part, quartzy roughing sand old sand 24-28 part, electrolytic aluminum residue powder 3-5 part, zircon sand 4-6 part, cenosphere 1-6 part, binding agent slip 16-18 part, water 22-26 part; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μm, binding agent is made up of following component by weight percentage: starch 36-40%, furane resins 6-8%, calcium-base bentonite 14-16%,-100 order Bagasse-cellulose powder 3-5%, zinc stearate 1-2%, sodium phosphate trimer 2-3%, surplus is water; Various sandy plain material is weighed by said ratio;
2) binding agent slip is prepared: get above-mentioned load weighted binder component raw material, water is added in stirred vessel, then add starch and stir to obtain outstanding mixed liquid, and add furane resins, calcium-base bentonite, zinc stearate, sodium phosphate trimer successively under agitation, 10-15 minute is stirred with the speed of 600-800rpm after all adding, then add-100 order Bagasse-cellulose powder, and stir 15-20 minute with the speed of 1000-1100rpm, obtain binding agent slip;
3) prepare molding sand: by step 2) binding agent slip and the step 1 prepared) in other green sand composition load weighted in blender, mix about 8-10 hour obtained molding sand.
4) make casting mold and running gate system, make casting mold according to by the shape of casting part, adopt teeming mode to make conventional ingate, cross gate and sprue and rising head, this running gate system adopts conventional casting moulding system, without the need to arranging chill;
5) melting ZL101 alloy; Control alloying component is Si6.8-7.2%, MgO.25-0.45%, FeO.5%, ZnO.3%, MnO.35%, Al surplus, adopt fine aluminium and intermediate alloy melting in resistance furnace, after whole fusing also homogeneous 15-20 minute, the Sr adding 0.035% in the aluminium liquid after melting carries out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 735-745 DEG C, after refining, leave standstill 10-12min;
6) pour into a mould: casting mold is toasted preheating in advance, preheat temperature is 120-150 DEG C, controlling aluminium alloy pouring temperature is 720-730 DEG C, poring rate controls as follows, the precontract 2/5 of always watering fluence adopts the speed of 6-8kg/s, middle about 2/5 adopts 4-5kg/s, and last about 1/5 adopts 6-8kg/s;
7) with after type cooling, die sinking, clears up and heat-treats.
The present invention passes through the improvement of molding sand and the control with smelting pouring technology; Make the thin-section casting defective workmanship of preparation few, product percent of pass is high, is specially:
One. the improvement about molding sand:
1) molding sand that prepared by the present invention does not adopt flyash to do raw material, and discharge is few, does not produce toxic gas, almost no pollution.
2) molding sand aggregate of the present invention adopts quartzy roughing sand fresh sand, quartzy roughing sand old sand to arrange in pairs or groups, conservation cost; Add the refractoriness that appropriate zircon sand can improve molding sand, the resistance to performance of watering of casting mold is improved.
3) creationaryly in molding sand, electrolytic aluminum residue powder is added, solve the problem of electrolytic aluminum residue waste recovery, save cost, find due to the aluminium containing remnants in electrolytic aluminum residue powder and aluminium oxide simultaneously, with by cast aluminium alloy homogeneous composition, the surface quality of aluminium alloy can be improved, serve unexpected technique effect.
4) permeability that appropriate cenosphere improves casting mold is added; Simultaneously by the blending powder of several powder, both made mould permeability energy good, and reduced casting flaw, make again any surface finish of foundry goods.
5) brand-new binding agent based on starch is adopted, collapsibility excellence after intensity, casting when making the casting-up by this sand conditioning.
Two. about smelting and pouring technology
1) the present invention is by improving refining temperature, and controls refining time, and the gas content in aluminium alloy melt is reduced;
2) the present invention makes the good fluidity of alloy by the temperature improving cast, avoids producing the defects such as misrun;
3) mode adopting control poring rate for thin-walled aluminum alloys component of the invention, early stage is fast, melt is made to fill type rapidly, mid-term is slightly slow few to make to be involved in gas, simultaneously because the cast in early stage makes alloy fill type better effects if, last Quick pouring is to ensure that alloy expiring in casting mold fills and feeding effect again, and such cooperation makes the cold shut defects of foundry goods substantially eliminate.
Through a large amount of experiment statisticses, adopt ZL101 thin-section casting prepared by the inventive method, scab, pore, crackle, cold shut, shrinkage cavity, the ratio of defects such as loose, below 3%, significantly can improve casting yield, reduce casting cost.
The inventive method is widely used in pedestal, hatch door, the ZL 101 alloy foundry goods that spiral case, jacket casing class thin-wall part and wall thickness differ greatly.
Detailed description of the invention
Embodiment one
A casting method for ZL101 thin-walled aluminum alloys component, the method comprises the steps:
1) molding sand raw material is prepared: the casting sand adopted forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 60 parts, quartzy roughing sand old sand 28 parts, electrolytic aluminum residue powder 3 parts, zircon sand 6 parts, cenosphere 1 part, binding agent slip 18 parts, 22 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μm, binding agent is made up of following component by weight percentage: starch 36%, furane resins 8%, calcium-base bentonite 14%,-100 order Bagasse-cellulose powder 5%, zinc stearate 1%, sodium phosphate trimer 3%, surplus is water; Various sandy plain material is weighed by said ratio;
2) binding agent slip is prepared: get above-mentioned load weighted binder component raw material, water is added in stirred vessel, then add starch and stir to obtain outstanding mixed liquid, and add furane resins, calcium-base bentonite, zinc stearate, sodium phosphate trimer successively under agitation, 15 minutes are stirred with the speed of 600rpm after all adding, then add-100 order Bagasse-cellulose powder, and stir 20 minutes with the speed of 1000rpm, obtain binding agent slip;
3) prepare molding sand: by step 2) binding agent slip and the step 1 prepared) in other green sand composition load weighted in blender, mix about 8 hours obtained molding sand.
4) make casting mold and running gate system, make casting mold according to by the shape of casting part, adopt teeming mode to make conventional ingate, cross gate and sprue and rising head, this running gate system adopts conventional casting moulding system, without the need to arranging chill;
5) melting ZL101 alloy; Control alloying component is Si6.8-7.2%, Mg0.25-0.45%, Fe0.5%, ZnO.3%, MnO.35%, Al surplus, adopt fine aluminium and intermediate alloy melting in resistance furnace, until all melting also, homogeneous is after 15 minutes, and the Sr adding 0.035% in the aluminium liquid after melting carries out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 735 DEG C, after refining, leave standstill 10min;
6) pour into a mould: casting mold is toasted preheating in advance, and preheat temperature is 120 DEG C, controlling aluminium alloy pouring temperature is 720 DEG C, poring rate controls as follows, the precontract 2/5 of always watering fluence adopts the speed of 6kg/s, and middle about 2/5 adopts 4kg/s, and last about 1/5 adopts 6kg/s;
7) with after type cooling, die sinking, clears up and heat-treats.
Embodiment two
A casting method for ZL101 thin-walled aluminum alloys component, the method comprises the steps:
1) molding sand raw material is prepared: the casting sand adopted forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 64 parts, quartzy roughing sand old sand 24 parts, electrolytic aluminum residue powder 5 parts, zircon sand 4 parts, cenosphere 6 parts, binding agent slip 16 parts, 26 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μm, binding agent is made up of following component by weight percentage: starch 40%, furane resins 6%, calcium-base bentonite 16%,-100 order Bagasse-cellulose powder 3%, zinc stearate 2%, sodium phosphate trimer 2%, surplus is water; Various sandy plain material is weighed by said ratio;
2) binding agent slip is prepared: get above-mentioned load weighted binder component raw material, water is added in stirred vessel, then add starch and stir to obtain outstanding mixed liquid, and add furane resins, calcium-base bentonite, zinc stearate, sodium phosphate trimer successively under agitation, 10 minutes are stirred with the speed of 800rpm after all adding, then add-100 order Bagasse-cellulose powder, and stir 15 minutes with the speed of 1100rpm, obtain binding agent slip;
3) prepare molding sand: by step 2) binding agent slip and the step 1 prepared) in other green sand composition load weighted in blender, mix about 10 hours obtained molding sand.
4) make casting mold and running gate system, make casting mold according to by the shape of casting part, adopt teeming mode to make conventional ingate, cross gate and sprue and rising head, this running gate system adopts conventional casting moulding system, without the need to arranging chill;
5) melting ZL101 alloy; Control alloying component is Si6.8-7.2%, MgO.25-0.45%, FeO.5%, ZnO.3%, MnO.35%, Al surplus, adopt fine aluminium and intermediate alloy melting in resistance furnace, until all melting also, homogeneous is after 20 minutes, and the Sr adding 0.035% in the aluminium liquid after melting carries out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 745 DEG C, after refining, leave standstill 12min;
6) pour into a mould: casting mold is toasted preheating in advance, and preheat temperature is 150 DEG C, controlling aluminium alloy pouring temperature is 730 DEG C, poring rate controls as follows, the precontract 2/5 of always watering fluence adopts the speed of 8kg/s, and middle about 2/5 adopts 5kg/s, and last about 1/5 adopts 8kg/s;
7) with after type cooling, die sinking, clears up and heat-treats.
Embodiment three
A casting method for ZL101 thin-walled aluminum alloys component, the method comprises the steps:
1) molding sand raw material is prepared: the casting sand adopted forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 62 parts, quartzy roughing sand old sand 26 parts, electrolytic aluminum residue powder 4 parts, zircon sand 5 parts, cenosphere 3 parts, binding agent slip 17 parts, 24 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μm, binding agent is made up of following component by weight percentage: starch 38%, furane resins 4%, calcium-base bentonite 15%,-100 order Bagasse-cellulose powder 4%, zinc stearate 1.5%, sodium phosphate trimer 2.3%, surplus is water; Various sandy plain material is weighed by said ratio;
2) binding agent slip is prepared: get above-mentioned load weighted binder component raw material, water is added in stirred vessel, then add starch and stir to obtain outstanding mixed liquid, and add furane resins, calcium-base bentonite, zinc stearate, sodium phosphate trimer successively under agitation, 13 minutes are stirred with the speed of 700rpm after all adding, then add-100 order Bagasse-cellulose powder, and stir 18 minutes with the speed of 1050rpm, obtain binding agent slip;
3) prepare molding sand: by step 2) binding agent slip and the step 1 prepared) in other green sand composition load weighted in blender, mix about 9 hours obtained molding sand.
4) make casting mold and running gate system, make casting mold according to by the shape of casting part, adopt teeming mode to make conventional ingate, cross gate and sprue and rising head, this running gate system adopts conventional casting moulding system, without the need to arranging chill;
5) melting ZL101 alloy; Control alloying component is Si6.8-7.2%, MgO.25-0.45%, FeO.5%, ZnO.3%, MnO.35%, Al surplus, adopt fine aluminium and intermediate alloy melting in resistance furnace, until all melting also, homogeneous is after 18 minutes, and the Sr adding 0.035% in the aluminium liquid after melting carries out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 740 DEG C, after refining, leave standstill 11min;
6) pour into a mould: casting mold is toasted preheating in advance, and preheat temperature is 135 DEG C, controlling aluminium alloy pouring temperature is 725 DEG C, poring rate controls as follows, the precontract 2/5 of always watering fluence adopts the speed of 7kg/s, and middle about 2/5 adopts 4kg/s, and last about 1/5 adopts 7kg/s;
7) with after type cooling, die sinking, clears up and heat-treats.
Applicant states, the present invention illustrates detailed process equipment and process flow process of the present invention by above-described embodiment, but the present invention is not limited to above-mentioned detailed process equipment and process flow process, namely do not mean that the present invention must rely on above-mentioned detailed process equipment and process flow process and could implement.Person of ordinary skill in the field should understand, any improvement in the present invention, to equivalence replacement and the interpolation of auxiliary element, the concrete way choice etc. of each raw material of product of the present invention, all drops within protection scope of the present invention and open scope.

Claims (1)

1. a casting method for ZL101 thin-walled aluminum alloys component, is characterized in that, the method comprises the steps:
1) molding sand raw material is prepared: the casting sand adopted is made up of following raw materials according with parts by weight: quartzy roughing sand fresh sand 60-64 part, quartzy roughing sand old sand 24-28 part, electrolytic aluminum residue powder 3-5 part, zircon sand 4-6 part, cenosphere 1-6 part, binding agent slip 16-18 part, water 22-26 part; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is 10-60 μm, binding agent slurry is made up of following component by weight percentage: starch 36-40%, furane resins 6-8%, calcium-base bentonite 14-16%,-100 order Bagasse-cellulose powder 3-5%, zinc stearate 1-2%, sodium phosphate trimer 2-3%, surplus is water; Various sandy plain material is weighed by said ratio;
2) binding agent slip is prepared: get above-mentioned load weighted binding agent pulp components raw material, water is added in stirred vessel, then add starch and stir to obtain outstanding mixed liquid, and add furane resins, calcium-base bentonite, zinc stearate, sodium phosphate trimer successively under agitation, 10-15 minute is stirred with the speed of 600-800rpm after all adding, then add-100 order Bagasse-cellulose powder, and stir 15-20 minute with the speed of 1000-1100rpm, obtain binding agent slip;
3) prepare molding sand: by step 2) binding agent slip and the step 1 prepared) in other green sand composition load weighted in blender, mix 8-10 hour obtained molding sand;
4) make casting mold and running gate system, make casting mold according to by the shape of casting part, adopt teeming mode to make conventional ingate, cross gate, sprue and rising head, this running gate system adopts conventional casting moulding system, without the need to arranging chill;
5) melting ZL101 alloy; Control alloying component is Si6.8-7.2%, Mg0.25-0.45%, Fe0.5%, Zn0.3%, Mn0.35%, Al surplus, adopt fine aluminium and intermediate alloy melting in resistance furnace, after whole fusing also homogeneous 15-20 minute, the Sr adding 0.035% in the aluminium liquid after melting carries out Metamorphism treatment, pass into argon gas rotation degasification after slagging-off and carry out refining when temperature is 735-745 DEG C, after refining, leave standstill 10-12min;
6) pour into a mould: casting mold is toasted preheating in advance, preheat temperature is 120-150 DEG C, controlling aluminium alloy pouring temperature is 720-730 DEG C, poring rate controls as follows, the precontract 2/5 of always watering fluence adopts the speed of 6-8kg/s, middle about 2/5 adopts 4-5kg/s, and last about 1/5 adopts 6-8kg/s;
7) with after type cooling, die sinking, clears up and heat-treats.
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HU230620B1 (en) * 2015-05-14 2017-04-28 ALU-ÖNTŐ Fémöntő és Fémmegmunkáló Ipari Gravitational aluminium moulding procedure for manufacturing of thin wall casting
CN104999024A (en) * 2015-07-06 2015-10-28 安徽三联泵业股份有限公司 Nanometre microlite-supported furan resin-modified moulding sand for pump body casting
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CN108787990A (en) * 2018-05-31 2018-11-13 益阳仪纬科技有限公司 A kind of preparation method of aluminium alloy casting sand
CN108465772B (en) * 2018-06-22 2020-02-07 佛山市高明利钢精密铸造有限公司 Preparation method of molding sand special for integral casting of large stainless steel parts
CN108705026B (en) * 2018-06-22 2020-07-14 佛山市高明利钢精密铸造有限公司 Preparation method of special molding sand for casting stainless steel parts with complex shapes
CN114042858B (en) * 2021-11-19 2024-05-10 桂林中铸机械科技有限公司 Method for self-collapsing high-strength lost foam cavity carbonless casting mold along with casting cooling

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CN101574725B (en) * 2008-05-09 2011-08-10 山东联诚集团有限公司 Molding sand for aluminum casting and preparation technology thereof
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Effective date of registration: 20160921

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Patentee before: Zhu Xiaoying