CN112501463A - Method for controlling quality of integrated cylinder cover of engine - Google Patents

Method for controlling quality of integrated cylinder cover of engine Download PDF

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Publication number
CN112501463A
CN112501463A CN202011278585.5A CN202011278585A CN112501463A CN 112501463 A CN112501463 A CN 112501463A CN 202011278585 A CN202011278585 A CN 202011278585A CN 112501463 A CN112501463 A CN 112501463A
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Prior art keywords
engine
integrated cylinder
mold
controlling
cylinder head
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杨当友
陈光跃
吴贵根
王太海
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Chery Automobile Co Ltd
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Chery Automobile Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/06Permanent moulds for shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/06Permanent moulds for shaped castings
    • B22C9/065Cooling or heating equipment for moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088Feeder heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D33/00Equipment for handling moulds
    • B22D33/02Turning or transposing moulds
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04Modified aluminium-silicon alloys

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Abstract

The invention discloses a method for controlling the quality of an integrated cylinder cover of an engine, which properly prolongs the turning time of a die by 1, slows down the turning speed and eliminates air holes; 2. the feeding sectional area of the riser is reduced, and air holes are eliminated; 3. repairing the die to ensure that the pouring cup and the side die do not protrude and eliminate air holes; 4. parameters such as chemical components, retention time and the like of the aluminum liquid are adjusted, and the cross section-spark plug column is increased by metallographic sampling, so that the quality problems of water leakage and the like caused by the integrated cylinder cover are effectively prevented, the quality of an engine is ensured, and the dynamic property of the whole vehicle is ensured.

Description

Method for controlling quality of integrated cylinder cover of engine
Technical Field
The invention belongs to the technical field of automobile engines, and particularly relates to a method for controlling the quality of an integrated cylinder cover of an engine.
Background
In the process of implementing the invention, the inventor finds that the prior art has at least the following problems:
the aluminum alloy cylinder cover structure (common cylinder cover for short) of the traditional engine is separated from a cast iron exhaust manifold independently, the common cylinder cover can not meet the requirements along with the improvement of parameters of cost reduction, weight reduction, oil consumption reduction, emission reduction of the whole engine and the like, the cast iron exhaust manifold is changed into an aluminum alloy material which is the same as that of the common cylinder cover to form an organic whole (integrated cylinder cover for short), and then a casting forming process is changed from a bottom casting type pouring system to a turnover type pouring system (a mold and a sand core are turned over along with a turnover machine).
But has the following disadvantages: 1. the control requirement of the casting process is high, if the overturning time of the 'overturning type pouring system' is short, the overturning speed is high, and gas is easy to be involved to generate gas holes; 2. because the structure of the integrated cylinder cover is more complex, the casting pouring design still uses a common cylinder cover (such as the feeding sectional area of a riser is too large), and gas is easy to be involved to generate air holes; 3. metallographic analysis and sampling are still carried out between the two combustion chambers, and the overall distribution condition of the metallographic structure of the integrated cylinder cover cannot be reflected.
Disclosure of Invention
The invention aims to solve the technical problem of providing a method for controlling the quality of an integrated cylinder cover of an engine, which effectively prevents the quality problems of water leakage and the like caused by the integrated cylinder cover.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows: a method of controlling the mass of an integrated cylinder head of an engine, comprising the steps of:
1) aluminum alloy smelting: chemical components, molten alloy → molten aluminum alloy are transferred into a holding furnace;
2) a core making step: core making → repairing, deburring → storing, core assembling → transporting, core assembling and core assembling;
3) a step of installing a die: cleaning a mold → preheating the mold → coating the mold → installing and heating the mold;
4) casting: mold closing → pouring → solidification → mold opening → part taking, code printing → cooling → core vibrating → sawn riser → deburring → heat treatment → preprocessing → size, water pressure, flaw detection and metallographic phase → packaging and warehousing.
Water pressure, flaw detection and metallographic structure requirements:
the hydrostatic test requires no bubbles;
the flaw detection requirement meets 1-2 grades in ASTM E505; the shrinkage cavity is less than or equal to 4.5 mm;
the metallographic structure requirement is as follows: the pinhole degree is rated in 1-2 grades according to JB/T7946.3 cast aluminum alloy pinhole, and can be 3 grades, but the 3 grades are not more than 25%; the dendrite spacing of the combustion chamber is less than or equal to 30 μm, and the dendrite spacing of the exhaust side is less than or equal to 40 μm; no black needle-like iron phase inclusions appear.
Eliminating bubbles in the hydrostatic test:
adding a vent plug on the exhaust side: an exhaust plug is added at the position corresponding to a boss at the exhaust outer side of the cylinder cover die, and the gap of the exhaust plug is 0.2-0.3 mm;
the turning time of the die is prolonged;
and reducing the feeding cross section area of the riser and repairing the die.
Eliminating the cracking on the exhaust side of the cylinder cover:
smelting in front of the furnace: the addition of the modifier strontium accounts for 90-100PPM of the weight of the molten aluminum, and the retention time in the molten aluminum is less than 4 hours;
the metallographic phase sampling position is added at the cross section-spark plug position on the basis of the sampling of the combustion chamber.
The aluminum alloy smelting alloy comprises the following components in percentage by weight: si: 6.5-7.5, Fe is less than 0.15, Mg: 0.25 to 0.45; mn is less than 0.10; ti is less than 0.25.
The turning time of the die is 16-20 seconds.
The feeding sectional area of the riser is 6000-8000 square millimeters.
The side die of the die is flush with the pouring cup.
One of the technical scheme has the following advantages or beneficial effects, and quality problems such as water leakage caused by the integrated cylinder cover are effectively prevented.
Drawings
FIG. 1 is a schematic diagram of a method of controlling integrated cylinder head mass of an engine provided in an embodiment of the present invention;
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
Referring to fig. 1, the technical parameters of the casting process of the 'turnover type gating system' are adjusted, the measures such as metallographic phase sampling positions and quantity are added in the aspect of quality control, and the problem of water leakage quality of an engine caused by air holes and cracking is solved, specifically as follows:
1. chemical components: the material grade of the integrated cylinder cover is selected from the aluminum alloy grade AlSi7Mg0.3 in DIN EN 1076.
2. The preparation method comprises the following steps: the integrated cylinder cover metal mold gravity turnover type casting process is as shown in figure 1:
1) aluminum alloy smelting: chemical components, molten alloy → molten aluminum alloy are transferred into a holding furnace;
2) a core making step: core making → repairing, deburring → storing, core assembling → transporting, core assembling and core assembling;
3) a step of installing a die: cleaning a mold → preheating the mold → coating the mold → installing and heating the mold;
4) casting: mold closing → pouring → solidification → mold opening → part taking, code printing → cooling → core vibrating → sawn riser → deburring → heat treatment → preprocessing → size, water pressure, flaw detection and metallographic phase → packaging and warehousing.
3. The technical requirements of water pressure, flaw detection and metallographic structure are as follows:
3.1, water pressure: the hydrostatic test does not allow the occurrence of bubble phenomena.
3.2, flaw detection: meets the 1-2 grade (shrinkage cavity is less than or equal to 4.5mm) in ASTM E505.
3.3, metallographic structure: the pinhole degree is rated from 1 to 2 according to JB/T7946.3 cast aluminum alloy pinhole, a small amount of 3 grades is allowed, but the 3 grades do not exceed 25%; alpha-dendrite + dotted or granular eutectic silicon (allowing a small amount of stripes); the dendrite spacing (DAS) of the combustion chamber is less than or equal to 30 μm, and the dendrite spacing (DAS) of the exhaust side is less than or equal to 40 μm; more black acicular iron phase inclusions are not allowed to occur.
The reason for bubble formation:
the air holes are checked for the fault part, the fault part enters from the exhaust side and is not discharged and stays in the cavity, defects are amplified, observed and analyzed, the flow direction of the air holes and tail traces are judged to be the air holes generated in the overturning process, simulation analysis and comparison are carried out on the overturning speed according to the position and the characteristics of the air holes, the overturning speed is high, the whole feeding surface is in an overturning shape and is fed integrally, more air is involved in the air, the aluminum liquid is still filled, the air holes are brought to the lowest point of the cavity by the filling pressure of the aluminum liquid, then the air holes float under the action of buoyancy, but at the moment, the filling is finished.
Countermeasure for eliminating air holes:
adding a vent plug on the exhaust side: the exhaust plug is added at the position corresponding to the boss at the exhaust outer side of the cylinder cover die, the gap of the exhaust plug is 0.2-0.3 mm, exhaust at the exhaust side is facilitated, and gas entering is reduced.
Properly prolonging the turning time of the die: the original 14.3 seconds is prolonged to the present 18.4 seconds, the turning time of the mold is prolonged, and the air exhaust time of the cavity is increased by slowing down the flow of the molten aluminum through slowing down the mold filling speed.
Reducing the feeding cross section area of a riser and repairing a mold:
the feeding sectional area of the riser is reduced from 11311 square millimeters to 7084 square millimeters, so that air is reduced to enter, and air holes are eliminated.
The mould is repaired to make the pouring cup and the side mould parallel and level.
The connection position of the side mold of the early-stage mold is provided with a step of 5mm, so that a first strand of aluminum water enters a cavity unstably during mold filling, and CAE (computer aided engineering) simulation analysis is performed during casting, so that the air pressure in the middle area exceeds the critical value of the pressure relief of the mold, cannot be removed in time, and is retained in a cylinder cover to form an air hole defect; the side die of the die is flush with the pouring cup, so that the defect of air holes is effectively eliminated, aluminum water is ensured to stably enter the cavity, and the air holes are eliminated.
Water pressure and flaw detection: the hydrostatic test has no bubble phenomenon, the flaw detection is in ASTM E505 grade 1, and the technical requirements are met.
The engine 500 hours rated power bench test, the fracture appears in the cylinder head exhaust side and causes the phenomenon of leaking, for eliminating the fracture defect, to the fracture formation reason carry out the analysis and make corresponding countermeasure measure:
the reason for the cracking of the cylinder head is as follows:
sampling a cracking source, and carrying out metallographic structure analysis: according to GB/T13298 metal microstructure inspection method, etching with 0.5% hydrofluoric acid water solution for 10 seconds, observing under microscope magnification of 100 times, and finding that eutectic silicon is in strip distribution;
etching with a 20% aqueous solution of sulfuric acid at 65. + -. 2 ℃ for about 25 seconds, and observing under a microscope at a magnification of 200 times, more black long needle-like iron phase inclusions are present.
The strip-shaped eutectic silicon exists in a large amount in the matrix, and the strength and the plasticity of the material are reduced; more hard and brittle black long needle-shaped iron phase inclusions crack the matrix, so that the impact resistance of the cylinder cover is reduced, and the cylinder cover is easy to generate fatigue cracking, thereby causing water leakage.
And (3) cracking elimination measures:
chemical components: the management of iron-containing elements such as smelting tools is enhanced, and the chemical composition of the aluminum liquid is in accordance with the table 1
Table 1 (Wt%)
Element(s) Si Fe Mg Mn Ti
Aluminium liquid 6.5~7.5 <0.15 0.25~0.45 <0.10 <0.25
Smelting in front of the furnace: the addition of the modifier strontium (Sr) accounts for 90-100PPM of the weight of the molten aluminum, and the retention time in the molten aluminum is less than 4 hours.
Metallographic phase sampling position: the common cylinder cover only takes a combustion chamber; the integrated cylinder cover is added with a cross section-spark plug on the basis of sampling of a combustion chamber.
After the adjustment, the metallographic structure of the cylinder cover is qualified by analysis, and the method specifically comprises the following steps:
the pinhole degree: grade 2 is evaluated according to JB/T7946.3 cast aluminum alloy pinhole and qualified.
Microstructure: alpha-dendrite + eutectic silicon is in granular distribution, and dendrite spacing (DAS) is according to a formula
Figure RE-GDA0002916775430000061
Figure RE-GDA0002916775430000062
The calculation is as follows:
the dendrite spacing (DAS) of the combustion chamber is approximately equal to 26.2 μm;
the branch-crystal spacing (DAS) on the exhaust side is approximately equal to 29.8 mu m;
no black needle-like iron phase inclusions were observed.
The platform verification:
the adjusted cylinder cover is used for carrying a 500-hour rated power bench test of an E-type engine, and quality problems such as water leakage and the like caused by air holes or cracking do not occur, so that the quality of the engine is ensured, and the dynamic property of the whole vehicle is ensured.
1. Properly prolonging the turning time of the die, slowing down the turning speed and eliminating air holes; 2. the feeding sectional area of the riser is reduced, and air holes are eliminated; 3. repairing the die to ensure that the pouring cup and the side die do not protrude and eliminate air holes; 4. adjusting parameters such as chemical components, retention time and the like of the aluminum liquid, and increasing the cross section-spark plug column position by metallographic phase sampling.
The advantages are that: 1. the casting of the integrated cylinder cover adopts the process, reduces a pouring system (without a sprue and the like), improves the utilization rate of molten aluminum by about 10 percent and reduces the cost; 2. the quality control mode is improved, and the cross section-spark plug column is added on the basis of metallographic analysis on the sampling of the combustion chamber; 3. the cost performance is high, and the weight is reduced; meanwhile, the engine has the advantages of quickly warming up, reducing oil consumption and reducing vehicle emission, and is easy to meet the national emission of the engine.
After the scheme is adopted, the quality problems of water leakage and the like caused by the integrated cylinder cover are effectively prevented, so that the quality of an engine is ensured, and the dynamic property of the whole vehicle is ensured.
The invention has been described above with reference to the accompanying drawings, it is obvious that the invention is not limited to the specific implementation in the above-described manner, and it is within the scope of the invention to apply the inventive concept and solution to other applications without substantial modification.

Claims (8)

1. A method of controlling the mass of an integrated cylinder head of an engine, comprising the steps of:
1) aluminum alloy smelting: chemical components, molten alloy → molten aluminum alloy are transferred into a holding furnace;
2) a core making step: core making → repairing, deburring → storing, core assembling → transporting, core assembling and core assembling;
3) a step of installing a die: cleaning a mold → preheating the mold → coating the mold → installing and heating the mold;
4) casting: mold closing → pouring → solidification → mold opening → part taking, code printing → cooling → core vibrating → sawn riser → deburring → heat treatment → preprocessing → size, water pressure, flaw detection and metallographic phase → packaging and warehousing.
2. The method of controlling the quality of an integrated cylinder head of an engine of claim 1, wherein hydraulic, fault detection and metallographic requirements:
the hydrostatic test requires no bubbles;
the flaw detection requirement meets 1-2 grades in ASTM E505; the shrinkage cavity is less than or equal to 4.5 mm;
the metallographic structure requirement is as follows: the pinhole degree is rated in 1-2 grades according to JB/T7946.3 cast aluminum alloy pinhole, and can be 3 grades, but the 3 grades are not more than 25%; the dendrite spacing of the combustion chamber is less than or equal to 30 μm, and the dendrite spacing of the exhaust side is less than or equal to 40 μm; no black needle-like iron phase inclusions appear.
3. The method of controlling engine integrated cylinder head mass of claim 2, wherein the step of eliminating hydrostatic test bubbles:
adding a vent plug on the exhaust side: an exhaust plug is added at the position corresponding to a boss at the exhaust outer side of the cylinder cover die, and the gap of the exhaust plug is 0.2-0.3 mm;
the turning time of the die is prolonged;
and reducing the feeding cross section area of the riser and repairing the die.
4. A method of controlling the mass of an integrated cylinder head of an engine according to claim 3, wherein the step of eliminating the occurrence of cylinder head exhaust side cracking comprises:
smelting in front of the furnace: the addition of the modifier strontium accounts for 90-100PPM of the weight of the molten aluminum, and the retention time in the molten aluminum is less than 4 hours;
the metallographic phase sampling position is added at the cross section-spark plug position on the basis of the sampling of the combustion chamber.
5. The method for controlling the quality of an integrated cylinder head of an engine according to claim 4, wherein the aluminum alloy melting alloy comprises the following components in percentage by weight: si: 6.5-7.5, Fe is less than 0.15, Mg: 0.25 to 0.45; mn is less than 0.10; ti is less than 0.25.
6. The method for controlling the quality of an integrated cylinder head of an engine according to claim 5, wherein the die turnover time is 16-20 seconds.
7. The method of controlling the mass of an integrated cylinder head of an engine of claim 6, wherein the riser feed cross-sectional area is 6000 to 8000 square millimeters.
8. The method of controlling the quality of an integrated cylinder head of an engine of claim 7, wherein the mold side is flush with the pour cup.
CN202011278585.5A 2020-11-16 2020-11-16 Method for controlling quality of integrated cylinder cover of engine Pending CN112501463A (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102781606A (en) * 2010-03-17 2012-11-14 株式会社Moresco Cylinder liner and method for producing same
CN102814486A (en) * 2011-06-07 2012-12-12 韦光东 Manufacturing method for cylinder head of all-terrain vehicle engine
CN106086539A (en) * 2016-06-30 2016-11-09 娄土岭 A kind of processing technology of valve mechanism cover

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102781606A (en) * 2010-03-17 2012-11-14 株式会社Moresco Cylinder liner and method for producing same
CN102814486A (en) * 2011-06-07 2012-12-12 韦光东 Manufacturing method for cylinder head of all-terrain vehicle engine
CN106086539A (en) * 2016-06-30 2016-11-09 娄土岭 A kind of processing technology of valve mechanism cover

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