CN116727606A - Riser-free casting forming method for high-strength gray cast iron diesel engine body - Google Patents
Riser-free casting forming method for high-strength gray cast iron diesel engine body Download PDFInfo
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- CN116727606A CN116727606A CN202310709625.4A CN202310709625A CN116727606A CN 116727606 A CN116727606 A CN 116727606A CN 202310709625 A CN202310709625 A CN 202310709625A CN 116727606 A CN116727606 A CN 116727606A
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- 238000005266 casting Methods 0.000 title claims abstract description 65
- 238000000034 method Methods 0.000 title claims abstract description 44
- 229910001060 Gray iron Inorganic materials 0.000 title claims abstract description 11
- 238000013461 design Methods 0.000 claims abstract description 25
- 238000003723 Smelting Methods 0.000 claims abstract description 11
- 238000000465 moulding Methods 0.000 claims abstract description 11
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 12
- 230000007547 defect Effects 0.000 claims description 11
- 229910001018 Cast iron Inorganic materials 0.000 claims description 10
- 229910001141 Ductile iron Inorganic materials 0.000 claims description 6
- 239000000919 ceramic Substances 0.000 claims description 6
- 239000002054 inoculum Substances 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 4
- 244000035744 Hura crepitans Species 0.000 claims description 3
- 229910000805 Pig iron Inorganic materials 0.000 claims description 3
- 229910052788 barium Inorganic materials 0.000 claims description 3
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical group [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 claims description 3
- 230000000903 blocking effect Effects 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 230000017525 heat dissipation Effects 0.000 abstract description 8
- 238000010521 absorption reaction Methods 0.000 abstract description 6
- 230000035939 shock Effects 0.000 abstract description 6
- 239000000463 material Substances 0.000 description 12
- 238000007711 solidification Methods 0.000 description 6
- 230000008023 solidification Effects 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 238000013016 damping Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000012938 design process Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000007712 rapid solidification Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Provides a riser-free casting molding method of a high-strength gray cast iron diesel engine body, belonging to the technical field of casting. The method is used for casting molding design in terms of parting surfaces, a pouring system, a riser, a chill, a shrinkage ruler and smelting process parameters; the method comprises the following steps: selecting a parting surface: the diesel engine body adopts a horizontal casting type, the cylinder hole surface is positioned on the side surface, and the parting surface is arranged on the crank hole in a two-open box casting mode; and (3) the design of a pouring system: an open bottom pouring system with a filter is adopted; riser-free design: no riser is designed at the highest point of the casting position of the diesel engine body, only air outlet pieces are arranged at two sides, and an air outlet rod is arranged at the middle large plane position; no chill design: no chill is used at the part with uneven wall thickness of the diesel engine body; and (3) reducing design: the reduced scale is determined to be 1.1%; smelting process and parameters. The invention has relatively high strength and hardness, can improve shock absorption, wear resistance and heat dissipation performance, and can reduce production cost.
Description
Technical Field
The invention belongs to the technical field of casting, and particularly relates to a riser-free casting molding method for a high-strength gray cast iron diesel engine body.
Background
The engine body is a key part of a diesel engine, mainly plays a role of a supporting bracket, is provided with hundreds of parts such as a crankshaft, a connecting rod, a cylinder cover, a cam shaft and the like, is one of the most key and complex bearing parts in a diesel engine unit, and is generally formed by casting. The casting material is generally the normal QT400-15. The common ductile iron QT400-15 material machine body, especially the more parts of the thin-wall hot junction, easily produce shrinkage porosity defects at the hot junction in the solidification process, generally adopt riser and chill processes to produce castings, but the quality is unstable, the production cost is high, the damping performance is poor, and the heat dissipation performance is poor.
With the development of high quality, the diesel engine body mainly plays a role of a supporting base, and the damping performance and the heat dissipation performance are considered under the condition of meeting the basic strength and the hardness of materials. The existing common QT400-15 material machine body has large shrinkage tendency, so that the casting production process is easy to generate shrinkage porosity, shrinkage cavity, and other defects. Although the QT400-15 material has relatively high strength, the shock absorption, wear resistance and heat dissipation performance are not as good as those of HT300 material.
According to the related scientific research: in the case of flake graphite under the same conditions, the heat dissipation in the longitudinal direction is 100 times that in the width direction, and graphite nodules of ductile iron can be regarded as being in the width direction in all directions. Therefore, the HT300 brand material is adopted to cast the engine body, and the engine body has the advantages in the aspects of casting performance, wear resistance and shock absorption, and the overall operation comprehensive performance of the diesel engine is better. Therefore, a method for manufacturing the diesel engine body by casting is required to be designed corresponding to HT300 grade materials.
Disclosure of Invention
The invention solves the technical problems that: the invention provides a riser-free casting molding method of a high-strength gray cast iron diesel engine body, which aims to design from the aspects of casting parting surface selection, pouring system design, chiller arrangement removal, scale control, smelting component parameters and the like, can stably produce an HT300 brand engine body with controllable internal quality and qualified mechanical property, has relatively high strength and hardness, and can improve shock absorption, wear resistance and heat dissipation performance and reduce production cost under the condition of the same power and load.
In order to achieve the above purpose, the invention adopts the technical scheme that:
the method mainly aims at the defect that HT300 model diesel engine body is easy to crack, takes a certain type of diesel engine body as an example, and performs casting molding design in terms of parting surface, pouring system, riser, chill, shrinkage scale and smelting process parameters; the method specifically comprises the following steps:
1) Selecting a parting surface: the diesel engine body adopts a horizontal pouring type, the cylinder hole surface is positioned on the side surface, and the parting surface is arranged on the crank hole to form a two-box casting mode, so that the diesel engine body casting sand box is divided into a lower box and an upper box;
2) And (3) the design of a pouring system: an open bottom pouring system with a filter is adopted, the open bottom pouring system comprises a sprue, a cross runner, a filter and an inner runner, the sprue is connected with the cross runner, the cross runner is connected with the filter, the filter is connected with the inner runner, and the inner runner is connected with a cavity;
3) Riser-free design: no riser is designed at the highest point of the casting position of the diesel engine body, only air outlet pieces are arranged at two sides, and an air outlet rod is arranged at the middle large plane position;
4) No chill design: no chill is needed to be designed at the part with uneven wall thickness of the diesel engine body;
5) And (3) reducing design: the shrinkage tendency of a diesel engine body of HT300 cast iron is larger than that of common ductile cast iron, so the shrinkage of the diesel engine body is determined to be 1.1 percent;
6) Smelting process and parameters: the HT300 cast iron comprises the following components in parts by weight: 29% pig iron, 40% scrap, 30% furnace return, and 1% carburant; the alloy composition is controlled as follows: c:2.9% -3.1%, si:1.7% -1.9%, mn:0.7% -0.9%, P < 0.1%, S:0.06% -0.10%, cu:0.4% -0.5%, cr:0.2% -0.3%. The inoculant is barium-containing inoculant, and the addition amount is 0.6%.
In the step 2), the section ratio of the open bottom pouring system is a sprue: and (3) a cross gate: ingate = 1:2.1:1.6.
In the step 2), the sprue is made of 1 phi 100mm ceramic tube, the cross runner is 80/90×100 trapezoid cross section, and the inner runner is made of a corresponding number of phi 30 ceramic tubes.
In the step 2), the sprue is used as a flow blocking section, molten iron is introduced from the sprue to the cross gate in a dispersed manner from the lowest surface of the cavity through a filter, the casting time is controlled to be about 60-70 seconds, and the casting temperature is 1360-1370 ℃.
In the step 3), the air outlet piece adopts a specification of 45×13×400mm, and the air outlet rod adopts a specification of Φ20mm.
Compared with the prior art, the invention has the advantages that:
1. according to the invention, for the cast iron brand HT300 machine body, in the solidification process, because graphite is precipitated and expands along with phase change, the self-feeding capability is very strong, so that shrinkage cavity and shrinkage porosity tendency are small, a riser-free design is adopted at the highest point of a casting pouring position, only an air outlet piece and an air outlet rod with certain specification are arranged, and a cold iron is not used at a thick part of the casting, so that the shrinkage porosity defect of the casting can be effectively eliminated; on the premise of ensuring the strength and rigidity of the machine body, the shock absorption, wear resistance and heat dissipation of the machine body are improved, and the casting process is simplified;
2. in the scheme, the casting temperature is 1360-1370 ℃ higher, and the casting time is controlled to be about 60-70 seconds by matching with an open bottom casting pouring system with a bottom casting belt filter, so that the defects of air holes and slag inclusion of castings can be effectively reduced, and the surface quality of the castings is good;
3. compared with the common QT400-15 material body, the HT300 material body is easier to crack, so that the material performance is ensured by controlling the purity and chemical components of smelting raw materials;
4. the diesel engine body manufactured by the method has the advantages that through the detection and the processing verification of the mechanical property of the field test, the tensile strength of a single casting sample exceeds 330MPa, the tensile strength of the body reaches 260MPa on average, the hardness is 178HB, the internal and external quality meets the design requirement of the diesel engine, and the overall operation comprehensive performance of the diesel engine is better.
Drawings
FIG. 1 is a schematic view of a parting plane of a diesel engine body according to the present invention;
FIG. 2 is a schematic side view of a casting system of a diesel engine block according to the present invention;
FIG. 3 is a schematic diagram of the bottom surface of the casting system of the diesel engine block according to the present invention;
fig. 4 is a diagram showing the arrangement of the air outlet piece and the air outlet rod of the diesel engine body according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation. The inclusion of an element as defined by the phrase "comprising one does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises an element.
Referring to fig. 1-4, embodiments of the present invention are described in detail.
Examples: the method mainly aims at the defect that HT300 brand diesel engine body is easy to generate cracks and the like, takes a certain type of diesel engine body as an example, the outline dimension of the engine body is 2638 multiplied by 968 multiplied by 1274mm, the blank weight is 4970Kg, the casting solution weight is 6100Kg, the main wall thickness is 15mm, and the maximum wall thickness is 108mm; and casting and forming design is carried out from the aspects of parting surfaces, a pouring system, a riser, a chill and a reduced scale and smelting technological parameters. The method specifically comprises the following steps:
1) Selecting a parting surface: the diesel engine body 1 adopts horizontal pouring type, and the jar hole face is located the side, and not only molding box assembly easy operation can also guarantee that the shape position of the holistic size of organism and side is accurate complete, and die joint 2 sets up two division box casting modes of department on the bent axle hole, see the fig. 1 and show, makes diesel engine body 1 casting sand box be divided into lower case 3 and upper case 4, and the foundry goods is located the lower case mostly, is favorable to guaranteeing the size, can guarantee internal quality simultaneously.
2) And (3) the design of a pouring system: the open bottom pouring system 5 with the filter is adopted, the open bottom pouring system 5 comprises a sprue 6, a runner 7, a filter 8 and an inner runner 9, the sprue 6 is connected with the runner 7, the runner 7 is connected with the filter 8, the filter 8 is connected with the inner runner 9, and the inner runner 9 is connected with a cavity.
Preferably, the cross section ratio of the open bottom pouring system 5 is a sprue: and (3) a cross gate: ingate = 1:2.1:1.6.
For the diesel engine in the embodiment, the sprue 6 is made of 1 ceramic tube with phi of 100mm, the cross runner 7 is of a trapezoid section with 80/90mm multiplied by 100mm, and the ingate 9 is made of 18 ceramic tubes with phi of 30 mm. Referring to fig. 2 and 3, the sprue 6 is taken as a flow blocking section, molten iron is introduced from the sprue 6 to the runner 7 in a dispersed manner from the lowest surface of the cavity through the filter 8, the casting time is controlled to be about 60-70 seconds, and the casting temperature is 1360-1370 ℃. The molten iron is introduced from the lowest part of the cavity, and is matched with an open type inner gate, so that the liquid level of the molten iron rises steadily, and the defects of air holes and slag inclusion caused by turbulent flow are reduced.
In the method, the higher pouring temperature is 1360-1370 ℃, and the pouring time is controlled to be about 60-70 seconds by matching with an open bottom pouring system with a bottom pouring filter, so that the defects of air holes and slag inclusion of castings can be effectively reduced, and the surface quality of the castings is good.
3) Riser-free design: because the material of the diesel engine body is changed, the liquid and solid solidification shrinkage modes are changed, the wall thickness of the upper part of the diesel engine body is thinner, a large amount of liquid feeding is not needed, and only smooth and rapid solidification is needed, so that a riser is not designed at the highest point of the casting position of the diesel engine body 1, only air outlet pieces 10 are arranged at two sides, and an air outlet rod 11 is arranged at the middle large plane position.
For the diesel engine body in this embodiment, the number of the air outlet pieces 10 is 18, and the specification of 45×13×400mm, and the specification of the air outlet rod 11 is Φ20mm. See fig. 4.
4) No chill design: no chiller is required to be designed at the part with uneven wall thickness of the diesel engine body 1.
In the past, a large number of chill blocks are arranged at the part with the wall thickness and the part with uneven wall thickness of the machine body and used for balancing the solidification speed of the part with the large wall thickness. The method has the advantages that the traditional chill is not designed during the design process, the production cost of various raw materials required for manufacturing the chill is greatly reduced, and meanwhile, the surface quality of castings is improved and the production efficiency is improved because no chill is arranged.
For the cast iron brand HT300 machine body, in the solidification process, graphite is precipitated and expands along with phase change, so that the cast iron brand HT300 machine body has strong self-feeding capability, and the tendency of shrinkage cavity and shrinkage porosity is small. The highest point of the casting pouring position is required to be designed without a riser, and only the air outlet piece and the air outlet rod with certain specifications are arranged, so that the shrinkage porosity defect of the casting can be effectively eliminated without using a chill at the thick and large part of the casting.
5) And (3) reducing design: the shrinkage ratio of the cast iron introduced in the casting manual ranges from 0.8% to 1.3%, and the shrinkage tendency of the diesel engine body 1 of the HT300 cast iron is larger than that of the common ductile iron according to the wall thickness shape structure of the casting, so that the shrinkage scale of the diesel engine body 1 is determined to be 1.1%; later examination of the casting dimensions indicated that a 1.1% reduction was appropriate.
6) Smelting process and parameters: because gray cast iron is different from spheroidal graphite cast iron, and belongs to sequential solidification, the casting performance is good, shrinkage porosity defect is not easy to generate, and the difficulty is that high strength is realized. Therefore, a reasonable design of the proportioning mode and the alloy component proportion are key to realizing high strength. The HT300 cast iron in the method comprises the following steps: 29% pig iron, 40% scrap, 30% furnace return, and 1% carburant; the alloy composition is controlled as follows: c:2.9% -3.1%, si:1.7% -1.9%, mn:0.7% -0.9%, P < 0.1%, S:0.06% -0.10%, cu:0.4% -0.5%, cr:0.2% -0.3%. The inoculant is barium-containing inoculant, and the addition amount is 0.6%.
The invention is designed from the aspects of casting parting surface selection, pouring system design, chiller arrangement removal, scale control, smelting component parameters and the like, can stably produce HT300 brand organisms with controllable internal quality and qualified mechanical properties, has relatively high strength and hardness, and can improve shock absorption, wear resistance and heat dissipation performance and reduce production cost under the condition of the same power and load.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present disclosure describes embodiments, not every embodiment is provided with a separate embodiment, and that this description is provided for clarity only, and that the disclosure is not limited to the embodiments described in detail below, and that the embodiments described in the examples may be combined as appropriate to form other embodiments that will be apparent to those skilled in the art.
Claims (5)
1. A riser-free casting molding method for a high-strength gray cast iron diesel engine body is characterized by comprising the following steps of: the method is mainly used for casting, forming and designing parting surfaces, a pouring system, a riser, a chill, a shrinkage ruler and smelting process parameters aiming at the defect that HT 300-grade diesel engine bodies are easy to crack; the method specifically comprises the following steps:
1) Selecting a parting surface: the diesel engine body (1) adopts a horizontal pouring type, the cylinder hole surface is positioned on the side surface, and the parting surface (2) is arranged on the crank hole to form a two-open box casting mode, so that a casting sand box of the diesel engine body (1) is divided into a lower box (3) and an upper box (4);
2) And (3) the design of a pouring system: an open bottom pouring system (5) with a filter is adopted, the open bottom pouring system (5) comprises a straight pouring gate (6), a transverse pouring gate (7), a filter (8) and an inner pouring gate (9), the straight pouring gate (6) is connected with the transverse pouring gate (7), the transverse pouring gate (7) is connected with the filter (8), the filter (8) is connected with the inner pouring gate (9), and the inner pouring gate (9) is connected with a cavity;
3) Riser-free design: no riser is designed at the highest point of the pouring position of the diesel engine body (1), only air outlet pieces (10) are arranged at two sides, and an air outlet rod (11) is arranged at the middle large plane position;
4) No chill design: no chiller is required to be designed at the part with uneven wall thickness of the diesel engine body (1);
5) And (3) reducing design: the shrinkage tendency of the HT300 cast iron diesel engine body (1) is larger than that of common spheroidal graphite cast iron, so that the shrinkage scale of the diesel engine body (1) is determined to be 1.1%;
6) Smelting process and parameters: the HT300 cast iron comprises the following components in parts by weight: 29% pig iron, 40% scrap, 30% furnace return, and 1% carburant; the alloy composition is controlled as follows: c:2.9% -3.1%, si:1.7% -1.9%, mn:0.7% -0.9%, P < 0.1%, S:0.06% -0.10%, cu:0.4% -0.5%, cr:0.2% -0.3%; the inoculant is barium-containing inoculant, and the addition amount is 0.6%.
2. The riser-free casting molding method of the high-strength gray cast iron diesel engine body according to claim 1, wherein the method comprises the following steps of: in the step 2), the section proportion of the open bottom pouring system (5) is a sprue: and (3) a cross gate: ingate = 1:2.1:1.6.
3. The riser-free casting molding method of the high-strength gray cast iron diesel engine body according to claim 2, wherein the method comprises the following steps of: in the step 2), the sprue (6) is made of 1 ceramic tube with phi of 100mm, the cross runner (7) is of a trapezoid section with 80/90mm multiplied by 100mm, and the inner runner (9) is made of ceramic tubes with phi of 30mm in corresponding number.
4. The riser-free casting molding method of the high-strength gray cast iron diesel engine body according to claim 3, wherein the method comprises the following steps of: in the step 2), the sprue (6) is used as a flow blocking section, molten iron is introduced from the sprue (6) to the cross gate (7) in a dispersed manner from the lowest surface of the cavity through the filter (8), the casting time is controlled to be about 60-70 seconds, and the casting temperature is 1360-1370 ℃.
5. The riser-free casting molding method of the high-strength gray cast iron diesel engine body according to claim 1, wherein the method comprises the following steps of: in the step 3), the air outlet piece (10) adopts a specification of 45 multiplied by 13 multiplied by 400mm, and the air outlet rod (11) adopts a specification of phi 20mm.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310709625.4A CN116727606A (en) | 2023-06-15 | 2023-06-15 | Riser-free casting forming method for high-strength gray cast iron diesel engine body |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310709625.4A CN116727606A (en) | 2023-06-15 | 2023-06-15 | Riser-free casting forming method for high-strength gray cast iron diesel engine body |
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