wear resistant castings by lost foam process · 3.3 dip-coating & drying the whole foam need be...
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Wear Resistant Castings by Lost Foam Process
Zhang Jianman, Liang Qingmin, Lei Bo, Ding HuanjunWeb:www.jianhengid.com Email: [email protected]
Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Wuhan Jianheng industrial technology Co.,Ltd is an integrated service company
committed to the development of foundry industry. The company owns a team with
professional knowledge and rich practical experience in casting technology and
management, engaging a number of senior foundry experts as consultant; the company
will strive to become a modern service industry enterprises focusing on foundry
consulting, research, technology, production, supplyment, trade, human resources and
other service.
Lost foam process have been widely used in many foundries and getting good
performance for many kinds of castings. This process is also been widely used for
production of wear parts especially for those which have smaller size but with many
different kind of types. If use this process for right castings, the production cost will be
greatly reduced and the casting quality will be enough for all kinds of working
conditions.
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Brief introduction:
Hammer:13% Mn or 18% Mn, usually weight is less than 50kg;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
ⅠIntroduction & typical products
Lining plate:
Including many kinds of lining plate made by manganese steel and high chrome
iron material.13% Mn, 18% Mn 20% Cr, 26% Cr; Alloy steel; Alloy cast iron;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
ⅠIntroduction & typical products
Blow bar: smaller size blow bar, with 20% and 26% Cr content;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
ⅠIntroduction & typical products
Pump parts: high Cr castings for pump parts;
Others: heat resistant castings; some special shape castings which is
difficult to produce by sand casting process, etc;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
ⅠIntroduction & typical products
ⅡWhat is Lost foam casting?
White foam
makingMolding
Pouring CleaningShake out
Coating &
drying
Heat treatment
Foam
assembling
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
3.1 White foam making
Ⅲ How it works:
Manual cutting: for small quantity and simple shape castings;
Automatic cutting: for more complex shape castings;
Foam machine: use special pattern for big batch of castings or for high surface
requirement castings;
Manual cutting Automatic cutting machine
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Foam machine
Note:1. The dia. of resistance wire is less than or equal to 0.3mm;2. During mass batch production, we should using eps beads of lost foam, and control density of foam less than 18kg/m3.
3.2 Foam checking & assembling
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
For complex castings usually use different foam sheets,meanwhile assembling
gating system togather,assisted by wood strips and asbestos sheets under glue;
Note:1. Choose the right reduced scale of white foam to make sure right size of casting.
3.3 Dip-Coating & drying
The whole foam need be coated 2~3 times ,and dryed in special heating room to
get good coating layer, for every coating layer, the heating will be important.
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Note:1. Ensure the quality first while paying attention to power savings.2. India and other Southeast Asian countries has high humidity and needs to
make the necessary dehumidification measures.
3.4 Molding & Pouring
we use dry sand for molding, and the sand will be reused after shakeout, no any binderand chemical agents; when molding, sand will be filled by several times and assisted byvibrating; we also use ceramic sand instead of silica sand or olivine sand;
Pouring will be under suitable parameters: Vacuum pressure, pouring time andtemperature
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
.
3.5 Shaking out
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Due to the use of dry sand, it is only necessary to tilt the flask to pour the casting
out of the flask. The recovery rate of sand is greatly improved.
Ⅳ Advantage of lost foam casting
1) Low investment;
For easiest equipment and trial, we just need a flask, vibration table and vacuum
system; if we want to produce 200-300T wear parts per month, equipment investment as
follows.
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Purpose Workshop Key equipment Price/usd
200-300T/month
White area Foam cutting device 700-800
CNC foam cutting machine 4400-4500
Yellow area Mix station 3700-3800
Black area
Vibration table 17500-18500
Sand filling system 2300-2500
Sand preparation system 17000-18000
Vacuum system 14000-15000
Ⅳ Advantage of lost foam casting
1) Low investment cost;
Lost foam equipment including some flask (make by oneself), sand hopper (make by
oneself), screw conveyor, vibration table and sand preparation system (because use dry
sand, it is very simple), vacuum system.
Equipment of small wear resistant parts is more simple, make production is more
flexible suit for multi-variety castings.
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Ⅳ Advantage of lost foam casting
2) Low production cost
①White foam: No need to develop wood patterns, especially for small batch products;
② use dry sand: no any binder, sand recovery rate >95%, less molding labor;
③ high efficiency: for small parts, we can pour a string at a time, high molding efficiency;
④ Surface quality: better surface quality and no parting line, reduced clean work;
⑤ labor cost more less, because better work environment.
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
3) More environment friendly.
① Production environment is better;
② use dry sand, no binder, low energy and simple flow for sand circulation; sand
recovery rate >95%;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Ⅴ. Typical simple equipment
1)Production efficiency: 2-5 mold/h;
2)Lower investment cost;
3)More flexible production;
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
For small wear resistant castings, our service including:
1. Basic casting technique consulting and data analysis;
2. Plant and shop layout designing and implement;
3. Equipment designing and selection;
4. Foundry materials selection and using guidence ;
5. Casting defects analyze and solution;
6. Workers training and operation guidance;
7. Guidance and advice on production control and management
8. Supply for any necessary equipment and material.
We will offer whole support for the project till the production stable
For more information please visit: www.jianhengid.com
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.
Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China
Contact information
Zhang JianmanTel: +86-135-45239290 Email: [email protected]
Liang QingminTel: +86-187-71036713 Email: [email protected]
Lei BoTel: +86-156-23247330Email: [email protected]
www.jianhengid.com www.jhcasting.cn
武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.