We have two advanced production lines, namely sand casting and precision casting. We have rich manufacturing experience in casting parts made of low-temperature, high-temperature and corrosion-resistant materials. We offer high-quality cast steel parts for pump and valve applications, covering a wide range of materials such as carbon steel, corrosion-resistant steel, ultra-low carbon stainless steel, super duplex stainless steel, Hastelloy nickel-based alloys, etc., in accordance with standards like ASTM, GB, DIN-EN RCC-M, etc., totaling over 50 types.
There are 10 professionals in various fields such as materials, casting, heat treatment, welding, etc., including 4 senior engineers and 2 casting experts. They possess the ability to design the process of pump-type castings professionally. A group of technical quality management personnel have been cultivated and introduced, forming a professional and experienced technical team.
n Production area: 15,000 m2；
n Annual casting capacity: 3,000 tons, manufacturing various pump and valve cast steel parts;
n Maximum casting weight: ≤ 9,500 kg;
n Advanced casting simulation software is used to assist in the process design of product manufacturing;
n Manufacturing process: alkaline phenolic resin sand molding, mid-frequency furnace melting + AOD refining technology. The maximum melting capacity of molten steel is 16.5 tons, with AOD refining, decarburization and degassing capabilities, suitable for ultra-low carbon materials and high-end cast parts from both domestic and international markets.
n Quick manufacturing capability: Voxeljet (VJ) sand mold 3D printing technology is available, enabling 7 to 15 days from 3D design to casting part delivery without molds.
Material Details1 for Casting Component Manufacturing
Material Details2 for Casting Component Manufacturing
Material Details3 for Casting Component Manufacturing
Material Details4 for Casting Component Manufacturing
n Production area: 3000 m2；
n Production capacity of castings: 100 tons per year, manufacturing high-precision over-flow castings;
n Weight of castings: ≤ 200 kg;
n Dimensions of castings: One-way dimension ≤ 800 mm;
n Advanced casting simulation software is used to assist in the process design of product manufacturing;
n Manufacturing process: Wax patterns made with medium-temperature wax and low-temperature wax, shell made with silica sol;
n High dimensional accuracy: GB6414 CT4-6 or ISO 8062 DCTG4-6;
n Manufacturing cycle: 25 to 35 days.
Material Details1 for Casting Component Manufacturing
Material Details2 for Casting Component Manufacturing
Material Details3 for Casting Component Manufacturing
Material Details4 for Casting Component Manufacturing
Sand mold 3D printing technology can economically print out sand molds and sand cores for casting. Different-sized and -structured sand molds can be placed in the same molding box and printed out quickly and flexibly. The printed cores can be directly used for pouring, eliminating a large amount of rework time and also being compatible with traditional casting processes. This manufacturing method without mold opening enables faster production of small and medium batch components and is an ideal choice for complex casting parts. It can achieve delivery of castings from 3D design within 7 to 15 days, and the production and manufacturing process is unmanned.
Sand mold 3D printing equipment
Sand mold 3D printing equipment
3D printed core bushing
The casting simulation analysis covers aspects such as design of gating and risering systems, solidification analysis, filling analysis, solidification time, and time when the molten steel stops flowing. It is applicable to casting methods like sand casting and precision casting, and the materials simulated include carbon steel, stainless steel, duplex steel, and nickel-based alloys, etc. It can achieve optimization of gating and risering system design, ensure a high process yield rate, and improve product quality.
3D design of casting process
Analysis of Simulation Casting Solidification
Analysis of Pouring and Cooling Time for Castings
The foundry factory is equipped with one 15t/h mobile sand mixer，one 10t/h mobile sand mixer， one 10t/h fixed sand mixer, with a maximum molding size of 4000x3000x2500mm. Adopting alkaline phenolic resin technology, all molding sand is made of ceramic foundry sand as the core raw material. Compared to traditional quartz sand materials, it significantly improves the appearance quality of castings and reduces casting defects such as sand sticking and sand holes. The supporting sand treatment system has a regeneration capacity of 10t/h and a regeneration efficiency of ≥ 90%.
Preparation of sand core for casting core inserts
n Intermediate frequency furnace melting：
The factory is equipped with a 3000kW tandem-type 5t, 3t, and 1t medium frequency electric furnace, which can achieve simultaneous melting of each furnace body, with a maximum melted molten steel volume of about 12.5 tons. High melting efficiency, in the hot furnace state, 5 tons of molten steel can be melted in 60 minutes, approximately 20 tons of molten steel per shift. The equipment is equipped with leak monitoring, alarm functions for circulating water flow, pressure, temperature detection, remote control operation, and a full-digital control system.
n AOD refining：
The factory is equipped with 5t and 10t AOD refining systems, using argon oxygen decarbonization method to achieve carbon reduction, desulfurization, gas and slag removal functions for molten steel. Realize the purification of molten steel, improve quality, and achieve a gas content of less than 100ppm. The maximum refining capacity is 10 tons, and the refined materials include various types of materials such as martensitic stainless steel, ultra-low carbon austenitic stainless steel, and super duplex steel. Used for refining molten steel for domestic, international high-end, nuclear power and other products. The equipment is equipped with the intelligent refining control system, intelligent ingredient calculation, decarbonization, and data restoration guidance.
Equipment for melting in a medium-frequency furnace
AOD equipment for refining molten steel
The factory is equipped with automated heat treatment equipment, which can achieve a solution time of ≤ 45 seconds (from the opening of the furnace door to the immersion in water), meeting the solution time requirements for super duplex stainless steel during heat treatment. The equipment is equipped with an automated control system, including one-button furnace entry, furnace exit solution, water circulation and stirring system, water temperature cooling circulation system, and paperless heat treatment time-temperature curve.
Automated heat treatment equipment
The factory is equipped with multiple types of hook-type shot blasting machines. The maximum capacity of each machine is 10 tons for shot blasting, which can handle the maximum diameter of the workpiece for rotation of about 3 meters. It is also equipped with an environmental protection dust removal room for cleaning the workpieces and a centralized dust removal system, including 4 cutting dust removal rooms, 8 grinding dust removal rooms, and 4 supplementary welding dust removal rooms. It has various welding process technologies such as electric welding, argon arc welding, and gas welding. The surface of the workpieces is also equipped with anti-rust technology.
The area for grinding and cleaning of castings
Chamber for cleaning and dust removal of castings
The precision casting production line is equipped with the wax mold-making process using medium-temperature wax and low-temperature wax, as well as the shell-making process with silica sol. The main products are high-precision hydraulic flow casting parts such as pump bodies and impellers, with a maximum weight of 200kg and a single-directional size of ≤ 0.8m. It is equipped with advanced manufacturing equipment and a safe and environmentally friendly wax treatment system. The product dimensions have high precision and the surface quality is good. It also has advanced casting simulation software to assist in process design, enabling the development of complex-structured products.
The operation area of the precision casting production line
The operation area of the precision casting production line
Having qualified QA and QC personnel engaged in quality management, quality control, and inspection and testing. Obtained NORSOK M650 5A casting manufacturing qualification certification and ISO 9001 quality management system certification. The factory has complete testing and control measures for the chemical composition, mechanical properties, geometric dimensions, and inherent defects of casting materials：
n Complete sand performance testing instruments and equipment. By timely testing of the molding sand, its performance and quality can be stabilized and improved, reducing defects such as erosion, sand sticking, and sand holes.
n Introduce one imported photoelectric direct reading spectrometer, equipped with a portable spectrometer (PMI). Quickly and accurately measure the chemical composition and properties of materials in front of the furnace.
n Capable of testing mechanical properties such as stretching, bending, hardness, and low-temperature impact, as well as corresponding metallographic testing and intergranular corrosion testing, etc.
n Equipped with a radiographic (RT) flaw detection room (Co60 radiation source and linear accelerator radiographic testing), with a maximum penetration wall thickness of 200mm; Equipped with endoscopic visual inspection equipment, dye penetrant testing and other non-destructive testing methods.
n Have a complete set of manufacturing process control capabilities, including cavity endoscopy inspection, steel temperature measurement, welding preheating temperature measurement, portable hardness testing, sample size and wall thickness testing, etc.
Universal testing machine
Molding sand inspection equipment
Spectral analysis of chemical composition of castings
Liquid penetration testing of castings
RT inspection area for castings
