First, the main user of castings - the automotive industry
The car has been in existence for a hundred years, and now there are 760 million cars in service worldwide, and the increase in global car ownership has not decreased. In the 21st century, Asia's demand for automotive will grow at the top of the world. According to analysis, the demand for automobiles in Asia will increase by an average of about 7% per year. It is much higher than the average growth rate of the world. China is a highly promising auto market and the world's largest potential auto market. China's auto industry will soon become one of the world's largest auto industries.
The automobile industry is very strong in driving other industries. The development of the automobile industry will promote the development of metallurgy, energy, materials, chemicals, machinery, electronics and other industries, and promote the construction of highways, cities and finance, insurance, trade, transportation, information, etc. The prosperity of the tertiary industry. According to statistics, one out of every seven jobs in Germany is related to the automotive industry. The role of the automobile industry in promoting consumption, expanding employment, improving people's living standards, and driving economic development is obvious. Therefore, while China is vigorously developing trucks, the development of cars is also very fast. Recently, private cars have been encouraged. Banks have issued private car loans. Vehicle taxes and fees are also being reformed. With the increase of roads and the city to the outer suburbs and the health city. With the development, the demand for Chinese cars will surely increase.
The 63rd World Foundry Conference was held in Hungary in 1998. The report of the conference pointed out that the biggest buyer of castings in the world is the automobile manufacturing industry. The United States is the world's highest producer of castings, and the largest user of castings in the United States is its automotive industry. China's automobile production is still not high, but China's automobile manufacturing industry is becoming the main user of castings in China. According to incomplete statistics, in 1998, the output of China's automotive cast iron parts was about 700,000 tons, and the output of automotive cast aluminum parts was about 80,000 tons. The development of the automotive industry is an important factor in stimulating the development of the manufacturing industry. Many large-scale foundries in China are suppliers of automotive castings in China.
Second, the young Chinese automobile foundry industry
As an ancient country with thousands of years of casting history, China's automobile foundry industry has only forty years of history. Such a young Chinese automobile foundry industry is basically a self-sufficient foundry under the planned economic system. This is also because the automobile industry itself is China's emerging infant industry, and the ability and level of the whole society to supply the automotive industry collaboratively was extremely limited at that time. Therefore, the automobile foundry was “big and complete†in the past, and “small and complete†was also a last resort. Automobile castings are more complex than traditional industrial castings, with high quality requirements and fast delivery tempo. Therefore, casting equipment and facilities with a certain level of high productivity must be used, and capital investment is also high. However, due to the subordinate factory and the main professional of the main engine factory, the actual investment that can be arranged is very limited. Even if some foreign equipments are introduced, only some of the main equipments can be introduced due to limited funds, and the inability to introduce a complete set of equipment leads to the technical level of the professional factory of machining, assembly and other specialized factories that are also affiliated to the main engine factory. Lagging behind, low production efficiency, often become a "bottleneck" that restricts the OEM. After struggling to get through the start-up phase, China's auto foundry industry is facing increasingly high demands on its customers, the automotive industry, and facing increasingly stringent demands from the society for the foundry industry. In order to implement a sustainable development strategy, it is necessary to achieve the goal of energy saving and environmental protection. Therefore, cars must strive to improve the economy of fuels and strictly control emissions. The European Community has embarked on a car with a fuel consumption of less than 3 liters/100 kilometers. The US target is 80 mpg (ie 34 km/l petrol). In order to achieve such a goal, reducing the weight of the car is an important measure. Each car loses 100 kilograms, and 100 kilometers can save 0.3 liters of gasoline. For every 10% reduction in vehicle weight, it can reduce vehicle emissions by 10%. In order to reduce the weight of the car, it is required that the car casting must be lightweight, thin, precise, and tough. Therefore, the castings of automobiles are constantly being replaced by lightweight aluminum castings. In the past ten years, American automotive aluminum castings have increased by 1.7 times. By 2007, 95% of the American car engine cylinder heads will be made of aluminum castings, and 50% of the cylinders will be aluminum castings. The aluminum castings per car in Europe were 55 kg in 1990 and will reach 98 kg in 2006. The application of magnesium alloy castings, which are one-third lighter than aluminum alloys, has been greatly improved in cars. In recent years, the application of magnesium castings for cars has grown at a rate of 20% per year. In 1996, GM's cars used 45 magnesium alloy castings per car. In 1998, the annual output of American automotive magnesium alloy castings reached 13,000 tons. China's car development is in line with the trend of the world. China's requirements for automobile emissions are that it meets the European Community's emission standards in one step (first to implement Euro 1 standard, 2003 to Euro II standard...), and Beijing has The implementation began, and other cities also implemented. Therefore, the requirements for automotive castings are the same as the world trend. The requirements for lightweight, thin-walled, and toughened automotive castings have created tremendous pressure on the level of casting industry, the level of equipment and molds, and the level of casting and auxiliary materials for automotive cast iron parts in China. China's automotive aluminum casting, just in recent years with the rise of the car industry has just begun, automotive magnesium casting almost from scratch. It shows that the pressure of China's automobile foundry industry is great. On the other hand, the society can no longer forgive the casting industry, the energy-consuming and polluting households. The protection of resources and the protection of the environment are everyone's consensus. At the 63rd World Foundry Conference in 1998, the Foundry Environmental Protection Awards were awarded. Ten of the world's first foundries that passed the ISO14000 certification were awarded. The total level of environmental pollution in China is equivalent to the most serious degree in the history of developed countries. China's automobile foundry industry must take the road of high efficiency, energy saving, material saving and environmental protection, and take the road of green casting. There is no choice. The young Chinese car casting industry has a long way to go.
Third, several typical automotive castings
Even though China's automobile foundry industry is still young, many foundry workers in China have already appreciated the equipment status of China's automobile foundry industry with a large amount of water production capacity. In fact, the typical castings used in China's cars, such as cylinders, cylinder heads, etc., have not yet been localized, and still rely on imported castings. We must get the level of China's automobile foundry industry as soon as possible. Let's start with some typical automotive castings and further analyze the automotive foundry industry.
1, the cylinder
The most important and complex casting in the car is located on the heart of the car, the engine. In order to prevent the car from having a "heart disease", the quality of the main castings on the engine is particularly important. The cylinder is the largest and most complex casting on the engine. The thinnest part of the wall is often less than 3mm. It is mostly cast from high-strength gray cast iron and also has vermicular cast iron. Due to the progress of lightweight vehicles, the more aluminum alloys are used, some automotive manufacturers have even begun to consider casting cylinders with magnesium alloys. The casting method used in the production of cylinders is different depending on the material, and there are various options depending on the conditions of the various manufacturers, including the air punching shape in the wet sand molding, static pressure molding, high pressure multi-contact molding, boxless extrusion molding, and vibration. For molding, etc., for cast aluminum cylinders, low pressure casting, lost foam casting, extrusion casting (pre-inlaid cylinder liner with aluminum matrix composite), die casting (DOULER sand core with impact resistant aluminum solution, etc.) and semi-solid Casting, etc., as well as sand casting (such as DISA modeling process).
At present, for the cast iron cylinder, the most widely used is still the wet sand shape, especially the static pressure or air rushing shape of the air pre-compacting, which also shows many advantages - low energy consumption, noise Small, less polluting, efficient, and reliable. Recently, foreign equipment manufacturers have continuously improved the molding machine, and successively appeared improved methods such as gas stamping, airflow gain, gas pressure and pressure, static pressure and pressure, active multi-contact compaction, and forming extrusion compaction. The sand hardness is more uniform. With the development of high-power semiconductor components and computers, microelectronics technology, the use of electric servo system instead of the hydraulic and pneumatic drive used in the molding line, the molding line beats are further accelerated, and the operational reliability is greatly improved, and the simplification is significantly simplified. The hydraulic control system reduces the maintenance workload accordingly. The double-cylinder falling machine is used for the molding line, so that the casting and the pouring riser can be pre-cleaned while falling sand. The casting of the molding line often restricts the starting rate of the whole line, and automatic pouring equipment should be used. Some manufacturers use air pressure ladle and contact casting process, which is conducive to saving iron water, ensuring quality and protecting the sand box. In the pouring process, more is used in the pouring process, and some use in-type incubation and filtration.
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