Large-scale special-shaped casting refers to the production of non-standard metal parts with complex structures, oversized dimensions, and high performance requirements through processes such as sand casting and investment precision casting. The products typically have irregular geometric shapes (such as curved surfaces, special-shaped cavities, integrated multifunctional structures) and strict requirements for material strength, toughness, high temperature resistance, and corrosion resistance. They are widely used as core load-bearing or key functional parts in heavy machinery, metallurgical equipment, energy engineering, mining machinery, and other fields. These products require customized mold development, relying on precise casting processes and heat treatment technologies to ensure the accuracy and performance of large and complex structures.
Product Applications
1. Metallurgical Machinery: Forging press beams, rolling mill frames, crystallizer copper plate seats, etc., bearing high-intensity rolling pressure or high-temperature environments.
2. Construction Machinery: Hydraulic support top beams, excavator turntables, mining heavy truck frames, enduring impact loads and complex working conditions.
3. Energy Equipment: Wind power gearbox housings, nuclear power equipment support rings, steam turbine foundation frames, requiring sealing and long-term operational stability.
4. Ceramic Machinery: Ceramic press beams, key load-bearing parts of forming machines, balancing precision and heavy load capacity.
5. Special Vehicles: Heavy-duty special vehicle chassis parts, military equipment structural parts, customized to meet extreme environmental operation requirements.
Product Features
1. Large-scale and Integrated: Single piece weight ranges from several tons to hundreds of tons, integrating multiple functional structures (such as mounting interfaces, fluid channels, reinforcing ribs), reducing assembly welds, and improving equipment reliability.
2. Customized Material Performance: Using high-strength steels (such as QT700-2, QT900-2), heat-resistant steels (such as Cr-Mo alloy steel), wear-resistant white cast iron, etc., precisely controlling hardness and toughness balance through heat treatments (normalizing, quenching and tempering).
3. Precise Forming of Complex Structures: Utilizing 3D modeling and precision mold technology to achieve stable casting of thin walls (≥5mm), deep cavities, and high-precision mating surfaces (tolerance CT7-CT9 grade).
4. Adaptability to Extreme Conditions: Resistant to high temperatures (>800°C), fatigue (>10^7 cycles), and corrosion (seawater/chemical media), ensuring long-term operation in harsh environments.
5. Green Manufacturing: Optimizing gating systems to reduce scrap rates, using environmentally friendly coated sand/water-based coatings, with waste sand recycling rates over 80%.
Product Functions
1. Core Load Bearing and Support: Such as beams and frame parts, bearing main equipment loads (static load >10,000 kN, dynamic impact load >3,000 kN), providing a rigid foundation for system operation.
2. Transmission and Guidance: Such as ring gears and slide rail seats, cooperating with gears/guides to achieve motion transmission or precise positioning.
3. Sealing and Fluid Management: Complex cavity parts integrating cooling water channels and hydraulic oil interfaces, ensuring system thermal balance and energy transmission.
4. Energy Absorption and Protection: Buffer structural parts (such as explosion-proof cabins), energy-absorbing beams, enhancing equipment safety performance.
Product Technical Parameters
Parameter Categories |
Technical Specification Range |
Dimensions and Specifications |
Length: 1m-10m+; Maximum wall thickness: 200mm-1200mm |
Weight |
Single piece: 1t-200t |
Material Grades |
Ductile cast iron (QT400-18~QT900-2), carbon steel (ZG270-500~ZG45), alloy steel (ZG35CrMo, ZG1Cr18Ni9Ti) |
Mechanical Properties |
Tensile strength: ≥400MPa (cast iron) ~ ≥900MPa (alloy steel); yield strength: ≥270MPa ~ ≥600MPa; elongation: ≥18% (cast iron) ~ ≥10% (steel) |
Hardness |
HB180-320 (quenched and tempered steel); HB400-600 (wear-resistant cast iron) |
Accuracy Grade |
Dimensional tolerance: CT7-CT11; geometric tolerance: IT8-IT12 |
Surface Roughness |
Unmachined surface Ra 12.5-25μm; machining allowance: 3mm-10mm |
Internal Quality |
Ultrasonic testing (JB/T 7947): Level II and above; fracture defects ≤Φ3mm, single area ≤10mm² |
Keywords
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Large-scale casting of special-shaped parts
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