FAW Foundry Co.

Changchun, China

FAW Foundry Co.

Changchun, China
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Du S.,Changchun Jinma Heat Treatment Co. | Fang J.,FAW Foundry Co. | Yang M.,SBW Group Geared Compressor Corporation
Jinshu Rechuli/Heat Treatment of Metals | Year: 2014

An age-hardened nitriding gear steel 20CrNi3Mn2Al was developed. The test results show that the steel under air cooling solid solution condition has a good machinability with hardness of 283-332 HB. After deep layer plasma nitriding, the steel can obtain high hardness greater than 900 HV on surface layer and core hardness of 400-450 HV(42-46 HRC) and the nitrided depth can reach 0.7-1.0 mm. It can be used to replace partially the carburizing steel, which can leave out the carburizing and oil quenching processes, and simplify the technology and reduce the gear distortion. ©, 2014, Chinese Mechanical Engineering Society of Heat Treatment. All right reserved.

Zhao H.-R.,FAW Foundry Co. | Bian Q.-Y.,FAW Foundry Co.
Zhuzao/Foundry | Year: 2012

In order to eliminate blowhole defects on the top surface of 2 K cylinder, ferric oxide powder was added into molding sand, then the blowhole defect problem was released temporarily. But addition of ferric oxide powder could worsen properties of molding sand, scab defects could occur and cleaning could be very hard. Through the analysis on the cause of the problem, the defect could be confirmed to a nitrogen blowhole. The series of comparison were made to solve the problem including adding ferric oxide powder into molding sand and core sand respectively, opening a launder near blowhole area, and adding ferric oxide powder to the cores that were the nearest ones to the defects areas. The proper content of ferric oxide powder in the sand was calculated. Results show that ferric oxide powder was effective to solve the nitrogen blowhole defect, and the defect could be restrained to occur while the concentration of ferric oxide powder had reach 1.95%-3.9%. Setting a core contained ferric oxide powder to contact with blowhole on the top surface of the cylinder, and the concentration of ferric oxide powder in the core sand reached 3%, were testified to be a more suitable method in terms of this kind of problems.

Zhang W.,Tsinghua University | Fang J.-R.,FAW Foundry Co. | Xiong S.-M.,Tsinghua University
Zhuzao/Foundry | Year: 2012

After a detailed comparison of the mold filling simulation results of three different runner systems in the die design of a seven-gear auto transmission case casting, the optimal scheme of the runner system was obtained. Through the evaluation of the solidification simulation results on locations of hot spots and shrinkage porosities, the cooling design for the die was determined. The optimal die design of the casting was successfully used in practical application and the results for air-leakage test and the appearance observation of the castings show that numerical simulation could be used as a tool for the die design of large and complex die design and this optimal die design of the seven-gear auto transmission case could be used as a reference for the die design of similar products.

Sun X.,Jilin University | Cao Z.Y.,Jilin University | Liu H.F.,FAW Foundry Co. | Jiang W.,Jilin University | Liu L.P.,Jilin University
Applied Mechanics and Materials | Year: 2014

In this paper, experimental and finite element modeling methods were adopted to investigate the effects of microporosity on the tensile properties and fracture behavior of high-pressure die-casting (HPDC) AM50 alloy. By specimen-to-specimen fractographic analysis, the variability in tensile properties could be quantitatively correlated with the areal fraction of the porosity presented in the corresponding fracture surfaces by using a simple power law equation. Numerical models of synthetic microstructures with different pore sizes, areal fractions of pores and pore distributions were established. Based on the experimental and numerical simulation results, it could be concluded that the fracture will initially occur in the region where has the highest intensity of equivalent stress field (i.e., contains the most highly localized cluster of pores and shrinkage), and then, fracture crack will fast propagate through the adjacent regions which have the relatively high intensity of stress field. © (2014) Trans Tech Publications, Switzerland.

Sun Y.-L.,Jiangsu Nanjing Technician College | Liu H.-F.,FAW Foundry Co. | Sun F.,FAW Foundry Co.
Zhuzao/Foundry | Year: 2013

The integrated casting, lightweight casting, and digital technology application for automobile casting development trend were presented in this paper. Combined the present development of Chinese foundry industry, thin-walled castings production technology, large-scale structure of aluminum/magnesium alloy casting parts production technology and precision casting forming technology were also discussed. Based on the above discussion, the trend for automotive castings and its technology development was also put forward.

Wu G.-H.,MAGMA Engineering Suzhou Co. | Lu B.-S.,FAW Foundry Co.
Zhuzao/Foundry | Year: 2013

As casting geometries become more and more challenging in their designs, the demand for intricate and high quality sand cores will also continue to increase. New modules MAGMAcore+mold have been added to MAGMAsoft, which enable its use more comprehensive and accurate. In this paper, the cylinder body core as an example, the physical modeling and simulation application of core shooting and binder hardening are described, the simulation result and practice is matched.

Wang Z.-Y.,FAW Foundry Co. | Zhang X.-Y.,FAW Foundry Co. | Feng X.-C.,FAW Foundry Co.
Zhuzao/Foundry | Year: 2015

The defects of water jacket core break, sand inclusion, leakage and blowhole of 1002011-90D block casting with small batch production were analyzed, and some measures were adopted. The process was traced and carried out, the defects of 90D block casting were solved by the effect process. The yield of the product has been significantly improved, good economic results were achieved. ©, 2015, Chinese Mechanical Engineering Society. All right reserved.

Xu X.-Y.,FAW Foundry Co.
Zhuzao/Foundry | Year: 2010

Basing on casting process, the characteristics of production operations and limitation of manual cost accounting, the importance and the overall framework of cost accounting system were elaborated. Detailed cost accounting and the level of cost center in the overall framework, and costs control and input-output control in the cost flow were presented. The role and the actual results of the cost accounting system in our plant were explained. The cost accounting system improves the level of cost control and provides the reliable data for effective decision-making of cost and price.

Zhang Q.,Xi'an Jiaotong University | Chen Y.,Xi'an Jiaotong University | Fang J.,FAW Foundry Co.
Hsi-An Chiao Tung Ta Hsueh/Journal of Xi'an Jiaotong University | Year: 2011

To design high-pressure casting die for box-like workpieces, a new optimization strategy for cooling channel arrangement is proposed, solid fraction of a box-like workpiece, and thermal balance, temperature field, thermal stress and thermal fatigue of a high-pressure casting die for workpieces are analysed by FE simulation. The relationship between cooling channel heat-transfer coefficient and flow rate in cooling channels is presented. In the cases of cooling channel arrangement along the cross and longitudinal directions, the die thermal stress, thermal fatigue and workpiece solidification are investigated with the increasing cooling channel intervals. Because the yield stress of die material varies with temperature, a factor related to thermal stress is applied to evaluate the margin of die safety under thermal stress. On the premise of the productivity effect and an appropriate solidification of workpieces, the cooling channel intervals ought to be increased as possible to decrease the mold thermal stress. When the channels are arranged with interval of 25 mm, the mold needs 6 cycles to reach thermal balance; and n gets less than 0.5, the area of the mold thermal stress and thermal fatigue is located 10 mm below the cavity.

Jiang W.,Jilin University | Cao Z.,Jilin University | Sun X.,Jilin University | Liu H.,FAW Foundry Co.
Microscopy and Microanalysis | Year: 2015

High-pressure die-casting (HPDC) AZ91 tensile specimens were used to investigate characteristics of gas pores and their effects on mechanical properties of HPDC AZ91 magnesium (Mg) alloy. Combining the stereoscopic morphology of gas pores obtained from a three-dimensional (3D) reconstruction technique with the experimental data from uniaxial tensile testing, we worked on finite element simulation to find the relationship between gas pores and the mechanical properties of HPDC AZ91 Mg alloy. Results indicate that the 2D metallography images have one-sidedness. Moreover, gas pores >100 µm in the center region have a remarkable negative influence on the ultimate tensile strength (UTS) and elongation. With an increase in the size of large gas pores in the center region, the UTS and elongation of the material decreases. In addition, the distribution of gas pores in the specimens and the areal fraction of gas pores >100 µm on cross sections can also affect the UTS and elongation to some extent. © Microscopy Society of America 2015

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