(3) Rapid metallographic spheroidization rate detection of molten iron after spheroidization;
(4) Rapid detection and prediction of iron carbon equivalent, carbon and silicon content, inoculation effect, spheroidization rate and mechanical properties of the cast iron grades before the furnace by thermal analysis;
(5) Rapid detection of oxygen content, nitrogen content and hydrogen content in the molten iron before the furnace.
2.3 Quality inspection of cupola melting process
(1) Detection and automatic control of cupola air volume, air temperature and wind pressure;
(2) Continuous temperature measurement and automatic recording of molten iron at the bridge of the cupola;
(3) Detection of CO and CO 2 in the furnace gas at the feed port of the cupola;
(4) Monitoring and automatic control of the cupola level;
(5) Calculation, detection and automatic control of the optimal ingredients of the cupola;
(6) Detection of the height of the bottom of the cupola;
(7) Detection of molten iron melting rate of cupola;
(8) Detection of the amount of molten iron in the furnace before the cupola;
(9) Detection of alkalinity and ferrous oxide content of cupola slag.
2.4 Casting properties of casting alloys
(l) testing of the fluidity of the cast alloy liquid;
(2) Testing of shrinkage and body shrinkage characteristics of cast alloy wires;
(3) Testing of the stress characteristics of the cast alloy;
(4) Testing of the tendency of casting alloy cracks;
(5) Test of gas content of casting alloy.
2.5 Quality inspection and control of sand mixing, modeling and core making process
(1) Automatic control of batching microcomputer during sand-mixing process and automatic detection and automatic control of old sand temperature, molding sand moisture, binder and compaction rate;
(2) Automatic control of the batching microcomputer in the process of core sand blending and automatic adjustment of components such as resin and hardener;
(3) During the sand-matching process, the rapid detection and analysis of the performance of each sampling of the core sand timing;
(4) Detection of sand hardness and size in modeling;
(5) Automatic detection and automatic control of sanding amount and compaction parameters in modeling;
(6) The automatic line of modeling uses the micro-electronic technology program controller and the automatic control of the microcomputer;
(7) Microcomputer program control and core shooting, hardening, purification and environmental protection testing during core making.
2.6 Quality inspection and control of the cleaning process
(1) The rapid metallographic detection of the ball iron in the cleaning station and its guiding parts;
(2) Ultrasonic detection of the spheroidal spheroidization rate of the secondary cleaning station and the on-line automatic detection and automatic component of the eddy current electromagnetic method of the matrix hardness;
(3) rapid metallographic examination of ductile iron annealed test blocks;
(4) Microcomputer control for cleaning the special line shot blasting machine;
(5) Automatic control of casting riser cutting and deburring burr operation with CNC machine tools;
(6) The detection of the main dimensions and positioning points of key castings by special-purpose fixtures;
(7) Testing of water (gas) pressure test on certain key castings;
(8) One-time cleaning station sampling to detect the final silicon content of the ductile iron.
2.7 Inspection of final finished castings
(1) Detection of surface roughness of castings;
(2) The measurement of the dimensional accuracy of the casting and the detection of the scribing;
(3) periodic detection of casting weight deviation;
(4) Inspection and inspection of debris in the casting cavity;
(5) Anatomical inspection of important complex castings;
(6) Detection of X-ray internal flaw detection and surface crack magnetic particle inspection of important security castings;
(7) Using special test benches and other equipment to test the quality of various critical (or fatigue performance) and running performance of critical or security castings;
(8) Full analysis and inspection of metallographic structure, mechanical properties and chemical composition of various cast iron post-furnace mechanical test bars and main casting bodies representing casting materials.
2.8 Quality inspection of cooperative parts and diffusers
(1) Perform a full analysis of the chemical composition, metallographic structure and mechanical properties of the cast iron test bars for the cooperative parts and the diffusion parts.
(2) Conducting random inspection of the hardness of each vehicle skin of the cooperative factory and the diffusion plant and the surface quality inspection of the casting.
It can be seen from the above that comprehensive and advanced casting quality inspection and quality control is a set of modern complex and multi-disciplinary integrated technologies and means.
3. The main direction and measures of China's automobile casting inspection technology in the early 21st century
In order to solve the problem that the quality inspection and quality control technology of China's automobile foundry industry must be more backward than that of foreign countries, in order to adapt to the future of the 21st century, automotive castings must go to high quality, refined, high grade, multi-variety, thin wall and complex. , security, "longevity" goals and high-tech, high-efficiency, low-cost production of castings, and closely combined with China's automobile casting industry's national conditions, factory conditions and the actual situation, the main direction and efforts of this topic in the early 21st century Should start from the following aspects.
3.1 Casting quality inspection
3.1.1 Determination of molten iron composition before furnace
For the detection method of the molten iron composition in the furnace before the production of large-flow water in automobile castings, high-speed automatic vacuum direct reading spectrometry has been widely used in foreign countries, and the traditional backward pre-furnace chemical method has been eliminated. Since the 1980s, the domestic application has gradually been applied to various large and medium-sized automobile foundries, and its enormous work efficiency, quality and economic benefits have been unquestionable. Small and medium-sized automobile foundries should promote small, benchtop spectrum analyzers that are affordable and affordable. In the large-scale water-based automobile foundry, the direct reading spectrometer far away from the melting workshop can be equipped with the domestic "remote high-speed pneumatic sample feeder" and "remote component digital display terminal" will be the best choice. In the future, we should pay attention to the development of pre-furnace direct reading spectral analysis of the "harmful trace element group" composed of a large number of trace elements in cast iron, in order to effectively solve the excessive amount of harmful trace elements in automobile casting, resulting in "unpredictable" Batch waste, timely and strictly control the content of harmful trace elements in the furnace material during casting melting. In particular, the development of direct reading spectral analysis of gas elements N, 0, H should be carried out in depth, and its significance is very significant. In recent years, the “Liquid Pure Nitrogen High Pressure Tank†developed and developed in China for the direct reading spectrometer has provided the best technology for solving the daily manual labor of carrying a large amount of nitrogen cylinders, especially to greatly reduce the cost of the existing argon raw materials of the spectrometer. It is worth promoting. .
3.1.2 Pre-furnace iron temperature detection
China's pre-furnace rapid thermocouple temperature measurement technology is close to foreign standards. The domestic "wall-mounted microcomputer digital display temperature measuring instrument" has the advantages of precision, durability, high reliability and low failure rate. It can be promoted for automobile foundry factories with strict control of tapping temperature; its portable small instrument is very suitable for Detection of pouring temperature. In order to solve the temperature measurement process discipline and temperature waste assessment that the factory has been difficult to monitor for a long time, the latest patented domestically produced secondary temperature measurement instrument with emission function and its "wireless remote temperature measurement data automatic acquisition system" are the most Good detection mode. For non-contact infrared temperature measurement, after many years of practice, it is easy to be disturbed by smoke, dust, water vapor and iron surface oxide scale in front of the furnace; sometimes the deviation is large. Poor stability, further improvement, improvement and selection of more suitable applications.
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