For the production of alloy steel pallet castings, how to effectively control the defect rate in the casting process?

In the production of alloy steel pallet castings, effectively controlling the defect rate in the casting process (such as pores, shrinkage and cracks) is the key to ensuring product quality and reliability. Here are some specific control methods and suggestions:

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1. Optimize casting process design
Gating system design: Rationally design the gating system and riser to ensure uniform flow of molten metal and avoid turbulence and gas entrapment. At the same time, use technologies such as cold iron to control the solidification rate to prevent shrinkage and shrinkage.
Solidification sequence control: Follow the principle of directional solidification, reasonably arrange the position of the inner flow channel and the pouring process, ensure that the thick wall part solidifies last, and avoid isolated hot spots.
Mold preparation: Ensure that the mold is clean, dry, and properly preheated to reduce gas generation and thermal stress.

2. Strictly control the quality of raw materials
Chemical composition control: Strictly control the content of harmful elements (such as sulfur and phosphorus) in alloy steel to avoid these elements causing cracks and inclusions.
Raw material inspection: Chemical composition analysis and mechanical property testing of raw materials to ensure that they meet process requirements.

3. Melting and pouring process control
Stable melting temperature: Maintain a stable melting temperature to avoid excessively high or low temperatures that lead to poor fluidity or inclusions in the molten metal.
Potting process optimization: Use vacuum pouring or inert gas protection pouring to reduce oxidation and gas mixing. At the same time, control the pouring speed and temperature to avoid pores and inclusions.

4. Heat treatment process optimization
Heat treatment parameter control: Strictly control the heat treatment temperature and time to eliminate internal stress, refine the grains, and improve the mechanical properties and crack resistance of the casting.

5. Quality inspection and feedback
Non-destructive testing: Use non-destructive testing technologies such as X-ray and ultrasonic testing to detect whether there are defects such as pores and cracks inside the casting.
Defect analysis and improvement: Identify the root cause of the defect through failure analysis, and apply the analysis results to subsequent production to optimize the process.