How to choose high quality cast steel parts? Analysis of key factors | EATHU Foundry

11th November, 2024

In the selection of large steel casting plant, for the special requirements of large cast steel parts, in addition to the conventional quality control, technical level and delivery time, etc., but also need to give special consideration to its size, structural complexity, strength requirements and material properties and other factors. Large cast steel parts are usually used in mining machinery, metallurgical equipment, shipbuilding, nuclear power facilities and large-scale construction machinery and other fields, the manufacturing process has a high technical threshold and process difficulty. The following are a few core elements for large cast steel parts:

The structure and size requirements of cast steel parts


Large cast steel parts usually have a large weight and complex geometry, which puts high requirements on the casting process. When selecting a steel casting plant, it is important to consider its ability to handle large, heavyweight castings. This includes:


Casting mold design: 


Large cast steel parts casting mold design must have good fluidity and thermal stability, to avoid uneven pouring or porosity defects due to oversized castings.


Casting equipment and capabilities:


Large cast steel parts may require large electric arc furnace, electroslag remelting furnace (ESR), vacuum furnace and other smelting equipment, as well as large-scale melting and casting mold equipment, lifting equipment, etc.. Manufacturers should have the appropriate equipment and process capabilities.


Dimensional control and precision requirements: 


The dimensional accuracy of large steel castings requires a high degree of precision, especially in the case of prolonged load use, small dimensional deviations may lead to structural failure. When choosing a manufacturer, you should check whether it has accurate measuring tools and dimensional control processes.


Material selection and smelting process


Large cast steel parts in the application of high temperature, high pressure, shock load and other extreme conditions, so the strength, toughness, wear resistance, corrosion resistance and other high requirements on the material. Common cast steel materials include ordinary carbon steel, alloy steel, high-strength steel, heat-resistant steel, corrosion-resistant steel and so on. When choosing a steel casting plant, you need to consider whether its smelting process can produce steel that meets these special requirements:


Smelting process: 


Whether it has advanced smelting equipment such as Electric Arc Furnace (EAF), Electroslag Remelting (ESR), etc., and whether it can control the elemental content and smelting temperature to ensure the uniformity of the castings and the stability of the performance.


Material customization ability: 


Large-scale steel castings often involve special material ratios or customized alloy design, whether the casting plant is able to design, adjust and optimize the composition of the material according to the demand is the key.


Heat treatment process


Large steel castings often need to go through a rigorous heat treatment process to improve their mechanical properties and durability. The heat treatment process can effectively eliminate the stress within the casting and improve the strength, hardness, toughness and wear resistance of the material. Common heat treatment processes include:


Annealing: 


Used to improve the internal organization of cast steel parts, increase toughness and reduce internal stress.


Normalizing: 


By heating the cast steel parts to the appropriate temperature and then air cooling, can improve its strength and wear resistance.


Quenching and tempering:

 

Particularly suitable for cast steel parts requiring high strength and wear resistance, such as gears, bearings, etc., to ensure that the castings have excellent fatigue resistance and impact resistance.


Aging treatment: 


For certain alloy cast steel parts, aging treatment is required to further enhance their strength and stability.


Defect control and detection


Due to the large size of large cast steel parts and the large loads they are subjected to, the quality of the castings is particularly demanding. Tiny casting defects can lead to structural damage or failure, so the detection and control of defects is particularly important. Common types of defects include porosity, shrinkage, slag entrapment, cracks, and so on. To ensure the high quality of cast steel parts, the casting plant should have perfect defect detection and control technology, including:


Non-destructive testing (NDT):


Including ultrasonic testing (UT), ray testing (RT), magnetic particle testing (MT), penetration testing (PT), etc., especially for internal defects and surface defects of large cast steel parts.


X-ray and CT inspection:


For certain highly demanding cast steel parts, X-ray or Computed Tomography (CT) is used for high-precision inspection of internal defects to ensure that there are no hidden defects affecting the service performance.


Metallographic analysis: 


Analyze the microstructure of the cast steel parts through metallographic microscope to ensure that it meets the requirements of the material standards, to avoid the uneven grain or carbide precipitation and other problems affecting the use of performance.


Mechanical performance and reliability analysis


Large-scale steel castings are usually subject to large dynamic loads or long-term static loads, so the requirements on their mechanical properties are particularly stringent. When choosing a steel casting plant, attention should be paid to whether it can provide comprehensive mechanical performance testing and reliability analysis to ensure the stability of cast steel parts in practical applications. Key test items include:


Tensile strength, yield strength and elongation:


Ensure that the cast steel part has sufficient load carrying capacity and good plastic deformation capability.


Hardness testing:


Determine the wear and impact resistance of cast steel parts.


Fatigue test:


Fatigue testing of cast steel parts that are often subjected to alternating loads to ensure their reliability in long-term use.


Impact toughness test:


Especially for the cast steel parts used in low temperature or harsh working conditions, impact toughness test is needed to ensure its crack resistance in extreme environments.


Post-processing and machinability


After casting, large cast steel parts often require post-treatment and machining to meet specific dimensional accuracy, surface quality and fit requirements. Post-treatment steps may include:


Surface treatment:


e.g. sandblasting, grinding, coating, etc., to improve surface quality and corrosion resistance.


Machining: 


Large cast steel parts often require finish machining after casting, such as turning, milling, drilling, etc., to ensure the final dimensional and fit accuracy of the casting. It is necessary to choose a steel casting plant with advanced machining equipment and technology.


Environmental adaptability and durability analysis


Large cast steel parts are often used in extreme environments, so it is necessary to ensure that they have good corrosion resistance, high temperature resistance, oxidation resistance and so on. For example, in the marine engineering used in the cast steel parts need to have good seawater corrosion resistance, and in the high-temperature environment cast steel parts need to work in a good high-temperature performance. This requires the steel foundry not only to provide customized alloy formulations, but also need to be able to carry out targeted environmental adaptability testing.


Summarize:


When choosing a large steel casting plant, you need to pay special attention to its ability to deal with large size and weight castings, including casting process, smelting technology, heat treatment process, defect detection, mechanical properties testing and other aspects. The manufacture of large cast steel parts not only requires advanced equipment and technical support, but also requires suppliers to have strong process research and development capabilities, customized solutions and a good quality assurance system.

EATHU Foundry has become a leader in the production of cast steel parts by virtue of its profound technical accumulation, strict quality control and flexible customer service. Through continuous innovation and optimization of production processes, EATHU is able to provide high-performance cast steel parts to meet the needs of different industries, and ensure the reliability of product quality through precise heat treatment and non-destructive testing. Its advanced equipment, customized solutions and global service network make it a trusted long-term partner for customers. Whether in the domestic or international market, EATHU has won wide recognition for its excellent products and services and plays an important role in many fields.

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