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The steel casting industry undergoes transformation and upgrading.
Release date:
2017-06-21
In China, the annual output of cast steel parts has reached 11 million tons, with the primary molding materials being hard sand, ester-hardened alkali-phenolic resin self-hardening sand, and ester-hardened water-glass sand. Among these, 8 million tons of cast steel components are produced using the water-glass sand molding (core) process, while the remaining ones utilize alkali-phenolic and resin sands, among other materials. Due to their stringent requirements for high quality, precision, and performance, large-scale hydroelectric generators and thermal power units pose significant challenges in meeting these exacting standards. As a result, many large and medium-sized cast steel parts have already been successfully manufactured using these advanced techniques. Meanwhile, with the continuous advancements toward cleaner production, energy efficiency, lightweight design, digitalization, and智能化 (intelligentization), the steel industry is increasingly focusing on research and development aimed at achieving low-carbon solutions.
In China, the annual output of cast steel parts has reached 11 million tons, with the primary molding materials being hard sand, ester-hardened alkali-phenolic resin self-hardening sand, and ester-hardened water-glass sand. Among these, 8 million tons of cast steel components are produced using the water-glass sand molding (core) process, while the remaining ones utilize alkali-phenolic and resin sands, among other materials. Large-scale hydroelectric generators and thermal power units—due to their stringent requirements for high quality, precision, and performance—are particularly challenging to manufacture under these demanding conditions. As a result, many large and medium-sized cast steel parts have already been successfully produced using these advanced techniques. Moreover, with the ongoing advancements in clean technologies, energy efficiency, lightweight design, digitalization, and intelligent manufacturing, the steel industry is increasingly focusing on research and development aimed at reducing carbon emissions, conserving energy, and minimizing pollution—key priorities driving innovation in the sector.
Large cast steel components use specialized sands such as chromite sand for their surfaces, which are significantly more expensive than regular sand. Therefore, the separation technology in chromite and quartz sand regeneration systems is also a critical key technology. However, in casting cores, pearl sand will be used instead of zircon sand.
Currently, ester-hardened water glass sand is widely recognized as the most promising solution for green sand-mold casting of steel components. It is colorless, odorless, and non-toxic, producing no pungent smells or harmful gases during mixing, molding, casting, and sand processing—making it completely safe for human health. Additionally, it boasts excellent casting performance, earning widespread acceptance within the casting industry. However, its only significant drawback is the difficulty in regeneration, which leads to substantial solid waste pollution. If the issue of water glass sand regeneration can be effectively addressed, water glass sand casting will undoubtedly become a pioneer in green casting practices—and, more importantly, pave the way for critical improvements and upgrades in casting equipment.
Facing the vast demand for high-end and large-scale steel castings in China, foreign manufacturers are stepping up their efforts to enhance their production capabilities in intelligent casting equipment, aiming to capture a larger share of the Chinese market. Meanwhile, domestic enterprises should seize these opportunities, embrace the challenges, and proactively implement competitive strategies to stay ahead in the evolving landscape.
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