Aluminum ash is classified as hazardous waste by the country because it contains harmful elements.It contains a large amount of metallic aluminum and alumina, which has a high recycling value.According to the current research progress of comprehensive utilization of aluminum ash, the advantages and disadvantages of different process technologies have been analyzed; according to the characteristics of existing aluminum recycling technology, it is pointed out that cold treatment of aluminum ash has more advantages; Aluminum ash has been used as a base material for the production of refractory materials, building materials and environmental materials.Its application in different fields has been introduced and prospects for the future development of aluminum ash have been put forward.

The current situation of foundry equipment in China has been introduced from the aspects of enterprise quantity, equipment technology, equipment quality, safety measures, equipment price and service life. Moreover, the innovation, intelligence and green development of foundry equipment have been expounded from the aspects of melting, molding, core making, sand preparation, cleaning, logistics, management, environmental protection and energy saving. Finally, the development road of foundry equipment in China, which is "rules, new, and specialty", has been put forward. It is hoped to play a role in promoting the development of the foundry equipment industry.

The application conditions and technical requirements of ductile iron castings in wind turbines have been introduced.The influence of current material selection trends, smelting methods, forming and heat treatment processes in the ductile iron industry to metallographic structure and low-temperature performance of ductile iron materials have been elaborated.The heat treatment process curve has been provided, and the application characteristics of software simulation at present have been discussed.A new era outlook for intelligent and green production of ductile iron materials has been proposed.

The design process of a casting workshop with an annual production of one million crankshafts has been introduced.The electric furnace has been used to melt molten iron.A shell mold line has been selected with an iron shot cooling and conveying system.The shell has been produced by use of the coated sand hot core process; at the same time, the cleaning process of castings has been introduced.The layout of process equipment in the workshop is reasonable and the logistics is smooth.

The lightweight of new energy vehicle body structural components has become an important solution for energy conservation and emission reduction.Key components are developing towards thin-walled, high-performance, large-scale, and other directions.The application of die-casting technology in automobiles has gradually shifted from small parts to high-pressure die-casting, large-scale, and integrated large parts.Three research advances have been proposed from the aspects of new materials, process parameter control, and the impact of structural design on quality required for integrated die casting, which can provide reference for the research of integrated die casting technology.

With the reform and construction of new engineering disciplines, ordinary universities also need to gradually improve the teaching content of engineering training and vigorously cultivate new professional and technical talents.Vehicle engineering practical training is a type of engineering training that mainly cultivates students' foundation in engineering practice and also emphasizes the enhancement of engineering innovation ability.However, there are still problems such as outdated course content, single teaching methods, and simplified teaching evaluations.Based on this, in combination with the reform tasks and key measures of the new engineering discipline, ordinary universities need to innovate the content of the lathe engineering course, optimize teaching links and activities, and increase formative evaluation.

Under the trend of light weight and energy saving, aluminum alloy wheels have become the first choice for automobile wheels, and the mainstream method of forming is low pressure casting.The application of low pressure casting in the production of aluminum alloy wheels has been briefly introduced, and the defects of low pressure casting aluminum alloy wheels have been reviewed.The direction for future research has been put forward.

The design of casting chilling system is an important part in the design of casting process. It has great influence on the quality of castings. A reasonable chilling system can effectively prevent or reduce casting defects including shrinkage, porosity, cracking, sticking of the castings, and metallographic abnormalities. The standardized design and management of cold iron is conducive to obtaining qualified and high-quality castings, ensuring the quality of castings, improving the casting yield and production efficiency, and reducing production costs. The design methods, misunderstandings and design flaws of various chilling system as well as standardization of cold iron applications in the design of ferrous metal casting process have been highlighted, including the design and prevention of metal cold iron, graphite cold iron, chilled sand, chilled paint, and forced cooling system. It can provide experience and reference for the industry.

In the process of foundry sand preparation, the commonality and characteristics of the core new equipment and technical performance of the regeneration, crushing and cooling of old sand have been discussed.For the regeneration of waste sand used in self-setting sand and clay sand casting processes, reasonable and simple treatment methods have been selected to achieve effective measures to save costs, improve working conditions and improve the comprehensive benefits of resource reuse.The purpose is to better understand the importance and necessity of old sand regeneration.

The hanging chain shot blasting machine has been analyzed and the characteristics of the accumulative hanging chain shot blasting machine have been introduced.The difference between ordinary chain and accumulative chain, the structural characteristics of the three-stage chamber body and four doors and the application scope of accumulative hanging chain shot blasting machine have been analyzed in detail.

Based on the background of the lightweight development trend of new energy vehicles, the development and current status of die-casting spraying technology for new energy vehicles have been summarized, while the key technologies of the new high-efficiency intelligent flexible micro spraying device required for die-casting large-sized integrated metal structural components have been analyzed.The influence of micro spray pressure, flow rate and mold release agent composition on the comprehensive performance of die casting of integrated large size parts, the methods of online detection of mold temperature and edge computing of process parameters, and the optimization methods of relevant parameters of flexible micro spray nozzle have been systematically proposed.It provides reference for high-quality forming processes of large-sized and complex thin-walled aluminum alloy die-casting parts.

With the increasingly severe environmental protection situation, the requirements for the emission of SO₂ in cupola flue gas are becoming stricter.By comparing various desulfurization methods and combining with the actual situation of 35 t/h cupola on-site, the SDS sodium-based dry desulfurization process has been adopted to desulfurize the cupola flue gas and achieve standard discharge.

Aiming at some quality problems in the lost foam die-casting process of ductile iron castings, the various factors affecting the structure of ductile iron in the process of lost foam casting have been systematically analyzed, including white mold, original sand, vacuum degree, pouring temperature and metallurgical quality etc. The improvement measures and suggestions have been put forward.

The reasonable configuration of dust removal system in the casting production process is very beneficial to the working environment, especially for small and medium-sized enterprises to choose economical, reasonable and practical dust removal equipment. It is very important to realize the environmental protection treatment of working conditions. The type and configuration of simple and practical cyclone and bag dust collector have been described in the text.

By comparing to traditional furan resin for casting, phenolic resin, inorganic resin and other binders have many advantages as the ideal casting binder.However, at the same time, this type of binder has the problem of being difficult to solidify at room temperature.It is necessary to quickly evaporate the moisture inside the binder under high temperature conditions to improve the speed of sand mold solidification.Combining the molding principle and equipment structure of the casting sand 3D printer, the rapid solidification of the sand mold has been considered from the printing equipment itself.The solidification speed of the sand mold has been improved from five aspects∶firstly, increasing the temperature of the adhesive; secondly, increasing the temperature of the sand; thirdly, installing infrared heating lamps on the sand spreader to bake the sand surface to increase the temperature of the sand surface and accelerate the evaporation of moisture in the binder; fourthly, designing a special working box structure with heating coils, during the printing process, as the printing sand molds are continuously stacked, the formed sand molds are continuously heated to quickly improve the solidification speed of the sand molds; at last, controlling the environmental temperature and humidity inside the printing room.

The wound induction motor has been widely used in overhead traveling cranes. The motor can well limit the starting current and has a good starting torque. The principle and characteristics of the motor speed control mode (rotor cut-off resistance speed regulation and stator voltage regulation speed regulation) have been introduced, as well as the elimination method of motor fault in the working process. More and more contactor rectification resistance speed regulations have been improved into the stator voltage regulation, which brings safer and more reliable speed control to the production. Meanwhile, it is necessary to connect the theory with the actual ones to exert its performance.

Due to its high wear resistance and corrosion resistance, high chromium cast iron is widely used in the production of flow parts of slurry pumps.Many researchers have carried out a lot of research on the alloying of high chromium cast iron and have achieved certain results.In order to reduce costs, new alloying methods have been explored at home and abroad.In the text, it is proposed to add an appropriate amount of silicon and nitrogen elements to control the microstructure and comprehensive mechanical properties of high-chromium cast iron, which provides new ideas for the development of new high-chromium cast iron for slurry pumps.The research results of silicon and nitrogen alloying in high-chromium cast iron have been reviewed.The existing forms and distribution rules of silicon and nitrogen in high-chromium cast iron as well as their effects on the microstructure, hardness, wear resistance and corrosion resistance of high-chromium cast iron have been summarized.In combination with the current research situation, the future research and development direction of high-chromium cast iron alloying has been prospected.

The application of aluminum alloy die-casting parts in automobile bodies is becoming more and more common. Through the introduction of full production process of aluminum alloy structural parts for some European automobile body, the main procedures have been briefly described according to the production sequence, which provides reference for domestic die-casting and post-processing companies.

By consulting a large number of literatures to understand the harm of phosphorus to steel, by studying the occurrence state and existence form of phosphorus in ores, different kinds of de-phosphorization technology including microbial leaching method, chemical method, ordinary sintering gasification method, direct reduction roasting method and microwave method have been studied to different types of ores.The advantages and disadvantages have been summarized.The scientific problem of phosphorus removal mechanism in the process of iron and steel smelting and preparation has been systematically analyzed, as well as the kinetic mechanism of the de-phosphorization process, which has great significance to achieve the goals of increasing production, reducing costs, expanding scale, and energy-saving & high efficiency.Based on this, it is hoped to help more scholars to develop more mature improved dephosphorization technology in the future, which is of great significance to the development of the world's iron and steel industry and the progress of science and technology.

The current status, pollution situation, and problems faced by the casting and forging industry have been briefly described. The beneficial exploration of green manufacturing in the enterprise in recent years, which is combined with the technological transformation of cupola, cleaning, new-built lost foam and used sand regeneration, has been introduced. It is put forward that the green manufacturing is the concept of enterprises to change their development mode and realize sustainable development.

Intelligent manufacturing technology is at the core position of the intelligent manufacturing industry, and its concept lies in innovation. Internet plus manufacturing is the future direction of smart manufacturing. Among them, modeling & simulation technology and industrial Internet technology have a wide range of uses. By mastering and applying these technologies, it can help the development of intelligent manufacturing enterprises.

By analyzing the mechanism of ester hardened modified alkaline phenolic resin sand and testing its related physical and chemical properties, the process characteristics have been explored.The process formula has been obtained through process experiments, and the process trial production and batch production of steel castings have been carried out.On the basis of achieving good technical results, the process trial production and production of cast iron (ductile iron) and aluminum castings have been expanded.Process validation and production practice have shown that the ester hardened modified alkaline phenolic resin sand process has strong adaptability, which can meet the production process requirements of cast steel, cast iron, and cast aluminum.It has achieved the "three in one"ester hardened modified alkaline phenolic resin sand innovation process of producing cast steel, cast iron, and cast aluminum in the same molding sand process and production line (unit), which solves the problem of the interweaving issues in the past of various molding sand processes including cast steel, cast iron, and cast aluminum.It lays a solid foundation for the high-quality development of the company.

Due to inconsistent printing density, 3DP products have uneven colors after being sprayed, resulting in color difference defects.The way to choose a suitable anti- penetration agent and treatment process is the primary research problem to solve the color difference problem of 3DP products.The surface penetration prevention treatment process and methods of 3DP products have been briefly discussed.

Foundry machinery is an important component of China's machinery and equipment manufacturing industry and a fundamental industry for national economic development.The domestic and international standardization management institutions for foundry machinery undertaken by China have been introduced in the text, as well as the current status of centralized management of foundry machinery standards.By benchmarking with international advanced standards, discussion and some suggestions have been put forward for the future standardization work of China's foundry machinery from the perspective of standards leading and promoting high-quality industry development.

The inert powder fluidized bed has been creatively implanted into the pulse dust collector, so that the inert powder is pre-coated on the surface of the filter elements after the pulse is sprayed and cleaned, and the viscous aerosol smoke has been isolated and filtered. It specially has wide application prospect on the dust removal of lost foam and resin sand casting. The inertia powder bubbling fluidized bed has circular tempering and stratifying properties of the adhesive dust to make the inertia powder fully used. Thus in this way, a pulse jet filter is feasible for the long-term dust removal of sticky aerosol like adhesive casting dusts. The model and operation mechanism of the new dust removal method have been expounded. The properties of the viscous agglomerated particle bubbling fluidized bed, the selection of the inert powder calcium carbonate and the consumption have been effectively studied.

The characteristics and applicability of the current reclamation method for used foundry sand have been overviewed in the text. The new method and progress based on the research and application of reclaiming used foundry sand at home and abroad in recent years have been highlighted. These new methods and characteristics have been comprehensively evaluated. The future development trend of used foundry sand reclamation technology should include:the development of low-cost reclamation and reuse method and its equipment can be suitable for all kinds of used foundry sand or mixed used foundry sand in order to achieve reasonable reclamation and comprehensive utilization of all kinds of used sand; as the dry (mechanical) reclamation method is relatively simple,the research and development of thermal method, wet method, and the multiple composite reclamation method as well as the equipment should be paid more attention; different reclamation method should be adopted according to the performance characteristics of different used sand; the new technologies and applications should be paid attention and expectation, which include the reuse of waste heat from thermal reclamation process, alkaline materials from reclaiming used sodium silicate sand or alkaline phenolic resin sand, biological reclamation method, ultrasonic wet reclamation method, and microwave reclamation method.

During the transportation of a certain type of liquid ammonia tank truck, the safety valve suddenly jumped, causing ammonia leakage.After later disassembly, it is found that the safety valve spring has been broken in multiple places.In order to ensure the safe transportation of liquid ammonia tank trucks, instruments such as direct reading spectrometer, ultra depth of field three-dimensional microscope, scanning electron microscope, metallographic microscope, and Rockwell hardness tester have been used to analyze the failed springs.The results show that there are non-metallic inclusions in the spring, and the transformation of martensite is incomplete during the quenching process of the spring.After tempering, there are still carbides and ferrites in the structure, which reduces the hardness of the material.After scanning electron microscopy analysis, it is found that the fracture characteristics are rock sugar like, belonging to intergranular brittle fracture.At the same time, there are many spherical particles of oxides and carbides on the fracture surface, which further increases the brittleness of the spring.Therefore, non-metallic inclusions, as well as residual carbides and oxides after tempering, are the main causes of spring fracture.

Made in China 2025 focuses on the development of automation, digitization and intelligent manufacturing, which prompts the manufacturing industry to be digitized, networked and intelligentized. The automation and intelligence of the equipment in the enterprise is a prerequisite for building a digital foundry factory. The automated equipment for automatic molding and pouring production line has been discussed in the text.

The vibration-free shell shot blasting machine for investment precision castings has changed the traditional process by replacing the original vibration shell machine with the shot blasting process.Meanwhile, the casting and riser casting system have been roughly blasted, and the blasted shell materials are separated, stored and reused according to the particle size.The equipment not only greatly improves the work efficiency and the atmospheric environment, but also avoids the secondary turnover of workpieces and the waste of raw materials.

Based on the dust removal problem in the casting workshop, the way to achieve the goal of efficient dust removal at lower costs by renovating existing equipment or adding some small equipment has been discussed.After repeated investigation of the on-site environment, the plan to achieve directional air flow has high feasibility.The dust and smoke have been sent to the desired location through different methods, and then controlled by using of dust collection and dust reduction devices to supplement the collection of dust and smoke.Statistical analysis of the data after installation and implementation shows that this plan can achieve significant dust reduction and removal effects without occupying a large amount of capital investment from the enterprise.In the future, other functions can be designed and researched according to one's own needs, which develops towards automation and intelligence.

Austempered ductile iron has the characteristics of high strength, high toughness, high hardness, good wear resistance and excellent casting performance.It is described in details in the text that the austempered ductile iron can move the C curve to the right, expand the bainite zone and avoid the pearlite zone through alloying and continuous cooling control technology to obtain as-cast carbide-containing austempered ductile iron.The successful development of as-cast CADI on rolls for the first time will lead to a new round of technological transformation in the roll industry.

The working principle, structural characteristics and use status of the continuous swing bed, continuous steel crawler and continuous mesh belt three kinds of pass-through shot blasting machines have been introduced in the text.Currently most of the casting shot blasting machines are independent and intermittent production methods, which has the disadvantages of high logistics cost, low cleaning efficiency, and time-consuming labor.The continuous pass-through shot blasting machine is suitable for online and continuous production.It can not only realize the automation of the production process of online production of castings but also improve production efficiency and the working environment while reduce the number of operators.The cleaning speed of the continuous pass-through shot blasting machine can be adjusted, so it can adapt to various changes in production cycle and production efficiency.

The foundry industry in China has shifted from a stage of rapid growth to a stage of high-quality development."Intelligent foundry" has become a hot word in the industry.However, regarding the definition of intelligent foundry factory, the relationship between intelligent foundry factory and high-quality development, and to way to realize intelligent foundry factory, different people has different understanding at different positions and angles.The definition of intelligent foundry factory has been expounded from multiple angles.The advantages of intelligent foundry factory and the relationship with high-quality development have been explained from multiple aspects; finally, the way to realize intelligent foundry factory has been introduced from the aspects of understanding, investment, collaboration, risk control, and talents.

The current status of the casting polishing industry has been introduced, as well as the problems and solutions in automatic polishing.By using auxiliary tools such as laser detection and 3D vision, the trajectory planning and correction of castings have been carried out, ultimately achieving precise polishing, reducing labor costs, and effectively improving the polishing efficiency of castings.

The classification of wall thickness uniformity of cast pipes and the main reasons affecting wall thickness uniformity have been studied.Based on the actual production situation, by standardizing the production and repair standards for the shape and size of the fan-shaped package, adjusting the fast flipping delay, fast flipping speed, and flipping return delay of the fan-shaped package, increasing the slope of the flow channel on the basis of the original equipment of the centrifuge, and installing cooling equipment at the centrifuge socket to strengthen the cooling of the socket, various measures have been taken to reduce the negative tolerance of the casting pipe and improve the wall thickness uniformity of the casting pipe.It provides certain data support for optimizing the wall thickness uniformity of cast pipes in the future.

A rotary table shot peening strengthening machine has been developed to improve the fatigue strength of the shoulder of the needle valve body in automotive engine.This strengthening machine uses two working stations, one is for loading and unloading workpieces, and the other is for shot peening strengthening.By using compressed air as the power, high hardness steel sand has been driven to impact the shoulder of the needle valve body at a speed of approximately 70 m/s, resulting in a shot coverage rate of over 99% and an A-type test piece arc height value of 0.55 A.The PLC automation control and a 10 inch touch screen for visual operation have been adopted in this machine with a compact structure.It is a green and environmentally friendly equipment with good reinforcement effect, low noise, and less pollution.

The structure and working process of a belt type vibration core dropping machine have been introduced.This device can be used in conjunction with a robotic manipulator assembly line to achieve the automation of engine cylinder core dropping, which reduces labor intensity and improves production efficiency.

In view of the problems such as uncontrollability of operation and increased staffing caused by manual charging in front of the furnace in the smelting process, the molten iron inoculation system in front of the furnace has been analyzed and studied to ensure the stability of the process, improve the level of process automation, incorporate charging data into MES management, and lay the foundation and provide data support for enterprises to achieve intelligent and digital transformation.

With the development of the domestic hydro-power industry market, the casting level of integrated casting runners and semi-integrated casting runners has also been correspondingly improved.The traditional Francis turbine runner is usually composed of three parts∶the upper crown, lower ring, and blade.The three parts have been cast separately and welded together after final processing.With the development of casting technology, the mixed flow runner has achieved three integrated casting, successfully solving the problems of high manufacturing cost and low casting quality.

As one of the pillar industries of Cangzhou City in China, the foundry industry is characterized by a large number of enterprises and a large scale, and it is also a key ecological environment supervision industry.Facing the requirements of ecological and environmental management in the new situation, the chapter content of emergency plans for sudden environmental events has been sorted out.The characteristics of environmental risks in casting enterprises have been analyzed while the key points and precautions for emergency plan preparation have been summarized.