What are the problems that lead to high costs in the processing of large cast steel parts?

2024-08-14 13:40:09

The balance between quality and cost has always been a concern for large foundry manufacturers. What issues during casting operation can lead to increased costs?

The selection and management of raw materials are a factor that affects costs. Inaccurate material selection in the casting of large castings not only increases material waste, but also leads to recasting due to substandard material quality, further increasing production costs.

Unreasonable mold design or dimensional problems can lead to dimensional deviations and surface defects in castings, requiring secondary processing or even scrapping. This not only increases costs, but also raises working hours and labor costs. In addition, unreasonable mold design may lead to uneven flow of molten metal during the casting process, further increasing the probability of internal defects in large cast steel parts.

Large castings typically require multiple heat treatments to achieve the desired mechanical properties and hardness. If the temperature control is improper or the heat treatment parameters are set improperly, it is likely to result in castings that are not qualified and require rework or scrapping, undoubtedly increasing production costs.

Unreasonable production arrangements lead to an increase in costs. Any problem in any link of the production line can lead to delays in the entire production chain.

Castings require a significant amount of energy, such as electricity and gas, during the casting process. Improper energy management not only increases direct production costs, but also brings environmental costs and additional equipment maintenance costs.

Therefore, large casting and processing manufacturers pay attention to and value multiple aspects during production, which can reduce costs while ensuring quality.