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The production of high-precision metals is inseparable from high-end manufacturing equipment, testing equipment and a stable production environment. In order to meet these conditions, Zhengdao Machinery has specially built a mold production workshop covering an area of 2,000 square meters. The mold workshop is equipped with various mold processing and manufacturing process equipment, including wire cutting, precision engraving machines, spark machines, four-axis turning and milling compound machine tools, turning and milling compound machining centers, three-axis machining centers, CNC lathes, drilling machines and other mold production equipment. The processing equipment brands are OKUMA, FANUC, Jinshang, and Harting well-known brands. All equipment has the production capacity to manufacture high-precision molds. The company employs professional technical consultants in terms of mold manufacturing talents for mold design and mold manufacturing to ensure the stability of mold production quality. There are 5 senior technicians in the production link, with more than 15 years of production experience and technology, and product production has strict quality process, manufacturing cost and delivery time control, and has a group of high-quality and highly skilled staff; at the same time, we also have independent and complete after-sales service. Testing equipment: Hexagon 3D coordinates, Tokyo precision profiler, metallographic microscope, hardness tester, a full set of processing and testing instruments. Professional quality inspectors conduct all-round testing on the shipped products to ensure that the quality of the shipped products is 100% qualified.
Product Application: Applied to the first groove of aluminum pistons in internal combustion engines, primarily used in diesel engine aluminum pistons, with aftermarket sales predominating. Features: 1. Integration of Wear-Resistant Insert Rings with Internal Cooling Channels through brackets offers several advantages over pistons simultaneously using insert rings and salt cores: (1) Single positioning reduces operational and process difficulties and CT time, improving production efficiency. (2) Before casting, simple shot blasting and preheating of wear-resistant insert rings are sufficient, eliminating the need for separate treatment (3) Reduces quality loss caused by using salt cores, enhancing piston yield.(4) Decreases flushing procedures and costs associated with salt cores. (5) Minimizes wastewater handling and management. 2. Customized Design: Tailored design of bracket-type internal cooling channel wear-resistant insert rings to meet diverse piston and industry requirements, ensuring optimal adaptability. 3. Material: The wear-resistant insert rings are made of high-nickel austenitic cast iron, while aluminum pistons are typically made of silicon-aluminum alloy. Their similar coefficients of expansion form the basis for the application of wear-resistant insert rings in the first groove of pistons. Wear Resistance: High-nickel austenitic cast iron exhibits outstanding wear resistance, optimizing friction with piston rings at high temperatures, thereby increasing piston lifespan. Thermal Conductivity: The material boasts excellent thermal conductivity, facilitating heat transfer and dissipation to maintain piston head temperature within a reasonable range. Corrosion Resistance: Strong corrosion resistance enables adaptation to various working environments, ensuring stability under different conditions. Environmental Friendliness: Prolonging piston lifespan ensures combustion chamber sealing during piston operation, enhancing combustion efficiency, and reducing exhaust emissions. Precision Machining: Precise machining techniques during manufacturing ensure products meet design requirements, enhancing performance.
Product Application: Ceramic salt cores are primarily used in the casting process of liquid forging aluminum alloy pistons. By forming cavities inside the piston, ceramic salt cores help achieve an internal cooling structure for the piston. Features: High Strength: By adding ceramic additives, ceramic salt cores achieve high strength, enhancing their ability to withstand high temperatures and pressures of aluminum liquid. High Density: Multiple granulation techniques are employed to achieve high density in ceramic salt cores, contributing to the overall quality of the castings. Low Linear Expansion Coefficient: Through innovative sintering techniques, ceramic salt cores achieve a low linear expansion coefficient, reducing the impact of thermal expansion on aluminum alloy pistons. Ceramic salt cores are typically used in the casting of liquid forging aluminum alloy pistons. Compared to traditional salt cores, ceramic salt cores meet the requirements of high-pressure casting processes for salt cores by increasing ceramic additives, using multiple granulation techniques, and innovative sintering techniques to achieve high strength, high density, and low linear expansion coefficient performance.
Product Application: Forming of complex cavities inside aluminum castings. Features: 1. Compared to ring-shaped piston salt cores, irregular-shaped salt cores, through optimized process upgrades, can produce salt core products of any shape. 2. Irregular-shaped salt cores have higher strength than ordinary piston salt cores. 3. Compared to sand cores and ceramic cores, they are easier to clean and have better surface finish. 4. Widely applicable in the forming of cavities in aluminum alloy products. (1) New salt cores applied to all lightweight castings' internal cavities. Advantages: Currently, most lightweight castings use resin sand cores to form complex internal cavities. During later cleaning, sand sticking may occur locally, making it difficult to clean the internal cavities, which is an unavoidable technical problem. The development of new salt cores can easily solve the problem of difficult sand cleaning in castings. Salt dissolves in water, and only water flushing is needed to meet the technical requirements for removing internal core sand. The use of salt cores in the piston field is already a very mature technology. The new salt core is an extension of piston salt core technology. (2) New salt cores applied to difficult-to-machine areas of injection-molded products. Advantages: For products with difficult-to-machine areas in the later stages of injection molding, new salt cores can be used to directly form the parts that need to be machined later. Place the salt core in the mold before injection molding. This eliminates the technical difficulties of difficult machining in the later stages.
Product Application: Used in the first groove of aluminum pistons in internal combustion engines, initially applied to diesel engine aluminum pistons, with wear-resistant insert rings widely used and promoted on gasoline engine aluminum pistons in recent years as industry demands for gasoline engine pistons have increased. Features: Compared to traditional aluminum pistons, pistons with insert rings have seen an average increase in lifespan of 5-8 times, enhancing energy utilization and combustion efficiency, while reducing emissions. Additionally, it significantly improves the performance and reliability of internal combustion engines. Material: The wear-resistant insert rings are made of high-nickel austenitic cast iron, while aluminum pistons are typically made of silicon-aluminum alloy. Their similar coefficients of expansion form the basis for the application of wear-resistant insert rings in the first groove of pistons. Wear Resistance: High-nickel austenitic cast iron exhibits outstanding wear resistance, optimizing friction with piston rings at high temperatures, thereby increasing piston lifespan. Thermal Conductivity: The material boasts excellent thermal conductivity, facilitating heat transfer and dissipation to maintain piston head temperature within a reasonable range. Corrosion Resistance: Strong corrosion resistance enables adaptation to various working environments, ensuring stability under different conditions. Environmental Friendliness: Prolonging piston lifespan ensures combustion chamber sealing during piston operation, enhancing combustion efficiency, and reducing exhaust emissions. Precision Machining: Precise machining techniques during manufacturing ensure products meet design requirements, enhancing performance.
Product Application: Salt cores, when flushed out of the piston, form internal cooling passages, reducing the temperature of the piston head and the first ring groove area, thus enhancing the piston's lifespan. Features: 1. High Strength, Excellent High-Temperature Resistance: Salt cores do not fracture when preheated in a 720�°C furnace or during piston casting operations. 2. Immersion Resistance: Salt cores do not rupture or generate gas when poured with aluminum solution, nor do they cause salt to float on the solution's surface. 3. Easy Dissolution, Quick Flushing: After casting into the piston blank, salt cores can be completely flushed out within a maximum of 10 seconds under a water pressure of 200 bar. 4. Surface Quality: Salt cores exhibit no quality defects on the surface, such as cracks, sharp edges, burrs, notches, oil stains, etc., with smooth arc transitions. In modern internal combustion engines, pistons inevitably bear increasing thermal loads. Particularly with the increasing use of turbocharged engines in mid-to-high-end vehicles worldwide, turbocharging technology has become popular to enhance engine power and torque, improve fuel economy, reduce exhaust emissions, and lower fuel consumption. To meet the growing power requirements and ensure the safety of piston operation, pistons with internal cooling passages, formed by salt cores during the aluminum piston casting process and then removed by water flushing after casting, have become the inevitable choice for high-speed, high-power engines.
