山东省铸造行业概况

general introduction of Shandong foundry industry

一、生产规模及配套行业

    据不完全统计，山东2023年铸件年产量达1306万吨，其中灰铁件约占比例为39.2%，球墨铸铁件约占比例为28.1%，可锻铸件约占2.0%，蠕墨铸铁约占3.8%，铸钢件11.2%，有色合金及其他约占15.7%。山东铸造厂点众多，初步统计有3072家，从业人员约27.13万人。

配套行业：主要配套于汽车、摩托车、船舶、机床、通用机械、工程机械、农业机械、建筑机械、电力、冶金、化工、市政及其他装备行业。

二、技术装备水平与质量保证

    熔炼技术：黑色铸造多以中频感应电炉熔炼为主，部分企业采用了冲天炉一电炉双联工艺。有色合金多以燃气熔化炉、电阻炉为主。

    造型、制芯技术：冷热芯盒自动化制芯工艺得到推广应用,自动化气冲造型线，高压多触头造型线，挤压型生产线被广泛使用，负压实型铸造、熔模精密铸造、真空铸造、差压铸造、重力铸造、“V法"、脂硬化水玻璃工艺等多种工艺随着产品的开发得到普及应用。

    智能制造技术：计算机模拟软件、3D打印技术、智能化生产系统得到推广应用。

    质保体系：炉前铁水智能分析仪、直读光谱分析仪，无损探伤仪和三座标测量被广泛应用，大多数企业已通过ISO9000质量体系认证。

三、铸造设备和材料供应

    山东铸造设备的生产已形成产业集群，主要有造型、制芯、熔化、清理、砂处理等方面的设备。铸造生铁、原砂、造型和制芯材料、清理用钢丸、钢砂、各类耐火材料的供应配套齐全。

四、产业集聚区：

培育了章丘明水工业园生产重型汽车、风机铸件产业集聚区、烟台市刹车盘产业集群、平度和东营地区生产精密铸件与铸造设备产业集聚区、潍坊市沟槽管件铸造产业集聚区、临沂白沙埠水表壳体产业集聚区、滨州耐磨镶圈产业集聚区、 平度、胶州地区熔炼环保设备、浇铸设备产业集群、周村、邹平地区生产钢丸钢砂、金属磨料产业聚集区。

1. Production scale and Supporting industries    According to inadequate statistics, the annual production of castings in Shandong reaches 13.06 million tons in 2023,in which grey iron castings, ductile iron castings, malleable iron castings, vermicular graphite iron castings, ductile iron pipes and tubes, steel casting, nonferrous casting and others accounted take 39.2%,28.1%,2.0%,3.8%,11.2%,15.7%,respectively.There are many foundries in Shandong. According to preliminary statistics, there are more than 3,072 foundries, employing about 216,700 people.     Associated enterprise:

The castings are mainly used in automobiles, motorcycles, ships, machine tools, general machinery,construction machinery, agricultural machinery, construction machinery, electric power, metallurgy, chemical industry, municipal and other equipment industries.

2.Technical equipment level and quality assurance    Smelting technology:  Medium frequency induction furnaces are mainly used in black casting, and some enterprises have adopted the double process of cupola and electric furnace.Non-ferrous alloys are mainly use gas melting furnaces and resistance furnaces.

Molding and core-making technology:

The automatic core making process of hot and cold core boxes has been popularized and applied,automatic air punch molding line, high-pressure multi-contact molding line, extrusion molding production line is extensively used, Vacuum casting, differential pressure casting, gravity casting, "V method", and grease hardening water glass processes and so on With the development of products has been widely used.    

Intelligent manufacturing technology:Computer simulation software, 3D printing technology, and intelligent production systems have been popularized and applied.    Quality control system: The intelligent analyzer for molten iron in front of the furnace, the spectrum analyzer, the non-destructive flaw detector and the three-coordinate measurement are widely used, and most enterprises have passed the ISO9000 quality system certification.3.Casting equipment produced in shandong Province includes molding, smelting, cleaning and sand treating equipment. Pig iron materials such as sand molding and core-making materials, steel balls for sand cleaning and all kinds of fire-resistant materials are all available in Shandong.4.Industrial conglomeration area:

Shandong province have been cultivated Zhangqiu Mingshui Industrial Park to produce heavy duty vehicle and fan castings industrial agglomeration, Longkou and Laizhou city brake disc industrial agglomeratione,, Pingdu and Dongying areas to produce precision castings and foundry equipment industrial agglomeration, Weifang City grooved pipe fittings foundry industrial agglomeration,Linyi Baisha Port water meter shell industrial agglomeration,  Binzhou wear-resistant insert ring industry cluster,Pingdu, Jiaozhou area melting environmental protection equipment, casting equipment industrial cluster,  Zhoucun and Zouping area production of steel shot and steel sand industry agglomeration.