Copper castings, as an important metal material, have a long history and are widely used. With the continuous advancement of technology, the production process and application fields of copper castings will continue to expand, providing strong support for the development of modern industry. In the future, copper castings will continue to play an important role in fields such as mechanical manufacturing, electrical industry, and building decoration, and will develop towards high performance, precision, environmental protection, and intelligence.

Design and manufacture corresponding molds based on the shape and size requirements of the castings. The mold material can be sand mold, metal mold, or other composite materials. Copper and its alloys are melted into liquid form at high temperatures, and then the molten metal is injected into the mold through a pouring system. During the melting process, it is necessary to control the temperature, composition, and impurity content to ensure the quality of the castings. After pouring, the molten metal cools in the mold and gradually solidifies to form a casting. The cooling rate has a significant impact on the microstructure and properties of castings and needs to be adjusted according to specific circumstances.

What are the solutions to the wear problem of copper castings during use?

Repair wear and tear

Welding repair: Using welding method to weld one or more layers of metal material on the worn area to restore the size and performance of the part. For copper castings with significant wear, welding is a commonly used repair method. Select copper based welding rods or wires that match the material of the copper casting, and weld them on the worn surface through reasonable welding process parameters such as welding current, voltage, welding speed, etc. After welding, it is necessary to perform appropriate processing on the welding layer, such as grinding, turning, etc., to ensure the dimensional accuracy and surface roughness of the parts.

Electric brush plating: This is a technique for rapidly depositing metal on the surface of parts. Using the workpiece as the cathode and the plating pen as the anode, during the process of contact and relative motion between the plating pen and the workpiece surface, metal ions in the plating solution deposit on the surface of the workpiece under the action of an electric field, forming a uniform metal coating. Electric brush plating is suitable for repairing the surface of copper castings with low wear and high precision requirements. Different plating solution components can be selected as needed, such as copper plating, nickel plating, etc., to achieve good wear resistance and corrosion resistance.

Thermal spraying: Heating metal or ceramic spraying materials to a molten or semi molten state, atomizing them through high-speed airflow, and spraying them onto the worn surface of copper castings to form a coating with good wear resistance and corrosion resistance. Thermal spray coatings have high hardness and thickness, which can effectively improve the wear resistance of parts. Common thermal spraying methods include flame spraying, plasma spraying, etc. Select appropriate spraying materials and process parameters based on the usage environment and wear condition of copper castings.

Inlay repair: For areas with severe local wear, the inlay method can be used for repair. For example, machining a suitable groove in the worn area of a copper casting, and then embedding a pre machined copper alloy or other material with good wear resistance into the groove, fixing it by welding, riveting, or interference fit to restore the size and function of the part.

Prevent wear and tear

Reasonable material selection: Select suitable copper alloy materials based on the usage environment and working conditions of copper castings. For copper castings working at high speeds and high loads, materials with high strength and wear resistance such as tin bronze can be selected; For copper castings working in environments with corrosive media, materials with good corrosion resistance and wear resistance such as aluminum bronze can be selected.

Optimization design: When designing copper castings, factors that reduce wear should be considered. For example, designing the structure of parts reasonably, avoiding stress concentration, and reducing the possibility of local wear; Optimize the surface shape and size of parts to reduce friction and wear; Reasonably select the fitting clearance to ensure that the parts can operate normally and reduce wear during the working process.

Improving lubrication conditions: Using appropriate lubricants and lubrication methods can effectively reduce the friction coefficient on the surface of copper castings and minimize wear. Choose the appropriate lubricating oil or grease according to the working conditions. For example, synthetic lubricating oil with high temperature resistance can be used in high-temperature environments, and lubricating grease with anti-corrosion properties can be selected in environments with corrosive media. At the same time, reasonable lubrication methods should be adopted, such as regular refueling, using oil mist lubrication or oil air lubrication, to ensure the lubrication effect.

Strengthening surface treatment: Proper treatment of the surface of copper castings, such as oxidation treatment, phosphating treatment, hard chromium plating, etc., can form a protective film with high hardness and good wear resistance on the surface, improving the surface's wear resistance.

Control the working environment: Try to control the working environment of copper castings as much as possible, reduce the intrusion of hard particles such as dust and sand, and avoid using them in harsh environmental conditions. For example, in workplaces with dust, effective dust prevention measures should be taken, such as installing dust collection equipment, sealing the equipment, etc., to prevent dust from entering the friction pair of copper castings and reduce abrasive wear.

Copper castings, as one of the earliest metal materials used in human history, can be traced back to around 8000 BC. Early humans discovered that copper had good ductility and conductivity, and gradually used it to make tools, weapons, and decorations. With the advancement of smelting technology, the application scope of copper castings continues to expand, becoming an important component of ancient civilization.

Copper has good corrosion resistance in the atmosphere and fresh water, and can maintain stable performance for a long time. It is suitable for manufacturing parts used in humid or corrosive media environments, such as valves, pipe fittings, etc. Through reasonable alloying and process control, copper castings can achieve high strength and toughness, withstand certain external forces and impacts, and meet the requirements of different engineering applications.