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山东省铸造行业概况一、生产规模及配套行业据不完全统计，山东2008年铸件年产量达350余万吨，其中灰铁件约占比例为50％，球墨铸铁件约占比例为18％，可锻铸件约占3.5%，球墨铸铁管约占13％，普通铸钢件约占8%，精密钢件约占2.5%，有色铸件约占5%。山东铸造厂点众多，具备一定生产规模的铸造厂点有1400余家，从业人员约13.5万人左右。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，部分产品远销欧美和日韩等东南亚国家。二、技术装备水平与质量保证。熔炼技术：以冲天炉熔炼技术为主，部分企业采用了冲天炉一电炉双联工艺。造型、制芯技术：树脂砂生产工艺已基本取代潮模干型工艺：气冲造型线，高压多触头造型线，挤压型生产线被引进和使用：许多新工艺如负压实型铸造、熔模精密铸造、真空铸造、差压铸造、重力铸造、“V法、脂硬化水玻璃工艺得到推广应用。模拟技术：计算机模拟凝固软件得到推广应用。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群体，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：省内培育了章丘明水工业园生产重型汽车、风机和有色合金铸件产业集群、龙口和莱州地区出口刹车盘产业集群、平度和东营地区生产精密铸件与设备产业集群、昌邑市围子镇铸造园区、胶州地区制造冲天炉产业集群、邹平地区生产钢丸钢砂产业集群和青州地区供应铸造生铁的产业聚集区。五、人员培训山东大学和山东建筑工程学院是我省铸造人才的主要培养基地：山东大学已经培养铸造专业本科生2210名，硕士研究生260名，博士研究生44名：山东建筑工程学院已培养大中专毕业生1700名。为加快行业专业人才培养，山东省铸造协会与山东大学联合，自2002年开始举办铸造《专业证书》大专班，已培养毕业生50余名。1.productivityofCastingandAssociatedEnterpriseAccordingtoinadequatestatistics,theproductionofcastingofShandongProvincereaches3,500,000tonsin2008,inwhichgreyironcasrting,ductileironcasting,malleableironcasting,ductileironpipesandtubes,commonsteelcasting,nicesteelcastingandnonferrouscastingtake50%,18%,3.5%,13%8%,2.5%and5%,respectively.TherearemanycastingfactoriesinshandongProvince,inwhichmorethan1,400factoriesareoflargeones.Thereareabout135,000peopleengagedinthisfield.Associatedenterprise:Thecastingsaremainlyusedincars,motorcycles,ships,machinetools,generalmachineryaswellasmachineryforengineering,agriculture,railwaysandconstruction.Theyarealsousedinpowerindustry,metallurgyindustry,chemicalindustryandmunicipalprojects,etc.SomecastingsareexportedtoOccident,Japan,KoreaandSouth-eastAsiancountries.2.TechnicalEquipmentandQualityControlSmeltingtechnology:Cupolasaremainlyused.However,somefactoriesusebothcupolasandelectricfurnaces.Moldingtechnology:Greensandmoldshavebeenreplacedmainlybyresinsandmolds.Gaspressingmoldingline,high-pressureandmoretouchesmoldinglineandextrusionmoldinglinehavebeenintroducedtomanyfactories.Newtechmologies,suchasminuspressuresolidmoldcasting,loseolefincastingloseolefincasting,vacuumcasting,differencetomanyfactories.Newtechnologes,suchasminuspressuresolidmokdcasting,loseolefincasting,vacuumcasting,differencepressurecasting,gravitycasting,”Vmethod”andSelfstrengtheningsodiumsilicatetechnologywereusedwidely.Simulationtechnology:Computersimulationtechnlogiesforsolidificationprocesshavefoundapplicationinfactories.Qualitycontrolsystem:Intelligentanalyzerforliquidironbeforemolding,spectralanalyzer,scathelessdetectorandthree-dimensionalcoordinatemeasurerarewidelyused.MostenterpriseshavepassedIS09000QualityAuthentication.3.CastingEquipmentandMaterialSupplyCastingequipmentproducedinshandongProvinceincludesmolding,smelting,cleaningandsandtreatingequipment.Materialssuchassand,moldingandcore-makingmaterials,steelballsforsandcleaningandallkindsoffire-resistantmaterialsareallavailableinShandong.4.TrainingofEnterpriseEmployeesSandongUniversityandSandongUniversityofArchitecturearetwomaintrainingbasesforrcastingengineersinShandongprovince.Uptonow,2,210bachelors,260mastersand44doctorsofcastingmajorshavegraduatedfromShandongUniversity.1,700technicalgraduatesgraduatedfromShandongUniversityofArchitecturehavejoindeworkingforceinthisarea.Fortrainingmorepersonnel,theCastingAssociationandShandongUniversityhavejointlysponsoredacollegetrainingprogramforcastingspecialtysince2002,sofar,therehavebeen50gradrates.