During the 12th Five-Year Plan period, China has made remarkable progress in casting technology innovation and industry progress. The total casting output in 2014 reached 46.2 million tons, an increase of 3.8% compared with 44.5 million tons in 2013, ranking the first in the world for 15 years in a row. However, the problem of "large but not strong" casting industry is not solved. On the one hand, we need to import a large number of high-end castings while exporting a large number of low-end castings; On the other hand, in the research and development process of major technologies and equipment urgently needed for national defense and national key projects, due to foreign technology blockade, key castings often become the bottleneck restricting the development of related fields.



The 13th Five-Year Plan period is a crucial period for further implementing the strategy of innovation-driven development and accelerating the building of an innovation-driven country. For the foundry industry, which plays an important role in the equipment manufacturing industry, it is an important opportunity period for technological upgrading, industrial transformation and enhancing core competitiveness. In order to clearly understand the development trend of international casting technology and plan the development direction of casting technology, according to the goals and tasks proposed in the Outline of National Medium - and Long-term Scientific and Technological Development Plan (2006-2020), the National 13th Five-Year Plan for Scientific and Technological Development and Made in China 2025, combined with the actual development of Chinese casting industry, The "13th Five-Year Plan for Technological Development of Foundry Industry" (hereinafter referred to as the "Outline") has been formulated.



The Program consists of 18 parts: cast steel, cast iron, cast nonferrous alloys, cast metal matrix composite materials, cast wear-resistant materials, rapid casting, investment casting, die casting, antigravity casting, extrusion casting, lost mold casting, numerical simulation, network manufacturing, molding materials, casting equipment and testing technology, Environmental protection and safety, automotive castings, casting standards. Among them, the 13 fields in the Outline involve all five major projects under the Made in China 2025 initiative, covering 8 of the 10 major fields of high-end equipment innovation projects.



According to the development status of foundry technology at home and abroad, combined with the development hot issues and the development needs of China's foundry technology, the Outline points out the development goals and development priorities, and puts forward the key development projects and key technologies. The Outline highlights the strategic and macroscopic, is targeted and operable, and can be used as a guide for the development of foundry technology in China's foundry industry from 2016 to 2020.



The eighth chapter focuses on the technical development planning of die casting, and is hereby excerpted for readers to read.



1 Development status and trend at home and abroad



1.1 Domestic development status and trend

Die casting is one of the most widely used and rapidly developed metal hot working forming processes in casting technology. As an advanced non-ferrous alloy precision parts forming technology, die casting ADAPTS to the requirements of complex, precision, lightweight, energy-saving and green products in modern manufacturing industry. Its products have been widely used in many fields such as automobiles, machinery, household appliances, communications, hardware and so on.



Domestic die casting started in the 1950s, with an annual growth rate of more than 10% in the first 30 years. Since 1990, it has grown at an average annual rate of more than 15 percent, reaching 3.18 million tons in 2012. After many years of efforts, our country has built up a complete die-casting industry and its supporting industrial chain and some relatively developed die-casting industrial bases, the output of which is the largest in the world, becoming a major die-casting country in the world.



1.1.1 Alloy material for die casting

The alloy materials of die casting are mainly non-ferrous metals and their alloys, and the amount of die casting aluminum alloy is the most prominent. In addition to the expansion of the range of traditional die casting aluminum alloy, new technology of die casting is used to produce mechanical components with high mechanical properties. Special aluminum alloy required for automobile structural parts is also begun to be adopted in the production of die casting at home. The material and properties of die-cast magnesium alloy are further studied, and the application and development of automobile magnesium alloy die-cast parts are further strengthened. In the advanced countries, the application and research of high silicon, special aluminum alloy and aluminum alloy for structural parts are more advanced than those in China, and the research of magnesium alloy is equivalent to that in China. In addition, the international research on the basis of materials is more extensive and in-depth than the domestic research, and the results are remarkable, while the domestic investment in this aspect is small. The output of zinc alloy die casting is decreasing gradually, mostly small and medium parts. The output of copper alloy die casting is small, and there are many small and medium parts. Black metal and alloy die casting in our start is close to foreign, but the development at home and abroad has been in a long period of almost standstill.



1.1.2 Die casting equipment

The rapid development of the automobile industry and the increasing demand for large and high-end die casting parts have promoted the improvement of domestic die casting machine technology. The high pressure injection speed, short pressure building time, real-time control injection system, 4000 t large die casting machine, automatic peripheral supporting equipment and die casting units have been introduced into the market, narrowing the gap with foreign advanced equipment. However, there is still a big gap between domestic equipment and foreign advanced equipment in stability, durability of sealing components, precision and repeatability. Large two-plate machine occupy the domestic market, to the traditional die casting machine market has brought great impact, some domestic manufacturers have begun the development of two-plate machine. There is a big gap between magnesium alloy hot chamber die casting machine and foreign countries. In the die casting machine automation integration, domestic manufacturers began to set foot in, but there is still a large gap between the supporting resources and processing methods and advanced manufacturers. In recent years, the domestic independent research and development of die casting and extrusion casting dual-use equipment, become the international innovation of the new machine.



1.1.3 Die casting mold

Domestic die casting mold with die casting professional by leaps and bounds, has also made great progress. The development, manufacture and market use of precision and complex moulds represented by engine cylinder block and transmission housing have established the position of domestic manufacturers. In mold design, simulation analysis software is widely used, but the lack of excellent designers with rich process skills and practical experience, mold export advantage is not strong. Die processing methods (equipment) and means have gradually drawn closer to the international, the gap is narrowing, but most of the high precision processing equipment rely on imports. Die steel material also need to strengthen the establishment of domestic materials in the industry position. In addition, in the mold material heat treatment technology, improve the life of the mold means, mold cooling technology, mold surface treatment technology, mold adaptation automation and improve production efficiency to reduce failure and other issues, but also need to increase the intensity of research and development and investment.



1.1.4 Die casting process

Great progress has been made in the experimental research of casting properties, physical properties and service conditions of various die casting alloy materials, especially the research of magnesium alloy is more in-depth, and more investment has been invested in the experimental research of structural alloy materials with stress. Die casting machine control system is more perfect and easy to use, speed, pressure, time, displacement, temperature, release agent, cooling and other parameters set and adjust conveniently and quickly. However, compared with foreign countries, there is still a gap in setting points (segments), and the experimental studies on pouring, overflow, filling and vacuum systems are not enough. Internationally, there have been many new changes in die casting technology, such as local extrusion technology, point cooling and local super cooling, ultra-low speed die casting, semi-solid die casting, laser welding technology on die surface, etc., which has a great promotion effect on the industry. The national standards for alloy materials and die casting technology have been prepared, but the experimental studies on the basic data of the standards are not sufficient and detailed.



1.1.5 Die casting quality control and testing technology

Die casting quality control and testing technology has been paid attention by more and more manufacturing enterprises. Many enterprises are equipped with domestic or imported instruments and equipment ranging from spectral analysis, density and density index, metallographic inspection and mechanical properties of material testing to X-ray inspection, industrial CT inspection, size and finish inspection, cleanliness inspection, sealing inspection and porosity inspection of product testing. Improve the overall testing level and ability of the die-casting profession. In the die casting professional service for the supporting downstream processes such as heat treatment, shot blasting, surface treatment and coating, infiltration, auxiliary materials have been greatly developed and improved.



1.1.6 Energy saving and environmental protection of die casting operations

The energy consumption of die casting is large. Alloys melted with oil, gas, or fuel in addition to electricity. At present, the domestic die casting machine and melting furnace have good energy saving effect on the market supply. Die casting production belongs to hot processing operation, heat prevention and cooling is very important. Industrial pollutants will be produced in the process of production, which need to be treated comprehensively. Some domestic die casting enterprises have taken measures, mainly starting from the treatment of waste gas and smoke, waste oil and wastewater.



1.2 Development status and trend of foreign countries

Foreign countries focus on developing new technology to produce high-quality aluminum alloy die casting parts instead of steel materials for automobile lightweight requirements. Breaking through the limitation of traditional die casting process, this kind of die casting can be heat treated and welded to achieve high elongation and sufficient strength. Typical components include shock towers, chassis parts, door frames, subframes, space brackets, and automatic transmissions. The research on the material and process of aluminum alloy die casting has always been in a more important position, developing rapidly and widely used in the market. Foreign aluminum alloy die-casting can eliminate the internal porosity, and can be T6 heat treatment and welding, elongation can reach more than 10%, tensile strength can reach more than 210 MPa. Foreign die casting production efficiency is higher, such as automobile four cylinder block die casting can reach 150,000 pieces/year. High - performance injection system, real-time control technology and two - plate closing system are important manifestations of the advanced nature of current die casting equipment. Large - scale die casting equipment has stable performance and mature technology.



1.3 Gap at home and abroad

At present, there is a great gap between our die-casting industry and foreign countries in the aspects of high-end die-casting equipment, material performance, casting quality, mold development and design, intelligence degree, production efficiency and so on.

(1) The competitiveness of the enterprise is not strong, and the technical strength is insufficient;

(2) The investment in scientific research projects is not enough, and the establishment of the subject is not close to the current actual needs;

(3) the popularization and application of advanced technology is not widespread enough;

(4) There is still a gap between the parameter range and accuracy of domestic die casting equipment. There is a large gap between the design and manufacture of large die-casting machine (more than 2000 tons) and foreign countries, mainly reflected in the stability of equipment and injection performance.



1.4 Problem analysis and solution

From the above gap, the main problems are roughly as follows: serious shortage of professional and technical personnel and production operators; Related industries in casting do not form an interrelated whole, and the industrial chain is not close enough; For foreign advanced technology, domestic enterprises have the ability to accept not many. Therefore, it is necessary to implement die-casting production to realize automation and intelligence, and create a good production environment. Attracting more employees and stepping up the training of professional personnel; Appropriate research and development projects are selected according to our conditions and abilities.



2. Development Objectives

Overall development goal - with the "Made in China - 2025", build a powerful die casting country, die casting enterprises to "high-end, intelligent, export-oriented, service-oriented" march, and emerge a number of high-end die casting equipment and die casting production enterprises.

(1) To carry out the test of advanced die casting technology;

(2) Forward to higher melting point metal die casting;

(3) Promote the development of semi-solid processing technology and expand the processing of composite materials;

(4) Setting up die casting operation station.



3 Development priorities

3.1 Technical Route

(1) Establish an incubation base as a demonstrative and replicable benchmark by realizing the results of major projects;

(2) Establish a production design and development team, participate in the joint design of products of upstream customers, make it adapt to die casting technology as much as possible, the application of product rapid prototyping technology and 3D printing technology in product design, the design of thin-wall and thick large-wall die casting parts and die casting process technology development;

(3) Develop complete sets of die casting technology and equipment for aluminum alloy thin-wall structural parts, cooperate with the automobile industry, and design by the domestic, then each link, based on the domestic first, if necessary, by foreign supporting.



3.2 Technical Research

3.2.1 Generic technology research

(1) Thin-walled structural parts design and die casting technology;

(2) Experimental research and development of precision and complex die manufacturing technology, die temperature automatic control technology, extending die life and so on, which are suitable for high efficiency;

(3) Research and promotion of filling simulation technology, die casting gate technology, optimization and selection of die casting parameters, defect and die thermal state analysis;

(4) Research and development of high performance, high reliability and high precision automatic die casting machine units and ancillary equipment, combined with a number of high-end die casting technology.



3.2.2 Research on key technologies

(1) Research and application of basic die casting technology and special die casting technology. Such as vacuum die casting, semi-solid die casting, slow injection technology, pre-filling technology, salt core technology, structural parts die casting technology (double vacuum), extrusion casting, local pressurization technology, etc.

(2) Research and development of die-casting alloy materials and melting technology. Further improve the die-casting performance and usability test research of non-ferrous alloy materials, develop new alloy varieties, such as composite materials, structural alloy materials, high ductility materials, etc., improve the thermal efficiency of melting equipment research and development and product application;

(3) Research and development of high performance and reliability automatic die casting machine and auxiliary equipment. Research and development of high reliability real-time control injection system and automatic parameter control adjustment system, application of automatic integration technology of all auxiliary equipment, development of die casting equipment suitable for the promotion of a variety of advanced technology;

(4) Development of precision and complex mold manufacturing technology. Efficient cooling technology, improvement of die materials and development of new steel, die temperature automatic control technology and equipment, extension of die life method of the experimental research and promotion, die surface treatment technology research;

(5) Research and popularization of die casting simulation technology. Such as metal filling, speed, pressure, temperature, solidification, defects (porosity, shrinkage), thermal state analysis (mold surface temperature field, temperature gradient); Optimization and selection of die casting parameters.



4 Key Projects

In order to achieve the development goals of the 13th Five-Year Plan, the following key projects are proposed:

(1) High-grade die casting equipment -- real-time control (numerical control) injection system of die casting machine and die casting unit of fully automated robot;

(2) Developing complete sets of die casting technology and equipment for aluminum alloy thin-wall structural parts -- combining production, learning, research and application with automobile industry;

(3) Green die casting -- creating replicable demonstration enterprises.

5 Policy Suggestions

(1) To provide appropriate supportive policies for environmental governance;

(2) If conditions permit, concentrated smelting of alloy materials can be used to reduce energy consumption and pollutant emissions. The state should give appropriate tax exemptions or subsidies;

(3) Strengthen the support for the basic technology research of die-casting specialty with large investment and slow effect, and establish industry-university-research institutions to tackle key problems and popularize them;

(4) Standardize the statistical work of the industry and stop the blind and disordered release of statistical data.