Room Temperature Low-Carbon Casting Process and Mold
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Solution Overview
Problem
Traditional metal casting methods emit high levels of carbon dioxide due to energy-intensive heating processes, leading to significant carbon footprints and challenges in maintaining mechanical characteristics for precision machinery operating in high-temperature and high-pressure environments.
Innovation Solution
A low-carbon emission casting process that forms the casting main body at room temperature, incorporating embedded parts and a connecting portion, using a low-carbon ore casting material composed of binders, aggregates, and additives, which allows for energy-saving and carbon footprint reduction while enhancing heat resistance, thermal insulation, and shock-absorbing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal casting methods are used, then casting strength and structural integrity are achieved, but carbon emissions and energy consumption increase significantly
Solution Approach 1:
The patent changes the temperature parameter from high-temperature melting to room temperature casting. The low-carbon ore casting material is designed to solidify at room temperature rather than requiring melting, fundamentally altering the thermal parameters of the casting process to eliminate carbon emissions while maintaining structural integrity
Solution Approach 2:
The patent uses composite low-carbon ore casting material composed of binders, aggregates, and additives. This composite material structure allows the casting to achieve sufficient strength at room temperature without requiring metal melting, thus resolving the contradiction between strength and carbon emissions
2Ease of manufacture
If heating metal to molten state is performed, then casting can be formed, but energy consumption increases significantly
Solution Approach 1:
The patent eliminates the heating parameter entirely by designing a casting process that operates at room temperature. The low-carbon ore casting material is formulated to be poured and solidified without thermal energy input, fundamentally changing the energy parameters of the manufacturing process
Solution Approach 2:
The patent replaces the thermal-mechanical melting process with a purely mechanical pouring and solidification process. Instead of heating metal to molten state, the material is poured in a semi-solid or slurry state and solidifies upon contact with the mold, substituting thermal energy with mechanical processing
3Strength
If conventional metal casting is used, then structural strength is achieved, but maintaining casting strength at high temperatures becomes difficult
Solution Approach 1:
The patent changes the operational temperature parameter from high-temperature operation to room temperature operation. The casting is designed and used at room temperature, eliminating the problem of maintaining strength at elevated temperatures while still providing sufficient strength for the intended application
Solution Approach 2:
The patent accepts that the casting is designed for room temperature service rather than high-temperature service. This approach prioritizes low-carbon emission and ease of manufacture over high-temperature durability, effectively treating the casting as a disposable or short-service-life component that doesn't require high-temperature resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The low-carbon emission casting process reduces energy consumption and carbon emissions, improves heat resistance, lowers thermal conductivity, and enhances mechanical properties, making it suitable for high-temperature applications with reduced thermal expansion and improved vibration absorption.
Implementation Method 1
a casting main body formed by casting and solidification at room temperature
Implementation Method 2
improves heat resistance, lowers thermal conductivity
Implementation Method 3
enhances mechanical properties, making it suitable for high-temperature applications with reduced thermal expansion and improved vibration absorption
Data Source
AI summary
A low-carbon emission casting and a mold thereof, and equipment comprising the low-carbon emission casting are provided. The low-carbon emission casting includes a casting main body, a plurality of embedded parts, and a connecting portion. The casting main body is formed by casting and solidification at room temperature. The plurality of embedded parts are embedded in the casting main body. The connecting portion is disposed on at least one surface of the casting main body. The mold of the low-carbon emission casting includes a mold bottom portion, a plurality of mold side portions, and at least one supporting member. The equipment comprising the low-carbon emission casting includes the low-carbon emission casting and a machining device. The machining device is connected to the low-carbon emission casting.