Current Production Status
In 2007, the output of the lost foam casting process was 648,000 tons, with 266,000 tons produced via FMC and 372,000 tons made through EPC. In 2009, China produced 760,000 tons of lost foam castings (333,000 tons of FMC and 427,000 tons of EPC). Te largest FMC part produced in China in 2009 was
75 tons, and the largest EPC component was 12 tons. More than 1,000 lost foam facilities are operating in China today. Among these, more than 30 are capable of producing 10,000 tons or more. More than 50 companies are engaged in the production of raw materials for lost foam, including equip- ment manufacturers, colleges, universities and institutes. According to a survey of 78 foundries in 2005 and 128
foundries in 2007, the castings produced in the lost foam process in China are 86.5% iron, 13% steel and less than 0.5% aluminum (Table 2). Before 2003, more than two-thirds of the lost foam cast-
ing facilities in China produced fewer than 2,000 tons per year, and 46.7% of factories produced fewer than 1,000 tons per year. Since 2005, the significant features of Chinese lost foam facilities are: 1. Te number of small-scale foundries (fewer than 2,000
tons per year) has decreased. Te number of small found- ries with an output of fewer than 1,000 tons per year has decreased from 46.7% of the market segment in 2003 to 12.8% in 2005. 2. As production technology has matured, foundries have begun large-scale production. Since 2005, ferrous castings have accounted for 99.5% of the parts produced in the lost foam process. Te number of large-scale factories with a yield greater than 4,000 tons per year has increased from 11.6% of the segment in 2003 to 43.7% in 2007. Since 2007, the overall level of lost foam casting has
improved, and casting sizes have increased. Raw and auxiliary materials production, pattern die and equipment manu- facturing and casting
逐年增加；特别是2009年实型铸件产量达到33万t，实 型铸件增长速度大大快于消失模铸件的增长速度。 1999~2005年我国实型铸件产量占主导地位，是消 失模铸件的2～3倍，从2007年开始实型铸件产量逐渐 接近消失模铸件产量；从2005年到2009年我国实型铸 件和消失模铸件产量同步快速地增长。见表1所示。 2.2 我国实型/消失模铸造目前的生产现状 2007年我国实型铸件/消失模铸件产量为64.8万t， 其中实型铸件26.6万t，消失模铸件37.2万t，超过美国 和日本为全球第一。到2009年我国实型铸件/消失模铸 件产量76万t，其中实型铸件和消失模铸件分别为33.3 万t和42.7万t；最大实型铸件75t，最大消失模铸件 12t。目前我国实型/消失模铸造企业达到1000余家，万 吨以上企业目前有30余家。从事实型/消失模铸造的原 辅材料、装备制造及高等院校和研究院所50多家。 据对2005年78家、2007年对128家生产厂调查资料统 计，2007年实型铸件/消失模铸件产量中铸铁、铸钢和铸铝 件分别占86.5%、13%和＜0.5%（＜0.1%）。按生产规模 分，2007年我国实型/消失模铸造行业生产情况见如表2所示。 从表1和表2以及5年来生产状况分析，我国实型/消 失模铸造的发展和进步主要表现如下： （1）自2005年，我国实型/消失模铸造生产发展较快。 （2）2003年前实型/消失模铸造产量在2 000t/年以下 小规模生产企业占三分之二以上，1 000t/年以下的 小企业占46.7%；即近半数工厂是小企业。 （3）2005年后，实型/消失模铸造生产企业发展的显著 特点是：
① 2 000t/年以下的小规模企业大幅度减少，1 000t/年 以下的小企业从2003年 的46.7%降到2005年的 12.8%。
The special equipment required for EPC is divided into two major categories: pattern manufacturing (white side) and molding and pour- ing (black side), including vibration tables (shown).
② 采用实型/消失模铸 造技术生产铸铁件、铸 钢件的铸造企业的生产 技术逐趋成熟，进而走 向规模化生产，2005年 后实型/消失模黑色金属 铸件产量占整个实型铸 件/消失模铸件总产量的 99.5%。4 000t/年以上 较大规模的铸造企业数 量从2003年的11.6%提 高到2007年的43.7%。
铸件造型浇注（黑区）： 振动台、负压系统、砂处 理系统、砂箱输送系统、 砂冷却系统等。
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Spring 2012
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