CN113976828A - Carbon-free precision casting method for evaporative shell of evaporative pattern by adopting high-temperature ceramic coating gasification - Google Patents
Carbon-free precision casting method for evaporative shell of evaporative pattern by adopting high-temperature ceramic coating gasification Download PDFInfo
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- CN113976828A CN113976828A CN202111383918.5A CN202111383918A CN113976828A CN 113976828 A CN113976828 A CN 113976828A CN 202111383918 A CN202111383918 A CN 202111383918A CN 113976828 A CN113976828 A CN 113976828A
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- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000002309 gasification Methods 0.000 title claims abstract description 26
- 238000005524 ceramic coating Methods 0.000 title claims abstract description 19
- 238000005495 investment casting Methods 0.000 title claims abstract description 15
- 239000011248 coating agent Substances 0.000 claims abstract description 54
- 238000000576 coating method Methods 0.000 claims abstract description 54
- 238000005266 casting Methods 0.000 claims abstract description 29
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000006260 foam Substances 0.000 claims abstract description 14
- 238000001035 drying Methods 0.000 claims abstract description 13
- 239000004576 sand Substances 0.000 claims abstract description 13
- 239000000203 mixture Substances 0.000 claims abstract description 11
- 229910052742 iron Inorganic materials 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 6
- 230000001680 brushing effect Effects 0.000 claims abstract description 4
- 238000007766 curtain coating Methods 0.000 claims abstract description 4
- 238000003618 dip coating Methods 0.000 claims abstract description 4
- 238000011049 filling Methods 0.000 claims abstract description 4
- 239000000945 filler Substances 0.000 claims description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 2
- 239000000843 powder Substances 0.000 claims description 2
- 239000011812 mixed powder Substances 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 230000008569 process Effects 0.000 abstract description 7
- 230000003670 easy-to-clean Effects 0.000 abstract description 2
- 239000004794 expanded polystyrene Substances 0.000 description 16
- 239000010410 layer Substances 0.000 description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- 238000010114 lost-foam casting Methods 0.000 description 6
- 229910052799 carbon Inorganic materials 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000001354 calcination Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000010304 firing Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000011247 coating layer Substances 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 230000009970 fire resistant effect Effects 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 229910001339 C alloy Inorganic materials 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000010977 jade Substances 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000009991 scouring Methods 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a carbon-free precision casting method for a lost foam by gasifying a hollow shell through high-temperature ceramic coating, which comprises the following steps: the coating comprises, by weight, 8-12% of Guilin No. 5 and 88-92% of bauxite, which are uniformly mixed to obtain a coating powdery mixture, and 60-80% of water is added and stirred for 30 minutes; and (3) drying the coating: coating the prepared coating on the surface of the EPS pattern in a brushing, dip-coating or curtain coating manner, and drying layer by layer at the drying temperature of 50-55 ℃ for more than 4 hours for each layer; the thickness of the coating is 5-6 mm or 8-10 mm; boxing and furnace entering: placing the EPS pattern in an iron bucket or an iron box and filling dry sand with the granularity of 3-5 cm; and (3) gasification in a furnace: controlling the gasification temperature of the EPS pattern to be 700-800 ℃, and obtaining the casting mold after the gasification time is more than 40 minutes. Compared with the traditional investment precision casting method, the method has the advantages that the process is simplified, the casting cost is greatly reduced, the production process is less and pollution-free, the energy is saved, the emission is reduced, and the casting is easy to clean.
Description
Technical Field
The invention relates to the field of lost foam casting, in particular to a high-temperature ceramic coating gasification shell carbon-free precision casting method for a lost foam.
Background
Lost foam casting is an advanced process technology with light weight and high efficiency in 21 st century, more than 4000 lost foam casting enterprises exist in China, more than 1500 lost foam casting enterprises exist, the process of oxygen enrichment, air firing and metal liquid pouring under dry sand negative pressure is adopted, for example, the China patent with the publication number of CN101690976A, the name is that lost foam casting adopts a high-performance coating negative pressure combustion air shell pouring airflow rapid cooling method for eliminating carbon defects, the method has great breakthrough and advancement compared with the traditional full mold pouring, the carbon increase defect of lost foam casting is better controlled, but due to the limitation that the air firing time is different from the structure and the size of the casting, the Polystyrene foam (Expanded Polystyrene, EPS for short) in the general situation is difficult to be completely fired in the empty mold, the air firing degree is mostly in the range of 80-90 percent, namely, the threat of micro carbon increase also exists, and for castings with high requirements, such as weapons, war industry, military industry, and the like, The special castings of national defense equipment, high-speed rail, aviation, aerospace and other equipment can not meet the requirements, and the EPS model can be quickly and completely gasified without carbon residue only above 700 ℃. If the investment imitating shell-in-shell method is adopted, and the water glass or silica sol coating is cast by adopting the investment, the process is complicated, the production period is long, the pollution is large in the coating curing process, the energy consumption is remarkable, the air permeability of the shell can be ensured only by roasting for more than 2 hours at 1000-1100 ℃, and the coating is not easy to desand and clean, so that the popularization and the application are not popular, the loss is not paid, and the slow cost is low. Among 4000 lost foam foundries nationwide, quite a plurality of factories usually need to accept one or more single, small or even large lots of urgent castings with high-quality and strictly controlled carbon components, particularly castings of low-carbon steel and low-carbon alloy steel, which are 100% useless, so that the problem is a real problem to be solved urgently.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a carbon-free precision casting method for a lost foam by gasifying a hollow shell through high-temperature ceramic coating, which simplifies the procedures compared with the traditional investment precision casting method, greatly reduces the cost of castings, has less production process and no pollution, saves energy, reduces emission and ensures that the castings are easy to clean.
The technical scheme for realizing the purpose of the invention is as follows:
a high-temperature ceramic coating gasification empty shell carbon-free precision casting method for a lost foam comprises the following steps:
s1, preparing a coating:
the method comprises the steps of uniformly mixing 8-12 wt% of Guilin No. 5 high-temperature ceramic coating and 88-92 wt% of bauxite to obtain a coating powdery mixture, adding water accounting for 60-80 wt% of the coating powdery mixture, and stirring for 30 minutes;
s2, drying the coating:
the prepared coating is coated on the surface of an EPS mould in a brushing, dip-coating or curtain coating mode, and is dried layer by layer, wherein the drying temperature is 50-55 ℃, and the drying time of each layer is more than 4 hours; the thickness of the coating is 5-6 mm or 8-10 mm;
s3, boxing and furnace entering:
placing the EPS pattern in an iron bucket or an iron box, and filling dry sand with the thickness of 5-10 cm, wherein the particle size of the dry sand is 2-5 mm;
s4, gasifying in the furnace:
controlling the gasification temperature of the EPS pattern to be 700-800 ℃, and the gasification time to be more than 40 minutes to obtain a casting mold;
s5, discharging from the furnace and pouring:
and pouring molten metal after the casting mold is discharged, and pouring according to casting production.
Further, in S1, the first and second layers of the coating material are applied with a bauxite refractory filler of 200 mesh size and Al2O3The content is more than or equal to 75 percent.
Further, in S1, the coating bauxite refractory filler coated on the third layer is a coating powdery mixture with the specification of 50-150 meshes, and Al is contained in the coating powdery mixture2O3The content is more than 60 percent.
The invention adopts a composite additive with the trade name of Guilin No. 5, namely an environment-friendly casting coating disclosed by Chinese patent with the publication number of CN104525851A and the name of high-temperature ceramic scouring-resistant dust pollution-free environment-friendly casting coating, the environment-friendly casting coating is prepared according to the production convention of a lost foam and coated on the surface of an EPS mould, the environment-friendly casting coating is dried layer by layer at the temperature of 50-55 ℃, 5-6 layers are continuously coated and dried, the drying thickness of the coating layer is 5-8 mm, 3-4 layers of coating can be scraped like putty scraping according to different conditions, then the coating is placed in a gasification furnace with the controllable temperature of 700-800 ℃, and molten steel can be discharged and poured when the EPS mould is completely gasified to form a carbon-free shell mould.
The invention has the characteristics, advantages or effects that:
1. from the practical production point of view, the temperature of 700-800 ℃ is the optimal temperature for ceramic transformation of Guilin No. 5 coating. The coating which can not convert the coating into ceramic under the condition of 700 ℃ can not be used for evaporative shell casting of the lost foam of the invention, and the coating used by the invention is a high-temperature ceramic coating of national invention patent commercial product Guilin No. 5;
2. the fire-resistant filler of the coating selected by the invention is calcined bauxite, and the calcined bauxite is a neutral fire-resistant material, so that the applicability is wide, the process performance and the working performance are superior, the cost is moderate, more importantly, the raw material before calcination contains 10-16% of crystal water, micropores with excellent air permeability are formed after calcination, the deformation amount after calcination is extremely small, the high-temperature resistance and molten steel erosion resistance are very strong, the shell mould deformation or cracking in the gasification or pouring process is effectively prevented, and the pouring back-spray phenomenon is eliminated. The advantages of the calcined bauxite refractory filler selected in the invention are that the common and common bauxite refractory filler such as quartz, graphite, Baozhu sand, brown jade sand, mullite, kyanite and the like does not have;
3. the Guilin No. 5 high-temperature ceramic coating additive mainly comprises natural plant powder including industrial starch, is completely carbonized under a high-temperature condition, and generates a plurality of breathable micropores in a ceramic coating, which are not possessed by the traditional or current coating (water glass or silica sol) cast by a paraffin wax investment, so that the shell mold of the invention does not need to be baked for a long time at the temperature of 1000-1100 ℃ like the traditional investment shell mold.
Drawings
FIG. 1 is a schematic diagram of a pattern packing of a lost foam carbon-free precision casting by gasifying an empty shell through a high-temperature ceramic coating in the embodiment of the invention.
In the figure, 1, an EPS model 2, a coating 3, dry sand 4, a box body 5, a pouring gate 6, a riser 7 and a lifting hook are arranged.
Detailed Description
The technical solutions of the present invention will be fully described below with reference to the accompanying drawings and embodiments, and it is to be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example (b):
a high-temperature ceramic coating gasification empty shell carbon-free precision casting method for a lost foam comprises the following steps:
s1, preparing a coating:
uniformly mixing a Guilin No. 5 high-temperature ceramic coating and a calcined bauxite refractory filler according to the weight percentage of 10 percent of Guilin No. 5 and 90 percent of bauxite to obtain a coating powdery mixture, adding water accounting for 70 percent of the weight of the coating powdery mixture, and stirring for 30 minutes;
the first and second layers of coating material bauxite refractory filler is 200 meshes to raise the surface smoothness of casting, its Al is2O3The content is more than or equal to 75 percent so as to improve the sand adhesion resistance of the coating;
the bauxite refractory filler coated on the third layer is a coating powdery mixture with the specification of 50-150 meshes and Al of the bauxite refractory filler2O3The content is more than 60 percent to improve the strength, the air permeability, the crack resistance and the deformation resistance of the coating;
s2, drying the coating:
the prepared coating is coated on the surface of an EPS mould in a brushing, dip-coating or curtain coating mode, and is dried layer by layer, wherein the drying temperature is 50-55 ℃, and the drying time of each layer is more than 4 hours; the thickness of the coating is 5-6 mm or 8-10 mm;
s3, boxing and furnace entering:
as shown in figure 1, an EPS pattern 1 with a coating 2 of 5-6 mm in thickness is generally suitable for small pieces with a casting weight within 100kg, and in order to prevent the shell from being damaged or from expanding and cracking when metal liquid is poured, the EPS pattern 1 is preferably placed in an iron barrel body or a box body 4 and filled with dry sand 3 with the granularity of 2-5 mm, wherein the filling thickness is 5-10 cm; the EPS pattern 1 with the thickness of 8-10 mm of the coating 2 can be directly gasified in a gasification furnace or packed with dry sand 3 to protect gasification in the furnace according to different structures and different operational reliability of castings; a pouring gate 5 is arranged to be communicated with one end of the EPS mould sample 1, and a dead head 6 is arranged to be communicated with the other end of the EPS mould sample 1;
s4, gasifying in the furnace:
the intermediate-speed gasification temperature of the EPS pattern is about 500 ℃, the gasification temperature is preferably controlled to be 700-800 ℃ from the comprehensive consideration of factors such as production period, ceramic transformation temperature of a coating layer, reduction of electric energy loss and the like, the complete gasification time cannot be regulated in textbook, and the gasification time is more than 40 minutes under the general condition that the gasification time is more than 40 minutes due to different casting structures, different furnace performances, different mold sample capacities in furnaces and the like and the combination of production experience and actual inspection to obtain a casting mold;
s5, discharging from the furnace and pouring:
when the casting mold is discharged, the casting mold is at the high temperature of 700-800 ℃, and is preferably hoisted to a pit filled with dry sand through a hoisting hook 7 arranged on the box body 4 for casting metal liquid, and casting is carried out according to casting production.
The preferred embodiments of the present invention have been disclosed for illustrative purposes only and are not intended to limit the invention to the specific embodiments described. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention.
Claims (5)
1. A high-temperature ceramic coating gasification empty shell carbon-free precision casting method for a lost foam is characterized by comprising the following steps:
s1, preparing a coating:
the method comprises the steps of uniformly mixing 8-12 wt% of Guilin No. 5 high-temperature ceramic coating and 88-92 wt% of bauxite to obtain a coating powdery mixture, adding water accounting for 60-80 wt% of the coating powdery mixture, and stirring for 30 minutes;
s2, drying the coating:
the prepared coating is coated on the surface of an EPS mould in a brushing, dip-coating or curtain coating mode, and is dried layer by layer, wherein the drying temperature is 50-55 ℃, and the drying time of each layer is more than 4 hours; the thickness of the coating is 5-6 mm or 8-10 mm;
s3, boxing and furnace entering:
placing the EPS pattern in an iron bucket or an iron box, and filling dry sand with the thickness of 5-10 cm, wherein the particle size of the dry sand is 2-5 mm;
s4, gasifying in the furnace:
controlling the gasification temperature of the EPS pattern to be 700-800 ℃, and obtaining the casting mold after the gasification time is more than 40 minutes.
2. The lost foam carbon-free precision casting method using high temperature ceramic coating gasification hollow shell according to claim 1, wherein in S1, the coating bauxite refractory filler coated with the first and second layers is 200 mesh size and Al is used as Al2O3The content is more than or equal to 75 percent.
3. The lost foam carbon-free precision casting method by high-temperature ceramic coating gasification hollow shell according to claim 1, wherein in S1, the coating bauxite refractory filler coated on the third layer is a coating powder mixture with 50-150 mesh specification and Al2O3The content is more than 60 percent.
4. The lost foam carbon-free precision casting method by using high-temperature ceramic coating gasification hollow shell according to claim 1, wherein the components in S1 by weight percentage are Guilin No. 5 of 10% and bauxite of 90%.
5. The lost foam carbon-free precision casting method using high temperature ceramic coating gasification empty shell according to claim 1, wherein water is added in an amount of 70% by weight of the mixed powder in S1.
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CN202111383918.5A CN113976828A (en) | 2021-11-19 | 2021-11-19 | Carbon-free precision casting method for evaporative shell of evaporative pattern by adopting high-temperature ceramic coating gasification |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115945642A (en) * | 2023-01-04 | 2023-04-11 | 淄博水环真空泵厂有限公司 | EPS foaming mold casting process of dry screw vacuum pump rotor |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN115945642A (en) * | 2023-01-04 | 2023-04-11 | 淄博水环真空泵厂有限公司 | EPS foaming mold casting process of dry screw vacuum pump rotor |
CN115945642B (en) * | 2023-01-04 | 2024-05-28 | 淄博水环真空泵厂有限公司 | EPS foaming die casting process of dry screw vacuum pump rotor |
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