This paper comprehensively introduces the complete manufacturing process of Liyang Propellers, with a focus on our innovative breakthroughs in casting technology, machining processes, and quality control. By adopting 12 patented technologies—including quick-drying sand mold casting and five-axis simultaneous machining—our propeller products outperform industry standards by more than 20% across key indicators such as precision, efficiency, and service life. Additionally, the paper details the 23 critical processes from mold design to finished product delivery, shedding light on the technical underpinnings of Liyang Propellers’ outstanding performance.
1.Process Overview
Liyang Propellers adopts a composite manufacturing process combining “precision casting + CNC machining”. The entire production workflow comprises 6 major stages and 23 critical procedures, with the ISO 9001 quality management system implemented throughout. Compared with traditional processes, this advanced approach shortens the manufacturing cycle by 30%, enhances product performance by 25%, and controls the scrap rate to below 0.5%.
2.Mold Design and Manufacturing
2.1 3D Modeling
Technical Highlights：
- Adoption of parametric design software
- Airfoil curves optimized based on over 20 years of experience
- Automatic generation of machining paths
2.2 Mold Core Machining
3.Casting Process
3.1 Rapid-Drying Sand Mold Preparation (Patented Technology)
Technological Breakthroughs：
- Novel Binder Formulation：
- Drying Time: Traditional 72 hours → Our 8 hours
- Strength Increased by 40%
- Permeability Improved by 35%
- Mold-Making System：
- Molding Precision：±0.1mm
- Multi-Cavity Mold Technology
3.2 Melting and Pouring
Process Control：
- Medium-Frequency Induction Furnace (Maximum Capacity: 20T)
- Temperature Control Precision：±5℃
- Degassing Treatment: Argon Rotational Degassing
- Full-Process Composition Monitoring
- Low-Pressure Pouring Process：
- Pouring Speed：3-5kg/s
- Temperature Gradient Control
- Sequential Solidification Technology
4.Heat Treatment Process
4.1 Solution Treatment
Parameter Control：
- Temperature：950±10℃
- Holding Time: Wall Thickness (mm) × 1.2 minutes
4.2 Aging Treatment
Innovative Processes：
- Stepwise Aging Technology
- Temperature Uniformity Control (±5℃)
- Furnace Atmosphere Composition Monitoring
5.Machining Process
5.1 Rough Machining
Equipment Configuration：
- Large Vertical Lathe
- Maximum machining diameter：5m
- Positioning accuracy：01mm
- Equipped with an automatic measuring system
6.Surface Treatment Technology
6.1 Polishing Process
All polished manually by experienced senior technicians to ensure a silky-smooth finish like a work of art.
6.2 Anti-Corrosion Coating
Patented Technology：
- Multi-Layer Spray Composite Coating
- Thickness：80-120μm
- Non-Destructive Testing (NDT): Ensures a defect-free surface
- Friction coefficient reduced by 30%
7.Quality Inspection System
7.1 Whole-Process Inspection
Key Nodes：
- 12-item inspection for incoming raw materials
- 8 quality control points during the casting process
- 23-item performance testing for finished products
7.2 Advanced Testing Equipment
8.Process Advantage Analysis
8.1 Comparison with Traditional Processes
Performance Improvements：
- Propulsion Efficiency：+18-25%
- Service Life：+30-40%
- Vibration Noise：-15dB
- Weight Accuracy：±1%
8.2 Core Technological Breakthroughs
- 1. Fast-Drying Sand Mold Technology
- Shortens manufacturing cycle by72%
- Reduces mold cost by45%
- Improves dimensional accuracy by 2 grades
- Hybrid Machining Process：
- Machining efficiency increased by60%
- Tool life extended by 3 times
- Energy consumption reduced by 35%
9.Application Cases
9.1 Large Container Ship Propeller
Project Data：
- Diameter：5.5m
- Weigh：12T
- Delivery Cycle: 45 days (industry average: 60 days
- Measured Efficiency: 72.5% (2.3% higher than the contractual value)
9.2 Luxury Cruise Ship Propeller
Technological Innovations：
- Low-Noise Design
- Asymmetric Blade Profile
- Intelligent Monitoring System
10.Conclusion
Liyang Propellers has achieved a comprehensive improvement in product quality through an innovative manufacturing process system：
- Precision Advantage：Key dimensional tolerances meet IT6 grade
- Efficiency Advantage：Propulsion efficiency leads the industry by15-20%
- Service Life Advantage:：Design life exceeds 10 years
- Service Advantage：Delivery cycle shortened by 30%
Our Core Competitiveness Lies in：
- 12 Core Patented Technologies
- Whole-Process Quality Control
- Continuous Process Innovation
- Customization Service Capability
Choose Liyang Propellers, and You Will Get：
- Proven Excellent Performance
- Significant Economic Benefits
- Reliable Quality Assurance
- Comprehensive Technical Support
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