国铸造行业的整体技术水平比发达国家落后约十几年，无法满足国民经济快速发展的需要。技术落后、设备陈旧、能耗和原材料消耗高、环境污染严重以及工人作业环境恶劣等问题，已经成为行业的共识。
The overall technical level of the national casting industry is about a decade behind that of developed countries, which cannot meet the needs of rapid economic development. The problems of outdated technology, outdated equipment, high energy and raw material consumption, severe environmental pollution, and poor working environment for workers have become a consensus in the industry.
具体表现在如下四大问题。
Specifically manifested in the following four major issues.
1. 工艺水平低，铸件质量差
1. Low process level and poor casting quality
（1）铸件加工余量大。由于缺乏科学的设计指导，工艺设计人员凭经验难以控制变形问题，铸造的加工余量一般比国外大1～3倍。加工余量大，铸件的能耗和原材料消耗严重，加工周期长，生产效率低，已成为制约行业发展的瓶颈。
(1) There is a large machining allowance for castings. Due to the lack of scientific design guidance, process designers find it difficult to control deformation issues based on experience, and the machining allowance for casting is generally 1-3 times larger than that of foreign countries. The large processing allowance, severe energy consumption and raw material consumption of castings, long processing cycles, and low production efficiency have become bottlenecks restricting the development of the industry.
（2）大型铸件偏析和夹杂物缺陷严重。大型铸钢件和大型钢锭在凝固结束后，在冒口根部、铸件的厚大断面存在宏观偏析、晶粒粗大问题。
(2) Large castings have severe segregation and inclusion defects. After the solidification of large steel castings and ingots, there are problems of macroscopic segregation and coarse grain size at the root of the riser and the thick cross-section of the casting.
（3）铸件裂纹问题严重。
(3) The problem of casting cracks is severe.
（4）浇注系统设计不合理。由于设计不当，存在卷气、夹杂等缺陷，导致铸件出品率和合格率低。
(4) The design of the pouring system is unreasonable. Due to improper design, defects such as curling and inclusions exist, resulting in low yield and qualification rates of castings.
（5）模拟软件应用不普及。铸造过程模拟是铸件生产的一个必要环节，在国外，如果没有计算机模拟技术，就拿不到订单。我国的铸造业计算机模拟起步较早，虽然核心计算部分开发能力较强，但整体软件包装能力较差，导致成熟的商业化软件开发远落后于发达国家，相当一部分铸造企业对计算机模拟技术望而却步，缺乏信任。目前这种局面虽有所好转，但在购买了铸造模拟软件的企业中，能够发挥其作用的还不多见，急需对企业员工进行软件应用培训。
(5) Simulation software applications are not widespread. Casting process simulation is a necessary part of casting production. In foreign countries, without computer simulation technology, orders cannot be obtained. The computer simulation of China's casting industry started early. Although the development ability of the core computing part is strong, the overall software packaging ability is poor, resulting in mature commercial software development falling far behind developed countries. A considerable number of casting enterprises are hesitant and lack trust in computer simulation technology. At present, although this situation has improved, there are not many enterprises that have purchased casting simulation software that can play its role, and there is an urgent need to provide software application training for enterprise employees.
（6）普通铸件的生产能力过剩，高精密铸件的制造依然困难，核心技术和关键产品仍依赖进口。
(6) The production capacity of ordinary castings is surplus, the manufacturing of high-precision castings remains difficult, and core technologies and key products still rely on imports.
2. 能耗和原材料消耗高
2. High energy consumption and raw material consumption
我国铸造行业的能耗占机械工业总耗能的25%～30%，能源平均利用率为17%，能耗约为铸造发达国家的2倍。我国每生产1吨合格铸铁件的能耗为550～700公斤标准煤，国外为300～400公斤标准煤，我国每生产1吨合格铸钢件的能耗为800～1000公斤标准煤，国外为500～800公斤标准煤。据统计，铸件生产过程中材料和能源的投入约占产值的55%～70%.中国铸件毛重比国外平均高出10%～20%，铸钢件工艺出品率平均为55%，国外可达70%。
The energy consumption of China's casting industry accounts for 25% to 30% of the total energy consumption of the mechanical industry, with an average energy utilization rate of 17%. The energy consumption is about twice that of developed casting countries. The energy consumption for producing 1 ton of qualified cast iron in China is 550-700 kilograms of standard coal, while in foreign countries it is 300-400 kilograms of standard coal. The energy consumption for producing 1 ton of qualified cast steel in China is 800-1000 kilograms of standard coal, and in foreign countries it is 500-800 kilograms of standard coal. According to statistics, the input of materials and energy in the production process of castings accounts for about 55% to 70% of the output value. The gross weight of Chinese castings is 10% to 20% higher than the average of foreign countries. The average yield rate of steel castings is 55%, and it can reach 70% in foreign countries.
