Precision-Cast Axle Box: The Sodium Silicate Sand Casting Advantage

1. The Axle Box: an important part of the Locomotive Drive System

1.1 In a locomotive’s drive system, the axle box is a very important part. It is a heavy casting, big and robust, often weighing over 200 kg, mounted directly on the locomotive’s axle. It acts as a solid support for the traction motor. It holds the motor’s weight and transfers its powerful drive force to the wheels. So we can say that the strength and reliability of the axle box are fundamental for safe locomotive operation and pulling power.

1.2 Demanding Operating Conditions

Because of its critical role, the axle box faces extremely tough conditions. It must handle constant vibration from the tracks, strong impact forces, and repeated stress cycles. Any internal flaw, like a shrinkage cavity or crack, could grow over time and cause the part to fail. This could lead to serious operational problems. Therefore, the casting quality must meet the highest standards.

2. Sodium Silicate Sand Casting: Our Chosen Manufacturing Process

2.1 Process Overview

We use Sodium Silicate Sand Casting to produce our products. This process, also known as the CO₂ Sand process or Water Glass Sand casting, uses sodium silicate as a kind of binder for the molding sand. When exposed to CO₂ gas, the sand mold quickly hardens. By this method, we can create a mold that has very high strength and precision, so this process is a very good way for heavy axle box production.

2.2 Advantages for Axle Box Production

For heavy railway products production, the Sodium Silicate Sand process has specific benefits:

Excellent Dimensional Accuracy: The hard mold perfectly copies the complex shape. This ensures each axle box has stable dimensions and accurate internal cavities, which is crucial for assembly.

Superior Surface Finish: This CO₂ Sand process produces castings with a very smooth surface. A smooth surface has fewer stress points, which directly improves the axle box’s fatigue resistance and service life.

Strong Internal Quality: Sodium Silicate Sand Casting helps create a dense and uniform microstructure in the casting. This is essential for ensuring consistent mechanical properties throughout the heavy 200+ kg axle boxes, with no weak areas.

3. Our Quality Assurance:

3.1 Strict Process Control

We understand that quality is very important. That’s why we have strict controls for every step of our Sodium Silicate Sand Casting process. We pay special attention to the key parameters, ensuring every sand mold has good quality, such as qualified hardness, function and strength.

3.2 Comprehensive Inspection and Testing

Every axle box undergoes rigorous checks before it leaves our factory. This includes checking its dimensions, looking for surface defects, and using non-destructive testing methods like ultrasonic inspection. These tests ensure there are no internal defects such as shrinkage cavities, pores, or cracks. We deliver our products that are built to last and perform reliably.

4. Dependable Products, casting with Expertise.

Luoyang Fonyo Heavy Industries Co., Ltd. delivers robust axle boxes for the railway sector through our mastery of Sodium Silicate Sand Casting. We offer end-to-end solutions—from design to machining—in various materials like carbon steel and ductile iron, ensuring performance under the most demanding conditions.

We are your reliable supply chain partner for heavy industrial castings.

Please learn more about us on our website: www.railwaypart.com