Yadda Ake Yin Karfe Mai Alloy Don Kayan Inji
Alloys su ne kayan da aka fi amfani da su wajen kera kayan injina saboda suna haɗa kyawawan halaye waɗanda ba a samu a cikin ƙarfe masu tsabta ba. Ta hanyar haɗa abubuwa biyu ko fiye - misali, ƙarfe da carbon, chromium, nickel, molybdenum, ko vanadium - za mu iya samun ƙarin ƙarfin tauri, juriyar lalacewa, juriyar tsatsa, tauri, har ma da kwanciyar hankali a yanayin zafi mai yawa. A cikin masana'antar injina, ingancin ƙarfe yana ƙayyade tsawon rayuwar kayan aiki kamar shafts, gears, bearings, springs, goro da bolts, injin tubalan, da sassa daban-daban waɗanda ke aiki a ƙarƙashin nauyi mai ƙarfi. Saboda haka, dole ne a gudanar da tsarin yin ƙarfe a ƙarƙashin iko mai ƙarfi, daga zaɓin abu zuwa gwaji na ƙarshe.
1. Tantance buƙatun sassan injin
Mataki na farko kafin ƙirƙirar ƙarfe shine fahimtar aikin ɓangaren injin da za a ƙera. Kowane sashi yana da buƙatun kayan aiki daban-daban. Gears yana buƙatar tauri mai yawa da kuma ductile core don jure girgiza. Shafts suna buƙatar tauri mai yawa da juriya ga gajiya. Abubuwan da ke cikin muhallin lalata, kamar famfunan sinadarai ko injunan ruwa, suna buƙatar juriya mai kyau ga tsatsa. Dangane da waɗannan buƙatun, injiniyoyin kayan aiki suna ƙayyade halayen da aka nufa: ƙarfin tensile (UTS), ƙarfin samarwa, tauri, tauri mai tasiri, ductility, juriya ga lalacewa, da juriya ga tsatsa ko zafin jiki mai yawa.
Da zarar an tabbatar da halayen da ake so, ana zaɓar nau'in ƙarfe mai dacewa, kamar ƙarfen carbon, ƙarfe mai ƙarancin ƙarfe, bakin ƙarfe, ƙarfe mai siminti, ƙarfe mai aluminum, ko ƙarfe mai tagulla. Wannan zaɓin kuma yana la'akari da farashin samarwa, samuwar kayan aiki, iya sarrafawa, da ƙa'idodin masana'antu masu dacewa.
2. Zaɓar abun da ke cikin ƙarfe
Tsarin ƙarfe shine babban "girki" wanda ke ƙayyade ƙananan tsarin abu da halayen injina. Misali mafi yawan shine ƙarfe, gami da ƙarfe (Fe) da carbon (C). Carbon yana ƙara tauri da ƙarfi, amma yawan da ya wuce kima na iya rage juriya. Ƙara chromium (Cr) na iya inganta tsatsa da tauri, yayin da nickel (Ni) ke inganta tauri da juriyar karyewa. Molybdenum (Mo) yana haɓaka juriyar zafi mai yawa kuma yana ƙara ƙarfi, yayin da vanadium (V) ke tace girman hatsi kuma yana inganta juriyar sawa.
A cikin masana'antu, abubuwan da aka haɗa da ƙarfe galibi suna bin ƙa'idodi kamar ASTM, JIS, DIN, ko SNI don tabbatar da daidaiton inganci. Misali, giya galibi suna amfani da ƙarfe na ƙarfe kamar SCM (Cr-Mo), waɗanda suka dace da maganin zafi. Don muhallin da ke lalata abubuwa, ƙarfe na bakin ƙarfe kamar nau'in 304 ko 316 (wanda ke ɗauke da Cr da Ni, kuma a cikin 316, an ƙara Mo).
3. Shirya kayan aiki da kuma kula da ingancin farko
Kayan da ake amfani da su wajen haɗa ƙarfe masu tsabta, ferroalloys (misali, ferrochrome, ferromanganese), da kuma tarkacen da aka tsara. Ana amfani da tarkacen sosai don ingancinsa, amma dole ne a sarrafa su sosai domin yana iya ƙunsar ƙazanta kamar sulfur (S), phosphorus (P), ko wasu abubuwa marasa kyau. Yawan sinadarin sulfur da phosphorus na iya sa kayan ya yi rauni, ya yi fashewa da zafi, kuma ya rage juriya ga gajiya.
Kafin narkewar kayan, ana duba su: rarrabawa ta nau'in kayan, cire mai/tsatsa da ya wuce kima, da kuma gwajin abubuwan da aka haɗa ta amfani da hanyoyi kamar Optical Emission Spectroscopy (OES). Wannan iko yana da mahimmanci don tantance daidaiton abun da aka haɗa na ƙarshe.
4. Tsarin narkewa da kuma yin ƙarfe
Babban matakin yin ƙarfe mai ƙarfe shine narkewa da haɗa abubuwan da ke cikin tanderu. Nau'ikan tanderu da aka saba amfani da su sun haɗa da:
1. Tanderu Mai Sanya Wuta: Ya dace da ƙarfe masu sarrafa tsari mai kyau da kuma tsaftar ƙarfe. Ana amfani da shi sosai don ƙarfe masu haɗa ƙarfe da ƙarfe marasa ƙarfe.
2. Wutar Lantarki Mai Lantarki (EAF): An saba da ita a manyan masana'antun ƙarfe, waɗanda ke iya narkar da tarkace mai yawa.
3. Wutar Lantarki da Mai Canza Wuta (BOF): Gabaɗaya don samar da ƙarfe da ƙarfe mai yawa, musamman daga ma'adinai.
A lokacin narkewa, ana gabatar da kayan a matakai. Da zarar an kai ga ƙarfe mai narkewa, ana ƙara abubuwan da ke haɗa ƙarfe bisa ga lissafi. Dole ne a yi taka tsantsan: wasu abubuwa suna canzawa ko kuma suna amsawa da iskar oxygen, don haka tsari da lokacin ƙari suna shafar sakamakon sosai. Misali, ana ƙara Manganese (Mn) sau da yawa don taimakawa wajen "daure" sulfur, yayin da ake amfani da aluminum (Al) sau da yawa don cire iskar oxygen (rage narkewar iskar oxygen) don hana samuwar porosity da abubuwan da ke haifar da illa.
5. Tace ƙarfe mai ruwa: cire iskar shaka, rage sulfurization, da kuma rage iskar shaka
Domin sassan injin su kasance masu ƙarfi da aminci, ƙarfen da aka narke dole ne ya kasance "mai tsabta." Datti kamar iskar oxygen, hydrogen, nitrogen, sulfur, da abubuwan da ba ƙarfe ba na iya haifar da tsagewa da rage juriya ga gajiya.
Wasu hanyoyin tsarkakewa sun haɗa da:
– Shakar iskar oxygen: Ƙara Al, Si, ko Mn don haɗa iskar oxygen.
– Rage sinadarin sulfur: Rage sinadarin sulfur ta hanyar ƙara lemun tsami (CaO) da kuma samar da tarkacen da ke iya jawo sinadarin sulfur.
– Rufe iskar gas ta injin: Cire iskar gas da aka narkar (musamman hydrogen da nitrogen) ta hanyar amfani da injin, wanda yake da mahimmanci a cikin ƙarfe mai inganci don mahimman abubuwa kamar shafts na turbine ko giyar wutar lantarki mai ƙarfi.
– Gyaran slag: Slag yana taka rawa wajen kama ƙazanta. Sarrafa abubuwan da ke cikin slag (lime, fluorspar, alumina) yana ƙayyade ingancin tsaftacewa.
6. Zubawa da kuma fara samar da abu (siminti)
Da zarar narkakken ƙarfe da tsarkinsa suka cika maƙasudin da aka gindaya, mataki na gaba shine yin siminti. Akwai manyan hanyoyi guda biyu:
1. Simintin Ingot: Ana zuba ƙarfe mai narkewa a cikin babban mold, sannan a ƙara sarrafa ingot ɗin ta hanyar ƙirƙira ko birgima. Wannan hanyar ta zama ruwan dare ga abubuwan da ke buƙatar tsari mai yawa da kuma manyan halayen injiniya.
2. Ci gaba da yin siminti: Ana zuba ƙarfe mai narkewa akai-akai a cikin billets, furanni, ko faranti. Wannan hanyar tana da inganci don samar da taro da inganci mai kyau.
Kula da zafin jiki yana da matuƙar muhimmanci wajen zuba. Yawan zafin jiki na iya ƙara yawan iskar shaka; ƙarancin zafin jiki na iya haifar da gurɓataccen ruwa (ƙarfe ba ya cika mold ɗin gaba ɗaya). Bugu da ƙari, ƙirar hanyar zuba ruwa da riser yana shafar raguwar porosity da rabuwar abubuwa.
7. Tsarin ƙirƙirar: ƙirƙira, birgima, da kuma injin farko
Ana ƙera kayan injina da yawa ta hanyar amfani da tsarin filastik don inganta tsarin kayan. Misali, ƙirƙirowa na iya ƙara ƙarfi da tauri ta hanyar tace hatsi da kuma jagorantar kwararar hatsi don bin sifar kayan. Sau da yawa ana amfani da birgima don siffanta sanduna, faranti, ko siffofi.
Bayan an samar da kayan, galibi ana yin aikin farko (na'urar sarrafa abubuwa) don samun siffar da ta kusa da girman ƙarshe, wanda hakan ke barin damar yin amfani da zafi da kuma kammala aikin.
8. Maganin zafi don cimma halayen da ake so
Alloys na kayan injin kusan koyaushe suna buƙatar maganin zafi don cimma kyawawan halaye. Wasu hanyoyin magance zafi sun haɗa da:
– Zubar da ruwa: Yana laushi kayan, yana rage damuwa da ta rage, yana inganta danshi.
– Daidaita: Yana daidaita tsarin microstructure, yana inganta daidaito da ƙarfi idan aka kwatanta da annealing.
– Kashewa da kuma rage zafi: Kashewa (sanyaya cikin sauri) yana ƙara tauri, sannan rage zafi yana rage karyewa kuma yana daidaita ƙarfi da tauri.
– Carburizing/nitriding: Maganin taurare saman giya da abubuwan da ke haifar da gogayya. Carburizing yana ƙara carbon a saman; nitriding yana ƙara nitrogen don samar da Layer mai tauri, mai jure lalacewa.
Zaɓin sigogi—zafin jiki, lokacin riƙewa, da kuma yanayin sanyaya (ruwa, mai, polymer, iskar gas)—yana da babban tasiri ga tauri, karkacewa, da kuma haɗarin fashewa.
9. Kammalawa, dubawa da gwaji
Mataki na ƙarshe shine kammalawa da kuma kula da inganci. Kammalawa na iya haɗawa da injinan da suka dace, niƙa, gogewa, da kuma shafa fenti, idan ya cancanta. Bayan haka, ana yin gwaji don tabbatar da cewa kayan ya cika ƙa'idodi:
– Gwajin sinadaran da aka yi amfani da su (OES ko XRF).
– Gwajin tauri (Rockwell, Brinell, Vickers).
- Gwaje-gwajen juriya da tasiri (Charpy).
- Gwaje-gwajen ƙarfe don ganin tsarin ƙananan abubuwa, girman hatsi, da abubuwan da aka haɗa.
– NDT (Gwajin da Ba Ya Lalacewa) kamar gwajin ultrasonic, barbashi mai maganadisu, da kuma shigar da fenti don gano lahani ba tare da lalata sassan ba.
- Gwajin gajiya ga abubuwan da aka sanya wa nauyin da ke zagaye.
Idan aka sami wani bambanci, ana ɗaukar matakin gyara: daidaita abubuwan da aka haɗa, inganta maganin zafi, ko inganta tsarin zubar da ruwa da samar da shi.
Kammalawa
ƙera ƙarfe don sassan injina jerin matakai ne masu alaƙa da juna: daga tantance halayen kayan da ake buƙata, zaɓar abun da ke ciki, narkewa da tacewa, jefawa, ƙirƙirar abu, maganin zafi, da gwaji na ƙarshe. Mabuɗin nasara yana cikin sarrafa abun da ke ciki da tsabtar ƙarfe, da kuma sarrafa tsari daidai don tabbatar da cewa ƙaramin tsari da aka samu ya cika buƙatun kayan. Tare da tsari mai tsari da ƙa'idodi, ƙarfe na iya samar da kayan injin da ke da ƙarfi, ɗorewa, kuma amintacce don amfani a aikace-aikace daban-daban na masana'antu.
Idan kuna so, zan iya tsara wannan labarin don ya zama takamaiman bayani - misali, mai da hankali kan ƙarfen ƙarfe na gear, ƙarfe na aluminum na mota, ko ƙarfen famfo mai bakin ƙarfe - tare da misalan abubuwan da aka tsara da zane-zanen kwararar aiki.
