Yadda Ake Yin Tungsten Metal Don Kayan Yankewa
An san Tungsten a matsayin ɗaya daga cikin muhimman ƙarfe a duniyar injina da masana'antu, musamman don amfani da kayan aikin yankewa. Fa'idodinsa sun ta'allaka ne da yawan narkewar sa, tauri, juriyar lalacewa, da kwanciyar hankali a yanayin zafi mai tsanani. Duk da haka, yana da mahimmanci a fahimci cewa "kayan aikin yanke tungsten" a masana'antar kusan ba sa amfani da tungsten tsantsa, amma a maimakon haka, tungsten carbide (WC) tare da manne kamar cobalt (Co) ko nickel. Wannan haɗin yana samar da kayan carbide mai siminti (simintin carbide) wanda ya fi dacewa da yanke ƙarfe fiye da tungsten tsantsa.
Wannan labarin ya tattauna yadda ake ƙera kayan da aka yi da tungsten don kayan aikin yanka, daga tushen ma'adinai zuwa abubuwan da aka gama sakawa ko guntun yankewa.
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1. Tushen Tungsten: Daga Ma'adinai zuwa Mai da Hankali
Ana samun Tungsten a yanayi a cikin ma'adanai na wolframite ((Fe,Mn)WO_4) da scheelite ((CaWO_4). Matakin farko na samarwa shine haƙa da sarrafa ma'adinan don samun sinadarin tungsten mai ƙarfi.
Tsarin ya haɗa da:
– Murkushewa da niƙa ma'adinai don samun ƙananan girman ƙwayoyin cuta.
– Raba nauyi (saboda ma'adanai na tungsten suna da nauyi).
– Rabuwar ruwa ko kuma rabuwar maganadisu (ya danganta da nau'in ma'adinai).
– Busar da sinadarin da aka tattara a matsayin kayan da ake buƙata don matakin sinadarai.
Sakamakon wannan matakin ba ƙarfen tungsten ba ne, sai dai sinadarin tungsten da aka haɗa wanda aka shirya don sarrafa shi ta hanyar sinadarai.
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2. Cire Sinadarai: Yin APT (Ammonium Paratungstate)
Masana'antar tungsten ta zamani tana amfani da hanyoyin aiwatarwa waɗanda ke samar da APT (ammonium paratungstate) a matsayin babban matsakaici. Ana ɗaukar APT a matsayin "ma'auni" saboda yawan tsarkinsa da sauƙin sarrafawa a cikin samfuran tungsten daban-daban.
Bayani:
1. Zubar da sinadarin ta hanyar amfani da maganin alkaline (misali NaOH) ko acid, ya danganta da nau'in ma'adinan.
2. Tungsten yana narkewa don samar da mahaɗan tungstate a cikin ruwan magani.
3. Tsarkakewar maganin don cire ƙazanta kamar molybdenum, phosphorus, arsenic, da silica.
4. Kirkirar APT ta hanyar daidaita pH, zafin jiki, da kuma ƙara ammonia don samar da lu'ulu'u na APT.
Ana saka wannan APT a cikin tungsten oxide.
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3. Calcination: Canza APT zuwa Tungsten Oxide (WO₃)
Ana dumama APT a wani zafin jiki don cire ruwa da abubuwan ammonium, yana samar da tungsten trioxide (WO₃). Wannan matakin yana da mahimmanci saboda WO₃ shine babban kayan da ake amfani da shi wajen yin:
– foda ƙarfe na tungsten (foda mai tsarki na tungsten), ko
– foda mai kama da tungsten carbide (foda ta WC) don kayan aikin yankewa.
Kula da zafin jiki da lokacin calcination yana shafar:
- girman barbashi na oxide,
- yankin saman,
- amsawa yayin aikin ragewa.
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4. Ragewa: Daga WO₃ zuwa Foda Tungsten (W)
Domin samun ƙarfe na tungsten, ana rage WO₃ ta amfani da iskar hydrogen a yanayin zafi mai yawa. Yawanci ana yin martanin ne a matakai, misali, ta hanyar samar da tsaka-tsakin oxides kafin a sami tsantsar W. Ana gudanar da aikin a cikin tanderu na musamman a ƙarƙashin tsauraran matakai don tabbatar da cewa:
- tsarki mai girma,
- ƙarancin iskar oxygen,
- girman ƙwayar foda kamar yadda ake buƙata.
Sakamakon shine foda na tungsten, wanda za'a iya amfani dashi don wasu aikace-aikace. Duk da haka, don kayan aikin yankewa, masana'antar galibi tana ci gaba har zuwa matakin ƙirƙirar tungsten carbide.
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5. Carburization: Yin Tungsten Carbide (WC)
Domin ya dace da kayan aikin yankewa, galibi ana canza tungsten zuwa tungsten carbide (WC). Wannan tsari ana kiransa carburization, wanda ya ƙunshi yin martani ga foda tungsten tare da tushen carbon (kamar carbon black) a yanayin zafi mai yawa a cikin yanayi mai sarrafawa.
Manyan manufofi:
- samar da yanayin kwanciyar hankali na WC,
– hana samuwar matakai marasa kyau kamar wuce gona da iri \(W_2C\),
- a kula da girman hatsin WC domin wannan yana da matuƙar tasiri ga juriyar lalacewa da kuma tauri.
Sannan a rarraba foda da aka samu daga WC (a yanka/a auna don rarraba girman) don tabbatar da daidaiton inganci.
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6. Haɗawa da Binder: Yin "Simintin Carbide"
Wuraren wanka kaɗai yana da tauri amma yana da rauni. Don kayan aikin yankewa, ana haɗa WC da abin ɗaurewa (yawanci kashi 6-12% na cobalt ga aikace-aikacen injina da yawa) don ƙirƙirar abu tare da haɗin:
- babban tauri (daga WC),
- tauri da juriyar tsagewa (na mahaɗin).
Matakai masu gauraya:
1. Aunawa: auna abun da ke cikin WC da manne bisa ga ma'auni.
2. Niƙa ƙwallon ƙwallo/niƙa mai hana ruwa: haɗa shi sosai da ruwa da mai (sau da yawa ana amfani da sinadarai masu narkewa na halitta) don daidaita shi.
3. Ƙara kakin zuma/manne na wucin gadi don taimakawa wajen samar da shi (danna shi).
4. Busarwa har sai ya zama foda da aka shirya don bugawa (granules).
A wannan matakin, kula da gurɓatawa yana da matuƙar muhimmanci. Ko da ƙaramin datti zai iya lalata aikin kayan aiki sosai.
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7. Ƙirƙira (Ƙirƙira): Matsawa cikin Siffar Shigarwa
Sai a samar da gaurayen foda ya zama "kore mai laushi" (irin da ba a saba gani ba kafin a yi nika). Hanyoyi guda biyu da aka saba amfani da su:
- Matsi na Uniaxial: an matse shi a cikin wani tsari zuwa ga siffofi na yau da kullun.
- Matsi mai sanyi (CIP): har ma da matsin lamba daga kowane bangare, ya dace da ƙarin daidaiton yawa.
Koren ƙaramin har yanzu yana da rauni, amma ya riga ya yi kama da siffar ƙarshe ta kayan aikin yankewa.
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8. Sintering: Matsewa da Tsarin Ƙananan Sifofi
Matakin da ya fi muhimmanci shi ne a yi siminti a yanayin zafi mai yawa (yawanci sama da 1300°C, ya danganta da abun da ke ciki). A cikin simintin carbide, simintin sau da yawa yana faruwa ne yayin da ake yin simintin ruwa: mai ɗaurewa (misali, Co) yana narkewa kuma yana taimakawa wajen ƙarfafa tsarin, yana cike ramuka, kuma yana "manne" ƙwayoyin WC tare.
Kyakkyawan sakamakon sintering ana siffanta shi da:
- babban yawa (ƙananan porosity),
- har ma da rarraba manne,
- Girman hatsin WC bisa ga darajar (mai kyau, matsakaici, mai kauri),
- daidaiton tauri da tauri.
Ana yin HIPS (Hot Isostatic Pressing) sau da yawa bayan an yi wa ƙwanƙwasa don rufe ƙananan ramuka da kuma ƙara juriyar tsagewa.
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9. Kammalawa: Niƙa, EDM, da Sarrafa Girma
Bayan an yi siminti, carbide mai siminti yana da tauri sosai har ana yin siffa ta ƙarshe ta hanyar:
- niƙa ta amfani da dabaran lu'u-lu'u,
- EDM don takamaiman geometrics (musamman idan akwai fasaloli masu wahala),
- yin chamfering da kuma shirya gefen don kada gefen yankewa ya yi rauni cikin sauƙi.
Wannan matakin yana ƙayyade halayen siffofi na kayan aikin: kusurwar sharewa, radius na tip, da kuma rashin ƙarfi a saman.
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10. Shafawa (Zaɓi ne amma gama gari): Yana Inganta Aikin Yankan
Ana shafa kayan aikin yanke carbide da yawa don ingantawa:
- juriya ga lalacewa,
- juriya ga iskar oxygen,
- aiki a manyan saurin yankewa.
Fasahohin rufewa na yau da kullun:
– CVD (misali TiC, TiCN, Al₂O₃)
– PVD (misali TiAlN, AlTiN)
Zaɓin shafi ya dogara da kayan aikin (ƙarfe, bakin ƙarfe, ƙarfe mai siminti, superalloy), yanayin yankewa, da dabarun sanyaya.
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11. Kula da Inganci: Gwaje-gwajen Tauri, Yawa, da Tsarin
Kafin a sake shi kasuwa, ana gwada kayan sakawa/kayan aiki ta hanyar:
- tashin hankali (Vickers),
- yawan porosity da yawa;
- gwajin TRS (ƙarfin fashewa mai juyewa),
- gwajin ƙananan ƙwayoyin halitta (girman hatsi, rarrabawar mahaɗin),
- duba girma da lahani na saman.
Ingancin kayan aikin tungsten carbide galibi yana da alaƙa da daidaiton tsarin daga foda zuwa sintering.
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Kammalawa
Samar da kayan tungsten don kayan aikin yankewa ba wai kawai narke tungsten zuwa siffar chisel ba ne, a'a, jerin tsare-tsare ne masu tsawo: daga tarin ma'adinai, tsaftacewa zuwa APT, yin WO₃, ragewa zuwa foda tungsten, carburization zuwa WC, haɗawa da binder, matsi, sintering, kammalawa, da kuma shafawa. Sakamakon ƙarshe da aka fi amfani da shi a masana'antar shine tungsten carbide mai tushen WC-Co saboda yana ba da haɗin kai mai kyau na tauri da tauri don yankewa.
Idan kuna so, zan iya ƙirƙirar sigar fasaha ta wannan labarin tare da jadawalin tsarin aiki, sigogin zafin jiki na gabaɗaya ga kowane mataki, da misalan abubuwan da aka haɗa na matakin carbide don juyawa, niƙa, da haƙa.
