Momwe Mungapangire Zitsulo za Alloy za Zigawo za Makina
Ma alloy ndi zinthu zomwe zimagwiritsidwa ntchito kwambiri popanga zida zamakina chifukwa zimaphatikiza zinthu zabwino kwambiri zomwe sizipezeka mu zitsulo zoyera. Mwa kusakaniza zinthu ziwiri kapena zingapo—monga chitsulo ndi kaboni, chromium, nickel, molybdenum, kapena vanadium—titha kupeza mphamvu yowonjezera yogwira ntchito, kukana kuwonongeka, kukana dzimbiri, kulimba, komanso kukhazikika kutentha kwambiri. Mu makampani opanga makina, ubwino wa alloy umatsimikiza kwambiri nthawi yogwirira ntchito ya zida monga shafts, gears, bearing, springs, nati ndi bolts, engine blocks, ndi zigawo zosiyanasiyana zomwe zimagwira ntchito pansi pa katundu wovuta. Chifukwa chake, njira yopangira ma alloy iyenera kuchitidwa motsogozedwa kwambiri, kuyambira kusankha zinthu mpaka kuyesa komaliza.
1. Dziwani zofunikira pa gawo la makina
Gawo loyamba musanapange alloy ndikumvetsetsa ntchito ya gawo la makina lomwe likuyenera kupangidwa. Gawo lililonse lili ndi zofunikira zosiyanasiyana pa katundu wa chinthu. Magiya amafunika kuuma kwambiri pamwamba ndi pakati pa ductile kuti athe kupirira kugwedezeka. Ma shaft amafunika kulimba kwambiri komanso kukana kutopa. Zigawo zomwe zili m'malo owononga, monga mapampu a mankhwala kapena injini za m'madzi, zimafuna kukana bwino dzimbiri. Kutengera ndi zofunikira izi, mainjiniya azinthu amazindikira zomwe akufuna: mphamvu yolimba (UTS), mphamvu yotulutsa, kuuma, kulimba, kuuma, kukana kukalamba, komanso kukana dzimbiri kapena kutentha kwambiri.
Zinthu zomwe mukufuna kuzipeza zikadziwika, mtundu woyenera wa aloyi umasankhidwa, monga chitsulo cha kaboni, chitsulo chopanda aloyi wambiri, chitsulo chosapanga dzimbiri, aloyi wachitsulo chopangidwa ndi chitsulo, aloyi wa aluminiyamu, kapena aloyi wa mkuwa. Kusankha kumeneku kumaganiziranso ndalama zopangira, kupezeka kwa zinthu zopangira, kuthekera kokonza, ndi miyezo yoyenera yamakampani.
2. Kusankha kapangidwe ka aloyi
Kapangidwe ka aloyi ndiye "njira" yayikulu yomwe imatsimikiza kapangidwe kake kakang'ono komanso ka makina. Chitsanzo chodziwika kwambiri ndi chitsulo, aloyi wa chitsulo (Fe) ndi kaboni (C). Mpweya umawonjezera kuuma ndi mphamvu, koma kuchuluka kwambiri kumatha kuchepetsa kulimba. Kuwonjezera chromium (Cr) kumatha kusintha dzimbiri ndi kuuma, pomwe nickel (Ni) kumathandizira kulimba ndi kukana kusweka. Molybdenum (Mo) imawonjezera kukana kutentha kwambiri ndikuwonjezera mphamvu, pomwe vanadium (V) imawongolera kukula kwa tirigu ndikuwonjezera kukana kukalamba.
Mu mafakitale, zinthu zopangidwa ndi alloy nthawi zambiri zimatsatira miyezo monga ASTM, JIS, DIN, kapena SNI kuti zitsimikizire kuti zinthuzo ndi zabwino nthawi zonse. Mwachitsanzo, magiya nthawi zambiri amagwiritsa ntchito zitsulo zopangidwa ndi alloy monga SCM (Cr-Mo), zomwe ndizoyenera kutenthedwa. Pamalo owonongeka, zitsulo zosapanga dzimbiri monga mtundu wa 304 kapena 316 (zomwe zili ndi Cr ndi Ni, ndipo mu 316, Mo zimawonjezeredwa).
3. Konzani zipangizo zopangira ndi kuwongolera khalidwe koyamba
Zipangizo zopangira aloyi zingakhale ndi zitsulo zoyera, ma ferroalloy (monga ferrochrome, ferromanganese), ndi zidutswa zosankhidwa. Zidutswa zimagwiritsidwa ntchito kwambiri chifukwa cha mtengo wake wotsika, koma ziyenera kulamulidwa mosamala chifukwa zimatha kukhala ndi zinthu zosafunika monga sulfure (S), phosphorous (P), kapena zinthu zina zosafunikira. Kuchuluka kwa sulfure ndi phosphorous m'zinthuzo kungayambitse kuti zinthuzo zikhale zofooka, kutentha kwambiri, komanso kuchepetsa kutopa.
Asanayambe kusungunuka, amafufuza zinthu zopangira: kusankha malinga ndi mtundu, kuchotsa mafuta/dzimbiri lochulukirapo, ndi kuyesa kapangidwe kake pogwiritsa ntchito njira monga Optical Emission Spectroscopy (OES). Kuwongolera kumeneku ndikofunikira kuti adziwe molondola kapangidwe komaliza ka alloy.
4. Njira yosungunula ndi kupanga aloyi
Gawo lalikulu popanga zitsulo zosungunula ndi kusakaniza zinthu mu uvuni. Mitundu yodziwika bwino ya uvuni ndi iyi:
1. Ng'anjo Yopangira Zinthu: Yoyenera kugwiritsa ntchito zitsulo zokhala ndi mphamvu yowongolera kapangidwe kake komanso ukhondo wabwino wa zitsulo. Imagwiritsidwa ntchito kwambiri pa zitsulo zachitsulo ndi zitsulo zopanda chitsulo.
2. Furnace ya Electric Arc (EAF): Yodziwika bwino m'mafakitale akuluakulu achitsulo, yomwe imatha kusungunula zinyalala zambiri.
3. Chotenthetsera ndi chosinthira (BOF): Kawirikawiri chimagwiritsidwa ntchito popanga chitsulo ndi chitsulo pamlingo waukulu, makamaka kuchokera ku miyala.
Pakusungunuka, zinthuzo zimayikidwa pang'onopang'ono. Chitsulo chosungunuka chikafika, zinthu zosakaniza zimawonjezedwa malinga ndi kuwerengera. Zowonjezera ziyenera kusamalidwa: zinthu zina zimakhala zosinthasintha kapena zimayanjana ndi mpweya, kotero dongosolo ndi nthawi yowonjezerera zimakhudza kwambiri zotsatira zake. Mwachitsanzo, Manganese (Mn) nthawi zambiri amawonjezedwa kuti athandize "kumanga" sulfure, pomwe aluminiyamu (Al) nthawi zambiri imagwiritsidwa ntchito pochotsa okosijeni (kuchepetsa mpweya wosungunuka) kuti apewe kupanga ma porosity ndi zinthu zovulaza.
5. Kuyeretsa zitsulo zamadzimadzi: kuchotsa oxidation, kuchotsa sulfurization, ndi kuchotsa gasi
Kuti zipangizo za injini zikhale zolimba komanso zodalirika, chitsulo chosungunukacho chiyenera kukhala "choyera." Zodetsa monga mpweya, haidrojeni, nayitrogeni, sulfure, ndi zinthu zina zomwe sizili zachitsulo zingayambitse ming'alu ndikuchepetsa kutopa.
Njira zina zoyeretsera ndi izi:
– Kuchotsa okosijeni: Kuwonjezera Al, Si, kapena Mn kuti igwirizane ndi okosijeni.
– Kuchotsa sulfure: Kuchepetsa sulfure powonjezera laimu (CaO) ndikupanga slag yomwe imatha kukoka sulfure.
– Kuchotsa mpweya mu vacuum: Kuchotsa mpweya wosungunuka (makamaka haidrojeni ndi nayitrogeni) pogwiritsa ntchito vacuum, yofunika kwambiri pa chitsulo chapamwamba kwambiri pazinthu zofunika kwambiri monga ma turbine shafts kapena magiya amphamvu kwambiri.
– Kuyeretsa zinyalala: Zinyalala zimathandiza kwambiri pogwira zinyalala. Kulamulira kapangidwe ka zinyalala (laimu, fluorspar, alumina) kumatsimikizira momwe kuyeretsako kumagwirira ntchito.
6. Kuthira ndi kupanga koyamba (kuponya)
Kapangidwe ka chitsulo chosungunuka ndi kuyera kwake zikafika pa zolinga zake, gawo lotsatira ndi kuumba. Pali njira ziwiri zazikulu:
1. Kuthira Ingot: Chitsulo chosungunuka chimathiridwa mu nkhungu yayikulu, kenako ingot imakonzedwanso kudzera mu forging kapena roll. Njirayi ndi yofala kwambiri pazinthu zomwe zimafuna kapangidwe kolimba komanso mphamvu zambiri zamakanika.
2. Kupopera kosalekeza: Chitsulo chosungunuka chimathiridwa mosalekeza m'magawo ang'onoang'ono, maluwa, kapena matabwa. Njira iyi ndi yothandiza kwambiri popanga zinthu zambiri komanso yabwino nthawi zonse.
Kulamulira kutentha n'kofunika kwambiri pothira. Kutentha kwambiri kumatha kuwonjezera okosijeni; kutentha kochepa kwambiri kungayambitse zolakwika (chitsulo sichidzaza nkhungu kwathunthu). Kuphatikiza apo, kapangidwe ka njira yothira ndi chokwezera chimakhudza kufooka kwa ming'alu ndi kugawikana kwa zinthu.
7. Njira zopangira: kupanga, kupukutira, ndi makina oyamba
Zipangizo zambiri za makina zimapangidwa pogwiritsa ntchito njira zopangira pulasitiki kuti ziwongolere kapangidwe ka chinthucho. Mwachitsanzo, kupanga kungawonjezere mphamvu ndi kulimba mwa kuyeretsa tirigu ndikuwongolera kayendedwe ka tirigu kuti katsatire mawonekedwe a chinthucho. Kuzungulira nthawi zambiri kumagwiritsidwa ntchito popanga ndodo, mbale, kapena ma profiles.
Pambuyo popangidwa, zigawozo nthawi zambiri zimachimbidwa koyamba (makina okhwima) kuti zipeze mawonekedwe ofanana ndi kukula komaliza, zomwe zimasiya nthawi yoti zigwiritsidwe ntchito pokonza kutentha ndi kumaliza.
8. Kuchiza ndi kutentha kuti mupeze zinthu zomwe mukufuna
Ma alloy a zida za makina nthawi zambiri amafunika kutentha kuti apeze mawonekedwe abwino. Mankhwala ena odziwika bwino otenthetsera ndi awa:
- Kuphimba: Kumafewetsa zinthuzo, kumachepetsa kupsinjika kotsalira, komanso kumawonjezera kulimba.
– Kubwezeretsa: Kubwezeretsa kapangidwe kake ka zinthu, kukulitsa kufanana ndi mphamvu poyerekeza ndi kubwezeretsanso.
– Kuzimitsa ndi kuziziritsa: Kuzimitsa (kuzizira mwachangu) kumawonjezera kuuma, kenako kuziziritsa kumachepetsa kufooka ndi kulimbitsa mphamvu ndi kulimba.
– Kukonza ma carburizing/nitriding: Kukonza kuuma kwa pamwamba pa magiya ndi zigawo zina zokangana. Kukonza ma carburizing kumawonjezera kaboni pamwamba; kukonza ma nitriding kumawonjezera nayitrogeni kuti apange gawo lolimba komanso losawonongeka.
Kusankha magawo—kutentha, nthawi yosungira, ndi malo ozizira (madzi, mafuta, polima, gasi)—kumakhudza kwambiri kuuma komaliza, kupotoka, ndi chiopsezo cha ming'alu.
9. Kumaliza, kuyang'anira ndi kuyesa
Gawo lomaliza ndi kumaliza ndi kuwongolera khalidwe. Kumaliza kungaphatikizepo kukonza makina molondola, kupera, kupukuta, ndi kupaka utoto, ngati kuli kofunikira. Pambuyo pake, mayeso amachitidwa kuti atsimikizire kuti zinthuzo zikugwirizana ndi zofunikira:
- Kuyesa kapangidwe ka mankhwala (OES kapena XRF).
- Mayeso a kuuma (Rockwell, Brinell, Vickers).
- Mayeso a kukoka ndi kukhudza (Charpy).
- Mayeso a metallographic kuti awone kapangidwe kake kakang'ono, kukula kwa tirigu, ndi zinthu zomwe zili mkati mwake.
– NDT (Kuyesa Kosawononga) monga mayeso a ultrasound, tinthu ta maginito, cholowetsa utoto kuti chizindikire zolakwika popanda kuwononga zigawo.
- Kuyesa kutopa kwa zigawo zomwe zikukhudzidwa ndi katundu wozungulira.
Ngati pali kusiyana kulikonse, njira zowongolera zimatengedwa: kusintha kapangidwe kake, kukonza kutentha, kapena kukonza njira yothira ndi kupanga.
Mapeto
Kupanga ma alloy a zigawo za makina ndi njira zingapo zogwirizana: kuyambira kudziwa zinthu zofunika, kusankha kapangidwe kake, kusungunula ndi kuyeretsa, kuponyera, kupanga, kutentha, ndi kuyesa komaliza. Chinsinsi cha kupambana chili pakulamulira kapangidwe kake ndi ukhondo wa chitsulocho, komanso kuyang'anira bwino njira kuti zitsimikizire kuti kapangidwe kake kakukwaniritsa zofunikira za gawolo. Ndi njira yolongosoka komanso yokhazikika, ma alloy amatha kupanga zigawo za makina zomwe ndi zolimba, zolimba, komanso zotetezeka kuti zigwiritsidwe ntchito m'mafakitale osiyanasiyana.
Ngati mukufuna, nditha kusintha nkhaniyi kuti ikhale yeniyeni—monga, kuyang'ana kwambiri zitsulo za aloyi a giya, zitsulo za aluminiyamu zamagalimoto, kapena zitsulo zosapanga dzimbiri za gawo la pampu—zokhala ndi zitsanzo za kapangidwe kake ndi zithunzi za kayendedwe ka njira.
