Amasu okukhiqiza i-alloy yensimbi yezakhiwo zokwakha
Ezweni lesimanje lokwakha, isidingo sezinto eziqinile, ezihlala isikhathi eside, nezisebenza kahle siyaqhubeka nokukhula. Esinye sezimpendulo eziyinhloko zalesi sidingo yi-alloy—izinsimbi ezenziwe ngokuxuba izakhi ezimbili noma ngaphezulu, ngokuvamile ukuze kufezwe izakhiwo ezingcono zemishini kanye nokumelana nemvelo kunezinsimbi ezihlanzekile. Ezakhiweni zokwakha, i-alloy isetshenziswa ozimele bensimbi, amajoyinti, amapuleti, amakholomu, imishayo, izintambo, ngisho nezinamathiselo. Lesi sihloko sixoxa ngamasu okukhiqiza i-alloy ahlobene nezicelo zesakhiwo, kusukela ekukhetheni ukwakheka kuya ezinqubweni zokwakha kanye nokuhlolwa kwekhwalithi.
1. Izimiso eziyisisekelo ze-alloys zensimbi ekwakheni
Izinsimbi ezimsulwa njengensimbi noma i-aluminium zinemikhawulo: zingaba thambile kakhulu, ziguge kalula, noma zingazinzi emazingeni okushisa athile. Ngama-alloy, abakhiqizi bangalawula izakhiwo zezinto, isibonelo:
– Amandla okunamathela kanye namandla okukhiqiza (okubalulekile ekuthwaleni umthwalo).
– Ukuqina ukuze kungaphuki kalula.
– Ukuqina kokumelana nokuguguleka.
– Ukumelana nokugqwala ezindaweni ezinomswakama, ezisogwini, noma ezimbonini.
– Amakhono okushisela nokukhiqiza ukuze kube lula ukuhlanganisa ensimini.
Ezakhiweni zokwakha, ama-alloy avame kakhulu yile:
– Insimbi yekhabhoni kanye nensimbi ephansi ye-alloy yemishayo namakholomu.
– Insimbi engagqwali yezindawo ezigqwalisayo noma imiklamo yezakhiwo.
– Ama-alloy e-aluminium ezakhiwo zangaphambili, ozimele abakhanyayo, kanye nezinto ezithile ezingezona izakhiwo.
2. Ukwakheka kwe-alloy
Amasu okukhiqiza i-alloy aqala ngokuklama ukwakheka. Onjiniyela be-Metallurgical banquma ukuthi yiziphi izakhi okufanele bangeze ngokusekelwe ekusebenzeni kanye nezinhloso zezindleko. Izibonelo zezindima zezakhi:
– Ikhabhoni (C) ensimbini yandisa amandla nokuqina, kodwa ukweqisa kunganciphisa ukushibilika.
– I-Manganese (Mn) isiza ukukhulisa amandla futhi ibopha isibabule ngaleyo ndlela inciphise ubuthakathaka.
– I-Chromium (Cr) yandisa ukumelana nokugqwala kanye nokushiswa kwe-oxidation.
– I-Nickel (Ni) yandisa ukuqina, ikakhulukazi emazingeni okushisa aphansi.
– I-Molybdenum (Mo) yandisa ukumelana nokukhukhuleka kanye nokugqwala okuthile.
– I-Silicon (Si) isiza inqubo yokususa i-oxidation futhi ingandisa amandla.
Kuma-alloy e-aluminium, izinto ezifana ne-Mg, Si, Zn, Cu zikhethwa ukwandisa amandla noma ukumelana nokugqwala, kuyilapho kusacatshangelwa ukulula kokukhipha kanye nokushisela.
3. Amasu okuncibilikisa nokucwenga
Ukukhiqizwa kwe-alloy yesikali sezimboni ngokuvamile kwenziwa ngenqubo yokuncibilikisa esithandweni, kulandelwe ukuhlanzwa ukuze kususwe ukungcola.
a) Isithando Somlilo kanye Nesithando Somoya-mpilo Esiyisisekelo (BOF)
Ngensimbi yokwakha ngobuningi, indlela yakudala ihilela:
1. I-Blast Furnace (i-blast furnace) ikhiqiza insimbi encibilikisiwe (insimbi eshisayo) kusuka ku-iron ore.
2. I-BOF (i-basic oxygen furnace) iguqula insimbi encibilikisiwe ibe yinsimbi ngokufutha i-oxygen ukuze kuncishiswe okuqukethwe yikhabhoni futhi kususwe ukungcola.
Lo mzila ufanelekela ukukhiqizwa okukhulu njengephrofayili yensimbi yesakhiwo.
b) Isithando Somlilo Se-Arc Sikagesi (i-EAF)
Ama-EAF asetshenziswa kabanzi ekuvuseleleni kabusha izinsalela kanye nokukhiqiza amazinga ahlukahlukene ensimbi. Izinzuzo zawo zifaka:
- Ukuguquguquka okwengeziwe kokulawula ukwakheka.
– Ifanele ukukhiqizwa kwezinsimbi ezithile ze-alloy.
- Kulula ukuzivumelanisa nekhwalithi nezidingo zephrojekthi.
c) Ukucwengisisa okwesibili (i-metallurgy yesibili)
Ukuze insimbi ihlangabezane nezindinganiso zesakhiwo, kwenziwa ukucutshungulwa okwengeziwe okufana nalokhu:
– Ukususa i-oxidation (ukunciphisa i-oxygen encibilikisiwe) ukuvimbela ukubhoboka.
– Ukususa i-sulfurization (ukunciphisa isibabule) ukuze kwandiswe ukuqina.
– Ukususa igesi nge-vacuum (ukususwa kwamagesi anjenge-hydrogen) ukuvimbela ukuqhekeka kwe-hydrogen kanye nokukhubazeka kwangaphakathi.
- Ukwengezwa okunembile kwezinto ezixubayo ukuqinisekisa izakhiwo zezinto ezihambisanayo.
Isigaba sesibili sokucwenga sibaluleke kakhulu ezinsimbini noma ezinsimbini ezinamandla aphezulu ezizoshintshwa ensimini.
4. Amasu okuphonsa kanye nokwakheka kokuqala
Uma ukwakheka sekufanele, insimbi encibilikisiwe yenziwa ibe yifomu eliqediwe kancane.
a) Ukuphonsa okuqhubekayo
Namuhla, ukubumba okuqhubekayo kuyindlela evelele. Insimbi encibilikisiwe ithululelwa kuma-slab, izimbali, noma ama-billets njalo, bese inqunywa ngobude. Izinzuzo zayo:
– Ukusebenza kahle kakhulu.
– Isakhiwo esincane esifanayo.
– Kunciphisa amaphutha uma kuqhathaniswa nokuphonswa kwe-ingot yendabuko.
b) Ukuphonswa kwe-Ingot (okungavamile kakhulu)
Isetshenziselwa izinhlelo ezithile ezikhethekile, kodwa ithambekele kakhulu ekuhlukaniseni izakhi zokuhlanganisa futhi idinga ukucutshungulwa okwengeziwe.
5. Ukwakheka kwe-Thermomechanical: ukugoqa, ukuhlanganisa, kanye nokukhipha
Izimo zesakhiwo ezifana ne-I-beams, i-H-beams, iziteshi ze-C, amapuleti, noma imigoqo yokuqinisa zidinga inqubo yokwakha.
a) Ukugingqika okushisayo
I-slab noma i-bloom iyashiswa bese igoqwa ibe:
– Amapuleti okuxhumanisa namapuleti esisekelo.
– Amaphrofayili esakhiwo (H, I, U, L) emishayo namakholomu.
– Amabha nezinduku zocingo zezinto zokubopha.
Ukugoqa okushisayo kusiza futhi ekucwengisiseni isakhiwo sezinhlamvu nokuthuthukisa izakhiwo zemishini.
b) Ukugoqa okulawulwayo / i-TMCP (Ukucubungula Okulawulwayo Kwe-Thermo-Mechanical)
Lena inqubo ebalulekile yezinsimbi ezinamandla aphezulu, ezingena-alloy ephansi. Ngokulawula izinga lokushisa kanye nokunciphisa ngesikhathi sokugoqa, abakhiqizi bafeza okulandelayo:
– Okusanhlamvu okucolekile (ukucwengwa kokusanhlamvu).
– Amandla aphezulu ngaphandle kokwandisa kakhulu okuqukethwe yikhabhoni.
– Ukushibilika okuthuthukisiwe, okufanelekela ukwakhiwa kwamabhuloho nezakhiwo eziphakeme.
c) Ukwakha
Isetshenziselwa izingxenye ezidinga ukuqina okuphezulu, njenge-flanges ekhethekile, ama-anchor, noma izingxenye zokuxhuma ezisindayo. Ukwakha kuthuthukisa ukuqondiswa kwezinhlamvu zensimbi futhi kunciphisa ama-pores angaphakathi.
d) Ukukhipha (i-aluminium kuphela)
Amaphrofayili e-aluminium ezinhlaka zangaphambili kanye nohlaka olulula enziwa nge-extrusion: ama-billet ayashiswa bese ecindezelwa nge-diye ukuze kukhiqizwe amaphrofayili ayinkimbinkimbi, alula.
6. Ukwelashwa ngokushisa (ukwelashwa ngokushisa) ukulawula izakhiwo
Ukwelashwa ngokushisa kuhlose ukushintsha isakhiwo esincane ukuze izakhiwo zokugcina zihlangabezane nezimfuneko zomklamo.
Ensimbini yokwakha:
– Ukulungisa izinto ngendlela evamile kuthuthukisa ukufana kwesakhiwo nokuqina kwaso.
– Ukucima nokushisa (Q&T) kukhiqiza amandla aphezulu, avame ukusetshenziswa ezingxenyeni ezithile ezidinga amandla amakhulu.
– Ukunciphisa ukucindezeleka kunciphisa ukucindezeleka okusele okubangelwa ukushisela noma ukwakheka.
Kwezinye izinhlobo ze-aluminium:
– Ukwelashwa kokushisa kwesisombululo kanye nokuguga (isb. 6xxx noma 7xxx series) kwandisa amandla ngesikhathi semvula.
Ukukhetha ukwelashwa kokushisa kufanele kucabangele ukumelana nokuqhekeka, ukushibilika, kanye nokusebenza kwesikhathi eside.
7. Amasu okuthuthukisa ukumelana nokugqwala ezindaweni zokwakha
Izakhiwo zezakhiwo zivame ukuchayeka emvuleni, emswakama, ekusawotini (ogwini), noma ezingcoleni zezimboni. Ngakho-ke, ngaphezu kokukhetha ingxube efanele, kusetshenziswa amasu okuvikela:
– I-Galvanizing (i-zinc coating) ivame kakhulu ukuthi insimbi yesakhiwo ikwazi ukumelana nokugqwala.
– Insimbi eshintshayo (okungukuthi, ama-alloy athile akha i-patina evikelayo) ifanele izimo ezithile zomkhathi.
– Insimbi engagqwali yezindawo ezidinga ukumelana nokugqwala okuphezulu kanye nokunakekelwa okuphansi.
– Izinhlelo zokumboza (i-epoxy, i-polyurethane, njll.) njengesivikelo esengeziwe.
Ukumelana nokugqwala akuyona nje indaba yobuhle, kodwa futhi nokuphepha ngoba ukugqwala kunganciphisa ukusebenza kahle kwe-cross-section futhi kubangele ukwehluleka kwesakhiwo.
8. Ukulawulwa kwekhwalithi kanye nokuhlolwa kwezinto ezibonakalayo
Izinsimbi zensimbi zezakhiwo zokwakha kumele zihlangabezane nezindinganiso ezithile zobuchwepheshe (isb., ukwakheka, amandla, kanye nezindinganiso zokuqina). Izinqubo zekhwalithi ngokuvamile zifaka:
- Ukuhlolwa kokudonsa ukuze kutholakale amandla okudonsa, amandla okudonsa, kanye nobude.
– Ukuhlolwa komthelela (i-Charpy) ukuhlola ukuqina, ikakhulukazi ezinsimbini ezisebenza emazingeni okushisa aphansi.
– Ukuhlolwa kokuqina njengesibonakaliso sezakhiwo zemishini.
– Ukuhlaziywa kwamakhemikhali ukuqinisekisa ukuthi ukwakheka kwe-alloy kulungile.
– I-NDT (Ukuhlolwa Okungabhubhisi) njengokuhlolwa kwe-ultrasonic, i-radiography, ukuhlolwa kwezinhlayiya zamagnetic, noma ukuhlolwa kokufaka udayi ukuze kutholakale amaphutha angaphakathi/ongaphezulu.
– Ukuhlolwa kobukhulu nokubekezelelana ukuqinisekisa ukuthi amaphrofayili ayahlangabezana nezidingo zokwenziwa.
Ukulawulwa kwekhwalithi enhle kuqinisekisa ukuthi izinto ziphephile ukuzisebenzisa, kulula ukuzishibiliza, futhi zisebenza kahle kusukela kubhetshi kuya kubhetshi.
9. Izinselele kanye neziqondiso zentuthuko
Imboni ye-alloy yokwakha iyaqhubeka nokukhula. Izinselele ezibalulekile zifaka:
– Ukulinganisela phakathi kwamandla kanye nokushibilika (amandla aphezulu avame ukuba nengozi yokuzwela kakhulu ekuqhekekeni kweshibili uma kungaklanywanga kahle).
– Ukusebenza kahle kwezindleko ngoba ezinye izinto zokuhlanganisa ziyabiza.
– Ukusimama ngokwandisa ukuvuselelwa kabusha, ukusebenza kahle kwamandla kanye nokunciphisa ukukhishwa kwegesi.
Iziqondiso zokuthuthukiswa zifaka phakathi ukusetshenziswa kwensimbi ye-HSLA (High Strength Low Alloy) elula kodwa enamandla, ukusetshenziswa kwe-TMCP enembile kakhudlwana, kanye nokuthuthukiswa kwezinqubo ze-EAF ezisuselwe ezinhlakeni ukuze kuncishiswe ukusabalala kwekhabhoni.
Isiphetho
Ubunjiniyela bezinsimbi zensimbi zezakhiwo zokwakha buhilela uchungechunge lwezinqubo ezihlobene: kusukela ekwakhiweni kokwakheka, ukuncibilikisa nokucwenga, ukuphonswa, ukwakheka kwe-thermomechanical, ukwelashwa kokushisa, kuya ekuvikelweni kokugqwala kanye nokulawulwa kwekhwalithi. Izinsimbi zensimbi eziklanywe kahle futhi ezicutshungulwe kahle zikhiqiza izinto eziqinile, ezihlala isikhathi eside, neziphephile ezikwazi ukumelana nemithwalo nezimo zemvelo amashumi eminyaka. Ngokuthuthuka kobuchwepheshe bensimbi kanye nezidingo zokwakha eziyinkimbinkimbi ngokwengeziwe, ukuqonda ubunjiniyela bezinsimbi zensimbi kuyisisekelo esibalulekile sekhwalithi kanye nokusimama kokwakhiwa kwesikhathi esizayo.
