Lokacin da mafi yawan mutane suka ji 'high zafin jiki gami', nan da nan sukan yi tunanin injunan jet ko watakila turbin na ƙasa. Wannan ba laifi ba ne, amma kallon matakin sama ne wanda ya rasa ainihin ƙalubalen aiki da waɗannan kayan. Takaddun takaddun takaddun suna lissafin lambobi masu ban sha'awa - juriya mai raɗaɗi, iyakokin iskar oxygen, ƙarfin ƙarfi a 1000 ° C - amma ba sa gaya muku game da warping a lokacin mashin ɗin, tsarin hatsi mara daidaituwa daga ɗayan zafi mai yawa zuwa na gaba, ko wahalar samun tsabtataccen simintin simintin gyare-gyare mara lahani daga superalloy na tushen nickel. Wannan ita ce tazarar da ke tsakanin ka'idar da filin shago.
Rikicin Casting: Inda Ka'idar ta Haɗu da Ƙarƙashin Ƙarƙashin Ƙira
Bari muyi magana game da simintin gyare-gyare, musamman simintin saka hannun jari wanda shine gurasarmu da man shanu a QSY. Tare da high zafin jiki gami, musamman masu tushen nickel kamar Inconel 718 ko Hastelloy X, tsarin gaba ɗaya tafiya ne mai tsauri. Matsakaicin zafin narke yana da mahimmanci, amma haka ma yawan sanyaya a cikin ƙirar harsashi. Da sauri, kuma kuna haifar da damuwa da hawaye masu zafi; ya yi jinkiri sosai, kuma kuna samun haɓakar hatsi mai yawa wanda ke kashe kayan aikin injiniya daga baya. Mun sami sassan da suka fito suna kama da kamala, kawai mun gaza yin duban X-ray tare da ƙaƙƙarfan ƙanƙantar ƙasa. Takardar bayanan ta ce kyakkyawan simintin gyare-gyare, amma ba ta taɓa fayyace ma'anar kyakkyawar ma'ana ga hadadden injin turbine tare da bushing mai sauƙi ba.
Na tuna wani aiki a 'yan shekarun baya ga abokin ciniki a cikin sashin sarrafa zafi. Suna buƙatar bututu masu haskakawa na al'ada da aka yi daga aikin da aka yi high zafin jiki gami, amma lokacin jagora don hannun jarin mashaya ya haramta. Mun ba da shawarar jefa su ta hanyar tsarin ƙirar mu na harsashi ta amfani da nau'in simintin simintin nau'in nau'in. Chemistry ya kusa, amma ba iri ɗaya ba. Batches na farko sun fashe yayin maganin zafi na maganin. Batun? Abubuwan da aka gano-wani abu kamar ɗan bambanci a cikin boron ko abun ciki na zirconium tsakanin ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun kayan aikin mu da mai sarrafa simintin mu—wanda ya shafi ƙarfin iyakar hatsi a matsanancin zafin jiki. Ba a cikin ainihin ƙayyadaddun bayanai ba; ya kasance a cikin rubutun ƙasa. Dole ne mu koma baya, mu tweak ɗin zafin jiki kuma mu gyara ƙimar hawan zafin zafi na musamman don narkewar mu. Ya yi aiki, amma ya ƙara makonni na gwaji da kuskure. Gaskiyar kenan.
Wannan shi ne inda gwanintar kafuwar ke da ƙima. A Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), tare da fiye da shekaru talatin a cikin harsashi da simintin saka hannun jari, mun gina ɗakin karatu na waɗannan dalla-dalla, sigogin da ba a rubuta ba don nau'ikan geometries da gami. Ba kawai game da samun tanderu ba; yana da game da sanin cewa ga wani musamman cobalt tushen gami, kana bukatar ka daidaita mold pre-zafi zafin jiki daban-daban fiye da na nickel tushen daya cimma wani uniform cika a cikin bakin ciki sassan. Wannan ilimin ba a sauke shi ba; yana tarawa ta hanyar maimaitawa, kuma a, ta hanyar gazawar lokaci-lokaci.
Machining: Gaskiya mai Tauri Game da Yanke Kayayyaki masu wuya
Idan simintin raye-raye ne mai laushi, yin inji high zafin jiki gami yaƙin sarrafawa ne. Kaddarorin da ke sa waɗannan allunan suna da girma - tsananin zafi mai zafi da aiki mai ƙarfi - suna sa su zama mafarki mai ban tsoro don yanke kayan aikin. Mutane sukan raina wannan. Suna tunanin, Muna da CNC na zamani, kawai za mu rage shi. Ya fi nuanced.
Babban kuskuren shine kula da shi kamar machining bakin karfe. Tare da wani abu kamar Inconel 625, idan kayan aikinku ba su da kaifi, idan saurin ku da ciyarwarku sun ɗan kashe, ko kuma idan mai sanyaya ba ya buga daidai daidai, ba za ku sami guntu mai kyau ba. Kuna samun gefen da aka gina akan kayan aiki, wanda sannan yayi aiki-taurara saman sashin da kuke yankewa. Yanzu kuna ƙoƙarin yanke ta cikin fata mai ƙarfi, wanda ke haifar da ƙarin zafi, wanda ke ƙara lalata kayan aiki. Mugunyar zagayowar ce da ke kaiwa ga ɓangarori da aka lalatar da abubuwan saka carbide masu tsada. Mun koyi wannan hanya mai wuya tun da wuri, muna ƙonawa ta hanyar kasafin kayan aiki kafin mu buga a cikin sigogi.
A gare mu a QSY, haɗa mashin ɗin CNC tare da ayyukan simintin mu shine fa'idar dabara. Mu sau da yawa muna yin gyare-gyaren mashin ɗin farko akan abubuwan simintin mu. Wannan yana nufin dole ne mu yi la'akari da fata na simintin, yuwuwar ɗan murdiya, da damuwa da ke tattare da tsarin simintin. Mun ƙirƙira ka'idoji na cikin gida don daidaitawa da aiwatar da ayyuka don rage girman sake dawo da damuwa. Misali, za mu iya yin maganin zafi na kawar da damuwa bayan munanan injina amma kafin mu gama haƙuri mai mahimmanci. Yana ƙara mataki, amma yana hana ɓangaren motsi daga baya a cikin sabis - darasi da aka koya daga rukunin bawul ɗin da ya fita daga ƙayyadaddun bayanai bayan bayarwa na ƙarshe.
Musamman a cikin Alloys na Musamman: Samfuran Kayan Abu & Abun Ganewa
Wani Layer sau da yawa ba a kula da shi shine albarkatun kasa da kansa. Ba duk Inconel 718 aka ƙirƙira daidai ba. Ayyukan da aka yi a kan tsabtataccen kayan budurwa da kuma daidaitattun abubuwan da aka haɗa da kayan haɗin gwal. Mun canza masu samar da kayan a baya saboda rashin daidaituwar iskar oxygen ko abun ciki na nitrogen tsakanin narkewa, wanda ya bayyana azaman rayuwar gajiyawa a sassan simintin ƙarshe. Lokacin da kuke mu'amala da high zafin jiki gami don aikace-aikace masu mahimmanci, takardar shaidar bincike (CoA) ita ce Littafi Mai-Tsarki. A QSY, muna duba wannan a hankali kuma sau da yawa muna yin gwajin walƙiya na kanmu ko bincike kan kayan da ke shigowa, musamman na tushen cobalt ko na tushen nickel. Ba za ku iya sarrafa abin da ba ku auna ba.
Wannan mayar da hankali kan mutuncin abin duniya ya kai ga dukkan tsarin mu. Don yin simintin saka hannun jari, muna amfani da takamaiman tsarin harsashi na yumbu masu jituwa tare da alluna masu amsawa don guje wa gurɓacewar ƙasa. Rashin ƙazanta daga harsashi na iya haifar da rauni mai rauni wanda ya zama wurin farawa da fashewa a ƙarƙashin keken zafi. Yana da daki-daki wanda ba ya nunawa akan ma'aunin da aka gama, amma komai ne don rayuwar sabis ɗin sa a cikin yanayi mai zafi.
Binciken Kasawa: Babban Malami
Wasu daga cikin mafi kyawun iliminmu sun fito ne daga sassan da ba su yi ba. A farkon aikinmu tare da babban gabobin nickel na chromium don ɓangaren tanderun pyrolysis, mun sami gazawar filin. Bangaren ya fashe tare da ga alama bazuwar layi. Binciken ƙarfe na ƙarfe ya yi nuni ga ɓarnar lokaci na sigma. Alloy ɗin ya kasance mai saurin kamuwa da shi idan an riƙe shi a cikin takamaiman yanayin zafin jiki na dogon lokaci. Zagayowar maganin zafin mu, wanda ya kasance daidaitaccen kayan haɗin gwal, ya tura shi cikin wannan taga ba da gangan ba. Gyaran ba game da canza simintin ba; ya kasance game da sake fasalin maganin zafi bayan jefawa don kashe ta cikin wannan yanki mai tsananin zafi cikin sauri. Yanzu, ga kowane sabo high zafin jiki gami aikin, ba kawai mu kalli daidaitaccen magani ba; mun tono cikin zane-zane na zamani da kuma yuwuwar hanyoyin ƙwanƙwasa. Al'adar kariya ce da aka haifa daga darasi mai raɗaɗi.
Wannan tunanin yana tsara yadda muke kusanci sabbin ayyuka tare da abokan ciniki. Lokacin da abokin ciniki daga sashin samar da wutar lantarki ya zo mana tare da buƙatun ɓangarorin ƙera zafi na musamman ta amfani da gami na musamman, tambayoyinmu na farko ba kawai game da girma ba ne. Suna game da yanayin aiki (oxidizing? carburizing?), bayanin yanayin yanayin zafi, da yanayin damuwa da ake tsammanin. Wannan yana sanar da komai daga zaɓin gami (wataƙila ƙimar haɓakar silicon don ingantaccen juriya na iskar shaka?) Zuwa ƙirar masu ciyarwa da masu tashi a cikin ƙirar don tabbatar da sauti a cikin mafi mahimmancin wurare.
Haɗin kai: Daga Foundry zuwa Ƙarshe Sashe
Haƙiƙanin ƙimar yawancin abokan cinikinmu a QSY ya ta'allaka ne a cikin haɗin kai tsaye - sarrafa tafiya daga narkakken ƙarfe zuwa na'ura mai na'ura, wanda aka shirya don shigarwa. Domin high zafin jiki gami, wannan ci gaba yana da mahimmanci. Mashin ɗin yana buƙatar fahimtar yuwuwar tsarin simintin na ciki; injiniyan kafuwar yana buƙatar sanin inda mahimman kayan aikin injin za su kasance don tabbatar da ƙarin yawa a wurin.
Kwanan nan mun kammala aikin turbine shrouds don haɓaka injin turbocharger na masana'antu. Kayan ya kasance ƙalubale na tushen nickel superalloy. Ta hanyar sarrafa duka simintin gyare-gyare da madaidaicin mashin ɗin CNC a cikin gida, za mu iya daidaitawa. Mun jefa sassan tare da ƙarin haja akan fuskokin mating, sannan mu yi maganin matsi mai zafi mai zafi (HIP) don rufe duk wani micro-porosity. Sai bayan HIP mun yi aikin injin ƙarshe. Wannan jeri, da aka yanke shawara ta haɗin gwiwa tsakanin ƙungiyoyin simintin gyaran kafa da na injina, sun tabbatar da cewa mun cire duk wata karkatacciyar hanya daga HIP yayin da muke samun mafi kyawun ƙimar kayan. Sakamakon ya kasance wani sashi tare da daidaiton aiki mafi kyau fiye da idan an raba hanyoyin tsakanin masu siyarwa daban.
Karshen wasan kenan. Yin aiki tare da gawawwakin zafin jiki ba kawai game da zaɓin abu ne daga kasida ba. Yana nufin fahimtar halayensa ta kowane mataki na canji-daga ruwa zuwa m, daga simintin simintin gyare-gyare zuwa daidaitaccen sashi. Lambobin da ke kan takaddun ƙayyadaddun bayanai sune farkon tattaunawa, ba ƙarshe ba. Sauran ana koyan su a cikin tushe, a cikin kulawar CNC, kuma wani lokacin, a cikin hasken tunani na rahoton bincike na gazawa. Filaye ne mai buƙata, amma wannan shine abin da ke samar da kayan aiki cikin nasara, bayan shekaru a cikin yanayin zafi mai zafi, mai gamsarwa. Yana nufin kun sami duk cikakkun bayanai marasa ganuwa daidai.
