Lokacin da wani ya yi tambaya game da 'nau'in ƙarfe na foda,' amsar littafin rubutu yawanci jeri ne mai kyau: latsa da sinter, gyare-gyaren ƙarfe na ƙarfe, latsawar isostatic mai zafi, da sauransu. Amma a aikace, wannan rarrabuwar ya kusan tsafta. Ya rasa dalilin da yasa za ku zaɓi ɗaya a kan wani don takamaiman sashi, da kuma sasantawa na ainihi wanda ya zo tare da kowane. Na ga ƙira da yawa sun shigo inda zaɓin ya yi kama da kwatancen kasida maimakon zurfin fahimtar ƙayyadaddun tsari. Bari mu yi magana game da abin da waɗannan nau'ikan ke nufi a zahiri lokacin da kuke ƙoƙarin yin ɓangaren da ke aiki, dawwama, kuma baya busa kasafin kuɗi.
Dokin Aiki: Jarida na Al'ada da Sinter
Wannan shine inda yawancin mutane suka fara, kuma saboda kyawawan dalilai. Yana da tsada-tasiri don babban kundin sifofi masu sauƙi. Za ki ɗauki foda na ƙarfe, ki cika mutu, danna shi ƙarƙashin matsi mai ƙarfi, sa'an nan kuma kirfa shi a cikin tanderu don haɗa barbashi. Makullin anan shine 'dan kadan mai sauƙi.' Yankewa? Manta shi. Mahimman bambance-bambance a cikin kauri na bango? Kuna neman matsala tare da ƙananan gradients waɗanda za su nuna a cikin aiki.
Mun taɓa samun aikin don ƙaramin ɓangaren kayan aiki. Zane ya yi kama da kyau latsa da sinter. Amma abokin ciniki yana da kaifi, tsagi mai zurfi don zoben riƙewa. A cikin ɓangarorin ɓangarorin, ɓangaren bakin bakin ya karkace. Dole ne mu koma mu sake tsara tsagi zuwa radius mai laushi mai laushi, wanda sannan ya buƙaci canji zuwa ɓangaren mating. Waɗannan ƙananan bayanai ne waɗanda ba a cikin ƙasidar. Kaddarorin injiniyoyi suna da kyau, amma sun kasance anisotropic - sun fi karfi daidai da hanyar latsawa. Idan harkallar lodin ku ba ta daidaita da wancan ba, kuna buƙatar sani.
Kewayon kayan a nan yana da faɗi, daga haɗe-haɗe-haɗe-haɗe-haɗe-haɗe-haɗe-haɗin-karfe-carbon don sassa na tsari na asali zuwa ƙananan ƙarfe. Amma lokacin da kuka shiga cikin buƙatun abubuwa kamar bakin karfe don latsawa da ɓangaren sinter, dole ku yi hankali. Yanayin sintering yana buƙatar kulawa sosai don hana oxidation na chromium, wanda ke ƙara farashi. Wani lokaci, yana da hankali a ba da shawarar wani foda karfe hanya ko ma tsarin masana'antu daban-daban gaba ɗaya.
Lokacin da Complexity ba Negotiable: Metal Injection Molding (MIM)
MIM ita ce amsar lokacin da sashinku yayi kama da kayan allurar filastik amma yana buƙatar zama ƙarfe. Ka yi tunanin hadaddun, ƙanana, rikitattun sifofi-bangaye masu ramuka masu yawa a kusurwoyi marasa kyau, muƙamuƙan kayan aikin tiyata, ƙananan abubuwan kullewa. Tsarin yana haɗa foda mai kyau na ƙarfe tare da abin ɗaure polymer, allura ya ƙera shi, ya ƙaddamar da abin ɗaure, kuma ya sa shi. Kuna samun kusanci-cikakken yawa da ingantaccen siffa.
Kama? Yana da tsayi, mafi m sarkar tsari. Matsayin ƙaddamarwa yana da mahimmanci kuma a hankali; a garzaya da shi, kuma za ku sami tsagewa ko blisters. Ƙunƙasa a lokacin sintering na ƙarshe yana da mahimmanci kuma ana iya faɗi, amma dole ne ku tsara kayan aikin ƙirar don rama shi daidai. Na tuna da tarin abubuwan haɗin haɗin inda aka yanke kayan aikin bisa ga wani wuri da wuri, abubuwan rage ɓacin rai. Gabaɗayan gudu ya fito da ƙarancin maki kaɗan. Mara amfani. Darasin shine koyaushe, koyaushe gudanar da gwaji tare da ainihin foda da kayan abinci mai ɗaure da kuke shirin amfani da su don samarwa.
Tsari-hikima, yana da girma kowane sashi fiye da latsawa da sinter, amma don aikace-aikacen da ya dace, ba za a iya doke shi ba. Mun samo sassa na MIM don abokan ciniki masu buƙatar hadaddun, sifofi masu inganci inda injina daga mai ƙarfi zai yi tsada da tsada. Kamfanoni kamar Qingdao Qiangsenyuan Technology Co., Ltd.(QSY), tare da zurfin bayanan su a cikin madaidaicin simintin gyaran gyare-gyare da machining, sau da yawa suna samar da ayyuka masu mahimmanci na biyu akan sassa na MIM, kamar madaidaicin CNC machining mai mahimmancin datum surface bayan sintering don buga juriya cewa tsarin MIM kadai ba zai iya tabbatarwa ba.
Filin Babban Ayyukan Ayyuka: Hot Isostatic Pressing (HIP) da Bayan
Wannan shi ne inda za ku je ga sassan da ba su da komai. Ina nufin, sifili porosity. Gilashin injin turbine na sararin sama, ƙwararrun kayan aikin likitanci, mahimmin man ƙasa da abubuwan gas. HIP yana ba da ɗan ƙaramin foda da aka riga aka yi (sau da yawa ana lulluɓe shi a cikin akwati da aka rufe) zuwa babban zafin jiki da matsin iskar gas daga kowane bangare lokaci guda. Sakamakon shine cikakken mai yawa, microstructure mai kama da juna.
Kudin yana da tsada. Kayan aikin yana da tsadar gaske don siye da gudanarwa. Ba tsari mai girma ba ne. Kuna amfani da shi don aikace-aikacen da suka fi buƙata. Hanya mai ban sha'awa ga matasan shine amfani da HIP don warkar da lahani na ciki a cikin simintin gyare-gyare. Wannan yanki ne inda gwanintar kayan mai kaya ke da mahimmanci. Misali, yin aiki tare da gami na musamman kamar na tushen nickel ko na cobalt-na kowa a cikin ayyukan simintin saka hannun jari da kamfanoni kamar QSY suka yi (zaka iya ganin kewayon kayansu a https://www.tsingtaocnc.com) - yana buƙatar daidaitaccen ilimin yadda foda ke aiki a lokacin zagayowar HIP don kauce wa samuwar lokaci maras so.
Bayan HIP, akwai dukan duniya na fitowa da nau'ikan na musamman. Spark Plasma Sintering don ci gaba da yumbu da abubuwan haɗin gwiwa. Ƙarfafa masana'antu na karafa, wanda shine ainihin Layer-by-Layer foda karfe. Amma tare da AM, kuna cinikin matsi na isotropic na HIP don matsananciyar zafi na laser ko katako na lantarki. Ƙarshen da aka gina kamar yadda aka gina da yanayin damuwa na ciki gaba ɗaya dabbobi ne daban-daban, sau da yawa suna buƙatar tsarin bayan HIP ta wata hanya don rufe micro-porosity. Ba shi da wani nau'i na musamman da ƙarin sabon kayan aiki a cikin akwatin kayan aikin ƙarfafa foda.
Material shine Saƙo
Ba za ku iya raba nau'in tsari daga kayan ba. Magana akai foda karfe iri ba tare da tattauna foda ba kamar magana ne game da dafa abinci ba tare da ambaton kayan abinci ba. Ruwa atomized foda yana da arha, mara kyau a siffa, kuma yana da kyau ga latsawa da sintiri. Gas atomized foda yana da siffar zobe, yana gudana mafi kyau ga MIM ko AM, amma ya fi tsada. Hanyar haɗakarwa tana da mahimmanci kuma-shin kuna amfani da foda da aka riga aka yi amfani da shi ko hadawa na asali? Pre-alloyed yana ba da ƙarin kaddarorin iri ɗaya amma ya fi tsada. Haɗuwa da abubuwa na iya haifar da rashin daidaituwa idan ba a sarrafa shi daidai ba.
Muna da shari'ar bincike ta gazawa akan ɓangaren ƙarfe mai ƙarfi na sinter. An ƙayyade shi don aikace-aikacen sawa mai girma. Sashin ya wuce QC na farko amma ya gaza da wuri a filin. Metallurgy ya nuna wuraren da aka keɓe na austenite, wanda yake da taushi. Tushen dalili? Haɗin da ba daidai ba na graphite (carbon) ƙari tare da foda na ƙarfe na tushe kafin dannawa. Lokacin sintering, carbon ɗin bai yaɗu daidai gwargwado, don haka wasu wuraren ba su yi tauri da kyau ba. Gyaran ya kasance canzawa zuwa foda na karfe da aka riga aka yi da carbon da aka rigaya a cikin bayani. An warware matsalar, amma a karuwar farashin kayan abu 15%. Wannan shine irin cinikin da ke faruwa a kullum.
Wannan shine dalilin da ya sa haɗin gwiwa tare da wurin ganowa ko kantin injin da ke fahimtar kayan a wannan matakin yana da mahimmanci. Kamfanin da ke da shekaru 30 a cikin simintin gyare-gyare da injina, kamar QSY, yana kawo wannan tunanin ƙarfe. Wataƙila ba za su yi foda ba, amma sun san yadda waɗannan kayan ke aiki a ƙarƙashin zafi da damuwa daga aikin su jefa baƙin ƙarfe, karfe, bakin karfe, da kuma musamman gami. Wannan ilimin tsarin giciye yana da matukar amfani yayin da kuke zabar hanyar PM da tsammanin yadda sashin zai yi bayan-sintering.
Haɗuwa tare da Masana'antar Gargajiya
Layukan suna blurring. Hanya gama gari yanzu ita ce a foda karfe tsari kusa-net-tsari wanda ke biye da mashin daidaici. Kuna iya MIM ko danna kuma raba wani sashi zuwa kashi 95% na sifarsa ta ƙarshe, sannan ku kawo injin niƙa na CNC don injin madaidaicin bugu, zaren, ko madaidaicin saman rufewa. Wannan tsarin haɗin gwiwar yana haɓaka farashi da aiki.
Na yi aiki a jikin bawul inda aka samar da babban hadaddun hanyoyin ciki ta hanyar MIM, amma fuskokin flange da tashoshin zaren sun kasance injinan CNC bayan sintering. Ita ce hanya ɗaya tilo don cimma maƙasudin ƙarewar da ake buƙata da juriya na geometric akan waɗannan takamaiman abubuwan. Mai ba da kaya wanda ke ba da ƙwararrun PM biyu da injina a cikin gida, kamar yadda aka nuna a cikin QSY ta mayar da hankali kan simintin gyare-gyaren harsashi, simintin saka hannun jari, da injinan CNC, an sanya shi da kyau don irin wannan haɗin gwiwar masana'anta. Yana daidaita sadarwa da kuma rikon amana.
Zaɓin nau'in PM, to, ba yanke shawara bane keɓe. Mataki ne na farko a cikin shirin masana'antu. Dole ne ku yi tambaya: Wadanne ayyuka na biyu za a buƙaci? Yaya za a gama sashin? Rufi? Tsarin sintering yana rinjayar sinadarai na saman, wanda zai iya tasiri ga mannewa ko aikin fenti. An haɗa duka. Yin la'akari da shi azaman kawai ɗaukar 'nau'i' daga menu shine babban kuskuren da za ku iya yi. Yana game da aikin injiniya sarkar samar da kayayyaki da sarkar tsari wanda ke ba da sashin aiki. Foda shine farkon farawa.
