Lokacin da akasarin mutane suka ji 'na'urorin haɗi na musamman', suna tunanin ƙarfin ƙarfi don injin jet ko motar tsere. Wannan wani bangare ne na shi, tabbas, amma kuma a nan ne babban kuskuren farko ya ta'allaka. Ba wai kawai game da ƙarfin juriya na ƙarshe ba ne. Yana da game da yanayin da ya kasa a ciki. Na ga ayyuka da yawa da yawa inda tawagar ta samo wani babban nickel galoy don juriya na lalata, kawai don yin hawan jini da kamawa a lokacin shigarwa saboda sun yi watsi da halin da ake ciki na annealed. musamman gami fasteners a cikin aikace-aikacen ƙarfi mai ƙarfi. Takaddun bayanin ya ce 'ba shi da lalata,' kuma sun daina karantawa a wurin. Aiki na gaske yana farawa bayan kun zaɓi kayan tushe.
Musamman a cikin Alloy Ba Sihiri bane
Bari mu yi magana game da abin da ke sa alloy 'na musamman' ga fasteners. Yawanci ƙari ne na abubuwa kamar nickel, cobalt, molybdenum, ko chromium a cikin kaso mai mahimmanci don cimma takamaiman bayanin martabar dukiya. Ka yi tunanin Inconel 718, Hastelloy C-276, ko MP35N. Amma ga yadda ake kamawa: waɗannan allunan suna da wahalar injin. Matsakaicin ƙarfin aikin su yana da yawa. Idan sigogin injin ɗin ku sun ƙare da ɗan ɗan-lokacin ciyarwa da jinkirin, alal misali-ba za ku sake yanke kayan ba, kuna kawai taurara saman sa tare da gefen kayan aikin, wanda ke haifar da saurin lalacewa na kayan aiki da yuwuwar lahani na ƙasa a cikin na'urar. Wannan ba ka'idar ba ce. Mun koyi wannan hanya mai wuya da wuri tare da ɗimbin ingarma na Waspaloy. Zaren sun yi kama da cikakken aikin injin, amma yayin binciken ultrasonic, mun sami ƙananan fashe-fashe suna farawa daga tushen zaren. Dalilin? Ragowar damuwa daga aikin juyi mai wuce gona da iri wanda ba a magance damuwa ba da kyau. Abubuwan 'na musamman' na gami sun haɓaka matsalar.
Wannan shine inda haɗin gwiwa tare da kantin kafa da injina wanda ke da shekaru da yawa na zahiri a cikin lamuran wasan. Ina tunanin wani mai kaya da muka yi aiki da shi, Qingdao Qiangsenyuan Technology Co., Ltd. (QSY). Asalinsu a cikin simintin saka hannun jari da gyare-gyaren harsashi sama da shekaru 30, musamman tare da cobalt da na tushen nickel, yana ba su mahimmancin jin yadda waɗannan kayan ke aiki daga yanayin ruwa zuwa gama sashi. Ba kawai game da gudanar da shirin CNC ba. Yana da game da sanin cewa wani nau'i na nickel yana buƙatar takamaiman zafin jiki na tsaka-tsakin lokacin yin inji ko kuma zai gurbata. Ba za ku iya cire wannan ilimin daga daidaitaccen littafin injuna ba. Kuna iya samun ƙarin bayani kan tsarin su a rukunin yanar gizon su, tsingtaocnc.com. Wannan fahimtar matakin-tsari ce ke raba mai ɗaure mai amfani da abin dogaro.
Wani nuance shine maganin zafi. Don yawancin bakin karfe, kuna da madaidaiciyar kashewa da fushi. Tare da hazo-hardening nickel gami, da tsufa sake zagayowar shi ne komai. Lokaci da zafin jiki dole ne a sarrafa su zuwa minti daya don samun daidaitaccen ma'auni na ƙarfi da ductility. Na tuna wani shari'ar da abokin ciniki ya yi korafin karaya a cikin inconel 718 bolts. Za su fitar da su zuwa ga daidaitattun AMS. Bayan bincike, mun gano cewa sun tsufa a daidai zafin jiki, amma nauyin tanda ya yi yawa, yana haifar da dumama mara kyau da kuma yaduwar kayan inji a cikin batch. Wadanda suka kasa sun kasance daga wuraren sanyaya a cikin tanderun. Alloy na 'musamman' an bar shi ta hanyar daidaitaccen tsarin masana'antu wanda aka aiwatar ba tare da isasshen kulawa ba.
Abubuwan Kasawa Baku Ganin Suna Zuwa
Lalata kalma ce mai faɗi. Tare da musamman gami fasteners, Mu sau da yawa muna ma'amala da pitting, crevic corrosion, ko stress corrosion cracking (SCC) a cikin takamaiman kafofin watsa labarai. Na'urar ɗamara na iya zama cikakke don yanayin iskar gas mai tsami (H2S mai jurewa) amma zai yi nasara cikin bala'i daga SCC da ta haifar da chloride a cikin yanayin bakin teku. Zaɓin ba kawai lalata ba ne ko a'a. Yana da game da ainihin miyar sinadari da take zaune a ciki, gami da abubuwan ganowa. Mun taɓa yin amfani da haɗe-haɗe na alloy na titanium don aikace-aikacen ruwan teku, mai haske don lalata gabaɗaya. Amma tsarin yana da alamun methanol a matsayin mai hana ruwa. A ƙarƙashin wasu matakan damuwa, wannan ya gabatar da haɗarin methanol-induced SCC, yanayin gazawar ba akan radar mu ta asali ba. Dole ne mu ja da baya kuma mu koma ga bakin karfe mai daraja na duplex.
Sannan akwai lalata galvanic. Haɗa mai daraja musamman gami fastener kamar tushen cobalt tare da aluminum ko carbon karfe tsarin yana neman matsala. Da gaske kuna sadaukar da tsarin tushe. Fastener zai kasance mai tsabta yayin da yake cinye kayan da ke kewaye da shi. Maganin ba koyaushe ba ne daban-daban fastener; wani lokacin yana game da keɓewa tare da takamaiman wanki ko sutura, amma waɗancan suturar da kansu dole ne su dace kuma kada su gabatar da haɗarin haɓakar hydrogen. Yana da jerin abubuwan dogaro.
Shigarwa filin naki ne nasa. Babban ƙarfin waɗannan maɗauran sau da yawa yana nufin maɗaukakin ƙarfin da ake buƙata. Samun wannan matsewar ƙarfi ba tare da karkatar da kai ba ko ƙetare madaidaicin abin da ake samu na ɓangaren mating yana buƙatar daidaito. Lubrication yana da mahimmanci. Yin amfani da man shafawa mara kyau na iya gurɓata tsarin a cikin sararin samaniya ko aikace-aikacen kayan abinci. Yin amfani da ba zai iya haifar da ciwon da na ambata a baya. Mun daidaita kan takamaiman, ƙwararrun mahaɗan anti-kame don iyalai daban-daban, kuma wannan matakin mai sauƙi ya kawar da kusan kashi 80% na al'amurran shigar filin mu.
Lokacin da simintin gyare-gyare ya haɗu da Mahimman Machining
Wannan haɗin gwiwa ne mai ban sha'awa. Don hadaddun geometries mai haɗaɗɗiya - yi tunanin babban, mai siffa mai kama da kulle goro don rumbun injin turbine, ko abin ɗamara tare da haɗaɗɗen hanyoyin ruwa - simintin saka hannun jari na iya zama madaidaicin mafari zuwa ƙirƙira ko yin injina daga hannun mashaya. Kuna samun kusan-net-siffa, wanda ke rage adadin gami mai tsada da kuke buƙatar injin nesa. Kamfanin kamar QSY, tare da mayar da hankali ga dual kan harsashi / zuba jari da kuma CNC machining, an kafa shi don irin wannan haɗin gwiwar masana'antu.
Amfani shine kwararar hatsi na kayan abu. Wani ɓangaren injin yana yanke ta tsarin hatsi. Simintin gyaran gyare-gyaren da ya dace, tare da zagayowar matsi mai zafi mai zafi (HIP) don kawar da porosity na ciki, na iya samun tsari mai kama da juna don hadaddun siffofi. Sa'an nan kuma, mahimman fasalulluka masu ɗaukar kaya - zaren, filaye masu ɗaukar nauyi, radiyoyin ƙasan kai - daidaitattun injina ne a cikin gida. Wannan yana sarrafa dukkan sarkar darajar. Haɗarin samun simintin simintin gyare-gyare daga mai siyarwa ɗaya, aika shi zuwa kantin injin da bai saba da takamaiman tsarin dendritic ɗin sa da sauran yanayin damuwa ba, yana da girma. Fatsawa a lokacin mashin ɗin ƙarshe abu ne na gama-gari, kuma mai tsada, sakamako.
Na tuna kimanta wani babban simintin Monel K500 da injuna flange bolt don haɗakar ruwa. Samfurori na farko daga sarkar samar da kayayyaki sun gaza a canjin zaren. Binciken gazawar ya yi nuni zuwa ga ƙananan raguwa daga simintin gyare-gyaren da ba a rufe shi ta hanyar HIP ba, wanda kuma ya zama mai mai da hankali a lokacin zaren. Ƙirƙirar tsari tare da mai ba da tushe guda ɗaya wanda ke sarrafa amincin simintin gyare-gyare da ma'aunin injin na ƙarshe ya warware shi. Sun daidaita tsarin gating akan simintin simintin gyare-gyaren kuma sun riga sun yi injin ɗin da ba komai kafin sake zagayowar HIP na ƙarshe, sannan suka gama zaren. Bambancin dare ne da rana.
Farashin vs. Dogara: Ƙididdigar Gaskiya
Babu tattaunawa game da musamman gami fasteners ya cika ba tare da kudin magana ba. Kullin Inconel guda ɗaya na iya tsada sau 50-100 fiye da aron ƙarfe na Grade 8. Hankali shine don ganin inda zaku iya darajar injiniya. Wannan shine inda gwaninta ke kururuwa don yin taka tsantsan. Maye gurbin ƙaramin allo ko karɓar juriyar juzu'i mai faɗi don adana 15% akan ɓangaren na iya ninka haɗarin gazawa, wanda farashinsa ya haɗa da raguwar lokaci, lalacewar lamuni, da abin alhaki.
Lissafin yana jujjuya daga farashin yanki zuwa jimillar farashin mallaka. A cikin bishiyar Kirsimeti da ke ƙarƙashin teku, gazawar fastener ba batun kulawa ba ne; bala'i ne na muhalli mai yuwuwa da katsewar samarwa da ke kashe miliyoyin a kowace rana. Anan, amincin da aka ƙera shi cikin maɗauran ta hanyar zaɓin kayan aiki na musamman, masana'anta sarrafawa, da gwaji mai ƙarfi (kamar gwajin ASTM F606 don kaddarorin injina da NACE MR0175 don fashewar damuwa na sulfide) shine gabaɗayan ƙimar ƙimar. Manufar inshora ce.
Wani lokaci, maganin ba shine mafi ƙarancin gami ba. Muna da aikace-aikacen zafin jiki mai zafi (kimanin 650 ° C) inda ƙirar farko ta kira ga superalloy na tushen cobalt mai tsada sosai. Ta hanyar sake duba ƙirar, mun gane cewa za mu iya rage damuwa a kan fastener ta hanyar gyara ƙirar flange dan kadan. Wannan ya ba mu damar rage ƙima zuwa ga gama gari amma har yanzu iyawar nickel-chromium gami, adana farashi mai mahimmanci ba tare da lalata rayuwar ƙirar shekaru 20 ba. Makullin shine yin aiki tare da na'ura mai ɗaukar hoto da ƙwarewar kayan aiki a farkon lokacin ƙira, ba azaman siyayya ba bayan tunani.
Takeaway: Tsari ne, Ba Kansa ba
To, menene amfanin wannan duka? A musamman gami fastener Ba abu ne kawai na kayayyaki da kuke ciro daga kundin kasida ba. Sashin tsarin aikin injiniya ne sosai. Ayyukansa aikin ƙarfe ne, sarkar tsarin masana'anta (ko daga haɗaɗɗen mai kaya kamar QSY ko ƙungiyar haɗin gwiwa), tsarin shigarwa, da takamaiman yanayin aiki. Yin watsi da kowane ɗayan waɗannan hanyoyin haɗin gwiwar gayyata ce zuwa gazawa.
Masana'antar tana motsawa zuwa ƙarin ganowa da takaddun bayanai. Ya daina isa samun takardar shedar. Abokan ciniki suna son cikakken yanayin ganowa, bayanan sarrafa injina, da sigogin maganin zafi. Wannan matakin sarrafawa yana zama daidaitattun aikace-aikace masu mahimmanci. Yana tura ku zuwa ga masu samar da kayayyaki waɗanda ke da tsarin da horo don samar da shi, ba kawai kayan aikin injin ba.
A ƙarshe, yin aiki tare da waɗannan kayan yana koya muku girmamawa. Ba harsashin azurfa ba ne. Kayayyakin aiki ne waɗanda, idan aka fahimce su kuma aka yi amfani da su tare da zurfin fahimtar abubuwan da suke buƙata da buƙatunsu, suna ba da damar fasaha ta yi aiki a wuraren da ba za ta iya ba—a cikin injin injin jet, a ƙasan teku, ko a cikin shukar sinadarai masu lalata. Wannan shine ainihin darajar. Mai ɗaurawa kanta ita ce kawai bayyanar jiki na ɗimbin ilimi na musamman da tsarin sarrafawa.
