Thaum koj hnov 'Alloy 1' hauv qhov kev lag luam no, thawj cov tshuaj tiv thaiv feem ntau yog qhov tsis txaus ntseeg. Nws tsis yog lub npe flashy superalloy, thiab qhov ntawd yog thawj ntxiab. Cov neeg xav tias nws yog cov khoom siv dav dav, tus nqi qis ua haujlwm, tej zaum ib qho yooj yim carbon steel variant. Qhov kev xav ntawd tau raug nqi ntau dua ib qhov project ntawm kev ua tau zoo thiab, ncaj ncees, nyiaj. Hauv kuv peb lub xyoos dhau los nyob ib puag ncig cov chaw tsim khoom thiab cov khw muag khoom, Kuv tau pom 'Alloy 1' tau teev nyob rau ntawm cov duab kos uas tus kws ua haujlwm pom tseeb tsuas yog xav tau 'qee yam hlau,' thiab kuv kuj tau pom tias nws yog qhov tseem ceeb, tsis muaj kev xaiv xaiv rau cov khoom ua tsis tau lwm yam. Qhov tseeb yog, 'Alloy 1' tsis yog ib yam. Nws yog ib pawg, qhov chaw pib, thiab nws tus cwj pwm yog tag nrho los ntawm kev kho cua sov tshwj xeeb, txheej txheem casting, thiab tom qab machining. Tau txais nws txoj cai yog tsawg dua txog cov ntaub ntawv pov thawj thiab ntau ntxiv txog tag nrho cov saw ntawm kev saib xyuas los ntawm yaj kom tiav.
Lub Foundry Floor Reality
Wb tham txog casting nws. Nyob rau hauv plhaub pwm casting, uas peb siv hnyav heev ntawm peb qhov chaw, Alloy 1 nthuav tawm ib qho kev sib tw tshwj xeeb hauv fluidity piv rau shrinkage. Nws tsis zoo li ib co grey irons, yog li lub rooj vag system tsim ua qhov tseem ceeb. Kuv nco qab ib pawg ntawm cov twj tso kua mis, tej zaum 500 units, qhov twg peb siv cov txheej txheem gating layout los ntawm qhov zoo sib xws ntawm cov hlau txuas. Qhov tshwm sim yog tsis tu ncua shrinkage porosity nyob rau hauv tuab mounting flange. Lub alloy cia li solidified txawv. Peb yuav tsum rov qab mus, nce qhov loj me, thiab hloov pauv qhov kub ntawm qhov kub ntawm 25 ° C. Qhov ntawd kho nws. Nws yog cov kev hloov pauv hloov maj mam cais qhov siv tau los ntawm cov khoom seem. Cov txiv neej nyob Qingdao Qiangsenyuan Technology (QSY) tau pom qhov no ib txhiab zaug-peb caug xyoo hauv casting txhais tau hais tias koj tau tsim lub tsev qiv ntawv ntawm cov kev kho me me rau cov geometries thiab alloys sib txawv.
Kev nqis peev casting yog lwm zaj dab neeg. Ntawm no, nrog Alloy 1, qhov saum npoo tiav yog zoo heev, tab sis tus nqi ntawm lub plhaub ceramic rau cov hlau uas tsis yog kub-kub alloy tuaj yeem yog ib qho nyuaj muag. Koj tab tom ua rau qhov nyuaj thiab qhov ze-net-puab cov txiaj ntsig, tsis yog vim tias alloy xav tau nws. Peb ib zaug machined kev nqis peev-ntxuav Alloy 1 turbine sensor bracket uas tuaj yeem ua lub plhaub molded, tab sis cov kev sib txuas sab hauv tau nyuaj heev uas cov machining lawv yuav tau them tus nqi ob npaug. Yog li, tus nqi them rau cov txheej txheem peev tau raug tsim nyog. Nws yog ib qho kev suav tas mus li.
Lub pitfall tiag tiag yog xav tias cov khoom siv zoo ib yam los ntawm cov neeg muag khoom sib txawv. 'Alloy 1' los ntawm Mill A tuaj yeem tshuab zoo li butter, thaum los ntawm Foundry B nws ua hauj lwm-hardens thiab noj cov cuab yeej. Qhov sib txawv feem ntau yog nyob rau hauv cov kab lus thiab kev xyaum deoxidation thaum melting. Aluminium-tua piv rau silicon-tua? Nws hloov txhua yam downstream. Koj tsim ib qho kev nyiam rau qhov chaw, tsis yog raws li tus nqi, tab sis yuav ua li cas kwv yees lawv cov khoom coj los ntawm koj lub tshuab CNC.
CNC Machining: Qhov Kev Xav Tau Raws Li Txoj Cai
Qhov no yog qhov uas cov roj hmab tau raws txoj kev. Ntawm daim ntawv, Alloy 1 muaj machinability ntsuam xyuas. Hauv kev xyaum, cov kev ntsuas no yog ib qho kev pom zoo. Thawj qhov uas peb ua nrog ib pawg tshiab yog kev txiav txim siab. Peb tab tom nrhiav kev tsim chip. Stringy, nruam chips yog ib tug npau suav phem rau automation thiab ib tug kos npe rau peb tej zaum yuav tsum tau kho noj los yog rake kaum. Qhov zoo tshaj plaws yog tawg, 'C'-puab nti. Nrog ib co batch ntawm Alloy 1, koj tau txais qhov ntawd yooj yim. Nrog rau lwm tus, koj nyob nraum fiddling nrog coolant concentration thiab chip-breaker geometry txhua hnub.
Cov cuab yeej hnav yog qhov ntsiag to killer. Nws tsis zoo li machining stainless qhov twg koj pom ua-up ntug tsim pom. Nrog Alloy 1, lub flank hnav yog gradual. Tej zaum koj yuav tau txais qhov chaw zoo kawg nkaus rau thawj tsib caug ntu, tom qab ntawd ntawm ib feem tsib caug-ib, koj pib pom lub kua muag me ntsis lossis ib qho me me. Yog tias koj tab tom ua haujlwm tsis muaj teeb pom kev tsim tawm, qhov no tuaj yeem ua rau tag nrho cov pallet ntawm workpieces. Peb kawm qhov no nyuaj heev thaum ntxov nrog lub siab ntim valve lub cev txoj haujlwm. Peb teeb tsa lub cuab yeej lub neej raws li tus neeg muag khoom cov ntaub ntawv. Daim ntawv teev cov ntaub ntawv yog optimistic. Peb tau xaus nrog ib puas feem ntawm kev ua siab ntev ua ntej lub cuab yeej tsis ua haujlwm lub tswb tshwm sim. Tam sim no, peb tsim nyob rau hauv qhov kev ruaj ntseg margin thiab saib xyuas spindle load kev ntseeg.
Coolant tsis yog ua kom txias xwb; nws yog ib tug lubricant rau lub shear cheeb tsam. Rau Alloy 1, semi-synthetic coolant nrog zoo lubricity nyhav ua hauj lwm zoo dua ib tug ncaj hluavtaws. Nws txo cov txiav quab yuam thiab pab nrog nti khiav tawm. Tab sis tom qab ntawd koj yuav tsum tswj cov roj tramp thiab cov kab mob loj hlob ntau dua. Txhua qhov kev xaiv yog kev sib pauv.
Cov ntsiab lus tshwj xeeb Alloys
Vim li cas txawm siv Alloy 1 Thaum koj muaj cobalt-based lossis nickel-based superalloys? Nws yog qhov kev sib cav ' haum-rau-lub hom phiaj' classic. Kuv tau koom nrog hauv ib qhov project rau kev ua tshuaj lom neeg. Tus neeg siv khoom pib spec hu rau nickel alloy rau txhua qhov chaw ntub dej vim 'corrosion resistance.' Tom qab tshuaj xyuas cov tshuaj lom neeg tiag tiag - cov kuab tshuaj me me ntawm qhov kub thiab txias - peb tau thov kom muaj qib passivated zoo ntawm Alloy 1 (a 316L variant, nyob rau hauv cov ntaub ntawv ntawd). Tus nqi txuag tau tshaj 60%, tsis yog nyob rau hauv cov khoom, tab sis nyob rau hauv lub sij hawm machining. Ib feem tau ua haujlwm tau xya xyoo tam sim no tsis muaj teeb meem. Txoj kev xav rau kev tshaj tawm yog qhov muaj zog, tshwj xeeb tshaj yog nyob rau hauv kev tswj hwm kev lag luam, tab sis kev paub qhia koj kom thawb rov qab nrog cov ntaub ntawv thiab lwm cov kev daws teeb meem.
Hais tias, ua hauj lwm nrog cov kab txawv alloys muab rau koj ib tug sib sib zog nqus appreciation rau lub qhov rais ua ntawm Alloy 1. Nickel alloys yog viscous thaum nrum, cobalt alloys yog hnyav heev rau tshuab. Alloy 1 yog, los ntawm kev sib piv, zam txim. Tab sis 'kev zam txim' tsis txhais hais tias 'yooj yim.' Nws txhais tau tias cov npoo ntawm qhov yuam kev yog dav dua, tab sis qhov yuam kev tseem tshwm sim yog tias koj tsis quav ntsej. Nws yog qhov sib txawv ntawm kev tsav tsheb ntawm txoj kev dav thiab hla roob nqaim; koj tseem yuav tau xyuam xim.
Ntawm QSY, qhov tseeb tias lawv tuav ob qhov kawg ntawm cov spectrum - los ntawm cov alloys rau cov tshwj xeeb - yog qhov zoo dua. Nws txhais tau tias cov txheej txheem npaj rau kev ua haujlwm hauv Alloy 1 raug ceeb toom los ntawm kev qhuab ntuas huab cua xav tau rau cov superalloys. Qhov kev nruj me ntsis txo qis.
Failures thiab Lessons Learned
Lub sijhawm qhia ntawv tshaj plaws yog los ntawm kev ua tsis tiav. Muaj ib tug ncej, txog 75mm nyob rau hauv txoj kab uas hla, teev nyob rau hauv Alloy 1 nrog lub zog tensile siab. Nws yog induction hardened tom qab machining. Hauv kev sim, nws tsim cov kab nrib pleb radial. Thawj qhov kev thuam tau mus rau tus kws kho cua sov. Tom qab ntau qhov rov qab thiab tawm mus, peb taug qab nws rov qab mus rau yaj. Cov khoom muaj me ntsis siab dua li cov ntsiab lus ntawm leej faj, uas tsim elongated manganese sulfide inclusions. Cov no ua raws li kev ntxhov siab concentrators thaum lub sij hawm cua kub ceev thiab quenching ntawm induction hardening. Cov khoom ua tau raws li tus qauv tshuaj muaj pes tsawg leeg ntawm daim ntawv pov thawj, tab sis nws yog nyob rau ntawm ntug ntawm qhov ntau rau leej faj. Zaj lus qhia? Rau qhov tseem ceeb, tom qab ua haujlwm kub-kho qhov chaw, koj yuav tsum tau ceev cov khoom tshwj xeeb tshaj li tus qauv ASTM ntau thiab qhia meej txog kev tswj hwm. Koj them nyiaj ntau dua rau cov yaj, tab sis koj txuag tau txiaj ntsig hauv kev zam kev ua tsis tiav.
Lwm hom, yuav luag dag, tsis ua hauj lwm hom yog galvanic corrosion. Bolting ib Alloy 1 (hais tias, carbon steel) flange mus rau lub stainless hlau yeeb nkab uas tsis muaj rwb thaiv tsev. Nws yog ib qho yooj yim, tab sis nyob rau hauv complex sib dhos nrog ntau yam ntaub ntawv, nws tau overlooked. Cov Alloy 1 Cheebtsam ua lub sacrificial anode thiab corrodes tam sim ntawd. Nws tsis yog cov khoom tsis ua haujlwm; nws yog ib tug tsim thiab sib dhos saib xyuas. Koj pom cov khoom no rov qab los rau 'kev hnav ntxov ntxov,' thiab qhov kho yog $ 0.50 insulating gasket.
Cov kev ua tsis tiav no yog qhov tsim kom muaj kev paub txog kev ua haujlwm hauv ib lub tuam txhab. Yog vim li cas ib lub khw nrog 30 xyoo keeb kwm, zoo li ib tug qab tsi.com, muaj nuj nqis tshaj nws cov npe tshuab. Tej zaum lawv tau ntsib thiab daws cov teeb meem tshwj xeeb, gritty.
Xaus Tsis Muaj Kev Txiav Txim Siab
Yog li, qhov twg ua rau peb nrog Alloy 1? Nws tsis yog lub ntsiab lus uas koj tuaj yeem xaus zoo. Nws yog ib yam khoom uas txhais los ntawm nws cov txheej txheem. Nws qhov kev ua tau zoo yog kev sib koom tes ntawm metallurgist, foundry engineer, CNC programmer, thiab cov kws kho cua sov. Koj tsis tuaj yeem yuav 'Alloy 1' thiab cia siab tias yuav tau txais txiaj ntsig. Koj yuav tsum txhais nws, ua nws, txiav nws, thiab kho nws nrog lub hom phiaj tshwj xeeb hauv siab.
Qhov kev txawj ntse tiag tiag nyob rau hauv kev paub txog qhov levers los rub rau daim ntawv thov twg. Puas yog nws xav tau ib qho anneal normalized lossis quench thiab temper? Nws puas yuav tsum tau rough machined ua ntej kev kho cua sov thiab tom qab ntawd tiav machined, los yog koj puas tuaj yeem tshuab nws tag nrho hauv lub xeev annealed? Tsis muaj ib lo lus teb. Cov ntawv teev lus muab rau koj pib, tab sis daim ntawv qhia txheej txheem kawg yog sau los ntawm kev sim, kev ua yuam kev, thiab kev soj ntsuam ntawm lub khw hauv pem teb.
Thaum kawg, Alloy 1 yog ib qho pov thawj rau lub tswv yim tias hauv kev tsim khoom, tsis muaj cov khoom siv tho txawv, tsuas yog cov txheej txheem nkag siab tsis txaus. Nws xav tau kev hwm tsis yog rau nws cov kab txawv txawv, tab sis rau nws qhov chaw nyob thiab qhov subtlety ntawm nws cov variations. Tau txais nws txoj cai tsis tu ncua, batch tom qab batch, xyoo dhau los, yog dab tsi cais lub khw ua haujlwm los ntawm tus khub tsim khoom tiag. Qhov ntawd yog qhov tsis zoo, ua haujlwm txhua hnub uas ua rau kev lag luam tig.
