Thaum cov neeg feem coob hnov 'siab kub alloy', lawv tam sim ntawd xav txog lub dav hlau cav lossis tej zaum av-raws li turbines. Qhov ntawd tsis yog qhov tsis ncaj ncees lawm, tab sis nws yog qhov pom ntawm qhov chaw uas nco txog qhov kev sib tw tiag tiag ntawm kev ua haujlwm nrog cov ntaub ntawv no. Cov nplooj ntawv spec sau cov lej zoo - nkag siab tsis kam, oxidation txwv, tensile lub zog ntawm 1000 ° C - tab sis lawv tsis qhia koj txog kev sib hloov thaum lub sij hawm machining, cov qauv nplej tsis sib xws los ntawm ib qho cua sov mus rau lwm qhov, los yog qhov nyuaj ntawm kev tau txais kev huv, tsis muaj qhov tsis xws luag los ntawm nickel-based superalloy. Qhov ntawd yog qhov sib txawv ntawm txoj kev xav thiab lub khw hauv pem teb.
Lub Casting Conundrum: Qhov twg Theory ntsib tus Crucible
Wb tham txog casting, tshwj xeeb peev casting uas yog peb lub khob cij thiab butter ntawm QSY. Nrog kub kub alloys, tshwj xeeb tshaj yog cov nickel-raws li zoo li Inconel 718 lossis Hastelloy X, tag nrho cov txheej txheem yog kev taug kev nruj. Kev tswj qhov kub thiab txias yog qhov tseem ceeb, tab sis yog li yog qhov txias txias hauv lub plhaub pwm. nrawm dhau, thiab koj ua rau muaj kev ntxhov siab thiab kua muag kub; qeeb dhau, thiab koj tau txais cov qoob loo ntau dhau uas tua cov khoom siv kho tshuab tom qab. Peb tau muaj cov khoom tawm los saib zoo meej, tsuas yog ua tsis tiav X-ray tshuaj ntsuam nrog subsurface shrinkage porosity. Cov ntaub ntawv hais tias zoo heev castability, tab sis nws yeej tsis txhais hais tias zoo heev txhais tau tias rau ib tug complex turbine hniav piv rau ib tug yooj yim bushing.
Kuv nco qab txog qhov project ob peb xyoos rov qab rau tus neeg siv khoom hauv kev ua haujlwm thermal. Lawv xav tau kev cai radiant raj ua los ntawm wrought kub kub alloy, tab sis lub sij hawm ua cov khoom lag luam bar yog txwv tsis pub. Peb npaj siab casting lawv ntawm peb lub plhaub pwm txheej txheem siv cov qib zoo sib xws casting alloy. Cov chemistry tau nyob ze, tab sis tsis zoo ib yam. Thawj ob peb lub pob tawg tawg thaum lub sij hawm kho cua sov. Qhov teeb meem? Cov ntsiab lus-ib yam dab tsi zoo li qhov sib txawv me ntsis hauv boron lossis zirconium cov ntsiab lus ntawm cov wrought spec thiab peb tus tswv casting-uas cuam tshuam rau lub zog ciam teb ntawm qhov kub thiab txias. Nws tsis yog nyob rau hauv lub ntsiab spec; nws yog nyob rau hauv cov footnotes. Peb yuav tsum rov qab mus, tweak lub ncuav kub thiab hloov kho cov cua sov ramp-up tus nqi tshwj xeeb rau peb yaj. Nws ua haujlwm, tab sis nws ntxiv lub lim tiam ntawm kev sim thiab ua yuam kev. Qhov ntawd yog qhov tseeb.
Qhov no yog qhov uas tus foundry qhov kev suav suav. Ntawm Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), nrog ntau tshaj peb xyoo caum nyob rau hauv lub plhaub thiab peev casting, peb tau tsim ib lub tsev qiv ntawv ntawm cov subtle, unwritten parameters rau txawv geometries thiab alloys. Nws tsis yog hais txog qhov muaj qhov cub; Nws yog hais txog kev paub tias rau ib qho tshwj xeeb cobalt-raws li alloy, koj yuav tsum tau kho cov pwm ua ntej kub kub txawv dua li cov npib tsib xee-raws li ib qho kom ua tiav ib qho kev sib sau hauv nyias ntu. Qhov kev paub no tsis rub tawm; nws tau sau los ntawm iterations, thiab yog, los ntawm qee zaus ua tsis tiav.
Machining: Qhov tseeb nyuaj txog txiav cov ntaub ntawv nyuaj
Yog hais tias casting yog ib tug ilv seev cev, machining kub kub alloys yog kev sib ntaus sib tua. Cov khoom zoo heev uas ua rau cov alloys zoo heev - siab kub hardness thiab ua haujlwm hardening nyiam - ua rau lawv npau suav phem rau cov cuab yeej txiav. Cov neeg feem ntau underestimate qhov no. Lawv xav tias, Peb muaj CNC niaj hnub, peb yuav cia li qeeb. Nws yog deb tshaj nuanced.
Qhov yuam kev loj tshaj yog kho nws zoo li machining stainless hlau. Nrog ib yam dab tsi zoo li Inconel 625, yog tias koj lub cuab yeej tsis ntse, yog tias koj qhov nrawm thiab txau tawm txawm tias me ntsis tawm, lossis yog tias koj lub coolant tsis tsoo qhov chaw zoo, koj tsis tau txais cov nti zoo. Koj tau txais ib tug built-up ntug ntawm lub cuab tam, uas ces ua hauj lwm-hardens nto ntawm ib feem koj nyob nraum txiav. Tam sim no koj tab tom sim txiav los ntawm ib qho tawv nqaij tawv dua, uas ua kom muaj cua sov ntau dua, uas ntxiv cov cuab yeej degrades. Nws yog lub voj voog tsis zoo uas ua rau cov khoom seem thiab rhuav tshem, kim carbide inserts. Peb kawm qhov no nyuaj rau thaum ntxov, hlawv los ntawm cov cuab yeej siv nyiaj ua ntej peb hu rau hauv qhov tsis muaj.
Rau peb ntawm QSY, kev koom ua ke CNC machining nrog peb cov kev ua haujlwm casting yog qhov zoo tshaj plaws. Peb feem ntau ua qhov pib ntxhib machining ntawm peb cov khoom ua-cam khwb cia. Qhov no txhais tau hais tias peb yuav tsum suav rau cov tawv nqaij casting, muaj peev xwm cuam tshuam me ntsis, thiab qhov kev ntxhov siab uas tshwm sim los ntawm cov txheej txheem casting. Peb tau tsim cov txheej txheem hauv tsev rau kev txhim kho thiab kev ua haujlwm sib luag kom txo qis kev ntxhov siab rov qab los. Piv txwv li, peb tuaj yeem ua qhov kev ntxhov siab-txhim kho cua sov tom qab kev ua haujlwm tsis zoo tab sis ua ntej ua tiav qhov tseem ceeb heev. Nws ntxiv ib kauj ruam, tab sis nws tiv thaiv ib feem ntawm kev txav mus tom qab hauv kev pabcuam - ib qho kev kawm tau kawm los ntawm ib pawg ntawm lub cev valve uas tau tawm ntawm spec tom qab xa khoom kawg.
Qhov tshwj xeeb hauv Cov Alloys Tshwj Xeeb: Cov Khoom Muag Khoom & Traceability
Lwm txheej feem ntau overlooked yog cov khoom siv raw nws tus kheej. Tsis yog tag nrho Inconel 718 yog tsim sib npaug. Qhov kev ua tau zoo hinges ntawm purity ntawm cov ntaub ntawv nkauj xwb thiab qhov tseeb ntawm tus tswv alloy ntxiv. Peb tau hloov cov khoom lag luam ua ntej vim tias tsis sib xws ntawm cov pa oxygen lossis nitrogen cov ntsiab lus ntawm melts, uas tshwm sim ua lub neej qaug zog tsis zoo nyob rau hauv qhov kawg cam khwb cia. Thaum koj nrog kub kub alloys rau cov ntawv thov tseem ceeb, daim ntawv pov thawj ntawm kev txheeb xyuas (CoA) yog koj phau bible. Ntawm QSY, peb tshawb xyuas qhov ze thiab feem ntau ua peb tus kheej lub txim taws los yog kev soj ntsuam spectral ntawm cov khoom tuaj, tshwj xeeb tshaj yog rau cobalt-based lossis nickel-based alloys. Koj tswj tsis tau qhov koj ntsuas tsis tau.
Qhov no tsom rau cov khoom siv ncaj ncees txuas mus rau peb cov txheej txheem tag nrho. Rau kev nqis peev casting, peb siv cov txheej txheem ceramic plhaub tau sib xws nrog cov khoom siv reactive kom tsis txhob muaj qhov paug paug. Ib qho kev tsis huv ntawm lub plhaub tuaj yeem tsim qhov tsis muaj zog uas dhau los ua qhov chaw pib tawg nyob rau hauv thermal cycling. Nws yog ib qho kev nthuav dav uas tsis tshwm sim ntawm qhov ua tiav qhov ntev, tab sis nws yog txhua yam rau nws lub neej kev pab cuam nyob rau hauv ib puag ncig kub.
Failure Analysis: Tus Xib Hwb Tshaj Lij Tshaj
Qee qhov kev paub tseem ceeb tshaj plaws yog los ntawm qhov chaw uas tsis ua rau nws. Thaum ntxov ntawm peb ua hauj lwm nrog high-chromium nickel alloy rau ib tug pyrolysis rauv tivthaiv, peb muaj ib tug tsis ua hauj lwm teb. Ib feem tawg raws li ib txoj kab zoo li random. Metallurgical tsom xam taw tes rau sigma theem embrittlement. Lub alloy yog nquag mus rau nws yog nyob rau hauv ib tug tej yam kub ntau yam rau ntev heev. Peb lub voj voog kho cua sov, uas yog tus qauv rau cov hlau zoo sib xws, tau thawb nws mus rau hauv lub qhov rais. Qhov kho tsis yog hais txog kev hloov cov casting; nws yog hais txog redesigning lub tom qab-casting tshav kub kho kom quench los ntawm qhov tseem ceeb kub cheeb tsam sai. Tam sim no, rau tej yam tshiab kub kub alloy qhov project, peb tsis tsuas yog saib cov qauv kev kho mob; peb khawb rau hauv cov duab kos duab thiab muaj peev xwm embrittlement mechanisms. Nws yog ib qho kev tiv thaiv uas yug los ntawm kev mob siab rau zaj lus qhia.
Qhov kev xav no qhia peb li cas rau cov haujlwm tshiab nrog cov neeg siv khoom. Thaum ib tus neeg siv khoom siv hluav taws xob tsim hluav taws xob tuaj rau peb nrog kev thov rau qhov kev cai tsim cov khoom siv hluav taws xob siv hluav taws xob tshwj xeeb, peb cov lus nug thawj zaug tsis yog hais txog qhov ntev xwb. Lawv hais txog qhov chaw ua haujlwm (oxidizing? carburizing?), thermal voj voog profile, thiab lub xeev kev ntxhov siab. Qhov no qhia txhua yam los ntawm kev xaiv cov hlau nplaum (tej zaum yog qib silicon-txhim kho kom zoo dua oxidation tsis kam?) rau kev tsim cov feeders thiab risers hauv pwm los xyuas kom muaj suab nrov hauv thaj chaw tseem ceeb tshaj plaws.
Kev sib xyaw ua ke: Los ntawm Foundry mus rau qhov kawg
Tus nqi tiag tiag rau ntau ntawm peb cov neeg siv khoom ntawm QSY lus dag nyob rau hauv txoj kab ntsug kev koom ua ke - tuav txoj kev taug kev los ntawm molten hlau mus rau ib tug machined, npaj-rau-nruab tivthaiv. Rau kub kub alloys, qhov txuas ntxiv no tseem ceeb heev. Tus machinist yuav tsum to taub qhov casting qhov zoo li tus qauv sab hauv; tus engineer foundry yuav tsum paub qhov chaw machining qhov chaw tseem ceeb yuav ua kom muaj qhov ntom ntom ntxiv.
Peb nyuam qhuav ua tiav kev khiav ntawm turbine shrouds rau kev hloov kho turbocharger. Cov khoom siv yog ib qho nyuaj nickel-based superalloy. Los ntawm kev tswj ob qho tib si casting thiab precision CNC machining hauv tsev, peb tuaj yeem koom tes. Peb nrum cov khoom nrog cov khoom lag luam ntxiv rau ntawm lub ntsej muag mating, tom qab ntawd ua qhov kub isostatic nias (HIP) kev kho mob kom kaw txhua qhov micro-porosity. Tsuas yog tom qab HIP peb tau ua qhov kawg machining. Qhov kev sib tw no, txiav txim siab sib koom tes ntawm peb pawg casting thiab machining teams, ua kom peb tshem tawm txhua qhov kev cuam tshuam ntawm HIP thaum ua tiav cov khoom siv kom pom qhov ntom ntom. Qhov tshwm sim yog ib qho kev tivthaiv nrog kev ua tau zoo dua qub dua li cov txheej txheem tau muab cais ntawm cov neeg muag khoom sib cais.
Qhov ntawd yog qhov kawg. Ua hauj lwm nrog cov kub kub alloys tsis yog tsuas yog xaiv cov khoom siv los ntawm cov ntawv teev npe. Nws yog hais txog kev nkag siab txog nws tus cwj pwm los ntawm txhua kauj ruam ntawm kev hloov pauv - los ntawm cov kua rau cov khoom, los ntawm cov ntxhib casting mus rau qhov tseeb. Cov lej ntawm daim ntawv spec yog qhov pib rau kev sib tham, tsis yog qhov xaus. Tus so yog kawm nyob rau hauv lub foundry, ntawm CNC tswj, thiab tej zaum, nyob rau hauv lub sobering teeb ntawm ib tug tsis ua hauj lwm tsom xam daim ntawv qhia. Nws yog qhov xav tau, tab sis qhov ntawd yog qhov ua rau kev ua haujlwm tau zoo, xyoo tom qab hauv qhov chaw kub kub, txaus siab heev. Nws txhais tau tias koj tau txais tag nrho cov ntsiab lus pom tsis raug.
