Xa usiva 'inxalenye ye-nickel esekelwe kwi-alloy', umfanekiso ongoko nangoko udla ngokuba ngowokungatshatyalaliswa, ubugcisa obuphezulu obumiselwe iinjini zejethi okanye iirigi zolwandle. Ayonto iphosakeleyo, kodwa ngumbono womgangatho ophezulu obonisa ubunyani bobunyani bokwenza ngokwenene. Ibali lokwenyani alikho nje malunga nezinto ezinomtsalane zemathiriyeli-amandla obushushu obuphezulu, ukuxhathisa ukubola-malunga nomsantsa omkhulu phakathi kokuba nemodeli ye-CAD nokubamba inxalenye egqityiweyo, esebenzayo engasileli phantsi koxinzelelo. Amaqela amaninzi okuthenga abona ibakala le-alloy, njenge-Inconel 718 okanye i-Hastelloy C-276, kwaye bacinga ukuba umsebenzi wenziwa kakhulu. Inyaniso kukuba, kulapho umsebenzi wokwenyani, kunye neentloko zokwenyani, ziqala khona.
I-Casting Conundrum: Yonke into ikwi-Fied
Masithethe ngotyalo-mali, indlela eqhelekileyo yeejometri ezintsonkothileyo. Ngama-alloys e-nickel, ayikhe ibe malunga nokugalela isinyithi esinyibilikisiweyo kwiqokobhe leceramic. Ukuziphatha kokuqina kuliphupha elibi ukuba awuyilawuli ngobunono. Ukushwabana lutshaba. Awunako nje ukongeza iifeeder ezinkulu kuyo yonke indawo; ujongene nezinto ezixabisa kakhulu, kwaye ubunzima obugqithisileyo buhlala busisithintelo esibalulekileyo soyilo. Ndibone iindawo apho uyilo lokuqala lwenkqubo yokungena, esebenze kakuhle kwintsimbi engatyiwa, ikhokelele ekucuthekeni kwentlekele kwindawo eshinyeneyo ialloy esekwe nickel umzimba wevalvu. Inxalenye yayijongeka igqibelele ngaphandle, kodwa uvavanyo lwe-ultrasonic luveze i-porous core eyayiza kuqhekeka phantsi koxinzelelo. Ulungiso lwalungeloncedo olulula; ibandakanye uhlengahlengiso olupheleleyo lwenkqubo yokutya, kusetyenziswa isoftwe yokulinganisa ukulinganisa i-thermal gradients, kwaye emva koko iqinisekise ngothotho lweendleko zokugalela ulingo.
Apha kulapho amava avela kwi-Foundry eye yajikeleza ibhloko ihlawula khona. Inkampani efana Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), kunye neminyaka yabo engamashumi amathathu ekujuleni, baya kuba neeprothokholi zangaphakathi zale nto. Babengayi kuthembela nje kukulinganisa; bangaba nethala ledatha yembali evela kwiijometri ezifanayo, esazi ukuba kwinguqu ethile yobunzima bodonga kwi inxalenye ye-alloy esekelwe kwi-nickel, udinga i-feeder yomlinganiselo othile we-diameter-to-height, obekwe kwi-engile echanekileyo. Olo hlobo lolwazi olufihlakeleyo alukho kuyo nayiphi na incwadi yesifundo; yakhiwe kwiicasts ezingaphumelelanga kunye nabaphumeleleyo kwiminyaka.
Inkqubo yokubumba iqokobhe ngokwayo ibalulekile. Ukwandiswa kwe-thermal ye-ceramic kufuneka ihambelane ne-alloy ukunqanda ukukrazuka okushushu okanye iziphene zomhlaba. Kwi-alloys ephezulu ye-gamma-prime efana ne-IN-738, esetyenziswa kwiincakuba ze-iturbine, iqondo lobushushu lokungunda ngaphambi kobushushu kunye neqondo lobushushu lokugalela linefestile enokuba ngama-30 ngokukaCelsius. Uyiphose, kwaye ufumana i-misruns okanye ukukhula okuziinkozo okugqithisileyo. Yibhola yobushushu obugqithisileyo kunye nexesha elichanekileyo.
Machining: Apho izixhobo ziya kuFa
Ukuba ukuphosa kukutsha okulawulwayo, ukwenza i-nickel alloys yimfazwe yokuyeka. Isantya sokusebenza nzima siyingozi. Uthatha i-cut, kwaye izinto ezingaphantsi kwesixhobo ziba nzima ngoko nangoko. Ngena ngeeparitha ezingalunganga, kwaye awuyi kusika-uhlikihla kwaye uvelise ubushushu obaneleyo ukuze udibanise i-workpiece kwisixhobo. Ndiyifunde le ndlela kabuhlungu kwangethuba, ndizama ukwehlisa idiameter kwi-Inconel 625 shaft. Kusetyenziswe isixhobo se-positive-rake, isantya esisemgangathweni kunye nokutya kwentsimbi eqinile. Kwimizuzu nje embalwa, eso sihlomelo sasingasekho, yaye inxalenye engaphezulu yayibubugxwayiba obuqinileyo, obumenyezelayo obuthabatha iiyure zokusila ukuze kusindiswe.
Isicwangciso sichasene ne-intuitive. Udinga izixhobo ezibukhali, ezingalunganga, rhoqo i-carbide okanye i-ceramic, ngokuseta okungqongqo kakhulu. Izantya zomphezulu ophantsi, amazinga aphezulu okutya, kunye nobunzulu obuqinileyo bokusika. Injongo kukungena phantsi komsebenzi owenziwe lukhuni ukusuka kwipaseji yangaphambili kunye nokucheba izinto ngaphambi kokuba zibe lukhuni ngokuchasene nesixhobo. Isipholisi asenzelwa ukupholisa nje; sisithambiso sokuthintela ukwakhiwa kwaye kufuneka kuhanjiswe ngoxinzelelo oluphezulu kanye kwindawo yokusika. Nangoko, ubomi besixhobo bulinganiswa ngemizuzu, hayi iiyure. Yento entsonkothileyo ialloy esekwe nickel i-impeller isenziwa kwi-5-axis CNC, iindleko zezixhobo zinokuba yinxalenye ebalulekileyo yomsebenzi wonke.
Kungenxa yoko le nto amandla omatshini adweliswe kwiwebhusayithi efana ne-QSY's ayisiyobhokisi yokukhangela. Ukuxela ukuba bayayenza CNC Machining kuba i-alloys ekhethekileyo ithetha ukuba batyale imali kwizixhobo zomatshini ezichanekileyo (i-torque ephezulu, i-spindles high-rigidity spindles), banokufikelela kwisixhobo esikhethekileyo, kwaye, ngokubaluleke kakhulu, baneprogram kunye nabaqhubi abaziqondayo ezi parameters zingekho umgangatho. Ngumahluko phakathi kwevenkile enokusebenzisa indawo kunye nenye enokuvelisa indawo echaneke ngokomlinganiselo ophezulu ngengqibelelo engaphezulu engayi kuqalisa iintanda kwinkonzo.
I-Dimensional Stability Ghost
Omnye umgibe ofihlakeleyo luxinzelelo olushiyekileyo. La malungu ahlala ephuma ekujuleni okanye ekwenziweni ngoxinzelelo olukhulu lwangaphakathi. Uzitshiza ngokunyamezela ngokugqibeleleyo kwiqondo lobushushu begumbi. Emva koko, usebenzisa unyango lwe-post-machining heat-machining, unyango lwesisombululo kunye nokuguga kwi-precipitation-hardening alloys-ukufezekisa iimpawu zokugqibela zomatshini. Loo mjikelo wobushushu unokuphelisa uxinzelelo, kwaye inxalenye iyajika. Ngamanye amaxesha bambalwa wena, kodwa ngokwaneleyo ukuyilahla ukuba unyamezelo oluqinileyo luyafuneka kumacandelo amancinci.
Iworkaround lulandelelwano lomatshini orhabaxa, isiqabu soxinzelelo, emva koko ugqibezele ukwenziwa. Ngamanye amaxesha kufuneka wenze unyango lokuguga oluphakathi. Yongeza amanyathelo, iindleko, kunye nexesha. Ndikhumbula iprojekthi yezihlandlo ezininzi apho siphoswe khona oku. Igqitywe ngomatshini indawo kwisithuba esingenanto, emva koko yathunyelwa ukuba iphathwe ubushushu. Yabuya yagoba okwebhanana. Kuye kwafuneka ukuba sizame ukuyilungisa, nto leyo eyingozi, kwaye ekugqibeleni kwafuneka siyilahle. Isifundo yayikukuhlala sixoxa ngolandelelwano olupheleleyo lwemveliso-ukusuka ekungenanto ukuya kunyango lokugqibela-kunye nomthengisi ngaphambili. Iqabane elinamava liyakuxela loo ngozi ngoko nangoko.
I-Welding kunye nokulungiswa: Qhubeka ngokuqaphela okugqithisileyo
Ngamanye amaxesha, impazamo yokuphosa ifunyenwe, okanye inxalenye ifuna ukwakhiwa okanye kudityaniswe. I-Welding nickel alloys yinto ekhethekileyo kuyo. Baqhelene nokuqhekeka okushushu, i-porosity, kunye nokwahlulwa kwezinto ezixutywayo. Intsimbi yokuzalisa kufuneka ifaniswe ngokucokisekileyo, ngokufuthi ibe nokwakheka okwahluke kancinane ukulawula ukuqhekeka. Indawo leyo imele icoceke ngokugqibeleleyo—ingabi nasalfure, ingabi nalo ilothe, ingabi naoli. Nkqu izixa umkhondo kunokubangela embrittlement.
Ukushisa kwangaphambili kunye nokulawula ubushushu be-interpass akunakuxoxisana, njengonyango oluthile lwe-post-weld ubushushu kumabakala amaninzi ukubuyisela ukuxhathisa ukubola kwindawo echaphazelekayo kubushushu. Ndiyibonile imizamo yokudibanisa i-weld isiphene somphezulu omncinci kwi-casing yempompo usebenzisa intonga yokuzalisa engenasici. Kwakubonakala kulungile ekuqaleni, kodwa kwinkonzo, loo ndawo ye-weld yaba yindawo yokuqaliswa koxinzelelo olunzima lokuqhekeka kwe-corrosion. Iindleko zokulungisa zigqithise kakhulu ixabiso lenxalenye. Kumacandelo abalulekileyo, iinkqubo ze-welding kufuneka zifaneleke, kwaye i-welders ngokwayo idinga uqeqesho oluthile kwezi zinto.
Inxaki yoMboneleli: Ngaphezulu koLuhlu lwezinto eziphathekayo
Oku kundizisa kumbindi wokukhangela iindawo ze-alloy ezisekelwe kwi-nickel. Awuthengi nje umbandela; uthenga inkqubo yolwazi oluqokelelweyo lwabaxhasi kunye nokukhula kwabo kokusombulula iingxaki. Xa bevavanya inkampani, iminyaka yabo kwishishini, njengeQSY's 30 iminyaka, icebisa ukuba bajonge le migibe. Kodwa kufuneka umbe nzulu. Ngaba banazo ii-metallurgists kubasebenzi okanye kwifowuni? Ngaba banokukubonisa imizekelo yendlela abazisombulule ngayo iingxaki ezifanayo-ezifana nokulawula ukwakhiwa kweenkozo kudonga olubhityileyo lokugalela okanye ukunxitywa kwesixhobo sokulawula kwi-pocket milling? Ngaba banokuyichaza indlela yabo yokuqinisekiswa kwenqaku lokuqala, ngaphaya kokujonga nje imilinganiselo?
Intshayelelo yewebhusayithi ikhankanya ukuba basebenza nabo ii-alloys ezikhethekileyo (i-cobalt-based alloys, i-nickel-based alloys, njl.. Oko njl. kubalulekile. Ilatha kwisakhono esidlulela ngaphaya kwemenyu eqhelekileyo. Abona baboneleli bangcono ngabo babandakanyeka kumngeni. Baza kubuza malunga nokusingqongileyo kwesicelo, imijikelezo yomthwalo, iindlela zokungaphumeleli ozama ukuziphepha. Baza kuthandabuza uyilo lwakho lokwenziwa kokwenziwa, bacebise ngee-engile ezifihlakeleyo zedrafti okanye utshintsho lweradiyasi olwenza ukuba indawo iphoseke ngakumbi okanye isebenze ngaphandle kokubeka esichengeni umsebenzi. Loo ngxoxo ixabisa ngaphezulu kwexabiso eliphantsi ngekhilogram.
Ekugqibeleni, amacandelo e-nickel alloy aphumelele azalwa kwintsebenziswano phakathi komyili ocingayo kunye nomenzi okwaziyo, onxibelelanayo. Izinto eziphathekayo zisithembiso sokusebenza, kodwa eso sithembiso sizaliseka kuphela ngokuqonda okunzulu kohambo lonke ukusuka kwingot ukuya kwinxalenye efakiweyo. Kumdaka, kuyabiza, kwaye kugcwele ngamanqaku anokusilela. Kodwa xa yenziwe ngokufanelekileyo, akukho nto yimbi enokwenza umsebenzi.
