Ubona 'i-stellite' kumzobo kwaye into yokuqala ethi qatha engqondweni 'inzima, ayigugi, iyabiza'. Nantso umphezulu. Ibali lokwenyani liqala xa uzama ukulimatshini, ukulidibanisa, okanye likhuphe i-casting engaqhekeziyo phantsi koxinzelelo lwangaphakathi. Kukho ingcamango ephosakeleyo eqhelekileyo yokuba ngenxa yokuba i-cobalt-based superalloy, ngandlela-thile ifana nomlingo. Ngokwesiqhelo, umahluko phakathi kwesihlalo sevalve ye-Stellite 6 esithatha ishumi leminyaka kunye nesinye esigaqayo ngonyaka sihlala sihla kwisakhono se-Foundry ngokugalela kunye nonyango lobushushu lwasemva kokuphosa-iinkcukacha ezininzi zokuthengwa kwe-specs gloss ngokupheleleyo.
I-Casting Conundrum: Yonke into ikwi-Fied
Ukwenziwa kotyalo-mali kukuya kwi-complex Amalungu e-Stellite alloy, njengokutywinwa kweblade ye-iturbine okanye iinxalenye zempompo ezintsonkothileyo. Kodwa nge-Stellite, indawo ephezulu yokunyibilika kunye neempawu zokumanzi likrele elintlangothi-mbini. Ndikhumbula iprojekthi ye-directional solidification casting-eyenzelwe ukudala i-columnari ye-grain structure yokumelana nokudinwa kwe-thermal. Ithiyori yayivakala, kodwa lo mkhuba wawuliphupha elibi lokukrazula okushushu. Umba yayingengokwakheka kwengxubevange; yayiyindlela yokungena kunye neyokunyuka. Kuye kwafuneka ukuba sisuke kuyilo lweencwadi zesikhokelo siye esikhulu ngakumbi, isondlo esishushu ukubuyisela ukushwabana kokuqina kwealloyi ngokukhawuleza. Ivenkile esetyenziselwa kuphela intsimbi okanye i-nickel alloys iya kuhlala ingaphantsi kwezi zinto, ezikhokelela ekunciphiseni kwe-porosity engenakwenzeka ukubonwa ngaphandle kovavanyo olutshabalalisayo. Kulapho amashumi eminyaka esiseko solwazi olucekethekileyo, njengale nto ungayifumana kwingcali efana I-Qingdao Qiangsenyuan Technology (QSY), iba yinto engenakuxoxisana. Baneminyaka engama-30 beqhuba ukungunda kweqokobhe; baye babona lonke uhlobo lwesiphene sokushwabana kwaye banepateni yohlengahlengiso ukuyithintela.
Unyango lobushushu bobunye ubugcisa obumnyama. Unyango lwesisombululo kunye nemijikelo yokuguga yamabakala okuqina kwemvula njengeStellite 21 ibalulekile. Kodwa i-curves yobushushu bexesha oyifumanayo kwidatha yedatha? Ziyindawo yokuqala. Owona mjikelo kufuneka uphendule ubukhulu becandelo lenxalenye yakho ethile. Umzimba wevalve yecandelo elityebileyo kunye nomkhono obhityileyo wodonga uya kuziphatha ngendlela eyahlukileyo kwisithando somlilo esifanayo. Ndizibonile iindawo ziphuma zinobulukhuni obuchanekileyo kodwa zibeke esichengeni ukuqina kuba ivenkile ilandele iresiphi yegeneric. Isiphumo? Inxalenye edlula i-QC kodwa isilele kwangethuba kwinkonzo phantsi kweempembelelo. Udinga umthengisi oqonda isinyithi, hayi nje ukulandela itshati yobushushu.
Emva koko kukho igalelo lemathiriyeli ekrwada. Ayizizo zonke 'i-stellite' ezenziwe zalingana. Umxholo ohlaziyiweyo, ukulandelela ukulawulwa kwezinto (njengekhabhoni kunye ne-silicon), kunye nefom ye-master alloy ingot inokuchaphazela ukuchithwa kunye neepropati zokugqibela. Iqabane elithembekileyo liya kulandelela isitokhwe sabo esinyibilikayo kwaye sikwazi ukuxoxa ngeziphumo, sithi, i-0.5% vs.
Machining: Apho isixhobo siya kufa (ukuba awukhathali)
Ukuba ucinga ukuba ukwenza i-stainless kunzima, I-Stellite alloys yiligi eyahlukileyo. Izinga lokuqina komsebenzi liyamangalisa. Ikhaphukhaphu, ukusikwa kokugcina kunokwenza umonakalo omkhulu kunokulungileyo, ukwenza umsebenzi ube lukhuni umphezulu kwaye wenze ukuba ipasi elandelayo ibenzima nangakumbi. Ubuqhetseba kukungena phantsi kwaloo maleko owenziwe lukhuni ngoko nangoko. Oku kuthetha ukuseta okuqinileyo, akukho nto ishukumayo, kunye nokusebenzisa i-positive-rake, amabakala abukhali e-carbide enzelwe i-alloys yobushushu obuphezulu. Ukufakwa kweCeramic okanye kwe-CBN kunokusebenzela ukugqiba, kodwa ixabiso lokuqala liphezulu kwaye lincinci.
Ukupholisa kubalulekile, kodwa kungekhona ngenxa yesizathu sokuba uninzi lucinga. Incinci malunga nokupholisa kwaye ngaphezulu malunga nokuthambisa kunye nokukhutshwa kwetshiphu. Uxinzelelo oluphezulu, inkqubo yokupholisa ngesixhobo iphantse yanyanzeliswa xa kugrunjwa umngxuma onzulu okanye ukungqusha. Injongo kukuthintela i-chip kwi-welding ukuya kwi-cut cut, eyindlela ekhawulezayo yokungaphumeleli kwesixhobo esiyingozi. Oomatshini owomileyo? Libala. Uya kuvelisa ubushushu obugqithisileyo obubamba i-substrate engaphantsi kwesisiki sakho.
Oku sikufunde kabuhlungu kwibhetshi yeStellite 12 yokwaleka kwizikhondo zevalvu yesango. Ushicilelo lwalufuna ukugqitywa komphezulu ocolekileyo kwidayamitha yokutywina. Iinzame zethu zokuqala ngelathe ye-CNC eqhelekileyo kunye nesipholisi sesikhukula zibangele incoko kunye nomphezulu okrazukileyo. Isisombululo asizange sikhawuleze i-RPM okanye i-geometry eyahlukileyo yodwa. Kuye kwafuneka sitshintshe lonke ulandelelwano lwenkqubo: ujiko olurhabaxa, emva koko i-anneal yokunciphisa uxinzelelo (ewe, nasemva komatshini), emva koko ugqibezele ukucofa. Inyathelo elongezelelweyo longeze iindleko kunye nexesha, kodwa yayikuphela kwendlela yokufumana uzinzo kunye nokugqiba. Apha kulapho umniki-mpahla ngokudibeneyo CNC Machining kunye nolwazi lwe-metallurgical lugcina intloko ebuhlungu. Bayazi ukuba ulandelelwano lubaluleke kakhulu njengendlela yesixhobo.
Indawo yeWelding kunye neMigodi eWalekeneyo
Ukujongana nzima ngentonga ye-Stellite okanye ucingo kuxhaphakile, kodwa i-dilution ngumbulali othuleyo. Ukuba isiseko sesinyithi (ngokuqhelekileyo i-carbon steel okanye i-stainless) iyancibilika kakhulu kwaye ixube kunye ne-Stellite weld metal, uhlambulula i-matrix ye-cobalt ngentsimbi. Oku kunciphisa kakhulu ukuqina okushushu kunye nokuxhathisa umhlwa. Eyona nto ilungileyo yinkqubo yokuhlanjululwa okuncinci njengePTA (i-Plasma Transferred Arc) okanye i-laser cladding. Nokuba ngezi, ulawulo lweparamitha yinto yonke. Igalelo lobushushu elininzi kakhulu, kwaye wenza ialloyi ebiza kakhulu, ephantsi ye-iron-cobalt.
Ndiye ndahlola amacandelo anqamlezileyo apho i-spec ibiza i-3mm ye-Stellite 6 engaphezulu, kwaye umaleko osebenzayo, ongaxutywanga wawungaphantsi kwe-1mm emva komatshini. Inxalenye yayiza kuphelelwa kubomi obulindelweyo. Ukulungiswa kubandakanya ulawulo olungqongqo kumbane we-arc, isantya sokuhamba, kunye nesantya sokutya komgubo. Yinkqubo efuna amaxwebhu kunye nokuphinda-phinda, hayi nje imvakalelo yomtshisi.
Unyango lobushushu lwasemva kwe-weld (PWHT) yenye indawo enobuqili. Kwiindawo eziyifunayo kwisiseko sengqibelelo yentsimbi (njengamacandelo aqulathe uxinzelelo), umjikelo we-PWHT unobudala obungaphezulu kokwaleka kweStellite, ukuthambisa. Ngamanye amaxesha kufuneka wamkele ulungelelwaniso okanye uyilo icandelo ukuze indawo yeStellite isetyenziswe emva kwePWHT engundoqo, eyongeza ukuntsonkotha kolungiselelo. Akukho mpendulo igqibeleleyo, kuphela urhwebo ubuncinane-libi-off iimeko nkonzo.
Ukungaphumeleli kwehlabathi lokwenyani: Ityala leGalvanic Corrosion
Sakhe sabonelela ngeeseti zeStellite 21 sleeves zempompo yamanzi olwandle. Izinto eziphathekayo zikhethwe ngenxa yokumelana nokukhukuliseka kwe-cavitation. Zasilela ngendlela ephawulekayo kwiinyanga, kungekhona ngenxa yokuguga, kodwa ngenxa yemingxuma enzima. Oyena nobangela? Zaye zafakelwa umatshini wokushicilela kwindlu yentsimbi engatyiwayo. Kwi-electrolyte yamanzi olwandle, senze i-galvanic cell enkulu. I-Stellite ehloniphekileyo ngakumbi (i-cobalt-based) yenza njenge-cathode, kwaye izindlu zentsimbi ezingenasici ezingenasidima zaba yi-anode yedini, isantya sayo isantya. Isifundo sasikhohlakele: ukhetho lwemathiriyeli alunakwenzeka kwindawo engenanto. Kuya kufuneka uqwalasele yonke indawo yendibano-ulwelo, amaqondo obushushu, kwaye, ngokubaluleke kakhulu, ezinye izinto ezinxibelelana nazo. Iqabane elilungileyo lobugcisa liya kubuza le mibuzo yenqanaba lenkqubo, hayi nje ukwamkela ushicilelo lwenxalenye enye.
Yiyo loo nto ukusebenza nengcali yezinto ezininzi kunengqiqo. Inkampani efana QSY, ephethe yonke into ukusuka kwintsimbi etyhidiweyo ukuya kwi-nickel alloys, kunokwenzeka ukuba ibone le miba ye-interface kwangethuba. Amava abo kwiintsapho eziphathekayo abanika umbono obanzi weengxaki zokuhambelana ezinokuphoswa yivenkile yealloyi enye.
Ukulungiswa kwakubandakanya ukuyila ngokutsha i-interface kunye ne-insulating coating kunye nokutshintsha ukunyamezela okufanelekileyo. Kwakuyindleko ngokutsha enokuthi igwenywe ngokuphononongwa kwe-front-end design-for-manufacture. Ngoku, sihlala sibuza: Yintoni echukumisayo, kwaye yintoni imeko-bume?
Ukubonelela kunye neChina Factor
Masisebenziseke. Uninzi lwe iindawo ze-stellite alloy ukukhangela kukhokelela eChina, kunikwe ixabiso le-cobalt eluhlaza kunye neenkqubo ezisebenza ngamandla. Uloyiko luhlala luhambelana nomgangatho. Umahluli ongundoqo ayilolizwe, kukuvuthwa kokusebenza kwesiseko esithile. Udinga ubungqina bolawulo lwenkqubo: izenzo eziqinisekisiweyo zokunyibilika, iitshati ezibhaliweyo zonyango lobushushu kwibhetshi nganye, kunye ne-NDT eyomeleleyo (njengeeFPI zokuqhekeka komphezulu kwiindawo ezibalulekileyo).
Iwebhusayithi efana ne-tsingtaocnc.com ibonisa imbali ende yokusebenza (iminyaka eyi-30+) kunye nokugxila kwigobolondo kunye nokuphosa utyalo-mali. Ubomi obude kule niche luphawu. Icebisa ukuba bajonge ijiko lokufunda kwii-alloys ezinobuqili kwaye bagcine iipateni ezinobuchule kunye nee-metallurgists ezifunekayo. Uvavanyo lwangempela lukwingxoxo yabo yobugcisa. Ngaba banokuxoxa ngamaqondo obushushu angaphambi kobushushu bokuwelda iStellite 1 ukuya kwi-410 engenastainless? Ngaba banokucebisa ngokulandelelana komatshini kumsesane obhityileyo weStellite 3? Impendulo yabo kule mibuzo ikuxelela ngaphezu kwaso nasiphi na isatifikethi.
Ekugqibeleni, iinxalenye zeStellite eziphumeleleyo zivela ekuphatheni i-alloy ngentlonipho kwii-quirks zayo. Asiyontsimbi yempahla. Ifuna ubudlelwane be-symbiotic phakathi komyili, i-metallurgist, kunye ne-machinist. Injongo kukunyusa iipropati zayo ezimangalisayo ngaphandle kokutshatyalaliswa yimingeni yayo yokuvelisa. Ababoneleli abafumana oku ngabo abaye badlula emlilweni-ngokoqobo nangokomfanekiso-weziko lokuphosa kunye neziko lomatshini, kwaye banezisombululo ezisebenzayo, ngamanye amaxesha ezinzima, zokubonisa.
