Uma abantu bezwa 'izingxenye zokuphonsa ingxubevange ye-cobalt', ukuhlotshaniswa okuseduze kuvame ukuba 'ukusebenza okuphezulu', 'i-aerospace', noma 'izimila zezokwelapha'. Lokho akulona iphutha, kodwa ukuqonda kwezinga eliphezulu okucwebezela phezu kweqiniso elingenalutho lokwenza lezi zingxenye. Inselele yangempela ayikho eshidini le-alloy kuphela; kusekulawuleni ukuguquka kusuka echibini elincibilikisiwe, elisebenzayo lensimbi ukuya engxenyeni ezinzile, engenasici engaphila ku-turbine noma emzimbeni womuntu. Abaningi bacabanga ukuthi uma ungaphonsa insimbi, ungaphonsa ama-alloys e-cobalt. Lokho kucatshangelwa kuye kubiza ngaphezu kwezitolo ezimbalwa imali eningi.
Ingxubevange Akuyona Nje Ifomula, Kuyindlela Yokuziphatha
Ukusebenza ngama-alloys e-cobalt-chromium, njengamamaki avamile e-CoCrMo, kuyisifundo sokuthobeka. Ubhekene nento enendawo encibilikayo ephezulu ngendlela emangalisayo kanye nokuthambekela okubi kokwenza ama-oxide azinzile. I ukukhishwa kwe-cobalt alloy inqubo, ikakhulukazi ukufakwa kwe-investimenti esiyisebenzisa kakhulu, iba yintambo eqinile yokuhamba phakathi kwezinga lokushisa, ukushisa kwesikhunta, kanye nesivinini sokuthulula. Amadigri ambalwa ekushiseni kwesikhunta, bese uthola ama-mistruns. Uphuza kakhulu ekutheleni, bese uthola ama-shucks abandayo. Ngokushesha kakhulu, bese ubamba igesi noma ucekela phansi igobolondo le-ceramic. Akuyona iresiphi oyilandelayo; ukusabela ozama ukukulindela nokulawula.
Ngikhumbula iqoqo lesegimenti ye-gas turbine seal eminyakeni embalwa edlule. I-chemistry yayiphelele, isihlahla sephethini ye-wax sasingenasici. Kodwa sasinomfana omusha esithandweni ngalolo suku. Ulandele iphrothokholi ejwayelekile ye-superalloy esekwe ku-nickel nathi esiyisebenzisayo. Umphumela? 'I-pancaked' yensimbi esikhunjeni—yalahlekelwa uketshezi ngokushesha. Izingxenye zazibukeka zilungile ngokubukeka, kodwa i-X-ray ibonise ukuncipha kwangaphakathi kwe-porosity ezingxenyeni eziwugqinsi. Konke ukushisa kwaqedwa. Yilolo suku iqembu elafaka ngalo ngempela ukuthi ama-cobalt alloys awaxoleli. Ibanga labo lokuqiniswa kanye ne-thermal conductivity yizilwane eziyingqayizivele. Awukwazi ukusebenzisa ijenerikhi ukuphonsa imithetho.
Yilapho isipiliyoni sesikhathi eside, njengeminyaka engu-30+ esitolo esinjenge-QSY, sibonakala. Akukhona mayelana nokuba neqhinga lomlingo; imayelana nokuba nomtapo wolwazi ojulile, cishe onembile wembangela-nomphumela wamajiyometri ahlukahlukene. Ufunda ukuthi ingxenye yevalvu enezindonga ezincanyana idinga isu elihluke kakhulu lokungena nokukhuphuka uma liqhathaniswa nepuleti eligugile, ngisho noma liphuma ebangeni elifanayo lealloy. Ulwazi lukubunjiniyela bephethini kudala ngaphambi kokuba insimbi incibilike.
I-Shell Mold Casting: Ukunemba Ngesikhumba Sobumba
Kokuyinkimbinkimbi, ubuqotho obuphezulu izingxenye ze-cobalt alloy, ukubunjwa kwegobolondo—uhlobo lokutshala imali—ngokuvamile kuwukuphela kwendlela esebenzayo. Indawo engaphezulu kanye nokunemba kobukhulu akufani nokusakazwa kwesihlabathi. Kodwa igobolondo le-ceramic ngokwalo liyinguquko ebalulekile. Ama-cobalt alloys ayasebenza. Uma i-binder yegobolondo noma into ephikisayo inokungcola okunganciphisa amandla komoyampilo wendawo ezingeni lokushisa eliphezulu, uthola into ebizwa ngokuthi 'i-metal-mold reaction'. Idala ungqimba lwangaphezulu oluqinile, olushwabene, oluvamise ukungcoliswa ekubumbeni okuyiphupho elibi ukulivala futhi lingafihla imifantu.
Sichithe izinyanga sidayela ohlelweni lwethu lwamagobolondo ngomsebenzi osuselwa ku-cobalt. Kuyinhlanganisela yobunikazi, kodwa ingqikithi isebenzisa i-alumina ehlanzekile kakhulu ne-zirconia refractories enesistimu yokuhlanganisa i-silica-free. Imijikelezo yokomisa nokudubula inonya—amarempu ahamba kancane ukuya emazingeni okushisa aphakeme kakhulu ukuze kushiswe izinto eziphilayo kanye nokucwilisa igobolondo esitsheni esiqinile, esingenasici. Umjikelezo wokudubula osheshayo uholela egobolondweni elibuthakathaka elingaqhekeka ngesikhathi sokuthulula noma, okubi nakakhulu, lidale imifantu emincane evumela insimbi ukuthi ingene, yonakalise indawo. Ngike ngabona izingxenye ziphuma zibukeka sengathi zinentshebe yobumba. Konke lokho kungukusebenza kabusha, noma ukuchithwa.
Ukubambisana negumbi leshell kubalulekile. Kwa-QSY, ukulingisa nomshini kungaphansi kophahla olulodwa, okusizayo. Ochwepheshe bemishini kamuva okufanele basike le nto eqinile bazokhononda ngokushesha uma inqubo yegobolondo ivaliwe, ngoba ukuphila kwamathuluzi abo kuyehla lapho beshaya ungqimba olungaphezulu olusebenzayo. Leyo ndlela yempendulo yangaphakathi ibalulekile. Kuphoqa uhlangothi lwe-Foundry ukuthi lube ngumnikazi wenkinga kusukela ekuqaleni kuze kube sekugcineni, hhayi nje kuze kube yilapho ingxenye inyakaziswa esihlabathini.
Lapho Imishini Ye-CNC Ingena Engxoxweni
Cha ukukhishwa kwe-cobalt alloy ingxenye 'i-net-shape' ngempela. Uhlala udinga imishini, futhi kulapho irabha ihlangana khona nomgwaqo. Ama-alloys e-cobalt aziwa kakhulu ukuthi kunzima ukuwenza umshini. Zisebenza-zinzima ngokushesha, ziyaluma, futhi zigcina amandla emazingeni okushisa aphezulu. Ingxenye engasebenzanga kahle ngomshini ingaba nokucindezeleka okuyinsalela noma imifantu emincane ezobangela ukwehluleka ngaphambi kwesikhathi kusevisi. Yingakho ukusebenza okuhlanganisiwe kubaluleke kakhulu.
Ingxenye ye-as-cast ine-scale, isistimu yesango, kanye nempahla eyeqile ('isitoko'). Isinyathelo sokuqala ngokuvamile ukususa amasango ngesondo elinqamukile elinqamukile—izinhlansi ezindiza yonke indawo. Bese ingena kumshini wokugaya we-CNC noma i-lathe. Ukukhetha ithuluzi yikho konke. Udinga iziphathi-mathuluzi eziqinile, amamaki e-premium carbide, ngezinye izikhathi ngisho nokufaka kwe-ceramic noma kwe-CBN ukuze uqedele. Ingcindezi epholile kanye nevolumu akuxoxiswana ngayo; kufanele ukhukhule i-cut ukuze ulawule ukushisa futhi ugeze ama-chips. I-chip esika kabusha imosha ukufakwa.
Senze uchungechunge lwezihlalo ze-alloy ezisekelwe ku-cobalt zamavalvu asebenza kanzima. Ukubekezelela ezindaweni zokuvala kwakukuma-microns. Inselele yayiwukuthi ukulingisa, ngemva kokwelashwa kokushisa, kwaba nokuhlanekezela okuncane, okungalindelekile. Abahleli bethu bezinhlelo ze-CNC kwadingeka bakhe ekuhloleni izindlela ukuze 'bafake imephu' yejiyomethri yangempela yengxenye ngaphambi kokudlula kokugcina. Yangeza isikhathi, kodwa kwakuwukuphela kwendlela yokuqinisekisa uphawu. Lolu hlobo lwemishini eguquguqukayo alukho encwadini yokufunda; izalwa ngokukhipha ukulingisa okumbalwa okubizayo nokuthola ukuthi kungani.
Ukwelashwa Kokushisa: Isiguquli Segeyimu Ethule
Lokhu kungase kube isici esinganakwa kakhulu. Izakhiwo ze-cobalt alloy casting zenziwe esithandweni sokushisa ukushisa, hhayi isithando somlilo. Ukwelashwa kwesixazululo, ukuguga-le mijikelezo ichaza i-microstructure yokugcina, ukusatshalaliswa kwe-carbide, kanye nezakhiwo zemishini. Kwenze kungalungile, futhi unengxenye nekhemistri elungile esebenza njengodoti.
Inkinga ukungaguquguquki. Ingxenye enkulu, ewugqinsi kanye nencane, ezacile evela ekushiseni okufanayo ayikwazi ukubona iphrofayili yezinga lokushisa elifanayo lesikhathi. Ingqikithi yengxenye ewugqinsi ingase ingafinyeleli izinga lokushisa lesixazululo, ishiye izigaba ezingathandeki. Lokhu sikufunde kabuhlungu ngochungechunge lwama-prototypes okufakelwa kokuhlinzwa. Amandla aqinile kanye nempilo yokukhathala bekungahambisani ngokwengxenye. Icala kwaba ukufana kwesithando somlilo kanye nephethini yethu yokulayisha. Kwadingeka sitshale kumafurnase anembayo anokulawula izindawo eziningi kanye nemithetho eqinile yokuphatha umthwalo. Manje, ngezingxenye ezibalulekile, sisebenzisa ngisho nama-thermocouples ashumekwe ezingxenyeni zomhlatshelo ngaphakathi komthwalo ukuze siqinisekise umlando wokushisa.
Kuyisinyathelo esibizayo, kodwa yilokho okuhlukanisa ukusakaza kwempahla nengxenye enokwethenjelwa okuphezulu. Awukwazi ukuhlola i-microstructure ibe ingxenye; kufanele ukucubungule. Leli khono le-backend yilona elenza umphakeli onjenge-QSY athembeke emsebenzini wezokwelapha kanye ne-aerospace, lapho amaphepha (ishadi lokuphatha ukushisa) libaluleke njengengxenye ngokwayo.
Isilinganiso Sangempela: Ukuhlaziywa Kokwehluleka Nokuphindaphinda
Ukuhlolwa kweqiniso kobungcweti ku izingxenye ze-cobalt alloy casting akusona isiqephu sokuqala esiphelele. Kuyindlela ophatha ngayo labo abahlulekayo. Sasinengxenye yephampu yamakhemikhali ehlulekile ngenxa yokukhathala ngemva kwamahora ambalwa. Ikhasimende, ngokuqondakalayo, lalicasukile. Ukuhlolwa kwesidumbu kwakuhilela ukuhlukanisa ingxenye, ukwenza ukuhlaziywa kwe-SEM/EDS endaweni ephukile. Sithole iqoqo lezinto ezifakiwe ezingezona ezensimbi—okungenzeka ucezu lwe-ceramic ephukile kusuka kugobolondo noma izinhlayiya ze-slag—olusebenza njengendawo yokuqalisa ukuqhekeka.
Lokho kuholele ekubuyekezweni okugcwele kwenqubo: ukwenza ngcono ukuhlunga kwethu kwensimbi ngesikhathi sithela (sashintshela kusihlungi segwebu le-ceramic ohlelweni lokungena), ukuhlolwa okuqinile kwamagobolondo e-ceramic ngaphambi kokuhlanganiswa, nokusebenzisa ukushushuluza kwe-slag okuvamile ngesikhathi sokuncibilika. 'Ukulungisa' kwakungesona isenzo esisodwa; bekuwukuqiniswa okuhlelekile kwezilawuli. Iqoqo elilandelayo liqhube ngaphandle kokukhishwa. Lokho kwehluleka, nakuba kwakunzima, mhlawumbe kwenza okuningi ukuthuthukisa inqubo yethu kunokugijima okuyimpumelelo okuyishumi nambili.
Lolu wuhlangothi olungathandeki. Akukhona mayelana nokuthengisa i-sizzle 'ye-aerospace-grade'. Kumayelana nokuba nelebhu ye-metallurgical, amasistimu ekhwalithi, nesiko lokuhlukanisa umsebenzi wakho, uthole umsuka, futhi uguqule indlela osebenza ngayo. Lokho iminyaka engu-30 yokukhuluma. Ukuqoqwa kwalezi zilungiso ezincane, eziwine kanzima, okwakha inqubo enokwethenjelwa yokwenza okuthile kube nzima njenge ingxubevange esekelwe cobalt ukuphonsa. Ekugcineni, ingxenye inhle kuphela njengesixhumanisi esibuthakathaka kuketango elide kakhulu, kusukela kuphethini ye-wax kuya ekuhlolweni kokugcina.
