Lapho abantu abaningi bezwa 'ingxube yezinga lokushisa eliphezulu', bavele bacabange ngezinjini zejethi noma mhlawumbe izinjini zomoya ezisebenza emhlabeni. Lokho akulona iphutha, kodwa umbono wezinga eliphezulu ogeja izinselele zangempela, ezilukhuni zokusebenza ngalezi zinto. Amashidi akhethekile abhala izinombolo ezihlaba umxhwele—ukumelana nokukhasa, imikhawulo ye-oxidation, amandla e-tensile ku-1000°C—kodwa awakutsheli mayelana nokungqubuzana ngesikhathi somshini, ukwakheka okusanhlamvu okungaguquki kusuka endaweni eyodwa yokushisa kuya kokulandelayo, noma ubunzima obukhulu bokuthola ukusakaza okuhlanzekile, okungenasici kusuka ku-superalloy esekelwe ku-nickel. Leso yigebe phakathi kwethiyori kanye nesitezi sesitolo.
I-Casting Conundrum: Lapho I-Theory Ihlangana Ne-Crucible
Ake sikhulume ngokusakaza, ikakhulukazi ukutshala imali okuyisinkwa sethu nebhotela kwa-QSY. Nge izinga lokushisa eliphezulu, ikakhulukazi asekelwe ku-nickel njenge-Inconel 718 noma i-Hastelloy X, yonke le nqubo iwuhambo oluqinile. Ukulawula izinga lokushisa lokuncibilika kubalulekile, kodwa kunjalo nezinga lokupholisa kusikhunta segobolondo. Ngokushesha kakhulu, futhi udala ukucindezeleka nezinyembezi ezishisayo; kancane kakhulu, futhi uthola ukukhula okusanhlamvu ngokweqile okubulala izici zomshini kamuva. Sibe nezingxenye eziphume zibukeka zilungile, kodwa sahluleka ukuhlola i-X-ray nge-subsurface shrinkage porosity. Ishidi ledatha lisho ukusakazeka okuhle kakhulu, kodwa alilokothi lichaze ukuthi yiziphi izindlela ezinhle kakhulu zeblade ye-turbine eyinkimbinkimbi ngokumelene ne-bushing elula.
Ngikhumbula iphrojekthi eminyakeni embalwa edlule yeklayenti emkhakheni wokucubungula okushisayo. Babedinga amashubhu akhazimulayo enziwe ngokwezifiso izinga lokushisa eliphezulu ingxubevange, kodwa isikhathi sokuhola esitokisini sebha sasinqandekile. Siphakamise ukuwasakaza ngenqubo yethu yokubumba igobolondo sisebenzisa ingxubevange yokusakaza yezinga elifanayo. I-chemistry yayiseduze, kodwa ingafani. Amaqoqo okuqala ambalwa aqhekekile ngesikhathi sokwelashwa kokushisa kwesixazululo. Inkinga? Landela izakhi—okuthile okufana nokuhluka okuncane kokuqukethwe kwe-boron noma i-zirconium phakathi kwe-spec esetshenzisiwe kanye nenkosi yethu yokulingisa—okuthinte amandla omngcele wokusanhlamvu ebangeni lokushisa elibalulekile. Kwakungekho ku-spec eyinhloko; yayisemibhalweni yaphansi. Bekufanele sibuyele emuva, silungise izinga lokushisa lokuthulula futhi siguqule izinga lokukhuphuka kokwelashwa kokushisa ukuze sincibilike. Isebenzile, kodwa yengeza amasonto okuzama nephutha. Yilokho iqiniso.
Lapha yilapho okuhlangenwe nakho kwe-Foundry kubalwa khona. Ngo I-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), ngaphezu kweminyaka engamashumi amathathu kugobolondo nokusakazwa kokutshalwa kwezimali, sakhe umtapo walezi zimiso ezicashile, ezingabhalwanga zamajometri nama-alloys ahlukahlukene. Akukhona nje ngokuba nesithando somlilo; kumayelana nokwazi ukuthi ku-alloy ethile esekelwe ku-cobalt, udinga ukulungisa ukushisa kwangaphambi kokushisa kwesikhunta ngokuhlukile kunesisekelo esisekelwe ku-nickel ukuze uzuze ukugcwaliswa kweyunifomu ezingxenyeni ezincane. Lolu lwazi alulandiwe; iqoqwa ngokuphindaphinda, futhi yebo, ngokwehluleka ngezikhathi ezithile.
Imishini: Iqiniso Elinzima Mayelana Nokusika Izinto Eziqinile
Uma ukulingisa kuwumdanso othambile, ukwenza imishini izinga lokushisa eliphezulu iyimpi elawulwayo. Zona kanye izakhiwo ezenza lezi zingxubevange zibe zinhle—ukuqina kokushisa okuphakeme kanye nokuthambekela kokuqina komsebenzi—ziwenza abe yiphupho elibi lamathuluzi okusika. Abantu bavame ukukuthatha kancane lokhu. Bacabanga ukuthi, Sine-CNC yesimanje, sizovele siyibambezele. I-nuanced kakhulu.
Iphutha elikhulu ukuliphatha njengomshini wensimbi engagqwali. Ngokuthile okufana ne-Inconel 625, uma ithuluzi lakho lingacijile, uma isivinini sakho nokuphakelayo kucishwe kancane, noma uma isipholile sakho singashayi endaweni efanele, awutholi chip enhle. Uthola unqenqema olwakhelwe phezu kwethuluzi, elibe selisebenza-lukhuni ingxenye oyisikayo. Manje uzama ukusika esikhumbeni esiqine nakakhulu, esikhiqiza ukushisa okwengeziwe, okwehlisa isithunzi sethuluzi. Umjikelezo ononya oholela ezingxenyeni ezilahliwe nezicekelwe phansi, ezibizayo ze-carbide. Sifunde lokhu kabuhlungu kusenesikhathi, sisebenzisa ibhajethi yamathuluzi ngaphambi kokuthi sishayele amapharamitha.
Kithina kwa-QSY, ukuhlanganisa imishini ye-CNC nemisebenzi yethu yokusakaza kuyinzuzo yamasu. Sivamise ukwenza umshini wokuqala onzima ezintweni zethu ezisakazwayo. Lokhu kusho ukuthi kufanele siphendule ngesikhumba esilingisayo, ukuhlanekezela okuncane okungaba khona, kanye nengcindezi eyinsalela yenqubo yokulingisa. Senze amaphrothokholi angaphakathi endlini okulungisa kanye nokulandelanisa imisebenzi ukuze kuncishiswe ukwethulwa kabusha kwengcindezi. Isibonelo, singenza ukwelashwa okushisa okwehlisa ingcindezi ngemuva komshini onzima kodwa ngaphambi kokuqeda ukubekezelela okubalulekile. Yengeza isinyathelo, kodwa ivimbela ingxenye ukuthi inganyakazi kamuva enkonzweni—isifundo esitholakala eqoqweni lemizimba yama-valve eyakhukhuleka ngaphandle kokucaciswa ngemva kokulethwa kokugcina.
I-Special in Special Alloys: Material Sourcing & Traceability
Olunye ungqimba oluvame ukunganakwa yimpahla eluhlaza ngokwayo. Akuwona wonke ama-Inconel 718 adalwe alingana. Ukusebenza kuncike ekuhlanzekeni kwempahla emsulwa kanye nokunemba kwezithako ze-alloy master. Sike sashintsha abahlinzeki bezinto ezibonakalayo ngenxa yokuqukethwe kwe-oksijini okungahambisani noma i-nitrogen phakathi kokuncibilika, okubonakala njengempilo embi yokukhathala ezindaweni zokugcina. Lapho ubhekene izinga lokushisa eliphezulu ngezicelo ezibucayi, isitifiketi sokuhlaziya (CoA) yibhayibheli lakho. Kwa-QSY, sihlola lokho eduze futhi ngokuvamile senza okwethu ukuhlola inhlansi noma ukuhlaziya okubonakalayo ezintweni ezingenayo, ikakhulukazi ama-alloys asekelwe ku-cobalt noma asekelwe ku-nickel. Awukwazi ukulawula lokho ongakukali.
Lokhu kugxila ekuthembekeni kwezinto ezibonakalayo kudlulela kuyo yonke inqubo yethu. Ngokufaka utshalomali, sisebenzisa amasistimu amagobolondo e-ceramic athile ahambisana nama-alloys asebenzayo ukugwema ukungcoliswa kwendawo. Ukungcola okunhlanhlathayo okuvela kugobolondo kungakha iphuzu elibuthakathaka eliba isizinda sokuqalisa ukuqhekeka ngaphansi kokuhamba ngebhayisikili okushisayo. Kuyimininingwane engabonisi kubukhulu bengxenye eqediwe, kodwa iyiyo yonke into yempilo yayo yesevisi endaweni enezinga lokushisa eliphezulu.
Ukuhlaziywa Kokwehluleka: Uthisha Obaluleke Kakhulu
Olunye ulwazi lwethu olubalulekile luvela ezingxenyeni ezingaphumelelanga. Ekuqaleni komsebenzi wethu nge-high-chromium nickel alloy yengxenye yesithando somlilo we-pyrolysis, saba nokwehluleka kwenkambu. Ingxenye yaqhekeka ngomugqa obonakala sengathi awuhleliwe. Ukuhlaziywa kwe-Metallurgical kukhomba ku-sigma phase embrittlement. Ingxubevange yayithambekele kuyo uma igcinwe ebangeni elithile lokushisa isikhathi eside kakhulu. Umjikelezo wethu wokwelapha ukushisa, owawujwayelekile kuma-alloys afanayo, wawuphushele kulelo windi ngokungaqondile. Ukulungiswa bekungekona ngokushintsha ukulingisa; kwakumayelana nokuklama kabusha ukwelashwa kokushisa kwangemva kokusakazwa ukuze kucime kuleyo ndawo yokushisa ebucayi ngokushesha. Manje, nganoma yikuphi okusha izinga lokushisa eliphezulu ingxubevange iphrojekthi, asibheki nje ukwelashwa okujwayelekile; simba emidwebeni yesigaba kanye nezindlela ezingaba khona ze-embrittlement. Kuwumkhuba wokuzivikela ozalwa esifundweni esibuhlungu.
Lesi simo sengqondo silolonga indlela esibhekana ngayo namaphrojekthi amasha namakhasimende. Uma iklayenti elivela emkhakheni wokuphehla amandla liza kithi nesicelo sengxenye yesishintshi sokushisa eyakhelwe ngokwezifiso sisebenzisa ingxubevange ekhethekile, imibuzo yethu yokuqala ayigcini nje ngokuphathelene nobukhulu. Zimayelana nomoya wokusebenza (i-oxidizing? carburizing?), iphrofayili yomjikelezo oshisayo, nesimo sokucindezeleka esilindelekile. Lokhu kwazisa yonke into kusukela ekukhethweni kwe-alloy (mhlawumbe ibanga elithuthukisiwe le-silicon lokumelana ne-oxidation engcono?) kuya ekwakhiweni kwama-feeders kanye nezikhuphukeli esikhunjini ukuze kuqinisekiswe ukuzwakala ezindaweni ezibucayi kakhulu.
Ukuhlanganiswa: Kusukela ku-Foundry kuya Engxenyeni Eqediwe
Inani langempela kumakhasimende ethu amaningi QSY ilele ekuhlanganisweni okuqondile—ukuphatha uhambo olusuka ensimbi encibilikisiwe ukuya engxenyeni emshinini, elungele ukufakwa. Ngoba izinga lokushisa eliphezulu, lokhu kuqhubeka kubalulekile. Umakhi wemishini udinga ukuqonda ukwakheka kwangaphakathi okungenzeka kokulingisa; unjiniyela we-Foundry udinga ukwazi ukuthi izindawo ezibucayi zomshini zizoba kuphi ukuze kuqinisekiswe ukuminyana okwengeziwe lapho.
Muva nje siqedele ukusebenzisa ama-turbine shrouds sokuthuthukisa i-turbocharger yezimboni. Izinto ezisetshenziswayo bekuyinselelo eyinselele esekelwe ku-nickel. Ngokulawula kokubili ukusakaza nokunemba kwemishini ye-CNC endlini, singaxhumanisa. Siphonsa izingxenye ngesitoko esengeziwe ebusweni bokukhwelana, bese senza ukwelashwa okushisayo kwe-isostatic pressing (HIP) ukuvala noma iyiphi i-micro-porosity. Kungemva kwe-HIP kuphela lapho senza imishini yokugcina. Lokhu kulandelana, kunqume ngokubambisana phakathi kwamaqembu ethu okulingisa nemishini, kuqinisekise ukuthi sisusa noma yikuphi ukuhlanekezela okungaphezulu kusuka ku-HIP kuyilapho sifinyelela ukuminyana okuphelele kokubalulekile. Umphumela waba ingxenye enokuqina kokusebenza okungcono kunalapho izinqubo zihlukaniswa phakathi kwabathengisi abahlukene.
Yilokho ukuphela komdlalo. Ukusebenza ngama-alloys okushisa aphezulu akusho nje ukukhetha into ethile kukhathalogi. Imayelana nokuqonda ukuziphatha kwayo ngesinyathelo ngasinye sokuguqulwa—kusuka oketshezini kuya kokuqinile, ukusuka ekubunjweni okungalungile ukuya engxenyeni enembayo. Izinombolo eziseshidini lokucacisa ziyisiqalo sengxoxo, hhayi isiphetho. Okunye kufundwa endaweni esunguliwe, ekulawuleni i-CNC, futhi kwesinye isikhathi, ekukhanyeni okusangulukisayo kombiko wokuhlaziya ukwehluleka. Kuyinkundla enzima, kodwa yilokho okwenza ingxenye esebenza ngempumelelo, eminyakeni eminingi kamuva endaweni eshisayo eshisayo, yanelise kakhulu. Kusho ukuthi uthole yonke imininingwane engabonakali kahle.
