Uma uzwa 'izingxenye ze-nickel based alloy', isithombe esiseduze ngokuvamile singesinye sezingxenye ezingabhubhi, zobuchwepheshe obuphezulu ezihloselwe izinjini zejethi noma izinsimbi ezijulile zolwandle. Lokho akulona iphutha, kodwa umbono wezinga eliphezulu ocwebezela iqiniso elibi lokuzenza. Indaba yangempela ayigcini nje ngokuphathelene nezinto ezibonakalayo ezihlaba umxhwele—amandla aphezulu okushisa, ukumelana nokugqwala—imayelana negebe elikhulu phakathi kokuba nemodeli ye-CAD nokubamba ingxenye ephelile, esebenzayo engahluleki ngaphansi kwengcindezi. Amaqembu amaningi kakhulu okuthenga abona ibanga lengxubevange, njenge-Inconel 718 noma i-Hastelloy C-276, futhi acabanga ukuthi umsebenzi wenziwa kakhulu. Iqiniso liwukuthi, yilapho umsebenzi wangempela, kanye nekhanda elibuhlungu langempela, liqala khona.
I-Casting Conundrum: Konke Kukusiphakeli
Ake sikhulume ngokusakazwa kokutshalwa kwezimali, umzila ojwayelekile wamajiyometri ayinkimbinkimbi. Ngama-nickel alloys, akugcini nje ngokuthela insimbi encibilikisiwe egobolondweni le-ceramic. Ukuziphatha kokuqinisa kuyiphupho elibi uma ungakulawuli ngokucophelela. Ukuncipha yisitha. Awukwazi nje ukwengeza ama-feeders amakhulu yonke indawo; ubhekene nezinto ezibizayo, futhi isisindo eseqile kuvame ukuba yisithiyo esibalulekile sokuklama. Ngibone izingxenye lapho idizayini yokuqala yesistimu yokugenca, esebenze kahle ngensimbi engagqwali, yaholela ekuncipheni komugqa ophakathi nendawo engxenyeni ewugqinsi. ingxubevange ye-nickel umzimba we-valve. Le ngxenye yayibukeka iphelele ngaphandle, kodwa ukuhlolwa kwe-ultrasonic kwembule i-porous core eyayingaqhekeka ngaphansi kwengcindezi. Ukulungisa kwakungeyona into elula; kwakuhilela ukuklanywa kabusha okuphelele kohlelo lokuphakelayo, kusetshenziswa isofthiwe yokulingisa ukumodela amagradient ashisayo, bese iqinisekisa ngochungechunge lokuthululwa kwesilingo esibizayo.
Yilapho okuzuzayo okuvela ku-Foundry kade kunebhulokhi. Inkampani efana I-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), ngeminyaka yabo engamashumi amathathu ekulingiseni, izoba nemigomo yangaphakathi yalokhu. Babengeke nje bathembele ekufanisweni; bangaba nelabhulali yedatha yomlando evela kumajiyometri afanayo, bazi ukuthi ngoshintsho oluthile lokujiya kodonga ku-a ingxenye yengxube ye-nickel esekelwe, udinga okokuphakelayo kwesilinganiso esithile se-diameter-to-height, esibekwe nge-engeli enembile. Lolo hlobo lolwazi oluyimfihlo alukho kunoma iyiphi incwadi; yakhiwe ngabalingisi abahlulekile kanye nabaphumelele eminyakeni edlule.
Inqubo yokubumba igobolondo ngokwayo ibalulekile. Ukunwetshwa kokushisa kwe-ceramic kumele kuhambisane nama-alloy ukugwema ukudabuka okushisayo noma ukonakala kwendawo. Kuma-alloys e-high-gamma-prime anjenge-IN-738, asetshenziswa kuma-turbine blades, izinga lokushisa lokushisa ngaphambi kwesikhunta kanye nezinga lokushisa lokuthela linefasitela mhlawumbe elingu-30 degrees Celsius. Ungaphuthelwa, futhi uthola ukungahambi kahle noma ukukhula okusanhlamvu ngokweqile. I-ballet yokushisa okudlulele kanye nesikhathi esinembayo.
Imishini: Lapho Ithuluzi Liya Ukufa
Uma ukusakaza kuwukushisa okulawulwayo, ama-machining nickel alloys kuyimpi ye-attrition. Izinga lokuqinisa umsebenzi liyingozi. Uthatha ukusika, futhi impahla engaphansi kwethuluzi iba lukhuni ngokushesha. Ngena namapharamitha angalungile, futhi awusika—uhlikihla nje futhi ukhiqiza ukushisa okwanele ukuze ushisele ucezu lokusebenza ethuluzini. Ngifunde lokhu kabuhlungu kusenesikhathi, ngizama ukwehlisa ububanzi kushafti ye-Inconel 625. Kusetshenziswe ithuluzi le-positive-rake, isivinini esijwayelekile kanye nokuphakelayo kwensimbi eqinile. Ngemizuzu nje embalwa, ishuqulo lase lingasekho, futhi ingxenye engaphezulu yayisiqinile, icwebezela eyayidinga amahora amaningi ukuze igaywe.
Isu liphambene. Udinga amathuluzi abukhali, ama-rake-rake, ngokuvamile i-carbide noma i-ceramic, enokusetha okuqinile. Izivinini eziphansi, amazinga okuphakela aphezulu, nokujula okungaguquki, okunolaka kokusika. Umgomo uwukungena ngaphansi kwesendlalelo esiqiniswe ngumsebenzi kusuka kuphasi yangaphambilini bese ugunda impahla ngaphambi kokuthi iqine ngokumelene nethuluzi. Ukupholisa akukona nje ukupholisa; iyi-lubricant yokuvimbela unqenqema olwakhelwe futhi kufanele ilethwe ngomfutho ophezulu khona kanye endaweni yokusika. Nalapho, ukuphila kwamathuluzi kukalwa ngemizuzu, hhayi amahora. Okwe-complex ingxubevange ye-nickel I-impeller yenziwa ngomshini ku-5-axis CNC, izindleko zamathuluzi zingaba ingxenye ebalulekile yawo wonke umsebenzi.
Kungakho amandla okwenza imishini asohlwini lwewebhusayithi efana ne-QSY angelona nje ibhokisi lokuhlola. Esho ukuthi bayakwenza CNC imishini ama-alloys akhethekile asho ukuthi batshale imali kumathuluzi omshini afanele (i-torque ephezulu, ama-spindle aqinile), banokufinyelela kumathuluzi akhethekile, futhi, ngokubaluleke kakhulu, banabahleli bohlelo kanye nama-opharetha abaqondayo le mingcele engajwayelekile. Umehluko phakathi kwesitolo esingasebenzisa ingxenye kanye naleso esingakhiqiza ingxenye enembe ngokwengxenye enobuqotho obungaphezulu obungeke buqalise ukuqhekeka kusevisi.
I-Dimensional Stability Ghost
Olunye ugibe olucashile ukucindezeleka okuyinsalela. Lezi zingxenye zivame ukuphuma ekubunjweni noma ekubunjweni ngokucindezeleka okukhulu kwangaphakathi. Uwashicilele ukuze abekezelele kahle ezingeni lokushisa legumbi. Khona-ke, usebenzisa ukwelashwa kokushisa kwangemva komshini—ukuthi, ukwelashwa kwesixazululo nokuguga kwama-alloys aqina imvula—ukufeza izici zokugcina zemishini. Lowo mjikelezo wokushisa ungadambisa ukucindezeleka, futhi ingxenye iwabe. Kwesinye isikhathi bambalwa wena, kepha okwanele ukukuchitha uma ukubekezelelana okuqinile kuyadingeka ezigabeni ezincanyana.
I-Workaround iwukulandelana komshini onzima, ukukhulula ingcindezi, bese uqeda ukukhanda. Ngezinye izikhathi kufanele wenze ukwelashwa kokuguga okuphakathi. Yengeza izinyathelo, izindleko, nesikhathi. Ngikhumbula iphrojekthi yezikhathi eziningi lapho siphuthelwe khona lokhu. Iqedile ukwenza ingxenye ngomshini kusuka ku-cast blank, wabe eseyithumela ukuze izophathwa ngokushisa. Yabuya yakhothama okobhanana. Kwadingeka sizame ukuyiqondisa, okuyinto eyingozi, futhi ekugcineni kwadingeka siyilahle. Isifundo kwakuwukuxoxa ngaso sonke isikhathi ngokulandelana okugcwele kokukhiqiza—kusuka kokungenalutho kuya ekuphathweni kokugcina—nomphakeli kusengaphambili. Uzakwethu ongumakadebona ngabe umaka leyo ngozi ngokushesha.
Ukushisela nokulungisa: Qhubeka Ngokuqapha Okudlulele
Ngezinye izikhathi, kutholakala iphutha lokulingisa, noma ingxenye idinga ukwakhiwa noma ihlanganiswe. Ama-alloys e-nickel e-Welding yinto ekhethekile ngokwayo. Bathambekele ekuqhekekeni okushisayo, i-porosity, kanye nokuhlukaniswa kwezakhi ze-alloying. I-filler metal kufanele ifaniswe ngokucophelela, ngokuvamile ibe nokwakheka okuhluke kancane ukuze kulawulwe ukuqhekeka. Indawo kumelwe ihlanzeke ngendlela efanele—ingabi nasibabule, ingabi nomthofu, ingabi namafutha. Ngisho namanani okulandelela angabangela i-embrittlement.
Ukulawula ukushisa kwangaphambi kokushisa ne-interpass akuxoxiswana ngakho, njengokwelashwa okukhethekile kokushisa kwangemva kokushiswa kwamabanga amaningi ukubuyisela ukumelana nokugqwala endaweni ethinteke ukushisa. Ngiyibonile imizamo yokuhlanganisa ukushisela isici esincane sobuso ku-casing yepompo kusetshenziswa intonga evamile yokugcwalisa i-stainless. Bekubukeka kulungile ekuqaleni, kodwa kusevisi, leyo ndawo yokushisela yaba yindawo yokuqala yokuqhekeka kokugqwala kwengcindezi. Izindleko zokulungisa zaledlula kude inani lengxenye. Ezingxenyeni ezibucayi, izinqubo zokushisela kufanele zifaneleke, futhi abashiseli ngokwabo badinga ukuqeqeshwa okuqondile kwalezi zinto.
I-Supplier Equation: Ngaphezu Kohlu Lwezinto Ezibalulekile
Lokhu kungiletha emnyombweni wokufuna izingxenye ze-alloy ezisekelwe ku-nickel. Awugcini nje ngokuthenga impahla; uthenga inqubo yolwazi lomphakeli kanye nokuvuthwa kwabo kokuxazulula izinkinga. Uma uhlola inkampani, iminyaka yayo ebhizinisini, njengeminyaka engama-30 ye-QSY, iphakamisa ukuthi izulazule kulezi zingozi. Kodwa udinga ukumba ujule. Ingabe banazo ama-metallurgist kubasebenzi noma lapho befona? Bangakubonisa izibonelo zokuthi bazixazulule kanjani izinkinga ezifanayo—njengokulawula isakhiwo sokusanhlamvu ekubunjweni okunezindonga ezincane noma ukugqokwa kwethuluzi lokuphatha ekugayweni kwe-deep-pocket milling? Bangakwazi yini ukucacisa indlela yabo yokuqinisekisa i-athikili yokuqala, ngaphandle kokuhlola nje ubukhulu?
Isingeniso sewebhusayithi sisho abasebenza nabo ama-alloys akhethekile (ama-alloys asekelwe ku-cobalt, ama-alloys asekelwe ku-nickel, njll.). Lokho njll kubalulekile. Ibonisa amandla adlulela ngale kwemenyu evamile. Abahlinzeki abangcono kakhulu yilabo abenza inselele. Bazobuza ngendawo yohlelo lokusebenza, imijikelezo yokulayisha, izindlela zokuhluleka ozama ukuzigwema. Bazongabaza idizayini yakho yokwenza izinto, baphakamise ama-engeli asalungiswa acashile noma izinguquko zerediyasi ezenza ingxenye iphonseke kakhudlwana noma ikwazi ukuhleleka ngaphandle kokufaka engozini umsebenzi. Leyo ngxoxo ibaluleke ngaphezu kwenani eliphansi ngekhilogremu.
Ekugcineni, izingxenye ze-nickel alloy eziphumelelayo zizalwa ngokubambisana phakathi komklami ocabangelayo kanye nomkhiqizi onekhono, okwaziyo ukuxhumana. Okuqukethwe kuyisithembiso sokusebenza, kodwa leso sithembiso sifezwa kuphela ngokuqonda okujulile kwalo lonke uhambo olusuka engot kuya engxenyeni efakiwe. Imoshekile, iyabiza, futhi igcwele amaphuzu okungenzeka awehluleki. Kodwa uma senziwe kahle, akukho okunye okungenza umsebenzi.
