Uma uzwa 'ukunemba kwe-wax investment casting', iningi licabanga ukuthi kumayelana nokwenza izimo eziyinkimbinkimbi. Yilokho okungaphezulu. Indaba yangempela isekulweleni ukwethembeka kohlangothi, impi emelene nokuhlanekezelwa kwegobolondo le-ceramic, kanye nezingxoxo eziqhubekayo phakathi kokuziphatha kwe-alloy kanye nengcindezi yokushisa. Akuwona umlingo; kuwuchungechunge lokuvumelana okulawulwayo.
Umdlalo Weshell: Lapho Ukunemba Kunqotshiwe noma Kulahlekile
Wonke umuntu ubheka iphethini ye-wax, futhi ngokuqinisekile, umjovo omuhle uyisiqalo. Kodwa isakhiwo igobolondo? Yilokho okunqumayo buthule. Ngike ngabona izitolo zithela imali kumaphethini aphrintiwe we-3D anokulungiswa okuphezulu kuphela ukuze zilahlekelwe yiyo yonke leyo ncazelo yonqenqema kujazi lokuqala lokucwilisa. I-slurry viscosity, usayizi wezinhlamvu ze-stucco kanye ne-morphology-thola lokhu okungalungile, futhi ubhaka ngokuhlanekezela kusukela ngosuku lokuqala. Igobolondo alisona nje isikhunta; iyi-corset yesakhiwo ngesikhathi sokuthela kanye nesithiyo ngesikhathi sokupholisa. Uma ukunwetshwa kwayo okushisayo kungenabo ubudlelwano obungabikezelwa nensimbi yakho, ujaha umsila wakho ekubekezeleni.
Thatha umgodi ojwayelekile: ukuthatha igobolondo elijiyile kuhlala kungcono ekuzinzeni kohlangothi. Ngokusakazwa kwensimbi enesigaba esisindayo, mhlawumbe. Kodwa engxenyeni ye-aerospace enodonga oluncane olusekelwe ku-nickel superalloy, igobolondo eliqine kakhulu lingabangela ukudabuka okushisayo njengoba likhawulela ukufinyela. Udinga igobolondo eliqine ngokwanele ukubamba insimbi, kodwa elinokwanele 'kupha' ezingeni lokushisa elifanele. Kulapho amasistimu wokuhlanganisa ama-proprietary binder kanye ne-stucco application egqinsiwe evela kwabasunguli abanolwazi kwenza umehluko. Ukuzwakala nomuzwa, hhayi nje ishidi elicacisiwe.
Ngikhumbula iphrojekthi yendawo yenzwa ye-turbine, lapho i-spec yayidinga ukubekezelelana okungu-±0.1mm kubhore yangaphakathi. I-wax yayiphelele. Sisebenzise ijazi elijwayelekile lobuso be-zirconia. Ukuthulula kokuqala kungena ngokuqhubekayo ku-+0.15mm. Inkinga? Ijazi lobuso belisebenza kakhulu nge-superalloy, lidala isendlalelo sokusabela esijiyile kunokulindelwe esishintshe ngempumelelo usayizi we-cavity. Sashintshela ku-silica-based prime slurry—ukusabela okuncane, umgoqo ongasebenzi—futhi sabuyela ekubekezeleni. I ukunemba elahlekile utshalomali lwe-wax casting inqubo igcwele lokhu kusebenzisana okuncane.
Ukuziphatha kwe-alloy: Uzakwethu Ongabikezeli
Uma sikhuluma ngama-alloys, kulapho ulwazi olujwayelekile lwehluleka khona. Ukunemba kokutshala imali ye-304 stainless iwumhlaba ngaphandle kokuwenza nge-alloy esekwe ku-cobalt njenge-Stellite 6 noma i-nickel-based efana ne-Inconel 718. Ubumanzi bazo, izici zokushwabana, nokugcina ukushisa kuhluke kakhulu. Awukwazi ukusebenzisa i-gating efanayo nefilosofi ekhuphukayo.
718, ngokwesibonelo, inalolo hlobo olukhulu lokuqandisa. Ifuna ukwenza i-micro-porosity uma ungalawuli indlela yokuqinisa ngamandla. Lokhu sikufunde kabuhlungu emsebenzini wokuqala wobakaki benjini. Indawo enhle, yadlula i-X-ray, kodwa yehlulekile ekuhloleni ukukhathala. Inkinga iye yahlukaniswa yaba sempambanweni engondlekile kahle. Isixazululo bekungekona nje ukwengeza insimbi eyengeziwe (isikhuphukeli esikhulu); kwakumayelana nokubeka kabusha amasango ukuze kwakheke izinga lokushisa eliqhubekayo. Kwadingeka sicishe sicabange emuva sisuka esimweni esiqinile siye ekuthululeni uketshezi.
Kungakho umlando we-Foundry's material ubalulekile. Isitolo esifana I-Qingdao Qiangsenyuan Technology (QSY), ekhuluma ngamashumi eminyaka ngama-alloys akhethekile, ayigcini nje ngokubhala izinto. Babonisa imininingwane egciniwe eqoqiwe yamazinga okushisa okuthela, izinga lokushisa langaphambi kokushisa kwamagobolondo, nezimiso zokupholisa zomndeni ngamunye. Leyo nkumbulo yesikhungo iyona evimbela ukuhlolwa nephutha elibizayo kumaphrojekthi amasha.
I-Machining Handshake: As-Cast vs. Finished
Ayikho ingxenye 'enemba' ngempela ephuma egobolondweni. Kukhona njalo isibonelelo somshini. Ikhono langempela ukulinciphisa. Umgomo ukuletha ukusakaza okuzinzile, okunengcindezi encane eyinsalela, ukuze kuthi uma ishaya umshini we-CNC, inganyakazi ngokungalindelekile njengoba usika kuyo.
Ngike ngaphikisana nabaklami abacacisa isibonelelo sokunciphisa insingo yonke indawo, njengo-0.5mm. Lokho kuyiphupho lamajiyometri amaningi. Ibeka ingcindezi engenakwenzeka enqubweni yokuphonsa futhi ngokuvamile iholela ekulahlekeni ngesikhathi somshini lapho ithuluzi livele liqabule indawo enyakazeke kancane. Indlela ewusizo kakhulu ingeyokuhlanganyela: thola izici ezibalulekile zedatha nezindawo zokuvala. Bamba ukubekezelela okuqine kakhulu futhi uqedele kahle kulabo abasenqubweni yokusakaza (ngezinye izikhathi ngisho nokuma kwenetha), bese uvumela ukuvunyelwa okuvulekile kumavolumu angabalulekile. Yilapho izinsiza ezididiyelwe zikhanya khona. Imodeli ye-QSY yokunikela ngazo zombili ukutshala imali kanye nokwenza imishini ye-CNC ngaphansi kophahla olulodwa kusho ukuthi iluphu yempendulo imfushane. Ithimba lemishini lingatshela i-Foundry, Hey, sibona indawo eqinile engashintshi kule flange, futhi lingakwazi ukuyilandelela emuva enkingeni yokupholisa yendawo ekubunjweni.
Sake saba nomzimba we-valve lapho abaphathi bentambo ye-as-cast babengaphakathi kwe-spec, kodwa ngesikhathi sokuthepha, ithuluzi lalizulazula ngezikhathi ezithile. Umlandu? Hhayi ukunemba kobukhulu, kodwa amaqoqo amancane e-micro-porosity ayengaminyene ngokwanele ukuthi abonakale ku-X-ray kodwa aguqule amandla okusika. Ukulungiswa bekuwukulungisa ukukhuphuka kwendawo ukuze kuthuthukiswe ukuqiniswa kokuqondisa ngakulabo baphathi. Kwakuyisixazululo sokusakaza senkinga yemishini.
I-Tooling Mindset: Digital to Physical
Ukuthuthela kwemboni ku-3D wax ephrintiwe noma amaphethini e-resin kuwuguquko, kodwa akuqondakali. Kuhle kuma-prototypes nama-cores angaphakathi ayinkimbinkimbi. Ukuze kukhiqizwe umthamo, ithuluzi lensimbi lendabuko lomjovo we-wax kuseyinkosi yokuvumelana nokuqedwa kwendawo. Iphuzu ukukhetha indlela efanele.
Intambo yedijithali ibalulekile, nokho. Imodeli ye-CAD ephelele ayisho lutho uma umklami wamathuluzi engabaleli izici zokuncipha ngendlela efanele. Futhi akulona iphesenti elifanayo. I-anisotropic—ihlukile ngezimbazo ezihlukene ngokusekelwe engxenyeni yejometri kanye nokuvinjelwa egobolondweni. Abasunguli abahle basebenzisa izinto eziguquliwe zokuncipha, ngokuvamile kusukela kudatha yabo yomlando emimo efanayo nama-alloys. Bakha isinxephezelo ekusetshenzisweni kwamathuluzi kusukela ekuqaleni. Lokhu kulungiswa kwangaphambilini kuwuphawu lweqiniso ukunemba elahlekile wax umsebenzi.
Ngikhumbula ngihlola umhlinzeki ngochungechunge lwama-impeller. Amasampula omthengisi oyedwa abenezindawo ezinhle ze-aerodynamic kodwa ahluleka ukuhlola ukugeleza. Siwadwebe futhi sathola ukuthi amaphrofayili e-vane ayecishiwe ngokucashile—iphethini yayikalwe ngesici esisodwa, sokuncipha okufanayo. Omunye umthengisi, owake wenza umsebenzi ofanayo esikhathini esidlule, wasebenzisa isici sesikali esiguquguqukayo, wajiya iphethini kancane ekuqondeni kokuphoqeleka kwehabhu elimaphakathi. Ukulingwa kwabo kwenziwa ngokucaciswa. Lolo ulwazi olufihliwe.
Ikhwalithi Iwuhlelo, Hhayi Ukuhlola
Okokugcina, ukunemba akuqinisekiswanga ekugcineni; yakhelwe kuzo zonke izinyathelo. Yindawo elawulwayo yegumbi le-wax (izinga lokushisa, umswakama). Ukuhlola ngokucophelela ama-cluster assemblies ngaphambi kokuqoqwa kwamagobolondo. Kuyijika lokudubula elibhaliwe le-autoclave yokukhipha inwayi kanye nesithando somlilo sokucwilisa. Ukuchezuka kumazinga okushisa okudubula kwegobolondo kungashintsha ukungena kwawo namandla, okuholela ekuqhekekeni kwamagobolondo ngesikhathi sokuthela.
Izinqubo zangemuva kokusakazwa nazo zibalulekile. Uzisika kanjani izingxenye zesihlahla? Isondo eliqhumayo lingadala ingcindezi kanye nemifantu emincane uma lingenziwanga ngokucophelela. Ukwelashwa kokushisa kungenye indawo yamabhomu. Isixazululo esiphatha ukusakaza okuyinkimbinkimbi ukuze kuthuthukiswe izakhiwo ze-alloy ngaphandle kokudala i-warpage noma isikali se-sintering esichitha izindawo kuyibhalansi ethambile.
Lo mbono ophelele yiwo ohlukanisa ingxenye yomphakeli nozakwethu wokukhiqiza. Lapho inkampani ithanda QSY igcizelela iminyaka engu-30 ekulingiseni nasekukhiqizeni imishini, kuyikhodi yokuthi uphile kulezi zinkinga ezixhumene. Cishe babonile ukuthi uguquko esihlabathini segobolondo luthinta kanjani ukusebenza kahle, noma ukuthi ukushintshwa kokwelashwa kokushisa kungasindisa kanjani iqoqo lezingxenye ezinobukhulu obuseceleni. Lokho ukuthungwa komhlaba wangempela ukunemba elahlekile utshalomali lwe-wax casting-ubuciko obujulile, kwesinye isikhathi obungcolile, obuhlala bunemininingwane yokuxhuma okuguquguqukayo okuyikhulu ukuze ushaye ishidi elilodwa, elingathetheleli. Akukona nje mayelana nengcina.
