Masikhulume iqiniso, lapho abantu abaningi bezwa 'i-wax metal casting', babona ngeso lengqondo ingcweti eyedwa eqopha ngokucophelela umfanekiso oqoshiwe wezinyosi ngaphambi kokuba unyamalale kushunqa intuthu ukuze ufakwe esikhundleni sensimbi ekhazimulayo. Leso sithombe sothando siyingxenye yendaba, kodwa iqiniso lezimboni-lokho esikubiza ngokuthi ukutshala imali-i-ballet eqinile, enembile, futhi evame ukukhungathekisa ye-chemistry, thermodynamics, nokubekezela okuphelele. Umbono oyiphutha omkhulu? Ukuthi kuyisinyathelo esilula, inqubo eyodwa 'ye-wax elahlekile'. Akunjalo. Kuwuchungechunge, futhi sonke isixhumanisi, kusukela kuphethini ye-wax yokuqala kuya ekunyakazeni kokugcina, kuyiphuzu elingase lehluleke. Ngibone ukulingisa okuningi kukhishwe kubhamuza lomoya elincane elivaleleke egobolondweni le-ceramic kunanoma iyiphi i-metallurgical flaw. Kulapho-ke kwenzeka khona umsebenzi wangempela.
I-Wax iyisiqalo nje
Wonke umuntu ubheka i-wax, futhi ngokuqinisekile, ibalulekile. Kodwa hlobo luni lwe-wax? Akuyona ingcina yokuqopha ngobuciko. Sisebenzisa ama-wax omjovo akhiwe ngobunjiniyela, izingxube ezakhelwe amanani athile okushwabana, okuqukethwe komlotha, nokuqina. Endaweni efana ne-Qingdao Qiangsenyuan Technology Co., Ltd. (QSY), namashumi eminyaka abo kugeyimu, bazoba nomtapo wezincwadi we-wax wemisebenzi ehlukene. Abakaki be-aerospace abanezindonga ezincane badinga isici sokugeleza esihlukile kunomzimba wevalvu oqinile. Ukwenza amapharamitha womjovo angalungile lapha—izinga lokushisa, ingcindezi, isikhathi somjikelezo—kusho ukuthi iphethini izohlanekezelwa kamuva. Futhi ukuhlanekezela esigabeni se-wax kuphindaphindeka engxenyeni yokugcina yensimbi. Ngifunde ukuthi indlela enzima kusenesikhathi, ukukhiqiza inqwaba yezikhala zegiya ebezingaphandle ngendlela engaqondakali; Wayilandelela emuva ekupholiseni kwengcina kancane edayini.
Ukuhlanganiswa kwephethini, noma 'isihlahla', kungobunye ubuciko obungalinganiselwe. Akukhona nje ukunamathisela izingxenye ze-wax ku-sprue. Uklama isistimu yokudla yensimbi encibilikisiwe. Ukuthi uziqondisa kanjani izingxenye, ububanzi babagijimi, ukubekwa kwamasango—lokhu kudinga ukuqina. Ukungangeneli kahle kuholela emigodini eshwabene, izinkinga zangaphakathi ezingase zivele ku-X-ray. Ngikhumbula iphrojekthi ye-pump impeller ku-duplex stainless steel lapho sasilokhu sithola khona i-porosity kuhabhu. Sidizayine kabusha isihlahla se-wax, sengeza amashaneli amancane, aqondiswe kokuphakelayo, futhi sacwengeka. Yilawa ma-tweaks, azalwa ngenxa yokwehluleka, ahlukanisa isitolo semisebenzi nochwepheshe.
Bese kuba ijazi lokuqala, idiphu yokuqala ye-ceramic. Lokhu akuyona into evamile. I-slurry, ingxube kafulawa we-silica ocolekileyo kanye ne-binder, kufanele imanzise i-wax kahle ukuze ibambe yonke imininingwane. Noma isiphi isiqeshana esiludaka alunamatheli ekubeni 'amafins' noma iqhubu ekubumbeni. I-stucco, noma isihlabathi esiphikisayo, sisetshenziswa ngokushesha ngemva kwalokho. Usayizi wegrit waleli jazi lokuqala yiwona omuhle kakhulu - yilokho okukunikeza isiphetho esingaphezulu. Ngisebenzise amahora amaningi ngesibonakhulu ngiqhathanisa ufulawa we-zircon vs. i-silica ehlanganisiwe yalelo jazi lokuqala engxenyeni edinga ukuqedwa kwe-Ra 3.2 microinch. Ukukhetha kubalulekile.
I-Shell Building: Ukuhlolwa Kwesineke
Ukwakha igobolondo kuwumjaho wemarathoni, hhayi ukugijima. Ugcoba ijazi ngemva kwejazi, ushintshana phakathi kwe-slurry kanye ne-stucco eqinile ngokuqhubekayo (njenge-aluminosilicate), uyeke ungqimba ngalunye lome ngokuphelele endaweni elawulwayo. Umswakamo yisitha lapha. Umswakama ophezulu ubambezela ukomisa, okuholela ebuthakathaka begobolondo. Ngokushesha kakhulu, futhi uthola imifantu. Sihlose izendlalelo eziyisi-7 kuye kweziyi-9 ngokujwayelekile, kodwa ekubunjweni kwensimbi okukhulu, kungaba ngu-12 noma ngaphezulu. Isendlalelo ngasinye sengeza ukujiya namandla ukuze simelane nokucindezela kwe-ferrostatic kwensimbi encibilikisiwe. Ngike ngaba namagobolondo ahlulekayo—ukuqhekeka okuyinhlekelele phakathi nokuthela—ngoba saphuthuma imijikelezo yokomisa ngosuku olunomswakama lwasehlobo. Isifundo esibizayo ekuhlonipheni inqubo.
I-Dewaxing yilapho igama elithi 'i-wax elahlekile' livela khona, futhi kuyisigaba esinodlame. Asiyincibilikisi ingcina ngobumnene. Indlela evamile i-autoclave dewaxing: igobolondo lingaphansi kwe-steam ephezulu yokucindezela, eshisa ngokushesha i-wax, ibangele ukuba yande futhi iphume. Uma igobolondo lingomile ngokuphelele, umfutho we-steam ungawuphephethela ngaphandle ngaphakathi. Ngaphandle kwalokho, ukukhishwa kwe-flash fire dewaxing—ukuphonsa igobolondo esithandweni esishisayo—kuyashesha kodwa kuyingozi kakhulu ekushaqekeni okushisayo. Umgomo uwukushiya umgodi we-ceramic ophelele, ohlanzekile. Noma yimuphi umlotha we-wax osele ungangcolisa indawo yensimbi kamuva.
Ngemuva kokukhishwa kwe-wax, igobolondo lishiswa esithandweni ekushiseni okuphezulu, ngokuvamile cishe ku-1000 ° C. Lokhu kwenza izinto ezimbili: kushisa noma yiziphi izinsalela zokugcina ze-wax noma i-binder, futhi kushise izinhlayiya ze-ceramic ndawonye, kwakhe isikhunta esiqinile, esivuzekayo esilungele ukuthululwa. Uhlelo lokudubula lubalulekile. Khuphuka ngokushesha kakhulu, futhi ingcindezi yokushisa iqhekeza igobolondo. Igobolondo elibasiwe lintekenteke kodwa likwazi ukumelana nokushisa ngendlela emangalisayo. Uyiphatha ngohlobo lwenhlonipho eshubile.
Ukuthulula, Ukuthuthumela, kanye Nomzuzu Weqiniso
Ukuthela kuyingxenye emangalisayo. Isikhunta, sisashisa esithandweni, sifakwa eflaskini egcwele isihlabathi ukuze sisekelwe. Insimbi—ithi, a ingxubevange esekwe nickel i-turbine blade-incibilika ku-vacuum noma esithandweni sokungenisa ukushisa okunembayo okushisisa kakhulu. Ukuthela kudinga ukushesha futhi kuqhubeke ukugwema ukuvala okubandayo. Ubona insimbi igcwala inkomishi ye-sprue, bese kuba umdlalo wokulinda njengoba iqina. Izici ezishisayo zegobolondo zithonya ngokuqondile ukwakheka okusanhlamvu kwensimbi. Kungakho iresiphi ye-ceramic ibaluleke kakhulu ezisekelweni eziningi.
Uma sekupholile, sekuyisikhathi sokuxubha. Lawa amandla anonya ahlangabezana ne-finesse. Uphula igobolondo le-ceramic, ngokuvamile ngesando somoya noma itafula lokudlidliza. Kunomsindo, umsebenzi owubhuqu. Okusele yisihlahla sensimbi, esimbozwe ngembongolo eqinile yobumba. Izingxenye zinqunywa ku-sprue ophakathi kusetshenziswa amasondo abrasive noma ama-band saw. Uyaqala ngqa ukubona ukulingisa okungahluziwe. Umuzwa lapho ubona ifomu elihlanzekile, eliphelele liphuma kuwukukhululeka okumsulwa. Umuzwa lapho ubona ingxenye engekho noma ukuncipha okukhulu? Dread.
Ukuhlanza kokuqala kuhilela ukuqhunyiswa kwesihlabathi noma ukuhlanzwa kwamakhemikhali ukuze kukhishwe izingcezu zokugcina zegobolondo. Bese kuqala ukuhlolwa. Ukuhlolwa kobukhulu, ukuhlolwa okubukwayo kokulimala kwendawo, ukuhlolwa kokungena kodayi kokuqhekeka. Ezingxenyeni ezibucayi, njengalezo ezikhiqizwa yi-QSY ukuze zenziwe izingxenye zokugcina, uya ku-radiographic (X-ray) noma ukuhlolwa kwe-ultrasonic ukuze uthole amaphutha angaphakathi. Yilapho izinyathelo zangaphambili zahlulelwa khona. Iqoqo le-porosity kufilimu ye-X-ray ngokuvamile lingalandelelwa emuva odabeni lwephethini ye-wax noma iphutha lokuklama isango kusukela ezinsukwini ezedlule.
Kungani Kungelona Ngokuphathelene Nokusakaza
Nansi into mayelana nesimanje ukukhishwa kwensimbi ye-wax: akuvamile ukuphela komugqa. Ingxenye ye-as-cast iyisimo esiseduze nenethi esingenalutho. Ukuze isebenze, idinga ukwenziwa ngomshini. Yilapho ukuhlanganiswa kubalulekile. I-Foundry eqonda ukwenziwa kwemishini igolide. Bazoklama ukusakaza becabanga ngama-datum omshini, bengeze isibonelelo esincane kodwa esanele sesitoko, futhi bacabangele amaphuzu okubamba. Imodeli ye-QSY yokunikeza kokubili ukukhishwa kokutshalwa kwezimali kanye CNC imishini ngaphansi kophahla olulodwa kwenza umqondo ophelele. Bangakwazi ukuphonsa umzimba wevalvu yensimbi engenasici engu-17-4PH enobuso obubalulekile bophawu obushiywe njengobusakazwa, bazi kahle ukuthi singakanani isitokwe okufanele sishiyelwe izigayo zabo ze-CNC ukuze ziqedele ku-Ra 0.8 ephelele. Iqeda ukukhombana ngeminwe phakathi kwezitolo ezihlukene zokusakaza nemishini.
Ukukhethwa kwezinto ezibonakalayo nakho kuyingxenye yenqubo. Ukutshala imali idlula kakhulu ngama-alloys okunzima ukuwenza ngomshini. Kuyonga kakhulu ukwenza umumo oyinkimbinkimbi ukusuka ku-Inconel 718 kunokuwumshini usuka kubhulokhi eqinile. Imfucuza yenqubo incane. Ezingxenyeni ezincane ezinevolumu ephezulu, njengamakhanda ekilabhu yegalofu noma izimila zamazinyo, zisebenzisa i-wax enezimbotshana eziningi kanye nokuhlanganiswa kwesihlahla okuzenzakalelayo. Ngevolumu ephansi, izingxenye ezinkulu - cabanga ngendlu yepompo eyodwa yokusebenza kwezimayini - kungase kube isihlahla esihlanganiswe ngesandla esivela kumaphethini enziwe nge-prototyping esheshayo. Izikali zenqubo, kodwa izimiso eziyinhloko azishintshi.
Ngike ngabona izitolo zizama ukusika amakhona—ziphinde zisebenzise i-slurry izikhathi eziningi, zifinyeza izikhathi zokumisa, zeqa ukuhlaziya okugcwele okushisayo ekwakhiweni kwengxenye entsha. Cishe njalo ibuyisela emuva, okuholela emazingeni aphezulu alahliwe asula noma yikuphi ukonga okucatshangelwayo. Izinkampani ezihlala njalo, njengalezo ezinomlando weminyaka engama-30, ziyakuqonda ukuthi wuhlelo. Imayelana nokulawula amakhulu okuguquguqukayo ukuze kuzuzwe ukuvumelana. Akuwona umlingo; iyacophelela, kwesinye isikhathi iyacika, iyalawula.
Imicabango Yokugcina: Inqubo Yokucwengwa
Ngakho-ke, i-wax metal cast, noma ukutshala imali, akuyona indlela eyodwa. Kuwuhlaka. I-wax iyindawo yokuqala, kodwa uhlelo lwegobolondo le-ceramic luyinhliziyo yeqiniso, futhi i-metallurgy ingumphefumulo. Impumelelo ilele endleleni okuphatha ngayo ukusebenzisana phakathi kwabo. Kuyinqubo efanele ubunkimbinkimbi, yama-alloys ahleka amathuluzi okusika, kanye nezinhlelo zokusebenza lapho ukusebenza kugcizelela yonke into.
Konjiniyela abaklama ingxenye entsha, iseluleko sami esingasicelanga esokuthi ukhulume nomsunguli wakho kusenesikhathi. Ungavele uthumele imodeli yokugcina ye-CAD ukuze uthole ikhotheshini. Bafake esigabeni sokudizayina kokwenziwa. Ukushintsha kwe-engeli yokusalungiswa okuncane, ukulungiswa kwerediyasi okucashile, noma isango elithuthiwe kungasho umehluko phakathi kwesivuno esingu-95% kanye nesivuno esingu-70%. Ubungcweti bomkhiqizi odidiyelwe abukho nje ekuthululeni insimbi; isekuzulazuleni lonke iketango ukusuka ku-wax kuya engxenyeni eseyiqedile eyenziwe ngomshini.
Ekugcineni, okuphuma egobolondweni le-ceramic eliphukile kungaphezu kwensimbi. Kuwumvuthwandaba wokulandelana okude kwezinyathelo ezilawulwayo, ngasinye sincike kwesokugcina. Uma isebenza, izwakala ingaphansi njengokukhiqiza futhi ifana ne-alchemy, etholwe ngokuzama, iphutha, negrit eqoqiwe. Leyo yindaba yangempela ngemuva kwengcina.
