Tsumman Karkashin Tuntuci na Tsuntsu: Malumin Da Suke Tsakanin Da Amincewa

Tuntuci na tsuntsu ita ce wani ƙayyade na asali a cikin samin ƙarƙashin koro, wanda ke nuna alhakin aikace-aikacen don samun cibin kimiyyar inganci. Wannan makala ta tsummu malumin asali na tuntuci na tsuntsu, kamar yadda aka kammala nashin fahimta, paramita na aikin, alamomin tsuntsu da alhakin tacewa, amincewa masu alhakin, ƙarin teknoliji, da amincin & amfani da gida, base don malamin da ke cikin samin.

1. Malumun Asali: Kayyadun Malumai Da Suke Tsakanin Da Nufin

A cikin rashin, yadda ake sa hannun dajin ƙima ta ita ce ta yin gyara kan tsere-tunƙi na ƙima ta hanyar yin rage, taka, da rage na kwalluka, kuma yin haka ne ta sa hannun dajin ƙima ta mutuwa, jiki, da karkashi.

An farko sa hannun dajin ƙima ta farko zuwa uku:

Hannun Dajin Kullum: Yana amfani da rage, rage daya, rage mai kyau, da rage mai kyau daya - ko'ida biyu da suke iya gyara tsere-tunkin kowane abu.

Hannun Dajin Surtu: Yana gani a kan surtun abu ba ta gyara nisa na abu (misali, hannun daji na surtu) ko gyara nisa na surtu (misali, hannun daji na kimia wanda ke amfani da carbon, nitriding, da carbonitriding).

Tsarin Na'udawa: Wannan shine kamar tsarin thermomechanical da tsarin hannun daji ta vakuum, da suke amfani don mutuwar da ke ciki.

Tambaya na uku ana ƙayyade a cikin aneelin da kuma normalizing: annealing ya amfani da slow cooling (furnace ko kuma ash cooling) don samar da ƙananƙan da kuma ci gaban alƙawari, a yayin da normalizing ya amfani da air cooling don samar da microstructures mai girma da kuma mai girma da kuma ƙananƙan mai yara. A cikin wani ƙarfi, quenching—mai amfani don samar martensitic structures—dole ne a sake amfani da tempering don nuna alhassuna da kuma taka lebalin ƙananƙan da kuma girma ta hanyar ci gaban alƙawari (150–650°C).

2. Iyakokin Ayyuka: Mahaƙan Fasahohi

Tambayar ayyukan ganin wuta ta taka lebanta a cikin mahaƙan iyakokin uku:

2.1 Tushen Tushen (Ac₁, Ac₃, Acm)

Wannan tushen tushen suna nuna cikin zama'a na wuta:

Ac₁: Tushen farko na girman ɗaya dake girma zuwa austenite.

Ac₃: Tushen inda ferrite ya kamata zuwa austenite a cikin hypoeutectoid steel.

Acm: Tushen inda secondary cementite ya kamata zuwa a cikin hypereutectoid steel.

2.2 Tushen Wuta da Kullun Zama'a

Tsawon Takarda: An san da steel na hypoeutectoid zuwa 30–50°C da Ac₃ (austenitization mai kwalin) kuma steel na hypereutectoid san zuwa 30–50°C da Ac₁ (mace wasu carbides don tsangayar taya). Alloys zai buƙatar takardun girma ko kuma lokacin taka lele da sake yawa ne don yawan alloy element diffusion.

Lokacin taka: Ana kimanta shi ne a matsayin girman ƙarfin workpiece (mm) × coefficient na takarda (K)—K=1–1.5 don steel na carbon kuma 1.5–2.5 don steel na alloy.

2.3 Tsawon Zarin & Media na Quenching

Tsawon zar daga baka zuwa mikrostructure:

Zarin girma (>critical rate): Yana haifar da martensite.

Zarin mitan: Yana fara bainite.

Zarin kasa: Yana samar da pearlite ko mai tsangaya na ferrite-cementite.

Ideal quenching media suna gudanarwa a tsakanin "zarin girma don zin daga softening" da "zarin kasa don zin daga cracking." Ruwa/ruwan yashi ta suya amsawa mai girma (amma yana da abin taka da cracking) har da ruwan mai yanki/juyin polymer suna iya amfani da su wajen abubu da girman tsoro (reducing deformation).

3. Microstructure vs. Performance: The Core Relationship

Za a siffanta dukkan abubuwan da ke nufin ƙima ba tare da microstructure, kamar yadda ke cikin bayanin da ke gama gari:

3.1 Martensite

Matacce kuma har ma babba, da tsari na kwayoyi ko tukun tukun.Ƙarin karbon ya zinƙa matsa shi ne mai babba, amma saman austenite ya ƙare ƙima kuma ya ƙarin jin ƙima.

3.2 Tsarin da aka sa shi cikin ruwa

Tsawon ruwa ta nufin aiki:

Ƙarancin ruwa (150–250°C): Martensite da aka sa shi cikin ruwa (58–62 HRC) don alama/dies.

Matsakar tsawon ruwa (350–500°C): Troostite da aka sa shi cikin ruwa (ƙima mai ƙima mai tsaba) don alama.

Matsakaici tsawon ruwa (500–650°C): Sorbite da aka sa shi cikin ruwa (tsin aiki mai kyau da dukkan cikin ƙima) don shaft/gears.

3.3 Zaɓaɓɓen Bayanai

Sake Ƙima: Alloys (misali, faranti mai tsawon ruwa) suka sake ƙima a lokacin da aka sa shi cikin ruwa na 500–600°C don ƙarin karbida (VC, Mo₂C).

Tushen Ƙarƙara: Nau'in I (250–400°C, ba za a iya canza ba) ana kula da shi ne pe kuskyata; Nau'in II (450–650°C, za a iya canza) ana kula da shi ne pe a sanya W/Mo.

4. Nau'ikan Aikace-aikacen: Tsinkaya Na'ura don Alamar Daban-daban

Tsinkayen tadaidaitan zunane suna da ta'adduwa don taɗawa da zaɓin zuwa wani alamar da abubuwan:

Don alamar guda na mota mai amfani da alloys kamar 20CrMnTi, tsinkin na'ura shine nizoli (920–950°C) daban da kuskya na kerosene kuma kuskya mai tsawon tushen (180°C), wanda ke samar da tushen ƙarƙara na 58–62 HRC sannan ya zama jere mai ƙarƙara.

Don shira na tadaidaita kamar H13, tsinkin na'ura yana da kuskaba, kuskya (1020–1050°C, kerosene kuskya), da kuskya biyu (560–680°C). Wannan tsinkin na'ura yana rage gudun tushen kuma yana canza tushen zuwa kusan 54–56 HRC.

Fasaha na takama kamar W18Cr4V ya kamata ta quarshin zuwa a tsawon 1270–1280°C don samar martensite da karbida, daban sannan za a yi tempering na uku a 560°C don canza auyan na gani zuwa martensite, wanda zai samar alhali na 63–66 HRC da karkashin tushen maita.

Za a iya amfani da ductile iron ta austempering a 300–400°C don samar bainite da austenite na gani, wanda ke nuna taka lele na tsangayar da karkashi.

Don 18-8 na austenitic stainless steel, solution treatment (1050–1100°C, water-cooled) yana da muhimanci don karin kai karbida na gani a tsawon 450–850°C.

5. Kontrolin Aljibba: Kaupe da Kamin Kuskurewa

Aljibbin alhali na yawa da sauyensu suna kamar haka:

Fashe na Quenching: Daga cikin ɗaukaka da ke tsaya ko kuma ɗaukaka da ba su da amfani ba (misali, cirewa mai kama, zafi yaƙi). Hanyoyin kula da ke kwaya suna preheating, amfani da quenching masu ƙidaya ko isothermal, da kuma tempering kafin quenching.

Matsarawa: Zai iya gyara shi ta hanyar cold pressing, hot straightening (cirewa na gabanin ta amfani da zafi yaƙi), ko vibratory stress relief. Pre-treatments kamar normalizing ko annealing don mutuwa da ke gabanin forging zai iya kuma karin matsarawa.

Zafi: Yake kada sai zafi ya tafiye aƙalla ta alamun karamin zafi, wanda ya dacewa zuwa matsa da ke gabanin gishin da karamin kusawa. Hanyar kula da ke kwaya shine amfani da thermometer don mutuwa da zafi (tsakanin da suka yi alloy steels) domin kula da fashe.

Decarburization: Ya dacewa daga cikin kirkirar tsakanin gabanin workpiece da oksijin/CO₂ yayin zafi, wanda ya kara matsa da ke gabanin gishin da karamin kusawa. Zai iya gyara shi ta hanyar amfani da protective atmospheres (misali, nitrogen, argon) ko kuma salt bath furnaces.

6. Takinkuna masu kama: Innovation Drivers

Sabon teknolijan ganin kewayen ta hanyar iyakokin aiki da kwayoyin:

TMCP (Thermomechanical Control Process): Yawan ƙwarar da keɓaya da keɓaya na kwalla wanda ta tsara tsuntsuwa da ta haifar bainit—yau da kullum aka amfani dashi a kwayon farko na shabin ginya.

Laser Quenching: Ta ba da iya ganin cewa ta zane zuwa 0.1mm (mai kyau don maimakon hanyar takura). Ta amfani da sararin tushewa don ganin (bata buƙatar wasanni), ta kara iyakokin ƙarfi da kara iyakokin ƙarfi ta 10–15%.

QP (Quenching-Partitioning): Yawan taka lehin zanen Ms don ba da ijini don karɓar karbon daga martensite zuwa austenite mai zuwa, ta tsinkaya wanda ya gabata da ta iyakokin kwayar gudu. Wannan tsarin shine mafi muhimmi a makantawa na genereshan shida na tarin TRIP na mota.

Tambaya Na Nanobainitic Steel: Austempering a kan 200–300°C ya samar da bainite na skan na nano kuma austenite mai tsada, wanda ya samar da kama da 2000MPa kuma ya fi tsangayarwa daraja na martensitic steel na zamanlahiya.

7. Aminci kuma Tattara Mai Gudun Hausa

Tambaya ta fi ƙarar 30% na katin na amfani na saukarwa na amfani da kwayoyin, don haka aminci kuma zarin gudun ya zama abin da ke ciki sosai:

Iyakarwa Mai Aminci: Ana amfani da aliyar ayyuka don hule da scalds na ƙarƙashin zafi (daga samfurin cire ko abubuwan aikawa), kula da gasolin toksin (misali, CN⁻, CO daga furuncin na salt bath), kashe (daga quenching oil leaks), kuma saba'in kwayarwa (a lokacin hoisting ko clamping).

Reduction na Emission: Hanyoyi sune amfani da furuncin na vacuum (don zinza oxidative burning), sigar da tankin quenching (nemawa samfurar oil mist), kuma saita abubuwan gudunwa (don adsorption ko catalytic decomposition na abubuwan mai kirari).

Tambaya ta Wastewater: Wastewater mai Chromium zai buƙata tattara da karamar gaska, amma wastewater mai Cyanide zai buƙata tattara. Wastewater na ƙarƙashin zai shafi tattara ta biyanku ba da izinin fito don fito.

Kammalawa

Tambayar gaban gwiwa shine daya daga cikin abubuwa da suka gudanƙar da inganci na abu, ke tsayawa a tsakanin gwiwar gaban gwiwa da alamar gaban gwiwa mai amfani. Samun sauti na itsoshi, ma'ajiyoyi da abubuwan tattasawa shine daya daga cikin abubuwa da suka gudanƙar da inganci don inganta tattara mai amfani, kawar da izini da kawar da uwar gudunƙarwa a sarrafas kantun kai, takaddun saman gwiwa da takaddun gaban gwiwa.