Hom smelting txheej txheem ntawm ntshiab tooj liab thiab tooj liab alloys rau casting
Ntshiab tooj liab thiab tooj liab alloys rau casting yog ib pawg tseem ceeb ntawm cov hlau tsis muaj hlau thiab tau siv dav hauv kev tsim khoom tiag tiag. Feem ntau siv tooj liab alloys tuaj yeem muab faib ua ob pawg raws li lawv qhov sib txawv, xws li cam khwb cia tooj dag thiab cam khwb cia tooj liab. Txawm hais tias nws yog xuab zeb casting lossis peev casting, smelting yog ib qho tseem ceeb ntawm kev tsim khoom. Lub smelting ntawm ntau yam tooj liab alloys muaj qhov sib xws thiab sib txawv. Nyob rau hauv ntau xyoo ntawm kev xyaum ntau lawm, peb tau sau cov ntshiab Cov txheej txheem smelting ntawm tooj liab thiab tooj liab alloys (tsuas yog tooj liab thiab tooj dag) yog rau koj siv.
Smelting khoom siv: nruab nrab zaus induction rauv, thermocouple, ladle, graphite crucible, thiab lwm yam.
1. Smelting ntawm ntshiab tooj liab
(1) Ua ntej preheat lub crucible rau tsaus liab, thiab ntxiv ib txheej ntawm qhuav charcoal los yog npog tus neeg sawv cev (borax 63% + tawg iav 37%) nrog ib tug tuab ntawm txog 30-50cm nyob rau hauv qab ntawm lub crucible. Tom qab ntawd ntxiv cov khoom seem, khib nyiab thiab cov tuav hauv ib ntus, thiab thaum kawg ntxiv electrolytic tooj liab.
(2) Cov ntsiab lus alloying ntxiv tuaj yeem muab tso rau ntawm qhov cub rau preheating. Nws yog txwv tsis pub ntxiv cov khoom txias rau hauv cov kua hlau. Tus nqi yuav tsum tau txav mus ntau zaus thaum lub sij hawm tag nrho cov txheej txheem melting los tiv thaiv bridging.
(3) Nce qhov kub kom yaj tag nrho cov hlau. Tom qab cov alloy yog tag nrho melted thiab kub ncav cuag 1200-1220 degree, 0.3%-0.4% ntawm qhov hnyav ntawm cov kua alloy yog ntxiv rau deoxidize phosphorus tooj liab. Cov tshuaj tiv thaiv hauv qab no tshwm sim ntawm phosphorus thiab cuprous oxide: 5Cu2O+2P=P2O5+10Cu thiab Cu2O+P2O5= 2CuPO3, cov phosphorus pentoxide tsim tawm los ntawm cov hlau, tooj liab phosphate tuaj yeem ntab rau ntawm cov kua dej, thiab cov slag raug tshem tawm, yog li ua tiav lub hom phiaj ntawm deoxidation. Nruam stirring yog yuav tsum tau thaum lub sij hawm deoxidation txheej txheem.
(4) Thaum kawg, cov slag raug tshem tawm ntawm lub qhov cub, thiab qhov kub ntawm cov kua alloy feem ntau yog 1100-1200 degree .
2. Smelting ntawm tooj dag
Cov tooj liab-raws li alloy nrog zinc ua lub ntsiab alloy tseem ceeb yog tooj dag, uas tau muab faib ua ob pawg: tooj dag zoo tib yam thiab tooj dag tshwj xeeb. Ordinary tooj dag yog binary alloy tsim ntawm tooj liab thiab zinc, feem ntau yog siv rau kev ua haujlwm siab. Tshwj xeeb tooj dag yog tsim los ntawm kev ntxiv lwm yam alloying ntsiab (xws li silicon, aluminium, manganese, lead, hlau, npib tsib xee, thiab lwm yam) rau tooj dag zoo tib yam. Casting tooj dag feem ntau yog tooj dag tshwj xeeb.
(1) Alloy cov khoom xyaw thiab cov khoom siv hlau. Nyob rau hauv cov tshuaj muaj pes tsawg leeg ntawm tooj liab alloys, vim muaj ntau yam variation ntawm lub ntsiab Cheebtsam, nyob rau hauv tus txheej txheem ntawm kev suav cov khoom, cov khoom xyaw tsim nyog yuav tsum tau xaiv raws li lawv cov kev ua tau zoo. Cov tshuaj muaj pes tsawg leeg ntawm cov hlau yuav tsum ua raws li GB1176-87. Cov khoom xyaw ntawm ob peb feem ntau siv tooj dag smelting cov khoom xyaw yog teev nyob rau hauv Table 1.
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Nws yog qhov yuav tsum tau hais tias cov khoom siv rau hauv qhov cub yuav tsum qhuav thiab huv si, thiab txhua qhov av thiab xeb yuav tsum tau ntxuav los ntawm xuab zeb tshuab.
(2) Tus nqi them raws li kev coj ua dav dav, cov khoom siv tshiab yuav tsum suav nrog ntau dua lossis sib npaug li 30% ntawm tag nrho qhov hnyav ntawm tus nqi, thiab cov khoom siv rov ua dua yuav tsum tsawg dua lossis sib npaug li 70%. Txawm li cas los xij, hauv kev tsim khoom tiag tiag, peb xav tias tooj liab alloys muaj ntau cov khoom siv rov ua dua tshiab. Thaum qhov feem pua ntawm cov khoom siv rov ua dua yog ntau dua lossis sib npaug li 90% hauv qhov feem pua ntawm cov khoom siv hluav taws xob, qhov zoo ntawm melting tseem zoo heev. Tshuaj spectrum tsom xam ua pov thawj tias muaj pes tsawg leeg ntawm cov castings yog tsim nyog. Thaum muaj ntau cov khoom siv rov ua dua tshiab, nws yuav tsum tau txiav txim siab seb cov impurities hauv cov hlau puas tshaj tus qauv.
(3) Kev npaj ua ntej smelting.
① Kev npaj cov nqi hlau: Cov nqi rov ua dua yog cov khoom pov tseg, nchuav cov risers thiab cov khoom siv rov ua dua tshiab ntawm tib hom, uas yuav tsum muaj cov tshuaj muaj pes tsawg leeg. Ua ntej nkag mus rau hauv lub qhov cub, cov xuab zeb tshuab yog siv los tshem tawm cov av, thiab lub cub tawg yog loaded tom qab preheating (thawj batch ntawm txias rauv melts yuav preheated nrog lub cub tawg); electrolytic tooj liab yog xuab zeb tshuab kom tshem tawm cov av, thiab tom qab preheating ntawm 500-550 degree kom tshem tawm cov dej noo, (thawj batch ntawm lub qhov cub txias melts tuaj yeem preheated nrog rau qhov cub; cov ntsiab lus hlau ntshiab tuaj yeem preheated ntawm lub cub tawg ua ntej nkag mus rau hauv lub cub tawg. Qhov siab tshaj plaws ntawm cov hlau yuav tsum tsis pub tshaj 1/3 ntawm txoj kab uas hla ntawm lub crucible, thiab qhov ntev yuav tsum tsis txhob tshaj 4/5 ntawm qhov tob ntawm lub crucible ② Kev npaj cov khoom siv crucible thiab smelting: Lub crucible yuav tsum tsis txhob muaj cov kab nrib pleb thiab lwm yam kev puas tsuaj uas cuam tshuam rau kev nyab xeeb ua ntej siv lub crucible tshiab yuav tsum maj mam muab tso rau ntawm qhov kub thiab txias kom tsis txhob muaj cov kab nrib pleb; hom smelting alloy, lub crucible yuav tsum tau melted nrog tib series ntawm alloys ua ntej smelting thiab ntxuav; xim, ces qhuav thiab tso tseg rau siv; lub ingot pwm yuav tsum tau muab ntxuav kom huv si ua ntej siv, thiab preheated rau 100-150 degree tom qab siv xim rau siv.
(4) Kev npaj ntawm tus neeg sawv cev npog thiab flux
①Charcoal yuav tsum muab tso rau hauv lub qhov cub kaw thiab ci ntawm qhov kub tsis tshaj 800 degree rau 4 teev. Nws yuav tsum tau tiv thaiv los ntawm absorbing noo noo thaum npaj rau siv. ②Cov ntaub npog muaj 63% borax thiab 37% iav tawg. Cov charcoal qhuav tuaj yeem siv los ua tus neeg sawv cev npog. Npog cov neeg sawv cev yuav tsum tau ziab thiab tshem tawm cov khib nyiab.
(5) Alloy smelting txheej txheem
① Preheat lub crucible rau tsaus liab ua ntej, thiab ntxiv 20-40cm tuab charcoal rau hauv qab.
②Ntxiv cov tooj liab electrolytic, kub sai thiab yaj, ces ntxiv cov intermediate alloy nyob rau hauv qhov kev txiav txim ntawm thawj zaug nrog lub siab tshaj plaws melting point thiab ces nrog rau qhov qis tshaj melting point (yog tias muaj ntxiv), thiab thaum kawg ntxiv rov qab mus rau lub cub tawg nqi, thiab ntxiv. charcoal tib lub sij hawm los xyuas kom meej tias cov alloy kua theem tsis raug rau saum huab cua.
③ Smelting tooj dag feem ntau kuj yuav tsum tau deoxidation. Tom qab tag nrho cov tooj liab yog yaj, phosphorus tooj liab (xws li P nyiaj rau 0.04%-0.06% ntawm qhov hnyav ntawm cov tooj liab molten) yog ntxiv thaum kub nce mus txog 1150-1200 degree rau deoxidation. Tom qab kev sib piv cov txiaj ntsig ntawm deoxidation thiab non-deoxidation, qhov zoo ntawm deoxidized castings zoo dua qhov tsis muaj deoxidation.
④ Ntxiv cov ntsiab lus alloying ntxiv raws li qhov yuav tsum tau muaj ntawm txhua qib alloy: ntxiv aluminium-tooj liab master alloy ntawm 1100-1120 degree, ntxiv cov zinc ntshiab thiab ntshiab txhuas hauv cov khoom ntawm 1100-1150 degree thaum lub zog hluav taws xob thiab do. Thaum melting silicon tooj dag, silicon yuav tsum tau ntxiv ua ntej thiab tom qab ntawd zinc; Thaum melting txhuas tooj dag, zinc yuav tsum tau ntxiv ua ntej thiab tom qab ntawd txhuas. Qhov ntxiv kub ntawm zinc ntsiab yuav tsum tau tswj. Yog tias qhov kub thiab txias poob tom qab ntxiv zinc, lub zog tuaj yeem xa mus rau nruab nrab. Thaum qhov kub ntawm cov kua alloy siab tshaj 1200 degree, tsis pub ntxiv zinc.
⑤ Tshem tawm cov slag los ntawm lub cub tawg, kho cov kua alloy kom qhov kub thiab txias uas yuav tsum tau ua los ntawm daim npav txheej txheem casting, thiab tom qab ntawd tso tawm sai sai los ntawm lub qhov cub rau pouring. Qhov ntsuas kub ntawm cov hlau yog ib qho ntawm cov yam ntxwv uas cuam tshuam rau kev ua haujlwm ntawm cov casting. Lub qhov cub dav dav yog ZCuZn38: 1100-1130 degree ; ZCuZn40Pb2: 1080-1100 degree ; ZCuZn31Al2: 1120-1140 degree ; ZCuZn16Si4: 1100-1140 degree .
⑥ Thaum ob qib sib txawv ntawm cov hlau yog smelted thiab lawv cov tshuaj muaj pes tsawg leeg raug cuam tshuam, lub cub tawg yuav tsum tau ntxuav hauv nruab nrab. Piv txwv li, siv cov crucible thiab cov cuab yeej uas tau siv los smelt aluminium bronze rau yaj tin bronze, thiab cov crucible thiab cov cuab yeej yuav tsum muaj txhuas. Txawm hais tias txhuas yog cov khoom tsim nyog hauv txhuas bronze, nws yog qhov teeb meem tshaj plaws hauv tin bronze. .
Tom qab cov tooj liab dav dav yog deoxidized, tsim nyog castings tuaj yeem tau txais. Txawm li cas los xij, aluminium bronze, aluminium brass, silicon bronze, thiab lwm yam yog yooj yim oxidized los tsim high melting point oxides Al2O3 thiab SiO2, ua rau castings los tsim slag inclusions, uas yuav tsum tau muab tshem tawm los ntawm refining. Feem ntau siv cov tshuaj refining muaj xws li: sodium chloride nrog qhov sib piv ntawm 60% +40% cryolite lossis 20% cryolite +20% fluorite +60% sodium fluoride, thiab lwm yam.
3. smelting ntawm bronze
Cast bronze tuaj yeem muab faib ua tin bronze thiab tin-dawb bronze raws li nws muaj pes tsawg leeg. Tin bronze yog tooj liab-raws li alloy nrog tin ua lub ntsiab alloy khoom. Nws muaj kev hnav zoo, corrosion kuj, zoo zog thiab plasticity. Tin-free bronze muaj xws li txhuas bronze, txhuas bronze, silicon bronze, thiab lwm yam, uas muaj cov ntsiab lus sib txawv. Piv txwv li, aluminium bronze yog tooj liab-raws li alloy nrog txhuas ua lub ntsiab alloying.
(1) Alloy cov khoom xyaw thiab cov khoom siv hlau. Cov khoom xyaw rau smelting ob peb feem ntau siv bronze alloys yog teev nyob rau hauv Table 2.
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Yuav tsum muaj: Nws raug tso cai ntxiv {{0}}.7% ~ 0.9% Ni thiab 0.3% ~ 0.4% Mn rau hauv ZCuAl10Fe3 alloy los txhim kho cov khoom siv kho tshuab ntawm lub alloy.
(2) Tus nqi them. Qhov sib xyaw ntawm cov ntaub ntawv tshiab yuav tsum suav rau ntau dua lossis sib npaug li 30% ntawm tag nrho qhov hnyav ntawm cov khoom siv rau hauv qhov cub, thiab cov khoom siv rov ua dua yuav tsum suav rau tsawg dua lossis sib npaug li 70%.
(3) Kev npaj ua ntej smelting. Kev npaj ua ntej smelting bronze yog tib yam li cov smelting tooj dag. Charcoal yuav tsum muab tso rau hauv lub qhov cub kaw thiab ci ntawm qhov kub tsis tshaj 800 degree rau 4 teev. Nws yuav tsum tau tiv thaiv los ntawm absorbing noo noo thaum npaj rau siv. Straw tshauv yuav tsum tau muab tso rau hauv hmoov, tshem tawm cov dej noo, thiab qhuav kom huv si. Ua tib zoo saib xyuas cov dej noo-pov thawj ua ntej siv. Npog cov neeg sawv cev yuav tsum tau ziab thiab tshem tawm cov khib nyiab.
(4) Alloy smelting txheej txheem. Muaj ntau hom cam khwb cia tooj liab. Tsuas yog ob peb yam alloys raug tham ntawm no. Lwm cov tooj liab alloys ntawm tib hom tuaj yeem siv los ua kev siv.
Smelting ntawm ZCuSn10Pb1 thiab ZCuPb10Sn10:
① Preheat lub crucible rau tsaus liab ua ntej, thiab ntxiv 20cm-40cm tuab charcoal rau hauv qab.
②Ntxiv cov tooj liab electrolytic, sai sai thiab yaj nws, tom qab ntawd ntxiv cov khoom siv rov ua dua, thiab ntxiv charcoal tib lub sijhawm kom ntseeg tau tias cov kua alloy tsis raug rau saum huab cua.
③ Tom qab tus nqi xa rov qab yog yaj, ntxiv phosphor tooj liab (feem ntau 0.5% ntawm qhov hnyav ntawm tus nqi, thiab tag nrho cov phosphor tooj liab siv thaum melting phosphor-tin bronze ntxiv).
④ Ntxiv zinc, tin, thiab txhuas hauv ib ntus (raws li cov khoom xyaw). Tom qab tus nqi dhau los yog yaj tag, ntxiv ib qho ntxiv thiab do cov kua alloy tsis tu ncua.
⑤ Kho cov kua dej kub ntawm qhov nruab nrab ntawm 1100-1150 degree .
⑥ Tshem tawm slag tawm ntawm lub qhov cub, ntxiv phosphor tooj liab (feem ntau 0.1% ntawm tus nqi them), deoxidize, do tusyees, thiab nphoo ib txheej ntawm straw tshauv rau saum npoo ntawm cov kua alloy, kho cov kua alloy. mus rau qhov kub uas yuav tsum tau los ntawm daim npav txheej txheem casting (feem ntau yog 1130 -1180 degree), ces sai sai ncuav tawm ntawm lub cub tawg.
Smelting ntawm ZCuAl10Fe3 thiab ZCuAl10Fe3Mn2:
① Tsis txhob siv cov crucibles uas tau yaj lwm qib ntawm cov alloys kom yaj ob lub alloys.
② Preheat lub crucible rau tsaus liab thiab ntxiv cov flux npaj. (Flux muaj pes tsawg leeg: cryolite 20% (mas feem pua), sodium fluoride 60%, calcium fluoride 20%).
③Ntxiv cov ntawv uas tsis tshua muaj carbon nyias nyias preheated txog 200 degree thiab siv cov ntaub ntawv rov qab rau tib lub sijhawm, do cov hlau tom qab melting, thiab nce qhov kub ntawm 1150-1180 degree .
④ Ntxiv 0.3% ntawm cov alloy hnyav ntawm phosphor tooj liab rau deoxidation, thiab ntxiv flux.
⑤ Ntxiv ntshiab txhuas thiab ntshiab manganese (raws li cov khoom xyaw) preheated rau 200 degree hauv batch. Tom qab txhua batch ntxiv, nias rau hauv nrog ib tug stirring qws kom yaj sai sai, thiab do tsis tu ncua kom cov khoom xyaw sib xws, ** Thaum kawg, kho qhov kub ntawm cov kua alloy mus rau ntawm 1120-1220 degree .
⑥ Npog lub slag nrog straw tshauv, kho cov alloy kub raws li daim npav txheej txheem casting (feem ntau yog 1160-1200 degree), thiab tom qab ntawd kho cov txheej txheem casting sai.
4. Kev ceev faj txog kev nyab xeeb
Kev nyab xeeb kev tsim khoom yog ib qho tseem ceeb hauv kev lag luam foundry. Lub smelting ntawm ntshiab tooj liab thiab tooj liab alloys yuav tsum:
(1) Cov neeg ua haujlwm yuav tsum hnav cov cuab yeej tiv thaiv, ua kom lub chaw ua haujlwm huv si, thiab tsis txhob tso dej los yog khib nyiab.
(2) Ua ntej pib lub qhov cub, xyuas seb cov khoom siv puas zoo lawm. Yog tias muaj qee yam tsis zoo, lawv yuav tsum raug tshem tawm raws sijhawm.
(3) Preheating tsuas tuaj yeem ua tau tom qab ua tib zoo tshuaj xyuas thiab lees paub tias tsis muaj cov khoom tawg lossis phom sij hauv cov nqi.
(4) Smelting thiab pouring cov cuab yeej, xws li nplawm rods, hlau diav, slag tshem tawm cov cuab yeej, thiab lwm yam, yuav tsum tsis txhob tuaj mus rau hauv kev sib cuag nrog cov alloy kua yam tsis tau preheating.
(5) Cov kua nplaum uas tseem tshuav thaum lub sij hawm pouring yuav tsum tau nchuav rau hauv lub preheated ingot pwm thiab tsis tso cai rau poured ncaj qha rau hauv av los yog poured rov qab rau hauv lub cub tawg.
5. Ntau qhov teeb meem uas yuav tsum tau them sai sai rau thaum smelting
(1) Lub sijhawm melting yuav tsum tau tswj. Lub sij hawm txij thaum pib ntawm melting mus rau qhov kawg ntawm melting (lub alloy los ntawm lub cub tawg) yog hu ua lub sij hawm melting. Qhov ntev ntawm lub sijhawm melting yuav tsis tsuas yog cuam tshuam rau kev tsim khoom, tab sis kuj tseem cuam tshuam rau qhov zoo ntawm cov khoom cam khwb cia. Vim hais tias lub sij hawm melting nce, lub caij hlawv tus nqi ntawm cov alloy nce thiab lub caij nyoog ntawm cov pa nqus tau nce. Yog li ntawd, lub melting ua hauj lwm yuav tsum tau ua kom tiav nyob rau hauv lub shortest tau lub sij hawm. Qhov twg ua tau, qhov kub ntawm qhov preheating ntawm tus nqi yuav tsum tau nce ntau npaum li qhov ua tau, thiab kev ua haujlwm yuav tsum yog compact thiab ceev.
(2) Cov pas nrig nplawm siv rau smelting yuav tsum yog carbon pas nrig. Qee cov ntsiab lus hauv tooj liab alloys, xws li hlau thiab txhuas, muaj nyob rau hauv daim ntawv ntawm cov khoom sib tov thaum yaj. Kuj tseem muaj qee cov ntsiab lus uas yuav ua rau muaj kev sib cais tshwj xeeb thiab stratification vim muaj qhov sib txawv. Kev xyaum tau ua pov thawj tias cov ntsiab lus no tuaj yeem yooj yim ua rau cov tshuaj tsis tsim nyog thiab cov khoom tsis tsim nyog thaum lub sij hawm smelting thiab pouring txheej txheem. Yuav kom kov yeej qhov tshwm sim no, peb yuav tsum siv nplawm, uas yog ib feem tseem ceeb ntawm melting thiab pouring. Txawm li cas los xij, stirring feem ntau tsis tas yuav tsum tau thaum ntsuas kub thiab txias. Cov khoom muaj pes tsawg leeg ntawm cov stirrer siv feem ntau yog graphite. Qhov no yog vim hais tias yog siv lwm cov ntaub ntawv nplawm xws li cov pas nrig hlau, cov pas nrig hlau yuav yaj thaum lub sijhawm nplawm, cuam tshuam rau cov tshuaj lom neeg muaj pes tsawg leeg. Nyob rau tib lub sijhawm, yog tias cov pas nrig hlau yog preheated ntawm qhov kub siab dua hauv qhov cub lossis lub sijhawm nplawm ntev dua, cov oxides ntawm cov pas hlau yuav nkag mus rau cov kua alloy thiab ua impurities; Yog hais tias lub pas nrig hlau yog preheated ntawm qhov kub thiab txias, lub alloy yuav tsum tau stirred thaum stirring. Txhawm rau ua raws li tus pas hlau, qhov no tuaj yeem pom hauv kev tsim khoom.
(3) Teeb meem nrog kev siv cov npog tus neeg sawv cev thaum smelting. Rau smelting tooj liab alloys, tus nqi ntawm tus neeg sawv cev npog feem ntau yog: 0.8%-1.2% ntawm qhov hnyav ntawm tus nqi thaum siv iav thiab borax, vim hais tias lub thickness ntawm txheej yuav tsum yog. khaws cia ntawm 10- 15cm; thaum siv charcoal, qhov ntau npaum li cas yog li ntawm 0.5%-0.7% ntawm qhov hnyav ntawm tus nqi, thiab lub thickness ntawm txheej txheej yuav tsum tau khaws cia ntawm 25-35 cm. Lub sij hawm tshem tawm ntawm tus neeg sawv cev npog feem ntau yog ua ntej nchuav. Yog tias ua tiav ntxov dhau, nws yuav ua rau oxidation thiab huab cua nqus ntawm cov tooj liab alloy. Yog tias charcoal siv los ua tus neeg sawv cev npog thiab cov nyhuv slag-blocking zoo, nws tsis tas yuav tshem tawm tus neeg sawv cev npog, kom nws tuaj yeem ua si lub luag haujlwm slag-thaiv thaum lub sijhawm nchuav, thiab cov nyhuv yog qhov zoo tagnrho.
