Ukwakhiwa kweekhemikhali zesanti ye-ceramic ubukhulu becala yi-Al2O3 kunye ne-SiO2, kunye nesigaba seminerali yesanti ye-ceramic ikakhulu isigaba se-corundum kunye nesigaba se-mullite, kunye nenani elincinci lesigaba se-amorphous. I-refractoriness yesanti ye-ceramic idla ngokungaphezulu kwe-1800 ° C, kwaye yinto enobunzima obuphezulu be-aluminium-silicon refractory.
Iimpawu zesanti ye-ceramic
● Ukuchasa okuphezulu;
● I-coefficient encinci yokwandiswa kwe-thermal;
● I-thermal conductivity ephezulu;
● Imilo emalunga nengqukuva, i-engile encinci, ulwelo oluhle kunye nobuchule obubambekayo;
● Umphezulu ogudileyo, akukho zintanda, akukho ziqhuma;
● Izinto ezingathathi hlangothi, ezifanelekileyo kwizixhobo ezahlukeneyo zetsimbi;
● Amasuntswana anamandla aphezulu kwaye awophuka lula;
● Uluhlu lobungakanani beqhekeza lubanzi, kwaye ukuxuba kungenziwa ngokwezifiso ngokweemfuno zenkqubo.
Ukusetyenziswa kweSanti yeCeramic kwi-Engine Castings
1. Sebenzisa isanti ye-ceramic ukusombulula i-veining, ukuncamathelisa isanti, undoqo owaphukileyo kunye nokuguqulwa kwesiseko sesanti ye-cast iron cylinder head.
● Ibhloko yesilinda kunye nentloko ye-cylinder zezona zibalulekileyo zokusaswa kwe-injini
● Ubume bomngxuma ongaphakathi buntsonkothile, kwaye iimfuno zokuchaneka komgangatho kunye nokucoceka komngxuma ongaphakathi ziphezulu.
● Ibhetshi enkulu
Ukuze kuqinisekiswe ukusebenza kakuhle kwemveliso kunye nomgangatho wemveliso,
● Isanti eluhlaza (ikakhulukazi i-Hydrostatic styling line) imveliso yomgca wendibano isetyenziswa ngokubanzi.
● Iintsimbi zesanti zisebenzisa ibhokisi ebandayo kunye nentlaka egqunywe ngentlaka (iqokobhe) inkqubo, kwaye ezinye iindawo zesanti zisebenzisa inkqubo yebhokisi eshushu.
● Ngenxa yobume obuntsonkothileyo bombindi wesanti yebhloko yesilinda kunye nokuphosa intloko, ezinye iinqununu zesanti zinendawo encinci ye-cross-sectional, inxalenye encinci ye-cylinder blocks kunye ne-cylinder head jacket yamanzi yi-3-3.5mm kuphela, kwaye indawo yokuphuma kwesanti incinci, isiseko sesanti emva kokuphosa ejikelezwe yintsimbi etyhidiweyo ephezulu yokushisa ixesha elide, kunzima ukucoca isanti, kunye nezixhobo ezikhethekileyo zokucoca ezifunekayo, njl. Ngaphambili, yonke isanti ye-silica yayisetyenziselwa ukuphosa. ukuveliswa, okubangele imithambo kunye neengxaki zokubambelela kwisanti kwi-castings yebhatyi yamanzi ye-cylinder block kunye nentloko ye-cylinder. I-core deformation kunye neengxaki ezingundoqo ezaphukileyo zixhaphake kakhulu kwaye kunzima ukuzicombulula.
Ukuze kusonjululwe iingxaki ezinjalo, ukususela malunga no-2010, ezinye iinkampani ezaziwayo-kakuhle zokuphosa injini yasekhaya, ezifana ne-FAW, i-Weichai, i-Shangchai, i-Shanxi Xinke, njl. iibhatyi zamanzi ze-cylinder, kunye neepaseji zeoli. Iicores zesanti ezilinganayo ziphelisa okanye zinciphisa ngempumelelo iziphene ezinje ngomgodi ongaphakathi, ukuncamathela kwesanti, ukuguqulwa kombindi wesanti, kunye neecores ezaphukileyo.
Landela imifanekiso yenziwe ngesanti yeceramic enenkqubo yebhokisi ebandayo.
Ukusukela ngoko, isanti yeceramic exubeneyo yokukhuhla isanti iye yanyuswa ngokuthe ngcembe kwibhokisi ebandayo kunye neenkqubo zebhokisi eshushu, kwaye isetyenziswa kwi-cylinder head jacket cores. Sele ikwimveliso ezinzileyo iminyaka engaphezu kwe-6. Ukusetyenziswa kwangoku kwesiseko sesanti yebhokisi ebandayo kukuba: ngokwemilo kunye nobukhulu bombindi wesanti, inani lesanti ye-ceramic eyongeziweyo yi-30% -50%, isixa esipheleleyo se-resin eyongeziweyo yi-1.2% -1.8%, kwaye amandla okuqina yi-2.2-2.7 MPa. (Idatha yovavanyo lwesampulu yaseLabhoratri)
Isishwankathelo
Ibhloko ye-cylinder kunye nentloko ephoswe ngentsimbi iqulathe izakhiwo ezininzi ezimxinwa zangaphakathi, kwaye ubushushu bokuthululwa buphakathi kwe-1440-1500 ° C. Indawo enodonga olubhityileyo yombindi wesanti igalelwa lula phantsi kobushushu obuphezulu bentsimbi enyibilikisiweyo, efana nentsimbi enyibilikisiweyo ingena kumbindi wesanti, okanye ivelise ujongano olubonakalayo ukwenza isanti encangathi. I-refractoriness yesanti ye-ceramic ingaphezulu kwe-1800 ° C, okwangoku, ubuninzi bokwenyani besanti ye-ceramic buphezulu kakhulu, amandla e-kinetic amasuntswana esanti kunye nobukhulu obufanayo kunye nesantya ngama-1.28 amaxesha e-silica sand particles xa ukudubula isanti, engakwazi ukwandisa ukuxinana kweentsimbi zesanti.
Ezi zinzuzo zizathu zokuba ukusetyenziswa kwesanti ye-ceramic kunokusombulula ingxaki yokunamathela kwesanti kwindawo yangaphakathi ye-cylinder head castings.
Ijacket yamanzi, indawo yokungena kunye nokukhupha i-cylinder block kunye nentloko ye-cylinder zihlala zineziphene ze-veining. Inani elikhulu lophando kunye nezenzo zokuphosa ziye zabonisa ukuba ingcambu yeengxaki ze-veining kwi-casting surface yinguqu yesigaba sokwandiswa kwesanti ye-silica, ebangela uxinzelelo lwe-thermal lukhokelela ekuqhekekeni kumphezulu we-santi core, obangela isinyithi esinyibilikisiweyo. ukungena kwiintanda, ukuthambekela kweemvini kukhulu ngakumbi kwinkqubo yebhokisi ebandayo. Enyanisweni, izinga lokunyuka kwe-thermal ye-silica sand liphezulu kwi-1.5%, ngelixa izinga lokunyuka kwe-thermal yesanti ye-ceramic kuphela i-0.13% (ishushu kwi-1000 ° C imizuzu eyi-10). Ithuba lokuqhekeka lincinci kakhulu apho kumphezulu wesiseko sesanti ngenxa yoxinzelelo lokwandiswa kwe-thermal. Ukusetyenziswa kwesanti ye-ceramic kwisiseko sesanti se-cylinder block kunye nentloko ye-cylinder okwangoku isisombululo esilula nesisebenzayo kwingxaki ye-veining.
I-complex, i-thick-walled, i-cylinder ende kunye nemxinwa ye-cylinder ye-jacket yamanzi i-sand cores kunye ne-cylinder ye-oyile yeshaneli ye-sand cores ifuna amandla aphezulu (kubandakanywa namandla aphezulu okushisa) kunye nokuqina, kwaye ngexesha elifanayo kufuneka lilawule ukuveliswa kwegesi yesanti engundoqo. Ngokwesiko, inkqubo yesanti egqunyiweyo isetyenziswa kakhulu . Ukusetyenziswa kwesanti ye-ceramic kunciphisa inani le-resin kwaye kufezekise umphumo wamandla aphezulu kunye nesizukulwana segesi esiphantsi. Ngenxa yokuphuculwa okuqhubekayo kokusebenza kwe-resin kunye nesanti ekrwada, inkqubo yebhokisi ebandayo iye yanda indawo yenkqubo yesanti egqunyiweyo kwiminyaka yakutshanje, iphucula kakhulu ukusebenza kakuhle kwemveliso kunye nokuphucula imeko yemveliso.
2. Ukusetyenziswa kwesanti ye-ceramic ukusombulula ingxaki ye-sand core deformation ye-exhaust pipe
Ukukhutshwa kwezinto ezininzi zisebenza phantsi kweemeko zokutshintsha kobushushu obuphezulu ixesha elide, kwaye ukuchasana kwe-oxidation yezinto kumaqondo okushisa aphezulu kuchaphazela ngokuthe ngqo ubomi benkonzo yokukhupha amaninzi. Kwiminyaka yakutshanje, ilizwe liye laqhubeka liphucula imigangatho yokukhupha umbhobho wemoto, kwaye ukusetyenziswa kwetekhnoloji ye-catalytic kunye netekhnoloji ye-turbocharging kuye kwanyusa kakhulu ubushushu bokusebenza bokuphuma kwezinto ezininzi, ukuya kuthi ga kwi-750 °C. Ngophuculo olongezelelweyo lokusebenza kwe-injini, ubushushu bokusebenza bombhobho wokukhupha buya kwanda. Okwangoku, i-cast-resistant cast steel cast isetyenziswa ngokubanzi, njenge-ZG 40Cr22Ni10Si2 (JB / T 13044), njl., kunye nobushushu obungangeni bushushu be-950 ° C-1100 ° C.
Umngxuma wangaphakathi we-exhaust manifold ngokubanzi ufuneka ukuba ukhululeke kwiintanda, ukuvalwa okubandayo, i-shrinkage cavities, i-slag inclusions, njl. njl. ezichaphazela ukusebenza, kunye noburhabaxa bombhobho ongaphakathi bufuneka ukuba bungabi ngaphezu kwe-Ra25. Ngelo xesha, kukho imimiselo engqongqo kunye ecacileyo malunga nokuphambuka kodonga lombhobho. Ixesha elide, ingxaki yobunzima bodonga olungalinganiyo kunye nokutenxeka ngokugqithiseleyo kodonga lwemibhobho ekhuphayo iye yathwaxa iindawo ezininzi zokukhupha izinto ezininzi.
I-Foundry yaqala yasebenzisa i-silica sand cores egqunywe ngesanti ukuvelisa iindlela zokukhupha intsimbi ezikwaziyo ukumelana nobushushu. Ngenxa yobushushu obuphezulu bokuthulula (1470-1550 ° C), iingcingo zesanti zazinokukhubazeka ngokulula, okubangela ukuba kubekho izinto ezingaphandle kokunyamezelana kwimibhobho eludongeni. Nangona isanti ye-silica iye yaphathwa ngotshintsho lwesigaba sobushushu obuphezulu, ngenxa yempembelelo yezinto ezahlukeneyo, ayinakoyisa ukuguqulwa kwesiseko sesanti kwiqondo lokushisa eliphezulu, okukhokelela kuluhlu olubanzi lokuguquguquka kobunzima bodonga lombhobho. , yaye kwiimeko ezinzima, iya kuchithwa. Ukuze kuphuculwe amandla ombindi wesanti kunye nokulawula isizukulwana segesi sombindi wesanti, kwagqitywa ekubeni kusetyenziswe isanti yeceramic egqunywe isanti. Xa isixa se-resin esongeziweyo sasingaphantsi kwama-36% kunesanti egqunywe yisanti ye-silica, amandla okugoba kwegumbi lawo kunye namandla okugoba anyuka ngama-51%, ama-67%, kwaye isixa sokuvelisa igesi sincitshiswe ngama-20%. Iimfuno zenkqubo zamandla aphezulu kunye nokuveliswa kwegesi ephantsi.
Umzi-mveliso usebenzisa i-silica i-sand cores ye-sand cores kunye ne-santi ye-ceramic efakwe kwi-sand cores ukwenzela ukuphosa ngaxeshanye, emva kokucoca i-castings, yenza uhlolo lwe-anatomical.
Ukuba i-core yenziwe nge-silica sandcoated sand, i-castings inodonga olungalinganiyo kunye nodonga oluncinci, kunye nodonga oluyi-3.0-6.2 mm; xa i-core yenziwe ngesanti ye-ceramic ehlanganiswe isanti, ubukhulu bodonga lwe-casting bufana, kunye nobukhulu bodonga buyi-4.4-4.6 mm. njengomfanekiso olandelayo
Isanti yesilika egqunywe isanti
Isanti yeCeramic egqunywe isanti
Isanti ye-Ceramic egqunywe isanti isetyenziselwa ukwenza ii-cores, eziphelisa ukuqhekeka kwesiseko sesanti, ukunciphisa ukuguqulwa kwesiseko sesanti, iphucula kakhulu ukuchaneka komgangatho wejelo lokuhamba kombhobho ongaphakathi we-manifold yokukhupha, kunye nokunciphisa ukuncamathela kwesanti kumgodi ongaphakathi, ukuphucula umgangatho ukuphoswa kunye nezinga leemveliso ezigqityiweyo kwaye zizuze inzuzo ebalulekileyo yezoqoqosho.
3. Ukusetyenziswa kwesanti ye-ceramic kwizindlu ze-turbocharger
Iqondo lobushushu elisebenzayo ekupheleni kwe turbine yeqokobhe le turbocharger ngokubanzi lingaphezulu kwe 600°C, kwaye abanye bade bafikelele kuma 950-1050°C. Izinto zeqokobhe kufuneka zimelane namaqondo obushushu aphezulu kwaye zisebenze kakuhle. Ukwakhiwa kwegobolondo kugxininise ngakumbi, ubukhulu bodonga buncinci kwaye bufana, kwaye i-cavity yangaphakathi ihlambulukile, njl., ifuna kakhulu. Okwangoku, izindlu ze-turbocharger zenziwe ngentsimbi ekwazi ukumelana nobushushu (efana ne-1.4837 kunye ne-1.4849 yomgangatho waseJamani we-DIN EN 10295), kunye nentsimbi ekwazi ukumelana nobushushu iyasetyenziswa (njengeGGG SiMo eqhelekileyo yaseJamani, yaseMelika. umgangatho ophezulu we-nickel austenitic nodular iron D5S, njl.).
A 1.8 T injini turbocharger izindlu, izinto: 1.4837, ezizezi GX40CrNiSi 25-12, ukwakheka imichiza eziphambili (%): C: 0.3-0.5, Si: 1-2.5, Cr: 24-27, Mo: Max 0.5, Ni: 11 -14, ukugalela iqondo lobushushu 1560 ℃. I-alloy ine-high melting point, isantya esikhulu sokuncipha, ukuthambekela okunamandla okutshisa okutshisa, kunye nobunzima obuphezulu bokuphosa. Isakhiwo se-metallographic sokuphosa sineemfuno eziqinileyo kwi-carbides eseleyo kunye ne-non-metallic inclusions, kwaye kukho nemimiselo ethile malunga nokuphosa iziphene. Ukuze kuqinisekiswe umgangatho kunye nokusebenza kakuhle kwemveliso yokuphosa, inkqubo yokubumba ithatha i-core casting kunye ne-cored shell shell shell cores (kunye nebhokisi ebandayo kunye nebhokisi eshushu). Ekuqaleni, kwakusetyenziswa isanti yokukhuhla i-AFS50, emva koko kwasetyenziswa isanti ye-silica egcadiweyo, kodwa iingxaki ezifana nokuncamathela kwesanti, i-burrs, iintanda ze-thermal, kunye ne-pores kumgodi ongaphakathi zibonakala ngeendlela ezahlukeneyo.
Ngokwesiseko sophando kunye novavanyo, umzi-mveliso wagqiba ukusebenzisa isanti ye-ceramic. Ekuqaleni kuthengwe isanti egqunyiweyo egqityiweyo (i-100% yesanti ye-ceramic), kwaye emva koko yathengwa izixhobo zokuvuselela kunye nokugquma, kwaye ngokuqhubekayo uphucula inkqubo ngexesha lenkqubo yokuvelisa, sebenzisa isanti ye-ceramic kunye nesanti yokukhuhla ukuxuba isanti ekrwada. Okwangoku, isanti egqunyiweyo iphunyezwa ngokufanelekileyo ngokwetheyibhile ilandelayo:
| Inkqubo yesanti egqunywe ngesanti yeCeramic yezindlu ze-turbocharger | ||||
| Ubungakanani beSanti | Umlinganiselo wesanti yodongwe % | Udibaniso lweresin% | Ukugoba iMPa yamandla | Imveliso yegesi ml/g |
| AFS50 | 30-50 | 1.6-1.9 | 6.5-8 | ≤12 |
Kwiminyaka embalwa edlulileyo, inkqubo yokuveliswa kwesi sityalo iqhube ngokuzinzile, umgangatho we-castings ulungile, kwaye izibonelelo zoqoqosho kunye nokusingqongileyo ziyamangalisa. Isishwankathelo simi ngolu hlobo lulandelayo:
a. Ukusebenzisa isanti ye-ceramic, okanye ukusebenzisa umxube wesanti ye-ceramic kunye nesanti ye-silica ukwenza i-cores, isusa iziphene ezifana nokunamathela kwesanti, i-sintering, i-veining, kunye nokuqhekeka kwe-thermal ye-castings, kunye nokuqonda imveliso ezinzileyo nesebenzayo;
b. I-core casting, ukusebenza kakuhle kwemveliso, umlinganiselo ophantsi we-santi-iron (ngokuqhelekileyo ungabi ngaphezu kwe-2: 1), ukusetyenziswa kwesanti eluhlaza, kunye neendleko eziphantsi;
c. Ukugalelwa kondoqo kunceda ekusetyenzisweni ngokutsha kunye nokuhlaziywa kwesanti yenkunkuma, kwaye ukuvuselelwa kwe-thermal kwamkelwa ngokufanayo ukuze kuhlaziywe. Ukusebenza kwesanti ehlaziyiweyo kuye kwafikelela kwinqanaba lesanti entsha yokukhuhla isanti, eye yafikelela umphumo wokunciphisa iindleko zokuthengwa kwesanti eluhlaza kunye nokunciphisa ukukhutshwa kwenkunkuma eqinile;
d. Kuyimfuneko ukujonga rhoqo umxholo wesanti ye-ceramic kwisanti ehlaziyiweyo ukugqiba inani lesanti entsha ye-ceramic eyongeziweyo;
e. Isanti yeCeramic inemilo engqukuva, i-fluidity elungileyo, kunye nokucaciswa okukhulu. Xa ixutywe nesanti ye-silica, kulula ukubangela ukwahlukana. Ukuba kuyimfuneko, inkqubo yokudubula isanti kufuneka ilungiswe;
f. Xa ugubungela ifilimu, zama ukusebenzisa i-phenolic resin ephezulu, kwaye usebenzise izongezo ezahlukahlukeneyo ngokuqaphela.
4. Ukusetyenziswa kwesanti ye-ceramic kwi-injini ye-aluminium alloy cylinder head
Ukuphucula amandla eemoto, ukunciphisa ukusetyenziswa kwepetroli, ukunciphisa ungcoliseko, kunye nokukhusela okusingqongileyo, iimoto ezikhaphukhaphu ziyindlela yophuhliso lweshishini leemoto. Okwangoku, ii-injini zeemoto (kubandakanywa ne-injini ye-diesel), ezifana neebhloko ze-cylinder kunye neentloko ze-cylinder, ziphonswa ngokubanzi kunye ne-alloys ye-aluminium, kunye nenkqubo yokuphosa iibhloko ze-cylinder kunye neentloko ze-cylinder, xa usebenzisa ii-core cores, i-metal mold gravity casting kunye noxinzelelo oluphantsi. ukuphosa (LPDC) ngabona bamele kakhulu.
Isiseko sesanti, isanti edibeneyo kunye nenkqubo yebhokisi ebandayo ye-aluminium i-alloy cylinder block kunye ne-head castings zixhaphake kakhulu, zilungele ukuchaneka okuphezulu kunye neempawu ezinkulu zokuvelisa. Indlela yokusebenzisa isanti ye-ceramic ifana nokuveliswa kwentloko ye-cylinder yentsimbi. Ngenxa yobushushu obuphantsi bokugalelwa kunye nobunzima obuthile obuncinci be-aluminium ialloy, kusetyenziswa isanti engundoqo esezantsi, njengesiseko sesanti yebhokisi ebandayo kumzi-mveliso, isixa se-resin esongeziweyo yi-0.5-0.6%, kwaye amandla okuqina 0.8-1.2 MPa. Isanti engundoqo iyafuneka Inokubhibilika kakuhle. Ukusetyenziswa kwesanti ye-ceramic kunciphisa inani le-resin eyongeziweyo kwaye iphucula kakhulu ukuwa kwesiseko sesanti.
Kwiminyaka yakutshanje, ukuze kuphuculwe imeko yemveliso kunye nokuphucula umgangatho wokusa, kukho uphando oluninzi kunye nokusetyenziswa kwe-inorganic binders (kubandakanywa neglasi yamanzi eguquliweyo, i-phosphate binders, njl.). Lo mfanekiso ungezantsi yindawo yokugalela yomzi-mveliso usebenzisa isanti yeceramic inorganic binder core sand aluminiyam ialloy cylinder head.
Umzi-mveliso usebenzisa isanti ye-ceramic i-inorganic binder ukwenza undoqo, kwaye isixa se-binder esongeziweyo yi-1.8 ~ 2.2%. Ngenxa yobuninzi besanti ye-ceramic, undoqo wesanti uxinene, umphezulu uphelele kwaye ugudileyo, kwaye kwangaxeshanye, ubungakanani begesi yegesi buncinci, buphucula kakhulu isivuno sesanti, kuphucula ukubola kwesanti engundoqo. , iphucula indawo yokuvelisa, kwaye ibe ngumzekelo wemveliso eluhlaza.
Ukusetyenziswa kwesanti ye-ceramic kwishishini lokuphosa i-injini kuphucule ukusebenza kakuhle kwemveliso, kuphuculwe indawo yokusebenza, kusonjululwe iziphene zokuphosa, kwaye kufezekiswe izibonelelo ezibalulekileyo zoqoqosho kunye neenzuzo ezilungileyo zokusingqongileyo.
Umzi-mveliso we-injini kufuneka uqhubeke nokwandisa ukuvuselelwa kwesanti engundoqo, ukuphucula ngakumbi ukusetyenziswa kwesanti ye-ceramic, kunye nokunciphisa ukukhutshwa kwenkunkuma eqinileyo.
Ngokwembono yesiphumo sokusetyenziswa kunye nobubanzi bokusetyenziswa, isanti ye-ceramic okwangoku iyeyona ntlabathi ekhethekileyo yokuphosa esebenza ngokugqibeleleyo kunye nosetyenziso olukhulu kwishishini lokuphosa injini.
Ixesha lokuposa: Mar-27-2023
