Ukwakhiwa kwamakhemikhali esihlabathi se-ceramic ikakhulukazi i-Al2O3 ne-SiO2, futhi isigaba samaminerali sesihlabathi se-ceramic ngokuyinhloko isigaba se-corundum nesigaba se-mullite, kanye nenani elincane lesigaba se-amorphous. I-refractoriness yesihlabathi se-ceramic ngokuvamile ingaphezulu kuka-1800°C, futhi iwubulukhuni obuphezulu be-aluminium-silicon refractory.
Izici zesihlabathi se-ceramic
● High refractoriness;
● I-coefficient encane yokwandisa ukushisa;
● High conductivity ezishisayo;
● Umumo ocishe ube yindilinga, i-engeli encane, i-fluidity enhle nekhono elihlangene;
● Indawo ebushelelezi, akukho mifantu, awekho amaqhubu;
● Izinto ezingathathi hlangothi, ezifanele izinto ezihlukahlukene zensimbi;
● Izinhlayiya zinamandla amakhulu futhi aziphuka kalula;
● Ububanzi besayizi yezinhlayiyana bubanzi, futhi ukuxuba kungenziwa ngokwezifiso ngokuvumelana nezidingo zenqubo.
Ukusetshenziswa kwe-Ceramic Sand ku-Engine Castings
1. Sebenzisa isihlabathi se-ceramic ukuxazulula i-veining, ukunamathela kwesihlabathi, umgogodla ophukile kanye ne-sand core deformation ye-cast iron cylinder head.
● Ibhulokhi yesilinda nekhanda le-cylinder yikona okulingisa okubaluleke kakhulu kwenjini
● Umumo womgodi ongaphakathi uyinkimbinkimbi, futhi izidingo zokunemba kobukhulu kanye nokuhlanzeka komgodi ongaphakathi ziphezulu.
● Iqoqo elikhulu
Ukuze kuqinisekiswe ukusebenza kahle kokukhiqiza kanye nekhwalithi yomkhiqizo,
● Isihlabathi esiluhlaza (ikakhulukazi i-Hydrostatic styling line) ukukhiqizwa komugqa wokuhlanganisa ngokuvamile kusetshenziswa.
● Izinhlayiya zesihlabathi ngokuvamile zisebenzisa ibhokisi elibandayo kanye nenqubo yesihlabathi esimbozwe inhlaka (umgogodla wegobolondo), kanti ezinye izinhlaka zesihlabathi zisebenzisa inqubo yebhokisi elishisayo.
● Ngenxa yokuma okuyinkimbinkimbi komgogodla wesihlabathi we-cylinder block kanye nokukhishwa kwekhanda, amanye ama-sand cores anendawo encane ene-cross-sectional, ingxenye encane kakhulu yamabhulokhi angama-cylinder kanye nama-cylinder head jacket cores ingu-3-3.5mm kuphela, futhi i-sand outlet incane, umgogodla wesihlabathi ngemuva kokusakazwa okuzungezwe insimbi encibilikisiwe ephezulu yokushisa isikhathi eside, kunzima ukuhlanza isihlabathi, kanye nemishini ekhethekile yokuhlanza iyadingeka, njll Ngaphambili, sonke isihlabathi se-silica sasisetshenziswa ekubunjweni. ukukhiqizwa, okubangele imithambo kanye nezinkinga zokunamathela kwesihlabathi ku-castings yejacket yamanzi ye-cylinder block kanye nekhanda le-cylinder. I-Core deformation kanye nezinkinga zemongo ephukile zivame kakhulu futhi kunzima ukuzixazulula.
Ukuze kuxazululwe izinkinga ezinjalo, kusukela cishe ngo-2010, ezinye izinkampani ezifuywayo ezikhiqiza injini yasekhaya, njenge-FAW, Weichai, Shangchai, Shanxi Xinke, njll., zaqala ukucwaninga nokuhlola ukusetshenziswa kwesihlabathi se-ceramic ukukhiqiza amabhulokhi angama-cylinder, amajakhethi amanzi ekhanda le-cylinder, namaphaseji kawoyela. Ama-sand cores alinganayo aqeda noma anciphisa ngempumelelo iziphambeko ezifana nokucwiliswa kwesikhala esingaphakathi, ukunamathela kwesihlabathi, ukuwohloka komgogodla wesihlabathi, nama-cores aphukile.
Landela izithombe zenziwa ngesihlabathi se-ceramic ngenqubo yebhokisi elibandayo.
Kusukela ngaleso sikhathi, isihlabathi se-ceramic esixubile sokukhuhla siye sathuthukiswa kancane kancane ebhokisini elibandayo kanye nezinqubo zebhokisi elishisayo, futhi sisetshenziswa kuma-cylinder head jacket cores. Sekuyiminyaka engaphezu kwengu-6 ekukhiqizeni okuzinzile. Ukusetshenziswa kwamanje kwe-cold box sand core yilokhu: ngokuya ngokuma nobukhulu bomgogodla wesihlabathi, inani lesihlabathi se-ceramic elingeziwe lingama-30% -50%, inani eliphelele le-resin elengeziwe ngu-1.2% -1.8%, futhi amandla okubamba yi-2.2-2.7 MPa. (Idatha yokuhlola isampula yaselabhorethri)
Isifinyezo
I-cylinder block kanye ne-head cast iron izingxenye ziqukethe izakhiwo eziningi ezincane zangaphakathi, futhi izinga lokushisa elithela ngokuvamile liphakathi kuka-1440-1500°C. Ingxenye enodonga oluncane lwe-sand core ifakwa kalula ngaphansi kwesenzo sensimbi encibilikisiwe yezinga lokushisa eliphezulu, efana nensimbi encibilikisiwe ingena kumongo wesihlabathi, noma ikhiqize ukusabela kokusebenzelana ukuze kwakhe isihlabathi esinamathelayo. I-refractoriness yesihlabathi se-ceramic inkulu kune-1800 ° C, okwamanje, ukuminyana kweqiniso kwesihlabathi se-ceramic kuphakeme kakhulu, amandla e-kinetic ezinhlayiya zesihlabathi ezinobubanzi obufanayo kanye nesivinini siphindwe izikhathi ezingu-1.28 kunezinhlayiya zesihlabathi se-silica lapho ukudubula isihlabathi, okungase ukwandisa ukuminyana kwezinhlamvu zesihlabathi.
Lezi zinzuzo ziyizizathu zokuthi kungani ukusetshenziswa kwesihlabathi se-ceramic kungaxazulula inkinga yokunamathela kwesihlabathi emgodini wangaphakathi we-cylinder head castings.
Ibhantshi lamanzi, izingxenye zokungenisa kanye ne-exhaust ze-cylinder block kanye nekhanda le-cylinder kuvame ukuba namaphutha emithanjeni. Inombolo enkulu yocwaningo kanye nemikhuba yokuphonsa ibonise ukuthi imbangela eyinhloko yokukhubazeka kwe-veining endaweni yokuphonsa ukunwetshwa kwesigaba sokushintsha kwesihlabathi se-silica, okubangela ukucindezeleka okushisayo kuholela ekuqhekekeni ebusweni bomgogodla wesihlabathi, okubangela insimbi encibilikisiwe. ukungena emifantwini, ukuthambekela kwemithambo kukhulu ikakhulukazi kwinqubo yebhokisi elibandayo. Eqinisweni, izinga lokunwetshwa okushisayo kwesihlabathi se-silica liphezulu njengo-1.5%, kuyilapho izinga lokushisa elishisayo lesihlabathi se-ceramic lingu-0.13% kuphela (lishiselwa ku-1000 ° C imizuzu engu-10). Amathuba okuqhekeka kuncane kakhulu lapho ebusweni bomgogodla wesihlabathi ngenxa yokucindezeleka kokwanda okushisayo. Ukusetshenziswa kwesihlabathi se-ceramic emgodleni wesihlabathi we-cylinder block kanye nekhanda le-cylinder okwamanje kuyisixazululo esilula nesisebenzayo senkinga ye-veining.
Eziyinkimbinkimbi, ezincane-izindonga, eside futhi emincane isilinda ikhanda ibhantshi amanzi sand cores kanye cylinder uwoyela channel sand cores kudinga amandla aphezulu (kuhlanganise high lokushisa amandla) kanye nokuqina, futhi ngesikhathi esifanayo kudingeka ukulawula isizukulwane igesi yesihlabathi core. Ngokwesiko, inqubo yesihlabathi esimboziwe isetshenziswa kakhulu. Ukusetshenziswa kwesihlabathi se-ceramic kunciphisa inani le-resin futhi kufinyelele umphumela wamandla aphezulu kanye nesizukulwane esincane segesi. Ngenxa yokuthuthukiswa okuqhubekayo kokusebenza kwe-resin nesihlabathi esingavuthiwe, inqubo yebhokisi elibandayo iye yanda esikhundleni senqubo yesihlabathi esimboziwe eminyakeni yamuva, ithuthukisa kakhulu ukusebenza kahle kokukhiqiza kanye nokwenza ngcono indawo yokukhiqiza.
2. Ukusetshenziswa kwesihlabathi se-ceramic ukuxazulula inkinga ye-sand core deformation ye-exhaust pipe
I-exhaust manifolds isebenza ngaphansi kwezimo ezishintshashintshayo zokushisa okuphezulu isikhathi eside, futhi ukumelana ne-oxidation kwezinto emazingeni okushisa aphezulu kuthinta ngqo impilo yesevisi ye-exhaust manifolds. Eminyakeni yamuva nje, izwe liye lathuthukisa ngokuqhubekayo izindinganiso zokukhipha umoya wezimoto, futhi ukusetshenziswa kobuchwepheshe be-catalytic kanye nobuchwepheshe bokushaja kwe-turbo kukhulise kakhulu izinga lokushisa lokusebenza kwe-exhaust eningi, yafinyelela ngaphezu kuka-750 °C. Ngokuthuthuka okuqhubekayo kokusebenza kwenjini, izinga lokushisa lokusebenza le-multifold exhaust nalo lizokhuphuka. Njengamanje, insimbi engazweli ukushisa ivame ukusetshenziswa, njenge-ZG 40Cr22Ni10Si2 (JB/T 13044), njll., enezinga lokushisa elimelana nokushisa elingu-950°C-1100°C.
Umgodi ongaphakathi we-exhaust manifold ngokuvamile udingeka ukuze ungabi nemifantu, ukuvala okubandayo, imigodi enciphayo, ukufakwa kwe-slag, njll. okuthinta ukusebenza, futhi ubulukhuni bendawo engaphakathi kuyadingeka ukuthi bungabi ngaphezu kuka-Ra25. Ngesikhathi esifanayo, kunemithetho eqinile futhi ecacile yokuphambuka kodonga lwamapayipi. Sekuyisikhathi eside, inkinga yokuqina kodonga olungalingani kanye nokuphambuka ngokweqile kodonga lwamapayipi okukhipha amanzi amaningi kuye kwahlupha izindawo eziningi zokukhipha amanzi.
I-Foundry yaqale yasebenzisa ama-sand cores e-silica ahlanganiswe ne-silica ukukhiqiza ama-multifold exhaust ensimbi angangeni. Ngenxa yokushisa okukhulu okuthululwayo (1470-1550 ° C), ama-sand cores akhubazeka kalula, okuholela ezenzweni zokungabekezelelani ekugqileni kodonga lwamapayipi. Nakuba isihlabathi se-silica siye saphathwa ngokushintsha kwesigaba sokushisa okuphezulu, ngenxa yethonya lezici ezihlukahlukene, asikwazi ukunqoba ukuguqulwa kwengqikithi yesihlabathi ekushiseni okuphezulu, okuholela ekuguquguqukeni okubanzi kobukhulu bodonga lwamapayipi. , futhi ezimweni ezimbi kakhulu, iyochithwa. Ukuze kuthuthukiswe amandla omgogodla wesihlabathi nokulawula isizukulwane segesi somgogodla wesihlabathi, kwanqunywa ukuthi kusetshenziswe isihlabathi se-ceramic esiboshwe. Lapho inani le-resin elengeziwe laliphansi ngo-36% kunesihlabathi esimbozwe isihlabathi se-silica, amandla ayo okugoba egumbi lokushisa kanye namandla okugoba okushisayo akhuphuka ngo-51%, 67%, kanti inani lokukhiqizwa kwegesi lehla ngo-20%, elihlangabezana izidingo zenqubo zamandla aphezulu kanye nesizukulwane segesi esiphansi.
Imboni isebenzisa ama-sand cores ahlanganiswe nesihlabathi se-silica kanye nezinhlayiya zesihlabathi ezimbozwe nge-ceramic ukuze zibunjwe kanyekanye, ngemva kokuhlanza ukukhishwa, zenza ukuhlolwa kwe-anatomical.
Uma umgogodla wenziwe ngesihlabathi se-silica esihlanganiswe nesihlabathi, ama-castings anodonga olungalingani nodonga oluncane, futhi ubukhulu bodonga buyi-3.0-6.2 mm; lapho umnyombo wenziwe ngesihlabathi se-ceramic esimbozwe isihlabathi, ubukhulu bodonga be-casting bufana, futhi ubukhulu bodonga buyi-4.4-4.6 mm. njengesithombe esilandelayo
I-silica sand camera isihlabathi
Isihlabathi se-Ceramic esihlanganiswe nesihlabathi
Isihlabathi se-Ceramic camera sisetshenziselwa ukwenza ama-cores, aqeda ukuphuka komgogodla wesihlabathi, kunciphisa ukuguqulwa kwe-sand core, kuthuthukisa kakhulu ukunemba kwe-dimensional yesiteshi sokugeleza sangaphakathi se-exhaust manifold, futhi kunciphisa ukunamathela kwesihlabathi emgodini ongaphakathi, ukuthuthukisa ikhwalithi yensimbi. ukulingwa nezinga lemikhiqizo eqediwe futhi kuzuzwe izinzuzo ezibalulekile zezomnotho.
3. Ukusetshenziswa kwesihlabathi se-ceramic ezindlini ze-turbocharger
Izinga lokushisa elisebenzayo ekugcineni kwe-turbocharger igobolondo ngokuvamile lingaphezu kuka-600°C, kanti amanye aze afinyelele phezulu aze afike ku-950-1050°C. Impahla yegobolondo idinga ukumelana nokushisa okuphezulu futhi ibe nokusebenza okuhle kokulingisa. Isakhiwo segobolondo sihlangene kakhulu, ubukhulu bodonga buncane futhi bufana, futhi indawo yangaphakathi ihlanzekile, njll., idinga kakhulu. Okwamanje, izindlu ze-turbocharger ngokuvamile zenziwe ngensimbi engamelani nokushisa (njenge-1.4837 kanye ne-1.4849 ye-DIN EN 10295 ejwayelekile yaseJalimane), kanye nensimbi ekwazi ukumelana nokushisa nayo iyasetshenziswa (njenge-GGG SiMo ejwayelekile yaseJalimane, i-American. standard high-nickel austenitic nodular iron D5S, njll.).
I-1.8 T injini yezindlu ze-turbocharger, impahla: 1.4837, okuyi-GX40CrNiSi 25-12, ukwakheka kwamakhemikhali okuyinhloko (%): C: 0.3-0.5, Si: 1-2.5, Cr: 24-27, Mo: Max 0.5, Ni: 11 -14, ukuthulula izinga lokushisa 1560 ℃. I-alloy inezinga eliphezulu lokuncibilika, izinga elikhulu lokushwabana, ukuthambekela okuqinile kokuqhekeka okushisayo, nobunzima bokuphonsa okuphezulu. Isakhiwo se-metallographic sokusakaza sinezidingo eziqinile kuma-carbides asele kanye nokufaka okungezona ezensimbi, futhi kukhona nemithethonqubo ethile mayelana nokukhubazeka kokuphonsa. Ukuze kuqinisekiswe ikhwalithi nokusebenza kahle kokukhiqizwa kokulingisa, inqubo yokubumba isebenzisa ukulingwa okuyisisekelo ngamagobolondo esihlabathi ambozwe ifilimu (kanye nebhokisi elibandayo nezinhlamvu zamabhokisi ashisayo). Ekuqaleni, kwakusetshenziswa isihlabathi sokukhuhla se-AFS50, kwase kusetshenziswa isihlabathi se-silica esigazingiwe, kodwa izinkinga ezinjengokunamathela kwesihlabathi, ama-burrs, imifantu eshisayo, nezimbotshana zomgodi ongaphakathi zabonakala ngamazinga ahlukahlukene.
Ngesisekelo socwaningo nokuhlola, imboni yanquma ukusebenzisa isihlabathi se-ceramic. Ekuqaleni kuthengwe isihlabathi esinamekiwe esiqediwe (100% isihlabathi se-ceramic), kwase kuthengwa izinto zokuvuselela nokuhlanganisa, futhi ngokuqhubekayo kwenziwa ngcono inqubo phakathi nenqubo yokukhiqiza, sebenzisa isihlabathi se-ceramic nesihlabathi sokukhuhla ukuhlanganisa isihlabathi esingavuthiwe. Njengamanje, isihlabathi esimboziwe sisetshenziswa ngokulandela ithebula elilandelayo:
| Inqubo yesihlabathi ehlanganiswe nesanti ye-Ceramic yezindlu ze-turbocharger | ||||
| Usayizi Wesanti | Izinga lesihlabathi se-ceramic% | Ukwengezwa kwe-resin% | Amandla okugoba i-MPa | Okukhipha igesi ml/g |
| AFS50 | 30-50 | 1.6-1.9 | 6.5-8 | ≤12 |
Eminyakeni embalwa edlule, inqubo yokukhiqiza yalesi sitshalo ibisebenza ngokuzinzile, izinga lokulingisa lihle, futhi izinzuzo zezomnotho nezemvelo ziyamangalisa. Isifinyezo simi kanje:
a. Ukusebenzisa isihlabathi se-ceramic, noma ukusebenzisa ingxube yesihlabathi se-ceramic nesihlabathi se-silica ukwenza ama-cores, kuqeda iziphambeko ezifana nokunamathela kwesihlabathi, i-sintering, i-veining, nokuqhekeka okushisayo kokusakazwa, futhi ibona ukukhiqizwa okuzinzile nokusebenza kahle;
b. Ukubunjwa okuyisisekelo, ukusebenza kahle kokukhiqiza okuphezulu, isilinganiso esiphansi sesihlabathi ne-iron (ngokuvamile asikho ngaphezu kuka-2:1), ukusetshenziswa kwesihlabathi esingavuthiwe okuncane, nezindleko eziphansi;
c. Ukuthululwa kwe-core kulungele ukugaywa kabusha kanye nokukhiqizwa kabusha kwesihlabathi semfucumfucu, futhi ukubuyisela kabusha okushisayo kwamukelwa ngokufanayo ukuze kuvuselelwe. Ukusebenza kwesihlabathi esivuselelwe sekufinyelele ezingeni lesihlabathi esisha sokukhuhla isihlabathi, esizuze umphumela wokunciphisa izindleko zokuthengwa kwesihlabathi esiluhlaza kanye nokunciphisa ukuchithwa kwemfucuza eqinile;
d. Kuyadingeka ukuthi uhlole njalo okuqukethwe kwesihlabathi se-ceramic esihlabathini esivuselelwe ukuze unqume inani lesihlabathi esisha se-ceramic esingeziwe;
e. Isihlabathi se-Ceramic sinomumo oyindilinga, i-fluidity enhle, nokucaciswa okukhulu. Uma ihlanganiswe nesihlabathi se-silica, kulula ukubangela ukuhlukaniswa. Uma kunesidingo, inqubo yokudubula isihlabathi idinga ukulungiswa;
f. Uma umboza ifilimu, zama ukusebenzisa i-phenolic resin yekhwalithi ephezulu, futhi usebenzise izithasiselo ezihlukahlukene ngokuqapha.
4. Ukusetshenziswa kwesihlabathi se-ceramic enjinini ye-aluminium alloy cylinder head
Ukuze kuthuthukiswe amandla ezimoto, kuncishiswe ukusetshenziswa kukaphethiloli, kuncishiswe ukungcoliswa komoya, futhi kuvikelwe imvelo, izimoto ezingasindi ziwumkhuba wokuthuthukiswa kwemboni yezimoto. Njengamanje, ukusakaza kwenjini yezimoto (kuhlanganise nenjini ye-diesel), njengamabhulokhi angamasilinda nama-cylinder heads, kuvamise ukuphonswa ngama-alloys e-aluminium, kanye nenqubo yokusakazwa kwamabhulokhi angamasilinda namakhanda angama-cylinder, lapho kusetshenziswa ama-sand cores, isikhunta sensimbi ukuphonsa amandla adonsela phansi kanye nengcindezi ephansi. casting (LPDC) yibo abamele kakhulu.
Umgogodla wesihlabathi, inqubo yesihlabathi esimboziwe kanye nebhokisi elibandayo le-aluminium alloy cylinder block kanye nokukhishwa kwekhanda kuvame kakhulu, kulungele ukunemba okuphezulu kanye nezici zokukhiqiza ezinkulu. Indlela yokusebenzisa isihlabathi se-ceramic ifana nokukhiqizwa kwekhanda le-cylinder yensimbi. Ngenxa yokushisa okuphansi okuthululwayo kanye namandla amancane adonsela phansi e-aluminium alloy, ngokuvamile kusetshenziswa isihlabathi esiwumgogodla esinamandla aphansi, njengesihlabathi esibandayo sebhokisi efektri, inani le-resin elengeziwe ngu-0.5-0.6%, futhi amandla aqinile 0.8-1.2 MPa. Kudingeka isihlabathi esiwumgogodla Inokugoqeka okuhle. Ukusetshenziswa kwesihlabathi se-ceramic kunciphisa inani le-resin eyengeziwe futhi kuthuthukisa kakhulu ukuwa komgogodla wesihlabathi.
Eminyakeni yamuva nje, ukuze kuthuthukiswe indawo yokukhiqiza futhi kuthuthukiswe izinga lokulingisa, luyanda ucwaningo kanye nokusetshenziswa kwezibophezelo ze-inorganic (okuhlanganisa ingilazi yamanzi eguquliwe, ama-phosphate binder, njll.). Isithombe esingezansi yindawo yokuphonsa yemboni esebenzisa isihlabathi se-ceramic binder core sand aluminium alloy cylinder head.
Imboni isebenzisa i-ceramic sand binder ye-inorganic binder ukwenza umongo, futhi inani le-binder elingeziwe lingu-1.8~2.2%. Ngenxa ye-fluidity enhle yesihlabathi se-ceramic, umgogodla wesihlabathi uminyene, ubuso buphelele futhi bushelelezi, futhi ngasikhathi sinye, inani lokukhiqiza igesi lincane, lithuthukisa kakhulu isivuno se-castings, lithuthukisa ukugoqa kwesihlabathi esiwumgogodla. , ithuthukisa indawo yokukhiqiza, futhi ibe imodeli yokukhiqiza okuluhlaza.
Ukusetshenziswa kwesihlabathi se-ceramic embonini yokukhipha injini kuye kwathuthukisa ukusebenza kahle kokukhiqiza, kwathuthukisa indawo yokusebenza, kwaxazulula izinkinga zokuphonsa, futhi kwazuza izinzuzo ezinkulu zezomnotho kanye nezinzuzo ezinhle zemvelo.
Imboni yokusungula injini kufanele iqhubeke nokwandisa ukuvuselelwa kwesihlabathi esiwumgogodla, ithuthukise ukusebenza kahle kwesihlabathi se-ceramic, futhi inciphise ukukhishwa kwemfucuza eqinile.
Ngokombono wokusetshenziswa nobubanzi bokusetshenziswa, isihlabathi se-ceramic njengamanje siyisihlabathi esikhethekile sokuphonsa esisebenza kahle kakhulu futhi esisetshenziswa kakhulu embonini yokulingisa injini.
Isikhathi sokuthumela: Mar-27-2023
