TS Hong Vn Gt (Ch biờn) 671.734 TS o Duy Trung H407G m mm HtỡPTH NH XUT BN KHOA HC V K THUT HONG VN GT - O DUY TRUNG NH XUT BN KHOA HC V K THUT H NễI -2012 MC LC Trang M U .7 Chng TNG QUAN V CễNG NGH PHUN PH 1.1 BN CHT, C IM V PHM VI NG DNG CA CễNG NGH PHUN PH KIM LOI 1.2 CC PHNG PHP PHUN PH KIM LOI BNG NHIT K H 19 Chng VT LIU DNG CHO PHUN PH BNG NHIT KH 2.1 VT LIU PH DNG D Y 34 2.2 VT LIU PH DNG THANH 36 2.3 VT LIU PH DNG BT 36 Chng THIT B PHUN PH KIM LOI BNG NHIT KH 3.1 PHN LOI THIT B 38 3.2 THIT B PHUN PH BNG KH CHY ễXY-AXấTYLEN 39 3.3 U PH U N 40 Chng NH HNG CA CC YU T CễNG NGH N BẩN BM DNH CA LP PHUN PH KIM LOI 4.1 PHN LOI CC YẫU T NH HNG N CHT LNG LP P H 41 4.2 NH HNG CA CC YU T CễNG NGH N BN BM DNH 43 4.3 NH HNG CA DềNG Hễ QUANG IN V DềNG VT LIU PH 46 4.4 NH HNG CA V TR TNG QUAN U PHUN V B MT CHI TIT P H 47 4.5 NH HNG CA PHNG PHP CHUN B Bẩ M T .50 4.6 NH HNG CA NG SUT D TRONG LểP PH 51 4.7 NH HNG CA CễNG NGH X Lí NHIT SAU PHUN PH 51 Chng CễNG N G H CHUN B Bẩ MT KIM LOI NẩN TR C PHUN P H 5.1 MC CH CA CễNG NGH CHUN B B M T .55 5.2 KHI NIM V CHT BN B M T 55 5.3 CễNG NGH CHUN B Bẩ M T .56 5.4 PHNG PHP LM SCH B M T 56 5.5 TO NHM B MT TRC KHI PHUN PH 57 5.6 MT S PHNG PHP CHUN B TO NHM Bấ M T 59 Chng M T S PHNG PHP NH GI CHT LNG LP PH KIM LOI 6.1 TNH CHT C HC CA LểP PH KIM LO I 65 6.2 TNH CHT CHNG MI MềN CA LP PH KIM LO I 65 6.3 KH NNG CHNG G CA LP PH KIM LO I 65 6.4 KIấM TRA BN KẫO 65 6.5 KIấM TRA BN BM TRT .66 6.6 KIấM TRA BN BM DNH 66 6.7 KIM TRA BN U N 67 6.8 KIấM TRA CHT LNG LểP PH BNG TèNH TRNG VT PH H Y 68 6.9 KIM TRA CNG CA LP PH KIM LO I 69 6.10 KIM TRA NG SUT D CA LểP PH KIM L O I 69 6.11 KIM TRA XP LểP PH .70 6.12 KIấM TRA CHT LNG LểP PH BNG PHNG PHP KIM TNG HC 72 6.13 KIấM TRA KH NNG CHU MI MềN CA LP PH BNG PHNG PHP c HC 72 6.14 KIM I RA KH NNG CHU NHIT CA LểP PH 76 16.15 KIấM TRA TNH CHU N MềN CA LP PH KIM LO I 77 Chng BẩN BM DNH V CC YU Tể NH HNG TI BẩN BM DNH 7.1 Lc BM DNH CA HT KIM LOI LềNG LấN B MT CC CHT R N 78 7.2 Lc VANDERVAN 80 7.3 L c LIấN KT DO NH HNG CA LP IN TCH KẫP 81 7.4 LIấN KT KIM LOI 82 7.5 NHNG NHN Tể NH HNG N BM D N H 83 7.6 S' NH HNG NG THI CA NHIU YấU T CễNG NGH TI BN BM D N H 92 7.7 NH HNG CA x ự ' Lí NHIT SAU PHUN ẫN CHT LNG LP P H .98 Chng THIẫT B V PHONG PHP KIM TRA CHAT LNG LP PHUN PH 8.1 THIT B TH NGHIM PHUN PH BNG ễXY-AXấTYLEN 104 8.2 PHNG PHP XC NH BN KẫO CA LP PH 108 8.3 PHU ONG PHP XC NH BẩN TRT CA LP P H 109 8.4 PHNG PHP XC NH BN BM DNH PHP CA LP PH 11 8.5 PHNG PHP NGHIấN c u CHT LNG LP PH BNG KIM TNG H C 112 Chng NGHIấN CU THC NGHIM NH HNG CA MT S YU Tể CễNG NGH ẫN BM DNH CA LP PH V NG DNG 9.1 QUY TRèNH CễNG NGH PHUN PH 113 9.2 Mễ HèNH TON HC QUAN H GIA BN KẫO CA LP PH V BA THễNG s : KHONG CCH PHUN, P LC KH THI V P Lc KH ễ X Y 117 9.3 Mễ HèNH TON HC UAN H GIA BN TRT CA LP PH V BA THễNG S: KHONG CCH PHUN, P L c KH THI V P Lc KH ễ X Y 126 9.4 Mễ HèNH TON HC QUAN H GI A BN BM DNH PHP CA LP PH VI BA THễNG S: KHONG CCH PHUN, P LC KH THễI V P Lc KH ễ X Y 133 Chng 10 X Lí NHIT ấ CI THIN LP PH 10.1 CHN PHUệNG PHP x Lí N H I T 141 10.2 IU KIN TH NGHIM 141 10.3 Mễ T TH N G H IM 142 10.4 NG DNG KT QU NGHIấN cu PHC HểI TRC T THẫP C45 153 TI LIU THAM KHO 157 M U Trong nhng nm gn mnh m, ca nú úcỏch mng khoa õy,khoa hc cụng ngh th cụng ngh t n inh Phun phự kim loi cng l lnhvc khoa hc n vi cỏc phng phỏp cụng ngh khỏc Nm Ă912 ý tng phun phu kim mi c mt k s ngiới Thy S tờn l Schoop thc hin sau c ng dng vo mc ớch trang trớ n Chin tranh th th phun ph kim loi ó c ng dng mt quy mụ rng hu ht chõu u Phng phỏp ny ó trthnh mt phng phỏp cụng cụng dng v cnhiu u vittrong lnhvc chng tit kim kim loi quý en nhng nm 1970, 1980 phun kim ó thnh mt vc khoa hc cụng ngh riờngc biờuhin giụng nh ngh x lý b mt,mt khỏc nú cnggi ngh chto snxut Nhng nm 1990 khoa hc cụng n n inh cao cakhoa hc ng dng ờỏnh giỏ s phỏt cú thda trờn c s phỏt phm ving dng cỏc triờnmnh m ca cúng ngh phun phu trin v lnhvc Hin trờnth gii, nhiu nct v cụng ngh phun ph kim loiu cỳc hóng nghiờ xut v ng dng cỏc thit bphun Castolim (Thy S),MeICO Plasmaday, Avko (M), Nobel Brocl (Phỏp), EciaGhiken (Nht), Arcrosse (Bi), (Thy Vit Nam khoa hc cụng ngh phun phự kim cũn ang giai on nghiờn cung dng cỏc thnh qu ca th gii Cỏc nh khoa hc quan tõmn cụng ngh phự kim s vt liuphự nh nhụm, km phc v cho dng kt cu Hin ó nghiờn cu ng dng phun ph kim i hc, loihc u chong phm cmt cp loca mt s Vic nghiờn cu, xem xột mt cỏchy ỏnh cụng ngh nh: khong cỏch phun, ỏp khớ ụxy, dũng ht kim loi, c ht,ch cp vt liu v x lý n bn bỏm dớnh ca lp ph kim loi t mt hp C kim loinn bng phng phỏp nhit khớ nõng v kha nng ng dng ti nc ta l iu rttrong ph l mt ch tiờumang tnh chtquy bỏm dớnh ph thuc vo rtnhiu yu t phun, ỏp lc khụng khớ thi,ỏp lc Trc nhu cu ũi hi cp bỏch phỏt cụng ngh phun kim nc ta, cun sỏch "Nghiờn cu ng dng cụng ngh phun ph bng phng phỏp thc nghim" s giỳp ớch cho trng ihc v saui hc cng nh ng dng vo sn xut v phc hi chitit mỏy Tỏc gi xinchõn thnh cỏm n b mt - Vin Nghiờn cu Ckhớ, Trng i PGS Hong Tựng cựng cỏc Giỏos cỏc nh kh kin tỏc gihon thnh cỏc th nghin v K thut ó giỳptỏc gi hon thnh bỏn Nhúm tỏc gió Chong TNG QUAN Vẩ CNG NGH PHUN PH 1.1 BN CHT, C IM V PHM VI NG DNG CA CễNG NGH PHUN PH KIM LOI Phun kim loi bng nhit khớ hoc l Schoop (theo tờn mt k s c khớ ngi Thy S l u M Schoop ụng ó tỡm phng phỏp ny nm 1992) cú nguyờn lý nh sau: kim loi lng c dũng khớ nộn thụi lm phõn tỏn thnh cỏc ht nh, bay va p bỏm lờn b mt vt ó c chun b sch, nh vy s to lp kim loi ph dy, ú cú cỏc phn t kim loi ố lờn theo tng lp Phun kim loi cú thờ ph c cỏc kim loi nguvờn cht, cỏc hp kim ca chỳng hoc vt liu phi kim lờn mt kim loi hoc b mt cng khỏc nh g, giy, vi, s, Bang phun kim loi cng cú th to nhng lp dn in trờn vt khụng dn din, to cỏc lp chu nhit, Nhng cụng dng ny rt cú ý ngha cỏc lnh vc k thut Trờn hỡnh 1.1 l s nguyờn lý lm vic ca u phun kim loi dõy (t chy kim loi bng ngn la khớ chỏy) Hỡnh 1.1.S nguyờn lý u phun bng khớ chỏy Nguyờn lý theo hỡnh 1.1: Kim loi c a vo u phun di dng dõy cú ng kớnh khong , - mm Cỏc ng dn khớ ụxy, axờtylen v khụng khớ nộn cú ỏp sut c a ti u phun Hn hp khớ ụxy v axờtylen chỏy cho ngn la nh ngn la hn khớ Di tỏc dng ca ngn la u dõy b t núng chy, ng thi khụng khớ nộn thi git kim loi lng lm bn nhng ht kim loi nh bay theo dũng khớ nộn vi tc cao (khong 100 - 200 m/s) p lờn b mt vt p u s dch chuyn ca dõy c thc hin bng c cu dch chuyn c khớ Lp kim loi ph lờn b mt vt s cú cng ln hn kim loi dõy v cú sc bn kộo khụng ln lm Sc bn liờn kt vi vt liu c s cng nh Nhng tớnh cht ca lp ph s cú nhiu tỏc dng khỏc nh tớnh chu mi mũn ma sỏt t, cú kh nng gi du nõng cao bỏm ca lúp ph, b mt c s phi hon ton sch v c chun b trc bng phng phỏp thớch hp nh gia cụng c khớ, phun bi, gi in, Sau lm sch v to nhp nhụ, tt nht l tin hnh phun v khụng chm hn gi, nu lõu b mt lm sch li b ụxy hoỏ bi khụng khớ Kim loi hoc hp kim trng hp khụng th to c di dng dõy thỡ cú th a vo u phun di dng bt (gi l u phun bt kim loi) B truyn Hỡnh S nguyờn iý lm vic ca u phun bng h quang in Nhit dựng t chỏy kim loi cú th thu c bng ngn la ụxy-axờtylen hoc bng h quang in Hỡnh 1.2 l u phun s dng h quang in Bng u phun ny cú th phun cỏc kim loi cú im núng chy cao 10 Hm lng ca nguyờn t st (Fe) tng lờn nhiu Hin tng nguyờn t Fe tng thờm nhiu thnh phn lp ph ti vựng tip giỏp vi b mt kim loi nn thộp C45 cho thy nguyờn t Fe ó khuch tỏn sang lúp ph thi gian thiờu kt kộo di; Hm lng nguyờn t Fe khuch tỏn t kim loi nn thộp C45 sang lp ph l nguyờn nhõn lm gim cng ca lúp ph cú chiu dy nh T phõn tớch trờn cho phộp kt lun; Tu thuc vo chiu dy lúp ph, thi gian thiờu kt la chn phi phự hp m bo cng cho lúp ph Kt lun ny cú ý ngha thc tin rt cao cụng tỏc phc hi v x lý b mt chi tit mỏy 10.4 NG DNG KẫT QU NGHIấN c u PHC HềI TRC T THẫP C45 10.4.1 c im ca trc Trc (hỡnh 10.7) c lp rỏp trờn mỏy chi dõy chuyn sn xut si thuc Cụng ty Dt may Hu Trc thc hin chc nng dn di si, chy trờn mt 060 X 90 mm Khi cỳi si chy qua mt trc 060 mm phi chu lc ộp khong kg Do vy mt trc ti v trớ cỳi si chy qua chu ti mũn ma sỏt Trong dõy chuyn sn xut cú 40 mỏy chy si v tng ng cú 40 trc ộp cỳi Hng nm phi thay th 40 cỏi trc nguyờn nhõn mt 060 b mũn Dõy chuyn thit b hóng TEXTIMA ca CHDC c trang b; trc õy trc thng nhp ca hóng Do vic nhp trc vi giỏ quỏ cao v khụng ch ng nờn khong nm tr li õy trc c ch to nc Trc õy thng ch to trc l thộp C45 vi cụng ngh tụi b mt bng phng phỏp tụi cao tn nờn cng b mt 060 X 90 ram ch t 45 - 48 HRC Do vy tui th ch c khong - thỏng Neu dựng cỏc phng phỏp x lý b mt khỏc nh: hoỏ nhit thỡ phi thay vt liu trc v chi phớ cho x lý b mt cao hn Dựng m x lý h mt thỡ d b bong trúc Thay th vt liu trc bng cỏc vt 153 liu c ch cú c tớnh cao cựng vi kv thut nhit luyn thỡ gii quyt c yờu cu k thut nhng khụng kinh t 10.4.2 Gii phỏp k thut mi Trc c ch to bng thộp C45 Kớch thc mt trc 060 X 90 cú cng >55 HRC ó s dng phng phỏp phun ph b mt 060 X 90 mm vi chiu dy l mm t vt liu ca nhúm hp kim nn niken: Ni70Crl 7S4B4 v c x lý nhit sau phun bng u t ụxy-axờtylen Trc ang c x lý nhit trờn mỏy (hỡnh 10.7) Bang phng phỏp ny b mt trc t cng 55 - 58 HRC bỏm dớnh lp ph t c yờu cu s dng v trc ỏp ng c yờu cu cựa cỏc phng phỏp cụng ngh gia cụng c khớ thụng dng vi chớnh xỏc thit k Hỡnh 10.7 nh trc ang c x lý nhit bng mt u phun Tui th ca trc: Trc ó c kim tra tỡnh trng k thut (sau thỏng chy ti) vi s lng 10 chic; kt qu: mũn ca mt 060 X 90 mm ti v trớ cỳi chy qua nm dung sai cho phộp v ỏp ng c cỏc yờu cu s dng Trc sau c phc hi (hỡnh 10.8) 154 Hỡnh 10.8 nh trc cỳi sau c phc hi Nhn T xột: kt qu thc nghim cho phộp kt lun nh sau: 1) Trong gii hn khong cỏch phun èOO - 200 mm, ỏp sut khớ thi 0,3 - 0,4 MPa v ỏp sut khớ ụxy o, 15 0,25 MPa thỡ tng khong cỏch phun, tng ỏp lc khớ thi v khớ ụxy thi bn kộo, bn bỏm dớnh lp phun ph kim loi tng, ú khong cỏch phun nh hng nhiu hn Khi khong cỏch phun tng ln hn 200 mm thỡ bn li gim xung S nh hng ng thi ca c hai hoc ba thụng s gõy cho bn khụng ỏng k 2) Sau x lý nhit thớch hp lp phun ph kim loi c ci thin v d bn v cu trỳc kim tng, c th l: bn kộo tng hn bn ln, d bn bỏm tng hn hai ln so vi trc x lý nhit; cng lp phỳ tng t 20 - 25% so vi trc x lý nhit; Cu trỳc kim tng cú xp c gim hu nh khụng cũn 3) Thi gian trỡ nhit thiờu kt tng chiu dy lp khuch tỏn tng v lm tng bn bỏm dớnh, nhng lm gim cng b mt lp ph (i vi lp ph cú chiu dy < 0,5 mm) 155 4) Thi gian trỡ nhit thiờu kt thiờu kt nờn chn khong - 10 s cho lp ph cú chiu dy n 0,5 mm, 10 - 20 s cho lúp ph > mm 5) Ch phun ti u bng phng phỏp ngn la ụxy-axờtylen, vt liu ph t nhúm hp kim N - Cr - Si - B cho bn bỏm dớnh vi b ba thụng s l: Khong cỏch phun: 170 - 200 mm; p sut khớ thi: 0,3 - 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