Masana'antar Haƙar Ma'adinai
Bayanan Masana'antu da Fasahar Laser Cladding Analysis Aikace-aikace
1. Binciken Bayanan Masana'antu
1. Tasirin Muhalli Masu Tsanani akan Kayan Aiki
Muhalli na hakar kwal a ƙarƙashin ƙasa yana haifar da ƙalubale masu yawa ga dorewar injina. Tare da matakan zafi sau da yawa sun wuce kashi 90% da kuma kasancewar iskar gas mai lalata kamar H₂S da SO₂, sassan ƙarfe suna fuskantar saurin lalata lantarki. Misali, silinda masu amfani da hydraulic, waɗanda suke da mahimmanci don kiyaye kwanciyar hankali a cikin rami, suna da saurin kamuwa da tsatsa a saman ƙasa wanda ke lalata aikin rufewa, wanda ke haifar da gazawar tsarin hydraulic. Bugu da ƙari, ƙwayoyin ƙurar kwal (Mohs hardness 3-4) suna aiki azaman abubuwan gogewa, suna haifar da lalacewa mai tsanani akan sassan watsawa kamar sprockets da scrapers. Ƙurar kwal mai sauri na iya rage tsawon rayuwar waɗannan abubuwan da har zuwa kashi 40% idan aka kwatanta da muhallin tsafta.
2. Hanyoyin Rashin Tsarin Sassan
(1) Gajiyawa: Lodawa mai zagaye akan sprockets da scrapers yana haifar da ƙananan fasa a saman. Bayan kimanin sa'o'i 1,000 na aiki, waɗannan fasa na iya shiga zurfin 0.5mm, wanda ke haifar da fashewar abu da lalacewar aiki.
(2) Rage Rufi: Layukan gargajiya masu amfani da wutar lantarki (misali, plating mai tauri na chrome) suna haɗuwa da ƙasa mai rauni da substrates (20-30 MPa), wanda hakan ke sa su zama masu sauƙin barewa a ƙarƙashin tasirinsu. Sabanin haka, lacing na laser yana ba da ƙarfin haɗin gwiwa na 400-600 MPa, wanda ke tabbatar da mannewa na dogon lokaci.
2. Fa'idodin Fasahar Rufe Laser
Rufin Laser na Waje
Wannan dabarar ta yi fice wajen shirya rufin da ke jure lalacewa da kuma jure tsatsa a kan sassan shaft kamar silinda da sandunan piston. Manyan fa'idodi sun haɗa da:
● Ƙarancin Rage Narkewa: Kasa da kashi 5%, kiyaye ainihin kayan.
● Ƙarancin Canzawa: Yankunan da zafi ke shafa yawanci
● Ingantaccen Kayan Aiki: Yawan amfani da foda ya wuce kashi 90%, wanda hakan ke rage farashi idan aka kwatanta da na al'ada.
● Ingancin Fuskar: Ra ≤ 6.3μm gamawa, yana kawar da buƙatar yin aiki bayan an gama aiki a lokuta da yawa.
Gilashin Laser na Cikin Gida
Ya dace da silinda na hydraulic da sandunan piston, wannan hanyar tana ba da damar amfani da launuka daban-daban na ƙarfe (misali, bakin ƙarfe, ƙarfen da aka yi da nickel) waɗanda kaurinsu ya kama daga 0.5mm zuwa 3mm. Misali:
● Rufin Bakin Karfe: Samar da juriyar tsatsa sau 5 fiye da ƙarfe mara sinadari a yanayin da ke ɗauke da sinadarin acid.
● Alloys Masu Tushen Nickel: Ƙara tauri daga 200 HV zuwa sama da 600 HV, wanda hakan ke inganta juriyar lalacewa sosai.
Lankwasa Surface Laser Cladding
An tsara shi don siffofi masu rikitarwa kamar sprockets da picks, wannan tsari yana ba da:
● Kula da Hanyar Daidaitawa: Yana amfani da tsarin CNC mai tsawon axis 5 don cimma kauri mai kauri iri ɗaya (±0.1mm) akan saman da ba daidai ba.
● Ƙarfin Haɗin Kai Mai Girma: Haɗin ƙarfe yana tabbatar da juriya ga nauyin tasiri. Misali, yadudduka masu laushi akan tsintsaye suna riƙe da inganci koda ƙasa da 200 J na kuzarin tasiri.
3. Sigogi na Fasaha da Ma'aunin Aiki
| Sigogi | Rufin Waje | Rufin Bango na Ciki | Rufin Sama Mai Lankwasa |
| Ƙarfin Laser (kW) | 2-4 | 1.5-3 | 1.2-3 |
| Saurin Dubawa (mm/s) | 50-200 | 30-120 | 40-150 |
| Yawan Ciyar da Foda (g/min) | 5-25 | 3-15 | 4-20 |
| Taurin Shafi (HV) | 400-1200 | 350-1000 | 450-1100 |
| Ƙarfin Haɗi (MPa) | >400 | >350 | >450 |
4. Nazarin Shari'a: Gyaran Silinda Mai Haɗakar Ruwa
Wata ma'adanar kwal a lardin Shanxi ta ba da rahoton raguwar farashin maye gurbin silinda da kashi 65% bayan amfani da rufin laser. Tsarin ya dawo da silinda da suka lalace (asali φ140mm × 2.5m) zuwa yanayin da za a iya gyarawa, tare da layin da aka lulluɓe (NiCrBSi gami, kauri 1.2mm) wanda ke nuna:
● Ƙarfin haɗakar gogayya ya fi kashi 86% ƙasa da ƙarfe na asali.
● Tsawon rai sau 3 a lokacin gwajin gogewa.
● Matsakaicin izinin wucewa 100% a gwaje-gwajen rufewa mai ƙarfi (35 MPa).
5. Fa'idodin Muhalli da Tattalin Arziki
● Tanadin Kayayyaki: Rufin Laser yana amfani da foda mai kauri ƙasa da kashi 70% idan aka kwatanta da hanyoyin saman da aka saba amfani da su.
● Ingantaccen Makamashi: Yana rage yawan amfani da makamashi da kashi 40% yayin gyaran hanyoyin.
● Rage fitar da hayaki: Yana kawar da hayakin hexavalent chromium da ke da alaƙa da electroplating, yana daidaita da ƙa'idodin muhalli masu tsauri.
A ƙarshe, fasahar rufewar laser tana ba da cikakkiyar mafita don yaƙi da lalacewar sassan a cikin mawuyacin yanayin hakar ma'adinai, tana ba da ingantaccen aiki da dorewa idan aka kwatanta da hanyoyin gargajiya.
Aikace-aikacen Shari'a
Rufin Laser na Sprocket
Silinda ciki ramin Laser cladding
Silinda na waje da'irar laser cladding