铸件特种修复技术的研究与应用
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摘要
铸件的合格率和缺陷铸件的修复率是制约我国铸造工业的瓶颈。再制造作为一项符合可持续性发展战略的重要途径,通过采用特种修复技术将损坏或报废的铸件性能达到或超过新品,而成本仅是新品的50%、节能60%、节材70%,为企业提高效率、节能降耗提供了全新思路和手段,符合国家构建循环经济、建设节约型社会和发展创新型国家的战略目标。
本文从机械铸造零件的再制造入手,介绍了本课题的研究背景和研究意义及再制造在国内外的发展现状,铸件典型磨损及特种修复技术的相关知识,比较了传统修复技术与特种修复技术的优缺点。以北京奥宇可鑫表面工程有限公司特种修复技术为依托,从理论上分析和研究奥宇可鑫公司常温冷熔焊特种修复技术的修复效果,并针对铸件胶粘修复中出现的问题进行改进,提出了一种基于胶粘技术和新型螺纹技术的复合修复技术。在对奥可常温冷焊重熔技术理论研究的基础上,运用常温冷熔焊重熔技术进行铸件修复研究,经宏观检测基体在修复过程中温度始终保持常温,修复后无焊补痕迹、无裂纹；采用电镜和能谱仪分析其微观组织形态：会相组织和元素成分。通过金相分析得出基体组织基本没有改变,过渡区渗碳体的出现数量很少。通过能谱仪分析出在特种修复过程中有明显的元素扩散现象,说明采用常温冷焊重熔特种修复技术后,补材与基体是冶金结合,结合强度高。分析比较了低碳钢、铁丝、同材质铁屑三种不同补材对铸件缺陷修复质量的影响。最后,针对铸件缺陷胶粘技术的不足,提出了胶粘技术与新型螺纹的复合修复技术,并通过实验验证了其可行性。
Our country casting industry is seriously restricted by the two bottlenecks--low eligible rate of casting and low repair rate of casting defects. As an important way of sustainable development strategy, remanufacture is more and more valued by people.50% cost,60% energy and 70% material of a new one will be saved by remanufacturing the damaged or scrapped casings to meet or exceed performance of new products, in which special repair technology will be used. It not only provides a new mean for enterprises to improve efficiency and low energy consumption but also meets the strategic objective of constructing national circular-economy, building a conservation-oriented society and developing an innovative country.
From the start of machine tool castings and vehicle casings, the research background, the research significance of this paper, and the status of remanufacture technology developing at home and abroad are introduced in this paper firstly. Also, the related typical castings'wears and current special repair technologies are presented, the advantages and disadvantages of special technologies and traditional methods are compared and an unprecedented repair instance of shield's drive shell by the special technologies is suggested. Basing on the Beijing Aoyukexin Surface Engineering Co., Ltd, this paper mainly theoretically analysis and studies the repair and its results of Aoyukexin's room-temperature cold fusion technology, and improves the traditional adhesive technology for the problem at practical applications and innovatively composites the adhesive technology and new type of thread technology to a new technology. After the study of theory of room-temperature cold fusion technology, a repair example of this technique is recommended. Through the macro-test, the base metal was always kept at room temperature, and no welding marks or cracks after repair. Under the metallurgical microscope, metallographic analysis represents the microstructure of base metal having slightly changes and having small number of cementite in transition zone. Spectroscopy analysis displays markedly elements diffusion, which says that the fill material is a metallurgical bonding with the base material, combined with high bonding strength. Then, the repair results of the different fill materials:low carbon, wire and iron filings of the same material with the base material are compared to analysis the influence to repair results. Finally, for the lack of casting defects repair in adhesive technology, a new technology compositing adhesive technology and new type of thread is proposed and its feasibility is verified by experiment.
本文从机械铸造零件的再制造入手,介绍了本课题的研究背景和研究意义及再制造在国内外的发展现状,铸件典型磨损及特种修复技术的相关知识,比较了传统修复技术与特种修复技术的优缺点。以北京奥宇可鑫表面工程有限公司特种修复技术为依托,从理论上分析和研究奥宇可鑫公司常温冷熔焊特种修复技术的修复效果,并针对铸件胶粘修复中出现的问题进行改进,提出了一种基于胶粘技术和新型螺纹技术的复合修复技术。在对奥可常温冷焊重熔技术理论研究的基础上,运用常温冷熔焊重熔技术进行铸件修复研究,经宏观检测基体在修复过程中温度始终保持常温,修复后无焊补痕迹、无裂纹；采用电镜和能谱仪分析其微观组织形态：会相组织和元素成分。通过金相分析得出基体组织基本没有改变,过渡区渗碳体的出现数量很少。通过能谱仪分析出在特种修复过程中有明显的元素扩散现象,说明采用常温冷焊重熔特种修复技术后,补材与基体是冶金结合,结合强度高。分析比较了低碳钢、铁丝、同材质铁屑三种不同补材对铸件缺陷修复质量的影响。最后,针对铸件缺陷胶粘技术的不足,提出了胶粘技术与新型螺纹的复合修复技术,并通过实验验证了其可行性。
Our country casting industry is seriously restricted by the two bottlenecks--low eligible rate of casting and low repair rate of casting defects. As an important way of sustainable development strategy, remanufacture is more and more valued by people.50% cost,60% energy and 70% material of a new one will be saved by remanufacturing the damaged or scrapped casings to meet or exceed performance of new products, in which special repair technology will be used. It not only provides a new mean for enterprises to improve efficiency and low energy consumption but also meets the strategic objective of constructing national circular-economy, building a conservation-oriented society and developing an innovative country.
From the start of machine tool castings and vehicle casings, the research background, the research significance of this paper, and the status of remanufacture technology developing at home and abroad are introduced in this paper firstly. Also, the related typical castings'wears and current special repair technologies are presented, the advantages and disadvantages of special technologies and traditional methods are compared and an unprecedented repair instance of shield's drive shell by the special technologies is suggested. Basing on the Beijing Aoyukexin Surface Engineering Co., Ltd, this paper mainly theoretically analysis and studies the repair and its results of Aoyukexin's room-temperature cold fusion technology, and improves the traditional adhesive technology for the problem at practical applications and innovatively composites the adhesive technology and new type of thread technology to a new technology. After the study of theory of room-temperature cold fusion technology, a repair example of this technique is recommended. Through the macro-test, the base metal was always kept at room temperature, and no welding marks or cracks after repair. Under the metallurgical microscope, metallographic analysis represents the microstructure of base metal having slightly changes and having small number of cementite in transition zone. Spectroscopy analysis displays markedly elements diffusion, which says that the fill material is a metallurgical bonding with the base material, combined with high bonding strength. Then, the repair results of the different fill materials:low carbon, wire and iron filings of the same material with the base material are compared to analysis the influence to repair results. Finally, for the lack of casting defects repair in adhesive technology, a new technology compositing adhesive technology and new type of thread is proposed and its feasibility is verified by experiment.
引文
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[7]田世江,杨丽君,王杰.我国发展节约型铸造业的思考[J].特种铸造及有色合金.2005,25(12)：727-728.
[8]侯华玲.中国铸造业的发展与循环经济的实施[J].铸造技术.2005,26(12)：1175-1176.
[9]颜爱民.中国铸造行业现状及发展对策[J].铸造技术.2003,24(2)：77-79.
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[20]幺开宇,幺炳唐.机床再制造的思考[J].制造技术与机床,2011,(02)：44-45.
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[29]Xu Binshi,Liu Shican,Wang Haidou. Developing Remanufacturing, Constructing Cycle Economy and Building Saving-Oriented Society[J]. Journal of Central South University of Technology,2005,12(s2):1-6.
[30]Xu Binshi, Zhang Wei, Liu Shican, et al. Remanufacturing Technology for the 21st Century. The 15th European Maintenance Conference, March,2000 in Gothenburg, Sweden:335-339.
[31]徐滨士.绿色再制造工程及其在我国的应用前景[R].中国工程院咨询报告.2000.12.
[32]徐滨士.中国特色的再制造工程及其发展[R].2009中国汽车零部件再制造技术交流与应用国际研讨会,国谊宾馆,2009.
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[35]刘韶光.汽车曲轴再制造评价技术研究[D].武汉：武汉理工大学,2010.
[36]戴雄念.摩擦学基础[M].上海：上海科学出版社,1984.
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[38]徐锦烽,钱翰城.铸铁缺陷修补方法[J].铸铁技术,1994(3)：10-13.
[39]彭兴礼.奥宇可鑫修复技术-逆变脉冲电刷镀技术[J].设备管理与维修,2005,(8)：17.
[40]李建跃,李穗冬.采用电刷镀技术提高零件表面防腐蚀性能[J].金属材料与冶金工程,2007,35(2)：36-39.
[41]高应岑.胶接与表面粘涂技术专题报告[J].机械零件再制造,2007,特刊：29-37.
[42]李江英.林宋.陈超.盾构机驱动外壳密封位修复残余应力浅析[J].金属加工2010：45-46.
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[2]孙国雄,周尧和.铸造行业的可持续发展策略[J].铸造,1999,增刊：1-2.
[3]张立波,葛晨光,田世江.关于我国铸造业走自主创新道路的思考[J].铸造.2006,5(55)：429-431.
[4]严爱民.中国铸造产业状况及发展策略[J].China Foundry,2003,24(2):7-9.
[5]鲁永杰.铸造行业绿色铸造技术发展战略[J].铸造,1999(S1)：70-76.
[6]尚俊玲,陈维平,李元元.中国铸造行业发展策略分析[J].铸造技术,2007,28(10)：1387-1389.
[7]田世江,杨丽君,王杰.我国发展节约型铸造业的思考[J].特种铸造及有色合金.2005,25(12)：727-728.
[8]侯华玲.中国铸造业的发展与循环经济的实施[J].铸造技术.2005,26(12)：1175-1176.
[9]颜爱民.中国铸造行业现状及发展对策[J].铸造技术.2003,24(2)：77-79.
[10]徐滨士.再制造工程基础及其应用[M].哈尔滨：哈尔滨工业大学出版社,2005
[11]徐滨士,马世宁.优质高效电弧喷涂技术的应用和发展[J].表面工程.1996,11.(4)：7-14.
[12]万仁芳.汽车铸件市场展望及对策[J].现代铸铁,2003,(1)：34-38.
[13]支德瑜.铸铁在重要汽车零件上的应用实例以及与其他材质的比较[J].现代铸铁,2002,(2)：1-7.
[14]刘谦,戴庆荣.汽车发动机再制造发展现状及其关键技术[J].设备管理与维修,2003,(2)：9-10.
[15]邢忠,姜爱良,谢建军,等.汽车发动机再制造效益分析及表面工程技术的应用[J].中国表面工程,2004,(4)：1-6.
[16]周常英,张景来.关于发展我国汽车再制造的探讨[J].企业技术开发,2005,24(8)：3-5.
[17]田国富,张国胜,陈宝庆,等.工程机械的损伤形式与再制造技术分析[J].筑路机械与施工机械化[J],2007,(10)：62-64.
[18]刘飞,曹华军,杜彦斌.机床再制造技术框架及产业化策略研究[J].中国表面工程,,2006(11)：26-28.
[19]张小芬,何庆.废旧机床的绿色再制造及表面工程技术[J].制造技术与机床, 2008,(10)：33-35.
[20]幺开宇,幺炳唐.机床再制造的思考[J].制造技术与机床,2011,(02)：44-45.
[21]徐滨士,张伟,马世宁,等.再制造工程一绿色系统工程[J].中国设备工程,2000(1)：50-52.
[22]Xu Bin-shi. Nano surface engineering and remanufacturing engineering [J]. Trans Nonferrous Met Soc China,2004,14(10):1-6.
[23]徐滨士,朱胜,马世宁.装备再制造工程学科的建设和发展[J].中国表面工程,2003,(03)：50-52.
[24]Robot T Lund. The Remanufacturing Industry-Hidden Giant[R].Research Report, 1996.
[25]装甲兵工程学院.徐滨士院士教学、科研文选[R].北京：化学工业出版社,2010.
[26]徐滨士,朱绍华.表面工程与维修[M].北京：机械工业出版社,1996.
[27]杨清秀.汽车零部件再制造与应用实例[J].汽车运用,2010,(01)：46-47
[28]刘谦,戴庆荣.汽车发动机再制造发展现状及其关键技术[J].设备管理与维修,2003,(2)：9-10
[29]Xu Binshi,Liu Shican,Wang Haidou. Developing Remanufacturing, Constructing Cycle Economy and Building Saving-Oriented Society[J]. Journal of Central South University of Technology,2005,12(s2):1-6.
[30]Xu Binshi, Zhang Wei, Liu Shican, et al. Remanufacturing Technology for the 21st Century. The 15th European Maintenance Conference, March,2000 in Gothenburg, Sweden:335-339.
[31]徐滨士.绿色再制造工程及其在我国的应用前景[R].中国工程院咨询报告.2000.12.
[32]徐滨士.中国特色的再制造工程及其发展[R].2009中国汽车零部件再制造技术交流与应用国际研讨会,国谊宾馆,2009.
[33]全永听.施高义.摩擦磨损原理[M].浙江：浙江大学出版社,1988.
[34]李健.汽车再制造工程及其部件再制造技术的研究[D].武汉：武汉理工大学,2009.
[35]刘韶光.汽车曲轴再制造评价技术研究[D].武汉：武汉理工大学,2010.
[36]戴雄念.摩擦学基础[M].上海：上海科学出版社,1984.
[37]顾朝阳,翟卫平.氧乙炔焰金属粉木喷焊技术的应用[J].山东建材.1999(2)：31-32.
[38]徐锦烽,钱翰城.铸铁缺陷修补方法[J].铸铁技术,1994(3)：10-13.
[39]彭兴礼.奥宇可鑫修复技术-逆变脉冲电刷镀技术[J].设备管理与维修,2005,(8)：17.
[40]李建跃,李穗冬.采用电刷镀技术提高零件表面防腐蚀性能[J].金属材料与冶金工程,2007,35(2)：36-39.
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