3003 aluminum zagaye na zane mai zagaye: Tushen abin da ya dogara da sigogi na danniya akan nakatar da thermal

1. Shigowa da: Yanayin aikace-aikace na 3003 Aluminum dis dism

3003 aluminum disc Ana amfani da tushe mai zafi mai zafi a cikin na'urorin lantarki (e.g., Cpu zafi, Direbobi masu jagoranci) da kayan aikin gida (e.g., comprickoror).

A bayyane, yana da shahararsa zuwa matsakaicin ƙarfin inji (140-160MPa tensile), kyau kwarai thermal watsin (150-160W /(MİI K)), da fa'ida (20%-25% ƙasa da 6061 aluminum)- maɓalli masu mahimmanci waɗanda suka sa ya zama zaɓin da aka fi so don yanayin watsar zafi na tsakiyar wuta.

2. Nakasar zafi: Mahimman Ciwo Mai Mahimmanci

Duk da haka, Tushen dumama zafi yana buƙatar m flatness (≤0.05mm/100mm) da kwanciyar hankali na thermal don ingantaccen canja wurin zafi. Ko da ƙananan nakasawa na iya rushe hanyoyin tafiyar da zafi.

Gudanarwa (yin hatimi, Farashin CNC) yana haifar da damuwa na ciki. Lokacin zafi zuwa 50-100 ℃ (yanayin zafin na'urar lantarki na yau da kullun), wannan damuwa ta saki, haifar da warping ko damuwa.

Wannan nakasawa kai tsaye yana rage wurin hulɗa tare da abubuwan da ke haifar da zafi da wuce gona da iri 30% kuma yana ƙara juriya ta thermal ta 50%-80%, mai tsananin ɓata aikin ɓata zafi da rage tsawon rayuwar na'urar.

3. Matsayin Mn Element a cikin Rarraba Matsi na Ciki

Musamman, Mn in 3003 aluminum taka dual role: yana haɓaka juriya na lalata da ƙarfin injina amma kuma yana canza halin damuwa na ciki.

Lokacin sarrafawa, Mn yana amsawa da Al don samar da matakan Al₆Mn (0.5-1.0μm in size). Waɗannan matakai masu wuyar gaske suna hana motsin ɓarna, yana haifar da tarin damuwa a cikin mu'amalar lokaci-tare da matsananciyar damuwa ta kai 80-120MPa. Wannan matsananciyar damuwa ya zama babban direba na nakasar thermal.

4. Bukatar Ingantaccen Taimakon Taimakon Damuwa

Don haka, damuwa da damuwa yana fitowa a matsayin mahimmin tsari don kawar da damuwa na ciki da kuma hana lalatawar thermal.

Duk da haka, zaɓin siga mara kyau (e.g., zafi fiye da kima yana haifar da haɓakar hatsi, saurin sanyi yana haifar da sabon damuwa) zai iya dagula nakasawa ko rage zafin zafin jiki - yana lalata ainihin aikin ramin zafi.

Don haka, nazarin yadda annealing sigogi (ƙarfin zafi, lokaci, yawan sanyaya) shafi nakasar zafi yana da mahimmanci don haɓaka ingantattun hanyoyin kimiyya.

5. Tushen nakasar thermal: Matsalolin Ciki Mai Sarrafawa

Asali, sarrafawa yana haifar da nau'ikan damuwa na ciki guda biyu waɗanda ke haifar da nakasar zafin jiki tare da tushe mai nutsewar zafi:

(1) Damuwar Ciki na Macroscopic (Nau'in I)

Tambari, Mafi na kowa tsari tsari ga irin wannan fayafai, yana haifar da nakasar filastik mara daidaituwa: yankunan baki suna fuskantar 15%-20% nakasawa, yayin da yankunan tsakiya kawai ke kwarewa 5%-8%.

Wannan nau'in rashin daidaituwa ya haifar da a “gefen-tashin hankali, tsakiyar-matsi” filin damuwa, tare da ƙimar damuwa sun kai 60-90MPa. Lokacin zafi, wannan damuwa yana huta, ja gefuna zuwa sama da tura tsakiyar ƙasa-sakamakon warping.

(2) Damuwar Ciki Mai Karan gani (Nau'in II)

A cikin microscale, Al₆Mn Phases toshe ɓata lokaci, yana haifar da tari (Dilocation yawa yana tashi daga farkon 1.0 × 10¹⁵ m⁻² zuwa 2.5 × 10¹⁵ m⁻² bayan sarrafawa).

Wannan tarin yana haifar da yawan damuwa na gida (mafi girman damuwa 100-120MPa) a lokaci musaya. Lokacin zafi, waɗannan ƙananan matsalolin suna haifar da juyawar hatsi da zamewar iyaka, yana kara tsananta nakasar gaba daya.

6. Ka'idar Taimakon Damuwa Annealing

Domin magance wannan batu, damuwa da damuwa yana kawar da damuwa na ciki ta hanyar matakai guda uku-duk wanda aka gudanar a kasa 3003 aluminum recrystalization zafin jiki (300-350℃) don kauce wa ci gaban hatsi da lalacewar aiki:

(1) Matsayin Yaduwa Atomic (250-300℃)

Dumama yana ƙarfafa Al atom, wanda ke yaduwa tare da iyakokin hatsi da layukan tarwatsawa.

Wannan yaduwa yana kawar da yawan damuwa a cikin mu'amalar lokaci na Al₆Mn, kawar da 30%-40% na danniya na ciki na microscopic ba tare da canza tsarin asali na gami ba.

(2) Matakin Motsawa (300-320℃)

Yayin da zafin jiki ya tashi, dislocations suna samun isasshen kuzari don shawo kan cikas na Al₆Mn, ba da damar zamewa da hawa.

Ƙwaƙwalwar ƙaura ya faɗi ƙasa 1.2×10¹⁵ m⁻², kawar da 60%-70% na macroscopic ciki danniya. Wannan mataki yana da mahimmanci don rage yawan yaƙe-yaƙe.

(3) Matsayin Kwanciyar Damuwa (Jiki)

Ci gaba da jikewa a yanayin zafin da aka yi niyya yana ba da damar sakin damuwa iri ɗaya a cikin duka diski, guje wa nakasar gida da ke haifar da rashin daidaituwar annashuwa.

Matsakaicin kawar da damuwa na ƙarshe ya wuce 80%, tare da girman hatsi saura barga a 5-8μm (girman farko 4-6μm) da hasarar isar da wutar lantarki da aka iyakance ga ≤5% - tabbatar da cewa an kiyaye aikin magudanar zafi..

7. Tasirin Zazzabi Mai Ragewa akan Nakasar Zazzabi

Daga cikin duk sigogi na annealing, zafin jiki shine mafi mahimmanci don kawar da damuwa. Tasirinsa sun bambanta sosai a cikin jeri daban-daban:

Musamman, mabuɗin ƙarshe shine: zafin jiki dole ne ya kasance a cikin 300-320 ℃. Wannan kewayon yana tabbatar da ingantaccen taimako na danniya yayin guje wa ci gaban hatsi (wanda ke raunana karfin inji) ko kuma Al₆Mn lokaci coarsing (wanda ke rage tasirin thermal).

8. Tasirin Lokacin Jiki akan Nakasar Zafi

Bayan zafin jiki, lokacin jiƙa yana da mahimmanci daidai don tabbatar da sakin damuwa iri ɗaya. Ana nuna tasirin sa akan tushe mai zafi mai zafi a ƙasa:

A bayyane, 2-3h shine mafi kyawun lokacin jiƙa. Shortan jiƙa yana haifar da sauƙaƙan damuwa mara daidaituwa (bambancin tsaka-tsaki >15%), haifar da asymmetric warping; dogon jikewa, yayin inganta daidaito, yana ƙara kauri fim ɗin oxide (wanda ke haifar da juriya na thermal) kuma yana rage yawan samarwa.

9. Tasirin Matsayin Sanyi akan Nakasar Zazzabi

Bugu da kari, Adadin sanyaya yana sarrafa haɓakar sabbin damuwa na thermal yayin matakin ƙarshe na annealing:

A zahiri, matsakaicin matsakaicin sanyaya 3-5 ℃ / min yana daidaita sarrafa nakasa da ingantaccen samarwa don yawancin sansanonin rahusa zafi na kasuwanci.. Sanyaya cikin sauri yana haifar da sabon damuwa, yayin da jinkirin sanyaya yana yiwuwa kawai don madaidaicin madaidaici, aikace-aikacen ƙananan ƙaranci saboda tsawon lokacin zagayowar sa.

10. Tabbatar da Gwaji: Tsarin Tsarin

Don tabbatar da ƙimar da ke sama, an gudanar da gwaje-gwaje ta amfani da 3003 aluminum fayafai (100mm diamita, 5mm kauri) tare da danniya na farko na 70-90MPa (kwaikwayon yanayin post-stamping).

L9 ku(3³) An ƙera gwajin orthogonal don ware tasirin ma'auni guda uku:

• Zazzabi: 280℃ (ƙananan), 310℃ (mafi kyau duka), 340℃ (babba)

• Lokaci: 1h (gajere), 2.5h (mafi kyau duka), 4h (dogo)

• Yawan sanyaya: 2℃/min (a hankali), 4℃/min (matsakaici), 8℃/min (m)

Abubuwan gwajin sun haɗa da nakasar zafi (ΔL), danniya taimako kudi (ko), thermal watsin (l), da flatness-duk sun dace da ka'idojin ingancin masana'antu.

11. Sakamakon Gwaji: Muhimmancin Siga

Binciken bayanan gwaji ya nuna cewa tasirin siga ya biyo baya: T (R=0.18) > t (R=0.07) > v (R=0.05).

Wannan yana tabbatar da cewa zafin jiki yana da tasiri mafi mahimmanci akan nakasar thermal, daidai da nazarin ka'idar da ke sama. Mahimmin sakamakon gwaji an haskaka a ƙasa:

12. Haɗin Madaidaicin Siga

Bisa wadannan sakamakon, Gwaji A'a. 5 (T=310℃, t=2.5h, v=2℃/min) an gano a matsayin mafi kyawun haɗin siga:

• ΔL = 0.04mm (da kyau a ƙasa da iyakar masana'antu na ≤0.1mm)

• h=85% (rage yawan damuwa zuwa 10-12MPa)

• λ=156W/(MİI K) (kyakkyawan yanayin zafi mai kyau da aka riƙe)

• Karancin kwanciyar hankali: girman hatsi 6-7μm, Girman lokaci na Al₆Mn 0.6-0.8μm (babu girma ko girma)

13. Tabbatar da Sakamakon Gwajin

Don tabbatar da kwanciyar hankali na mafi kyawun tsari, 100 an sarrafa samfurori ta amfani da sigogi da aka gano:

• Matsakaicin ΔL=0.038mm (daidaitaccen sabawa 0.005mm), cimma a 100% Adadin Kasa

• Matsakaicin adadin agajin damuwa=84.5%, matsakaiciyar zafin jiki = 155.2W /(MİI K)

• Zaman lafiyar tsari ya cika buƙatun samar da taro, ba tare da wani gagarumin canji na aiki tsakanin batches.

14. Aikace-aikacen Injiniya: Daidaita Ƙayyadaddun Bayani

A aikace aikace-aikacen injiniya, daban-daban zafi tushe bayani dalla-dalla (kauri, diamita) suna buƙatar madaidaitan ma'auni na annealing-saboda bambance-bambance a cikin rarraba damuwa na ciki da ingancin canja wurin zafi:

Fayafai masu kauri, misali, suna buƙatar ƙarin yanayin zafi kaɗan da tsawon lokacin jiƙa don tabbatar da cewa an saki damuwa sosai daga yankunansu na tsakiya.

15. Matakan Kula da Inganci

Don tabbatar da daidaiton aiki a cikin samar da yawa, ana buƙatar cikakken tsarin kula da ingancin tsari:

(1) Dubawa mai shigowa

• Farkon damuwa na ciki na 3003 Aluminum fayafai dole ne su zama ≤100MPa (Ana buƙatar pre-annealing idan ya wuce wannan ƙimar)

• Girman hatsi dole ne ya zama 4-6μm, da Al₆Mn lokaci juzu'i 0.3%-0.5% (tabbatarwa ta hanyar SEM)

(2) Annealing Kulawa

• Daidaitaccen yanayin zafin wuta dole ne ya zama ≤±5℃ (ana saka idanu a ainihin lokacin ta amfani da ma'aunin zafi da sanyio) don guje wa zafi na gida

• Nitrogen yanayi tsarki ≥99.99% don hana surface hadawan abu da iskar shaka (oxide fim kauri ≤0.8μm)

(3) Gwajin Samfuran da aka gama

• ΔL ≤0.1mm (gwada amfani da Laser flatness mita tare da ± 0.001mm daidaito)

• Rage damuwa ≤20MPa (samfurin kuma an gwada ta ta hanyar nazarin damuwa na X-ray akan GB/T 7704-2019)

• Ƙarfafawar thermal ≥145W/(MİI K) (samfurin da kuma gwada ta hanyar Laser flash hanya ta GB/T 22588-2008)

16. Ma'auni na Ƙarfin Kuɗi

Yayin inganta aikin yana da mahimmanci, Dole ne kuma a yi la'akari da ƙimar farashi da ingancin samarwa a cikin saitunan masana'antu:

• Don yawan samarwa: Yi amfani da tanderun murɗawa mai ci gaba da aiki a mafi kyawun sigogi (310℃ × 2.5h, 4℃/min sanyaya). Wannan saitin yana samun ƙarfin ≥500 guda a kowane tsari da kuma amfani da makamashi naúrar ≤0.5kW · h/kg-daidaita aiki da farashi.

• Don rashin kulawa: Samfurori masu nakasa (ΔL = 0.12-0.15mm) za a iya sha na biyu annealing (300℃ × 1.5h, 3℃/min sanyaya). Wannan tsari yana rage ΔL zuwa ƙasa da 0.08mm, tare da farashin sake yin aiki ≤15% na farashin samarwa na asali — rage sharar gida.

17. Ƙarshe: Mabuɗin Bincike

a takaice, Wannan binciken ya haifar da sakamako mai mahimmanci guda uku dangane da 3003 aluminum diski zafi nutse sansanonin:

(1) Mafi kyawun Matsakaicin Rage

Madaidaicin madaidaicin sassaucin ra'ayi na damuwa shine zafin jiki na 300-320 ℃, 2-3h lokacin jin dadi, da 3-5 ℃/min yawan sanyaya. A tsakanin wannan kewayon:

• Adadin rage damuwa na ciki ≥80%

• Nakasar thermal ΔL ≤0.08mm

• Riƙewar thermal conductivity ≥95%

(2) Core Mechanism

Dole ne a sarrafa matakan Al₆Mn a 0.6-0.8μm don guje wa yawan damuwa. Dole ne ma'auni na ɓarnawa su dace da halayen watsawa na Al₆Mn don hana haɓaka lokaci ko haɓakar hatsi-dukansu yana lalata aiki..

(3) Darajar Injiniya

Aiwatar da waɗannan ingantattun sigogin yana rage juriyar yanayin zafi ta tushe mai ratsawa 40%-50% kuma yana inganta haɓakar zafi ta hanyar 25% -30% - yadda ya kamata ya magance yanayin zafi na zafi a cikin na'urorin lantarki na tsakiya..

18. Jagoran Bincike na gaba

Daura, biyu kwatance zai kara ciyar da yi na 3003 aluminum diski zafi nutse sansanonin:

(1) Ƙarƙashin zafin jiki da sauri

Ƙara alamar Zr (0.05%-0.1%) ku 3003 aluminum don tace hatsi. Wannan gyare-gyare yana rage zafin recrystallization zuwa 280 ℃, ba da damar annealing cikin sauri cikin sa'o'i 1.5 - haɓaka ingantaccen samarwa ta hanyar 40% yayin da ake kula da nakasa.

(2) Kula da Zazzabi na hankali

Haɗa algorithms na AI tare da gano danniya na ɗan lokaci na ultrasonic don haɓaka sigogin annealing ta atomatik. Wannan tsarin zai daidaita yanayin zafi, lokaci, da yawan kwantar da hankali a hankali dangane da damuwa na farko na fayafai masu shigowa, cimma daidaitaccen sarrafa nakasar thermal (ΔL ≤0.05mm) don manyan aikace-aikace.

Wannan binciken yana ba da ƙididdiga, jagora mai aiki don tsarin maganin zafi na 3003 aluminum diski zafi nutse sansanonin. Ta hanyar warware matsalar nakasar zafi mai haifar da gazawar zafi, yana haɓaka aikace-aikacen mafi fa'ida na wannan abu mai tsada a cikin manyan kayan lantarki da sabbin filayen makamashi.