铸件特种修复技术的研究与应用

【作者】 司丹；

【导师】 林宋；

【作者基本信息】 北方工业大学 ， 机械制造及其自动化， 2011， 硕士

【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。更多还原

【Abstract】 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.更多还原