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H N V C T Kim Lo I: KH I Niöm Chung
H N V C T Kim Lo I: KH I Niöm Chung
Hn v ct kim loi
Chng 1:
1.1. Thc cht v c im ca qu trnh hn 1.1.1. Thc cht ca qu trnh hn Hn l phng php ni hai hay nhiu chi tit kim loi thnh mt m khng th tho ri c bng cch nung nng chng ti vng tip xc n trng thi nng chy hay do, sau khng dng p lc hoc dng p lc p chi tit hn dnh cht vi nhau. Khi hn nng chy, kim loi b nng chy, sau kt tinh hon ton to thnh mi hn. Khi hn p lc, kim loi c nung n trng thi do, sau c p to nn mi lin kt kim loi v tng kh nng thm thu, khch tn ca cc phn t vt cht gia hai mt chi tit cn hn lm cho cc chi tit lin kt cht vi nhau to thnh mi hn. 1.1.2. c im ca qu trnh hn - Tit kim kim loi: so vi tn ri v tit kim t 1020 %, so vi phng php c c th tit kim c t 3050 % lng kim loi ... - Gim c thi gian v gi thnh ch to kt cu nh dm, gin, khung v.v... - C th to c cc kt cu nh nhng kh nng chu lc cao. - bn v kn ca mi hn ln. - C th hn c hai kim loi c tnh cht khc nhau. - Thit b hn n gin, vn u t khng cao. - Trong kt cu hn tn ti ng sut nhit ln, nn vt hn d b bin dng v cong vnh. - T chc kim loi gn mi hn b dn nn kt cu hn chu xung lc km. Hn c s dng rng ri to phi trong tt c cc ngnh kinh t quc dn, c bit trong ngnh ch to my, ch to cc kt cu dng khung, gin trong xy dng, cu ng, cc bnh cha trong cng nghip. 1.2. Phn loi cc phng php hn 1.2.1.Theo trng thi hn a. Hn nng chy: Hn h quang, hn kh, hn in x, hn bng tia in t, hn bng tia laze, hn plasma ... Khi hn nng chy, kim loi mp hn c nung n trng thi nng chy kt hp vi kim loi b sung t ngoi vo in y khe h gia hai chi tit hn, sau ng c to ra mi hn. b. Hn p lc
Trng i hc bch khoa - 2006
Hn tip xc, hn ma st, hn n, hn siu m, hn kh p, hn cao tn, hn khuch tn ... Khi hn bng p lc kim loi vng mp hn c nung nng n trng thi do sau hai chi tit c p li vi lc p ln, to ra mi hn. c. Hn nhit Hn nhit l s dng nhit ca cc phn ng ha hc pht nhit nung kim loi mp hn n trng thi nng chy ng thi kt hp vi lc p to ra mi hn 1.2.2. Theo nng lng s dng a. in nng: Hn h quang, hn in tip xc ... b. Ho nng: Hn kh, hn nhit ... c. C nng: Hn ma st, hn ngui ... 1.2.3. Theo mc t ng ho a. Hn bng tay. b. Hn bn t ng. c. Hn t ng. 1.3. T chc kim loi mi hn v vng ph cn Sau khi hn, kim loi lng vng hn s ngui v kt tinh to thnh mi hn. Do nh hng ca tc dng nhit nn c s thay i t chc v tnh cht ca vng mi hn. Quan st t chc kim loi vng mi hn hnh ch V c th phn bit ba vng khc nhau: vng vng hn (1), vng vin chy (2) v vng nh hng nhit (3). 1.3.1. Vng mi hn Trong vng ny, kim loi nng chy hon ton, thnh phn bao gm c kim loi vt hn v kim loi b sung t ngoi vo, lp bin c ht nh mn, lp tip theo c ht hnh nhnh cy ko di v vng tm c ht ln v c ln cht phi kim (x v.v...). 1.3.2. Vng vin chy Trong vng ny kim loi nng chy khng hon ton, do s thm thu qua li ca kim loi vng vng hn v kim loi vt hn nn vng ny c thnh phn trung gian gia kim loi vng hn v kim loi vt hn. Chiu dy ca vng ny rt hp.
Phn phi kim Vin chy
Vng KL kt tinh c ht ln
Vng KL kt tinh c ht nh
00C 1 1500 2
1100
Kim loi vt hn trong vng ny b nung nng sau ngui cng mi hn. Do nh hng ca nung nng v lm ngui, t chc kim loi trong vng ny thay i, dn n c l tnh thay i theo. Tu thuc vt liu hn, nhit nung nng, trong vng ny c th nhn c nhiu t chc khc nhau. Xt trng hp khi hn thp cc bon, t chc ca vng nh hng nhit c th chia thnh nm min (t lp gip vi vin chy) : a. Min qu nhit 2: st vi vin chy, c nhit trn 11000C kim loi b qu nhit mnh, cc ht stenit bt u pht trin mnh, vng ny c ht rt ln c dai va chm v tnh do km, bn thp v tnh dn cao l min yu nht ca vt hn. b. Min thng ha 3: l min c nhit 9000 11000C, kim loi c t chc c cc ht ferit nh v mt s ht peclit, n c c tnh rt cao. c. Min kt tinh li khng hon ton 4: l min c nhit 7200 9000C c t chc ht ln ca pherit ln vi ht stenit nh, v th c tnh khng u. d. Min kt tinh li 5: l min c nhit 5000 7000C. Min ny t chc ging t chc kim loi vt hn, nhng nhit ny l nhit bin mm lm mt hin tng bin cng, cc sai lch mng c khc phc, do kim loi phc hi. . Min dn xanh 6: l min c nhit < 5000C t chc kim loi trong vng ny hon ton ging vi t chc ban u nhng do nh hng nhit nn tn ti ng sut d nn khi th mu hn, min ny thng b t. Vng nh hng nhit c chiu rng thay i tu thuc rt ln vo chiu dy vt hn, ngun nhit hn, iu kin thot nhit khi vng hn. Chng 2: Hn
h quang tay
2.1. Khi nim v h quang hn 2.1.1. Thc cht ca h quang hn Hn h quang l phng php hn nng chy dng nhit ca ngn la h quang sinh ra gia cc in cc hn. H quang hn l dng chuyn ng ca cc in t v ion v hai in cc, km theo s pht nhit ln v pht sng mnh. Trong cc iu kin bnh thng, khng kh khng dn in, gia 2 in cc ca cc loi my hn h quang c in p khng ti nh thua 80 vn, v vy khng c s phng in gia chng. gy h quang, ngi ta gy ra hin tng on mch lc mt dng in ti ch tip xc ca 2 in cc rt ln, theo nh lut Jun-lenc th
Trng i hc bch khoa - 2006
Q = 0,24 RI2t, nhit lng ny c cc in t t do mt u catt hp th. Sau khi nhn c nng lng di dng nhit cc in t ny c th nng ln v bt ra khi qu o ca mnh v phng v ant, trn ng i chng s bn ph ln cc nguyn v phn t cht kh bo ho cho hoc ly i ca chng mt vi in t (tu theo ho tr ca chng) v bin chng thnh nhng ion. Mi trng ion l mi trng dn in rt tt cho nn qu trnh gy h quang ch xy ra giai on ban u. Nh vy h quang hn l dng chuyn dch ca cc ion dng v catt; ion m v cc in t v ant. Cc ht ny s bn ph ln cc vt cc, c nng s bin thnh nhit nng lm nng chy hoc hao mn cc in cc. Qu trnh gy h quang khi hn xy ra ba giai on: + + +
H.2.1. Qu trnh gy h quang khi hn a. Giai on chm mch ngn (a): cho hai in cc chm vo nhau, do din tch tit din ngang ca mch in b v in tr vng tip xc gia cc in cc ln v vy trong mch xut hin mt dng in cng ln, hai mp in cc b nung nng mnh. b. Giai on ion ho (b): Khi nng mt in cc ln khi in cc th hai mt khong t 25 mm. Cc in t bt ra kh qu o ca mnh v chuyn ng nhanh v pha ant (cc dng), trn ng chuyn ng chng va chm vo cc phn t kh trung ho lm chng b ion ha. S ion ho cc phn t kh km theo s pht nhit ln v pht sng mnh. c. Giai on h quang chy n nh (c): Khi mc ion ho t ti mc bo ha, ct h quang ngng pht trin, nu gi cho khong cch gia hai in cc khng i, ct h quang c duy tr mc n nh. Khi hn, in p cn thit gy h quang khong t 3555 V i vi dng in mt chiu, t 5580 V i vi dng in xoay chiu. in p duy tr h quang chy n nh khong 1635 V khi dng dng in mt chiu v t 2545 V khi dng dng in xoay chiu. 2.1.2. S chy ca h quang S chy ca h quang ph thuc vo: in th gia 2 in cc khi my cha lm vic, cng dng in v khong cch gia chng. Quan h gia in th vi cng dng in gi l ng c tnh tnh ca h quang. Khi h quang chy n nh, nhit trong ct h quang t ti 6000oC, ca-tt khong 2400oC v a-nt khong 2600oC.
Trng i hc bch khoa - 2006
c tnh tnh V-A ca h quang hn c ba vng c trng: vng in p gim (I), vng in p khng i (II), v vng in p tng (III). in p khng i ca ct h quang c th xc nh theo cng thc:
U hq = a + b. Lhq
Uhq(V)
Uh
I II III
Ihq(A)
Trong : a - l tng in th ri trn 2 H.2.2. ng c tnh tnh cc, i vi que hn nng chy a = 1520 v; ca h quang hn vi que hn khng nng chy a = 3035 V b - in th ri trn 1 n v chiu di h quang ly b = 15,7 v/cm. Lhq - l chiu di ct h quang. 2.1.2. Tc dng ca in trng i vi h quang hn Ct h quang c th xem nh l mt dy dn mm v di tc dng ca in trng ct h quang cng b chuyn dch, hnh dng b thay i. Khi hn, lc in trng tc dng ln h quang gm c lc in trng tnh ca mch hn v lc in trng sinh ra bi st t lm h quang b lch i rt nhiu do lm nh hng xu n qu trnh hn. i vi dng xoay chiu do cc thay i, do chiu ca in trng cng thay i theo v hin tng lch h quang khng ng k. Chng ta ch quan tm n nh hng ca dng mt chiu n h quang hn.
a/
b/
c/
- H quang b lch do tc dng ca in trng khng i xng (a): t pha dng in i vo mt ng sc dy hn, th in trng mnh hn. Do h quang b x y v pha in trng yu hn. - in trng i xng xung quanh h quang (b): h quang cn bng khng b thi lch. - nghing ca que hn (c): Chn gc nghing que hn thch hp c th thay i tnh cht phn b ng sc v c th to ra ddin trng ng u khc phc c hin tng thi lch h quang.
Trng i hc bch khoa - 2006
b. nh hng ca st t
Vt liu st t t gn h quang th tng t thm ln hng ngn ln so vi khng kh. T thng i qua st t c tr khng nh s lm cho h quang b thi lch v hng . V vy khi hn gc, hn n on cui cn ch n v tr ca que hn cho ph hp. 2.1.3. Tc dng nhit ca h quang
- Trng lc ca git kim loi lng: lc ny c kh nng chuyn dch kim loi
lng vo vng hn khi hn sp v c tc dng ngc li khi hn trn.
P +
in trng, ranh gii nng chy ca que hn b tht li, tit din ngang gim xung, mt dng in tng ln. Mt khc y in tr cao nn nhit sinh ra kh ln v kim loi lng t n trng thi si to p lc y git kim loi chy vo vng hn. Mt dng in gim dn t que hn n vt hn, nn khng bao gi c hin tng kim loi lng chuyn dch t vt hn vo que hn c.
b. in cc hn nng chy
Trng i hc bch khoa - 2006
in cc hn nng chy (que hn) c ch to t kim loi hoc hp kim c thnh phn gn vi thnh phn kim loi vt hn. Li que hn c ng knh theo l thuyt dq = 612 mm. Trong thc t thng dng dq = 16 mm. Chiu di ca que hn L = 250450 mm; chiu di phn kp l1 = 305 mm; l2 < 15mm; l3 = 12 mm.
1 2 l3 L H.2.6. Kt cu ca que hn in Que hn nng chy 1- li kim loi 2- thuc bc
l1
l2
Lp thuc bc c ch to t hn hp gm nhiu loi vt liu dng dng bt, sau trn u vi cht dnh v bc ngoi li c chiu dy t 1-2 mm. Tc dng ca lp thuc bc que hn: Tng kh nng ion ha d gy h quang v duy tr h quang chy n nh. Thng thng ngi ta a vo cc hp cht ca kim loi kim. Bo v c mi hn, trnh s xy ho ho tan kh t mi trng. To x lng v u, che ph kim loi tt gim tc ngui ca mi hn trnh nt. Kh xy trong qu trnh hn. Ngi ta a vo trong thnh phn thuc bc cc loi phe-r hp kim hoc kim loi sch c i lc mnh vi xy c kh nng to xyt d tch khi kim loi lng. 2.2.3. Phn loi theo cch u dy cc in cc khi hn
a- u dy trc tip
b- u dy gin tip
c- u dy 3 pha
H.2.7. Cc cch u dy in cc hn
Ngun in hn trong hn h quang tay c th l ngun in xoay chiu hoc mt chiu. Nhn chung ngun in hn v my hn phi m bo cc yu cu chung sau: in p khng ti phi Hh < U0 < 80 v. u (V) - i vi my hn xoay chiu: 1 U0 = 5580 V, Hh = 3055 V. A 2 - i vi my hn mt chiu: U0 = 2545 V, Hh = 1635 V. B I (A) ng c tnh ng V-A ca my hn phi l ng dc lin tc. H.2.8.1- ng c tnh tnh ca h quang C kh nng chu qu ti khi ngn 2- ng c tnh ng ca my hn mch I = (1,31,4)Ih. C kh nng iu chnh dng in hn trong phm vi rng. My hn phi c khi lng nh, h s hu ch ln, gi thnh r, d s dng v d sa cha. 2.3.2. My hn h quang in xoay chiu My hn h quang dng dng in xoay chiu c s dng rng ri trong hn h quang tay v chng c kt cu n gin, gi thnh ch to thp, d vn hnh v sa cha. Tuy nhin cht lng mi hn khng cao v h quang chy khng n nh so vi h quang dng dng in mt chiu. My hn mt chiu c nhiu loi, mi loi c tnh nng v nhng c im ring, sau y gii thiu mt s my hn xoay chiu c s dng nhiu nht trong thc t cng nghip. a. My bin p hn xoay chiu: Loi my hn ny iu chnh cng dng in hn bng cch thay i in p hn nh vo s thay i s vng dy ca cun th cp. My hn loi ny n gin, d ch to, gi thnh r tuy nhin ch thay i dng vi c mt vi cp gi l iu chnh th. P = U.I = U1.I1 = U2.I2
A
u1
W1 W2
u2
uh
b. My hn xoay chiu vi li t di ng
Loi my hn ny c th iu chnh tinh cng hn (Ih) bng cch thay i t thng mc vng vo cun W2 nh vo s thay i v tr ca li t trong khung t. 1 = r + 2
r 2 1 B A
u1
W1 W2
u2
uh
c. My hn t hp My hn t hp l loi my thng dng nht hin nay v c th iu chnh Ih bng t hp va th va tinh ca 2 phng php trn c trnh by nh hnh v sau:
r 2 B A
u1
W1 W2
u2
uh
My hn kiu ny c mt li t di ng (A) nm trong gng t (B) ca my bin p. Khi li t (A) nm hon ton trong mt phng ca gng t (B) th t thng do cun s cp sinh ra c mt phn r nhnh qua li t lm cho t thng i qua cun th cp gim, do in p trn cun th cp (u2) im. Khi di ng li t (A) ra ngoi (theo phng vung gc vi mt phng ca gng t B), khe h gia li t v gng t tng, t thng r nhnh gim lm cho t thng qua cun th cp tng v in p trn cun th cp tng. My hn ny c th iu chnh cng dng in hn bng 2 cch: Thay i in p ca mch th cp bng cch thay i s vng dy W2. Cch ny ch thay i c cng dng in hn phn cp. Thay i v tr li t trong khung t c th iu chnh dng in hn v cp. 2.3.3. My hn h quang in mt chiu
a/ My pht hn h quang
Hnh sau trnh by s nguyn l ca mt my hn mt chiu dng my pht c cun kch t ring v cun kh t mc ni tip.
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10
My hn gm my pht in mt chiu (M) c cun dy kch t ring (2) c cp in ring t ngun in xoay chiu qua b chnh lu (1). Trn mch ra ca my pht t cun kh t (3). Ngi ta b tr sao cho t thng (c) sinh ra trn cun kh t lun lun ngc hng vi t thng (kt) sinh ra trong cun kch t. ch khng ti, dng in hn Ih = 0 nn t thng c = 0, my pht c kch t bi t thng (kt) do cun dy kch t (2) sinh ra: W 1 kt = I kt . 2 kt Rk Trong Ikt l dng in kch t, W v Rk l s vng dy v t tr ca cun kch t. Khi in p khng ti xc nh theo cng thc: ukt = C.kt M n p c
ch lm vic, dng in hn Ih K 0 nn t thng c 0, my pht c kch t bi t thng tng hp () do cun dy kch t (2) v cun kh t (3) sinh ra: H.2.12. My pht hn h quang = kt c Sc in ng sinh ra trong phn cm ca my ph thuc vo t thng kch t: E = C. = C.(kt c ) . Trong C l h s ph thuc vo my.
R
Uh 0
Ih(A) t(s)
2
a/
Ih(A) t(s)
0
b/
My hn dng dng in chnh lu c h quang chy n nh hn my hn xoay chiu, phm vi iu chnh dng in hn rng, h s cng sut hu ch cao, cng sut
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11
khng ti nh, kt cu n gin hn. Nhc im ca my hn chnh lu l cng sut b hn ch, cc i-t d b hng khi ngn mch lu v dng in hn ph thuc ln vo in p ngun. Ngoi ra cn mt s loi my hn mt chiu: my pht hn mt chiu Diezen, my pht hn mt chiu ng c in v.v... 2.4. Cng ngh hn h quang tay
60-1200
Cng ngh hn h quang tay ph thuc rt ln vo v tr mi hn trong khng gian v kt cu mi hn. Theo v tr mi hn trong khng H.2.14. V tr mi hn trong khng gian IV tr hn sp; II- V tr hn ng; IIIgian, ngi ta phn ra cc dng hn sau: Hn V tr hn trn sp, hn ngang, hn ng v hn nga. Hn sp: mt phng hn to vi mt phng ngang mt gc t 060o. Hn ngang: phng hn song song vi mt phng ngang v nm trong mt phng hn to vi mt phng ngang mt gc t 60120o. Hn ng: mt phng hn to vi mt phng ngang mt gc t 60120o tr phng song song vi mt phng ngang. Hn trn: mt phng hn to vi mt phng ngang mt gc t 120180o.
b/ Cc loi mi hn
- Mi hn gip mi (a): c th khng cn vt mp khi s 4 mm v vt mp khi s > 4 mm. - Mi hn gp mp (b): dng khi s 2 mm. - Mi hn chng (c): dng khi sa cha cc kt cu hn. - Mi hn c tm m (d): dng khi sa cha cc kt cu hn. - Mi hn gc (): c th vt mp hoc khng vt mp. - Mi hn ch T (e): dng trong cc kt cu chu un. - Mi hn mt u (g): dng khi lp ghp 2 tm c b mt tip xc nhau. - Mi hn vin mp (h): dng trong trng hp chi tit hn khng cho php tng kch thc. - Mi hn kiu cht (i): khoan l ln 2 chi tit chng ln nhau, sau hn theo tng l mt.
a/ b/ c/ d/
e/
g/
h/
i/
H.2.15. Cc loi mi hn
c/ Chun b mp hn
12
Cht lng mi hn ph thuc rt ln vo vic lm sch v chun b mp hn. Tu thuc kiu mi hn, chiu dy vt hn... c th tin hnh chun b mp hn trn my bo hay bng m ct kh theo cc cch sau: Kiu chun b mp Khng vt mp Gp mp Dng vt mp mi hn
a S a b S
Kch thc
S=58 a=12 S=13 a=01 b=S+2 S = 4 26 a=22 b=21 = 60050
a /2 a b S
Vt mp ch V v na ch V
a b S
a/ ng knh que hn
ng knh que hn ph thuc vo vt liu hn, chiu dy vt hn, v tr mi hn trong khng gian, kiu mi hn... chn c th tra theo s tay cng ngh hn hoc xc nh theo cc cng thc kinh nghim. i vi hn thp, ng knh que hn c xc nh nh sau: - Hn gip mi: - Hn gc, hn ch T:
S +1 2 K dq = + 2 2 dq =
S
b S
Vt mp ch U v na ch U
S = 20 60 a=22 b=21 R = 51
[mm] [mm]
Cng dng in hn chn ph thuc vo vt liu hn, ng knh que hn, v tr mi hn trong khng gian, kiu mi hn...c th tra theo s tay cng ngh hoc xc nh theo cc cng thc kinh nghim sau i vi khi hn sp:
I h = ( + d q )d q
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13
Trong : v l cc h s ph thuc vo vt liu vt hn, i vi thp = 6; = 20; dq - ng knh que hn ly theo mm. Ch : - Khi chiu dy chi tit S > 3dq th nn tng cng dng in khong 15% cn S < 1,5dq th nn gim 15% so vi tr s tnh ton. - Cng dng in hn khi hn ng nn gim 1015% v khi hn trn nn gim 1520% so vi hn sp.
[cm/s]
L - Chiu di mi hn (cm). t - thi gian hn (giy). Tc hn ph thuc vo cng dng in hn v tit din mi hn, c th tnh theo cng thc kinh nghim sau: d .Ih [cm/s] Vh = 3600 Fd Trong : d l h s p, d = 7 11 [g/A.h] - khi lng ring kim loi que hn [g/cm3] Ih - cng dng in hn [A] Fd - tit din p ca mi hn [cm2]
f/ Thi gian hn
Thi gian hn bao gm thi gian my (thi gian h quang chy) v thi gian ph: th = tm + tp .
Gd = d . I d . tm 3600
14
t m = 3600. .
Fd . L (s). d . I h
Thi gian ph tnh ton rt kh khn v vy khi tnh ton da vo h s iu chnh K nh sau:
th = tm K
- Nu t chc sn xut kh th ly K = 0,50,6. - Nu t chc sn xut trung bnh th ly K = 0,30,4. - Nu t chc sn xut km th ly K < 0,3. 2.4.3. Thao tc hn Khi hn h quang tay, gc nghing que hn so vi mt vt hn thng t 7585o, que hn c dch chuyn dc trc duy tr chiu di ct h quang, ng thi chuyn ng ngang mi hn to b rng mi hn v chuyn ng dc ng hn theo tc hn cn thit. Khi hn sp, nu mi hn c b rng b, que hn c dch chuyn dc ng hn, khng c chuyn ng ngang. Khi mi hn c b rng ln, chuyn dch que hn c th thc hin theo nhiu cch m bo chiu rng mi hn B = (35).dq. Thng thng chuyn ng que hn theo ng dch dc (1, 2, 3). Khi hn cc mi hn gc, ch T nu cn nung nng phn gia nhiu th dch chuyn que hn theo s (4) v khi cn nung nng nhiu hai bn mp hn nh theo s (5).
L > 1000
2.5.4. Hn cc v tr khc hn sp
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15
a/ hn ng (H.2.15a)
Hn ng rt phc tp v kh khn v kim loi lng d chy ra khi vng hn, c th hn t trn xung hoc di ln. Khi hn phi nghing que hn mt gc: = 10150, chiu di h quang phi ngn, Ih phi gim i so vi hn sp 1520%; B = (1,52)dq; dq < 5 mm.
a/
b/
b/ Hn ngang (H.2.15b)
Khi hn ngang kim loi lng thng b chy nhiu xung mp di. Yu cu trnh th hn phi cao, khi hn nn vt mp trn que hn d chuyn ng. Cc thng s k thut ly ging hn ng, khi gy h quang nn t mp di chuyn ln.
c/ Hn trn (H.2.16c)
Kim loi lng c chuyn t que hn vo vng hn l nh sc cng b mt, cng in trng v p lc kh. Khi hn trn nn chn: dq < 4 mm; Ih gim t 1520%; chiu di h quang ngn. Dng que hn c thuc bc dy v c nhit nng chy cao hn li que hn to ra hnh phu ly kim loi lng vng hn.
d/ Hn gc (d)
Khi hn gc, kim loi bao gi cng c khuynh hng chy xung mp di, nn nu vt hn nh th nghing i 450 thc hin mi hn sp. Nu vt nng th khi hn que hn nn nm trong mt phng phn gic ca kt cu hn.
45o
c/ d/
Chng 3: Hn
h quang t ng v bn t ng
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Hn h quang t ng l qu trnh hn trong cc khu ca qu trnh c tin hnh t ng bi my hn, bao gm: Gy h quang, chuyn dch in cc hn xung vng hn duy tr h quang chy n nh, dch chuyn im hn dc mi hn, cp thuc hn hoc kh bo v. Khi ch mt s khu trong qu trnh hn c t ng ha ngi ta gi l hn bn t ng. Thng khi hn bn t ng ngi ta ch t ng ha khu cp in cc hn vo vng hn cn di chuyn in cc thc hin bng tay.
3.1.2. c im
Nng sut hn cao (thng gp 5 - 10 so vi hn h quang tay) nh s dng dng in hn cao. Cht lng mi hn tt v n nh. Tit kim kim loi nh h s p cao. Tit kim nng lng v s dng trit ngun nhit. Ci thin iu kin lao ng. Thit b hn t ng v bn t ng t, khng hn c cc kt cu hn v v tr hn phc tp. 3.2- hn h quang di lp thuc bo v
3.2.1. Thc cht, c im v phm vi ng dng
a. Thc cht Hn h quang di lp thuc bo v cn gi l hn h quang chm, ting Anh vit tt l SAW (Submerged Arc Welding), l qa trnh hn nng chy m h quang chy gia dy hn (in cc hn) v vt hn di mt lp thuc bo v. Di tc dng nhit ca h quang, mp hn, dy hn v mt phn thuc hn st h quang b nng chy to thnh vng hn. Dy hn c y vo vng hn bng mt c cu c bit vi tc ph hp vi tc chy ca n (hnh 1.1a). Theo chuyn dch ca ngun nhit (h quang) m kim loi vng hn s ngui v kt tinh to thnh mi hn (hnh 1.1b). Trn mt vng hn v phn mi hn ng c hnh thnh mt lp x c tc dng tham gia vo cc qa trnh luyn kim khi hn, bo v v gi nhit cho mi hn, v s tch khi mi hn sau khi hn. Phn thuc hn cha b nng chy c th s dng li. Hn h quang di lp thuc bo v c th c t ng c hai khu cp dy vo vng h quang v chuyn ng h quang theo trc mi hn. Trng hp ny c gi l hn h quang t ng di lp thuc bo v. Nu ch t ng ho khu cp dy hn vo vng h quang cn khu chuyn ng h quang dc theo trc mi hn c thao tc bng tay th gi l hn h quang bn t ng di lp thuc bo v.
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Hn h quang di lp thuc bo v c cc c im sau: - Nhit lng h quang rt tp trung v nhit rt cao, cho php hn tc ln. V vy phng php hn ny c th hn nhng chi tit c chiu dy ln m khng cn phi vt mp. - Cht lng lin kt hn cao do bo v tt kim loi mi hn khi tc dng ca xy v nit trong khng kh xung quanh. Kim loi mi hn ng nht v hnh phn ho hc. Lp thuc v x hn lm lin kt ngui chm nn t b thin tch. Mi hn c hnh dng tt, u n, t b khuyt tt nh khng ngu, r kh, nt v bn to. - Gim tiu hao vt liu hn (dy hn). - H quang c bao bc kn bi thuc hn nn khng lm hi mt v da ca th hn. Lng khi (kh c) sinh ra trong qa trnh hn rt t so vi hn h quang tay. - D c kh ho v t ng ho qa trnh hn. b. Phm vi ng dng Hn h quang di lp thuc bo v c ng dng rng ri trong nhiu lnh vc c kh ch to, nh trong sn xut: cc kt cu thp dng tm v kch thc ln, cc dm thp c khu v chiu cao, cc ng thp c ng knh ln, cc bn, b cha, bnh chu p lc v trong cng nghip ng tu... Tuy nhin, phng php ny ch yu c ng dng hn cc mi hn v tr hn bng, cc mi hn c chiu di ln v c qu o khng phc tp.
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Phng php hn h quang di lp thuc bo v c th hn c cc chi tit c chiu dy t vi mm cho n hng trm mm. Bng 3-1 ch ra cc chiu dy chi tit hn tng ng vi hn mt lp v nhiu lp, c vt mp v khng vt mp bng phng php hn t ng di lp thuc bo v. Chiu dy chi tit hn tng ng vi cc loi mi hn Bng 3-1 Chiu dy chi tit (mm) Loi mi hn 1,3 1,4 1,6 3,2 4,8 6,4 10 12,7 19 25 51 102 Hn mt lp khng vt mp -- -- -- Hn mt lp c vt mp -- -- Hn nhiu lp -- -- -- 3.2.2. Vt liu, thit b hn h quang t ng v bn t ng di lp thuc bo v a. Vt liu hn Cht lng ca lin kt hn di lp thuc bo v c xc nh bng tc ng tng hp ca dy hn (in cc hn) v thuc hn. Dy hn v thuc hn c la chn theo loi vt liu c bn, cc yu cu v c l tnh i vi lin kt hn, cng nh iu kin lm vic ca n. - Dy hn: Trong hn h quang t ng v bn t ng di lp thuc bo v, dy hn l phn kim loi b sung vo mi hn, ng thi ng vai tr in cc dn in, gy h quang v duy tr s chy h quang. Dy hn thng c hm lng C khng qu 0,12%. Nu hm lng C cao d lm gim tnh do v tng kh nng xut hin nt trong mi hn. ng knh dy hn h quang t ng di lp thuc t 1,6 6 mm, cn i vi hn h quang bn t ng l t 0,8 2 mm. - Thuc hn: c tc dng bo v vng hn, n nh h quang, kh xy, hp kim ho kim loi mi hn v m bo lin kt hn c hnh dng tt, x d bong. b. Thit b hn h quang di lp thuc bo v Thit b hn h quang di lp thuc bo v rt a dng, song hu ht chng li rt ging nhau v nguyn l v cu to mt s b phn chnh. - C cu cp dy hn v b iu khin gy h quang v n nh h quang (u hn). - C cu dch chuyn u hn dc theo trc mi hn hay to ra cc chuyn ng tng i ca chi tit hn so vi u hn. - B phn cp v thu thuc hn. - Ngun in hn v cc thit b iu khin qu trnh hn.
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Ty theo tng loi thit b c th, cc c cu ny c th b tr thnh mt khi hoc thnh cc khi c lp. V d trong cc loi xe hn hnh 3.2 th u hn, c cu dch chuyn u hn, cun dy hn, c cu cung cp thuc hn v c h thng iu khin qa trnh hn c b tr thnh mt khi. Nh vy xe hn c th chuyn ng trc tip theo mp rt linh ng, n c th chuyn ng theo cc qu o khc nhau trn kt cu dng tm, thm ch c th thc hin c cc mi hn vng trn cc mt trn v ng ng c ng knh ln. i vi my hn bn t ng di lp thuc bo v th u hn c thay bng m hn hay sng hn nh gn, d iu khin bng tay. C cu cp dy hn c th b tr ri hoc cng khi trong ngun hn vi cc c cu khc. Ngun in hn h quang di lp thuc bo v phi c h s lm vic lin tc 100% v c phm vi iu khin dng in rng t vi trm n vi ngn ampe. My hn bn t ng di lp thuc Dy hn c cp t ng t c cu cp dy (3), qua ng mm (4) ti tay cm (5). Thuc hn c cp qua phu (6).
1 2 3 4 5 6
MPH 7
Trn tay cm c cng tc ng ct dng in hn v c cu cp dy. My pht hoc bin p hn (1) cp dng in hn, cn t in (2) iu khin vic cp dy v kim tra ch hn.
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a. Chun b lin kt trc khi hn Chun b vt mp v g lp vt hn cho hn h quang di lp thuc bo v yu cu cn thn hn nhiu so vi hn h quang bng tay. Mp hn phi bng phng, khe h hn u cho mi hn u n, khng b cong vnh, r... Vi hn h quang di lp thuc bo v, nhng lin kt hn c chiu dy nh hn 20 mm khng phi vt mp khi hn hai pha. Nhng lin kt hn c chiu dy ln c th vt mp bng m ct kh, my ct plasma hoc gia cng trn my ct kim loi. Trc khi hn phi lm sch mp trn mt chiu rng 50 60 mm v c hai pha ca mi hn, sau hn nh bng que hn cht lng cao. b. Ch hn Dng in hn: Chiu su ngu ca lin kt hn t l thun vi dng in hn. Tuy nhin khi tng dng in, lng dy hn nng chy tng theo, h quang chm su vo kim loi c bn nn chiu rng ca mi hn khng tng r rt m ch tng chiu cao phn nh ca mi hn, to ra s tp trung ng sut, gim cht lng b mt mi hn, x kh tch. Nu dng in qu nh th chiu su ngu s gim, khng p ng yu cu (hnh 3.3). Thng chn 100 A/mm. B B B e e e
Dng in hp l