I. Core Material Composition
1. Hard Phase: Tungsten Carbide (WC)
- Matsakaicin Rage: 70-95%
- Maɓalli Properties: Yana nuna taurin ultra-high da juriya, tare da taurin Vickers ≥1400 HV.
- Tasirin Girman Hatsi:
- Hatsi mara nauyi (3-8μm): Babban ƙarfin ƙarfi da juriya mai tasiri, dacewa da tsari tare da tsakuwa ko tsaka-tsakin tsaka-tsakin.
- Hatsi Mai Kyau/Ultrafine (0.2-2μm): Ingantacciyar taurin ƙarfi da juriya, manufa don ƙirar abrasive sosai kamar dutsen quartz sandstone.
2. Matakin Binder: Cobalt (Co) ko Nickel (Ni)
- Matsakaicin Rage: 5-30%, aiki a matsayin "metallic m" zuwa bond tungsten carbide barbashi da kuma samar da tauri.
- Nau'i da Halaye:
- Madogaran Cobalt (Mainstream Choice):
- Abũbuwan amfãni: Babban ƙarfi a yanayin zafi mai girma, kyakkyawan yanayin zafi mai kyau, da ingantattun kaddarorin inji.
- Aikace-aikace: Yawancin tsarin al'ada da yanayin zafi mai zafi (cobalt ya kasance barga a ƙasa da 400 ° C).
- Tushen Nickel (Bukatun Musamman):
- Abũbuwan amfãni: Ƙarfin juriya na lalata (mai jure wa H₂S, CO₂, da ruwan hakowa mai-salinity).
- Aikace-aikace: Filayen gas ɗin acidic, dandamali na teku, da sauran mahalli masu lalata.
- Madogaran Cobalt (Mainstream Choice):
3. Additives (Ƙara haɓaka matakin ƙarami)
- Chromium Carbide (Cr₃C₂): Yana inganta juriya na iskar shaka kuma yana rage asarar lokaci mai ɗaure a ƙarƙashin yanayin zafi mai zafi.
- Tantalum Carbide (TaC)/Niobium Carbide (NbC): Yana hana haɓakar hatsi kuma yana haɓaka taurin zafin jiki.
II. Dalilan Zaba Tungsten Carbide Hardmetal
| Ayyuka | Bayanin Amfani |
|---|---|
| Saka Resistance | Taurin na biyu kawai ga lu'u-lu'u, mai jurewa da zaizayar ƙasa ta ɓangarorin abrasive kamar yashi quartz (yawan sawa sau 10+ ƙasa da ƙarfe). |
| Juriya Tasiri | Tauri daga cobalt/nickel binder lokaci yana hana rarrabuwar kawuna daga girgizar ƙasa da ɗan bouncing (musamman maƙarar hatsi + babban cobalt formulations). |
| Tsananin Zazzabi Mai Girma | Yana kiyaye aiki a yanayin zafi na ƙasa-rami na 300-500 ° C (alloys na tushen cobalt yana da iyakacin zafin jiki na ~ 500 ° C). |
| Juriya na Lalata | Alloys na tushen nickel suna tsayayya da lalata daga ruwan hakowa mai ɗauke da sulfur, ƙara rayuwar sabis a cikin yanayin acidic. |
| Tasirin Kuɗi | Mafi ƙarancin farashi fiye da lu'u-lu'u/cubic boron nitride, tare da rayuwar sabis sau 20-50 fiye da na nozzles na ƙarfe, yana ba da fa'idodi gabaɗaya. |
III. Kwatanta da Sauran Kayayyakin
| Nau'in Abu | Rashin amfani | Yanayin aikace-aikace |
|---|---|---|
| Diamond (PCD/PDC) | High brittleness, rashin ƙarfi juriya; tsada sosai (~ 100x na tungsten carbide). | Da wuya a yi amfani da su don nozzles; lokaci-lokaci a cikin matsanancin yanayi na gwaji masu ɓarna. |
| Cubic Boron Nitride (PCBN) | Kyakkyawan juriya na zafin jiki amma ƙarancin ƙarfi; tsada. | Ƙirƙirar ƙaƙƙarfan yanayin zafi mai zurfi mai zurfi (wanda ba na al'ada ba). |
| Ceramics (Al₂O₃/Si₃N₄) | Babban taurin amma gagarumin brittleness; matalauta thermal girgiza juriya. | A cikin matakin tabbatar da lab, har yanzu ba a daidaita sikelin kasuwanci ba. |
| Karfe Mai Karfi | Rashin isasshen juriya, gajeriyar rayuwar sabis. | Ƙananan ƙananan rago ko madadin wucin gadi. |
IV. Jagoran Juyin Halitta na Fasaha
1. Haɓaka kayan abu
- Nanocrystalline Tungsten Carbide: Girman hatsi <200nm, taurin ya karu da 20% ba tare da lalata tauri ba (misali, jerin Sandvik Hyperion™).
- Tsarin Digiri na Aiki: High-taurin fine-hatsi WC a kan bututun ƙarfe saman, high-tauri m-hatsi + high-cobalt core, daidaita lalacewa da karaya juriya.
2. Ƙarfafawar Sama
- Rufin Diamond (CVD): 2-5μm fim yana haɓaka taurin ƙasa zuwa> 6000 HV, yana haɓaka rayuwa ta hanyar 3-5x (ƙarin farashin 30%).
- Laser Cladding: WC-Co yadudduka da aka ajiye akan wuraren bututun ƙarfe don haɓaka juriya na gida.
3. Ƙarfafa Manufacturing
- 3D-Buga Tungsten Carbide: Yana ba da damar haɗa haɗin haɗaɗɗun tashoshi masu gudana (misali, tsarin Venturi) don haɓaka haɓakar hydraulic.
V. Mabuɗin Abubuwan Zaɓar Kayan Kaya
| Yanayin Aiki | Shawarwari na Abu |
|---|---|
| Samfurin abrasive sosai | Kyakkyawan / ultrafine- hatsi WC + matsakaici-ƙananan cobalt (6-8%) |
| Sassan tasiri/masu iya girgiza | M-Hatsi WC + babban cobalt (10-13%) ko tsari mai daraja |
| Acid (H₂S/CO₂) muhallin | Daure mai tushen nickel + Cr₃C₂ ƙari |
| Rijiyoyi masu zurfi (> 150°C) | Abubuwan da ke tushen Cobalt + TaC/NbC (a guji tushen nickel don ƙarfin zafi mai rauni) |
| Ayyuka masu tsada | Matsayin matsakaici-matsakaici WC + 9% cobalt |
Kammalawa
- Mallakar Kasuwa: Tungsten carbide hardmetal (WC-Co/WC-Ni) shine cikakkiyar al'ada, yana lissafin> 95% na kasuwannin bututun bututun ruwa na duniya.
- Babban Ayyuka: Daidaitawa ga ƙalubalen ƙira daban-daban ta hanyar daidaitawa a cikin girman hatsin WC, rabon cobalt/nickel, da ƙari.
- Rashin maye gurbinsa: Ya kasance mafi kyawun bayani don daidaita juriya na lalacewa, taurin kai, da farashi, tare da fasaha mai mahimmanci (nanocrystalization, coatings) yana kara fadada iyakokin aikace-aikacensa.
Lokacin aikawa: Juni-03-2025
