Gio trnh: cng ngh hn

Hn v ct kim loi
Chng 1:

Khi nim chung

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
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Gio trnh: cng ngh hn

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 chy khng hon ton

Vng KL kt tinh c ht nh

H.1.1. Vng kim loi mi hn

1.3.3. Vng nh hng nhit

Vng chy Vng chy khng ho n

00C 1 1500 2
1100

Trng i hc bch khoa Vng qu nhit - 2006 Vng thng ha

Gio trnh: cng ngh hn

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
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Gio trnh: cng ngh hn

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.
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Gio trnh: cng ngh hn

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. nh hng ca in trng tnh

in trng tnh pht sinh khi c dng in chy qua dy dn, que hn v ct h quang. Chng lm cho h quang b thi lch i ph hoi qu trnh hn bnh thng. C 3 trng hp c th xy ra khi ni mch hn: + + +

a/

b/

c/

H.2.3. nh hng ca in trng tnh n h quang hn

- 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.
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Gio trnh: cng ngh hn

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

H.2.4. nh hng ca st t n h quang

a. Nhit v nhit ca h quang hn

H quang hn l mt ngui nhit tp trung rt ln, in nng bin thnh nhit nng. Nng lng ny pht ra t cc dng, cc m v trong ct h quang dng nung nng chy que hn, vt hn gn ct h quang. Nhit vng cc dng, cc m xp x bng nhit si v nhit bc hi ca vt liu in cc. Nhit cao nht l trung tm ct h quang do s ion ho cc cht kh; cn nhit cc vt cc l do s bn ph ca cc in t v ion to nn, cn vng ln cn nhit thp hn v kim loi b qu nhit. Nhit do h quang sinh ra s phn b qua mi trng, vt hn, que hn, kim loi mi hn.

b. Qu trnh chuyn dch kim loi lng t que hn vo vng hn

Kim loi t que hn vo vng hn dng nhng git nh c kch thc khc nhau. Khi hn, bt c v tr no trong khng gian kim loi lng bao gi cng chuyn t que hn vo vng hn nh cc lc sau y:

- 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.

- Sc cng b mt: lc ny sinh ra do tc

dng ca lc phn t. Lc phn t lun lun c khuynh hng to cho b mt cht lng mt nng lng nh nht, nn cc git kim loi c dng hnh cu. Nhng git ny ch mt i khi ri vo vng hn v b sc cng b mt ca vng hn ko vo thnh dng chung ca vng hn. Sc cng b mt gi cho kim loi lng ca vng hn khi hn trn khng b ri v hnh thnh mi hn.

- Cng in trng: dng in i qua que

hn sinh ra xung quanh n mt in trng p ln que hn, lc ny ct kim loi lng u que hn thnh nhng git. Do sc cng b mt v cng
Trng i hc bch khoa - 2006

P +

Gio trnh: cng ngh hn

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.

- p lc trong: kim loi u mt que hn b qu nhit rt ln, nhiu phn ng

ho hc xy ra v sinh ra cc cht kh. nhit cao th tch ca cac cht kh tng ln kh ln v gy nn mt p lc mnh y cc git kim loi lng tch khi que hn. V d khi c phn ng hon nguyn xyt st s to ra kh xyt ccbon (CO). 2.2. Phn loi hn h quang tay 2.2.1. Phn loi theo dng in hn

a/ Hn bng dng in xoay chiu

Hn bng dng in cho ta mi hn c cht lng khng cao, kh gy h quang v kh hn song thit b hn dng xoay chiu n gin v r tin nn trn thc t hin c khong 80% l my hn xoay chiu.

b/ Hn bng dng in mt chiu

Hn bng dng in mt chiu tuy my hn t tin nhng d gy h quang, d hn v cht lng mi hn cao. Hn bng dng in mt chiu c 2 cch ni dy: - Ni thun: l ni que hn vi cc m ca ngun in, cn vt hn ni vi cc dng ca ngun. Do nhit vt hn ln nn dng hn thp c chiu dy ln. Khi dng in cc khng nng chy th nn dng cch ni ny in cc b mn. - Ni nghch: que hn ni vi cc dng, vt hn ni vi cc m ca ngun in. Cch ny thng dng khi hn vt mng, kim loi mu hoc gang bng que hn thp. 2.2.2. Phn loi theo in cc

a. in cc hn khng nng chy

in cc hn khng nng chy c ch to t cc vt liu c kh nng chu nhit cao nh grafit, vonfram. ng knh que hn dq = 15 mm i vi que hn vonfram v dq = 612 mm i vi que hn grafit, chiu di que hn thng l 250 mm, u vt cn. Que hn khng nng chy cho h quang hn n nh, b sung kim loi cho mi hn phi s dng thm que hn ph.

b. in cc hn nng chy
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Gio trnh: cng ngh hn

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

2.3. Ngun in v my hn 2.3.1. Yu cu chung i vi ngun in v my hn

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Gio trnh: cng ngh 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

H.2.9. S nguyn l ca my bin p hn xoay chiu

b. My hn xoay chiu vi li t di ng

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Gio trnh: cng ngh hn

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

H.2.10. S nguyn l ca my hn xoay chiu vi li t di ng

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

H.2.11. S nguyn l ca my hn xoay chiu t hp

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

Gio trnh: cng ngh hn

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.

b/ My hn dng dng in chnh lu

My hn dng dng in chnh lu c hai b phn chnh: Bin p hn (1) v b chnh lu (2), b bin tr R (3) dng iu chnh cng dng in hn.
1 2 3

R
Uh 0

Ih(A) t(s)
2

a/

Ih(A) t(s)
0

b/

H.2.13. a/ S nguyn l my hn chnh lu ba pha b/ S nguyn l my hn chnh lu mt pha

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

Gio trnh: cng ngh hn

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

2.4.1. V tr, phn loi v chun b mp hn

II 0-600 I 120-1800 III

a/ V tr mi hn trong khng gian

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 I- V 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

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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

H.2.16. Cc kiu chun b mp hn

2.4.2. Ch hn h quang tay

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

Trong S l chiu dy vt hn, K l cnh ca mi hn.

b/ Cng dng in hn (Ih)

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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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.

c/ in p hn: in p hn thng t thay i khi hn h quang tay. d/ S lt cn phi hn

hon thnh mt mi hn c th tin hnh trong mt ln hn hoc mt s ln hn. Khi tit din mi hn ln, thng tin hnh qua mt s ln hn. S lt hn c th tnh theo cng thc sau: F F0 n= d +1 Fn Trong Fd - l din tch mt ct ngang ca kim loi p. F0 - din tch mt ct ngang ca ng hn u tin: F0 = (6 8)dq (mm2). Fn - din tch mt ct ngang ca nhng ng hn tip theo: Fn = (8 12)dq (mm2). e/ Tc hn (Vh): Tc hn c xc nh bi chiu di mi hn trong mt n v thi gian.
Vh = L t

[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

Mt khc G = F L. cho nn:

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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).

H.2.17. Cc phng php chuyn ng que hn

Phng php hon thnh mi hn ph thuc vo chiu dy v chiu di ca chi tit hn :

L < 250 L = 2501000 L > 1000

L > 1000

H.2.18. Cc phng php hon thnh mi hn

2.5.4. Hn cc v tr khc hn sp
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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/

H.2.15. K thut hn ng v hn ngang

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/

H.2.16. K thut hn trn (c) v hn gc (d)

Chng 3: Hn

h quang t ng v bn t ng
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3.1. Thc cht v c im

3.1.1. Thc cht

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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Hnh 3.1. S hn di lp thuc bo v a. S nguyn l; b. Ct dc theo trc mi hn

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

H.3.3. S thit b hn bn t ng di lp thuc hn

1/ My pht dng in hn, 2/ T iu khin in, 3/ Thit b cp dy hn 4/ ng dn dy hn, 5/ Tay cm, 6/ Phu cha thuc hn, 7/ Cng tc, 8/ Vt hn

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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3.2.3. Cng ngh hn h quang di lp thuc bo v

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 qu nh khng ngu

Dng in hp l

Dng in qu ln chiu cao mi hn tng

Hnh.3.3. nh hng ca dng in hn ti hnh dng mi hn.

in th h quang: H quang di th in th h quang cao, p lc ca n ln kim loi lng gim, do chiu su ngu gim v tng chiu rng mi hn. iu chnh tc cp dy th in th ct h quang s thp v ngc li. Tc hn: Tc hn tng, nhit lng h quang trn n v chiu di ca mi hn s gim, do su ngu gim, ng thi chiu rng mi hn gim. Theo cng thc kinh nghim, khi hn thp vi chiu dy vt hn s = 814 mm c xc nh theo cng thc sau:
Vh = 25.000 Ih

(m/h)

ng knh dy hn: Khi ng knh dy hn tng m dng in khng i th chiu su ngu gim tng ng. ng knh dy hn gim th h quang n su hn vo kim loi c bn, do mi hn s hp v chiu su ngu ln.
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Cc yu t cng ngh khc ( di phn nh ca dy hn, loi v cc tnh dng in hn...): di phn nh ca dy hn tng ln th tc dng nung nng ca kim loi in cc trc khi vo vng h quang tng ln. Vn tc cp dy hn (Vd): 4. Vh . F (m/h) Vd = . d 2 Trong F l tit din ngang mi hn, d l ng knh dy hn. Vi cc loi hn ang dng hin nay, khi i t ni thun sang ni nghch, chiu su ngu s tng ln. Hn bng dng xoay chiu c chiu su ngu mc trung bnh so vi khi hn bng dng mt chiu ni thun v ni nghch. C ca ht thuc hn c nh hng nht nh n ngu ca mi hn. Thuc hn c c ht nh s lm gim bt tnh hot ng ca h quang v lm tng chiu su ngu. c. K thut hn Khi hn gip mi mt lp, trnh chy thng, c ngu hon ton v c s to hnh tt mt tri ca mi hn ta c th p dng cc bin php nh: hn lt pha di, dng m thp, m thuc, dng kho chn hoc tm m. 2 1 3 a) c) n 5 d) 6 e) 4 bn n b)

Hnh 3.5. Bin php chng kim loi chy khi khe h hn

n = (0,3 0,5); bn = 4 + 5

1. Chi tit hn; 2. mi hn; 3 mi hn lt; 4. m thp; 5. m ng; 6. m ng + thuc hn

Nu chiu dy vt hn tng i ln, c th hn lt bng phng php th cng, ri sau mi hn chnh thc (hnh 3.5a). Trong trng hp khng th hn lp lt c, c th dng m thp c nh c th hn ngu hon ton (hnh 3.5b). Kho chn (hnh 3.5c) tng t nh hn vi m thp. Kho chn hay dng cho mi hn ca cc vt hnh tr nh ng, bn cha, ni hi... C th dng tm m ri bng ng hoc m ng kt hp vi thuc nh hnh 3.5e. Khi hn h quang t ng hoc bn t ng di lp thuc bo v, tt nht nn dng m thuc ngn kim loi lng chy khi khe h hn. 3.3. hn h quang nng chy trong mi trng kh bo v
3.3.1. Thc cht, c im v phm vi ng dng
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a. Thc cht v c im Hn h quang nng chy trong mi trng kh bo v l qu trnh hn nng chy trong ngun nhit hn c cung cp bi h quang to ra gia in cc nng chy (dy hn) v vt hn; h quang v kim loi nng chy c bo v khi tc dng ca xy v nit trong mi trng xung quanh bi mt loi kh hoc mt hn hp kh. Ting Anh phng php ny gi l GMAW (Gas Metal Arc Welding).

Hnh 3.6. S hn h quang nng chy trong mi trng kh bo v

a. S nguyn l; b. S thit b Kh bo v c th l kh tr (Ar; He hoc hn hp Ar+He) khng tc dng vi kim loi lng trong khi hn hoc l cc loi kh hot tnh (CO2; CO2+O2; CO2+Ar...) c tc dng y khng kh ra khi vng hn v hn ch tc dng xu ca n. Khi in cc hn hay dy hn c cp t ng vo vng h quang thng qua c cu cp dy, cn s dch chuyn h quang dc theo mi hn c thao tc bng tay th gi l hn h quang bn t ng trong mi trng kh bo v. Nu tt c chuyn ng c bn c c kh ho th c gi l hn h quang t ng trong mi trng kh bo v. Hn h quang bng in cc nng chy trong mi trng kh tr (Ar; He) ting Anh gi l phng php hn MIG (Metal Inert Gas). V cc loi kh tr c gi thnh cao nn khng c ng dng rng ri, ch dng hn kim loi mu v thp hp kim. Hn h quang bng in cc nng chy trong mi trng kh hot tnh (CO2; CO2+O2...) ting Anh gi l phng php hn MAG (Metal Active Gas). Phng php hn MAG s dng kh bo v CO2 c pht trin rng ri do c rt nhiu u im:
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- CO2 l loi kh d kim, d sn xut v gi thnh thp. - Nng sut hn trong CO2 cao, gp hn 2,5 ln so vi hn h quang tay. - Tnh cng ngh ca hn CO2 cao hn so vi hn h quang di lp thuc v c th tin hnh mi v tr khng gian khc nhau. - Cht lng hn cao, sn phm hn t b cong vnh do tc hn cao, ngun nhit tp trung, hiu sut s dng nhit ln, vng nh hng nhit hp. - iu kin lao ng tt hn so vi vi hn h quang tay v trong qa trnh hn khng pht sinh kh c. b. Phm vi ng dng Trong nn cng nghip hin i, hn h quang nng chy trong mi trng kh bo v chim mt v tr rt quan trng. N khng nhng c th hn cc loi thp kt cu thng thng m cn c th hn cc loi thp khng g, thp chu nhit, thp bn nng, cc hp kim c bit, cc hp kim nhm, magi, niken, ng, cc hp kim c i lc ho hc mnh vi xy. Phng php ny c th s dng c mi v tr trong khng gian, chiu dy vt hn t 0,4 4,8 mm th ch cn hn mt lp m khng phi vt mp; t 1,6 10 mm hn mt lp c vt mp; cn t 3,2 25 mm th hn nhiu lp.
1.2.2- Vt liu, thit b hn h quang nng chy trong mi trng kh bo v

a. Vt liu hn Dy hn Khi hn trong mi trng kh bo v, s hp kim ho kim loi mi hn cng nh cc tnh cht yu cu ca mi hn c thc hin ch yu thng qua dy hn. Do vy, nhng c tnh ca qa trnh cng ngh hn ph thuc rt nhiu vo tnh trng v cht lng dy hn. Khi hn MAG, ng knh dy hn t 0,8 2,4 mm. S n nh ca qa trnh hn cng nh cht lng ca lin kt hn ph thuc nhiu vo tnh trng b mt dy hn. Cn ch n phng php bo qun, ct gi v bin php lm sch dy hn nu dy b g hoc bn. Mt trong nhng cch gii quyt l s dng dy c bc lp m ng. Dy m ng s nng cao cht lng b mt v kh nng chng g, ng thi nng cao tnh n nh ca qa trnh hn. Theo h thng tiu chun AWS, k hiu dng cho dy hn thp C nh sau: ER 70 S- X trong , ER: k hiu in cc hn hoc que hn ph. 70: bn ko nh nht (ksi). S: dy hn c. X: thnh phn ho hc v kh bo v. Mt s loi dy hn thp C thng dng iu kin hn
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Bng 1-2 C tnh

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Gio trnh: cng ngh hn

dn bn ko Gii hn chy di % ca mi hn Cc tnh Kh bo v ca lin kt (min) (min-psi) (min-psi) E70S-2 72000 DCEP 60000 CO2 22 CO2 E70S-3 72000 DCEP 60000 22 CO2 E70S-4 72000 DCEP 60000 22 CO2 E70S-5 72000 DCEP 60000 22 CO2 E70S-6 72000 DCEP 60000 22 CO2 E70S-7 72000 DCEP 60000 22 DCEP l dy hn ni vi cc dng ca ngun in (u nghch) K hiu theo Thnh phn ho hc (%) AWS C Mn Si Cc nguyn t khc E70S-2 0,6 Ti: 0,050,15; Zi: 0,02 0,400,70 0,12; Al: 0,050,15 E70S-3 0,060,15 0,901,40 0,450,70 E70S-4 0,070,15 0,650,85 E70S-5 Al: 0,500,90 0,070,19 0,300,60 E70S-6 0,070,15 1,401,85 0,801,15 E70S-7 0,070,15 1,502,00 0,500,80 K hiu theo AWS Kh bo v Kh Ar tinh khit (~ 100%) thng dng hn cc vt liu thp. Kh He tinh khit (~ 100%) thng c dng hn cc lin kt c kch thc ln, cc vt liu c tnh gin n nhit cao nh Al, Mg. Cu... Argon l kh tr thng cha trong bnh thp vi p sut 150 at, dung tch 40 lt. argon khng chy, khng n v khi lm vic phi c gim p sut t 150 n 0,5 at v duy tr khng i nh van gim p t iu chnh. Kh CO2 dng hn phi c sch n trn 99,5%, p sut trong bnh khong (50 - 60) at. y l kh hot tnh khi nhit cao n phn ly ra CO v xy nguyn t, cho nn CO2 c tc dng bo v tt v CO t ho tan trong kim loi lng v c tc dng kh xy. CO2 c dng rng ri hn thp C trung bnh do gi thnh thp, mi hn n nh, c tnh ca lin kt hn t yu cu, tc hn cao v ngu su. Nhc im ca hn trong kh bo v CO2 l gy bn to kim loi lng.

Mt s loi kh bo v tng ng vi kim loi c bn Bng 3-3 Kh bo v Kim loi c bn

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Gio trnh: cng ngh hn

Ar (He) Ar + 1% O2 Ar + 2% O2 Ar + 5% O2 Ar + 20% CO2 Ar + 15% CO2 + 5% O2 CO2 Thit b hn

Kim loi v hp kim khng c st. Thp austenit Thp ferit (hn ng t trn xung) Thp ferit (hn tm mng, hn ng t trn xung) Thp ferit v austenit (hn mi v tr) Thp ferit v austenit (hn mi v tr) Thp ferit (hn mi v tr)

Hnh (H.3.6) trnh by s mt thit b hn h quang trong mi trng kh Acgng vi in cc nng chy.
2 3 4 5 6 8
MP C

x
7

1
MPH

9 10

12

11

H.3.7. S my hn t ng trong mi trng kh bo v 1. Bnh kh acgng 2. Van gim p 3. ng h o p 4. Van tit lu 5. My pht mt chiu 6. ng c quay c cu cp dy 7. Dy hn 8. C cu cp dy 9. ng dn kh 10. Mng kh bo v 11).Vt hn 12) Bin tr

Trong qu trnh hn, kh Acgng t bnh cha (1) qua van gim p (2) v van tit lu (4) c cp vo vng vng hn to thnh mng kh ngn cch vng hn vi mi trng kh quyn. Khi hn h quang t ng trong mi trng kh Acgng, dng in hn t (30 400) A, lng tiu th kh khong (300 - 900) lt/h. u im ca hn kh Acgon l mi hn p khng r, khng c x, cht lng mi hn tt, c bit chuyn dng hn thp hp kim c chiu dy S < 5 mm. H thng thit b cn thit dng cho hn h quang nng chy trong mi trng kh bo v bao gm: ngun in hn, c cu cp dy hn t ng, m hn hay sng hn i cng cc ng ng dn kh, dn dy hn v cp in, chai cha kh bo v km theo b ng h, lu lng k v van kh. Hnh sau trnh by s thit b hn bn t ng trong mi trng kh CO2 bng in cc nng chy. Khi hn, kh CO2 c phun vo vng mi hn, di tc dng nhit ca ngn la h quang kh b phn hu theo phn ng: CO2 = 2CO +O2
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Kh CO khng ho tan vo thp, hnh thnh mi trng bo v khi hn, trnh s xy ha ca xy ngi ta s dng que hn ph c hm lng Mn v Si cao.
2 3 4 5 6 9 7 1

10 11

H.3.8. S thit b hn bn t ng trong mi trng kh CO2 1/ Bnh kh; 2/ Thit b nung kh; 3/ Van gim p; 4/ p k; 5)Van tit lu; 6/ ng dn kh; 7/ Thit b cp dy hn; 8/ My pht in 9/ ng dn dy hn; 10/ Tay cm; 11/ Vt hn

M hn (sng hn) bao gm bp tit din chuyn dng in hn n dy hn, ng dn kh v chp kh hng dng kh bo v bao quanh vng h quang, b phn lm ngui c th bng kh hoc nc tun hon, cng tc ng ngt ng b dng in hn, dy hn v dng kh bo v. Ngun in hn thng thng l ngun in mt chiu DC. Ngun in xoay chiu AC khng thch hp do h quang b tt na chu k v s chnh lu chu k phn cc ngui lm cho h quang khng n nh.

Hnh 3.9. M hn c cong, lm ngui bng kh

c tnh ngoi ca ngun in hn thng thng l c tnh cng (in p khng i). iu ny c dng vi tc cp dy hn khng i, cho php iu chnh t ng chiu di h quang.
1.2.3. Cng ngh hn h quang nng chy trong mi trng kh bo v

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a. Chun b lin kt trc khi hn Cc yu cu v hnh dng, kch thc, b mt lin kt trong phng php hn h quang nng chy trong mi trng kh bo v tng t nh cc phng php hn khc. Tuy nhin, do ng knh ca dy hn nh hn so vi hn di lp thuc bo v nn gc vt mp s nh hn (thng khong 45 600) do dy hn c kh nng n su vo trong rnh hn. b. Cc dng truyn kim loi lng vo vng hn Truyn kim loi dng cu Git kim loi hnh thnh chm trn in cc v lu li y lu. Nu kch thc git kim loi lng ln, git kim loi lng s chuyn vo vng hn theo cc hng khc nhau (ng trc hoc lch trc dy hn) do trng lc hoc do s on mch. Kch thc git kim loi lng dng cu ph thuc vo loi kh s dng, vo vt liu v kch thc in cc, in p h quang, cng dng in v cc tnh. Khi in p h quang v kch thc in cc tng th ng knh git tng. Cng dng in tng s lm gim ng knh git. Qu trnh hn vi s truyn kim loi dng cu c ng dng ch yu cho cc lin kt hn bng. Truyn kim loi dng phun dng ny, kim loi i qua h quang dng git rt nh c nh hng ng trc. ng knh git kim loi bng hoc nh hn ng knh in cc. Hn h quang kiu phun rt thch hp hn cc chi tit tng i dy vi dng in cao v hn v tr hn ng t trn xung. Truyn kim loi dng ngn mch hoc nh git K thut hn h quang ngn mch hoc nh git thch hp khi hn cc tm mng cc v tr hn khc nhau. K thut hn truyn kim loi dng nh git s dng dy hn ng knh nh (0,8 1,6mm), in p h quang thp (16 22V), dng in thp (60 180A). K thut hn ny t gy ra bn to git kim loi lng. c. Ch hn Dng in hn Dng in hn c chn ph thuc vo kch thc in cc (dy hn), dng truyn kim loi v chiu dy ca lin kt hn. Khi dng in qu thp s khng m bo ngu ht chiu dy lin kt, gim bn ca mi hn. Khi dng in qu cao s lm tng s bn to kim loi, gy ra r xp, bin dng, mi hn khng n nh. Vi loi ngun in c c tnh ngoi cng (in p khng i) dng in hn
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Gio trnh: cng ngh hn

tng khi tng tc cp dy v ngc li. in p hn y l thng s rt quan trng trong hn GMAW, quyt nh dng truyn kim loi lng. in p hn s dng ph thuc vo chiu dy chi tit hn, kiu lin kt, kch c v thnh phn in cc, thnh phn kh bo v, v tr hn... c c gi tr in p hn hp l, c th phi hn th vi ln, bt u bng gi tr in p h quang theo tnh ton hay tra bng, sau tng hoc gim theo quan st ng hn chn gi tr in p thch hp. Tc hn Tc hn ph thuc rt nhiu vo trnh tay ngh ca th hn. Tc hn quyt nh chiu su ngu ca mi hn. Nu tc hn thp, kch thc vng hn s ln v ngu su. Khi tng tc n, tc cp nhit ca h quang s gim, lm gim ngu v thu hp ng hn. Phn nh ca in cc hn l khong cch gia u in cc v mp bt tit din (hnh 1.9). Khi tng chiu di phn nh, nhit nung nng on dy hn ny s tng, dn ti l;m gim cng dng in hn cn thit nng chy in cc theo tc cp dy nht nh. Khong cch ny rt quan trng khi hn thp khng g, s bin thin nh cng c th lm tng s bin thin dng in mt cch r rt. Chiu di phn nh qu ln s lm d kim loi nng chy mi hn, lm gim ngu v lng ph kim loi hn. Tnh n nh ca h quang cng b nh hng. Nu chiu di phn nh qu nh s gy ra s bn toe, kim loi lng dnh vo m hn, chp kh lm cn tr dng kh bo v, gy ra r xp trong mi hn.
Dng in hn (A) Dy hn ng 200 knh 1,2 mm 250 Chp kh Khong cch chp kh- chi tit Bp tit din Phn nh in cc hn 150

Chiu di h quang

Dy hn ng Khong cch bp 100 knh 0,8mm tit din- chi tit 50 0 3,15 6,4 9,5 12,7 15,9 19 22,2 Phn nh in cc (mm)

a)

b)

Hnh 3.10. Chiu di in cc pha ngoi m hn (a) v quan h dng in - phn nh in cc (b)

d. K thut hn Khi hn mt pha, cn phi c m lt thch hp di ng hn. i khi c th thc hin ng hn chn (hn lt) bng k thut ngn mch c ngu ng u, sau cc lp tip theo c thc hin bng k thut truyn kiu phun vi dng
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Gio trnh: cng ngh hn

in cao. Cng nh vi mi phng php hn h quang khc, gc v v tr m hn v in cc vi ng hn c nh hng r rt ti ngu v hnh dng mi hn. Gc m hn thng nghing khong 10 200 so vi chiu thng ng. 1.3- hn h quang in cc khng nng chy trong mi trng kh tr
1.3.1- Thc cht, c im v phm vi ng dng

Hn h quang in cc khng nng chy trong mi trng kh tr (GTAW) l qa trnh hn nng chy, trong ngun nhit cung cp bi h quang c to thnh gia in cc khng nng chy v vng hn (hnh 3.13). Vng h quang c bo v bng mi trng kh tr (Ar, He hoc Ar+He) ngn cn nhng tc ng c hi ca xy v nit trong khng kh. in cc khng nng chy thng dng l Volfram nn phng php hn ny ting Anh gi l TIG (Tungsten Inert Gas). Vng h quang c ch ra trn hnh 3.14. H quang trong n TIG c nhit rt cao, c th t ti hn 61000C. Kim loi mi hn c th to thnh ch t kim loi c bn khi hn nhng chi tit mng vi lin kt gp mp, hoc c b sung t que hn ph. Ton b vng hn c bao bc bi kh tr thi ra t chp kh. Phng php ny c mt s u im ng ch : - To mi hn c cht lng cao i vi hu ht kim loi v hp kim. - Mi hn khng phi lm sch sau khi hn. - H quang v vng hn c th quan st c trong khi hn. - Khng c kim loi bn to. - C th hn mi v tr trong khng gian. - Nhit tp trung cho php tng tc hn, gim bin dng lin kt hn.

Hnh 3.11- S nguyn l hn h quang nng chy trong mi trng kh tr.

Phng php hn TIG c p dng trong nhiu lnh vc sn xut, c bit rt

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Gio trnh: cng ngh hn

thch hp trong hn thp hp kim cao, kim loi mu v hp kim ca chng... Phng php hn ny thng thng c thao tc bng tay v c th t ng ho hai khu di chuyn h quang cng nh cp dy hn ph.

Hnh 3.12. Vng h quang v vng hn. 1.3.2- Vt liu v thit b hn TIG

a. Vt liu Vt liu s dng trong phng php hn TIG bao gm: kh bo v, in cc Wolfram v que hn ph. Kh bo v (kh tr) Ar l kh c iu ch t kh quyn bng phng php ho lng khng kh v tinh ch n tinh khit 99,99%. Kh ny c cung cp trong cc bnh di p sut cao hoc dng lng vi nhit di -1840C trong cc thng cha ln. He c trng lng ring bng hong 1/10 so vi Ar c ly t kh t nhin, thng c cha trong cc bnh di p sut cao. Sau khi ra khi chp kh m hn, Ar to thnh lp bo v pha trn vng hn. Do nh hn, He c xu hng dng ln to thnh cun xoy xung quanh h quang. bo v hiu qu, lu lng He phi gp 2 3 ln so vi Ar. c tnh quan trng khc ca He l i hi in p h quang cao hn vi cng chiu di h quang v dng in so vi Ar. H quang He nng hn so vi Ar; He thng dng hn cc vt liu c chiu dy ln, c dn nhit cao (nh Cu) hoc nhit nng chy cao. im khc bit na l Ar cho tnh n nh h quang nh nhau i vi dng in xoay chiu (AC) v mt chiu (DC) v c tc dng lm sch tt vi dng AC. Trong lc , He to h quang n nh vi dng in DC nhng tnh n nh h quang v tc dng lm sch vi dng AC tng i thp. Do khi cn hn Al, Mg bng dng AC th nn dng Ar. Cc hn hp Ar v He vi hm lng He n 75% c s dng khi cn s cn bng gia cc c tnh ca hai loi kh ny.
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C th b sung H2 vo Ar khi hn cchk Ni, Ni-Cu, thp khng g. in cc Wolfram Wolfram c dng lm in cc do c tnh chu nhit cao (nhit nng chy l 34100C), pht x in t tng i tt, lm in ho h quang v duy tr tnh n nh h quang. Wolfram c tnh chng xy ho rt cao. Bng 3-4 Thnh phn ho hc ca mt s loi in cc Volfram Tiu chun AWS W (min) Th Zr Tng tp cht % % % (max) % 0,5 99,5 EWP 0,5 98,5 EWTh-1 0,8 1,2 0,5 97,5 EWTh-2 1,7 2,2 0,5 98,95 EWTh-3 0,35 0,55 0,5 99,2 EWZr 0,15 0,40 Cc in cc Wolfram c ng knh 0,25 6,4 mm vi chiu di 76 610 mm. Cc in cc Wolfram c thm Thori (Th) c tnh pht x in t, dn in v chng nhim bn tt, mi h quang tt hn v h quang n nh hn. Cc in cc Wolfram c thm Zircon (Zr) c cc tnh cht trung gian gia in cc W v in cc W-Th. Mu nhn din mt s loi in cc thng dng Bng 3-5 K hiu Thnh phn Mu nhn din EWP Wolfram tinh khit Xanh l cy EWCe-2 97,3% W, 2% oxit ceri Da cam EWLa-1 98,3% W, 1% oxit lantan en EWTh-1 98,3% W, 1% oxit thori Vng EWTh-2 97,3% W, 2% oxit thori EWZa-1 99,1% W, 0,25% oxit zircon Nu EWG 94,5% W Xm Mt s yu cu khi s dng in cc Wolfram: - Cn chn dng in thch hp vi kch c in cc c s dng. Dng in qu cao s lm hng u in cc, dng in qu thp s gy ra s n mn, nhit thp v h quang khng n nh. - u in cc phi c mi hp l theo hng dn km theo in cc. - in cc phi c s dng v bo qun cn thn, trnh nhim bn. - Dng kh bo v phi c duy tr khng ch trc v trong khi hn m c sau khi ngt h quang cho n khi in cc ngui. - Phn nh in cc pha ngoi m hn (chp kh) phi c gi mc ngn nht, ty theo ng dng v thit b dm bo c bo v tt bng dng kh tr.
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- Cn trnh s nhim bn in cc, s tip xc gia in cc nng vi kim loi mi hn. - Thi b, c bit l chp kh phi c bo v v lm sch. u chp kh b bn s nh hng ti kh bo v, nh hng ti h quang hn; do lm gim cht lng mi hn. Que hn ph Que hn ph c cc kch thc tiu chun theo ISO/R564 nh sau: chiu di t 500 1000 mm vi ng knh 1,2; 1,6; 2; 2,4; 3,2 mm. Cc loi que hn ph gm c: ng v hp kim ng, thp khng g Cr cao v Cr-Ni, nhm v hp kim nhm, thp C thp, thp hp kim thp... b. Thit b dng cho hn TIG Thit b dng cho hn TIG c cc b phn chnh sau (hnh 1.13): - Ngun in hn, bao gm c h thng iu khin kh bo v, nc lm mt, dng in v in p hn. - M hn; - Chai cha kh tr v van iu khin lu lng kh. M hn TIG Chc nng ca m hn TIG l dn dng in v kh tr vo vng hn. in cc Wolfram dn in c gi chc chn trong m hn bng ai gi vi cc vt lp bn trong thn m hn.

Hnh 3.13. Cu to m hn TIG. a) M hn TIG lm mt bng nc; b) M hn TIG c ng hi t kh.

Cc ai ny c kch thc ph hp vi ng knh in cc. Kh c cung cp vo vng hn qua chp kh. Chp kh c ren c lp vo u m hn hng v phn phi dng kh bo v. M hn c cc kch thc v hnh dng khc nhau ph hp vi tng cng vic hn c th. M hn TIG c phn lm 2 loi theo c cu lm mt: - M hn lm mt bng kh - tng ng vi cng dng in hn < 120A. - M hn lm mt bng nc - tng ng vi cng dng in hn > 120A. Ngun in hn
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Ngun in hn cung cp dng hn mt chiu hoc xoay chiu, hoc c hai. Ty ng dng, n c th l bin p, chnh lu, my pht in hn. Ngun in hn cn c ng c tnh ngoi dc (ging nh cho hn h quang tay). tng tc n nh h quang, in p khng ti khong 70 80V. B phn iu khin thng c b tr chung vi ngun in hn v bao gm b contact ng ngt dng hn, b gy h quang tn s cao, b iu khin tun hon nc lm mt (nu c) vi h thng cnh tn nhit v qut lm mt, b khng ch thnh phn dng mt chiu (vi my hn xoay chiu, mt chiu). * Ngun in hn xoay chiu: thch hp cho hn nhm, magi v hp kim ca chng. Khi hn, na chu k dng (ca in cc) c tc dng bn ph lp mng xit trn b mt v lm sch b mt . Na chu k m nung kim loi c bn. Hin nay c hai loi ngun xoay chiu chnh dng cho hn bng in cc khng nng chy trong mi trng kh bo v. * Ngun in hn mt chiu: khng gy ra vn ln W vo mi hn hay hin tng t nn dng (nh khi hn nhm bng ngun hn xoay chiu). Tuy nhin, iu quan trng cn lu khi s dng n l vic gy h quang v kh nng cho dng hn s ti thiu. Hu ht my mt chiu u s dng phng php ni thun (nn 2/3 lng nhit ca h quang i vo vt hn). in cc W tinh khit nh trong trng hp my xoay chiu t c dng hn mt chiu cc thun v kh gy h quang. Thay vo l in cc W + 1,5 2%ThO2 hoc ZrO2 hoc oxt t him LaO... Cc ngun in hn TIG thng dng Vit Nam l my hn TG 160 ca hng WIM (Malaysia), my hn KEPMI 2500 ca hng Kempi (Phn Lan).

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