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        Non-ferrous casting

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        Kunshan Non-ferrous metals Casting Co., Ltd.

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        Nonferrous Casting Technology Development and Industrial Applications

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        Nonferrous Casting Technology Development and Industrial Applications

        Release date:2016-01-15 00:00 Source:http://www.rscharitas.com Click:

        Adhesive technology in addition to simple, fast, efficient, inexpensive and other characteristics, but also can be bonded to some other connections can not connect the material or structure, such as the realization of metal and non-metallic bonding, to overcome the cast iron, aluminum cracking when welding And aluminum can not be connected with cast iron, steel welding and other issues. And in some occasions can effectively replace the welding, riveting, screwing and other mechanical connections. At present, the application of adhesives has penetrated into various sectors of the national economy, becoming an indispensable technology in industrial production, and has also been widely used in high-tech fields. For example, it is reported that foreign companies must use 5 to produce a car. 10kg adhesive; the adhesion area of a Boeing aircraft reaches 2400m2; a spacecraft needs to bond 30,000 ceramics.


        Adhesive Classification and Development of Adhesive Technology


        At the beginning of this century, due to the successful development of various types of synthetic resins and synthetic rubbers, especially the production and commercialization of representative polymers such as phenolic resins, urea-formaldehyde resins, unsaturated resins, epoxy resins, and neoprene rubber, etc. Has promoted the rapid development of modern adhesive and adhesive technology. Since the 1980s, adhesives and bonding technology have made significant progress. New adhesives with excellent performance have emerged, and due to their unique adhesive technology, they have extraordinary versatility and can achieve multiple purposes. Therefore, it has been more widely used. There are many ways to classify adhesives and they are not uniform. Commonly used are:


        1) Classification by chemical composition: This is a more scientific classification method. It classifies adhesives into organic and inorganic adhesives. Organic adhesives are divided into synthetic adhesives and natural adhesives. Synthetic adhesives are resin type, rubber type, composite type, etc.; natural adhesives are animal, plant, mineral, natural rubber and other adhesives. Inorganic adhesives include chemical compounds such as phosphates, silicates, sulfates, borates, and many others.


        2) According to the shape classification: can be divided into liquid adhesives and solid adhesives. There are solution type, emulsion type, paste, film, tape, powder, rubber particles, glue sticks and so on.


        3) Classification according to purpose: This can be divided into structural adhesives, non-structural adhesives and special adhesives (such as high temperature, ultra-low temperature, conductive, thermal conductivity, magnetic, sealing, water glue, etc.) three categories.


        4) Classification according to application methods: There are room temperature curing type, thermosetting type, hot melt type, pressure sensitive type, rewetting type, etc. In order to adapt to the needs of bonding technology for industrial and agricultural production and social life, various countries have devoted great efforts in the development of adhesives, and they have developed rapidly. Some fast curing, one-component, high-strength, high-temperature resistant, and solvent-free have emerged. , Low viscosity, non-pollution, energy saving, multi-function and other characteristics of the adhesive. In the field of synthetic adhesives, the use of molecular design to develop high-performance adhesives; use of grafting, copolymerization, blending, interpenetrating network polymer (IPM) and other technologies to improve the performance of the adhesive. New progress has been made in the study of the adhesion mechanism; new developments have also been made in sizing equipment and tools. For example, the combination of adhesive and mechanical connection methods, adhesive and brush plating technologies, etc. form a new composite repair technology. Since the 1980s, China's adhesive and adhesive technologies have also developed rapidly. The number of varieties has increased, production has increased, and the quality has greatly improved. Many adhesives have reached or even exceeded the quality and performance of similar adhesives in the world. Here, Tiangong "super metal" repair agent is taken as an example to reflect the development of adhesives and bonding technologies in China. Tiangong "super metal" repair agent is a two-component composite material consisting of a high molecular polymer and metal powder, ceramic powder, fiber and curing agent, also called "polymer alloy". It has excellent physical and mechanical properties, abrasion resistance, corrosion resistance, and its comprehensive indicators can be comparable with similar foreign products; varieties are general-purpose, wear-resistant, anti-friction, corrosion-resistant, fast curing, wet Nine series of 26 types of repair agents, such as face repair type, high strength type, and conductivity type, can be adapted to different conditions and require bonding and repair.


        Tiangong "super metal" repair agent application and effect


        1) Application in equipment maintenance When equipment parts are worn out, cracked, corroded, scratched, fractured, or oil leaks, leaks, or leaks in tanks, tanks, pipes, etc., they can generally be repaired using bonding techniques.


        Such as using TG103 steel repair agent to repair Beijing Shougang imported from Germany, 1000t fast forging machine, with TG301 anti-friction repair agent for the Tianjin Waterway Bureau to repair the 215 dredger hydraulic cylinder imported from Japan, with TG801 high-strength structural adhesive repair tank Gearbox bearing holes, reactors for repairing chemical equipment with TG406, TG416 anti-corrosive repair agents have been successful, and have been well received by users. In Wuhan, we use the core components of the 1800t hydraulic press of used equipment imported from Germany: The main plunger (diameter Φ879mm, length 3130mm) with severe wear (unilateral wear averages 1.5 to 2mm) and the guide bush (diameter Φ875mm, length 500mm) ), pressure sleeve (diameter Φ876.5mm, length 210mm) for stick coating repair, repair cost is only 1/20 to 1/25 of the new product, and repair time only spent a few days, for the early production to fight for time. For the sealing of oil storage, gas storage tanks, chemical equipment; for aluminum alloy, cast iron box, plastic, glass fiber reinforced plastic parts of the crack. Using traditional welding, riveting, brush plating, thermal spraying and other methods difficult to solve, we used tiangong "super metal" repair agent to repair, have achieved satisfactory results. Such as the repair of crankcase body, aluminum alloy gearbox cracking and leakage of oil pipes, oil tanks, water pipes, radiators, etc. in armored vehicle engines; severe leakage of heating equipment near the central TV tower, for a certain plant on the 4GC boiler The perforation of the water pump pipe was leaked, and the TG518 and TG528 fast repairing agents were used to make up for plugging and plugging. Both were successful.


        2) Repairing defective new parts and pre-applying protective cast iron, cast aluminum, and cast copper parts to new parts, often have casting defects such as pores, trachoma, etc., so that the scrap rate reaches 10 to 30%, or even 50%. . In order to save the parts with casting defects, TG101, YG111 iron repair agent and TG103 steel repair agent can be used to repair large defects of cast iron and steel castings. For small pores and trachoma, it can be filled with TG102 iron repair agent; The defects of aluminum castings can be repaired with TG104 aluminum repair agent. For copper castings, repair is performed with TG105 copper repair agent. Many factories have applied this shimming repair technology to make many castings rejuvenate and have very good economic benefits. Also use TG406, TG416 anti-corrosive repair agent to pre-stick a layer of protective layer on the hovercraft corrosion parts to protect the parts and prolong the service life.


        3) to solve the difficult requirements in the conventional mechanical processing such as the stirring magnetic ring in the graphite milk pump, the precision is very high, is a ring-shaped part composed of many magnetic steels with N and S poles intertwined. Since magnets cannot be magnetized after combination, each magnet must be magnetized separately and cannot be excessively processed after magnetization is combined, otherwise the magnetism will be greatly reduced. The hardness of the magnetic steel is high, the processing is difficult, and cannot be solved by conventional mechanical processing. The combination of the mechanical processing and the bonding technology solves this problem very well and smoothly processes the agitated magnetic ring that meets the technical requirements.


        4) Extend the scope of repair Adhesives are used in conjunction with other technologies to complement each other's strengths and make full use of the features of various technologies to expand the scope of repairs. Such as: large cylinder liner or piston on the depth of the pull, can be filled with TG205 wear repair agent, and then stick coated with TG918 conductive repair agent, and finally brush plating on the conductive repair agent brushed metal layer. This is a combination of stick-coating technology and brush plating technology, which can quickly fill the scratches and reveal the true nature of the metal. Adhesive technology is compatible with mechanical reinforcement, spot welding reinforcement, glass fiber cloth reinforcement and other measures, and can be used for sealing with temperature and pressure. If an aluminum alloy gearbox of a combined harvester imported from the United States in Jiamusi accidentally broke, we reinforced it with a steel plate and repaired it with adhesive and achieved satisfactory results. The rolling mill of the rolling mill of Wuhan Iron & Steel Co., Ltd. was broken and used adhesives and machinery. The three technologies of reinforcement and spot welding, together with repairs, have also been successful. The use of adhesive repair technology has resulted in many successful experiences in the repair of many large-scale equipment and the repair of new product defects. It has gained tremendous economic benefits and has been praised and affirmed by users. Such as Beijing Fangshan Cement Factory large blower shaft and bearing with a serious bite, the site removed the bearing repair, only one day, reducing downtime, for the plant to recover the huge economic losses. Another example is the rotary generator of the ozone generator Roots blower in the Beijing Water Repairing Plant. The unilateral wear is up to 1mm, which seriously affects the pressure of the fan. It is directly coated and solidified by the TG205 wear-resisting refinisher, and then it is mechanically processed and costs only a few hundred yuan. In two days, all three rotators were repaired and significant economic benefits were achieved. From the above example using the Tiangong “Super Metal” repair agent, it can be proved that the bonding technology has the advantages of time saving and labor saving in the maintenance of industrial equipment and the repair of new product defects, saving energy, saving materials, and saving funds. With a very strong potential for development, it will surely play an increasingly important role in the construction of various sectors of the national economy.


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