Development and Prospects of Advanced Heat Treatment Technology (3)
The induction heat treatment is not severely oxidized by heating, and it should be in the category of less oxidation technology. Some workpieces that do not allow any oxidation must be subjected to atmospheric protection even during induction heating. At present, a similar technique has been developed by the Japanese electronics industry. Heating in a flowing particle furnace and a normal deoxidized salt bath can also achieve less oxidation-free effects. It can be heated in air after being packaged in paint or stainless steel foil in a single small batch production condition or when heating large workpieces and lacking atmosphere furnace equipment.
When the steel is heated in air and oxidizing gas (CO2, H2O), the oxidation is accompanied by a decrease in the surface carbon content, that is, surface decarburization. After quenching the workpiece, the surface hardness is low, it is not wear-resistant, and the surface is easy to form tensile stress, which is unfavorable against fatigue. The process with less decarburization heating is basically the same as less oxidation, but the requirements for the process conditions are less than that of oxidation. It is not enough to have less decarbonization protection gas, but it should have a certain carbon potential. For the multi-component mixed atmosphere CO-CO2, N2-CO-CO2-H2-H2O, in order to avoid decarburization, the carbon potential of the furnace gas must be adapted to the carbon content of the steel surface. Therefore, the decarburization heating of medium and high carbon steel must control the carbon potential of the furnace gas. In this way, the decarburized steel can be restored to its original carbon content by heating in the atmosphere of the corresponding carbon potential. This process is called complex carbon. When the steel is heated in a vacuum, if the degree of vacuum is guaranteed to be non-oxidized, it will not decarburize. However, when heated in an inert inert gas or a neutral gas, the requirement for water content is more stringent in order to completely decarburize. Flow particle furnaces, salt baths, coatings and post-packaging heating have little decarburization. Although there is a slight change in induction heating, there is no obvious decarburization.
3.7 Less waste
From the design of parts, the choice of materials, the guarantee of material quality, the determination of processing and process routes, the use of database and expert decision-making systems to optimize processes and equipment, equipment reliability assurance, process parameters and product quality online control, non-destructive automatic Quality inspection system to complete the entire processing and heat treatment production process, to achieve total quality control of product quality, making 100% product qualified is not a dream. Strict management, superb craftsmanship, reliable equipment, precise sensors, and precision-controlled complete system engineering are sufficient guarantees for waste-free production.
3.8 Less man-free
The manual operation of heat treatment is a heavy physical labor in a harsh environment. At present, some developed countries have felt the difficulty of recruiting heat treatment operators. Manual operation can also cause fluctuations in product quality that vary from person to person.
Of course, excessive use of labor will also increase production costs. Therefore, the automatic production and unmanned operation as soon as possible under the premise of mass production can not be the embarrassment of future heat treatment. Modern enterprises in some developed countries can already witness the miracle of this manufacturing technology. But we must correct an understanding that no one does not mean no one to monitor. Of course, to achieve this "expectation", there must be sufficient guarantees in technology, management and talent quality. Conditions such as continuous and normal supply of energy and power, high-reliability and trouble-free equipment, sound regular maintenance system, reliable control system, timely alarm of accidents, remote control of operation, automatic diagnosis and elimination of faults are all indispensable. Mistakes in any one link can have serious or even catastrophic consequences. In addition, any advanced equipment, not only must be affordable, but must also be used. It is necessary to accept the automatic production line that some enterprises in the past have spent a lot of money to introduce, because they will not sleep and sleep, and even open the lessons of single use. Unmanned production lines can only be a natural product of a country to a certain level of development, a company to a fairly advanced level.
4 Ways of technical transformation of heat treatment production
In order to develop in the fierce competition, state-owned enterprises and private enterprises specializing in heat treatment and processing must first carry out innovation and transformation of production technology. The first action of technological transformation should be the renovation of facilities, because equipment is the carrier of advanced technology; secondly, it improves the management and technical level and operational skills of enterprise employees, and actively carries out re-education and training; Improve the company's self-development capabilities and continue to research and develop new technologies (Dofnewtechnologies). To sum up, it is to work hard on these three Rs.
4.1 Device Update
In the past 20 years, through the introduction of technology and digestion and absorption, the heat treatment of the automobile, aviation, weapons and mechanical basic parts industry has made great progress. Many advanced equipments and processes have been introduced, and the production technology has reached a high level. However, the heat treatment production conditions of most machinery manufacturers are still simple, the process is backward, the manual operation is heavy, and the equipment with 40 years of service age accounts for 80%. the above. These devices have large energy consumption, old technology, large temperature difference, high failure rate and low mechanization. It is difficult to manufacture quality products using this type of equipment. Therefore, it can be said that in order to maintain the core competitiveness of enterprises, it is imperative to transform the production technology with the renewal of equipment as the main measure.
The main starting point for updating equipment should be high reliability, energy saving, high temperature uniformity, high degree of automation, and high performance-price ratio. Although the domestic heat treatment equipment is cheap, it has a large gap between the international famous brand products in terms of energy consumption, temperature uniformity and automation degree, especially reliability, that is, the failure rate is the largest during service. Many users would rather spend a lot of money on imported, domestic-owned, joint venture products. Therefore, equipment manufacturers must recognize the situation, seriously learn from others, grasp market trends and technological development directions, strengthen the digestion and absorption of imported technologies, and rapidly improve their self-development capabilities. In the process of designing and manufacturing new equipment, we use high-quality supporting components and instruments. First, we have made a big breakthrough in the reliability of domestically produced equipment. Only then can we emerge in the climax of the upcoming technological transformation that has arrived in some fields. It may be protected from extinction in the more intense market competition that is coming.
The rise of heat-treated private SMEs also has a large demand for heat treatment equipment. Since last year, there have been clear signs that even companies that manufacture conventional equipment have begun to have better sales. But we must not be confused by these superficial phenomena. Many small and medium-sized enterprises have fully realized the high starting point in production technology and the importance of adopting advanced equipment. They also have sufficient funds to afford advanced equipment. In order to seize the mold processing market, the heat treatment processing enterprises with a large scale in the coastal areas of South China and East China are rushing to purchase vacuum heating high-pressure gas quenching furnaces of 0.6MPa (6bar) or more. The rise of the automobile and motorcycle industries, the demand for carburizing, quenching, cleaning, tempering multi-purpose furnace production lines and gas nitrocarburizing furnace production lines will further increase. Equipment manufacturers must seize this favorable opportunity to provide high-quality, reliable, advanced heat treatment process equipment that meets the requirements of their high-tech starting point.
The progress of science and technology is changing with each passing day. The technological transformation of enterprises is constantly going on, and higher requirements are placed on the quality, knowledge and skills of the management cadres, technicians and operating workers. After the implementation of the market economic system in China, especially after joining the WTO, many state-owned enterprises and most private and joint-stock enterprises lack knowledge of market economy laws, international trade rules and procurement channels. Many people have not yet entered the scientific management of modern enterprises. character of. The knowledge of factory technicians is aging, and the introduction of advanced equipment and processes, especially computer simulation and control, as well as CAD and CAM technology, are so unfamiliar that they often fail to perform all the functions of advanced equipment. Most of the operators are not trained in technology, and they are not able to get a certificate. Some old workers can't cope with the current production technology by relying on the knowledge and skills that should be known. Many of them have recognized the shortcomings in this regard and are eager to change the status quo as soon as possible.
The overall quality of employees is the primary condition for the core competitiveness of enterprises. To improve the overall quality is to encourage enterprise employees to develop a culture of continuing education and lifelong learning, to cultivate talents in technology, management, management, operational skills, etc., to build a team of workers who master modern technology and have self-development capabilities and skilled operation skills. Industry groups such as societies and associations should play a major role in this regard.
4.3 Continuously improve the ability of high-tech development
The market competition of enterprise products can be said to be the dispute between human ability and quality. Before China joined the WTO, Chinese enterprises have already shown obvious weaknesses in this regard. Its main performance is due to the lack of knowledge updates or slow updates of business leaders and technicians to form a weak new product and new technology development capabilities. Due to the weak concept of intellectual property rights and the lack of independent development capabilities, blind plagiarism is involved in the digestion and absorption of imported technologies. On the one hand, infringement is illegal, affecting the reputation of the state, enterprises and individuals, and weakening the enthusiasm of international investors in investing in China; on the other hand, blind plagiarism without any investigation and analysis will also form plagiarism, or continue to have defects s consequence. In addition, for equipment manufacturers, current and future user requirements and product use levels are constantly increasing, so that each product is ordered with many special technical conditions. This requires manufacturers to continually modify the design or completely redesign. That is to say, the manufacturers are all producing non-standard products. According to the concept of the planned economy period in the past, production is carried out in the process of continuously developing new products, and such development and production must be as successful as possible, otherwise it will obviously increase the manufacturing cost and product price, and it is difficult to participate in market competition. This requires business leaders to be far-sighted and brave enough to invest in the knowledge update of personnel, so that enterprise technicians can establish a strong desire for knowledge renewal, first accept basic training in technology development, and secondly care about domestic and international market demand and technology development dynamics, through continuous investigation. Analysis, mastering the advantages of foreign famous brand names, and constantly drawing on the strengths of others, can quickly improve the independent development capabilities, produce international top products, and can achieve a success. Of course, while improving their own development capabilities, enterprises accept the transfer of mature technology from research institutes and colleges and universities, and establish close relationships between production, learning, and research in cultivating personnel and joint development, and establish a strong technical development backing. A very important aspect of improving development capabilities.
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