tags:
Electric spark, Alloying, Processing, Surface, Tool, Material, Part, Characteristics The manufacture of most parts of machines and mechanisms is based on mechanical processing by pressure and cutting, which has traditionally been used for many centuries. One of the significant achievements of the 20th century is the discovery more than 70 years ago by the Soviet scientists spouses B.R. and N.I. Lazarenko developed a fundamentally new method of processing metal materials - electric spark. It is based on the use of electrical discharges for controlled destruction of the workpiece material to obtain the required shapes and sizes or for processing the working surface of a part (tool) and creating a surface layer with the required performance properties. Back in the 40s of the last century, the advantage of the electric spark method of metalworking over mechanical cutting in terms of technological capabilities was experimentally proven. This abstract discusses the use of the electric spark processing method for coating, this method is commonly called electric spark alloying (ESA).
1
. Electrospark alloying
Electrospark alloying is the transfer of EI material that meets certain requirements to the workpiece surface by a spark electric discharge. This method ensures strong adhesion of the introduced alloying material to the surface of the part; it is easy to implement.
1.1
General diagram of the electric spark process
During ESA, metal surfaces in a gaseous environment are exposed to short (up to 1000 μs) electrical discharges with an energy ranging from hundredths to a dozen or more joules and a frequency usually not exceeding 1000 Hz. During periodic contact of electrode A (anode) - (Figure 1), vibrating in the interelectrode gap of the MET with a frequency fa, with the workpiece K (cathode) and its rupture, electrical discharges arise, created by the GI pulse generator.
Figure 1 - General diagram of an electric spark drive
As a result, the following occurs: the processes of primary destruction of the electrode (anode) material and the formation of secondary structures in its working part take place; the electrode erosion products are transferred to the part (cathode); micrometallurgical processes occur on the surface of the processed product; elements of the electrode material diffuse into the surface layer of the product; the surface of the product acquires a new specific relief (Figure 2 a); a modified layer is formed on the surface of the product (Figure 2 b), including a white layer, a diffusion zone and a thermally affected zone, while the properties of the surface layer change; a surface layer of finely dispersed composition is formed, down to the nanolevel (Figure 2 c); the size of the product changes.
14 pages, 6538 words
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Figure 2 - Change in surface relief (a) and structure of the surface layer (b, c)
Thus, a new layer is formed on the surface of the part, which is given properties different from the initial state, depending on the parameters of the spark discharge, the composition of the electrode material, the material of the workpiece and other factors. These properties are controlled within wide limits (Table 1) and provide the required qualities: increased microhardness, wear resistance, heat resistance and others.
Table 1 - Characteristics of coatings applied by ESA
The wide technological capabilities and advantages of ESA are the basis for its effective successful use in various industries when strengthening objects made of metallic materials or restoring dimensions lost during operation. This fully applies to machine-building enterprises. Here, electric spark technologies are used to increase the wear resistance of cutting tools for procurement and main production, various technological equipment, including dies for cold and hot processing of metals and non-metallic materials, and machine parts (Figure 3).
Figure 3 - Examples of objects undergoing strengthening electric spark treatment
Advantages of electric spark alloying of metal surfaces
- the ability to apply coating to a microscopic area not exceeding a fraction of a millimeter;
- the surface area of the object not involved in processing does not receive any damage - therefore, does not require protection during the alloying process;
- sufficiently high adhesion of the applied layer to the surface of the substrate ensures reliable, strong, durable adhesion - due to the effect of diffusion (penetration) of the outer layer deep into the metal;
- alloying technology is accompanied by minimal heating of the processed object, there is not even a minimal percentage of metal corrosion;
- there are no requirements for the nature of the metal surface intended for application - there is no need for any preparation.
Practical use
2.1 Working tools and parts, equipment and their restoration and repair
electric spark alloying woodworking tool
Guillotines (press shears), metal saws (band, pendulum, Heller, segment, hacksaw, etc.), any length and diameter. Turning cutters, high-speed planing cutters, drills, cutters, taps, dies, incl. and for machining centers. Thread rolling rollers, dies, mandrels, guide bushings, collets, crackers. Matrices and punches for cutting, drawing and bending dies. Impact, straightening and straightening devices, clamping, cutting, navigating, stepping and feeding mechanisms. Molds for non-ferrous casting, in order to protect the sprue channels, radii, slopes, pushers, signs (processing does not allow the appearance of scorched nets, flash and gravy).
Knives of all types and configurations. Blades of turbines and pumps, extruders, screws, spindles.
Figure 4 — EIL installation
Table 4 - Technical characteristics of ESP installations
Conclusion
The widespread and effective use in Russia and abroad of the electric spark method of processing metal materials confirms the words of Boris Romanovich Lazarenko, said back in 1947: “The centuries-old reign of the mechanical method of processing metals, which turned the world upside down in past centuries, is ending. Its place is undoubtedly occupied by a more highly organized process, when metal processing is carried out by electrical forces... The future will belong to it, and, moreover, the near future.”
Bibliography
[Electronic resource]//URL: https://inzhpro.ru/referat/elektroiskrovoe-legirovanie/
Lazarenko, N.I. Electrospark alloying of metal surfaces: Mechanical engineering / N. I. Lazorenko. - M.: 1976. - 44 p. , Ivanov, G.P. Technology of electrospark hardening of tools and machine parts: Mashgiz / G.P. Ivanov. - M.: 1961. - 303 p.
Electrospark alloying of metal surfaces: textbook / G.V. Samsonov, A.D. Verkhoturov, G.A. Bovkun, V.S. Sychev. - Kyiv: Naukova Dumka, 1976. - 220 p.
Electrospark alloying of metal surfaces: reference manual / A.E. Gitlevich, S.A. Velichko, P.A. Ionov and others - Chisinau: Shtiintsa, 1985. - 145 p.
Electrospark alloying of metal surfaces: monograph / F.Kh. Burumkulov, P.V. Senin, P.P. Lezin and others - Saransk: Moscow State University Publishing House, 2004. - 346 p.
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Electric spark coating
Electrospark plating is a micro-welding manufacturing process often used to repair damage to precision or high-value parts such as tools, watches, etc. This process may also be referred to as “spark peening” or “spark alloying.”
Economy by industry Industry by industry Metalworking Welding
1. Technology
Electrospark coating is carried out using plasma pulsed spark discharges in air with periodic contact of the electrode with the product. In this case, the electrode material is transferred to the surface of the object. Electrodes made of nickel, tin and silver are used as electrodes for coating copper busbars. electrodes, as well as metal alloys T15K6, T17K12, VK6, VK8, VK20, materials based on metal carbides and borides - TiC, WC, Mo2B5, CrB2, TaB2 and graphite.
2. Advantages of the method
The advantages of electrospark coating include: high material transfer coefficient - from 60 to 80%. locality of coatings in certain places with a radius of fractions of a millimeter; simplicity of technology; high adhesion; no heating or deformation of the product;
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We deliver electrospark flaw detectors for coatings throughout Russia by courier services and transport companies. Electrospark. Prospects for the use of electrode SHS materials. For citation: Blazheev V.V., Ivanochkin P.G., Lichkovakha A.S. Study of the mechanical properties of coatings applied by the electric spark method. Experience in applying electric spark coatings to cutting tools. Improving the quality of electric spark intermetallic coatings. Methods for improving the quality of the coating surface on samples have been studied. UDC 621. 357. 76 technology for applying antifriction. The experience of using drills with a coating made by electric spark alloying is presented. Coating and base materials are described. As a manuscript from Omsk State Technical University. The experience of using electric spark coating on cutting tools and parts of technological equipment is considered.
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General technical conditions. ST SEV 4841 84 Installations for local electrospark testing. Applied electrospark coating. Aluminum Slav AL 9 was used as a test sample. An electric spark test was carried out. Study of the mechanical properties of Readera coating. OSU, 2008. – 16 p. Application of strengthening coatings using the electrospark alloying method 1.3 Carry out electric spark alloying on the samples. Ministry of Education and Science of the Russian Federation. Electric spark alloying discharge energy erosion mass transfer coating formation wear hardness heat resistance phase. do-it-yourself electric spark alloying, electric spark alloying of metal surfaces, what is the essence of electric spark alloying
