Kvalitetssäkring av gjutgods till verktyg och utrustningar

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Ricardo Canto Leyton

Kvalitetssäkring av gjutgods till verktyg och utrustningar

för karosstillverkning inom bilindustrin

2001:334

EXAMENSARBETE

Civilingenjörsprogrammet Materialteknik (EEIGM)

Institutionen för Material- och produktionsteknik Avdelningen för Materialteknik

2001:334 • ISSN: 1402-1617 • ISRN: LTU-EX--01/334--SE

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Av: Ricardo Canto Leyton Handledare: Veikko Hemming, ABB

Bengt Bergh, IUC

Esa Vuorinen, LTU

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1 INLEDNING... 4

1.1 SYFTE... 4

1.2 MÅL... 4

2 GJUTLEGERINGAR... 5

2.1 EGENSKAPER... 5

2.1.1 Allmänt om järn och gjutjärn... 5

2.1.2 Gråjärn... 7

2.1.3 Segjärn... 8

2.1.4 Aducerjärn... 9

2.1.5 Kompaktgrafitjärn... 9

2.1.6 Vitjärn... 9

2.1.7 Gjutstål... 9

2.1.8 Aluminiumlegeringar... 10

2.1.9 Kopparlegeringar... 11

2.2 KEMISK SAMMANSÄTTNING... 14

2.2.1 Gråjärn... 14

2.2.2 Segjärn... 14

2.2.3 Aducerjärn... 15

2.2.5 Vitjärn... 15

2.2.6 Gjutstål... 16

2.2.7 Kopparlegeringar... 17

3 GJUTNING... 18

3.1 SMÄLTNING... 18

3.2 MODELLER... 18

3.3 FORMAR... 19

3.3.1 Engångsformar... 19

3.3.2 Permanenta formar... 19

3.4 BLACKNING... 20

3.5 GJUTTEKNIKER... 20

3.5.1 Gjutning i sandform... 20

3.5.2 Gjutning i keramisk form... 23

3.5.3 Kokillgjutning... 25

3.5.4 Pressgjutning... 27

3.5.5 Centrifugalgjutning... 29

3.5.6 Stränggjutning... 29

3.5.7 Formmaterial i de olika gjutmetoderna... 30

3.5.8 Lämpliga gjuttekniker... 30

3.6 RENSNING... 31

4 VÄRMEBEHANDLING AV GJUTNA MATERIAL... 32

4.1 AVSPÄNNINGSGLÖDGNING... 32

4.2 HÄRDNING/ANLÖPNING... 32

4.3 MJUKGLÖDGNING... 32

4.4 NORMALISERING... 32

4.5 BAINITHÄRDNING... 32

4.6 SLÄCKGLÖDGNING... 32

4.7 UTSKILJNINGSHÄRDNING... 33

4.8 YTHÄRDNING OCH YTBELÄGGNING... 33

4.8.1 Nitrering... 33

4.8.2 Jonnitrering... 33

4.8.3 Nitrokarburering... 33

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4.8.4 CVD (Chemical Vapour Deposition)... 33

4.8.5 PVD (Physical Vapour Deposition)... 33

4.8.6 Laserbehandling... 33

4.8.7 Krombeläggning... 34

4.9 EXEMPEL PÅ VÄRMEBEHANDLINGAR... 34

4.9.1 Gråjärn... 35

4.9.2 Segjärn... 35

4.9.3 Aducerjärn... 36

4.9.5 Vitjärn... 36

4.9.6 Gjutstål (inkl. rostfritt stål)... 37

5 GJUTDEFEKTER... 38

5.1 UTÅTGÅENDE YTFEL... 38

5.1.1 Grov yta... 38

5.1.2 Vidhäftning... 38

5.1.3 Inträngning... 38

5.1.4 Partgrad... 40

5.1.5 Sprickgrad... 41

5.1.6 Erosion... 41

5.1.7 Skorv... 41

5.2 INÅTGÅENDE YTFEL... 42

5.2.1 Råttsvans... 42

5.2.2 Skolla... 42

5.2.3 Garskumsgropar... 43

5.2.4 Brännsår... 43

5.2.5 Slaggsår... 43

5.2.6 Partfåra... 43

5.2.7 Apelsinyta... 44

5.2.8 Elefanthud... 44

5.3 SUGNINGAR... 45

5.3.1 Sjunkning... 46

5.3.2 Öppen sugning... 46

5.3.3 Inre sugning... 46

5.3.4 Sugningsporer... 47

5.3.5 Mikrosugning... 47

5.4 GASBLÅSOR... 47

5.4.1 Ytblåsa... 47

5.4.2 Slaggblåsa... 47

5.4.3 Småblåsor... 48

5.4.4 Stickblåsor... 48

5.4.5 Kommablåsa... 49

5.5 INNESLUTNINGAR... 49

5.5.1 Sandinneslutning... 49

5.5.2 Slagginneslutning... 49

5.5.3 Slagginneslutning vid gjutjärn... 50

5.5.4 Oxidinneslutning... 50

5.5.5 Blackinneslutning... 50

5.6 STRUKTURFEL... 50

5.6.1 För hög hårdhet (grå- och segjärn)... 50

5.6.2 För låg hårdhet (gjutjärn)... 51

5.6.3 Anrikning av grafitnoduler (segjärn)... 51

5.6.4 Felaktig grafitform (segjärn)... 51

5.6.5 Onormal struktur hos gråjärn... 52

5.6.6 Uppkolad yta... 52

5.6.7 Avkolad yta... 53

5.6.8 Kväveupptagning i ytan (gjutstål)... 53

5.6.9 Oxidbildning under värmebehandling... 53

5.6.10 Tennsvett (Cu-legeringar)... 53

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6 OFÖRSTÖRANDE PROVNING AV GJUTGODS... 54

6.1.1 Magnetpulverprovning... 54

6.1.2 Radiografisk provning... 54

6.1.3 Ultraljudsprovning... 55

6.1.4 Standarder... 55

7 KVALITETSSÄKRING... 57

7.1 LEVERANTÖRSBEDÖMNING... 57

7.2 UTFORMNING... 58

7.3 SPECIFIKATION PÅ RITNING... 58

7.3.1 Zonmarkerade områden... 58

7.4 KONTROLL... 59

7.5 FEM-BERÄKNING... 59

7.6 SIMULERING AV GJUTNING... 59

8 RESULTAT... 60

8.1.1 Fall 1... 60

8.1.2 Fall 2... 60

9 DISKUSSION OCH SLUTSATSER... 62

9.3 KVALITETSSÄKRING... 62

9.4 FORTSATT ARBETE... 64

10 REFERENSER... 65

BILAGOR

BILAGA 1: EXEMPEL PÅ UTFORMNING AV GJUTGODS.

BILAGA 2: EXEMPEL PÅ RITNING MED GJUTSPECIFIKA KRAV.

BILAGA 3: FÖRSLAG TILL CHECKLISTA FÖR LEVERANTÖRSBEDÖMNING.

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Kvalitetssäkring av gjutgods till verktyg och utrustningar

Ricardo Canto Leyton