Walda Karfe Galvanized ya kasance daidaitaccen aiki a cikin ƙirƙira masana'antu da injiniyan tsari. Rufin tutiya mai ɗorewa yana ba da kyakkyawan juriya na lalata. Wannan ya sa waɗannan kayan su zama makawa don matsananciyar muhallin waje da buƙatar ayyukan more rayuwa.
Koyaya, haɗa waɗannan kayan yana gabatar da ƙalubalen ƙarfe na ƙarfe da aminci idan aka kwatanta da aiki akan ƙarancin ƙarfe na carbon. Tushen zinc mai karewa yana haifar da rikice-rikice kai tsaye. Za ku fuskanci al'amura game da kwanciyar hankali, tsaftar tafkin walda, da lafiyar ma'aikaci. Ba za ku iya kawai buga baka akan rufin ba kuma kuyi tsammanin tsaftataccen haɗin gwiwa mai ƙarfi ba tare da sakamako mai tsanani ba.
Wannan jagorar tana ba da tsarin tushen shaida ga injiniyoyi, manajojin ƙirƙira, da ƙungiyoyin saye. Za mu kimanta buƙatun shiri na tilas, zaɓin tsari mafi kyau, da ƙa'idodi masu mahimmanci kamar OSHA da AWS. Za ku koyi yadda ake kiyaye mutuncin tsari da kare ma'aikatan ku yadda ya kamata.
Key Takeaways
Yana da yuwuwar yuwuwa sosai don walda galvanized karfe, idan har ana bin shirye-shiryen pre-weld mai tsauri da kuma dawo da shafi bayan walda (ASTM A780).
Zinc yana vaporizes a ~ 420 ° C, yana haifar da gurɓataccen tafkin walda, porosity, da kuma mummunan haɗari na lafiya (Ƙarƙar Fume Fever) idan ba a sarrafa shi tare da PPE mai dacewa da samun iska.
Abubuwan zaɓin zaɓi na tsari: Flux-Cored Arc Welding (FCAW) da Garkuwar Karfe Arc Welding (SMAW/Stick) suna riƙe da tutiya mafi kyau fiye da Gas Metal Arc Welding (MIG), yayin da Gas Tungsten Arc Welding (TIG) yakamata a nisanta shi da ƙwazo saboda tsananin hankali ga gano zinc.
Ana kiyaye mutuncin tsarin: Dangane da binciken ILZRO, walda da aka aiwatar da kyau akan ƙarfe mai galvanized yayi daidai da taurin karye da ƙarfin gajiyar haɗin gwiwar ƙarfe mara rufi.
The Physics na Welding Galvanized Karfe: Tsarin Hadarin
Don fahimtar dalilin da yasa kayan galvanized ke yin rashin kyau a ƙarƙashin baka, dole ne ku kalli ma'aunin thermodynamics. Batun mahimmanci ya ta'allaka ne a cikin babban rashin daidaituwa na thermal tsakanin rufin kariya da ƙarfe tushe.
Zinc yana narkewa a kusan 420°C (788°F). Yana yin tururi gaba daya a kusa da 906°C (1663°F). Karfe na Carbon yana buƙatar zafi mai yawa don narkewa, yawanci tsakanin 1370°C da 1500°C (2500°F zuwa 2732°F). Lokacin da kake shafa baka na walda, Layer na zinc ya juya ya zama iskar iskar gas da dadewa kafin karfen da ke ciki ya fara yin ruwa.
Kayan abu |
Matsayin narkewa |
Wurin Wuta |
Halayyar Ƙarƙashin Arc |
Karfe Karfe |
~ 1370°C - 1500°C |
~3000°C |
Forms barga narkakkun tafkin |
Tufafin Zinc |
~420°C |
~906°C |
Hatsari mai fashewa |
Idan ba a yanke ba, wannan turɓayar zinc ta zama tarko a cikin tafkin walda mai ƙarfi. Gas kumfa suna kokawa don tserewa karfen ruwa mai danko kafin ya daskare. Wannan tarko yana haifar da porosity na ciki mai tsanani. Hakanan za ku ga haɗaɗɗun slag masu nauyi da ƙarancin haɗuwa tare da yatsun walda.
Welding kai tsaye a kan rufi ya kasance babban alhaki na tsari. Dole ne ku kula da layin zinc a matsayin gurɓataccen haɗari a cikin yankin da zafi ya shafa (HAZ). Duk wani ƙoƙari na ƙonawa ta hanyar sutura ba tare da shiri ba zai lalata ƙarfin haɗin gwiwa kuma ya haifar da wuce kima, spatter maras tabbas.
Hatsarin Lafiya da Yarda da Muhalli (OSHA & Matsayin AWS)
Bayan lahani na tsari, tururi zinc yana gabatar da mummunan haɗari na halitta. Lokacin da baka ya buge murfin, yana haifar da lokacin farin ciki, farin zinc oxide hayaki. Shakar wadannan tururi mai guba yana kaiwa kai tsaye zuwa yanayin da ake kira Metal Fume Fever.
Ƙarfe Fume Fever yana haifar da cututtuka masu kama da mura. Ma'aikata akai-akai suna ba da rahoton sanyi mai tsanani, zazzabi mai zafi, tashin zuciya, gajiya, da ɗanɗano mai daɗi a baki. Waɗannan alamomin yawanci suna bugi sa'o'i da yawa bayan motsi ya ƙare. Za su iya hana ma'aikaci gaba ɗaya aiki.
Masana'antar tana riƙe da tatsuniyoyi masu haɗari da yawa game da gubar zinc. Dole ne mu fayyace ainihin ilimin halitta don kare ma'aikata yadda ya kamata.
Na farko, zinc yana da ruwa mai narkewa. Jikin ɗan adam yana metabolizes kuma yana fitar da shi cikin lokaci. Sabanin gubar ko bayyanar chromium hexavalent, shakar zinc oxide baya haifar da tarin ƙarfe mai nauyi na dogon lokaci. Ciwon yana zama mai rauni sosai har tsawon sa'o'i 24 zuwa 48, amma da wuya yana haifar da lalacewa na yau da kullun.
Na biyu, shan madara yana ba da kariyar halitta sifili daga shakar zinc oxide. Wannan ya ci gaba a matsayin tatsuniya mai yaɗuwar kanti. Madara tana zuwa ciki. Fushi yana zuwa huhu. Dogaro da madara a matsayin tsarin tsaro yana sanya masu aiki cikin haɗari kai tsaye.
Tsananin bin ƙa'idodin OSHA da ka'idojin ANSI/ASC Z-49.1 yana tabbatar da yanayin aiki mai aminci. Dole ne ku aiwatar da sarrafa injiniyoyi da ingantaccen kayan kariya na sirri.
Cire Tushen: Sanya iskar shaye-shaye kai tsaye a yankin walda. Masu fitar da hayaki dole ne su cire hayakin daga yankin numfashi na ma'aikacin.
Kariyar Numfashi: Masu aiki dole ne su sa na'urorin numfashi na rabin abin rufe fuska wanda aka sanye da matatun P100 HEPA.
Advanced Systems: Don rufaffiyar wurare ko ci gaba da samarwa, umurci yin amfani da Powered Air-Purifying Respirators (PAPR) hadedde a cikin walda kwalkwali.
Gabaɗaya Samun iska: Tabbatar da musanyen iska na kantuna sun haɗu da mafi ƙarancin maƙasudin amincin muhalli.
Pre-Weld Preparation: Dokokin '1-4 inch'
Shirye-shiryen shimfidar wuri yana nuna babban nasarar haɗin gwiwa. Ƙungiyar Welding ta Amurka ta zayyana tsauraran jagorori ƙarƙashin AWS D-19.0 don shirya karafa masu rufi. Ma'auni na hukuma yana buƙatar masu aiki su cire murfin zinc 1 zuwa 4 inci (ƙananan 10-25mm) daga ɓangarorin biyu na haɗin haɗin walda da aka yi niyya.
Kuna da hanyoyi biyu na farko don share sutura. Kowace hanya tana ɗaukar takamaiman fa'idodi da iyakancewa.
Cire Injini (wanda aka zaɓa): Yi amfani da diski mai niƙa mai wuya ko dabaran murɗa. Nika haɗin gwiwa zuwa ƙasa mai haske, mara ƙarfe. Wannan hanyar tana da sauri kuma tana da tasiri sosai. Koyaya, yarda da haɗarin aiwatarwa. Ko da niƙa mai ƙarfi sau da yawa yakan bar abin da ba a iya gani ba na zinc a cikin saman ƙarfe.
Cire Sinadari: Yi amfani da sinadari kamar muriatic acid hade da farin vinegar. Wannan yana cire zinc ɗin da tsafta ba tare da cire ƙarfen tushe ba. Dole ne ku yi aiki mai tsauri daga baya. Rashin kurkura da kawar da acid nan da nan yana haifar da tsatsawar walƙiya mai sauri akan ƙarfe da aka fallasa.
Sikeli yana nuna dabarun shirye-shiryen ku. Gudanar da manyan ci gaba da gudana daga a galvanized karfe coil sau da yawa yana buƙatar goga na inji mai sarrafa kansa ko dumama shigar da ƙara kafin tashar walda. Sabanin haka, ƙirƙira al'ada akan guda ɗaya galvanized karfe takardar yawanci sa manual kada-faifai nika mafi tsada-tasiri da kuma m zabi.
Ƙimar Tsarin walda don Kayayyakin Galvanized
Cire rufin da kyau ba shi da wuya a samu a yanayin filin. Zinc ɗin da ba a iya gani ba yakan wanzu. Don haka, dole ne ka zaɓi tsarin walda wanda zai iya jure ƙananan gurɓatawa.
Tsarin walda |
Gano Haƙurin Zinc |
Abubuwan da aka Shawarar |
Dace da aikace-aikace |
FCAW (Flux-Cored) |
Babban |
Garkuwa biyu ko waya mai kariya |
Tsari mai nauyi, aikin filin waje |
SMAW (Stick) |
Babban |
E7018 low-hydrogen lantarki |
Kulawa, sassa masu kauri |
GMAW (MIG) |
Matsakaici |
ER70S-6 m waya |
High-gudun samarwa, bakin ciki zanen gado |
GTAW (TIG) |
Sifili |
N/A |
Karya sosai |
FCAW (Flux-Cored) & SMAW (Stick): Waɗannan matakan suna nuna babban juriya don gano zinc. Ma'aikatan motsi da aka gina a cikin na'urorin lantarki suna yin tururi da sauri a cikin narkakken tafkin. Suna ƙwace kududdufi da ƙarfi, suna ɗaga ƙazanta da iskar gas ɗin da suka kama su a cikin tudu. Don ayyukan SMAW, injiniyoyi suna ba da shawarar E7018 ƙananan lantarki na lantarki. Suna samar da ƙwaƙƙwaran walƙiya mai ƙarfi ko da lokacin da ragowar raƙuman sutura suka ragu.
GMAW (MIG): MIG waya mai ƙarfi yana ba da kyakkyawan saurin samarwa. Yana aiki musamman da kyau akan bakin ciki galvanized karfe takardar majalisai. Koyaya, MIG bashi da wakilai masu jujjuyawa masu aiki. Yana buƙatar sarrafawa mai tsauri. Dole ne ku yi amfani da dabarun shigar da ƙananan zafi kamar gajeriyar kewayawa ko canja wurin fesa. Yi amfani da waya ta ER70S-6 koyaushe. Silicone da manganese da aka ƙara a cikin ER70S-6 suna aiki azaman deoxidizers, suna taimakawa wajen daidaita ƙwanƙwasa da yaƙi da porosity na ciki.
GTAW (TIG) - Yankin Warewa: Kwarewar filin yana tabbatar da TIG yana aiki kamar mafarki mai ban tsoro akan waɗannan kayan. Lantarki na tungsten mara amfani yana buƙatar cikakken tsabta. Yana zama nan take ya gurɓata ta kowane alamar zinc da aka rasa yayin shiri. Arc zai tofa, yawo, kuma a ƙarshe zai mutu. Cire TIG daga ayyukanku gaba ɗaya sai dai idan kun yi aiki akan ƙarancin ƙarfe 100% tabbatacce.
Tabbacin Ingancin Haɗin gwiwa da Maidowa Bayan-Weld
Masu ƙirƙira da yawa suna damuwa game da dorewar amincin waɗannan taro. Suna tambayar idan kayan kaddarorin sun lalace yayin zagayowar thermal.
Ƙungiyar Bincike ta Zinc ta Duniya (ILZRO) ta gudanar da gwaje-gwaje na jiki mai yawa akan waɗannan gidajen abinci. Kaddarorin injina sun kasance gaba ɗaya m. Bayanan ILZRO yana tabbatar da haɗin gwiwar galvanized ɗin da aka welded da kyau suna nuna daidaitaccen ƙarfin ƙarfi, lanƙwasa radi, da aikin tasiri idan aka kwatanta da tarukan ƙarfe marasa rufi.
Duk da haka, ƙananan ƙananan ƙwayoyin cuta sau da yawa yakan ci gaba. Kuna iya rama gajiyar porosity ta amfani da dabarun injiniya masu wayo. Don haɗin gwiwa da ke fuskantar matsanancin nauyin gajiyar zagayowar, injiniyoyi akai-akai suna ƙayyadad da ''mafi girman walda''.'Yan ƙara girman walda na fillet ɗin yana daidaita ƙarar da ta ɓace zuwa ƙaramin porosity. Wannan haɓakar jiki yana rage yawan ƙarfin damuwa gaba ɗaya. Yana hana mai shigar da sinadarin zinc da ke shiga tsakani daga yaduwa ta tushen.
A ƙarshe, niƙa da waldawa suna lalata shingen hadaya. Dole ne ku aiwatar da kariyar lalata bayan walda don hana saurin tsatsawar yanayi. Ƙayyade ƙaƙƙarfan bin ƙa'idodin ASTM A780 don maido da kariyar Layer.
Ƙayyade amfani da fenti mai arzikin zinc, wanda aka fi sani da sanyi galvanizing spray. Aiwatar da wannan sosai akan HAZ da duk wuraren ƙasa. Tabbatar bushewar fim ɗin busassun ya yi daidai da shimfidar zafi-tsoma da ke kewaye. Ga manyan membobin tsarin, thermal metallizing (zinc spraying) yana ba da ingantaccen haɗin masana'anta. Biyan ASTM A780 yana tabbatar da sabon haɗin gwiwa da aka yi wa welded ya cimma daidaiton rayuwar rayuwa tare da ainihin murfin tsomawa.
Kammalawa
Walda waɗannan allunan kariyar gaba ɗaya mai yiwuwa ne don aikace-aikacen tsari da masana'antu. Dole ne ku kusanci shi azaman tsari mai ƙarfi maimakon gajeriyar hanyar walda kai tsaye. Tsallake matakan shirye-shirye suna yin illa ga amincin gini da amincin ɗan adam. Ɗaukar lokaci don tsige haɗin gwiwa yana tabbatar da shiga mai zurfi, arcs barga, da ingantaccen aikin injiniya.
Don inganta sakamakon ƙirƙira, ɗauki waɗannan matakai na gaba nan take:
Bincika kayan aikin fitar da hayaki na gida na yanzu don tabbatar da isassun saurin kamawa.
Sabunta WPS ɗinku (Ƙa'idodin Tsarin Welding) don nuna a sarari 1 zuwa 4 inch nesa na cire zinc.
Daidaita abubuwan da ake amfani da su bayan walda don daidaita daidai da buƙatun kaurin fim ɗin busasshen ASTM A780.
Canza aikace-aikace masu mahimmanci daga TIG da aiwatar da FCAW mai garkuwoyi biyu ko ƙwanƙwasa MIG don mafi kyawun haƙuri.
FAQ
Q: Shin waldi galvanized karfe raunana karfe?
A: A'a. Lokacin da aka shirya daidai, ƙarfin tauri da taurin karaya sun kasance iri ɗaya da ƙarfe mara rufi. Cire Layer zinc kafin bugun baka yana tabbatar da shigar da ya dace kuma yana hana manyan lahani na tsari.
Tambaya: Zan iya shan madara don hana zazzabin hayaƙin ƙarfe?
A: Babu shakka. Madara ba ta da kariyar numfashi. Yana shiga cikin fili na narkewa, yana ba da kariya ga huhu. Cire tushen tushen kawai da PPE daidai (kamar P100 respirators) suna hana bayyanar haɗari ga zinc oxide.
Q: Zan iya amfani da TIG don walda galvanized karfe?
A: Yana da sanyin gwiwa. TIG yana buƙatar wuri mai tsabta na musamman. Ko da ragowar zinc da aka bari bayan niƙa mai ƙarfi zai gurɓata lantarki ta tungsten sosai, yana haifar da baka ta yawo, tofa, kuma a ƙarshe ta gaza.
Tambaya: Yaya nisa nake buƙatar niƙa galvanizing kafin walda?
A: Matsayin masana'antu (kamar AWS D-19.0) suna ba da shawarar share inci 1 zuwa 4 daga yankin walda. Wannan mahimmin buffer yana hana zafin yanayi daga turɓayar da zinc ɗin da ke kewaye da shi da kuma ja shi cikin narkakken tafkin walda.
