A cikin hanzarin faɗaɗa sabbin nau'ikan batirin abin hawa makamashi, tsarin ajiyar makamashi na hotovoltaic, da ultra{0}} babban ƙarfin watsa wutar lantarki,Polymer Diffusion Welding(sau da yawa ana kiransa kawai da Watsawa Welding a cikin wannan mahallin) ya zama fasaha mai mahimmanci don cimma matakin haɗin gwiwar kwayoyin halitta{0}} a cikin bassan bas masu sassauƙa na bas ɗin bas. Wannan tsari yana amfani da babban zafin jiki da matsa lamba don haɓaka tsaka-tsakin atomic{2}}watsawa, samar da haɗin gwiwa tare da ƙarancin juriya na lantarki da ƙarfin injina.
Duk da haka, "Rashin Fusion" (LOF) -inda keɓancewar hanyar walda ba ta da isasshiyar haɗin kai{1}} shine babban ƙuncin fasaha na gama gari ga masana'antun da yawa. Wannan lahani ba wai kawai yana ƙara juriya da samar da zafi a cikin mai haɗawa ba amma kuma yana iya haifar da gazawa a ƙarƙashin girgiza, mai yuwuwar haifar da haɗari mai tsanani na tsarin wutar lantarki. Wannan labarin yana ba da bincike mai zurfi na - abubuwan da ke haifar da LOF kuma yana ba da ƙididdiga, dabarun ingantawa.
A cikin -Bincike mai zurfi: Me yasa Yaduwa Weld ɗinku ke fama da "Rashin Fusion"?
Ma'anar walda mai yaduwa ya dogara da makamashin zafi da matsa lamba don kawo saman biyu tsakanin kewayon jan hankali na atomic. Rashin Fusion yawanci yana faruwa ne lokacin da "shigarwar kuzari" ko "tuntuɓar jiki" yayin aikin walda ya kasa cimma mahimmin ƙima.
1. Rashin daidaituwar Input Makamashi: "Mafi ƙarancin haɗin gwiwa" na Zazzabi da Lokaci
Yanayin walda shine farkon direba don yaduwar atomic. Gabaɗaya, dole ne a saita zafin walda ɗin watsawa tsakanin sau 0.5 zuwa 0.8 madaidaicin wurin narkewa ($T_m$) na kayan tushe (a cikin Kelvin). Idan yanayin zafi ya yi ƙasa sosai, makamashin atom ɗin bai isa ya shawo kan shingen makamashi na tsaka-tsaki ba.
Bugu da ƙari, lagwar haɓakar thermal shine babban dalilin LOF a cikin kayan aiki mai kauri. Misali, lokacin walda bas mai kauri mai kauri wanda ya kunshi yadudduka 100 na foil na jan karfe 0.1mm, idan lokacin walda ya yi guntu, zafi na iya shiga cikin yadudduka na waje kawai. Wannan yana haifar da babban yankin ya kasa kaiwa ga zafin da ake buƙata, yanayin yanayin "wanda aka fi dafawa a waje, ba a dafa shi a ciki".
2. Matsalolin Jiki: Ganuwar Ganuwa na Fina-Finan Oxide da Machining Precision.
Duk da yake watsa walda a cikin yanayin iska, ta amfani da hanyar dumama ta musamman, tana hana iskar shaka mai tsanani, fina-finan oxide da ke wanzuwa a saman kayan (kamar $ Al_2O_3 $ akan foil na aluminum) suna da maki narke sosai. Idan matsa lamba bai isa ya murkushe wannan fim ba a yanayin zafi mai zafi, yana aiki azaman shinge mai rufewa, yana hana haɗin gwiwar ƙwayoyin cuta. A lokaci guda, idan shimfiɗar saman da za a walda ba ta da kyau (rauni ya zarce 0.1mm), ainihin wurin tuntuɓar zai zama ƙanƙanta fiye da yankin da ba a sani ba, wanda zai haifar da ɓarna a cikin wuraren da ba -.
Magani Masu Aiki: Hanya Biyar-Hanyar Inganta Mataki don Kawar da Lalacewar Welding
Don magance matsalar LOF, kamfanoni kada su dogara ga ƙarar sigogi a makance amma a kafa tsarin kimiyya, rufaffiyar tsarin inganta madauki{0}.
1. Madaidaicin Sarrafar Zazzabi: Ƙirƙirar Abun -Takamaiman "Matrix Temperatuur"
Kayayyaki daban-daban suna da yanayin zafin jiki daban-daban. Lokacin daidaita waldar watsawa, ana ba da shawarar a bi waɗannan ƙayyadaddun ƙa'idodi don inganta lokaci:
| Yanayin aikace-aikace | Shawarwari Temp. Rage ($^\\circ$C) | Rage Matsi (MPa) | Mabuɗin Tsari Dabaru |
| Aluminum Foil Flex Busbar (0.1mm x 50 yadudduka) | 480 - 540 | 5 - 8 | Mayar da hankali kan saurin hawan zafin jiki don rage iskar oxygen. |
| Busbar Busbar Foil Flex (0.1mm x 100 yadudduka) | 550 - 620 | 10 - 15 | Yana buƙatar matakin preheating don tabbatar da shigar ainihin ciki. |
| Copper -Haɗuwa da Bambancin Aluminum | 500 - 580 | 8 - 12 | Tsananin sarrafa lokaci don hana samuwar mahadi intermetallic gaggautsa. |
2. Gudanar da Matsi: Abubuwan da ake buƙata na jiki don tuntuɓar kwayoyin halitta
Ba wai kawai ana amfani da matsa lamba don matsa kayan aikin ba amma, mafi mahimmanci, don haifar da gurɓataccen gurɓataccen filastik, yana tabbatar da kusancin kusanci tsakanin saman. Idan LOF na gida ya faru, ya kamata a bincika daidaitattun abubuwan da suka mutu (molds). Ana ba da shawarar yin amfani da matsa lamba -fim mai hankali don gwada rarrabawar matsa lamba, tabbatar da cewa ana sarrafa cikakken{3}} jujjuyawar jirgin sama a cikin $\\pm 10%$. Ƙara matsa lamba zuwa 12-15 MPa na iya inganta LOF mai mahimmanci wanda ya haifar da rashin isasshen shimfidar wuri, amma dole ne a kula da shi don hana lalacewar extrusion mai yawa a gefuna na workpiece.
3. Tsarkakewar Sama: Tsaftace Tsaftace Tsarin Tsabtace Bayan Sauƙaƙe Shafa
Don manyan motocin bus ɗin ajiyar makamashi mai ƙarfi{0}, shafaffen barasa mai sauƙi na iya rashin isa don cire mai da mai mai zurfi{1}}. Ana ba da shawarar gabatar da tsarin tsinke acid ko tsarin tsabtace plasma don cire yadudduka na oxide tare da kauri wanda ya wuce 10nm. Bayanan gwaji sun nuna cewa kayan aikin da aka yiwa zurfin tsaftacewa na iya samun haɓakar ƙarfin ƙarfi sama da 20% a ƙarƙashin sigogin walda iri ɗaya.
Nazarin Harka da Aka Yi Niyya: Aikace-aikace daban-daban a cikin Sabbin Makamashi da Masana'antu na Wuta
1. Aluminum Foil Flex Busbars don Batir EV: Ƙananan -Matsi, Mai sauri{2}} Dabarar Weld
A cikin nau'ikan baturi na EV, foil na aluminum yana da saurin kamuwa da iskar shaka kuma yana da ƙarancin narkewa. Makullin warware LOF shine sauri. Ta hanyar haɓaka saurin amsawar wutar lantarki na walda, ana kammala aikin watsawa kafin fim ɗin oxide yayi kauri sosai. Dabarar ƙananan matsa lamba (5-7 MPa) haɗe tare da ɗan gajeren lokaci (5-15 seconds) yawanci ana aiki dashi.
2. Babban -Bassan Busbar Ƙarfin Wutar Lantarki: Babban -Matsi, Tsayawa{3}}Dabarun Zazzabi
Motocin bas ɗin wuta suna da kauri kuma suna watsa zafi da sauri. Makullin warware LOF shine shiga. Ana ba da shawarar yanayin dumama mataki guda biyu{{2}: na farko, fara zafi a ƙaramin wuta zuwa $300^\\circ$C kuma riƙe tsawon daƙiƙa 20 don rage girman bambancin zafin ciki/ waje. Sa'an nan, da sauri hawan zuwa zafin waldi, haɗe tare da babban matsi na 15 MPa a lokacin riko, don tabbatar da cikakken Fusion na kowane tagulla Layer.
Shawarwari na Saye da Zaɓi: Yadda Ake Zaɓan Ingantacciyar Na'urar Walƙiya Yaduwa
Lokacin zabar ko siyan injin walda, masu amfani yakamata su mai da hankali kan alamun fasaha masu zuwa don rage haɗarin LOF daga hangen nesa na hardware:
- Rufe - Sa ido kan Tsarin Gudanarwa: Shin kayan aikin sun ƙunshi ainihin matsi na lokaci{2}} saka idanu na ƙaura? Ikon yin rikodin ainihin adadin matsar lokaci{3} yayin walda shine mahimmin alama don tantance shigar walda.
- Uniformity Dumama: Nemi game da rarraba zafin jiki na induction coil ko juriya dumama farantin. Na'ura mai inganci ta - yakamata ta tabbatar da bambancin zafin jiki a saman aikin yana tsakanin $\\pm 5^\\circ$C.
- Non{0}}Vacuum Anti{{1}Fasahar Oxidation: Bincika ko kayan aikin suna ba da kariya ta iskar gas na gida ko na musamman na matsi{2} oxidation. Wannan yana da mahimmanci don magance lamuran LOF a cikin waldawar aluminium a cikin yanayin iska.
Kammalawa
Magance Rashin Fusion a cikin waldawar watsawa shine ainihin batun daidaita yanayin zafin jiki, matsa lamba, lokaci, da ingancin saman. Ta hanyar kafa ƙayyadaddun matrix na zafin jiki{1}, haɓaka daidaitattun mutu, da aiwatar da tsarkakewar ƙasa mai zurfi, kamfanoni za su iya kawar da haɗarin walda da haɓaka gasa na samfuran su a cikin sabbin kasuwannin makamashi da wutar lantarki. Lokacin zabar kayan aiki, ba da fifikon samfura tare da saka idanu na bayanai da kuma madaidaicin iyawar sarrafa zafin jiki, saboda wannan zai kafa tushe mai ƙarfi don samarwa ta atomatik na gaba.
