ford-magna热处理培训中文本.doc

Heat Treat Presentation热处理介绍Young KimSTA Heat Treat Process Specialist供应商支持-热处理工艺专家Ford Motor Company福特汽车公司The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Heat Treat Expert (?)热处理行家？You will 你会Understand the fundamentals of Heat Treating 懂得热处理的基本原理Gain an appreciation for the problems/challenges faced by the Heat Treater 获得正确评价热处理问题及面对来自热处理供应商的挑战Learn the language of heat treating了解到热处理的专业术语You will not 你不会Become an expert in heat treating today 今天就变成热处理行家Learn in one (1) day what it takes a lifetime to learn in the heat treating industry 在一天的时间内学习到要在热处理行业花费一生的精力所得到的认识use for any purpose other t Content of Heat Treat Presentation;热处理介绍的内容Section 1: Heat Treat Performance of NA (15 minutes) 第1节 热处理性能不好的危害Section 2: Heat Treat Standard (30 minutes) 第2节 热处理标准Section 3: Technical Training (2.5 hours) 第3节 工艺培训 The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited“4Section 1: Heat Treat Performance of NA 不适当的热处理性能Improper heat treat could lead to Field Action or stop shipment 不适当的热处理会导致招回和停运Customer Perception for quality (Market Share) 顾客对质量的感觉（市场占有率）Cost 成本How can we prevent potential Heat Treat Problems? 怎样预防潜在的热处理问题？Robust heat treat design 可靠的热处理设计Material Selection 材料选择Part configuration 零件结构Select proper heat treat process 选择适当的热处理工艺过程Robust Heat treat Process (Suppliers/Sub-Suppliers) 可靠的热处理工艺过程（供应商/分供应商）Conduct Heat Treat System Survey 实施热处理调查评估Conform to Global W-HTX document 对照与W-HTX文件的符合程度Identify Safety/Critical parts for new MY Programs 对于新的MY计划项目识别安全/关键的零件Manage heat treat process changes (SREA) 管理热处理过程变化点Heat Treat PV test & PSW cont-热处理工艺过程验证及零件提交保证书n is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Section 2: Heat Treat System Survey and Standard 热处理体系评估和标准Ford Heat Treat System Survey (2000) 福特热处理评估（2000）Global W-HTX document Revision date (2006) 全球W-HTX文件规范-2006修订版AIAG Heat Treat Assessment Document (2Nd Quarter of 2006)2 AIAG汽车行业行动小组热处理评估文件规范0The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Ford Heat Treat System Survey and Hydrogen Embrittlement (WSS -M99A3) 福特热处理体系评估和氢脆htssHTSS.doc 热处理体系评估文件规范Heat Treat SpecWSS-M99A3-A.pdf 工程材料规范The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this When do you perform a Heat Treat System Survey? 什么时候要进行热处理体系评估？New heat treat Suppliers 新的热处理供应商New heat treat equipment or re-location 新的热处理设备或重新布局New Program (Part specific audit) 新的热处理作业程序（零件细节审核）Follow up survey, when score was not satisfaction 当评价得分不满意时继续强化热处理评估改进Audit/training at heat treat site for 1st Tier Suppliers. 对第一级热处理供应商在热处理现场进行审核/培训Any special request by PD/Purchasing任何来自PD产品设计师/采购方的特殊要求Global W-HTX Heat Treat Requirements 全球W-HTX热处理要求规范Heat Treat SpecWHTX 9200398.pdf(Revision Date: 1996) 热处理过程及辅助设备Heat Treat Specfinalwhtx.doc (Revision Date: 2006)The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Other HT Process Standards 其它热处理过程标准F:Heat Treat SpecWHT2-8 9200158.pdf 淬火及回火规范F:Heat Treat SpecWHT4-1 9200314.pdf 渗碳及淬火规范F:Heat Treat SpecWHT4-2 9200317.pdf 碳氮共渗及淬火规范New Initiative: AIAG Heat Treat Assessment 新的初始版本：AIAG汽车行业行动小组热处理评估AutoTechrevision 082505.ppt 汽车工艺技术修订本 AIAG Heat Treat Assessment Document AIAG汽车行业行动小组热处理评估文件规范CQI - 9 HTmerged2-7-06.pdf 热处理体系评估合订本Section 3: Technical Training (Material and Heat Treat Processes) 工艺培训（材料和热处理工艺过程）What is Heat Treating? 什么叫热处理？Heat Treatment is the controlled application of time and temperature to produce a predictable change in the internal structure of a material d 热处理是通过对时间和温度的控制运用来在材料的内部结构组织方面产生可预见的变化A highly manipulative manufacturing process 一个操作控制要求非常高的制造工艺过程Heat treating can alter the (mechanical, physical, metallurgical) properties of material and thus influence the end product 热处理能改变材料的特性性能（机械的，物理的，冶金学的），并且因此影响最终的结果Why Iron? 什么是铁？Iron has the ability to combine with many other elements and these elements are capable of changing the properties of iron 铁具有与很多其它元素结合的能力，这些元素能够改变铁的性能Adding carbon, and sometimes manganese produce STEEL 添加碳以及有时添加锰元素产生钢 Steel is not only stronger than iron, but the properties of steel can be dramatically changed by heat treating 钢不仅仅是强度高于铁，而且钢的性能能通过热处理发生引人注目的改变 The information contained herein is FAdding carbon to iron has the following general effects 在铁中添加碳具有如下的总的效果：Raising the ultimate strength 提高极限强度Enhancing wear resistance 提高耐磨性Improving the uniformity of hardness 改善硬度的均匀性Lowering the ductility and toughness 降低塑性和韧性The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Property特性Condition处理条件YS (Mpa)屈服强度TS (Mpa)断裂强度Elongation (%) 延伸率Pure Iron纯铁Untreated未处理20031026Steel 钢Untreated 未处理c37968912Steel 钢Heat Treat & Slow cool 热处理缓冷42877310Steel 钢HT & Fast Quenching water 热处理及快速水冷淬火138013801The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Material Designation 材料指定规范10XX Plain carbon steels 普通碳钢（Mn1.0%）11XX11Plain carbon (Resulfurized for machinability) 普通碳钢（添加硫改善切削性能）15XX15Manganese (1.0-2.0%)2 含锰钢40XX Molybdenum (0.20-0.30%) 含钼钢41XX41Chromium (0.40-1.2%), 1Molyl. (0.08-0.25%)含铬0.401.2%，钼0.080.25%43XX Ni (1.65-2.0%) Cr(0.40-0.90), Mo (0.20-0.30) 镍铬钼钢51XX51Cr (0.70 1.2%)铬钢61XX Cr (0.70-1.10%), V (0.10) 铬钒钢86XX86Ni (0.30-0.70%), Cr (0.4-0.85%), Mo (0.08-0.25%)镍铬钼钢92XX92Silicon (1.8-2.20%) 含硅1.82.2%硅锰钢12L14 Contains Lead for machinability 含铅易切削钢10B2110Contains Boron for increased hardenability 含硼提高淬透性钢Europeon 欧洲Steel Designation 材料指定规范DIN Number (Abbreviation) 材料编号（缩写）Example: 16MnCr5 例子：(0.16% Carbon碳, 1.25% Manganese锰)(0.16% Carbon, 1.25% Example: 22CrMoS3-5(0.22% Carbon碳, 0.8% Chrome铬, 0.5% Molybdenum钼), 0The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this “2 1t Iron Carbon Phase Diagram 铁碳相图 n Ir on C ar bo P ha se D ia gr am The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited“22 TTT Diagram 等温转变相图 TT T D ia gr amThe information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this 3Hardenability 淬透性The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Various Types Heat Treat Processes: 不同类型的热处理工艺过程Neutral Hardening in Atmosphere 在保护气氛中的中性淬火Nitriding & Nitrocarburising 氮化及氮碳共渗Annealing 退火Normalizing 正火Carburizing/Carbonitriding 渗碳/碳氮共渗Induction Hardening 感应淬火Aus-Tempering 等温淬火T6 Solution and Aging Process T6铝合金固溶处理及时效工艺过程 Types Heat Treat Processes: 热处理工艺过程类型：Transformation Involved 含组织转变的Neutral Hardening 中性淬火Carburize 渗碳Carbonitride 碳氮共渗Normalize 正火Annealing 退火No transformation Involved 不含组织转变的Nitriding 氮化Stress Relief 去应力退火The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Print Specification: 图纸技术规范表述：The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Material Specification 材料技术规范Type of heat treat process 热处理工艺过程的种类Hardness (Core and Surface) 硬度（心部及表面） -Gauge 硬度标尺 -Location 检测部位Case Depth 硬化层深度-Total Case Depth 总硬化层深度-Effective Case Depth (depth equal to Rc50) 有效硬化层深度（相当于HRC50处的深度）Microstructure 显微组织结构Purpose of heat treatment: 热处理的目的Alter properties of economical grades of steel 经济地改变钢的性能等级Increasing toughness 提高韧性Increasing wear resistance 提高耐磨性Increases fatigue resistance (service life) 提高耐疲劳性能（服役）Softening or removing stresses 软化和去应力处理Improve machinability 改善机加工性能Developing desired properties 获得所需要的性能Homogenization of the microstructure 均匀化显微组织结构The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Example: 举例：Carburizing/Carbonitriding Process: 渗碳/碳氮共渗(Application: High Wear Resistance)（应用：高耐磨性）The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Composition of Typical Carburizing Steel 典型渗碳钢的化学成分SAE 1018 普通碳钢，含碳量0.18%SAE 1117 普通碳钢（添加硫改善切削性能），含碳量0.17%SAE 12L14 含铅易切削钢，含碳量0.15%SAE 3310 镍铬钢，Ni (3.25-3.75%) Cr(1.25-1.75%), C（0.10%）SAE 4320镍铬钼钢Ni (1.65-2.0%) Cr(0.40-0.90%), Mo (0.20-0.30%)，C（0.20%）SAE 5120 铬钢Cr (0.70 1.2%)，C（0.20%）SAE 8620镍铬钼钢Ni 0.30-0.70%, Cr 0.4-0.85%, Mo 0.08-0.25%，C0.20%ACI（Alloy Casting Institute）美国合金铸造学会AISI（AmericanIron and Steel Institute）美国钢铁学会AMS（Aerospace Material Specifications）美国航空航天材料技术规范ANSI（AmericanNational Standards Institute）美国国家标准学会ASM（AmericanSociety for Metals）美国金属学会ASME（AmericanSociety of Mechanical Engineers）美国机械工程师协会ASTM（AmericanSociety for Testing andaterials）美国材料与试验协会AWS（AmericanWelding Society）美国焊接协会SAE（AmericanSociety of Automotive Engineers）美国汽车工程师协会UNS（United Numbering System for etals and Alloys）金属与合金牌号的统一数字系统方案，1974年由ASTM和SAE等团体提出，简称UNS系统，本身不是标准，有时被采用 MIL（Military Specification）美国政府军事规范FED （Federal Specification）美国联邦政府规范Three main operations are: 三个主要的操作是：Austenitizing 奥氏体化Quenching 淬火Tempering 回火The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction Austenitizing: 奥氏体化Heating to a temperature that allow for Austenite to form and carbon to dissolve (Fe C Diagram) T 加热到一个温度以便奥氏体形成和碳的溶解（Fe-C相图）Quenching: 淬火Control the cooling rate to achieve transformation of Austenite to Martensite and therefore maximum hardness (TTT Diagram)控制冷却的速率以实现奥氏体向马氏体的转变从而获得最高的硬度（TTT相图）Caution: High alloy steels require slower cooling rates and therefore less size and shape changes i注意：高合金钢需要较低的冷却速率以获得较小的尺寸和形状变化Tempering: 回火Tempering is accomplished in the temperature range of 300-1200 degree F 回火是在3001200F的温度范围内完成的（150650）Tempering times average are 2 hours by inch of thickness 回火时间每英寸厚度平均为2小时Hardness decrease with increasing tempering temperature 随着回火温度的升高，硬度降低Toughness increase with increasing tempering temperature 随着回火温度的升高，韧性提高Primary purpose is to enhance ductility (toughness) of t 回火的主要目的是提高塑性（韧性）he information, and use for any purpose other than the conduct of business with Ford is expressly prohibited34Carburizing/Carbonitriding: 渗碳/碳氮共渗closure of the information, and use for any purpose other than the conduct of business with Ford iProcesses designed to add carbon and nitrogen 以增加碳和氮的工艺过程Generally used on low carbon (1020) or low carbon alloy steels(8620,4320) 一般用于低碳（1020）或者低碳合金钢（8620，4320）Used to increase the surface hardness of the steel and also improve wear resistance f用于提高钢的表面硬度同时提高耐磨性 Atmosphere Carburizing: i保护气氛渗碳n contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information Gas Carburizing is most often done in the temperature range of 1550F to 1750F 气体渗碳大都是在15501750F（840950）温度范围内完成的Lower Carburizing temperatures are used for better case depth uniformity and where distortion is a concern 较低的渗碳温度大多是用于更佳的层深均匀一致性及关注变形的场合Higher Carburizing temperatures are used to shorten overall heat treat cycle times 较高渗碳温度大多是用于缩短整个热处理周期的时间The nominal carrier gas composition created from either an Endothermic gas generator or from Nitrogen/Methanol is approximately: 不管是吸热式气体发生器或者是氮气/甲醇所产生的名义上的气体组成成分都是近似的：-40% Nitrogen(N2) 氮气-40% Hydrogen(H2) 氢气-20% Carbon Monoxide(CO) 一氧化碳eThe equation is THE WATER GAS RECTION: 反应的平衡等式是著名的水煤气反应等式 CO+H2O=CO2+H2 Dew Point looks at H2O/H2 ratio 露点是着眼于H2O/H2的所占比率Infrared or Oxygen Probe looks at the CO/CO2 ratio 红外分析仪或者氧探头是着眼于气氛中的CO/CO2的所占比率Key Product Charactristics for Carburizing Process: 渗碳工艺过程关键的产品特性参数：As quenched hardness 淬火的硬度Tempering hardness 回火的硬度Microstructure Evaluation 显微组织结构评价Case Depth Measurement 层深的测量Tolerance or Distortion (if applicable) 尺寸公差或者变形（如果要求）Verify load rate 核实装炉量 Time at Austeniting Temperature 奥氏体化时的时间Time to Quench 到淬火的时间Quench Oil Temperature 淬火油温度Atmosphere Control 气氛控制Tempering Temperature and Time 回火的温度和时间The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this W-HTX 1.3: Process Specification 工艺规范 The supplier shall establish a written process specification (complete with a control plan) for all processes used to heat treat parts supplied directly or indirectly to the Ford. 热处理供应商必须建立一个零件热处理相关的所有工艺过程的书面的工艺过程规范（连同一个控制计划）直接地或间接地提交给FORDExample: Quenching and Temper Process: (Application: Fasteners) 例子：淬火及回火工艺：（应用：紧固件）The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Composition of Typical Carburizing Steel 典型渗碳钢的成分：SAE 1030SAE 5140SAE 4130SAE 86300.30 0.40 % Carbon contentThe information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Incoming Material: 材料纳入：Spheriodizing (Annealing Process to improve formability during cold heading) 球化处理（用于改善冷镦时可成形性能）Decarburization 脱碳Carbon Restore 复碳Set Point of carbon potential: Slightly higher 碳势设定点：略高于材料含碳量Verification of carbon potential 碳势的校验Depth of decarburization (Time) 脱碳的深度（时间）Hardness (Less than 2 points between core and surface) 硬度（在心部及表面少于2点）rein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Cold Heading Process: 冷镦工艺过程：Metal Movement (Grain Flow) 金属的移动（晶粒流线） Die Set Up 模具装配安装Annealing Process 退火工艺Neutral Atmosphere: 中性保护气氛：Cleanliness of part before heat treat 零件热处理前的清洁度Carbon Potential is set for same as carbon content of the material 碳势设定与材料的碳含量一样Example: set for 0.30 % for SAE 1030 如：对于SAE1030碳势设定为0.30%4Equipment: 设备：Continuous Furnace: 连续炉Wash 清洗Loading 装料进料Each zone temperature 各区温度Temperature chart 温度记录图表Verification of Carbon Potential碳势的校验Non-contact infrared thermometry 非接触红外温度计Quenching temperature & Agitation 淬火时温度及搅拌Wash 清洗Tempering temperature & Time 回火温度及时间The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Product Characteristics: 产品特性参数Hardness 硬度Typical Spec: Rc 33-39 or 32-38 典型规范：HRC3339或3238Quenched Hardness 淬火后的硬度Hardness after Tempering (Same between surface and core) 回火后的硬度（心部与表面之间的硬度相同）Tensile Strength 抗拉强度Microstructure 显微组织The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Fords Global Information Standard II. Reproduction of this Plating & Coating: 电镀或涂层覆盖Hydrogen Embrittlement (WSS-M99A3) 氢致氢脆Hardness 硬度Stress 应力Acid Cleaning 酸洗Baking Process 烘焙工艺Thermocouple to oven temperature 烘箱温度的热电偶Thermocouple to actual part 实际零件的热电偶Min. time 1 hour at target temperature 在目标温度最短时间1小时The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in F