Views: 0 Author: Site Editor Publish Time: 2025-01-29 Origin: Site
Before starting the iPress - 1M Manual Metallographic Mounting Press, it is of utmost importance to comprehensively and thoroughly study all relevant safety regulations. Strictly adhering to these guidelines is the core element to ensure the smooth progress of the operation process, as well as to safeguard the safety of personnel and the integrity of the equipment. There should be no room for any slack. Next, please strictly follow the following professional steps for standardized operation: Pre - operation Preparation: First, select a workbench with sufficient rigidity and stability. Its natural frequency should be kept quite different from the vibration frequency of the iPress - 1M during operation to effectively avoid the influence of resonance phenomena on the mounting accuracy. Place the iPress - 1M firmly on the workbench. Conduct a comprehensive inspection of the sample to be mounted. Use a surface roughness tester and an electron microscope to preliminarily detect the surface roughness and microstructure of the sample. If there are contaminants on the surface, such as dust, oil stains, or oxide layers, use anhydrous ethanol in combination with an ultrasonic cleaning device for deep cleaning to ensure that the surface cleanliness of the sample meets the requirements of the mounting process. According to the geometric shape, dimensional tolerance, and material characteristics of the sample, select a suitable fixture from the supporting series of fixtures specifically designed for iPress - 1M. By using the six - point positioning principle, through high - precision bolts or magnetic adsorption devices, firmly fix the sample on the workbench of the iPress - 1M to ensure that the sample has no displacement or deformation during the mounting process, thus guaranteeing the consistency and accuracy of the mounting. Prepare Mounting Materials: Open the material placement area of the iPress - 1M. Based on the hardness, chemical stability of the sample, and subsequent analysis requirements, accurately select appropriate mounting materials. For samples with high hardness and high - temperature resistance, phenolic resin can be selected as the mounting material, which has good thermal stability and mechanical strength. For samples with soft texture and high requirements for chemical stability, epoxy resin is a more ideal choice, as it has a low shrinkage rate after curing and good sealing performance. At the same time, prepare the matching curing agent. Strictly according to the stoichiometric ratio specified in the iPress - 1M product manual, use an electronic balance to accurately weigh the mounting material and the curing agent. Subsequently, use a mechanical stirrer or a magnetic stirrer for thorough stirring. The stirring time and rotation speed need to be adjusted according to the material characteristics to ensure that the two materials are evenly mixed to form a uniform and stable system. If the mixing is uneven, it will lead to inconsistent internal structures of the mounted body, affecting subsequent metallographic analysis. Debug the iPress - 1M: Connect the power supply of the iPress - 1M and press the start button. Under the no - load operation state of the equipment, use a vibration monitor and a sound sensor to closely monitor the operation of all components of the iPress - 1M to ensure that the vibration amplitude and sound frequency are within the normal range. According to the size, shape of the sample, and the thermal expansion coefficient of the material, refer to the parameter recommendation table in the iPress - 1M operation manual to accurately adjust the pressure and temperature of the iPress - 1M. Generally, the pressure range is controlled between 5 - 10MPa, and the temperature range is set between 150 - 180℃. For samples with larger sizes and higher thermal expansion coefficients, the pressure can be appropriately increased to 8 - 12MPa, and the temperature can be raised to 160 - 190℃. For samples with smaller sizes and lower thermal expansion coefficients, the pressure can be reduced to 3 - 7MPa, and the temperature can be decreased to 140 - 160℃. During the adjustment process, it is necessary to ensure the stability of the pressure and temperature and avoid significant fluctuations. Start Mounting: After the iPress - 1M is debugged and the sample is firmly fixed, start the mounting operation. Slowly pour the evenly mixed mounting material into the mounting mold, and the pouring amount is about half of the mold volume to reserve enough space to accommodate the sample and prevent the mounting material from overflowing. Then, carefully place the fixed sample into the mold to ensure that the sample is at the center of the mold and is completely and evenly wrapped by the mounting material. Next, place the mold on the workbench of the iPress - 1M, and through the positioning device unique to iPress - 1M, accurately adjust the position of the mold to ensure that the mold is perpendicular and concentric with the pressure - applying direction of the iPress - 1M. Press the mounting button. During the mounting process, use a pressure sensor and a temperature sensor to monitor the pressure and temperature changes of the iPress - 1M in real - time. If the pressure deviation exceeds ±5% of the set value and the temperature fluctuation exceeds ±10℃, immediately stop the operation, check the iPress - 1M equipment and process parameters, and continue after troubleshooting. Cooling and Demoulding: After the mounting is completed, to avoid cracks or internal stress concentration in the mounted body due to a sudden drop in temperature, it is necessary to cool slowly according to the preset cooling curve. The cooling method can be natural cooling or cooling in a specific cooling device. The cooling time depends on the size and material characteristics of the mounted body, generally ranging from 30 - 60 minutes. After the temperature drops to room temperature, use special demoulding tools, such as a release agent in combination with a mechanical ejection device, to carefully remove the mounted sample from the mold. During the demoulding process, pay attention to controlling the force and direction to avoid damaging the sample and the mounted body. Inspection and Cleaning: After taking out the mounted sample, use detection equipment such as a metallographic microscope and a hardness tester to comprehensively detect the firmness, surface flatness, hardness distribution, and internal microstructure of the mounted body. If defects such as looseness, uneven surface, uneven hardness, or internal pores and cracks are found in the mounted body, it is necessary to adjust the mounting parameters, such as material ratio, pressure, temperature, etc., according to the specific situation, and re - perform the mounting operation. After the inspection is completed, use special cleaning agents and tools suitable for iPress - 1M to clean the remaining mounting material inside the iPress - 1M. Wipe the working area and the equipment shell with alcohol to remove oil stains and impurities. Turn off the power supply of the iPress - 1M, return the operation handles, control buttons, and other components of the equipment to their initial states, and regularly conduct a comprehensive maintenance of the iPress - 1M, including checking the wear of transmission components, the performance of the heating system, and the safety of the electrical system to ensure that the iPress - 1M is always in good operating condition. |