CN115323186B - Process for controlling height of high-temperature alloy vacuum arc remelting ingot crown - Google Patents
Process for controlling height of high-temperature alloy vacuum arc remelting ingot crown Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 47
- 239000000956 alloy Substances 0.000 title claims abstract description 41
- 238000010313 vacuum arc remelting Methods 0.000 title claims abstract description 25
- 229910045601 alloy Inorganic materials 0.000 title claims description 36
- 238000003723 Smelting Methods 0.000 claims abstract description 37
- 229910000601 superalloy Inorganic materials 0.000 claims abstract description 27
- 238000000137 annealing Methods 0.000 claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 8
- 238000007789 sealing Methods 0.000 claims abstract description 6
- 238000012545 processing Methods 0.000 claims abstract description 4
- 238000002844 melting Methods 0.000 claims description 20
- 230000008018 melting Effects 0.000 claims description 20
- 238000001816 cooling Methods 0.000 claims description 16
- 238000010438 heat treatment Methods 0.000 claims description 15
- 239000001307 helium Substances 0.000 claims description 14
- 229910052734 helium Inorganic materials 0.000 claims description 14
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 14
- 238000011049 filling Methods 0.000 claims description 9
- 239000007789 gas Substances 0.000 claims description 7
- 238000007599 discharging Methods 0.000 claims description 6
- 230000003746 surface roughness Effects 0.000 claims description 4
- 238000003466 welding Methods 0.000 claims description 4
- 230000000087 stabilizing effect Effects 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 abstract description 6
- 229910000797 Ultra-high-strength steel Inorganic materials 0.000 abstract description 2
- 238000005266 casting Methods 0.000 abstract 2
- 230000007547 defect Effects 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 241000519995 Stachys sylvatica Species 0.000 description 3
- 238000010891 electric arc Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000005204 segregation Methods 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- 238000005275 alloying Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 206010027146 Melanoderma Diseases 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
- 238000002224 dissection Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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- 230000009897 systematic effect Effects 0.000 description 1
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/16—Remelting metals
- C22B9/20—Arc remelting
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
- C21D1/30—Stress-relieving
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Abstract
The invention belongs to the technical field of high-quality superalloy preparation for aeroengines, and relates to a process for controlling the height of a superalloy vacuum arc remelting ingot crown. The method comprises the steps of high-temperature stress relief annealing of an electrode ingot, processing of the electrode ingot, arc starting stage, stable smelting stage, heat sealing top stage ingot casting process parameter design and the like, and the vacuum consumable remelting superalloy electrode ingot crown prepared by the process is lower than 100mm in average, so that shrinkage cavity of the ingot casting is reduced, material yield is improved, and internal metallurgical quality is excellent. The invention meets the requirement of the engine on the high-quality superalloy, not only can be applied to the vacuum arc remelting preparation of the high-quality superalloy, but also can be used for producing high-alloy materials such as ultrahigh-strength steel and the like, and has wide application prospect.
Description
Technical Field
The invention belongs to the technical field of high-quality superalloy preparation for aeroengines, and relates to a process for controlling the height of a superalloy vacuum arc remelting ingot crown.
Background
The background technology of the patent is advanced smelting technology of high-temperature alloy materials for aeroengines.
Smelting is a key process link in the preparation process of the high-temperature alloy. The vacuum arc remelting is a process for remelting a high-temperature alloy electrode by using a direct current arc as a high-temperature heat source in a vacuum and slag-free environment, wherein metal at the top end of the electrode is melted into molten drops by the high-temperature arc, and the molten drops are sequentially solidified into ingots in a copper water-cooling crystallizer. Along with the progress of industrial technology, the superalloy is widely applied in the fields of aerospace, combustion engines, petrochemical industry, nuclear power and the like, and the size specification of the arc remelting ingot of the deformed superalloy is larger and larger due to the fact that the alloying degree is higher and contains more Nb, mo, al, ti and other easily segregated elements, and the probability of metallurgical defects in the smelting process is increased. The vacuum arc remelting preparation of the high-temperature alloy requires careful control of melting speed and arc length so as to avoid metallurgical defects such as ring lines, spots, white spots and the like, and the arc remelting process is completed in a vacuum environment, so that not only is pollution of air to alloy materials avoided, but also the gas content of the high-temperature alloy and the content of low-melting-point harmful inclusions are reduced, and the purity of the alloy is improved. The metallurgical problems of greatest concern in the wrought superalloy melting process are two types of metallurgical defects, namely "black spots" and "white spots". A consumable ingot with phi 508mm is prepared by changing the diameter of a consumable electrode and an arc gap, and the ingot center corresponding to parameter change is found to be 1/2R part by dissection, so that a large number of black spots are generated, and microscopic tissue analysis shows that the black spots are a mixture of Nb, mo and Ti interdendritic segregation elements and dendrites. The view that the change of the melting speed has an influence on the metallurgical quality is currently common. The thermal field characteristics of the consumable electrode in the consumable alloy remelting process are researched and put forward by combining experimental measurement with numerical simulation, microcracks in the consumable electrode are found to have obvious influence on the alloy melting speed, and the importance of the internal metallurgical quality of the electrode is illustrated.
At present, most engineering technicians in the field of deformation superalloy at home and abroad mainly pay attention to white spot and black spot metallurgical defects in vacuum arc remelting deformation superalloy, rarely pay attention to the control problem of the shape, size and height of the ingot crown at the top of an ingot which is also easy to bring metallurgical defects, and no current process method for controlling the ingot crown of the superalloy vacuum arc remelting ingot is available at home.
The ingot crown refers to a feeding end at the top of a high-temperature alloy vacuum arc remelting ingot, a layer of metal with higher inclusion content, which is formed by the annular periphery close to the inner wall of a crystallizer and is higher than the ingot body, and when the smelting process is poor, the stress of an electrode ingot is high, the voltage fluctuation and the like, the ingot crown with high size and uneven edge can be generated. Excessive crown size can cause metal spalling off the block to the superalloy melt pool, which can easily form metallurgical defects.
The vacuum arc remelting process of the high-temperature alloy can be divided into three stages, namely an arcing stage, a stable smelting stage and a heat-sealing top stage. The heat capping stage is a stage of gradually reducing smelting power to realize ingot feeding and improve yield after the high-temperature alloy is about to be smelted. In the vacuum consumable remelting process, two very important process parameters are melting speed and cooling speed. The former generally requires a suitable "slow" while the latter requires "as fast" as possible. Many studies have been carried out by students at home and abroad. The metallurgical quality of the arc remelting cast ingot is calculated to be related to the temperature field of the alloy which is partially melted in the electrode, and the distribution and melting speed of the temperature field and finally the solidification structure of the cast ingot are seriously influenced by the small change of the consumable current.
Tests and theoretical analysis are combined to prove that the main reasons for forming the ingot crown in the arc remelting process of the wrought superalloy include: (1) crystallizer packing is relatively small. When filling is smaller, the gap between the consumable electrode and the inner wall of the crystallizer is larger, and the periphery of the molten pool is cooled faster in the smelting feeding stage, so that a ingot crown with higher size and thicker size is formed; (2) the current is overlarge and the voltage is smaller; the smelting electric arc is too short, periodic short circuit is easy to generate, so that the temperature of a molten pool is suddenly high and low, the alloy melt is seriously splashed, the surface quality of an ingot is deteriorated, the uniformity of the structure and the components of the ingot is affected, and a crown with higher size and larger thickness is generated. In addition, the raw material gas content is higher, the volatile matters are not thoroughly removed, the fluctuation of a molten pool is large, and a higher ingot crown can be formed. In summary, the reason for the formation of tall crowns in the vacuum arc remelting process for metallic materials is complex.
Through systematic searching of domestic patents and articles, no invention patent related to high-temperature alloy ingot crown size control is referred at present, and the invention has higher innovation and application value.
Disclosure of Invention
The invention aims to:
the invention provides a smelting process for controlling the height of a high-temperature alloy vacuum arc remelting ingot crown, which is mainly used for reducing metallurgical defects in the smelting process of the high-temperature alloy and improving the quality of materials so as to meet the requirements of an aeroengine on high-quality high-temperature alloy materials.
The technical scheme is as follows:
a process for controlling the height of a high-temperature alloy vacuum arc remelting ingot crown comprises the following steps:
step 1, stress relief annealing of a high-temperature alloy electrode ingot;
step 2, processing an electrode ingot; the surface of the high-temperature alloy consumable electrode ingot and the surface of the auxiliary electrode welding ingot are flat, and the surface roughness is less than 6.4 mu m;
step 3, controlling the filling ratio range of the consumable electrode ingot and the crystallizer to be 0.63-0.9, and controlling the unilateral gap control range of the electrode ingot and the inner wall of the crystallizer to be 20-55 mm;
step 4, an arcing stage; the required process parameters are as follows, the melting speed control range: 3 Kg/min-5 Kg/min, voltage range: 15V-30V; arc length range: 25 cm-30 cm;
step 5, stabilizing a smelting stage; the technological parameters are as follows, the melting speed control range is as follows: 2 Kg/min-4 Kg/min, voltage range: 20V-30V; arc length range: 25 cm-30 cm; and cooled by helium gas, helium gas flow rate range: 500Pa to 2000Pa;
step 6, heat-sealing the top; the process parameters are as follows: melting speed control range: 2 Kg/min-3 Kg/min, voltage range: 12V-25V; arc length range: 25 cm-30 cm; helium flow rate range: 300 Pa-1000 Pa;
and 7, after smelting, powering off, cooling and discharging.
Vacuum arc remelting is carried out before stress relief annealing of the high-temperature alloy electrode ingot.
The step 1 stress relief annealing is performed in a heat treatment furnace.
The stress relief annealing treatment in the step 1 comprises the following steps: and (3) feeding the material into a furnace at room temperature, heating to 850-900+/-10 ℃ at a heating rate of 5 ℃/min, preserving the heat for 2 h+/-20 min, and then cooling along with the furnace.
The step 2 auxiliary electrode welding requires that the whole electrode has good flatness and symmetry.
And 2, the coaxiality difference range of the auxiliary electrode axis and the consumable electrode axis in the step is less than or equal to 3mm.
And (3) after the smelting in the step (7) is completed, keeping the vacuum degree in the crystallizer to be 0.1 Pa-5 Pa after power failure.
And 7, cooling the cast ingot in the step to below 300 ℃ and discharging the cast ingot.
The invention has the advantages and effects that:
the invention provides a smelting process for optimizing and controlling the vacuum arc remelting ingot crowns of deformed superalloy, which has important effects of improving the surface quality of superalloy, increasing the yield and reducing the occurrence probability of metallurgical defects.
At present, as the high-temperature alloy has high alloying degree and complex smelting process, the ingot crown size is easy to be excessively high in the smelting process, so that the ingot is stripped off, metallurgical defects are formed in the ingot, and the product quality is affected. The invention solves a technical problem which puzzles the metallurgical quality of the high-temperature alloy. The main innovation points of the invention are as follows: (1) smelting electrode quality requirements. The high-temperature stress relief annealing is carried out on the high-temperature alloy consumable electrode cast ingot, the main purpose is to slowly release internal stress, reduce splashing in the smelting process, and also consider the influence of electrode surface finish, the cast ingot surface roughness after machining is required to be less than 6.4 mu m, and the coaxiality difference range of the auxiliary electrode axis and the consumable electrode axis is less than or equal to 3mm; and (2) designing a low ingot crown smelting process. The invention provides an arcing stage, a melting speed control range: 3 Kg/min-5 Kg/min, voltage range: 15V-30V, arc length range: 25 cm-30 cm; and the melting speed control range in the stable melting stage: 2 Kg/min-4 Kg/min, voltage range: 20V-30V, arc length range: 25 cm-30 cm, and increased helium cooling, helium flow rate range: 500Pa to 2000Pa; in the heat-sealing top stage of the final smelting stage, the smelting voltage is reduced, and developed ingot crowns are avoided. The high-temperature alloy arc remelting cast ingot produced by the process has small height dimension (average height is lower than 100 mm), high material yield and excellent internal metallurgical quality. The invention can be applied to vacuum arc remelting preparation of high-quality superalloy, and can be used for producing high-alloy materials such as ultrahigh-strength steel, and has wide application prospect.
Detailed Description
The invention is further illustrated below in connection with specific examples:
the technical implementation of the invention mainly comprises the following steps:
and step 1, high-temperature stress relief annealing of the electrode ingot. The high-temperature alloy electrode ingot remelted by the vacuum arc is placed into a heat treatment furnace to carry out stress relief annealing treatment, and the main purpose is to reduce the solidification shrinkage stress in the electrode and improve the stability of the smelting process. The adopted annealing system is as follows: feeding the material into a furnace at room temperature, heating to 850 ℃ -900+/-10 ℃ at a heating rate of 5 ℃/min, preserving heat for 2 h+/-20 min, and then cooling along with the furnace;
and 2, processing an electrode ingot. The ingot head of the high-temperature alloy electrode is processed, the surface of the ingot is flat, and after the ingot is welded with the auxiliary electrode, the whole electrode is required to have good flatness and symmetry. Wherein, the coaxiality difference range of the axis of the auxiliary electrode and the axis of the consumable electrode is less than or equal to 3mm, and the surface roughness of the processed consumable electrode cast ingot is less than 6.4 mu m;
and 3, controlling the filling ratio range of the electrode ingot to the crystallizer to be 0.63-0.9, and controlling the unilateral gap control range of the consumable electrode ingot to the inner wall of the crystallizer to be 20-55 mm. The higher filling ratio is favorable for forming a planar solidification front edge on the melted end face of the consumable electrode cast ingot in the remelting process, thinning the electrode end face film to gather molten drops, and strengthening the alloy refining effect. Meanwhile, the high filling ratio can reduce the electricity consumption of ton steel, and is beneficial to optimizing the smelting speed, the component segregation, the cooling speed and other technological parameters, but the excessively high filling ratio is easy to generate side arcs between the cast ingot and the inner wall of the crystallizer (namely, the arcing between the consumable electrode and the inner wall of the crystallizer) so as to influence the normal running of the smelting process;
and 4, an arcing stage. The arcing stage is to generate an electric arc between the consumable electrode and the bottom of the crystallizer to form a metal molten pool with a certain size and depth, and to keep a stable electric arc between the consumable electrode and the molten pool so as to prepare for a stable smelting stage. The required process parameters are as follows, the melting speed control range: 3 Kg/min-5 Kg/min, voltage range: 15V-30V; arc length range: 25 cm-30 cm;
and 5, stabilizing the smelting stage. The phase is a main phase of arc remelting of the high-temperature alloy, and has important effects of removing gas and low-melting-point metal impurities in the alloy, removing nonmetallic inclusions, reducing element segregation and obtaining ideal ingot tissue. The technological parameters are as follows, the melting speed control range is as follows: 2 Kg/min-4 Kg/min, voltage range: 20V-30V; arc length range: 25 cm-30 cm; helium flow rate range: 500Pa to 2000Pa;
and 6, heat-sealing the top. The heat capping is the final stage of consumable remelting, and aims to reduce shrinkage cavity of the remelting ingot head, promote floating of inclusions and feeding of the ingot, and improve yield. The process parameters are as follows: melting speed control range: 2 Kg/min-3 Kg/min, voltage range: 12V-25V; arc length range: 25 cm-30 cm; helium flow rate range: 300 Pa-1000 Pa;
and 7, cooling. After smelting, power is cut off, the crystallizer continues to vacuumize, and the vacuum degree in the crystallizer is kept at 0.1 Pa-5 Pa. And cooling the cast ingot to below 300 ℃, and discharging the cast ingot.
Example 1
And (3) placing the high-temperature alloy electrode ingot remelted by the vacuum arc into a heat treatment furnace for stress relief annealing treatment. The adopted annealing system is as follows: feeding the material into a furnace at room temperature, heating to 850+/-10 ℃ at a heating rate of 5 ℃/min, preserving heat for 2 hours, and then cooling along with the furnace; the ingot head of the high-temperature alloy electrode is processed and the surface of the ingot is flat, after the ingot is welded with the auxiliary electrode, the coaxiality difference range between the axis of the auxiliary electrode and the axis of the consumable electrode is 1.5mm, and the roughness of the surface of the processed consumable electrode ingot is 3.2 mu m; the filling ratio range of the electrode ingot and the crystallizer is controlled to be 0.7, and the unilateral gap control range of the consumable electrode ingot and the inner wall of the crystallizer is controlled to be 20mm. The technological parameters of the arcing stage are as follows, and the melting speed control range is as follows: 3Kg/min, voltage range: 15V, arc length range: 25cm; the technological parameters of the stable smelting stage are as follows, and the smelting speed control range is as follows: 2Kg/min, voltage range: 20V, arc length range: 25cm, helium flow rate range: 500Pa; the process parameters are as follows: and (3) melt rate control: 2Kg/min, voltage: 12V; arc length: 25cm; helium flow rate 300Pa; after smelting, power is cut off, the crystallizer continues to vacuumize, and the vacuum degree in the crystallizer is kept to be 0.1Pa. And cooling the cast ingot to 260 ℃ and discharging.
Example 2
Placing the vacuum arc remelted high-temperature alloy electrode ingot into a heat treatment furnace for stress relief annealing treatment, wherein the adopted annealing system is as follows: feeding the material into a furnace at room temperature, heating to 900+/-10 ℃ at a heating rate of 5 ℃/min, preserving heat for 140min, and then cooling along with the furnace; machining the ingot head of the high-temperature alloy electrode, leveling the surface of the ingot, and enabling the coaxiality difference range of the axis of the auxiliary electrode and the axis of the consumable electrode to be 3mm, wherein the roughness of the surface of the machined consumable electrode ingot is 6.4 mu m; the filling ratio range of the electrode ingot and the crystallizer is controlled to be 0.8, and the unilateral gap control range of the consumable electrode ingot and the inner wall of the crystallizer is controlled to be 55mm. The technological parameters in the arcing stage are as follows, the melting speed is 5Kg/min, and the voltage range is as follows: 30V, arc length: 30cm; the technological parameters in the stable smelting stage are as follows, the smelting speed is controlled to be 4Kg/min, and the voltage is 30V; arc length 30cm; helium flow rate 2000Pa; the technological parameters of the heat-seal top stage are as follows: the melting speed is 3Kg/min, and the voltage is 25V; arc length 30cm; helium flow rate 1000Pa; after smelting, power is cut off, the crystallizer continues to vacuumize, and the vacuum degree in the crystallizer is kept to be 5Pa. And cooling the cast ingot to 280 ℃ and discharging the cast ingot.
Claims (8)
1. A process for controlling the height of a superalloy vacuum arc remelting ingot crown, comprising the steps of:
step 1, stress relief annealing of a high-temperature alloy electrode ingot;
step 2, processing an electrode ingot; the surface of the high-temperature alloy consumable electrode ingot and the surface of the auxiliary electrode welding ingot are flat, and the surface roughness is less than 6.4 mu m;
step 3, controlling the filling ratio range of the consumable electrode ingot and the crystallizer to be 0.63-0.9, and controlling the unilateral gap control range of the electrode ingot and the inner wall of the crystallizer to be 20-55 mm;
step 4, an arcing stage; the required process parameters are as follows, the melting speed control range: 3 Kg/min-5 Kg/min, voltage range: 15V-30V; arc length range: 25 cm-30 cm;
step 5, stabilizing a smelting stage; the technological parameters are as follows, the melting speed control range is as follows: 2 Kg/min-4 Kg/min, voltage range: 20V-30V; arc length range: 25 cm-30 cm; and cooled by helium gas, helium gas flow rate range: 500Pa to 2000Pa;
step 6, heat-sealing the top; the process parameters are as follows: melting speed control range: 2 Kg/min-3 Kg/min, voltage range: 12V-25V; arc length range: 25 cm-30 cm; helium flow rate range: 300 Pa-1000 Pa;
and 7, after smelting, powering off, cooling and discharging.
2. The process for controlling the crown height of a superalloy vacuum arc remelting ingot according to claim 1 wherein the superalloy electrode ingot is vacuum arc remelted prior to the destressing anneal.
3. The process for controlling the crown height of a superalloy vacuum arc remelting ingot according to claim 1 wherein the step 1 destressing anneal is performed in a heat treatment furnace.
4. The process for controlling the crown height of a superalloy vacuum arc remelting ingot according to claim 1 wherein step 1 is a stress relief annealing process comprising: and (3) feeding the material into a furnace at room temperature, heating to 850-900+/-10 ℃ at a heating rate of 5 ℃/min, preserving the heat for 2 h+/-20 min, and then cooling along with the furnace.
5. The process for controlling the height of a superalloy vacuum arc remelting ingot crown as in claim 1 wherein step 2 auxiliary electrode welding requires good flatness and symmetry for the entire electrode.
6. The process for controlling the height of a crown of a superalloy vacuum arc remelting ingot according to claim 1 wherein the step 2 auxiliary electrode axis is coaxial with the consumable electrode axis by a range of no more than 3mm.
7. The process for controlling the height of a vacuum arc remelting ingot crown of a superalloy according to claim 1, wherein the vacuum degree in the crystallizer is maintained at 0.1Pa to 5Pa after power failure after the smelting in the step 7 is completed.
8. The process for controlling the crown height of a superalloy vacuum arc remelting ingot according to claim 1 wherein the ingot is tapped after the ingot is cooled to below 300 ℃ in step 7.
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