CN115612877A - Method for intelligently vacuum induction smelting of high-temperature alloy master alloy - Google Patents
Method for intelligently vacuum induction smelting of high-temperature alloy master alloy Download PDFInfo
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- 239000000956 alloy Substances 0.000 title claims abstract description 160
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 156
- 230000006698 induction Effects 0.000 title claims abstract description 77
- 238000003723 Smelting Methods 0.000 title claims abstract description 69
- 238000000034 method Methods 0.000 title claims abstract description 68
- 238000002844 melting Methods 0.000 claims abstract description 60
- 230000008018 melting Effects 0.000 claims abstract description 58
- 230000008569 process Effects 0.000 claims abstract description 36
- 239000004615 ingredient Substances 0.000 claims abstract description 12
- 239000007788 liquid Substances 0.000 claims description 25
- 238000007670 refining Methods 0.000 claims description 25
- 238000007600 charging Methods 0.000 claims description 20
- 238000012840 feeding operation Methods 0.000 claims description 16
- 238000003756 stirring Methods 0.000 claims description 16
- 230000001502 supplementing effect Effects 0.000 claims description 15
- 238000009529 body temperature measurement Methods 0.000 claims description 13
- 238000001514 detection method Methods 0.000 claims description 12
- 239000002994 raw material Substances 0.000 claims description 12
- 238000005070 sampling Methods 0.000 claims description 10
- 238000004364 calculation method Methods 0.000 claims description 9
- 229910052759 nickel Inorganic materials 0.000 claims description 9
- 229910052735 hafnium Inorganic materials 0.000 claims description 8
- 238000004458 analytical method Methods 0.000 claims description 5
- 239000013589 supplement Substances 0.000 claims description 4
- 230000009466 transformation Effects 0.000 claims description 4
- 238000005275 alloying Methods 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 21
- 238000013461 design Methods 0.000 abstract description 5
- 238000002360 preparation method Methods 0.000 abstract description 5
- 238000002474 experimental method Methods 0.000 abstract description 3
- 238000011161 development Methods 0.000 abstract description 2
- 238000010308 vacuum induction melting process Methods 0.000 abstract 1
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 239000000047 product Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- 238000005457 optimization Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 206010063385 Intellectualisation Diseases 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- 229910000601 superalloy Inorganic materials 0.000 description 2
- 230000000153 supplemental effect Effects 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/06—Forming or maintaining special atmospheres or vacuum within heating chambers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/06—Forming or maintaining special atmospheres or vacuum within heating chambers
- F27D2007/066—Vacuum
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0028—Regulation
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Abstract
The application provides a method for intelligently vacuum induction smelting of a master alloy of a high-temperature alloy, which comprises the steps of establishing a full-automatic intelligent vacuum induction smelting model, realizing the optimal design of a high-temperature alloy smelting ingredient, judging production preparation conditions, automatically smelting the high-temperature alloy after the preparation conditions are met, judging alloy components and temperature and compensating measures when the smelting process is carried out to a set time point, judging a pouring condition after the components and the temperature reach the standard, and pouring after the conditions are met. This application can increase substantially the intelligent level of vacuum induction melting process, effectively reduces personnel's operation to the influence of experiment, production result, will promote the production efficiency, the product percent of pass and the alloy yield of vacuum induction furnace simultaneously by a wide margin, promotes the development of vacuum induction melting technique.
Description
Technical Field
The application relates to the technical field of metallurgy, in particular to a method for intelligently vacuum-induction smelting of a high-temperature alloy master alloy.
Background
The high-temperature alloy refers to nickel-based, nickel-iron-based and cobalt-based alloys with a face-centered cubic structure and suitable for being used at the temperature of more than 540 ℃. The high-temperature-resistant steel has excellent high-temperature strength, oxidation resistance, corrosion resistance, fatigue resistance, creep resistance and other high-temperature comprehensive properties, and is suitable for long-term operation at high temperature under certain stress. The high-temperature alloy becomes an indispensable important structural material in the fields of aerospace, energy resources, transportation, heavy equipment and the like.
At present, the annual demand of the high-temperature alloy materials in China exceeds 2 ten thousand tons, the annual output of the high-temperature alloy materials in China is only about 1 ten thousand tons, the phenomenon of short supply and short demand of the high-temperature alloy materials in China is obvious, and one of the main reasons is insufficient production capacity. The demand of high-temperature alloy materials exceeds 40 ten thousand tons in the future 10 years, and great demand is made on the production capacity of the high-temperature alloy.
Vacuum induction melting is used as a main process method for producing high-temperature alloy, the processes of ingredient calculation, feeding, melting, pouring and the like all need manual judgment and manual operation, the production efficiency is low, simultaneously, alloy overburning is easily caused, the product percent of pass is low, the alloy yield is low, the condition of calculation or control error is easy to occur, the condition that the components of the master alloy cannot reach the standard is caused, and the industrial production is influenced.
Disclosure of Invention
In order to solve the technical problem, the application provides a method for intelligently vacuum induction melting a high-temperature alloy master alloy. According to the method, the full-automatic intelligent vacuum induction smelting model is established, the processes of burdening, feeding, smelting, pouring and the like are intelligently set and operated, the full-automatic process of intelligent vacuum induction smelting is realized, the effects of improving the production efficiency, improving the product percent of pass and the alloy yield and reducing the production cost are achieved, and meanwhile, the quality of the alloy liquid is not influenced. The technical scheme adopted by the application is as follows:
a method for intelligently vacuum-melting a superalloy master alloy comprises the following steps:
step 1, determining the ingredients of a master alloy and the addition of each alloy element according to a smelting target, a raw material component library and a raw material proportion;
step 2, during smelting, the vacuum induction furnace sets the smelting process into six stages, namely a charging stage, a melting stage, a primary refining stage, a secondary refining stage, a stirring stage and a pouring stage, and respectively sets the charging condition, power supply power, power supply time and vacuum degree of each stage;
step 3, after the secondary refining period is finished, the full-automatic intelligent vacuum induction melting model sends a sampling signal to a Programmable Logic Controller (PLC), the components of the sampling are analyzed by a furnace-front rapid analysis and detection device, and data are fed back to the full-automatic intelligent vacuum induction melting model;
step 4, judging whether the components of the high-temperature master alloy reach the standard or not by the full-automatic intelligent vacuum induction melting model according to the alloy components of the smelting target; if the components do not reach the standard, performing feeding operation, returning to the step 4, and continuously judging whether the components of the high-temperature master alloy reach the standard or not; if the components reach the standard, executing the step 5;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to the temperature measurement equipment for temperature measurement, and whether the measured temperature reaches the standard or not is judged; if the measured temperature does not reach the standard, executing power supplementing operation, returning to the step 5, and continuously judging whether the measured temperature reaches the standard; if the measured temperature reaches the standard, executing the step 6;
step 6, the full-automatic intelligent vacuum induction melting model sends a pouring instruction to the furnace body, and the furnace body is controlled to gradually incline according to a set inclination speed; in the pouring process, analyzing the pouring speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the pouring speed of the alloy liquid according to a set value; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy grade and the corresponding pouring speed so as to realize the smooth pouring of the alloy liquid.
Further, before the step 1, the method further comprises: and carrying out automatic transformation and upgrading of equipment of the vacuum induction furnace so as to realize automatic operation of the processes of material calculation, charging, smelting and pouring, realize real-time display of various smelting data and equipment data in the smelting process and compile a full-automatic intelligent vacuum induction smelting model.
Further, the determining of the ingredients of the master alloy and the addition of each alloying element comprises: adding alloy elements in three batches in sequence;
the first batch of alloy elements comprise Ni, cr, co, mo and W, and the adding sequence is Ni, cr, co, mo and W;
the second batch of alloy elements comprise Hf and B, and the addition sequence is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the adding sequence is Al and Ti;
the above elements can also be added by way of intermediate alloy, and the yield of the above alloy elements is determined according to the yield of volatile elements.
Further, for an application scenario of the 500kg vacuum induction furnace, the setting of the charging condition, the power supply power, the power supply time and the vacuum degree at each stage respectively includes:
in the feeding period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, the power supply power to be more than or equal to 60KW and the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply power is not less than 120KW, and the power supply time is not less than 40min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 100KW, and the power supply time is more than or equal to 2min.
Further, aiming at the application scene of the 2T vacuum induction furnace, the respectively setting of the charging condition, the power supply power, the power supply time and the vacuum degree at each stage comprises the following steps:
in the charging period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, the power supply power to be more than or equal to 450KW and the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply is not less than 850KW, and the power supply time is not less than 30min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 300KW, and the power supply time is more than or equal to 2min.
Further, if the components do not reach the standard, performing feeding operation, including: and if the components do not reach the standard, judging the type and the weight of the supplemented alloy, sending a feeding instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute feeding operation, and waiting for 5 minutes after the feeding operation of the supplemented alloy is finished.
Further, in step 4, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 5min;
if the temperature does not reach the standard, executing power supplement operation, including: setting the supplemented power to 120KW, calculating the time for supplementing the power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of supplementing the power according to the time; in step 5, the vacuum degree is set to be less than or equal to 15Pa.
Further, in step 4, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 5min;
if the temperature does not reach the standard, executing power supplement operation, including: setting the supplemented power to 250KW, calculating the time of the supplemented power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of the supplemented power according to the time; in step 5, the vacuum degree is set to be less than or equal to 15Pa.
Further, the tilting speed is 0.2 °/s to 2 °/s; the pouring speed of the alloy liquid is 1.04kg/s-9.21kg/s.
Further, the tilting speed is 0.2 °/s to 1.5 °/s; the pouring speed of the alloy liquid is 2kg/s-10kg/s.
Through the embodiment of the application, the following technical effects can be obtained: by establishing the full-automatic intelligent vacuum induction smelting model, the real-time monitoring of various smelting data and equipment data in the smelting process is realized, scientific research production personnel can master experiments and production in an all-around and deep manner, the full-automatic process of the processes of proportioning, feeding, smelting, pouring and the like is realized, the production rate is improved by 3-5%, the product percent of pass is improved by more than 5%, and the alloy yield is improved by more than 3%. The application of the technology provides a new process method and theory for improving the intellectualization of vacuum induction smelting, greatly improves the intellectualization level of the vacuum induction smelting process, effectively reduces the influence of personnel operation on experiments and production results, greatly improves the production efficiency, the product qualification rate and the alloy yield of vacuum induction, and promotes the development of the vacuum induction smelting technology.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following descriptions are some embodiments of the present application, and those skilled in the art can obtain other drawings without inventive labor.
Fig. 1 is a schematic flow chart of the method of the present application.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
Fig. 1 is a schematic flow chart of the method of the present application. The method realizes the full-automatic process of intelligent vacuum induction melting by establishing a full-automatic intelligent vacuum induction melting model and intelligently setting and operating the processes of burdening, feeding, melting, pouring and the like, thereby achieving the effects of improving the production efficiency, improving the product qualification rate and the alloy yield, reducing the production cost and simultaneously not influencing the quality of the alloy liquid.
In a specific implementation mode, the method is applied to a smelting process of 500kg intelligent vacuum induction smelting high-temperature alloy master alloy, and the specific scheme is as follows:
step 1, determining the ingredients of a master alloy and the addition of each alloy element according to a smelting target and a raw material component library;
the method for determining the ingredients of the master alloy and the addition amount of each alloy element comprises the following steps: adding alloy elements in three batches in sequence;
the first batch of alloy elements comprise Ni, cr, co, mo and W, and the alloy elements are added in the order of Ni, cr, co, mo and W;
the second batch of alloy elements comprise Hf and B, and the adding sequence of the alloy elements is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the adding sequence of the alloy elements is Al and Ti;
the above elements can also be added by way of intermediate alloy, and the yield of the above alloy elements is determined according to the yield of volatile elements.
Before step 1 above, the method further comprises: carrying out automatic transformation and upgrading of equipment of a 500kg vacuum induction furnace to realize automatic operation of the processes of material calculation, charging, smelting, pouring and the like, realize real-time display of various smelting data and equipment data in the smelting process, and compile a full-automatic intelligent vacuum induction smelting model;
step 2, during smelting, the smelting process is set to six stages of a charging stage, a melting stage, a primary refining stage, a secondary refining stage, a stirring stage and a pouring stage by a 500kg vacuum induction furnace, and the charging condition, the power supply power, the power supply time and the vacuum degree of each stage are respectively set;
in the charging period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, setting the power supply power to be more than or equal to 60KW and setting the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply power is not less than 120KW, and the power supply time is not less than 40min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 100KW, and the power supply time is more than or equal to 2min;
step 3, after the secondary refining period is finished, the full-automatic intelligent vacuum induction melting model sends a sampling signal to a Programmable Logic Controller (PLC), the components of the sampling are analyzed by a furnace-front rapid analysis and detection device, and data are fed back to the full-automatic intelligent vacuum induction melting model;
step 4, judging whether the components of the high-temperature master alloy reach the standard or not by the full-automatic intelligent vacuum induction melting model according to the alloy components of the smelting target; if the components do not reach the standard, the feeding operation is executed, the step 4 is returned, and whether the components of the high-temperature master alloy reach the standard or not is continuously judged; if the components reach the standard, executing the step 5;
if the components do not reach the standard, the feeding operation is executed, and the method comprises the following steps: if the components do not reach the standard, judging the type and the weight of the supplemented alloy, sending a feeding instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute feeding operation, and waiting for 5 minutes after finishing the feeding operation of the supplemented alloy;
in step 4, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 5min;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to the temperature measurement equipment for temperature measurement, and whether the measured temperature reaches the standard is judged; if the measured temperature does not reach the standard, executing power supplementing operation, returning to the step 5, and continuously judging whether the measured temperature reaches the standard; if the measured temperature reaches the standard, executing step 6;
the performing the supplemental power operation includes: setting the supplemented power to 120KW, calculating the time for supplementing the power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of supplementing the power according to the time; in step 5, setting the vacuum degree to be less than or equal to 15Pa;
step 6, the full-automatic intelligent vacuum induction melting model sends a pouring instruction to the furnace body, and the furnace body gradually inclines at an inclination speed of 0.2-2 degrees/s; in the pouring process, analyzing the pouring speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the pouring speed of the alloy liquid to be 1.04kg/s-9.21kg/s; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy type and the corresponding pouring speed so as to realize the pouring of the alloy liquid.
After the scheme is implemented, the production rate of the 500kg smelting furnace is improved by 3.8%, the product yield is improved by 5.5%, and the alloy yield is improved by 3.6%.
In another specific embodiment, the method is applied to a 2T intelligent vacuum induction melting superalloy master alloy smelting process, and the specific scheme is as follows:
step 1, determining the ingredients of a master alloy and the addition of each alloy element according to a smelting target and a raw material component library;
the method for determining the ingredients of the master alloy and the addition amount of each alloy element comprises the following steps: adding alloy elements in three batches in sequence;
the first batch of alloy elements comprise Ni, cr, co, mo and W, and the adding sequence of the alloy elements is Ni, cr, co, mo and W;
the second batch of alloy elements comprise Hf and B, and the adding sequence of the alloy elements is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the adding sequence of the alloy elements is Al and Ti;
the above elements can also be added by way of intermediate alloy, and the yield of the above alloy elements is determined according to the yield of volatile elements.
Before step 1 above, the method further comprises: carrying out automatic transformation and upgrading of equipment of the 2T vacuum induction furnace so as to realize automatic operation of the processes of material calculation, charging, smelting, pouring and the like, realize real-time display of various smelting data and equipment data in the smelting process, and compile a full-automatic intelligent vacuum induction smelting model;
step 2, when smelting is carried out, the 2T vacuum induction furnace sets the smelting process into six stages, namely a charging stage, a melting stage, a primary refining stage, a secondary refining stage, a stirring stage and a pouring stage, and respectively sets the charging condition, power supply power, power supply time and vacuum degree of each stage;
in the charging period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, the power supply power to be more than or equal to 450KW and the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply is not less than 850KW, and the power supply time is not less than 30min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 300KW, and the power supply time is more than or equal to 2min;
step 3, after the secondary refining period is finished, the full-automatic intelligent vacuum induction melting model sends a sampling signal to a Programmable Logic Controller (PLC), the components of the sampling signal are analyzed by a furnace-front rapid analysis and detection device, and data are fed back to the full-automatic intelligent vacuum induction melting model;
step 4, judging whether the components of the high-temperature master alloy reach the standard or not by the full-automatic intelligent vacuum induction melting model according to the alloy components of the smelting target; if the components do not reach the standard, performing feeding operation, returning to the step 4, and continuously judging whether the components of the high-temperature master alloy reach the standard or not; if the components reach the standard, executing the step 5;
if the components do not reach the standard, performing feeding operation, including: if the components do not reach the standard, judging the type and the weight of the supplemented alloy, sending a feeding instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute feeding operation, and waiting for 5 minutes after finishing the feeding operation of the supplemented alloy;
in step 4, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 5min;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to the temperature measurement equipment for temperature measurement, and whether the measured temperature reaches the standard is judged; if the measured temperature does not reach the standard, executing power supplementing operation, returning to the step 5, and continuously judging whether the measured temperature reaches the standard; if the measured temperature reaches the standard, executing step 6;
the performing the supplemental power operation includes: setting the supplemented power to 250KW, calculating the time for supplementing the power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of supplementing the power according to the time; in step 5, setting the vacuum degree to be less than or equal to 15Pa;
step 6, the full-automatic intelligent vacuum induction melting model sends a pouring instruction to the furnace body, and the furnace body gradually inclines at an inclination speed of 0.2-1.5 degrees/s; in the pouring process, analyzing the pouring speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the pouring speed of the alloy liquid to be 2kg/s-10kg/s; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy type and the corresponding pouring speed so as to realize the pouring of the alloy liquid.
After the scheme is implemented, the production rate of the 2T smelting furnace is improved by 4.1%, the product yield is improved by 5.8%, and the alloy yield is improved by 3.8%.
On the basis of the above description, the above technical solutions of the present application are summarized. From the aspect of realizing functions, the technical scheme of the application comprises five stages of pre-preparation of full-automatic intelligent vacuum induction melting, model ingredient optimization design, automatic setting of a melting process, judgment and compensation measures of alloy components and temperature and judgment of pouring conditions, and the following stages are summarized and summarized respectively:
stage 1: pre-stage preparation of full-automatic intelligent vacuum induction melting
The automatic equipment modification and upgrading are carried out in the processes of feeding, smelting, pouring and the like, the automatic operation in the processes of ingredient calculation, feeding, smelting, pouring and the like is realized, and the real-time display of various smelting data and equipment data in the smelting process is realized. On the basis, a full-automatic intelligent vacuum induction melting model is compiled.
And (2) stage: model ingredient optimization design
According to material balance calculation, performing high-temperature alloy master alloy batching optimization design according to smelting target components, a raw material component library and a raw material ratio, and comprehensively considering factors such as the adding sequence of alloy elements, the yield of the alloy elements and the like during calculation to determine the alloy and the weight which need to be added in batches for the heat. And sending the raw material list to a raw material warehouse, enabling the raw material warehouse to carry out batching according to the list, and sending the prepared raw materials to a production site.
And (3) stage: automated setting of a smelting process
After the material proportioning optimization design is completed, the full-automatic intelligent vacuum induction melting model sends tooling requirements to the production department according to program setting and historical smelting conditions, and the production department assembles and preheats the tooling.
When the batching and the tool preparation are finished, the full-automatic intelligent vacuum induction melting model sets the feeding sequence, the power supply power, the power supply time, the vacuum degree and the like in stages (feeding, melting, refining and the like) according to the requirements of smelting target components, temperature and the like, adds different alloys in different smelting time by controlling a PLC system, and simultaneously realizes the automatic control of the parameters of the power supply power, the power supply time, the vacuum degree and the like.
And (4) stage: alloy composition and temperature determination and compensation measures
When smelting is carried out to a set time point, the full-automatic intelligent vacuum induction smelting model sends a signal to the PLC system, the PLC sends an instruction to the sampling equipment for sampling, and the rapid analysis and detection equipment carries out component detection and sends data to the full-automatic intelligent vacuum induction smelting model. At the moment, the model judges whether the components of the high-temperature master alloy reach the standard according to the target components of the alloy, judges the type and the weight of the supplemented alloy if the components of the high-temperature master alloy do not reach the standard, sends an instruction to feed the material, and carries out component detection and judgment again after the supplemented alloy is added for a certain time.
And after the components are detected to be qualified, the model sends a signal to the temperature measuring equipment to measure the temperature, if the temperature does not reach the standard, the power and time for supplementing power are calculated through the model, and after the power is supplemented, the temperature measurement and judgment process is carried out again.
And (5) stage: determination of pouring conditions
And after the components and the temperature are detected to be qualified, the model sends a pouring instruction to the furnace body, the furnace body starts to gradually incline, the pouring speed of the alloy liquid is analyzed constantly through liquid flow detection equipment in the process of pouring the master alloy into the tool and is fed back to the model, and the model adjusts the inclination angle according to the type of the alloy and the historical optimal pouring speed, so that the optimal pouring of the alloy liquid is realized.
The method for intelligently vacuum induction smelting the high-temperature alloy master alloy is suitable for 20kg-20T vacuum induction smelting equipment.
The functions described above in this application may be performed at least in part by one or more hardware logic components. For example, without limitation, exemplary types of hardware logic components that may be used include: a Field Programmable Gate Array (FPGA), an Application Specific Integrated Circuit (ASIC), an Application Specific Standard Product (ASSP), a system on a chip (SOC), a load programmable logic device (CPLD), and the like.
Further, while operations are depicted in a particular order, this should be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Under certain circumstances, multitasking and parallel processing may be advantageous. Likewise, while several specific implementation details are included in the above discussion, these should not be construed as limitations on the scope of the disclosure. Certain features that are described in the context of separate embodiments can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination.
Although the subject matter has been described in language specific to structural features and/or logical acts of devices, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
Claims (10)
1. The method for intelligently vacuum-melting the high-temperature alloy master alloy is characterized by comprising the following steps of:
step 1, determining the ingredients of a master alloy and the addition of each alloy element according to a smelting target, a raw material component library and a raw material proportion;
step 2, during smelting, the vacuum induction furnace sets the smelting process into six stages, namely a charging stage, a melting stage, a primary refining stage, a secondary refining stage, a stirring stage and a pouring stage, and respectively sets the charging condition, power supply power, power supply time and vacuum degree of each stage;
step 3, after the secondary refining period is finished, the full-automatic intelligent vacuum induction melting model sends a sampling signal to a Programmable Logic Controller (PLC), the components of the sampling are analyzed by a furnace-front rapid analysis and detection device, and data are fed back to the full-automatic intelligent vacuum induction melting model;
step 4, judging whether the components of the high-temperature master alloy reach the standard or not by the full-automatic intelligent vacuum induction melting model according to the alloy components of the smelting target; if the components do not reach the standard, the feeding operation is executed and the operation is returned
Step 4, continuously judging whether the components of the high-temperature master alloy reach the standard; if the components reach the standard, executing the step 5;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to the temperature measurement equipment for temperature measurement, and whether the measured temperature reaches the standard is judged; if the measured temperature does not reach the standard, executing power supplementing operation, returning to the step 5, and continuously judging whether the measured temperature reaches the standard; if the measured temperature reaches the standard, executing step 6;
step 6, the full-automatic intelligent vacuum induction melting model sends a pouring instruction to the furnace body, and the furnace body is controlled to gradually incline according to a set inclining speed; in the pouring process, analyzing the pouring speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the pouring speed of the alloy liquid according to a set value; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy grade and the corresponding pouring speed so as to realize the smooth pouring of the alloy liquid.
2. The method of claim 1, wherein prior to step 1, the method further comprises: and carrying out automatic transformation and upgrading of equipment of the vacuum induction furnace so as to realize automatic operation of the processes of proportioning calculation, charging, smelting and pouring, realize real-time display of various smelting data and equipment data in the smelting process and compile a full-automatic intelligent vacuum induction smelting model.
3. The method of claim 1 or 2, wherein determining the batch of master alloy and the addition of each alloying element comprises: adding alloy elements in three batches in sequence;
the first batch of alloy elements comprise Ni, cr, co, mo and W, and the adding sequence is Ni, cr, co, mo and W;
the second batch of alloy elements comprise Hf and B, and the addition sequence is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the adding sequence is Al and Ti;
the above elements can also be added by way of intermediate alloy, and the yield of the above alloy elements is determined according to the yield of volatile elements.
4. The method of claim 3, wherein the setting of the charging condition and the power supply, the power supply time and the vacuum degree of each stage respectively comprises:
in the feeding period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, the power supply power to be more than or equal to 60KW and the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply power is not less than 120KW, and the power supply time is not less than 40min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 80KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 100KW, and the power supply time is more than or equal to 2min.
5. The method according to claim 3, wherein for a 2T vacuum induction furnace application scenario, the setting of the charging condition and the power supply power, the power supply time and the vacuum degree of each stage respectively comprises:
in the charging period, adding a first batch of alloy elements, setting the vacuum degree to be less than or equal to 30Pa, the power supply power to be more than or equal to 450KW and the power supply time to be more than or equal to 10min;
in the melting period, the vacuum degree is set to be less than or equal to 20Pa, the power supply is more than or equal to 850KW, and the power supply time is more than or equal to 30min;
in the primary refining period, adding a second batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the secondary refining period, adding a third batch of alloy elements, setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 100KW and the power supply time to be more than or equal to 10min;
in the stirring period, the set vacuum degree is less than or equal to 15Pa, the power supply power is the inherent stirring power set by the equipment, and the power supply time is more than or equal to 5min;
in the pouring period, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 300KW, and the power supply time is more than or equal to 2min.
6. The method of claim 1, wherein if the composition does not meet the standard, performing a feeding operation comprising: and if the components do not reach the standard, judging the type and the weight of the supplemented alloy, sending a feeding instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute feeding operation, and waiting for 5 minutes after the feeding operation of the supplemented alloy is finished.
7. The method according to claim 4, wherein in step 4, the vacuum degree is set to be less than or equal to 15Pa, the power supply is set to be more than or equal to 80KW, and the power supply time is set to be more than or equal to 5min;
if the temperature does not reach the standard, executing power supplement operation, including: setting the supplemented power to 120KW, calculating the time for supplementing the power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of supplementing the power according to the time; in step 5, the vacuum degree is set to be less than or equal to 15Pa.
8. The method according to claim 5, wherein in step 4, the vacuum degree is set to be less than or equal to 15Pa, the power supply is set to be more than or equal to 100KW, and the power supply time is set to be more than or equal to 5min;
if the temperature does not reach the standard, executing power supplement operation, including: setting the supplemented power to 250KW, calculating the time for supplementing the power through a full-automatic intelligent vacuum induction melting model, and finishing the operation of supplementing the power according to the time; in step 5, the vacuum degree is set to be less than or equal to 15Pa.
9. The method according to claim 4, characterized in that the tilting speed is between 0.2 °/s and 2 °/s; the pouring speed of the alloy liquid is 1.04kg/s-9.21kg/s.
10. The method according to claim 5, characterized in that the tilting speed is between 0.2 °/s and 1.5 °/s; the pouring speed of the alloy liquid is 2kg/s-10kg/s.
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