CN115612877B - Intelligent vacuum induction melting method for high-temperature alloy master alloy - Google Patents
Intelligent vacuum induction melting method for high-temperature alloy master alloy Download PDFInfo
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- 239000000956 alloy Substances 0.000 title claims abstract description 150
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 146
- 230000006698 induction Effects 0.000 title claims abstract description 80
- 238000000034 method Methods 0.000 title claims abstract description 57
- 238000002844 melting Methods 0.000 title claims description 40
- 230000008018 melting Effects 0.000 title claims description 40
- 238000003723 Smelting Methods 0.000 claims abstract description 90
- 230000008569 process Effects 0.000 claims abstract description 31
- 238000005266 casting Methods 0.000 claims abstract description 26
- 239000004615 ingredient Substances 0.000 claims abstract description 14
- 239000007788 liquid Substances 0.000 claims description 25
- 238000007670 refining Methods 0.000 claims description 25
- 238000001514 detection method Methods 0.000 claims description 12
- 239000002994 raw material Substances 0.000 claims description 12
- 238000009529 body temperature measurement Methods 0.000 claims description 10
- 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
- 238000003756 stirring Methods 0.000 claims description 8
- 238000012840 feeding operation Methods 0.000 claims description 6
- 238000004458 analytical method Methods 0.000 claims description 5
- 230000009466 transformation Effects 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 3
- 238000005275 alloying Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 20
- 229910000601 superalloy Inorganic materials 0.000 abstract description 8
- 238000012797 qualification Methods 0.000 abstract description 6
- 238000002360 preparation method Methods 0.000 abstract description 5
- 238000013461 design Methods 0.000 abstract description 4
- 238000005516 engineering process Methods 0.000 abstract description 3
- 238000002474 experimental method Methods 0.000 abstract description 3
- 238000011161 development Methods 0.000 abstract description 2
- 241001417490 Sillaginidae Species 0.000 abstract 1
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 230000000694 effects Effects 0.000 description 3
- 206010063385 Intellectualisation Diseases 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000000153 supplemental effect Effects 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- 230000009471 action Effects 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
- 238000005272 metallurgy Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 238000005457 optimization 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
- 230000009469 supplementation Effects 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- 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
-
- 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
-
- 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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Chemical & Material Sciences (AREA)
- General Engineering & Computer Science (AREA)
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- Organic Chemistry (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Crucibles And Fluidized-Bed Furnaces (AREA)
Abstract
The application provides a method for intelligent vacuum induction smelting of a superalloy master alloy, which realizes the optimal design of a superalloy smelting ingredient by establishing a full-automatic intelligent vacuum induction smelting model, then judges production preparation conditions, automatically smelts the superalloy after the preparation conditions are provided, judges alloy components and temperature and compensates when the smelting process is carried out to a set time point, judges casting conditions after the components and the temperature reach the standard, and performs casting after the conditions are met. The application can greatly improve the intelligent level of the vacuum induction smelting process, effectively reduce the influence of personnel operation on experiment and production results, and simultaneously greatly improve the production efficiency, the product qualification rate and the alloy yield of the vacuum induction furnace and promote the development of the vacuum induction smelting technology.
Description
Technical Field
The application relates to the technical field of metallurgy, in particular to an intelligent vacuum induction smelting method for high-temperature alloy master alloy.
Background
The superalloy refers to nickel-based, nickel-iron-based and cobalt-based alloys having face-centered cubic structure suitable for use above 540 ℃. The alloy 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 work under the action of high temperature and certain stress. Superalloys have become an indispensable important structural material in the fields of aerospace, energy resources, transportation, important equipment and the like.
At present, the annual demand of the high-temperature alloy materials in China exceeds 2 ten thousand tons, the annual production capacity of the high-temperature alloy materials in China is only about 1 ten thousand tons, the phenomenon that the domestic high-temperature alloy materials are not supplied is obvious, and one of main reasons is the insufficient production capacity. The demand of high-temperature alloy materials exceeds 40 ten thousand tons in the next 10 years, and great demands are put on the production capacity of the high-temperature alloy.
Vacuum induction melting is used as a main process method for producing high-temperature alloy, and the processes of proportioning calculation, feeding, melting, pouring and the like all need manual judgment and manual operation, so that the production efficiency is low, meanwhile, the alloy is easy to burn, the product qualification rate is low, the alloy yield is low, the situation of calculation or control errors is easy to occur, and the condition that the master alloy composition cannot reach the standard is caused, so that the industrial production is influenced.
Disclosure of Invention
In order to solve the technical problems, the application provides an intelligent vacuum induction smelting method for high-temperature alloy master alloy. The application establishes the full-automatic intelligent vacuum induction smelting model, intelligently sets and operates the processes of batching, charging, smelting, pouring and the like, realizes the full-automatic process of intelligent vacuum induction smelting, and achieves 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 alloy liquid. The technical scheme adopted by the application is as follows:
an intelligent vacuum melting method for high-temperature alloy master alloy, which comprises the following steps:
step 1, determining ingredients of master alloy and addition amount of each alloy element according to smelting targets, a raw material component library and raw material proportions;
step 2, setting a smelting process into six stages of a charging period, a melting period, a primary refining period, a secondary refining period, a stirring period and a pouring period by a vacuum induction furnace during smelting, and setting charging conditions, power supply time and vacuum degree of each stage respectively;
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 sampling component is analyzed by a stokehole rapid analysis and detection device, and data is 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 standards according to the alloy components of the smelting target by the full-automatic intelligent vacuum induction smelting model; if the components do not reach the standards, feeding operation is carried out, and the step 4 is returned to continuously judge whether the components of the high-temperature master alloy reach the standards; if the components reach the standards, executing the step 5;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to temperature measurement equipment to measure the temperature, and whether the measured temperature meets the standard is judged; if the measured temperature does not reach the standard, the additional power operation is executed, and the step 5 is returned to, and whether the measured temperature reaches the standard is continuously judged; if the measured temperature reaches the standard, executing the step 6;
step 6, the full-automatic intelligent vacuum induction smelting model sends a pouring instruction to the furnace body, and the furnace body is controlled to incline gradually according to a set inclination speed; in the casting process, the casting speed of the alloy liquid is analyzed in real time through liquid flow detection equipment, and the casting speed of the alloy liquid is controlled according to a set value; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy mark and the corresponding pouring speed so as to realize the smooth pouring of the alloy liquid.
Further, before the step 1, the method further includes: the automatic transformation and upgrading of the equipment of the vacuum induction furnace are carried out so as to realize the automatic operation of the processes of batching calculation, feeding, smelting and pouring, realize the real-time display of various smelting data and equipment data in the smelting process, and write a full-automatic intelligent vacuum induction smelting model.
Further, the 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 alloying elements included Ni, cr, co, mo, W with an addition sequence of Ni, cr, co, mo, W;
the second alloy elements comprise Hf and B, and the adding sequence is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the addition sequence is Al and Ti;
the above elements may also be added by way of a master alloy, the yield of which is determined according to the yield of the volatile element.
Further, for the 500kg vacuum induction furnace application scenario, the setting of the charging condition, the power supply time and the vacuum degree of each stage respectively includes:
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 60KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 120KW, and the power supply time is more than or equal to 40min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
the casting period 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, for the application scenario of the 2T vacuum induction furnace, the setting of the charging condition, the power supply time and the vacuum degree of each stage respectively comprises:
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 450KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 850KW, and the power supply time is more than or equal to 30min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
the casting period 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 standards, a charging operation is performed, including: if the components do not reach the standards, judging the types and the weights of the additional alloy, sending a charging instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute charging operation, and waiting for 5 minutes after the completion of the charging operation of the additional alloy.
Further, in the step 4, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 80KW, and the power supply time is more than or equal to 5min;
and if the temperature does not reach the standard, executing the additional power operation, including: setting the additional power to 120KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in step 5, the vacuum degree is set to be 15Pa or less.
Further, in the step 4, 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 5min;
and if the temperature does not reach the standard, executing the additional power operation, including: setting the additional power to 250KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in step 5, the vacuum degree is set to be 15Pa or less.
Further, the tilting speed is 0.2 °/s to 2 °/s; the casting 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 casting speed of the alloy liquid is 2kg/s-10kg/s.
By the embodiment of the application, the following technical effects can be obtained: by establishing a full-automatic intelligent vacuum induction smelting model, not only is real-time monitoring of smelting data and equipment data in the smelting process realized, scientific research production personnel can comprehensively and deeply control experiments and production, but also full-automatic processes of proportioning, feeding, smelting, pouring and the like are realized, the productivity is improved by 3-5%, the product qualification rate is improved by more than 5%, and the alloy yield is improved by more than 3%. The application of the technology provides a new technological method and theory for improving the intellectualization of the vacuum induction smelting, greatly improves the intellectualization level of the vacuum induction smelting process, effectively reduces the influence of personnel operation on experiment and production results, and simultaneously greatly improves the production efficiency, the product qualification rate and the alloy yield of the vacuum induction and promotes the development of the vacuum induction smelting technology.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are some embodiments of the present application, and other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of the method of the present application.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present application more apparent, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application, and it is apparent that the described embodiments are some embodiments of the present application, but not all embodiments of the present application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the 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 smelting by establishing a full-automatic intelligent vacuum induction smelting model, intelligently setting and operating the processes of batching, feeding, smelting, pouring and the like, and achieves the effects of improving the production efficiency, improving the product qualification rate and the alloy yield, reducing the production cost and not affecting the quality of alloy liquid.
In a specific embodiment, the method is applied to a 500kg intelligent vacuum induction smelting superalloy master alloy smelting process, and the specific scheme is as follows:
step 1, determining ingredients of master alloy and addition amount of each alloy element according to smelting targets and a raw material component library;
the determining of 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 comprises Ni, cr, co, mo, W, and the addition sequence of the alloy elements is Ni, cr, co, mo, W;
the second batch of alloy elements comprise Hf and B, and the addition sequence of the alloy elements is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the addition sequence of the alloy elements is Al and Ti;
the above elements may also be added by way of a master alloy, the yield of which is determined according to the yield of the volatile element.
Before the step 1, the method further comprises: carrying out automatic transformation and upgrading on equipment of a 500kg vacuum induction furnace to realize automatic operation on processes of batching calculation, feeding, smelting, pouring and the like, realize real-time display of various smelting data and equipment data in the smelting process, and write a full-automatic intelligent vacuum induction smelting model;
step 2, during smelting, the 500kg vacuum induction furnace sets a smelting process as six stages of a charging period, a melting period, a primary refining period and a secondary refining period, and sets charging conditions, power supply time and vacuum degree of each stage respectively;
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 60KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 120KW, and the power supply time is more than or equal to 40min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
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 2min in the casting period;
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 sampling component is analyzed by a stokehole rapid analysis and detection device, and data is 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 standards according to the alloy components of the smelting target by the full-automatic intelligent vacuum induction smelting model; if the components do not reach the standards, feeding operation is carried out, and the step 4 is returned to continuously judge whether the components of the high-temperature master alloy reach the standards; if the components reach the standards, executing the step 5;
and if the components do not reach the standards, executing feeding operation, including: if the components do not reach the standards, judging the types and the weights of the additional alloy, sending a charging instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute charging operation, and waiting for 5 minutes after the completion of the charging operation of the additional alloy;
in the step 4, the vacuum degree is set to be less than or equal to 15Pa, the power supply power is more than or equal to 80KW, and the power supply time is more than or equal to 5min;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to temperature measurement equipment to measure the temperature, and whether the measured temperature meets the standard is judged; if the measured temperature does not reach the standard, the additional power operation is executed, and the step 5 is returned to, and whether the measured temperature reaches the standard is continuously judged; if the measured temperature reaches the standard, executing the step 6;
the performing the supplemental power operation includes: setting the additional power to 120KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in the step 5, the vacuum degree is set to be less than or equal to 15Pa;
step 6, the full-automatic intelligent vacuum induction smelting model sends a pouring instruction to the furnace body, and the furnace body is gradually inclined at an inclination speed of 0.2-2 degrees/s; in the casting process, analyzing the casting speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the casting 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 types and the corresponding pouring speed so as to realize the pouring of the alloy liquid.
After the scheme is implemented, the production rate of a 500kg smelting furnace is improved by 3.8%, the product percent of pass 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 smelting superalloy master alloy smelting process, and the specific scheme is as follows:
step 1, determining ingredients of master alloy and addition amount of each alloy element according to smelting targets and a raw material component library;
the determining of 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 comprises Ni, cr, co, mo, W, and the addition sequence of the alloy elements is Ni, cr, co, mo, W;
the second batch of alloy elements comprise Hf and B, and the addition sequence of the alloy elements is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the addition sequence of the alloy elements is Al and Ti;
the above elements may also be added by way of a master alloy, the yield of which is determined according to the yield of the volatile element.
Before the step 1, the method further comprises: performing automatic transformation and upgrading on equipment of the 2T vacuum induction furnace to realize automatic operation on processes of batching calculation, feeding, smelting, pouring and the like, realize real-time display of various smelting data and equipment data in the smelting process, and write a full-automatic intelligent vacuum induction smelting model;
step 2, during smelting, the 2T vacuum induction furnace sets a smelting process as six stages of a charging period, a melting period, a primary refining period and a secondary refining period, and sets charging conditions, power supply time and vacuum degree of each stage respectively;
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 450KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 850KW, and the power supply time is more than or equal to 30min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
setting the vacuum degree to be less than or equal to 15Pa, the power supply power to be more than or equal to 300KW and the power supply time to be more than or equal to 2min in the casting period;
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 sampling component is analyzed by a stokehole rapid analysis and detection device, and data is 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 standards according to the alloy components of the smelting target by the full-automatic intelligent vacuum induction smelting model; if the components do not reach the standards, feeding operation is carried out, and the step 4 is returned to continuously judge whether the components of the high-temperature master alloy reach the standards; if the components reach the standards, executing the step 5;
and if the components do not reach the standards, executing feeding operation, including: if the components do not reach the standards, judging the types and the weights of the additional alloy, sending a charging instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute charging operation, and waiting for 5 minutes after the completion of the charging operation of the additional alloy;
in the step 4, 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 5min;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to temperature measurement equipment to measure the temperature, and whether the measured temperature meets the standard is judged; if the measured temperature does not reach the standard, the additional power operation is executed, and the step 5 is returned to, and whether the measured temperature reaches the standard is continuously judged; if the measured temperature reaches the standard, executing the step 6;
the performing the supplemental power operation includes: setting the additional power to 250KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in the step 5, the vacuum degree is set 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 is gradually inclined at an inclination speed of 0.2-1.5 degrees/s; in the casting process, analyzing the casting speed of the alloy liquid in real time through liquid flow detection equipment, and controlling the casting 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 types and the corresponding pouring speed so as to realize the pouring of the alloy liquid.
After the scheme is implemented, the productivity of the 2T smelting furnace is improved by 4.1 percent, the product percent of pass is improved by 5.8 percent, and the alloy yield is improved by 3.8 percent.
On the basis of the above description, the above technical solutions of the present application are summarized. From the viewpoint of realizing functions, the technical scheme of the application comprises five stages of early preparation of full-automatic intelligent vacuum induction smelting, optimal design of model ingredients, automatic setting of smelting process, judgment and compensation measures of alloy components and temperature and judgment of casting conditions, and the following steps are summarized respectively:
stage 1: early preparation of full-automatic intelligent vacuum induction smelting
The automatic transformation and upgrading of equipment are carried out on the processes of feeding, smelting, pouring and the like, the automatic operation on the processes of proportioning 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 smelting model is compiled.
Stage 2: model batching optimization design
According to material balance calculation, high-temperature alloy master alloy ingredients are optimally designed according to smelting target components, a raw material component library and raw material proportions, and the addition sequence of alloy elements, the yield of the alloy elements and other factors are comprehensively considered during calculation, so that the alloy and the weight which need to be added in batches in the furnace are determined. And sending the raw material list to a raw material warehouse, enabling the raw material warehouse to dose according to the list, and sending the dosed raw materials to a production site.
Stage 3: automatic setting of smelting process
After the optimal design of ingredients is completed, the full-automatic intelligent vacuum induction smelting model can send tooling requirements to the production part according to program setting and historical smelting conditions, and the production part assembles the tooling, performs preheating treatment and the like.
When the preparation of ingredients and tools is completed, the full-automatic intelligent vacuum induction smelting model performs staged setting (feeding, melting, refining and the like) on feeding sequence, power supply time, vacuum degree and the like according to the requirements of ingredients, temperature and the like of smelting targets, and different alloys are added at different smelting times by controlling a PLC system, so that the automatic control of parameters such as the power supply, the power supply time, the vacuum degree and the like is realized.
Stage 4: determination and compensation measures for alloy composition and temperature
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 detects components and sends data to the full-automatic intelligent vacuum induction smelting model. At this time, the model judges whether the components of the high-temperature master alloy reach the standards according to the target components of the alloy, if the components do not reach the standards, the type, the weight and the weight of the added alloy are judged, a command is sent to carry out feeding, and the component detection and judgment flow is carried out again after the added alloy is added for a certain time.
And after the component detection is qualified, the model sends a signal to the temperature measurement equipment to measure the temperature, if the temperature does not reach the standard, the power and the time of the power supply are calculated and supplemented through the model, and after the equal power supplementation is completed, the temperature measurement and the judgment flow are carried out again.
Stage 5: determination of casting conditions
When 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 incline gradually, in the process of pouring the master alloy into the tool, the pouring speed of the alloy liquid is analyzed at any time through the liquid flow detection equipment and is fed back to the model, and the model adjusts the inclination angle according to the alloy type and the historical optimal pouring speed, so that the optimal pouring of the alloy liquid is realized.
The intelligent method for vacuum induction melting of the superalloy master alloy is suitable for 20kg-20T vacuum induction melting equipment.
The functions described above in the present 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), etc.
Moreover, although 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. In 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 limiting the scope of the present 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 apparatus logic acts, 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 example forms of implementing the claims.
Claims (9)
1. An intelligent vacuum melting method for high-temperature alloy master alloy is characterized by comprising the following steps:
step 1, determining ingredients of master alloy and addition amount of each alloy element according to smelting targets, a raw material component library and raw material proportions;
step 2, setting a smelting process into six stages of a charging period, a melting period, a primary refining period, a secondary refining period, a stirring period and a pouring period by a vacuum induction furnace during smelting, and setting charging conditions, power supply time and vacuum degree of each stage respectively;
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 sampling component is analyzed by a stokehole rapid analysis and detection device, and data is 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 standards according to the alloy components of the smelting target by the full-automatic intelligent vacuum induction smelting model; if the components do not reach the standards, feeding operation is carried out, and the step 4 is returned to continuously judge whether the components of the high-temperature master alloy reach the standards; if the components reach the standards, executing the step 5;
step 5, the full-automatic intelligent vacuum induction melting model sends a temperature measurement signal to temperature measurement equipment to measure the temperature, and whether the measured temperature meets the standard is judged; if the measured temperature does not reach the standard, the additional power operation is executed, and the step 5 is returned to, and whether the measured temperature reaches the standard is continuously judged; if the measured temperature reaches the standard, executing the step 6;
step 6, the full-automatic intelligent vacuum induction smelting model sends a pouring instruction to the furnace body, and the furnace body is controlled to incline gradually according to a set inclination speed; in the casting process, the casting speed of the alloy liquid is analyzed in real time through liquid flow detection equipment, and the casting speed of the alloy liquid is controlled according to a set value; the full-automatic intelligent vacuum induction melting model adjusts the inclination angle according to the alloy mark and the corresponding pouring speed so as to realize the smooth pouring of the alloy liquid;
the determining of 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 alloying elements included Ni, cr, co, mo, W with an addition sequence of Ni, cr, co, mo, W;
the second alloy elements comprise Hf and B, and the adding sequence is Hf and B;
the third batch of alloy elements comprise Al and Ti, and the addition sequence is Al and Ti;
the above elements may also be added by way of a master alloy, the yield of which is determined according to the yield of the volatile element.
2. The method according to claim 1, wherein prior to step 1, the method further comprises: the automatic transformation and upgrading of the equipment of the vacuum induction furnace are carried out so as to realize the automatic operation of the processes of batching calculation, feeding, smelting and pouring, realize the real-time display of various smelting data and equipment data in the smelting process, and write a full-automatic intelligent vacuum induction smelting model.
3. The method according to claim 1, wherein the setting of the charging condition and the power supply, the time of the power supply and the vacuum degree of each stage for the application scenario of the 500kg vacuum induction furnace comprises:
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 60KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 120KW, and the power supply time is more than or equal to 40min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
the casting period 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.
4. The method according to claim 1, wherein the setting of the charging condition and the power supply, the time of the power supply and the vacuum degree of each stage respectively comprises, for the application scenario of the 2T vacuum induction furnace:
adding a first batch of alloy elements in the feeding period, setting the vacuum degree to be less than or equal to 30Pa, and supplying power to be more than or equal to 450KW for more than or equal to 10min;
the melting period is set to be less than or equal to 20Pa, the power supply power is more than or equal to 850KW, and the power supply time is more than or equal to 30min;
adding a second batch of alloy elements in the primary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
adding a third batch of alloy elements in the secondary refining period, setting the vacuum degree to be less than or equal to 15Pa, and setting 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;
setting the vacuum degree to be less than or equal to 15Pa, and setting the power supply power to be the inherent stirring power set by the equipment, wherein the power supply time is more than or equal to 5min;
the casting period 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.
5. The method of claim 1, wherein the performing the dosing operation if the composition does not meet the criteria comprises: if the components do not reach the standards, judging the types and the weights of the additional alloy, sending a charging instruction to the PLC by the full-automatic intelligent vacuum induction melting model to execute charging operation, and waiting for 5 minutes after the completion of the charging operation of the additional alloy.
6. A method according to claim 3, wherein in step 4, the vacuum degree is set to be 15Pa or less, the power supply power is 80KW or more, and the power supply time is 5min or more;
and if the measured temperature does not reach the standard, executing the additional power operation, including: setting the additional power to 120KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in step 5, the vacuum degree is set to be 15Pa or less.
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 power is more than or equal to 100KW, and the power supply time is more than or equal to 5min;
and if the measured temperature does not reach the standard, executing the additional power operation, including: setting the additional power to 250KW, calculating the time of the additional power through a full-automatic intelligent vacuum induction smelting model, and finishing the additional power operation according to the time; in step 5, the vacuum degree is set to be 15Pa or less.
8. A method according to claim 3, wherein the tilting speed is 0.2 °/s to 2 °/s; the casting speed of the alloy liquid is 1.04kg/s-9.21kg/s.
9. The method of claim 4, wherein the tilt speed is from 0.2 °/s to 1.5 °/s; the casting speed of the alloy liquid is 2kg/s-10kg/s.
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