CN116904755A - Vacuum consumable remelting smelting method for reducing oxide inclusion content - Google Patents
Vacuum consumable remelting smelting method for reducing oxide inclusion content Download PDFInfo
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- 238000003723 Smelting Methods 0.000 title claims abstract description 45
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- 238000005728 strengthening Methods 0.000 claims abstract description 3
- 230000008569 process Effects 0.000 claims description 33
- 238000005259 measurement Methods 0.000 claims description 11
- 229910052799 carbon Inorganic materials 0.000 claims description 8
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 239000007772 electrode material Substances 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 2
- 229910045601 alloy Inorganic materials 0.000 abstract description 53
- 239000000956 alloy Substances 0.000 abstract description 53
- 239000007788 liquid Substances 0.000 abstract description 28
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- 230000008018 melting Effects 0.000 abstract description 19
- 238000006243 chemical reaction Methods 0.000 abstract description 12
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- 238000005242 forging Methods 0.000 description 20
- 239000010963 304 stainless steel Substances 0.000 description 16
- 229910000589 SAE 304 stainless steel Inorganic materials 0.000 description 16
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- 238000011156 evaluation Methods 0.000 description 7
- 230000002349 favourable effect Effects 0.000 description 6
- 239000002893 slag Substances 0.000 description 6
- 229910001220 stainless steel Inorganic materials 0.000 description 6
- 239000010935 stainless steel Substances 0.000 description 6
- 230000001276 controlling effect Effects 0.000 description 5
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- 229910000975 Carbon steel Inorganic materials 0.000 description 1
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Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/16—Remelting metals
- C22B9/20—Arc remelting
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/06—Deoxidising, e.g. killing
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/04—Refining by applying a vacuum
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Abstract
The invention provides a vacuum consumable remelting smelting method for reducing oxide inclusion content, which is characterized in that the remelting speed is determined according to the inner diameter of a crystallizer, oxide inclusion is removed in a mode of strengthening reduction of C element oxide by controlling the remelting speed, and a reaction product is CO. Further, by employing a larger remelting arc spacing and liquid level ring width, the occurrence of C-deoiling reaction is promoted under low melting rate conditions. The high vacuum is matched, more O in remelted alloy is removed from a smelting system in a CO form through vacuumizing, and the problem of oxide inclusion residues is reduced.
Description
Technical Field
The invention relates to the technical field of alloy smelting, in particular to a vacuum consumable remelting smelting method for reducing oxide inclusion content.
Background
The high-quality alloy is usually cast into an electrode by vacuum induction smelting, and then remelted into an ingot by a vacuum consumable arc furnace, so that the properties of plasticity, high-temperature durable strength, fatigue strength and the like of the alloy can be improved. The arc length is usually controlled during smelting to ensure the smelting process to be stable, and the final capping process is optimized to reduce shrinkage cavity. Low voltage, high current dc power supplies are typically used for power.
Vacuum consumable arc melting (Vacuum Arc Remelting, abbreviated as VAR) is to generate an electric arc between an electrode and a copper crucible bottom plate placed in a water jacket by using a direct current power supply under a vacuum state, the electric arc is heated to generate high heat, the electrode is melted, the electrode is continuously lowered and melted, a molten pool is formed in a water-cooled copper crucible, and the melted metal is rapidly solidified, crystallized and solidified into ingots.
The vacuum arc melting is generally used for refining easily-oxidized metals and alloys such as stainless steel, super alloy, titanium zirconium tantalum niobium tungsten molybdenum, and the like, reduces the loss of active elements (such as Al and Ti), has controllable ingot solidification process, and remarkably improves the cleanliness, uniformity, fatigue resistance and fracture toughness of the ingot, so that the structure of the alloy is good in uniformity and uniformity, the number of inclusions is small, and the purity of the alloy is further improved. Vacuum arc melting is well suited for melting special steels, reactive and refractory metals such as titanium, molybdenum, niobium.
In conventional vacuum consumable remelting, inclusions float up to the surface of the molten pool mainly by a floating action, and then move around and are removed by being discharged to the surface area of the remelted ingot, so that the inclusion content is reduced. However, oxide inclusions in the removal process still maintain the compound form and are not truly excluded from the smelting system.
Therefore, there is a need for a vacuum consumable remelting method for reducing the content of oxide inclusions so as to reduce the oxide inclusions in alloy spindles obtained by the vacuum consumable remelting method, thereby obtaining high-quality alloys.
Disclosure of Invention
In view of the above, the invention provides a vacuum consumable remelting smelting method for reducing oxide inclusion content, which aims at reducing or even removing oxide inclusion in an alloy to obtain a high-quality alloy.
In order to achieve the above purpose, the present invention mainly provides the following technical solutions:
the embodiment of the invention provides a vacuum consumable remelting smelting method for reducing oxide inclusion content, which is characterized in that the remelting speed is determined according to the inner diameter of a crystallizer, oxide inclusion is removed in a mode of strengthening reduction of C element oxide by controlling the remelting speed, and a reaction product is CO.
In some embodiments, the average kg number of remelting per hour = millimeter value of the inner diameter of the crystallizer x
(0.4-0.7) to reduce the total amount of substances in the plasma in the arc zone, thereby increasing the time for deoxidizing the carbon and reducing the number of inclusions in the consumable remelted ingot.
In some embodiments, the arc spacing of the remelting is controlled to be maintained within the range of 15-19mm to enlarge the volume of an arc zone, so that oxide inclusions are mainly removed in a reduced form of C element in the vacuum consumable remelting smelting process, and a reaction product is CO.
In some embodiments, the bath level loop width = (crystallizer inside diameter x 0.06+19) ±2.5, in mm, is controlled to increase the bath exposed level area.
In some embodiments, calibration of the arc spacing of the consumable remelting is measured using a method that forces the electrodes to drop quickly to a short circuit.
In some embodiments, the method of arc distance measurement is: before operation, the stroke position of the electrode material rod is recorded, then the electrode is forced to quickly descend until short circuit occurs, namely remelting arc light disappears, and the corresponding stroke position of the electrode material rod is recorded at the moment; and subtracting the travel position before operation from the travel position at the moment of short circuit occurrence, wherein the difference is the arc distance.
In some embodiments, the timing of the measurement is selected when the remelted ingot height is in the range of 1/2 crystallizer diameter to 2/3 crystallizer diameter.
In some embodiments, the rate of force electrode descent is between 1.3mm/s and 1.7mm/s.
In some embodiments, the remelting vacuum is controlled below 0.5 Pa.
In some embodiments, kg number per hour remelting = millimeter value of crystallizer inside diameter x (0.44-0.65) is averaged to reduce the total amount of material of the arc zone plasma.
Compared with the prior art, the vacuum consumable remelting smelting method for reducing the oxide inclusion content has at least the following beneficial effects:
the effect of C reduced oxide inclusion in consumable remelting is enhanced, and deoxidized product CO is removed from a smelting system in a gas form, so that the amount of oxide inclusion residues in remelted ingots is reduced. Specifically:
(1) The remelting speed in the steady-state stage is set at a lower level, so that the total deoxidization reaction time is prolonged, and oxide inclusion is promoted to be reduced by C element more;
(2) On the basis of (1), the arc distance of the consumable remelting is set to a specific size, so that favorable conditions can be further provided for CO gas escape of a reaction product of C reduction oxide inclusion;
(3) On the basis of (1), the width of the liquid level ring of the molten pool is set to be larger, so that more favorable conditions can be further provided for the CO gas escape of the reaction product of C reduction oxide inclusion; if superimposed on (2), further favorable conditions are provided for CO gas escape of the reaction product of C reduction oxide inclusion;
(4) Further, by reducing the smelting vacuum, more ideal metallurgical thermodynamic conditions can be provided for the inclusion of the C-reduced oxide.
The foregoing description is only an overview of the present invention, and is intended to provide a better understanding of the present invention, as it is embodied in the following description, with reference to the preferred embodiments of the present invention and the accompanying drawings.
Drawings
FIG. 1 is a vacuum consumable remelting 15Cr-15Ni-Fe post-forging inclusion for example 1 of the present invention; wherein, the (a) diagram in FIG. 1 is the case of the alloy head inclusion prepared in example 1; FIG. 1 (b) is a view showing the case of inclusions in the middle of the alloy prepared in example 1; fig. 1 (c) shows the case of the alloy tail inclusion prepared in example 1.
FIG. 2 is a diagram of example 2 of the present invention showing inclusions after vacuum consumable remelting 316 stainless steel forging; wherein, the (a) diagram in fig. 2 is the case of the alloy head inclusion prepared in example 2; fig. 2 (b) shows the case of the alloy tail inclusion prepared in example 2.
FIG. 3 is a diagram of example 3 vacuum consumable remelting 304 stainless steel post-forging inclusion conditions in accordance with the invention; wherein, the (a) diagram in FIG. 3 is the case of the alloy head inclusion prepared in example 3; fig. 3 (b) shows the case of the alloy tail inclusion prepared in example 3.
FIG. 4 is a graph showing the case of different types of inclusions after forging the vacuum consumable remelting 304 stainless steel of comparative example 1; wherein, the graph (a) in FIG. 4 shows the case of the alloy head inclusion prepared in comparative example 1, D Thin and fine =0.5; FIG. 4 (b) is a view showing the case of the alloy head inclusion prepared in comparative example 1, D Coarse size =0.5; fig. 4 (c) shows the case of the alloy head inclusion prepared in comparative example 1, ds=0.5; FIG. 4 (D) is a diagram showing the condition of the alloy tail inclusion prepared in comparative example 1, D Thin and fine =1.0; FIG. 4 is a graph (e) showing the condition of the alloy tail inclusion prepared in comparative example 1, D Coarse size =0.5; fig. 4 (f) shows the case of the alloy tail inclusion prepared in comparative example 1, ds=0.5.
FIG. 5 is a graph of different types of inclusions after forging of comparative example 2 vacuum consumable remelting 304 stainless steel; wherein, the graph (a) in FIG. 5 shows the case of the alloy head inclusion prepared in comparative example 2, D Thin and fine =1.0; FIG. 5 (b) is a view showing the case of the alloy head inclusion prepared in comparative example 2, D Coarse size =0.5; fig. 5 (c) shows the case of the alloy head inclusion prepared in comparative example 2, ds=0.5; FIG. 5 (D) is a diagram showing the condition of the alloy tail inclusion prepared in comparative example 2, D Thin and fine =1.0; FIG. 5 (e) is a diagram showing the condition of the alloy tail inclusion prepared in comparative example 2, D Coarse size =0.5; fig. 5 (f) shows the case of the alloy tail inclusion prepared in comparative example 2, ds=0.5.
FIG. 6 is a graph of different types of inclusions after forging of comparative example 3 vacuum consumable remelted 316 stainless steel; wherein (a) in FIG. 6) FIG. D is a drawing showing the case of the alloy head inclusion prepared in comparative example 3 Thin and fine =1.5; FIG. 6 (b) is a view showing the condition of the alloy tail inclusion prepared in comparative example 3, D Thin and fine ＝1.5。
FIG. 7 is a graph of different types of inclusions after forging of comparative example 4 vacuum consumable remelted 316 stainless steel; wherein FIG. 7 (a) is a view showing the case of the alloy head inclusion prepared in comparative example 4, D Coarse size =0.5; FIG. 7 (b) is a view showing the case of the alloy head inclusion prepared in comparative example 4, D Thin and fine =1.0; FIG. 7 (c) is a view showing the condition of the alloy tail inclusion prepared in comparative example 4, D Coarse size =0.5; FIG. 7 (D) is a diagram showing the condition of the alloy tail inclusion, D, prepared in comparative example 4 Thin and fine ＝1.0。
Detailed Description
In order to further describe the technical means and effects adopted for achieving the preset aim of the invention, the following detailed description refers to the specific implementation, structure, characteristics and effects according to the application of the invention with reference to the accompanying drawings and preferred embodiments. In the following description, different "an embodiment" or "an embodiment" do not necessarily refer to the same embodiment. Furthermore, the particular features, structures, or characteristics of one or more embodiments may be combined in any suitable manner.
In conventional vacuum consumable remelting, inclusions are removed primarily by floating up to the surface of the molten pool, then moving around and being removed to the surface area of the remelted ingot. The oxide inclusions in the removal process still maintain the compound form and are not truly excluded from the smelting system.
The conception of the invention is as follows: only when oxygen is changed into gas, the oxygen can be thoroughly separated from the smelting system, so that the problem that oxides are mixed in metal does not exist. Therefore, oxide inclusions smelted by the method are mainly removed in a form of reduction by C element, and a reaction product CO is removed from a smelting system by vacuumizing. In order to obtain better C-O reaction to deoxidize and reduce the content of alloy inclusions, the inventor discovers that the melting speed selection of alloy vacuum consumable remelting has a clear corresponding relation with the diameter of a crystallizer. Vacuum consumable remelting of stainless steel under conventional conditions, wherein when the diameter of a crystallizer is 508mm, the remelting speed is basically 508X (1.1-0.9) kg/h, namely 559kg/h-457kg/h; when the diameter of the mold is 350mm, the rate of remelting can be selected to be 350X (1.1-0.9) kg/h, i.e., 385kg/h to 315kg/h. The invention discloses an average remelting kg number per hour=millimeter value of the inner diameter of a crystallizer x (0.4-0.7), wherein the measurement unit kg/h at the left end and the measurement unit mm at the right end of an equation are ignored, only specific values are considered, and the process principle is as follows: the remelting speed directly determines the total smelting time of the alloy, namely the duration time equivalent to the vacuum refining deoxidation of the alloy. In the invention, the average remelting kg number per hour=the millimeter value of the inner diameter of the crystallizer is x (0.4-0.7), and compared with the total smelting time of x (1.1-0.9), the method can prolong the total smelting time by 28-57%, more effectively improve the time of deoxidizing and reducing the oxide by carbon, and ensure that the number of inclusions of the consumable remelting ingot is effectively reduced. The purpose of the average remelting kg number per hour > the millimeter value of the inner diameter of the crystallizer multiplied by 0.4 is to avoid the necessary input of limiting the melting power by excessively low melting speed, so that the surface quality of a consumable remelting ingot can be deteriorated, the lower limit of the remelting speed can be defined, the activity degree of a molten pool in the remelting process can be ensured, and the metallurgical kinetic condition of carbon deoxidized reduced oxide is ensured.
Further, the inventors have found that the lower the actual vacuum value of the reaction arc zone, the better.
In the vacuum consumable remelting process, a vacuum gauge for monitoring the running state of equipment shows a vacuum degree value which is not consistent with the vacuum degree of an actual reaction arc zone. The actual reaction arc zone is typically much more evacuated than the vacuum gauge displays, and there are reports that the vacuum is between about 133Pa and 1330Pa, but there is no support for more evidence of reliability. Although the vacuum level of the reaction arc zone cannot be measured accurately, the inventors found that the magnitude of the vacuum level is mainly influenced by the total amount of plasma substances in the arc zone and the volume of the arc zone. Therefore, in order to achieve the purpose of the invention, the invention ensures that oxide inclusions are mainly removed in a form of reduction by C element in the vacuum consumable remelting smelting process by reducing the total amount of plasma substances in an arc zone and expanding the volume of the arc zone, and the reaction product is CO. Wherein the total amount of plasma substances in the arc zone is reduced by controlling the average remelting kg number per hour=millimeter value of the inner diameter of the crystallizer x (0.4-0.7), and the volume of the arc zone is enlarged by controlling the arc interval to be maintained in the range of 15-19 mm.
Conventional vacuum consumable remelting arc spacing control mainly has two options, one is to maintain the arc spacing by adopting a voltage control method, and the operation belongs to long-arc operation, and the arc spacing is generally controlled to be 20-30 mm. The other is to use a droplet control method to maintain the arc distance, and the operation belongs to a short arc operation, and basically the arc distance is controlled to be 5-12.5 mm.
The inventors of the present invention found that a remelted ingot with a low inclusion content could not be obtained by controlling the arc distance to be larger than 19mm under the conditions of melting kg number per hour=millimeter value of the inner diameter of the mold x (0.4 to 0.7). Further analysis and research show that the arc distance is larger than 19mm for smelting, and the heat radiated outwards from the liquid surface of the molten pool is large due to the large arc distance, so that the liquid surface of the molten pool is severely cooled, the liquid surface temperature distribution is uneven, and particularly the fluidity of the alloy liquid near the cooling wall of the crystallizer is greatly reduced. In the remelting process, slag formed by oxide inclusions which are not reduced into CO gas by C floats on the metal liquid surface, and the floating slag flows to the surrounding (namely the inner wall of the crystallizer) position under the drive of heat flow and possibly is captured by the wall of the crystallizer, namely stays on the surface of a consumable ingot and is stripped in the stripping process. However, due to the large distance between consumable remelting arcs, the alloy liquid near the wall of the crystallizer has poor fluidity, and floating slag can be fixed by pasty alloy liquid and finally solidified and remained in the consumable ingot when the slag does not reach the wall of the crystallizer, so that oxides are randomly distributed in the consumable ingot for remelting, and the inclusion content of the remelted ingot is increased. Meanwhile, under the condition that the arc distance is larger than 19mm, a large amount of splashed metal droplets adhere to the inner wall of the crystallizer in the remelting process. As the smelting progresses, the alloy level rises and eventually covers the metal splatters adhering to the inner walls of the crystallizer. Due to the strong cooling effect of the crystallizer, the pre-adhered metal splashes cannot be heated by alloy liquid to remelt and melt, so that the residues of the metal splashes seriously deteriorate the surface quality of a remelted ingot, and the peeling and turning quantity of the consumable ingot is increased.
The inventors found that it was also difficult to obtain good remelted ingot quality when the arc spacing was controlled to be less than 15 mm. Further studies have been carried out to find that, within this parameter range, if the raw material electrode is thoroughly deoxidized, the remelting operation can be smoothly carried out, and excellent consumable ingot surface quality can be obtained. However, it is not preferable to perform consumable remelting in a region of less than 15mm for a raw electrode having a general deoxidizing effect (particularly, stainless steel). The reason for this is that the CO gas escape of deoxidization products generated by combining a large amount of oxygen and carbon in the alloy under vacuum conditions is inhibited by short arc distance, so that the exhaust is not smooth. The amount of CO that is suppressed gradually builds up and after exceeding the critical conditions for evolution, the CO gas will evolve explosively. The short-time large amount of escaped CO gas causes the remelting arc to be changed into gathering distribution from dispersion distribution, the remelting electrode is directly conducted with the crystallizer, natural fluctuation of smelting voltage and current disappears, the arc heat is no longer uniform to heat the remelting electrode, finally, the alloy liquid level is forced to be cooled and even solidified, and obvious fluctuation occurs in the remelting process. In the process of cooling or even solidifying the alloy liquid surface, slag floating on the liquid surface can be randomly wrapped by solidified alloy, so that inclusions in a consumable ingot are increased. And the CO is generated again after bursting, is restrained by a short arc and gradually accumulated until the CO is escaped again in a large amount in a short time after exceeding a critical condition, so that the inclusion wrapping action can also periodically occur in consumable remelting, and further the quality of a finished product is reduced.
The inventor aims to overcome the defects that the long arc distance molten pool crystallizer has poor edge fluidity and is easy to roll slag and short arc distance CO burst to escape, selects a specific 15-19mm arc distance as a selected range of operation parameters, and can avoid the problems that the surface quality of a consumable ingot is poor, inclusions remain at the edge of a nearly consumable ingot but cannot be peeled off and removed due to long arc operation on the basis that the remelting speed in a steady-state stage is set at a lower level, and can also effectively avoid the problems that the remelting periodicity is interrupted and the inclusions are randomly wrapped by low-temperature alloy liquid due to short arc operation.
Preferably, the width of the molten pool liquid level ring is = (the inner diameter of the crystallizer is multiplied by 0.06 plus 19) +/-2.5 (unit mm) so as to increase the exposed area of the molten pool, thereby better ensuring that the number of inclusions of the consumable remelted ingot is reduced in the vacuum consumable remelting smelting process. In order to pursue a smooth ingot surface and a shallow and flat bath shape, the width of the bath level ring (annular metal level with the inner wall of the mold as the outer diameter and the outer contour of the remelting electrode as the inner diameter, as seen by a camera) is usually selected to be 20-25mm. Wherein 20mm is selected when the crystallizer diameter is less than 200mm and 25mm is selected when the crystallizer diameter is greater than 400 mm. The inventors found that when the width of the molten pool liquid level ring is < (crystallizer inner diameter x 0.06+19) -2.5 (unit mm) under the condition that the average remelting kg number per hour=millimeter value of the inner diameter of the crystallizer is x (0.4-0.7), and the arc interval is 15-19mm (for example, the inner diameter of the crystallizer is 160mm corresponding to 26.1mm and the inner diameter of the crystallizer is 508mm corresponding to 46.98 mm), the reduction of the exposed area of the molten pool is affected during the vacuum consumable process, the degree of C deoiling is inhibited, the carbon reduction reaction is not facilitated, and the remelted ingot inclusion level is not low. When the width of the liquid level ring of the molten pool is > (the inner diameter of the crystallizer is multiplied by 0.06+19) +2.5 (unit mm) (for example, the inner diameter of the crystallizer is 160mm and corresponds to 31.1mm, the inner diameter of the crystallizer is 508mm and corresponds to 51.98 mm), the liquid level ring is influenced by the non-uniform temperature of the electric arc heating area, the solidification phenomenon occurs at the position of the molten pool close to the edge of the crystallizer in the vacuum self-consumption process, floating inclusions on the liquid level of the molten pool are captured by viscous paste metal, and the level of the remelted ingot inclusions is not low.
Further preferably, the arc distance is measured by a method of forcing the electrode to quickly descend to a short circuit, the control range of the descending speed of the electrode is 1.3mm/s-1.7mm/s, and the measuring time is selected when the height of the remelting ingot reaches the range of 1/2 crystallizer diameter-2/3 crystallizer diameter.
The conventional consumable remelting operation has loose control over the arc spacing, and the arc spacing measurement is less performed. Even if the arc distance measurement is performed, the arc distance measurement is performed in the final heat capping stage of smelting, and the speed of manually forcing the electrode to descend is not specially regulated. The arc distance measuring method has three defects: 1. the moment for measuring the arc distance at the final smelting stage is too late to find the abnormality of the arc length control parameters as early as possible; 2. the melting power is lower at the end of smelting, and the measurement of the arc distance can force the temperature of a molten pool to drop, so that abnormal solidification inclusion is clamped; 3. the descending speed of the electrode is not controlled specially, and the improper timing or inaccurate data of the travel position of the electrode material rod can be caused.
The invention has the difference that the control requirement on the arc distance is very high, and the arc distance must be measured and controlled by adopting corresponding means. The invention specially designs a process method for measuring the arc distance when the remelting ingot height reaches the range of 1/2 crystallizer diameter to 2/3 crystallizer diameter. The process method has the advantages that firstly, the arc distance can be measured as early as possible, the arc distance can be found and corrected in advance when the process operation is not ideal, and the arc distance can be controlled more accurately; secondly, the arc distance is measured in the early stage of smelting, so that the problems of abnormal solidification of molten steel and inclusion caused by short circuit temperature loss in the arc distance measuring period can be avoided by utilizing the characteristics of relatively large smelting current and relatively high molten pool temperature in the stage. In addition, the distance between the molten pool and the bottom plate of the crystallizer is short in the stage, the cooling intensity is high, the crystallization structure is basically in the vertical direction, the inclusion can be effectively pushed to float upwards, and the risk of inclusion increase caused by arc interval measurement is further reduced.
The method for measuring the arc distance comprises the steps of recording the stroke position of an electrode rod before operation, then forcing the electrode to quickly descend until a short circuit occurs (namely remelting arc disappears), and recording the corresponding stroke position of the electrode rod at the moment. And subtracting the travel position before operation from the travel position at the moment of short circuit occurrence, wherein the difference is the arc distance. After the specific electrode rapid descent operation described by the invention is adopted, the electrode descent speed is 1.3mm/s-1.7mm/s. The arc distance can be measured rapidly by adopting the speed reduction on the one hand, and the interference of electrode reduction of automatic control output on the accuracy of measurement data is avoided; on the other hand, the moment when the remelting arc light disappears can be clearly judged, and the judgment that the stroke position of the electrode rod is accurately read due to the fact that the electrode rod is excessively fast descended is avoided.
Preferably, the vacuum degree of the consumable remelting is controlled below 0.5 Pa.
In order to obtain better C-O reaction conditions for deoxidizing and reducing the content of alloy inclusions, the lower the smelting vacuum degree value is, the better. At a vacuum level of less than 0.5Pa, the actual vacuum value in the reaction arc zone is correspondingly reduced. The lower remelting speed can reduce the total amount of substances in the plasma in the arc zone, and the volume of the arc zone can be greatly enlarged by controlling the remelting arc interval to be maintained within the range of 15-19mm so as to obtain good C-O reaction conditions in a matched manner. The liquid level area of the molten pool is increased, and more ideal C-O reaction conditions can be further obtained by matching. In addition, a remelting vacuum of less than 0.5Pa also provides advantages for the C-O reaction in the exposed bath level ring region. The most preferable purpose of promoting the remelting C-O deoxidization reaction to remove the inclusions is achieved through the comprehensive application of four measures of low remelting speed, medium-high arc distance, large exposed molten pool area and high vacuum degree.
In the process method provided by the invention, the technical mechanism is as follows:
(1) The remelting speed in the steady-state stage is set at a lower level, so that the total deoxidization reaction time is prolonged, and oxide inclusions are promoted to be reduced by C element more;
(2) On the basis of (1), the arc distance of the consumable remelting is set to a specific size, so that favorable conditions can be further provided for CO gas escape of a reaction product of C reduction oxide inclusion;
(3) On the basis of (1), the width of the liquid level ring of the molten pool is set to be larger, so that more favorable conditions can be further provided for the CO gas escape of the reaction product of C reduction oxide inclusion; if superimposed on (2), further favorable conditions are provided for CO gas escape of the reaction product of C reduction oxide inclusion;
(4) Further, by reducing the smelting vacuum, more ideal metallurgical thermodynamic conditions can be provided for the inclusion of the C-reduced oxide.
The invention has the advantages that: the effect of C reduced oxide inclusion in consumable remelting is enhanced, and deoxidized product CO is removed from a smelting system in a gas form, so that the amount of oxide inclusion residues in remelted ingots is reduced.
The invention is further illustrated by the following examples:
example 1
Smelting 15Cr-15Ni-Fe novel stainless steel on a 3 ton vacuum self-consuming melting furnace. The diameter of the remelting electrode is phi 410mm, the inner diameter of the crystallizer is phi 508mm, and the width of a molten pool liquid level ring is 49mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.16Pa and then starting arc melting. After the melt pool was established and stabilized, when the remelted ingot height reached 260mm and the vacuum was maintained at a level of 0.3Pa, the electrode was rapidly lowered by manual force at a rate of 1.5mm/s, and the arc gap was measured at 15mm and maintained. The ratio of the "hour melt rate to the inner diameter of the mold" at this time was found to be 0.47 by manually adjusting the current so as to maintain the melt rate at 4.0kg/min, that is, 240kg/h in the steady state period. Feeding is carried out when the residual weight of the electrode is less than 240kg, and smelting is finished when the residual weight of the electrode is 55 kg.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 210mm multiplied by 11110mm. The head is 0.5m away from the top of the rod, the tail is 0.5m away from the tail of the rod, 10mm thick slices are cut at the head, tail and middle positions of the forged finished bar, inclusion evaluation samples are prepared at 1/2 radius positions, and the levels of the inclusions at three positions are checked by adopting the GB/T10561 standard. None of the three samples were found to contain A, B, C, D class inclusions. Among them, class a-sulfides, class B-aluminas, class C-silicates, class D-spherical oxides. The vacuum consumable remelting 15Cr-15Ni-Fe post-forging inclusion conditions are specifically shown in Table 1 and FIG. 1.
TABLE 1 grading of inclusions after vacuum consumable remelting 15Cr-15Ni-Fe forging
Example 2
316 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 105mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 27.5mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.25Pa and then starting arc melting. After the melt pool was established and stabilized, when the remelted ingot height reached 93mm and the vacuum was maintained at a level of 0.35Pa, the electrode was rapidly lowered by manual force at a lowering speed of 1.7mm/s, and the arc spacing was measured and maintained at 19 mm. The "hour melt rate/crystallizer internal diameter" ratio was calculated to be 0.65 by manual current adjustment to maintain a steady state melt rate of 107 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The position 0.25m away from the top of the rod is the head, the position 0.25m away from the tail of the rod is the tail, 10mm thick slices are cut at the head and tail positions of the forged finished bar because of smaller ingot shape, inclusion evaluation samples are prepared at the 1/2 radius positions, and the inclusion levels at the two positions are checked by adopting the GB/T10561 standard. No A, B, C class inclusions were found by inspection, very few class D inclusions were found, and the rating was a fine class 0.5. Among them, class a-sulfides, class B-aluminas, class C-silicates, class D-spherical oxides. The inclusion conditions after vacuum consumable remelting 316 stainless steel forging can be seen in particular in table 2 and fig. 2.
TABLE 2 inclusion rating after vacuum consumable remelting 316 stainless steel forging
Example 3
304 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 98mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 31mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.25Pa and then starting arc melting. After the melt pool was established and stabilized, the arc gap was measured and maintained at 17mm by manually forcing the electrode to rapidly drop at a rate of 1.3mm/s after the remelting ingot height reached 107mm and the vacuum was maintained at a level of 0.35 Pa. The "hour melt rate/crystallizer internal diameter" ratio was calculated to be 0.44 by manually applying a current to maintain a steady state melt rate of 70 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The position 0.25m away from the top of the rod is the head, the position 0.25m away from the tail of the rod is the tail, 10mm thick slices are cut at the head and tail positions of the forged finished bar because of smaller ingot shape, inclusion evaluation samples are prepared at the 1/2 radius positions, and the inclusion levels at the two positions are checked by adopting the GB/T10561 standard. No A, B, C class inclusions were found by inspection, very few class D inclusions were found, and the rating was a fine class 0.5. Among them, class a-sulfides, class B-aluminas, class C-silicates, class D-spherical oxides. The inclusion conditions after forging the vacuum consumable remelting 304 stainless steel can be seen in particular in table 3 and fig. 3. Since there is only one type of inclusion at all locations in examples 1-3, there is only one picture at each location.
TABLE 3 rating of inclusions after vacuum consumable remelting 304 stainless steel forging
Comparative example 1
304 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 98mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 31mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.25Pa and then starting arc melting. The molten pool is built and stabilized, the vacuum degree is maintained at the level of 0.35Pa when the height of the remelted ingot reaches 107mm, the electrode is forced to rapidly descend by hand, the descending speed is 1.3mm/s, and the arc distance is measured and maintained to be 17 mm. The "hour melt rate/crystallizer inside diameter" ratio was calculated to be 0.80 by manually applying a current to maintain a steady state melt rate of 128 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The part 0.25m away from the rod top is the head part, the part 0.25m away from the rod tail is the tail part, and the ingot type is smaller, so that the rod head of the forged finished product is10mm thick sections were cut at the head and tail positions, inclusion evaluation samples were prepared at 1/2 radius positions, and three-position inclusion levels were examined using the GB/T10561 standard. No A, B, C inclusions were found, D, DS inclusions were found, and the ratings were D Thin and fine =0.5 to 1.0 grade, D Coarse size Level=0.5, ds=0.5. Wherein, the group A-sulfides, the group B-aluminas, the group C-silicates and the group D-spherical oxides, and the DS refers to punctiform inclusions of more than 13 μm.
The inclusion condition after forging of the vacuum consumable remelting 304 stainless steel of comparative example 1 can be seen in table 4 and fig. 4.
TABLE 4 inclusion rating after vacuum consumable remelting 304 stainless steel forging
Comparative example 2
304 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 98mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 31mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.25Pa and then starting arc melting. The molten pool is built and stabilized, the vacuum degree is maintained at the level of 0.35Pa when the height of the remelted ingot reaches 107mm, the electrode is forced to rapidly descend by hand, the descending speed is 1.3mm/s, and the arc distance is measured and maintained to be 17 mm. The "hour melt rate/crystallizer internal diameter" ratio was calculated to be 0.31 by manually applying a current to maintain a steady state melt rate of 50 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface quality of the consumable remelted ingot is poor, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The part 0.25m away from the top of the rod is the head part, the part 0.25m away from the tail of the rod is the tail part, 10mm thick slices are cut at the head part and the tail part of the forged finished bar because of smaller ingot shape, inclusion evaluation samples are prepared at the 1/2 radius positions, and the inclusion level at three positions is checked by adopting the GB/T10561 standard. No A, B, C inclusions were found and D, DS inclusions were foundRating of D respectively Thin and fine Level=1.0, D Coarse size Level=0.5, ds=0.5. Wherein, the group A-sulfides, the group B-aluminas, the group C-silicates and the group D-spherical oxides, and the DS refers to punctiform inclusions of more than 13 μm. The inclusion condition after forging of the vacuum consumable remelting 304 stainless steel of comparative example 2 can be seen in table 5 and fig. 5.
TABLE 5 rating of inclusions after vacuum consumable remelting 304 stainless steel forging
Comparative example 3
316 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 98mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 31mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.5Pa and then starting arc melting. The molten pool was established and stabilized, and the arc gap was measured and maintained at 17mm by manually forcing the electrode to rapidly drop at 1.3mm/s, with the vacuum maintained at a level of 1Pa, and the remelted ingot height reaching 107 mm. The "hour melt rate/crystallizer internal diameter" ratio was calculated to be 0.44 by manually applying a current to maintain a steady state melt rate of 70 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The part 0.25m away from the top of the rod is the head part, the part 0.25m away from the tail of the rod is the tail part, 10mm thick slices are cut at the head part and the tail part of the forged finished bar because of smaller ingot shape, inclusion evaluation samples are prepared at the 1/2 radius positions, and the inclusion level at three positions is checked by adopting the GB/T10561 standard. No A, B, C, DS inclusions were found by examination, D inclusions were found, and the ratings were D Thin and fine =1.5. Wherein, the group A-sulfides, the group B-aluminas, the group C-silicates and the group D-spherical oxides, and the DS refers to punctiform inclusions of more than 13 μm. The inclusion condition of the 304 stainless steel smelted by vacuum consumable remelting in comparative example 3 can be particularly referred toSee table 6 and fig. 6.
TABLE 6 grading inclusions after vacuum consumable remelting 304 stainless steel forging
Comparative example 4
316 stainless steel was smelted on a 0.2 ton vacuum self-weight furnace. The diameter of the remelting electrode is phi 80mm, the inner diameter of the crystallizer is phi 160mm, and the width of a molten pool liquid level ring is 40mm. And vacuumizing the equipment after furnace combination, and adopting a three-stage vacuum pump to suck the vacuum degree to 0.15Pa and then starting arc melting. The molten pool is built and stabilized, the vacuum degree is maintained at the level of 0.35Pa when the height of the remelted ingot reaches 107mm, the electrode is forced to rapidly descend by hand, the descending speed is 1.3mm/s, and the arc distance is measured and maintained to be 17 mm. The "hour melt rate/crystallizer internal diameter" ratio was calculated to be 0.44 by manually applying a current to maintain a steady state melt rate of 70 kg/h. Feeding is carried out after the residual length of the electrode is less than 200mm, and smelting is finished after power failure when the residual length of the electrode is 40mm.
The surface of the consumable remelting ingot is smooth, the consumable ingot is forged, and the size of a finished product is phi 80mm multiplied by 5100mm. The part 0.25m away from the top of the rod is the head part, the part 0.25m away from the tail of the rod is the tail part, 10mm thick slices are cut at the head part and the tail part of the forged finished bar because of smaller ingot shape, inclusion evaluation samples are prepared at the 1/2 radius positions, and the inclusion level at three positions is checked by adopting the GB/T10561 standard. No A, B, C, DS inclusions were found by examination, D inclusions were found, and the ratings were D Thin and fine Level=1.0, D Coarse size =0.5 stage. Wherein, the group A-sulfides, the group B-aluminas, the group C-silicates and the group D-spherical oxides, and the DS refers to punctiform inclusions of more than 13 μm. The inclusion condition after forging of the vacuum consumable remelting 304 stainless steel of comparative example 4 can be seen in table 7 and fig. 7.
TABLE 7 rating of inclusions after vacuum consumable remelting 304 stainless steel forging
Although both examples and comparative examples are stainless steel, the skilled artisan will appreciate that the process of the present invention is applicable not only to alloys such as stainless steel, carbon steel or Ni-based alloys that are suitable for vacuum consumable arc melting, but also to the process of the present invention.
The above description is only of the preferred embodiments of the present invention, and is not intended to limit the present invention in any way, but any simple modification, equivalent variation and modification made to the above embodiments according to the technical substance of the present invention still fall within the scope of the technical solution of the present invention.
Claims (10)
1. A vacuum consumable remelting smelting method for reducing oxide inclusion content is characterized by comprising the following steps: and determining the remelting speed according to the inner diameter of the crystallizer, and removing oxide inclusions in a mode of strengthening reduction of C element oxide by controlling the remelting speed, wherein a reaction product is CO.
2. The vacuum consumable remelting process for reducing oxide inclusion content of claim 1 wherein: average kg number per hour remelted = millimeter value of inner diameter of crystallizer x (0.4-0.7) to reduce total amount of substances in plasma in arc zone, thereby increasing time for deoxidizing oxide by carbon and reducing inclusion number of consumable remelted ingot.
3. The vacuum consumable remelting process for reducing oxide inclusion content of claim 1 wherein: the arc interval of remelting is controlled to be maintained within the range of 15-19mm so as to enlarge the volume of an arc zone, and oxide inclusions are mainly removed in a form of reduction by C element in the vacuum consumable remelting smelting process, and a reaction product is CO.
4. The vacuum consumable remelting process for reducing oxide inclusion content of claim 1 wherein: the bath level ring width = (crystallizer inside diameter x 0.06+19) ±2.5, unit mm was controlled to increase the bath exposed level area.
5. A vacuum consumable remelting process for reducing oxide inclusion content according to claim 3 wherein: calibration of the arc spacing of the consumable remelting is measured by a method of forcing the electrode to quickly drop to a short circuit.
6. The vacuum consumable remelting process for reducing oxide inclusion content of claim 5 wherein: the arc distance measuring method comprises the following steps: before operation, the stroke position of the electrode material rod is recorded, then the electrode is forced to quickly descend until short circuit occurs, namely remelting arc light disappears, and the corresponding stroke position of the electrode material rod is recorded at the moment; and subtracting the travel position before operation from the travel position at the moment of short circuit occurrence, wherein the difference is the arc distance.
7. The vacuum consumable remelting process for reducing oxide inclusion content of claim 5 wherein: the measurement time of the arc distance is selected when the remelting ingot height reaches the range of 1/2 crystallizer diameter to 2/3 crystallizer diameter.
8. The vacuum consumable remelting process for reducing oxide inclusion content of claim 5 wherein: the speed of the forced electrode drop is 1.3mm/s-1.7mm/s.
9. The vacuum consumable remelting process for reducing oxide inclusion content of claim 1 wherein: the remelting vacuum degree is controlled below 0.5 Pa.
10. The vacuum consumable remelting process for reducing oxide inclusion content of claim 1 wherein: average kg per hour remelting = millimeter value of crystallizer inside diameter x (0.44-0.65) to reduce total amount of material of the arc zone plasma.
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