EP1334214A1

EP1334214A1 - Method and device for producing ingots or strands of metal by melting electrodes in an electroconductive slag bath

Info

Publication number: EP1334214A1
Application number: EP01996632A
Authority: EP
Inventors: Wolfgang Holzgruber; Harald Holzgruber; Lev Medovar; Izrail Lantsman
Original assignee: Inteco Internationale Techinsche Beratung GmbH
Current assignee: Inteco Internationale Techinsche Beratung GmbH
Priority date: 2000-11-14
Filing date: 2001-11-09
Publication date: 2003-08-13
Anticipated expiration: 2021-11-09
Also published as: JP2004522852A; WO2002040726A1; AU2002221836A1; ATA19052000A; DE50105485D1; AT410413B; US20040040688A1; DE10154721A1; EP1334214B1; JP3676781B2; US6913066B2

Abstract

The invention relates to a method for producing metallic ingots or strands, especially from steel and Ni and Co based alloys, by melting self-consuming electrodes in an electroconductive slag bath, using an alternating current or a direct current in a short water-cooled mould which opens downwards, via which an electric contact can be produced for the slag bath. The supplied melt current is passed via the consumable electrode, the bottom plate, the remelt ingot and the melting bath, and optionally at least one electroconductive element of the mould, to the slag bath. The current distribution can be regulated in a controlled manner and the return circuit of the melt current passes back via at least one other electroconductive element of the mould, which is electrically isolated in relation to a first part of the mould which forms the remelt ingot. The proportion of the entire melt current supplied via the bottom plate is selected between 0 and 100 %. The device for carrying out said method uses a short, water-cooled mould having a bottom plate for creating a remelt ingot, and having at least one electroconductive element which is provided in the region of the slag bath. Said element is isolated in relation to the lower region of the mould, which forms the remelt ingot, and/or in relation to other electroconductive elements.

Description

DESCRIPTION

METHOD AND DEVICE FOR PRODUCING BLOCKS OR STRANDS OF METAL BY MELTING ELECTRODES IN AN ELECTRO-SLAG BATH

The invention relates to a method for producing blocks or strands of metal - in particular from steel as well as Ni and Co-based alloys - by melting self-consuming electrodes in an electrically conductive slag bath using alternating or direct current in a short, after water-cooled mold open at the bottom, via which a current contact to the slag bath can be established. The invention also includes a device for performing this method.

When remelting blocks are produced using the process of electroslag remelting in stand molds - but also in short slide molds - it is common, depending on the susceptibility of the remelted alloy to segregate, to set a melting rate in kilograms (kg) per hour, which for round blocks is between 70% and 110% of the block diameter in millimeters (mm). In the case of block shapes deviating from the round cross-section, such as square or flat formats, an equivalent diameter can be used, which is calculated from the cross-sectional circumference divided by the number π (Pi). The lower area is mainly used for strongly segregating alloys - such as tool steels or high-alloyed nickel base alloys - in which a flat metal sump is aimed at to avoid segregation. The value of 70% can hardly be undercut in the conventional ESR process, since then the power supply from the melting electrode into the slag bath has to be reduced very much, which results in a low temperature of the slag bath and subsequently a poor, often grooved surface of the remelting block has the consequence. If the power supply is too low for Slag bath then often also forms a thick slag jacket between the block and the mold, which in turn hinders the heat dissipation from the block surface, so that the desired flat melt sump cannot be achieved. On the other hand, even with steels and alloys that are not susceptible to segregation, a value of 110% cannot be exceeded in conventional electroslag remelting, the so-called ESR process, since otherwise the overheating of the slag bath together with the increased melting rate will result in an inadmissible deep sump and melting point for remelting blocks thus resulting in an undesirably coarse block structure - combined with segregations. As can easily be seen from what has been said above, in the conventional ESR process, in which the melt stream is conducted via the melting electrode into the slag bath and is then discharged again via the remelted block and the base plate, the slag bath temperature and the melting rate are - and in context thus the depth of the swamp and the formation of the surface - closely linked and cannot be controlled and controlled independently of one another and separately.

When manufacturing large diameter blocks of 1000 mm and above, it is shown that compliance with the desired low melting rates mentioned above, especially when using large diameter melting electrodes, corresponding to 65 to 85% of the mold diameter, leads to a slag bath temperature that is too low, which in turn then results in a poor, often grooved surface on the remelting block. Increasing in this case, the power supply to the slag, it does have an improvement in the ingot surface results in the same time the melting rate increases by more than the permissible limit, resulting in a lower melting ^"swamp and less favorable solidification. At that increase The melting rate with increased power supply to the slag bath occurs because the melting electrode serves on the one hand to supply energy to the slag bath, but on the other hand all the more melts faster, the more you increase the energy supply to the slag bath. The electrode must then be fed into the slag bath at the speed at which it melts. If the melting electrode were not topped up, it would melt to just above the surface of the slag bath, which would interrupt the electrical contact and thus the power supply to the slag bath. The remelting process would come to a standstill.

Another way to increase the slag bath is of smaller diameter electrodes zen umzusch ^'mel-. In this case, the end face of the electrode immersed in the slag bath is smaller, so that a comparatively hotter slag bath is required in order to achieve the desired melting rate. Although this measure can often be used to improve the surface of the block, the use of small-diameter electrodes leads to an increased heat concentration in the center of the block, which can result in a V-shaped recessed sump with an increased tendency to segregate.

All of the above-mentioned difficulties are caused by the fact that on the one hand the melting rate of the electrode is controlled by the energy supplied to the slag bath and on the other hand this energy supply must also be sufficient to keep the melting sump sufficiently liquid up to its edge and on to temporarily prevent the solidification from progressing beyond the meniscus of the melting sump. If, namely, due to a too low temperature of the slag bath temporarily to such a solidification progress across the meniscus of time, will result in the formation of an unfavorable for further processing of the blocks rilligen O ^'berflache result.

Industrial electro-slag remelting plants are operated practically exclusively with alternating current today, although alternating current plants with high current intensities, like the one at Electro-slag remelting are common and result in not inconsiderable losses in efficiency and blindness. These disadvantages are accepted, however, since both good metallurgical results and acceptable energy consumption figures are achieved when using alternating current. Already at the beginning of the technical application of the ESR process, attempts were made to operate the process with direct current. It was shown in the conventional routing of the melt stream via electrode, slag bath and block and base plate in conventional ESU systems that, regardless of the system switching, the liquid metal always formed either the cathode or the anode either at the electrode tip or in the melting sump. In principle, it would be desirable to switch the liquid metal as the cathode, since the process of metallurgical refining reactions, such as the breakdown of oxygen and sulfur, is promoted at the cathode interface. On the other hand, little heat is released at the cathode during the current transfer, since the contact resistance is low there due to the accumulation of extremely mobile small cations. At the anode, where large, hard-to-move anions collect, the contact resistance for the electrical current and thus the energy yield is high, but the absorption of anions, such as oxygen, sulfur, etc. from the slag must be expected, which is a Deterioration in the quality of the remelted metal. In contrast to this, when remelting with alternating current, the polarity of the interface changes constantly, both at the electrode tip and at the phase boundary between slag and melt sump with the frequency of the alternating current used. On the one hand, this leads to a relatively good use of current for the melting of the electrode metal and, on the other hand, to good metallurgical results, since the constant changing of the polarity at the phase interfaces favors the achievement of the thermodynamic equilibrium state. If, however, it is possible to switch all the occurring phase boundaries between metal and slag as the cathode, then a further improvement in the metallurgical results can also be expected.

EP 786 521 B1 by the applicant shows a process for remelting electroslag in which, by melting electrodes of comparatively large diameter, higher deposition rates are set than in conventional electroslag remelting. In the method described, part of the melt flow can be returned via current-conducting elements built into the mold wall. The arrangement leads to a division of the return line currents incorrectly proportional to the total resistance of the conductor loops used.

Knowing these circumstances, the inventor set the goal of being able to control the melting rate of the electrode independently of the temperature of the slag bath and at the same time to ensure a good block surface. In addition, when using direct current, it should be possible to switch both the end face of the melting electrode and the surface of the melting sump as the cathode.

The teaching of the independent claim leads to the solution of this task; the subclaims indicate favorable further training. In addition, all combinations of at least two of the features disclosed in the description, the drawing and / or the claims fall within the scope of the invention.

The problem outlined above is achieved in a surprisingly simple manner if, for the remelting of self-consuming electrodes under slag, a mold known per se with electrically insulated current-conducting elements built into the mold wall in the area of the slag bath and against the lower part of the mold that forms the remelting block is used, which can also be insulated from one another when using at least two such current-conducting elements. This will make it possible lent to supply or remove energy from the slag bath via the current-conducting elements in the mold wall and to heat it regardless of the current supply or discharge via the electrode or the block, so that the metal sump extends to the edge over the meniscus can be kept liquid. On the other hand, the melting rate of the consumable electrode can be controlled in a simple manner by the feed rate with which it is pushed into the overheated slag bath. The achievable melting rate will be higher the larger the end face and the immersion depth of the electrode immersed in the slag bath and the higher its temperature. The melting electrode can be completely currentless. However, it is also possible to conduct a partial flow over the electrode. It can be of interest here if the partial current passed through the electrode is a direct current which is switched in such a way that the electrode forms the negative pole, that is to say is the cathode. In principle, the block sump can also remain de-energized or a partial flow can be applied. When using direct current, a circuit as a cathode is also of interest for the block sump for the reasons mentioned above. If the block and the electrode are connected as the cathode, the return line can take place via current-conducting elements in the mold connected as an anode.

The remelting blocks formed in the lower part of the mold can either be pulled down from this or the mold is raised in the manner in which the block standing on a base plate grows.

The present invention thus relates to a method for producing blocks or strands from metals, in particular from steels and Ni and Co base alloys, by melting self-consuming electrodes in an electrically conductive slag bath in a short, water-cooled mold which is open at the bottom and is built into the mold wall current conducting elements, about which in In a manner known per se, a current contact to the slag bath can be produced, the melt flow supplied being able to be introduced into the slag bath both via the remelting block and the melt sump and, if appropriate, at least one current-conducting element of the mold, the melt flow being returned via at least one current-conducting element of the mold , which is electrically insulated from any former and also the part of the mold that forms the remelting block. In addition, it has proven to be advantageous that the proportion of current supplied via the melting electrode can be 0 to 100% of the total supplied melting current.

This method according to the invention described here in principle can be adapted in many ways to the requirements of the operator.

For example, the short, current-conducting mold can be permanently installed in a work platform and the remelting block can be removed downwards.

However, the block can also be built up on a fixed base plate and the mold can be raised in the manner in which the block grows. The block can be removed or the mold can be lifted continuously or step by step.

There is also the possibility of causing the mold to oscillate, which can be of particular interest in the case of continuous block removal.

In the case of a step-by-step block withdrawal or mold-lifting movement, an additional counter-stroke step can directly follow each stroke step, the step length of which can be up to 60% of the step length of the withdrawal stroke step. Further advantages, features and details of the invention result from the following description of preferred exemplary embodiments and from the drawing; this shows in:

1, 2, 4: each a longitudinal section through a

Casting device for metals with mold;

Fig. 3: an enlarged section through Fig. 2 along the line III - III.

A water-cooled mold 10 with a hollow ring-shaped mold body 12 is assigned a bottom plate 14, which in turn is hollow, according to FIG. 1, the outer diameter of which is slightly shorter than the inner diameter d of the mold 10; For starting up the plant, the base plate 14 can be pushed into the mold opening or the mold interior space 11 of height h until it runs directly below the upper edge 13 of the mold hollow body 12.

A ring-like insulating element 16 rests on the upper edge 13 and a current-conducting element 18 — likewise ring-like and / or made of several parts — rests on this; the latter is electrically insulated from the - nonconductive - insulating elements 16 against the water-cooled lower region 20 of the mold 10 and is separated from the top by an upper insulating element 16 _a from a water-cooled hollow ring 22. For the inventive use of the system described here, however, the upper insulating element 16 _{a is} not absolutely necessary.

On the base plate 14 there is - below a slag bath 24 and a sump 26 covered by this - a water-cooled lower one generated by a remelting process with self-consumable electrode 28 Area 20 of the mold 10 shaped remelting or pre-block 30. In order to start the process, liquid slag can, for example, be poured into the mold gap delimited by the mold 10 and the electrode 28, until the slag level 25 of the slag bath 24 that is formed approximately becomes the upper edge of the current-conducting element 16 _{a has} reached.

The supply of the melt stream to the slag bath 26 from an AC or DC source 36 takes place - depending on the position of high-current contacts 38 and 39 - in high-current lines 32, 32 _a either only via the electrode 28 or only via the base plate 14, the remelting block 30 and the Melt sump 24 or at the same time via electrode 28 and base plate 14, the proportions of the current flowing through electrode 28 and base plate being adjustable by means of adjustable resistors 42, 42 _a or other devices which are comparable in their effect. In this arrangement, the entire melt flow is returned exclusively via the current-conducting element 18 built into the mold wall and a return line 35 connecting it to the current source 36.

In another arrangement according to FIG. 2, the mold 10 is provided with at least two by insulating elements 16, 16 _a both against one another and against the lower region 20 of the mold 10 and — in this case — against the upper region 22 of the mold 10, namely those Hollow ring 12, insulated current conducting elements 18, 18 _a . 3 shows two partially circular current-conducting elements 18, 18 _a , which are separated from one another by — correspondingly shaped insulating elements 16 _b — forming a ring with them; If, as described here, two or more current-conducting elements 18, 18 _a lying at different potentials are required, these can also be formed in a circular manner as a ring and arranged one above the other and in particular in the case of molds 10 with a circular cross section around a longitudinal axis A. angeord- Neten - also annular - insulating elements 16 to be isolated from each other.

Here it is possible to apply the power supply line between the mold 10 and the power source from two AC or DC power sources 36, 36 _a to only one of the current-carrying elements 18 or 18 _a . These current-conducting elements 18, 18 _a , which are at different potential, can be divided into several individual elements over the circumference of the mold 10, each isolated from one another. The return of the current may then take place via the other current-conducting element 18 _a or 18.

Depending on the position of the high-current switches 38, 39, current can be fed from the right-hand current source 36 in FIG. 2 either only via the electrode 28 through line 32 or only via base plate 14 together with block 30 through line 32 _a or via both together into the slag bath 26 , When supplying via the base plate 14 and block 30 together, the division of the current can be adjusted by means of adjustable resistors 42, 42 _a . The return can then take place via one of the two current-conducting elements - here 18 - the mold 10 and return line 35. From return line 35 leads a branch line 37 to the left power source 36 _a , which on the other hand is connected by a line 31 to the current-carrying element 18 _a . If the current source 36 is a direct current source, it is possible to switch the electrode 28 and block 30 as a cathode.

If - as described here - two or more current-conducting elements 18, 18 _a lying at different potentials are required, these can also be formed in a circular manner as a ring and arranged one above the other, in particular in the case of molds 10 with a circular cross section, and by means of annular insulating elements arranged in between be isolated from each other. 4 shows an arrangement for carrying out the method according to the invention with three melt current supplies or current sources 36, 36 _a , 36 b arranged in parallel and separately controllable. Here, for example, the supply line from the melt current supply 36 _b on the left in FIG. 4 to the base plate 14 and the remelting block 30 via line 31 _a , the supply line from the central melt current supply 36 _a to at least one current-conducting element 18 _a via line 31 and the supply line from the right melting power supply 36 led to the melting electrode 28 via line 32. A common return line is returned from at least one further current-conducting element 18, which is insulated from the former and from the lower and the upper region 20 and 22 of the mold 10, to the three power supplies 36, 36 _a , 36 b. The individual circuits can be interrupted via high-current switches 41, 41 _a , 41 _b in return line 35 or branch lines 37 _a , 37 _b . This arrangement enables different ways of working. If three alternating current sources 36, 36 _a , 36 _b connected in parallel are used as melt current supplies _{, then} independently adjustable currents can be run via each of the feed lines 32, 31, 31 _a .

The three power supplies or power sources 36, 36 _a , 36 _b can, for example, also be connected to the three phases of a three-phase power supply, the return line being led to the star point. This makes it possible to build up a Ruhr movement induced by the rotating field in the slag bath and metal sump. However, it is also possible to switch the electrode 28 and base plate 14 as cathode if direct current sources are used as current sources or melt current supplies 36 and 36 _b , the individual current intensities being able to be set and regulated independently of one another. An AC power source can then be used as the power supply 36 _a , which ensures efficient heating of the slag bath 24 via the current-conducting elements 18, 18 _{a of} the mold 10. By changing the electrodes 28, long remelting blocks can also be produced in the systems according to the invention, regardless of the electrode length.

The electrode 28 and the slag bath 24 can be protected against air access by gas-tight hoods, not shown here, which can also be sealed against the mold flange. This allows the remelting to take place in a controlled atmosphere and the exclusion of atmospheric oxygen, which also enables the production of highly pure remelting blocks 30 and prevents burn-off of oxygen-affine elements.

Claims

1. A method for producing blocks or strands of metal, in particular of steel and Ni and Co base alloys, by melting self-consuming electrodes in an electrically conductive slag bath using AC or DC in a short, water-cooled mold open at the bottom which a current contact to the slag bath can be established,

characterized,

that the melt stream supplied is introduced into the slag bath both via the melting electrode and also via the base plate, the remelting block and the melt sump and, if appropriate, at least one current-conducting element of the mold, the current distribution being adjustable and the return flow of the melt stream being controlled via at least one further against a possible former and against the part of the mold that forms the remelting block, the electrically insulated current-conducting element of the mold can be traced.

A method according to claim 1, characterized in that the proportion of the total melt flow supplied via the base plate is selected between 0 and 100%.

A method according to claim 1, characterized in that the proportion of the total melt flow supplied via the melting electrode is selected between 0 and 100%.

4. The method according to claim 1, characterized in that the proportion of the total melt flow supplied via the at least one current-conducting element of the mold is selected between 0 and 100%.

5. The method according to any one of claims 1 to 4, characterized in that when using direct current, the lead to the electrode and / or base plate and block is switched as a cathode.

6. The method according to any one of claims 1 to 5, characterized in that the block formed is continuously withdrawn from the mold.

7. The method according to any one of claims 1 to 5, characterized in that the block formed is gradually withdrawn from the mold.

8. The method according to any one of claims 1 to 5, characterized in that the block formed is fixed and the mold is continuously raised.

9. The method according to any one of claims 1 to 5, characterized in that the block formed is fixed and the mold is gradually raised.

10. The method according to any one of claims 6 or 8, characterized in that the mold executes an oscillating movement.

11. The method according to claim 7 or 9, characterized in that, after each stroke step, a counter-stroke step immediately follows in the opposite direction, the stroke length of the counter-stroke step being at most 60% of the stroke length of the previous stroke step.

12. Device for performing the method according to one of the preceding claims, using a short water-cooled mold (10) with a base plate (14) for building a remelting block (30) and with at least one in the area

Slag bath (24) provided current-conducting element (18, 18 _a ), which are insulated from the lower region (20) of the mold (10) forming the remelting block (30) and / or from other current-conducting elements, characterized in that the feed line (32, 32 _a ) of the melt stream from at least one current source (36, 36 _a ) both to the melting electrode (28) and to the base plate (14) and optionally to a current-conducting element (18 _a ) of the mold (10) that the current distribution between the feed lines can be adjusted in a controlled manner, and that the return line (35) to the at least one current source or melt power supply (36, 36 _a , 36 _b ) is carried out by at least one current-conducting element (18 _a ) of the mold (10), which is opposite the at least one other current-conducting element (18 _a ) and the part (20) of the mold (10) which forms the remelting block (30) is electrically insulated.

13. The apparatus according to claim 12, characterized in that two or three mutually independently controllable current sources or power supplies (36, 36 _a , 36 _b ) are used.

14. The apparatus according to claim 12, characterized in that the current source (36) is connected on the one hand to a current-conducting element (18) of the mold (20) and on the other hand is designed to be connectable to the melting electrode (28) and to the base plate (14).

15. The apparatus of claim 12 or 13, characterized in that at least two current sources (36, 36 _a ) are connected on the one hand to a current-conducting element (18) of the mold (10) and on the other hand one of the current sources (36 _a ) with another current-conducting element (18 _a ) of the mold and the other current source (36) can be connected to the melting electrode (28) and to the base plate (14).

16. The apparatus of claim 12 or 13, characterized in that at least the current sources (36, 36 _a , 36) are connected on the one hand to a current-conducting element (18) of the mold (10) and on the other hand one of the current sources (36) with the consumable electrode (28), a further current source (36 _b ) with the base plate (14) and a further current source (36 _a ) with another current-conducting element (18 _a ) of the mold.

17. Device according to one of claims 12 to 16, characterized in that the division of the currents between the individual supply lines (31, 31 _a , 32, 32 _a ) is adjustable by means of adjustable resistors (42, 42 _a ).

18. The apparatus according to claim 17, characterized in that the resistors (42, 42 _a ) in the line (32, 32 _a ) for the melting electrode (28) and for the base plate (14) are arranged.

19. The apparatus of claim 13 or 16, characterized in that when using three power sources or power supplies (36, 36 _a , 36 _b ) these are connected to the three phases of a three-phase network ^" .

20. Device according to one of claims 12 to 19, characterized in that rectifier systems are provided as the melt current supply.