Effect of interaction of refractories with Ni-based superalloy on inclusions during vacuum induction melting

This study documents laboratory-scale observation of the interactions between the Ni-based superalloy FGH4096 and refractories.Three different crucibles were tested—MgO,Al2O3,and MgO–spinel.We studied the variations in the compositions of the inclusions and the alloy–crucible interface with the reaction time using scanning electron microscopy equipped with energy dispersive X-ray spectroscopy and Xray diffraction.The results showed that the MgO and MgO–spinel crucibles form MgO-containing inclusions(Al–Mg oxides and Al–Mg–Ti oxides),whereas the inclusions formed when using the Al2O3 crucible are Al2O3 and Al–Ti oxides.We observed a new MgAl2O4 phase at the inner wall of the MgO crucible,with the alloy melted in the MgO crucible exhibiting fewer inclusions.No new phase occurred at the inner wall of the Al2O3 crucible.We discuss the mechanism of interaction between the refractories and the Ni-based superalloy.Physical erosion was found to predominate in the Al2O3 crucible,whereas dissolution and chemical reactions dominated in the MgO crucible.No reaction was observed between three crucibles and the Ti of the melt although the Ti content(3.8wt%)was higher than that of Al(2.1wt%).

Mechanisms of reactive element Y on the purification of K4169 superalloy during vacuum induction melting

The effects of rare earth element Y on the purification of K4169 superalloy during vacuum induction melting were investigated at different superheating temperatures. The corresponding interaction mechanisms were also clarified. Results showed that the addition of Y remarkably promoted the purification effect on the K4169 melt. The contents of O and S in the K4169 as-cast alloy ingots after purification were 3–4 and 8–10 ppm, respectively. The degrees of deoxidation and desulfurization increased to 50% and 57%, respectively, upon the addition of 0.1 wt% Y. The yttrium-rich phase that precipitated at the grain boundary blocked the diffusion of C and the accumulation of S, thereby contributing to the purification of the alloy.

Denitrogenation and desulphurization during vacuum induction melting refining Ni-base superalloy

The denitrogenation and desulphurization behavior during vacuum induction melting (VIM) refining Ni base superalloy using CaO crucible was studied. It has been found that the desulphurization process did not occur by only using CaO crucible. Combining with the results of XRD and composition analysis, the desulphurization mechanism of CaO crucible was proposed. Al addition limits effect on denitrogenation, but it is very important for desulphurization. Ti addition has adverse effect on denitrogenation. The increase of vacuum is a powerful measurement to accelerate the denitrogenation process.

VIM真空感应炉真空度修复分析

以太钢技术中心基础研究所的德国ALD真空感应炉作为研究对象,其连续服役十余年,大量的冶炼试验对真空炉的抽真空系统造成了严重的影响,工作真空度不断降低,导致钢锭质量下降。通过分析真空炉抽真空泵级系统原理,提出将真空泵级系统进行拆解维护修复方案。经过实践证明,该修复方案切实可行,能够大幅度提高真空感应炉的工作真空度。

Evolution of inclusions in vacuum induction melting of superalloys containing 70%return material

The variation law of inclusions type and size in the vacuum induction melting process and ingot of Ni-based superalloy containing 70%return material was studied by industrial test sampling,and the mechanism of inclusions formation was analyzed with thermodynamic calculations.The results show that there are mainly two types of composite inclusions in the vacuum induction melting of Ni-based superalloys,which are nitride-and oxide-based composite inclusions,like Al_(2)O_(3)-SiO_(2)-Cr_(2)O_(3),TiN-(Mo,Nb)C,etc.The type and proportion of inclusions from the center to the edge of the vacuum induction ingot did not change significantly.The number density of inclusions from the center to the edge of the ingot varied less,and the size of inclusions became smaller from the center to the edge.In addition,thermodynamic calculations show that oxides(M_(2)O_(3))are present in the liquid phase and mainly contain Al,Ti,Cr,Fe and O elements.The nitride consists mainly of Ti and N and contains small amounts of Cr,C,Nb,and Mo elements.This is consistent with the results of industrial tests.As the temperature decreases,the precipitation phases such as M_(2)O_(3),MN,γ,MC,δ,γ'andμphases are gradually precipitated,where oxides and nitrides are present in the liquid phase.The contents of O and N elements are the main influencing factors for the inclusions content and precipitation temperature;when the nitrogen content is reduced to below 0.0015%,it can make MN precipitate below the liquid-phase line.

VIM法中采用CaO坩埚对Ni基高温合金脱S的影响

研究了使用CaO坩埚在VIM法精炼Ni基高温合金过程中S的变化规律及加Al对脱S的影响。试验表明 :当CaO坩埚中的含S量高于液态金属中的含S量时 ,坩埚中的S将进入金属液中而使液态金属增S。加入 0 .5 %的Al经 30min精炼后可以使液态金属中的S含量从 30mg/kg降低至小于 5mg/kg。对CaO坩埚内壁的XRD及成分分析表明 ,加Al脱S是由于在CaO坩埚壁和金属液间形成低熔点的具有很强脱S能力的 3CaO·Al2

PdNiCrBSi合金钎料粉末的制备及钎焊应用研究

针对航空航天钎焊用钎料合金粉末的需求,采用真空感应熔炼气雾化法制备PdNiCrBSi合金钎料粉末,研究了该粉末的物理性质、微观形貌与结构以及在高温合金基材上的钎焊性能。结果表明:PdNiCrBSi粉末主要为球形,由多种物相组成,且在GH3536母材上具有良好的润湿铺展性和可钎焊性。该钎料焊后的焊缝最大拉力38.2~38.9 kN,钎焊接头剪切强度为382~389 MPa,基本与母材强度相近,其断裂方式为脆性断裂。

Fe_(0.5)CrMnAlCu高熵合金及涂层的组织与性能

采用真空电弧熔炼与冷喷涂辅助感应重熔制备Fe_(0.5)CrMnAlCu高熵合金及涂层。利用XRD、SEM、显微硬度计、磨料磨损实验机对高熵合金及涂层的相结构、微观组织以及耐磨损等性能进行测试分析。结果表明:真空电弧熔炼制备的Fe_(0.5)CrMnAlCu高熵合金为FCC和BCC相固溶体结构,其组织形貌主要为枝晶和枝晶间组织,冷喷涂辅助感应重熔合成Fe_(0.5)CrMnAlCu高熵合金涂层的相结构为单一的BCC结构,其组织形貌为枝晶和枝晶间组织。由于感应重熔合成Fe_(0.5)CrMnAlCu高熵合金涂层较电弧熔炼制备的高熵合金具有更大的晶粒尺寸,同时涂层的原子尺寸差δ大于合金的原子尺寸差,导致感应重熔合成Fe_(0.5)CrMnAlCu高熵合金涂层的硬度是真空电弧熔炼高熵合金的1.37倍,其磨损率比真空电弧熔炼制备的高熵合金磨损率降低18%。真空电弧熔炼与冷喷涂辅助感应重熔制备Fe_(0.5)CrMnAlCu高熵合金及涂层的磨损机制主要是黏着磨损、磨粒磨损。

GH738返回料合金组织及纯净度的研究

该研究针对GH738合金不能直接使用的返回料进行了真空感应拼锭处理,并针对返回料拼锭再进行了电渣重熔。相应分析了双联工艺过程的化学成分变化,比较了感应拼块锭及电渣锭中的碳化物及非金属夹杂的差别,对比了枝晶组织的特征差异。返回料熔炼高温合金主要的问题在于其相对更高的N、O气体元素含量,需要在真空感应熔炼阶段严格控制以避免对成品性能的影响。经过电渣重熔后,枝晶生长有明显的取向性,且枝晶间析出的碳化物尺寸及数量均较真空感应熔炼状态有所增大,夹杂物分布相对也更加弥散且尺寸有所减小。最终验证了对于无法直接使用的返回料进行感应拼锭处理再作为高温合金冶炼原料的可行性。

LAZ811合金水冷凝固工艺设计与组织性能研究

对LAZ811合金水冷凝固模具与工艺进行了探索,主要包括熔铸工艺分析、水冷模具的结构设计及浇注参数的确定,并制备出了LAZ811合金铸锭。结果表明:真空感应熔炼+氩气保护,合理的水冷模具结构能够使合金快速凝固,有效防止铸锭内部缩孔及缩松的形成,并获得组织细小、拉伸性能优良的镁锂合金材料,并适用于类似合金的生产。

真空感应悬浮熔炼技术在高纯材料制备中的应用

叙述了真空感应悬浮熔炼技术在制备高温、高纯等合金材料方面的优点,介绍了真空感应悬浮炉的关键技术以及装备的最新发展与应用,讨论了该技术在熔炼高质量特种钢等新材料方面的应用,并分析了该技术在熔炼其他材料等领域的应用及可行性。

脱氧剂Cu-10P对真空熔铸Cu-10Sn-3Pb-4Ni合金微观组织和力学性能的影响

Cu-10Sn-3Pb-4Ni合金由于较高的Sn含量以及凝固组织中存在硬脆δ-Cu41Sn11相,具备较高的强度、硬度和耐磨性,广泛应用于具有高速滑动摩擦场景的机械部件中。本文通过真空感应熔炼Cu-10Sn-3Pb-4Ni合金,采用光学显微镜、X射线及荧光探伤对添加脱氧剂Cu-10P前后Cu-10Sn-3Pb-4Ni合金的组织和力学性能进行测试表征。结果表明,添加0.05%(质量分数)脱氧剂Cu-10P后,铸锭组织更加均匀,树枝晶的生长更加充分,δ相的生长得到抑制。铸锭的边缘抗拉强度由323 MPa提升到了342 MPa,断后伸长率由12.5%提升到了16.5%;铸锭芯部抗拉强度由300 MPa提升到了324 MPa,断后伸长率由11%提升到了19%。

高温合金增材制造粉末回收工艺研究

高温合金制粉存在50%以上粒径不满足增材制造3D打印需求的粉末称为废粉,本文主要研究不满足粒径要求的废粉回收利用方法。以GH4169高温合金废粉为例,回收利用工艺为粗粉和细粉末混合、粉末压块、压块保护气氛烧结、压块熔炼。研究结果表明:当细粉和粗粉混合比例1∶4时,粉末压块能够完全成型,表面光滑,无缺角和表面碎粉;850℃高温烧结后粉末压块具有较高的强度,满足真空感应熔炼加料需求;使用90%氩气+10%氢气保护气氛,压块表面和芯部出现轻微氧增加,氮无增加;以30%压块+70%新料和50%压块+50%新料的配料比例以≤10 kg/min的化料速度,1560℃精炼温度、≤0.1 Pa精炼真空度、90 min的精炼时间,精炼后的合金液面浮渣等级<2级,成品棒料的氧含量<10 ppm,氮含量<25 ppm,达到了全新料水平。

Ingredient Losses during Melting Binary Ni-Ti Shape Memory Alloys

Losses of the alloying elements during vacuum induction melting of the binary NiTi alloys were evaluated by visual observation and chemical analysis of the NiTi melted specimens and the scalp formed on the internal surface of the crucible. The results indicated that the major sources of the losses were （a） evaporation of the metals, （b） formation of the NiTi scalp and （c） the sprinkling drops splashed out of the melt due to the exothermic reactions occurring between Ni and Ti to form the NiTi parent phase. Quantitative evaluations were made for the metallic losses by holding the molten alloy for 0.5, 3, 5, 10 and 15 min at around 100℃ above the melting point inside the crucible.Chemical analysis showed that there existed an optimum holding time of 3 min during which the alloying elements were only dropped to a predictable limit. Microstructure, chemical composition, shape memory and mechanical properties of the cast metal ingots were determined to indicate the appropriate achievements with the specified 3 min optimum holding time.

Investigation of the stress rupture behavior of GTD-111 superalloy melted by VIM/VAR

The effects of vacuum induction melting(VIM) and vacuum arc remelting(VAR) processes on the microstructure and stress rupture properties of Ni-based GTD-111 superalloy were investigated. Samples of GTD-111 master alloy were melted in VIM and VAR furnaces and then poured into a preheated ceramic mold for VIM melt or into a water-cooled copper mold for VAR melt. The as-cast samples were examined radiographically to ensure that no casting defects were present in the final castings; the samples were then heat-treated using a standard heat-treatment cycle. The microstructure of the samples was investigated using optical microscopy and scanning electron microscopy in conjunction with energy-dispersive X-ray spectroscopy for microanalysis. On the basis of standard ASTM-E139, stress rupture tests were carried out at 1000°C under a stress of 300 MPa. The results showed that a γ matrix, fine γ′ precipitates, a γ–γ′ eutectic structure, carbide particles, and some harmful phases such as σ and η phases were present in the as-cast samples. The γ′ precipitates with cubic morphology appeared in the matrix after the standard heat-treatment process. The extent of segregation and the amount of γ–γ′ eutectic structure formed in the VAR-prepared sample were less than in the VIM-prepared sample. The results of stress rupture tests showed that the rupture time for the VAR sample was 43% longer than that for the VIM sample.

GH3128合金“VIM+ESR”和“NVIM+ESR”冶炼过程中的脱气行为及夹杂物研究

利用氧氮分析仪对"真空感应熔炼+电渣重熔"(VIM+ESR)和"非真空感应熔炼+电渣重熔"(NVIM+ESR)两种冶炼工艺下冶炼GH3128合金中的氧含量、氮含量进行检测,并进行了脱氧、脱氮的热力学计算;利用ASPEX扫描电镜分析了两种冶炼工艺下GH3128合金中夹杂物的成分、尺寸分布以及数量。结果表明,采用"VIM+ESR"工艺更能有效的去除合金液中的氮,夹杂物类型主要是Al-Ti-O型复合氧化物夹杂,还有少部分的Al2O3、TiOx氧化物夹杂,而采用"NVIM+ESR"的双联工艺,合金中产生的夹杂除氧化物夹杂类,还有硫化物、氮化物夹杂;且采用真空冶炼工艺更能有效降低夹杂物数量,并细化夹杂物。

CuCr25 W1 Ni2 contact material of vacuum interrupter

CuCr25W1Ni2 alloy was prepared by means of vacuum induction melting (VIM). A series of Cu/Cr alloys with different compositions (mass fraction, 25%～75%) and Cr grain sizes (up to 150 μm) were investigated for their differences in physical properties and breakdown voltage. The influence of alloy elements and microstructure on the performance of CuCr25W1Ni2 alloy was also discussed. Experimental results show that the chromium phase is strengthened and its size is minimized by the addition of tungsten powder. After electrical breakdown, very fine tungsten particles in the melt layer form the external nuclei in the solidification process. The microstructure of surface melt layer of CuCr25W1Ni2 alloy is much flatter. It can notably improve the dielectric strength. On the other hand, the nickel can enhance the mutual solubility of copper and chromium, and the whole alloy is strengthened. [

Evaluation of Mechanical Properties According to Nb Content of High Strength Steel Manufactured in VIM

As the aircraft and aerospace industry and the automobile industry are developed, the demand of reliable materials with high strength and high toughness is steadily increased. The grain miniature method which improves the ductility and the toughness simultaneously under high strength is the miniature of the casting microstructure. In this paper, the Nb which affects the austenite grain miniature is added by 0.00%, 0.03% and 0.06% in this steel and the ingot is manufactured in a vacuum induction melting furnace （VIM）. The casting microstructure and the mechanical property of the maraging steel according to Nb contents are analyzed by conducting the solution annealing and the age hardening after hot rolling. In this result, a specimen containing 0.03% Nb is most miniature. When it does the long time age hardening, the precipitation estimated as the carbide is appeared. The mechanical properties are excellent if a specimen containing 0.06% Nb does the age hardening during 8 h in 482℃.

VIM真空感应熔炼法制备锆铁合金工艺研究

介绍了利用等外海绵锆和废钢,使用中频感应加热炉,采用真空熔炼技术在真空和保护气氛下进行熔化冶炼,制备含锆60%~80%的锆铁合金,分析合金的纯度,考察合金成分的稳定性及分布的均匀性,验证真空感应熔炼制备锆铁合金技术的可行性,并摸索相应的工艺路线及技术参数,提高等外海绵锆附加值,开发锆系合金新产品。

低氧氮含量K417G镍基高温合金生产工艺

介绍了低氧氮含量K417G镍基高温合金的生产工艺,着重讨论了合金制备不同阶段的脱气处理方法,并阐述了不同工艺环节避免气体带入的措施。在合金熔炼前通过预脱气尽可能去除表面吸附气体;在化料期将化料功率设定为300~750kW,并将单次加料量控制在500kg以下,使氧氮含量分别降至0.0018%和0.0014%;在精炼期控制合金熔液温度在1582℃,并利用碳脱氧反应精炼80min,使氧氮含量分别降低到0.0006%和0.0002%;精炼结束后加入活泼元素作为强脱氧剂,并维持20min以上,进一步将氧含量降低到0.0003%,顺利完成了低氧氮含量K417G镍基高温合金的生产。