阅读说明：本技术 一种使用镍基高温合金粉末返回料制备高温合金粉末的方法 (Method for preparing high-temperature alloy powder by using nickel-based high-temperature alloy powder return material ) 是由 刘娜 李周 郑亮 许文勇 张国庆 于 2021-07-07 设计创作，主要内容包括：本发明涉及一种使用镍基高温合金粉末返回料制备高温合金粉末的方法,包括原材料准备：原材料采用选定成分的镍基高温合金母合金棒料和镍基高温合金粉末返回料,按照粉末返回料重量占比20％～75％进行配料；装料：先将镍基高温合金母合金棒料装入雾化制粉炉内,然后放入镍基高温合金粉末返回料；真空熔炼：抽真空后采用中频电源感应加热镍基高温合金棒料和镍基高温合金粉末返回料；步骤四、雾化制粉：采用高纯氩气作为雾化介质对熔融的高温合金进行雾化,获得气雾化镍基高温合金粉末。本发明采用镍基高温合金粗粉作为返回料,直接进行重熔和雾化,制备出满足技术要求的高品质低成本镍基高温合金粉末,大幅降低镍基粉末高温合金产品的研制成本。(The invention relates to a method for preparing high-temperature alloy powder by using a nickel-based high-temperature alloy powder return material, which comprises the following steps of: the raw materials are nickel-based high-temperature alloy master alloy bar stock and nickel-based high-temperature alloy powder return material with selected components, and the raw materials are mixed according to the weight ratio of the powder return material of 20-75%; charging: firstly, putting a nickel-based high-temperature alloy master alloy bar into an atomization powder making furnace, and then putting a nickel-based high-temperature alloy powder return material; vacuum smelting: after vacuumizing, adopting a medium-frequency power supply to inductively heat the nickel-based high-temperature alloy bar and the nickel-based high-temperature alloy powder return; step four, atomizing to prepare powder: and (3) atomizing the molten high-temperature alloy by using high-purity argon as an atomizing medium to obtain the atomized nickel-based high-temperature alloy powder. The invention adopts the nickel-based high-temperature alloy coarse powder as the return material, and directly performs remelting and atomization to prepare the high-quality low-cost nickel-based high-temperature alloy powder meeting the technical requirements, thereby greatly reducing the development cost of the nickel-based powder high-temperature alloy product.)

1. A method of preparing superalloy powder using a nickel-based superalloy powder return, comprising the steps of:

step one, raw material preparation: the raw materials are nickel-based high-temperature alloy master alloy bar stock and nickel-based high-temperature alloy powder return material with selected components, and the raw materials are mixed according to the weight ratio of the powder return material of 20-75%;

step two, charging: firstly, putting a nickel-based high-temperature alloy master alloy bar into an atomization powder making furnace, and then putting a nickel-based high-temperature alloy powder return material;

step three, vacuum melting: after vacuumizing, adopting a medium-frequency power supply to inductively heat the nickel-based high-temperature alloy bar and the nickel-based high-temperature alloy powder return;

step four, atomizing to prepare powder: and atomizing the molten high-temperature alloy by using high-purity argon as an atomizing medium, and collecting the powder prepared by atomization to obtain the gas atomized nickel-based high-temperature alloy powder.

2. The method of claim 1, wherein the nickel-base superalloy powder return is a coarse powder of +270 mesh nickel-base superalloy.

3. The method of claim 1, wherein the evacuation is performed by rough vacuum in the melting chamber of the atomizing pulverizer and then high vacuum in the furnace body of the atomizing pulverizer.

4. A method according to claim 3, wherein the vacuum of said high vacuum is below 0.1 Pa.

5. The method as claimed in claim 1, wherein in the vacuum melting, the intermediate frequency power is reduced by 5% to 10% after the bar is melted, and the intermediate frequency power is recovered after the powder return is completely cleared.

6. The method of claim 1, wherein during vacuum melting, the method further comprises filling the melting chamber of the atomizing powder furnace with high-purity argon when the temperature of the alloy melt reaches 1500-1600 ℃.

7. The process of claim 1 wherein the powder return is present in an amount of 30% to 40% by weight.

8. The process of claim 1 wherein the powder return is present in an amount of 40% by weight.

Technical Field

The invention belongs to the technical field of powder metallurgy, and particularly relates to a method for preparing high-temperature alloy powder by using a nickel-based high-temperature alloy powder return material.

Background

Turbine disks are important core hot end components of aircraft engines, the metallurgical quality of which is critical to the reliability, life and performance of the engine and even the aircraft. The powder superalloy turbine disc is the preferred material of the aircraft engine turbine disc with the thrust-weight ratio of more than 8, and the non-metallic inclusion defect of the powder superalloy is the limiting factor of the reliability and the service life of the turbine disc. Some engine failure cases abroad and in recent years domestically show that the failure reasons of the powder turbine disk are mainly caused by defects such as non-metallic inclusions in powder. Therefore, the high-quality pure high-temperature alloy powder becomes a key factor for restricting the development of advanced aeroengine core components, and is the basis and guarantee for the development and production of advanced aeroengine powder turbine disks. The mainstream process for preparing the powder turbine disk of the world advanced aeroengine adopts argon to atomize high-temperature alloy powder. With the continuous improvement of the thrust-weight ratio and the power-weight ratio of the aero-engine, the reliability, the stability and the economy of the powder high-temperature alloy disk are also continuously improved, so that the argon atomization powder preparation technology is promoted to develop towards the directions of thinning, narrow granularity, few impurities, high sphericity, high efficiency and low cost.

The control of the size and quantity of non-metallic inclusions in powder is a worldwide problem, and the currently generally adopted strategy is to use fine powder to reduce the size of the largest inclusions, so as to fundamentally limit the size of the non-metallic inclusions possibly brought in, thereby improving the intrinsic metallurgical quality of the powder turbine disk, which is a key measure for ensuring the reliability of the turbine disk. The maximum size of the powder particles must not exceed 106 μm, and the powder particle size for the important component must be less than 53 μm, even less than 45 μm, and is reduced further in the future. The particle size distribution of the argon atomized superalloy powder is lognormal distribution, and the powder cannot be completely used in the whole particle size range, namely, part of coarse powder is always not used. Currently argon gas atomizes superalloy powders with a fine-powder yield of-270 mesh (< 53 μm) of 60%, meaning about 40% of the coarse powder is unusable. At present, a large amount of coarse powder is left unused after powder screening, and is not applied yet, so that great waste is caused, and the manufacturing cost of the powder turbine disc is high. Along with the development and application of advanced aeroengines in China, the demand for high-quality argon atomization superalloy powder is getting larger and larger, the demand for annual superalloy powder is more than one hundred tons at present, and a large amount of superalloy coarse powder is wasted in an idle mode.

Disclosure of Invention

In view of the above-mentioned circumstances of the prior art, an object of the present invention is to provide a method for preparing superalloy powder using a nickel-based superalloy powder return material, so as to solve the problem of high cost of the nickel-based powder superalloy.

The above purpose of the invention is realized by the following technical scheme:

a method of preparing superalloy powder using a nickel-based superalloy powder return, comprising the steps of:

step one, raw material preparation: the raw materials are nickel-based superalloy master alloy bar stock and nickel-based superalloy powder return material which are selected, the raw materials are mixed according to the weight proportion of 20-75% of the powder return material, the weight proportion of the powder return material is preferably 30-40%, and the powder return material is preferably 40%, so that the once recycling of the unusable coarse powder of about 40% of the argon atomized superalloy powder at present is realized. Wherein the nickel-based superalloy powder return material can be nickel-based superalloy coarse powder with a plus 270-mesh (not less than 53 mu m), and can also be nickel-based superalloy coarse powder with a plus 325-mesh (not less than 45 mu m), for example.

Step two, charging: firstly, a nickel-based high-temperature alloy master alloy bar is placed into an atomization powder making furnace, then a nickel-based high-temperature alloy powder return material is placed, and the nickel-based high-temperature alloy master alloy bar is used for guiding and melting the powder return material so as to solve the problem that the powder is difficult to conduct electricity and transfer heat.

Step three, vacuum melting: after vacuumizing, the nickel-based high-temperature alloy bar material and the nickel-based high-temperature alloy powder return material are inductively heated by adopting a medium-frequency power supply. During vacuumizing, firstly, a mechanical pump is adopted to perform rough vacuum on a smelting chamber of the atomization powder making furnace at a low speed for 10min, then an oil booster pump is started to perform high vacuum on a furnace body of the powder making furnace so as to solve the problem of serious powder suction in vacuum, and the vacuum degree of the high vacuum is preferably lower than 0.1 Pa; during vacuum melting, the intermediate frequency power is slightly reduced by 5-10% after the bar stock is melted so as to prevent the powder return material from splashing, and the original intermediate frequency power is recovered after the powder return material is completely cleaned. In addition, when the temperature of the alloy melt reaches 1500-1600 ℃, high-purity argon is filled into the smelting chamber of the atomization powder making furnace to prevent the burning loss of alloy elements and ensure the alloy components.

Step four, atomizing to prepare powder: and atomizing the molten high-temperature alloy by using high-purity argon as an atomizing medium, and collecting the powder prepared by atomization to obtain the gas atomized nickel-based high-temperature alloy powder.

The method adopts the nickel-based high-temperature alloy coarse powder which is left unused after screening as the return material, and directly performs remelting and atomization to prepare the high-quality low-cost nickel-based high-temperature alloy powder meeting the technical requirements, thereby greatly reducing the development cost of products such as the nickel-based powder high-temperature alloy turbine disc and the like.

Detailed Description

In order to clearly understand the objects, technical solutions and advantages of the present invention, the present invention will be further described in detail with reference to the following embodiments.

Example 1

Materials: nickel-base superalloy: the mass content of the alloy elements is 16.14 percent of Cr, 13.08 percent of Co, 3.99 percent of W, 3.98 percent of Mo, 2.16 percent of Al, 3.70 percent of Ti, 0.70 percent of Nb, 0.048 percent of C, 0.016 percent of B, 0.04 percent of Zr, 0.003 percent of O and the balance of Ni. Mixing the high-temperature alloy master alloy bar and + 270-mesh (not less than 53 mu m) high-temperature alloy coarse powder (namely, powder return material) according to the weight ratio of the powder return material of 30 percent; firstly, putting a high-temperature alloy master alloy bar into a crucible of a melting chamber of an atomization powder making furnace, and then putting high-temperature alloy coarse powder into the crucible; firstly, slowly vacuumizing, vacuumizing the smelting chamber for 10min by using a mechanical pump, and then starting an oil booster pump to pump high vacuum to the furnace body; and under the condition that the vacuum degree is lower than 0.1Pa, a medium-frequency power supply is adopted to inductively heat the high-temperature alloy bar stock and the high-temperature alloy returning stock powder, and 75 percent of medium-frequency power is kept. Slightly reducing the intermediate frequency power after the bar stock is melted, keeping 70% of the intermediate frequency power, preventing the return material powder from splashing, increasing the intermediate frequency power to 75% after the return material powder is completely cleared, and filling high-purity argon into the atomization powder making furnace when the temperature of the molten alloy reaches 1550 ℃; the method comprises the steps of atomizing molten high-temperature alloy by using high-purity argon as an atomizing medium, collecting powder prepared by atomization in a powder collecting tank, and filling the high-purity argon into the powder collecting tank after the powder is sufficiently cooled to obtain the gas atomized high-temperature alloy powder meeting the technical requirements, wherein the chemical components of the powder are shown in table 1.

TABLE 1 superalloy powder prepared in example 1 has chemical composition (mass fraction/%)

Example 2

Materials: nickel-base superalloy: the mass content of the alloy elements is 16.14 percent of Cr, 13.08 percent of Co, 3.99 percent of W, 3.98 percent of Mo, 2.16 percent of Al, 3.70 percent of Ti, 0.70 percent of Nb, 0.048 percent of C, 0.016 percent of B, 0.04 percent of Zr, 0.003 percent of O and the balance of Ni. Mixing the high-temperature alloy mother alloy bar and high-temperature alloy coarse powder with a particle size of +270 meshes (not less than 53 mu m) according to the proportion of return material powder of 55 percent; firstly, putting a high-temperature alloy master alloy bar into an atomized powder-making crucible, and then putting high-temperature alloy coarse powder into the atomized powder-making crucible; firstly, slowly vacuumizing, vacuumizing the smelting chamber for 10min by using a mechanical pump, and then starting an oil booster pump to pump high vacuum to the furnace body; and under the condition that the vacuum degree is lower than 0.1Pa, a medium-frequency power supply is adopted to inductively heat the high-temperature alloy bar stock and the high-temperature alloy returning stock powder, and 80 percent of medium-frequency power is kept. Slightly reducing the medium-frequency power after the bar stock is melted, keeping 75% of the medium-frequency power, preventing the return material powder from splashing, increasing the temperature to recover to 80% of the medium-frequency power after the return material powder is completely cleared, and filling high-purity argon into the atomization powder making furnace when the temperature of the alloy melt reaches 1580 ℃; the method comprises the steps of atomizing molten high-temperature alloy by using high-purity argon as an atomizing medium, collecting powder prepared by atomization in a powder collecting tank, and filling the high-purity argon into the powder collecting tank after the powder is sufficiently cooled to obtain the gas atomized high-temperature alloy powder meeting the technical requirements, wherein the chemical components of the powder are shown in table 2.

Table 2 superalloy powder prepared in example 2 had chemical composition (mass fraction/%)

Example 3

Materials: nickel-base superalloy: the mass content of the alloy elements is 16.14 percent of Cr, 13.08 percent of Co, 3.99 percent of W, 3.98 percent of Mo, 2.16 percent of Al, 3.70 percent of Ti, 0.70 percent of Nb, 0.048 percent of C, 0.016 percent of B, 0.04 percent of Zr, 0.003 percent of O and the balance of Ni. Mixing the high-temperature alloy mother alloy bar and high-temperature alloy coarse powder with a particle size of +270 meshes (not less than 53 mu m) according to the proportion of return material powder of 75 percent; firstly, putting a high-temperature alloy master alloy bar into an atomized powder-making crucible, and then putting high-temperature alloy coarse powder into the atomized powder-making crucible; firstly, slowly vacuumizing, vacuumizing the smelting chamber for 10min by using a mechanical pump, and then starting an oil booster pump to pump high vacuum to the furnace body; and under the condition that the vacuum degree is lower than 0.1Pa, a medium-frequency power supply is adopted to inductively heat the high-temperature alloy bar stock and the high-temperature alloy returning stock powder, and 80 percent of medium-frequency power is kept. Slightly reducing the intermediate frequency power after the bar stock is melted, keeping 70% of the intermediate frequency power, preventing the return material powder from splashing, increasing the intermediate frequency power to 80% after the return material powder is completely cleared, and filling high-purity argon into the atomization powder making furnace when the temperature of the molten alloy reaches 1600 ℃; the method comprises the steps of atomizing molten high-temperature alloy by using high-purity argon as an atomizing medium, collecting powder prepared by atomization in a powder collecting tank, and filling the high-purity argon into the powder collecting tank after the powder is sufficiently cooled to obtain the gas atomized high-temperature alloy powder meeting the technical requirements, wherein the chemical components of the powder are shown in table 3.

Table 3 superalloy powder chemical composition (mass fraction/%) prepared in example 3

The invention directly adopts the idle coarse powder of the high-temperature alloy powder to carry out remelting and atomization, and the returned material does not need to be subjected to any treatment such as purification, thereby realizing the low-cost short-flow utilization of the returned material.

The invention solves the technical problems of serious vacuum powder absorption, difficult powder conduction and heat transfer, burning loss of alloy elements and the like by controlling the smelting and atomizing processes, and the quality of the high-temperature alloy powder prepared by adopting the return material powder is consistent with that of the powder prepared by adopting the new material, thereby meeting the use requirement of the product.

The invention innovatively adopts powder to directly atomize and prepare the powder, and has the advantages of low cost, short flow, high speed and simple process operation.