阅读说明：本技术 一种高铌高温合金大尺寸铸锭的冶炼工艺及高铌高温合金大尺寸铸锭 (Smelting process of high-niobium high-temperature alloy large-size ingot and high-niobium high-temperature alloy large-size ingot ) 是由 黄烁 赵光普 张北江 段然 秦鹤勇 李连鹏 丑英玉 齐超 于 2019-08-28 设计创作，主要内容包括：本发明公开了一种高铌高温合金大尺寸铸锭的冶炼工艺及高铌高温合金大尺寸铸锭,用于解决高铌高温合金大尺寸铸锭的直径或重量扩大后因偏析加剧形成黑斑和白斑冶金缺陷、因热应力大造成钢锭炸裂以及因真空感应熔炼设备吨位限制造成的钢锭重量无法增大的问题。冶炼工艺包括：真空感应熔炼,制得多支成分相同的真空感应锭,进而制得相同数量的电渣电极,进行交换电渣重熔,再利用所得电渣锭制得自耗电极,然后以该自耗电极为起始原料,进行多次真空自耗重熔。采用该工艺能够实现锭重15吨以上、直径800mm以上的高铌高温合金大尺寸铸锭的制备,最大限度地抑制黑斑和白斑冶金缺陷形成,降低元素偏析程度,有效预防钢锭炸裂。(The invention discloses a smelting process of a high-niobium high-temperature alloy large-size ingot and the high-niobium high-temperature alloy large-size ingot, which are used for solving the problems that the diameter or weight of the high-niobium high-temperature alloy large-size ingot is enlarged, black spots and white spot metallurgical defects are formed due to the aggravation of segregation, steel ingots are cracked due to large thermal stress, and the weight of the steel ingots cannot be increased due to the tonnage limitation of vacuum induction smelting equipment. The smelting process comprises the following steps: vacuum induction smelting to obtain several vacuum induction ingots with the same components, preparing electroslag electrodes in the same number, exchange electroslag remelting, preparing consumable electrode with the obtained electroslag ingots, and vacuum consumable remelting for several times with the consumable electrode as the initial material. By adopting the process, the preparation of the large-size high-niobium high-temperature alloy ingot with the ingot weight of more than 15 tons and the diameter of more than 800mm can be realized, the formation of black spots and white spot metallurgical defects is inhibited to the maximum extent, the element segregation degree is reduced, and the steel ingot is effectively prevented from being cracked.)

1. A smelting process of a high-niobium high-temperature alloy large-size ingot is characterized by comprising the following steps:

vacuum induction melting: adopting pure metal raw materials and/or return materials as raw materials, carrying out vacuum induction smelting, and pouring a plurality of vacuum induction ingots with the same components;

exchange electroslag remelting: manufacturing the same number of electroslag electrodes by using the manufactured vacuum induction ingot; adopting all prepared electroslag electrodes, carrying out exchange electroslag remelting under the argon protection state, cooling and demoulding after the exchange electroslag remelting is finished, thus preparing an electroslag ingot:

carrying out multiple times of vacuum consumable remelting: carrying out primary annealing, secondary annealing and forging drawing on the demoulded electroslag ingot to a preset size to obtain a primary consumable electrode, wherein the secondary annealing temperature is higher than the primary annealing temperature; and then, performing vacuum consumable remelting at least twice by taking the primary consumable electrode as a starting material, wherein a consumable remelting ingot obtained by each vacuum consumable remelting is used for preparing a consumable electrode for standby in the next vacuum consumable remelting, the diameter of the consumable remelting ingot obtained by each vacuum consumable remelting is sequentially increased until the fluctuation of the melting speed in the last vacuum consumable remelting process is not more than +/-10% of the steady-state melting speed, and finally preparing a cast ingot with the target diameter by using the last consumable remelting ingot obtained by the last vacuum consumable remelting.

2. The smelting process according to claim 1, wherein in the vacuum induction smelting step, the Nb content is 2.8 to 5.5wt.%, the Al content is 0.2 to 1.0wt.%, and the Ti content is 0.5 to 2.0 wt.%.

3. The smelting process according to claim 1, wherein in the vacuum induction smelting step, the melting temperature is 1300-1550 ℃, after the raw materials are melted down, the raw materials are refined for 15-120 min under the action of electromagnetic stirring, and the refining temperature is 1350-1550 ℃; then cooling for 1-10 hours, and demolding to obtain a vacuum induction ingot; the vacuum induction melting process is repeated for a plurality of times to obtain a plurality of vacuum induction ingots with the same components.

4. The smelting process according to claim 1, wherein the electroslag electrode is prepared by performing direct stress relief annealing on each vacuum induction ingot, wherein during annealing, the temperature is raised to 600-800 ℃ in advance, then raised to 800-1000 ℃ at a speed of 5-45 ℃/h, and kept for 4-32 h, then cooled to 600-800 ℃ at a speed of 1-35 ℃/h, kept for 4-32 h, then air-cooled, and then polished and blunt-ended to obtain the electroslag electrode.

5. The process according to claim 1, wherein the slag system used in the exchange electroslag remelting is (CaF)₂-CaO-Al₂O₃-TiO₂) Quaternary slag, (CaF)₂-CaO-Al₂O₃-TiO₂) CaF in quaternary slag₂60-75 wt.%, CaO 10-25 wt.%, and Al₂O₃10-25 wt.% of TiO₂1-10 wt.%;

the steady-state melting speed of electroslag remelting is controlled to be 5-15 kg/min,

before each electrode exchange, when the residual weight of the previous electrode is 500 kg-1000 kg, the melting speed is increased to 12-25 kg/min by a slope of 0.5-2 kg/min on the basis of the steady-state melting speed, the electrode is kept stable until the electroslag electrode is exchanged, the smelting parameters before the exchange are kept in the process of exchanging the electrode, and the exchange time is not more than 2 min; after electrode exchange is completed every time, after the next electrode is melted to 100 kg-500 kg, the melting speed is reduced to 5-15 kg/min of the steady-state melting speed by the slope of 0.5-2 kg/min, remelting is continued until 200-600 kg of the last electrode is remained, and then heat capping is started;

and after the exchange electroslag remelting is finished, cooling for 2-10 h, and demolding to obtain an electroslag ingot.

6. The process of claim 1, wherein the step of vacuum consumable remelting is performed a plurality of times, and the step of performing primary annealing, secondary annealing, forging and drawing on the demolded electroslag ingot to a predetermined size to obtain the primary consumable electrode is performed in the following manner,

starting primary annealing for the electroslag ingot within 0.5-2 h after demoulding, specifically, preheating to 300-550 ℃, keeping the temperature for 12-32 h to realize temperature equalization, then heating to 600-750 ℃ at the speed of 1-25 ℃/h, keeping the temperature for 4-32 h, then heating to 800-1000 ℃ at the speed of 5-35 ℃/h, keeping the temperature for 4-32 h, then cooling to 550-750 ℃ at the speed of 1-35 ℃/h, keeping the temperature for 4-32 h, and then air cooling;

carrying out secondary annealing on the electroslag ingot after the primary annealing is finished, specifically, heating to 800-1000 ℃ at a speed of 5-35 ℃/h, then heating to 1050-1150 ℃ at a speed of 1-25 ℃/h, carrying out heat preservation for 4-32 h, then heating to 1150-1250 ℃ at a speed of 1-25 ℃/h, carrying out heat preservation for 24-72 h, then cooling to 800-950 ℃ at a speed of 1-35 ℃/h, carrying out heat preservation for 4-32 h, and then carrying out air cooling;

heating the electroslag ingot subjected to secondary annealing to 1100-1180 ℃ before forging, wherein the heating time before forging is 4-12 hours, free forging adopts a fast forging machine with the length being pulled out in one direction of more than 3000 tons, the single-side reduction amount of each pass is controlled to be 5-30 mm, and the final forging temperature is 850-1000 ℃;

and (4) polishing and flatly flattening the steel ingot after the free forging and drawing to obtain the primary consumable electrode.

7. The process of claim 1, wherein the multiple vacuum consumable remelting steps are performed in a manner such that the primary vacuum consumable remelting and the secondary vacuum consumable remelting are performed as follows:

when the vacuum consumable remelting is carried out for one time, the steady-state melting speed is controlled to be 3.5-7.5 kg/min; starting helium cooling after smelting of 800-2000 kg; reducing the current to adjust the melting speed to 3.0-7.0 kg/min after 1500-5000 kg of the alloy is remained; starting hot capping after the residual 200-1000 kg to prepare a one-time consumable remelting ingot;

when secondary vacuum consumable remelting is carried out, firstly polishing and flatting the primary consumable remelting ingot to obtain a secondary consumable electrode;

when secondary vacuum consumable remelting is carried out, the steady-state melting speed is controlled to be 4.0-8.5 kg/min; introducing helium gas for cooling after 1000-3000 kg of smelting is started; after 2000-5500 kg of residual alloy is obtained, reducing the current to adjust the melting speed to 3.0-7.5 kg/min; starting the heat sealing top after the rest of 250-1500 kg;

after the secondary consumable remelting is finished, vacuum cooling is carried out for 1-8 hours, and then stress relief annealing is started within 2 hours; during annealing, the annealing furnace is preheated to 300-750 ℃, the temperature is kept for 4-32 h to realize temperature equalization, then the temperature is raised to 800-1000 ℃ at the speed of 5-50 ℃/h, the temperature is kept for 4-32 h, then the annealing furnace is cooled to 550-750 ℃ at the speed of 1-35 ℃/h, the temperature is kept for 4-32 h, and then the annealing furnace is air-cooled.

8. The process of any one of claims 1 to 7, wherein if the melting rate fluctuation in the secondary consumable remelting process exceeds ± 10% of the steady-state melting rate, the obtained secondary consumable remelting ingot is used to perform the same primary annealing, secondary annealing and forging drawing by preparing the primary consumable electrode to obtain the consumable electrode for next vacuum consumable remelting, and then the secondary consumable remelting process is repeated again.

9. The large-size high-niobium high-temperature alloy ingot prepared by the smelting process of the large-size high-niobium high-temperature alloy ingot according to any one of claims 1 to 8, is characterized in that the large-size high-niobium high-temperature alloy ingot is 706 alloy with the diameter of more than 800mm, and the 706 alloy comprises the following chemical components in percentage by mass:

less than or equal to 0.02 percent of C, 15.5 to 16.5 percent of Cr, 40.0 to 43.0 percent of Ni, 2.8 to 3.2 percent of Nb, 1.5 to 1.8 percent of Ti, 0.1 to 0.3 percent of Al, less than or equal to 0.10 percent of Si, less than or equal to 0.20 percent of Mn, less than or equal to 0.015 percent of P, less than or equal to 0.0013 percent of S, less than or equal to 0.30 percent of Co, less than or equal to 0.20 percent of Mo, less than or equal to 0.006 percent of B, less than or equal to 0.30 percent of Cu, less than or equal to 0.005.

10. The large-size high-niobium high-temperature alloy ingot prepared by the smelting process of the large-size high-niobium high-temperature alloy ingot according to any one of claims 1 to 8, is characterized in that the large-size high-niobium high-temperature alloy ingot is 718 alloy with the diameter of more than 80mm, and the 718 alloy comprises the following chemical components in percentage by mass:

0.005-0.04% of C, 17.0-19.0% of Cr, 52.0-55.0% of Ni, 4.9-5.5% of Nb, 0.75-1.15% of Ti, 0.35-0.65% of Al, less than or equal to 0.10% of Si, less than or equal to 0.15% of Mn, less than or equal to 0.008% of P, less than or equal to 0.002% of S, less than or equal to 0.50% of Co, 2.8-3.3% of Mo, less than or equal to 0.006% of B, less than or equal to 0.10% of Cu, less than or equal to 0.005% of Ca, less than or equal.

Technical Field

The invention relates to the technical field of high-niobium high-temperature alloy large-size ingots, in particular to a smelting process of a high-niobium high-temperature alloy large-size ingot and a high-niobium high-temperature alloy large-size ingot prepared by the smelting process.

Background

With the improvement of the thermal efficiency and power of the industrial gas turbine, the turbine wheel disc material of the advanced heavy-duty gas turbine above 200MW level is gradually upgraded from alloy steel to high-temperature alloy. Compared with alloy steel, the yield strength of the high-temperature alloy at 500 ℃ is improved by more than 40%, the lasting strength of the alloy at 550 ℃ is improved by more than 300%, the high-temperature strength and the long-term lasting performance of the heavy-duty gas turbine wheel disc can be obviously improved, the structural design is simplified, and the reliability and the heat efficiency of the gas turbine are improved.

The size of the turbine wheel disc of the heavy-duty gas turbine exceeds 2000mm generally, the weight of a required forged piece exceeds 10 tons, and the weight of a required cast ingot exceeds 15 tons. The prepared turbine wheel disc can be reliably used for more than 10 ten thousand hours in a service environment for a long time, and high requirements are provided for the metallurgical quality of cast ingots.

For 706 and 718 alloys with Nb content of more than 3%, the triple smelting process of vacuum induction smelting, electroslag remelting and vacuum consumable remelting is commonly adopted in Europe and America to produce high-temperature large ingots of more than 10 tons. For example, US 20020170386a1 discloses a triple smelting process for 718 and other large ingot shapes with an alloy diameter of 762mm or more. During the use of the triple smelting equipment, the diameters of the ingot shape and the electrode need to be matched, and several matching examples of the ingot shape and the electrode are given in the patent.

For the high-temperature alloy consumable ingot with the weight of more than 15 tons, the weight of the vacuum induction ingot is more than 20 tons in consideration of the loss between the triple smelting ring joints (electrode polishing and flat head and tail), and the requirement on the equipment capacity of a vacuum induction furnace and an electroslag remelting furnace is higher. At present, the main technical bottleneck of domestic production of large ingots of high-temperature alloys with the capacity of more than 15 tons is that no vacuum induction melting equipment with the nominal capacity of more than 20 tons exists, and a single vacuum induction electrode ingot blank with the capacity of more than 20 tons cannot be prepared. In order to solve the problem, the method is suitable for domestic equipment conditions, 2 induction ingots of 10 tons are poured by a vacuum induction furnace, double-support-arm exchange electrodes are used for remelting, two short electrodes of small tonnage are used for preparing high-temperature alloy electroslag ingots of large tonnage, and the electrodes are forged for subsequent vacuum consumable remelting.

The alloy 706 and 718 has high alloying degree, is very sensitive to consumable remelting smelting process parameters, and has easy parameter fluctuation to generate smelting defects such as black spots, white spots and the like, so the stability of the smelting process parameters in the consumable remelting process is required. However, the method of remelting by using a double-support-arm exchange electrode to prepare a large-size electroslag ingot is easy to form a series of quality defects such as continuous casting, steel flowing, component fluctuation, inclusion and the like in the electrode exchange process. The above-mentioned quality defects cannot be completely eliminated even by the subsequent high-temperature diffusion annealing and electrode forging. In the subsequent vacuum consumable remelting process, when the consumable ingot is smelted to the electrode joint, the quality defects can cause smelting parameters of the consumable remelting process to fluctuate, and further influence the metallurgical quality of the consumable ingot.

Disclosure of Invention

Aiming at the defects in the prior art, the first purpose of the invention is to provide a smelting process of a large-size high-niobium high-temperature alloy ingot, which can effectively solve the problems of metallurgical defects of black spots and white spots formed by the aggravation of segregation after the diameter or weight of the large-size high-niobium high-temperature alloy ingot is enlarged, steel ingot explosion cracking caused by large thermal stress and steel ingot weight incapable of being increased caused by the limitation of the tonnage of an electrode arm of an electroslag remelting device, further realize the preparation of the large-size high-niobium high-temperature alloy ingot with the ingot weight of more than 15 tons and the diameter of more than 800mm, furthest inhibit the formation of the metallurgical defects of the black spots and the white spots, reduce the element segregation degree and effectively prevent the steel ingot explosion cracking.

The second purpose of the invention is to provide a large-size high-niobium high-temperature alloy ingot prepared by the smelting process, the weight of the obtained ingot can reach at least 15 tons, no hot crack occurs, no metallurgical defects such as black spots and white spots exist, Al and Ti elements have no obvious burning loss, and the bar forged by the ingot has no abnormal signal at an electroslag remelting joint through nondestructive inspection.

In order to achieve the purpose, the invention provides the following technical scheme: a smelting process of a high-niobium high-temperature alloy large-size ingot comprises the following steps:

vacuum induction melting: adopting pure metal raw materials and/or return materials as raw materials, carrying out vacuum induction smelting, and pouring a plurality of vacuum induction ingots with the same components;

exchange electroslag remelting: manufacturing the same number of electroslag electrodes by using the manufactured vacuum induction ingot; adopting all prepared electroslag electrodes, carrying out exchange electroslag remelting under the argon protection state, cooling and demoulding after the exchange electroslag remelting is finished, thus preparing an electroslag ingot:

carrying out multiple times of vacuum consumable remelting: carrying out primary annealing, secondary annealing and forging drawing on the demoulded electroslag ingot to a preset size to obtain a primary consumable electrode, wherein the secondary annealing temperature is higher than the primary annealing temperature; and then, performing vacuum consumable remelting at least twice by taking the primary consumable electrode as a starting material, wherein a consumable remelting ingot obtained by each vacuum consumable remelting is used for preparing a consumable electrode for standby in the next vacuum consumable remelting, the diameter of the consumable remelting ingot obtained by each vacuum consumable remelting is sequentially increased until the fluctuation of the melting speed in the last vacuum consumable remelting process is not more than +/-10% of the steady-state melting speed, and finally preparing a cast ingot with the target diameter by using the last consumable remelting ingot obtained by the last vacuum consumable remelting.

In the technical scheme of the invention, in order to overcome the problem of insufficient capacity of vacuum induction melting equipment, a vacuum induction furnace with conventional tonnage (such as 12 tons) is adopted to prepare a plurality of induction ingots with the same components (so that the requirement on the weight of a single induction ingot is reduced), so that a plurality of electroslag electrodes are prepared, then electrode exchange remelting is adopted to prepare electroslag ingots with large tonnage, and then vacuum consumable remelting is carried out for a plurality of times, wherein the metallurgical quality at an electrode exchange joint can be improved through one-time vacuum consumable remelting, and then the problem of metallurgical quality can be thoroughly solved through two or more times of vacuum consumable remelting, so that the prepared high-temperature alloy large-size consumable ingots with high quality and no metallurgical defects and at least up to 15 tons can be prepared. Considering the loss, the weight of the plurality of vacuum induction ingots is 125-160% of the target weight of the ingots.

In a preferred embodiment, in the vacuum induction melting step, the content of Nb in the raw material is 2.8 to 5.5wt.%, the content of Al is 0.2 to 1.0wt.%, and the content of Ti is 0.5 to 2.0 wt.%. .

In a preferred embodiment, in the step of vacuum induction melting, the melting temperature of the raw materials is 1400-1550 ℃, after melting down, refining is carried out for 15-120 min under the action of electromagnetic stirring, and the refining temperature is 1350-1550 ℃; then cooling for 1-10 hours, and demolding to obtain a vacuum induction ingot; the vacuum induction melting process is repeated for a plurality of times to obtain a plurality of vacuum induction ingots with the same components.

In fact, when the diameter of the vacuum induction ingot exceeds 800mm and the single-support weight exceeds 10 tons, a large-size induction ingot made of high-niobium high-temperature alloy can generate large thermal stress in the solidification process after the casting is finished, particularly aging precipitation type alloy containing Al and Ti can precipitate strengthening phases to cause larger structural stress after being cooled to the strengthening aging precipitation temperature range, and the steel ingot can be directly burst in severe cases. However, the demoulding time is too short, the steel ingot is not completely solidified, and the steel ingot is easy to crack after being demoulded prematurely.

Therefore, in a preferred embodiment, the electroslag electrode is prepared by directly performing stress relief annealing on each vacuum induction ingot, wherein during annealing, the temperature is raised to 600-800 ℃ in advance, then raised to 800-1000 ℃ at the speed of 5-45 ℃/h and kept for 4-32 h, and then cooled to 600-800 ℃ at the speed of 1-35 ℃/h and kept for 4-32 h; then air cooling, polishing and flat-end tail treatment are carried out, and the electroslag electrode is obtained. Generally, the diameter of the obtained electroslag electrode should be adapted to the diameter of the matching crystallizer of the consumable vacuum arc furnace used in the consumable vacuum remelting step, i.e. the diameter of the matching crystallizer and the diameter of the electrode should be kept in a proper ratio, i.e. the filling ratio, is about 0.8-0.9.

By adopting the scheme, the direct stress relief annealing of the vacuum induction ingot has many advantages, and firstly, the excessive tissue stress formed when the temperature falls into the aging precipitation region due to air cooling after the steel ingot is demoulded can be avoided in time; secondly, the temperature of the steel ingot can be increased at a reasonable heating rate, and large thermal stress generated inside and outside the steel ingot is avoided aiming at the problem of low thermal conductivity of high-temperature alloy; thirdly, the steel ingot is kept at the temperature of 800-1000 ℃ for a certain time to ensure that the temperature of the steel ingot is fully uniform and the solidification internal stress is released; fourthly, the steel ingot can be effectively prevented from forming larger thermal stress and structural stress again through slow cooling at the speed of 1-35 ℃/h and heat preservation at the temperature of 600-800 ℃ for a certain time.

In a preferred embodiment, when exchange electroslag remelting is carried out, the slag system used is (CaF)₂-CaO-Al₂O₃-TiO₂) Quaternary slag, (CaF)₂-CaO-Al₂O₃-TiO₂) CaF in quaternary slag₂60-75 wt.%, CaO 10-25 wt.%, and Al₂O₃10-25 wt.% of TiO₂1-10 wt.%; controlling the steady-state melting speed of electroslag remelting to be 5-15 kg/min, and before each electrode exchange, when the residual weight of the current electrode is 500-1000 kg, increasing the melting speed to 12-25 kg/min by a slope of 0.5-2 kg/min on the basis of the steady-state melting speed, keeping the stable state until the electroslag electrode exchange is started, keeping the smelting parameters before the electrode exchange in the process of exchanging the electrodes, and ensuring that the exchange time is not more than 2 min; after electrode exchange is completed every time, after the next electrode is melted to 100 kg-500 kg, the melting speed is reduced to 5-15 kg/min of the steady-state melting speed by the slope of 0.5-2 kg/min, remelting is continued until 200-600 kg of the last electrode is remained, and then heat capping is started; after the exchange electroslag remelting is finished, cooling for 2-10 h, and demolding to obtain electroslagAn ingot.

By adopting the technical scheme, the TiO in the electroslag₂The content of (1-10 wt.%) can solve the problem of burning loss of Ti element at the head and tail of electroslag ingot. Aiming at an ingot type with the diameter larger than 1000mm, the steady-state melting speed of electroslag remelting is controlled to be 5-15 kg/min, and the subsequent melting speed before and after the exchange electrode is adjusted, so that the depth of a molten pool during the exchange electrode can be reasonably increased, the problem of reduced fluidity of the molten pool caused by the suspension of melting during the exchange electrode process can be solved, the disturbance of the electrode instantly embedded into the slag pool to the molten pool is reduced, and the metallurgical quality problems of inclusion, injection connection and the like are reduced.

In a preferred embodiment, in the step of performing multiple vacuum consumable remelting, the demolded electroslag ingot is subjected to primary annealing, secondary annealing, forging and drawing to a predetermined size to obtain the consumable electrode,

starting primary annealing for the electroslag ingot within 0.5-2 h after demoulding, specifically, preheating to 300-550 ℃, keeping the temperature for 12-32 h to realize temperature equalization, then heating to 600-750 ℃ at the speed of 1-25 ℃/h, keeping the temperature for 4-32 h, then heating to 800-1000 ℃ at the speed of 5-35 ℃/h, keeping the temperature for 4-32 h, then cooling to 550-750 ℃ at the speed of 1-35 ℃/h, keeping the temperature for 4-32 h, and then air cooling;

carrying out secondary annealing on the electroslag ingot after the primary annealing is finished, specifically, preserving heat for 4-24 hours at the temperature of 550-750 ℃, then heating to 800-1000 ℃ at the speed of 5-35 ℃/h, then heating to 1050-1150 ℃ at the speed of 1-25 ℃/h, preserving heat for 4-32 hours, then heating to 1150-1250 ℃ at the speed of 1-25 ℃/h, preserving heat for 24-72 hours, then cooling to 800-950 ℃ at the speed of 1-35 ℃/h, preserving heat for 4-32 hours, and then air cooling;

heating the electroslag ingot subjected to secondary annealing to 1100-1180 ℃ before forging, wherein the heating time before forging is 4-12 hours, free forging adopts a fast forging machine with the length being pulled out in one direction of more than 3000 tons, the single-side reduction amount of each pass is controlled to be 5-30 mm, and the final forging temperature is 850-1000 ℃;

and (4) polishing and flatly flattening the steel ingot after the free forging and drawing to obtain the primary consumable electrode. Generally, the diameter of the primary consumable electrode should be adapted to the diameter of the mating mold of the consumable vacuum arc furnace used for the primary consumable remelting.

The reason for adopting the technical scheme is that the thermal stress of the obtained electroslag ingot with the diameter of the high-niobium high-temperature alloy being more than 1000mm is extremely large in the solidification process, so that the electroslag ingot is very easy to crack; because the consumable electrode and the corresponding crystallizer require reasonable filling ratio, the large-size electroslag ingot cannot be directly used for one-time consumable remelting, and free forging and drawing needs to be utilized to reduce the diameter, for example, the diameter can be 800-900 mm; however, the diameter of the electroslag ingot is too large, so that solidification segregation is very serious, serious dendrite element segregation and a low-melting-point phase among dendrites exist, and the thermoplasticity is extremely poor.

In order to solve the problem of thermal stress of high-niobium high-temperature alloy electroslag ingots with the diameter of more than 1000mm, water is introduced into a water-cooled crystallizer in an adopted electroslag remelting furnace for cooling for 2-10 hours after electroslag remelting so as to ensure that steel ingots are fully solidified and cooled to be below an aging precipitation temperature, and primary annealing is started within 0.5-2 hours after demolding. During primary annealing, preheating to 300-550 ℃, avoiding excessive thermal stress generated by overhigh temperature, then preserving heat for 12-32 hours at 300-550 ℃ to realize temperature equalization, then heating to 600-750 ℃ at the speed of 1-25 ℃/h, preserving heat for 4-32 hours, then heating to 800-1000 ℃ at the speed of 5-35 ℃/h, preserving heat for 4-32 hours, then cooling to 550-750 ℃ at the speed of 1-35 ℃/h, preserving heat for 4-32 hours, and then air cooling. Through one-time annealing, the thermal stress formed by the temperature gradient in the solidification process of the electroslag ingot can be released, meanwhile, the strengthening phase is coarsened by utilizing overaging treatment to avoid forming structural stress, and further, the direct explosion cracking of the large-size high-temperature alloy electroslag ingot after demoulding is inhibited.

In order to improve the thermoplasticity of the high-niobium high-temperature alloy electroslag ingot with the diameter of more than 800mm, the electroslag ingot is subjected to secondary annealing, namely high-temperature diffusion annealing after the annealing is finished. In order to avoid overlarge thermal stress, the temperature rising speed is strictly controlled, therefore, the electroslag ingot is charged into a furnace and is kept warm for 4-24 hours at the temperature below 550-750 ℃, then the temperature rises to 800-1000 ℃ at the speed of 5-35 ℃/h, then the temperature rises to 1050-1150 ℃ at the speed of 1-25 ℃/h and is kept warm for 4-32 hours, then the temperature rises to 1150-1250 ℃ at the speed of 1-25 ℃/h and is kept warm for 24-72 hours, then the temperature is cooled to 800-950 ℃ at the speed of 1-35 ℃/h and is kept warm for 4-32 hours, and then air cooling is carried out. Through multi-stage slow temperature rise, explosive cracking caused by overlarge thermal stress formed in the steel ingot can be avoided, and in addition, through high-temperature long-time diffusion annealing, low-melting-point phases in the alloy can be redissolved, the segregation of dendritic crystal elements is weakened, the thermoplasticity of the steel ingot is further improved, and the high-plasticity steel ingot is provided for preparing a consumable electrode through subsequent forging.

In a preferred embodiment, the multiple vacuum consumable remelting steps are performed, wherein the primary vacuum consumable remelting and the secondary vacuum consumable remelting are performed as follows:

when the vacuum consumable remelting is carried out for one time, the steady-state melting speed is controlled to be 3.5-7.5 kg/min; starting helium cooling after smelting of 800-2000 kg; reducing the current to adjust the melting speed to 3.0-7.0 kg/min after 1500-5000 kg of the alloy is remained; starting hot capping after the residual 200-1000 kg to prepare a one-time consumable remelting ingot;

when secondary vacuum consumable remelting is carried out, firstly polishing and flatly cutting the tail of the primary consumable remelting ingot to obtain a secondary consumable electrode with the diameter matched with the diameter of a crystallizer used for secondary vacuum consumable remelting;

when secondary vacuum consumable remelting is carried out, the steady-state melting speed is controlled to be 4.0-8.5 kg/min; introducing helium gas for cooling after 1000-3000 kg of smelting is started; after 2000-5500 kg of residual alloy is obtained, reducing the current to adjust the melting speed to 3.0-7.5 kg/min; starting the heat sealing top after the rest of 250-1500 kg;

after the secondary consumable remelting is finished, vacuum cooling is carried out for 1-8 hours, and then stress relief annealing is started within 2 hours; during annealing, the annealing furnace is preheated to 300-750 ℃, the temperature is kept for 4-32 h to realize temperature equalization, then the temperature is raised to 800-1000 ℃ at the speed of 5-50 ℃/h, the temperature is kept for 4-32 h, then the annealing furnace is cooled to 550-750 ℃ at the speed of 1-35 ℃/h, the temperature is kept for 4-32 h, and then the annealing furnace is air-cooled.

In the primary vacuum consumable remelting process, because the volume of the spindle is reduced in the solidification process and gaps are formed between the spindle and the wall of the crystallizer, the steel ingot and cooling water on the outer wall of the crystallizer cannot be in direct contact under the vacuum condition to realize heat dissipation, and helium is introduced for heat conduction; the steel ingot can dissipate heat through the bottom and the crystallizer in the early stage of smelting, the heat dissipation of the bottom is limited after the steel ingot is smelted to a certain stage, therefore, a proper amount of helium needs to be introduced after the steel ingot is smelted to a certain stage, too much helium breaks through a molten pool to be not beneficial to smelting stability, and too little helium cannot play a cooling effect; because the steel ingot is too large, the more the steel ingot is solidified, the larger the heat capacity is, the more difficult the heat transfer is, therefore, the melting speed needs to be properly reduced in the final stage of smelting, the depth of a molten pool is stabilized, and the formation probability of metallurgical defects is further reduced; the timing of heat capping is judged according to the residual weight of the consumable electrode, so that the cutting amount of the steel ingot can be saved, and the yield can be improved.

In the process of primary vacuum consumable remelting, because the primary consumable electrode is forged by utilizing electroslag ingots prepared by exchanging and remelting electroslag by a plurality of vacuum induction ingots, metallurgical quality fluctuation exists at an electrode exchange joint, and the fluctuation can not be completely eliminated even through high-temperature diffusion and forging. Because the consumable remelting process is very sensitive to the quality of the electrode, abnormal problems such as melting speed fluctuation, electrode block falling and the like are easy to occur when remelting is carried out to the electrode exchange joint, metallurgical defects such as black spots, white spots and the like are easy to form, the metallurgical defects cannot be eliminated through subsequent high-temperature diffusion annealing, forging or heat treatment procedures, and the prepared bar or forge piece can be directly scrapped in severe cases. Therefore, the secondary consumable electrode is prepared by polishing and flatly facing the primary consumable remelting ingot, and then secondary consumable remelting is carried out. The diameter of the steel ingot subjected to secondary consumable remelting exceeds 800mm, and large thermal stress exists, so that after secondary consumable remelting is completed, vacuum cooling is performed, then the blank is broken, stress relief annealing is started within 2h, explosion and cracking of the steel ingot after demolding are avoided, the steel ingot is preheated to 300-750 ℃ for heat preservation for 4-32 h to realize temperature equalization during annealing, then the temperature is increased to 800-1000 ℃ for heat preservation for 4-32 h at the speed of 5-50 ℃/h, then the steel ingot is cooled to 550-750 ℃ for heat preservation for 4-32 h at the speed of 1-35 ℃/h, air cooling is performed, and then the mode is adopted subsequently, so that the thermal stress formed by temperature gradient in the solidification process of the primary consumable remelting ingot can be released, meanwhile, overaging treatment is utilized, a strengthening phase is coarsened, the formation of tissue stress is avoided, and further, and direct electroslag cracking of large-size high-temperature alloy after demolding.

In a preferred embodiment, if the melting rate fluctuation in the secondary consumable remelting process exceeds +/-10% of the steady-state melting rate, the obtained secondary consumable remelting ingot is utilized, the same primary annealing, secondary annealing and forging drawing are carried out in a mode of preparing a primary consumable electrode, the consumable electrode for standby next vacuum consumable remelting is prepared, and then the secondary consumable remelting process is repeated again. Usually, the diameter of the consumable electrode to be used for the next vacuum consumable remelting should be adapted to the diameter of the mating crystallizer of the vacuum consumable arc furnace used for the next vacuum consumable remelting.

The invention provides a large-size high-niobium high-temperature alloy ingot prepared by adopting the smelting process, which is specifically 706 alloy with the diameter of more than 800mm, wherein the 706 alloy comprises the following chemical components in percentage by mass:

less than or equal to 0.02 percent of C, 15.5 to 16.5 percent of Cr, 40.0 to 43.0 percent of Ni, 2.8 to 3.2 percent of Nb, 1.5 to 1.8 percent of Ti, 0.1 to 0.3 percent of Al, less than or equal to 0.10 percent of Si, less than or equal to 0.20 percent of Mn, less than or equal to 0.015 percent of P, less than or equal to 0.0013 percent of S, less than or equal to 0.30 percent of Co, less than or equal to 0.20 percent of Mo, less than or equal to 0.006 percent of B, less than or equal to 0.30 percent of Cu, less than or equal to 0.005.

The invention provides a large-size high-niobium high-temperature alloy ingot prepared by adopting the smelting process, in particular to a 718 alloy with the diameter of more than 800mm, and the 718 alloy comprises the following chemical components in percentage by mass:

0.005-0.04% of C, 17.0-19.0% of Cr, 52.0-55.0% of Ni, 4.9-5.5% of Nb, 0.75-1.15% of Ti, 0.35-0.65% of Al, less than or equal to 0.10% of Si, less than or equal to 0.15% of Mn, less than or equal to 0.008% of P, less than or equal to 0.002% of S, less than or equal to 0.50% of Co, 2.8-3.3% of Mo, less than or equal to 0.006% of B, less than or equal to 0.10% of Cu, less than or equal to 0.005% of Ca, less than or equal.

The invention has the following advantages:

1. the tonnage limitation of an induction furnace and an atmosphere protection electroslag furnace can be broken through, a plurality of electrodes are prepared by adopting a conventional tonnage (such as 12 tons) vacuum induction furnace, then a plurality of induction ingots are smelted into 1 electroslag ingot by utilizing an electroslag furnace exchange electrode, and then the electroslag ingot is used for manufacturing vacuum consumable ingots of at least 15 tons;

2. the method can utilize an electroslag furnace with limited tonnage of an electrode support arm to prepare a 20-ton-grade high-temperature alloy electroslag ingot by adopting an exchange electroslag remelting method;

3. electroslag ingots prepared by exchange electroslag remelting are subjected to high-temperature diffusion annealing to obtain certain thermoplasticity, and free forging cogging and drawing are utilized to prepare consumable electrodes with proper diameters, so that the smelting stability in the one-time consumable remelting process can be obviously improved;

4. the secondary consumable electrode prepared from the primary consumable remelting steel ingot is used for secondary consumable remelting, and further consumable remelting is carried out for multiple times when necessary, so that the problems of metallurgical defects such as inclusion and the like at the joint of an electroslag ingot exchange electrode in the exchange electroslag remelting process can be effectively solved, and the high-niobium high-temperature alloy consumable ingot without metallurgical defects, with the diameter of more than 800mm and the weight of more than 15 tons, can be prepared.

Detailed Description

The present invention will be described in further detail with reference to examples.