CN114749616A - Ingot mould for large-scale high-length-diameter ratio steel ingot and blank forming method - Google Patents
Ingot mould for large-scale high-length-diameter ratio steel ingot and blank forming method Download PDFInfo
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- CN114749616A CN114749616A CN202210233938.2A CN202210233938A CN114749616A CN 114749616 A CN114749616 A CN 114749616A CN 202210233938 A CN202210233938 A CN 202210233938A CN 114749616 A CN114749616 A CN 114749616A
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- ingot
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/10—Hot tops therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/02—Use of electric or magnetic effects
Abstract
An electromagnetic induction riser is arranged at a riser of the ingot mold, and the electromagnetic induction riser is adopted to treat the blank in the solidification process, so that the effects of refining grains, improving the uniformity of the structure and the yield of cast ingots are achieved. The invention utilizes an induction pulse magnetic field to influence the solidification process of the casting blank riser, and the ingot mould can adapt to different blank length requirements by a multilayer splicing means. The forming method provided by the invention has obvious effects of improving the axial element segregation distribution uniformity, material yield and structure performance of the blank, and is beneficial to saving the cost.
Description
Technical Field
The invention relates to the technical field of casting, in particular to an ingot mould for a large-scale steel ingot with high length-diameter ratio and a blank forming method.
Background
The length-diameter ratio is used as an important parameter of the ingot and has important influence on the quality of the produced steel ingot. At present, the length-diameter ratio of most steel ingots in the die casting production process is between 1:1.5 and 1:2, and the short and thick ingots have the advantage of reducing center porosity, but can achieve higher quality only through more forging and pressing procedures, and have lower yield. Although the required forging frequency of the high-length-diameter ratio ingot is reduced, the problem of center looseness is difficult to solve, and the ingot is usually cracked and scrapped in the forging or rolling process. Therefore, although the high aspect ratio has many advantages, improvement in center segregation is required.
The riser has the functions of heat preservation and feeding in large-scale cast ingots. In the application of a common heat-insulating riser in a large ingot, some macrosegregation still exists obviously, and the tissue uniformity is poor, so that the tissue performance of the ingot is reduced. There is a need for methods that improve tissue performance while maintaining thermal insulation and feeding requirements.
CN112974740B discloses a riser structure which can not only effectively ensure the alloy liquid to slowly solidify to achieve feeding effect, but also can make the alloy liquid in the cast ingot solidify more quickly to reduce segregation; in addition, the shape of the heat-insulating riser is wide at the top and narrow at the bottom, so that the upper surface can play a heat-insulating effect, and the lower surface can play a quick cooling effect, thereby reducing segregation. However, for large-scale shaft blanks, the existing technology of combining electromagnetic stirring with a heating riser is difficult to realize in die casting production, and the riser can achieve the double effects of heat preservation and segregation reduction by changing the output parameters of a connected power supply.
Although CN112974740B also discloses an electromagnetic stirring device, it can disturb the liquid alloy, break the dendrite, increase the nucleation rate, reduce the grain size, and increase the alloy strength during the alloy solidification process; in addition, the alloy liquid is uniformly mixed, so that the temperature gradient is reduced, and the solidification thermal stress is reduced. However, the electromagnetic stirring technology is not suitable for the feeder head of the large-sized steel ingot because the electromagnetic stirring technology generally accelerates the cooling speed of the steel ingot, and affects the heat preservation effect of the feeder head when the feeder head is applied and processed, thereby affecting the quality of the steel ingot.
The prior patent CN107214322B also discloses that the electromagnetic oscillation effect generated by a composite magnetic field and the rotational flow induced stirring effect of a rotating magnetic field are used for promoting nucleation, breaking the tips of dendritic crystals, refining grains, uniformly solidifying tissues and reducing macro segregation, and the method is used for the casting process of large-scale cast ingots. However, in the process of treatment, the pulse current adopted by the invention can generate oscillation on a solid-liquid interface through an electromagnetic effect, so that the formation, movement and falling of crystal nuclei are promoted, crystal rain is formed, and thus, the crystal grains are refined and the flow is promoted. The invention has simple structure relative to the composite magnetic field, has the heat preservation and heating effect, and is beneficial to sequential solidification and homogenization of large ingots.
The existing ingot casting mold is usually only suitable for one diameter and height size, is difficult to meet the requirements of blanks with different sizes, has low repeated utilization rate and reduces the selection space when the ingot casting mold receives orders with different requirements.
Disclosure of Invention
Aiming at solving the problems of high forming difficulty and low product quality of the existing large-scale high-length-diameter-ratio ingot blank, the invention provides an ingot mould for a large-scale high-length-diameter-ratio steel ingot and a blank forming method. The electromagnetic induction riser is adopted to process the blank in the solidification process, so that the effects of refining grains, improving the uniformity of the structure and the yield of cast ingots are achieved.
The electromagnetic riser of the invention has the following principle:
after the pulse current is introduced into the induction coil, a pulse magnetic field is generated in the riser, and the continuous application of the pulse magnetic field reduces the temperature gradient at the front edge of a solid-liquid interface, namely, the magnetic supercooling effect is generated, the nucleation work and the critical nucleation radius are reduced, and the nucleation rate is improved; meanwhile, the electromagnetic force applied to the melt is rapidly changed along with the pulse magnetic field, so that magnetic oscillation is generated in the melt, the falling, movement and deposition of crystal nuclei on the mold wall are promoted, and the effects of refining grains and improving ingot casting homogenization are achieved, as shown in figure 1.
The technical solution of the invention is as follows:
an ingot mould for large-scale high-length-diameter-ratio steel ingots comprises a riser and is characterized in that an electromagnetic induction riser is arranged at the riser of the ingot mould and comprises an induction coil, a refractory material layer, a stainless steel shell and a coil connector, the refractory material layer is arranged inside the stainless steel shell in a clinging manner, a riser cavity communicated with a cavity of the ingot mould is arranged in the center of the refractory material layer, and the induction coil is embedded inside the refractory material layer and is connected with an external induction power supply through the coil connector arranged on the outer surface of the stainless steel shell; when the molten steel is poured to the riser, the induction power supply generates pulse current or alternating current with a certain pulse width and inputs the pulse current or the alternating current into the induction coil, the molten steel in the riser is processed in a solidification temperature range, a magnetic supercooling effect is generated to improve the nucleation rate, meanwhile, forced convection in the molten steel melt is caused, and the purposes of refining grains and improving the homogenization of cast ingots are achieved.
The frequency range of the pulse current is 5-500Hz, and the pulse width is 1-50 ms; the frequency range of the alternating current is 500-2000 Hz.
The ingot mould is a splicing ingot mould.
The ingot mould also comprises an auxiliary riser.
A blank forming method for large-scale high-length-diameter-ratio steel ingots is realized by adopting the ingot mould, and is characterized by comprising the following steps: pulse current or alternating current is introduced into an induction coil of the electromagnetic induction riser to generate an electromagnetic effect, a continuous pulse magnetic field is generated in the riser of the ingot mould, oscillation is generated on a solid-liquid interface, the temperature gradient at the front edge of the solid-liquid interface is reduced, so that a 'magnetic supercooling' effect is generated, the nucleation function and the critical nucleation radius are reduced to improve the nucleation rate, meanwhile, the molten steel melt is oscillated under the action of the pulse magnetic field to cause forced convection in the melt, so that the formation, falling, movement and deposition of crystal nuclei are promoted to form 'crystal rain', and the purposes of refining grains, homogenizing ingot castings and improving the metallographic structure performance are achieved.
The method comprises the following specific steps:
and 6, stripping the steel ingot from the ingot casting mold, cutting off a dead head part, and performing subsequent hot working.
The spliceable ingot mold has various diameters and heights for splicing, and meets the requirements of most large steel ingots, such as the diameter of 500mm, 800mm and 1200mm, and the height of 800mm, 1600mm and 2400 mm.
The riser coil connected with the pulse power supply is an electromagnetic induction coil, and the connected pulse power supply can generate pulse current with a certain pulse width.
The feeder head consists of a main feeder head and an auxiliary feeder head, wherein the main feeder head is internally provided with an electromagnetic induction coil, and the auxiliary feeder head has the functions of ensuring feeding effect and ensuring forced convection of a magnetic field to molten steel.
Compared with the prior art, the invention has the beneficial effects that:
1) the solidification process of the casting blank riser is influenced by the induction pulse magnetic field, and the ingot mould can adapt to different blank length requirements by a multi-layer splicing means.
2) The ingot casting structure is refined, the structure uniformity and the metal yield are improved by selecting the ingot casting mold and processing parameters of the pulse magnetic field, and different quality requirements of various blanks can be met by only adopting a plurality of commonly used sections. The method has obvious effects of improving the axial element segregation distribution uniformity, the material yield and the structure performance of the blank, and is favorable for saving the cost.
Drawings
FIG. 1 is a schematic diagram of the feeder of the present invention, wherein a is the critical temperature gradient G' when no compositional supercooling occurs and no magnetic field is applied, and b is the temperature gradient G after magnetic supercooling is generated in the liquid phase when the magnetic field is applied.
Fig. 2 is an outline view of the electromagnetic riser of the present invention.
Fig. 3 is a cross-sectional view of an electromagnetic riser of the present invention.
FIG. 4 is a sectional view of the structure of the present invention at the solidification stage
Fig. 5 shows the time for turning on the coil power and the time for turning off the power in embodiment 1 of the present invention.
FIG. 6 is a microstructure comparison of the central position of the feeder head, (a) untreated ingot, (b) treated ingot
FIG. 7 microstructure comparison of the center position of the ingot in the middle part, (a) untreated ingot, (b) treated ingot
FIG. 8 microstructure comparison of the ingot bottom center position, (a) untreated ingot, (b) treated ingot
FIG. 9 shows a comparison of the average size of the grains in the equiaxed areas at the centers of different positions of the ingot.
Figure 10 longitudinal cross-sectional macroscopic structures of a comparative ingot and a low power, high power processing ingot, (a) the comparative ingot (b) the low power processing ingot (c) the high power processing ingot.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the drawings. The present embodiment gives a detailed implementation and a specific workflow of the present invention, but the scope of the present invention is not limited to the following embodiments.
Referring to fig. 2 and fig. 3, as shown in the drawings, an ingot mold for large-sized high-length-diameter-ratio steel ingots includes a riser, an electromagnetic induction riser is disposed at the riser of the ingot mold, the electromagnetic induction riser includes an induction coil 8, a refractory material layer 9, a stainless steel outer shell 10 and a coil connector 11, the refractory material layer 9 is disposed inside the stainless steel outer shell 10, a riser cavity communicated with a cavity of the ingot mold is disposed at the center of the refractory material layer 9, and the induction coil 8 is embedded inside the refractory material layer 9 and is connected to an external induction power supply through the coil connector 11 disposed on the outer surface of the stainless steel outer shell; when the molten steel is poured to the riser, the induction power supply generates pulse current or alternating current with a certain pulse width and inputs the pulse current or the alternating current into the induction coil, the molten steel in the riser is processed in a solidification temperature range, a magnetic supercooling effect is generated to improve the nucleation rate, meanwhile, forced convection in the molten steel melt is caused, and the purposes of refining grains and improving the homogenization of cast ingots are achieved.
The spliceable ingot mould has various diameters and heights for splicing, and meets the requirements of most large steel ingots, such as the diameter of 500mm, 800mm and 1200mm, and the height of 800mm, 1600mm and 2400 mm.
The riser coil connected with the pulse or intermediate frequency power supply is an electromagnetic induction coil, and the connected pulse or intermediate frequency power supply can generate pulse current with a certain pulse width.
Example 1
A, selecting an ingot mould 5, an ingot mould 6 and an ingot mould 7 which are 1000mm high and 800mm in diameter and two ingot moulds 5, 6 and 7 which are 800mm high and 800mm in diameter, and splicing the two ingot moulds into an upper part, a middle part and a lower part.
And B, arranging the electromagnetic riser 8 at the top, arranging an induction coil 10 in the electromagnetic riser, and externally connecting an induction power supply.
And C, taking 20 tons of cast ingots of the steel grade 18CrNiMo as an example, pouring molten steel into the ingot mold through a casting ladle.
And D, as shown in figure 4, adding a proper amount of exothermic agent 9 at the top of the position where the molten steel is poured to the auxiliary riser 2/3.
E, when the temperature of the molten steel 11 on the inner wall of the riser reaches the liquidus line, pulse current is conducted in the coil, the molten steel in cooling solidification is continuously treated, the power supply is turned off after the temperature of the molten steel is continuously treated to be lower than the solidus line, and the molten steel is cooled.
And F, cutting off a riser part after demolding, dismantling the ingot mold, and performing subsequent hot working.
The microstructure of the rolled bar after top, middle and bottom sampling is shown in FIGS. 6, 7 and 8 and is compared with a bar not using the method of the present invention. It can be found that the solidification structure of the cast ingot obtains larger thinning effect at each part, and the uniformity of the structure is obviously improved. The grain sizes of the equiaxed crystal areas at the centers of three positions of the round billet are counted, and the result is shown in figure 9. It can be seen that the isometric crystal size at the bottom of the treated ingot was reduced from 2.3mm to 0.4mm for the comparative billet, from 2.3mm to 1.0mm in the middle, and from 2.2mm to 0.8mm at the riser, by 83%, 56%, and 64%, respectively.
Example 2
A, two ingot molds with the diameter of 190mm and the height of 250mm are selected and spliced into an upper part and a lower part.
And B, arranging the electromagnetic riser at the top, arranging an induction coil in the electromagnetic riser, and externally connecting an induction power supply.
C, taking 45 steel (medium carbon steel) as an example, pouring molten steel into the ingot mold through a ladle,
d, adding a proper amount of heating agent when the molten steel is poured to the riser 2/3,
and E, when the temperature of the molten steel on the inner wall of the riser reaches a liquidus line, the pulse current is conducted in the coil, the molten steel in cooling and solidification is continuously treated, the power supply is turned off after the temperature of the molten steel is continuously treated to be lower than the solidus line, and the molten steel is cooled.
F, demolding and detecting.
The ingot was cut longitudinally and subjected to macroscopic corrosion, and FIG. 10 shows the macroscopic structure of the longitudinal section of the comparative ingot and the ingot treated with a small power (peak current: 5000A, frequency: 45Hz, pulse width: 9ms) and with a large power (peak current: 8000A, frequency: 45Hz, pulse width: 9 ms). It can be seen that the comparative ingot center shrinkage porosity and shrinkage cavity appear at the longitudinal middle position of the ingot, and the distribution distance is long (within the dotted line frame in the figure). After low-power treatment, shrinkage porosity and shrinkage cavity move upwards; after the high-power treatment, the shrinkage porosity and the shrinkage cavity basically disappear, only a small amount of shrinkage porosity exists, and the shrinkage porosity and the shrinkage cavity are distributed at the position close to about one third of the height of the ingot body, so that the electromagnetic treatment has an obvious effect on reducing or eliminating the shrinkage porosity and the shrinkage cavity of the ingot and has great application potential on improving the tissue compactness of the ingot. Table 1 shows the average density of the comparative ingot and the treated ingot in different regions of the ingot body, and it can be seen from the table that the density of the solidification structure of the whole ingot after being treated by the electromagnetic riser is significantly increased.
TABLE 1 density of different positions of comparative ingot and treatment ingot
Example 3
A, three ingot molds with the diameter of 800mm and the height of 800mm are selected and spliced into an upper part, a middle part and a lower part.
And B, arranging the electromagnetic riser 4 at the top, wherein an induction coil 6 is arranged in the electromagnetic riser, and an induction power supply is connected externally.
C, taking an 18-ton steel ingot of which the steel grade is GCr15 (high carbon bearing steel) as an example, pouring molten steel into the ingot mold through a ladle,
d, adding a proper amount of heating agent when the molten steel is poured to the riser 2/3 as shown in figure 4,
e, when the temperature of the molten steel 7 on the inner wall of the riser reaches a liquidus line, pulse current is conducted in the coil, the molten steel in cooling solidification is continuously processed with low power (6000A, frequency 37Hz and pulse width 13ms), when the temperature in the molten steel reaches a solidification platform, high power (10000A, frequency 37Hz and pulse width 13ms) is switched to continuously process until the temperature of the molten steel is reduced below a solidus line, then a power supply is turned off, and the molten steel is kept stand for cooling.
And F, cutting off a riser part after demolding, dismantling the ingot mold, and performing subsequent hot working.
Example 4
A, four ingot molds with the diameter of 80mm and the height of 1000mm are selected and spliced into four parts.
And B, arranging the electromagnetic riser 4 at the top, arranging an induction coil 6 in the electromagnetic riser, and externally connecting an induction power supply.
C, taking 30 tons of steel ingots with the steel grade ZG30Cr13 (stainless steel) as an example, adopting bottom pouring type pouring, pouring molten steel into the ingot mold through a pouring ladle,
d, adding a proper amount of carbonized rice hulls when molten steel is poured to the ingot mold 1/3 as shown in figure 4, continuously pouring, and adding a proper amount of heating agent when the liquid level of the molten steel rises to a riser 2/3.
E, when the temperature of the molten steel 7 on the inner wall of the riser reaches a liquidus line, the coil is electrified with alternating current to continuously treat the molten steel in cooling solidification, and the power supply is turned off after the continuous treatment is carried out until the temperature of the molten steel is reduced to be lower than the solidus line, and the molten steel is cooled.
And F, cutting off a riser part after demolding, dismantling the ingot mold, and performing subsequent hot working.
Claims (6)
1. The ingot mould for the large-scale steel ingot with high length-diameter ratio comprises a riser and is characterized in that an electromagnetic induction riser is arranged at the riser of the ingot mould, and the electromagnetic induction riser comprises an induction coil, a refractory material layer, a stainless steel shell and a coil joint; the refractory material layer is arranged in the stainless steel shell in a close fit manner, and a riser cavity communicated with the cavity of the ingot mould is arranged in the center of the refractory material layer; the induction coil is embedded in the refractory material layer and is connected with an external induction power supply through a coil joint arranged on the outer surface of the stainless steel shell; when the molten steel is poured to the riser, the induction power supply generates pulse current or alternating current with a certain pulse width and inputs the pulse current or the alternating current into the induction coil, the molten steel in the riser is processed in a solidification temperature range, a magnetic supercooling effect is generated to improve the nucleation rate, meanwhile, forced convection in the molten steel melt is caused, and the purposes of refining grains and improving the homogenization of cast ingots are achieved.
2. The ingot riser for the large-sized high-aspect-ratio steel ingot according to claim 1, wherein the pulse current has a frequency range of 5-500Hz and a pulse width of 1-50 ms; the frequency range of the alternating current is 500-2000 Hz.
3. The ingot mold for large-sized high aspect ratio steel ingot according to claim 1, wherein the ingot mold is a splittable ingot mold.
4. The ingot mold for large high aspect ratio steel ingot according to claim 1, wherein the ingot mold further comprises a secondary riser.
5. A blank forming method for large high aspect ratio ingots, carried out using the ingot mould of any of claims 1 to 4, characterized in that it comprises: pulse current or alternating current is introduced into an induction coil of an electromagnetic induction riser to generate an electromagnetic effect, a continuous pulse magnetic field is generated in the riser of the ingot mould, oscillation is generated at a solid-liquid interface, the temperature gradient at the front edge of the solid-liquid interface is reduced, so that a 'magnetic supercooling' effect is generated, the nucleation power and the critical nucleation radius are reduced to improve the nucleation rate, meanwhile, the molten steel melt is oscillated under the action of the pulse magnetic field to cause forced convection in the melt, so that the formation, falling, movement and deposition of crystal grains are promoted to form 'crystal rain', and the purposes of refining the crystal grains, homogenizing the ingot and improving the performance are achieved.
6. A blank-forming method according to claim 5, characterized in that the method comprises the steps of:
step 1, selecting the diameter of an ingot mold according to actual needs, and converting the height of the ingot mold into the height of the needed ingot mold;
step 2, placing a riser coil connected with a pulse power supply or a medium-frequency power supply at a riser above the ingot mould;
step 3, pouring molten steel into the ingot casting mold;
step 4, spraying a heating agent at a riser 2/3 after the molten steel is poured to keep the temperature;
step 5, starting a riser coil power supply, continuously treating molten steel in a riser within the time of the steel solidification interval, and then closing the power supply to be cooled;
and 6, stripping the steel ingot from the ingot casting mold, cutting off a dead head part, and performing subsequent hot working.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210233938.2A CN114749616A (en) | 2022-03-10 | 2022-03-10 | Ingot mould for large-scale high-length-diameter ratio steel ingot and blank forming method |
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| CN202210233938.2A CN114749616A (en) | 2022-03-10 | 2022-03-10 | Ingot mould for large-scale high-length-diameter ratio steel ingot and blank forming method |
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Cited By (1)
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| CN115365486A (en) * | 2022-08-12 | 2022-11-22 | 中国兵器装备集团西南技术工程研究所 | Control system of multi-field pressure casting equipment |
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