CN117245095A - Ultrasonic atomization pulverizing system and method for vacuum consumable arc melting - Google Patents
Ultrasonic atomization pulverizing system and method for vacuum consumable arc melting Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000002844 melting Methods 0.000 title claims abstract description 39
- 238000000889 atomisation Methods 0.000 title claims abstract description 36
- 230000008018 melting Effects 0.000 title claims abstract description 36
- 238000010298 pulverizing process Methods 0.000 title claims description 19
- 239000000843 powder Substances 0.000 claims abstract description 114
- 229910052751 metal Inorganic materials 0.000 claims abstract description 57
- 239000002184 metal Substances 0.000 claims abstract description 57
- 239000000956 alloy Substances 0.000 claims abstract description 41
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 40
- 238000002360 preparation method Methods 0.000 claims abstract description 28
- 239000002245 particle Substances 0.000 claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 claims abstract description 13
- 238000004544 sputter deposition Methods 0.000 claims abstract description 11
- 238000003723 Smelting Methods 0.000 claims description 49
- 239000007788 liquid Substances 0.000 claims description 29
- 238000001816 cooling Methods 0.000 claims description 18
- 238000010891 electric arc Methods 0.000 claims description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 230000000694 effects Effects 0.000 claims description 8
- 239000000155 melt Substances 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 7
- 238000007789 sealing Methods 0.000 claims description 7
- 230000005540 biological transmission Effects 0.000 claims description 4
- 239000011261 inert gas Substances 0.000 claims description 4
- 238000007711 solidification Methods 0.000 claims description 3
- 230000008023 solidification Effects 0.000 claims description 3
- 230000001502 supplementing effect Effects 0.000 claims description 3
- 238000003801 milling Methods 0.000 claims description 2
- 238000009826 distribution Methods 0.000 abstract description 8
- 238000005516 engineering process Methods 0.000 abstract description 8
- 238000009689 gas atomisation Methods 0.000 abstract description 8
- 239000000654 additive Substances 0.000 abstract description 5
- 230000000996 additive effect Effects 0.000 abstract description 5
- 239000003595 mist Substances 0.000 abstract description 5
- 238000004663 powder metallurgy Methods 0.000 abstract description 5
- 239000003870 refractory metal Substances 0.000 abstract description 5
- 229910001338 liquidmetal Inorganic materials 0.000 abstract description 3
- 239000002994 raw material Substances 0.000 description 13
- 239000000463 material Substances 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- 230000001276 controlling effect Effects 0.000 description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 229910001069 Ti alloy Inorganic materials 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000009690 centrifugal atomisation Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 239000011148 porous material Substances 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000009210 therapy by ultrasound Methods 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0832—Handling of atomising fluid, e.g. heating, cooling, cleaning, recirculating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0836—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with electric or magnetic field or induction
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0844—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid in controlled atmosphere
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0848—Melting process before atomisation
Abstract
The invention provides a vacuum consumable arc melting ultrasonic atomization powder making system and method, which takes metal or alloy bar stock as a cathode, forms a micro-molten pool through consumable arc remelting, combines ultrasonic waves as an energy source for atomization powder making, generates sputtering or forms metal mist for liquid metal or alloy under the action of the ultrasonic waves, and makes powder in a vacuum environment, so that powder particles with high sphericity (more than or equal to 0.95), high compactness (more than or equal to 99) and narrow granularity distribution (less than or equal to 60 mu m) are obtained while the problems of hollow powder and satellite powder which are easy to generate under the gas atomization process are avoided, the powder using requirements of near-net forming technologies of additive manufacturing, powder metallurgy and the like are met, the problem that the preparation of metal powder by ultrasonic atomization is limited by a low-melting metal range is solved, and the preparation of high-melting point or even refractory metal and alloy powder is realized.
Description
Technical Field
The invention relates to the technical field of production and preparation of metal powder materials, in particular to a vacuum consumable arc melting ultrasonic atomization pulverizing system and method.
Background
The metal powder is an important raw material for powder near-net forming technologies such as additive manufacturing, powder metallurgy and the like, and the self performance of the metal powder has important influence on the stability of a forming process and the performance of a finished product. The spherical metal powder has good sphericity, surface smoothness and proper granularity distribution, so that the process performances of the powder such as fluidity, apparent density and the like are effectively ensured, and the spherical metal powder has positive significance for enlarging a forming process window and improving the stability and consistency of the performance of a product, thereby being widely applied.
The main flow technology for preparing the spherical metal powder at present belongs to an atomization method, and specifically comprises the processes of gas atomization, centrifugal atomization, plasma atomization and the like, wherein the gas atomization method is most widely applied, but has the defect of satellite powder, hollow powder and the like; the plasma rotary electrode atomization method has the advantages that the sphericity and the surface smoothness of the powder are high, but compared with gas atomization, the fine powder yield is low, the requirement on raw materials (dimensional tolerance) is relatively high, the manufacturing cost is not advantageous, and the large-scale application is limited; the plasma atomization technology significantly improves the yield of fine powder, but the manufacturing efficiency is relatively low.
The ultrasonic atomization process of preparing metal powder is one kind of new powder making technology, and has the principle of utilizing ultrasonic high frequency vibration to produce directional pressure to metal melt to raise and crack the surface of metal melt and produce metal drop, and may be used in preparing low melting point metal powder, such as tin powder.
The ultrasonic atomization method which takes wires and rods as raw materials and takes laser as a melting heat source can also be used for preparing high-temperature alloy powder such as stainless steel, nickel base and the like, but in the preparation process, metal liquid drops generated by laser melting freely fall onto an ultrasonic vibration sieve, and the liquid drops fall and continuously attenuate the superheat degree during the period of contacting with a sieve surface due to the loss of the heat source effect, so that the viscosity of the liquid drops is increased, the subsequent liquid drop breaking and spheroidizing processes are not facilitated, and the metal powder with the particle size less than or equal to 150 mu m and the sphericity more than or equal to 0.95 is difficult to obtain.
Prior art literature:
chinese patent: CN113664208A
Disclosure of Invention
Aiming at the defects in the existing ultrasonic atomization preparation of metal powder, the invention provides a vacuum consumable arc melting ultrasonic atomization powder preparation system and a method, which can heat and melt metal or alloy raw materials, refine and cool the materials through physical action to obtain spherical metal powder with high sphericity and narrow particle size distribution, and meet the powder use requirements of powder near-net forming technologies such as additive manufacturing, powder metallurgy and the like; meanwhile, the problems of hollow powder, satellite powder and the like which are easy to generate in the gas atomization process can be effectively avoided, the problem that the metal powder prepared by ultrasonic atomization is limited by the range of low-melting-point metal is solved, and the preparation of high-melting-point and even refractory metal and alloy powder is realized.
According to a first aspect of the object of the present invention, there is provided a vacuum consumable arc melting ultrasonic atomizing powder process system comprising:
the transmission conductive system is provided with a clamping and conductive device, and a first end of the clamping and conductive device is connected with the driving device and the power supply device and is used for providing feeding power and electric energy for the clamping and conductive device;
the side wall of the vacuum chamber is provided with a first channel and a second channel, the vacuum chamber is vacuumized through the first channel, and the vacuum chamber is supplemented with air through the second channel, so that the vacuum chamber reaches a required pressure condition;
a circulating water cooling system is arranged in the side wall surface of the vacuum chamber, and the side wall surface of the vacuum chamber is kept at the cooling temperature required by powder preparation through the circulating water cooling system;
the upper end surface of the vacuum chamber is provided with a through hole, and the second end of the clamping and conducting device penetrates through the through hole and is connected with a powder preparation system arranged in the vacuum chamber;
the milling system comprises an electrode bar, a smelting device and an ultrasonic generating device, wherein the electrode bar is fixedly connected with the second end of the clamping and conducting device, so that the working end face of the electrode bar is positioned right above the smelting device, and the ultrasonic generating device is arranged below the smelting device;
the electric rod is driven by the clamping and conducting device to descend, and electric arc is generated between the electrode bar and the smelting device through electric energy, so that the working end face of the electrode bar is melted, a molten pool is generated in the smelting device, under the action of the ultrasonic generating device, molten liquid in the molten pool is broken by ultrasonic waves and sputtered to generate liquid drops, the liquid drops are contacted with the side wall of the vacuum chamber for cooling, and metal or alloy particles are formed by solidification and fall into a powder collecting device connected with the lower end face of the vacuum chamber for collection.
As an alternative embodiment, the lower end of the vacuum chamber is provided with a cone with a big top and a small bottom, and the lower part of the cone is connected with the powder collecting device.
As an alternative embodiment, the second channel is provided in the wall of the vertebral body.
As an alternative embodiment, a sealing device is arranged at the position of the through hole of the second end of the clamping and conducting device, which enters the vacuum chamber.
According to a second aspect of the object of the present invention, there is provided a method for preparing metal or alloy powder using the aforementioned vacuum consumable arc melting ultrasonic atomizing powder making system, comprising the steps of:
connecting and fixing one end of a metal or alloy bar with a clamping and conducting device to serve as an electrode bar, wherein the other end of the metal or alloy bar serves as a working end surface and is positioned right above the smelting device;
sealing and vacuumizing the vacuum chamber until the vacuum chamber reaches a first pressure range, if the metal or alloy bar contains volatile elements, controlling the vacuum chamber to be in a second pressure range by supplementing inert gas, and starting a circulating water cooling system in the side wall surface of the vacuum chamber to maintain the side wall surface of the vacuum chamber in a required temperature range;
driving the clamping and conducting device to drive the electrode bar to descend until the required distance between the electrode bar and the smelting device is met, and starting the power supply device and the ultrasonic generating device according to the output power of the power supply device and the frequency of the ultrasonic generating device which are set by preset parameters to finish arc striking and form ultrasonic waves;
adjusting each parameter according to a preset process and an actual effect, and starting powder preparation after confirming that the electric arc state and the molten pool page state are normal;
the method comprises the steps of taking an electrode bar as a cathode, taking a smelting device as an anode, heating the working end face of the electrode bar to be gradually melted after electrifying and striking an arc, continuously dripping the working end face into the smelting device, continuously heating the melt of the smelting device by an electric arc between the cathode and the anode to form a molten pool, performing ultrasonic impact crushing on the melt in the molten pool, sputtering or flowing the formed liquid drops outside the smelting device to contact with the side wall of a vacuum chamber, and cooling and solidifying to form metal or alloy particles.
As an alternative embodiment, the first pressure range is not higher than 6.5x10 -2 Pa, a second pressure range of 1X 10 4 Pa～4×10 4 Pa。
As an alternative embodiment, the vacuum chamber sidewall surface temperature is maintained below 40 ℃.
As an alternative embodiment, the speed of the electrode bar is between 5mm/min and 100mm/min, and the electrode bar descends until the distance between the electrode bar and the smelting device is between 30mm and 50mm.
As an alternative embodiment, the output power of the power supply device is adjusted by controlling the current magnitude to be between 500A and 3500A; the initial frequency of the ultrasonic generating device is 5 kHz-15 kHz, and the frequency in the stable pulverizing process is 20 kHz-60 kHz.
As an alternative embodiment, the diameter of the electrode bar is 5 mm-150 mm and the length is 200 mm-2500 mm
Compared with the prior art, the invention has the remarkable beneficial effects that:
1. the vacuum consumable arc melting ultrasonic atomization powder making system adopts ultrasonic waves as an energy source for atomization powder making, liquid metal or alloy generates sputtering or forms metal mist under the action of the ultrasonic waves, compared with the gas atomization, a particle motion speed field has lower gradient, the liquid drop size distribution is narrower, the swirling airflow effect is avoided, the collision probability of particles with different sizes is reduced, the problems of hollow powder and satellite powder which are easy to generate under the gas atomization process are effectively avoided, and powder particles with high sphericity (more than or equal to 0.95), high compactness (more than or equal to 99) and narrow particle size distribution (less than or equal to 60 mu m) are favorably obtained.
2. The powder preparation system takes the metal or alloy bar as a cathode, forms a micro-molten pool through consumable arc remelting, ensures the superheat degree of a melt required by atomization powder preparation, is beneficial to promoting droplet sputtering and even cavitation to form metal mist (micro droplets), simplifies the structural composition of the smelting atomization system, and has positive effects on improving the purity of the powder and reducing impurity introduction.
3. The powder preparation system and the method are applicable to various materials, and besides the conventional titanium alloy and the nickel-based superalloy, refractory metals and alloys, light metals and alloys are also applicable; meanwhile, the raw material electrode can adopt an electrode rod formed by pressing elemental materials, and powder preparation is completed in the same system through arc melting-ultrasonic atomization, so that related procedures for preparing prefabricated master alloy bars are omitted, and the powder manufacturing cost is reduced.
Drawings
Fig. 1 is a schematic structural view of the vacuum consumable arc melting ultrasonic atomization pulverizing system of the present invention.
Fig. 2 is a schematic diagram of a partial structure of the vacuum consumable arc melting ultrasonic atomizing pulverizing system of the present invention.
Fig. 3 is a flow chart of the ultrasonic atomizing pulverizing method of the vacuum consumable arc melting of the present invention.
Reference numerals illustrate:
100. a transmission conductive system; 110. clamping and conducting devices; 200. a vacuum chamber; 210. a first channel; 220. a second channel; 300. a pulverizing system; 310. electrode bar stock; 320. a smelting device; 330. an ultrasonic wave generating device; 340. an arc; 350. a molten pool; 360. a droplet; 400. a powder collecting device; 500. metal or alloy particles.
Detailed Description
For a better understanding of the technical content of the present invention, specific examples are set forth below, along with the accompanying drawings.
Aspects of the invention are described in this disclosure with reference to the drawings, in which are shown a number of illustrative embodiments. The embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in more detail below, may be implemented in any of a wide variety of ways.
Ultrasonic atomization pulverizing system for vacuum consumable arc melting
Referring to fig. 1 and 2, an exemplary vacuum consumable arc melting ultrasonic atomization pulverizing system of the present invention comprises:
the transmission conductive system 100 is provided with a clamping and conductive device 110, a first end of the clamping and conductive device 110 is connected with a driving device and a power supply device and is used for providing feeding power and electric energy for the clamping and conductive device, and a second end of the clamping and conductive device 110 is connected with electrode bars in the powder making system and is used for providing descending power for the electrode bars and electric energy for striking arcs.
The vacuum chamber 200, the sidewall of the vacuum chamber 200 is provided with a first channel 210 and a second channel 220, the vacuum chamber 200 is vacuumized through the first channel 210, and the vacuum chamber 200 is supplemented with air through the second channel 220, so that the vacuum chamber reaches the required pressure condition; a circulating water cooling system is arranged in the side wall surface of the vacuum chamber 200, and the side wall surface of the vacuum chamber is kept at a cooling temperature required for pulverizing by the circulating water cooling system.
In an alternative embodiment, the first channel 210 is disposed at an upper portion of a sidewall of the vacuum chamber, the second channel 220 is disposed at a lower portion of the sidewall of the vacuum chamber, and the number of the first channels and the number of the second channels may be plural.
It will be appreciated that in order to ensure the tightness of the vacuum chamber, sealing means are provided at the first and second channels.
The upper end surface of the vacuum chamber 200 is provided with a through hole through which the second end of the clamping and conducting device 110 passes and is connected with the pulverizing system 300 arranged in the vacuum chamber; the lower end of the vacuum chamber 200 is connected to the powder collecting device 400.
In an alternative embodiment, the lower end of the vacuum chamber 200 is configured as a cone with a large upper part and a small lower part, the lower part of the cone is connected with the powder collecting device 400, and the second channel 220 is formed on the wall surface of the cone.
In another alternative embodiment, a baffle is provided at the connection between the vacuum chamber 200 and the powder collecting device 400, and the baffle is automatically opened at intervals to allow the powder accumulated at the lower end of the vacuum chamber to fall into the powder collecting device.
In another alternative embodiment, a sealing device is arranged at the position of the through hole of the second end of the clamping and conducting device, which enters the vacuum chamber, so that the tightness of the whole vacuum chamber is ensured.
As shown in fig. 2, the powder manufacturing system 300 comprises an electrode bar 310, a smelting device 320 and an ultrasonic wave generating device 330, wherein the electrode bar 310 is fixedly connected with the second end of the clamping and conducting device 110, so that the working end surface of the electrode bar 310 is positioned right above the smelting device 320, and the ultrasonic wave generating device 330 is arranged below the smelting device 320.
In an alternative embodiment, the smelting device 320 may be a copper crucible with a water cooled runner, with a hemispherical smelting station in the center of the crucible.
The electric charge rod pole 310 descends under the drive of the clamping and conducting device 110, and an electric arc 340 is generated between the electrode rod 310 and the smelting device 320 through electric energy, so that the working end face of the electrode rod 310 is melted, a molten pool 350 is generated in the smelting device 320, under the action of the ultrasonic wave generating device 330, molten liquid in the molten pool 350 is broken up by ultrasonic waves and sputtered to generate liquid drops 360, the liquid drops 360 are contacted with the side wall of the vacuum chamber for cooling, metal or alloy particles 500 are formed by solidification, and the liquid drops fall into a powder collecting device 400 connected with the lower end face of the vacuum chamber for collection.
It is understood that the electrode bar is a bar made of raw material metal or alloy, the diameter of the electrode bar is preferably 5 mm-150 mm, and the length of the electrode bar is preferably 200 mm-2500 mm.
Ultrasonic atomization pulverizing method for vacuum consumable arc melting
With reference to the flow chart of fig. 3, using the foregoing vacuum consumable arc melting ultrasonic atomizing powder making system of the present invention, an exemplary method for preparing a metal or alloy powder is provided, comprising the steps of:
connecting and fixing one end of a metal or alloy bar with a clamping and conducting device to serve as an electrode bar, wherein the other end of the metal or alloy bar serves as a working end surface and is positioned right above the smelting device;
sealing and vacuumizing the vacuum chamber until the vacuum chamber reaches a first pressure range, if the metal or alloy bar contains volatile elements, controlling the vacuum chamber to be in a second pressure range by supplementing inert gas, and starting a circulating water cooling system in the side wall surface of the vacuum chamber to maintain the side wall surface of the vacuum chamber in a required temperature range;
driving the clamping and conducting device to drive the electrode bar to descend until the required distance between the electrode bar and the smelting device is met, and starting the power supply device and the ultrasonic generating device according to the output power of the power supply device and the frequency of the ultrasonic generating device which are set by preset parameters to finish arc striking and form ultrasonic waves;
adjusting each parameter according to a preset process and an actual effect, and starting powder preparation after confirming that the electric arc state and the molten pool page state are normal;
the method comprises the steps of taking an electrode bar as a cathode, taking a smelting device as an anode, heating the working end face of the electrode bar to be gradually melted after electrifying and striking an arc, continuously dripping the working end face into the smelting device, continuously heating the melt of the smelting device by an electric arc between the cathode and the anode to form a molten pool, performing ultrasonic impact crushing on the melt in the molten pool, sputtering or flowing the formed liquid drops outside the smelting device to contact with the side wall of a vacuum chamber, and cooling and solidifying to form metal or alloy particles.
As an alternative embodiment, the first pressure range is not higher than 6.5X10 -2 Pa。
As an alternative embodiment, the second pressure range is 1X 10 4 Pa～4×10 4 Pa。
As an alternative embodiment, the electrode bar is lowered at a speed of between 5mm/min and 100mm/min.
As an alternative embodiment, the electrode bar is lowered until a distance of 30-50 mm is reached from the smelting device.
As an alternative embodiment, the output power of the power supply device is adjusted by controlling the current level to be between 500A and 3500A.
As an alternative implementation mode, the initial frequency of the ultrasonic generating device is between 5kHz and 15kHz, and the frequency in the process of stabilizing the powder preparation is between 20kHz and 60kHz.
As an alternative embodiment, the diameter of the electrode bar is 5-150 mm and the length is 200-2500 mm.
In one specific embodiment, the ultrasonic atomization powder preparation method for vacuum consumable arc melting comprises the following specific steps:
1) Raw material preparation: the raw materials used in the method are metals or alloys, the shape of the raw materials is bar-shaped, the diameter is 5 mm-150 mm, the length is 200 mm-2500 mm, the raw materials are put into the electrode position, the raw materials are right above the smelting crucible, and an ultrasonic generating system is arranged below the smelting crucible.
The raw materials can be prefabricated master alloy bars, and also can be electrode bars formed by mixing simple substance materials and pressing alloy scraps.
2) Atmosphere and temperature guarantee: vacuumizing the pulverizing system to obtain a target vacuum degree of 6.5X10 -2 Pa or lower, if the alloy material contains volatile elements, inert gas such as argon with purity of 99.99% or more can be filled, and the pressure after filling is 1×10 4 Pa～4×10 4 Pa; the outlet temperature of the circulating water on the side wall of the vacuum chamber is ensured to be lower than 40 ℃.
3) Starting ultrasonic treatment: starting an ultrasonic generating system, generating high-frequency ultrasonic waves and transmitting the high-frequency ultrasonic waves to a smelting crucible;
wherein, the initial frequency of the ultrasonic generating device is between 5kHz and 15kHz, and the frequency in the stable pulverizing process is between 20kHz and 60kHz.
4) Consumable arc melting: the raw material rod is used as a cathode, a smelting device (such as a crucible) is used as an anode, the tail end of a bar is heated and gradually melted after electrifying and striking an arc, and continuously drops into the smelting crucible, and an electric arc between the cathode and the anode continuously heats melt in the crucible and forms a melting pool with shallower depth;
the specific process comprises the following steps: the electrode bar is driven by the clamping and conducting device to vertically drop downwards, the dropping speed is between 5mm/min and 100mm/min, when the distance between the tail end of the electrode bar and the upper surface of the smelting device is between 30mm and 50mm, a power supply is started and arc striking is completed, the dropping speed and the power supply output power of the electrode bar are controlled, the electrode bar begins to melt under the arc heating effect, the molten drops fall into the smelting device below and are further heated by the electric arc, refining is realized, and the power supply output power is adjusted by controlling the current, and is between 500A and 3500A.
5) Ultrasonic atomization: the molten metal in the smelting device is impacted and broken by high-frequency sound waves to form tiny liquid drops or even mist, and the tiny liquid drops or even mist is sputtered or flows to the outside of the crucible and is cooled and solidified to form metal or alloy particles;
the specific process is as follows: the ultrasonic generating system generates directional sound waves which are transmitted to the molten pool through the crucible, and excites the liquid drop jet flow, and after the liquid drop is separated from the molten pool, the liquid drop is further refined, cooled and solidified to form metal or alloy powder;
the ultrasonic frequency and duration are regulated, the liquid drop sputtering rate is controlled, and the arc flame length, the melting rate, the molten pool depth and the temperature stability are maintained in cooperation with the electrode bar descending rate and the smelting power regulation.
The ultrasonic operation modes comprise two modes, namely continuous operation, melting and ultrasonic atomization are adopted for conventional materials, and continuous operation is carried out; the refractory material is operated intermittently with ultrasound to allow sufficient time for the melt to warm up.
The sputtering rate and the droplet size of the droplets in the molten pool are regulated by controlling the ultrasonic frequency and the operation mode, so that the maximum sputtering rate is not more than 100cm 3 /min。
The arc flame length has influence on the heat output of the electric arc, and the melting rate of the electrode bar can be adjusted by matching with the descending speed of the electrode bar, namely the rate of newly added molten liquid of a molten pool; through the matching of the melting rate and the sputtering rate, the stability of the depth and the temperature of a molten pool is maintained, and the stability of the yield and the particle characteristics (morphology and size) of the ultrasonic atomization pulverizing process is further ensured.
6) Powder collection, namely separating or settling the powder from the exhaust port into the bottom collection device under the action of air flow or dead weight.
The invention relates to a vacuum consumable arc melting ultrasonic atomization powder making method, which uses metal or alloy bar as cathode, forms micro-melting pool through consumable arc remelting, combines ultrasonic wave as energy source of atomization powder making, and produces sputtering or forming metal fog by liquid metal or alloy under the action of ultrasonic wave, and powder making in vacuum environment, avoiding the problems of hollow powder and satellite powder which are easy to produce under the gas atomization process, at the same time, obtaining powder particles with high sphericity (more than or equal to 0.95), high compactness (more than or equal to 99%), narrow particle size distribution (less than or equal to 60 mu m), meeting the powder using requirement of powder near-net forming technology such as additive manufacturing, powder metallurgy, etc., solving the problem that the metal powder prepared by ultrasonic atomization is limited in the range of low melting point metal, and realizing the preparation of high melting point or even refractory metal and alloy powder.
The technical scheme of the invention is further described below by taking TC4 titanium alloy powder materials as an example in combination with a process flow chart and a preparation system chart of the invention.
The TC4 powder comprises the following components: 6.03%, V:4.11%, fe:0.065%, O:0.1259%, N:0.0076, H:0.0007%, C:0.0025%, ti: bal.
Example 1
First, a TC4 pre-fabricated electrode rod 310 having a diameter of 50mm and a length of 2000mm is fixed to the clamping and conducting device 110 such that the electrode rod 310 is located directly above the melting device 320. After the system is closed, the powder preparation system is vacuumized through the first channel 210 to reach the target vacuum degree of 6.5 x 10 -2 Pa, and feeding high purity argon through the second channel 220 to a system pressure of 3 x 10 4 Pa, argon purity was 99.999%.
The lowering speed of the electrode bar 310 was set to 25mm/min, and the ultrasonic wave generating device 330 was started to set the frequency to 10kHz. When the distance between the electrode bar and the smelting device is 40mm, a power supply is started, the current is set to 1400A, and under the thermal effect of an electric arc, the end part of the electrode bar is gradually melted, and a molten pool is generated.
According to the preset process and actual effect, setting atomizing powder making process parameters, wherein the current intensity is 1600A, the bar feeding speed is 27mm/min, the ultrasonic frequency is 40kHz and maintained, and observing and confirming that the state of the electric arc 4 and the liquid level state of the molten pool 5 are normal.
In the stable pulverizing process, the end part of the TC4 electrode bar fed at a low speed is continuously melted by an electric arc and is replenished into a molten pool, under the action of ultrasonic waves, molten liquid in the molten pool is sputtered to generate liquid drops, the liquid drops contact with a cooling wall in flight and fall into a powder collecting tank through a lower cone section, and TC4 titanium alloy powder is obtained.
And (3) sieving the prepared powder with a 100-mesh screen to obtain target segment powder, detecting granularity and particle shape, and observing the compactness of the section.
The powder was found to have a D50 of 76.92. Mu.m, a particle size distribution (D84-D16) of 47.8. Mu.m, a sphericity of 0.96 and a density of 99.5%.
The less pores at the interface of the particles, the higher the density, which indicates that the less hollow powder is; the higher the sphericity of the powder is, the closer the appearance of the powder is to perfect sphericity (sphericity is 1.0), so the preparation process effectively avoids the problems of hollow powder and satellite powder which are easy to generate in the air atomization process.
Therefore, the metal powder prepared by the vacuum consumable arc melting ultrasonic atomization powder preparation system has high sphericity (more than or equal to 0.95), high density (more than or equal to 99 percent) and narrow particle size distribution (less than or equal to 60 microns), meets the powder utilization requirements of powder near-net forming technologies such as additive manufacturing, powder metallurgy and the like, can effectively avoid the defects of hollow powder, satellite powder and the like which are easy to generate in an air atomization process, solves the problems that the ultrasonic atomization preparation of the metal powder is limited by the range of low-melting-point metal, and realizes the preparation of high-melting-point even refractory metal and alloy powder.
While the invention has been described with reference to preferred embodiments, it is not intended to be limiting. Those skilled in the art will appreciate that various modifications and adaptations can be made without departing from the spirit and scope of the present invention. Accordingly, the scope of the invention is defined by the appended claims.
Claims (10)
1. A vacuum consumable arc melting ultrasonic atomization pulverizing system, comprising:
the transmission conductive system (100) is provided with a clamping and conductive device (110), and a first end of the clamping and conductive device (110) is connected with the driving device and the power supply device and is used for providing feeding power and electric energy for the clamping and conductive device;
the vacuum chamber (200), the sidewall of the vacuum chamber (200) is provided with a first channel (210) and a second channel (220), the vacuum chamber (200) is vacuumized through the first channel (210), and the vacuum chamber (200) is supplemented with air through the second channel (220), so that the vacuum chamber reaches the required pressure condition;
a circulating water cooling system is arranged in the side wall surface of the vacuum chamber (200), and the side wall surface of the vacuum chamber is kept at the cooling temperature required by powder preparation through the circulating water cooling system;
the upper end surface of the vacuum chamber (200) is provided with a through hole, and the second end of the clamping and conducting device (110) penetrates through the through hole and is connected with a powder preparation system (300) arranged in the vacuum chamber;
the milling system (300) comprises an electrode bar (310), a smelting device (320) and an ultrasonic generating device (330), wherein the electrode bar (310) is fixedly connected with the second end of the clamping and conducting device (110) so that the working end face of the electrode bar (310) is positioned right above the smelting device (320), and the ultrasonic generating device (330) is arranged below the smelting device (320);
the electric rod pole (310) is driven to descend by the clamping and conducting device (110), and an electric arc (340) is generated between the electrode rod pole (310) and the smelting device (320) through electric energy, so that the working end face of the electrode rod pole (310) is melted, a molten pool (350) is generated in the smelting device (320), under the action of the ultrasonic generating device (330), molten liquid in the molten pool (350) is broken by ultrasonic waves and sputtered to generate liquid drops (360), the liquid drops (360) are cooled by contacting with the side wall of the vacuum chamber, and metal or alloy particles (500) are formed by solidification and fall into a powder collecting device (400) connected with the lower end face of the vacuum chamber to be collected.
2. The ultrasonic atomizing powder manufacturing system for vacuum consumable arc melting according to claim 1, wherein the lower end of the vacuum chamber (200) is provided as a cone with a large upper part and a small lower part, and the lower part of the cone is connected with the powder collecting device (400).
3. The vacuum consumable arc melting ultrasonic atomizing powder manufacturing system according to claim 2, characterized in that the second channel (220) is provided on a wall surface of the cone.
4. The ultrasonic atomizing powder manufacturing system for vacuum consumable arc melting according to claim 1, wherein a sealing device is arranged at a position where the second end of the clamping and conducting device (110) enters the through hole of the vacuum chamber.
5. A method of preparing metal or alloy powder using the vacuum consumable arc melting ultrasonic atomizing powder process system of any one of claims 1-4, comprising the steps of:
connecting and fixing one end of a metal or alloy bar with a clamping and conducting device to serve as an electrode bar, wherein the other end of the metal or alloy bar serves as a working end surface and is positioned right above the smelting device;
sealing and vacuumizing the vacuum chamber until the vacuum chamber reaches a first pressure range, if the metal or alloy bar contains volatile elements, controlling the vacuum chamber to be in a second pressure range by supplementing inert gas, and starting a circulating water cooling system in the side wall surface of the vacuum chamber to maintain the side wall surface of the vacuum chamber in a required temperature range;
driving the clamping and conducting device to drive the electrode bar to descend until the required distance between the electrode bar and the smelting device is met, and starting the power supply device and the ultrasonic generating device according to the output power of the power supply device and the frequency of the ultrasonic generating device which are set by preset parameters to finish arc striking and form ultrasonic waves;
adjusting each parameter according to a preset process and an actual effect, and starting powder preparation after confirming that the electric arc state and the molten pool page state are normal;
the method comprises the steps of taking an electrode bar as a cathode, taking a smelting device as an anode, heating the working end face of the electrode bar to be gradually melted after electrifying and striking an arc, continuously dripping the working end face into the smelting device, continuously heating the melt of the smelting device by an electric arc between the cathode and the anode to form a molten pool, performing ultrasonic impact crushing on the melt in the molten pool, sputtering or flowing the formed liquid drops outside the smelting device to contact with the side wall of a vacuum chamber, and cooling and solidifying to form metal or alloy particles.
6. The method of claim 5, wherein the first pressure range is no higher than 6.5x10 -2 Pa, a second pressure range of 1X 10 4 Pa～4×10 4 Pa。
7. The method of claim 5, wherein the vacuum chamber sidewall surface temperature is maintained below 40 ℃.
8. The method according to claim 5, wherein the electrode bar is lowered at a speed of 5-100 mm/min until a distance of 30-50 mm is reached from the melting device.
9. The method of claim 5, wherein the output power of the power supply device is adjusted by controlling the magnitude of the current to be between 500A and 3500A; the initial frequency of the ultrasonic generating device is 5 kHz-15 kHz, and the frequency in the stable pulverizing process is 20 kHz-60 kHz.
10. The method of claim 5, wherein the electrode bar has a diameter of 5mm to 150mm and a length of 200mm to 2500mm.
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