High-performance nodular cast iron material rapid development method and system based on electronic metallurgy

Abstract

The invention discloses a rapid development method and system for a high-performance nodular cast iron material based on electronic metallurgy, and relates to the technical field of electronic metallurgy, and the rapid development method comprises the steps that a high-performance nodular cast iron raw material is smelted through multi-stage electron beams, and uniform molten metal is obtained; monitoring the chemical components and temperature change of the molten metal in real time, and dynamically adjusting the addition of the spheroidizing agent; the pouring speed and pressure of the molten metal subjected to spheroidizing treatment are intelligently controlled, and casting pouring is conducted; the internal stress change of the casting is monitored in real time through an embedded stress sensor, and the casting cooling process is adjusted; the cooled casting is subjected to surface treatment, heat treatment and machining; component detection and performance testing are conducted on the casting obtained after treatment and machining are completed; through the multi-stage electron beam melting technology, accurate control over the temperature and chemical components of the molten metal is achieved, and the uniformity and stability of the molten metal are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of electronic metallurgy, in particular to a method and system for rapid development of high-performance ductile iron materials based on electronic metallurgy. Background Art

[0002] Ductile iron, as an important engineering material, has been widely used in the fields of automobile, machinery manufacturing, aerospace, etc. due to its excellent mechanical properties and cost-effectiveness. Traditional processes have many shortcomings, such as the difficulty in accurately controlling the temperature and chemical composition during the smelting process, uneven spheroidization, defects during the pouring process, and internal stress during the cooling process. These problems seriously affect the performance and quality of castings.

[0003] Although the application of multi-stage electron beam melting technology and intelligent control systems in ductile iron production has made some progress, there are still some shortcomings. Due to the lack of real-time monitoring and dynamic adjustment mechanisms, the temperature and chemical composition of the molten metal are difficult to maintain within the ideal range, resulting in uneven spheroidization treatment and affecting the microstructure and mechanical properties of the castings. Summary of the invention

[0004] In view of the above existing problems, the present invention is proposed.

[0005] Therefore, the present invention provides a method and system for rapid development of high-performance ductile iron materials based on electronic metallurgy to solve the problem of uneven graphite spheroidization treatment during the smelting process.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: In a first aspect, the present invention provides a method for rapid development of high-performance ductile iron materials based on electronic metallurgy, which comprises: The high-performance ductile iron raw material is melted by multi-stage electron beam to obtain uniform molten metal; Real-time monitoring of the chemical composition and temperature changes of the molten metal, and dynamic adjustment of the addition of spheroidizing agent; Intelligently control the pouring speed and pressure of the molten metal after spheroidization to cast the castings; Monitor the internal stress changes of castings in real time through embedded stress sensors and adjust the cooling process of castings; Surface treatment, heat treatment and machining of cooled castings; The castings after processing are subjected to composition inspection and performance testing.

[0007] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy described in the present invention, wherein: the high-performance ductile iron raw materials are melted by multi-stage electron beam to obtain uniform molten metal, and the specific steps are as follows: Determine the performance requirements and raw material ratio of high-performance ductile iron materials according to customer needs; Use electronic scales to weigh various materials; Use a multi-stage electron beam melting furnace equipped with multiple electron beam generators, evenly arranged at different positions in the furnace, and each electron beam generator can independently control the power density and scanning path; Install multi-point temperature sensors and composition analysis equipment evenly distributed at different locations in the molten pool to monitor the temperature changes and alloy element content in the furnace in real time; Put the raw materials into the furnace and preheat them; After preheating, all electron beam generators are started, and the initial power density and initial scanning speed are set; According to the casting performance requirements and raw material properties, the target temperature range of the furnace is set. According to the real-time data of the multi-point temperature sensor, the power density and scanning path of the nearest electron beam generator are adjusted to adjust the temperature of the area that is not within the target temperature range; During the smelting process, alloy elements are added according to the real-time monitoring of the alloy element content in the furnace; After the smelting is completed, turn off the electron beam generator, keep the temperature in the furnace within the target temperature range, and perform insulation treatment; Generate temperature distribution curve based on real-time data from multi-point temperature sensors to check the uniformity of furnace temperature; Based on the real-time data of chemical composition analysis equipment, the content of alloy elements in molten metal is checked.

[0008] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy of the present invention, the chemical composition and temperature changes of the molten metal are monitored in real time, and the addition of the spheroidizing agent is dynamically adjusted. The specific steps are as follows: The molten metal is transferred to the spheroidizing treatment pool through a dedicated high-temperature pipeline, and the temperature of the molten metal is always kept within the target range during the transfer process; By installing a temperature sensor in the pipeline, the temperature of the molten metal is monitored in real time. When the temperature drops outside the target temperature range, the temperature is raised through the heating device in the pipeline. The spheroidizing temperature range is set based on the properties of the spheroidizing agent and the requirements of the graphite spheroidizing process; Install multi-point temperature sensors to monitor the internal temperature of the spheroidizing treatment pool in real time; According to the quantity of raw materials and the performance requirements of castings, the initial spheroidizing agent addition amount is set, and the initial spheroidizing agent addition amount is less than the actual addition amount; Add spheroidizer in small amounts and multiple times through a metering pump, turn on the stirring device to increase the fluidity of the molten metal; Install an online electron microscope to monitor the graphite morphology and distribution in the molten metal in real time, and transmit the image data to the data terminal through a wired connection; The electron microscope starts to transmit images when the spheroidizing agent is added, and updates the image data in real time each time the spheroidizing agent is added; Perform denoising, contrast adjustment and background correction on images; Use professional image processing software to process and analyze images; The graphite spheres are separated from the background using the threshold segmentation method to generate a binary image; Extract the features, roundness, diameter and distribution uniformity of graphite balls from binary images, and evaluate the roundness of graphite balls by calculating the roundness factor of graphite balls. By measuring the diameter of graphite balls, the average diameter of graphite balls is calculated; Calculate the distribution coefficient of graphite balls and evaluate the distribution uniformity of graphite balls; After the initial spheroidizing agent addition amount is fully added to the spheroidizing treatment tank, the image data collected each time and the extracted characteristic values ​​are summarized to generate a data table; Statistical analysis was performed on the data table to calculate the average roundness factor, average diameter and distribution coefficient of the graphite spheres; If the characteristics of the graphite balls meet the expected requirements, proceed to the next step; If the roundness factor and average diameter of the graphite spheres are lower than expected, increase the amount of spheroidizer by a small amount. After each increase, re-evaluate the spheroidization effect. If the distribution coefficient of the graphite spheres does not meet the expected requirements, extend the stirring time and re-evaluate the graphite sphere distribution coefficient.

[0009] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy of the present invention, wherein: the pouring speed and pressure of the molten metal after spheroidization treatment are intelligently controlled to perform casting, and the specific steps are as follows: The molten metal after spheroidization is transferred to the pouring area through a special high-temperature pipe with a high-temperature resistant coating on the inner wall; Clean and assemble the mold, apply high temperature resistant coating on the inner wall of the mold, and preheat the mold; Determine the pouring temperature range according to the casting performance requirements and the molten metal spheroidization treatment temperature range, and determine the pouring speed and pressure range according to the casting size and shape; The temperature of the molten metal is monitored in real time by installing multiple temperature sensors in the pouring pipe and pouring equipment. The flow rate of the molten metal is monitored in real time by installing flow sensors in the pouring pipe. The pressure of the pouring equipment is monitored in real time by installing pressure sensors in the pouring equipment. The temperature, flow and pressure data of molten metal are collected in real time through sensors and transmitted to the intelligent control center; The intelligent control center automatically adjusts the power of the heating equipment according to the temperature difference to keep the temperature of the molten metal in the pouring pipe and pouring equipment within the pouring temperature range; The intelligent control center calculates the flow deviation in real time based on the data from the flow sensor. Based on the flow deviation, the intelligent control center dynamically adjusts the pump speed. Each adjustment is determined based on the size of the flow deviation. The intelligent control center calculates the pressure deviation in real time based on the data from the pressure sensor. Based on the pressure deviation, the intelligent control center dynamically adjusts the opening of the pressure regulating valve. The amplitude of each adjustment should be determined according to the size of the pressure deviation.

[0010] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy of the present invention, wherein: the embedded stress sensor is used to monitor the internal stress changes of the casting in real time and adjust the cooling process of the casting. The specific steps are as follows: Install embedded stress sensors at the thick walls, thin walls and corners of the casting to monitor stress changes inside the casting; Install multiple temperature sensors at the thick wall, thin wall and corners of the mold to monitor the temperature changes of the casting and mold in real time; Collect stress and temperature data in real time through sensors and transmit the data to the intelligent control center; Set the cooling rate and stress threshold range according to the performance requirements of the casting; The intelligent control center calculates the stress change value of each point in real time based on the data of the stress sensor; When local stress concentration is detected, the intelligent control center reduces the cooling rate of the area. When the stress value exceeds the highest value of the threshold range, the cooling equipment is reduced and the power of the cooling equipment is reduced to reduce the cooling rate. When the stress value is lower than the minimum value of the threshold range, the cooling device is added and the power of the cooling device is increased to increase the cooling rate; The intelligent control center calculates the temperature change value in real time based on the data from the temperature sensor, and adjusts the cooling rate by adjusting the number and power of the cooling equipment.

[0011] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy of the present invention, the surface treatment, heat treatment and machining of the cooled casting are specifically performed as follows: After cooling, the mold is removed and the casting is transported to the processing area; Use high-pressure sandblasting equipment to remove the oxide layer on the surface of the casting; Use alkaline cleaning agents in the cleaning tank to remove residues and impurities from the casting surface; Place the cleaned castings into a drying oven for drying; The dried casting is placed in an annealing furnace for annealing to release the internal stress of the casting; Fix the casting on the CNC lathe for rough and fine machining; Use a three-coordinate measuring machine to inspect the dimensions of the processed castings, use a surface roughness meter to inspect the surface finish of the castings, and use a Rockwell hardness tester to inspect the hardness of the castings.

[0012] As a preferred solution of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy of the present invention, the following specific steps are performed to perform composition detection and performance testing on the castings after processing: Select different parts from the finished castings, cut out test samples using a plasma cutter, and grind and polish the samples; Use component analysis equipment, direct reading spectrometer (OES) to analyze the components of the sample, record the spectral analysis results, and compare them with the expected components; The samples were tested for hardness, tensile strength, impact toughness and fatigue, and the test results were recorded and compared with the expected performance indicators.

[0013] Using a scanning electron microscope, the morphology, size and distribution of the graphite nodules of the samples were observed and compared with the expected requirements.

[0014] In a second aspect, the present invention provides a high-performance ductile iron material rapid development system based on electronic metallurgy, including a raw material smelting module, a graphite spheroidizing module, a casting pouring module, a casting cooling module, a casting processing module and a casting detection module. The raw material smelting module is used to melt high-performance ductile iron raw materials through multi-stage electron beam to obtain uniform molten metal; The graphite spheroidizing module is used to monitor the chemical composition and temperature changes of the molten metal in real time and dynamically adjust the addition of the spheroidizing agent; The casting pouring module is used to intelligently control the pouring speed and pressure of the molten metal after spheroidization treatment to perform casting pouring; The casting cooling module is used to monitor the internal stress changes of the casting in real time through the embedded stress sensor and adjust the cooling process of the casting; The casting processing module is used to perform surface treatment, heat treatment and machining on the cooled casting; The casting detection module is used to perform composition detection and performance testing on the casting after processing.

[0015] In a third aspect, the present invention provides a computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: when the computer program is executed by the processor, any step of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy as described in the first aspect of the present invention is implemented.

[0016] In a fourth aspect, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program is executed by a processor, any step of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy as described in the first aspect of the present invention is implemented.

[0017] The beneficial effects of the present invention are as follows: The present invention realizes precise control of the temperature and chemical composition of the molten metal through multi-stage electron beam melting technology, ensuring the uniformity and stability of the molten metal. Real-time monitoring and dynamic adjustment of the addition of spheroidizing agent ensure the uniformity of spheroidizing treatment and the roundness, size and distribution uniformity of graphite balls. The intelligent control system accurately controls the pouring speed and pressure, avoiding defects such as uneven pouring, pores and inclusions, and improving the density and integrity of the casting. The embedded stress sensor monitors the internal stress changes of the casting in real time, dynamically adjusts the cooling rate and cooling method, avoids internal stress concentration, and improves the dimensional stability and mechanical properties of the casting. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0019] Figure 1 This is a flow chart of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy in Example 1.

[0020] Figure 2 This is a schematic diagram of the rapid development system of high-performance ductile iron materials based on electronic metallurgy in Example 1. DETAILED DESCRIPTION

[0021] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0022] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0023] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0024] Example 1, reference Figure 1 and Figure 2 , which is the first embodiment of the present invention, provides a rapid development method for high-performance ductile iron materials based on electronic metallurgy, comprising the following steps: S1. High-performance ductile iron raw materials are melted by multi-stage electron beam to obtain uniform molten metal.

[0025] Furthermore, the performance requirements and raw material ratio of high-performance ductile iron materials are determined according to customer needs; Use electronic scales to weigh various materials; Use a multi-stage electron beam melting furnace equipped with multiple electron beam generators, evenly arranged at different positions in the furnace to ensure that the electron beam scans the path in the molten pool evenly, avoiding overheating of some areas and underheating of other areas. Each electron beam generator can independently control the power density and scan path; Install multi-point temperature sensors and composition analysis equipment evenly distributed at different locations in the molten pool to monitor the temperature changes and alloy element content in the furnace in real time; Further, the raw materials were put into the furnace for preheating, the preheating temperature was set to 1200°C, and the preheating time was set to 20 minutes to ensure uniform preheating of the surface of the raw materials; After preheating, start all electron beam generators, set the initial power density to 10kW / cm² and the initial scanning speed to 50mm / s, and keep the temperature in the furnace rising steadily; According to the casting performance requirements and raw material properties, the target temperature range of the furnace is set. According to the real-time data of the multi-point temperature sensor, the power density of the nearest electron beam generator and the width and direction of the scanning path are adjusted to adjust the temperature of the area that is not within the target temperature range, so as to ensure that the temperature of the molten pool is evenly distributed and avoid local overheating. During the smelting process, alloy elements are added according to the real-time monitoring of the alloy element content in the furnace to ensure that the content of the alloy elements is within the predetermined range. If the content of a certain alloy element is monitored to be lower than the predetermined value, the corresponding alloy element is added through the automatic addition system; Furthermore, after the smelting is completed, the electron beam generator is turned off to maintain the temperature in the furnace within the target temperature range and perform heat preservation treatment to ensure the uniformity and stability of the molten metal; Based on the real-time data of multi-point temperature sensors, a temperature distribution curve is generated to check the uniformity of the furnace temperature and ensure that the temperature difference in the furnace does not exceed 10°C; Based on the real-time data of chemical composition analysis equipment, the content of alloy elements in the molten metal is checked to ensure that the content is within the predetermined range.

[0026] S2. Monitor the chemical composition and temperature changes of the molten metal in real time and dynamically adjust the addition of spheroidizing agent.

[0027] Furthermore, the molten metal is transferred to the spheroidizing treatment pool through a dedicated high-temperature pipe with a high-temperature resistant coating on the inner wall, and the temperature of the molten metal is always kept within the target range during the transfer process; By installing a temperature sensor in the pipeline, the temperature of the molten metal is monitored in real time. When the temperature drops outside the target temperature range, the temperature is raised through the heating device in the pipeline. The spheroidizing temperature range is set based on the properties of the spheroidizing agent and the requirements of the graphite spheroidizing process; Install multi-point temperature sensors to monitor the internal temperature of the spheroidizing treatment pool in real time, and combine with heating devices to ensure that the temperature of the molten metal remains within the spheroidizing temperature range; According to the quantity of raw materials and the performance requirements of castings, the initial spheroidizing agent addition amount is set. To prevent excessive addition of spheroidizing agent, the initial spheroidizing agent addition amount is less than the actual addition amount. Furthermore, the spheroidizing agent is added in small amounts and multiple times through a metering pump, and a stirring device is turned on to increase the fluidity of the molten metal so that the spheroidizing agent is quickly and evenly blended into the molten metal; Install an online electron microscope to monitor the graphite morphology and distribution in the molten metal in real time, and transmit the image data to the data terminal through a wired connection; The electron microscope starts to transmit images when the spheroidizing agent is added, and updates the image data in real time each time the spheroidizing agent is added; Perform image denoising, contrast adjustment and background correction to improve image quality and analysis accuracy; Use professional image processing software, ImageJ, for image processing and analysis; The graphite spheres are separated from the background using the threshold segmentation method to generate a binary image; The features of graphite balls, including roundness, diameter and distribution uniformity, are extracted from the binary image. The roundness of graphite balls is evaluated by calculating the roundness factor of graphite balls. A roundness factor above 0.85 indicates that the shape of graphite balls is relatively round. By measuring the diameter of the graphite spheres, the average diameter of the graphite spheres was calculated. The average diameter was in the range of 100-200 μm, indicating that the size of the graphite spheres was moderate. Calculate the distribution coefficient of graphite balls and evaluate the distribution uniformity of graphite balls. A distribution coefficient below 0.2 indicates that the distribution of graphite balls is relatively uniform. Further, after the initial spheroidizing agent addition amount is fully added to the spheroidizing treatment tank, the image data collected each time and the extracted characteristic values ​​are summarized to generate a data table; Statistical analysis was performed on the data table to calculate the average roundness factor, average diameter and distribution coefficient of the graphite spheres; If the characteristics of the graphite balls meet the expected requirements, proceed to the next step; If the roundness factor and average diameter of the graphite spheres are lower than expected, increase the amount of spheroidizer by a small amount. After each increase, re-evaluate the spheroidization effect. If the distribution coefficient of the graphite spheres does not meet the expected requirements, extend the stirring time and re-evaluate the graphite sphere distribution coefficient.

[0028] S3, intelligently control the pouring speed and pressure of the molten metal after spheroidization treatment to cast the casting.

[0029] Further, the molten metal after the spheroidization treatment is transferred to the casting area through a special high-temperature pipe with a high-temperature resistant coating on the inner wall; Clean and assemble the mold, apply a high-temperature resistant coating on the inner wall of the mold to prevent the casting from sticking, and preheat the mold to reduce the temperature difference between the mold and the molten metal to avoid cracks and deformation; Determine the pouring temperature range according to the casting performance requirements and the molten metal spheroidization treatment temperature range, and determine the pouring speed and pressure range according to the casting size and shape; By installing multiple temperature sensors in the pouring pipe and pouring equipment, the temperature sensors should be evenly distributed at key locations where the molten metal flows to ensure the comprehensiveness and accuracy of the temperature data, and monitor the temperature of the molten metal in real time. By installing flow sensors in the pouring pipe, the flow of the molten metal is monitored in real time. By installing pressure sensors in the pouring equipment, the pressure of the pouring equipment is monitored in real time. Furthermore, the temperature, flow rate and pressure data of the molten metal are collected in real time through sensors and transmitted to the intelligent control center; The intelligent control center automatically adjusts the power of the heating equipment according to the temperature difference to keep the temperature of the molten metal in the pouring pipe and pouring equipment within the pouring temperature range; The intelligent control center calculates the flow deviation in real time based on the data from the flow sensor. Based on the flow deviation, the intelligent control center dynamically adjusts the pump speed. Each adjustment is determined based on the size of the flow deviation. When the flow rate is lower than the preset minimum pouring speed, increase the pump speed, otherwise reduce the speed; The intelligent control center calculates the pressure deviation in real time based on the data from the pressure sensor. Based on the pressure deviation, the intelligent control center dynamically adjusts the opening of the pressure regulating valve. The amplitude of each adjustment should be determined according to the size of the pressure deviation. When the pressure is lower than the preset minimum pouring pressure, the valve opening is increased, otherwise the valve opening is reduced; It should be noted that through the coordinated work of multi-point temperature sensors, flow sensors and pressure sensors, all-round monitoring and control of the pouring process can be achieved to ensure that each key parameter is within the optimal range. By dynamically adjusting the heating power, pump speed and valve opening, the intelligent control center can quickly respond to changes in temperature, flow and pressure to ensure the continuity and efficiency of the pouring process.

[0030] S4. Use embedded stress sensors to monitor the internal stress changes of the casting in real time and adjust the cooling process of the casting.

[0031] Furthermore, embedded stress sensors are installed at thick walls, thin walls, and corners of the casting to monitor stress changes inside the casting; Install multiple temperature sensors at the thick wall, thin wall and corners of the mold to monitor the temperature changes of the casting and mold in real time; Collect stress and temperature data in real time through sensors and transmit the data to the intelligent control center; Set the cooling rate and stress threshold range according to the performance requirements of the casting; The intelligent control center calculates the stress change value of each point in real time based on the data of the stress sensor; Furthermore, when local stress concentration is detected, the intelligent control center reduces the cooling rate of the area. When the stress value exceeds the highest value of the threshold range, the cooling equipment is reduced and the power of the cooling equipment is reduced to reduce the cooling rate. When the stress value is lower than the minimum value of the threshold range, the cooling device is added and the power of the cooling device is increased to increase the cooling rate; The intelligent control center calculates the temperature change value in real time based on the data from the temperature sensor, and adjusts the cooling rate by adjusting the number and power of the cooling equipment; It should be noted that by dynamically adjusting the cooling rate based on real-time data of stress and temperature, excessive stress concentration can be avoided and the efficiency and quality of the cooling process can be improved.

[0032] S5. Perform surface treatment, heat treatment and machining on the cooled casting.

[0033] Further, after cooling is completed, the mold is removed and the casting is transported to the processing area; Use high-pressure sandblasting equipment to remove the oxide layer on the surface of the casting to ensure that the surface of the casting is smooth and free of residue; Use alkaline cleaning agent in the cleaning tank to remove residues and impurities on the casting surface. The cleaning time is set to 10 minutes and the temperature is set to 60°C. Place the cleaned castings in a drying oven for drying, set the temperature to 120°C, and ensure that the casting surface is completely dry; The dried castings were placed in an annealing furnace for annealing treatment. The heating temperature was set to 900°C and the heating rate was set to 10°C / min to ensure that the castings were evenly heated. The castings were kept warm for 1 hour to ensure that the internal structure of the castings was homogenized. After the insulation was completed, the castings were taken out of the normalizing furnace and placed in the air to cool naturally to room temperature to release the internal stress of the castings. Fix the casting on the CNC lathe, perform rough machining and fine machining, remove excess material, and ensure that the shape, dimensional accuracy and surface finish of the casting meet the requirements; Furthermore, a three-coordinate measuring machine is used to inspect the dimensions of the processed castings, a surface roughness meter is used to inspect the surface finish of the castings, and a Rockwell hardness tester is used to inspect the hardness of the castings.

[0034] S6. Carry out composition inspection and performance test on the castings after processing.

[0035] Select different parts from the finished castings, cut out test samples using a plasma cutter, and grind and polish the samples; Use component analysis equipment, direct reading spectrometer (OES) to analyze the components of the sample, record the spectral analysis results, and compare them with the expected components; The samples were tested for hardness, tensile strength, impact toughness and fatigue, and the test results were recorded and compared with the expected performance indicators.

[0036] Using a scanning electron microscope, the morphology, size and distribution of the graphite nodules of the samples were observed and compared with the expected requirements.

[0037] This embodiment also provides a high-performance ductile iron material rapid development system based on electronic metallurgy, including: a raw material smelting module, a graphite spheroidizing module, a casting pouring module, a casting cooling module, a casting processing module and a casting detection module. The raw material melting module is used to melt high-performance ductile iron raw materials through multi-stage electron beam melting to obtain uniform molten metal; Graphite spheroidizing module, used to monitor the chemical composition and temperature changes of molten metal in real time and dynamically adjust the addition of spheroidizing agent; Casting pouring module, used to intelligently control the pouring speed and pressure of the molten metal after spheroidization treatment to perform casting pouring; Casting cooling module, which is used to monitor the internal stress changes of castings in real time through embedded stress sensors and adjust the casting cooling process; Casting processing module, used for surface treatment, heat treatment and machining of cooled castings; The casting inspection module is used to perform composition inspection and performance testing on the castings after processing.

[0038] This embodiment also provides a computer device, which is suitable for the case of a rapid development method of high-performance ductile iron materials based on electronic metallurgy, including: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute computer-executable instructions to implement the rapid development method of high-performance ductile iron materials based on electronic metallurgy as proposed in the above embodiment.

[0039] The computer device may be a terminal, and the computer device includes a processor, a memory, a communication interface, a display screen and an input device connected through a system bus. Among them, the processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The communication interface of the computer device is used to communicate with an external terminal in a wired or wireless manner, and the wireless manner can be achieved through WIFI, an operator network, NFC (near field communication) or other technologies. The display screen of the computer device may be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device may be a touch layer covered on the display screen, or a key, trackball or touchpad provided on the housing of the computer device, or an external keyboard, touchpad or mouse, etc.

[0040] The present embodiment also provides a storage medium having a computer program stored thereon, which, when executed by a processor, implements the method for rapid development of high-performance ductile iron materials based on electronic metallurgy as proposed in the above embodiment; the storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, disk or optical disk.

[0041] In summary, the present invention achieves precise control of the temperature and chemical composition of the molten metal through multi-stage electron beam melting technology, ensuring the uniformity and stability of the molten metal. Real-time monitoring and dynamic adjustment of the addition of spheroidizing agent ensure the uniformity of the spheroidizing treatment and the roundness, size and distribution uniformity of the graphite balls. The intelligent control system accurately controls the pouring speed and pressure, avoiding defects such as uneven pouring, pores and inclusions, and improving the density and integrity of the casting. The embedded stress sensor monitors the internal stress changes of the casting in real time, dynamically adjusts the cooling rate and cooling method, avoids internal stress concentration, and improves the dimensional stability and mechanical properties of the casting.

[0042] Example 2, referring to Table 1, is the second example of the present invention. To further verify the technical solution of the present invention, experimental simulation data of a rapid development method for high-performance ductile iron materials based on electronic metallurgy are provided.

[0043] The performance requirements and raw material ratio of high-performance ductile iron materials are determined according to customer needs, and various materials are weighed using electronic scales, including iron filings, carbon powder, ferrosilicon, magnesium alloys, etc.

[0044] A multi-stage electron beam melting furnace is used to melt the raw materials. Alloy elements are added based on real-time monitoring of the alloy element content in the furnace to ensure that the content of the alloy elements is within a predetermined range.

[0045] Based on the real-time data of chemical composition analysis equipment, the content of alloy elements in the molten metal is checked to ensure that the content is within the predetermined range.

[0046] The molten metal is transferred to the spheroidizing treatment pool through a dedicated high-temperature pipeline, and the temperature of the molten metal is always kept within the target range during the transfer process.

[0047] According to the quantity of raw materials and the performance requirements of the casting, the initial amount of spheroidizer is set, and the spheroidizer is added in small amounts and multiple times through a metering pump. The stirring device is turned on to increase the fluidity of the molten metal so that the spheroidizer can be quickly and evenly integrated into the molten metal.

[0048] By statistically analyzing the image data of the electron microscope, the average circularity factor, average diameter and distribution coefficient of the graphite spheres are calculated to determine whether the characteristics of the graphite spheres meet the expected requirements.

[0049] The molten metal after spheroidization is transferred to the pouring area for pouring through a special high-temperature pipe with a high-temperature resistant coating on the inner wall.

[0050] By monitoring the stress changes inside the casting and the temperature changes of the casting and mold, the casting cooling process can be adjusted.

[0051] After cooling, the mold is removed and the casting is transported to the processing area for cold, heat treatment and mechanical processing.

[0052] Different parts are selected from the finished castings, and test samples are cut out using a plasma cutting machine, and the samples are then ground and polished.

[0053] Use component analysis equipment, direct reading spectrometer (OES) to analyze the components of the samples, record the spectral analysis results, and compare them with the expected components.

[0054] The samples were tested for hardness, tensile strength, impact toughness and fatigue, and the test results were recorded and compared with the expected performance indicators.

[0055] Using a scanning electron microscope, the morphology, size and distribution of the graphite nodules of the samples were observed and compared with the expected requirements.

[0056] The details are shown in Table 1 below: Table 1 Data comparison table Test subjects Graphite ball roundness factor Average diameter of graphite balls (μm) Graphite nodule distribution coefficient Method of the present invention 0.99 150 0.15 Induction furnace melting method 0.80 200 0.30 A higher roundness factor means that the shape of the graphite sphere is more rounded, which helps to improve the mechanical properties and service life of the casting. The invention method ensures the roundness of the graphite sphere by real-time monitoring and dynamic adjustment of the addition of the spheroidizing agent.

[0057] Smaller average diameter of graphite balls helps to improve the density and mechanical properties of castings and reduce potential defects. The invention method optimizes the average diameter of graphite balls by precisely controlling the amount of spheroidizing agent added and the stirring time.

[0058] A lower distribution coefficient indicates that the graphite nodules are more evenly distributed, which helps improve the overall performance and consistency of the casting. The inventive method ensures the uniformity of the graphite nodule distribution through real-time monitoring and image processing of an online electron microscope.

[0059] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A rapid development method for high-performance ductile iron materials based on electronic metallurgy, characterized by: include, The high-performance ductile iron raw material is melted by multi-stage electron beam to obtain uniform molten metal; Real-time monitoring of the chemical composition and temperature changes of the molten metal, and dynamic adjustment of the addition of spheroidizing agent; Intelligently control the pouring speed and pressure of the molten metal after spheroidization to cast the castings; Monitor the internal stress changes of castings in real time through embedded stress sensors and adjust the cooling process of castings; Surface treatment, heat treatment and machining of cooled castings; The castings after processing are subjected to composition inspection and performance testing.

2. The method for rapid development of high-performance ductile iron materials based on electronic metallurgy according to claim 1, characterized in that: The high-performance ductile iron raw material is melted by multi-stage electron beam to obtain uniform molten metal. The specific steps are as follows: Determine the performance requirements and raw material ratio of high-performance ductile iron materials according to customer needs; Use electronic scales to weigh various materials; Use a multi-stage electron beam melting furnace equipped with multiple electron beam generators, evenly arranged at different positions in the furnace, and each electron beam generator can independently control the power density and scanning path; Install multi-point temperature sensors and composition analysis equipment evenly distributed at different locations in the molten pool to monitor the temperature changes and alloy element content in the furnace in real time; Put the raw materials into the furnace and preheat them; After preheating, all electron beam generators are started, and the initial power density and initial scanning speed are set; According to the casting performance requirements and raw material properties, the target temperature range of the furnace is set. According to the real-time data of the multi-point temperature sensor, the power density and scanning path of the nearest electron beam generator are adjusted to adjust the temperature of the area that is not within the target temperature range; During the smelting process, alloy elements are added according to the real-time monitoring of the alloy element content in the furnace; After the smelting is completed, turn off the electron beam generator, keep the temperature in the furnace within the target temperature range, and perform insulation treatment; Generate temperature distribution curve based on real-time data from multi-point temperature sensors to check the uniformity of furnace temperature; Based on the real-time data of chemical composition analysis equipment, the content of alloy elements in molten metal is checked.

3. The rapid development method of high-performance ductile iron material based on electronic metallurgy as claimed in claim 2, characterized in that: The real-time monitoring of the chemical composition and temperature changes of the molten metal and the dynamic adjustment of the addition of the spheroidizing agent are carried out in the following specific steps: The molten metal is transferred to the spheroidizing treatment pool through a dedicated high-temperature pipeline, and the temperature of the molten metal is always kept within the target range during the transfer process; By installing a temperature sensor in the pipeline, the temperature of the molten metal is monitored in real time. When the temperature drops outside the target temperature range, the temperature is raised through the heating device in the pipeline. The spheroidizing temperature range is set based on the properties of the spheroidizing agent and the requirements of the graphite spheroidizing process; Install multi-point temperature sensors to monitor the internal temperature of the spheroidizing treatment pool in real time; According to the quantity of raw materials and the performance requirements of castings, the initial spheroidizing agent addition amount is set, and the initial spheroidizing agent addition amount is less than the actual addition amount; Add spheroidizer in small amounts and multiple times through a metering pump, turn on the stirring device to increase the fluidity of the molten metal; Install an online electron microscope to monitor the graphite morphology and distribution in the molten metal in real time, and transmit the image data to the data terminal through a wired connection; The electron microscope starts to transmit images when the spheroidizing agent is added, and updates the image data in real time each time the spheroidizing agent is added; Perform denoising, contrast adjustment and background correction on images; Use professional image processing software to process and analyze images; The graphite spheres are separated from the background using the threshold segmentation method to generate a binary image; Extract the features, roundness, diameter and distribution uniformity of graphite balls from binary images, and evaluate the roundness of graphite balls by calculating the roundness factor of graphite balls. By measuring the diameter of graphite balls, the average diameter of graphite balls is calculated; Calculate the distribution coefficient of graphite balls and evaluate the distribution uniformity of graphite balls; After the initial spheroidizing agent addition amount is fully added to the spheroidizing treatment tank, the image data collected each time and the extracted characteristic values ​​are summarized to generate a data table; Statistical analysis was performed on the data table to calculate the average roundness factor, average diameter and distribution coefficient of the graphite spheres; If the characteristics of the graphite balls meet the expected requirements, proceed to the next step; If the roundness factor and average diameter of the graphite spheres are lower than expected, increase the amount of spheroidizer by a small amount. After each increase, re-evaluate the spheroidization effect. If the distribution coefficient of the graphite spheres does not meet the expected requirements, extend the stirring time and re-evaluate the graphite sphere distribution coefficient.

4. The method for rapid development of high-performance ductile iron materials based on electronic metallurgy as claimed in claim 3, characterized in that: The intelligent control of the pouring speed and pressure of the molten metal after spheroidization is performed to cast the casting, and the specific steps are as follows: The molten metal after spheroidization is transferred to the pouring area through a special high-temperature pipe with a high-temperature resistant coating on the inner wall; Clean and assemble the mold, apply high temperature resistant coating on the inner wall of the mold, and preheat the mold; Determine the pouring temperature range according to the casting performance requirements and the molten metal spheroidization treatment temperature range, and determine the pouring speed and pressure range according to the casting size and shape; The temperature of the molten metal is monitored in real time by installing multiple temperature sensors in the pouring pipe and pouring equipment. The flow rate of the molten metal is monitored in real time by installing flow sensors in the pouring pipe. The pressure of the pouring equipment is monitored in real time by installing pressure sensors in the pouring equipment. The temperature, flow and pressure data of molten metal are collected in real time through sensors and transmitted to the intelligent control center; The intelligent control center automatically adjusts the power of the heating equipment according to the temperature difference to keep the temperature of the molten metal in the pouring pipe and pouring equipment within the pouring temperature range; The intelligent control center calculates the flow deviation in real time based on the data from the flow sensor. Based on the flow deviation, the intelligent control center dynamically adjusts the pump speed. Each adjustment is determined based on the size of the flow deviation. The intelligent control center calculates the pressure deviation in real time based on the data from the pressure sensor. Based on the pressure deviation, the intelligent control center dynamically adjusts the opening of the pressure regulating valve. The amplitude of each adjustment should be determined according to the size of the pressure deviation.

5. The rapid development method of high-performance ductile iron material based on electronic metallurgy according to claim 4, characterized in that: The embedded stress sensor is used to monitor the internal stress changes of the casting in real time and adjust the cooling process of the casting. The specific steps are as follows: Install embedded stress sensors at the thick walls, thin walls and corners of the casting to monitor stress changes inside the casting; Install multiple temperature sensors at the thick wall, thin wall and corners of the mold to monitor the temperature changes of the casting and mold in real time; Collect stress and temperature data in real time through sensors and transmit the data to the intelligent control center; Set the cooling rate and stress threshold range according to the performance requirements of the casting; The intelligent control center calculates the stress change value of each point in real time based on the data of the stress sensor; When local stress concentration is detected, the intelligent control center reduces the cooling rate of the area. When the stress value exceeds the highest value of the threshold range, the cooling equipment is reduced and the power of the cooling equipment is reduced to reduce the cooling rate. When the stress value is lower than the minimum value of the threshold range, the cooling device is added and the power of the cooling device is increased to increase the cooling rate; The intelligent control center calculates the temperature change value in real time based on the data from the temperature sensor, and adjusts the cooling rate by adjusting the number and power of the cooling equipment.

6. The method for rapid development of high-performance ductile iron materials based on electronic metallurgy according to claim 5, characterized in that: The cooling casting is subjected to surface treatment, heat treatment and machining, and the specific steps are as follows: After cooling, the mold is removed and the casting is transported to the processing area; Use high-pressure sandblasting equipment to remove the oxide layer on the surface of the casting; Use alkaline cleaning agents in the cleaning tank to remove residues and impurities from the casting surface; Place the cleaned castings into a drying oven for drying; The dried casting is placed in an annealing furnace for annealing to release the internal stress of the casting; Fix the casting on the CNC lathe for rough and fine machining; Use a three-coordinate measuring machine to inspect the dimensions of the processed castings, use a surface roughness meter to inspect the surface finish of the castings, and use a Rockwell hardness tester to inspect the hardness of the castings.

7. The method for rapid development of high-performance ductile iron materials based on electronic metallurgy according to claim 6, characterized in that: The specific steps of conducting composition detection and performance testing on the casting after processing are as follows: Select different parts from the finished castings, cut out test samples using a plasma cutter, and grind and polish the samples; Use component analysis equipment, direct reading spectrometer (OES) to analyze the components of the sample, record the spectral analysis results, and compare them with the expected components; Conduct hardness, tensile strength, impact toughness and fatigue tests on samples, record test results and compare with expected performance indicators; Using a scanning electron microscope, the morphology, size and distribution of the graphite nodules of the samples were observed and compared with the expected requirements.

8. A high-performance ductile iron material rapid development system based on electronic metallurgy, based on the high-performance ductile iron material rapid development method based on electronic metallurgy according to any one of claims 1 to 7, characterized in that: Including raw material melting module, graphite spheroidizing module, casting pouring module, casting cooling module, casting processing module and casting detection module. The raw material smelting module is used to melt high-performance ductile iron raw materials through multi-stage electron beam to obtain uniform molten metal; The graphite spheroidizing module is used to monitor the chemical composition and temperature changes of the molten metal in real time and dynamically adjust the addition of the spheroidizing agent; The casting pouring module is used to intelligently control the pouring speed and pressure of the molten metal after spheroidization treatment to perform casting pouring; The casting cooling module is used to monitor the internal stress changes of the casting in real time through the embedded stress sensor and adjust the cooling process of the casting; The casting processing module is used to perform surface treatment, heat treatment and machining on the cooled casting; The casting detection module is used to perform composition detection and performance testing on the casting after processing.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy as described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for rapid development of high-performance ductile iron materials based on electronic metallurgy as described in any one of claims 1 to 7 are implemented.

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