A new material fusion molding device and molding method

Abstract

The application provides a novel material fusion forming device and a forming method thereof, and the fusion forming device comprises a main mold capable of limiting a blank and a vertical rapid cooling tool system for regulating the temperature of the blank; the working surface of the main mold is metal; the vertical rapid cooling tool system comprises a barrier mold with a metal working surface, a sensing and signal collecting system enabling the barrier mold to move up and down through feedback, and a lifting power system; the main mold is connected with a lifting screw through a screw nut; the barrier mold is directly or indirectly connected with the lifting screw through a screw nut; a consumable electrode is in an insulating and isolated state with the barrier mold, and the consumable electrode is melted in a to-be-fused area or a to-be-filled area through slag resistance heat; the application adopts a barrier electroslag fusion method, and is based on a conventional electroslag single circumferential clamping and cooling main mold; the barrier mold is used to block the slag in a precise height to regulate the temperature of the blank through gravity direction fluid cooling; the device and the related process principle of the application are simple, the material fusion is relatively easy to realize, the cost is low, and the effect is good.

Description

Technical Field

[0001] This invention belongs to the field of composite material molding, and specifically relates to a novel material melting and molding device and molding method. Background Technology

[0002] Currently, internationally, composite material manufacturing technologies utilize various thermal processing methods such as solid-solid composite materials, arc welding, and spray deposition. Electroslag lamination is a process in which a consumable electrode 3 melts and solidifies within a mold using protective slag for heat resistance. The subsequent forming process of the deposited metal is accompanied by advantages such as sequential solidification, self-compensation, and purification, resulting in high bonding rates and good quality.

[0003] With the rapid development of the equipment manufacturing industry, the demand for composite material manufacturing is increasing daily, and solid-liquid composite manufacturing processes are emerging one after another: electroslag fusion blades, electroslag solid-liquid composite rolls, centrifugal composite rolls, etc. Conventional electroslag solid-liquid fusion processes can refer to technologies such as electroslag step-by-step forming. This type of method is mainly suitable for fusing materials of the same kind. Regarding this technology, there are Chinese patents CN201610783482.1 and ZL201610783482.1, Japanese patent JP 1999019791A, and Chinese patent CN102029378A, etc., which each propose a method for fusing plates of the same material with a large width-to-thickness ratio (width-to-thickness ratio > 10) using electroslag technology to fuse two original blanks together. This method is difficult to apply to the welding of materials of the same kind or dissimilar materials where the solid-liquid interface melting depth is critical.

[0004] Electroslag remelting (ESR) is a feasible solid-liquid fusion molding process for homogeneous and dissimilar materials with stringent requirements for melting depth, but its implementation and control are extremely challenging. While ESR offers advantages such as refining and sequential near-net-shape forming, controlling the fusion depth remains extremely difficult. Furthermore, when electroslag casting dissimilar materials undergo solid-liquid fusion, it is difficult to reasonably address the issue of significant deviations in composition from standards in the area to be filled. Therefore, within the framework of ESR, addressing these issues through process and tooling adjustments becomes crucial. Due to the unique cooling state of the area to be filled or melted, the solid-liquid fusion process requires solutions to rapid fusion and rapid cooling from the perspective of heat transfer.

[0005] When existing electroslag remelting processes achieve the generally required solid-liquid fusion of the same material, a single circumferentially clamped main cooling mold is typically used, usually without needing to consider the difficulties in controlling the melt depth of the solid-liquid fusion zone or the large compositional variations. However, once it is required that the melt depth of the solid-liquid fusion of the same material be sufficiently shallow or that the width of the compositional gradient zone in the solid-liquid fusion of dissimilar materials meet the target, a single circumferentially clamped main cooling mold is extremely difficult to achieve the target requirements. Summary of the Invention

[0006] To address the problem in existing technologies where a single circumferentially clamped main cooling mold is insufficient to ensure a sufficiently narrow transition zone in the filling or fusion-deposited area to meet product requirements, this invention provides a novel material fusion molding device and method. This invention employs a barrier electroslag slag deposition method. Based on the conventional single circumferentially clamped main cooling mold used in electroslag welding, it uses gravity-directed fluid cooling to block slag within a precise height. This method is a novel solution proposed based on solid-liquid composite experiments using wire electroslag welding, electroslag fixed electrode methods, conventional single-series electroslag methods, and conventional bipolar series electroslag methods. It aims to flexibly adjust the supply temperature of the fusion-deposited area 4 without constraints, ensuring rapid solidification of the fusion-deposited area 4. Its process principle is simple, easy to implement, low-cost, and produces good fusion results.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows: a novel material melting and molding device, the novel material melting and molding device comprising a main body mold 10 for limiting the position of the blank and a barrier mold 2 for regulating the temperature of the blank;

[0008] The strong cooling tooling system includes a vertical barrier mold 2 with a metal working surface, a sensing and signal acquisition system 5 that can move up and down the feedback barrier mold 2, and a lifting power system 6.

[0009] The main mold 10 is connected to the lifting screw 1 via the screw nut 11, preventing the mold 2 from being directly or indirectly connected to the lifting screw 1 via the screw nut 11.

[0010] The consumable electrode 3 and the barrier mold 2 are in an insulated state. The consumable electrode 3 melts in the area to be melted or filled 4 through the heat resistance of the slag generated by the molten slag pool.

[0011] The barrier mold 2 is equipped with an inlet pipe 8 and an outlet pipe 9 for cooling.

[0012] The main mold 10 is a metal mold or a fluid-cooled metal mold.

[0013] The self-consuming electrode 3 is a freeform independent or combined electrode.

[0014] This invention provides a molding method based on a novel material melting and molding apparatus. The method employs the aforementioned novel material melting and molding apparatus, and specifically includes the following steps:

[0015] Step 1: Material preparation: Based on the inner cavity size of the main mold 10, limit the blank 7, prepare the consumable electrode 3 to be fused, and select the consumable electrode 3 as a forged plate electrode or a die-cast electrode. The filling ratio of the consumable electrode 3 (the ratio of the area of ​​the consumable electrode 3 to the area of ​​the area to be fused or filled) is 0.08 to 0.75.

[0016] Step 2: Determine the molding process using a novel material melting and molding device: The consumable electrode 3 supplies voltage U by controlling the instantaneous melting rate. ti (ti = 1, 2, ..., n) and current I ti (ti=1,2,……n), to form its sequence.

[0017] Step 3, Slag System and Slag Quantity Control: The slag quantity is based on the slag layer thickness and is 25-80% of the equivalent diameter of the effective heating zone; the mass percentage of the components of the slag system is as follows: CaF2: 40-80%, Al2O3: 25-45%, CaO: 0-20%, with the balance being MgO, SiO2 and other components.

[0018] Step 4: Power supply control and position control of barrier mold 2, voltage 40~125V, current 1500~30000A; the lower end face of barrier mold 2 is lower than the upper surface of slag liquid. Through the sensing and signal acquisition system 5 and the lifting power system 6, the lower end face of barrier mold 2 is always kept 0-180mm lower than the upper surface of slag liquid.

[0019] Step 5: Replacement and shrinkage of consumable electrode 3.

[0020] The replacement of the consumable electrode 3 is specifically as follows: depending on the fusion height, the electrode is connected 0 to 6 times. When the consumable electrode 3 is completed in a stage, the power supply to the corresponding branch is cut off, and the power supply is resumed after the consumable electrode 3 is replaced. The power supply is continuously supplied in stages until the fusion is completed.

[0021] The specific compensation method is as follows: under the condition of maintaining the lower limit of voltage, the compensation current is reduced to 200-1500A and maintained for 2-4 minutes; then the current is uniformly increased to 65-85% of the normal melting and casting current within 2-3 minutes, and this process is repeated 2-10 times, with the last time it being reduced to zero.

[0022] Compared with the prior art, the advantages of the present invention are as follows:

[0023] 1. The method of this invention, by installing a barrier mold 2, enables precise temperature control at the solid-liquid interface. The barrier mold 2 is composed of a specially structured fluid-cooled metal mold, equipped with an inlet pipe 8 and an outlet pipe 9. While ensuring normal filling of the area to be melted 4, it self-feedback to achieve the lifting and lowering movement of the barrier mold 2 relative to the mother billet 7 (or the mother billet 7 moving downward relative to the barrier mold 2 and the main mold 10 under the drive of a motor), so as to ensure that the height difference between its specific end face and the slag-liquid surface remains relatively stable. This effectively solves the problem of mismatch between the power required for the area to be melted 4 and heat transfer, thereby achieving better control over the depth and width of the molten pool in the area to be melted 4.

[0024] 2. The method of the present invention employs a sensing and signal acquisition system 5 and a lifting power system 6 to form a position monitoring and adjustment mechanism for the barrier mold 2, ensuring that the consumable electrode 3 melts at the instantaneous melting rate v. i Current I i With voltage U i The melting and forming process involves sequential filling and self-compensation; it solves the problem of heat transfer failure in the overheated area 4 to be melted, and enables the on-demand, real-time, and precise supply of molten metal to the consumable electrode 3.

[0025] 3. The method of the present invention uses a sensing and signal acquisition system 5 and a lifting power system 6 to form a position monitoring device and adjustment mechanism for the barrier mold 2, and monitors the instantaneous temperature T of the slag liquid surface and the mold monitoring point. i By monitoring indicators such as the lifting screw 1 and screw nut 11 and moving them up and down in a timely manner, leakage of molten metal and slag is avoided and good control of heat compensation is achieved, so as to realize the coordinated and quantifiable relationship between cooling and solidification conditions, slag quantity, lifting speed and other factors. Attached Figure Description

[0026] Figure 1 : Schematic diagram of the material melting and molding device of this invention;

[0027] Figure 2 Example 2: A three-dimensional schematic diagram (top view) of the steel-copper composite structure;

[0028] Figure 3 Example 3 is a schematic diagram of the repair of large, thick parts;

[0029] Figure 4 Example 4 is a schematic diagram of double-sided welding;

[0030] Figure 5 : Schematic diagram of the main structure of the barrier mold;

[0031] Figure 6 Schematic diagram of a forced cooling tooling system;

[0032] Among them, 1-lifting screw, 2-barrier mold, 3-consumable electrode, 4-area to be melted or filled, 5-sensing and signal acquisition system, 6-lifting power system, 7-basis blank, 8-inlet pipe, 9-outlet pipe, 10-main mold, 11-screw nut, 12-working panel, 13-non-working panel, 14-fluid cooling cavity, 15-strong cooling tooling system. Detailed Implementation

[0033] The following are specific implementation cases and appendices. Figure 1-6 The present invention will be further described, but the present invention is not limited to these embodiments.

[0034] Example 1

[0035] This embodiment provides a novel material melting and molding device and its molding method, such as Figure 1 and 2 As shown, the electroslag fusion hammerhead is formed by fusing a blank 7 and a consumable electrode 3. The fusion process is blocked by a barrier mold 2, and the cooling fluid is circulating oil.

[0036] The selected blank is Q345, the fusion zone material is high manganese steel ZGMn13-2, the maximum width of the hammer head is about 800mm, the maximum height is about 500mm, the maximum thickness is about 400mm, and the minimum thickness is about 180mm.

[0037] Based on the shape and cross-sectional dimensions of the hammerhead, a Q345 master blank 7 is manufactured in advance using sand casting, electroslag casting, or slab cutting processes, and placed in the limiting main body mold 10 in advance. Then, using the method of the present invention, the high manganese steel consumable electrode 3 is fused by electroslag equipment. During the fusion process, the molten slag is blocked by the barrier mold 2 to achieve good fusion between the Q345 master blank and the high manganese steel.

[0038] The molten metal from the consumable electrode 3 is fused together with the precast blank placed in the main mold 10 to form a composite curved hammerhead composed of dissimilar materials.

[0039] It includes the following steps:

[0040] Step 1, Electrode Selection:

[0041] Sand-cast electrodes are selected, and the filling ratio of consumable electrode 3 is 0.1 to 0.4.

[0042] Step 2, Process Control:

[0043] (1) The consumable electrode 3 is properly installed and melted in the electroslag casting equipment to ensure that the consumable electrode 3 is melted according to the real-time melting rate requirement v. i (i = 1, 2, ..., n) Match a suitable melting rate current I i (i = 1, 2, ..., n) and voltage U i (i = 1, 2, ..., n), to make it sequentially filled and self-compacted;

[0044] (2) The barrier mold 2 is equipped with temperature and position monitoring, corresponding to the instantaneous temperature T at the mold monitoring point. i Vertical height h i Monitoring indicators such as heat compensation ensures good control; ultimately, the barrier mold 2 moves intermittently or continuously upward relative to the blank 7.

[0045] Step 3, Slag System and Slag Quantity Control:

[0046] The main components of the electroslag system are as follows (mass percentage): CaF2: 48%, Al2O3: 42%, CaO: 5.5%, and other components ≤5%; forming a multi-component slag system, with the remaining components being one or more of MgO, SiO2, etc., and the slag layer thickness being 65% of the equivalent diameter of the area to be filled.

[0047] Step 4, Power supply control: Electroslag melting power supply voltage: Determine the melting and casting voltage as 55V±5V and the current as 3000A±600A; The lower end face of the barrier mold 2 is lower than the upper surface of the slag liquid, and according to the requirements, it is always kept 30mm lower than the upper surface of the slag liquid.

[0048] Step 5, Electrode replacement and shrinkage treatment: The cast product is connected to the consumable electrode 3 once. The consumable electrode 3 is completed in stages. This replacement is repeated until the casting is completed.

[0049] During the feeding period, the normal current is first reduced to the feeding current of 200A within 4 minutes and maintained for 2 minutes; then the feeding current is increased to 65% of the normal melting and casting current within 3 minutes. This process is repeated 6 times, and finally reduced to zero in the last time.

[0050] The hammerhead prepared in this embodiment has dimensions that meet the drawing requirements, good internal and surface quality, and a penetration depth of about 3-30mm. After conventional heat treatment, the mechanical properties of the working surface are Rm / 701Mpa, A / 26%, KV2 / 138J, and HBS / 241, which meet the delivery requirements.

[0051] Example 2

[0052] This embodiment provides a novel material melting and molding device and its molding method for steel-copper composite materials. The implementation process of Embodiment 2 is similar to Embodiment 1; the difference lies in the following: the main components of the electroslag system are as follows (mass percentage): CaF2: 40%, Al2O3: 35%, CaO: 15%, and the remaining components ≤15%; wherein the remaining components are one or more of MgO, SiO2, etc., and the slag layer thickness is 70% of the equivalent diameter of the area to be filled; the lower end face of the barrier mold 2 is lower than the upper surface of the slag liquid, and according to requirements, it is always maintained at 20mm below the upper surface of the slag liquid. The cooling fluid is circulating high-pressure gas.

[0053] Example 3

[0054] This embodiment provides a novel material melting and molding device and its molding method, such as Figure 3 As shown, the repair of large thick parts by electroslag casting is formed by fusing the blank 7 to be repaired and the consumable electrode 3. The fusing process is blocked by the barrier mold 2. The material of the part to be repaired is 1Cr13, the material of the repair area is 1Cr13, the product width is about 600mm, the maximum height is 600mm, the thickness is 500mm, the repair area is 300mm wide, and the cooling fluid is circulating water.

[0055] According to the cross-sectional dimensions of the repair area, the blank 7 to be repaired is placed in the limiting main mold 10 in advance; the 1Cr13 consumable electrode 3 is manufactured in advance using sand casting, electroslag casting or slab cutting process, and then the consumable electrode 3 is melted using electroslag equipment using the method of the present invention. During the melting process, the molten slag is blocked by the barrier mold 2 to ensure that the thickness of the transition zone during the repair process is shallow.

[0056] It includes the following steps:

[0057] Step 1, Electrode Selection:

[0058] For the large, thick parts to be repaired, conformal steel plate electrodes were fabricated with a filler ratio of 0.2.

[0059] Step 2, Process Control:

[0060] (1) The consumable electrode 3 is properly installed and melted in the electroslag casting equipment to ensure that the consumable electrode 3 is melted according to the real-time melting rate requirement v. i (i = 1, 2, ..., n) Match a suitable melting rate current I i (i = 1, 2, ..., n) and voltage U i (i = 1, 2, ..., n), to make it sequentially filled and self-compacted;

[0061] (2) The barrier mold 2 is equipped with temperature and position monitoring, corresponding to the instantaneous temperature T at the mold monitoring point. i Vertical height h i Monitoring of indicators ensures good control of heat compensation; ultimately, the blank 7 moves intermittently or continuously downward relative to the barrier mold 2 and the main mold 10 under the drive of the motor.

[0062] Step 3, Slag System and Slag Quantity Control:

[0063] The main components of the electroslag system by mass percentage are: CaF2: 60%, Al2O3: 25%, CaO: 5%, and other components ≤10%; constituting a multi-element slag system, with the remaining components being one or more of MgO, SiO2, etc., and the slag layer thickness being 60% of the equivalent diameter of the area to be filled.

[0064] Step 4, Power supply control: Electroslag melting voltage: Determine the melting and casting voltage as 70V±5V and the current as 5000A±1000A; The lower end face of the barrier mold 2 is lower than the upper surface of the slag liquid, and according to the requirements, it is always kept 25mm lower than the upper surface of the slag liquid.

[0065] Step 5, Electrode replacement and feeding treatment: Do not replace consumable electrode 3 for cast products until casting is completed;

[0066] During the feeding period, the normal current is first reduced to the feeding current of 400A within 5 minutes and maintained for 3 minutes; then the feeding current is increased to 75% of the normal melting and casting current within 5 minutes. This process is repeated 8 times, and finally reduced to zero in the last time.

[0067] The product repaired in this embodiment has dimensions that meet the drawing requirements, good internal and surface quality, and a melt depth of approximately 3-30mm. After conventional heat treatment, the mechanical properties of the working surface meet the usage requirements.

[0068] Example 4

[0069] This embodiment provides a novel material melting and molding device and its molding method, such as Figure 4 As shown, the welding of large, thick parts by electroslag casting is formed by fusing the mother blank 7 to be welded and the consumable electrode 3. The welding process is blocked by the barrier mold 2. The selected mother blank 7 to be welded is distributed on the left and right sides. The material is ZG20SiMn. The width of the left side of the product is 1100mm, the height is 1500mm, and the average thickness (average of thickness at various locations) is 500mm. The width of the right side of the product is about 1100mm, the height is 1500mm, and the average thickness is 200mm. The width of the area to be welded is 1100mm, the height is 1500mm, and the average thickness is 260mm. The cooling fluid is circulating oil.

[0070] According to the cross-sectional dimensions of the area to be fused, the blank 7 to be fused is placed in the limiting main body mold 10 in advance; the ZG20SiMn consumable electrode 3 is manufactured in advance using sand casting, electroslag casting or slab cutting process, and then the consumable electrode 3 is melted using electroslag equipment using the method of the present invention. During the melting process, the barrier mold 2 is used to block the transition zone of the fusion process to ensure that the thickness is shallow and to prevent excessive stress.

[0071] It includes the following steps:

[0072] Step 1, Electrode Selection:

[0073] A conformal steel plate electrode was fabricated for the fusion region of a large, thick component, with a filler ratio of 0.3.

[0074] Step 2, Process Control:

[0075] (1) The consumable electrode 3 is properly installed and melted in the electroslag casting equipment to ensure that the consumable electrode 3 is melted according to the real-time melting rate requirement v. i (i = 1, 2, ..., n) Match a suitable melting rate current I i (i = 1, 2, ..., n) and voltage U i (i = 1, 2, ..., n), to make it sequentially filled and self-compacted;

[0076] (2) The barrier mold 2 is equipped with temperature and position monitoring, corresponding to the instantaneous temperature T at the mold monitoring point. i Vertical height h i Monitoring indicators such as heat compensation ensures good control; ultimately, the barrier mold 2 moves upward relative to the blank 7 in a timely manner.

[0077] Step 3, Slag System and Slag Quantity Control:

[0078] The main components of the electroslag system by mass percentage are: CaF2: 65%, Al2O3: 25%, CaO: 4%, and other components ≤6%; constituting a multi-element slag system, with the remaining components being one or more of MgO, SiO2, etc., and the slag layer thickness being 50% of the equivalent diameter of the area to be filled.

[0079] Step 4, Power supply control: Electroslag melting voltage: Determine the melting and casting voltage as 90V±10V and the current as 10000A±2000A; The lower end face of the barrier mold 2 is lower than the upper surface of the slag liquid, and according to the requirements, it is always kept 15mm lower than the upper surface of the slag liquid.

[0080] Step 5, Electrode replacement and shrinkage treatment: Replace the consumable electrode 3 in the cast product. The consumable electrode 3 is replaced 3 times. During the replacement, the current and voltage are interrupted momentarily. After the replacement, the current and voltage are given again as needed until the casting is completed.

[0081] During the feeding period, the normal current is first reduced to the feeding current of 500A within 6 minutes and maintained for 3 minutes; then the feeding current is increased to 80% of the normal melting and casting current within 5 minutes. This process is repeated 9 times, and finally reduced to zero in the last time.

[0082] The product repaired in this embodiment has dimensions that meet the drawing requirements, good internal and surface quality, and a melt depth of approximately 3-30mm. After conventional heat treatment, the mechanical properties of the working surface meet the usage requirements.

Claims

1. A material fusion forming apparatus, characterized by: The fusion forming device comprises a main mold (10) capable of limiting the blank (7) and a strong cooling tool system (15) for temperature control of the blank (7); The strong cooling tool system (15) comprises a vertical barrier mold (2) with a metal working surface, a sensing and signal acquisition system (5) for feeding the up-down movement state of the strong cooling tool, and a lifting power system (6) for driving the up-down movement of the strong cooling tool; The main body of the main mold (10) is connected with the lifting screw (1) through the screw nut (11), and the barrier mold (2) is directly or indirectly connected with the lifting screw (1) through the screw nut (11); The consumable electrode (3) is in an insulating and isolated state with the barrier mold (2), and the consumable electrode (3) is melted in the area (4) to be fused or filled by the slag resistance generated by the molten slag pool; The barrier mold (2) is composed of a working surface plate (12) opposite to the consumable electrode (3), a remaining non-working surface plate (13), and a fluid cooling cavity (14) surrounded by the working surface plate (12) and the non-working surface plate (13), and the inlet pipe (8), the outlet pipe (9), and the fluid cooling cavity (14) on the barrier mold (2) form a fluid cooling circulation with the outside; The main mold (10) is a metal mold or a fluid-cooled metal mold.

2. The material fusion forming apparatus of claim 1, wherein: The consumable electrode (3) is a conformal independent or combined electrode.

3. A method of material fusion forming based on the apparatus of any one of claims 1-2, characterized by: The specific forming method comprises the following steps: Step one, preparation of materials: according to the size of the inner cavity of the main mold (10), the blank is limited, and the consumable electrode (3) to be fused is prepared, the consumable electrode (3) is selected as a forged and rolled plate electrode or a die-cast electrode, and the filling ratio of the consumable electrode (3) is 0.08-0.75; Step two, using material fusion molding device to determine real-time power supply control process: self-consumption electrode (3) through the control of real-time melting speed demand to supply voltage U ti (ti = 1, 2, … n) and current I ti (ti = 1, 2, … n), so that sequential molding; Step three, slag system and slag amount control: the slag amount is 25-80% of the effective diameter of the effective heat supply area according to the slag layer thickness; Step four, position control of the barrier mold (2) under power supply control; Step five, replacement and feeding treatment of the consumable electrode (3).

4. The material fusion forming method of claim 3, wherein: The mass percentage of the components of the slag system is: CaF2: 40-80%, Al2O3: 25-45%, CaO: 0-20%, and the balance is MgO, SiO2 and other components.

5. The method of material fusion forming of claim 3, wherein, The replacement of the consumable electrode (3) is as follows: when the fusion height is high, 1-5 electrodes are connected in succession, the corresponding branch power supply is cut off after the consumable electrode (3) is fused and cast in stages, and the power supply is continued after the consumable electrode (3) is replaced; the power supply is continuously supplied until the fusion and casting are completed.

6. The method of material fusion forming of claim 3, wherein, The feeding is as follows: the feeding current is reduced to 200-1500 A under the lower limit of the voltage maintenance, and maintained for 2-4 minutes; then the current is uniformly increased to 65-85% of the normal fusion and casting current within 2-3 minutes, and the process is repeated 2-10 times, and the current is finally reduced to zero.

7. The method of material fusion forming of claim 3, wherein, In step four, the voltage is 40-125 V, and the current is 1500-30000 A; the lower end surface of the barrier mold (2) is lower than the upper surface of the slag liquid surface, and the lower end surface of the barrier mold (2) is always kept at 0-180 mm below the upper surface of the slag liquid surface through the signal acquisition and feedback mechanism.

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