Cutting method for reducing the secondary shrinkage rejection of high-temperature alloy master alloy ingot

Abstract

The application discloses a cutting method for reducing the quantity of high-temperature alloy master alloy ingot secondary shrinkage rejection, which comprises the following steps: placing the high-temperature alloy master alloy ingot on a fixing frame, making the central axis parallel to the horizontal plane, and coating a layer of coupling agent on the detection part; tightly combining the curved surface part of the ultrasonic probe with the outer surface of the master alloy ingot end mold, moving the ultrasonic probe in different detection zones in sequence, observing the change of the waveform diagram, then judging whether the detection zone contains secondary shrinkage according to the change of the waveform diagram, if it is judged that the detection zone contains secondary shrinkage, adjusting the size parameters of the ultrasonic probe until it is judged that the detection zone does not contain secondary shrinkage according to the change of the waveform diagram, at this time, cutting is carried out at a certain distance near the junction surface of two adjacent detection zones, and the cutting of the high-temperature alloy master alloy ingot is completed. The cutting method can detect the specific position of the internal defects of the master alloy ingot, achieve accurate cutting, and ensure that the cutting end surface is smooth and flat without secondary shrinkage.

Description

Technical Field

[0001] This invention belongs to the field of high-temperature alloy casting technology, specifically relating to a cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots. Background Technology

[0002] Shrinkage cavities are one of the main defects in high-temperature alloy master alloy ingots, resulting from poor feeding during solidification. High-temperature alloy master alloy ingots prepared using the steel tube method can be classified into primary shrinkage cavities at the top and secondary shrinkage cavities below them, depending on their location. After demolding, the primary shrinkage cavities are completely removed, while the secondary shrinkage cavities remain inside the ingot. Although the secondary shrinkage cavities themselves do not contain impurities, during cutting and handling, foreign inclusions may enter the ingot through these open cavities, forming foreign inclusions that affect the purity and yield of castings, powder trays, etc. Therefore, according to the specifications for powder master alloy ingots, primary shrinkage cavities should be removed, and secondary shrinkage cavities are not allowed on the cut end face.

[0003] Currently, the cutting method for master alloy bars involves operators judging the feed rate based on experience. After cutting away the first shrinkage cavity, the cut end face is visually inspected. If a connection is found between the first and second shrinkage cavities, further cutting is performed, repeating this process multiple times until the cut end face is free of voids. This traditional cutting method cannot accurately determine the connection position and state between the first and second shrinkage cavities, relying solely on experience for multiple cuts. This leads to high cutting losses, low cutting efficiency, and a large amount of scrap due to shrinkage cavities. Therefore, it is necessary to develop a cutting method that can reduce the scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots to address the problems of traditional techniques.

[0004] The invention patent application with publication number CN116519792A discloses a water immersion ultrasonic flaw detection method, device, and system, which is performed before cutting a metal rod to a standard length. The method includes the following steps: controlling the metal rod to pass through a water tank, and controlling the water level in the tank after the metal rod enters the tank; controlling the ultrasonic probe to immerse in the water along a preset path and emitting ultrasonic signals; receiving the reflected wave signals after the ultrasonic signals propagate in the water tank, and determining whether there is a defect area in the metal rod at the current node based on the reflected wave signals; if there is a defect area, marking the defect area in the metal rod to generate corresponding defect marker points.

[0005] The invention patent with publication number CN116203133A discloses a method for locating single-point reflection defects in high-temperature alloy bars, including the following steps: cold-working the high-temperature alloy bar into a diameter of Φ100-500mm, ensuring a surface roughness ≤1.6μm; placing the high-temperature alloy bar in a water tank, and scanning it along the axis of the bar using a probe of a water immersion ultrasonic detector to achieve a full inspection of the bar, obtaining a C-scan image of the bar's planar projection after the inspection, and locating and evaluating the defect based on the position shown in the C-scan image; cutting the bar to remove the defect; repositioning the sample and marking the defect location; recutting the sample with the marked defect location into a square sample; grinding the cut square sample until the defect is found; and observing and qualitatively testing the square sample for the defect.

[0006] Both of the above technical solutions use ultrasonic waves to detect defects on metal rods, but there is no record of the technical parameters in the detection process. However, the accuracy of the detection is closely related to the synergistic effect of many technical parameters. Although both of the above technical solutions can improve the detection efficiency, the detection accuracy needs to be improved. Summary of the Invention

[0007] To address the problems existing in the prior art, this invention provides a cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots, comprising the following steps in sequence:

[0008] Step 1: After the casting process of the high-temperature alloy master alloy ingot is completed, remove the ingot mold system and take the high-temperature alloy master alloy ingot out of the ingot mold;

[0009] Step 2: Place the high-temperature alloy master alloy ingot horizontally on the fixed frame, making the central axis of the high-temperature alloy master alloy ingot parallel to the horizontal plane, and at the same time apply a layer of coupling agent to the detection part of the high-temperature alloy master alloy ingot.

[0010] Step 3: Place the ultrasonic probe of the ultrasonic flaw detection system vertically on the high-temperature alloy master alloy ingot, so that one end of the ultrasonic probe is flush with the interface between the riser end master alloy ingot and the mold end master alloy ingot, and the other end of the ultrasonic probe rests on the mold end master alloy ingot, so that the curved part of the ultrasonic probe is in close contact with the outer surface of the mold end master alloy ingot.

[0011] Step 4: Start the ultrasonic flaw detection system and begin detecting secondary shrinkage cavities in the first detection area. Move the ultrasonic probe within the first detection area and observe the changes in the detection waveform. Determine whether there are secondary shrinkage cavities in the first detection area based on the changes in the detection waveform. If it is determined that there are no secondary shrinkage cavities, cut at a certain distance from the interface between the master alloy ingot at the riser end and the master alloy ingot at the mold end. If it is determined that there are secondary shrinkage cavities, pause the ultrasonic flaw detection system.

[0012] Step 5: Adjust the size parameters of the ultrasonic probe and place it in the second detection area. Start the ultrasonic flaw detection system and begin detecting secondary shrinkage cavities in the second detection area. Move the ultrasonic probe in the second detection area and observe the changes in the detection waveform. Determine whether there are secondary shrinkage cavities in the second detection area based on the changes in the detection waveform. If there are no secondary shrinkage cavities, cut at a certain distance from the interface between the first and second detection areas. If there are secondary shrinkage cavities, pause the ultrasonic flaw detection system.

[0013] Step Six: Repeat the operation method of Step Five, continue to adjust the size parameters of the ultrasonic probe, and continue to detect secondary shrinkage cavities in the next adjacent detection area until it is determined from the changes in the detection waveform that there are no secondary shrinkage cavities in the detection area. At this time, cut at a certain distance from the interface between two adjacent detection areas to complete the cutting to reduce the scrap amount of secondary shrinkage cavities in the high-temperature alloy master alloy ingot.

[0014] Preferably, in step one, the high-temperature alloy master alloy ingot is composed of a riser-end master alloy ingot and a mold-end master alloy ingot; both the riser-end master alloy ingot and the mold-end master alloy ingot are cylindrical in shape, wherein the cross-sectional diameter of the mold-end master alloy ingot is 100mm; the total length of the high-temperature alloy master alloy ingot is 900-1500mm, wherein the length of the riser-end master alloy ingot is 90-150mm.

[0015] In any of the above schemes, it is preferred that, in step three, the ultrasonic flaw detection system includes an ultrasonic flaw detector, an ultrasonic probe, and a signal line, with both ends of the signal line connected to the ultrasonic flaw detector and the ultrasonic probe, respectively; the detection surface of the ultrasonic probe is a curved surface, which is in close contact with the outer surface of the master alloy ingot at the mold end.

[0016] In any of the above schemes, it is preferred that, in steps four to six, the length of several detection zones along the central axis of the master alloy ingot at the mold end increases sequentially; the arc length of the ultrasonic probe used in different detection zones increases sequentially, and its diameter decreases sequentially; after determining that there is a secondary shrinkage cavity, the cutting distance in different detection zones is equal.

[0017] In any of the above schemes, it is preferred that, within the first detection zone, the arc length of the curved surface of the ultrasonic probe is 15-25% of the circumference of the master alloy ingot at the mold end, the diameter of the ultrasonic probe is 30-40 mm, and the length of the first detection zone along the central axis of the master alloy ingot at the mold end is 1-2 times the diameter of the ultrasonic probe.

[0018] In any of the above schemes, it is preferred that, starting from the second detection zone, the arc length of the ultrasonic probe increases by 10-20% sequentially, the diameter of the ultrasonic probe decreases by 10-20% sequentially, and the length of the detection zone along the central axis of the master alloy ingot at the mold end increases by 0.2-0.6 times sequentially.

[0019] In any of the above schemes, it is preferred that, after determining that there is a secondary shrinkage cavity, the cutting distance in different detection zones is 2-5mm.

[0020] In this invention, for a high-temperature alloy master alloy ingot with a cross-sectional diameter of 100 mm, in order to improve the accuracy and reliability of detecting secondary shrinkage cavities, it is necessary to customize ultrasonic probes with different dimensional parameters to be suitable for detecting secondary shrinkage cavities in different detection areas of the high-temperature alloy master alloy ingot. When detecting secondary shrinkage cavities in different detection areas, a layer of coupling agent needs to be coated on the detection area of ​​the high-temperature alloy master alloy ingot. Then, the curved surface of the ultrasonic probe with the corresponding dimensional parameters is tightly fitted to the arc surface of the high-temperature alloy master alloy ingot. Then, the presence of secondary shrinkage cavities in the detection area is determined according to the detection waveform diagram. The detection waveform diagram includes defect waves and noise waves. The peak of the defect wave is significantly higher than that of the noise wave. If a certain peak in the detection waveform diagram is significantly higher than that of the noise wave, it is determined that the position corresponding to the peak is the location of the secondary shrinkage cavity. This position should be avoided during cutting to obtain a smooth and flat cutting end face without secondary shrinkage cavities.

[0021] In this invention, the casting process and process parameters of the high-temperature alloy master alloy ingot are not specifically limited, but the size parameters of the ultrasonic probe are specifically limited. In particular, the arc length and diameter of the ultrasonic probe, as well as the synergistic effect of the arc length, diameter, and detection zone length, are key to this invention. Throughout the cutting process, the size parameters of the ultrasonic probe need to be adjusted multiple times. The diameter of the ultrasonic probe cannot be less than 10mm, and the arc length of the ultrasonic probe cannot exceed the semicircular length of the high-temperature alloy master alloy ingot. At least one bar with a length of 550-700mm needs to be cut from the high-temperature alloy master alloy ingot. If, after several detection zones, the diameter of the ultrasonic probe is less than 10mm and / or the arc length of the ultrasonic probe exceeds the semicircular length of the high-temperature alloy master alloy ingot and / or a 550-700mm bar cannot be cut, then the entire high-temperature alloy master alloy ingot is scrapped. Using the cutting method of this invention, completing one to four detection zones typically avoids secondary shrinkage cavities on the cut end face, preventing the entire high-temperature alloy master alloy ingot from being scrapped.

[0022] The cutting method of the present invention for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots has the following beneficial effects:

[0023] (1) Ultrasonic testing is used to determine the specific location of internal defects in the master alloy ingot, thereby achieving precise cutting and ensuring that the cut end face is flat and smooth without secondary shrinkage cavities.

[0024] (2) It avoids repeated cutting losses and scrap due to secondary shrinkage, improves the cutting efficiency of the master alloy ingot in the later process, reduces cutting losses and secondary shrinkage scrap costs, and increases the delivery rate of master alloy ingot products.

[0025] (3) It can replace the traditional method of judging the feed rate based on experience to carry out cutting. Attached Figure Description

[0026] Figure 1 A flowchart of a preferred embodiment of the cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots according to the present invention;

[0027] Figure 2 for Figure 1 A schematic diagram showing the connection relationship between the ultrasonic flaw detection system and the high-temperature alloy master alloy ingot in the embodiment shown.

[0028] Figure 3 for Figure 1 A schematic diagram of the ultrasonic probe in the illustrated embodiment;

[0029] Figure 4 for Figure 1 The diagram shown in the embodiment illustrates the distribution of each detection zone on the master alloy ingot at the mold end.

[0030] Figure 5 for Figure 1 The waveform diagrams of the first to fourth detection areas in the embodiment shown are as follows: (1) is the waveform diagram of the first detection area, (2) is the waveform diagram of the second detection area, (3) is the waveform diagram of the third detection area, and (4) is the waveform diagram of the fourth detection area.

[0031] Explanation of annotations in the image:

[0032] 1-High temperature alloy master alloy ingot, 101-Riser end master alloy ingot, 102-Die end master alloy ingot, 103-First detection zone, 104-Second detection zone, 105-Third detection zone, 106-Fourth detection zone, 107-Cutting distance;

[0033] 2-Ultrasonic flaw detection system, 201-Ultrasonic flaw detector, 202-Ultrasonic probe, 203-Signal line, 204-Arc length of the curved surface of the ultrasonic probe, 205-Diameter of the ultrasonic probe;

[0034] 3-Fixed bracket. Detailed Implementation

[0035] To further understand the invention, the following detailed description of the invention will be provided in conjunction with specific embodiments.

[0036] Example 1:

[0037] like Figure 1 As shown, a preferred embodiment of the cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots according to the present invention includes the following steps in sequence:

[0038] Step 1: After the casting process of the high-temperature alloy master alloy ingot is completed, remove the ingot mold system and take the high-temperature alloy master alloy ingot out of the ingot mold;

[0039] Step 2: Place the high-temperature alloy master alloy ingot horizontally on the fixed frame, making the central axis of the high-temperature alloy master alloy ingot parallel to the horizontal plane, and at the same time apply a layer of coupling agent to the detection part of the high-temperature alloy master alloy ingot.

[0040] Step 3: Place the ultrasonic probe of the ultrasonic flaw detection system vertically on the high-temperature alloy master alloy ingot, so that one end of the ultrasonic probe is flush with the interface between the riser end master alloy ingot and the mold end master alloy ingot, and the other end of the ultrasonic probe rests on the mold end master alloy ingot, so that the curved part of the ultrasonic probe is in close contact with the outer surface of the mold end master alloy ingot.

[0041] Step 4: Start the ultrasonic flaw detection system and begin detecting secondary shrinkage cavities in the first detection area. Move the ultrasonic probe within the first detection area and observe the changes in the detection waveform. Determine whether there are secondary shrinkage cavities in the first detection area based on the changes in the detection waveform. If it is determined that there are no secondary shrinkage cavities, cut at a certain distance from the interface between the master alloy ingot at the riser end and the master alloy ingot at the mold end. If it is determined that there are secondary shrinkage cavities, pause the ultrasonic flaw detection system.

[0042] Step 5: Adjust the size parameters of the ultrasonic probe and place it in the second detection area. Start the ultrasonic flaw detection system and begin detecting secondary shrinkage cavities in the second detection area. Move the ultrasonic probe in the second detection area and observe the changes in the detection waveform. Determine whether there are secondary shrinkage cavities in the second detection area based on the changes in the detection waveform. If there are no secondary shrinkage cavities, cut at a certain distance from the interface between the first and second detection areas. If there are secondary shrinkage cavities, pause the ultrasonic flaw detection system.

[0043] Step Six: Repeat the operation method of Step Five, continue to adjust the size parameters of the ultrasonic probe, and continue to detect secondary shrinkage cavities in the next adjacent detection area until it is determined from the changes in the detection waveform that there are no secondary shrinkage cavities in the detection area. At this time, cut at a certain distance from the interface between two adjacent detection areas to complete the cutting to reduce the scrap amount of secondary shrinkage cavities in the high-temperature alloy master alloy ingot.

[0044] In step one, the high-temperature alloy master alloy ingot 1 is composed of a riser-end master alloy ingot 101 and a mold-end master alloy ingot 102; both the riser-end master alloy ingot 101 and the mold-end master alloy ingot 102 are cylindrical in shape, wherein the cross-sectional diameter of the mold-end master alloy ingot 102 is 100mm and the circumference is 314mm; the total length of the high-temperature alloy master alloy ingot 1 is 1300mm, wherein the length of the riser-end master alloy ingot 101 is 100mm and the length of the mold-end master alloy ingot 102 is 1200mm.

[0045] In step three, the ultrasonic flaw detection system 2 includes an ultrasonic flaw detector 201, an ultrasonic probe 202, and a signal line 203. The two ends of the signal line 203 are connected to the ultrasonic flaw detector 201 and the ultrasonic probe 202, respectively. The detection surface of the ultrasonic probe 202 is a curved surface, which is in close contact with the outer surface of the mold end master alloy ingot 102.

[0046] In this embodiment, the connection relationship between the ultrasonic flaw detection system 2 and the high-temperature alloy master alloy ingot 1 is as follows: Figure 2 As shown, the high-temperature alloy master alloy ingot 1 is placed on the fixing frame 3, and the ultrasonic probe 202 of the ultrasonic flaw detection system 2 is tightly attached to the outer surface of the master alloy ingot 102 at the mold end. The detection surface of the ultrasonic probe 202 is a curved surface, specifically as shown in the figure. Figure 3 As shown, the ultrasonic probe 202 includes two key dimensional parameters: the arc length 204 of the ultrasonic probe surface and the diameter 205 of the ultrasonic probe.

[0047] In steps four through six, the length of several detection zones along the central axis of the master alloy ingot at the mold end increases sequentially; the arc length of the ultrasonic probe used in different detection zones increases sequentially, while its diameter decreases sequentially; after determining the presence of secondary shrinkage cavities, the cutting distance is equal in all detection zones. In this embodiment, the distribution of each detection zone on the master alloy ingot at the mold end is as follows: Figure 4 As shown, starting from the interface between the riser end master alloy ingot 101 and the mold end master alloy ingot 102, there are sequentially a first detection zone 103, a second detection zone 104, a third detection zone 105 and a fourth detection zone 106. Cutting is performed at a certain distance from the interface between the third detection zone 105 and the fourth detection zone 106, and this distance is the cutting distance 107.

[0048] In this embodiment, after detection in four detection zones, the changes in the detection waveforms indicate that the cut end face of the high-temperature alloy master alloy ingot does not contain secondary shrinkage cavities. In each detection zone, the dimensional parameters of the ultrasonic probe and the length parameters of the detection zone both changed, as detailed below:

[0049] Within the first detection zone, the arc length of the ultrasonic probe is 20% of the circumference of the master alloy ingot at the mold end, i.e., the arc length of the ultrasonic probe is 62.8 mm; the diameter of the ultrasonic probe is 30 mm; the length of the first detection zone along the central axis of the master alloy ingot at the mold end is 1.5 times the diameter of the ultrasonic probe, i.e., the length of the first detection zone is 45 mm. Starting from the second detection zone, the arc length of the ultrasonic probe increases by 15% sequentially, the diameter of the ultrasonic probe decreases by 15% sequentially, and the length of the detection zone along the central axis of the master alloy ingot at the mold end increases by 0.2 times sequentially.

[0050] Within the second detection zone, the arc length of the ultrasonic probe is 72.22 mm, the diameter of the ultrasonic probe is 25.5 mm, and the length of the second detection zone is 54 mm.

[0051] Within the third detection zone, the arc length of the ultrasonic probe is 83.05 mm, the diameter of the ultrasonic probe is 21.68 mm, and the length of the third detection zone is 64.8 mm.

[0052] Within the fourth detection zone, the arc length of the ultrasonic probe is 95.51 mm, the diameter of the ultrasonic probe is 18.43 mm, and the length of the third detection zone is 77.76 mm.

[0053] During the detection process in the four detection zones, the ultrasonic probe was moved while the changes in the detection waveform were observed. Based on the changes in the detection waveform, it was determined whether there were secondary shrinkage cavities in the detection zone. The final determination result was that there were secondary shrinkage cavities in the first to the third detection zones, and no secondary shrinkage cavities were found in the fourth detection zone. Finally, a cut was made at a certain distance from the interface between the third and fourth detection zones, with a cutting distance of 3mm. This completed the cutting process to reduce the scrap amount of secondary shrinkage cavities in the high-temperature alloy master alloy ingot.

[0054] In this embodiment, the detection waveforms of the four detection areas are as follows: Figure 5 As shown, (1) is the detection waveform diagram of the first detection zone, (2) is the detection waveform diagram of the second detection zone, (3) is the detection waveform diagram of the third detection zone, and (4) is the detection waveform diagram of the fourth detection zone. The detection waveform diagram includes defect waves and noise waves. The peak of the defect wave is significantly higher than that of the noise wave. If a certain peak in the detection waveform diagram is significantly higher than that of the noise wave, then the position corresponding to that peak is determined to be the position of the secondary shrinkage cavity. This position should be avoided during cutting to obtain a smooth and flat cutting end face without secondary shrinkage cavities. Figure 5 It can be clearly seen that the first to third detection zones all contain secondary shrinkage cavities, while the fourth detection zone does not contain secondary shrinkage cavities.

[0055] In this embodiment, for a high-temperature alloy master alloy ingot with a cross-sectional diameter of 100 mm, in order to improve the accuracy and reliability of detecting secondary shrinkage cavities, it is necessary to customize ultrasonic probes with different dimensional parameters to be suitable for detecting secondary shrinkage cavities in different detection areas of the high-temperature alloy master alloy ingot. No special limitations are placed on the casting process and process parameters of the high-temperature alloy master alloy ingot, but special limitations are placed on the dimensional parameters of the ultrasonic probe, especially the arc length and diameter of the ultrasonic probe surface, and the synergistic effect of the arc length and diameter of the ultrasonic probe with the length of the detection area.

[0056] The cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots in this embodiment has the following beneficial effects: Ultrasonic testing is used to determine the specific location of internal defects in the master alloy ingot, thereby achieving precise cutting and ensuring a smooth and flat cut surface without secondary shrinkage cavities; it avoids repeated cutting losses and scrap due to secondary shrinkage cavities, improves the cutting efficiency of subsequent processes in the master alloy ingot, reduces cutting losses and secondary shrinkage cavity scrap costs, and increases the delivery rate of master alloy ingot products; it can replace the traditional method of judging the feed rate based on experience.

[0057] Example 2:

[0058] Another preferred embodiment of the cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots according to the present invention has basically the same process steps, equipment used, technical principles, and beneficial effects as in Embodiment 1, except that:

[0059] The total length of the high-temperature alloy master alloy ingot is 1500mm, of which the length of the master alloy ingot at the mold end is 1400mm, and its cross-sectional diameter is 100mm and its circumference is 314mm.

[0060] In this embodiment, after detection in three detection zones, the changes in the detection waveforms indicate that the cut end face of the high-temperature alloy master alloy ingot does not contain secondary shrinkage cavities. In each detection zone, the dimensional parameters of the ultrasonic probe and the length parameters of the detection zone both changed, as detailed below:

[0061] Within the first detection zone, the arc length of the ultrasonic probe is 25% of the circumference of the master alloy ingot at the mold end, i.e., the arc length of the ultrasonic probe is 78.5 mm; the diameter of the ultrasonic probe is 40 mm; the length of the first detection zone along the central axis of the master alloy ingot at the mold end is twice the diameter of the ultrasonic probe, i.e., the length of the first detection zone is 80 mm. Starting from the second detection zone, the arc length of the ultrasonic probe increases by 10% sequentially, the diameter of the ultrasonic probe decreases by 10% sequentially, and the length of the detection zone along the central axis of the master alloy ingot at the mold end increases by 0.4 times sequentially.

[0062] Within the second detection zone, the arc length of the ultrasonic probe is 86.35 mm, the diameter of the ultrasonic probe is 36 mm, and the length of the second detection zone is 112 mm.

[0063] Within the third detection zone, the arc length of the ultrasonic probe is 94.99 mm, the diameter of the ultrasonic probe is 32.4 mm, and the length of the third detection zone is 156.8 mm.

[0064] During the detection process in the three detection zones, the ultrasonic probe was moved while the changes in the detection waveform were observed. Based on the changes in the detection waveform, it was determined whether there were secondary shrinkage cavities in the detection zones. The final judgment was that there were secondary shrinkage cavities in both the first and second detection zones, but no secondary shrinkage cavities in the third detection zone. Finally, a cut was made at a certain distance from the interface between the second and third detection zones, with a cutting distance of 5 mm. This cut was sufficient to reduce the scrap amount of secondary shrinkage cavities in the high-temperature alloy master alloy ingot.

[0065] Example 3:

[0066] Another preferred embodiment of the cutting method for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots according to the present invention has basically the same process steps, equipment used, technical principles, and beneficial effects as in Embodiment 1, except that:

[0067] The total length of the high-temperature alloy master alloy ingot is 1400mm, of which the length of the master alloy ingot at the mold end is 1300mm, and its cross-sectional diameter is 100mm and its circumference is 314mm.

[0068] In this embodiment, after detection in two detection zones, the changes in the detection waveform indicate that the cut end face of the high-temperature alloy master alloy ingot does not contain secondary shrinkage cavities. In each detection zone, the size parameters of the ultrasonic probe and the length parameters of the detection zone have changed, as detailed below:

[0069] Within the first detection zone, the arc length of the ultrasonic probe is 15% of the circumference of the master alloy ingot at the mold end, i.e., the arc length of the ultrasonic probe is 47.1 mm; the diameter of the ultrasonic probe is 30 mm; the length of the first detection zone along the central axis of the master alloy ingot at the mold end is twice the diameter of the ultrasonic probe, i.e., the length of the first detection zone is 60 mm.

[0070] Within the second detection zone, the arc length of the ultrasonic probe increases by 20%, to 56.52 mm; the diameter of the ultrasonic probe decreases by 20%, to 24 mm; and the length of the second detection zone increases by 0.6 times, to 96 mm.

[0071] During the detection process in the two detection zones, the ultrasonic probe is moved while the changes in the detection waveform are observed. Based on the changes in the detection waveform, it is determined whether there are secondary shrinkage cavities in the detection zone. The final judgment is that there are secondary shrinkage cavities in the first detection zone and no secondary shrinkage cavities in the second detection zone. Finally, a cut is made at a certain distance from the interface between the first and second detection zones, with a cutting distance of 2mm. This completes the cutting process to reduce the scrap amount of secondary shrinkage cavities in the high-temperature alloy master alloy ingot.

[0072] Special Note: The technical solution of this invention involves numerous parameters, and the synergistic effects between these parameters must be comprehensively considered to achieve the beneficial effects and significant progress of this invention. Furthermore, the value ranges of each parameter in the technical solution were obtained through extensive experimentation. For each parameter and the combinations thereof, the inventors have recorded a large amount of experimental data; however, due to space limitations, the specific experimental data is not disclosed here.

[0073] Those skilled in the art will readily understand that the cutting method of the present invention for reducing the amount of scrap due to secondary shrinkage cavities in high-temperature alloy master alloy ingots includes any combination of the inventive content and specific embodiments described in the above specification and the various parts shown in the accompanying drawings. Due to space limitations and for the sake of brevity, not all of these combined solutions have been described in detail. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A cutting method for reducing the amount of superalloy master alloy ingot rejected due to secondary shrinkage, comprising the following steps in order: Step one: after the pouring process of the superalloy master alloy ingot is completed, remove the ingot mold system, and remove the superalloy master alloy ingot from the ingot mold; Step two: place the superalloy master alloy ingot horizontally on a fixed frame, so that the central axis of the superalloy master alloy ingot is parallel to the horizontal plane, and at the same time, apply a layer of coupling agent to the detection part of the superalloy master alloy ingot; Step three: place the ultrasonic probe of the ultrasonic flaw detection system vertically on the superalloy master alloy ingot, so that one end of the ultrasonic probe is flush with the interface between the riser end master alloy ingot and the mold end master alloy ingot, and the other end of the ultrasonic probe falls on the mold end master alloy ingot, and the curved surface of the ultrasonic probe is tightly attached to the outer surface of the mold end master alloy ingot; Step four: start the ultrasonic flaw detection system to detect secondary shrinkage in the first detection zone, move the ultrasonic probe in the first detection zone, and at the same time, observe the changes in the detection waveform diagram, determine whether the first detection zone contains secondary shrinkage according to the changes in the detection waveform diagram, if it is determined that there is no secondary shrinkage, cut at a certain distance from the interface between the riser end master alloy ingot and the mold end master alloy ingot, if it is determined that there is secondary shrinkage, pause the ultrasonic flaw detection system; Step five: adjust the size parameters of the ultrasonic probe, place it in the second detection zone, start the ultrasonic flaw detection system to detect secondary shrinkage in the second detection zone, move the ultrasonic probe in the second detection zone, and at the same time, observe the changes in the detection waveform diagram, determine whether the second detection zone contains secondary shrinkage according to the changes in the detection waveform diagram, if it is determined that there is no secondary shrinkage, cut at a certain distance from the interface between the first detection zone and the second detection zone, if it is determined that there is secondary shrinkage, pause the ultrasonic flaw detection system; Step six: repeat the operation method of step five, continue to adjust the size parameters of the ultrasonic probe, and continue to detect secondary shrinkage in the next adjacent detection zone, until it is determined that there is no secondary shrinkage in the detection zone according to the changes in the detection waveform diagram, at this time, cut at a certain distance from the interface between the two adjacent detection zones, and the cutting of the superalloy master alloy ingot to reduce the amount of rejection due to secondary shrinkage is completed.

2. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy mother alloy ingot according to claim 1, characterized in that: In step one, the superalloy master alloy ingot is composed of a riser end master alloy ingot and a mold end master alloy ingot; the shapes of the riser end master alloy ingot and the mold end master alloy ingot are both cylindrical, wherein the cross-sectional diameter of the mold end master alloy ingot is 100 mm; the total length of the superalloy master alloy ingot is 900-1500 mm, wherein the length of the riser end master alloy ingot is 90-150 mm.

3. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy mother alloy ingot according to claim 2, characterized in that: In step three, the ultrasonic flaw detection system includes an ultrasonic flaw detector, an ultrasonic probe, and a signal line, the two ends of the signal line are connected with the ultrasonic flaw detector and the ultrasonic probe respectively; the detection surface of the ultrasonic probe is a curved surface which is tightly attached to the outer surface of the mold end master alloy ingot.

4. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy master alloy ingot according to claim 3, characterized in that: In the fourth step to the sixth step, the length of the several detection zones along the direction of the center axis of the die end mother alloy ingot increases successively; the curved surface arc length of the ultrasonic probe used in different detection zones increases successively, and the diameter of the ultrasonic probe decreases successively; after judging containing secondary shrinkage, the cutting distance in different detection zones is equal.

5. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy mother alloy ingot according to claim 4, characterized in that: In the first detection zone, the curved surface arc length of the ultrasonic probe is 15-25% of the circumference length of the die end mother alloy ingot, the diameter of the ultrasonic probe is 30-40mm, and the length of the first detection zone along the direction of the center axis of the die end mother alloy ingot is 1-2 times of the diameter of the ultrasonic probe.

6. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy mother alloy ingot according to claim 5, characterized in that: From the second detection zone, the curved surface arc length of the ultrasonic probe increases successively by 10-20%, the diameter of the ultrasonic probe decreases successively by 10-20%, and the length of the detection zone along the direction of the center axis of the die end mother alloy ingot increases successively by 0.2-0.6 times.

7. The cutting method for reducing the secondary shrinkage cavity rejection amount of the superalloy mother alloy ingot according to claim 6, characterized in that: After judging containing secondary shrinkage, the cutting distance in different detection zones is 2-5mm.

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