System and method for producing small gauge high strength low plasticity specialty wire

Abstract

The application discloses a small-size high-strength low-plasticity special wire rod preparation system and method, which comprises a smelting furnace, a flow guide pipe, a cooling device, an induction heating device, a winding device, a nitrogen pressure regulating device and an argon filling device; the smelting furnace is provided with an air inlet at the top, and the argon filling device is communicated with the air inlet through the nitrogen pressure regulating device; the smelting furnace is provided with a discharge port at the bottom, and one end of the flow guide pipe is communicated with the discharge port; the cooling device is used for cooling the flow guide pipe and the molten steel in the flow guide pipe; the induction heating device is used for heating the wire rod output from the other end of the flow guide pipe; and the winding device is used for winding the wire rod heated by the induction heating device. The system and the method omit the processes of ingot casting, blank forging, hot rolling, solid solution, drawing and the like, can avoid material plastic deformation, shorten the construction period by more than 80%, meanwhile, can avoid material loss in the processes of forging, hot rolling and drawing, and can improve the material yield by more than 40%; and different specifications of products can be prepared according to the wire rod demand.

Description

Technical Field

[0001] The present invention belongs to the field of metal material processing and forming, and in particular to a system and method for preparing small-sized, high-strength, low-plasticity special wire. Background Art

[0002] Currently, demand for wire rod products is extremely high. The conventional wire rod production process involves smelting, refining, forging (continuous casting), rolling, and drawing, a complex and lengthy process. Due to their inherent poor plasticity and high strength, some high-alloy specialty materials exhibit cracking defects during hot and cold deformation processes such as forging, rolling, and drawing. This makes it impossible to produce small-sized wire rod products, significantly impacting material yield and serviceability. In severe cases, the products may break and become scrapped. To meet product supply requirements, some manufacturers must produce wire rod from steel ingots through methods such as wire cutting and turning, which is extremely costly in terms of processing, time, and raw material costs. This problem requires urgent resolution. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a small-size high-strength low-plasticity special wire preparation system that realizes integrated preparation; the present invention also provides a small-size high-strength low-plasticity special wire preparation method.

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is as follows: it includes a melting furnace, a drainage pipe, a cooling device, an induction heating device, a winder, an argon pressure control device and an argon filling device; the top of the melting furnace is provided with an air inlet, and the argon filling device is connected to the air inlet through the argon pressure control device; the bottom of the melting furnace is provided with a discharge port, and one end of the drainage pipe is connected to the discharge port; the cooling device is used to cool the drainage pipe and the molten steel inside it; the induction heating device is used to heat the wire output from the other end of the drainage pipe; and the winder is used to reel in the wire heated by the induction heating device.

[0005] Furthermore, the drainage tube has several models according to the wire specifications.

[0006] Furthermore, the cooling device includes a cooling pipe and a coolant circulation device; the cooling pipe is coiled outside the drainage pipe.

[0007] Furthermore, it also includes a guide wheel; the guide wheel is used to guide the wire heated by the induction heating device to the winder.

[0008] Furthermore, a pressure sensor is provided in the smelting furnace; the argon pressure regulating device is provided with a flow control valve and a flow controller; the flow controller regulates the flow control valve through the pressure feedback from the pressure sensor.

[0009] To solve the above technical problems, the present invention adopts the above system, and the technical solution adopted includes the following steps: 1) adding alloy raw materials into the melting furnace according to the wire composition requirements, vacuuming, heating, and refining until the composition meets the wire product requirements;

[0010] 2) Filling the melting furnace with argon gas, and determining the argon pressure in the melting furnace according to the wire diameter and the finished product winding speed requirements; the argon pressure P in the melting furnace is calculated using the following formula (I);

[0011]

[0012] In formula (I), v is the winding speed, mm / min; d is the finished wire diameter, mm; P is the argon filling pressure, Pa; e is a natural constant;

[0013] 3) The molten steel in the smelting furnace flows into the draft pipe under the pressure of argon gas, is cooled by the cooling device, and solidifies into wire rod;

[0014] 4) The wire output from the drainage tube is heated by an induction heating device and then reeled on a reel.

[0015] Furthermore, the drainage tube is replaced with a corresponding model according to the wire specifications.

[0016] Furthermore, in step 4), the wire is heated by the induction heating device and then guided to the winder through the guide wheel.

[0017] The beneficial effects of adopting the above technical solution are: the present invention can solve the problem of forging and drawing cracking in the preparation process of high-strength, low-plasticity wire products, and prepare wire products in an integrated manner; the system and method of the present invention omits the processes of ingot casting, billet forging, hot rolling, solid solution, drawing, etc., which can effectively avoid plastic deformation of materials and shorten the construction period by more than 80%, while avoiding material loss in the forging, hot rolling and drawing processes, and increasing the yield rate by more than 40%; different specifications of products can be prepared according to wire requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0019] Figure 1 It is a structural diagram of the system of the present invention;

[0020] Figure 2 This is a photo of severe cracking during forging of the steel ingot of Example 1;

[0021] Figure 3 This is a photo of severe cracking during wire rolling in Example 2.

[0022] In the figure: smelting furnace 1, adapter 2, drainage pipe 3, cooling device 4, induction heating device 5, guide wheel 6, winder 7, wire 8, argon pressure control device 9, argon filling device 10, argon supply device 11. DETAILED DESCRIPTION

[0023] Figure 1 As shown, this small-size, high-strength, low-ductility specialty wire production system includes a melting furnace 1, a draft tube 3, a cooling device 4, an induction heating device 5, a guide wheel 6, a winder 7, an argon pressure control device 9, and an argon filling device 10. The top of the melting furnace 1 is equipped with an air inlet and a pressure sensor. The argon filling device 10 is connected to the air inlet of the melting furnace 1 through the argon pressure control device 9. The argon pressure control device 9 is equipped with a flow control valve and a flow controller; the flow controller controls the flow control valve based on pressure feedback from the pressure sensor. An argon supply device 11 is also provided to supply argon to the argon filling device 10.

[0024] Figure 1 As shown, in this small-sized high-strength low-plasticity special wire preparation system, the bottom of the smelting furnace 1 is provided with a discharge port, and one end of the drainage pipe 3 is connected to the discharge port of the smelting furnace 1. The drainage pipe 3 has several models according to the wire specifications, and can be connected to the discharge port of the smelting furnace 1 through an adapter 2; the adapter 2 is provided with a valve. The cooling device 4 is used to cool the drainage pipe 3 and the molten steel inside it; the cooling device 4 is preferably: including a cooling pipe and a coolant circulation device, the cooling pipe is coiled on the outside of the drainage pipe 3, and the two ends of the cooling pipe are connected to the coolant circulation device; in this way, the coolant is powered by the coolant circulation device, and the coolant circulates in the cooling pipe coil, thereby achieving cooling of the drainage pipe 3 and the molten steel inside it.

[0025] Figure 1 As shown, in this small-scale, high-strength, low-plasticity specialty wire preparation system, the induction heating device 5 is used to heat the wire 8 output from the other end of the drainage tube 3. The induction heating device 5 preferably includes an induction power supply and an induction coil, through which the wire 8 passes; thus, the induction coil heats the passing wire 8. The guide wheel 6 is used to guide and bend the wire 8 heated by the induction heating device 5 to the reel 7. A number of guide wheels 6 may be provided as needed. The reel 7 is used to reel the wire 8 heated by the induction heating device 5 and guided by the guide wheel 6.

[0026] Figure 1 As shown, the method for preparing small-sized high-strength low-plasticity special wire comprises the following steps:

[0027] 1) Replace the draft tube 3 with the corresponding model according to the wire material specifications. Add the alloy raw materials into the melting furnace 1 according to the wire material composition requirements, evacuate to <1Pa, and heat to melt and refine the alloy raw materials until the composition meets the wire material product requirements;

[0028] 2) Argon is charged into the melting furnace 1, and the argon pressure in the melting furnace 1 is determined according to the wire diameter and the winding speed requirement of the finished product; the argon pressure P in the melting furnace is calculated using the following formula (I);

[0029]

[0030] In formula (I), v is the winding speed, mm / min; d is the finished wire diameter, mm; P is the argon filling pressure, Pa; e is a natural constant;

[0031] 3) The molten steel in the smelting furnace 1 flows into the drainage pipe 3 under the pressure of argon gas, and is cooled by the cooling device 4 and solidified into the wire rod 8;

[0032] 4) The wire output from the drainage tube 3 is heated by the induction heating device 5 to soften the wire, and is then guided and bent by the guide wheel 6 and finally wound on the winder 7.

[0033] This method is suitable for preparing wire rods with a specification of 6 to 10 mm, and the preparation speed of the finished wire rods is 1000 to 1500 mm / min.

[0034] Example 1: This example prepares a 6.0 mm diameter high-strength Ni-Cr-W alloy. Since it has a severe tendency to crack during hot working, it cannot be prepared by hot working. Instead, it is prepared by the following method:

[0035] According to the required wire diameter of 6mm and the finished product winding speed requirement of 1000mm / min, replace the 6mm specification drainage tube 3. According to the alloy composition requirements, the raw materials required for smelting are added to the crucible of the melting furnace 1 according to the content requirements. After evacuating to <1Pa, heat and melt and refine until the composition meets the wire product requirements. Open the flow control valve of the argon pressure control device 9 and determine the pressure in the melting furnace according to formula (I) The valve of the adapter 2 is opened, and the molten steel flows into the drainage pipe 3. The argon pressure in the furnace pushes the molten steel to flow slowly and steadily in the drainage pipe 3. After passing through the cooling device 4, the molten steel slowly cools and solidifies, forming a wire 8 of a predetermined specification. The wire continues to move forward, and is softened by the heating of the induction heating device 5. It continues to move to the guide wheel 6, where it is coiled and finally wound on the winding system.

[0036] Example 2: This example prepares 8.0 mm diameter Ni55Cr40 alloy. Due to its severe tendency to crack during hot working and tight production cycle, the conventional smelting-forging-rolling process cannot meet the supply requirements. Therefore, the following method is used for preparation:

[0037] Given the required wire diameter of 8.0 mm and the required winding speed of 1300 mm / min, the 8.0 mm draft tube 3 is replaced. Based on the alloy composition requirements, the raw materials required for smelting are added to the crucible of the melting furnace 1 according to the required content. The crucible is evacuated to <1 Pa, then heated and melted, and refined until the composition meets the wire product requirements. The flow control valve of the argon pressure control device 9 is opened, and the pressure in the melting furnace is determined to be P = 0.81 MPa according to formula (I). The valve of the adapter 2 is opened, allowing the molten steel to flow into the draft tube 3. The argon pressure in the furnace propels the molten steel through the draft tube 3 at a steady rate. After passing through the cooling device 4, the molten steel slowly cools and solidifies, forming a wire 8 of the specified specifications. The wire continues to move forward, softened by heating from the induction heating device 5, and then moves to the guide wheel 6, where it is coiled and finally wound on the winding system.

[0038] The finished wire rod obtained in this embodiment has a smooth surface and standard dimensions.

[0039] Example 3: This example prepares a 10.0 mm diameter Ni58Cr16Mo16W4Fe5 nickel-based alloy that has a severe tendency to work hardening and cannot be formed by forging. The following method is used for preparation:

[0040] Given the required wire diameter of 10.0 mm and the required winding speed of 1500 mm / min, a 10.0 mm cooling tube is replaced. Based on the alloy composition requirements, the raw materials required for smelting are added to the crucible of melting furnace 1 according to the required content. The furnace is evacuated to a vacuum of <1 Pa, then heated and melted, and refined until the composition meets the wire product requirements. The flow control valve of argon pressure control device 9 is opened, and the pressure in the melting furnace is determined to be P = 1.08 MPa according to equation (I). The valve of adapter 2 is opened, allowing molten steel to flow into drainage tube 3. The argon pressure in the furnace propels the molten steel through drainage tube 3 at a steady rate. After passing through cooling device 4, the molten steel slowly cools and solidifies, forming wire 8 of the specified specifications. The wire continues to move forward, softened by heating from induction heating device 5, and then moves to guide wheel 6, where it is coiled and ultimately wound on the winding system.

[0041] The finished wire rod obtained in this embodiment has a smooth surface and standard dimensions.

[0042] Comparative Example 1: Ni-Cr-W alloy wire with a diameter of 6 mm was prepared by smelting-forging-rolling process. When the steel ingot was forged, severe cracking occurred. Figure 2 , requiring multiple grindings and huge losses, with a yield rate of only 51%.

[0043] Comparative Example 2: Preparation of φ10mmNi58Cr16Mo16W4Fe5 nickel-based alloy wire products, poor hot working plasticity leads to severe rolling cracking, seeFigure 3 , all products are scrapped. At the same time, the production cycle of this product is 20 working days, and the production pace is too slow.

[0044] The comparison of the yield rate and production cycle of Examples 1-3 and Comparative Examples 1-2 is shown in Table 1;

[0045] Table 1: Comparison of yield rate and production cycle

[0046]

[0047] As can be seen from Table 1, the system and method effectively improve the yield rate of wire rods and shorten the production cycle.

Claims

1. A method for preparing a small-size, high-strength, low-plasticity special wire, the preparation system of which comprises a smelting furnace (1), a drainage pipe (3), a cooling device (4), an induction heating device (5), a reel (7), an argon pressure control device (9) and an argon filling device (10); an air inlet is provided at the top of the smelting furnace (1), and the argon filling device (10) is connected to the air inlet via the argon pressure control device (9); a discharge port is provided at the bottom of the smelting furnace (1), and one end of the drainage pipe (3) is connected to the discharge port; the cooling device (4) is used to cool the drainage pipe (3) and the molten steel therein; the induction heating device (5) is used to heat the wire (8) outputted from the other end of the drainage pipe (3); the reel (7) is used to reel the wire (8) heated by the induction heating device (5); the method is characterized in that The steps include: 1) According to the wire material composition requirements, alloy raw materials are put into the melting furnace (1), vacuuming, heating, and refining are carried out until the composition meets the wire material product requirements; 2) Filling the melting furnace (1) with argon gas, and determining the argon pressure in the melting furnace (1) according to the wire diameter and the winding speed requirement of the finished product; the argon pressure P in the melting furnace is calculated using the following formula (I); ， In formula (I), v is the winding speed, mm / min; d is the finished wire diameter, mm; P is the argon filling pressure, Pa; e is a natural constant; 3) The molten steel in the smelting furnace (1) flows into the drainage pipe (3) under the action of argon pressure, and is cooled by the cooling device (4) and solidified into wire rod (8); 4) The wire material output from the drainage tube (3) is heated by the induction heating device (5) and then reeled on the reel (7).

2. The method for preparing small-sized, high-strength, low-plasticity special wire according to claim 1, characterized in that: The drainage tube (3) is replaced with a corresponding model according to the wire specifications.

3. The method for preparing small-sized, high-strength, low-plasticity special wire according to claim 1, characterized in that: The cooling device (4) comprises a cooling pipe and a cooling liquid circulation device; the cooling pipe is coiled outside the drainage pipe (3).

4. The method for preparing small-sized, high-strength, low-plasticity special wire according to claim 1, characterized in that: The preparation system further includes a guide wheel (6); the guide wheel (6) is used to guide the wire (8) heated by the induction heating device (5) to the reel (7); in step 4), the wire is heated by the induction heating device (5) and then guided to the reel (7) through the guide wheel (6).

5. The method for preparing a small-sized, high-strength, low-plasticity special wire according to any one of claims 1 to 4, characterized in that: A pressure sensor is provided in the smelting furnace (1); the argon pressure regulating device (9) is provided with a flow control valve and a flow controller; the flow controller regulates the flow control valve through the pressure feedback from the pressure sensor.

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