Process and apparatus for producing high-purity metal materials

Abstract

The application discloses a high-purity metal material preparation process and equipment, relates to the technical field of metal material refining, and solves the problems of low refining efficiency, coarse grains and long production process of traditional electroslag refining. The application adopts a three-stage purification and double-field refining architecture, fuses metal atomization deposition, pulse current crushing and liquid electroslag refining, and after primary smelting and secondary refining, atomizes the metal liquid into fine droplets through inert gas, and then performs secondary crushing through a high-strength pulse magnetic field, greatly increases the metal-molten slag contact interface, completes deep refining in combination with liquid electroslag, simultaneously crushes dendrites and refines grains through the pulse magnetic field, and realizes directional solidification of the metal ingot. The application realizes continuous short-process production, significantly improves the metal purity and grain refinement degree, reduces energy consumption, improves production efficiency, and can meet the needs of high-end fields such as aerospace and nuclear power for the prepared material, is suitable for refining of various metal materials, and has wide industrialization popularization prospects.

Description

Technical Field

[0001] This invention relates to the field of metal material refining technology, specifically to a process and equipment for preparing high-purity metal materials, used to produce high-purity, ultra-fine grain high-end metal materials. Background Technology

[0002] In the field of metallurgy, electroslag remelting (ESR), as a mature secondary refining technology, has been widely and indispensablely applied in key areas such as aerospace, nuclear power equipment, and high-precision manufacturing since its introduction in the 1940s, thanks to its unique advantages of integrating refining and purification with directional solidification. Electroslag casting, as a highly efficient refining method, can obtain solidified structures with high purity, uniform and dense microstructure, and few low-magnification defects through secondary refining. As a first-generation electroslag metallurgical technology, ESR is widely used in the production of high-quality steel ingots, high-end special steels, and high-temperature alloys due to its excellent desulfurization and inclusion removal capabilities and dense solidified structure. It has become a key refining technology for high-quality metallic materials and holds an irreplaceable position in the production of special steels. Traditional electroslag remelting (ESR) processes use pre-smelted steel ingots as consumable electrode material, inserting them into a liquid slag pool within a water-cooled crystallizer. The Joule heat generated by the current passing through the conductive slag gradually melts the tip of the consumable electrode. The resulting molten metal droplets pass through the high-temperature slag pool under gravity and undergo a complete slag-metal reaction to remove harmful impurities. Subsequently, the purified molten metal undergoes directional solidification from bottom to top within the water-cooled crystallizer, ultimately forming a high-quality steel ingot. This process effectively removes non-metallic inclusions, sulfur, lead, and other harmful elements from the metal, significantly reduces metallurgical defects such as central porosity and component segregation in the steel ingot, and greatly improves the density, surface quality, and overall mechanical properties of the steel ingot.

[0003] However, as high-end equipment demands increasingly higher standards for the purity, uniformity of microstructure, and performance of core metal materials, existing electroslag remelting technology still faces numerous limitations, severely hindering its further promotion and application in the preparation of high-end materials. These limitations are mainly reflected in three aspects: First, the refining efficiency of molten droplets is low, the refining interface is limited, and there is a purity bottleneck: Traditional electroslag remelting process relies on large-size electrodes for melting, and the size of the molten metal droplets is relatively large (usually 5-15mm). The slag-metal contact area is only about 300m² / t, and the size and distribution of the molten metal droplets cannot be effectively controlled. The refining reaction interface mainly occurs at the contact interface between the large single molten metal droplet and the slag pool. The metal-slag contact reaction interface area is relatively limited, and the residence time of the molten droplets in the slag pool is short, which is not conducive to the full metallurgical reaction. Usually, the desulfurization rate is <60%, the inclusion removal rate is difficult to exceed 80%, and the size of the residual inclusions can reach more than 10μm. It is difficult to achieve deep purification of the molten metal droplets, which limits the reaction efficiency between the molten steel and the refining slag. The ability to remove micron-sized and submicron-sized fine inclusions and certain gaseous elements has reached a bottleneck, and the refining effect is constrained. Furthermore, the limitations of self-consumable electrode oxidation and slag gas absorption limit the further improvement of refining efficiency, and cannot meet the stringent requirements for material purity in extreme service environments. Secondly, the grain refinement effect is insufficient, and the ability to control the solidification structure is weak. Existing processes mainly rely on directional solidification and rapid cooling for grain refinement, influencing the solidification structure by adjusting the melting rate and the cooling water volume in the crystallizer. Due to inherent process characteristics, their control capabilities and methods for grain refinement and suppression of solidification segregation are relatively limited. Long local solidification times and small temperature gradients in steel ingots easily lead to dendritic compositional segregation and coarse columnar crystal structures. This is especially true for large-section steel ingots, which are more prone to forming continuous coarse columnar crystals, inducing significant compositional segregation (such as typical V-shaped segregation bands), accompanied by internal defects such as central porosity and central segregation, significantly deteriorating the material's anisotropic properties and hot working properties.

[0004] Currently, the methods for controlling solidification structure are relatively passive, with equiaxed crystals accounting for less than 40%, and the methods for grain refinement are limited, making it difficult to achieve controllable preparation of ultrafine or even nanocrystalline structures, which directly restricts the further improvement of key mechanical properties of high-end metallic materials.

[0005] Third, the process is lengthy, lacks flexibility and continuity, and suffers from high energy consumption and significant environmental pressure. Traditional electroslag remelting requires the pre-preparation of consumable electrodes that match the cross-section of the crystallizer, followed by segmental melting and remelting using these electrodes. This results in a long production cycle, frequent shutdowns for electrode replacement, and lengthy preparation time and high costs when changing product specifications. Furthermore, it cannot achieve continuous connection with the primary refining furnace, hindering continuous production. Refining requires remelting the entire solid consumable electrode, limiting the remelting rate (typically ≤500 kg / h) and necessitating prolonged high-temperature refining, leading to low production efficiency. Moreover, the electroslag remelting process is essentially "warming one end of a cold iron rod with a pool of hot water," resulting in relatively low efficiency and high energy consumption, exceeding 1500 kWh per ton of steel. It also makes rapid switching between different steel grades difficult. Maintaining the slag pool at high temperatures consumes as much as 1200–1500 kWh / t, and the hydrogen fluoride produced by the high-temperature decomposition of fluorite-based slag corrodes equipment and pollutes the environment, contradicting the principles of green metallurgy.

[0006] To overcome the aforementioned problems, second-generation electroslag metallurgical technology—liquid electroslag casting (ESCC)—has been developed both domestically and internationally in recent years. This technology directly pours externally refined molten steel into the slag pool of the crystallizer for refining, separating smelting and refining, simplifying the process, eliminating the electrode preparation step, and improving flexibility. However, in the liquid electroslag process, the molten steel enters the slag pool in a continuous liquid flow, usually forming large liquid flows or droplets, which still fails to sufficiently increase the reaction interface between the metal and the slag. The contact area between the metal and the slag remains limited, and the refining effect is somewhat inferior to that of electroslag remelting, with only a minor improvement. Moreover, there are insufficient means to actively refine the solidification structure. Although some studies have attempted to introduce electromagnetic fields for stirring, these are mostly low-frequency or power-frequency continuous magnetic fields, with relatively mild stirring forces, mainly serving to homogenize composition and temperature, and having a weak effect on breaking up the molten metal, failing to achieve a revolutionary increase in the refining area.

[0007] In summary, both first-generation and second-generation electroslag refining technologies rely primarily on the slag-metal reaction as molten metal droplets (ESR) or metal streams (ESC) pass through the slag pool. This reaction has a limited interfacial area, resulting in a physical upper limit to refining efficiency. Meanwhile, while the solidification process of ingots can be improved through electromagnetic stirring, the control methods are relatively passive, lacking active and effective control over the solidification process. The effect on breaking up dendrites in the mushy region is limited, making it difficult to achieve ultra-fine grains. The solidification structure of ingots still depends on traditional cooling conditions, resulting in limited grain refinement, which has consistently hindered technological progress in the industry. There are no effective means to further break up dendrites, increase nucleation sites, and eliminate defects, failing to fundamentally solve the problem of controlling the solidification structure and grain refinement. This makes it difficult to obtain an extremely fine and dense solidification structure, affecting the mechanical properties of the material and the final quality of the steel ingot.

[0008] Based on the aforementioned technical challenges, traditional electroslag remelting (ESR) processes are no longer sufficient to meet the higher requirements of modern industry for steel purity, microstructure uniformity, and mechanical properties. Optimizing steel-slag reaction conditions, further improving the refining and purification effect of ESR casting, and refining grains to reduce ingot segregation are two core technical problems that urgently need to be solved in current ESR casting processes. To overcome these development bottlenecks, meet the urgent needs of modern industry for high-end steel, improve production efficiency, and reduce costs, the development of a novel ESR refining process and equipment is imperative. Therefore, there is an urgent need in this field to develop a novel continuous refining process and equipment that can overcome existing technical bottlenecks, integrate efficient refining, significantly increase the metal-slag reaction interface, strengthen the refining process, actively control the morphology and solidification process of molten metal droplets, and achieve high production efficiency and low energy consumption in a short-process manner to prepare high-quality, high-purity metal materials. This new, highly efficient refining technology, which enables ultra-large-scale contact reaction between metal and slag and simultaneously effectively refines the solidification microstructure, has become a pressing technical problem to be solved in this field. Summary of the Invention

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: To address the technical problems of complex production processes, limited refining effects, coarse grain size, and low production efficiency in existing electroslag refining technologies, the main objective of this invention is to overcome the shortcomings of existing electroslag refining technologies and provide a more efficient, energy-saving, and high-quality solution for the production of high-end metallic materials, offering a high-purity metallic material preparation process and equipment. The core idea of ​​this invention is: Employing a "three-stage purification + dual-field refinement" technical architecture, the process is a fully continuous, near-net-shape casting process. In the electroslag refining and casting process, molten metal atomization, high-intensity pulsed current droplet breaking, and continuous electroslag refining are organically combined. Inert high-pressure gas atomizes the molten metal into micron-sized ultrafine droplets, which are then deposited into the liquid slag pool. Simultaneously, a high-intensity pulsed electromagnetic field impacts the fine particles at the atomization end of the molten metal and the droplets in the liquid slag pool, causing them to burst and break down into even finer particles. Through its unique electromagnetic force effect, a secondary refining of the droplets is achieved, significantly increasing the metal-slag contact interface area and realizing the ultimate contact between the molten metal droplets and slag, thus improving refining. This technology improves efficiency by refining the solidification structure of molten metal pools and reducing ingot segregation through high-intensity pulsed power supply. The synergistic effect of multiple physical external fields in the composite refining mechanism effectively solves the problems in the background technology. It achieves multi-stage deep purification and refining of metal materials, along with simultaneous grain refinement, enabling proactive and precise control of the solidification structure through an integrated process and equipment. This allows for low-energy consumption, continuous, and short-process preparation of high-purity, ultra-fine-grained high-end metal materials, meeting the higher requirements of modern industry for the purity, uniformity, and mechanical properties of metal materials, and realizing industrial application value.

[0010] To achieve the aforementioned objectives of the invention, the concept of this invention is as follows: This invention provides a high-purity metal material preparation process and equipment. Its core working principle lies in the innovative and organic integration of three advanced metallurgical processes—metal atomization deposition, pulsed current crushing and pulsed electromagnetic grain refinement, and liquid electroslag refining—into a continuous system. Through synergistic effects, it achieves deep purification and ultra-fine microstructure of the metal material. This breakthrough overcomes the technical limitations and bottlenecks of traditional electroslag remelting, realizing a leap forward in the metal material refining process. This technology not only improves the purity and uniformity of the metal material but also achieves an ultra-fine grain structure through a dual refinement mechanism, significantly enhancing the material's overall performance. The core technical working principles of each part are as follows: The three advanced metallurgical processes of metal atomization deposition, pulsed current crushing, and liquid electroslag refining are innovatively integrated into a continuous system to achieve deep purification and ultrafine microstructure of metal materials through synergistic effects.

[0011] (1) Atomization deposition to increase the specific surface area of ​​molten metal droplets and slag: The process of atomizing molten steel using an inert gas atomizer is based on the principle of impact and breakage of molten steel by high-speed airflow. When molten steel flows out of the guide pipe, it encounters high-speed ejected inert gas (such as argon or nitrogen). Under the impact of the powerful high-pressure airflow, the continuous molten metal flow is sheared, torn, and broken into countless discrete micron-sized micro-droplets, forming a "metal mist". These droplets exchange heat with the cooling gas during flight. Due to the surface tension, they gradually shrink into spheres and rapidly solidify during the heat exchange with the surrounding environment, forming fine metal mist particles. This atomization method has the advantages of high efficiency and precise control of metal particle size. By adjusting parameters such as the pressure and flow rate of the inert gas, as well as the flow rate and temperature of the molten steel, the size of the atomized particles can be precisely controlled to obtain metal particles of different sizes and distributions.

[0012] The atomized metal microparticles are directly deposited into the liquid slag pool for liquid electroslag refining. The specific surface area of ​​these droplets can be tens to hundreds of times greater than that of traditional large molten droplets, significantly increasing the specific surface area and heat transfer efficiency between the metal droplets and the molten slag. This ensures that each tiny droplet is fully exposed to the refining environment of the liquid slag pool. This is analogous to crushing a boulder into fine sand, resulting in an order-of-magnitude increase in the surface area for subsequent chemical reactions, providing a foundation for sufficient contact with the molten slag and creating extremely favorable conditions for the subsequent refining process. Furthermore, the heat transfer object after atomization is no longer the huge solid electrode of traditional electroslag casting, but countless tiny liquid droplets with enormous specific surface areas. This allows for more thorough contact with the slag pool, higher heat transfer efficiency, and an exponential increase in heat transfer area and a sharp decrease in heat transfer resistance. This provides an extremely ample heat exchange area between the slag pool and the metal, accelerating heat transfer and the melting process. Heating tiny liquid droplets presents virtually no thermal resistance, allowing heat to be instantly transferred from the high-temperature slag pool to the entire droplet, rapidly reaching or even exceeding the pool's temperature. The heat energy from the slag pool directly affects numerous small particles. Due to their small size, the droplets are well-dispersed within the slag pool, ensuring more thorough contact and reducing "thermal bottlenecks." This minimizes heat loss, increases heat transfer efficiency, shortens heating time, and results in faster and more uniform melting. The large surface area allows for extremely rapid heat exchange between the droplet and the high-temperature slag pool, quickly absorbing heat to maintain the molten state without the concern of uneven heat transfer in solid-state electrodes. This is akin to "crushing a large block of ice into slush and then adding it to hot soup"—the slush melts almost instantly, reaching the soup's temperature. Its melting efficiency far surpasses that of traditional solid-state consumable electrode remelting, exhibiting extremely high heat transfer efficiency—almost instantaneous heat exchange—shortening the melting cycle by 30-50%, significantly improving energy utilization efficiency, and thus reducing energy consumption.

[0013] (2) The pulsed breaking of molten droplets brings about a greater multiplication of interface effects: The principle of the high-intensity pulsed power transient magnetic field coil to pulse current impact the atomized fine metal particles and the metal droplets deposited in the slag pool is based on the action of electromagnetic induction and Lorentz force. In this invention, a high-intensity pulsed power transient magnetic field coil is installed outside the slag pool of the water-cooled crystallizer. The high-intensity pulsed magnetic field generated by the coil directly acts on the atomized metal particles and metal droplets. When the pulsed current passes through the coil, a transient high-intensity magnetic field is generated. When the transient magnetic field acts on the metal particles and droplets, an induced current is generated in them. The magnetic field induces eddy currents in the conductive metal droplets. The interaction between the eddy currents and the magnetic field generates a strong electromagnetic force (Lorentz force). According to Ampere's law, the induced current in the magnetic field will be subjected to the Lorentz force. This force will cause the metal particles and droplets to oscillate strongly, deform violently, or even burst and break, causing the metal droplets to disperse explosively and decompose into a group of finer metal droplets. Utilizing the electromagnetic force effect generated by a high-intensity pulsed magnetic field, the molten metal droplets penetrating the slag layer are subjected to secondary crushing. This further decomposes the already refined atomized particles into even smaller droplet clusters, resulting in further droplet refinement. This process increases the interfacial area between the molten metal droplets and the slag, increasing refining efficiency by several to tens of times, promoting the refining reaction, and significantly improving refining efficiency. The pulse crushing technology also introduces a micro-stirring effect, enhancing the mass transfer process between slag and metal, and promoting the removal of inclusions and homogenization of composition. Furthermore, the transient magnetic field generates a pinch force effect in the molten metal pool, pushing the molten metal away from the crystallizer wall and creating soft contact conditions, which greatly improves the surface quality of the electroslag ingot. The pulse frequency and intensity can be adjusted according to process requirements.

[0014] (3) Deep Refining of Liquid Electroslag – Purification Reaction under Ultra-Large Interface: The extremely fine metal droplets, after being broken down twice, pass through the high-temperature liquid slag pool with a huge specific surface area, allowing each drop of metal to be fully and thoroughly purified and optimized, achieving deep purification and refining. The liquid electroslag refining slag pool is composed of electroslag with specific components, possessing good conductivity and refining capabilities. Current is input to the slag pool through electrodes, utilizing the resistance heat of the slag pool to maintain its molten state and providing the necessary heat source for the refining process. Unlike traditional electroslag remelting, the slag pool in this invention not only serves as a heat source and refining medium but also as a receiver for atomized particles. Therefore, the depth of the slag pool is specially designed to ensure that the atomized particles have sufficient residence time to complete the refining process. At the same time, the design of the slag composition also considers the chemical compatibility with the atomized particles to avoid harmful reactions. The liquid slag pool possesses excellent electrical conductivity, high resistance, and refining capacity. Current is input into the slag pool through electrodes. As the current flows through the pool, the resistance heat of the slag pool maintains its molten state, providing the necessary heat source for the refining process and heating and melting the deposited metal particles. During this process, a highly efficient metallurgical reaction occurs through full contact between the molten droplets and the slag. Harmful impurities in the steel, such as sulfur, phosphorus, and oxygen, react chemically with the components in the slag and are largely absorbed by the slag. Fine non-metallic inclusions are also effectively captured and dissolved in the slag pool, significantly improving the purity of the metal. Due to the large reaction interface, the efficiency and thoroughness of this process far exceed the effect of larger droplets in traditional electroslag remelting processes, thus achieving high-purity refining of the metal. Moreover, the entire process is carried out under the protection of an inert gas layer during atomized deposition, effectively preventing oxidation of the metal during refining and further improving the purity and quality of the metal.

[0015] (4) Sequential Solidification and Microstructure Control – Final Forming under Pulse Assistance: Another important function of pulsed current is its direct intervention in the solidification process. The refined molten metal solidifies sequentially from bottom to top at the bottom of the crystallizer. During the solidification process, grain growth is affected by various factors. In this process, the strong disturbance effect continuously generated by the pulsed magnetic field not only breaks the molten metal droplets but also stirs the molten metal pool. The electro-migration and pulse oscillation thermal effect and deformation generated by the pulsed current impact can break the growth of dendrites at the crystallization front. These dendrite fragments increase the nucleation nuclei in the molten metal, becoming new crystallization nuclei, allowing the grains to grow from more nuclei during solidification, thereby refining the solidified microstructure grains, reducing segregation, and obtaining a finer equiaxed crystal structure. Moreover, the pulsed current also affects the diffusion rate and trajectory of metal atoms, inhibiting grain growth and ultimately forming a high-quality steel ingot with finer grains and more uniform composition. Furthermore, this solidification method avoids the generation of defects such as shrinkage cavities, central porosity, and macroscopic segregation, ensuring the density and uniformity of the steel ingot. By controlling the deposition rate and cooling conditions, the density of the deposited body can reach more than 95% of the theoretical density, or even 99%. By precisely controlling the parameters of the high-intensity pulse power supply, such as pulse frequency, pulse width, and current intensity, the degree of grain refinement can be effectively controlled to meet the requirements of different metallic materials for crystal structure.

[0016] (5) Improved process continuity and production efficiency: Unlike the batch operation of traditional electroslag remelting, this technology achieves continuous production. The entire process from primary molten metal to final metal ingot is carried out continuously, significantly improving production efficiency and reducing energy consumption and production costs. This continuity makes the technology of this invention particularly suitable for large-scale, high-efficiency production of high-quality metal materials. Depending on the equipment scale and production requirements, the single continuous production time of this technology can reach tens of hours, and the single product can reach tens of tons or even more. This production efficiency is unmatched by traditional electroslag remelting, laying the foundation for large-scale industrial application.

[0017] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A process for preparing high-purity metallic materials includes the following steps: S1: Pre-treat the metal raw materials to remove surface oxide scale and impurities, and prepare the raw materials according to the material composition requirements to ensure that the purity of the raw materials meets the process requirements. Use a medium frequency furnace or electric arc furnace to melt the metal raw materials for primary metal smelting. Precisely control the metal material composition and melting temperature within the process requirements. After adjusting according to the metal material composition requirements to obtain the primary metal liquid, the primary metal liquid is obtained. S2: The molten primary metal liquid is transferred to the LF argon blowing refining furnace for argon blowing refining treatment to homogenize the composition and temperature and promote the floating of inclusions, thereby purifying the metal liquid; then the refined metal liquid is transferred to the VD vacuum degassing furnace for vacuum degassing treatment to deeply remove hydrogen, oxygen and nitrogen gases from the metal liquid. S3: Pour the refined molten metal from step S2 into a molten metal insulation tundish, sprinkle insulation agent into the tundish to cover the molten metal, prevent oxidation and heat leakage, start the tundish induction heating coil power controller to heat the molten metal in the tundish, and keep the molten metal in the tundish at a constant temperature for later use. S4: Place the bottom water tank of the electroslag refining process onto the mobile trolley at the electroslag refining station. Install the crystallizer of the electroslag refining process onto the bottom water tank. Install the inert gas sealing cover onto the crystallizer. Install the annular atomizing molten metal tundish onto the inert gas sealing cover on the crystallizer, ensuring a tight fit. Install the guide pipe at the bottom molten metal outlet of the annular atomizing molten metal tundish and seal it to prevent molten metal leakage. The outlet of the guide pipe should face the atomization chamber of the inert gas atomizer. Install the induction heating coil of the guide pipe outside the guide pipe at the bottom of the annular atomizing molten metal tundish. Install the inert gas atomizer below the guide pipe at the bottom of the annular atomizing molten metal tundish, and align the centerline of the inert gas atomizer with the centerline of the guide pipe at the bottom of the annular atomizing molten metal tundish. The center lines are kept concentric, and the center of the inner hole of the guide tube is kept on the same center line as the crystallizer. The inert gas inlet pipe is installed on the inert gas atomizer and connected to the inert gas supply cylinder. A high-intensity pulsed magnetic field coil, which is not in contact with the crystallizer, is installed around the outer side of the water-cooled crystallizer corresponding to the slag pool and molten metal pool. The high-intensity pulsed magnetic field coil is radially adjusted and fixedly connected to the high-intensity pulsed power supply coil in the pulsed magnetic field coil lifting device set around the crystallizer. It can move along the crystallizer axis via the high-intensity pulsed power supply lifting transmission mechanism and radially along the crystallizer via the high-intensity pulsed power supply coil radial adjustment and connector. A non-consumable electrode or a consumable electrode is installed on the electrode holder, which is raised and lowered via the electrode lifting transmission mechanism. S5: A pulsed magnetic field power supply and its control cabinet are installed around the crystallizer. The high-intensity pulsed power supply control system is connected to the high-intensity pulsed magnetic field coil through a water-cooled cable. The transient pulsed magnetic field generated by the high-intensity pulsed power supply applies a high-intensity pulsed current to the crystallizer through the high-intensity pulsed magnetic field coil, thereby generating a high-intensity pulsed magnetic field in the crystallizer. This high-intensity pulsed magnetic field can effectively cover and act on the ends of falling fine metal atomized particles, the liquid slag pool, and the ends of metal droplets heated and melted by the slag pool and the molten metal pool, and can generate a high-intensity, transient high-intensity pulsed magnetic field in the above areas. S6: Based on the metal material and performance requirements of the refined electroslag metal ingot, determine the composition and dosage of the electroslag agent, inspect and clean the crystallizer and bottom water tank to ensure that the inner wall of the crystallizer is smooth and free of impurities, and the surface of the bottom water tank is flat and smooth and free of impurities. Adjust the cooling water flow rate, cooling water temperature and cooling system parameters of the crystallizer according to the size of the refined electroslag metal ingot. S7: Add the prepared electrode arc-initiating agent and electroslag agent to the crystallizer. Insert a single non-consumable electrode or a single consumable electrode into the electrode arc-initiating agent in the crystallizer through the central hole of the annular atomized molten metal tundish on the crystallizer. The electroslag furnace is connected to the single non-consumable electrode or single consumable electrode using a DC or AC power supply. The current between the single non-consumable electrode or single consumable electrode and the electrode arc-initiating agent in the crystallizer heats the electroslag material, causing the arc-initiating agent and electroslag material to melt and form a liquid slag pool. Alternatively, the solid electroslag material can be melted directly in a dedicated slag-melting furnace. Add the prepared electrode arc-initiating agent and electroslag agent to the slag-melting furnace. Insert the non-consumable electrode into the electrode arc-initiating agent in the slag-melting furnace. Connect the DC or AC power supply to the slag-melting furnace. The current between the electrode arc-initiating agent and the non-consumable electrode in the slag-melting furnace heats the solid electroslag material, causing the arc-initiating agent and electroslag material to melt and form a liquid slag pool. Wait until the amount of liquid slag pool melts to the required rated value. After melting, the molten slag is poured into the crystallizer. A single non-consumable electrode or a single consumable electrode is inserted into the crystallizer through the central hole of the annular atomized molten metal tundish on the crystallizer to heat the molten slag pool, establishing a stable high-temperature molten conductive slag pool of the required depth. The high-temperature fluidity of the slag pool is maintained to continuously compensate for the heat loss caused by the pouring of molten metal, ensuring that the purification reaction proceeds fully. During the electroslag melting and electroslag refining process, the temperature of the high-temperature molten slag pool is monitored in real time. The slag pool temperature is adjusted according to the metal material to keep it within the preset temperature range, meeting the temperature requirements for electroslag refining of the metal material. This ensures that inclusions in the molten metal are fully floated and removed, and guarantees the directional solidification and equiaxed grain structure of the casting. The thickness of the slag pool is adjusted according to the metal material and the deposition rate of the molten metal to maintain the slag pool thickness within the preset thickness range, ensuring that the electroslag molten pool layer reaches a stable working state and meets the requirements for the purity of the refined metal material. S8: Transfer the high-temperature molten metal containing the LF furnace argon refining and VD vacuum degassing treatment to the top of the non-consumable electrode crystallizer, control the superheat of the molten metal at 50-150℃, and prepare for molten metal pouring atomization. S9: Molten metal reaching the preset temperature in the insulation intermediate tank is evenly flowed into the annular atomizing molten metal intermediate tank through the guide channel. It then flows evenly into the inert gas atomizer at a constant and controllable rate through the guide pipe at the bottom of the annular atomizing molten metal intermediate tank. The high-pressure inert gas valve is opened, allowing the high-speed, high-pressure inert gas flow in the atomizer to diffuse and spray onto the molten metal flowing out from the end of the guide pipe. Under the impact of the high-speed, high-pressure inert gas flow in the atomizer, the molten metal is broken into a fine, uniformly dispersed jet of molten metal particles (10–300 μm). This jet is then sprayed vertically downwards and diffused to deposit on the water cooler below. Inside the crystallizer, the atomized metal particles, heated by a single non-consumable electrode or a single consumable electrode heating system, come into contact with high-temperature molten slag in a high-temperature liquid slag pool. The large specific surface area of ​​the atomized particles causes them to undergo a violent physicochemical reaction with the molten slag as they pass through the slag pool, rapidly heating and melting them. They also undergo intense desulfurization, deoxidation, and inclusion absorption metallurgical reactions with the slag phase, achieving deposition and initiating refining. The molten metal atomized particles, initially refined by the liquid electroslag, achieve deep desulfurization, inclusion removal, and composition adjustment, completing the first stage of deep refining. During the atomization process, the particle size and distribution of the atomized metal droplets can be precisely controlled by controlling the gas pressure, flow rate, and temperature. S10: During the descent of the molten metal droplets into the slag pool, a high-intensity pulsed power supply is simultaneously activated, generating a high-intensity pulsed current around the water-cooled crystallizer. This drives a pulsed magnetic field coil to generate a millisecond-level high-intensity pulsed current magnetic field that penetrates the crystallizer wall, inducing eddy currents inside the molten metal droplets. Under the combined action of the powerful alternating Lorentz force and magnetic compression effect pressure wave generated by the interaction of this current and the applied magnetic field, a strong pulsed current electromagnetic force impact is generated on the flow of fine metal particles entering the slag pool, the atomized fine metal droplets depositing through the slag layer, the interior of the ends of molten metal droplets that have not completely merged into the molten pool, and the surface of the molten metal pool. This creates a non-uniform stress field, resulting in periodic electro-explosive impact fragmentation. This causes localized yielding and tearing of the surfaces of the incompletely molten metal particles and the molten metal droplets, triggering multi-point explosions within an extremely short time of <1ms, causing individual droplets to explode. The process involves crushing, dispersing, and activating the metal droplets, which then split into a cluster of fine droplets. These droplets are further crushed and decomposed into even finer clusters of 10–50 μm metal droplets. As the metal droplets descend within the slag pool, they undergo further refining by the liquid slag. The reduced droplet diameter increases the specific surface area of ​​the droplets, significantly increasing the contact area and refining interface between the metal droplets and the liquid slag. This allows for thorough penetration of the fine metal droplets into the high-temperature slag, shortening the distance that inclusions and impurities within the droplets migrate to the slag-metal interface, and extending the settling time of the droplets within the slag pool. This facilitates the removal of non-metallic inclusions and impurities from the droplets, resulting in more complete refining, improved refining efficiency, and deep purification refining. During the dripping of the metal droplets, a single non-consumable electrode or a single consumable electrode continuously supplies power within the crystallizer, maintaining the temperature of the liquid slag pool and preventing the metal droplet stream from solidifying during injection. Throughout the entire liquid electroslag refining and casting process, as the molten slag pool and the molten metal pool inside the crystallizer continuously rise, the electrode lifting transmission mechanism drives the electrode lifting screw to rotate, continuously adjusting the position of the single non-consumable electrode or single consumable electrode mounted on the electrode holder inside the crystallizer. This maintains the electrical parameters of the slag pool and the molten metal pool within a predetermined range, thus maintaining the temperature of the liquid slag pool. Simultaneously, the high-intensity pulse power coil lifting transmission mechanism drives the high-intensity pulse power coil lifting screw to rotate, continuously adjusting the position of the pulse magnetic field coil lifter outside the crystallizer. This causes the pulse magnetic field coil lifter to pull the pulse magnetic field coil upwards at a uniform and constant speed. By adjusting the position and height of the high-intensity pulse magnetic field coil, it is ensured that the central axis of the pulse magnetic field it generates coincides with the main stream of the metal atomized particle flow, the active reaction zone of the liquid slag pool, the melting end of the metal droplets, the molten slag pool, the upper central region of the molten metal pool, and the compositional region of the molten metal. The pulse frequency and intensity can be adjusted according to process requirements. After atomization stops, the high-intensity pulse power supply is turned off after a delay of 10–20 seconds. S11: The extremely fine metal droplet clusters formed through two crushing processes penetrate the high-resistivity liquid slag layer with their huge specific surface area. During this penetration, the fine metal droplets randomly disperse into the molten slag pool and are diffusely distributed within it, achieving efficient and thorough contact at the slag-gold interface with a high specific surface area. This ensures that each droplet of metal receives the most complete purification and optimization. The residence time of the metal droplets in the slag pool is significantly extended, the slag-gold contact specific surface area and reaction kinetics are greatly improved, and the overall refining reaction efficiency is enhanced. The comprehensive refining reaction rate is higher than that of the traditional ESR electroslag remelting process. The concentration is increased by tens to hundreds of times, ensuring that every drop of molten metal is fully and thoroughly purified and optimized in structure. During the process of full contact and rinsing between the molten droplet and the slag, a highly efficient metallurgical reaction occurs: harmful elements such as sulfur and oxygen in the metal are absorbed in large quantities by the slag, and non-metallic inclusions are effectively captured and dissolved by the slag pool. The active components in the electroslag react violently with S, P, oxide inclusions and other harmful impurities in the molten metal. Through the dissolution-diffusion-reaction kinetics of the slag-gold interface, the inclusions and impurities in the fine molten droplets migrate rapidly to the molten slag phase and form a high-melting-point, low-density compound phase. These compounds are captured by the slag under the action of interfacial tension, realizing the directional migration of sulfur, phosphorus, oxide inclusions and complex impurities and floating on the liquid slag layer. They are continuously adsorbed, dissolved and deeply removed by the slag, improving the desulfurization efficiency by more than 40%, thereby achieving deep desulfurization, dephosphorization and purification of the molten metal, forming a high-purity metal droplet phase, while the metal is further alloyed and homogenized. Thanks to the ultra-large reaction interface, the purification efficiency and purification depth of this process are far superior to those of the traditional electroslag remelting process. The entire refining process is carried out under the protection of inert gas for metal atomization, which can effectively inhibit the secondary oxidation of the metal. By dynamically matching the metal liquid injection and atomization rate, high-intensity pulse current intensity and frequency, electrode input power and crystallizer cooling intensity through the control system, the high temperature fluidity, molten pool morphology and solidification front interface of the slag pool and molten metal pool can be stably maintained. After secondary explosion dispersion and activation, the fine molten droplets fully contact the molten slag in the liquid slag pool, completing the deoxidation, desulfurization, and non-metallic inclusion removal refining reaction, and achieving deep purification under the synergistic effect of pulsed current, ultimately controlling the impurity content to below 5 ppm; S12: The alternating magnetic field generated during the liquid electroslag refining process and the pulsed transient magnetic field generated by the high-intensity pulsed power supply work synergistically on the liquid slag pool and the molten metal pool. Through multiple superposition effects, efficient grain refinement is achieved. The pulsed transient magnetic field can induce micro-region flow, balance the temperature distribution of the slag pool and the molten metal pool, reduce the temperature gradient at the solidification interface front, and create favorable conditions for endogenous growth. At the same time, the strong alternating Lorentz force and pressure wave generated can break the dendrites growing at the interface front, promote the shedding of crystal nuclei from the surface of the crystallizer wall to form a crystal nucleus proliferation effect, and the pressure wave can promote spontaneous nucleation in the molten metal pool, significantly improving the nucleation rate. The high-intensity pulsed magnetic field acts synchronously on the molten metal pool, and the electromagnetic stirring effect generated not only further homogenizes the composition and temperature of the molten pool, but also helps to break the dendrites at the solidification front, strengthens the dendrite breaking effect, and makes the broken dendrites form a large number of heterogeneous nucleation cores, strengthens the active refinement effect of the solidification structure, and helps the active refinement of the solidification structure. The pulsed transient magnetic field can further enhance the refining efficiency. The strong disturbance it continuously generates can both break up the molten metal droplets and stir the molten metal pool. Combined with the electro-migration, pulsed oscillatory thermal effect and deformation induced by the pulsed current impact, it can further interrupt the dendritic growth process at the crystallization front. These dendritic fragments serve as new nucleation sites, allowing the solidification process to start from multiple nuclei, effectively refining the solidification structure, reducing segregation, and forming fine equiaxed crystals. The pulsed current can regulate the diffusion rate and trajectory of metal atoms, inhibiting grain growth. The grain size can be reduced from 50-100 μm in traditional processes to 10-30 μm, ultimately obtaining a high-quality metal matrix with fine grains and uniform composition. After being treated by a transient magnetic field and pulse, followed by secondary refining of slag and gold and grain refinement, the liquid metal converges at the bottom of a water-cooled crystallizer to form a molten metal pool. Forced cooling within the crystallizer achieves sequential directional solidification from the bottom up, ultimately crystallizing into a dense metal ingot of a predetermined size. The synergistic effect of the magnetic field and pulse in refining and homogenizing effectively avoids common defects such as shrinkage cavities, central porosity, and macroscopic segregation, ensuring the density, uniformity, and high purity of the metal ingot. By optimizing the deposition rate and cooling conditions, the density of the deposit can reach over 95% of the theoretical density, and in some cases up to 99%. During the process, the degree of grain refinement is flexibly adjusted by precisely controlling the pulse frequency, pulse width, current intensity, and pulse transient magnetic field parameters of the high-intensity pulse power supply to meet the specific technical requirements of different metal materials for crystal structure. The continuous replenishment of refined molten metal in the tundish maintains the continuity of atomization deposition, pulse refining, and pulse alternating magnetic field. Throughout the refining and casting process, the slag pool temperature, molten metal pool level, and relevant parameters of the pulse power supply and transient magnetic field are monitored in real time. Based on the monitoring data, the inert gas pressure, pulse current peak value and frequency, cooling water flow rate and temperature are dynamically adjusted to ensure the coordinated matching of each process link, guarantee the stability of refining effect and metal ingot quality, and ultimately form a metal ingot with fine grains, uniform composition, and high purity. S13: Surface cleaning, quality inspection and necessary heat treatment are performed on the formed fine-grained metal ingot blank to finally obtain high-performance metal materials; A further improvement of the technical solution of the present invention is that: in step S4, the inner wall of the water-cooled crystallizer is made of copper or copper alloy, and the cooling water volume is 5 to 20 m³ / h; during the crystallization stage, the cooling water volume is controlled at 5 to 20 m³ / h, and the crystallization speed is controlled at 0.5 to 2.0 mm / min; A further improvement of the technical solution of the present invention is that: in step S4, the inner wall of the water-cooled crystallizer is coated with an anti-slag coating. The coating is made of Al2O3-ZrO2 composite ceramic material, the coating thickness is 0.1-0.5mm, and the high temperature resistance is not less than 2000℃. This can reduce the adhesion of molten metal to the inner wall of the crystallizer and improve the surface quality of the metal ingot. A further improvement of the technical solution of the present invention is that: in step S4, the material of the guide tube is ceramic matrix, metal ceramic matrix, refractory metal matrix, or graphite, and it is preheated to 800-1000°C before use; A further improvement of the technical solution of the present invention is that: in step S4, the inert gas atomizer is installed 10 to 200 mm below the outlet of the guide pipe, and the vertical distance between it and the liquid slag pool below can be adjusted within the range of 100 to 500 mm. A further improvement of the technical solution of the present invention is that: in step S4, the inert gas atomizer can be selected from an annular slit atomizer, an annular hole atomizer, a tightly coupled atomizer, a free-fall atomizer, a Laval nozzle-type tightly coupled atomizer, a rotary atomizer, a supersonic atomizer, or a composite structure atomizer; a single inert gas atomizer can be used, or 2 to 9 inert gas atomizers can be symmetrically distributed in the crystallizer; A further improvement of the technical solution of the present invention is that: in step S4, the particle size of the atomized metal droplets is 50-500 μm; A further improvement of the technical solution of the present invention is that: in step S4, the high-intensity pulsed magnetic field coil is made of water-cooled copper, the inner diameter of the coil is 30-150mm larger than the outer diameter of the crystallizer, and the coil height is 50-350mm; the positioning accuracy of the high-intensity pulsed power coil along the axial direction of the crystallizer is ±10mm; the cooling device for the high-intensity pulsed magnetic field coil is a water-cooled jacket matched with the coil, and circulating cooling water is introduced to control the coil temperature ≤60℃; A further improvement of the technical solution of the present invention is that: in step S4, the electrode lifting transmission mechanism of the electrode holder is driven by a servo motor or a variable frequency speed control motor, the lifting speed is set to 5-30 mm / min, and the speed control accuracy is ±1 mm / min; A further improvement to the technical solution of the present invention is that: in step S5, the high-intensity pulse power supply is a capacitor energy storage type or an IGBT inverter type pulse power supply. A further improvement of the technical solution of the present invention is that: in step S5, the peak voltage of the high-intensity pulse power supply is 0-50kV, the pulse frequency is 0.05-10kHz, the pulse width is 0.1-10ms, the peak current is 0-250kA, the magnetic field strength is 0.1-10T, the duty cycle is 0-100%, and the action time is 1-8s; the transient current waveform can be selected as sine wave, square wave, sawtooth wave, triangular wave, spike wave, or step wave, and the generated high-intensity pulse transient magnetic field applies electromagnetic impact force to the metal particles / droplets; A further improvement of the technical solution of the present invention is that: in step S5, the opening and closing of the pulse current is synchronized with the atomization process; when the atomization system is started, the pulse power supply is automatically turned on, and after atomization stops, it is turned off after a delay of 5 to 30 seconds. A further improvement of the technical solution of the present invention is that: in step S5, the high-intensity pulse power magnetic field coil positioning and adjustment device can adjust the position of the magnetic field coil on the water-cooled crystallizer online, and the axis of the high-intensity pulse power magnetic field coil should be basically coincident with the axis of the water-cooled crystallizer and the axis of the central stream of the atomized particle flow, so as to ensure that the magnetic field action area and the metal particle deposition area are precisely coincident, and realize precise magnetic field control of the metal particle deposition process. A further improvement of the technical solution of the present invention is that: in step S6, the electroslag refining process is started by solid slag arc initiation or directly by liquid slag; A further improvement of the technical solution of the present invention is that: in step S7, the depth of the slag pool is 50-300mm, and slag is replenished by a slag pool level monitoring and slag replenishment device to maintain the stability of the slag pool height; A further improvement of the technical solution of the present invention is that: in step S7, the temperature of the slag pool is controlled at 1500℃~1900℃; A further improvement of the technical solution of the present invention is that: in step S8, the temperature of the atomized metal liquid is controlled at 1480~1650℃; A further improvement of the technical solution of the present invention is that: in step S9, the atomized metal liquid can be metal liquid smelted by medium frequency furnace or metal liquid smelted by electric arc furnace, or metal liquid purified by filtering the metal liquid smelted by medium frequency furnace or metal liquid smelted by electric arc furnace through a three-dimensional continuous mesh foam ceramic filter. A further improvement of the technical solution of the present invention is that: in step S9, the pore size of the three-dimensional continuous mesh foam ceramic filter is 5-20 μm and the filtration speed is 50-200 kg / min, further removing macroscopic inclusions in the molten metal; A further improvement of the technical solution of the present invention is that: in step S9, the nozzle orifice diameter of the inert gas atomizer is 0.5 to 10 mm, and the spray angle is 0° to 60°; A further improvement of the technical solution of the present invention is that: in step S9, the atomizing gas is selected from high-purity argon, high-purity nitrogen, helium or Ar-He mixed gas, and the gas purity is ≥99.99%; the pressure of the atomizing gas is precisely controlled at 0.3 to 3.0 MPa by a pressure reducing valve, and the flow rate of the inert gas is 1000 to 3000 L / min, to ensure that the atomized particles are uniformly deposited on the surface of the liquid slag pool; A further improvement of the technical solution of the present invention is that: in step S9, the size distribution of the atomized particles is monitored in real time by a high-speed camera, and when the particle diameter deviates from the range of 10 to 300 μm, the inert gas pressure or the flow rate of the molten metal in the guide tube is adjusted for correction. A further improvement of the technical solution of the present invention is that: in step S11, the liquid slag pool uses fluorine-free or low-fluorine slag material to reduce the environmental pollution problem of traditional fluorite-based slag material, while ensuring the refining effect and fluidity of the slag pool; preferably, a dynamic reaction pool can be constructed using a CaF2-Al2O3-CaO ternary slag system, a CaO-Al2O3-SiO2 ternary slag system, a CaO-Al2O3-MgO ternary slag system, a CaO-Al2O3-CaF2-MgO quaternary slag system, or a CaF2-Al2O3-CaO-MgO-SiO2 pentagonal slag system, and the alkalinity is controlled within the range of 2.5 to 3.0 to achieve the optimal metallurgical effect; A further improvement of the technical solution of the present invention is that: in step S12, the high-purity metal material used in the electroslag remelting and refining includes ferrous metals and alloys, non-ferrous metals and alloys, high-temperature alloys, nickel-based high-temperature alloys, iron-based high-temperature alloys, cobalt-based high-temperature alloys, precision alloys, maraging steel, stainless steel, bearing steel, mold steel, and high-nitrogen steel; the solidified ingot obtained by electroslag remelting and refining is a round ingot, a square ingot, a plate ingot, a special-shaped ingot, or a near-net-shape billet; the solidification structure of the prepared solidified ingot is an equiaxed crystal structure, an axially growing refined dendritic structure, or an axially growing refined columnar crystal structure; A high-purity metal material preparation device is provided. The device is used to realize the above-mentioned high-purity metal material preparation process, including a primary melting unit, a pretreatment refining unit, an atomization deposition unit, a liquid electroslag refining unit, a pulse refining unit, a directional solidification unit, and a control system. The units work together to realize the continuous liquid electroslag refining of high-purity metal materials. 1. Primary smelting unit: including medium frequency furnace or electric arc furnace, used for primary smelting of metal raw materials. The inner wall of the furnace is lined with refractory material, and the furnace mouth is equipped with a guide channel to guide the smelted primary molten metal into the LF furnace. The primary smelting unit is equipped with temperature detection device and composition detection device, which can monitor and provide feedback on the temperature and composition of primary molten metal in real time to ensure that the quality of primary molten metal meets the requirements. 2. Pretreatment Refining Unit: Located downstream of the primary smelting equipment, it includes an LF argon-blown refining furnace and a VD vacuum degassing furnace. The LF argon-blown refining furnace is equipped with a molten metal bath, an argon-blowing system, a heating system, a temperature measurement and sampling system, and a control system. The capacity of the molten metal bath is matched to that of the primary smelting equipment. The argon-blowing system consists of an argon storage tank, a flow controller, and an adjustable argon-blowing gun, which can precisely control the argon flow rate, argon-blowing depth, and argon-blowing time to ensure the argon-blown refining effect. The molten metal outlet of the LF argon-blown refining furnace is connected to the molten metal inlet of the VD vacuum degassing furnace. The VD vacuum degassing furnace is located downstream of the LF furnace and is used for vacuum degassing refining of the molten metal after argon-blown refining. Its capacity is matched to that of the LF argon-blown refining furnace. The VD vacuum degassing furnace includes a furnace body, a vacuum system, a heating system, a temperature measurement system, and a control system. It can achieve stable control of vacuum degree, heating temperature, and degassing time to ensure degassing effect and process stability. The molten metal outlet of the VD vacuum degassing furnace is connected to the molten metal inlet of the molten metal insulation intermediate ladle 1. 3. Atomization Deposition Unit: The atomization deposition unit mainly includes an annular atomizing molten metal intermediate liner 8, a guide tube 35, and an inert gas atomizer 34; A stopper rod adjustment mechanism 2 is installed on one side of the molten metal insulation intermediate ladle 1. A stopper rod 3 is installed on top of the stopper rod adjustment mechanism 2. The stopper rod adjustment mechanism 2 drives the stopper rod 3 installed on the stopper rod adjustment mechanism 2 to move up and down, so as to precisely control the outflow speed of the molten metal 5. The molten metal insulation intermediate ladle 1 contains refined molten metal 5 that has undergone vacuum degassing treatment. The molten metal 5 is covered with a heat-insulating agent 4. An intermediate ladle induction heating coil 6 is installed on the outer side of the molten metal insulation intermediate ladle 1. The molten metal 5 in the molten metal insulation intermediate ladle 1 is heated by electromagnetic induction to maintain the temperature of the molten metal 5. Below the molten metal insulation intermediate ladle 1, an annular atomizing molten metal intermediate ladle 8 is installed to receive the molten metal. The molten metal 5 in the intermediate ladle 1 provides a stable flow of molten metal 36 to the inert gas atomizer 34. The annular atomizing molten metal intermediate ladle 8 is connected to the molten metal insulation intermediate ladle 1 via a guide channel 38. The molten metal 5 in the molten metal insulation intermediate ladle 1 flows into the annular atomizing molten metal intermediate ladle 8 through the guide channel 38. The annular atomizing molten metal intermediate ladle 8 contains molten metal 36, and a steel molten insulation agent 37 covers the molten metal 36 to reduce heat loss and prevent oxidation caused by contact with air. The annular atomizing molten metal intermediate ladle 8 is constructed with an insulation structure, and its inner wall is sequentially lined with aluminum silicate fiber insulation material, high-alumina insulation material, and high-alumina refractory material or magnesia-carbon brick refractory material. A non-stick coating is applied to effectively prevent secondary contamination of the molten metal and excessive cooling. An annular atomizing molten metal tundish 8 has an electromagnetic induction heating coil 9 on its outer side, which heats the molten metal 36 inside the annular atomizing molten metal tundish 8 using electromagnetic induction to maintain the temperature of the molten metal 36. The top of the annular atomizing molten metal tundish 8 has an inlet connected to the outlet of the molten metal insulation tundish 1, and an internal temperature monitoring device to monitor the temperature of the molten metal 36 in real time, ensuring that the temperature of the molten metal 36 remains stable within the preset temperature range. A high-temperature resistant guide pipe 35 is installed at the bottom of the annular atomizing molten metal tundish 8, and 2 to 9 symmetrically distributed inert gas atomizers 34 are installed at the bottom of the annular atomizing molten metal tundish 8. The inlet of the inert gas atomizer 34 and the outlet of the molten metal 36 in the guide tube 35 are arranged correspondingly. The guide tube 35 extends vertically downward through the bottom of the annular atomizing molten metal intermediate tundish 8 to the outlet nozzle of the molten metal 36 of the inert gas atomizer 34. The connection between the guide tube 35 and the annular atomizing molten metal intermediate tundish 8 is sealed with refractory material to prevent molten steel leakage. An electromagnetic induction heating coil 10 is installed outside the guide tube 35. By adjusting the power of the electromagnetic induction heating coil 10, the temperature of the molten metal 36 in the guide tube 35 is controlled to ensure that the molten metal 36 flows out smoothly from the guide tube 35. A level gauge and a thermometer are installed on the annular atomizing molten metal intermediate tundish 8 for real-time detection of the molten metal level and temperature.The inert gas atomizer 34 includes an atomizer body, an atomizing nozzle, an inert gas inlet pipe, a gas pressurization device, a gas filtration device, and a gas flow control system. The atomizer body adopts a ring structure and is made of high-temperature and corrosion-resistant stainless steel. The atomizing nozzle is made of high-temperature and wear-resistant material. The atomizing nozzle is located at the center of the atomizer body, with its lower part aligned with the liquid slag pool 31 inside the water-cooled crystallizer 23. An inert gas inlet pipe 12 is installed on one side of the inert gas atomizer 34, and the other end of the inert gas inlet pipe 12 is connected to a high-pressure inert gas cylinder and a pressure control valve. The inert gas cylinder is equipped with a pressure gauge and a flow valve to control the pressure of the inert gas. The inert gas atomizer 34 has an adjustable angle and a conical nozzle outlet, which enables the inert gas to form a high-speed airflow to atomize the molten metal into fine metal atomized particles 32. A gas pressurization device pressurizes the inert gas to 0.3–3.0 MPa. A gas filtration device filters impurities from the inert gas to prevent contamination of the molten metal. A gas flow control system precisely controls the flow rate of the inert gas, matching it with the outflow velocity of the molten metal 36 to ensure uniform size of the metal atomized particles 32. A sealing device is installed between the inert gas atomizer 34 and the annular atomizing molten metal intermediate tank 8 to prevent splashing of the molten metal 36 and gas leakage. 4. Liquid electroslag refining unit: The liquid electroslag refining unit mainly includes a water-cooled crystallizer 23, a non-consumable electrode or a consumable electrode 7, an electrode holder 13 and an electrode lifting device, an electroslag furnace control system 21 and an electroslag remelting transformer. The water-cooled crystallizer 23 is positioned below the inert gas atomizer 34 to receive the atomized metal particles 32 after the liquid metal is atomized, and to achieve liquid electroslag refining and continuous solidification of the metal. A sealing cover 11 is installed between the water-cooled crystallizer 23 and the inert gas atomizer 34 to prevent the leakage of inert gas, ensuring that the space between the water-cooled crystallizer 23 and the liquid slag pool 31 is filled with inert gas to prevent oxidation of the atomized metal particles 32. The water-cooled crystallizer 23 has a double-layered copper structure, with an inner copper crystallization chamber and an outer cooling water jacket made of carbon steel or stainless steel. The cooling layer is equipped with a circulating cooling water channel. The inner and outer layers are welded together to form a closed water jacket. A water outlet pipe 33 is located on the upper side of the water-cooled crystallizer 23, and a water inlet pipe 24 is located on the lower side of the water-cooled crystallizer 23, connecting to an external cooling water circulation system to achieve circulating cooling. The cooling water system includes a cooling water pool, a cooling water pump, a cooling tower, and cooling water pipes, used to provide circulating cooling water to the water-cooled crystallizer 23. The cooling water inlet temperature is controlled at 20–30℃, and the outlet temperature is ≤50℃. The inner cavity of the water-cooled crystallizer 23 is used to accommodate the liquid slag pool 31 and the gold... The water-cooled crystallizer 23 consists of a molten pool 30, a liquid slag pool 31 at the top, and a molten metal pool 33 at the bottom. A bottom water tank 28 and an ingot-pulling device are installed at the bottom of the water-cooled crystallizer 23 to support the high-purity electroslag metal ingots 29 that have solidified after refining. The ingot-pulling device slowly pulls out the solidified high-purity electroslag metal ingots to achieve continuous production. A water outlet pipe 27 is installed on the upper side of the bottom water tank 28, and a water inlet pipe 26 is installed on the lower side of the bottom water tank 28. Temperature detection devices and slag pool thickness detection devices are installed on the sidewalls of the water-cooled crystallizer 23 to monitor the liquid slag pool 31 and the molten metal pool in real time. The temperature of 30 and the thickness of the liquid slag pool 31 facilitate timely adjustment of process parameters; an electrode holder 13 and an electrode lifting device are provided on one side of the water-cooled crystallizer 23 for adjusting the up and down position of the non-consumable electrode or the consumable electrode 7; the electrode lifting device consists of a column 15, an electrode lifting screw 14, an electrode lifting transmission mechanism 25, an electrode holder 13, an electroslag furnace power control system 21, and an electroslag remelting transformer; the positive terminal 20 of the electroslag furnace power supply is connected to the electrode holder 13, and the negative terminal 22 of the electroslag furnace power supply is connected to the bottom water tank 28 and the ingot extraction device. 5. Pulsed magnetic field current crushing of molten droplets and secondary refining unit: mainly composed of high-intensity pulse power supply, high-intensity pulse transient magnetic field coil 16, insulation layer, cooling water system, magnetic ring, high-intensity pulse magnetic field coil lifting device and radial adjustment and connector, pulse power supply and control system 18, and water-cooled cable. All components work together to realize the core functions of crushing molten metal droplets and secondary refining of molten metal. A high-intensity pulse transient magnetic field coil 16 is wrapped around the outer side of the corresponding height of the liquid slag pool 31 and the molten metal pool 30 area of ​​the water-cooled crystallizer 23. The high-intensity pulse transient magnetic field coil 16 and the water-cooled crystallizer 23 are kept in a non-contact state and are arranged coaxially. In order to achieve reliable insulation and isolation between the two and eliminate the risk of leakage, an insulation layer is provided between the high-intensity pulse transient magnetic field coil 16 and the water-cooled crystallizer 23. The insulation layer is made of high-temperature resistant insulating material and is suitable for the high-temperature working conditions around the water-cooled crystallizer 23. The high-intensity pulse transient magnetic field coil 16 is made of hollow copper tube with a rectangular or circular cross-section. A cooling water channel is reserved inside the coil and is connected to the cooling water system. The high-intensity pulse transient magnetic field coil 16 is forcibly cooled by circulating cooling water. The working temperature of the high-intensity pulse transient magnetic field coil 16 is strictly controlled to not exceed 60℃, which effectively avoids damage to the high-intensity pulse transient magnetic field coil 16 due to overheating and ensures its long-term stable operation. The distance between the high-intensity pulse transient magnetic field coil 16 and the wall of the water-cooled crystallizer 23 is 30-150mm. It is attached to the outer wall of the copper sleeve of the water-cooled crystallizer 23 in a completely or partially covered manner. The axial height coverage of the high-intensity pulse transient magnetic field coil 16 must fully cover the three key areas: the impact zone of the upper atomized metal particles 32 entering the slag surface of the liquid slag pool 31, the heating zone of the middle slag pool body, and the liquid surface zone of the lower molten metal pool 30. This ensures that the magnetic field can fully act on the target area and ensure the operation effect of droplet crushing and secondary refining. Ferrite or silicon steel sheet magnetic rings are fitted around the high-intensity pulse transient magnetic field coil 16. With the magnetic focusing effect of the magnetic rings, the magnetic field strength in the slag pool area can be significantly enhanced, further improving the breaking effect of the pulse magnetic field on the molten metal droplets. At the same time, it can improve the secondary refining efficiency of the molten metal and help improve the purity of the metal material. A high-intensity pulse transient magnetic field coil lifting device and radial adjustment and connector are configured on one side of the outer circumference of the high-intensity pulse transient magnetic field coil 16. The lifting device consists of a high-intensity pulse magnetic field coil lifting column 40, a high-intensity pulse magnetic field coil lifting screw 39, a high-intensity pulse magnetic field coil lifting transmission mechanism 42, and a high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41. The high-intensity pulse transient magnetic field coil 16 is fixedly connected to the high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41 set on the periphery of the water-cooled crystallizer 23. Through the high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41, the high-intensity pulse transient magnetic field coil 16 can be driven to move flexibly up and down and left and right on the water-cooled crystallizer 23, thereby achieving precise positioning of the magnetic field action area. This ensures that the magnetic field can accurately coincide with the end of the atomized fine atomized metal particles 32, the liquid slag pool 31, the end of the metal particle droplets, and the molten metal pool 30, effectively guaranteeing the work efficiency and work effect. A pulse power supply and control system cabinet 18 is configured around the high-intensity pulse transient magnetic field coil 16. The high-intensity pulse power supply is connected to the pulse power supply and control system cabinet 18 via a water-cooled cable, ensuring stable and efficient transmission of pulse current. The pulse power supply and control system cabinet 18 can flexibly adjust the peak value of the pulse current, voltage, pulse frequency, pulse width, and duty cycle to provide a stable pulse current for the high-intensity pulse transient magnetic field coil 16, thereby generating a pulse transient magnetic field of 0.1 to 10T, which is precisely matched to the magnetic field of droplet crushing and secondary refining. Field strength requirements; the transient pulse magnetic field generated by the high-intensity pulse power supply is applied to the inside of the water-cooled crystallizer 23 through the high-intensity pulse transient magnetic field coil 16, forming a high-intensity pulse magnetic field with wide coverage and stable intensity; this magnetic field can effectively cover and act on the ends of the falling fine atomized metal particles 32, the liquid slag pool 31, and the ends of the molten metal droplets heated and melted by the liquid slag pool 31 and the molten metal pool 30, forming a high-intensity, transient pulse magnetic field environment in the above key areas; this can not only efficiently break the atomized metal particles 32 and molten droplets, but also complete the secondary refining of the molten metal, effectively improving the purity and comprehensive performance of the metal material; The high-intensity pulse power supply is equipped with a dedicated control system that can work in conjunction with the control systems of other equipment to achieve precise adjustment and real-time dynamic control of pulse parameters, flexibly adapting to the operational needs under different working conditions. At the same time, the high-intensity pulse transient magnetic field coil 16 is equipped with an insulating protective sleeve and a cooling device to further enhance the insulation performance of the coil, effectively prevent coil overheating damage and leakage accidents, and significantly improve the safety and reliability of the entire unit operation. 6. Directional solidification unit: includes a water-cooled bottom tank 28 at the bottom of the water-cooled crystallizer 23 and an ingot extraction mechanism; the water-cooled bottom tank 28 has a built-in cooling water channel, with a bottom water tank inlet pipe 26 on its side bottom and a bottom water tank outlet pipe 27 on its upper side. Both the inlet and outlet pipes are connected to the cooling water circulation system of the water-cooled crystallizer 23 to achieve cooling water circulation and cooling; the ingot extraction mechanism can adjust the descent speed according to the solidification progress, adopting a slow descent mode to ensure that the descent speed is precisely matched with the solidification speed, ensuring that the high-purity electroslag metal ingot 29 is directionally solidified from bottom to top, and ensuring the solidification quality of the high-purity electroslag metal ingot 29; 7. Electroslag Refining Power Supply System: Electrically connected to the liquid slag pool 31 within the water-cooled crystallizer 23, this system provides power for the liquid electroslag refining process and maintains the molten state of the liquid slag pool 31. The system uses DC or AC power with a rated current of 5000–15000A and a rated voltage of 30–50V, and can precisely adjust the output current and voltage. The system is equipped with overload protection, short-circuit protection, and temperature protection devices to ensure safe and stable operation. Simultaneously, the system works in conjunction with the control system to adjust output parameters in real time based on the temperature and thickness of the liquid slag pool 31, ensuring optimal electroslag refining results. 8. Control System: A PLC control system is adopted, which is electrically connected to the primary smelting equipment, LF argon blowing refining furnace, VD vacuum degassing furnace, atomizing tundish, inert gas atomizer, water-cooled crystallizer, high-intensity pulse power supply, electroslag refining power supply system, cooling water circulation system, inert gas supply system, temperature sensor, pressure sensor, vacuum sensor, liquid level sensor, flow controller and ingot pumping mechanism to realize the automated control and coordinated linkage of the entire process. The control system is equipped with a touch screen operating interface and data acquisition device, which can collect operating parameters such as molten metal temperature, composition, vacuum degree, inert gas flow rate, pulse parameters, slag pool temperature, and cooling water flow rate in real time, and complete parameter display, data recording, and abnormal alarm. Operators can set process parameters, start and stop equipment, and adjust operating status through the touch screen to achieve precise control of the process. At the same time, the control system has parameter storage and query functions, which facilitates production process traceability and process optimization. In addition, the control system can integrate online detection and simulation technology to achieve constant shape control of the molten metal pool 30, complete real-time monitoring, feedback and automatic adjustment of process parameters, ensure stable and reliable production process, and further improve the consistency and stability of refining effect; Preferably, both the annular atomized molten metal intermediate liner 8 and the guide tube 35 adopt electromagnetic induction heating and heat preservation methods to avoid the molten metal from cooling down too quickly during transmission, which could lead to solidification and blockage. Furthermore, the high-intensity pulse transient magnetic field coil 16 has a height of 50-350mm and a number of turns of 10-100. It is made of hollow copper tube with a rectangular or circular cross-section. The coil specifications are precisely matched with the high-intensity pulse power supply to ensure that a transient magnetic field can be stably generated. Furthermore, the atomizing nozzle of the inert gas atomizer 34 is an annular nozzle, the inner diameter of the annular nozzle matches the outer diameter of the guide tube 35, and 1 to 12 atomizing holes are evenly arranged on the annular nozzle, the diameter of the atomizing holes is 1 to 3 mm, and the multiple atomizing holes are evenly distributed in an annular shape to ensure that the inert gas can be sprayed out evenly and to achieve full atomization of the molten metal. Furthermore, the equipment also includes a molten metal conveying device, which is connected to a molten metal insulation intermediate liner 1 and a guide channel 38. The guide channel 38 is made of a high-temperature resistant material, and the inner wall of the guide channel 38 is provided with an anti-slag coating to prevent molten metal from adhering to the inner wall of the guide channel and reduce molten metal loss. Compared with existing technologies, this invention, through synergistic innovation in processes and equipment, organically integrates liquid metal atomization deposition, pulsed droplet crushing, and liquid electroslag refining technologies to construct an integrated composite refining system. This system overcomes the process bottlenecks and equipment limitations of traditional electroslag refining, effectively solving industry pain points such as incomplete refining, coarse grains, low production efficiency, high energy consumption, and process disconnect. It possesses outstanding substantive features and significant progress, with its advantages specifically reflected in the following aspects: 1. This invention provides a high-purity metal material preparation process and equipment. It develops an integrated synergistic preparation technology that combines LF furnace argon refining, VD vacuum degassing, atomization deposition, pulse-driven droplet crushing, continuous liquid electroslag refining, and fine-grain solidification microstructure control. Each process is seamlessly integrated and operates continuously, achieving simultaneous deep refining of the molten metal, grain refinement, and ingot forming. This constructs a comprehensive synergistic refining and grain refinement system, overcoming the limitations of traditional batch production. The fully enclosed synergistic operation effectively avoids secondary contamination of the molten metal, providing a solid guarantee for improving the cleanliness, microstructure homogeneity, and ingot quality stability of the molten metal, filling the technological gap in the synergistic continuous production of metal atomization and electroslag refining.

[0018] This invention centers on a three-stage synergistic refining process: LF furnace argon blowing refining, VD vacuum degassing, and liquid electroslag refining. It combines a dual mechanism of inert gas atomization and high-intensity pulsed magnetic field secondary fragmentation. First, inert gas atomization breaks the molten metal into fine droplets of 50–300 μm. Then, a pulsed magnetic field achieves explosive dispersion of the droplets, further refining their particle size to 10–50 μm. This process utilizes a transient strong magnetic field to create an "electromagnetic fragmentation" effect in the slag pool region, uniformly dispersing the droplets into a cluster of fine droplets of 10–100 μm. This fundamentally solves the problem of droplet agglomeration in traditional processes, increasing the contact surface area between the molten metal and slag by 50–200 times compared to traditional ESR processes. This significantly enhances mass and heat transfer efficiency, and, combined with a dedicated refining slag system, achieves deep purification of the molten metal.

[0019] As the micro-droplets pass through the high-temperature liquid slag pool, the reaction interface expands significantly and the contact time is effectively extended, providing the ultimate thermodynamic and kinetic conditions for desulfurization, deoxidation, removal of harmful impurities such as Pb, Sb, and Bi, as well as efficient adsorption and removal of non-metallic inclusions, enabling ultra-deep purification that is difficult to achieve with traditional processes.

[0020] The key indicators of the metallic materials prepared by this process can reach: oxygen content ≤15ppm (optimal ≤10ppm), sulfur content ≤0.005% (optimal ≤5ppm), hydrogen content ≤2.0ppm, and nitrogen content ≤80ppm; non-metallic inclusion removal rate ≥99%, inclusion size ≤5μm, and desulfurization efficiency ≥95%. The ultra-high cleanliness and microstructure homogeneity of the material are significantly better than those of the traditional electroslag remelting process, which can fully meet the stringent requirements of high-end fields such as aerospace and nuclear power. At the same time, the integrated continuous production mode improves production efficiency by 30-50%, achieving a triple breakthrough in material cleanliness, microstructure homogeneity, and production efficiency.

[0021] 2. The high-purity metal material preparation process and equipment provided by this invention, based on the three-stage synergistic refining process of LF furnace blowing argon refining + VD vacuum degassing + liquid electroslag refining, creatively adopts a single high-intensity pulsed power supply to construct a "one source, two effects" synergistic enhancement mechanism. Relying on the transient magnetic field acting synchronously on the slag droplets and the molten metal pool, it constructs an integrated system of "refining-structure-performance," overcoming the pain point of traditional processes where it is difficult to synergistically and maximize the improvement of cleanliness and structural properties. Compared with existing pulsed magnetic field technologies, its industrial implementation is easier, the grain refinement is more uniform, and it can simultaneously improve the microstructure of the ingot edge and core, achieving the dual goals of refining and grain refinement.

[0022] In addition, the transient magnetic field can penetrate the slag layer to apply electromagnetic stirring to the molten metal pool. Through periodic electromagnetic force, the melt is driven to convect and oscillate, which inhibits the growth of crystal nuclei and breaks up primary dendrites. Combined with the sequential solidification of the water-cooled crystallizer, the ingot structure is uniformly refined across the entire cross section, eliminating coarse columnar crystals and transforming them into fine equiaxed crystals.

[0023] After adopting this process, the ingot grain size is refined from the traditional 100-200μm to 20-50μm (optimal 5-20μm), achieving a refinement degree of 1 / 10 to 1 / 5 of the traditional process. Grain uniformity is improved by over 60%, equiaxed grain rate is ≥90%, and compositional segregation is reduced by over 50% with a segregation index ≤0.05. The final material exhibits a 20-30% increase in tensile strength, a 30-40% increase in impact toughness, and a hardness uniformity error ≤5HB. The risk of processing cracking is reduced, providing core technological support for the quality upgrade of key metal materials used in high-end equipment such as aerospace.

[0024] 3. The high-purity metal material preparation process and equipment provided by this invention breaks the traditional batch production pattern, integrates multiple separation processes, constructs an integrated continuous operation process, realizes the "one-step" ultra-short process manufacturing from metal raw materials to finished ingots, shortens the production cycle from several weeks to several hours, reduces energy consumption and metal loss in intermediate links, and the production efficiency is far higher than that of intermittent refining processes, achieving efficient continuous production.

[0025] The advantages of this system are reflected in its comprehensive optimization: eliminating intermediate steps such as the preparation of consumable electrodes, thus increasing production efficiency by 30-50%; the capacity of a single furnace can be flexibly adjusted, and continuous production can be achieved through an ingot extraction device, enabling the preparation of ingots of various specifications with diameters of 200-2000mm and lengths of 1000-6000mm, to meet industrial needs; the process parameters are adjustable, making it suitable for a variety of materials such as high-temperature alloys, special steels, mold steels, tool steels, and non-ferrous metals such as copper and aluminum, and possessing the potential to produce graded materials.

[0026] Significant green and energy-saving achievements: Fully utilize the sensible heat of molten metal, increase the heat utilization rate of slag pool by more than 40%, achieve an effective utilization rate of electricity of ≥60%, and reduce overall energy consumption by 20-35%; metal recovery rate of ≥98% (steel recovery rate of ≥95%), reducing raw material consumption; the process is carried out in a closed atmosphere, controlling the volatilization of smoke and alloying elements, reducing environmental protection investment, in line with green manufacturing and dual-carbon strategy, and optimizing production costs in all aspects.

[0027] 4. The high-purity metal material preparation process and equipment provided by this invention are designed to be an integrated continuous equipment system, which is orderly connected with core equipment such as primary smelting equipment, LF furnace, VD furnace, atomizer, and water-cooled crystallizer. It is equipped with adjustable high-intensity pulse transient magnetic field coils and precise control modules. The equipment layout is compact and highly integrated, integrating atomization, refining, solidification and grain refinement functions into one. It has a small footprint, a high degree of automation, and can realize fully enclosed oxidation-free production, which is convenient for industrial promotion.

[0028] The equipment boasts outstanding innovation and stability: the pulsed magnetic field adopts a dual-function coupling design, integrating "molten droplet refining" and "solidification control" into the same device to achieve "one source, two effects"; it adopts a PLC automatic control system, integrating online detection and simulation technology, which can accurately control key process parameters, making operation convenient and reducing human error; it is equipped with a complete set of protection devices, with optimized coil structure and adjustable position, combined with constant melt pool control technology, to ensure consistent refining effect, safe and reliable equipment operation, and suitability for large-scale industrial production.

[0029] 5. The high-purity metal material preparation process and equipment provided by this invention employs reasonable low-to-medium pulse parameters, making industrial implementation easy. It requires no large-scale modification of existing facilities and equipment and can be quickly adapted to upgrade existing production lines. The core components of the equipment utilize mature industrial technology and standardized parts, resulting in moderate manufacturing costs, convenient maintenance, a continuous process flow, and simple operation. Operators can be trained quickly, lowering the barriers to technology promotion and application.

[0030] The process and equipment are fully adjustable, with a wide range of applicability. It can be applied to the deep refining and ingot preparation of ordinary carbon steel, alloy steel, mold steel, tool steel, bearing steel, high-temperature alloys, titanium alloys, and non-ferrous metals such as copper and aluminum. It is particularly suitable for the production of high-end special steels for aerospace, aviation, and nuclear power. Process parameters can be flexibly adjusted according to the target steel grade and performance requirements, demonstrating outstanding flexibility and adaptability. This invention addresses the pain point of poor synergy in existing technologies, promotes the upgrading of electroslag refining technology, and balances quality, efficiency, and economy, possessing broad prospects for widespread application.

[0031] 6. The high-purity metal material preparation process and equipment provided by this invention, through synergistic innovation of process and equipment, leads the industry development. It is the first to integrate atomization deposition, pulse crushing, and liquid electroslag refining technologies, pioneering a "first atomization, then refining" process route, constructing an integrated synergistic system, coupling atomization powdering and electroslag refining, increasing the refining reaction interface area by 5-10 orders of magnitude, and achieving metal purity surpassing the level of traditional triple-process technology, solving the pain points of process disconnect and poor synergy.

[0032] The novel "one source, two effects" mechanism effectively solves the industry problem of the inability to deeply refine atomized particles, achieving dual refinement of "molten droplets + structure," which is impossible with traditional technologies. This invention eliminates the self-consumable electrode preparation process, achieving "one-step" forming, increasing production efficiency by 30-50%, reducing single ingot cycle time to ≤2 hours, lowering carbon emissions and costs, filling a technological gap in the industry, and forming an integrated composite refining system.

[0033] This invention overcomes many shortcomings of traditional electroslag refining, achieving breakthrough improvements in cleanliness, microstructure and properties, production efficiency, and energy conservation. It provides a brand-new solution for technological upgrading, leads industry innovation, and promotes the leapfrog development of electroslag refining technology. It is of great significance for enhancing my country's independent preparation capabilities of high-end metal materials and strengthening the industry's competitiveness. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the high-purity metal material preparation process and equipment of the present invention; Figure 2 This is a top view of the main structure of the present invention.

[0035] In the diagram: 1. Tundish for molten metal insulation; 2. Stopper rod adjustment mechanism; 3. Stopper rod; 4. Insulating agent; 5. Molten steel; 6. Tundish induction heating coil; 7. Non-consumable electrode; 8. Annular atomized molten metal tundish; 9. Annular atomized molten steel ladle induction heating coil; 10. Guide tube induction heating coil; 11. Sealing cover; 12. Inert gas inlet pipe; 13. Electrode holder; 14. Electrode lifting screw; 15. Column; 16. High-intensity pulse transient magnetic field coil; 17. Pulse power supply positive terminal; 18. Pulse power supply control system; 19. Pulse power supply negative terminal; 20. Electroslag furnace power supply positive terminal; 21. Electroslag furnace control... Control system; 22. Electroslag furnace power supply negative terminal; 23. Crystallizer; 24. Crystallizer water inlet pipe; 25. Electrode lifting transmission mechanism; 26. Bottom water tank water inlet pipe; 27. Bottom water tank water outlet pipe; 28. Bottom water tank; 29. ​​High-purity electroslag steel ingot; 30. Metal molten pool; 31. Slag pool; 32. Atomized metal particles; 33. Crystallizer water outlet pipe; 34. Inert gas atomizer; 35. Guide pipe; 36. Molten steel; 37. Molten steel heat preservation agent; 38. Guide groove; 39. High-intensity pulse power coil lifting screw; 40. High-intensity pulse power coil lifting column; 41. High-intensity pulse power coil lifting connector; 42. High-intensity pulse... The system includes a power supply coil lifting transmission mechanism; a stopper rod adjustment mechanism 2 is installed on one side of the molten metal insulation intermediate ladle 1, and a stopper rod 3 is installed on top of the stopper rod adjustment mechanism 2, which drives the stopper rod 3 to move up and down; the molten metal insulation intermediate ladle 1 contains refined molten metal 5 that has undergone vacuum degassing, and an insulating agent 4 covers the molten metal 5; an intermediate ladle induction heating coil 6 is installed on the outer side of the molten metal insulation intermediate ladle 1, which heats the molten metal 5 inside the molten metal insulation intermediate ladle 1 through electromagnetic induction; and an annular atomizing metal... The intermediate ladle 8, annular atomizing molten metal tundish 8, and the molten metal insulation intermediate ladle 1 are connected by a guide channel 38. The molten metal 5 in the molten metal insulation intermediate ladle 1 flows into the annular atomizing molten metal tundish 8 through the guide channel 38. A molten steel insulation agent 37 covers the molten metal 36 inside the annular atomizing molten metal tundish 8. An annular atomizing molten steel ladle electromagnetic induction heating coil 9 is installed on the outside of the annular atomizing molten metal tundish 8. A temperature monitoring device is installed inside the annular atomizing molten metal tundish 8. A high-temperature resistant guide pipe 35 is installed at the bottom of the annular atomizing molten metal tundish 8. 2 to 9 [other components] are installed below the annular atomizing molten metal tundish 8. A symmetrically distributed inert gas atomizer 34, with the metal liquid inlet at the center of the inert gas atomizer 34 corresponding to the metal liquid outlet 36 in the guide tube 35. The guide tube 35 extends vertically downward through the bottom of the annular atomizing metal liquid intermediate package 8 to the metal liquid outlet nozzle of the inert gas atomizer 34. The connection between the guide tube 35 and the annular atomizing metal liquid intermediate package 8 is sealed with refractory material. An electromagnetic induction heating coil 10 is installed on the outside of the guide tube 35.The annular atomizing molten metal intermediate ladle 8 is equipped with a level gauge and a thermometer for real-time monitoring of the molten metal level and temperature. The inert gas atomizer 34 includes an atomizer body, an atomizing nozzle, an inert gas inlet pipe, a gas pressurization device, a gas filtration device, and a gas flow control system. The atomizer body adopts an annular structure and is made of high-temperature and corrosion-resistant stainless steel. The atomizing nozzle is made of high-temperature and wear-resistant material. The atomizing nozzle is located at the center of the atomizer body and is aligned with the liquid slag pool 31 inside the water-cooled crystallizer 23. An inert gas atomizer 34 is installed on one side. An inert gas inlet pipe 12 is provided, the other end of which is connected to a high-pressure inert gas cylinder and a pressure control valve. The inert gas cylinder is equipped with a pressure gauge and a flow valve to control the pressure and flow rate of the inert gas. The angle of the inert gas atomizer 34 is adjustable, and the outlet of the atomizing nozzle in the inert gas atomizer 34 is conical, which enables the inert gas to form a high-speed airflow to atomize the molten metal into fine metal atomized particles 32. A sealing device is provided between the inert gas atomizer 34 and the annular atomizing molten metal intermediate tank 8 to prevent the molten metal 36 from splashing and gas from leaking. A water-cooled crystallizer 23 is positioned below the inert gas atomizer 34 to receive the atomized metal particles 32 after the liquid metal is atomized. A sealing cover 11 is installed between the water-cooled crystallizer 23 and the inert gas atomizer 34. A water outlet pipe 33 is provided on the upper side of the water-cooled crystallizer 23, and a water inlet pipe 24 is provided on the lower side of the water-cooled crystallizer 23, which is connected to an external cooling water circulation system to provide circulating cooling water for the water-cooled crystallizer 23. The inner cavity of the water-cooled crystallizer 23 is used to accommodate a liquid slag pool 31 and a molten metal pool 30, with the liquid slag pool 31 located at the upper part and the molten metal pool 33 located at the lower part. A bottom water tank 28 and an ingot-pulling device are provided at the bottom of the water-cooled crystallizer 23 to support the high-purity electroslag metal ingot 29 that has solidified after refining. The ingot-pulling device is used to slowly remove the solidified high-purity electroslag metal ingot 29. To achieve continuous production, a water outlet pipe 27 is installed on the upper side of the bottom water tank 28, and a water inlet pipe 26 is installed on the lower side of the bottom water tank 28. A temperature detection device and a slag pool thickness detection device are installed on the side wall of the water-cooled crystallizer 23 to monitor the temperature of the liquid slag pool 31 and the molten metal pool 30 and the thickness of the liquid slag pool 31 in real time. An electrode holder 13 and an electrode lifting device are provided on one side of the water-cooled crystallizer 23 for adjusting the vertical position of the non-consumable electrode or the consumable electrode 7. The electrode lifting device consists of a column 15, an electrode lifting screw 14, an electrode lifting transmission mechanism 25, an electrode holder 13, an electroslag furnace power control system 21, and an electroslag remelting transformer. The positive terminal 20 of the electroslag furnace power supply is connected to the electrode holder 13, and the negative terminal 22 of the electroslag furnace power supply is connected to the bottom water tank 28 and the ingot pulling device. A high-intensity pulse transient magnetic field coil 16 is wrapped around the outside of the corresponding height of the liquid slag pool 31 and the molten metal pool 30 area of ​​the water-cooled crystallizer 23. The high-intensity pulse transient magnetic field coil 16 and the water-cooled crystallizer 23 are kept in a non-contact state and are arranged coaxially. In order to achieve reliable insulation and isolation between the two and eliminate the risk of leakage, an insulation layer is provided between the high-intensity pulse transient magnetic field coil 16 and the water-cooled crystallizer 23. This insulation layer is adapted to the high-temperature working conditions around the water-cooled crystallizer 23. The high-intensity pulse transient magnetic field coil 16 is made of hollow copper tube with rectangular or circular cross-section. Circulating cooling water is introduced into the coil to force cooling the high-intensity pulse transient magnetic field coil 16. The distance between the high-intensity pulse transient magnetic field coil 16 and the wall of the water-cooled crystallizer 23 is 30-150mm. It is attached to the outer wall of the copper sleeve of the water-cooled crystallizer 23 in a completely or partially covered manner. The axial height coverage of the high-intensity pulse transient magnetic field coil 16 must fully cover the three key areas: the impact zone of the upper atomized metal particles 32 injected into the slag surface of the liquid slag pool 31, the middle slag pool main heating zone, and the liquid surface zone of the lower molten metal pool 30. Ferrite or silicon steel sheet magnetic rings are fitted around the high-intensity pulse transient magnetic field coil 16. With the magnetic focusing effect of the magnetic rings, the magnetic field strength in the slag pool area can be significantly enhanced, further improving the breaking effect of the pulse magnetic field on the molten metal droplets and helping to improve the purity of the metal material. A high-intensity pulse transient magnetic field coil lifting device and radial adjustment and connector are configured on one side of the outer circumference of the high-intensity pulse transient magnetic field coil 16. The lifting device consists of a high-intensity pulse magnetic field coil lifting column 40, a high-intensity pulse magnetic field coil lifting screw 39, a high-intensity pulse magnetic field coil lifting transmission mechanism 42, and a high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41. The high-intensity pulse transient magnetic field coil 16 is fixedly connected to the high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41 set on the periphery of the water-cooled crystallizer 23. Through the high-intensity pulse power magnetic field coil lifting connector and radial adjustment mechanism 41, the high-intensity pulse transient magnetic field coil 16 can be driven to move flexibly up and down and left and right on the water-cooled crystallizer 23, thereby achieving precise positioning of the magnetic field action area. This ensures that the magnetic field can accurately coincide with the end of the atomized fine atomized metal particles 32, the liquid slag pool 31, the end of the metal particle droplets, and the molten metal pool 30, effectively guaranteeing the work efficiency and work effect. A pulse power supply and control system cabinet 18 is configured around the high-intensity pulse transient magnetic field coil 16. The high-intensity pulse power supply is connected to the pulse power supply and control system cabinet 18 through a water-cooled cable to provide a stable pulse current to the high-intensity pulse transient magnetic field coil 16. The transient pulse magnetic field generated by the high-intensity pulse power supply is applied to the inside of the water-cooled crystallizer 23 through the high-intensity pulse transient magnetic field coil 16. It acts on the ends of the falling fine atomized metal particles 32, the liquid slag pool 31, and the ends of the metal droplets heated and melted by the liquid slag pool 31 and the molten metal pool 30, so as to efficiently break the atomized metal particles 32 and the molten droplets, and complete the secondary refining of the metal liquid to improve its purity and comprehensive performance. An insulating protective sleeve and a cooling device are provided outside the high-intensity pulse transient magnetic field coil 16 to effectively prevent coil overheating damage and leakage accidents, thereby improving the safety and reliability of the entire unit operation. A water-cooled bottom water tank 28 and an ingot-pulling mechanism are installed at the bottom of the water-cooled crystallizer 23. The water-cooled bottom water tank 28 has a built-in cooling water channel, and a bottom water tank inlet pipe 26 is provided on its bottom side and a bottom water tank outlet pipe 27 is provided on its upper side. Both the inlet and outlet pipes are connected to the cooling water circulation system of the water-cooled crystallizer 23 to realize cooling water circulation cooling. The ingot-pulling mechanism can adjust the descent speed according to the solidification progress to ensure that the high-purity electroslag metal ingot 29 is directionally solidified from bottom to top. Detailed Implementation The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise range thresholds, and these range thresholds should be understood to include values ​​close to these range thresholds. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0036] The following is in conjunction with the appendix Figure 1 The preparation process and equipment for high-purity metallic materials provided in the embodiments of this specification are described in detail.

[0037] Example 1 like Figure 1 , Figure 2 As shown, the present invention provides a process for preparing high-purity metallic materials, comprising the following process steps: This embodiment provides a high-purity metal material preparation process, using H13 hot work die steel as the target product to prepare electroslag ingots with a diameter of Ø500mm×2000mm. First, a 30t medium-frequency furnace is used to perform primary smelting of high-quality scrap steel and alloy raw materials such as ferrochrome, ferromolybdenum, and ferrovanadium, controlling the smelting temperature at 1620±10℃ to obtain primary molten metal with qualified composition, including C content of 0.38%, Si content of 1.0%, Mn content of 0.4%, Cr content of 5.0%, Mo content of 1.3%, and V content of 1.0%. The primary molten metal is then transferred to an LF argon-blown refining furnace for argon refining treatment, with the argon flow rate controlled at 150L / min, refining time of 45min, and temperature stabilized at 1600℃. Subsequently, it is transferred to a VD vacuum degassing furnace for vacuum degassing treatment, with the vacuum degree controlled below 67Pa and held for 20min, reducing the hydrogen content to below 1.5ppm. The refined molten metal is poured into a molten metal insulation tundish, covered with insulation agent, and the tundish induction heating coil is activated to maintain the molten metal temperature at 1550℃ and the superheat at 80℃.

[0038] The electroslag refining system is assembled using a Ø550mm×2500mm copper water-cooled crystallizer. The cooling water flow rate is controlled at 12m³ / h, with an inlet water temperature of 25℃ and an outlet temperature not exceeding 45℃. A high-intensity pulsed transient magnetic field coil is installed around the crystallizer. The coil is made of hollow copper tubing, with 50 turns, a coil height of 200mm, and a distance of 80mm from the crystallizer. An annular atomizing molten metal tundish is installed above the crystallizer. The guide tube is made of graphite and preheated to 900℃ before use. An electromagnetic induction heating coil is installed outside the guide tube to maintain the temperature. The inert gas atomizer is a tightly coupled annular atomizer with a nozzle orifice diameter of 2mm, installed 50mm below the outlet of the guide tube. The electroslag refining process uses a CaF2-Al2O3-CaO ternary slag system with an alkalinity of 2.8 and a slag layer thickness of 150 mm. The slag pool temperature is maintained at 1650±20℃ by heating with graphite non-consumable electrodes, and the electrode lifting speed is controlled at 15 mm / min.

[0039] The atomization deposition process is initiated by introducing molten metal from the insulated tundish into the annular atomizing molten metal tundish through a guide channel. The molten metal flows into the inert gas atomizer at a flow rate of 80 kg / min via a guide pipe. Simultaneously, the high-pressure argon valve is opened, with argon purity of 99.995%, pressure of 1.5 MPa, and flow rate of 1800 L / min. Under the impact of the high-speed gas flow, the molten metal is broken into a cluster of fine droplets of 50–200 μm, which are vertically sprayed downwards and deposited into the liquid slag pool below, achieving preliminary electroslag refining. Simultaneously with atomization initiation, a high-intensity pulsed power supply is activated, with a pulse frequency set to 2.5 kHz, pulse width of 2 ms, and peak current of 80 kA, generating a 2.5 T pulsed magnetic field to further break up the molten metal droplets during deposition, refining them to 15–40 μm. The pulsed power supply is turned off 15 seconds after atomization stops. After being crushed twice, the extremely fine molten droplets penetrate the slag pool with a huge specific surface area, fully contact the molten slag, and undergo a highly efficient metallurgical reaction to achieve deep desulfurization, deoxidation, and removal of inclusions.

[0040] The refined molten metal converges at the bottom of the crystallizer to form a molten pool. Under the continuous stirring action of a pulsed magnetic field, the dendrites at the solidification front are broken up, forming a large number of nucleation sites. Simultaneously, circulating cooling water is introduced into the crystallizer to achieve sequential directional solidification from bottom to top. The crystallization rate is controlled at 1.2 mm / min, and the ingot pulling speed is matched with the crystallization rate. With the ingot pulling speed matched with the crystallization rate, the final product is an H13 electroslag ingot.

[0041] Example 2 This embodiment provides a high-purity metal material preparation process, using Inconel 718 nickel-based superalloy as the target product, to prepare electroslag ingots of Ø300mm×1500mm, suitable for key components such as aero-engine turbine disks. First, a 10t vacuum induction furnace is used to perform primary smelting of pure metal raw materials such as electrolytic nickel, metallic chromium, metallic molybdenum, and ferroniobium, controlling the smelting temperature at 1550±10℃ to obtain a primary molten metal with qualified composition, containing 52.5% Ni, 19.0% Cr, 18.5% Fe, 5.0% Nb, 3.0% Mo, 1.0% Ti, and 0.5% Al. The primary molten metal is then transferred to an LF argon-blown refining furnace for argon refining, with the argon flow rate controlled at 100L / min, refining time at 60min, and temperature stabilized at 1520℃. Subsequently, it is transferred to a VD vacuum degassing furnace for vacuum degassing, with the vacuum degree controlled below 50Pa and held for 30min, reducing the hydrogen content to below 1.0ppm. The refined molten metal is poured into a molten metal insulation tundish, covered with insulation agent, and the tundish induction heating coil is activated to maintain the molten metal temperature at 1480℃ and the superheat at 60℃.

[0042] The electroslag refining system is assembled using a Ø350mm×2000mm copper water-cooled crystallizer. The cooling water flow rate is controlled at 8m³ / h, with an inlet water temperature of 22℃ and an outlet temperature not exceeding 40℃. A high-intensity pulsed transient magnetic field coil is installed around the crystallizer. The coil is made of hollow copper tubing with 60 turns, a coil height of 180mm, and a distance of 60mm from the crystallizer. A silicon steel sheet magnetic ring is fitted around the outer periphery of the coil. An annular atomized molten metal tundish is installed above the crystallizer. The guide tube is made of ceramic matrix composite material and preheated to 850℃ before use. An electromagnetic induction heating coil is installed outside the guide tube to maintain the temperature. The inert gas atomizer is a supersonic tight-coupled atomizer with a Laval nozzle structure and a nozzle orifice diameter of 1.5mm, installed 40mm below the outlet of the guide tube. The electroslag refining process uses a quaternary slag system of CaF2-Al2O3-CaO-MgO, with the basicity controlled at 2.5 and the slag layer thickness at 120 mm. The slag pool temperature is maintained at 1580±15℃ by heating with graphite non-consumable electrodes, and the electrode lifting speed is controlled at 10 mm / min.

[0043] The atomization deposition process is initiated by introducing molten metal from the insulated tundish into the annular atomizing molten metal tundish through a guide channel. The molten metal flows into the inert gas atomizer at a flow rate of 50 kg / min via a guide pipe. Simultaneously, the argon-helium mixed gas valve is opened, with a mixture ratio of Ar:He = 7:3, purity above 99.99%, pressure 2.0 MPa, and flow rate 2200 L / min. Under the impact of the high-speed gas flow, the molten metal is broken into a cluster of fine droplets of 30–150 μm, which are vertically sprayed downwards and deposited into the liquid slag pool below, achieving preliminary electroslag refining. Simultaneously with atomization initiation, a high-intensity pulsed power supply is activated, with a pulse frequency set to 5 kHz, pulse width 1 ms, and peak current of 120 kA, generating a 4.0 T pulsed magnetic field to further break up the molten metal droplets during deposition, refining them to 10–30 μm. The pulsed power supply is turned off after a 10-second delay following atomization cessation. After being crushed twice, the extremely fine molten droplets penetrate the slag pool with a huge specific surface area, fully contact the molten slag, and undergo a highly efficient metallurgical reaction to achieve deep desulfurization, deoxidation, and removal of inclusions.

[0044] The refined molten metal converges at the bottom of the crystallizer to form a molten pool. Under the continuous stirring action of a pulsed magnetic field, the dendrites at the solidification front are broken up, forming a large number of nucleation sites. Simultaneously, circulating cooling water is introduced into the crystallizer to achieve sequential directional solidification from bottom to top. The crystallization rate is controlled at 0.8 mm / min, and the ingot pulling speed is matched with the crystallization rate. The final product is an Inconel 718 electroslag ingot.

[0045] Example 3 This embodiment provides a high-purity metal material preparation process, using GCr15 bearing steel as the target product, to prepare electroslag ingots with a diameter of Ø200mm×2000mm, suitable for high-speed bearing manufacturing. First, a 20t electric arc furnace is used to perform primary smelting of high-quality scrap steel and ferrochrome, controlling the smelting temperature at 1640±10℃ to obtain primary molten metal with qualified composition, including 1.0% C, 0.25% Si, 0.35% Mn, 1.5% Cr, and 0.05% Mo. The primary molten metal is then transferred to an LF argon-blown refining furnace for argon refining, with the argon flow rate controlled at 200L / min, refining time at 50min, and temperature stabilized at 1610℃. Subsequently, it is transferred to a VD vacuum degassing furnace for vacuum degassing, with the vacuum degree controlled below 60Pa and held for 25min, reducing the hydrogen content to below 1.2ppm. The refined molten metal is filtered and purified through a three-dimensional continuous mesh foam ceramic filter, then poured into a molten metal insulation intermediate ladle, covered with insulation agent, and the intermediate ladle induction heating coil is activated to maintain the temperature of the molten metal at 1560℃ and control the superheat at 100℃.

[0046] The electroslag refining system is assembled using a Ø250mm×2500mm copper water-cooled crystallizer. The cooling water flow rate is controlled at 6m³ / h, with an inlet water temperature of 20℃ and an outlet temperature not exceeding 38℃. A high-intensity pulsed transient magnetic field coil is installed around the crystallizer. The coil is made of hollow copper tubing with 80 turns, a coil height of 150mm, and a distance of 50mm from the crystallizer. A ferrite magnetic ring is fitted around the outer periphery of the coil. An annular atomizing molten metal tundish is installed above the crystallizer. The guide tube is made of metal-ceramic matrix composite material and is preheated to 950℃ before use. An electromagnetic induction heating coil is installed outside the guide tube to maintain the temperature. The inert gas atomizer uses annular orifice atomizers, with four atomizers symmetrically distributed. The nozzle orifice diameter is 1.0mm, and it is installed 30mm below the outlet of the guide tube. The electroslag refining process uses a five-element slag system of CaO-Al2O3-CaF2-MgO-SiO2, with the basicity controlled at 3.0 and the slag layer thickness at 100mm. The slag pool temperature is maintained at 1680±15℃ by heating with graphite non-consumable electrodes, and the electrode lifting speed is controlled at 8mm / min.

[0047] The atomization deposition process is initiated by introducing molten metal from the insulated tundish into the annular atomizing molten metal tundish through a guide channel. The molten metal flows into the inert gas atomizer at a flow rate of 40 kg / min via a guide pipe. Simultaneously, the high-pressure nitrogen valve is opened, with nitrogen purity of 99.995%, pressure of 2.5 MPa, and flow rate of 1500 L / min. Under the impact of the high-speed airflow, the molten metal is broken into a cluster of fine droplets of 20–120 μm, which are vertically sprayed downwards and deposited into the liquid slag pool below, achieving preliminary electroslag refining. Simultaneously with atomization startup, a high-intensity pulsed power supply is activated, with a pulse frequency set to 8 kHz, pulse width of 0.5 ms, and peak current of 150 kA, generating a 5.0 T pulsed magnetic field to further break up the molten metal droplets during deposition, refining them to 10–20 μm. The pulsed power supply is turned off after an 8-second delay following atomization cessation. After being crushed twice, the extremely fine molten droplets penetrate the slag pool with a huge specific surface area, fully contact the molten slag, and undergo a highly efficient metallurgical reaction to achieve deep desulfurization, deoxidation, and removal of inclusions.

[0048] The refined molten metal converges at the bottom of the crystallizer to form a molten pool. Under the continuous stirring action of a pulsed magnetic field, the dendrites at the solidification front are broken up, forming a large number of nucleation sites. Simultaneously, circulating cooling water is introduced into the crystallizer to achieve sequential directional solidification from bottom to top. The crystallization rate is controlled at 0.6 mm / min, and the ingot pulling speed is matched with the crystallization rate. The final product is a GCr15 electroslag ingot.

[0049] Comparative Example 1 This comparative example uses the same H13 hot work die steel as Example 1 as the target product, and prepares an electroslag ingot of Ø500mm×2000mm for comparison with Example 1 of the present invention. First, a 30t medium-frequency furnace, identical to that in Example 1, is used for primary smelting of high-quality scrap steel and alloy raw materials such as ferrochrome, ferromolybdenum, and ferrovanadium. The smelting temperature is controlled at 1620±10℃ to obtain a primary molten metal with qualified composition, containing 0.38% C, 1.0% Si, 0.4% Mn, 5.0% Cr, 1.3% Mo, and 1.0% V. The primary molten metal is cast into a consumable electrode ingot, which is then forged or rolled into a consumable electrode of Ø400mm×2500mm. The electrode surface is machined to remove oxide scale before use. This consumable electrode preparation process increases the process cycle by approximately 8 hours and generates approximately 3% metal loss.

[0050] A copper water-cooled crystallizer with a diameter of Ø550mm × 2500mm, identical to that used in Example 1, was used. The cooling water flow rate was controlled at 12m³ / h, the inlet water temperature was 25℃, and the outlet temperature did not exceed 45℃. The prepared electroslag agent, a CaF₂-Al₂O₃-CaO ternary slag system, was added to the crystallizer. The alkalinity was controlled at 2.8, and the slag layer thickness was 150mm. A solid slag arc-initiating method was used, with graphite electrodes used to heat and melt the electroslag material, establishing an initial slag pool. The prepared consumable electrode was installed above the crystallizer using an electrode holder, ensuring that the centerline of the consumable electrode coincided with the centerline of the crystallizer. The electroslag remelting power supply was started, using AC power with a secondary voltage of 40V and a working current of 8000A. The consumable electrode was gradually inserted into the slag pool at a speed of 8mm / min, and the Joule heat generated by the current passing through the conductive molten slag gradually melted the tip of the consumable electrode. The molten metal at the consumable electrode tip forms droplets of approximately 5–15 mm in size. Under gravity, these droplets pass through a high-temperature slag pool, where they remain for about 0.5–1 second, undergoing a slag-metal reaction to achieve desulfurization and inclusion removal. The purified molten metal then undergoes directional solidification from bottom to top in a water-cooled crystallizer, with the crystallization rate controlled at 1.2 mm / min. The entire remelting process lasts approximately 4.5 hours and is a single-batch production process, making continuous operation impossible. During remelting, continuous replenishment of electroslag material is required to maintain the slag pool thickness. Maintaining the high temperature of the slag pool consumes approximately 1300 kWh / t of electricity, yielding H13 electroslag ingots.

[0051] The high-purity metallic materials prepared in Examples 1-3 and Comparative Example 1 were subjected to the following performance tests: 1. Oxygen content test Three Φ5mm×5mm cylindrical samples were taken from the core and edge of the electroslag ingot. The surface was ultrasonically cleaned with acetone to remove oil stains, then sanded with sandpaper to remove the oxide layer, and finally cleaned with anhydrous ethanol and dried for later use. Using an oxygen, nitrogen and hydrogen analyzer (such as LECOON H836), the instrument was preheated and stabilized for 30 minutes before blank calibration and standard sample calibration were performed.

[0052] The sample is placed in a high-purity graphite crucible and heated to over 3000°C under helium carrier gas protection using a pulse electrode to melt the sample. The oxygen in the metal reacts with the carbon in the graphite crucible to generate CO or CO2 gas. The gas is carried into the infrared detection cell by the carrier gas. The infrared absorption intensity is proportional to the oxygen content. The oxygen content is calculated from the standard curve, and the average value of 6 samples is taken as the final oxygen content.

[0053] 2. Sulfur content detection A sample from the core of an electroslag ingot was taken and machined into fine chips of 0.2–0.5 mm. Inclusions in the chips were removed by magnetic separation, and the chips were cleaned with anhydrous ethanol and dried. A high-frequency infrared carbon-sulfur analyzer (LECOCS844) was used, preheated and stabilized for 30 minutes, and the instrument was calibrated using a standard steel sample (with known sulfur content).

[0054] Accurately weigh 0.5g of sample and place it in a ceramic crucible. Add 1.5g of tungsten granules as a flux. Place the crucible in a high-frequency induction furnace and heat it at high frequency in an oxygen stream to melt the sample. The sulfur in the sample reacts with oxygen to generate SO2 gas, which is carried into the infrared detection cell by a carrier gas. The infrared absorption intensity is directly proportional to the sulfur content. The instrument automatically calculates the sulfur content and takes the average of three parallel measurements.

[0055] 3. Hardness uniformity error detection Twelve hardness test specimens were taken from the electroslag ingot at different axial heights (100mm, 500mm, 1000mm, and 1500mm from the bottom) and at different radial positions (center, half radius, and edge). The specimen dimensions were no less than 30mm × 30mm × 10mm, with parallel upper and lower surfaces. A Brinell hardness tester (e.g., HB-3000 type) was used, with a Φ10mm cemented carbide ball indenter. A test force of 29420N (3000kgf) was applied and held for 10–15 seconds. Measurements were taken using a reading microscope with an accuracy of 0.01mm. Three test points are evenly distributed on the surface of each sample. The distance between the centers of each indentation is not less than three times the diameter of the indentation. Record the diameter of each indentation and look up the table or calculate the hardness value.

[0056] Brinell hardness HBW = 0.102 × 2F / [πD(D - √(D² - d²))] Where: F is the test force (N), D is the diameter of the ball (mm), and d is the average diameter of the indentation (mm).

[0057] Table 1: Performance test results of Examples 1-3 and Comparative Example 1

[0058] As shown in Table 1, the oxygen contents of Examples 1-3 were 8.2 ppm, 6.5 ppm, and 7.8 ppm, respectively, all lower than the 22.5 ppm of Comparative Example 1. This indicates that the present invention, through the atomization-electroslag refining coupling process combined with the secondary crushing effect of the pulsed magnetic field on the molten metal droplets, significantly increases the contact area and reaction time between the droplets and the slag pool, resulting in a more complete deoxidation reaction and a significant reduction in oxygen content. Comparative Example 1, using the traditional electroslag remelting process, had larger droplet sizes and shorter residence times, resulting in significantly insufficient deoxidation effect.

[0059] As shown in Table 1, the sulfur contents of Examples 1-3 were 18 ppm, 12 ppm, and 15 ppm, respectively, which were significantly lower than the 45 ppm of Comparative Example 1. This indicates that in the process of this invention, extremely fine molten droplets penetrate the slag pool with a huge specific surface area, achieving a highly efficient metallurgical reaction with the molten slag, resulting in a significant deep desulfurization effect. In Comparative Example 1, the molten droplets had a short residence time in the slag pool, a limited reaction interface, and poor control over sulfur content.

[0060] As shown in Table 1, the hardness uniformity errors of Examples 1-3 are ±8 HBW, ±6 HBW, and ±7 HBW, respectively, which are significantly better than ±22 HBW of Comparative Example 1. This indicates that under the continuous stirring effect of the pulsed magnetic field, the dendrites at the solidification front are effectively broken up to form a large number of nucleation cores. At the same time, the sequential directional solidification from bottom to top in the crystallizer makes the microstructure more dense and uniform, with less hardness fluctuation. Comparative Example 1 lacks the stirring effect of the pulsed magnetic field, and the solidified microstructure is prone to compositional segregation and coarse grains, resulting in poor hardness uniformity.

[0061] In summary, the high-purity metal material preparation process provided by this invention significantly reduces oxygen and sulfur content and improves material purity by coupling atomization deposition with electroslag refining and combining it with the secondary crushing and stirring effect of pulsed magnetic field. At the same time, it greatly improves hardness uniformity and has obvious advantages over the traditional electroslag remelting process.

[0062] In the description of this specification, the reference to terms such as "embodiment," "various embodiments," etc., indicates that a specific feature, structure, material, or characteristic described in connection with that embodiment or preparation example is included in at least one embodiment of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments.

[0063] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A process for preparing high-purity metallic materials, characterized in that, Includes the following steps: S1: The refined molten metal is atomized into micron-sized metal droplets by an inert gas atomizer and directly deposited in a high-temperature liquid slag pool maintained by electrode heating. The increased specific surface area between the metal droplets and the liquid slag pool is used for the first stage of deep refining. S2: While step S1 is being performed, a high-intensity pulsed current is applied to generate a transient pulsed magnetic field. The transient pulsed magnetic field acts on the depositing metal droplets and uses the electromagnetic force effect to cause the metal droplets to undergo explosive secondary breakage, forming a smaller group of metal droplets, so as to further increase the slag-gold reaction interface and carry out the second stage of deep refining. S3: The molten metal after step S2 continues to fall in the liquid slag pool, so as to fully contact the liquid slag pool with the increased specific surface area and carry out the third stage of deep refining to remove impurities and harmful elements from the molten metal. S4: The molten metal after the three-stage refining in step S3 is solidified sequentially from bottom to top in a water-cooled crystallizer. At the same time, the high-intensity pulsed current is continuously applied to break the dendrites at the solidification front and increase the nucleation core by utilizing the electromagnetic stirring and oscillation effect generated by the current, thereby obtaining a refined solidified structure grain.

2. The high-purity metal material preparation process according to claim 1, characterized in that, In step S1, before the molten metal is atomized, it is first filtered and purified by a three-dimensional continuous mesh foam ceramic filter. The filter has a pore size of 5 to 20 μm and a filtration speed of 50 to 200 kg / min to further remove macroscopic inclusions in the molten metal.

3. The high-purity metal material preparation process according to claim 1, characterized in that, In step S4, the inner wall of the water-cooled crystallizer is coated with an anti-slag coating. The coating is made of Al2O3-ZrO2 composite ceramic material, with a thickness of 0.1-0.5 mm and a high temperature resistance of not less than 2000℃. This coating can reduce the adhesion of molten metal to the inner wall of the crystallizer and improve the surface quality of the metal ingot.

4. The high-purity metal material preparation process according to claim 1, characterized in that, In step S2, the particle size of the fine metal droplets is 10–300 μm; in step S3, after being broken by a pulsed magnetic field, the particle size of the even smaller droplet cluster is 10–50 μm.

5. The high-purity metal material preparation process according to claim 1, characterized in that, In step S1, the ladle refining includes sequential LF argon blowing refining and VD vacuum degassing treatment; the process is a continuous operation throughout the entire process.

6. The high-purity metallic material preparation process according to claim 1, characterized in that, The pulsed magnetic field described in step S3 is generated by the same high-intensity pulsed power supply system. The parameters of the pulsed magnetic field are: peak voltage 0-50kV, pulse frequency 0.05-10kHz, pulse width 0.1-10ms, peak current 0-250kA, and magnetic field strength 0.1-10T.

7. The high-purity metal material preparation process according to claim 1, characterized in that, The liquid slag pool in step S3 uses a fluorine-free or low-fluorine slag system, which is selected from one of the following: CaF2-Al2O3-CaO ternary slag system, CaO-Al2O3-SiO2 ternary slag system, CaO-Al2O3-MgO ternary slag system, CaO-Al2O3-CaF2-MgO quaternary slag system, or CaF2-Al2O3-CaO-MgO-SiO2 pentagonal slag system, and the alkalinity is controlled between 2.5 and 3.

0.

8. The high-purity metallic material preparation process according to claim 1, characterized in that, The metallic materials mentioned in step S1 include ferrous metals and alloys, non-ferrous metals and alloys, high-temperature alloys, stainless steel, bearing steel or mold steel; the solidified ingots prepared are round ingots, square ingots, plate ingots or near-net-shape billets.

9. The high-purity metal material preparation process according to claim 1, characterized in that, The atomization process described in step S1 is carried out under the protection of an inert gas, which is one or more of high-purity argon, high-purity nitrogen, helium or Ar-He mixed gas with a purity ≥99.99%, and the flow rate is 1000~3000L / min.

10. An apparatus for implementing the high-purity metallic material preparation process according to any one of claims 1-9, characterized in that, include: Primary smelting unit, including medium-frequency furnace or electric arc furnace; The pretreatment refining unit includes an LF argon blowing refining furnace and a VD vacuum degassing furnace connected in sequence; the atomization deposition unit includes a molten metal insulation tundish (1), an annular atomizing molten metal tundish (8), a guide pipe (35), and an inert gas atomizer (34), wherein the inert gas atomizer (34) is located at the bottom of the annular atomizing molten metal tundish (8); the liquid electroslag refining unit includes a water-cooled crystallizer (23), an electrode (7), an electrode holder (13), a lifting device for adjusting the vertical position of the electrode (7), and an electroslag remelting power supply for supplying power to the electrode. 23) A sealing cover (11) is installed between the inert gas atomizer (34); the water-cooled crystallizer (23) is used to contain the liquid slag pool (31) and the molten metal pool (30); the pulse refining unit includes a pulse magnetic field coil (16) surrounding the outside of the water-cooled crystallizer (23), a high-intensity pulse power supply and control system (18) for supplying power to the pulse magnetic field coil, and an adjustment device for driving the pulse magnetic field coil (16) to rise and move radially, the pulse magnetic field coil acting simultaneously on the molten metal droplets in the deposition process and the molten metal pool in the solidification process; And a directional solidification unit, including a bottom water tank (28) and a spindle extraction device disposed at the bottom of the water-cooled crystallizer (23).

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