Ni-Cu Alloy Composition for Non-Metallic Inclusion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ni-Cu alloys suffer from surface defects caused by non-metallic inclusions such as Ti(N,C) and MgO·Al2O3, which deteriorate corrosion resistance and require extensive grinding, leading to reduced yield and increased production costs.
Innovation Solution
Control the concentrations of Ti, N, C, and other elements within specified ranges, and generate harmless non-metallic inclusions like CaO-CaS, MgO-MgS, and CaO-MgO-CaS-MgS oxysulfides to prevent surface defects, using a production method involving melting, secondary refining, and controlled slag composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting methods are used, then production efficiency is maintained, but surface defects occur due to non-metallic inclusions
Solution Approach 1:
The patent applies preliminary action by controlling the composition of non-metallic inclusions during the casting process itself. Specifically, it adjusts the Ti, N, and C content to prevent the formation of harmful Ti(N,C) inclusions before they can cause surface defects. This preventive approach during manufacturing avoids the need for post-casting grinding operations, thereby maintaining both high surface quality and production yield.
2Reliability
If Ti is added to improve surface properties, then gas defects are reduced, but Ti(N,C) inclusions form and cause linear surface defects
Solution Approach 1:
The patent applies parameter changes by precisely controlling the concentrations of Ti, N, and C within specific ranges. It maintains Ti content at 0.01-0.05% while controlling the product [%Ti]×([%N]+1/100×[%C]) to be 0.0003 or less. This parameter optimization allows the alloy to benefit from Ti's corrosion resistance improvement while preventing the formation of harmful Ti(N,C) inclusions that cause surface defects.
3Manufacturing precision
If extensive grinding is performed to remove surface defects, then surface quality is improved, but production yield decreases and costs increase
Solution Approach 1:
The patent applies the taking out principle by removing the harmful Ti(N,C) inclusions from the system through compositional control. By limiting Ti, N, and C content to specific ranges, the harmful inclusions are prevented from forming in the first place. This eliminates the need for extensive grinding operations, thereby preventing material loss and maintaining high production yield while still achieving excellent surface quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces Ni-Cu alloys with excellent surface properties, minimizing defects and reducing grinding needs, thereby improving yield and reducing production costs.
Implementation Method 1
generate harmless non-metallic inclusions like CaO-CaS, MgO-MgS, and CaO-MgO-CaS-MgS oxysulfides
Data Source
Figure 1
AI summary
By reducing non-metallic inclusions having an influence on surface properties and by controlling composition, Ni-Cu alloys having excellent surface properties and their production methods are provided. The Ni-Cu alloy consists, in mass%, C: 0.01 to 0.20%, Si: 0.01 to 0.5%, Mn: 0.01 to 2%, P: not greater than 0.03%, Cu: 28 to 40%, Cr: 0.01 to 1%, Fe: 0.3 to 3%, Al: 0.01 to 0.5%, Ti: 0.01 to 0.40%, N: not greater than 0.010%, Mg: 0.005 to 0.04%, Ca: 0.0005 to 0.04%, O: 0.0003 to 0.005%, S: 0.0001 to 0.002%, Ni and inevitable impurities as a remainder, and mass concentrations of Ti, N and C satisfy the following formula. %Ti×%N+1/100×%C<0.0003