Superalloy Production via AOD Purification and Triple-Melt Process
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Solution Overview
Problem
Existing superalloy production methods fail to achieve uniform impurity removal and high homogeneity due to the limited charge size, preventing effective use of Argon Oxygen Decarburization (AOD) and resulting in uneven impurity distribution and presence of minor amounts of S, Pb, and Bi.
Innovation Solution
A triple-melt process involving an initial electric-arc furnace melting followed by Argon Oxygen Decarburization (AOD) with vigorous stirring, Vacuum Induction Degassing and Pouring (VIDP), and Vacuum Arc Remelting (VAR) to produce a superalloy with high homogeneity and minimal impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the charge size is limited to twenty-five tons for VIM melting, then the conventional triple-melt process can be completed, but the AOD purification procedure cannot be effectively applied and impurity removal is insufficient
Solution Approach 1:
The patent changes the charge size parameter from the conventional twenty-five tons to a range of forty to sixty tons. This parameter change enables the liquid bath to reach a sufficient volume and temperature stability required for effective AOD purification, while still maintaining production efficiency. The larger charge size allows the AOD process to proceed effectively, resolving the contradiction between production capacity and impurity removal precision.
2Manufacturing precision
If the charge size is increased to enable AOD purification, then impurity removal effectiveness improves, but the conventional VIM furnace capacity is exceeded
Solution Approach 1:
The patent modifies the charge size parameter to a specific range (40-60 tons) that optimizes both AOD purification effectiveness and furnace capacity utilization. This parameter adjustment ensures the liquid bath reaches sufficient volume for effective gas-blown purification while remaining within the operational limits of standard VIM furnaces, thus resolving the contradiction between impurity removal effectiveness and charge size constraints.
3Productivity
If conventional triple-melt process is used with limited charge size, then production can proceed, but impurities remain in uneven amounts in the final product
Solution Approach 1:
The patent introduces gas-blown Argon Oxygen Decarburization (AOD) purification into the melting process. The vigorous stirring caused by gases blown during AOD ensures intensive mixing and uniform distribution of impurities throughout the liquid bath, enabling consistent removal of S, Pb, and Bi impurities. This pneumatic action resolves the contradiction by maintaining production continuity while achieving uniform impurity removal and high chemical homogeneity in the final superalloy product.
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 achieves a superalloy with extremely low sulfur content (<5 ppm) and Bi and Pb levels (<1 ppm), ensuring high chemical homogeneity and stability, along with controlled chemical composition and minimized segregation.
Implementation Method 1
melting the same charge of materials in an electric-arc furnace to obtain a first melt
Implementation Method 2
Argon Oxygen Decarburization (AOD) with vigorous stirring
Implementation Method 3
Argon Oxygen Decarburization (AOD)
Implementation Method 4
Vacuum Induction Degassing and Pouring (VIDP)
Implementation Method 5
Vacuum Arc Remelting (VAR)
Data Source
Figure 1
AI summary
The present invention relates to a method (1) of producing a metal superalloy (10) comprising the steps of providing a charge of metal materials (2); melting said charge of metal materials (2) in an electric-arc furnace (3) to obtain a first melt (3A) of said charge of metal materials (2); solidifying (5) said first melt (3A) to obtain first ingots (5A); melting said first ingots (5 A) in a V.I.D.P. furnace (6) to obtain a second melt (6A); solidifying (7) said second melt (6A) to obtain second ingots (7A); melting said second ingots (7 A) in a V.A.R. furnace (8) to obtain a third melt (8A); solidifying (9) said third melt (8A) to obtain a metal superalloy (10). The method (1) is characterized in that the charge of metal materials (2) has a weight amount ranging from forty to sixty tons, and it includes a step of carrying out an A.O.D. treatment (4) on said first melt (3 A) to obtain a decarburized and refined first melt (4A); said melting in the V.I.D.P. furnace (6) and said melting in the V.A.R. furnace (8) are carried out sequentially on said first melt (4 A) resulting from said A.O.D. treatment (4).