基于电渣重熔的大型铸锭成型关键技术研究
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摘要
近年来,我国装备制造业水平进一步提高,装备制造业的一个突出技术发展趋势是极端制造,其中一个方向是朝着超大发展,电力、石化、冶金等领域装备大型化、复杂化对大型铸锻件行业提出了更高要求,未来10-15年将是中国推进工业化的关键时期,电力、石化、冶金、船舶等行业都将继续快速发展,孕育着对大型铸锻件的空前需求,而我国在大型铸锻件的自主技术水平与生产能力上严重不足,与此对应的却是国际上大型铸锻件明显的供不应求,依靠国外大型铸锻件,价格高昂,交货周期长,而且关键时候,国外对我国的技术封锁,且限制出口。因此大力发展我国自主技术的优质大型铸锻件,具有十分重要意义。
由于大型铸锻件产品的自身特点,要求优质的大型钢锭必须含杂质元素少；气体和夹杂物含量低；化学成分均匀,即偏析要小。而实际上,钢锭越大,这些要求越难实现,反而会有更多的缺陷产生。
电渣重熔工艺具有设备要求低,且同时具有以下优点：金属纯净、组织致密、成分均匀、表面光洁,在具有优良产品性能的同时,工艺的稳定性与质量的重现性高,且生产灵活,可生产各种锭型。电渣重熔工艺还有两个重要特点,即：电渣冶金的连续性与可叠加性,电渣重熔可通过更换自耗电极连续生产,以及可通过多台设备同時连续生产一个大型构件,这些特性决定了电渣重熔工艺在生产大型铸锻件上可以发挥重要作用!
但是简单的将电渣重熔系统扩大用于生产大型铸件,会面临着一些问题,如电效率降低,电渣长时间工作的稳定性,由于结晶器增大而带来的控制顺序凝固作用减弱,中心缩孔、疏松,电极更换时造成的工艺参数波动等,这些对铸件质量及其稳定性均会造成影响,因此有必要对电渣重熔生产大型铸件进行深入研究。
基于以上目的,本文提出了两种全新的基于电渣重熔工艺生产大型铸锭的方案,并设计了用于现在常用的抽锭式电渣重熔连铸设备的通用自动控制系统,具体内容如下：
(1)研究、设计了采用电渣重熔复合技术生产大型铸锭的方案,利用数模模拟与试验验证的方法,分析了该方案的可行性。通过数值模拟的结果显示,在电渣重熔过程中,自耗电极的末端将产生电流密度高的高温区,它具有使芯锭表层快速熔化的能力,有利于芯锭与熔融金属液的复合,为大型铸锭的生产创造条件；加大重熔电流或电压、增加电极在电渣中的插入深度、减小自耗电极与芯锭之间的距离等措施有利于实现芯锭与熔融金属液的复合,但在具体操作时,需要考虑操作的可行性与对设备的耐受性。
(2)研究设计了一种电渣浇铸实现大型铸锭的方案。该方案采用有衬电渣炉实现金属的熔化与提纯,以获得纯净的优良金属液,并可获得较高的功率因数,具有明显的节电效果。这些金属液在滑动水口的控制下,汇集并贮存于中间包内保温,用于大型铸锭的浇铸。为了解决浇铸过程中的缩孔、疏松等问题,提出在金属结晶过程中,利用高压气体的压力以及合适的振动制度以使铸件的结晶向有利的方向发展。
(3)针对常用的抽锭式电渣重熔连铸设备,设计了一种通用自动控制系统,用于抽锭全过程的自动控制、参数记录及质量监控。该系统采用PLC作自动控制执行器,工控机作上位机,实现电渣重熔工艺参数的设定、重熔过程的记录、监控以及打印。自动控制系统着重解决了电极的进给、金属液位的检测与稳定、铸锭的抽出等的自动控制。该系统实现了对一个完整大锭重熔全过程的自动控制,对于铸件质量的稳定、提高生产率、降低劳动强度具有重要意义,且具有通用性,亦可用于电渣企业实现技术改造与升级。
In recent years, equipment manufacturing industry of China has achieved to a higher level. One of its technology tendency is the extreme manufacturing. And the development of large scale is one of its directions. For the equipments become large-scale, complex, the power, petrochemical and metallurgical industries has put forward higher requirement on large-scale casts forging profession. It's a crucial period for industrialization of China in the next 10-15 years, the power, petrochemical, metallurgy, shipbuilding and other industries will continue to develop rapidly, and there are unprecedented demand for large casting and forging. However, in our country, the lack of autonomous technology and shortage of production capacity is serious, and the international demand is significant larger than supply. For the high prices, long delivery cycle, and the critical time, foreign to our technological blockade, and export restrictions when depend on foreign supply. Developing our own technology in high-quality casting and forging has great significance.
Because of the characteristics of large scale casting and forging products, requiring a large steel ingot must contain less quality of impurity elements, gas and inclusion content is low; chemical composition is uniformity, which means segregation is small. In fact, the greater the ingot is, the more difficult to achieve these requirements, and there also will be more defects.
Electroslag remelting (ESR) process has low equipment requirements, and also has the following advantages:metal pure, dense, homogeneous, smooth surface, with excellent performance, process stability and reproducibility is high, and production is flexibility, also can produce a variety of spindle types. ESR has two important features:the continuity and additivity. Large scale casting of ESR can be produced continously by replacing the consumable electrode, remelt simultaneously via multiple devices. These characteristics makes the ESR process to play an important role in the production of large castings and forgings!
However, expand the ESR system simply to product large scal castings, some problems will be faced, such as lower electrical efficiency and lower slag's stability after long working hours, weaker control ability for progressive solidification after the mold size increased, center shrinkage, porosity, fluctuations in process parameters caused by replacement of electrode, etc. This will lead to deterioration of the casting quality and stability. So it is necessary to study the production of large castings using ESR process.
Based on above purposes, two new techniques of the production of large scale ingot based on ESR process were proposed in this paper, and a universal automatic control system for the pumping ESR ingot casting equipment was designed, the details are as follows:
(1) studied and designed a large scale ingot production program, in which ESR composite technology was applied. And using digital simulation and experimental verification to analyze the feasibility of this program. The numerical simulation results show that, during the ESR process, at the end of the consumable electrode will produce a high temperature area with high current density, which has the capacity of speeding up the melting of the core ingot. That will benefit the core ingot and molten liquid metal compound, to create the conditions for the production of large ingots. Increasing the melting current, voltage, the depth of electrode insertion in the slag, or reducing the distance of electrode-ingot will benefit to the compound of core ingot and molten metal fluid, but in actual production, the feasibility and operation of the device tolerance has to be taken into account.
(2) studied and designed a large scale ingot production program using ESR cast. The program using lined electric slag furnace to for the metal melting and purification, obtaining pure liquid metal with higher power factor. This program reached a significant energy-saving effect. Under the control of the slide gate, the liquid metal for large ingot casting stored in the middle of the bag to keep heat. In order to solve the shrinkage in the casting process and osteoporosis and other issues, high-pressure gas and vibration system will be applied in order to makes the appropriate crystallization of castings to the favorable direction.
(3) for the common type pumping ESR ingot casting equipment, a universal automatic control system was designed for the control of whole pumping spindle process of, parameter records and quality monitoring and control. In the system, PLC was used as actuators, industrial computer was used as host computer for the parameters setting and ESR remelting process parameters recording, monitoring, and printing. The automatic control system solving the electrode feeding automatically, the detection of liquid metal level and its stability, and the cast ingot's drawing out automatically. This control system can meet the completely automatic control of whole process of a large ingot remelting, the program is important to the stability of the casting quality, increasing productivity, reducing labor intensity, and it also can be used to achieve business's transformation and slag upgrade.
由于大型铸锻件产品的自身特点,要求优质的大型钢锭必须含杂质元素少；气体和夹杂物含量低；化学成分均匀,即偏析要小。而实际上,钢锭越大,这些要求越难实现,反而会有更多的缺陷产生。
电渣重熔工艺具有设备要求低,且同时具有以下优点：金属纯净、组织致密、成分均匀、表面光洁,在具有优良产品性能的同时,工艺的稳定性与质量的重现性高,且生产灵活,可生产各种锭型。电渣重熔工艺还有两个重要特点,即：电渣冶金的连续性与可叠加性,电渣重熔可通过更换自耗电极连续生产,以及可通过多台设备同時连续生产一个大型构件,这些特性决定了电渣重熔工艺在生产大型铸锻件上可以发挥重要作用!
但是简单的将电渣重熔系统扩大用于生产大型铸件,会面临着一些问题,如电效率降低,电渣长时间工作的稳定性,由于结晶器增大而带来的控制顺序凝固作用减弱,中心缩孔、疏松,电极更换时造成的工艺参数波动等,这些对铸件质量及其稳定性均会造成影响,因此有必要对电渣重熔生产大型铸件进行深入研究。
基于以上目的,本文提出了两种全新的基于电渣重熔工艺生产大型铸锭的方案,并设计了用于现在常用的抽锭式电渣重熔连铸设备的通用自动控制系统,具体内容如下：
(1)研究、设计了采用电渣重熔复合技术生产大型铸锭的方案,利用数模模拟与试验验证的方法,分析了该方案的可行性。通过数值模拟的结果显示,在电渣重熔过程中,自耗电极的末端将产生电流密度高的高温区,它具有使芯锭表层快速熔化的能力,有利于芯锭与熔融金属液的复合,为大型铸锭的生产创造条件；加大重熔电流或电压、增加电极在电渣中的插入深度、减小自耗电极与芯锭之间的距离等措施有利于实现芯锭与熔融金属液的复合,但在具体操作时,需要考虑操作的可行性与对设备的耐受性。
(2)研究设计了一种电渣浇铸实现大型铸锭的方案。该方案采用有衬电渣炉实现金属的熔化与提纯,以获得纯净的优良金属液,并可获得较高的功率因数,具有明显的节电效果。这些金属液在滑动水口的控制下,汇集并贮存于中间包内保温,用于大型铸锭的浇铸。为了解决浇铸过程中的缩孔、疏松等问题,提出在金属结晶过程中,利用高压气体的压力以及合适的振动制度以使铸件的结晶向有利的方向发展。
(3)针对常用的抽锭式电渣重熔连铸设备,设计了一种通用自动控制系统,用于抽锭全过程的自动控制、参数记录及质量监控。该系统采用PLC作自动控制执行器,工控机作上位机,实现电渣重熔工艺参数的设定、重熔过程的记录、监控以及打印。自动控制系统着重解决了电极的进给、金属液位的检测与稳定、铸锭的抽出等的自动控制。该系统实现了对一个完整大锭重熔全过程的自动控制,对于铸件质量的稳定、提高生产率、降低劳动强度具有重要意义,且具有通用性,亦可用于电渣企业实现技术改造与升级。
In recent years, equipment manufacturing industry of China has achieved to a higher level. One of its technology tendency is the extreme manufacturing. And the development of large scale is one of its directions. For the equipments become large-scale, complex, the power, petrochemical and metallurgical industries has put forward higher requirement on large-scale casts forging profession. It's a crucial period for industrialization of China in the next 10-15 years, the power, petrochemical, metallurgy, shipbuilding and other industries will continue to develop rapidly, and there are unprecedented demand for large casting and forging. However, in our country, the lack of autonomous technology and shortage of production capacity is serious, and the international demand is significant larger than supply. For the high prices, long delivery cycle, and the critical time, foreign to our technological blockade, and export restrictions when depend on foreign supply. Developing our own technology in high-quality casting and forging has great significance.
Because of the characteristics of large scale casting and forging products, requiring a large steel ingot must contain less quality of impurity elements, gas and inclusion content is low; chemical composition is uniformity, which means segregation is small. In fact, the greater the ingot is, the more difficult to achieve these requirements, and there also will be more defects.
Electroslag remelting (ESR) process has low equipment requirements, and also has the following advantages:metal pure, dense, homogeneous, smooth surface, with excellent performance, process stability and reproducibility is high, and production is flexibility, also can produce a variety of spindle types. ESR has two important features:the continuity and additivity. Large scale casting of ESR can be produced continously by replacing the consumable electrode, remelt simultaneously via multiple devices. These characteristics makes the ESR process to play an important role in the production of large castings and forgings!
However, expand the ESR system simply to product large scal castings, some problems will be faced, such as lower electrical efficiency and lower slag's stability after long working hours, weaker control ability for progressive solidification after the mold size increased, center shrinkage, porosity, fluctuations in process parameters caused by replacement of electrode, etc. This will lead to deterioration of the casting quality and stability. So it is necessary to study the production of large castings using ESR process.
Based on above purposes, two new techniques of the production of large scale ingot based on ESR process were proposed in this paper, and a universal automatic control system for the pumping ESR ingot casting equipment was designed, the details are as follows:
(1) studied and designed a large scale ingot production program, in which ESR composite technology was applied. And using digital simulation and experimental verification to analyze the feasibility of this program. The numerical simulation results show that, during the ESR process, at the end of the consumable electrode will produce a high temperature area with high current density, which has the capacity of speeding up the melting of the core ingot. That will benefit the core ingot and molten liquid metal compound, to create the conditions for the production of large ingots. Increasing the melting current, voltage, the depth of electrode insertion in the slag, or reducing the distance of electrode-ingot will benefit to the compound of core ingot and molten metal fluid, but in actual production, the feasibility and operation of the device tolerance has to be taken into account.
(2) studied and designed a large scale ingot production program using ESR cast. The program using lined electric slag furnace to for the metal melting and purification, obtaining pure liquid metal with higher power factor. This program reached a significant energy-saving effect. Under the control of the slide gate, the liquid metal for large ingot casting stored in the middle of the bag to keep heat. In order to solve the shrinkage in the casting process and osteoporosis and other issues, high-pressure gas and vibration system will be applied in order to makes the appropriate crystallization of castings to the favorable direction.
(3) for the common type pumping ESR ingot casting equipment, a universal automatic control system was designed for the control of whole pumping spindle process of, parameter records and quality monitoring and control. In the system, PLC was used as actuators, industrial computer was used as host computer for the parameters setting and ESR remelting process parameters recording, monitoring, and printing. The automatic control system solving the electrode feeding automatically, the detection of liquid metal level and its stability, and the cast ingot's drawing out automatically. This control system can meet the completely automatic control of whole process of a large ingot remelting, the program is important to the stability of the casting quality, increasing productivity, reducing labor intensity, and it also can be used to achieve business's transformation and slag upgrade.
引文
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