鈦和鈦合金的(de)工業生產，不(bu)論是(shi)重熔的(de)自耗(hao)電(dian)極(ji)或鍛(duan)造用的(de)開坯料，或是(shi)異型鑄(zhu)件，大多都(dou)是(shi)通過真(zhen)空(kong)(kong)自耗(hao)電(dian)極(ji)電(dian)弧熔煉(lian)來獲得的(de)。隨著現代技(ji)術(shu)(shu)的(de)發展和進步，鈦和鈦合金的(de)熔煉(lian)，包括真(zhen)空(kong)(kong)自耗(hao)電(dian)極(ji)電(dian)弧熔煉(lian)在內，先后又發展了(le)一(yi)些新的(de)先進技(ji)術(shu)(shu)。近年代表性的(de)技(ji)術(shu)(shu)如下:
鈦(tai)合金的熔煉(lian)技術有(you)哪(na)些(xie)？
1、直(zhi)接添加高熔點金屬的鈦合金真空自耗熔煉用電極制備方法
在(zai)鈦合(he)金真(zhen)空(kong)自(zi)耗電弧(hu)熔(rong)煉用電極(ji)常規制備的基礎上(shang)，由直接壓制的具有(you)一定(ding)凹(ao)槽的電極(ji)塊(kuai)與適合(he)電極(ji)塊(kuai)凹(ao)槽形(xing)狀的高熔(rong)點(dian)金屬棒拼焊組成電極(ji)的方法，通過選擇合(he)適的真(zhen)空(kong)自(zi)耗電弧(hu)熔(rong)煉工藝，能夠(gou)熔(rong)煉出達到配比計算(suan)要求的、成分均勻(yun)的無(wu)偏析優質(zhi)鑄(zhu)錠。
2、鈦及鈦合金真空自耗熔(rong)煉(lian)過程中斷(duan)電后重新起弧的(de)工藝(yi)
鈦及鈦合金真空自耗熔(rong)(rong)煉(lian)(lian)過程(cheng)中(zhong)(zhong)斷(duan)電(dian)后(hou)重新起弧的(de)(de)工(gong)藝(yi)(yi)，包括如下步驟:當(dang)熔(rong)(rong)煉(lian)(lian)中(zhong)(zhong)斷(duan)后(hou)重新起弧時，將熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)快速提升至(zhi)正(zheng)常(chang)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)的(de)(de)75-80%，保(bao)(bao)持此時的(de)(de)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu);當(dang)熔(rong)(rong)池的(de)(de)邊緣到達坩堝壁(bi)后(hou)，保(bao)(bao)持2-3min，再(zai)將此時的(de)(de)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)快速提升至(zhi)正(zheng)常(chang)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)。該工(gong)藝(yi)(yi)優勢在于，使總的(de)(de)起弧時間(jian)大幅縮短(duan)，減小鑄錠(ding)的(de)(de)冷(leng)卻(que)體積收縮后(hou)與(yu)坩堝壁(bi)間(jian)產生的(de)(de)間(jian)隙(xi)及避免(mian)(mian)鑄錠(ding)冷(leng)卻(que)凝(ning)固(gu)形(xing)成的(de)(de)內部縮孔:當(dang)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)達到正(zheng)常(chang)熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)的(de)(de)75~80%時，保(bao)(bao)持該熔(rong)(rong)煉(lian)(lian)電(dian)流(liu)(liu)一段時間(jian)，這樣可以較為準確地控制電(dian)極(ji)及已凝(ning)固(gu)熔(rong)(rong)池的(de)(de)熔(rong)(rong)化速度，避免(mian)(mian)瞬時產生大量的(de)(de)熔(rong)(rong)液流(liu)(liu)入鑄錠(ding)與(yu)坩堝壁(bi)的(de)(de)間(jian)隙(xi)，或造成冷(leng)隔缺陷。
3、純鈦塊狀(zhuang)廢料的熔煉(lian)回收方法
純(chun)鈦塊(kuai)(kuai)狀廢料(liao)(liao)的(de)熔(rong)煉(lian)回收(shou)(shou)(shou)方法，使用6個(ge)(ge)(ge)電(dian)子(zi)槍的(de)電(dian)子(zi)束冷(leng)床(chuang)爐，將(jiang)選定成分的(de)原料(liao)(liao)裝(zhuang)入電(dian)子(zi)束冷(leng)床(chuang)爐的(de)進料(liao)(liao)器，進行熔(rong)煉(lian)，然后將(jiang)得到的(de)鑄錠(ding)(ding)(ding)冷(leng)卻出(chu)爐，即(ji)可得到成品。該法直接使用TA1回收(shou)(shou)(shou)料(liao)(liao)進行熔(rong)煉(lian)，避免了(le)廢料(liao)(liao)破碎電(dian)極(ji)塊(kuai)(kuai)壓制，電(dian)極(ji)的(de)焊制。單(dan)錠(ding)(ding)(ding)熔(rong)煉(lian)每天單(dan)臺設(she)備可熔(rong)煉(lian)9個(ge)(ge)(ge)棒料(liao)(liao)總重(zhong)約(yue)6.5噸，雙(shuang)錠(ding)(ding)(ding)熔(rong)煉(lian)每天單(dan)臺設(she)備可熔(rong)煉(lian)18個(ge)(ge)(ge)棒料(liao)(liao)總重(zhong)約(yue)13噸，極(ji)大的(de)提高了(le)回收(shou)(shou)(shou)效率和(he)速(su)度。
4、鈦及鈦合金屑狀廢料的電(dian)子束冷床熔煉(lian)回收方法(fa)
鈦(tai)(tai)(tai)及鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)的(de)(de)電(dian)(dian)(dian)子(zi)(zi)(zi)束冷床(chuang)熔(rong)煉(lian)回收方(fang)(fang)法，過程為:根(gen)據(ju)所(suo)熔(rong)煉(lian)鈦(tai)(tai)(tai)及鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)成分，稱取純(chun)(chun)鈦(tai)(tai)(tai)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)，或稱取純(chun)(chun)鈦(tai)(tai)(tai)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)和鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)中的(de)(de)一(yi)(yi)種或兩種與(yu)海綿鈦(tai)(tai)(tai)以(yi)及純(chun)(chun)合(he)(he)金(jin)(jin)(jin)添加元(yuan)素和/或中間合(he)(he)金(jin)(jin)(jin)混(hun)合(he)(he)的(de)(de)混(hun)合(he)(he)料(liao)(liao)，混(hun)合(he)(he)料(liao)(liao)中的(de)(de)純(chun)(chun)鈦(tai)(tai)(tai)及鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)添加量按質量百分比計為10%~90%;然后將其壓制成電(dian)(dian)(dian)極塊(kuai)，用(yong)電(dian)(dian)(dian)子(zi)(zi)(zi)束冷床(chuang)熔(rong)煉(lian)爐將所(suo)述電(dian)(dian)(dian)極塊(kuai)進行一(yi)(yi)次(ci)電(dian)(dian)(dian)子(zi)(zi)(zi)束冷床(chuang)熔(rong)煉(lian)，得到鈦(tai)(tai)(tai)或鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)鑄錠。該方(fang)(fang)法可以(yi)利(li)用(yong)高達(da)100%純(chun)(chun)鈦(tai)(tai)(tai)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)生產出合(he)(he)格的(de)(de)純(chun)(chun)鈦(tai)(tai)(tai)鑄錠，或利(li)用(yong)高達(da)90%鈦(tai)(tai)(tai)及鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)屑狀(zhuang)(zhuang)廢(fei)(fei)料(liao)(liao)，生產出合(he)(he)格的(de)(de)鈦(tai)(tai)(tai)合(he)(he)金(jin)(jin)(jin)鑄錠;只需要電(dian)(dian)(dian)子(zi)(zi)(zi)束冷床(chuang)一(yi)(yi)次(ci)熔(rong)煉(lian)，不需要二次(ci)或三次(ci)熔(rong)煉(lian)。
5、潔凈鈦及鈦合金(jin)鑄錠的熔煉方法
潔凈(jing)鈦(tai)(tai)及(ji)鈦(tai)(tai)合(he)(he)(he)金(jin)(jin)鑄(zhu)錠的(de)熔(rong)(rong)(rong)煉(lian)(lian)方法，該方法為(wei):稱(cheng)取海綿(mian)鈦(tai)(tai)或稱(cheng)取純合(he)(he)(he)金(jin)(jin)添加元(yuan)(yuan)素、中(zhong)間合(he)(he)(he)金(jin)(jin)和海綿(mian)鈦(tai)(tai)，將(jiang)(jiang)(jiang)海綿(mian)鈦(tai)(tai)或將(jiang)(jiang)(jiang)混合(he)(he)(he)后(hou)的(de)純合(he)(he)(he)金(jin)(jin)添加元(yuan)(yuan)素、中(zhong)間合(he)(he)(he)金(jin)(jin)和海綿(mian)鈦(tai)(tai)壓制成(cheng)(cheng)電(dian)極(ji)塊(kuai)(kuai)，將(jiang)(jiang)(jiang)壓制成(cheng)(cheng)的(de)電(dian)極(ji)塊(kuai)(kuai)焊接為(wei)電(dian)極(ji)，用電(dian)子(zi)束冷床(chuang)爐將(jiang)(jiang)(jiang)電(dian)極(ji)進行一次電(dian)子(zi)束冷床(chuang)熔(rong)(rong)(rong)煉(lian)(lian)，得到(dao)潔凈(jing)的(de)、化學(xue)成(cheng)(cheng)分均勻(yun)的(de)鈦(tai)(tai)或鈦(tai)(tai)合(he)(he)(he)金(jin)(jin)鑄(zhu)錠;電(dian)子(zi)束冷床(chuang)熔(rong)(rong)(rong)煉(lian)(lian)的(de)熔(rong)(rong)(rong)煉(lian)(lian)真空度低于(yu)6×10-2Pa，熔(rong)(rong)(rong)煉(lian)(lian)速度為(wei)70~150kg/h，熔(rong)(rong)(rong)煉(lian)(lian)功率為(wei)100~300kw;純合(he)(he)(he)金(jin)(jin)添加元(yuan)(yuan)素和中(zhong)間合(he)(he)(he)金(jin)(jin)為(wei)鈦(tai)(tai)合(he)(he)(he)金(jin)(jin)鑄(zhu)錠總重量(liang)的(de)0%~20%。生產的(de)鈦(tai)(tai)及(ji)鈦(tai)(tai)合(he)(he)(he)金(jin)(jin)鑄(zhu)錠，化學(xue)成(cheng)(cheng)分均勻(yun)，鑄(zhu)錠宏觀組織(zhi)優于(yu)真空自(zi)耗電(dian)弧熔(rong)(rong)(rong)煉(lian)(lian)鑄(zhu)錠，無TiN和WC等高(gao)熔(rong)(rong)(rong)點夾(jia)雜。
6、含(han)高熔點合金元(yuan)素的(de)鈦合金的(de)熔煉方法(fa)
含高熔(rong)(rong)(rong)(rong)點(dian)合(he)金元(yuan)素鈦合(he)金鑄(zhu)(zhu)錠(ding)工業化(hua)制(zhi)(zhi)備方(fang)(fang)法。通過選擇合(he)金的(de)原(yuan)料，采(cai)(cai)用(yong)專門(men)組拼的(de)電(dian)(dian)極(ji)塊，采(cai)(cai)用(yong)常(chang)規的(de)真(zhen)空(kong)自耗(hao)(hao)電(dian)(dian)弧熔(rong)(rong)(rong)(rong)煉技術，調整三(san)次熔(rong)(rong)(rong)(rong)煉的(de)電(dian)(dian)流和電(dian)(dian)壓，制(zhi)(zhi)備化(hua)學(xue)成(cheng)分(fen)均勻，無夾(jia)雜(za)的(de)含高熔(rong)(rong)(rong)(rong)點(dian)合(he)金元(yuan)素的(de)鈦合(he)金鑄(zhu)(zhu)錠(ding)。高熔(rong)(rong)(rong)(rong)點(dian)金屬(shu)(shu)在自耗(hao)(hao)電(dian)(dian)極(ji)中(zhong)分(fen)布均勻，自耗(hao)(hao)電(dian)(dian)極(ji)制(zhi)(zhi)備方(fang)(fang)便、成(cheng)本(ben)(ben)低，熔(rong)(rong)(rong)(rong)煉時電(dian)(dian)流、電(dian)(dian)壓參數合(he)理，在傳統的(de)工藝路(lu)線(xian)基礎上(shang)，采(cai)(cai)用(yong)低成(cheng)本(ben)(ben)的(de)純金屬(shu)(shu)板按照特定的(de)自耗(hao)(hao)電(dian)(dian)極(ji)組拼方(fang)(fang)式(shi)，代(dai)替添加成(cheng)本(ben)(ben)高昂的(de)中(zhong)間合(he)金和其他純金屬(shu)(shu)加入鈦合(he)金方(fang)(fang)式(shi)，采(cai)(cai)用(yong)多次真(zhen)空(kong)自耗(hao)(hao)電(dian)(dian)弧熔(rong)(rong)(rong)(rong)煉爐進行熔(rong)(rong)(rong)(rong)煉獲得成(cheng)分(fen)均勻的(de)含高熔(rong)(rong)(rong)(rong)點(dian)合(he)金元(yuan)素鈦合(he)金鑄(zhu)(zhu)錠(ding)，適(shi)于工業化(hua)應用(yong)。
7、電子束冷床爐熔煉制(zhi)備TC4鈦(tai)合(he)金鑄錠的方法
電(dian)子(zi)束冷床(chuang)爐(lu)(lu)熔煉(lian)(lian)制備TC4鈦(tai)合(he)(he)金(jin)(jin)鑄(zhu)錠(ding)(ding)的(de)方(fang)(fang)法(fa)，該方(fang)(fang)法(fa)為(wei):將(jiang)海(hai)綿(mian)(mian)鈦(tai)和(he)鋁豆(dou)混合(he)(he)均(jun)勻(yun)后(hou)壓(ya)制成(cheng)電(dian)極塊，焊(han)接成(cheng)電(dian)極后(hou)置(zhi)于真(zhen)空自耗(hao)電(dian)弧爐(lu)(lu)中(zhong)(zhong)(zhong)(zhong)，一次熔煉(lian)(lian)得(de)到Ti-AI中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin);將(jiang)Ti-Al中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin)破碎成(cheng)Ti-Al中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin)顆(ke)粒;將(jiang)海(hai)綿(mian)(mian)鈦(tai)、Al-V中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin)和(he)Ti-Al中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin)顆(ke)粒混合(he)(he)均(jun)勻(yun)后(hou)壓(ya)制成(cheng)電(dian)極塊，拼接成(cheng)電(dian)極后(hou)置(zhi)于電(dian)子(zi)束冷床(chuang)爐(lu)(lu)中(zhong)(zhong)(zhong)(zhong)，一次熔煉(lian)(lian)得(de)到TC4鈦(tai)合(he)(he)金(jin)(jin)鑄(zhu)錠(ding)(ding)。該法(fa)以Ti-Al中(zhong)(zhong)(zhong)(zhong)間(jian)(jian)合(he)(he)金(jin)(jin)代(dai)替鋁豆(dou)，減少了(le)Al元素的(de)揮(hui)發(fa)量(liang)(liang)，提(ti)(ti)高(gao)(gao)了(le)原材料的(de)利用(yong)率(lv)和(he)電(dian)子(zi)束冷床(chuang)爐(lu)(lu)的(de)使用(yong)效率(lv)，采用(yong)的(de)電(dian)子(zi)束冷床(chuang)爐(lu)(lu)一次熔煉(lian)(lian)在降(jiang)低鈦(tai)材的(de)加工成(cheng)本(ben)及提(ti)(ti)高(gao)(gao)生產效率(lv)方(fang)(fang)面具(ju)有更強(qiang)的(de)優勢，可提(ti)(ti)高(gao)(gao)鈦(tai)合(he)(he)金(jin)(jin)鑄(zhu)錠(ding)(ding)的(de)潔凈度(du)，獲得(de)高(gao)(gao)質量(liang)(liang)鑄(zhu)錠(ding)(ding)。
