Optimization of VAR melting process of TB9 titanium alloy based on numerical simulation
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摘要: 采用真空自耗电弧熔炼（VAR）法熔炼TB9钛合金会产生偏析和夹杂等冶金缺陷。采用MeltFlow-VAR仿真软件对某厂TB9钛合金VAR一次熔炼过程进行模拟，考察熔炼电流大小、稳弧类型对熔炼过程的影响，通过分析不同工艺条件下铸锭的元素分布、熔池深度、抛杂路径等，获得了最佳一次熔炼工艺，分别采用该厂原工艺和优化后的工艺参数，对TB9钛合金三次VAR熔炼过程进行全流程模拟，获得了三次锭的元素分布情况。结果表明，宏观偏析在多次熔炼过程中存在“遗传”现象，对该厂一次熔炼原工艺进行优化后，可以显著提高三次成品锭的成分均匀性。Abstract: Metallurgical defects such as segregation and inclusion will occur when vacuum arc remelting (VAR) is used to melt TB9 titanium alloy. MeltFlow-VAR simulation software was used to simulate the primary melting process of TB9 titanium alloy VAR, and the influence of melting current and arc stabilization type on the melting process was investigated. By analyzing the element distribution, molten pool depth and impurity throwing path of ingot under different technological conditions, the optimal primary melting process was obtained. Using the original process and optimized process parameters, the whole process of tertiary VAR melting process of TB9 titanium alloy was simulated, and the element distribution of tertiary ingots was obtained. The results show that there is a “genetic” phenomenon in the process of multiple melting. After optimizing the original process of primary melting in this factory, the composition uniformity of tertiary finished ingots can be significantly improved.
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Key words:
- TB9 titanium alloy /
- Vacuum arc remelting /
- Numerical simulation /
- Element distribution
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图 1 原工艺条件下，MeltFlow-VAR模拟TB9钛合金三次熔炼铸锭中Al、Cr、Mo、O、V、Zr元素分布
Figure 1. The distribution of Al, Cr, Mo, O, V and Zr in the tertiary melting ingot of TB9 titanium alloy was simulated by MeltFlow-VAR under the original process conditions
图 2 原工艺条件下，MeltFlow-VAR模拟TB9钛合金三次熔炼的熔池形状
Figure 2. MeltFlow-VAR simulates the molten pool shape of TB9 titanium alloy in the original process conditions
图 3 MeltFlow-VAR模拟TB9钛合金不同工艺下第一次熔炼的Al、Cr、Mo、O、V、Zr元素分布
Figure 3. MeltFlow-VAR simulates the distribution of Al, Cr, Mo, O, V and Zr in the first melting of TB9 titanium alloy under different processes
图 4 MeltFlow-VAR模拟TB9钛合金不同工艺下第一次熔炼的抛杂路径示意
Figure 4. MeltFlow-VAR simulation of impurity throwing path of TB9 titanium alloy in different processes for the first time
图 5 MeltFlow-VAR模拟TB9钛合金不同工艺下第一次熔炼的熔池深度与时间关系
Figure 5. MeltFlow-VAR simulates the relationship between bath depth and time for the first melting of TB9 titanium alloy under different processes
图 6 MeltFlow-VAR模拟TB9钛合金不同工艺下第一次熔炼的熔池体积与时间关系
Figure 6. MeltFlow-VAR simulates the relationship between bath volume and time for the first melting of TB9 titanium alloy under different processes
图 7 MeltFlow-VAR模拟不同的一次熔炼工艺下TB9钛合金三次铸锭中Al、Cr、Mo、O、V、Zr元素分布
Figure 7. MeltFlow-VAR simulates the distribution of Al, Cr, Mo, O, V and Zr in the tertiary ingot of TB9 titanium alloy under different primary melting processes
表 1 TB9钛合金铸锭化学成分范围值和计算输入值
Table 1. Chemical composition range value and calculation input value of TB9 titanium alloy ingot
% 元素 Al V Cr Zr Mo 范围值 3.0～4.0 7.5～8.5 5.5～6.5 3.5～4.5 3.5～4.5 计算输入值 3.8 8.0 6.0 4.0 4.0 
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表 2 第一次熔炼不同工艺参数的模拟计算
Table 2. Simulation calculation of different process parameters in the first melting
正常熔炼阶段电流 稳弧电流交流/直流 原工艺 原工艺 直流 工艺1 减少 直流 工艺2 增加 直流 工艺3 减少 交流 工艺4 原工艺 交流 工艺5 增加 交流 注：原工艺为某厂实际熔炼TB9钛合金的工艺
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表 3 不同的一次熔炼工艺对最终铸锭影响的模拟计算
Table 3. Simulation calculation of the influence of different primary melting processes on the final ingot
一次熔炼 二次熔炼 三次熔炼 最佳工艺 原工艺 原工艺 原工艺 原工艺 原工艺
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表 4 计算采用的TB9钛合金物性参数
Table 4. Physical parameters of TB9 titanium alloy used in calculation
液态密度/
（kg·m−3）固态密度/
（kg·m−3）体积膨胀
系数/K−1固相线
温度/K液相线
温度/K相变潜热/
（J·kg−1）导电率/
（S·m−1）导热性/
（W·m−1·K−1）比热(1800 K)/
（J· kg−1· K−1 ）动力粘度(1930 K)/
（Pa·s)4.33×103 4.84×103 9.78×10−5 1 825 1 930 2.84×105 8.5×105 34.48 8.35×102 5.52×10−3
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