Study on the effects of pouring speed and mold heating temperature on shrinkage cavity of superalloy induction ingot
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摘要: 高温合金感应锭存在大尺寸缩孔缺陷，会显著影响感应锭成材率、后续重熔工序的运行稳定性，以及产品质量。采用数值仿真模拟分析了浇注速度、锭模加热温度这两种典型工艺参数对感应锭缩孔深度的影响。结果表明：感应锭缩孔深度并未随浇注速度的增加呈现规律性变化。由于调整浇注速度未能改变感应锭凝固过程纵向温度分布规律及凝固顺序，因此无法通过该工艺参数的优化显著减小感应锭缩孔深度。采用锭模加热可以减小锭模与感应锭凝固过程纵向方向上的温差，在一定程度上改善了感应锭纵向凝固向着顺序凝固反方向发展的趋势，采用锭模加热可以显著减小感应锭缩孔深度。Abstract: Large-scale shrinkage cavity defects exist in superalloy induction ingots, which significantly affect the yield of the induction ingots, the operational stability of the subsequent remelting processes and the product quality. This paper analyzes the effects of two typical process parameters, namely pouring speed and mold heating temperature, on the depth of shrinkage cavities in induction ingots through numerical simulation. The results indicate that the depth of shrinkage cavities in induction ingots does not change regularly with increasing pouring speed. Since adjusting the pouring speed fails to alter the longitudinal temperature distribution and solidification sequence of the induction ingot during solidification. It is impossible to significantly reduce the depth of shrinkage cavities through optimization of this process parameter. Using mold heating can reduce the temperature difference of the mold and the induction ingot in the longitudinal direction during solidification, which to some extent improves the trend of longitudinal solidification of the induction ingot towards the opposite direction of sequential solidification. Using mold heating can significantly reduce the depth of shrinkage cavities in induction ingots.
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Key words:
- superalloy /
- induction ingot /
- pouring speed /
- ingot mold temperature /
- shrinkage cavity
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图 2 不同合金典型热物性参数
(a)导热系数；(b)密度；(c)黏度
Figure 2. Typical thermophysical properties of different alloys
图 3 试验解剖的[12]与模拟预测的缩孔形貌
(a)试验解剖；(b)模拟预测
Figure 3. Shrinkage cavity morphology obtained from experimental dissection and simulated prediction
图 4 不同浇注速度下感应锭凝固时的温度分布
Figure 4. Temperature distribution during the solidification of induction ingots under different pouring speeds
图 6 不同浇注速度下各监测点合金温度随时间变化曲线
Figure 6. The curve of temperature versus time of monitoring points under different pouring speeds
(a)1.96 kg/s；(b) 2.44 kg/s；(c) 3.21 kg/s
图 7 感应锭端部缩孔深度随浇注速度的变化
Figure 7. Change in shrinkage cavity depth at the end of induction ingot with the pouring speed
图 8 不同浇注速度下浇注充型结束锭模的温度分布
Figure 8. Temperature distribution of the ingot mold at the end of pouring and filling under different pouring speeds
图 9 不同浇注速度下锭模温差
Figure 9. Temperature difference of the ingot mold under different pouring speeds
图 10 不同浇注速度下不同牌号高温合金感应锭的缩孔深度
Figure 10. Shrinkage cavity depth of induction ingots of different grades of superalloy under different pouring speeds
图 11 不同锭模温度下凝固过程锭模及感应锭温度分布
(a) 锭模温度分布；(b)感应锭温度分布
Figure 11. Temperature distribution of the ingot mold and induction ingot during the solidification process at different ingot mold temperatures
图 12 不同锭模温度下不同牌号合金的感应锭缩孔深度
Figure 12. Induction ingot shrinkage cavity depth of different grades of alloys at different ingot mold temperatures
表 1 模拟采用的主要工艺参数
Table 1. Main process parameters used in the simulation
Pouring temperature/℃ Inlet diameter/mm Ingot mold temperature/℃ 1450 27、32、37 25、300、400、500 
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