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US2875034A - Production of metals - Google Patents

Production of metals Download PDF

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Publication number
US2875034A
US2875034A US574982A US57498256A US2875034A US 2875034 A US2875034 A US 2875034A US 574982 A US574982 A US 574982A US 57498256 A US57498256 A US 57498256A US 2875034 A US2875034 A US 2875034A
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United States
Prior art keywords
alloy
melting
titanium
electrode
base metal
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US574982A
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John L Ham
David I Sinizer
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National Research Corp
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National Research Corp
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B34/00Obtaining refractory metals
    • C22B34/10Obtaining titanium, zirconium or hafnium
    • C22B34/14Obtaining zirconium or hafnium
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21CPROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/10Handling in a vacuum
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B34/00Obtaining refractory metals
    • C22B34/10Obtaining titanium, zirconium or hafnium
    • C22B34/12Obtaining titanium or titanium compounds from ores or scrap by metallurgical processing; preparation of titanium compounds from other titanium compounds see C01G23/00 - C01G23/08
    • C22B34/1295Refining, melting, remelting, working up of titanium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting

Definitions

  • This invention relates to techniques for the melting and casting of refractory metals such as titanium, zirconium and the like and theiralloys. Although the invention is primarily directed toward the melting and casting of refractory metals, it can equally well be utilized in connection with any highly reactive metal or alloy, such as uranium-niobium alloys, for example. For the purposes of simplicity, only titanium will be specifically referred to in the remainerof the application, but it isnot to be construed that the invention is limited to titanium alone.
  • Another object of the invention is to produce homogeneous ingots of titanium and titanium alloys which are substantially free of occluded gases.
  • Still another object of the invention is to provide an improved method of utilizing scrap titanium in the production of homogeneous, hydrogen-free titanium ingots.
  • Still another object of the invention is to provide a process in'which scrap titanium, ranging in size from minute particles to pieces weighing several pounds or more, can be melted into homogeneous, hydrogen-free ingots.
  • Still another object of the invention is to produce alloys within close tolerances with respect to both substitutional and interstitial elements.
  • Still another object of the invention is to control the hydrogen content in ingots of titanium and titanium alloys.
  • the invention accordingly comprises the process involving the several steps and the relation and the order of one or more such steps with respect to each of the others which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.
  • Nonconsumable cold-mold melting is subject to the disadvantages of chemical inhomogeneity, tungsten inclusions or carbon contamination (depending upon the electrode used), restricted size of the charge material, and the possibility of highhydrogen content, although this last disadvantage can be minimized by flowing argon through the furnace in order to maintain a constant pressure of argon in the system while melting.
  • Consumable electrode cold-mold melting has been used to advantage utilizing either first-melted ingots or briquetted sponge blended with alloying elements as the electrode. Homogeneity and uniformity of ingots can be achieved by these means, but use of this technique has proved to be disadvantageously expensive.
  • a highly reactive refractory metal such as titanium is mixed with an alloying metal in a skull comprising the base metal or alloy.
  • the mixture is then melted to form a pool of a homogeneous alloy, and the molten alloy is poured'into a mold to form a consumable electrode of the alloy, which consumable electrode is subsequently arc melted under avacuum in a cold-moldfurnace to produce a hydrogen-free homogeneous alloy ingot.
  • skull melting the liquid melt is contained in a solid shell or. skullof titanium or titanium alloy, since no other known material will contain the melt without chemical reaction. 1
  • the skull is contained in a crucible which is preferably cooled by radiation to the furnace walls.
  • the skull thickness is determined by the power input and the cooling rate.
  • Melting can be done by D. C. are using nonconsumable tained molten for a sufiicient time to achieve homogeneity, 4
  • the molten metal is poured into a chill mold in order to form ingots which are utilized subsequently as consumable electrodes.
  • These consumable electrodes are then used in a cold-mold arc-melting process in which themetal or alloy is substantially completely degassed and a homogeneous ingot is obtained.
  • This ingot is also substantially hydrogen-free, a hydrogen content of below 50 p. p. in. being easily obtained.
  • Skull melting has the advantage that scrap of unspecified shape and size can be readily converted to a single massive ingot.
  • some scrap can be incorporated in the electrode but the size, shape and distribution must be carefully controlled, making this technique of scrap recovery difiicult and expensive.
  • scrap of any reasonable size can be charged to a skull furnace and remelted simply and economically to an ingot.
  • Virgin metal can be melted and alloying additions made to the skull melt in the liquid state to yield a homogeneous ingot of required composition. The only possibility for inhomogeneity comes from ingot solidification-segregation to which all metals and alloys are subject in varying degrees.
  • skull melting has made possible the replacement of alloy blending, briquetting and first melting in making melts from virgin materials. No blending or v 3 hriquetting is required since the alloys blend in the liquid state as the melting proceeds.
  • a process for melting-and castinga highly reactive base metal such astitanium'and zirconiumtdobtain a substantially uniform alloy which comprises mixing a quantity of virgin base metal, scrap base metal and at least onealloying metal in a preformed skull comprising thebase metaL'subsequent-ly meltingthe mixture by means of anonconsumable electrode to form a single 'molten pool of -a homogeneous alloy, the-formation of the-molten pool being carried out under an inert atmosphere, pouring the -molten alloy into'xa. mold to a consumable electrode of the alloy, and are melting the consumable electrode at-a pressure below 1 mmJ'Hgabs. in a cold mold to produce a substantially hydrogen-free, homogeneous alloy ingot.
  • a process for melting and casting a highly reactive metal such as titanium 1 and; zirconium which comprises mixing a quantity of virgin metal and scrap metal in a preformed skull comprising the metal, subsequently meltn h br us i a mm nwme k sle tredq 9 ton e s n e m n p o m teLtheiormationwf the molten 9001 being. carried outnnder an inert atmosphere, pouring the molten metal into a mold to form a consumable electrode, and are melting the consumable electrode at a pressure below 1mm, Hg abs. in a cold mold to produce a substantially hydrogen-free, homogeneous metal ingot. 7

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Description

United StatesPatentO PRODUCTION OF METALS John L. Ham, Wellesley Hills, and David I. Sinizer, Bedford, Mass, assignors to National Research Corporation, Cambridge, Mass., a corporation of Massachusetts No Drawing. Application March 30, 1956 Serial No. 574,982
2 Claims. (Cl. 75-10) This invention relates to techniques for the melting and casting of refractory metals such as titanium, zirconium and the like and theiralloys. Although the invention is primarily directed toward the melting and casting of refractory metals, it can equally well be utilized in connection with any highly reactive metal or alloy, such as uranium-niobium alloys, for example. For the purposes of simplicity, only titanium will be specifically referred to in the remainerof the application, but it isnot to be construed that the invention is limited to titanium alone.
In the past, it has been extremely difficult to produce ingots of titanium ortitanium alloys that were both homogeneous and free of hydrogen and occluded gases Moreover, the use of scrap titanium in the production of such ingots involved many expensive steps which were difficult to perform and which tended to obviate the advantages to be gained from the use of this relatively inexpensive starting material.
In the instant invention, the disadvantages of the prior method have been successfully resolved or circumvented.
Accordingly, it is a principal object of the present invention to produce homogeneous ingots of titanium and titanium alloys.
Another object of the invention is to produce homogeneous ingots of titanium and titanium alloys which are substantially free of occluded gases.
Still another object of the invention is to provide an improved method of utilizing scrap titanium in the production of homogeneous, hydrogen-free titanium ingots.
Still another object of the invention is to provide a process in'which scrap titanium, ranging in size from minute particles to pieces weighing several pounds or more, can be melted into homogeneous, hydrogen-free ingots.
Still another object of the invention is to produce alloys within close tolerances with respect to both substitutional and interstitial elements.
Still another object of the invention is to control the hydrogen content in ingots of titanium and titanium alloys.
Other objects of the invention will in part be obvious and will in part appear hereinafter.
The invention accordingly comprises the process involving the several steps and the relation and the order of one or more such steps with respect to each of the others which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description.
In the prior art, because of the high reactivity of molten titanium, the melting of titanium by standard induction techniques in conventional crucibles has been superseded by cold-mold arcmelting with either consumable or nonconsumable electrodes.
Nonconsumable cold-mold melting is subject to the disadvantages of chemical inhomogeneity, tungsten inclusions or carbon contamination (depending upon the electrode used), restricted size of the charge material, and the possibility of highhydrogen content, although this last disadvantage can be minimized by flowing argon through the furnace in order to maintain a constant pressure of argon in the system while melting.
. Consumable electrode cold-mold melting has been used to advantage utilizing either first-melted ingots or briquetted sponge blended with alloying elements as the electrode. Homogeneity and uniformity of ingots can be achieved by these means, but use of this technique has proved to be disadvantageously expensive.
In the present invention, a highly reactive refractory metal such as titanium is mixed with an alloying metal in a skull comprising the base metal or alloy. The mixtureis then melted to form a pool of a homogeneous alloy, and the molten alloy is poured'into a mold to form a consumable electrode of the alloy, which consumable electrode is subsequently arc melted under avacuum in a cold-moldfurnace to produce a hydrogen-free homogeneous alloy ingot. In skull melting,the liquid melt is contained in a solid shell or. skullof titanium or titanium alloy, since no other known material will contain the melt without chemical reaction. 1
In a preferred embodiment of the invention, the skull is contained in a crucible which is preferably cooled by radiation to the furnace walls. The skull thickness is determined by the power input and the cooling rate.
Melting can be done by D. C. are using nonconsumable tained molten for a sufiicient time to achieve homogeneity, 4
the molten metal is poured into a chill mold in order to form ingots which are utilized subsequently as consumable electrodes. These consumable electrodes are then used in a cold-mold arc-melting process in which themetal or alloy is substantially completely degassed and a homogeneous ingot is obtained. This ingot is also substantially hydrogen-free, a hydrogen content of below 50 p. p. in. being easily obtained.
In the arcmelting operation, the theoretical limitation due to hydrogen solubility equilibrium dictates that the pressure must be below 15 mm. Hg abs. if the hydrogen content of the titanium is to be less than p. p. m. Actually 15 mm. Hg abs. or more of argon are sufiicient to cause considerable heat loss by thermal conduction and convection in addition to radiation. Therefore, the upper limit of operability appears to be about 1 mm. Hg abs. It is preferred to operate at a pressure: of less than 10 microns, at which pressure a hydrogen content of less than 50 p. p. m. is easily attained.
Skull melting has the advantage that scrap of unspecified shape and size can be readily converted to a single massive ingot. In consumable electrode melting, some scrap can be incorporated in the electrode but the size, shape and distribution must be carefully controlled, making this technique of scrap recovery difiicult and expensive. On the other hand, scrap of any reasonable size can be charged to a skull furnace and remelted simply and economically to an ingot. Virgin metal can be melted and alloying additions made to the skull melt in the liquid state to yield a homogeneous ingot of required composition. The only possibility for inhomogeneity comes from ingot solidification-segregation to which all metals and alloys are subject in varying degrees.
The use of skull melting has made possible the replacement of alloy blending, briquetting and first melting in making melts from virgin materials. No blending or v 3 hriquetting is required since the alloys blend in the liquid state as the melting proceeds.
There is set forth below an example which is to be construed in an illustrative, and not a limiting, sense:
7 V v Example! A-mixture of 1162 grams titanium, 623 grams -zirconium and 623 grams vanadiumwas melted in'a'titanium baseskull at approximately 1650 C. under 250 mm. Hg abs. of 'argon-using a'tungsten electrode. The run lasted 35 minutes,
The molten metal-was poured into-a cold mold, solidified, and subsequently -remelte'd by using the ingot formed as a-consumable electrode. The latter run lasted about 2.5 minutes ata pressure-of less than 5 microns Hg abs The ingot formed weighed just less than -5 lbs. This ingot'had excellent-homogeneity and low'hydrogen content. V
Since certain changes may be madein the above process without departing from the scope ;of the invention herein involved, it is 'intended that allmatter contained in the above description shall be interpreted as illustrative and not in a limiting sense. '-What is claimedis:
'1. A process for melting-and castinga highly reactive base metal such astitanium'and zirconiumtdobtain a substantially uniform alloy which comprises mixing a quantity of virgin base metal, scrap base metal and at least onealloying metal in a preformed skull comprising thebase metaL'subsequent-ly meltingthe mixture by means of anonconsumable electrode to form a single 'molten pool of -a homogeneous alloy, the-formation of the-molten pool being carried out under an inert atmosphere, pouring the -molten alloy into'xa. mold to a consumable electrode of the alloy, and are melting the consumable electrode at-a pressure below 1 mmJ'Hgabs. in a cold mold to produce a substantially hydrogen-free, homogeneous alloy ingot.
2. A process for melting and casting a highly reactive metal such as titanium 1 and; zirconium which comprises mixing a quantity of virgin metal and scrap metal in a preformed skull comprising the metal, subsequently meltn h br us i a mm nwme k sle tredq 9 ton e s n e m n p o m teLtheiormationwf the molten 9001 being. carried outnnder an inert atmosphere, pouring the molten metal into a mold to form a consumable electrode, and are melting the consumable electrode at a pressure below 1mm, Hg abs. in a cold mold to produce a substantially hydrogen-free, homogeneous metal ingot. 7
References Cited in the file of this patent UNITED STATES PATENTS OTHER ,REFERENCES- Miller: The Iron Age, Septemberg23, 1954, BrqwnrThe Iron Age, October 1 6, 19,52.

Claims (1)

1. A PROCESS FOR MELTING AND CASTING A HIGHLY REACTIVE BASE METAL SUCH AS TITANIUM AND ZIRCONIUM TO OBTAIN A SUBSTANTIALLY UNIFORM ALLOY WHICH COMPRISES MIXING A QUANTITY OF VIRGIN BASE METAL, SCRAP BASE METAL AND AT LEAST ONE ALLOYING METAL IN A PREFORMED SKULL COMPRISING THE BASE METAL, SUBSTANTIALLY MELTING THE MIXTURE BY MEANS OF A NONCONSUMABLE ELECTRODE TO FORM A SIMPLE MOLTEN POOL OF A HOMOGENEOUS ALLOY, THE FORMATION OF THE MOLTEN POOL BEING CARRIED OUT UNDER AN INERT ATMOSPHERE, POURING THE MOLTEN ALLOY INTO A MOLD TO FORM A COMSUMABLE ELECTRODE OF THE ALLOY, AND ARC MELTING THE COMSUMABLE ELECTRODE AT A PRESSURE BELOW 1 MM. HG ABS. IN A COLD MOLD TO PRODUCE A SUBSTANTIALLY HYDROGEN-FREE, HOMOGENEOUS ALLOY INGOT.
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3101267A (en) * 1959-01-28 1963-08-20 Edward J Dunn Method of alloying titanium
US3318683A (en) * 1964-07-27 1967-05-09 Battelle Development Corp Refractory metal powders
US20200239979A1 (en) * 2017-10-31 2020-07-30 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for purifying titanium material

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US873958A (en) * 1907-03-18 1907-12-17 Siemens Ag Method of producing homogeneous bodies from tantalum or other highly-refractory metals.
US904831A (en) * 1904-01-05 1908-11-24 Siemens Ag Process of making homogeneous bodies from tantalum metal or other refractory metals.
US997883A (en) * 1911-02-23 1911-07-11 Gen Electric Treatment of refractory materials.
US2548897A (en) * 1947-04-07 1951-04-17 William J Kroll Process for melting hafnium, zirconium, and titanium metals
US2686822A (en) * 1950-09-12 1954-08-17 Rem Cru Titanium Inc Consumable electrode furnace and method for producing titanium
US2702239A (en) * 1952-05-27 1955-02-15 Henry L Gilbert Process of arc melting zirconium
US2727936A (en) * 1954-11-23 1955-12-20 Westinghouse Electric Corp Titanium furnace
US2727937A (en) * 1954-05-26 1955-12-20 Westinghouse Electric Corp High-vacuum titanium furnace

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US904831A (en) * 1904-01-05 1908-11-24 Siemens Ag Process of making homogeneous bodies from tantalum metal or other refractory metals.
US873958A (en) * 1907-03-18 1907-12-17 Siemens Ag Method of producing homogeneous bodies from tantalum or other highly-refractory metals.
US997883A (en) * 1911-02-23 1911-07-11 Gen Electric Treatment of refractory materials.
US2548897A (en) * 1947-04-07 1951-04-17 William J Kroll Process for melting hafnium, zirconium, and titanium metals
US2686822A (en) * 1950-09-12 1954-08-17 Rem Cru Titanium Inc Consumable electrode furnace and method for producing titanium
US2702239A (en) * 1952-05-27 1955-02-15 Henry L Gilbert Process of arc melting zirconium
US2727937A (en) * 1954-05-26 1955-12-20 Westinghouse Electric Corp High-vacuum titanium furnace
US2727936A (en) * 1954-11-23 1955-12-20 Westinghouse Electric Corp Titanium furnace

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3101267A (en) * 1959-01-28 1963-08-20 Edward J Dunn Method of alloying titanium
US3318683A (en) * 1964-07-27 1967-05-09 Battelle Development Corp Refractory metal powders
US20200239979A1 (en) * 2017-10-31 2020-07-30 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for purifying titanium material

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