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WO2016150024A1 - 一种制备均质化锻件的构筑成形方法 - Google Patents

一种制备均质化锻件的构筑成形方法 Download PDF

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Publication number
WO2016150024A1
WO2016150024A1 PCT/CN2015/083018 CN2015083018W WO2016150024A1 WO 2016150024 A1 WO2016150024 A1 WO 2016150024A1 CN 2015083018 W CN2015083018 W CN 2015083018W WO 2016150024 A1 WO2016150024 A1 WO 2016150024A1
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WIPO (PCT)
Prior art keywords
forging
blank
welded
billet
constructing
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PCT/CN2015/083018
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English (en)
French (fr)
Inventor
孙明月
徐斌
李殿中
李依依
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中国科学院金属研究所
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=55707974&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2016150024(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by 中国科学院金属研究所 filed Critical 中国科学院金属研究所
Priority to ES15885962T priority Critical patent/ES2768771T3/es
Priority to KR1020177030884A priority patent/KR102006372B1/ko
Priority to PL15885962T priority patent/PL3275585T3/pl
Priority to EP19161014.6A priority patent/EP3533554A1/en
Priority to US15/561,358 priority patent/US10413964B2/en
Priority to EP15885962.9A priority patent/EP3275585B1/en
Priority to JP2017550198A priority patent/JP6515376B2/ja
Publication of WO2016150024A1 publication Critical patent/WO2016150024A1/zh
Priority to US16/515,776 priority patent/US10953486B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B1/00—Cleaning by methods involving the use of tools
    • B08B1/10—Cleaning by methods involving the use of tools characterised by the type of cleaning tool
    • B08B1/14—Wipes; Absorbent members, e.g. swabs or sponges
    • B08B1/143—Wipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B1/00—Cleaning by methods involving the use of tools
    • B08B1/20—Cleaning of moving articles, e.g. of moving webs or of objects on a conveyor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/02—Cleaning by the force of jets or sprays
    • B08B3/022—Cleaning travelling work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B08B7/0035—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by radiant energy, e.g. UV, laser, light beam or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/02—Preliminary treatment of metal stock without particular shaping, e.g. salvaging segregated zones, forging or pressing in the rough
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/04—Shaping in the rough solely by forging or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/002—Hybrid process, e.g. forging following casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/06—Electron-beam welding or cutting within a vacuum chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/26—Auxiliary equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G57/00—Stacking of articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/14—Preventing or minimising gas access, or using protective gases or vacuum during welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/006—Safety devices for welding or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
    • B65G47/90—Devices for picking-up and depositing articles or materials
    • B65G47/92—Devices for picking-up and depositing articles or materials incorporating electrostatic or magnetic grippers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49947—Assembling or joining by applying separate fastener
    • Y10T29/49966—Assembling or joining by applying separate fastener with supplemental joining
    • Y10T29/49968—Metal fusion joining
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49972—Method of mechanical manufacture with separating, localizing, or eliminating of as-cast defects from a metal casting [e.g., anti-pipe]
    • Y10T29/49973—Compressing ingot while still partially molten
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49972—Method of mechanical manufacture with separating, localizing, or eliminating of as-cast defects from a metal casting [e.g., anti-pipe]
    • Y10T29/49975—Removing defects

Definitions

  • the invention relates to the field of forging forging, in particular to a method for constructing a homogenized forging, which is suitable for the forging and forming of a continuous casting of a forging.
  • Forgings as the core components of large-scale complete sets of equipment in the fields of metallurgical machinery, petrochemicals, transportation, energy and power, play an extremely important role in national economic construction, national defense equipment and major scientific installations. Their production capacity and quality level are measured. An important indicator of a country's autonomy and strength. Therefore, it is of great significance to improve the intrinsic quality of forgings and ensure the safety and reliability during their operation.
  • Forgings are generally forged from steel ingots.
  • a large number of microscopic shrinkage holes and loose defects are inevitably generated due to solidification and shrinkage of the metal. These hole-shaped defects are dispersed in the core of the steel ingot, which destroys the continuity of the material and affects Mechanical properties of forgings.
  • the solidification of large-section steel ingots is not only high in alloy concentration, but also enriches low-melting substances and impurity elements, forming macrosegregation, resulting in a large gap between the mechanical properties of the steel ingots. Affects the uniformity of the forging properties and the safety of use.
  • the steel ingot cutting head cutting method is generally used in the industry, and the resection rate is often more than 30%, which greatly reduces the material utilization rate and the product economy is poor.
  • Continuous casting board is one of the most stable and mature products in the current large-scale production of steel industry.
  • the continuous casting billet is characterized by low manufacturing cost, high production efficiency, and below a certain specification (general slab is 300mm, round billet is 600mm), and its internal organization is relatively dense and the degree of macrosegregation is light.
  • general slab is 300mm
  • round billet is 600mm
  • the center of the casting blank is prone to penetrating shrinkage, oxidation after cutting, and failure to pass subsequent rolling or forging. It heals, which limits its range of applications. Therefore, at present, high-quality forgings cannot be prepared by using continuous casting billets, and still use high-cost die-cast steel ingots as base materials.
  • the Z-direction tensile strength at the interface reached a level consistent with the matrix only when the reduction ratio reached 70%. This indicates that at a small reduction ratio, the interface welding is insufficient, and there are still microscopic porosity and oxide films. The mechanical properties of severe materials are especially unacceptable for some components that are subjected to alternating loads. Therefore, the current thick plate prepared by the vacuum composite rolling method is limited to use in a non-harsh load environment.
  • forging as a metal pressure processing method that lasted for thousands of years, although the efficiency is not high, but the deformation mode is flexible, it can achieve single large deformation and multi-directional deformation of the blank.
  • higher quality metal components such as swords, were produced using forging methods.
  • the base metal of the forging is sponge iron.
  • the toughness of the material can be improved by hundreds of folding forgings. And uniformity. Using this forging method, the tool with high hardness and high toughness is produced, and its craftsmanship and performance make the contemporary material industry stand out.
  • the fly in the ointment is that under the conditions of the craft level at that time, the folding forging can not avoid the pollution and oxidation of the interface, and only through the large deformation, the oxide film at the interface is fully broken and dispersed to achieve the welding.
  • a plasma cleaning technology which uses a high-voltage alternating electric field generated by a radio frequency power source to oscillate process gases such as oxygen, argon, and hydrogen into ions having high reactivity or high energy, and then Reacts or collides with organic pollutants and micro-particle contaminants to form volatile substances. These volatile substances are removed by working gas flow and vacuum pump to achieve surface cleaning and activation. It is the most thorough stripping cleaning method in cleaning method. .
  • the technology is characterized in that it can be deeply penetrated into the micro-holes and recesses on the surface of the blank to clean the surface, effectively remove surface oil, and increase its surface activity and improve the soldering effect. Moreover, it also avoids the use of harmful solvents, does not produce harmful pollutants after cleaning, and is environmentally friendly.
  • the object of the present invention is to provide a method for constructing a homogenized forging piece, which uses low-cost continuous casting billet as raw material, through surface processing and After cleaning, multiple slabs are sealed together by vacuum electron beam, and then a forging process characterized by large deformation holding pressure and multi-directional forging is applied, and the interface is sufficiently welded and dispersed to finally realize the composition at the interface. , the extent to which tissue and inclusion levels are consistent with the substrate.
  • a method for constructing a homogenized forging piece firstly preforming: cutting a plurality of continuously cast slabs into a specified size, The surface to be welded is flattened by a milling machine, and vacuum plasma cleaning is used, and the blanks are superposed and then subjected to electron beam sealing around the soldering surface in the vacuum chamber; then the blank is forged and homogenized: the welded billet is heated to The specified temperature is released, and the forging is performed on the hydraulic machine.
  • the first upsetting process is carried out to carry out the pressure-preserving and forging insulation measures in the forging, so that the interface is fully welded, and the subsequent drawing process adopts a three-way forging method to disperse the welding interface and make the interface
  • the composition, organization, and inclusions reach the level consistent with the substrate; final forming: forging the blank into the final size; the specific steps of the method are as follows:
  • the first step is to cut the continuous casting billet according to a certain specification
  • the second step is to process and clean the surface to be welded
  • the third step is vacuum electron beam welding of the blank
  • the fourth step is to perform pre-forging heating on the blank
  • the blank is subjected to upsetting and pressure-bearing forging
  • the high temperature diffusion connection is performed on the blank
  • the lengthening forging is performed in the Y direction
  • the lengthening forging is performed in the X direction
  • the lengthening forging is performed in the Z direction
  • the blank is forged into the final forging size.
  • the ratio of the length to the width is 2:3, and a suitable number of cut slabs are prepared and superimposed.
  • the method for constructing a homogenized forging piece is as follows.
  • the surface to be welded is processed by a gantry milling machine, and then placed in a vacuum chamber, and the surface to be welded is cleaned by plasma to ensure a clean surface and expose fresh metal. .
  • the blank is placed in a vacuum chamber and superimposed, and vacuum electron beam welding is performed around the surface to be welded, and the welding depth is 10 to 50 mm.
  • the heated blank is placed on the operation platform of the forging press to make the height direction coincide with the vertical direction; the thick plate is used to carry the blank along the height Z direction.
  • Upsetting; ⁇ roughing is carried out in two steps. First, 10% of the total height of the blank is pressed, and the pressure is applied to the blank for 5 minutes; then the boring is continued until the height of the blank is 50% of the original height, and the pressure is applied to the blank for 10 minutes. .
  • the method of forming the construct prepared homogenized forging, the sixth step, upsetting the billet heating furnace back, the heating temperature is 0.85T m, T m is the melting point of the material, the unit is °C; average blank holding time after temperature of 20T h h, T h is the height of the blank after upsetting, the unit is m.
  • the method for constructing and forming a homogenized forging piece, in the seventh step, using a flat anvil to lengthen the steel in the length Y direction to be wide (X): long (Y): high (Z) 3:4:2 The cuboid.
  • the method for constructing a homogenized forging piece is as follows.
  • the method for constructing a homogenized forging piece is as described.
  • the evolution process of the blank during the upset forging process is analyzed: as shown in Fig. 1, (a) at the beginning of the deformation, the hole is crushed and the grain is distorted; (b) the hole is macroscopically closed. Crack-like defects are formed, and the matrix recrystallizes; (c) the crack defects are decomposed into cylinders or spherical micropores; (d) grain boundary migration, grain growth, and micropores gradually disappear under atomic diffusion. Metallurgical bonding between the two slabs is achieved.
  • the healing process of the hole-type defect includes the sealing of the closed and closed surfaces of the hole: the closed means that the surface of the hole is physically contacted under the action of stress and strain, and the welding means that the closed surface is under a certain temperature, contact pressure and holding time.
  • Metallurgical bonding is achieved by diffusion, recrystallization, and the like.
  • Closure is the premise of achieving welding.
  • the forged welding blank is processed by forging, and the strain at the center of the blank is much larger than that of the rolling method. Welding is the key to achieve complete healing of the defects.
  • the inventor has systematically studied in the early stage and found that although some defects on the microscopic scale have been closed, they have not been welded, and it is easy to re-open under the action of external force. At the same time, the interface composition, the structure and the matrix of the solder joint are greatly different, forming a "bonding zone". This "scar" tissue needs to be deformed and can be completely eliminated after long-time high-temperature heat
  • the present invention proposes a method of "holding in forging”, “forging insulation”, and “multi-directional forging” to achieve healing of the interface and homogenization of components and tissues.
  • “Forging pressure in forging” can ensure the welding of the two surfaces to the greatest extent, avoiding the interface just welded together to re-open under external force;
  • “Forging insulation” can guarantee the diffusion through high temperature, so that the microscopic still exists during deformation The microscopic holes are completely healed;
  • multi-directional forging can ensure large deformation of the welding interface in multiple directions, so that the residual oxide film on the interface is dispersed into the matrix as much as possible, reducing its damage to mechanical properties.
  • the above methods can be used in combination to maximize the consistency of the interface with the substrate.
  • the invention breaks through the traditional means that the large-section forging can only adopt the die-cast steel ingot as the base material, and combines the advantages of the metallurgical industry and the mechanical industry through the method of continuous casting blank forging, which not only reduces the manufacturing cost but also improves the manufacturing cost.
  • the quality of the products while reducing the production of a large number of die-cast steel ingots, can also make an important contribution to energy saving and emission reduction.
  • the multi-piece continuous casting billet forging is far better than the die-cast steel ingot, especially the chemical composition of the two ends after the forming of the forging blank is basically the same, and the forgings made by the die-cast steel ingot have great differences.
  • the continuous casting billet is used as the base material of the forging, the weight of the blank can be accurately calculated, and the die-cast steel ingot is used as the base material of the forging, which is limited by the cutting riser, the nozzle, and the ingot type specification, and 20 to 30% of the material is wasted.
  • the continuous casting billet has the advantage of large-scale production, and the cost per ton of steel is only 70% of the cost of the die-cast steel ingot.
  • the continuous casting blank forging method reduces the manufacturing cost of the forging, and also broadens the application range of the continuous casting blank, and increases the added value of the product.
  • Figure 1 shows the mechanism of interface defect healing. Among them, (a) the beginning of deformation; (b) the macroscopic closure of the hole; (c) the instability decomposition of the crack defect; (d) metallurgical bonding.
  • FIG. 2 is a photograph of a continuous casting blank after superposition and sealing welding in an embodiment of the present invention.
  • Figure 3 is a photograph of a blank of a forging process in an embodiment of the present invention.
  • Figure 4 is a process flow diagram of the present invention. Among them, (a) continuous casting slab cutting and cutting; (b) milling the surface to be welded flat, exposing fresh metal, and performing plasma cleaning; (c) electron beam sealing around the interface in the vacuum chamber; ()) heating in a high-temperature furnace; (e) using a thick plate on the hydraulic machine to be upset in a direction perpendicular to the surface to be welded; (f) after the upset deformation is in place, maintaining pressure on the blank to fully weld the defect (g) The billet is roughed and then returned to the furnace for high temperature diffusion; (h) ⁇ (i) three-way forging of the billet to ensure large deformation in each direction; (j) forging the billet into the final part shape and size.
  • Fig. 5 is a view showing the metallographic structure corresponding to the position of the original welding interface after the forging is completed in the embodiment of the present invention.
  • Fig. 6 is a view showing the center position of the forging blank obtained by forging a conventional steel ingot in Comparative Example 1.
  • Fig. 7 is a view showing the metallographic structure corresponding to the position of the original welding interface after the deformation in the conventional lamination method is completed in Comparative Example 2. Among them, (a) the center area of the blank, and (b) the edge area of the blank.
  • the process flow of the continuous casting blank forging method for preparing a homogenized forging according to the present invention is as follows:
  • Continuous casting method is used to cast continuous casting slab with a width of 1200 mm and a thickness of 200 mm.
  • the steel type is 25Cr2Ni4MoV, and the chemical composition is listed in Table 1.
  • the steel is a common steel for pressure vessels. Cut the appropriate size blank, seal it in the vacuum chamber after processing and cleaning, and then forge it. The specific steps are as follows:
  • the second step is to process and clean the surface to be welded.
  • the surface to be welded is processed by a gantry milling machine, and then placed in a vacuum chamber, and the surface to be welded is cleaned by plasma to ensure that the surface is highly clean and exposes fresh metal.
  • the blank is subjected to vacuum electron beam welding.
  • the blank was placed in a vacuum chamber and superimposed, and vacuum electron beam welding was performed around the surface to be welded, and the welding depth was 50 mm (Fig. 2).
  • the billet is heated before forging.
  • the welded blank was sent to a heating furnace at a heating temperature of 1,250 °C.
  • the blank is subjected to upsetting and pressure-bearing forging. Place the heated billet on the forging press operating platform to make it high The degree direction is consistent with the vertical direction.
  • the billet is upset in the height Z direction by the upsetting plate, and the upsetting is carried out in two steps. First, 10% of the total height of the billet is pressed, and the pressure is applied to the billet for 5 min. Then continue to upset until the billet height is 50% of the original height and the pressure is applied to the billet for 10 min ( Figure 3).
  • the billet is subjected to a high temperature diffusion connection.
  • the billet after the upsetting is sent back to the heating furnace for heating, the heating temperature is 1250 ° C, and the holding time after the billet is uniform temperature is 6 hours.
  • the blank is forged into the final forging size, the thickness is 180 mm, the length is 1000 mm, and the width is 1000 mm.
  • Comparative Example 1 used a conventional die-cast steel ingot and forging process. The specific steps are as follows:
  • the first step is to make a steel ingot mold, a chassis, a riser box, and a middle injection tube.
  • the steel ingot steel ingot mold, the chassis, the riser box and the middle injection tube of the 2 tons of steel ingot are made of gray iron, and the riser insulation board, the protective slag, the carbonized rice husk, the heat generating agent and the like are prepared.
  • the second step is to assemble the ingot mold.
  • the ingot mold and the middle injection tube are seated on the chassis, and the riser is seated on the ingot mold, and the protective residue is hung in the ingot mold.
  • the third step is smelting and pouring. Smelt 2 tons of molten steel and carry out pouring. After the pouring is completed, the carbonized rice husk is placed on the upper part of the riser for heat preservation.
  • the fourth step is demoulding. Five hours after the ingot casting was completed, demolding was carried out to obtain a steel ingot having a size of ⁇ 280 ⁇ 1000 mm.
  • the fifth step is to cut the material.
  • the ingot riser and the nozzle are cut off to obtain a billet.
  • the sixth step is heating.
  • the billet was placed in a heating furnace at a heating temperature of 1250 ° C, and the holding time after the billet was allowed to stand for 6 hours.
  • the blank is forged into the final forging size, the thickness is 180 mm, the length is 1000 mm, and the width is 1000 mm.
  • Comparative Example 2 The chemical composition and final workpiece size selected in Comparative Example 2 were the same as in Example 1, and Comparative Example 2 was carried out by a conventional composite rolling process. The specific steps are as follows:
  • the second step is to process and clean the surface to be welded.
  • the surface to be welded is processed by a gantry milling machine, and then the surface to be welded is cleaned with alcohol or acetone. .
  • the blank is subjected to vacuum electron beam welding.
  • the blank was placed in a vacuum chamber and superimposed, and vacuum electron beam welding was performed around the surface to be welded, and the welding depth was 50 mm.
  • the fourth step is to heat the billet before rolling.
  • the welded blank was sent to a heating furnace at a heating temperature of 1,250 °C.
  • the billet is rolled.
  • the heated billet is placed on a wide plate mill for rolling, and the average reduction is 30 mm in a single pass.
  • the cross rolling and the longitudinal rolling are combined to form a total of 14 passes, and the billet is rolled to a thickness of 180 mm and a length of 1000 mm.
  • the width is 1000mm.
  • Example 1 and Comparative Example 1 and Comparative Example 2 the forged piece was sawed along the middle portion, and the test piece at the position of the welding interface was taken and etched with nitric acid alcohol.
  • the specific low-fold structure is shown in Fig. 5 and Fig. 6 and Fig. 7. It can be seen from the figure that the continuous casting slab forging according to the present invention is similar to the conventional method, and the microstructure is basically the same, and the structural abnormality is not found at the original interface position, but the continuous casting blank forging method of the present invention improves the material compared with the conventional method forging method. Utilization rate is 30%.
  • the thick plate produced by the continuous casting slab rolling method there is an interface that has not been completely rolled at the center position (Fig.
  • the results of the examples show that the invention breaks through the conventional method for manufacturing forgings by using a die-cast steel ingot, and adopts vacuum cleaning and electron beam welding of continuous casting blanks to implement the measures of forging and forging insulation in forging, so that the interface is fully welded.
  • the subsequent drawing process adopts a three-way forging method to disperse the welding interface, so that the composition, the structure and the inclusions at the interface reach a level consistent with the matrix.
  • the invention can greatly reduce the manufacturing cost, improve the material utilization rate, solve the problems of segregation, coarse crystal, inclusion and loose pores which are difficult to be overcome by the conventional steel ingot, and realize the heat manufacture of the homogenized forging. Additionally, the invention is also applicable to heterogeneous metal connections.

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Abstract

一种制备均质化锻件的构筑成形方法涉及锻件锻造领域。该方法包括：首先预制坯：将多块连铸板坯下料为指定尺寸，通过铣床将待焊合表面加工平整，并采用真空等离子清洗，将坯料叠合后在真空室内对待焊合面四周进行电子束封焊；然后坯料锻焊及均匀化：将焊后的坯料加热到指定温度出炉，在液压机上锻造，采取锻中保压、锻间保温、三向锻造的方法，使界面充分焊合并分散，保障原始界面处的成分、组织、夹杂物达到与基体一致的水平；最后成形：将坯料锻造成最终规格尺寸。该方法突破了采用模铸钢锭制造锻件的传统方法，利用较为廉价的连铸坯叠锻，不但可降低制造成本20％以上，而且彻底解决了大锻件的宏观偏析、中心缩孔疏松问题。

Description

一种制备均质化锻件的构筑成形方法 技术领域
本发明涉及锻件锻造领域，具体地说是一种制备均质化锻件的构筑成形方法，适于均质化锻件的连铸坯叠锻成形。
背景技术
锻件作为冶金机械、石油化工、交通运输、能源电力等领域大型成套装备的核心零部件，在国民经济建设、国防装备和重大科学装置中发挥着极其重要的作用，其生产能力和质量水平是衡量一个国家自主能力与国力强弱的重要标志。因此，提高锻件的内在质量，保证其运行过程中的安全性和可靠性具有十分重要的意义。
锻件一般由钢锭锻造而成，在钢锭内部，由于金属凝固收缩而不可避免地产生大量的显微缩孔和疏松缺陷，这些孔洞型缺陷弥散分布在钢锭心部，破坏了材料的连续性，影响锻件的力学性能。同时，由于凝固过程的溶质再分配，大断面的钢锭凝固末期不但合金浓度高，而且往往富集低熔点物质和杂质元素，形成宏观偏析，造成钢锭头尾之间的力学性能存在较大差距，影响锻件性能的均匀性和使用的安全性。为了降低这种负面作用，当前工业上普遍采用钢锭锭切头切尾方法，切除率常达30％以上，大幅降低了材料利用率，产品经济性较差。
连铸板是当前钢铁工业大生产中最稳定、最成熟的产品之一。连铸坯的特点是制造成本低、生产效率高，并且在一定规格以下(一般板坯为300mm，圆坯为600mm)，其内部组织较为致密、宏观偏析程度较轻。然而，由于快速凝固和无冒口补缩的特点限制，当连铸坯的截面尺寸达到上述规格以上时，铸坯中心容易产生贯穿性缩孔，切割后发生氧化，无法通过后续轧制或锻造使其愈合，进而限制了其应用范围。因此，目前高品质的锻件尚无法采用连铸坯进行制备，仍采用成本较高的模铸钢锭作为母材。
近年来，随着大功率电子束发生器的开发成功，在特厚板制造领域出现了一种真空复合轧制方法(文献：Development of new heavy gauge steel plate using cladding technology.JFE Technical Report,2004,5(8):65)，这种方法是将常规厚度的板坯叠加在一起，采用真空电子束对界面四周进行封焊，然后进行加热和轧制，进而获得特厚板的方法。这种方法利用了真空电子束焊接，避免了界面的严重污染和高温氧化，通过轧制过程金属的高温扩散焊原理，将多块板坯连接在一起，解决了钢厂不能生产特厚板坯的问题。然而，扩散焊过程的三要素是温度、压力和时间，虽然轧制过程在高温高压下进行，但轧制速度较快，压力仅在瞬间施加在复合界面上，难以实现界面的完全焊合和达到与基体一致。同时，相比锻造，轧制过程的 特点是变形方向单一、变形量较小，应变主要分布在坯料表面，中心的应变量最小，这对于处于中心位置的界面焊合是不利的。文献(谢广明等，轧制工艺对真空轧制复合钢板组织与性能的影响，钢铁研究学报，2011，23(12)27-30)研究了不同轧制压下率对界面焊合效果的影响，发现只有压下比达到70％时，界面处的Z向拉伸强度才能达到与基体一致的程度。这说明在较小的压下率下，界面焊合不充分，仍存在显微疏松和氧化膜，严重材料的力学性能，尤其对一些在交变载荷下服役的部件来说是不可接受的。因此，当前采用真空复合轧制方法制备的特厚板，仅限于在非苛刻载荷环境下使用。
相比之下，锻造作为一种延续了数千年的金属压力加工手段，虽然效率没有轧制高，但变形方式灵活，可实现坯料的单次大变形和多向变形。在当代工业革命之前，较高品质的金属器件，如：刀剑等均采用锻造方法生产。受当时冶炼水平限制，锻件的母材是海绵铁，通过反复大变形，可破碎金属内部的夹杂物，通过表面积延展和氧化可实现脱碳，通过上百次的折叠锻打可提升材料的韧性和均匀性。采用这种锻造方式，生产出兼具高硬度和高韧性的刀具，其工艺水平和性能令当代材料界叹为观止。美中不足的是，在当时的工艺水平条件下，折叠锻打还无法避免界面的污染和氧化，只能通过多次的大变形，使界面处的氧化膜充分破碎、分散而实现焊合。
近年来，在表面清洁领域发展出一种等离子清洗技术，这种技术利用射频电源产生的高压交变电场，将氧、氩、氢等工艺气体震荡成具有高反应活性或高能量的离子，然后与有机污染物及微颗粒污染物反应或碰撞形成挥发性物质，由工作气体流及真空泵将这些些挥发性物质清除出去，从而达到表面清洁活化的目的，是清洗方法中最为彻底的剥离式清洗。该技术的特点是可深入到坯料表面的微细孔眼和凹陷的内部完成清洗，有效清除表面油污，并能增加其表面活性，提高焊合效果。并且，还避免使用有害溶剂，清洗后不会产生有害污染物，绿色环保。
发明内容
基于刀剑的叠锻成形思想和等离子清洗、真空电子束焊接等技术，本发明的目的在于提供一种制备均质化锻件的构筑成形方法，以低成本的连铸坯为原料，通过表面加工和清洁后，利用真空电子束将多块板坯封焊在一起，然后施加以大变形保压和多向锻造为特点的锻焊工艺，将界面充分焊合并使其分散，最终实现界面处的成分、组织和夹杂物水平与基体一致的程度。
本发明的技术方案为：
一种制备均质化锻件的构筑成形方法，首先预制坯：将多块连铸板坯下料为指定尺寸， 通过铣床将待焊合表面加工平整，并采用真空等离子清洗，将坯料叠合后在真空室内对待焊合面四周进行电子束封焊；然后坯料锻焊及均匀化：将焊后的坯料加热到指定温度出炉，在液压机上进行锻造，首次镦粗过程实施锻中保压、锻间保温的措施，使界面充分焊合，后续镦拔过程采取三向锻造方法，将焊合界面分散，使界面处的成分、组织、夹杂物达到与基体一致的水平；最后成形：将坯料锻造成最终规格尺寸；该方法的具体步骤如下：
第一步，按照一定的规格裁切连铸坯；
第二步，加工、清洗待焊接表面；
第三步，对坯料进行真空电子束焊接；
第四步，对坯料实施锻前加热；
第五步，对坯料实施镦粗与保压锻焊；
第六步，对坯料实施高温扩散连接；
第七步，沿Y方向进行实施拔长锻造；
第八步，沿X方向进行实施拔长锻造；
第九步，沿Z方向进行实施拔长锻造；
第十步，将坯料锻造成形至最终锻件尺寸。
所述的制备均质化锻件的构筑成形方法，第一步中，裁切连铸坯时，使长度和宽度的比例为2:3，准备合适数量裁切后的连铸坯，使其叠加之后总高度与宽度的比例为2:1，即叠加后宽(X)：长(Y)：高(Z)＝2:3:4，便于实施三向锻造。
所述的制备均质化锻件的构筑成形方法，第二步中，采用龙门铣床加工待焊合表面，然后放入真空室中，使用等离子清洗待焊合表面，保障表面高度清洁，露出新鲜金属。
所述的制备均质化锻件的构筑成形方法，第三步中，将坯料放入真空室并叠加好，对待焊合面四周进行真空电子束焊接，焊接深度为10～50mm。
所述的制备均质化锻件的构筑成形方法，第四步中，将焊接完成的坯料送入加热炉加热，加热温度为0.85Tm，Tm为材料的熔点，单位为℃。
所述的制备均质化锻件的构筑成形方法，第五步中，将加热后的坯料放置于锻压机操作平台上，使高度方向与垂直方向一致；采用镦粗板沿高度Z方向对坯料进行镦粗；镦粗分两步进行，首先压下坯料总高度的10％，保持压力作用于坯料5min；然后继续镦粗，至坯料高度为原始高度的50％时停止，保持压力作用于坯料10min。
所述的制备均质化锻件的构筑成形方法，第六步中，将镦粗后的坯料送回加热炉加热，加热温度为0.85Tm，Tm为材料的熔点，单位为℃；坯料均温后的保温时间为20Th小时，Th 为坯料镦粗后的高度，单位为m。
所述的制备均质化锻件的构筑成形方法，第七步中，使用平砧沿长度Y方向将钢锭拔长为宽(X)：长(Y)：高(Z)＝3:4:2的长方体。
所述的制备均质化锻件的构筑成形方法，第八步中，使用平砧沿坯料长度Y方向进行镦粗50％，变形到指定尺寸后，沿宽度X方向将坯料拔长为宽(X)：长(Y)：高(Z)＝4:2:3的长方体。
所述的制备均质化锻件的构筑成形方法，第九步中，使用平砧沿坯料宽度X方向进行镦粗50％，变形到指定尺寸后，沿高度Z方向将坯料拔长为宽(X)：长(Y)：高(Z)＝2:3:4的长方体。
本发明的物理冶金学和力学分析如下：
在连铸坯叠加、封焊边缘之后，虽然在宏观上界面两侧的板接触在一起，实际上由于板坯表面存在一定的粗糙度，微观上两块板之间是多点接触，在接触点之间存在大量空隙，这种空隙可以等效为孔洞。
以其中一个孔洞为例，分析在坯料在镦粗锻造过程其演化历程：如图1所示，(a)变形开始阶段，孔洞被压扁，晶粒发生畸变；(b)孔洞宏观上闭合，形成裂纹状缺陷，基体发生再结晶；(c)裂纹缺陷失稳分解为圆柱体或球状微孔洞；(d)晶界迁移、晶粒长大，微孔洞在原子扩散作用下逐渐消失，两块板坯之间实现冶金结合。
孔洞型缺陷的愈合过程包括孔洞的闭合与闭合表面的焊合：闭合是指孔洞表面在应力应变的作用下实现物理接触，焊合是指闭合表面在一定温度、接触压力以及保温时间的条件下通过扩散、再结晶等方式实现冶金结合。闭合是实现焊合的前提，采用锻造方式加工叠焊后的坯料，坯料中心的应变量远大于采用轧制方法。焊合是实现缺陷完全愈合的关键，发明人前期通过系统的实验研究，发现显微尺度上一些缺陷虽然已经闭合，但尚未焊合，在外力作用下极易重新张开。同时，刚刚焊合的界面成分、组织与基体存在较大差异，形成“结合带”，这种“瘢痕”组织需变形后长时间高温热处理才能完全消除。
基于上述考虑，本发明提出了“锻中保压”、“锻间保温”，以及“多向锻造”的方法实现界面的愈合和成分、组织的均匀化。“锻中保压”可以保障最大程度上实现两个表面的焊合，避免刚刚焊合的界面在外力下重新张开；“锻间保温”可以保障通过高温扩散，使变形时微观上仍存在的显微孔洞完全愈合；“多向锻造”可以保障焊合界面在多个方向上均发生大变形，使界面上残留的氧化膜尽可能地分散到基体当中，降低其对力学性能的危害。上述方法结合使用，可以最大程度上实现界面与基体的一致性。
本发明突破了大断面锻件只能采用模铸钢锭作为母材的传统手段，通过连铸坯叠锻的方法，将冶金行业与机械行业的优势结合在一起，既降低了制造成本，又提升了产品品质，同时减少大量的模铸钢锭生产，还可为节能减排做出重要贡献。
本发明具有如下的优点和有益效果：
1、实现大断面锻件均质化制造。采用多块连铸坯叠锻，其成分均匀性远远好于模铸钢锭，尤其是锻坯成形后两端的化学成分基本一致，而模铸钢锭制成的锻件则存在较大差别。
2、实现大断面锻件致密化制造。采用的连铸坯组织比较致密，不存在中心疏松。焊合界面经保温、保压和多向锻造后，致密性高于模铸钢锭制成的锻件。
3、实现大断面锻件纯净化制造。钢厂生产连铸坯时一般采用RH炉脱气，机械厂生产模铸钢锭时一般采用VD炉脱气，RH炉因循环作用其脱气效果远好于VD炉，因此连铸坯中全氧含量低于模铸钢锭，进而夹杂物水平也相对较低。采用连铸坯叠锻方法制造锻件，夹杂物总体水平低于模铸钢锭制成的锻件。
4、实现大断面锻件低成本制造。采用连铸坯作为锻件母材，下料重量可以精确计算，而采用模铸钢锭作为锻件母材，受切割冒口、水口，以及锭型规格限制，有20～30％的材料浪费。同时，连铸坯存在规模化生产优势，吨钢成本仅为模铸钢锭成本的70％。连铸坯叠锻方法在降低锻件制造成本的同时，也拓宽了连铸坯的应用范围，提升了产品附加值。
5、实现大断面锻件清洁化、稳定化制造。模铸钢锭生产品种多、批量小，浇注前需准备模具、浇道、保温材料，人工准备工作较多，同时浇注后冒口发热剂和覆盖剂存在较大的环境污染。采用连铸坯真空电子束焊接和叠锻，过程可实现完全自动化，不但可以改善劳动环境，而且减少了人为因素影响，产品质量将更加稳定。
附图说明
图1为界面缺陷愈合机理。其中，(a)变形开始阶段；(b)孔洞宏观上闭合；(c)裂纹缺陷失稳分解；(d)冶金结合。
图2为本发明实施例中，叠加并封焊后的连铸坯照片。
图3为本发明实施例中，锻造过程的坯料照片。
图4为本发明工艺流程图。其中，(a)连铸板坯切割下料；(b)将待焊接表面铣磨平整，露出新鲜金属，并进行等离子清洗；(c)在真空室内对界面四周进行电子束封焊；(d)放入高温炉中加热；(e)在液压机上采用镦粗板沿垂直于待焊合面的方向镦粗；(f)镦粗变形到位后，保持压力作用于坯料，使缺陷充分焊合；(g)坯料镦粗后回炉高温扩散；(h)～(i)对坯料实施三向锻造，保障每个方向均有大变形；(j)将坯料锻造成最终零件形状和尺寸。
图5为本发明实施例中，锻造结束后，对应原焊接界面位置的金相组织。
图6为比较例1中，采用传统钢锭锻造后获得锻坯中心位置组织。
图7为比较例2中，采用传统叠轧方式变形结束后，对应原焊接界面位置的金相组织。其中，(a)坯料中心区域，(b)坯料边缘区域。
具体实施方式
如图4所示，本发明制备均质化锻件的连铸坯叠锻方法工艺流程如下：
(a)连铸板坯切割下料→(b)将待焊接表面铣磨平整，露出新鲜金属并进行等离子清洗→(c)在真空室内对界面四周进行电子束封焊→(d)放入高温炉中加热→(e)在液压机上采用镦粗板沿垂直于待焊合面的方向镦粗→(f)镦粗变形到位后，保持压力作用于坯料，使缺陷充分焊合→(g)坯料镦粗后回炉高温扩散→(h)～(i)对坯料实施三向锻造，保障每个方向均有大变形→(j)采用常规的镦粗、拔长、滚圆、冲孔、扩孔、芯棒拔长等自由锻手段，将坯料锻造成最终零件形状和尺寸。
下面通过实施例、比较例和实验例对本发明进一步详细说明。
实施例1
采用连铸方式，浇注宽度1200mm、厚度200mm连铸板坯，其钢种为25Cr2Ni4MoV，化学成分为列于表1，该钢种为常见的压力容器用钢。切取适当规格坯料，加工、清洗后在真空室内封焊，然后进行锻造，具体步骤如下：
表1 25Cr2Ni4MoV钢的实测成分(重量百分数，％)
元素 C Si Mn P S Cr Ni Mo V
成分 0.21 0.039 0.27 0.005 0.005 1.64 3.46 0.39 0.095
第一步，按照一定的规格裁切连铸坯。切取规格为200×450×300mm连铸坯3块，使其叠加之后，宽＝300mm，长＝450mm，高＝600mm，便于实施三向锻造。
第二步，加工、清洗待焊接表面。采用龙门铣床加工待焊合表面，然后放入真空室中，使用等离子清洗待焊合表面，保障表面高度清洁，露出新鲜金属。
第三步，对坯料进行真空电子束焊接。将坯料放入真空室并叠加好，对待焊合面四周进行真空电子束焊接，焊接深度为50mm(图2)。
第四步，对坯料实施锻前加热。将焊接完成的坯料送入加热炉加热，加热温度为1250℃。
第五步，对坯料实施镦粗与保压锻焊。将加热后的坯料放置于锻压机操作平台上，使高 度方向与垂直方向一致。采用镦粗板沿高度Z方向对坯料进行镦粗，镦粗分两步进行，首先压下坯料总高度的10％，保持压力作用于坯料5min。然后继续镦粗，至坯料高度为原始高度的50％时停止，保持压力作用于坯料10min(图3)。
第六步，对坯料实施高温扩散连接。将镦粗后的坯料送回加热炉加热，加热温度为1250℃，坯料均温后的保温时间为6小时。
第七步，沿Y方向进行实施拔长锻造，变形至坯料宽＝450mm，长＝600mm，高＝300mm。
第八步，沿X方向进行实施拔长锻造。变形至坯料宽＝600mm，长＝300mm，高＝450mm。
第九步，沿Z方向进行实施拔长锻造。变形至坯料宽＝300mm，长＝450mm，高＝600mm。
第十步，将坯料锻造成形至最终锻件尺寸，厚度180mm，长度1000mm，宽度1000mm。
比较例1
比较例1中选用的材料化学成分和最终工件尺寸均与实施例1中一致，比较例1采用常规的模铸钢锭、锻造工艺，具体步骤如下：
第一步，制造钢锭模、底盘、冒口箱、中注管。采用灰铁制造2吨钢锭的钢锭钢锭模、底盘、冒口箱、中注管，并准备冒口保温板、保护渣、碳化稻壳、发热剂等辅料。
第二步，装配钢锭模。在底盘上砌流钢砖，制作浇道。将钢锭模和中注管座于底盘上，将冒口座于钢锭模上，将保护渣挂于钢锭模内。
第三步，冶炼浇注。冶炼2吨钢水并进行浇注，浇注结束后，将碳化稻壳放于冒口上部进行保温。
第四步，脱模。钢锭浇注结束5小时后，进行脱模，获得尺寸为Φ280×1000mm的钢锭。
第五步，下料。将钢锭冒口、水口切除，获得坯料。
第六步，加热。将坯料放置于加热炉内，加热温度为1250℃，坯料均温后的保温时间为6小时。
第七步，沿Y方向进行实施拔长锻造，变形至坯料宽＝450mm，长＝600mm，高＝300mm。
第八步，沿X方向进行实施拔长锻造。变形至坯料宽＝600mm，长＝300mm，高＝450mm。
第九步，沿Z方向进行实施拔长锻造。变形至坯料宽＝300mm，长＝450mm，高＝600mm。
第十步，将坯料锻造成形至最终锻件尺寸，厚度180mm，长度1000mm，宽度1000mm。
比较例2
比较例2中选用的材料化学成分和最终工件尺寸均与实施例1中一致，比较例2采用常规的复合轧制工艺，具体步骤如下：
第一步，按照一定的规格裁切连铸坯。切取规格为200×450×300mm连铸坯3块，使其 叠加之后宽＝300mm，长＝450mm，高＝600mm。
第二步，加工、清洗待焊接表面。采用龙门铣床加工待焊合表面，然后采用酒精、丙酮清洗待焊接表面。。
第三步，对坯料进行真空电子束焊接。将坯料放入真空室并叠加好，对待焊合面四周进行真空电子束焊接，焊接深度为50mm。
第四步，对坯料轧前加热。将焊接完成的坯料送入加热炉加热，加热温度为1250℃。
第五步，对坯料实施轧制。将加热后的坯料放置于宽厚板轧机上进行轧制，单次压下量平均为30mm，采用横轧、纵轧相结合的方式，共轧14道，将坯料轧至厚度180mm，长度1000mm，宽度1000mm。
实验例1
对于实施例1中和比较例1、比较例2中的锻件沿中部锯开，取焊合界面位置处试片，用硝酸酒精进行腐蚀，具体低倍组织见图5和图6、图7。由图可见，采用本发明的连铸坯叠锻与采用常规方法锻造，显微组织基本一致，未在原界面位置发现组织异常，但本发明的连铸坯叠锻方法较常规方法锻造方法提高材料利用率30％。而采用连铸坯叠轧方式生产的厚板，在中心位置存在尚未完全轧合的界面(图7a)，在边缘位置，由于是多道次轧制，在前几道轧制过程中，叠加的复合面产生剪切应力，电子束焊接位置破裂，待焊合表面发生氧化，变形结束后，形成非常明显的界面组织，如图7b所示。
实施例结果表明，本发明突破了常规的使用模铸钢锭制造锻件的方法，通过连铸坯真空清洗、电子束焊接，实施锻中保压、锻间保温的措施，使界面充分焊合，后续镦拔过程采取三向锻造方法，将焊合界面分散，使界面处的成分、组织、夹杂物达到与基体一致的水平。本发明可大幅降低制造成本，提升材料利用率，解决常规钢锭难以克服的偏析、粗晶、夹杂和缩孔疏松等问题，实现均质化锻件的热制造。另外，本发明也可用于异质金属连接。

Claims (10)

  1. 一种制备均质化锻件的构筑成形方法，其特征在于，首先预制坯：将多块连铸板坯下料为指定尺寸，通过铣床将待焊合表面加工平整，并采用真空等离子清洗，将坯料叠合后在真空室内对待焊合面四周进行电子束封焊；然后坯料锻焊及均匀化：将焊后的坯料加热到指定温度出炉，在液压机上进行锻造，首次镦粗过程实施锻中保压、锻间保温的措施，使界面充分焊合，后续镦拔过程采取三向锻造方法，将焊合界面分散，使界面处的成分、组织、夹杂物达到与基体一致的水平；最后成形：将坯料锻造成最终规格尺寸；该方法的具体步骤如下：
    第一步，按照一定的规格裁切连铸坯；
    第二步，加工、清洗待焊接表面；
    第三步，对坯料进行真空电子束焊接；
    第四步，对坯料实施锻前加热；
    第五步，对坯料实施镦粗与保压锻焊；
    第六步，对坯料实施高温扩散连接；
    第七步，沿Y方向进行实施拔长锻造；
    第八步，沿X方向进行实施拔长锻造；
    第九步，沿Z方向进行实施拔长锻造；
    第十步，将坯料锻造成形至最终锻件尺寸。
  2. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第一步中，裁切连铸坯时，使长度和宽度的比例为2:3，准备合适数量裁切后的连铸坯，使其叠加之后总高度与宽度的比例为2:1，即叠加后宽(X)：长(Y)：高(Z)＝2:3:4，便于实施三向锻造。
  3. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第二步中，采用龙门铣床加工待焊合表面，然后放入真空室中，使用等离子清洗待焊合表面，保障表面高度清洁，露出新鲜金属。
  4. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第三步中，将坯料放入真空室并叠加好，对待焊合面四周进行真空电子束焊接，焊接深度为10～50mm。
  5. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第四步中，将焊接完成的坯料送入加热炉加热，加热温度为0.85Tm，Tm为材料的熔点，单位为℃。
  6. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第五步中，将加热后的坯料放置于锻压机操作平台上，使高度方向与垂直方向一致；采用镦粗板沿高度Z 方向对坯料进行镦粗；镦粗分两步进行，首先压下坯料总高度的10％，保持压力作用于坯料5min；然后继续镦粗，至坯料高度为原始高度的50％时停止，保持压力作用于坯料10min。
  7. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第六步中，将镦粗后的坯料送回加热炉加热，加热温度为0.85Tm，Tm为材料的熔点，单位为℃；坯料均温后的保温时间为20Th小时，Th为坯料镦粗后的高度，单位为m。
  8. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第七步中，使用平砧沿长度Y方向将钢锭拔长为宽(X)：长(Y)：高(Z)＝3:4:2的长方体。
  9. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第八步中，使用平砧沿坯料长度Y方向进行镦粗50％，变形到指定尺寸后，沿宽度X方向将坯料拔长为宽(X)：长(Y)：高(Z)＝4:2:3的长方体。
  10. 根据权利要求1所述的制备均质化锻件的构筑成形方法，其特征在于，第九步中，使用平砧沿坯料宽度X方向进行镦粗50％，变形到指定尺寸后，沿高度Z方向将坯料拔长为宽(X)：长(Y)：高(Z)＝2:3:4的长方体。
PCT/CN2015/083018 2015-03-26 2015-07-01 一种制备均质化锻件的构筑成形方法 WO2016150024A1 (zh)

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EP3683006A4 (en) * 2017-09-15 2021-06-09 China Institute of Atomic Energy PROCESS FOR MANUFACTURING A MODULAR METAL CONSTRUCTION
EP3682982A4 (en) * 2017-09-15 2021-06-16 China Institute of Atomic Energy METHOD OF MANUFACTURING A LARGE RING-SHAPED FORGING
EP3683007A4 (en) * 2017-09-15 2021-06-16 China Institute of Atomic Energy Profiled metal construction forming method
KR102325492B1 (ko) * 2017-09-15 2021-11-11 중국 원자능 과학연구원 대형 고리형 단조물의 제조 공정
KR102372970B1 (ko) * 2017-09-15 2022-03-10 중국 원자능 과학연구원 이형 금속 구축 성형 방법
CN113500183A (zh) * 2021-06-02 2021-10-15 维泰(南通)金属材料有限公司 一种基于磁场改善模具钢组织的方法
CN114505433A (zh) * 2022-02-23 2022-05-17 谷城鑫烽精锻有限公司 一种锻件的锻压成型方法

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