Deoxidation during Vacuum Induction Melting Process of DD10 Master Alloy AITranslate
Abstract AITranslate
Oxygen，a significant impurity element，is commonly found in nickel-based superalloy DD10 in the form of oxide inclusions and solid solutions. During practical service，oxide inclusions in superalloys can initiate cracks and diminish essential alloy properties such as plasticity，toughness，creep strength，and endurance. Hence，reducing both the dissolved oxygen content and oxide inclusions in the alloy is imperative for ensuring the cleanness of the nickel-based superalloy master alloy. Given the substantial presence of readily oxidizable constituents within nickel-based superalloys，this study referenced Gibbs free energies associated with various alloying elements reacting with one mole of oxygen in a nickel liquid，analysis of the alloy's deoxidation sequence throughout the complete smelting process was performed using an oxygen potential diagram. Additionally，a nine-element melt coexistence theoretical model for Ni-Ti-Al-Ta-Cr-Mo-Co-W-C was established，and the impact of temperature，vacuum level，and alloy element content on vacuum decarburization was analyzed sequentially. Furthermore，the composition and size of oxide inclusions in master alloy ingots were counted using a scanning electron microscope （SEM）and energy dispersive X-ray spectroscopy （EDS）. The evolution of these inclusions throughout the entire smelting process was summarized by referencing data from the thermodynamic software FactSage 8.2. Furthermore，the equilibrium of the Al-O reaction in the nickel liquid at 1873 K was illustrated employing the Wagner model. The essential quantity of Al required was determined by calculating the minimum balanced oxygen concentration at equilibrium in the model. Subsequently，a comprehensive process for deoxygenation during vacuum induction smelting was meticulously designed. Finally，the accuracy of the model's computational results was substantiated through smelting DD10 master alloy in a laboratory 2 kg vacuum induction furnace. The findings indicated a discernible deoxidation priority among the alloying elements，delineated as follows： Mg，Al，C，Ti，Ta，Cr，Mo，W，and Ni. Constrained by kinetic and temperature conditions，carbon deoxidation alone can only lower the dissolved oxygen content in the alloy to 50×10−6. An additional strong deoxidizing element，Al，was required for a secondary，more thorough deoxidation. Based on Al-O equilibrium theory calculations，as Al content increased，the dissolved oxygen content initially rose and then subsequently decreased. At the Al content reached 0.256%，the equilibrium oxygen content reached its theoretical minimum of 0.56×10−6. In summary，this paper designed a deoxygenation process in DD10 master alloy vacuum induction smelting，which comprised three stages： primary carbon deoxidation，secondary aluminum deoxidation，and aluminum alloying. Initially，the dissolved oxygen content was lowered to 50×10−6 through carbon deoxidation in the early smelting stage. Subsequently，0.265% Al was added to further reduce the dissolved oxygen content in the alloy to 0.56×10−6. Finally，the alloying of Al and other oxidation prone elements occurredin the late smelting stage.
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Basic Information:
DOI：10.13373/j.cnki.cjrm.XY23100006
Chinese Library Classification Number:TF133
Citation Information:
Oxygen，a significant impurity element，is commonly found in nickel-based superalloy DD10 in the form of oxide inclusions and solid solutions. During practical service，oxide inclusions in superalloys can initiate cracks and diminish essential alloy properties such as plasticity，toughness，creep strength，and endurance. Hence，reducing both the dissolved oxygen content and oxide inclusions in the alloy is imperative for ensuring the cleanness of the nickel-based superalloy master alloy. Given the substantial presence of readily oxidizable constituents within nickel-based superalloys，this study referenced Gibbs free energies associated with various alloying elements reacting with one mole of oxygen in a nickel liquid，analysis of the alloy's deoxidation sequence throughout the complete smelting process was performed using an oxygen potential diagram. Additionally，a nine-element melt coexistence theoretical model for Ni-Ti-Al-Ta-Cr-Mo-Co-W-C was established，and the impact of temperature，vacuum level，and alloy element content on vacuum decarburization was analyzed sequentially. Furthermore，the composition and size of oxide inclusions in master alloy ingots were counted using a scanning electron microscope （SEM）and energy dispersive X-ray spectroscopy （EDS）. The evolution of these inclusions throughout the entire smelting process was summarized by referencing data from the thermodynamic software FactSage 8.2. Furthermore，the equilibrium of the Al-O reaction in the nickel liquid at 1873 K was illustrated employing the Wagner model. The essential quantity of Al required was determined by calculating the minimum balanced oxygen concentration at equilibrium in the model. Subsequently，a comprehensive process for deoxygenation during vacuum induction smelting was meticulously designed. Finally，the accuracy of the model's computational results was substantiated through smelting DD10 master alloy in a laboratory 2 kg vacuum induction furnace. The findings indicated a discernible deoxidation priority among the alloying elements，delineated as follows： Mg，Al，C，Ti，Ta，Cr，Mo，W，and Ni. Constrained by kinetic and temperature conditions，carbon deoxidation alone can only lower the dissolved oxygen content in the alloy to 50×10−6. An additional strong deoxidizing element，Al，was required for a secondary，more thorough deoxidation. Based on Al-O equilibrium theory calculations，as Al content increased，the dissolved oxygen content initially rose and then subsequently decreased. At the Al content reached 0.256%，the equilibrium oxygen content reached its theoretical minimum of 0.56×10−6. In summary，this paper designed a deoxygenation process in DD10 master alloy vacuum induction smelting，which comprised three stages： primary carbon deoxidation，secondary aluminum deoxidation，and aluminum alloying. Initially，the dissolved oxygen content was lowered to 50×10−6 through carbon deoxidation in the early smelting stage. Subsequently，0.265% Al was added to further reduce the dissolved oxygen content in the alloy to 0.56×10−6. Finally，the alloying of Al and other oxidation prone elements occurredin the late smelting stage.
quote
| GB/T 7714-2015 | [1] Yuntian Zhang, Guoguang Cheng, Tao Zhang, et al. Deoxidation during Vacuum Induction Melting Process of DD10 Master Alloy[J]. Chinese Journal of Rare Metals, 2025, 49(9): 1376-1385. DOI:10.13373/j.cnki.cjrm.XY23100006. |
| MLA | [1] Yuntian Zhang, et al., "Deoxidation during Vacuum Induction Melting Process of DD10 Master Alloy." Chinese Journal of Rare Metals, vol. 49, no. 9, 2025, pp. 1376-1385, https://doi.org/10.13373/j.cnki.cjrm.XY23100006. |
| APA | [1] Yuntian Zhang, Guoguang Cheng, Tao Zhang, & Han Wang. (2025). Deoxidation during Vacuum Induction Melting Process of DD10 Master Alloy. Chinese Journal of Rare Metals, 49(9), 1376-1385. https://doi.org/10.13373/j.cnki.cjrm.XY23100006 |
| IEEE | [1] Yuntian Zhang, Guoguang Cheng, Tao Zhang, and Han Wang, "Deoxidation during Vacuum Induction Melting Process of DD10 Master Alloy," Chinese Journal of Rare Metals, vol. 49, no. 9, pp. 1376-1385, 2025, doi: 10.13373/j.cnki.cjrm.XY23100006. keywords: {DD10 master alloy;vacuum induction melting;oxide inclusions;deoxidation reaction;co-existence principle} |