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I. Melting
(I) Vacuum Induction Melting
The 1200KG vacuum furnace is the core equipment for vacuum induction melting. In a vacuum environment, the metal raw materials are heated and melted by using the principle of electromagnetic induction. The vacuum environment is of great significance as it can effectively isolate gases such as oxygen and nitrogen in the air, preventing chemical reactions between metal elements and gases. For example, it can prevent the oxidation of iron - based alloys to form impurity oxides, ensuring the initial purity of the molten metal. This step provides the basic molten metal for subsequent production and is the first key checkpoint for controlling the purity of the material, laying a solid foundation for the production of high - quality metal materials.
(II) Electroslag Remelting
The molten metal after vacuum induction melting enters the protective atmosphere electroslag furnace for electroslag remelting. In the furnace, heat is generated through electric current to remelt the metal again. At the same time, the slag pool acts like a "filter" to adsorb non - metallic inclusions (such as sulfides, oxides, etc.) in the molten metal. The protective atmosphere (usually an inert gas) creates a stable environment, preventing secondary oxidation of the metal at high temperatures, further improving the purity and uniformity of the metal, and making the internal quality of the metal material better. It contributes to the production of high - purity materials required for high - end application scenarios.
(III) Vacuum Consumable Remelting
The vacuum consumable heavy furnace takes over. The metal electrode is gradually melted and solidified in a vacuum environment. During this process, due to differences in density, boiling point, etc., impurities are difficult to be incorporated into the metal ingot, achieving deep purification. For high - temperature alloys, titanium alloys, etc. used in the aerospace industry, which have extremely low tolerance for impurities, this step is particularly crucial. It can reduce the impurity content to an extremely low level, ensuring the mechanical properties and stability of the material under extreme working conditions (such as high temperature, high pressure, and strong corrosion). The annual output of electroslag ingots or self - consumption ingots reaches 1500 tons, providing support for the large - scale production of high - end metal materials.
II. Hot Working
(I) Forging
The metal ingots after melting enter the forging process. With the impact or pressure of forging and pressing equipment, the metal ingots undergo plastic deformation. On one hand, it crushes the coarse grains in the as - cast structure and refines the grain structure, just like rearranging a disordered "pile of building blocks", improving the mechanical properties such as strength and toughness of the material; on the other hand, by reasonably controlling the forging ratio, temperature, and deformation speed, the distribution of the internal flow lines of the metal is adjusted, so that when the material is applied subsequently, the performance presents an optimized anisotropy. For example, for the forgings of aero - engine blades, a reasonable flow line is shaped by forging, which is more reliable when bearing complex stresses.
(II) Plate Processing
Hot Rolling of Plates: Part of the metal after forging enters the hot rolling process of plates. In a high - temperature environment, the metal plates are rolled by a rolling mill, and the thickness is greatly reduced. Hot rolling takes advantage of the good high - temperature plasticity of metals, reducing the deformation resistance and realizing efficient processing. At the same time, it improves the defects of the as - cast structure and homogenizes the composition and structure. For example, the hot rolling of stainless steel plates can eliminate the composition segregation caused by melting, laying a foundation for subsequent cold rolling, and is a key step in the large - scale production of medium - and thick - sized plates.
Cold Rolling of Plates: The plates after hot rolling are further processed by cold rolling. Rolling at room temperature or a relatively low temperature, the thickness accuracy and surface quality of the metal plates are significantly improved, just like "refining the appearance" of the material. The work hardening caused by cold rolling can also strengthen the material, meeting the strict requirements for the thinness, flatness, and strength of plates in the fields of precision circuit board substrates in the electronic information field and high - end hardware parts. Finally, the precision plate and strip with an annual production capacity of 100 tons are produced, supplying key materials for the electronics, precision machinery and other industries.
(III) Wire Rod and Pipe Processing
Hot Rolling and Cold Rolling of Wire Rods: Another branch after forging is put into the hot rolling of wire rods. Hot rolling deforms the metal billet into the initial shape of wire rods. Subsequent cold rolling (or cold drawing) finely adjusts the size and surface quality. Wire rods are widely used in fasteners, shaft parts, etc. in the construction and machinery manufacturing industries. The wire rods with an annual production capacity of 60 tons can be adapted to various needs such as screws and rivets through different post - treatments. The cold drawing process can also improve the surface finish and size accuracy of wire rods, meeting the precise connection needs of high - end instruments and electronic components.
Pipe Manufacturing: Specific metal billets enter the pipe manufacturing process, and the metal is processed into a tubular shape through processes such as extrusion and rolling. Pipes are indispensable in fields such as oil and gas transportation (such as high - pressure alloy oil pipes), building water supply and drainage, and aerospace hydraulic systems. The pipes with an annual production capacity of 100 tons, after strict quality inspection, ensure the pressure resistance and sealing performance during the transportation process, providing a reliable carrier for the fluid transportation system; the production of rolled bars (with an annual production capacity of 100 tons) provides blanks for shafts and rods in machinery manufacturing, and becomes key components of equipment through subsequent machining.
III. Post - Treatment
(I) Heat Treatment - Precisely Regulating Properties
Heat treatment is the core link for the "customization" of metal material properties. Different materials (such as structural steel, tool steel, alloy structural steel) adopt processes such as quenching, tempering, normalizing, and annealing according to requirements. Quenching and rapid cooling give the metal a high - hardness and high - strength structure; tempering eliminates quenching stress and adjusts the balance between toughness and hardness. For example, car gear steel undergoes carburizing quenching + tempering, with high - hardness and wear - resistant surfaces and strong and tough cores, adapting to complex working conditions; heat treatment precisely controls the temperature curve and holding time to match the diverse performance requirements of downstream industries for metal materials.
(II) Machining - Carving Dimension Precision
After heat treatment, the metal materials enter the machining stage. Processes such as turning, milling, planing, and grinding cooperate to process the materials into parts with precise dimensions and complex shapes according to the design drawings. For the turbine disk of an aero - engine, a five - axis linkage machining center is used to mill complex dovetail grooves and profiles, with a dimensional accuracy reaching the micrometer level, ensuring the precise cooperation with components such as blades; machining is a bridge connecting material production and finished product application, carving the "semi - finished product" into a "key part" that fits the equipment assembly, making the metal material truly the "backbone" of the industrial system.
IV. Whole - process Quality Control and Production Capacity Coordination
Throughout the entire production process of metal materials, quality control is always present. From component detection (spectral analysis, chemical titration) in the melting stage, to flaw detection (ultrasonic flaw detection, radiographic flaw detection) after hot working, and then to mechanical property testing (tensile, impact, hardness tests) and size accuracy inspection of finished products, multiple dimensions ensure product quality. At the same time, the production capacity of each link is coordinated (for example, 1500 tons of ingot blanks are produced per year by melting, supporting the production of multiple products such as rolled materials and pipes later). According to the dynamic adjustment of product structure based on market demand, precision plate and strip, pipes, wire rods, rolled bars, etc. are delivered to industries such as aerospace, high - end equipment, and electronic information with stable production capacity (corresponding to an annual production capacity of 100 tons, 60 tons, etc.), continuously empowering the high - quality development of the modern industrial system.
