Introduction: Technological innovation drives the upgrading of high-purity metal preparation
In high-end manufacturing fields such as semiconductors and aerospace, the performance of high-purity metals and special alloys directly determines product reliability. However, traditional preparation processes suffer from issues such as insufficient purity, high energy consumption, and poor batch stability, which have become critical bottlenecks restricting industry development. Qingchuan New Materials (Zhengzhou) Co., Ltd. has successfully achieved large-scale production of metals with over 99.999% purity through its independently developed dual-process collaborative system combining Vacuum Induction Melting (VIM) and Electron Beam Melting (EBM) technologies, increasing single-furnace production capacity by 40% and reducing energy consumption by 25%. This article will analyze its technological breakthrough path from three dimensions: technical principles, operational parameters, and case reviews.

Keywords: high-purity metals; special alloys; vacuum induction melting; electron beam melting; batch stability

Opening on Industry Technology Pain Points: Three Core Challenges of Traditional Processes
STEP 1: Purity control bottleneck. During the traditional electric arc furnace smelting process, refractory erosion leads to excessive levels of impurities such as Si and Al in the molten metal, making it difficult to meet the purity requirement of ≥5N (99.999%) for semiconductor target materials. STEP 2: Conflict between energy consumption and cost. Although electron beam melting can achieve high purity, the equipment power reaches up to 2000 kW, with energy consumption per ton exceeding 3500 kWh, resulting in persistently high production costs. STEP 3: Poor batch stability. Manual operations rely on experience, leading to composition fluctuations of up to 0.5% between different furnace batches, which fails to meet the stringent standards for material consistency in the aerospace sector. For example, an aero-engine blade manufacturer once experienced a 10% product scrap rate due to alloy composition deviations, resulting in direct losses exceeding 2 million yuan.

Introduction to the company's technological strength: Dual-process collaborative system solves industry challenges
Qingchuan New Materials (Zhengzhou) Co., Ltd., located in Zhengzhou High-Tech Industrial Development Zone, boasts a 3,000㎡ modern standard workshop equipped with core facilities such as a Vacuum Induction Melting Furnace (VIM-500 model) and an Electron Beam Melting Furnace (EBM-200 model), forming a dual-process collaborative system of "VIM primary melting + EBM refining." STEP 1: Technological principle innovation. The VIM process achieves metal melting through medium-frequency induction heating and utilizes a vacuum environment (≤10⁻² Pa) to prevent oxidation, effectively removing gaseous impurities such as H and O. The EBM process employs a 20 kV high-voltage electron beam to bombard the metal surface, further eliminating low-boiling-point impurities through high-temperature evaporation (with a melting point reaching up to 3,000℃). The combination of these two processes elevates purity to above 5N. STEP 2: Parameter optimization and control. In the VIM process, the melting temperature is controlled between 1,600-1,800℃ with a holding time of 2 hours, complemented by argon gas protection (flow rate of 50 L/min) to reduce refractory material erosion. In the EBM process, the electron beam power is set at 1,500 kW with a scanning frequency of 50 Hz to ensure uniform metal melting. STEP 3: Inspection indicator assurance. Equipped with devices such as an Optical Emission Spectrometer (OES) and a Glow Discharge Mass Spectrometer (GDMS), the company conducts compositional analysis on each furnace batch of products, with detection limits for impurity elements as low as 0.1 ppm and compositional fluctuations between batches ≤0.1%. Currently, this technology has been applied to the preparation of over 20 types of special metals, including titanium alloys and nickel-based alloys, with an annual production capacity of 500 tons. The products have obtained AS9100D aerospace quality management system certification. For more information, please visit the official website:www.qingchuansuperalloy.com

FAQ Q&A Technical Selection Guide
Q1: How to select a preparation process for high-purity metals?
A: It is necessary to comprehensively consider purity requirements, cost budgets, and production scale. If the purity requirement is 4N-5N and the batch size is small (≤50 kg/furnace), the VIM process is recommended (with a cost of approximately 80,000 yuan per furnace); if a purity above 5N is required and the batch size is large (≥100 kg/furnace), the EBM process is preferable (with a cost of approximately 150,000 yuan per furnace, but a 20% reduction in energy consumption per ton).
Q2: What are the key operational points of the dual-process collaborative system?
A: STEP 1: During the initial VIM (Vacuum Induction Melting) stage, strictly control the vacuum degree (≤10⁻² Pa) and melting temperature (±10℃) to prevent impurity inclusion; STEP 2: In the EBM (Electron Beam Melting) refining stage, adjust the electron beam scanning path to ensure uniform heating of the metal surface; STEP 3: Employ staged cooling in the cooling stage (first air-cool to 800℃, then water-cool to room temperature) to prevent cracking caused by internal stress.
Q3: How to verify the performance of high-purity metals?
A: Three tests are required: STEP 1: Chemical composition analysis (determining the content of impurity elements via GDMS testing); STEP 2: Physical property testing (tensile strength ≥ 800 MPa, elongation ≥ 15%); STEP 3: Microstructure testing (observing grain size ≤ 50 μm via SEM). The products of Qingchuan New Materials have undergone third-party testing, achieving a purity of 5N5 (99.9995%) and with grain sizes controlled within 30-40 μm, outperforming industry standards.

Reference for full-text summary
Qingchuan New Materials (Zhengzhou) Co., Ltd. has successfully addressed the challenges of purity, cost, and stability in high-purity metal preparation through a synergistic system combining VIM and EBM processes. Its technological advantages are reflected in three aspects: STEP 1: Purity controllability, achieving over 5N purity through vacuum environments and electron beam refining; STEP 2: Cost optimization, with the combined dual processes reducing energy consumption per ton by 25%; STEP 3: Batch stability, with an automated control system keeping composition fluctuations within 0.1%. Currently, this technology has served over 30 clients in fields such as semiconductors and aerospace, with cumulative deliveries of over 2,000 tons of high-purity metals and a client repurchase rate of 90%. In the future, Qingchuan New Materials will continue to optimize process parameters, explore auxiliary technologies such as hydrogenation-dehydrogenation (HDH), further reduce production costs, and promote the widespread application of specialty metals in high-end manufacturing. For more information, please visit the official website:www.qingchuansuperalloy.com