为研究超大尺寸GH4169铸锭真空自耗熔炼工艺，避免冶金缺陷。基于经过大量工业验证的MeltFlow软件构建了Ф1000 mm大尺寸GH4169真空自耗过程的工艺的优化方法，对真空自耗重熔过程中熔池形貌演变、元素的宏观分布特征、夹杂物的分布规律以及凝固特征进行了研究，并探究了熔速、冷却方式、热封顶工艺对成斑概率、二次枝晶间距、元素分布、缩孔以及元素宏观分布的影响。真空自耗重熔1055 min后熔池逐渐趋于稳定，最大熔池深度和糊状区宽度分别为316、37 mm，熔池整体形貌呈“U”形特征。稳定熔炼期间，模拟的铸锭表面和中心的冷却速率分别为0.39、0.025 K/s。铸锭表面和心部的一次枝晶间距分别为205、512 um，二次枝晶间距分别为60、174 um。总体上Nb，Mo，Ti，Al元素在整个铸锭上均匀分布。针对Ф1000 mm 超大尺寸GH4169铸锭，熔速控制在3~8 kg/min范围，采用水冷或氦气冷却时，熔速和冷却速率的增大会使二次枝晶间距减小，熔速和冷却条件的变化会影响Ra值的分布，但Ra值均小于1，产生黑斑的概率较小。在热封顶工艺中，快速降电流阶段、缓慢补缩阶段和低电流保温阶段三个阶段时间相同的热封顶工艺可以显著减小铸锭心部的二次枝晶间距并减轻铸锭心部的成斑概率。

To investigate the vacuum consumable remelting process of extra large-size GH4169 alloys and improve ingot quality, an optimiza-tion method for the vacuum consumable melting process of large-sized GH4169 ingots with a diameter of Ф1000 mm was devel-oped based on the MeltFlow software, which has been extensively validated in industrial applications. The study explored the evolu-tion of melten pool morphology, solidification characteristics, inclusion distribution, and macro-element distribution during the re-melting process. Additionally, the effects of melting rate, cooling condition, and hot topping process on segregation probability, sec-ondary dendrite arm spacing (SDAS), element distribution, shrinkage cavity formation, and macro-element distribution were ana-lyzed. After 1055 minutes of vacuum consumable remelting, the molten pool gradually stabilized, with a maximum depth and mushy zone width of 316 mm and 37 mm, respectively. The overall molten pool exhibited a "U" morphology. During stable remelting, the simulated cooling rates of the ingot surface and center were 0.39 K/s and 0.025 K/s, respectively. The primary dendrite arm spacings of the ingot surface and center were 205 μm and 512 μm, while the secondary dendrite arm spacings were 60 μm and 174 μm, re-spectively. Overall, elements such as Nb, Mo, Ti, and Al were evenly distributed throughout the ingot. For Φ1000 mm large-scale GH4169 ingot, when the melting rate is controlled within the range of 3-8 kg/min and water cooling or helium cooling is employed, an increase in melting rate and cooling rate will reduce the secondary dendrite arm spacing. Variations in melting rate and cooling conditions may influence the morphology of Ra values, but all Ra values remain below 1, resulting in a relatively low probability of freckle formation. The SDAS decreased with increasing melting rate and cooling speed, while the segregation probability decreased with increasing melting rate and decreasing cooling rate. Among various hot topping processes, a process with equal durations of the rapid current reduction phase, slow feeding phase, and low-current insulation phase reduced the SDAS and segregation probability in the ingot center.