本发明公开了一种采用高比例钛残料制备大规格TC4钛合金铸锭的方法，该方法包括：一、将块状和片状的TC4残料捆扎为残料电极；二、将残料电极进行焊接并清理；三、将经清理后的残料电极进行熔炼得到中间铸锭；四、将中间铸锭进行一火次锻造，得到长条状电极并进行修磨和酸洗；五、将经酸洗后的长条状电极与海绵钛电极块组焊得到自耗电极并进行清理；六、将经清理后的自耗电极进行熔炼，得到TC4钛合金铸锭。本发明通过合理布料和多次真空自耗电弧熔炼，得到大规格的TC4钛合金铸锭，提高了TC4钛残料的加入比例，减少了TC4钛残料成分的不均匀性，保证了TC4铸锭的洁净性，提高了TC4铸锭的成材率及生产效率。

The invention discloses a method for preparing a large-specification TC4 titanium alloy cast ingot through high-proportion defective titanium materials. The method comprises the steps that 1, the block-shaped and sheet defective TC4 materials are tied into defective material electrodes; 2, the defective material electrodes are welded and cleaned; 3, the cleaned defective material electrodes are smelted to obtain an intermediate cast ingot; 4, the intermediate cast ingot is subjected to one heating number forging, and a long-strip-shaped electrode is obtained and subjected to coping and pickling; 5, the long-strip-shaped electrode subjected to pickling and a sponge titanium electrode block are assembled and welded, and a consumable electrode is obtained and cleaned; and 6, the cleaned consumable electrode is smelted, and the TC4 titanium alloy cast ingot is obtained. According to the method, through reasonable material distribution and multiple times of vacuum consumable electric arc smelting, the large-specification TC4 titanium alloy cast ingot is obtained, the adding proportion of the defective TC4 titanium materials is increased, the content nonuniformity of the defective TC4 titanium materials is reduced, the cleanliness of the TC4 cast ingot is ensured, and the yield and the production efficiency of the TC4 cast ingot are improved.