Abstract:GH4151 is a new type of wrought superalloy used for aero-engine turbine discs. This superalloy has high-content strengthening elements, complex solidification behavior, and high cracking tendency, making it difficult to produce ingots with large size. In this study, the 2-ton GH4151 superalloy ingot with a diameter of 508 mm was prepared by the triple melting process. The solidification microstructure of the ingot was analyzed, and the composition uniformity of the ingot was evaluated. Industrial experiment show that a crack free ingot can be obtained, and the secondary dendrite arm spacings from the ingot edge to the center are 80 and 150 μm, respectively. The composition at the top and bottom of the ingot shows a good uniformity in transverse sections. The range of elements Co, Cr, W, and Mo is within 0.05wt%, and the range of the element Nb is lower than 0.07wt%. However, the variation for Al and Ti are relatively large, due to the melting loss in the axial direction. After homogenization, the segregation coefficients of the alloying elements can be controlled between 0.8 and 1.2. Superalloy bars with a diameter of 300 mm were prepared through free forging. The microstructure, properties, and flaw detection of the bars can meet the technical requirements, verifying that the prepared ingot has satisfactory metallurgical quality.