60Si2CrVA弹簧钢转炉冶炼过程夹杂物分布研究

对转炉冶炼60 Si2CrVA弹簧钢生产过程中的夹杂物种类、数量及分布进行了研究分析,研究表明,随着冶炼过程的进行,5μm的夹杂物所占的比例逐步升高,5μm的夹杂物逐步下降。弹簧钢中夹杂物种类主要有Al2O3,MnS,TiN及复合氧化物等。     

20MnCr5齿轮钢氧含量控制及其对钢的疲劳性能影响

提出了100 t EAF-LF-VD-CC-CR全流程控制齿轮钢氧含量的工艺措施;研究了0.00053%～0.00145%氧含量20MnCr5齿轮钢的旋转弯曲疲劳性能、断口和夹杂物尺寸。结果表明,钢中总氧含量越高,最大夹杂物尺寸也越大,疲劳强度越低,当[O]≤0.0010%时,随[O]降低,疲劳强度升高幅度较小;试验钢在表层不产生疲劳裂纹的临界夹杂物尺寸为21μm,距表面深度30～430μm的浅层区域为相对安全区域,其中的夹杂物很难引起疲劳开裂。     

夹杂物尺寸对60Si2CrVA高强度弹簧钢的高周疲劳性能的影响

利用旋转弯曲疲劳实验,研究了3种商业生产的60Si2CrVA弹簧钢的高周疲劳破坏行为.结果表明,虽然实验料的氧含量相同,但由于钢中夹杂物尺寸的差异,使其高周疲劳性能存在明显差异.随着夹杂物尺寸的减小,实验料的疲劳寿命和疲劳强度均逐渐提高.夹杂物最为粗大的D-60料(平均夹杂物尺寸φin≈44.4μm),疲劳S-N曲线连续降低,疲劳断裂主要起源于钢中的粗大夹杂物,传统的疲劳极限消失;夹杂物最为细小的A-60料(φin≈15.4μm),疲劳断裂主要起源于表面基体,存在传统的疲劳极限.对于在低应力幅、高循环周次(约大于106)下,内部夹杂物引起的疲劳破坏,在夹杂物周围往往存在粗糙的粒状区域.     

钙处理对硅脱氧弹簧钢55SiCr氧化物夹杂的影响

摘要：为了将硅脱氧弹簧钢中SiO2类高熔点硬质夹杂改性成低熔点夹杂物,在炼钢生产中进行了钙处理试验。利用FEI Explorer 4自动扫描电镜对硅脱氧弹簧钢55SiCr在正常工艺与钙处理工艺处理后的铸坯、盘条中氧化物夹杂的成分、尺寸、数量、形貌进行检测,统计分析2种工艺下夹杂物尺寸、夹杂物轧制变形性的差异,并通过弹簧钢丝Nakamura旋转弯曲疲劳测试对比2种工艺下夹杂物控制水平。分析结果表明：硅脱氧弹簧钢55SiCr钙处理工艺后氧化物夹杂主要为CaO SiO2 (CaS)类,尺寸较大,且此类夹杂物在盘条轧制过程中不易变形细化,最终恶化弹簧钢疲劳性能;正常工艺处理后氧化物夹杂尺寸随着夹杂物中Ca含量升高有增大倾向,CaO SiO2 Al2O3系相图中方石英、磷石英与莫来石交界区的夹杂物轧制变形性优于假硅灰石和钙长石共熔区的夹杂物。     

两种不同冶金工艺生产的60Si2CrVA弹簧钢的高周疲劳性能

 采用旋转弯曲疲劳试验研究了两种不同冶金工艺生产的60Si2CrVA弹簧钢的高周疲劳破坏行为。结果表明,尽管两种试验料的氧含量接近,但两者夹杂物特征的差异使其疲劳性能存在明显的差异。与采用电炉+LF+VD+CC工艺生产的X8料相比,采用转炉＋LF+RH+CC工艺生产的X6料中的夹杂物数量明显减少,夹杂物尺寸较小,同时还减少了不规则的多棱角富Al2O3夹杂,因而后者的疲劳强度得到明显提高,并具有良好的疲劳寿命稳定性。     

1950MPa级弹簧钢55SiCrA疲劳断口夹杂物来源分析

采用SEM-EDS对1950 MPa级油淬火钢丝Nakamura旋转弯曲疲劳断口和弹簧疲劳断口宏观夹杂物的成分及尺寸分布进行检测,借助ASPEX Explorer自动扫描电镜对弹簧钢55SiCrA盘条显微夹杂物成分、尺寸及分布进行检测统计。通过对比发现,疲劳断口宏观夹杂物与钢中显微夹杂物成分近乎一致,表明其主要来源为脱氧产物和钢渣反应产物。并根据断口夹杂物的尺寸分布特点推测此疲劳条件下夹杂物的临界尺寸为20μm,最后指出采用夹杂物的塑性化生产工艺,借助结晶器流场优化提高铸坯表层洁净度是后续改进方向。     

脱氧方式对高铝钢中非金属夹杂物的影响

摘要：为了研究不同脱氧方式对高铝钢中非金属夹杂物的影响,采用高温试验和热力学计算相结合的方法,对比分析了先SiMn后Al和先Al后SiMn两种脱氧方式下高铝钢中夹杂物形貌、类型、数量和尺寸特征。结果显示：先加入SiMn后,生成大量液态球形的Mn-Si-Al-O系复合夹杂物,再加入Al后夹杂物演变为Al2O3,且夹杂物数量明显减少;采用先Al后SiMn脱氧方式时,高铝钢中夹杂物始终以Al2O3为主,夹杂物最终数量相对较低。2种脱氧方式钢中夹杂物平均等效圆直径和尺寸分布相差不大。此外,采用先SiMn后Al进行脱氧时,发现尺寸较小的AlN颗粒附着在Al2O3夹杂物表面形成Al2O3-AlN复合夹杂物。而采用先Al后SiMn脱氧方式时,高铝钢中发现单一AlN夹杂物和Al2O3-AlN复合夹杂物,AlN夹杂物的形成与钢水中的氧势和合金原料有关。     

脱氧工艺对硅钢连铸坯非金属夹杂物的影响研究

 研究了Al+FeSi以及FeSi两种不同脱氧工艺对硅钢铸坯中非金属夹杂物的影响。通过合理的试验设计并运用T［O］含量测定、金相分析、SEM及EDS等研究手段,对铸坯中的夹杂物进行了分析,研究表明Al+FeSi复合脱氧不仅比FeSi脱氧具有更强的脱氧能力,且能使铸坯中的夹杂物在尺寸和数量上有明显降低,夹杂物的特征也由Si O Al Mn Ti Fe系变性为以尺寸＜5 μm的Al2O3夹杂为核心、包覆Al Si S Mn Ca Ti Fe O系的复合夹杂。     

60Si2MnA弹簧钢炼钢过程的洁净度变化

对"BOF→LF→CC"流程铝脱氧造较高碱度精炼渣工艺生产60Si2MnA弹簧钢冶炼过程的洁净度进行了调研分析,并从理论上分析了冶炼过程钢中T.O、氮含量和夹杂物数量、尺寸及类型的转变过程。结果表明:冶炼过程钢中T.O含量逐渐降低,氮含量增加,盘条中平均w(T.O)=14.5×10-6,w(N)=30.4×10-6。夹杂物类型变化为Al2O3-SiO_2→Al2O3-SiO_2-Mg O-CaO四元复合夹杂物→Al2O3-SiO_2-MgO-CaO-CaS五元复合夹杂物。控制钢中w(Al)=0.03%左右,钙处理后钢水w(Ca)/w(Al)=0.08~0.11,Al2O3夹杂物能得到充分变性,形成的四元夹杂物处于较低熔点区,而五元夹杂物因含较多高熔点CaS而偏离低熔点区。     

夹杂物尺寸和暗光区尺寸对高强度钢千兆周期疲劳性能的影响

对SCM440和SUJ2钢进行了高达10^9次循环的千兆用期疲劳试验。千兆周期疲劳性能试验结果被分戍两组：由SCM440和二次熔炼SUJ2钢构成的一组显现出其疲劳强度高于由一次熔炼SUJ2钢构成的另一组。高疲劳强度组中的鱼眼状裂纹基本上起源于一种小的Al2O3夹杂物，而在低疲劳强度组中则完全起源于大的（Cr、Fe）3C夹杂。当夹杂物尺寸小于约10μm时，大体上暗光区尺寸随夹杂物尺寸下降而增加。当夹杂物尺寸超过10μm时，暗光区尺寸呈稳定状态。由于这种关系，当夹杂物尺寸非常小时，10^9次循环时疲劳极限与夹杂物尺寸无关。估计夹杂物尺寸在10～20μm之间时疲劳极限便失去与夹杂物尺寸的依存性。另一方面，当夹杂物尺寸超过上述尺寸时，疲劳极限取决于夹杂物尺寸及暗光区尺寸。暗光区和大夹杂物与小夹杂物相似，其△Kth取决于裂纹尺寸的1／3次方，这意味着疲劳极限取决于暗光区尺寸和大夹杂物尺寸的-1／6次方。     

Gigacycle Fatigue Behavior of 1800 MPa Grade High Strength Spring Steel for Automobile Lightweight

Gigacycle fatigue behavior of 60Si2CrVA high strength spring steel was investigated by ultrasonic fatigue test machine. Fatigue fractography was observed by scanning electron microscopy （SEM）. Maximum inclusion sizes and fatigue strength in different volumes were estimated by statistics of extreme values （SEV） and generalized Pareto distribution （GPD） methods. The results showed that S N curves of 60Si2CrVA spring steels for two rolling processes were not horizontal asymptotes but a gradient in a regime of 109 cycles, and traditional fatigue limits were eliminated. Surface machined topography and inclusions in steel were major factors that led to elimination of fatigue limit for 60Si2CrVA spring steel. The SEV and GPD methods could effectively predict size of the maximum inclusion and fatigue strength in different volumes of 60Si2CrVA spring steel. Predicted fatigue strength was in accordance with experimental results by ultrasonic fatigue testing.     

弹簧钢夹杂物形态控制

分析了高应力条件下弹簧疲劳断裂的主要原因以及用稀土控制弹簧钢夹杂物形态的局限性。指出了ＭｎＯ－Ａｌ２Ｏ３－ＳｉＯ２或ＣａＯ－Ａｌ２Ｏ３－ＳｉＯ２三元塑性夹杂物的成分范围,并以６０Ｓｉ２ＣｒＶＡ为例确定之与相平衡的钢液脱氧条件,提出了相应的工艺措施。     

Influence of calcium treatment on cleanness and fatigue life of 60Si2MnA spring steel

Contrasting experiments of Al killed 60Si2MnA spring steel were carried out between using and excluding calcium treatment under LF refining slags with low and high basicity ratios (R: CaO/SiO₂?=?3.4, 5.0), respectively. Results showed the high basicity refining slag had a certain effect on controlling inclusions and improving the cleanness of spring steel similarly to calcium treatment. The T.[O] (total oxygen) content of steel without calcium treatment got to below 15?ppm and the fatigue life was long, up to 7.8?×?10⁶?cycles. But in order to reduce the T.[O] below 10?ppm, as well as inclusion number and size in spring steel further, meanwhile, the appropriate calcium treatment should still be used. Besides, as the [Ca] content in the steel with calcium treatment increased, inclusions transformed from Al₂O₃–SiO₂–CaO–MgO to Al₂O₃–SiO₂–CaO–MgO–CaS completely, which reduced the formations of voids between inclusions and steel matrix, and voids decreased with the increase of CaO/Al₂O₃ value and CaS content of inclusions. Finally, the fatigue life of spring steel with high basicity slag and calcium treatment increased to 9.1?×?10⁶ cycles.     

202不锈钢中非金属夹杂物的形成机理

通过工业试验对202不锈钢进行系统取样,分析试样中夹杂物的变化特征,结合热力学计算,研究了202不锈钢中非金属夹杂物的形成机理。在进行硅锰脱氧后,LF精炼过程中钢液内以球型Ca?Si?Mn?O夹杂物为主。对于硅锰脱氧钢,钢液中残余铝质量分数为1×10?5时,可以扩大Mn?Si?O相图的液相区,但铝质量分数超过3×10?5会导致钢中容易形成氧化铝夹杂物并减小液相区。在连铸坯中以Mn?Al?O类夹杂物为主,相较于LF精炼过程试样,连铸坯试样中夹杂物的MnO和Al₂O₃含量明显增加,CaO和SiO₂含量明显减小,夹杂物个数则由LF出钢试样的5.5 mm?2增加到11.3 mm?2。结合热力学计算发现,凝固过程中会有Mn?Al?O夹杂物形成,这也使其成为连铸坯中主要的夹杂物类型。      

304不锈钢不同精炼渣碱度下夹杂物的演变

 为了提高304不锈钢的产品质量,结合生产实际,利用热力学计算和扫描电镜能谱分析方法, 研究了硅脱氧条件下,LF精炼渣碱度对304不锈钢在LF精炼、连铸过程夹杂物变化规律的影响。试验结果表明,随着冶炼过程进行,全氧质量分数和夹杂物数量依次减小。304不锈钢采用1.75高碱度炉渣,可以得到较低的全氧质量分数和夹杂物数量,但是夹杂物中Al2O3质量分数高,夹杂物熔点高。采用1.53低碱度炉渣,钢液中全氧质量分数较采用高碱度炉渣高,但是夹杂物中CaO、Al2O3质量分数相对较低,SiO2和MnO质量分数较高,夹杂物熔点低。针对304不锈钢产品可以采用不同的生产工艺路线来满足产品的不同需求。     

超低氧钢中复合夹杂物形成的实验室研究简

 通过实验室真空感应炉试验,研究了超低氧条件下钢中复合非金属夹杂物的形成。研究发现：在含有一定硫的超低氧钢中高熔点氧化物夹杂很少,大部分为MnS。钢中Al2O3的尺寸较MgO-Al2O3系夹杂要大。以高熔点夹杂物为异质形核核心析出的MnS能显著提高钢材的疲劳寿命,此种复合夹杂物的形成与钢液成分、高熔点夹杂物的尺寸有关。     

Effect of Deoxidation Process on Inclusion and Fatigue Performance of Spring Steel for Automobile Suspension

55SiCrA spring steel was smelted in a vacuum induction levitation furnace. The liquid steel was treated by Si deoxidation, Al modification with Ca treatment and Al modification, and the steel samples were obtained with deformable Al₂O₃-SiO₂-CaO-MgO inclusions closely contacted with steel matrix, Al₂O₃-CaO-CaS-SiO₂-MgO inclusions surrounded by small voids or Al₂O₃(> 80 pct)-SiO₂-CaO-MgO inclusions surrounded by big voids, respectively. Effect of three types of inclusions on steel fatigue cracks was studied. The perpendicular and transverse fatigue cracks around the three types of inclusions leading to fracture were found to vary in behavior. Under the applied stress amplitude of 775 MPa, the fatigue lives of the three spring steels decreased from 4.0 × 10⁷ to 3.8 × 10⁷, and to 3.1 × 10⁷ cycles. For the applied stress amplitude of 750 MPa, the fatigue lives of the three spring steels decreased from 5.2 × 10⁷ to 4.1 × 10⁷, and to 3.4 × 10⁷ cycles. Based on the voids around inclusions, the equivalent size of initial fatigue crack has been newly defined as \( \sqrt {\frac{{{\text{area}}_{\text{inclusion}} }}{{(1 - {\text{CC}})}}} \), where the contraction coefficient CC of inclusion was introduced. A reliable forecast model of the critical size of inclusion leading to fracture was established by the incorporation of actual width b_inclusion or diameter d_inclusion of internal inclusion; the model prediction was found to be in agreement with experimental results.     

Theory and Practice of Oxide Inclusion Composition and Morphology Control in Spring Steel Production

Theoxideinclusionsinspringsteelcomemainlyfromtheproductsofdeoxidizationofmoltensteel .Ifthemoltensteelisalloyedwithferrosiliconandfinal lydeoxidizedwithaluminum ,thepropertiesofde oxidization productsarenotdeterminedbythechemicalcompositionofmoltensteel,butbythepropertiesofalloysanddynamicconditionsofdeoxi dization .Forspringsteel ,theoriginaldeoxidizationproductsfoundinfinishedproductsaretridymite ,a luminumsilicateandalumina[1] .Inordertoreducetheamountandthesizeofinclusionswhichdeterio rate…     

SiO2-Al2O3-CaO-MgO系夹杂物低熔点区域优化及控制的热力学计算

为了预测CaO-Al2O3-SiO2-MgO系夹杂物具有良好变形能力的成分控制范围,首次通过热力学软件Fact-Sage对CaO-Al2O3-SiO2-MgO系液相投影图、低熔点区域大小进行了计算分析,并以阀门弹簧钢60Si2CrA为例,对CaO-Al2O3-SiO2-MgO系低熔点夹杂物的生成条件进行了探讨.结果表明...