CN111101064A - 轴承座式关节的高性能螺栓及其制造方法 - Google Patents
轴承座式关节的高性能螺栓及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种轴承座式关节的高性能螺栓,其化学成分的质量百分比(wt%)为:C:0.20‑0.30%,Mn:0.45‑0.70%,Si≤0.08%,P≤0.01%,S≤0.01%,Ni:3.50‑3.85%,Cr:1.60‑2.20%,Mo:0.35‑0.55%,V:0.05‑0.10%,Nb:0.05‑0.10%,余量为Fe。本发明高性能螺栓的制造方法为:冶炼→模锻、正火回火→粗加工→调质处理→半精加工→去应力回火→表面处理→精加工。本发明高性能螺栓能够满足轴承座式关节等主传动万向轴对螺栓的高强韧性、高疲劳强度及耐腐蚀性的要求,从而提高轴承座式主传动万向轴使用寿命。本发明同时还提供了高性能螺栓的制造方法。
Description
技术领域
本发明涉及一种高性能螺栓及其制造方法,尤其涉及用于承受大扭矩、大工作倾角、并承受附加弯矩和冲击振动,在水及油污、氧化皮、高温等恶劣的工况下使用的轴承座式关节等主传动万向轴的锁紧螺栓。
背景技术
主传动万向轴是各钢厂的碳钢、不锈钢、特钢等轧钢生产线的重要设备。现在的万向轴中进口件占多数。万向轴下线后的检测和修复也大多由国外制造商完成,万向轴修复周期长、成本很高,大大增加了钢厂整体运行成本。
从图1可知,在主传动轴的轴承座式关节中,螺栓1连接十字轴总成2与叉头轴套4和叉头法兰3,螺栓1是传动轴中的核心零件。与进口螺栓相比,国产螺栓虽然在强度方面取得较大的突破,但韧性和接触疲劳强度往往不如进口产品,螺栓质量不稳定,在使用一定周期后会出现疲劳裂纹、断裂的问题,严重影响整个万向轴的使用寿命,现场更换麻烦,且一旦出现质量问题,将造成整条轧钢线停产。
具体地说,轴承座式关节主传动万向轴是轧钢生产线重要部件,设计扭矩一般在5000kN·m,5°工作倾角下关节附加弯矩约450kN·m,螺栓承受的最大拉应力可达850MPa。轴承座式关节螺栓设计要求不低于12.9级(即:σb≥1200MPa、σs≥1050MPa),进口螺栓选用SNCM630材质,国产螺栓一般选用34CrNi3Mo、34Cr2Ni2Mo、30Cr2Ni2Mo、40CrNiMoA等。在检修过程中经常发现紧固螺栓存在疲劳裂纹及断裂、腐蚀问题,经分析,进口螺栓冲击功在89J左右,而国产螺栓冲击功仅75J左右,螺栓在高强度下冲击功较低是导致螺栓疲劳断裂的主要原因。同时,普通螺栓防腐工艺为发黑或达克罗,有效涂层薄、表面粗糙度差、对环境有害、表面硬度不高、耐磨性不好。
发明内容
本发明所要解决的问题是提供一种高性能螺栓,它能够满足轴承座式关节等主传动万向轴对螺栓的高强韧性、高疲劳强度及耐腐蚀性的要求,从而提高轴承座式主传动万向轴使用寿命。本发明同时还提供了高性能螺栓的制造方法。
本发明轴承座式关节的高性能螺栓,其化学成分的质量百分比(wt%)为:C:0.20-0.30%,Mn:0.45-0.70%,Si≤0.08%,P≤0.01%,S≤0.01%,Ni:3.50-3.85%,Cr:1.60-2.20%,Mo:0.35-0.55%,V:0.05-0.10%,Nb:0.05-0.10%,余量为Fe。
进一步地,高性能螺栓其化学成分的质量百分比优选为:C:0.22%,Mn:0.51%,Si:0.056%,P:0.0005%,S:0.0019%,Ni:3.80%,Cr:1.88%,Mo:0.35%,V:0.08%,Nb:0.08%,余量为Fe。
进一步地,高性能螺栓其化学成分的质量百分比优选为:C:0.25%,Mn:0.66%,Si:0.046%,P:0.0008%,S:0.0012%,Ni:3.58%,Cr:2.14%,Mo:0.40%,V:0.09%,Nb:0.06%,余量为Fe。
进一步地,高性能螺栓其化学成分的质量百分比优选为:C:0.28%,Mn:0.62%,Si:0.06%,P:0.001%,S:0.001%,Ni:3.72%,Cr:1.96%,Mo:0.44%,V:0.07%,Nb:0.10%,余量为Fe。
本发明高性能螺栓的制造方法为:冶炼→模锻→一次正火回火→粗加工→调质处理→半精加工→去应力回火→表面处理→精加工。
本发明制造方法,其具体步骤为:
(1)冶炼:将优质合金原材进行电炉冶炼,并采取相应的LF炉外精炼、VD真空脱气工艺、电渣重熔;
(2)模锻并正火回火:将铸锭在1000~1150℃进行锻打,在900-950℃左右终锻成型,锻后缓冷至300~350℃保温6h,再经过900~920℃正火,快速冷却至620~650℃回火保温6h;
(3)粗加工:将锻坯按图纸进行粗加工;
(4)热处理:将粗加工的螺栓毛坯在880±10℃保温90min后油冷至室温,然后进行520±20℃保温6h油冷至室温;
(5)半精加工:将热处理后的螺栓毛坯按图纸进行半精加工,螺纹部分采用滚丝机滚压加工成型;
(6)去应力回火:将半成品螺栓在300~350℃回火处理;
(7)表面处理:将半成品螺栓和镍铝合金粉末进行80℃~100℃充分预热,使用高速氧-煤油火焰喷涂镍铝合金粉末,氮气保护;高纯氧气与煤油质量百分比为3~4,高纯氧气流量可选1800~2000scfh;煤油可选航空煤油,流量可选5~6gal/h,氮气流量可选20~40scfh,工件转速可选160~190rpm,送粉速度可选70~90g/min;
(8)精加工:将螺栓的六角头部过渡圆角、螺杆、螺纹及过渡圆角进行抛光处理。
进一步地,经步骤(1)和(2)后得到的螺栓坯料中:[H]≤1.0ppm、[O]≤15ppm、[N]≤40ppm、晶粒度≥9级、带状组织≤1级、夹杂物面积平均尺寸≤12μm2、夹杂物长度平均尺寸≤5μm、每平方厘米内可变形的MnS夹杂物数量≤60个。
进一步地,经步骤(4)调质处理后,螺栓硬度为370至400HB,组织为保持马氏体位向的回火索氏体,Nb和V元素以NbC、VC化合物方式在晶界、亚晶界等处沉淀析出,从而细化晶粒,晶粒度达到10级。
进一步地,经步骤(2)、(5)、(8)加工后,螺栓的螺纹部分含有明显的金属流线,粗糙度Ra0.8以上;经步骤(7)后,螺栓表面镍铝合金涂层0.1~0.2mm,涂层结合力≥70MPa,经过2400~4800h中性盐雾腐蚀试验,未发生明显腐蚀。
进一步地,螺栓23℃的力学性能为:抗拉强度≥1300MPa;屈服强度≥1200MPa;断后伸长率≥17%;断面收缩率≥65%;冲击功≥150J。
本发明轴承座式关节的高性能螺栓通过优化合金元素含量,配合VD真空脱气工艺、电渣重熔工艺,具有以下优点:一、降低S、P有害元素含量,以达到控制非金属夹杂物数量和形态,尤其是减少可变形的MnS夹杂物数量;二、在合金中增加0.05-0.10%的V元素,0.05-0.10%的Nb元素,控制Si元素含量≤0.08%;适量的Nb、V、Si元素能细化奥氏体基体晶粒,且Nb和V以NbC、VC等强化相析出,从而改善螺栓的力学性能,强度会增加;同时,Si元素含量减少使得冲击功较高;三、优化螺栓坯料锻造工艺,采用专用的模具锻造成型,并采用滚压加工方式精加工螺纹,使得螺栓的螺纹部分含有明显的金属流线,形成表面压应力,提升螺纹部位的抗疲劳性能;四、采用喷涂镍铝合金粉末,使螺栓表面具有较好的耐腐蚀、耐热、良好的耐金属-金属摩擦磨损性能的涂层,防腐保护周期长。
因此,本发明通过优化螺栓的合金成分设计,配合冶炼、锻造、防腐技术改进,减少氢脆和夹杂物危害,提升了螺栓的冲击功、强度、断后伸率、断面收率等各方面的力学性能指标,提高了螺栓的韧性、接触疲劳强度及耐腐蚀性,增加了产品的使用寿命。所以,本发明高性能螺栓解决了螺栓在满足高强度下冲击功较低及耐腐蚀性差的问题,可满足轴承座式关节主传动万向轴用于承受大扭矩,大工作倾角,并承受附加弯矩和冲击振动,并可适用于水及油污、氧化皮、高温等恶劣的工况。
附图说明
图1是轴承座式关节结构示意图。
图2是本发明轴承座式关节的高性能螺栓示意图。
图3是本发明轴承座式关节的高性能螺栓的组织金相照片。
图4是本发明轴承座式关节的高性能螺栓的螺纹金属流线。
具体实施方式
下面结合实施例更清楚地说明本发明高性能螺栓的技术方案,未注明具体条件的按照常规条件进行。
本发明轴承座式关节的高性能螺栓,其化学成分的质量百分比(wt%)为:C:0.20-0.30%,Mn:0.45-0.70%,Si≤0.08%,P≤0.01%,S≤0.01%,Ni:3.50-3.85%,Cr:1.60-2.20%,Mo:0.35-0.55%,V:0.05-0.10%,Nb:0.05-0.10%,余量为Fe。
实施例1
本发明轴承座式关节的高性能螺栓,其化学成分的质量百分比优选为:C:0.22%,Mn:0.51%,Si:0.056%,P:0.0005%,S:0.0019%,Ni:3.80%,Cr:1.88%,Mo:0.35%,V:0.08%,Nb:0.08%,余量为Fe。
实施例2
本发明轴承座式关节的高性能螺栓,其化学成分的质量百分比优选为:C:0.25%,Mn:0.66%,Si:0.046%,P:0.0008%,S:0.0012%,Ni:3.58%,Cr:2.14%,Mo:0.40%,V:0.09%,Nb:0.06%,余量为Fe。
实施例3
本发明轴承座式关节的高性能螺栓,其化学成分的质量百分比优选为:C:0.28%,Mn:0.62%,Si:0.06%,P:0.001%,S:0.001%,Ni:3.72%,Cr:1.96%,Mo:0.44%,V:0.07%,Nb:0.10%,余量为Fe。
本发明三个实施例与背景技术中的进口材料SNCM630的化学成分质量百分比如表1所示。
表1、轴承座式关节高性能螺栓材料成分(wt,%)
类别 | C | Mn | Si | P | S | Cr | Mo | Ni | V | Nb |
实施例1 | 0.22 | 0.51 | 0.056 | 0.0005 | 0.0019 | 1.88 | 0.35 | 3.80 | 0.08 | 0.08 |
实施例2 | 0.25 | 0.66 | 0.046 | 0.0008 | 0.0012 | 2.14 | 0.40 | 3.58 | 0.09 | 0.06 |
实施例3 | 0.28 | 0.62 | 0.06 | 0.001 | 0.001 | 1.96 | 0.44 | 3.72 | 0.07 | 0.10 |
对比例 | 0.33 | 0.44 | 0.24 | 0.023 | 0.012 | 2.76 | 0.68 | 2.57 | / | / |
从上表可以看出,本发明高性能螺栓:降低S、P有害元素含量,以达到控制非金属夹杂物数量和形态,尤其是减少可变形的MnS夹杂物数量;增加0.05-0.10%的V元素,0.05-0.10%的Nb元素,控制Si元素含量≤0.08%;适量的Nb、V、Si元素能细化奥氏体基体晶粒,且Nb和V以NbC、VC等强化相析出,从而改善螺栓的力学性能,强度会增加;同时,Si元素含量减少使得冲击功较高,提高抗疲劳强度,因此螺栓不易断裂。
本发明高性能螺栓的制造方法为:冶炼→模锻、正火回火→粗加工→调质处理→半精加工→去应力回火→表面处理→精加工。
本发明高性能螺栓的制造方法,其具体步骤为:
(1)冶炼:将优质合金原材进行电炉冶炼,并采取相应的LF炉外精炼、VD真空脱气工艺、电渣重熔;
(2)模锻并正火回火:将铸锭在1000~1150℃进行锻打,在900-950℃左右终锻成型,锻后缓冷至300~350℃保温6h,再经过900~920℃正火,快速冷却至620~650℃回火保温6h;
(3)粗加工:将锻坯按图纸进行粗加工;
(4)热处理:将粗加工的螺栓毛坯在880±10℃保温90min后油冷至室温,然后进行520±20℃保温6h油冷至室温;
(5)半精加工:将热处理后的螺栓毛坯按图纸进行半精加工,螺纹部分采用滚丝机滚压加工成型;
(6)去应力回火:将半成品螺栓在300~350℃回火处理;
(7)表面处理:将半成品螺栓和镍铝合金粉末进行80℃~100℃充分预热,使用高速氧-煤油火焰喷涂镍铝合金粉末,氮气保护;高纯氧气与煤油质量百分比为3~4,高纯氧气流量可选1800~2000scfh;煤油可选航空煤油,流量可选5~6gal/h,氮气流量可选20~40scfh,工件转速可选160~190rpm,送粉速度可选70~90g/min;
(8)精加工:将螺栓的六角头部过渡圆角、螺杆、螺纹及过渡圆角进行抛光处理,如图2所示。
其中,经过步骤(1)、(2)后,螺栓坯料中:[H]≤1.0ppm、[O]≤15ppm、[N]≤40ppm、晶粒度均≥9级、带状组织均≤1级、夹杂物面积平均尺寸≤12μm2、夹杂物长度平均尺寸≤5μm、每平方厘米内可变形的MnS夹杂物数量约30~60个。从上面可以看出,非金属夹杂物形态得到控制,尤其是MnS夹杂物的数量明显减少。
其中,经过步骤(4)调质处理后:螺栓硬度为370-400HB,组织均为保持马氏体位向的回火索氏体,Nb和V元素以NbC、VC化合物方式在晶界、亚晶界等处沉淀析出,从而细化晶粒,晶粒度达到10级,如图3所示。实施例1螺栓硬度为371-378HB;实施例2螺栓硬度为373-384HB,实施例3螺栓硬度为385-396HB。
其中,步骤(2)、(5)、(8):采用专用的模具锻造成型,并采用滚压加工方式精加工螺纹,使得螺栓的螺纹部分含有明显的金属流线,形成表面压应力,提升螺纹部位的抗疲劳性能,如图4所示。同时,螺栓表面粗糙度达到Ra0.8以上,避免应力集中产生疲劳裂纹。
其中,经过步骤(7)后:螺栓表面镍铝合金涂层0.1~0.2mm,涂层结合力≥70MPa,经过2400~4800h中性盐雾腐蚀试验,未发生明显腐蚀,因此螺栓表面具有较好的耐腐蚀、耐热、良好的耐金属-金属摩擦磨损性能的涂层,防腐保护周期长。因此,螺栓在200℃以上工况下具有较好的耐腐蚀性能。
需要注意的是,由于合金元素含量高,极易在锻造时产生氢脆裂纹。因此,应严格控制螺栓坯料锻造过程中的锻造温度、终锻温度,避免过热引起晶粒粗大,并在锻后及时进行正火回火处理。
本发明三个实施例与背景技术中的进口材料螺栓的标准力学性能试样检测结果如表2所示。
表2、轴承座式关节高性能螺栓力学性能(23℃)
从上表可以看出,本发明制造方法得到的高性能螺栓的室温力学性能均达到:抗拉强度≥1300MPa;屈服强度≥1200MPa;断后伸长率≥17%;断面收缩率≥65%;冲击功≥150J。所以,本发明轴承座式关节的高性能螺栓的力学性能明显优于背景技术中的进口材料,当然更优于国产螺栓性能。因此,本发明高性能螺栓的韧性、接触疲劳强度及耐腐蚀性得到了提高,使得其不易出现疲劳裂纹、断裂等问题,延长了整个传动轴的使用寿命。
Claims (10)
1.轴承座式关节的高性能螺栓,其特征是:其化学成分的质量百分比(wt%)为:C:0.20-0.30%,Mn:0.45-0.70%,Si≤0.08%,P≤0.01%,S≤0.01%,Ni:3.50-3.85%,Cr:1.60-2.20%,Mo:0.35-0.55%,V:0.05-0.10%,Nb:0.05-0.10%,余量为Fe。
2.根据权利要求1所述的高性能螺栓,其特征是:其化学成分的质量百分比优选为:C:0.22%,Mn:0.51%,Si:0.056%,P:0.0005%,S:0.0019%,Ni:3.80%,Cr:1.88%,Mo:0.35%,V:0.08%,Nb:0.08%,余量为Fe。
3.根据权利要求1所述的高性能螺栓,其特征是:其化学成分的质量百分比优选为:C:0.25%,Mn:0.66%,Si:0.046%,P:0.0008%,S:0.0012%,Ni:3.58%,Cr:2.14%,Mo:0.40%,V:0.09%,Nb:0.06%,余量为Fe。
4.根据权利要求1所述的高性能螺栓,其特征是:其化学成分的质量百分比优选为:C:0.28%,Mn:0.62%,Si:0.06%,P:0.001%,S:0.001%,Ni:3.72%,Cr:1.96%,Mo:0.44%,V:0.07%,Nb:0.10%,余量为Fe。
5.权利要求1-4任一所述的高性能螺栓的制造方法为:冶炼→模锻、正火回火→粗加工→调质处理→半精加工→去应力回火→表面处理→精加工。
6.根据权利要求5所述的制造方法,其具体步骤为:
(1)冶炼:将优质合金原材进行电炉冶炼,并采取相应的LF炉外精炼、VD真空脱气工艺、电渣重熔;
(2)模锻并正火回火:将铸锭在1000~1150℃进行锻打,在900-950℃左右终锻成型,锻后缓冷至300~350℃保温6h,再经过900~920℃正火,快速冷却至620~650℃回火保温6h;
(3)粗加工:将锻坯按图纸进行粗加工;
(4)热处理:将粗加工的螺栓毛坯在880±10℃保温90min后油冷至室温,然后进行520±20℃保温6h油冷至室温;
(5)半精加工:将热处理后的螺栓毛坯按图纸进行半精加工,螺纹部分采用滚丝机滚压加工成型;
(6)去应力回火:将半成品螺栓在300~350℃回火处理;
(7)表面处理:将半成品螺栓和镍铝合金粉末进行80℃~100℃充分预热,使用高速氧-煤油火焰喷涂镍铝合金粉末,氮气保护;高纯氧气与煤油质量百分比为3~4,高纯氧气流量可选1800~2000scfh;煤油可选航空煤油,流量可选5~6gal/h,氮气流量可选20~40scfh,工件转速可选160~190rpm,送粉速度可选70~90g/min;
(8)精加工:将螺栓的六角头部过渡圆角、螺杆、螺纹及过渡圆角进行抛光处理。
7.根据权利要求6所述的制造方法,其特征是:经步骤(1)和(2)后得到的螺栓坯料中:[H]≤1.0ppm、[O]≤15ppm、[N]≤40ppm、晶粒度≥9级、带状组织≤1级、夹杂物面积平均尺寸≤12μm2、夹杂物长度平均尺寸≤5μm、每平方厘米内可变形的MnS夹杂物数量≤60个。
8.根据权利要求6所述的制造方法,其特征是:经步骤(4)调质处理后,螺栓硬度为370至400HB,组织为保持马氏体位向的回火索氏体,Nb和V元素以NbC、VC化合物方式在晶界、亚晶界等处沉淀析出,从而细化晶粒,晶粒度达到10级。
9.根据权利要求6所述的制造方法,其特征是:经步骤(2)、(5)、(8)加工后,螺栓的螺纹部分含有明显的金属流线,粗糙度Ra0.8以上;经步骤(7)后,螺栓表面镍铝合金涂层0.1~0.2mm,涂层结合力≥70MPa,经过2400~4800h中性盐雾腐蚀试验,未发生明显腐蚀。
10.根据权利要求6所述的制造方法,其特征是:螺栓23℃的力学性能为:抗拉强度≥1300MPa;屈服强度≥1200MPa;断后伸长率≥17%;断面收缩率≥65%;冲击功≥150J。
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