CN113463103A - 强度2100-2400mpa预应力钢绞线的生产工艺 - Google Patents
强度2100-2400mpa预应力钢绞线的生产工艺 Download PDFInfo
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- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
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- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
- C21D9/525—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length for wire, for rods
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Abstract
本发明提供了一种强度2100‑2400mpa预应力钢绞线的生产工艺，包括如下步骤：(1)将盘条依次进行一次酸洗、二次酸洗，然后进行磷化、硼化、烘干和拉拔处理后得到半成品钢丝；(2)将所述的半成品钢丝进行捻股稳定化热处理后即得所述的强度2100‑2400mpa预应力钢绞线。本发明所述的强度2100‑2400mpa预应力钢绞线的生产工艺生产得到的超高强度钢绞线产品的合格率达98％以上。
Description
技术领域
本发明属于钢绞线生产领域，尤其是涉及一种强度2100-2400mpa预应力钢绞线的生产工艺。
背景技术
预应力钢绞线是公路、铁路桥梁,大型屋面板混凝土构件的受力主肋，国内年需求量近400万吨。多年来使用的1*7-15.2mm钢绞线强度级别几乎都是1860mpa级。为适应建设领域高质量发展的需求，提高大型构件使用钢绞线强度级别，优化设计走出一条节约资源、绿色环保、降低碳排放、降低造价、轻便施工创新之路，填补国产超高强预应力钢绞线的空白，它不但有重大经济效益，而且具有深远社会影响。
发明内容
有鉴于此，本发明旨在克服现有技术中的缺陷，提出一种强度2100-2400mpa预应力钢绞线的生产工艺。
为达到上述目的，本发明的技术方案是这样实现的：
一种强度2100-2400mpa预应力钢绞线的生产工艺，包括如下步骤：
(1)将盘条依次进行一次酸洗、二次酸洗，然后进行磷化、硼化、烘干和拉拔处理后得到半成品钢丝；
(2)将所述的半成品钢丝进行捻股稳定化热处理后即得所述的强度2100-2400mpa预应力钢绞线。
进一步，所述的步骤(1)中的一次酸洗步骤的酸洗液的浓度为8-15％，温度为30-40℃，亚铁含量≤250g/L，浸酸时间为15min；所述的一次酸洗步骤的酸洗液为稀硫酸；所述的一次酸洗步骤的酸洗液中添加有5‰的防氢脆缓释抑制剂；所述的防氢脆缓释抑制剂为阳离子性胺诱导体。
进一步，所述的步骤(1)中的二次酸洗步骤的酸洗液的浓度为15-20％，温度≥50℃，亚铁含量≤150g/L，浸酸时间为10min；所述的二次酸洗步骤的酸洗液为稀硫酸；所述的二次酸洗步骤的酸洗液中添加有5‰的防氢脆缓释抑制剂；所述的防氢脆缓释抑制剂为阳离子性胺诱导体。
进一步，所述的步骤(1)中的盘条的直径为13.0-14.0mm。
进一步，所述的步骤(1)中的磷化步骤的磷化时间为8-15min，磷化液的温度为70-85℃；所述的步骤(1)中的磷化步骤的磷化液中总酸度为60-90点，游离酸度6-12点，总锌量≥29g/L，硝酸≥21g/L，磷酸≥12g/L，亚铁≤5g/L；磷化步骤完成后盘条的上模量≥10g/m2。
进一步，所述的步骤(1)中的硼化步骤的硼化槽温度≥90℃，时间为3-5min，硼化液为硼酸钠，所述的硼化液的浓度为3-8波美度。硼化步骤不但能较彻底清除盘条表面的酸性离子，而且会均匀的形成附着力强，并有一定厚度致密的磷酸盐、硼酸盐润滑载体，明显减少多道次拉拔摩擦力，降低断头率，提高拉拔速度和单位产量。
进一步，所述的步骤(1)中的烘干步骤的时间为3-5min。
进一步，所述的步骤(1)中的拉拔处理步骤的总压缩率为80-90％，平均道次压缩率为15-25％；所述的步骤(1)中的拉拔处理步骤为分道次拉拔，其中，第二道次的平均道次压缩率大于其他道次；自第三道次至拉拔结束，各道次的平均道次压缩率依次降低。所述的拉拔处理符合超高强度盘条变形规律，优选第一道次部分压缩率要小，作为保护润滑载体，磷化硼化涂层与润滑粉紧密结合，形成高延展性润滑体。第二道次平均道次压缩率最大，然后依次逐道下降，使盘条等轴晶粒，随压缩道次增加，纤维化程度逐渐增大，珠光体片层间距越来越小，这样生产半成品不但有理想高强度，而且具有高的韧性。
进一步，所述的拉拔处理的拉丝摸工作锥角度为7-12度，定经带长度为0.3-0.5d，采用镂空式冷却模具外套；拉拔处理中前5道次采用的润滑剂为硬脂酸钙，第6道次后采用的润滑剂为硬脂酸钠；所述的步骤(1)中的拉拔处理步骤的温度小于等于230℃。采用不同的拉丝摸工作锥角度和定经带长度，以及采用镂空式冷却模具外套，明显减少硬线盘条在形变和摩擦中发热。拉拔前5道采用以硬脂酸钙为基的润滑剂，后几道更换为以硬脂酸钠为基的润滑剂，而每一道次模盒内都有自动搅拌设施和流体强迫润滑管，通过良好润滑体系作用，将硬线盘条与拉拔模具在模具内变形过程中不出现任何咬合，不但可以使拉拔顺利进行，而且能有力提高半成品的强韧性。拉拔使用拉丝罐鼓，采用世界上喷淋式冷却系统，拉丝模具高压强迫冷却尤其是使用了拉拔过程中，钢丝直冷技术，而每一道次都配备的水冷装置，使钢丝在整个变形过程中温度不超过230℃。克服了热时效产生不良影响。
进一步，所述的步骤(2)中的稳定化热处理步骤的温度为390-400℃。针对高碳、高硅较高合金元素的化学成分，稳定化热处理前进行捻股处理，捻距按公称直径14倍设定，实践证明稳定化处理张力按半成品平均实际强度的42-43％为宜。
相对于现有技术，本发明具有以下优势：
本发明所述的强度2100-2400mpa预应力钢绞线的生产工艺
本发明所述的强度2100-2400mpa预应力钢绞线的生产工艺生产得到的超高强度钢绞线产品的合格率达98％以上。
本发明所述的强度2100-2400mpa预应力钢绞线的生产工艺对表面处理拉拔工序进行改进，有效保证了超高强度钢绞线半成品钢丝优良质量，而且显著提高拉拔速度，提高劳动生产率，拉拔速度提升到4-5.5m/S。
具体实施方式
除有定义外，以下实施例中所用的技术术语具有与本发明所属领域技术人员普遍理解的相同含义。以下实施例中所用的试验试剂，如无特殊说明，均为常规生化试剂；所述实验方法，如无特殊说明，均为常规方法。
本发明所述的防氢脆缓释抑制剂采用北杉化学(济南)有限公司生产的酸洗腐触抑制剂HIBIRON Y-32LK-5。
本发明所述的生产工艺中采用的盘条的力学性能要求如表1所示，盘条的化学成分如表2所示。
表1下面结合实施例来详细说明本发明。
注：面缩率为时效后数据。
表2盘条的化学成分
盘条的内在质量要求具体如下：
1、素氏体化按标准要求≥90％；
2、盘条一边总脱碳后(铁素体+过渡层)不应≥0.07mm；
3、盘条不应有影响拉拔的网状渗碳体和马氏体；
4、晶粒度要求≥7级；
5、非金属夹杂物A、B、C、D、Ds不应大于1.5级。
盘条的表面质量要求具体如下：
1、盘条表面不应有裂纹，折叠，耳子等有害缺陷
2、盘条在运输、储存、搬运、装卸时严禁碰伤。
上述要求，随着我国钢铁行业转型发展以及上下游联合攻关，已有不少钢厂完全有能力批量生产超高强预应力钢绞线用盘条。
下面结合实施例来详细说明本发明。
实施例1
2200mpa预应力钢绞线生产工艺：原料化学成分质量分数为c：0.88％、si：0.94％、Mn0.56％、P：0.010％、S：0.001％、Cr、0.32％、V：0.035％。其余为Fe和杂质。基本可归属87mnSi类型φ13.0mm硬线，其平均抗拉强度为1420mpa，面缩率为29％。
盘条经过两步酸洗，磷化和硼化处理，最后烘干脱氢，已洗盘条磷化硼化涂层均匀致密，上膜量高达12g/㎡。酸洗液中添加5‰防氢脆缓释抑制剂，两步酸洗的参数如表3所示，盘条酸洗后经高压水冲洗，进行磷化涂层槽，磷化处理参数如表4所示，磷化后的盘条再次经高压水冲洗，进入硼化及烘干槽，硼化处理与烘干步骤的参数如表5所示。
表3两步酸洗的参数
| 浓度(％) | 温度(℃) | 亚铁含量(g/L) | 浸酸时间(min) | |
| 第一步酸洗 | 12 | 35 | 210 | 15 |
| 第二步酸洗 | 18 | 56 | 105 | 10 |
表4磷化处理的参数
表5硼化处理与烘干步骤的参数
2、拉拔在完全控冷条件下，以5.5m/s高速度拉9道次顺利完成。
具体拉拔路线：
φ13.0mm盘条，第一道拉拔为11.70mm(压缩率19.00％)，第二道拉拔为10.40mm(压缩率20.99％)，第三道拉拔为9.30mm(压缩率20.04％)，第四道拉拔为8.34mm(压缩率19.13％)，第五道拉拔为7.50mm(压缩率19.13％)，第六道拉拔为6.77mm(压缩率18.52％)，第七道拉拔为6.12mm(压缩率18.28％)，第八道拉拔为5.55mm(压缩率17.76％)，第九道拉拔为5.05mm(压缩率17.21％)。
以φ13.0mm盘条，在1200/9进口拉丝机上生产φ5.05mm边丝和φ5.23mm中心丝，其性能如下，边丝直径max为5.05mm、min为5.04mm中心丝直径为5.23mm,平均抗拉强度为2280mpa,平均反复弯曲次数为10.3次，标距为100mm、伸长率为2.4％、残余磷化膜厚度平均为4g/㎡。
针对半成品实际性能，制定了捻股稳定化处理工艺参数，加热温度执行390±5℃，施加张力为137±0.5KN(按半成品实际强度的43％计算)，运行速度为90m/min。
成品性能如下表6所示。
表6产品性能
各项指标均达到或高于GB/T5224《预应力混凝土用钢绞线》标准。
实施例2
2400mpa预应力钢绞线生产工艺：原料化学成分质量分数为C:0.95％、Si：0.96％、Mn:0.55％、P:0.009％、S:0.002％、Cr:0.35％、V:0.032％、其余为Fe和不可避免杂质成分。基本归属于95Si类型φ14.0mm硬线。其平均抗拉强度为1500mpa,面缩率平均为28％。
1、盘条经过两次酸洗，磷化、硼化处理，后经过烘干脱氢，已洗盘条无残留氧化铁皮，表面磷酸盐涂层均匀致密，经试验室检测上膜量为11g/㎡。酸洗液中添加5‰防氢脆缓释抑制剂，两步酸洗的参数如表7所示，盘条酸洗后经高压水冲洗，进行磷化涂层槽，磷化处理参数如表8所示，磷化后的盘条再次经高压水冲洗，进入硼化及烘干槽，硼化处理与烘干步骤的参数如表9所示。
表7两步酸洗的参数
| 浓度(％) | 温度(℃) | 亚铁含量(g/L) | 浸酸时间(min) | |
| 第一步酸洗 | 9 | 36 | 200 | 15 |
| 第二步酸洗 | 20 | 53 | 110 | 10 |
表8磷化处理的参数
表9硼化处理与烘干步骤的参数
2、在进口拉丝机上，实施控制冷却方案进行10道次拉拔作业，生产φ5.09mm边丝和φ5.27中心丝，良好的冷却润滑条件，使拉拔能在4m/s速度下顺利进行。
具体拉拔路线：
φ14.0mm盘条，第一道拉拔为13.00mm(压缩率13.78％)，第二道拉拔为11.70mm(压缩率19.00％)，第三道拉拔为10.40mm(压缩率20.98％)，第四道拉拔为9.30mm(压缩率20.04％)，第五道拉拔为8.34mm(压缩率19.58％)，第六道拉拔为7.53mm(压缩率18.48％)，第七道拉拔为6.80mm(压缩率18.45％)，第八道拉拔为6.15mm(压缩率18.20％)，第九道拉拔为5.58mm(压缩率17.68％)，第十道拉拔为5.09mm(压缩率16.79％)。
半成品平均抗拉强度达到2520mpa，平均反复弯曲次数为9.5次，标距为100mm断后伸长率平均为2.5％。经检测残余磷化膜厚度为3.8g/m2。
捻股稳定化处理工艺参数为，加热温度395±5℃,施加张力为150±0.5KN，运行速度80m/min,捻距为公称直径的14倍。
成品性能如下表10所示。
表10产品性能
各项指标均达到或高于GB/T5224《预应力混凝土用钢绞线》标准。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (10)
1.一种强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：包括如下步骤：
(1)将盘条依次进行一次酸洗、二次酸洗，然后进行磷化、硼化、烘干和拉拔处理后得到半成品钢丝；
(2)将所述的半成品钢丝进行捻股稳定化热处理后即得所述的强度2100-2400mpa预应力钢绞线。
2.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的一次酸洗步骤的酸洗液的浓度为8-15％，温度为30-40℃，亚铁含量≤250g/L，浸酸时间为15min；所述的一次酸洗步骤的酸洗液为稀硫酸；所述的一次酸洗步骤的酸洗液中添加有5‰的防氢脆缓释抑制剂；所述的防氢脆缓释抑制剂为阳离子性胺诱导体。
3.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的二次酸洗步骤的酸洗液的浓度为15-20％，温度≥50℃，亚铁含量≤150g/L，浸酸时间为10min；所述的二次酸洗步骤的酸洗液为稀硫酸；所述的二次酸洗步骤的酸洗液中添加有5‰的防氢脆缓释抑制剂；所述的防氢脆缓释抑制剂为阳离子性胺诱导体。
4.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的盘条的直径为13.0-14.0mm。
5.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的磷化步骤的磷化时间为8-15min，磷化液的温度为70-85℃；所述的步骤(1)中的磷化步骤的磷化液中总酸度为60-90点，游离酸度6-12点，总锌量≥29g/L，硝酸≥21g/L，磷酸≥12g/L，亚铁≤5g/L；磷化步骤完成后盘条的上模量≥10g/m2。
6.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的硼化步骤的硼化槽温度≥90℃，时间为3-5min，硼化液为硼酸钠，所述的硼化液的浓度为3-8波美度。
7.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的烘干步骤的时间为3-5min。
8.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(1)中的拉拔处理步骤的总压缩率为80-90％，平均道次压缩率为15-25％；所述的步骤(1)中的拉拔处理步骤为分道次拉拔，其中，第二道次的平均道次压缩率大于其他道次；自第三道次至拉拔结束，各道次的平均道次压缩率依次降低。
9.根据权利要求8所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的拉拔处理的拉丝摸工作锥角度为7-12度，定经带长度为0.3-0.5d，采用镂空式冷却模具外套；拉拔处理中前5道次采用的润滑剂为硬脂酸钙，第6道次后采用的润滑剂为硬脂酸钠所述的步骤(1)中的拉拔处理步骤的温度小于等于230℃。
10.根据权利要求1所述的强度2100-2400mpa预应力钢绞线的生产工艺，其特征在于：所述的步骤(2)中的稳定化热处理步骤的温度为390-400℃。
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