CN116334483A - 基于钢管轧机的减径辊辊环及其制造方法 - Google Patents
基于钢管轧机的减径辊辊环及其制造方法 Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 57
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Abstract
本发明属于钢管轧制技术领域,公开了一种基于钢管轧机的减径辊辊环,其化学组成成分(wt%)为:C:1.4~1.8;Si≦0.80;Mn≦0.40;P≦0.05;S≦0.05;Ni:0.3~1.0;Cr:2.0~4.0;Mo:2.0~5.0;W:0.3~6.0;V:2.0~5.0;Nb:0.3~1.5;Al≦0.4;Ti:0.05~0.20;Y:0.05~0.15;Ce:0.05~0.15;Fe:余量;辊环采用中频电炉熔炼,离心铸造成型后经热处理而成,辊环硬度能达到58~63HRC,且红硬性600℃时>58HRC,抗拉强度900~1050MPa,断裂韧性75~85MPa.m1/2,冲击韧性16~20J/cm2;在使用中不出现龟裂剥落和碎裂且耐磨性好,适用于钢管轧机各类减径辊上,轧钢量是原来中镍铬钼球墨铸铁的5倍以上,且生产的钢管表面光洁,尺寸稳定。
Description
技术领域
本发明涉及钢管轧制技术领域,尤其涉及一种基于钢管轧机的减径辊辊环及其制造方法。
背景技术
热轧无缝钢管中需要用到钢管轧机,其中的减径机用于缩减钢管的管径,减径机按主机架轧辊数分有三辊式和二辊式两种,三辊式应用较广,因三辊轧制变形分布较均匀,管材横剖面壁厚均匀性好,同样的名义辊径,三辊机架间距小可缩短12%~14%;二辊主要用于壁厚大于10~12mm的厚壁管。现有的减径辊由辊环和芯轴套装而成,芯轴可以重复使用,降低轧辊生产成本。
目前钢管轧机各类减径机轧辊辊环主要使用离心铸造或整体铸造中镍铬钼无限冷硬球墨铸铁材质。采用这种材质制成的减径辊虽然具有韧性好的特点,但是却存在硬度低、红硬性差、耐磨性差的问题。现有技术中具有一些耐磨性好的合金陶瓷辊环,如:中国专利文献CN1174764A公开了一种耐磨性好合金陶瓷辊环,这种辊环必须经过热压烧结成型,生产工艺复杂,而且辊环中加入非金属陶瓷,损害了辊环的韧性,导致辊环使用中出现碎裂。此外,由于钢管轧机的减径辊工作条件与线材或棒材轧机的高速钢轧辊的工作条件不一样,传统线材或棒材轧机的高速钢轧辊不适用于钢管轧机减径辊的工作条件。
发明内容
本发明旨在解决现有技术中存在的技术问题。为此,本发明提供一种具有硬度、强度和韧性高,红硬性和耐磨性好的满足钢管轧机减径辊工作条件的高速钢辊环的化学组成成分及其制造方法。
本发明解决其技术问题所采用的技术方案是:
提供一种基于钢管轧机的减径辊辊环,其化学组成成分(wt%)如下:
C:1.4~1.8;Si≦0.80;Mn≦0.40;P≦0.05;S≦0.05;Ni:0.3~1.0;Cr:2.0~4.0;Mo:2.0~5.0;W:0.3~6.0;V:2.0~5.0;Nb:0.3~1.5;Al≦0.4;Ti:0.05~0.20;Y:0.05~0.15;Ce:0.05~0.15;Fe:余量。
并提供获得上述减径辊辊环的制造方法,该方法采用中频电炉熔炼,离心铸造成型;具体包括以下步骤:
S1,将普通废钢、高速钢屑、生铁、钨铁、钼铁、铬铁、钒铁、镍板按上述成分要求混合放入中频电炉中熔炼;
S2,炉前温度升到1550~1660℃时,加入粒径为2mm的铌铁颗粒熔化,然后加入占钢水重量0.1~0.4%的铝脱氧和合金化后出炉;
S3,将粒径为10mm的含30%铈的铈硅石、粒径为10mm的含60%钇的钇铁、粒径为10mm的含30%钛的钛铁经100℃以上烘干水分后置于包底,冲入法对钢水进行复合变质处理,熔炼后熔融状态下所有元素组分含量稳定于如权利要求1所述的含量范围,经炉前调整成分合格后出炉;
S4、采用离心铸造法成型减径辊辊环,离心机铸型时的转速n按如下公式确定:
n=299(G/R)*1/2
式中,G为重力倍数,取值为30~100;R为浇注厚度的内半径,单位为:cm;
S5,浇注完成后内表面撒入防氧化的O型玻璃渣,然后打开水冷铸型上方的喷水冷却装置,钢水浇注完毕20~30分钟后,从铸型中取出辊环,直接入不用电的保温箱内进行高温退火处理,大于24小时后,吊出放置到缓冷坑缓冷,退火后辊环的硬度为25HRC~35HRC,在此条件下粗加工;
S6,辊环粗加工后进行高温淬火处理,淬火时辊环随炉加热到1000-1150℃后保温2~6小时,然后采用雾冷的方式快速冷却到马氏体转变温度之前,再进行中温回火处理(充分的等温时间),反复进行至少三次回火处理;
S7,精加工前对辊环表面残余应力和浅表层残余奥氏体进行检测,将残余奥氏体在上机轧钢前控制在5%以下;
S8,精加工,得到尺寸精度和表面光洁度符合要求的辊环。
在本发明的一种较佳实施例中,步骤S4中,铸型材质为20铸钢或耐热球铁,壁厚80~150mm,预热温度150~200℃,并在此温度下在铸型内表面衬上一层2~5mm的覆膜砂,铸型烘干后安装于卧式离心机上等待浇注,浇注时铸型温度为80~120℃,钢水浇注温度1440~1500℃,钢水浇注速度2~8Kg/s。
在本发明减径辊辊环的成分设计中:
C:C含量过多会增大材料的脆性,减径辊辊环工作时与红热状态下的钢管相接处,若C含量过高,增大了辊环表面出现龟裂的危险,最终将导致辊环的破裂。试验结果表明,C含量控制在1.4~1.8%为宜。
Si:Si是熔炼过程中不可缺少的还原剂和脱氧元素,Si可溶入奥氏体中提高基体的屈服强度和弹性极限,提高基体的抗氧化性,减少减径辊使用后环状痕的出现,但Si含量过量时会降低基体的淬透性,因此,其加入量控制在0.80%以下。
Mn:Mn元素强烈阻碍石墨化,含量高时会产生严重偏析,因此在满足性能要求下,尽可能低为宜,因此将其含量控制在0.4%以下。
P:P熔点低且最后凝固,会沿晶界析出磷共晶,使基体组织变脆,应严格控制含量,因此将其含量控制在≤0.05%以下。
S:S是反球化元素,含量高时易产生低熔点Fe分布在晶界上,降低强度和韧性,应严格控制含量,因此将其含量控制在≤0.05%以下。
Ni:Ni是非碳化物形成元素,主要固溶于基体,提高基体强韧性,使基体对碳化物提供良好的支撑,防止高温磨损时碳化物的剥落,有利于改善高速钢辊环的耐磨性。但是Ni含量过高,淬火组织中残留奥氏体增多,导致辊环回火次数增加,因此将其控制在0.3~1.0%。
Cr:Cr在高速钢中部分存在于M6C型碳化物中,也能够形成M23C6型碳化物,还有40%左右存在于基体中。含Cr的M23C6型碳化物在较低的淬火温度时便完全溶解,Cr同样能促使M6C型碳化物更好地溶解在奥氏体中,使高速钢产生较高的淬硬性和淬透能力。但是Cr含量过高,多余的Cr参与回火时沉淀析出的碳化物的形成,这种含Cr碳化物在较低温度时容易析出,降低了钢的热稳定性。因此,综合考虑将其含量控制在2.0~4.0%。
W:W在高速钢中主要以Fe4W2C形式存在,淬火加热时,一部分Fe4W2C溶入奥氏体,淬火后存在于马氏体中。W原子与C原子结合力较强,能提高回火马氏体的分解温度,W原子半径大,能提高铁的自扩散激活能,提高钢的回火温度,使高速钢中马氏体加热到600~625℃时还很稳定。回火过程中有一部分W以W2C的形式弥散析出,造成二次硬化。淬火加热过程中未溶解的Fe4W2C能阻止高温下奥氏体晶粒长大。W含量增加,可以提高高速钢红硬性及减少热过敏性,但W含量太高会增加碳化物的不均匀性,增大钢的脆性,因此将其含量控制在0.3~6.0%。
Mo:高速钢中加Mo使钢的包晶反应温度降低,反应剩下的液相减少,在更低的温度下形成的莱氏体较细小,而且莱氏体的形态也发生了变化,可改善W系高速钢的致命的冶金缺陷——一次碳化物的不均匀性,降低了脆性,同时回火固溶的Mo可以阻止碳化物沿晶界析出,使高速钢强度和韧性提高。此外,含Mo量超过3%~4%的高速钢中的残余奥氏体的热稳定性比W系高速钢中的要低,一次回火可以完全转变,两次回火完全消除含M0高速钢中的应力。但Mo增大高速钢的脱碳敏感性,对高速钢的晶粒变粗也有较高的敏感性。因此将其的含量控制在2.0~5.0%。
V:V在高速钢中除了净化钢液,减少夹杂物和气体含量外,主要形成高硬度的MC型碳化物,高温奥氏体化时MC溶解很困难,高速钢中增加V含量,可明显提高耐磨性,但含V含量过高,由于沿晶界易出现龟裂,基体易优先磨损,轧材粘附于辊面,辊表面易粗糙,降低轧材表面质量,反而加快了辊环更换周期。此外MC数量过多,硬度过高,导致磨削加工困难,因此将其含量控制在:2.0~5.0%。
Nb:高速钢中含有较多的W、Mo、Cr、V等合金元素,而这些元素及其形成的碳化物的密度差别很大,在离心力作用下,易产生偏析,降低了辊环的耐磨性。加入Nb可形成密度较大的MC型复合碳化物,降低碳化物和熔体密度差,减轻偏析,提高辊环耐磨性。但Nb提高钢的淬火温度,降低二次硬度峰值出现的温度,因此将其含量控制在0.3~1.5%。
Al:Al溶于基体中,可提高高速钢的回火稳定性、硬度和红硬性。Al还降低M2C共晶碳化物的分解温度,使共晶碳化物在高温加热时易于分解和粒化,有利于提高高速钢的韧性。但Al增加高速钢的脱碳敏感性,因此将其含量控制在0.4%以下。
Ti:Ti能细化高速钢晶粒,提高其强度、韧性和耐磨性,但降低高速钢红硬性,综合考虑将其含量控制在0.05~0.20%。
Y:Y能细化高速钢的晶粒,限制树枝晶偏析,提高机械性能、抗氧化性和耐磨性,将其含量控制在0.05~0.15%。
Ce:Ce是钢铁合金中的强成分过冷元素,在凝固过程中通过溶质再分配而富集在初生奥氏体生长前沿的熔体中,造成成分过冷,使奥氏体枝晶细化。由于奥氏体枝晶的细化,在凝固后期,在奥氏体枝晶间由于偏析而形成的共晶钢液熔池变小,从而使共晶碳化物也得到细化,提高高速钢的强韧性;因此将其成分控制在0.05~0.15%。
与现有技术相比,本发明的有益效果是:本发明制造的减径辊辊环只需要中频炉、离心铸造机、热处理炉等普通设备,生产工艺简单,金相组织以高硬度马氏体为主,还含有10~15%的高硬度共晶碳化物,辊环硬度能达到58~63HRC,且红硬性600℃时>58HRC,抗拉强度900~1050MPa,断裂韧性75~85MPa.m1/2,冲击韧性16~20J/cm2;本发明的减径辊在使用中不出现龟裂剥落和碎裂且耐磨性好,适用于钢管轧机各类减径辊上,轧钢量是原来中镍铬钼球墨铸铁的5倍以上,且生产的钢管表面光洁,尺寸稳定。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
实施例1
本实施例提供一种基于钢管轧机的减径辊辊环的制造方法,采用中频电炉熔炼,离心铸造成型,包括以下步骤:
S1,将普通废钢、高速钢屑、生铁、钨铁、钼铁、铬铁、钒铁、镍板按下表1中实施例1的辊环成分要求混合放入中频电炉中熔炼;
S2,炉前温度升到1550℃时,加入粒径为2mm的铌铁颗粒熔化,然后加入占钢水重量0.1%的铝脱氧和合金化后出炉;
S3,将粒径为10mm的含30%铈的铈硅石、粒径为10mm的含60%钇的钇铁、粒径为10mm的含30%钛的钛铁经100℃以上烘干水分后置于包底,冲入法对钢水进行复合变质处理,熔炼后熔融状态下所有元素组分含量稳定于如下表1实施例1中所述辊环成分的含量范围,经炉前调整成分合格后出炉;
S4、采用离心铸造法成型减径辊辊环,离心机铸型时的转速n按如下公式确定:
n=299(G/R)*1/2
式中,G为重力倍数,取值为30~100;R为浇注厚度的内半径,单位为:cm。具体实施时,本实施例根据辊环内半径选择铸型转速为500~900rpm。
在本实施例中,铸型材质为20铸钢或耐热球铁,壁厚80~150mm,预热温度160℃,并在此温度下在铸型内表面衬上一层2~5mm的覆膜砂,铸型烘干后安装于卧式离心机上等待浇注,浇注时铸型温度为85℃,钢水浇注温度1440℃,钢水浇注速度4Kg/s;
S5,浇注完成后内表面撒入防氧化的O型玻璃渣,然后打开水冷铸型上方的喷水冷却装置,钢水浇注完毕25分钟后,从铸型中取出辊环,直接入不用电的保温箱内进行高温退火处理,大于24小时后,吊出放置到缓冷坑缓冷,退火后辊环的硬度为25HRC,在此条件下粗加工;
S6,辊环粗加工后进行高温淬火处理,淬火时辊环随炉加热到1000℃后保温4小时,然后采用雾冷的方式快速冷却到马氏体转变温度之前,再进行中温回火处理(充分的等温时间),反复进行至少三次回火处理;
S7,精加工前对辊环表面残余应力和浅表层残余奥氏体进行检测,将残余奥氏体在上机轧钢前控制在5%以下;
S8,精加工,得到尺寸精度和表面光洁度符合要求的辊环。
本实施例中制造的辊环性能如下表2中的实施例1所示。
实施例2
本实施例提供一种基于钢管轧机的减径辊辊环的制造方法,采用中频电炉熔炼,离心铸造成型,包括以下步骤:
S1,将普通废钢、高速钢屑、生铁、钨铁、钼铁、铬铁、钒铁、镍板按下表1中实施例2的辊环成分要求混合放入中频电炉中熔炼;
S2,炉前温度升到1660℃时,加入粒径为2mm的铌铁颗粒熔化,然后加入占钢水重量0.4%的铝脱氧和合金化后出炉;
S3,将粒径为10mm的含30%铈的铈硅石、粒径为10mm的含60%钇的钇铁、粒径为10mm的含30%钛的钛铁经100℃以上烘干水分后置于包底,冲入法对钢水进行复合变质处理,熔炼后熔融状态下所有元素组分含量稳定于如下表1实施例2中所述辊环成分的含量范围,经炉前调整成分合格后出炉;
S4、采用离心铸造法成型减径辊辊环,离心机铸型时的转速n按如下公式确定:
n=299(G/R)*1/2
式中,G为重力倍数,取值为30~100;R为浇注厚度的内半径,单位为:cm;具体实施时,本实施例根据辊环内半径选择铸型转速为500~900rpm。
在本实施例中,铸型材质为20铸钢或耐热球铁,壁厚80~150mm,预热温度200℃,并在此温度下在铸型内表面衬上一层2~5mm的覆膜砂,铸型烘干后安装于卧式离心机上等待浇注,浇注时铸型温度为120℃,钢水浇注温度1500℃,钢水浇注速度6Kg/s;
S5,浇注完成后内表面撒入防氧化的O型玻璃渣,然后打开水冷铸型上方的喷水冷却装置,钢水浇注完毕30分钟后,从铸型中取出辊环,直接入不用电的保温箱内进行高温退火处理,大于24小时后,吊出放置到缓冷坑缓冷,退火后辊环的硬度为30HRC,在此条件下粗加工;
S6,辊环粗加工后进行高温淬火处理,淬火时辊环随炉加热到1150℃后保温5小时,然后采用雾冷的方式快速冷却到马氏体转变温度之前,再进行中温回火处理(充分的等温时间),反复进行至少三次回火处理;
S7,精加工前对辊环表面残余应力和浅表层残余奥氏体进行检测,将残余奥氏体在上机轧钢前控制在5%以下;
S8,精加工,得到尺寸精度和表面光洁度符合要求的辊环。
本实施例中制造的辊环性能如下表2中的实施例2所示。
表1:辊环成分
C | Si | Mn | P | S | Ni | Cr | Mo | |
实施例1 | 1.4 | 0.3 | 0.12 | 0.02 | 0.02 | 0.3 | 2.0 | 2.0 |
实施例2 | 1.8 | 0.8 | 0.40 | 0.05 | 0.05 | 1.0 | 4.0 | 5.0 |
W | V | Nb | Al | Ti | Y | Ce | Fe | |
实施例1 | 0.3 | 2.0 | 0.3 | 0.15 | 0.05 | 0.05 | 0.05 | 余量 |
实施例2 | 6.0 | 5.0 | 1.5 | 0.4 | 0.2 | 0.15 | 0.15 | 余量 |
表2:辊环性能
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书内容所作的等效结构或等效流程变换,或直接或间接运用在其它相关的技术领域,均同理包括在本发明的专利保护范围之内。
Claims (3)
1.一种基于钢管轧机的减径辊辊环,其特征在于:其化学组成成分(wt%)如下:
C:1.4~1.8;Si≦0.80;Mn≦0.40;P≦0.05;S≦0.05;Ni:0.3~1.0;Cr:2.0~4.0;Mo:2.0~5.0;W:0.3~6.0;V:2.0~5.0;Nb:0.3~1.5;Al≦0.4;Ti:0.05~0.20;Y:0.05~0.15;Ce:0.05~0.15;Fe:余量。
2.一种获得权利要求1中所述的基于钢管轧机的减径辊辊环的制造方法,采用中频电炉熔炼,离心铸造成型;其特征在于:包括以下步骤:
S1,将普通废钢、高速钢屑、生铁、钨铁、钼铁、铬铁、钒铁、镍板按上述成分要求混合放入中频电炉中熔炼;
S2,炉前温度升到1550~1660℃时,加入粒径为2mm的铌铁颗粒熔化,然后加入占钢水重量0.1~0.4%的铝脱氧和合金化后出炉;
S3,将粒径为10mm的含30%铈的铈硅石、粒径为10mm的含60%钇的钇铁、粒径为10mm的含30%钛的钛铁经100℃以上烘干水分后置于包底,冲入法对钢水进行复合变质处理,熔炼后熔融状态下所有元素组分含量稳定于如权利要求1所述的含量范围,经炉前调整成分合格后出炉;
S4、采用离心铸造法成型减径辊辊环,离心机铸型时的转速n按如下公式确定:
n=299(G/R)*1/2
式中,G为重力倍数,取值为30~100;R为浇注厚度的内半径,单位为:cm;
S5,浇注完成后内表面撒入防氧化的O型玻璃渣,然后打开水冷铸型上方的喷水冷却装置,钢水浇注完毕20~30分钟后,从铸型中取出辊环,直接入不用电的保温箱内进行高温退火处理,大于24小时后,吊出放置到缓冷坑缓冷,退火后辊环的硬度为25HRC~35HRC,在此条件下粗加工;
S6,辊环粗加工后进行高温淬火处理,淬火时辊环随炉加热到1000~1150℃后保温2~6小时,然后采用雾冷的方式快速冷却到马氏体转变温度之前,再进行中温回火处理(充分的等温时间),反复进行至少三次回火处理;
S7,精加工前对辊环表面残余应力和浅表层残余奥氏体进行检测,将残余奥氏体在上机轧钢前控制在5%以下;
S8,精加工,得到尺寸精度和表面光洁度符合要求的辊环。
3.根据权利要求2所述的基于钢管轧机的减径辊辊环的制造方法,其特征在于:步骤S4中,铸型材质为20铸钢或耐热球铁,壁厚80~150mm,预热温度150~200℃,并在此温度下在铸型内表面衬上一层2~5mm的覆膜砂,铸型烘干后安装于卧式离心机上等待浇注,浇注时铸型温度为80~120℃,钢水浇注温度1440~1500℃,钢水浇注速度2~8Kg/s。
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