CN116445681A - 一种含硫齿轮钢的冶炼方法 - Google Patents
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- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0075—Treating in a ladle furnace, e.g. up-/reheating of molten steel within the ladle
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- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
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- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
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- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
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- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
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- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
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Abstract
一种含硫齿轮钢的冶炼方法,属于冶金技术领域,包括顶底复吹转炉初炼、LF精炼、RH真空精炼和方坯连铸工序。转炉过程不加入铝制脱氧剂;LF精炼采用碳化硅脱氧,也不用铝脱氧,不用造还原性白渣脱硫,只需将钢液升温至1640~1650℃,加入覆盖剂保温;RH精炼采用深真空碳脱氧技术,脱氧结束后,据钢液定氧设备所测数据加入铝粒终脱氧,控制出站钢液中Als含量0.020~0.035%,待钢液纯循环≥5min后,加入钛铁合金,复压后无需再喂入硫磺线、不必进行钙处理。本发明采用真空下碳脱氧技术,减少了铝制品脱氧后产生的Al2O3夹杂物,取消了增硫操作,避免了传统工艺钙处理产生的CaS夹杂物,使钢水更趋于洁净化。
Description
技术领域
本发明属于冶金技术领域,具体涉及一种含硫齿轮钢的冶炼方法。
背景技术
随着我国钢铁行业竞争加剧,生产成本面临着进一步的压缩。而齿轮用钢在工业领域需求面广、需求量大。因此,改进齿轮用钢的生产工艺,减少生产过程的原辅料加入种类和加入量,达到降低成本,低碳环保的目的。这对钢铁企业竞争力的提升和环境的保护都具有重要的意义。
为满足工件的高加工精度要求,向齿轮钢中添加硫以改善切削性能、提高易加工性。同时,应严格控制硫的添加量,降低夹杂物含量,以保持齿轮钢所需的抗疲劳性能。脱氧剂铝和变质剂钙的加入致使钢液中生成高熔点的Al2O3和CaS夹杂物,这降低了钢水纯净度,不利于产品性能提升。因此,改进冶炼工艺,从源头控制,降低钢水中高熔点夹杂物的数量,对提高产品质量,改善材料性能均具有重要的作用。
发明内容
本发明提供一种在高真空下碳、硅代替铝制脱氧剂脱氧,保留钢液内初始硫含量,达到免增硫,无需钙处理的含硫齿轮钢的冶炼方法,以达到减少原辅料加入种类和数量,节约成本,洁净钢水的目的。相比原有工艺,在LF炉采用铝脱氧、脱硫,RH仅脱气去除部分夹杂物,恢复大气压后,进行钢液增硫、钙处理操作。本发明可减少冶炼过程原辅料加入,降低生产成本,减少夹杂物生成,洁净钢液。
本发明基于高真空条件下,脱氧是靠碳和氧发生反应生成一氧化碳气体随真空泵排出,平衡反应方程式为(1)式:
[C]+[O]=CO(g) (1)
[C]%·[O]%=ppCO/K=mppCO
平衡常数K为温度的函数,在1600℃和ppCO=1大气压时,m(ap/K)值为0.0020~0.0025,当真空程度越深,反应平衡向右发生移动,因此深真空条件下碳的脱氧能力很强,甚至可超过脱氧元素硅、锰,和铝相当。
高真空下,可以降低CO气体的分压,使该反应向正向反应,达到碳脱氧的目的。因生成物CO为气体,且随真空泵排出,利用真空状态下,碳是最理想的脱氧剂这一规律。
碳脱氧,可避免过量铝脱氧,减少Al2O3夹杂物的生成,故而也无需对钢进行钙处理。避免了过量钙在钢水中,因为钙对硫的亲和力大于铁和锰,钢液中有钙存在时,首先生成CaS。反应方程为(2)式:
[Ca]+[S]=(CaS) (2)
其中CaS熔点为1723℃,在钢液中呈现为固态夹杂物。
为实现上述发明目的,本发明采用的技术方案是:
一种含硫齿轮钢的冶炼方法,包括顶底复吹转炉初炼、LF精炼、RH真空精炼和方坯连铸工序;
(1)顶底复吹转炉初炼工序:冶炼终点硫含量控制在0.025wt%≤S≤0.045wt%,出钢过程不加入渣洗料和铝制品脱氧;
(2)LF精炼工序:加入4~6㎏/t钢石灰,加入0.3~0.5㎏/t钢碳化硅弱脱氧,不添加铝制脱氧剂,不造还原性白渣脱硫;采用埋弧方式升温至1640~1650℃之间,并加入覆盖剂保温;
(3)RH真空精炼工序:采用真空碳脱氧处理,待碳脱氧结束后,根据钢水定氧数据含量,加入铝粒终脱氧,加入铝粒后控制钢水中Als含量在0.020~0.035%范围(加铝计算依据为:加铝量=脱氧铝+合金化铝);铝粒加入结束后根据铝粒加入量使钢水纯循环5min~8min,若铝粒加入量较大,应使钢水循环时间为上限,之后加入钛铁合金;RH恢复大气压后不喂入硫线、不进行钙处理。
所述RH真空精炼工序,控制软吹气量5~10Nm3/h,时间≥15min。
所述方坯连铸工序,采用微正压保护浇铸的钢包长水口和浸入式水口进行全程无氧化浇注;中包过热度为20~40℃,恒拉速控制在1.2±0.1m/min,并配合结晶器电磁搅拌。
采用上述技术方案所产生的有益效果在于:本发明通过在转炉工序避免加入渣洗料和铝制品脱氧剂,降低了钢液中的铝含量,节省了渣料和脱氧剂用量。在LF精炼工序,通过减少了石灰用量7~9㎏/t钢,不加入铝制品脱氧剂,缩减原辅料的使用的成本。RH真空精炼工序完成碳脱氧、合金化,恢复大气压后与传统工艺不同,不再喂入硫线,也不进行钙处理,节约了硫线以及钙合金线消耗。因为在RH工序不再进行喂硫、钙操作,相对原有工艺,可节约生产节奏7~10min;除此之外,在生产过程,因采用深真空碳脱氧,减少了铝制品脱氧后产生的大量Al2O3夹杂物,以及增硫操作后进一步钙处理所产生的CaS夹杂物,使钢水更加洁净。
附图说明
图1为原工艺生产的铸坯中Al2O3夹杂物形貌及能谱图;
图2为本发明生产的铸坯中Al2O3夹杂物形貌及能谱图;
图3为原工艺生产的铸坯中Al2O3-SiO2-MnO-CaS复合夹杂物形貌及能谱图;
图4为本发明生产的铸坯中Al2O3-SiO2-MgO-CaS复合夹杂物形貌与能谱图。
具体实施方式
下面结合具体实施方式对本发明作进一步详细的说明。
本发明采用真空碳脱氧,控制钢水中硫含量,减少转炉、LF以及RH工序的原辅料加入,缩减生产成本。
基于上述理念,本发明含硫齿轮钢的冶炼方法,包括顶底复吹转炉初炼、LF精炼、RH真空精炼和方坯连铸工序。各工序步骤如下所述:
(1)顶底复吹转炉初炼工序:冶炼终点硫含量控制在0.025wt%≤S≤0.045wt%,出钢过程中按顺序加入硅锰铁、高碳锰铁、增碳剂、中碳铬铁,不加入渣洗料和铝制脱氧剂。
(2)LF精炼工序:精炼加热开始3min内加入4~6㎏/t钢石灰埋弧升温,加入0.3~0.5㎏/t钢碳化硅脱氧,取消造渣还原性白渣脱硫环节,升温至1640~1650℃。精炼结束后加入覆盖剂保温;精炼过程注意底吹氩气流量小于10Nm3/h,避免钢渣充分接触反应,同时也减少了氩气消耗。
(3)RH真空精炼工序:钢水进入RH精炼后,进行真空碳脱氧处理,待碳脱氧结束后,根据钢水定氧含量,加入铝粒终脱氧,当钢水中氧含量在20ppm~50ppm时,一般需加入35kg~60kg铝粒,加入铝粒后保证RH出站钢水中Als含量在0.020~0.035%;铝粒加入结束后根据铝粒加入量使钢水纯循环5min~8min,若铝粒加入量较大,应使钢水循环时间为上限,之后加入钛铁合金;RH恢复大气压后,与常规工艺不同,不喂入硫线、不进行钙处理;控制软吹气量5~10Nm3/h,软吹时间≥15min。
(4)方坯连铸工序:RH炉出站盛有合格的钢液钢包,采用天车吊运至连铸机,中包在开浇前采用惰性气体——氩气进行气氛置换,置换时间≥3min,气氛置换结束后钢包开浇;用微正压保护浇铸的钢包长水口和浸入式水口进行全程无氧化浇注,钢液的增氮量明显降低,有效抑制了钢液在浇铸过程中的二次氧化。方坯连铸断面为200mm×200mm,中包过热度控制范围为20~40℃,恒拉速控制在1.2±0.1m/min,并配合结晶器电磁搅拌。采用上述工艺后,结晶器液面平稳,浇注明显稳定。
实施例1-6:一种含硫齿轮钢的冶炼方法具体如下所述。
以120t转炉及精炼冶炼钢种H20CrMnTi-2为例,各实施例冶炼过程各工序的参数见表1;实施例1-6钢包样成分见表2~表7,缩减成本见表8。
表1:各实施例冶炼过程各工序的参数
表2:实施例1冶炼过程各工序的钢包样成分(wt%)
表3:实施例2冶炼过程各工序的钢包样成分(wt%)
表4:实施例3冶炼过程各工序的钢包样成分(wt%)
表5:实施例4冶炼过程各工序的钢包样成分(wt%)
表6:实施例5冶炼过程各工序的钢包样成分(wt%)
表7:实施例6冶炼过程各工序的钢包样成分(wt%)
从表2~表7中得知,LF加入少量石灰及合金,过程硫少量下降。在RH工序,在高真空状态下,碳可将氧脱至20~30ppm左右,随后加入铝粒和钛合金进一步完成终脱氧。
表8:两种工艺成本对比
注:原工艺,具体是指在LF炉采用铝制品脱氧、加入较多的石灰大渣量脱硫,RH仅脱气去除部分夹杂物,恢复大气压后,进行钢液增硫、钙处理操作。
从表8中的得知,采用本发明冶炼H20CrMnTi-2,可吨钢节省28.1~33.7元,除去冶炼过程需要多加的SiC、碳粉和覆盖剂,吨钢可节省27.8~33.4元。
为对比两种工艺条件下,钢水夹杂物水平,分别对实际过程3炉进行取饼样分析,制作为金相试样,金相试样经镶样、抛光处理后,在金相显微镜500倍视场下对显微夹杂物进行分析。统计各试样显微夹杂物个数,取当量直径为7.5μm,如表9所示。
表9:各试样中显微夹杂物含量(个/mm2)
从表9可得出,本发明因避免在RH喂入硫线及钙处理,在生产节奏上可增加静吹时间5~7min,夹杂物上浮去除明显。本发明所生产的铸坯较原工艺生产的铸坯夹杂物平均值降低了5.9%,本发明所生产的铸坯洁净度更高,主要是因为碳脱氧不生成夹杂物,用少量铝制品终脱氧,生成Al2O3夹杂物少,且生产节奏上利于增加软吹时间的控制,更有利于夹杂物上浮去除。
由图1、图2可知,钢液中存有,形状不一,本发明铸坯中Al2O3夹杂物数量更少,相对于原工艺,本发明铸坯中此类夹杂物数量可减少48%,且夹杂物的尺寸有所变小;由图3、图4可知,原工艺所产铸坯内含有Al2O3-SiO2-MnO-CaS复合夹杂物,尤其以CaS高熔点夹杂物不易在钢水中上浮去除,而本发明生产铸坯中,夹杂物的尺寸有所减少,且CaS夹杂物占比明显降低。
Claims (5)
1.一种含硫齿轮钢的冶炼方法,其特征在于,包括顶底复吹转炉初炼、LF精炼、RH真空精炼和方坯连铸工序;
(1)顶底复吹转炉初炼工序:冶炼终点硫含量控制在0.025wt%≤S≤0.045wt%,出钢过程不加入渣洗料和铝制脱氧剂;
(2)LF精炼工序:加入4~6㎏/t钢石灰埋弧升温,加入碳化硅弱脱氧,不添加铝制脱氧剂,不造还原性白渣脱硫,采用埋弧方式升温至1640~1650℃,并加入覆盖剂保温;
(3)RH真空精炼工序:采用真空碳脱氧处理,待碳脱氧结束后,根据钢水定氧数据含量,加入铝粒终脱氧,控制RH出站钢水中Als含量在0.020~0.035%;铝粒加入结束后,钢水纯循环5min~8min,之后加入钛铁合金;复压后不喂入硫线、不进行钙处理。
2.根据权利要求1所述的含硫齿轮钢的冶炼方法,其特征在于,所述LF精炼工序,碳化硅的加入量为0.3~0.5㎏/t钢,弱脱氧。
3.根据权利要求2所述的含硫齿轮钢的冶炼方法,其特征在于,所述RH真空精炼工序,控制软吹气量5~10Nm3/h,软吹时间≥15min。
4.根据权利要求3所述的含硫齿轮钢的冶炼方法,其特征在于,所述方坯连铸工序,采用微正压保护浇铸的钢包长水口和浸入式水口进行全程无氧化浇注。
5.根据权利要求1-4任一项所述的含硫齿轮钢的冶炼方法,其特征在于,所述方坯连铸工序,中包过热度控制范围为20~40℃,拉速控制在恒拉速1.2±0.1m/min,并配合结晶器电磁搅拌。
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