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摘要: 針對某石油套管鋼管壁內缺陷，采用掃描電鏡?能譜儀（SEM-EDS）分析，并結合FactSage8.0軟件計算進行研究，結果表明缺陷縱向面主要由淺條紋及深條紋組成，淺條紋處存在大量MgO·Al2O3夾雜物，深條紋處有大量的Al2O3、MgO·Al2O3、CaO·Al2O3·SiO2等夾雜物聚集在一起。缺陷橫截面上的夾雜物主要為CaO·Al2O3·SiO2、CaO·Al2O3·MgO和CaO·Al2O3·MgO·SiO2 3類。推測鋼管壁內缺陷形成機理主要為：①大包鋼水在澆注末期鋼水卷帶鋼包渣進入中間包鋼水中，該渣滴隨后吸附鋼中高Al2O3含量的微細xAl2O3·yCaO或Al2O3夾雜物，導致渣滴中的Al2O3含量升高；②大包鋼水在真空脫氣（VD）精煉過程大Ar氣攪拌下卷入了鋼包渣，該渣滴隨后吸附鋼中的微細Al2O3夾雜物，導致渣滴中的Al2O3含量升高；以上兩種形式形成的渣滴在凝固冷卻過程中，轉變為CaO·Al2O3·SiO2, CaO·Al2O3·MgO，CaO·Al2O3·SiO2·MgO 3種類型的夾雜物。圓管坯在穿孔變形過程中，在縱向拉應力和橫向切應力作用下，使卷入的大型渣滴沿縱向及橫截面延伸擴展，最終形成鋼管壁內的缺陷。Abstract: In this study, the defects in the wall of petroleum casing steel pipe were investigated. The morphology and composition of inclusions in the defects of the steel pipe were analyzed using scanning electron microscopy–energy-dispersive X-ray spectroscopy. The thermodynamic calculation of the Ca?Al equilibrium phase diagram of molten steel in tundish and the changes of the ladle slag phase composition with cooling temperature was performed using FactSage8.0. The results show that the longitudinal surface of the defect is mainly composed of shallow and deep stripes. A large number of MgO·Al2O3 inclusions containing a small amount of Mn is detected at shallow stripes, and a large number of inclusions, such as Al2O3, MgO·Al2O3, and CaO·Al2O3·SiO2 are detected at deep stripes. The three main types of inclusions in the cross-section of the defect zone are CaO·Al2O3·SiO2, CaO·Al2O3·MgO, and CaO·Al2O3·MgO·SiO2. According to the analysis results of inclusions in the cross-section and the calculation results of the phase transformation of slag droplets during solidification and cooling, the formation mechanism of the defects in the wall of steel pipe can be speculated as follows: (1) At the end of pouring, the ladle slag in molten steel in the ladle enters the tundish. Further, the slag droplets adsorb the fine xAl2O3·yCaO or Al2O3 inclusions with high Al2O3 content in molten steel, increasing the Al2O3 and CaO contents in the slag droplets. (2) Ladle slag in molten steel is subjected to strong stirring in Ar gas in the vacuum degassing (VD) refining process. Moreover, the slag droplets adsorb the fine Al2O3 inclusions in molten steel, increasing the Al2O3 content in the slag droplets. During solidification and cooling, the slag droplets formed in the two aforementioned forms of inclusions are transformed into three types of inclusions: CaO·Al2O3·SiO2, CaO·Al2O3·MgO, and CaO·Al2O3·SiO2·MgO. In the process of round billet piercing deformation, under the action of longitudinal tensile stress and transverse shear stress, the large slag droplets involved extend along the longitudinal cross-section and finally form defects in the wall of the steel pipe.
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Key words:
- steel pipe /
- defect /
- phase transformation of slag /
- phase diagram /
- ladle slag
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圖 1 樣品缺陷及缺陷處橫截面取樣示意圖
Figure 1. Schematic diagram of the sample defects and cross-sectional sampling of the defect zone
圖 2 樣品淺條紋缺陷處典型夾雜物形貌及成分面掃圖
Figure 2. Morphology and scanned maps of typical inclusions at the shallow stripe defect zone
圖 3 樣品深條紋缺陷處典型夾雜物形貌及面掃圖
Figure 3. Morphology and scanned maps of typical inclusions at the deep stripe defect zone
圖 4 各橫截面觀察單元取樣示意圖
Figure 4. Sampling diagrams of observation units on each cross-section
圖 5 各橫截面觀察單元及各橫截面總面積的變化
Figure 5. Changes of the area of each observation unit and the total area of each cross-section
圖 6 各橫截面處夾雜物組成在CaO?Al2O3?SiO2相圖中的分布(1600 °C)
Figure 6. Distribution of the inclusion composition in the CaO?Al2O3?SiO2 phase diagram at each cross-section (1600 ℃)
圖 7 各橫截面處夾雜物組成在CaO?Al2O3?MgO相圖中的分布 (1600 °C)
Figure 7. Distribution of the inclusion composition in the CaO?Al2O3?MgO phase diagram at each cross-section (1600 ℃)
圖 8 各橫截面上CaO·Al2O3·MgO·SiO2類夾雜物各組成平均成分及堿度R的變化
Figure 8. Changes of the average composition and basicity R of CaO·Al2O3·MgO·SiO2 inclusions on each cross-section
圖 9 橫截面缺陷處典型夾雜物的形貌與面掃描圖. (a~c) 形貌圖; (d) 面掃描圖
Figure 9. Morphology and scanned maps of typical inclusions at the cross-section of the defect zone: (a–c) morphology images; (d) scanned map images
圖 10 依據中間包鋼液成分的Mg?Al?Ca?O?S?Si夾雜物的平衡隨Ca和Al質量分數的變化(1600 °C)
Figure 10. Calculated equilibrium phase diagram of Mg?Al?Ca?O?S?Si inclusions in molten steel in tundish at different Ca and Al contents (1600 °C)
圖 11 卷入鋼包渣在凝固冷卻過程中的各相成分變化
Figure 11. Transformation of the ladle slag entrainment during solidification and cooling
圖 12 缺陷中夾雜物形成機理：第一種方式
Figure 12. Formation mechanism of inclusions at the defect zone: the first way
圖 13 缺陷中夾雜物形成機理：第二種方式
Figure 13. Formation mechanism of inclusions at the defect zone: the second way
表 1 鋼包渣的主要成分(質量分數)
Table 1. Composition of ladle slag
% CaO SiO2 Al2O3 MgO T.Fe 59.9 12.0 21.6 4.93 0.48 
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表 2 中間包鋼水成分(質量分數)
Table 2. Composition of molten steel in tundish
% C Si Mn P S Cr Mo Mg Als Ca O N Fe 0.29 0.26 0.45 0.009 0.0018 0.547 0.868 0.0004 0.022 0.0020 0.0015 0.0054 97.543
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表 3 缺陷處典型夾雜物組成(質量分數)
Table 3. Composition of typical inclusions at the defect zone
% No. O Mg Al Si Ca Mn 1 41.6 15.5 39.4 0 0 2.03 2 43.6 11.9 42.1 0 2.40 0 3 44.0 0 36.6 5.99 13.4 0
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