Key metallurgical technology for high-quality bearing steel production based on the nonaluminum deoxidation process
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摘要: 我國高品質軸承鋼生產技術已取得了長足進步，部分企業的軸承鋼質量處于世界先進水平，但質量穩定性與世界領先水平仍存在一定差距。目前，國內外主要采用鋁脫氧工藝生產軸承鋼，通過鋁脫氧和造高堿度渣快速降低鋼液中氧含量，高品質軸承鋼中全氧質量分數已經可以控制在5×10?6以下，但仍存在大顆粒球狀（Ds類）類夾雜物導致疲勞失效的難題，以及超低全氧和鈦含量難以穩定控制、小方坯連鑄水口堵塞等問題。針對上述問題，本研究提出了非鋁脫氧工藝生產軸承鋼，即在轉爐出鋼時加入硅錳合金預脫氧，鋼包精煉爐（LF）向渣面加入硅質脫氧劑擴散脫氧，真空循環脫氣精煉（RH）真空深脫氧，保證鋼液全氧質量分數在8×10?6左右。在保證鋼液低鋁低鈦的同時，利用低堿度渣改變夾雜物類型，控制夾雜物塑性化，從而有效地解決鋼液流動性問題。利用超聲疲勞試驗機對兩種工藝軸承鋼疲勞壽命進行測定，闡明了不同類型夾雜物對疲勞性能的影響，剖析了不同工藝軸承鋼的疲勞斷裂機理，研究了引起疲勞裂紋的夾雜物臨界尺寸。Abstract: Bearing steel is subjected to complex alternating stress conditions for a long time which requires excellent service properties such as high hardness, high wear resistance, high elastic limit, and high contact fatigue strength. Therefore, during bearing steel production, it is necessary to strictly control the process and improve the purity of steel to ensure high precision, long service life, and high reliability of bearings. China has made considerable progress in the production technology of high-quality bearing steel, and some enterprises can produce world-class bearing steel. However, the stability of bearing steel still requires improvement. Currently, the aluminum deoxidation process is mainly used to produce bearing steel at home and abroad. Through aluminum deoxidation and the production of high-alkalinity slag, the oxygen content in liquid steel can be rapidly reduced. The total oxygen mass fraction in high-quality bearing steel can be controlled below 5×10?6. However, fatigue failure caused by occasional Ds-type inclusions still occurs. Concurrently, other problems such as blockage of small billet continuous casting nozzle and difficulty in stable control of ultralow total oxygen and titanium content also occur. To circumvent the aforementioned problems, this study proposed a nonaluminum deoxidation process by adding silicon–manganese alloy for pre-deoxidation during converter tapping, adding silicon deoxidizer to the ladle furnace (LF) slag surface for diffusion deoxidation, and Ruhrstahl?Heraeus (RH) vacuum deep deoxidation to ensure that the total oxygen mass fraction of the molten steel was approximately 8×10?6, to produce bearing steel. While ensuring the low aluminum and low titanium contents of liquid steel, low-alkalinity slag is used to change the type of inclusions and control the plasticity of inclusions to effectively solve the problem of liquid steel fluidity. The fatigue life of bearing steels by two kinds of processes was evaluated using the ultrasonic fatigue testing machine, the effects of different types of inclusions on fatigue performance were verified, the fatigue fracture mechanism of bearing steels by different processes was analyzed, and the critical size of inclusions causing fatigue cracks was predicted. The application of the aforementioned key technologies plays a guiding role in the large-scale production of nonaluminum deoxidized high-quality bearing steel. However, its quality still lags behind the most advanced production level of bearing steel worldwide, including the poor desulfurization effect caused by the use of low-basicity slag in the refining process, which needs to be further investigated.
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Key words:
- bearing steel /
- silicomanganese deoxidation /
- vacuum deep deoxidation /
- inclusion /
- ultrasonic fatigue
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圖 1 合金元素與脫氧效果關系. (a) 不同錳硅比對脫氧產物占比及活度的影響；(b) [Si]平衡鋼液中[O]質量分數變化
Figure 1. Relationship between alloying elements and deoxidation effect: (a) effects of different manganese–silicon ratios on the proportion and activity of each deoxidation product; (b) variation of [O] mass content in [Si] equilibrium molten steel
圖 2 CaO?SiO2?Al2O3?12%MgO四元渣系等氧線
Figure 2. CaO?SiO2?Al2O3?12%MgO quaternary slag iso-oxygen line
圖 3 非鋁脫氧生產軸承鋼LF工序. (a) 全氧含量變化; (b) 氮含量變化
Figure 3. LF process of nonaluminum deoxidation production of bearing steel: (a) total oxygen change; (b) nitrogen content change
圖 5 非鋁脫氧生產軸承鋼RH工序.(a) 全氧含量變化;(b) 氮含量變化
Figure 5. RH process of nonaluminum deoxidation bearing steel: (a) total oxygen change; (b) nitrogen contents change
圖 7 低鈦控制技術應用效果. (a) 不同工序渣中TiO2含量；(b) 有害元素含量
Figure 7. Application effect of low titanium control technology: (a) TiO2 content in slag of different processes；(b) content of harmful elements
圖 9 精煉渣成分對CaO (a) 和Al2O3 (b)活度的影響
Figure 9. Effects of refining slag composition on the activities of CaO (a) and Al2O3 (b)
圖 10 鋁脫氧和非鋁脫氧軸承鋼鑄坯中各類型夾雜物分布
Figure 10. Distribution of various types of inclusions in aluminum and nonaluminum deoxidized bearing steel billets
圖 11 非鋁脫氧軸承鋼冶煉過程夾雜物形貌.(a~c) 轉爐; (d~f) LF; (g~j) RH
Figure 11. Morphology of inclusions in the smelting process of nonaluminum bearing steel: (a–c) BOF; (d–f) LF; (g–j) RH
圖 12 鋼液可澆性對比. (a) 非鋁脫氧工藝; (b) 低鋁脫氧工藝水口內壁結瘤情況; (c) 不同脫氧方式鋼液中夾雜物液相比例
Figure 12. Comparison of castability of molten steel: (a) nodulation on the inner wall of the nozzle in nonaluminum; (b) low-aluminum deoxygenation processes; (c) liquid phase ratio of inclusions with different deoxidation methods
圖 13 超聲疲勞試驗系統工作原理示意圖
Figure 13. Schematic diagram of the working principle of the ultrasonic fatigue test system
圖 14 1300 MPa下全氧含量與疲勞壽命(Nf)的關系
Figure 14. Relationship between total oxygen content and fatigue life (Nf) at 1300 MPa
圖 16 不同夾雜物造成的疲勞斷裂. (a) 門檻值; (b) 臨界尺寸
Figure 16. Fatigue fracture caused by different inclusions: (a) threshold value; (b) critical size
表 1 非鋁脫氧工藝冶煉軸承鋼LF精煉渣成分（質量分數）
Table 1. Composition of LF refining slag for smelting bearing steel by the nonaluminum deoxidation process
% Stage CaO SiO2 Al2O3 MgO MnO FeO R After the BOF 41.2 38.8 3.89 7.16 3.80 2.043 1.06 Start of LF refining 40.9 39.8 4.05 7.30 3.74 1.368 1.03 LF refining
before slagging48.7 34.8 3.74 7.73 0.736 2.133 1.40 LF refining
after slagging47.1 33.5 5.06 11.3 0.413 0.555 1.41 End of LF refining 37.8 42.0 4.71 12.2 0.805 0.900 0.90 
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表 2 非鋁脫氧工藝冶煉軸承鋼RH鋼包頂渣成分（質量分數）
Table 2. Composition of RH top slag smelting bearing steel by the nonaluminum deoxidation process
% Stage CaO SiO2 Al2O3 MgO MnO FeO R Start of RH 37.2 41.7 4.67 12.5 0.859 1.386 0.89 End of RH 37.6 41.8 4.76 12.4 0.882 0.945 0.90
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表 3 不同工藝下Ds類夾雜物評級
Table 3. Ds inclusion ratings under different processes
Grade Aluminum deoxidized Nonaluminum deoxidized Quantity (heats) Proportion/% Quantity (heats) Proportion/% Grade 0 210 45.45 154 91.67 Grade 0.5 178 38.53 14 8.33 Grade 1.0 63 13.64 0 0 Grade 1.5 10 2.16 0 0 Grade 2.0 1 0.22 0 0
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表 4 不同工藝下連澆爐數對比
Table 4. Comparison of continuous casting heats under different processes
Deoxidization process CC heats (heats) Average (heats) Total (heats) Nonaluminum 8–17 12.8 231 Low aluminum 5–10 7.9 270 Aluminum 5 5 —
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表 5 力學參數和熱物性系數
Table 5. Mechanical parameters and thermophysical coefficients
Materials α/(10?6 ℃?1) E/GPa $\upsilon $ Silicate 2.47 71 0.21 Calcium Aluminate 5.0 113 0.23 Steel substrate 23.0 206 0.50
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