轴承钢热轧组织控制机理与超快速冷却研究
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摘要
本文针对国内某特殊钢棒材厂连铸连轧机改造后,GCr15轴承钢棒材交货状态网状碳化物大量析出、网状级别超标问题,通过实验室热模拟实验、热轧实验和不同冷却工艺控冷实验,对热轧GCrl5轴承钢组织与性能进行研究。重点分析了不同轧制工艺和冷却工艺参数对其先共析二次碳化物的析出和珠光体转变的影响,探讨了得到抑制网状二次碳化物析出的细珠光体组织工艺方法。并在不改变特殊钢棒材厂原有连轧生产线设置的基础上,安装超快速冷却系统,高温终轧后进行超快速冷却工业实验和大批量工业化生产。论文的主要工作如下：
1在实验室自主研发的热力模拟实验机上对GCr15轴承钢进行热模拟实验。
高温变形促进GCr15轴承钢在连续冷却过程中二次碳化物的析出和珠光体的转变,随着变形量增加,二次碳化物和珠光体的开始析出温度升高,珠光体球团直径减小,但变形量变化对二次碳化物厚度影响甚微；低温变形促进晶界处二次碳化物的碎断,珠光体球团直径和片层间距减小。
GCr15轴承钢在连续冷却过程中,从高温到低温的相变产物主要有二次碳化物、珠光体和马氏体,随着冷却速度减小,马氏体转变曲线右侧发生抬高现象；晶界处二次碳化物为(Fe·Cr)3C型碳化物,抑制网状二次碳化物析出的临界冷却速度为8℃/s；完全发生珠光体转变的临界冷却速度为5℃/s,在756-510℃温度范围内保温20-200s就可以完全发生珠光体转变；随着连续冷却速度增加,二次碳化物和珠光体开始析出温度降低,晶界处二次碳化物由紧密的网状分布转变为半网状、短条状最后弥散析出,二次碳化物厚度减小,晶界处二次碳化物中C、Cr含量减小,珠光体球团直径和片层间距减小,显微硬度值增大,并有退化珠光体生成。
2在热力模拟实验机上对GCr15轴承钢进行高温变形后控冷工艺模拟。
GCr15轴承钢高温变形后以一定冷却速度快速冷却到不同温度的等温过程中,随等温时间延长,室温组织中珠光体含量增多的同时,晶界处二次碳化物析出趋势增大。随快速冷却阶段冷却速度的增加和等温温度的降低,二次碳化物沿晶界析出减弱,珠光体球团直径减小,珠光体片层结构变细变短,并有退化珠光体生成。以一定冷却速度快速冷却到不同温度的缓慢冷却过程中,随缓慢冷却速度的增加,珠光体球团直径减小,晶界处二次碳化物析出减少,缓慢冷却速度过大,将有淬火马氏体生成,晶界处无网状二次碳化物析出,珠光体组织大部分为铁素体和渗碳体层叠生长的片层状结构,有少量退化珠光体生成。通过制定不同温度区间的冷却工艺,增大快冷阶段冷却速度并配合以合理的缓冷阶段冷却速度,就可以达到抑制网状碳化物析出并得到细片层珠光体的目的。
3在实验室条件下对高温终轧后GCr15轴承钢板材进行新型冷却工艺实验,分析不同冷却工艺参数对轴承钢组织性能影响。
轴承钢板材热轧后常规冷却过程中,表面冷却速度较大,得到了抑制网状碳化物析出的珠光体组织,但内部由于冷却能力不足,室温组织为沿粗大晶界析出的网状二次碳化物和珠光体组织。轴承钢板材热轧后经过表面瞬时冷却速度可达到200℃／s的超快速冷却,整个断面均为抑制了网状二次碳化物析出的细珠光体组织,说明其内外部均达到了抑制网状碳化物析出的理想冷却速度；由于其心部冷却能力相对表面减弱,因此心部珠光体片层间距较表层有一定程度增大；随着终冷温度的降低,珠光体球团直径和片层间距减小,网状碳化物级别降低,其球化退火后冲击韧性值和硬度增大。
4对不同规格轴承钢棒材高温保温后超快速冷却过程温度场进行模拟,分析超快速冷却过程中,棒材断面不同位置温度和冷却速度变化。
在运用ANSYS软件对超快速冷却过程中棒材断面进行温度场分析时,采用计算超快速冷却终冷温度与实测终冷温度一致时停止计算的途径来确认换热系数的较精确值,不断修改传热模型,并对其温度场进行求解；空冷换热系数的确认,按照经验公式来处理。
针对Φ<60mm棒材,根据超快速冷却后棒材表面温度不低于马氏体转变温度、而返红后最高温度不超过700℃原则进行一次超快速冷却,棒材断面不同位置冷却速度均达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求；针对Φ≥60mm棒材,运用分段式二次超快速冷却,在不延长超快速冷却总时间前提下,解决了大断面棒材内部不易冷却的难题,提高了棒材内部的冷却速度,棒材断面不同位置冷却速度均可以达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求,达到了进行超快速冷却的目的；在超快速冷却总时间相同条件下,对棒材进行分段多次超快速冷却,其内部冷却强度明显高于一次超快速冷却,内部冷却速度提高。
5在不改变钢厂原有热连轧生产工艺的基础上,在连轧机组后安装三组超快速冷却系统,通过调节水压、喷嘴孔大小以及开水箱个数,针对不同规格棒材进行高温终轧后超快速冷却,其瞬时冷却速度可达到400℃/s以上。经过超快速冷却后,不同规格棒材断面不同位置冷却速度均可以达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求,网状碳化物级别均≤2级,达到轴承行业标准。
GCr15轴承钢棒材超快速冷却工艺的应用解决了其高温终轧后网状碳化物级别超标问题,不仅可以得到抑制网状碳化物析出的细珠光体组织,利于下一步球化退火工艺,而且保证了连轧生产线的轧制速度和避免待温工序,提高生产效率,使企业取得较大经济效益。“GCr15轴承钢热轧组织控制机理与超快速冷却研究”这一课题,对于提高我国轴承钢棒材质量、促进我国经济和社会发展具有着重要的指导意义。
Againsting the problem of precipitation of network carbide and over-proof of network level in bearing steel delivery state after conversion of continuous casting and continuous rolling in some domestic special steel mill, structure and property of GCr15 bearing steel were researched through thermo-mechanical simulations、hot rolling test and different controlled cooling test. Influence of different rolling processes and cooling processes to the precipitation of hypereutectoid secondary carbide and transformation of pearlite were analyzed. The technique, in which fine laminar pearlite without net-work carbide would be obtained were study. Ultra-fast cooling industrialized test and multitudinous industrialized manufacture after high temperature final rolling were processed through the installation of ultra-fast cooling system in the condition of keeping to the inhere continuous rolling production line of special mill. The main works involved as follows:
1 Thermal simulation was performed by MMS-300 thermo-mechanical simulator in GCr15 bearing steel.
High temperature deformation advanced the precipitation of secondary carbide and transformation of pearlite in continuous cooling process. With the increase of distortion, initial precipitation temperature of secondary carbide and pearlite rised, the diameter of pearlite grain decreased, but the influence of variety of distortion to secondary carbide thickness was minute; Low temperature deformation advanced the crushing of inter-granular secondary carbide, the laminar and diameter of pearlite grain decreased.
In the process of continuous cooling of GCr15 bearing steel, the phase transition staple were secondary carbide、pearlite and martensite. Along with reduce of cooling rate, the right side of martensite transformation curve raised. Secondary carbide in grain boundary was (Fe·Cr)3 C, the critical cooling rate of restraining the precipitation of network carbide was 8℃/s; the critical cooling rate of completely transformation of pearlite was 5℃/s, residual austentite can transformed to pearlite absolutely in the condition of thermal insulation 20-200s in 756-510℃. Along with the increased of cooling rate, initial precipitation temperature of secondary carbide and pearlite decreased, the pattern of inter-granular secondary carbide convert from compact network to dispersive scatter, thickness of secondary carbide and content of C、Cr in inter-granular secondary carbide reduced, the pearlite laminar and the diameter of pearlite grain decreased, and degenerate pearlite appeared along with the increase of micro-hardness.
2 Controlled cooling process was simulated by thermo-mechanical simulator in GCrl5 after high-temperature final rolling.
Content of pearlite increased and the inclination of inter-granular carbide precipitation enlarged along with extension of isothermal time in isothermal procedure after cooling to different temperature in a given cooling rate. Along with the increase of cooling rate and reduction of isothermal temperature in fast cooling period, carbide precipitation in grain boundary weakened, the diameter of pearlite grain decreased, lamellar structure of pearlite become thin and short, some degenerate pearlite appeared. In slow cooling period after cooling to different temperature in a given cooling rate, the diameter of pearlite grain reduced and precipitation of inter-granular secondary carbide weakened along with the increase of slow cooling rate. Quenching martensite appeared when slow cooling rate was oversized, the precipitation of inter-granular secondary carbide was nonexistent, majority pearlte structure was lamellar with ferrite and cementite and little degenerate pearlite appeared. The target of obtaining fine laminar pearlite without net-work carbide could accomplish through the technique, in which cooling process was formulated in different temperature province and increase the cooling rate in fast cooling period cooperating with rational slow cooling rate.
3 New style cooling technique was proceeded on bearing steel plate after high temperature final rolling in laboratory condition.
In the process of conventional cooling on steel plate after high temperature final rolling, pearlite structure without net-work carbide would be obtained in surface because of the major cooing rate, but room-temperature structure was coarse pearlite and network carbide precipitating in grain boundary in center due to the deficiency of cooling intensity; expected cooling rate of restraining precipitation of network carbide was reached and fine pearlite without net-work carbide was obtained in the whole cross-section of bearing steel plate through ultra-fast cooling with surfaced cooling rate being greater than 100℃/s; lamellar interval of center pearlite was greater than that of surface pearlite because of the weaker cooling intensity in center than in surface; along with the reduce of final cooling temperature, the pearlite laminar and the diameter of pearlite grain decreased, the level of network carbide reduced, impact ductility and hardnss after spheroidal annealing enlarged.
4 The variety of temperature and cooling rate in different site of bearing steel bar was analysed, through simulating the temperature pattern in ultra-fast cooling process after high temperature insulation.
In the process of simulating temperature pattern with ANSYS software, the accurate coefficient of ultra-fast cooling heat transfer was defined in the calculate procedure, which calculation was end while final cooling temperature being same with the measure value and the heat transfer mode was modified continuous. The coefficient of air cooling heat transfer was defined by empirical equation.
AgainstΦ<60mm bearing bar, once ultra-fast cooling was proceeded in the principle of which, surface temperature after cooling was above martensite and redding temperature was low than 700℃, cooling rate in different site of bearing bar was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely; AgainstΦ≥60mm bearing bar, the puzzle of internal cooling difficulty was settled and internal cooling rate was increased through segmented secondary ultra-fast cooling, cooling rate in different site of cross section was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely; in the condition of invariant ultra-fast cooling total time, internal cooling intensity was higher through segmented secondary ultra-fast cooling, internal cooing rate was increased.
5 Three-group ultra-fast cooling system was installed at the back of continuous rolling mill in the condition of keep to the inhere continuous rolling production line of special mill. Its instant cooling rate can reached to 400℃/s through adjusting water pressure、size of nozzle hole and number of opened water tank. cooling rate in different specs bar was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely, the level of network carbide was≤2, which was measured up to the bearing professional standard.
Apply of ultra-fast cooling process settled the problem of network carbide level over-proof in different specs bearing steel after high temperature final rolling. Not only fine laminar pearlite without net-work carbide was obtained, which was beneficial to next spheroidal annealing process, but also the rolling rate in continuous rolling production line was assurance, which increasing the efficiency and obtaining a rather large economic benefits. Subject about "Research of Structure Controlled Mechanism and Ultra-Fast Cooling Process of Bearing Steel afer Hot Rolling" would have guiding significant for increasing quality of domestic bearing steel bar and accelerating the development of economy and society.
1在实验室自主研发的热力模拟实验机上对GCr15轴承钢进行热模拟实验。
高温变形促进GCr15轴承钢在连续冷却过程中二次碳化物的析出和珠光体的转变,随着变形量增加,二次碳化物和珠光体的开始析出温度升高,珠光体球团直径减小,但变形量变化对二次碳化物厚度影响甚微；低温变形促进晶界处二次碳化物的碎断,珠光体球团直径和片层间距减小。
GCr15轴承钢在连续冷却过程中,从高温到低温的相变产物主要有二次碳化物、珠光体和马氏体,随着冷却速度减小,马氏体转变曲线右侧发生抬高现象；晶界处二次碳化物为(Fe·Cr)3C型碳化物,抑制网状二次碳化物析出的临界冷却速度为8℃/s；完全发生珠光体转变的临界冷却速度为5℃/s,在756-510℃温度范围内保温20-200s就可以完全发生珠光体转变；随着连续冷却速度增加,二次碳化物和珠光体开始析出温度降低,晶界处二次碳化物由紧密的网状分布转变为半网状、短条状最后弥散析出,二次碳化物厚度减小,晶界处二次碳化物中C、Cr含量减小,珠光体球团直径和片层间距减小,显微硬度值增大,并有退化珠光体生成。
2在热力模拟实验机上对GCr15轴承钢进行高温变形后控冷工艺模拟。
GCr15轴承钢高温变形后以一定冷却速度快速冷却到不同温度的等温过程中,随等温时间延长,室温组织中珠光体含量增多的同时,晶界处二次碳化物析出趋势增大。随快速冷却阶段冷却速度的增加和等温温度的降低,二次碳化物沿晶界析出减弱,珠光体球团直径减小,珠光体片层结构变细变短,并有退化珠光体生成。以一定冷却速度快速冷却到不同温度的缓慢冷却过程中,随缓慢冷却速度的增加,珠光体球团直径减小,晶界处二次碳化物析出减少,缓慢冷却速度过大,将有淬火马氏体生成,晶界处无网状二次碳化物析出,珠光体组织大部分为铁素体和渗碳体层叠生长的片层状结构,有少量退化珠光体生成。通过制定不同温度区间的冷却工艺,增大快冷阶段冷却速度并配合以合理的缓冷阶段冷却速度,就可以达到抑制网状碳化物析出并得到细片层珠光体的目的。
3在实验室条件下对高温终轧后GCr15轴承钢板材进行新型冷却工艺实验,分析不同冷却工艺参数对轴承钢组织性能影响。
轴承钢板材热轧后常规冷却过程中,表面冷却速度较大,得到了抑制网状碳化物析出的珠光体组织,但内部由于冷却能力不足,室温组织为沿粗大晶界析出的网状二次碳化物和珠光体组织。轴承钢板材热轧后经过表面瞬时冷却速度可达到200℃／s的超快速冷却,整个断面均为抑制了网状二次碳化物析出的细珠光体组织,说明其内外部均达到了抑制网状碳化物析出的理想冷却速度；由于其心部冷却能力相对表面减弱,因此心部珠光体片层间距较表层有一定程度增大；随着终冷温度的降低,珠光体球团直径和片层间距减小,网状碳化物级别降低,其球化退火后冲击韧性值和硬度增大。
4对不同规格轴承钢棒材高温保温后超快速冷却过程温度场进行模拟,分析超快速冷却过程中,棒材断面不同位置温度和冷却速度变化。
在运用ANSYS软件对超快速冷却过程中棒材断面进行温度场分析时,采用计算超快速冷却终冷温度与实测终冷温度一致时停止计算的途径来确认换热系数的较精确值,不断修改传热模型,并对其温度场进行求解；空冷换热系数的确认,按照经验公式来处理。
针对Φ<60mm棒材,根据超快速冷却后棒材表面温度不低于马氏体转变温度、而返红后最高温度不超过700℃原则进行一次超快速冷却,棒材断面不同位置冷却速度均达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求；针对Φ≥60mm棒材,运用分段式二次超快速冷却,在不延长超快速冷却总时间前提下,解决了大断面棒材内部不易冷却的难题,提高了棒材内部的冷却速度,棒材断面不同位置冷却速度均可以达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求,达到了进行超快速冷却的目的；在超快速冷却总时间相同条件下,对棒材进行分段多次超快速冷却,其内部冷却强度明显高于一次超快速冷却,内部冷却速度提高。
5在不改变钢厂原有热连轧生产工艺的基础上,在连轧机组后安装三组超快速冷却系统,通过调节水压、喷嘴孔大小以及开水箱个数,针对不同规格棒材进行高温终轧后超快速冷却,其瞬时冷却速度可达到400℃/s以上。经过超快速冷却后,不同规格棒材断面不同位置冷却速度均可以达到抑制网状碳化物析出、过冷奥氏体完全发生珠光体转变的冷却速度要求,网状碳化物级别均≤2级,达到轴承行业标准。
GCr15轴承钢棒材超快速冷却工艺的应用解决了其高温终轧后网状碳化物级别超标问题,不仅可以得到抑制网状碳化物析出的细珠光体组织,利于下一步球化退火工艺,而且保证了连轧生产线的轧制速度和避免待温工序,提高生产效率,使企业取得较大经济效益。“GCr15轴承钢热轧组织控制机理与超快速冷却研究”这一课题,对于提高我国轴承钢棒材质量、促进我国经济和社会发展具有着重要的指导意义。
Againsting the problem of precipitation of network carbide and over-proof of network level in bearing steel delivery state after conversion of continuous casting and continuous rolling in some domestic special steel mill, structure and property of GCr15 bearing steel were researched through thermo-mechanical simulations、hot rolling test and different controlled cooling test. Influence of different rolling processes and cooling processes to the precipitation of hypereutectoid secondary carbide and transformation of pearlite were analyzed. The technique, in which fine laminar pearlite without net-work carbide would be obtained were study. Ultra-fast cooling industrialized test and multitudinous industrialized manufacture after high temperature final rolling were processed through the installation of ultra-fast cooling system in the condition of keeping to the inhere continuous rolling production line of special mill. The main works involved as follows:
1 Thermal simulation was performed by MMS-300 thermo-mechanical simulator in GCr15 bearing steel.
High temperature deformation advanced the precipitation of secondary carbide and transformation of pearlite in continuous cooling process. With the increase of distortion, initial precipitation temperature of secondary carbide and pearlite rised, the diameter of pearlite grain decreased, but the influence of variety of distortion to secondary carbide thickness was minute; Low temperature deformation advanced the crushing of inter-granular secondary carbide, the laminar and diameter of pearlite grain decreased.
In the process of continuous cooling of GCr15 bearing steel, the phase transition staple were secondary carbide、pearlite and martensite. Along with reduce of cooling rate, the right side of martensite transformation curve raised. Secondary carbide in grain boundary was (Fe·Cr)3 C, the critical cooling rate of restraining the precipitation of network carbide was 8℃/s; the critical cooling rate of completely transformation of pearlite was 5℃/s, residual austentite can transformed to pearlite absolutely in the condition of thermal insulation 20-200s in 756-510℃. Along with the increased of cooling rate, initial precipitation temperature of secondary carbide and pearlite decreased, the pattern of inter-granular secondary carbide convert from compact network to dispersive scatter, thickness of secondary carbide and content of C、Cr in inter-granular secondary carbide reduced, the pearlite laminar and the diameter of pearlite grain decreased, and degenerate pearlite appeared along with the increase of micro-hardness.
2 Controlled cooling process was simulated by thermo-mechanical simulator in GCrl5 after high-temperature final rolling.
Content of pearlite increased and the inclination of inter-granular carbide precipitation enlarged along with extension of isothermal time in isothermal procedure after cooling to different temperature in a given cooling rate. Along with the increase of cooling rate and reduction of isothermal temperature in fast cooling period, carbide precipitation in grain boundary weakened, the diameter of pearlite grain decreased, lamellar structure of pearlite become thin and short, some degenerate pearlite appeared. In slow cooling period after cooling to different temperature in a given cooling rate, the diameter of pearlite grain reduced and precipitation of inter-granular secondary carbide weakened along with the increase of slow cooling rate. Quenching martensite appeared when slow cooling rate was oversized, the precipitation of inter-granular secondary carbide was nonexistent, majority pearlte structure was lamellar with ferrite and cementite and little degenerate pearlite appeared. The target of obtaining fine laminar pearlite without net-work carbide could accomplish through the technique, in which cooling process was formulated in different temperature province and increase the cooling rate in fast cooling period cooperating with rational slow cooling rate.
3 New style cooling technique was proceeded on bearing steel plate after high temperature final rolling in laboratory condition.
In the process of conventional cooling on steel plate after high temperature final rolling, pearlite structure without net-work carbide would be obtained in surface because of the major cooing rate, but room-temperature structure was coarse pearlite and network carbide precipitating in grain boundary in center due to the deficiency of cooling intensity; expected cooling rate of restraining precipitation of network carbide was reached and fine pearlite without net-work carbide was obtained in the whole cross-section of bearing steel plate through ultra-fast cooling with surfaced cooling rate being greater than 100℃/s; lamellar interval of center pearlite was greater than that of surface pearlite because of the weaker cooling intensity in center than in surface; along with the reduce of final cooling temperature, the pearlite laminar and the diameter of pearlite grain decreased, the level of network carbide reduced, impact ductility and hardnss after spheroidal annealing enlarged.
4 The variety of temperature and cooling rate in different site of bearing steel bar was analysed, through simulating the temperature pattern in ultra-fast cooling process after high temperature insulation.
In the process of simulating temperature pattern with ANSYS software, the accurate coefficient of ultra-fast cooling heat transfer was defined in the calculate procedure, which calculation was end while final cooling temperature being same with the measure value and the heat transfer mode was modified continuous. The coefficient of air cooling heat transfer was defined by empirical equation.
AgainstΦ<60mm bearing bar, once ultra-fast cooling was proceeded in the principle of which, surface temperature after cooling was above martensite and redding temperature was low than 700℃, cooling rate in different site of bearing bar was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely; AgainstΦ≥60mm bearing bar, the puzzle of internal cooling difficulty was settled and internal cooling rate was increased through segmented secondary ultra-fast cooling, cooling rate in different site of cross section was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely; in the condition of invariant ultra-fast cooling total time, internal cooling intensity was higher through segmented secondary ultra-fast cooling, internal cooing rate was increased.
5 Three-group ultra-fast cooling system was installed at the back of continuous rolling mill in the condition of keep to the inhere continuous rolling production line of special mill. Its instant cooling rate can reached to 400℃/s through adjusting water pressure、size of nozzle hole and number of opened water tank. cooling rate in different specs bar was reach to the cooling rate require of restraining network carbide and residual austensite transforming to pearlite absolutely, the level of network carbide was≤2, which was measured up to the bearing professional standard.
Apply of ultra-fast cooling process settled the problem of network carbide level over-proof in different specs bearing steel after high temperature final rolling. Not only fine laminar pearlite without net-work carbide was obtained, which was beneficial to next spheroidal annealing process, but also the rolling rate in continuous rolling production line was assurance, which increasing the efficiency and obtaining a rather large economic benefits. Subject about "Research of Structure Controlled Mechanism and Ultra-Fast Cooling Process of Bearing Steel afer Hot Rolling" would have guiding significant for increasing quality of domestic bearing steel bar and accelerating the development of economy and society.
引文
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