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WO2016011759A1 - 一种钢锭超高温软芯锻造方法 - Google Patents

一种钢锭超高温软芯锻造方法 Download PDF

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Publication number
WO2016011759A1
WO2016011759A1 PCT/CN2014/092623 CN2014092623W WO2016011759A1 WO 2016011759 A1 WO2016011759 A1 WO 2016011759A1 CN 2014092623 W CN2014092623 W CN 2014092623W WO 2016011759 A1 WO2016011759 A1 WO 2016011759A1
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forging
steel ingot
ingot
high temperature
ultra
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French (fr)
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李殿中
孙明月
栾义坤
刘宏伟
傅排先
徐斌
李依依
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Institute of Metal Research of CAS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor

Definitions

  • the present invention relates to the field of forging of steel, and more particularly to an ultra-high temperature soft core forging method for a die cast steel ingot.
  • the size and distribution of central defects are difficult to quantify by uniform standards.
  • Different ingot types are used for the same forging process, and some can pass the inspection.
  • the 42CrMo and H13 steel ingots are produced using a 15 ton ingot with a height to diameter ratio of 2, and the forging is also applied by the WHF method.
  • the forged piece of 42CrMo material can pass the flaw detection, but the H13 cannot pass, mainly because the H13 solidification interval is wide and the shrinkage hole is small. Loose defects are more serious. This status quo indicates that the current center compaction process is not sufficient to eliminate some of the more serious defects in the steel ingot center. Therefore, it is imperative to develop a more powerful and effective forging method and completely eliminate the defects in the center of the steel ingot.
  • Method 1 For some steel ingots with lower weight, the steel ingot is first poured, the ingot is cooled to 300-500 ° C in the ingot mold, and then to avoid cracking when it is cooled to room temperature, long-term stress relief annealing is required, and then Long-term gradient reheating in the furnace, the temperature inside and outside the steel ingot is evenly above 1200 °C, and finally forging, the processing cycle is very long; 2) Method 2: For some heavy steel ingots, the steel ingot is first poured, and the steel ingot is placed The ingot mold is cooled until the riser is completely solidified, and then the mold is released.
  • the temperature of the ingot is generally 700-900 ° C.
  • the warm steel ingot is placed in a heat preservation tank and sent to a heating furnace for heating, so that the temperature inside and outside the steel ingot is uniformly above 1200 ° C, and finally forging is performed. To some extent, it saves heating energy and shortens the processing flow; 3)
  • AlN precipitates along the as-cast coarse austenite grain boundary at 850-950 °C, weakening the grain boundary, and immediately red Sending heat, austenite decomposition and austenitization two phase transitions occur in a short time, which is easy to cause surface cracks.
  • the steel ingot has to be cooled to 200-300 ° C, and then heated, and the residual temperature of the steel ingot is lost. Causes great waste.
  • a soft reduction technique has been developed in the field of continuous casting blanks, which compensates for the solidification shrinkage of the slab by applying a certain amount of reduction in the vicinity of the end of the continuous casting/slab wick. .
  • it can eliminate or reduce the internal void formed by the shrinkage of the slab, prevent the molten steel with intergranular enrichment of solute elements from flowing to the center of the slab; on the other hand, the extrusion caused by the light pressing can also promote the center of the sap
  • the enriched solute element molten steel flows in the opposite direction of the casting direction, so that the solute elements are redistributed in the molten steel, so that the solidification structure of the casting blank is more uniform and dense, and the center segregation and the center looseness are improved.
  • the soft pressing technique is very important for the selection of the pressing position. If the pressing is too early, the center metal has not yet solidified, and the loose defect will form after the pressing; if the pressing is too late, the metal is in the two-phase region with a higher solid fraction. The fluidity is poor, and dense cracks are likely to occur under small deformation. It is generally believed that when the center solid fraction reaches 0.3 to 0.7, the press will play a good role. At the same time, the choice of reduction is also important. According to the equipment capacity, the general reduction rate is 1 to 3%.
  • the soft reduction technology of continuous casting billet can improve the central quality of ordinary carbon steel and low alloy steel billet to a certain extent, but it can't do anything for alloy steel which must be produced by die casting. In fact, the solidification interval of alloy steel tends to be wider, and the defects such as looseness of center shrinkage and dendrite segregation are more serious. It is necessary to combine the solidification and deformation means to eliminate or reduce the central defects of the billet.
  • the object of the present invention is to provide a steel ingot ultra-high temperature soft core forging method, which can eliminate the metallurgical defects such as shrinkage porosity of the steel ingot, reduce dendrite segregation, and refine the structure. Improve the metallurgical quality and mechanical properties of forgings, shorten the processing cycle, save energy, save materials, improve the service life of the mold, and reduce the purpose of forging.
  • the invention discloses a steel ingot ultra-high temperature soft core forging method, which firstly demolishes the poured steel ingot with a liquid core at a high temperature; then, it is placed in a heat preservation vehicle and is transported to a forging press, and the steel ingot is subjected to high temperature pressure forging, so that the steel ingot is subjected to high temperature pressure forging.
  • the solidified terminal dendrites are fully broken, forming a large number of equiaxed crystal structures, eliminating shrinkage porosity and loosening dendrite segregation; finally, conventional forging is performed to fully refine grains and structures.
  • the steel ingot ultra-high temperature soft core forging method the specific steps are as follows:
  • the first step is to remove the mold at a high temperature; the surface temperature of the ingot after demolding is not lower than 1100 ° C, and the center is 1300 ⁇ 1450 °C;
  • the second step is to close the top of the riser; use a spray or air blower to continuously act on the riser of the steel ingot to completely solidify the top of the riser;
  • the third step is to transfer and equalize the temperature; place the steel ingot in the heat preservation car, transport it to the forging press, and the average temperature is 0.5 to 2 hours, ready for forging;
  • the fourth step is to widen the large anvil; place the ingot on the table of the forging press, and use a wide flat anvil to deform 10 to 50% in the thickness direction;
  • the fifth step is to maintain the pressure at high temperature; after the steel ingot is deformed to the specified size, the wide flat anvil is used to maintain the pressure and continue to act on the steel ingot, the action time is not less than 5 minutes, and the deformation amount is not more than 5%;
  • the steel ingot is forged to the final forging size.
  • the temperature is lower than the final forging temperature, the temperature is returned to the high temperature furnace, and the next forging fire is performed.
  • the steel ingot ultra-high temperature soft core forging method in the first step, the steel ingot demoulding time is determined by computer simulation, the steel ingot mold is designed in two ways, one is reverse taper, that is, “upper down and large” mode, demoulding When the riser box and the body are removed at the same time; the other is a positive taper, that is, the "upper and lower” mode.
  • the boom After pouring, the boom is inserted at the edge of the riser, and after the edge of the riser is solidified, the riser box is removed and passed.
  • the lifting rod removes the steel ingot and the ingot mold.
  • the steel ingot ultra-high temperature soft core forging method in the second step, when the top of the riser is completely solidified, the surface temperature of the riser is lower than 1200 °C.
  • the steel ingot ultra-high temperature soft core forging method in the third step, before the opening and forging, the lowest surface temperature of the steel ingot is not lower than 1000 °C.
  • the steel ingot ultra-high temperature soft core forging method in the fourth step, during the main deformation process, the anvil width deformed by the wide flat anvil should cover the total length of the steel ingot, and once deformed into position, the shrinkage hole looseness defect is closed.
  • the steel ingot ultra-high temperature soft core forging method in the fifth step, after the main deformation is finished, the wide flat anvil is used for holding and micro-deformation, so that the closed defects are sufficiently welded.
  • the steel ingot ultra-high temperature soft core forging method in the sixth step, after the center compaction, the steel ingot is forged to the final forging size, and if the forging fire cannot be formed, the forging fire is formed.
  • the volume will change greatly.
  • the density in liquid state is about 7300 kg/m 3
  • the density in solid state is about 7800 kg/m 3 .
  • Such a large density difference will cause different degrees of shrinkage and loose defects in the as-cast microstructure after solidification.
  • the wider the solid-liquid two-phase zone the more severe the tendency to loosen.
  • the conventional method is to place a riser on the top of the ingot, and through good riser insulation conditions, the metal which maintains the liquid in the riser can replenish the volume shrinkage of the ingot under the action of gravity, thereby reducing the shrinkage cavity, Loose defects.
  • the larger the riser the better the insulation effect, and the better the shrinkage effect on the ingot.
  • shrinkage defects can be alleviated by subsequent forging, but for particularly severe shrinkage defects, especially when the purity of the molten steel is poor, the defect surface is enriched with low melting point materials, and these void defects are more difficult to heal by conventional forging.
  • a very large forging ratio is required to break and disperse the inclusions at the healing interface, resulting in extremely high production costs and unstable product quality.
  • the invention is based on the law of solidification and microstructure evolution of metal under pressure and deformation, and proposes to first demould the steel ingot with a liquid core at a high temperature, the surface temperature is not lower than 1100 ° C, the center is 1300 ⁇ 1450 ° C; Hold the forging and keep the pressure on the ingot.
  • the invention breaks through the method of completely forging and then forging the cast steel ingot, and fully combines the two original separation processes of the ingot and the forging, and creates the steel core with excellent fluidity through the ultra-high temperature liquid core release.
  • the semi-solid structure and the huge temperature difference between the surface and the core, combined with the subsequent heavy pressure and pressure holding process, can achieve forced feeding and pressure solidification, which not only solves the problem of shrinkage, looseness, segregation, and coarse structure in the center of the steel ingot.
  • the metallurgical quality is improved, the weight of the riser is reduced, the heating heat of the forging is reduced, the service life of the mold is prolonged, the processing flow is shortened, and the heat processing cost of the forging is greatly reduced.
  • the internal quality of the material has been greatly improved. Due to the ultra-high temperature deformation of the center of the ingot, the shrinkage porosity is completely eliminated, the dendrite segregation defects are alleviated, and the uniformity of the structure is improved. The central mechanical properties of the large-section forging blank can be close to or even reach the performance level of the surface.
  • the surface quality of steel ingots has been greatly improved. Since there is no need to worry about the problem of looseness of the center shrinkage hole, the pouring temperature and the pouring speed can be increased, and the surface quality of the alloy steel ingot can be greatly improved.
  • High-temperature demoulding can shorten the cooling time by 30 to 50%, and use the waste heat forging to reduce the heating time by 30 to 40%, which greatly improves the production efficiency.
  • the life of the ingot mold can be increased by 1 to 2 times due to the shortened demolding time.
  • the weight of the riser can be reduced by 30-50%, and the ingot is designed to have a shape with a height to diameter ratio of 5 or more. Compared with the traditional high-diameter ratio of 1 ⁇ 2, the utilization rate of the ingot-type lifting material is more than 15%. .
  • FIG. 1 is a schematic view of a forging process of a steel ingot ultra-high temperature soft core according to the present invention; wherein (a) is a steel ingot poured into a ladle, (b) is spray cooled after removing the riser box, and (c) is sent to the ingot in a heat preservation vehicle. And the average temperature, (d) is deformation along the diameter/thickness direction of the ingot, (e) is the pressure after deformation, and (f) is forged to the finished product.
  • Figure 2 is a schematic diagram of the healing process of shrinkage porosity defects during ultra-high temperature deformation; (a) is a loose defect that has just sprouted, (b) is loose under large deformation, and (c) is closed. Under the action of pressure retention, it is decomposed into microscopic pores, and (d) the microscopic pores gradually diffuse and disappear under high temperature and high pressure.
  • Fig. 3 is a schematic view showing the process of breaking and homogenizing dendrites when deformed at an ultrahigh temperature; wherein (a) is a solidified terminal dendrite and a residual liquid, and (b) is a dendrite broken and remelted under a large deformation. Decomposed into a multi-stage discrete structure, which becomes the nucleus of the subsequent solidification of the melt, (c) is an equiaxed crystal structure formed by the near-solidification of the center of the ingot under pressure, and (d) is an equiaxed crystal structure. The temperature below the solidus line is greatly deformed, and a finer equiaxed crystal structure formed after recrystallization occurs.
  • FIG. 4 is a photograph of the metallographic structure of the H13 forging obtained by the ultra-high temperature soft core forging method in the embodiment of the present invention.
  • Figure 5 is a photograph of the metallographic structure of the H13 forging obtained by a conventional forging process in a comparative example of the present invention.
  • the forging process of the ultra-high temperature soft core of the steel ingot of the present invention is as follows: (a) ladle pouring steel ingot ⁇ (b) spray cooling after removing the riser box ⁇ (c) placing the steel ingot into the heat preservation car and sending both Temperature ⁇ (d) deformation along the diameter/thickness direction of the ingot ⁇ (e) holding pressure after deformation ⁇ (f) forging to the finished product.
  • the method of the invention is applicable to carbon manganese steel, low alloy steel, medium and high alloy steel, especially for ultra high temperature soft core forging of steel ingot with wide solidification interval and particularly developed as-cast structure.
  • the steel ingot ultra-high temperature soft core forging method of the present invention firstly demolds the poured ingot with a liquid core at a high temperature; then, it is placed in a heat preservation vehicle and is transported to a forging press, and the steel ingot is carried out with a liquid core.
  • High-temperature pressure forging the solidification end dendrites are fully broken, forming a large number of equiaxed crystal structures, eliminating shrinkage porosity and loosening dendritic segregation; finally, conventional forging such as upsetting and lengthening, and fully refining grains and microstructure; Specific steps are as follows:
  • the first step is to demould the steel ingot with a liquid core at a high temperature, the surface temperature of the ingot is not lower than 1100 ° C (preferably 1150 ° C ⁇ 1250 ° C), and the center temperature is maintained at 1300 ⁇ 1450 ° C;
  • the healing process of the shrinkage porosity defect is as follows: (a) the loose defect just emerging ⁇ (b) the looseness is closed under the large deformation ⁇ (c) the closed looseness is in the continuous holding pressure Under the action of the decomposition into microscopic holes ⁇ (d) microscopic pores gradually diffuse and disappear under high temperature and high pressure. It can be seen from Fig. 2 that the large deformation at the solidification end of the steel ingot can accelerate the high-temperature diffusion of the closed interface of the hole, and the defect of the loose-hole defect is efficiently healed, thereby increasing the density of the material.
  • the large deformation at the solidification end of the ingot can more fully break the dendrites, form a larger number of smaller equiaxed grains, and further refine the material structure. Reduce dendrite segregation and promote uniform composition.
  • the second step is to use a spray or air blower to continuously act on the riser of the steel ingot to completely solidify the top of the riser;
  • the steel ingot is placed in the heat preservation car and transported to the forging press at an average temperature of 0.5 to 2 hours;
  • the steel ingot is placed on the table of the forging press, and the wide flat anvil is deformed by 10 to 50% along the diameter (thickness) direction;
  • the wide flat anvil is used to maintain the pressure and continue to act on the steel ingot, the action time is not less than 5 minutes, and the deformation amount is not more than 5%;
  • the steel ingot is forged to the final forging size.
  • the temperature is lower than the final forging temperature, the temperature is returned to the high temperature furnace, and the next forging fire is performed.
  • the demolding time of the ingot is determined by computer simulation.
  • the ingot mold is designed in two ways, one is the reverse taper, that is, the “upper and lower” mode, and the riser box and the ingot are simultaneously removed during demolding;
  • the other type is a positive taper, that is, a "upper and lower” mode.
  • a spray or air blower is used to continuously act on the riser of the steel ingot to completely solidify the top of the riser, and the surface temperature is lower than 1200 ° C (preferably 1100 ° C ⁇ 1180 ° C).
  • the steel ingot is placed in the heat preservation car for 0.5 to 2 hours, and is transported to the forging press.
  • the lowest surface temperature of the ingot before the forging is not less than 1000 ° C (preferably 1100 ° C to 1250 ° C).
  • a wide flat anvil should be used.
  • the width of the anvil should cover the total length of the ingot, and the deformation rate is 10 to 50% (preferably 20 to 50%). Once the deformation is in place, the shrinkage porosity is closed. ;
  • the wide flat anvil is used for holding pressure and slow micro-deformation, the pressure action time is not less than 5 minutes (preferably 5 to 10 minutes), and the deformation amount is not more than 5% (preferably 1 to 5). %), so that the closed defects are sufficiently welded.
  • the steel ingot is forged to the final forging size. If the fire cannot be formed, the fire forming may be increased.
  • the smelting and pouring ingot has a weight of 9 tons, a rectangular cross section, and a size of 720 ⁇ 1080 ⁇ 1450mm.
  • the material is H13 steel.
  • the measured components are shown in Table 1.
  • the first step is to remove the mold at an extremely high temperature. After the ingot is poured for 3.5 hours, the riser protection slag is blown off, so that the steel ingot is released from the liquid core at a high temperature, the surface temperature of the ingot is 1230 ° C, and the center temperature of the ingot is maintained above 1350 ° C.
  • the second step is to close the top of the riser.
  • the sprinkler is used to continuously act on the riser of the steel ingot for 10 min, so that the top of the riser is completely solidified, and the surface temperature is 1180 °C.
  • the third step is transshipment and temperature equalization.
  • the steel ingot is placed in the heat preservation car, and transported to the forging press in 30 minutes. After the average temperature is 30 minutes, the minimum temperature of the steel ingot surface is 1100 ° C, and the maximum temperature of the steel ingot surface is 1250 ° C. At this time, the steel car is separated from the heat preservation car and ready for forging.
  • the fourth step is the wide anvil deformation.
  • the steel ingot was placed on the table of the forging press, and the wide flat anvil was deformed by 240 mm in the thickness direction to be deformed once.
  • the fifth step is to keep the pressure at high temperature. After the steel ingot is deformed to the specified size, the wide flat anvil is used to maintain the pressure and continue to act on the steel ingot. The action time is 10 min, and the deformation amount is 3%, so that the closed defects are sufficiently welded.
  • the section of the ingot is drawn to 800 ⁇ 800 mm, and the chamfered to the height is 1200 mm, and the length is ⁇ 450 mm.
  • Comparative Example 1 uses a conventional steel ingot after complete solidification, demolding, annealing and reheating and forging processes, the specific steps are as follows:
  • the first step is to release the mold at medium temperature. After the ingot was poured for 8 hours, the ingot and the riser were completely solidified, and the ingot was demolded, and the surface temperature of the ingot was 700 °C.
  • the second step is high temperature annealing.
  • the steel ingot was placed in a heating furnace at 850 ° C, and after 15 hours of heat preservation, it was slowly cooled to a surface temperature of 300 ° C.
  • the third step is transshipment.
  • the ingot was placed in a heat preservation car, transported to a forging press in 30 minutes, then slowly heated to 850 ° C, and after 5 hours of heat preservation, slowly heated to 1230 ° C, ready for forging.
  • the fourth step is the first fire forging.
  • the ingot is upset 50% in the height direction, and then elongated to a section size of 800 ⁇ 800 mm, chamfered and then heated into the furnace.
  • the fifth step the second fire forging.
  • the ingot is upset 50% in the height direction, and then elongated to a section size of 800 ⁇ 800 mm, chamfered and then heated into the furnace.
  • the sixth step the third fire forging. Pull the steel ingot to ⁇ 450mm.
  • Example 1 and Comparative Example 1 were subjected to isothermal spheroidization treatment, respectively, incubated at 850 ° C and 750 ° C for 5 h, and slowly cooled to room temperature.
  • the center sample of the forging was taken, and the microstructure of the sample was measured by a metallographic microscope. Analysis, the specific metallographic organization is shown in Figure 4 and Figure 5. As can be seen from the figure, the structure in the examples was sufficiently refined, and the average grain size was only 10 ⁇ m, while the large crystal grains of 100 ⁇ m were still present in the comparative example.
  • the carbide distribution in the examples was very uniform, and there was no liquid carbonization, and the carbides in the comparative examples were segregated, unevenly distributed, and a small amount of liquid carbides.
  • the microstructure state of the post-forging heat treatment fully demonstrates that the conventional forging process is difficult to completely eliminate the liquid precipitation carbide, and the structure is coarse and the secondary carbide distribution is not uniform, and the ultra-high temperature soft core forging method of the present invention can effectively eliminate the liquid precipitation carbide.
  • the uniform fine crystal grains and the finely dispersed secondary carbides are obtained, so that the service life of the mold steel can be greatly improved.

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Abstract

一种模铸钢锭的超高温软芯锻造方法，包括首先将浇注后的钢锭带液芯超高温脱模；然后放置于保温车中均温并运送到锻压机，将钢锭带液芯实施高温保压锻造，使凝固末端树枝晶充分破碎，形成大量等轴晶组织，消除缩孔疏松，减轻枝晶偏析；最后，进行常规锻造，充分细化晶粒和组织。上述工艺突破了常规模铸钢锭完全凝固后再锻造的方法，通过超高温带液芯脱模，创造了钢锭心部流动性极好的半固态组织和表面与心部巨大的温度差，结合后续重压下及保压方法，可实现强制补缩和压力凝固，不但解决了钢锭中心的缩孔、疏松、偏析等问题，提升了冶金质量，而且降低了冒口重量、减少了锻造加热火次、延长了模具使用寿命。

Description

一种钢锭超高温软芯锻造方法 技术领域
本发明涉及钢的锻造领域，具体地来说是一种模铸钢锭的超高温软芯锻造方法。
背景技术
大型锻件作为冶金机械、石油化工、交通运输、能源电力等领域大型成套装备的核心零部件，在国民经济建设、国防装备和重大科学装置中发挥着极其重要的作用，其生产能力和质量水平是衡量一个国家自主能力与国力强弱的重要标志。因此，提高大型锻件的内在质量，保证其运行过程中的安全性和可靠性具有十分重要的意义。
大型锻件一般由大型钢锭锻造而成。在钢锭内部，由于金属凝固收缩而不可避免地产生大量的显微缩孔和疏松缺陷，这些孔洞型缺陷弥散分布在钢锭心部，破坏了材料的连续性，影响锻件的力学性能。同时，由于凝固过程的溶质再分配，凝固末端不但合金浓度高，而且往往富集低熔点物质和杂质元素，形成枝晶偏析，这种偏析在后续的锻造过程只能部分改善，不能完全消除，破坏材料的均质性，影响锻件的组织和性能。
为了改善锻件的致密性和均质性，大批科研人员长期致力于开发消除钢锭心部显微孔洞和改善显微偏析的“中心压实”工艺，目前已获得工业应用的工艺，如：WHF法(宽砧强压法)、FM法(心部消拉应力法)、JTS法(硬壳锻造法)等。这些工艺手段改善了锻件心部应力、应变状态，促进了孔洞类缺陷的愈合，通过再结晶破碎了铸态组织，使锻件以无缺陷或微缺陷状态服役，提升了重大装备的运行安全性。然而，由于材料成分和钢锭规格的多样性和复杂性，造成中心缺陷的大小和分布难以用统一的标准定量衡量，同样的锭型不同的材质，应用相同的锻造工艺进行锻造，有些能够通过探伤有些则不能。例如，采用高径比为2的15吨锭型生产42CrMo和H13钢锭，同样应用WHF法锻造，42CrMo材质的锻件能够通过探伤，而H13却不能通过，这主要是因为H13凝固区间宽，缩孔疏松缺陷更为严重。这种现状说明了当前中心压实工艺尚不足以消除一些钢锭中心比较严重的缺陷。因此，开发更为强力有效的锻造方法，彻底消除钢锭中心缺陷势在必行。
目前，几乎所有的锻件均采用冷(温)锭再加热的方式进行锻造生产。1)方式一：对于一些重量较小的钢锭，首先浇注钢锭，将钢锭在锭模中冷至300～500℃，然后为避免冷至室温时发生开裂，需进行长时间的消应力退火，然后在炉中进行长时间的梯度再加热，使钢锭内外温度均匀达到1200℃以上，最后进行锻造，加工周期非常长；2)方式二：对于一些重量较大的钢锭，首先浇注钢锭，将钢锭在锭模中冷至冒口完全凝固，然后进行脱模，此时 锭身温度一般为700～900℃，这种温态钢锭放入保温罐中热送(红送)到加热炉中进行加热，使钢锭内外温度均匀达到1200℃以上，最后进行锻造，这种方式在一定程度上节约了加热能源，缩短了加工流程；3)然而，对于一些钢种，在850～950℃时AlN沿铸态粗大奥氏体晶界析出，弱化了晶界，此时立即红送加热，短时间内发生奥氏体分解与奥氏体化两次相变，容易造成表面裂纹，这种钢锭不得不过冷到200～300℃，再进行加热，钢锭的余温白白损失掉，造成极大浪费。
近年来，在连铸坯制造领域发展出一种轻压下技术，这种技术是通过在连铸方/板坯液芯末端附近施加压力产生一定的压下量来补偿铸坯的凝固收缩量。一方面可以消除或减少铸坯收缩形成的内部空隙，防止晶间富集溶质元素的钢液向铸坯中心横向流动；另一方面，轻压下所产生的挤压作用还可以促进液芯中心富集的溶质元素钢液沿拉坯方向反向流动，使溶质元素在钢液中重新分配，从而使铸坯的凝固组织更加均匀致密，起到改善中心偏析和减少中心疏松的作用。轻压下技术对压下位置的选取非常重要，压下过早，中心金属尚未凝固，疏松缺陷在压下后还会形成；压下过晚，金属处于固相分数较高的两相区，流动性较差，小变形下容易产生密集性裂纹。一般认为中心固相分数达到0.3～0.7时压下会发挥较好作用。同时，压下量的选择也比较重要，根据设备能力，一般压下率为1～3％。连铸坯的轻压下技术能够在一定程度上改善普碳钢和低合金钢坯的中心质量，但对于必须采用模铸方式生产的合金钢却无能为力。事实上，合金钢的凝固区间往往较宽，中心缩孔疏松、枝晶偏析等缺陷更为严重，更需要结合凝固和变形手段，消除或减轻钢坯的中心缺陷。
发明内容
针对当前工业上产中钢锭的中心缺陷和内在质量问题，本发明的目的在于提供一种钢锭超高温软芯锻造方法，可以消除钢锭的缩孔疏松、减轻枝晶偏析等冶金缺陷，细化组织，提升锻件冶金质量和力学性能，达到缩短加工周期，节能、节材，提高模具使用寿命，降低锻造成本的目的。
本发明的技术方案为：
一种钢锭超高温软芯锻造方法，首先将浇注后的钢锭带液芯超高温脱模；然后放置于保温车中均温并运送到锻压机，将钢锭带液芯实施高温保压锻造，使凝固末端树枝晶充分破碎，形成大量等轴晶组织，消除缩孔疏松，减轻枝晶偏析；最后，进行常规锻造，充分细化晶粒和组织。
所述的钢锭超高温软芯锻造方法，具体步骤如下：
第一步，超高温脱模；使脱模后的钢锭锭身表面温度不低于1100℃，中心1300～1450 ℃；
第二步，封闭冒口顶部；采用喷淋或鼓风装置，持续作用于钢锭冒口，使冒口顶部完全凝固；
第三步，转运及均温；将钢锭放置于保温车中，运送至锻压机，均温0.5～2小时，准备锻造；
第四步，宽砧大变形；将钢锭放置于锻压机操作台上，使用宽平砧沿厚度方向变形10～50％；
第五步，高温保压；钢锭变形到指定尺寸后，使用宽平砧保持压力持续作用于钢锭，作用时间不小于5分钟，变形量不大于5％；
第六步，将钢锭锻造至最终锻件尺寸，对于形状复杂的锻件，若温度低于终锻温度，则回高温炉均温，执行下一锻造火次。
所述的钢锭超高温软芯锻造方法，第一步中，钢锭脱模时间采用计算机模拟确定，钢锭模设计为两种方式，一种为倒锥度，即“上小下大”模式，脱模时冒口箱和锭身同时脱除；另一种为正锥度，即“上大下小”模式，浇注后在冒口边缘插入起吊杆，冒口边缘凝固后，脱除冒口箱，通过起吊杆将钢锭与钢锭模脱除。
所述的钢锭超高温软芯锻造方法，第二步中，冒口顶部完全凝固时，冒口表面温度低于1200℃。
所述的钢锭超高温软芯锻造方法，第三步中，开锻前，钢锭表面温度最低点不低于1000℃。
所述的钢锭超高温软芯锻造方法，第四步中，主变形过程中，采用宽平砧变形的砧宽应覆盖钢锭总长度，一次变形到位，使缩孔疏松缺陷闭合。
所述的钢锭超高温软芯锻造方法，第五步中，主变形结束后，使用宽平砧进行保压和微变形，使闭合的缺陷充分焊合。
所述的钢锭超高温软芯锻造方法，第六步中，中心压实后，将钢锭锻造至最终锻件尺寸，若本锻造火次无法成形的，增加锻造火次成形。
本发明的物理冶金学和力学分析如下：
金属液在凝固相变过程中，体积将发生较大的改变。以钢铁材料为例，液态时密度约为7300kg/m3，固态时密度约为7800kg/m3，如此大的密度差将造成凝固后铸态组织中产生不同程度的缩孔、疏松缺陷。一般而言，固、液两相区越宽泛，产生疏松的倾向越严重。为了补充这种体积收缩，常规方法是在钢锭顶部放置冒口，通过良好的冒口保温条件，使冒口中保 持液态的金属在重力作用下，能够补充锭身的体积收缩，进而减轻缩孔、疏松缺陷。通常冒口越大，保温效果越好，对锭身的补缩效果越好。
然而，增大冒口是以牺牲钢锭的材料利用率为代价的，为了避免钢锭中心缩孔缺陷，一些冒口所占钢锭重量甚至超过30％，这是非常不经济的。理想情况下，材料利用率较高的钢锭应该是高径比较大、冒口较小的形状，但由于补缩距离过长，冒口部分的液态金属无法补充到钢锭中心，造成严重的二次缩孔缺陷。这种缩孔缺陷可以通过后续的锻造予以减轻，但对于特别严重的缩孔缺陷，尤其是钢水纯净度较差时，缺陷表面富集低熔点物质，这些孔洞型缺陷更加难以通过常规锻造方式愈合，需要非常大的锻造比才能将愈合界面的夹杂物打碎、分散，因此带来极高的生产成本和不稳定的产品质量。
一些国内外经典的凝固理论和实验研究表明，钢锭中缩孔疏松缺陷的形成是一个形核、长大的过程。最早的微型疏松往往起源于夹杂物或气泡，在随后的冷却收缩过程中，这些微型疏松在拉应力的作用下急剧长大，形成疏松甚至缩孔、缩裂缺陷。如果能在疏松形成的早期将其愈合，并在后续体积收缩过程中创造一个三向压应力的环境，将有望彻底抑制疏松缺陷的形成和扩展。
本发明前期通过系统的实验研究，提出了钢锭超高温带液芯脱模的工艺方法，这种方法通过巧妙的模具设计，采用反传统思想，将钢锭设计为上小下大的结构，实现了超高温带液芯脱模，钢锭表面温度达1100～1250℃，中心仍含有部分液芯，温度达1300～1450℃。此时中心的疏松缺陷刚刚形成，尚未长大，若实施重压下并进行保温、保压，可使较小的疏松缺陷完全焊合；同时，凝固末端的半固态金属在压力和变形的作用下，会发生局部重熔，搭接的枝晶被完全破碎，枝晶间的浓缩钢水和破碎的晶粒将被排挤到其它浓度较低的部位，与重熔的钢水混合在一起，降低了凝固末端的溶质浓度，提升了等轴晶的比例，进而减轻了枝晶偏析，促进了材料的均质化。
综上所述，本发明基于压力和变形作用下金属的凝固和组织演化规律，提出首先将钢锭带液芯超高温脱模，表面温度不低于1100℃，中心1300～1450℃；然后进行高温保压锻压，并保持压力持续作用于钢锭。本发明突破了常规模铸钢锭完全凝固后再锻造的方法，将铸锭和锻造两个原本分离的工序充分结合起来，通过超高温带液芯脱模，创造了钢锭心部流动性极好半固态组织和表面与心部巨大的温度差，结合后续重压下及保压工艺，可实现强制补缩和压力凝固，不但解决了钢锭中心的缩孔、疏松、偏析、组织粗大等问题，提升了冶金质量，而且降低了冒口重量，减少了锻造加热火次，延长了模具使用寿命，缩短了加工流程，大幅降低了锻件的热加工费用。
本发明具有如下的优点和有益效果：
1、材料内部质量大幅提升。由于钢锭中心的超高温大变形，彻底消除了缩孔疏松，减轻了枝晶偏析缺陷，组织均匀性获得提升，大截面锻坯的中心力学性能可接近甚至达到表面的性能水平。
2、钢锭表面质量大幅提升。由于不必担心中心缩孔疏松问题，可以提高浇注温度和浇注速度，大幅提升合金钢锭的表面质量。
3、降低加工费用，实现节能减排。由于超高温带液芯脱模，钢锭热容大，可节省主要一火加热，同时锻造操作时间可较常规加热方式延长1倍，大幅降低了加热与锻造费用。
4、大幅缩短加工流程和周期。高温脱模可缩短冷却时间30～50％，利用余热锻造减少加热时间30～40％，大幅提高生产效率。同时，由于脱模时间缩短，铸锭模的使用寿命可提升1～2倍。
5、材料利用率大幅提升。由于不依赖冒口重力补缩，冒口重量可降低30～50％，钢锭设计为高径比达5以上的形状，较传统高径比为1～2的锭型提升材料利用率15％以上。
6、降低对锻造设备能力的要求。由于钢锭处于超高温的两相区状态，中心区域的变形抗力不足完全固态的1/10，因此大幅降低了锻造过程对压机设备的能力需求，可以实现“用小设备制造大锻件”。
附图说明
图1为本发明钢锭超高温软芯锻造流程示意图；其中，(a)为钢包浇注钢锭，(b)为脱除冒口箱后喷雾冷却，(c)为将钢锭放入保温车中热送和均温，(d)为沿钢锭直径/厚度方向变形，(e)为变形后保压，(f)为锻造至成品。
图2为超高温变形时，缩孔疏松缺陷的愈合过程示意图；其中，(a)为刚刚萌生的疏松缺陷，(b)为疏松在大变形作用下闭合，(c)为闭合的疏松在持续保压的作用下分解为显微孔洞，(d)为显微孔洞在高温高压下逐渐扩散消失。
图3为超高温下变形时，枝晶的破碎及均质化过程示意图；其中，(a)为凝固末端树枝晶及残留液体，(b)为树枝晶在大变形作用下折断、重熔，分解为多段离散组织，成为后续熔体继续凝固的晶核，(c)为钢锭中心在压力作用下，以近似同时凝固的方式，形成的等轴晶组织，(d)为等轴晶组织在固相线以下温度大变形，发生再结晶后形成的更为细小的等轴晶组织。
图4为本发明实施例中，采用超高温软芯锻造方法获得的H13锻件金相组织照片。
图5为本发明比较例中，采用常规锻造工艺获得的H13锻件金相组织照片。
具体实施方式
下面，通过实施例和附图对本发明进一步详细描述。
如图1所示，本发明钢锭超高温软芯锻造流程如下：(a)钢包浇注钢锭→(b)脱除冒口箱后喷雾冷却→(c)将钢锭放入保温车中热送和均温→(d)沿钢锭直径/厚度方向变形→(e)变形后保压→(f)锻造至成品。本发明方法适用于碳锰钢、低合金钢、中高合金钢，尤其是凝固区间较宽、铸态组织特别发达的钢锭超高温软芯锻造。
在具体实施方式中，本发明钢锭超高温软芯锻造方法，首先将浇注后的钢锭带液芯超高温脱模；然后放置于保温车中均温并运送到锻压机，将钢锭带液芯实施高温保压锻造，使凝固末端树枝晶充分破碎，形成大量等轴晶组织，消除缩孔疏松，减轻枝晶偏析；最后，进行镦粗、拔长等常规锻造，充分细化晶粒和组织；具体步骤如下：
1)第一步，将钢锭带液芯超高温脱模，锭身表面温度不低于1100℃(优选为1150℃～1250℃)，中心温度保持在1300～1450℃；
如图2所示，超高温变形时，缩孔疏松缺陷的愈合过程如下：(a)刚刚萌生的疏松缺陷→(b)疏松在大变形作用下闭合→(c)闭合的疏松在持续保压的作用下分解为显微孔洞→(d)显微孔洞在高温高压下逐渐扩散消失。从图2可以看出，相比在完全固态下实施变形，在钢锭凝固末端实施大变形可加速孔洞闭合界面的高温扩散，使缩孔疏松型缺陷高效愈合，进而提升材料的致密度。
如图3所示，超高温下变形时，枝晶的破碎及均质化过程如下：(a)凝固末端树枝晶及残留液体→(b)树枝晶在大变形作用下折断、重熔，分解为多段离散组织，成为后续熔体继续凝固的晶核→(c)钢锭中心在压力作用下，以近似同时凝固的方式，形成的等轴晶组织→(d)等轴晶组织在固相线以下温度大变形，发生再结晶后形成的更为细小的等轴晶组织。从图3可以看出，相比在完全固态下实施变形，在钢锭凝固末端实施大变形可更加充分地破碎树枝晶，形成数量更多、尺寸更小的等轴晶，进而细化材料组织，减轻枝晶偏析，促进成分均匀。
2)第二步，采用喷淋或鼓风装置，持续作用于钢锭冒口，使冒口顶部完全凝固；
3)第三步，将钢锭放置于保温车中，运送至锻压机，均温0.5～2小时；
4)第四步，将钢锭放置于锻压机操作台上，使用宽平砧沿直径(厚度)方向变形10～50％；
5)第五步，钢锭变形到指定尺寸后，使用宽平砧保持压力持续作用于钢锭，作用时间不小于5分钟，变形量不大于5％；
6)第六步，将钢锭锻造至最终锻件尺寸，对于形状复杂的锻件，若温度低于终锻温度，则回高温炉均温，执行下一锻造火次。
第一步中，钢锭脱模时间采用计算机模拟确定，钢锭模设计为两种方式，一种为倒锥度，即“上小下大”模式，脱模时冒口箱和锭身同时脱除；另一种为正锥度，即“上大下小”模式，浇注后在冒口边缘插入起吊杆，冒口边缘凝固后，脱除冒口箱，通过起吊杆将钢锭与钢锭模脱除。
第二步中，采用喷淋或鼓风装置，持续作用于钢锭冒口，使冒口顶部完全凝固，且表面温度低于1200℃(优选为1100℃～1180℃)。
第三步中，钢锭放置于保温车中均温0.5～2小时，运送至锻压机，开锻前钢锭表面温度最低点不低于1000℃(优选为1100℃～1250℃)。
第四步中，主变形过程中，应采用宽平砧变形，砧宽应覆盖钢锭总长度，变形率10～50％(优选为20～50％)，一次变形到位，使缩孔疏松缺陷闭合；
第五步中，主变形结束后，使用宽平砧进行保压和缓慢微变形，压力作用时间不小于5分钟(优选为5～10分钟)，变形量不大于5％(优选为1～5％)，使闭合的缺陷充分焊合。
第六步中，中心压实后，将钢锭锻造至最终锻件尺寸，若本火次无法成形的，可增加火次成形。
实施例1
冶炼浇注的钢锭重量为9吨，截面为矩形，尺寸为720×1080×1450mm，材质为H13钢，其实测成分如表1所示。
表1 实施例1中H13钢的化学成分(重量百分数，％)
Figure PCTCN2014092623-appb-000001
对9吨重的H13钢锭进行超高温软芯锻造处理，具体步骤如下：
第一步，超高温脱模。钢锭浇注3.5h后，将冒口保护渣吹净，使钢锭带液芯超高温脱模，锭身表面温度1230℃，钢锭中心温度保持在1350℃以上。
第二步，封闭冒口顶部。采用喷淋装置，持续作用于钢锭冒口10min，使冒口顶部完全凝固，表面温度1180℃。
第三步，转运及均温。将钢锭放置于保温车中，30min运送至锻压机，再均温30min后：钢锭表面最低温度1100℃，钢锭表面最高温度1250℃，此时脱离保温车，准备锻造。
第四步，宽砧大变形。将钢锭放置于锻压机操作台上，使用宽平砧沿厚度方向变形240mm，一次变形到位。
第五步，高温保压。钢锭变形到指定尺寸后，使用宽平砧保持压力持续作用于钢锭，作用时间10min，变形量3％，使闭合的缺陷充分焊合。
第六步，将钢锭截面拔长至800×800mm，倒棱后镦粗至高度为1200mm，拔长至Φ450mm。
比较例1
比较例1中，选用钢锭的重量、材料化学成分、以及后续加工工艺和最终锻件尺寸均与实施例1中一致。比较例1采用常规的钢锭完全凝固后脱模、退火和再加热和锻造工艺，具体步骤如下：
第一步，中温脱模。钢锭浇注8h后，锭身及冒口完全凝固，使钢锭脱模，锭身表面温度700℃。
第二步，高温退火。将钢锭放置于850℃加热炉中，保温15h后缓冷到表面温度300℃。
第三步，转运。将钢锭放置于保温车中，30min运送至锻压机，然后缓慢加热到850℃，保温5h后，再缓慢加热到1230℃，准备锻造。
第四步，第一火锻造。将钢锭沿高度方向镦粗50％，然后拔长至截面尺寸800×800mm，倒棱后入炉再加热。
第五步，第二火锻造。将钢锭沿高度方向镦粗50％，然后拔长至截面尺寸800×800mm，倒棱后入炉再加热。
第六步，第三火锻造。将钢锭拔长至Φ450mm。
对于实施例1中和比较例1中的H13锻件进行等温球化处理，在850℃和750℃分别保温5h，缓慢冷却至室温，取锻件中心试样，采用金相显微镜对试样组织状态进行分析，具体金相组织见图4和图5。由图可以发现，实施例中的组织得到充分细化，平均晶粒尺寸仅为10μm，而比较例中仍存在100μm的大型晶粒。同时，实施例中的碳化物分布非常均匀，无液析碳化物，而比较例中的碳化物存在偏聚现象，分布不均匀并有少量液析碳化物。锻后热处理的组织状态充分说明，常规锻造工艺难以彻底消除液析碳化物，并且组织粗大，二次碳化物分布不均匀，而本发明的超高温软芯锻造方法可有效消除液析碳化物，获得均匀细小的晶粒，以及细小弥散的二次碳化物，因此可大幅提升模具钢的使用寿命。

Claims (8)

  1. 一种钢锭超高温软芯锻造方法，其特征是，首先将浇注后的钢锭带液芯超高温脱模；然后放置于保温车中均温并运送到锻压机，将钢锭带液芯实施高温保压锻造，使凝固末端树枝晶充分破碎，形成大量等轴晶组织，消除缩孔疏松，减轻枝晶偏析；最后，进行常规锻造，充分细化晶粒和组织。
  2. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，具体步骤如下：
    第一步，超高温脱模；使脱模后的钢锭锭身表面温度不低于1100℃，中心1300～1450℃；
    第二步，封闭冒口顶部；采用喷淋或鼓风装置，持续作用于钢锭冒口，使冒口顶部完全凝固；
    第三步，转运及均温；将钢锭放置于保温车中，运送至锻压机，均温0.5～2小时，准备锻造；
    第四步，宽砧大变形；将钢锭放置于锻压机操作台上，使用宽平砧沿厚度方向变形10～50％；
    第五步，高温保压；钢锭变形到指定尺寸后，使用宽平砧保持压力持续作用于钢锭，作用时间不小于5分钟，变形量不大于5％；
    第六步，将钢锭锻造至最终锻件尺寸，对于形状复杂的锻件，若温度低于终锻温度，则回高温炉均温，执行下一锻造火次。
  3. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第一步中，钢锭脱模时间采用计算机模拟确定，钢锭模设计为两种方式，一种为倒锥度，即“上小下大”模式，脱模时冒口箱和锭身同时脱除；另一种为正锥度，即“上大下小”模式，浇注后在冒口边缘插入起吊杆，冒口边缘凝固后，脱除冒口箱，通过起吊杆将钢锭与钢锭模脱除。
  4. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第二步中，冒口顶部完全凝固时，冒口表面温度低于1200℃。
  5. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第三步中，开锻前，钢锭表面温度最低点不低于1000℃。
  6. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第四步中，主变形过程中，采用宽平砧变形的砧宽应覆盖钢锭总长度，一次变形到位，使缩孔疏松缺陷闭合。
  7. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第五步中，主变形结束后，使用宽平砧进行保压和微变形，使闭合的缺陷充分焊合。
  8. 根据权利要求1所述的钢锭超高温软芯锻造方法，其特征是，第六步中，中心压实后，将钢锭锻造至最终锻件尺寸，若本锻造火次无法成形的，增加锻造火次成形。
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CN118122928A (zh) * 2024-03-05 2024-06-04 太原重工股份有限公司 大型火电汽轮机用Cr-Ni-Mo-V钢实心整体转子体锻件的加工方法

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