高速车轮钢韧化机理及工艺优化研究
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摘要
高速车轮是高速铁路运输中最重要的部件之一,到目前为止,我国高速铁路用车轮100%依赖进口。韧性不足是高速车轮国产化最大的难点,因此,如何提高车轮钢的韧性,实现高速车轮国产化,是发展我国高速铁路的重要研究课题。在过去数十年中,车轮钢的材料研究主要集中在化学元素的合金化机理和提高钢质的洁净度等方面,但是专门针对车轮钢特殊生产工艺条件下的韧化机理尚未开展系统的研究工作。为此,本论文以珠光体组织为主的中高碳车轮钢作为研究载体,以提高中高碳珠光体钢的韧性为研究目标,采用EBSD、Thermo-Calc热力学计算、Ansys有限元计算和断裂韧性测试等多种研究手段和测试方法,从夹杂物冶金、热加工温度参数的精确控制、特殊的淬火工艺等多方面探索了车轮钢的韧化机理,提出了与传统方法不同的韧化机制,获得了具有创新性的研究结果。
研究结果表明,车轮钢中的硫含量及其存在方式对车轮钢的韧性有显著影响。结果显示,车轮钢中的硫含量与传统钢不同,并不是硫含量越低车轮钢的韧性就越高,而是存在一个最佳含量范围,当硫含量由常规的0.001%增加至0.006～0.01%时,车轮钢的断裂韧性提高40%以上,可显著增加车轮高速运行时的安全裕量。适当增加硫含量后,车轮钢中的夹杂物由以单个裸露氧化物为主,绝大部分改性为以硫化物包裹氧化物的复合夹杂物；硫化物包裹在氧化物夹杂表面后,极大减轻了夹杂物周围基体区域的应力集中,防止了硬性夹杂物成为断裂启裂源,这是韧性改善的主要原因。添加适量的Ca,以提高硫化物的析出温度和适当降低车轮圆坯的加热温度,均有利于提高硫化物的包裹效果。在此基础上提出了硫化物在氧化物上析出和脱离的热力学模型。
研究发现,珠光体球团的细化及均匀化是改善车轮钢韧性的另一个原因。通过适当降低钢坯加热温度、终轧温度、踏面淬火温度等热加工过程中的关键温度控制参数,不仅可有效细化车轮钢原始奥氏体晶粒度,更为重要的是细化珠光体球团尺寸,并提高珠光体球团均匀性,降低大尺寸球团出现概率,从而提高车轮韧性水平。进一步研究表明,在解理断裂过程中,珠光体球团是解理断裂基本单元,能阻止球团内部滑移带扩展,说明珠光体球团是车轮钢中重要的韧性控制结构单元。
采用水冷—中断水冷—强水冷的间歇式踏面淬火,可以在不改变生产周期的前提下,获得与连续水冷方式相比更为理想的冷却特性和温度场分布,抑制贝氏体相变,使硬度梯度分布更均匀,显著细化了珠光体球团,改善了踏面附近的韧性；与连续淬火相比,间歇式淬火是获得细小珠光体球团的最佳冷却方式。
综上所述,本论文首次在车轮钢中采用夹杂物冶金技术,利用与基体变形能力接近的硫化物,巧妙地包裹在脆而硬的难变形的氧化物周围,减轻变形过程中的应力集中,显著提高了车轮钢的断裂韧性,获得了创新性的研究成果；同时采用精确控制多种热履历参数,细化了车轮钢的精细结构,也明显改善了车轮钢的韧性。
Most recently, higher demand on safety level of railway wheels has been proposed as high speed railway operation speed break through350km per hour, so it is more important to develop high toughness wheels for high speed train transport. There are certainly researches on elements alloying mechanism and cleanliness improvement could be found in wheel steels, but investigations focus on toughness improvement in specific manufacturing process for high speed railway wheels is not adequate and need to be strengthened. The present study pays attention on toughness improvement of medium-high carbon pearlite wheel steels. A serial of analysis and testing methods, such as EBSD, Thermo-Calc thermodynamic calculation, Ansys finite element analysis and fracture toughness testing, et al, have been employed in present paper. Toughening mechanism of railway wheel steels has been researched through inclusion metallurgic, precision controlling of thermal process temperature parameters and special quenching process, so that toughening mechanism different from conventional way have been suggested and innovate research results have been attained.
It is showed in this paper that there is makeable effect of sulphur content and its existing state on toughness of railway wheel steels. Traditionally, sulphur content was intently controlled at very low level with the purpose of toughening, but this attempting seldom worked. Distinct from traditional attempts, we find out that there is a best sulphur content scope. Fracture toughness increases about40%by increasing S from normal0.001to0.006～0.01%in this paper. And redundant safety assurance of wheels notablely increases as running at high speed. With sulphur adding in railway wheel steels, main inclusions change from naked oxides to complex inclusions which are specified as sulphides covering oxides. Stress concentration around complex inclusions essentially decreased with a cover of ductile MnS, so that microcracks original from oxides could be prevented, and that is the main reason of toughening. Adding with certain content of Ca, precipitation temperature increasing and proper decreasing in casting heating temperature of the steel, both could promote sulphides covered on oxides. Based on these work, thermodynamic model of MnS precipitation and dissolution from oxide has been proposed.
It is found that another reason of wheel steels toughening is refining and uniformity of pearlite colony size. As key parameters in thermal process of wheels, deformation temperature, finish rolling temperature and tread quenching temperature must keep at lower levels, so prior austenite grain size get fined, what more, uniformity of pearlite colony size increase, which means probability of big colony size reduce, and toughness level of wheel steels increase. Further study in fracture surface reveals that single pearlite colony could form into a fracture facet and slip bands in a facet ended at pearlite colony boundaries. So it is reasonable to consider the pearlite colony as controlling submicrostructure of railway wheel steels.
Adapted with interrupt tread quenching, which means a cooling way of a starting water quenching and then stop about100s and a further cooling, cooling rates and cooling fields better than that in continuous quenching could get, bainite phase transformation is depressed, hardness contribution gets uniform and pearlite colony size gets finer, toughness near tread get improved without changing in producing routine. It is indicated that interrupt quenching is more suitable for getting fine pearlite colony than continuous quenching.
In summary, with introducing inclusions metallurgic technology firstly in railway wheel steels, brittle and hard, undeforming oxides could be covered by sulphides, which have similar ability of deformation with steel matrix. So that stress concentration around inclusions decrease and fracture toughness essentially improve and a new toughening mechanism is developed. At the same time, after precision controlling of thermal process temperature parameters, toughness of wheel steels improve for finer pearlite submicrostructure.
研究结果表明,车轮钢中的硫含量及其存在方式对车轮钢的韧性有显著影响。结果显示,车轮钢中的硫含量与传统钢不同,并不是硫含量越低车轮钢的韧性就越高,而是存在一个最佳含量范围,当硫含量由常规的0.001%增加至0.006～0.01%时,车轮钢的断裂韧性提高40%以上,可显著增加车轮高速运行时的安全裕量。适当增加硫含量后,车轮钢中的夹杂物由以单个裸露氧化物为主,绝大部分改性为以硫化物包裹氧化物的复合夹杂物；硫化物包裹在氧化物夹杂表面后,极大减轻了夹杂物周围基体区域的应力集中,防止了硬性夹杂物成为断裂启裂源,这是韧性改善的主要原因。添加适量的Ca,以提高硫化物的析出温度和适当降低车轮圆坯的加热温度,均有利于提高硫化物的包裹效果。在此基础上提出了硫化物在氧化物上析出和脱离的热力学模型。
研究发现,珠光体球团的细化及均匀化是改善车轮钢韧性的另一个原因。通过适当降低钢坯加热温度、终轧温度、踏面淬火温度等热加工过程中的关键温度控制参数,不仅可有效细化车轮钢原始奥氏体晶粒度,更为重要的是细化珠光体球团尺寸,并提高珠光体球团均匀性,降低大尺寸球团出现概率,从而提高车轮韧性水平。进一步研究表明,在解理断裂过程中,珠光体球团是解理断裂基本单元,能阻止球团内部滑移带扩展,说明珠光体球团是车轮钢中重要的韧性控制结构单元。
采用水冷—中断水冷—强水冷的间歇式踏面淬火,可以在不改变生产周期的前提下,获得与连续水冷方式相比更为理想的冷却特性和温度场分布,抑制贝氏体相变,使硬度梯度分布更均匀,显著细化了珠光体球团,改善了踏面附近的韧性；与连续淬火相比,间歇式淬火是获得细小珠光体球团的最佳冷却方式。
综上所述,本论文首次在车轮钢中采用夹杂物冶金技术,利用与基体变形能力接近的硫化物,巧妙地包裹在脆而硬的难变形的氧化物周围,减轻变形过程中的应力集中,显著提高了车轮钢的断裂韧性,获得了创新性的研究成果；同时采用精确控制多种热履历参数,细化了车轮钢的精细结构,也明显改善了车轮钢的韧性。
Most recently, higher demand on safety level of railway wheels has been proposed as high speed railway operation speed break through350km per hour, so it is more important to develop high toughness wheels for high speed train transport. There are certainly researches on elements alloying mechanism and cleanliness improvement could be found in wheel steels, but investigations focus on toughness improvement in specific manufacturing process for high speed railway wheels is not adequate and need to be strengthened. The present study pays attention on toughness improvement of medium-high carbon pearlite wheel steels. A serial of analysis and testing methods, such as EBSD, Thermo-Calc thermodynamic calculation, Ansys finite element analysis and fracture toughness testing, et al, have been employed in present paper. Toughening mechanism of railway wheel steels has been researched through inclusion metallurgic, precision controlling of thermal process temperature parameters and special quenching process, so that toughening mechanism different from conventional way have been suggested and innovate research results have been attained.
It is showed in this paper that there is makeable effect of sulphur content and its existing state on toughness of railway wheel steels. Traditionally, sulphur content was intently controlled at very low level with the purpose of toughening, but this attempting seldom worked. Distinct from traditional attempts, we find out that there is a best sulphur content scope. Fracture toughness increases about40%by increasing S from normal0.001to0.006～0.01%in this paper. And redundant safety assurance of wheels notablely increases as running at high speed. With sulphur adding in railway wheel steels, main inclusions change from naked oxides to complex inclusions which are specified as sulphides covering oxides. Stress concentration around complex inclusions essentially decreased with a cover of ductile MnS, so that microcracks original from oxides could be prevented, and that is the main reason of toughening. Adding with certain content of Ca, precipitation temperature increasing and proper decreasing in casting heating temperature of the steel, both could promote sulphides covered on oxides. Based on these work, thermodynamic model of MnS precipitation and dissolution from oxide has been proposed.
It is found that another reason of wheel steels toughening is refining and uniformity of pearlite colony size. As key parameters in thermal process of wheels, deformation temperature, finish rolling temperature and tread quenching temperature must keep at lower levels, so prior austenite grain size get fined, what more, uniformity of pearlite colony size increase, which means probability of big colony size reduce, and toughness level of wheel steels increase. Further study in fracture surface reveals that single pearlite colony could form into a fracture facet and slip bands in a facet ended at pearlite colony boundaries. So it is reasonable to consider the pearlite colony as controlling submicrostructure of railway wheel steels.
Adapted with interrupt tread quenching, which means a cooling way of a starting water quenching and then stop about100s and a further cooling, cooling rates and cooling fields better than that in continuous quenching could get, bainite phase transformation is depressed, hardness contribution gets uniform and pearlite colony size gets finer, toughness near tread get improved without changing in producing routine. It is indicated that interrupt quenching is more suitable for getting fine pearlite colony than continuous quenching.
In summary, with introducing inclusions metallurgic technology firstly in railway wheel steels, brittle and hard, undeforming oxides could be covered by sulphides, which have similar ability of deformation with steel matrix. So that stress concentration around inclusions decrease and fracture toughness essentially improve and a new toughening mechanism is developed. At the same time, after precision controlling of thermal process temperature parameters, toughness of wheel steels improve for finer pearlite submicrostructure.
引文
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