Discussion on the action of non-metallic inclusions in the process of bearing steel
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Bearing steel is a crucial material used across various industries such as mechanical manufacturing, railway transportation, automotive production, and national defense. With the rapid advancement of technology, the demand for bearings has become increasingly stringent, requiring high durability, stability, and reliability. To meet these standards, the level of impurities in bearing materials must be minimized to an extremely low degree.
Non-metallic inclusions play a significant role in the performance of bearing steel. These inclusions are influenced by their composition and are closely related to the processes of melting, refining, and casting. Understanding the behavior and transformation of non-metallic inclusions during these stages is essential for improving the quality of bearing steel.
In a typical production process for GCr15 bearing steel in an electric arc furnace (EAF) plant, the steps include: 100-ton EAF melting → LF (Ladle Furnace) heating → VD (Vacuum Degassing) treatment → continuous casting using a 150mm x 150mm billet caster.
Research findings reveal several key points:
1. The main impurities in this process are Al₂O₃, sulfides, and large composite inclusions containing calcium and magnesium.
2. After VD treatment, point-like impurities such as alumina and sulfides are significantly reduced. However, ferrochrome and silicates remain more prominent.
3. In the final samples, only small amounts of inclusions rich in SiO₂, Al₂O₃, CaO, and S were detected. Most of the inclusions are below 10 micrometers in size.
4. Approximately 50% of the impurities in the LF sample are smaller than 10 micrometers, while 90% of those after VD treatment are under 10 micrometers. In the finished product, most impurities are below 5 micrometers.
The sources of these inclusions vary. Alumina inclusions mainly come from aluminum deoxidation products and refractory materials. Sulfides are typically formed through nucleation on oxides like alumina, or through chemical reactions involving sulfur and elements such as calcium and iron in the steel. Punctate non-deformable inclusions are usually derived from deoxidation products, while calcium and magnesium inclusions originate from the lining and slag.
Understanding and controlling non-metallic inclusions is critical for producing high-quality bearing steel that meets modern industrial demands. By optimizing each stage of the production process, manufacturers can significantly reduce the negative impact of these inclusions on the final product's performance.
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