新型压铸用模具钢R527的研究开发
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摘要
压力铸造可以铸出外形复杂、精度高、表面粗糙度小并且具有良好力学性能的零件,因此用压铸法生产的铝、锌、铜、镁、铅及其它合金件日益增长,压铸行业发展迅速；但压铸行业尚未寻得最佳的模具材料,均以热挤压模具材料替代。近年来,铝、锌等合金压铸行业对寻求一种性价比高、抗疲劳性能好、使用寿命长的新模具钢材料有巨大市场需求。
广州市冶金工业研究所曾以中频+电渣重熔+锻造的常规生产工艺,生产适于制作挤压模具H13钢提供给客户用作压铸模具材料,由于模具材料在锻造加工过程中容易出现表面微裂纹,压铸模具的使用寿命很短,而且压铸产品表面质量不高使用效果不理想。本论文工作通过对MO、Cr和V等合金元素的强化作用的研究,设计了R527钢的成分；研究了中频冶炼脱氧制度、电渣重熔冶炼过程的提纯作用；通过电渣重熔冶炼工艺参数及锻造工艺参数优化、退火新工艺等对钢的组织均匀性及改善夹杂物尺寸及分布影响的研究,达到提高R527钢的综合性能的目的,获得强度高、等向性好,耐磨性、抗热疲劳性能、耐蚀性高的模具钢材料,研究、开发适于制作压铸模具的新型R527模具钢材料及加工制备工艺。
研制出的新型R527压铸模具用钢,其强化元素的含量控制在较高水平并添加稀土元素,将S、P、O、N、H等杂质及有害元素的含量控制在较低水平,非金属夹杂物的数量、尺寸及分布控制在理想状态,组织均匀性良好。该钢种的抗热疲劳性能、耐磨性、耐蚀性均较普通H13钢提高10～20%；横向性能与纵向性能的比率提高20%以上；使用寿命提高15%以上,可广泛适用于高端型材挤压、有色合金的压铸、粉末冶金加工等,满足铝、锌压铸行业及更广范围的未来市场的更高需求。
Complicated and good size precision parts with excellent mechanical properties and surface roughness can be made by pressure die casting. Many mechanical parts of Al, Cu, Pb metals or their alloys are produced by pressure die casting and developed well in industry. But the problem in the pressure die casting is that there are not ideal mould materials for the die casting yet, the mould in die casting still use the extrusion mould. A new kind of mould with low price, high performance and long life using in die casting is neeed urgently.
Guangzhou Reseach Institute of metallurgical industry (GRIMI) have produced H13 steel by routine technique according to smelting at midium frenqucy, remelting in slag following by forging, which is much suitable for extrusion mould than to use in the die casting. The H13 steel used as mould in die casting is not so hopeful because of the tiny cracks occurance in forging, the short life-span of the mould and the low surface quality.
This work focus on the strengthen effects of Mo, Cr and V on the steel, a new kind steel mould composition is designed. The purification by medium frequency oxidize and electrical slag re-smelting was studied. Also the processing technique of electrical slag re-smelting, forging and anealing were studied to improve the microstructure uniformity, the size and distribution of the inclusions. The main aim is to develop a new type R527 isotropic mould steel and its processing technique suitable for pressure die casting with high strength, high wear-resistance, thermal fatigue and erosion properties.
The achieved new R527 steel mould for die casting contains relative high content of strengthening elements and rare earth elements, the detrimental elements such as S, P,O,N,H are controlled well at a low level. The number, the size and the distribution of the non-metal inclusions meet the requirement. The new R527 die casting steel mould shows much higher performance than that of H13 steel. Compared with H13 steel using for die casting, R527 steel using for die casting improve 10-20% by thermal fatigue, wear-resistance and thermal erosion; the isotropic of the tensile strength improves at least 20%; the life-span can improve at least 15%. The new R527 steel is much suitable for using in high-quality section materials extrusion, die casting of non-ferrous metals and powder metallurgy. The new R527 steel can meet the needs of die casting in Al, Zn and other die casting in a wide range.
广州市冶金工业研究所曾以中频+电渣重熔+锻造的常规生产工艺,生产适于制作挤压模具H13钢提供给客户用作压铸模具材料,由于模具材料在锻造加工过程中容易出现表面微裂纹,压铸模具的使用寿命很短,而且压铸产品表面质量不高使用效果不理想。本论文工作通过对MO、Cr和V等合金元素的强化作用的研究,设计了R527钢的成分；研究了中频冶炼脱氧制度、电渣重熔冶炼过程的提纯作用；通过电渣重熔冶炼工艺参数及锻造工艺参数优化、退火新工艺等对钢的组织均匀性及改善夹杂物尺寸及分布影响的研究,达到提高R527钢的综合性能的目的,获得强度高、等向性好,耐磨性、抗热疲劳性能、耐蚀性高的模具钢材料,研究、开发适于制作压铸模具的新型R527模具钢材料及加工制备工艺。
研制出的新型R527压铸模具用钢,其强化元素的含量控制在较高水平并添加稀土元素,将S、P、O、N、H等杂质及有害元素的含量控制在较低水平,非金属夹杂物的数量、尺寸及分布控制在理想状态,组织均匀性良好。该钢种的抗热疲劳性能、耐磨性、耐蚀性均较普通H13钢提高10～20%；横向性能与纵向性能的比率提高20%以上；使用寿命提高15%以上,可广泛适用于高端型材挤压、有色合金的压铸、粉末冶金加工等,满足铝、锌压铸行业及更广范围的未来市场的更高需求。
Complicated and good size precision parts with excellent mechanical properties and surface roughness can be made by pressure die casting. Many mechanical parts of Al, Cu, Pb metals or their alloys are produced by pressure die casting and developed well in industry. But the problem in the pressure die casting is that there are not ideal mould materials for the die casting yet, the mould in die casting still use the extrusion mould. A new kind of mould with low price, high performance and long life using in die casting is neeed urgently.
Guangzhou Reseach Institute of metallurgical industry (GRIMI) have produced H13 steel by routine technique according to smelting at midium frenqucy, remelting in slag following by forging, which is much suitable for extrusion mould than to use in the die casting. The H13 steel used as mould in die casting is not so hopeful because of the tiny cracks occurance in forging, the short life-span of the mould and the low surface quality.
This work focus on the strengthen effects of Mo, Cr and V on the steel, a new kind steel mould composition is designed. The purification by medium frequency oxidize and electrical slag re-smelting was studied. Also the processing technique of electrical slag re-smelting, forging and anealing were studied to improve the microstructure uniformity, the size and distribution of the inclusions. The main aim is to develop a new type R527 isotropic mould steel and its processing technique suitable for pressure die casting with high strength, high wear-resistance, thermal fatigue and erosion properties.
The achieved new R527 steel mould for die casting contains relative high content of strengthening elements and rare earth elements, the detrimental elements such as S, P,O,N,H are controlled well at a low level. The number, the size and the distribution of the non-metal inclusions meet the requirement. The new R527 die casting steel mould shows much higher performance than that of H13 steel. Compared with H13 steel using for die casting, R527 steel using for die casting improve 10-20% by thermal fatigue, wear-resistance and thermal erosion; the isotropic of the tensile strength improves at least 20%; the life-span can improve at least 15%. The new R527 steel is much suitable for using in high-quality section materials extrusion, die casting of non-ferrous metals and powder metallurgy. The new R527 steel can meet the needs of die casting in Al, Zn and other die casting in a wide range.
引文
1.中国模具工业协会.模具工业[J].2011,(4)：77
2.陈再枝、蓝德年编著.模具钢手册[M].北京：冶金工业出版社,2002
3.谢建新等编著.材料加工新技术与新工艺[M].北京：冶金工业出版社,2004
4.董瀚等编著.先进钢铁材料[M].北京：科学出版社,2008
5.亚洲产业资讯网.模具钢材报告：2011-2015年中国模具钢材行业市场调查及发展预测报告,2010
6.刘宗昌.珠光体转变与退火[M].北京：化学工业出版社,2007
7.胡心彬.铌微合金化H13钢的热疲劳行为[D].上海：上海大学,2005年
8.王振东,曹孔健,何纪龙.感应炉冶炼[M],北京：化学工业出版社,2007
9.耿茂鹏,孙达听.电渣熔铸过程控制与模拟仿真[M].北京：冶金工业出版社,2008
10.魏季和,任永莉.电渣重熔体系内熔渣流场的数学模拟[J].金属学报,1994(23)：1 5-17
11.杨小军,耿茂鹏,马新生.电渣熔铸渣池温度场数值模拟研究及解法改进[J].南昌大学学报(工科版),2003(1)：45-49
12.尧军平,耿茂鹏,马新生等.ESR熔池深度与重熔电流及锭高关系的数模研究[J].南昌大学学报(工科版),2004(3)：1-5
13.杨洪.以熔化率和极间距为中心的电渣炉计算机控制模型[C].中国特殊钢年会2005论文集,2005年
14.任慧平,李文学.H13钢退火用TTT图及球化工艺的研究[J].金属热处理,1997(5)：7-10
15.霍晓阳.影响H13热作模具钢等向性的因素[J].钢铁研究学报,2008,20(11)：15-29
16.倪利勇,张永军,刘助柏.水平V型砧锻造大型轴类锻件的数值模拟和实验[J].塑性工程学报,2010,1：37-42
17.杨勇、汤智涛.电渣重熔大充填比降低电耗的试验研究[J].铸造,2006,8：832-834
18.郭上型、董元篪、彭明.钢液二次精炼中CaO基熔剂脱磷效果的研究[J].炼钢,2005,21(3)：37-39
19.吴远飞,姜周华.电渣重熔过程中电极熔速的确定[J].材料与冶金学报,2002,1(2)：115-119
20.曹洪敏.电渣重熔炉电耗分析与计算[J].工业加热,1994,3：20-23
2.陈再枝、蓝德年编著.模具钢手册[M].北京：冶金工业出版社,2002
3.谢建新等编著.材料加工新技术与新工艺[M].北京：冶金工业出版社,2004
4.董瀚等编著.先进钢铁材料[M].北京：科学出版社,2008
5.亚洲产业资讯网.模具钢材报告：2011-2015年中国模具钢材行业市场调查及发展预测报告,2010
6.刘宗昌.珠光体转变与退火[M].北京：化学工业出版社,2007
7.胡心彬.铌微合金化H13钢的热疲劳行为[D].上海：上海大学,2005年
8.王振东,曹孔健,何纪龙.感应炉冶炼[M],北京：化学工业出版社,2007
9.耿茂鹏,孙达听.电渣熔铸过程控制与模拟仿真[M].北京：冶金工业出版社,2008
10.魏季和,任永莉.电渣重熔体系内熔渣流场的数学模拟[J].金属学报,1994(23)：1 5-17
11.杨小军,耿茂鹏,马新生.电渣熔铸渣池温度场数值模拟研究及解法改进[J].南昌大学学报(工科版),2003(1)：45-49
12.尧军平,耿茂鹏,马新生等.ESR熔池深度与重熔电流及锭高关系的数模研究[J].南昌大学学报(工科版),2004(3)：1-5
13.杨洪.以熔化率和极间距为中心的电渣炉计算机控制模型[C].中国特殊钢年会2005论文集,2005年
14.任慧平,李文学.H13钢退火用TTT图及球化工艺的研究[J].金属热处理,1997(5)：7-10
15.霍晓阳.影响H13热作模具钢等向性的因素[J].钢铁研究学报,2008,20(11)：15-29
16.倪利勇,张永军,刘助柏.水平V型砧锻造大型轴类锻件的数值模拟和实验[J].塑性工程学报,2010,1：37-42
17.杨勇、汤智涛.电渣重熔大充填比降低电耗的试验研究[J].铸造,2006,8：832-834
18.郭上型、董元篪、彭明.钢液二次精炼中CaO基熔剂脱磷效果的研究[J].炼钢,2005,21(3)：37-39
19.吴远飞,姜周华.电渣重熔过程中电极熔速的确定[J].材料与冶金学报,2002,1(2)：115-119
20.曹洪敏.电渣重熔炉电耗分析与计算[J].工业加热,1994,3：20-23