WO2021223660A1 - 一种冶炼极细金刚砂线用钢的工艺方法 - Google Patents

一种冶炼极细金刚砂线用钢的工艺方法 Download PDF

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Publication number
WO2021223660A1
WO2021223660A1 PCT/CN2021/091085 CN2021091085W WO2021223660A1 WO 2021223660 A1 WO2021223660 A1 WO 2021223660A1 CN 2021091085 W CN2021091085 W CN 2021091085W WO 2021223660 A1 WO2021223660 A1 WO 2021223660A1
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Prior art keywords
smelting
electroslag
wire
ingot
steel
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PCT/CN2021/091085
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English (en)
French (fr)
Inventor
徐迎铁
黄宗泽
刘湘江
万根节
齐彦峰
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Baoshan Iron and Steel Co Ltd
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Baoshan Iron and Steel Co Ltd
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Priority to EP21799770.9A priority Critical patent/EP4119687B1/en
Priority to JP2022562387A priority patent/JP7442675B2/ja
Priority to US17/920,166 priority patent/US20230175093A1/en
Priority to KR1020227036956A priority patent/KR102710385B1/ko
Priority to ES21799770T priority patent/ES2998540T3/es
Publication of WO2021223660A1 publication Critical patent/WO2021223660A1/zh
Anticipated expiration legal-status Critical
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/04—Removing impurities by adding a treating agent
    • C21C7/06—Deoxidising, e.g. killing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/525—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length for wire, for rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/16—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/52—Manufacture of steel in electric furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/52—Manufacture of steel in electric furnaces
    • C21C5/5241—Manufacture of steel in electric furnaces in an inductively heated furnace
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/04—Removing impurities by adding a treating agent
    • C21C7/064—Dephosphorising; Desulfurising
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/10—Handling in a vacuum
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D8/00—Modifying the physical properties of ferrous metals or ferrous alloys by deformation combined with, or followed by, heat treatment
    • C21D8/06—Modifying the physical properties of ferrous metals or ferrous alloys by deformation combined with, or followed by, heat treatment during manufacturing of rods or wires
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/16—Remelting metals
    • C22B9/18—Electroslag remelting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/006—Making ferrous alloys compositions used for making ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/001—Ferrous alloys, e.g. steel alloys containing N
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/04—Refining by applying a vacuum
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a process method for smelting steel for ultra-fine emery wire, and belongs to the technical field of steelmaking.
  • Emery wire is mainly used for cutting silicon wafers, gems, etc.
  • silicon wafers are the main raw material for photovoltaic and electronic industries.
  • the diamond wire In order to improve the cutting efficiency, the diamond wire requires very fine specifications.
  • the diameter of the very fine diamond yarn is usually 0.04 ⁇ 0.055mm, which is thinner than human hair.
  • the ultra-fine specification puts forward strict requirements on the control of inclusions in steel.
  • the width of all inclusions contained in steel should be less than 10 ⁇ m, and should not contain brittle aluminum inclusions.
  • the demand for emery wire is small, and its profit cannot offset the increase in the cost of refractory materials in the entire process. Therefore, the use of converter process or electric furnace process to produce emery line cannot achieve economic benefits.
  • the carbon content in the steel is required to be at least 0.92%, preferably more than 1%; in addition, the nitrogen content is required to be less than 50 ppm, and this composition cannot be used in other steel types.
  • the present invention provides a process method for smelting ultra-fine emery wire steel that can meet small-scale and high requirements.
  • the method can control the inclusions to produce an ultra-fine emery wire that does not break during the process of drawing the emery wire.
  • a technological method for smelting steel for ultra-fine emery line The production process can be summarized as vacuum induction furnace smelting-electroslag-forging-wire rolling. The main steps are as follows:
  • a vacuum induction furnace is selected as the primary smelting furnace, and the characteristics of the vacuum induction furnace that can be small-scale smelted and have a vacuum degassing function are used to meet the denitrification requirements of the present invention related to steel grades; in addition, the vacuum induction furnace can also achieve vacuum Protected pouring can avoid secondary oxidation and nitrogen absorption by molten steel caused by pouring in the atmosphere.
  • the weight of the cast ingot is 1.5 to 2.5 tons, when 1-2 ingots need to be cast, a vacuum induction furnace with a scale of 2 to 5 tons should be selected for production; if a larger-scale induction furnace is selected, 3 or The above ingot casting is difficult to achieve vacuum casting.
  • the choice of pure iron and pig iron as raw materials is mainly based on the configuration of the carbon content of this steel.
  • Pig iron contains about 4% carbon (mass percentage), which can achieve the carbon content requirement of about 1% (mass percentage) in the final molten steel; in addition, pure The content of harmful residual elements in iron and pig iron is low, which can ensure that the harmful residual elements in steel do not exceed the standard.
  • Degassing under high vacuum conditions for 15min to 20min is mainly to ensure that the denitrification meets the requirements of the steel grade, and it can also be dehydrogenated to ensure no hydrogen-induced cracks.
  • the composition of molten steel can be adjusted during the vacuum smelting process, and high-purity manganese and high-purity ferrosilicon can be added to meet the final composition requirements of the product.
  • high-purity ferrosilicon means: the mass percentage of silicon is 75-85%, and the mass percentage of aluminum is less than 0.05%. Of iron material.
  • the use of high-purity ferrosilicon as deoxidizer is mainly due to the high aluminum content of ordinary ferrosilicon, which easily causes the final aluminum content to exceed the standard. It is strictly forbidden to add aluminum-containing deoxidizers because the high alumina content inclusions contained in the steel for ultra-fine emery wire are brittle inclusions, which are very destructive to the drawing of emery wire.
  • the selection of the final ingot size is mainly set based on the size requirements of the electroslag electrode rod involved in the subsequent process.
  • the electrode rod is used as the raw material for electroslag furnace remelting smelting.
  • the electroslag mold powder includes CaF 2 : 45-55%, Al 2 O 3 : 15-25%, SiO 2 : 20-25% in terms of mass percentage. %, Na 2 O: 2 to 4%, K 2 O: 1 to 2%, and the electrode rod is smelted into a cylindrical electroslag ingot through an electroslag furnace, and the diameter of the electroslag ingot is 0.4 to 0.5 m.
  • Electroslag furnace remelting smelting is to connect the electrode rod, slag, and molten steel in the mold into an electric circuit, under the condition of low voltage (voltage 40 ⁇ 60V) and high current (current 10 ⁇ 20KA), using electroslag protective slag Local heating causes the part of the electrode rod that is in contact with the electroslag mold powder to gradually melt into droplets. A large number of droplets separated from the electrode rod pass through the slag layer of the electroslag mold powder and fall into the molten steel pool of the mold, and the molten steel is melted. The part of the pool in contact with the crystallizer solidifies again.
  • Electroslag furnace remelting smelting uses electroslag mold slag to filter molten steel, which can completely remove large inclusions, and the remaining inclusions are all less than 13 ⁇ m; at the same time, the electroslag ingots obtained by electroslag furnace remelting smelting have a uniform and dense structure.
  • the remaining inclusions in the steel are closer to the composition of the electroslag mold slag in the electroslag furnace, so this technical solution controls the composition of the electroslag mold slag to: CaF 2 : 45-55% , Al 2 O 3 : 15 to 25%, SiO 2 : 20 to 25%, Na 2 O: 2 to 4%, K 2 O: 1 to 2% (based on the total mass of electroslag mold powder as 100%) ,
  • the composition of the remaining small particle inclusions in the molten steel is also within this range.
  • part of the CaF 2 in the electroslag mold flux is transformed into CaO.
  • the inclusions in this range have the characteristics of low melting point and strong plasticization ability.
  • the width of the inclusions after deformation can be all less than 7 ⁇ m; and the contact surface between the inclusions and the steel is relatively smooth, and the damage to the steel is small during the drawing process, and it will not cause the drawing wire to break, and it also ensures that the emery wire is cutting silicon wafers.
  • the choice of electroslag ingot size is mainly based on the convenience of electroslag crystallizer design and the convenience of subsequent forging.
  • the forging billet is a square billet, the section of the square billet is square, the side length of the square section is 0.140 ⁇ 0.160m, and the length of the forging billet is greater than 6m, and Less than 14m.
  • the forging billet is rolled into a wire rod with a diameter of 4.5-5.5mm through a wire rolling process.
  • the components of the wire rod include [C]: 0.92 ⁇ 1.1%, [Si]: 0.3 ⁇ 0.4%, [Mn]: 0.5 ⁇ 0.8%, [Al] ⁇ 0.0008%, [N] ⁇ 0.005%, [S ] ⁇ 0.01%, [P] ⁇ 0.015%, the balance is iron and unavoidable impurities.
  • the wire rod produced by the invention can finally be drawn into a very fine emery wire bus bar with a diameter of 0.04-0.055mm.
  • the drawing process is continuous and can be used for high-efficiency cutting of silicon wafers, gems and the like.
  • step 1) it is further required that at the end of vacuum induction furnace smelting, the elements of the molten steel include [C]: 0.94-1.1% and [Si]: 0.35-0.45% in terms of mass percentage. , [Mn]: 0.6 ⁇ 0.8%, [Al] ⁇ 0.001%, [N] ⁇ 0.0045%, [S] ⁇ 0.01%, [P] ⁇ 0.015%, the balance is iron and unavoidable impurities.
  • the temperature of molten steel at the end of smelting in the vacuum induction furnace is controlled to 1460 ⁇ 1500°C; and after the smelting of the vacuum induction furnace is completed, argon protection is appropriately blown, and the pressure in the furnace is adjusted to 10000Pa ⁇ 20000Pa, and then poured under a protective atmosphere.
  • the protective atmosphere is, for example, but not limited to, argon, and the casting mold is a cast iron mold.
  • the content of carbon, silicon and aluminum in molten steel is slightly higher than their content in steel after electroslag furnace remelting smelting. This is mainly due to the fact that the electroslag furnace remelting smelting process will cause the There is a certain attenuation of carbon, silicon and aluminum content.
  • the temperature of molten steel at the end of vacuum induction furnace smelting is controlled at 1460 ⁇ 1500°C, mainly considering that the pouring superheat is between 20 ⁇ 60°C. This range of temperature can be used to cast qualified electrode rods for electroslag smelting.
  • the end temperature can be controlled close to the lower limit, that is, close to 1460°C; if two ingots are poured, the end temperature control is close to the upper limit, that is, close to 1500°C, otherwise the second ingot may not be completed.
  • Vacuum protection pouring is to prevent nitrogen absorption and secondary oxidation during the pouring process.
  • step 1) when the iron raw materials (iron raw materials include pure iron and low-phosphorus pig iron) are completely melted, 2 to 5 kg of lime is added to each ton of iron raw materials for slagging Dephosphorization and desulfurization.
  • slagging is lime
  • vacuum induction furnace smelting should not add too much slagging material (in this technical solution, slagging is lime), otherwise it will cause problems such as difficulty in melting the slagging material and affect degassing.
  • the raw materials since the raw materials inevitably contain sulfur and phosphorus, in order to ensure that the desulfurization and dephosphorization are in place, a small amount of lime can be added to meet the product's requirements for sulfur and phosphorus.
  • step 3 the electroslag process needs to be carried out under a protective atmosphere, which includes but is not limited to argon; the electroslag furnace remelting smelting adopts constant melting rate remelting smelting.
  • the electroslag furnace remelting smelting in a protective atmosphere is mainly to prevent oxidation. If the secondary oxidation is serious, it will easily cause the silicon and carbon in the molten steel to attenuate seriously due to oxidation; at the same time, the secondary oxidation of the molten steel will form more silica Inclusions are unfavorable to the control of inclusions in molten steel.
  • the present invention develops a brand-new process path, namely, through the steps of vacuum induction furnace smelting-electroslag-forging-wire rolling to produce steel wire rod for the emery line.
  • the adoption of this process path is mainly based on the demand for steel for the emery line Considering the characteristics of low volume and high requirements, it is convenient to organize the production of steel for emery lines on a small scale, and solves the problem of excess steel caused by the weight of each furnace when the steel is produced by a large-scale converter process or an electric furnace process. Problems that cannot be dealt with.
  • This method completely removes large-particle inclusions and brittle inclusions through the electroslag process, and can control the composition of the inclusions within the required range of plasticization of the inclusions, thereby achieving harmlessness of all the inclusions in the steel without causing emery wire Pull the broken wire.
  • This process can choose night production, which can make full use of the power grid capacity during low peak periods.
  • the final inclusion width in the wire rod is less than 7 ⁇ m, which ensures that the wire rod does not break due to inclusions during each process of drawing the emery wire.
  • the present invention provides a process method for smelting ultra-fine emery line steel.
  • a new steelmaking process path design high-end ultra-fine emery line steel is produced, which can realize the flexible and stable production of emery line steel.
  • the problem of wire breakage caused by poor control of inclusions in the subsequent diamond wire drawing process is fundamentally solved.
  • a vacuum induction furnace is used to smelt the molten steel of ultra-fine emery wire steel using pure iron without carbon and low-phosphorus pig iron with 3.5%-4.5% carbon and less than 0.06% phosphorus as raw materials, and then cast into a circle Shaped ingot
  • Electroslag steel ingots are produced by electroslag furnace remelting and smelting using electrode rods.
  • the composition of electroslag mold slag includes: CaF 2 : 45-55%, Al 2 O 3 : 15-25%, SiO 2 : 20 to 25%, Na 2 O: 2 to 4%, K 2 O: 1 to 2%;
  • the wire rod is rolled into a wire rod with a diameter of 4.5 ⁇ 5.5mm through the wire rod rolling process.
  • the chemical element composition in the wire rod includes by mass percentage, [C]: 0.92 ⁇ 1.1%, [Si]: 0.3 ⁇ 0.4% , [Mn]: 0.5 ⁇ 0.8%, [Al] ⁇ 0.0008%, [N] ⁇ 0.005%, [S] ⁇ 0.01%, [P] ⁇ 0.015%, the balance is iron and unavoidable impurities.
  • the wire rod can be drawn into a diamond wire with a diameter of 0.04-0.055mm, and the drawing process will not cause wire breakage due to poor control of inclusions.
  • the vacuum induction furnace has a vacuum casting function. It uses 1.5 tons of carbon-free pure iron rods and 0.5 tons of pig iron with 4% carbon (the phosphorus content of this pig iron is less than 0.06%)
  • the raw material is melted into 2 tons of liquid steel under the protection of argon. After the molten steel is completely melted, add 10kg of lime and apply a vacuum to start vacuum smelting.
  • the conditions of vacuum smelting are degassing for 15 minutes under a high vacuum condition of less than 300 Pa.
  • Blow argon gas into the vacuum induction furnace adjust the pressure in the furnace to 10000Pa or slightly higher, and adjust the temperature of molten steel to 1465°C, and cast into a round ingot under vacuum conditions.
  • the weight of a single ingot is 2 tons.
  • the diameter of the ingot is 0.35m and the length is 2.8m.
  • the electrode rod is used as a raw material to perform constant melting rate remelting smelting in an electroslag furnace under an argon protective atmosphere.
  • the electroslag mold slag contains CaF 2 : 45%, Al 2 O 3 : 25%, and SiO 2 in terms of mass percentage. : 25%, Na 2 O: 3%, K 2 O: 2%; the electrode rod is smelted into a cylindrical electroslag ingot through an electroslag furnace, the electroslag ingot has a diameter of 0.45m and a length of 1.6m.
  • the forging billet is a square billet.
  • the cross section of the square billet is square, the side length of the square section is 0.140m, and the length of the forging billet is 12.5m.
  • the forging billet is rolled into a wire rod with a diameter of 4.5 mm through a wire rolling process.
  • the chemical elements in the wire rod include [C]: 1.02%, [Si]: 0.35%, [Mn]: 0.6%, [Al]: 0.0005%, [N]: 0.0048%, [S]: 0.008%, [P]: 0.014%, the balance is iron and unavoidable impurities.
  • the inclusions in the wire rod are detected as CaF 2 -CaO-SiO 2 -Al 2 O 3 -Na 2 OK 2 O composite inclusions and SiO 2 -Al 2 O 3 -MnO-CaO-MgO-Na 2 OK 2 O composite inclusions Inclusions (the content of SiO 2 in the two types of inclusions is greater than 50%). Both of these two series of inclusions have good plasticity, and the width of the inclusions are all less than 6 ⁇ m. They are harmless inclusions and will not cause wire rod drawing. Broken wire phenomenon in the process.
  • the wire rod produced in this embodiment can finally be drawn into a diamond wire bus bar with a diameter of 0.05 mm, and the drawing process is continuous.
  • the diamond yarn can be used for high-efficiency cutting of silicon wafers, gems, and the like.
  • the vacuum induction furnace has a vacuum casting function. It uses 3.75 tons of carbon-free pure iron rods and 1.25 tons of pig iron with a carbon content of 3.9% as raw materials (the phosphorus content of the pig iron is less than 0.06 %), melted into 5 tons of liquid molten steel under the protection of argon. After the molten steel is completely melted, 20kg of lime is added, and vacuum is applied to start vacuum smelting. The conditions of vacuum smelting are degassing under high vacuum conditions of less than 300 Pa for 20 minutes. In the vacuum melting process, add 20kg of high-purity ferrosilicon (75% silicon) and 45kg of pure manganese alloy.
  • the content of each chemical element in the molten steel includes [C]: 0.96%, [Si ]: 0.45%, [Mn]: 0.75%, [Al]: 0.0009%, [N]: 0.0038%, [S]: 0.0095%, [P]: 0.013%, the balance being iron and unavoidable impurities.
  • Blow argon gas into the vacuum induction furnace adjust the pressure in the furnace to 12000Pa or slightly higher, and adjust the temperature of molten steel to 1485°C, and cast into 2 round ingots under vacuum conditions, each with a mass of 2.5 tons.
  • the diameter of the ingot is 0.4m and the length is 2.6m.
  • electroslag furnace constant melting rate remelting smelting is carried out under argon protective atmosphere.
  • the electroslag mold powder includes CaF 2 : 51%, Al 2 O 3 , 22%, SiO 2 in terms of mass percentage. : 23%, Na 2 O: 3%, K 2 O: 1%; the electrode rod is smelted through an electroslag furnace to produce a cylindrical electroslag ingot, the diameter of the electroslag ingot is 0.5m, and the length is 1.5m.
  • Electroslag ingot forging produces a forging billet that can be used for rolling wire rod.
  • the forging billet is a square billet.
  • the cross section of the square billet is square, the side length of the square section is 0.16m, and the length of the forging billet is 12m.
  • the forging billet is rolled into a wire rod with a diameter of 5mm through a wire rod rolling process.
  • the chemical elements in the wire rod contain [C]: 0.93%, [Si]: 0.4%, and [Mn]: 0.5 in terms of mass percentage. %, [Al]: 0.0006%, [N]: 0.0040%, [S]: 0.0095%, [P]: 0.013%, the balance is iron and unavoidable impurities.
  • the inclusions in the wire rod are detected as CaF 2 -CaO-SiO 2 -Al 2 O 3 -Na 2 OK 2 O composite inclusions and SiO 2 -Al 2 O 3 -MnO-CaO-MgO-Na 2 OK 2 O composite inclusions Inclusions (the SiO 2 content in the above two composite inclusions is greater than 60%), these two series of inclusions have good plasticity, and the width of the inclusions are all less than 7 ⁇ m. They are harmless inclusions and will not cause the wire rod drawing process. Broken wire phenomenon.
  • the wire rod produced in this embodiment can finally be drawn into a diamond wire bus bar with a diameter of 0.055 mm, and the drawing process is continuous.
  • the diamond yarn can be used for high-efficiency cutting of silicon wafers, gems, and the like.
  • the vacuum induction furnace has a vacuum pouring function.
  • the vacuum induction furnace uses 3 tons of carbon-free pure iron rods and 1 ton of carbon-containing 4.2% pig iron (the phosphorus content of the pig iron is less than 0.06 %) is the raw material melted into 4 tons of liquid molten steel under the protection of argon. After the molten steel is completely melted, 15kg of lime is added, and vacuum is applied to start vacuum smelting.
  • the conditions of vacuum smelting are degassing under a high vacuum of less than 250Pa for 18 minutes.
  • Blow argon gas into the vacuum induction furnace adjust the pressure in the furnace to 15000Pa or slightly higher, and adjust the temperature of molten steel to 1495°C, and cast into 2 round ingots under vacuum conditions, each of which has a mass of 2 tons.
  • the diameter of the ingot is 0.38m, and the length is 2.4m;
  • the electrode rod is used as the raw material, and the electroslag furnace constant melting rate remelting smelting is carried out under the protective atmosphere of argon.
  • the electroslag mold slag includes CaF 2 : 55%, Al 2 O 3 : 15%, and SiO 2 in terms of mass percentage. :24%, Na 2 O: 4%, K 2 O: 2%, electroslag smelting to produce cylindrical electroslag ingots, the diameter of electroslag ingots is 0.45m, and the length is 1.5m;
  • the forging billet is a square billet.
  • the cross section of the square billet is a square, the square side length is 0.15m, and the forging billet length is 10.3m.
  • the forging billet is rolled into a wire rod with a diameter of 5.5mm through a wire rod rolling process.
  • the chemical elements in the wire rod include [C]: 1.05%, [Si]: 0.3%, [Mn]: 0.5%, [Al]: 0.0005%, [N]: 0.0038%, [S]: 0.0099%, [P]: 0.012%, the balance is iron and unavoidable impurities.
  • the inclusions in the wire rod are detected as CaF 2 -CaO-SiO 2 -Al 2 O 3 -Na 2 OK 2 O composite inclusions and SiO 2 -Al 2 O 3 -MnO-CaO-MgO-Na 2 OK 2 O composite inclusions Inclusions (the SiO 2 content in the above two composite inclusions is greater than 50%), these two series of inclusions both have good plasticity, and the width of the inclusions are all less than 5 ⁇ m, which are harmless inclusions and will not cause the wire rod drawing process The broken wire phenomenon.
  • the wire rod produced in this embodiment can finally be drawn into a diamond wire bus bar with a diameter of 0.04 mm.
  • the drawing process realizes continuous filamentation.
  • the diamond yarn can be used for high-efficiency cutting of silicon wafers, gems, and the like.

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Abstract

一种冶炼极细金刚砂线用钢的工艺方法，包括：1)在真空感应炉中，以纯铁和低磷生铁为原料在氩气保护下熔成钢水；抽真空熔炼，在300Pa下脱气15-20min；用高纯硅铁做脱氧剂，调整钢水成分；在真空下浇铸为圆形铸锭；2)对圆形铸锭表面清理以制作可供电渣冶炼用电极棒；3)以电极棒作原料，进行电渣炉重熔冶炼，电渣保护渣包括：CaF 2：45～55％，Al 2O 3：15～25％，SiO 2：20～25％，Na 2O：2～4％，K 2O：1～2％；将电极棒通过电渣炉冶炼为圆柱形电渣锭，电渣锭直径为0.4～0.5m；4)将电渣锭锻造成可供轧制线材的方形坯；5)将锻造坯轧制为直径4.5～5.5mm的盘条，盘条包括[C]：0.92～1.1％，[Si]：0.3～0.4％，[Mn]：0.5～0.8％，[Al]<0.0008％，[N]<0.005％，[S]<0.01％，[P]<0.015％。

Description

一种冶炼极细金刚砂线用钢的工艺方法 技术领域
本发明涉及一种冶炼极细金刚砂线用钢的工艺方法，属于炼钢技术领域。
背景技术
金刚砂线主要用于切割硅片、宝石等。其中，硅片是光伏和电子行业的主体原料。为了提高切割效率，金刚砂线要求极细规格，极细金刚纱线的直径通常为0.04～0.055mm，比人类头发丝还细。极细规格对用钢的夹杂物的控制提出了苛刻的要求，钢包含的所有夹杂物的宽度应全部小于10μm，且不能包含脆性的铝质夹杂。
现有技术中，一些日本的企业通过转炉-精炼炉-连铸-初轧-线材轧制的流程进行生产，冶炼过程中对于夹杂物的控制主要通过严格控制耐材铝含量以及夹杂物变性处理等措施来实现夹杂物细化以使线材具有变形能力。即使如此，此流程生产的盘条在拉拔金刚砂线的过程中仍存在断丝现象，而导致断丝的主要原因是大颗粒硅铝质夹杂物。断丝对拉拔生产影响很大，断丝后接丝时间会超过2小时。
那些不具备在转炉流程和电炉流程生产金刚砂线用钢能力的企业，面临的主要问题是无法控制完全不含脆性氧化铝夹杂物和高含量的氧化镁夹杂物。若通过改进耐材来控制此类夹杂物，则整个流程的生产成本将会大大提升。
然而，金刚砂线需求量小，其利润无法抵充整个流程耐材成本的增加，因此利用转炉流程或电炉流程生产金刚砂线无法取得经济效益。为了确保金刚纱线有足够的破断力、能够高效率切割硅片，因而对钢中的碳含量有着较高要求。通常要求碳的质量百分比至少为0.92％以上，最好超过1％；另外，要求氮含量要小于50ppm，这样的成分并不能用到其他钢种。在采用转炉流程或电炉流程大规模生产金刚砂用钢的过程中，一旦夹杂物控制不合格，则整炉钢面临报废风险，同时也无法在连铸过程中连续生产。从市场需求看，金刚砂线因其持久耐用，在生产中的消耗并不是很大：中国市场需求量维持在2000～10000吨， 金刚砂线生产商向钢铁生产商订货每次也不高于30吨。这样的情况下，用100吨以上的电炉流程或转炉流程生产就会出现无法组织生产的问题。
发明内容
为克服现有技术的上述不足，本发明提供一种可满足小规模、高要求的冶炼极细金刚砂线用钢的工艺方法。该方法能够控制夹杂物，以产生在拉拔金刚砂线过程中不发生断丝的极细金刚砂线。
其所要解决的技术问题可以通过以下技术方案来实施。
一种冶炼极细金刚砂线用钢的工艺方法，其生产过程可概括为真空感应炉冶炼-电渣-锻造-线材轧制，其主要步骤如下：
1)采用2～5吨规模的真空感应炉，用不含碳的纯铁和含碳质量百分比为3.5％～4.5％、含磷质量百分比小于0.06％的低磷生铁为原料，在氩气保护条件下熔化成液态钢水2～5吨；随后抽真空以进行真空熔炼，在低于300Pa的高真空条件下脱气15min～20min，以高纯硅铁作为脱氧剂进行脱氧，以调整钢水成分；脱氧过程严禁加含铝脱氧剂。调整完钢水成分后，在真空条件下浇铸为圆形铸锭1～2支，每根铸锭质量1.5～2.5吨，铸锭直径0.35～0.4m，长度2～3m。
本工艺选用真空感应炉作为初冶炼炉，利用了真空感应炉能够小规模冶炼以及具备真空脱气功能的特点，以满足本发明涉及钢种的脱氮要求；另外，真空感应炉还能实现真空保护浇注，可避免在大气中浇注引发的二次氧化和钢水吸氮。考虑到浇注锭的重量为1.5～2.5吨，在需要浇注1-2支锭时，需要选择2～5吨规模的真空感应炉生产；如果选择更大规模的感应炉，则需要浇注3支或以上铸锭，这样很难实现真空浇注。选用纯铁和生铁为原料主要是考虑本钢种碳含量的配置，生铁约含4％左右的碳(质量百分比)，可以实现最终钢水约1％(质量百分比)的碳含量要求；另外，纯铁和生铁的有害残余元素含量均较低，可确保钢的有害残余元素不超标。高真空条件下脱气15min～20min，主要是为了确保脱氮达到钢种要求，同时也能脱氢以确保无氢致裂纹产生。在真空熔炼过程中可调整钢水成分，加入高纯锰和高纯硅铁满足产品最终成分要求，其中高纯硅铁是指：硅的质量百分比为75～85％、铝的质量百分比小于0.05％的铁质材料。用高纯硅铁做脱氧剂，主要是因为普通硅铁含铝量偏高，容易导致最终铝含量超标。严禁加含铝脱氧剂是因为极细金刚砂线用钢所含的 高氧化铝含量夹杂物为脆性夹杂物，对金刚砂线拉拔破坏性大。最终铸锭尺寸的选择主要是基于后工序所涉及的电渣电极棒尺寸要求设定的。
2)对圆形铸锭表面进行，切除收缩端5～10cm，制作为可供电渣冶炼用的电极棒。本申请所说的“收缩端”是指铸锭最后凝固的端部。
3)采用电极棒为原料，进行电渣炉重熔冶炼，电渣保护渣按质量百分比计包括：CaF 2：45～55％，Al 2O 3：15～25％，SiO 2：20～25％，Na 2O：2～4％,K 2O：1～2％,并将所述电极棒通过电渣炉冶炼为圆柱形电渣锭，电渣锭的直径为0.4～0.5m。
电渣炉重熔冶炼是将电极棒、炉渣、以及结晶器中的钢水连成一个通电回路，在低压(电压40～60V)高电流(电流10～20KA)的条件下，利用电渣保护渣局部发热，使得电极棒顶端与电渣保护渣接触的部分逐步熔化成液滴，大量与电极棒分离的液滴穿越电渣保护渣的渣层下落到结晶器的钢水熔池中，并且钢水熔池接触结晶器的部分再次凝固。电渣炉重熔冶炼通过电渣保护渣对钢水过滤，可彻底去除大型夹杂物，剩余夹杂物全部小于13μm；同时，经过电渣炉重熔冶炼得到的电渣锭组织均匀致密。电渣炉重熔冶炼过后，钢中剩余的夹杂物与电渣炉中的电渣保护渣成分更为接近，所以本技术方案通过将电渣保护渣成分控制在：CaF 2：45～55％，Al 2O 3：15～25％，SiO 2：20～25％，Na 2O：2～4％,K 2O：1～2％(以电渣保护渣的总质量为100％计)，以控制钢水中剩余的小颗粒夹杂物的成分也在这个范围内。其中，电渣保护渣中部分CaF 2转变为CaO，此范围内夹杂物具有熔点低、塑性化能力强的特点，在后序锻造和轧制过程中，可充分沿着锻造或轧制方向变形，变形后夹杂物宽度可全部小于7μm；且夹杂物与钢的接触面相对圆滑，在拉拔过程中对钢的破坏小，不会导致拉拔断丝，也保证了金刚砂线在切割硅片的过程中不断丝。电渣锭尺寸的选择主要是考虑电渣结晶器设计方便以及后序方便锻造。
4)将电渣锭锻造成可供轧制线材的锻造坯，锻造坯为方形坯，所述方形坯的断面为正方形，正方形断面的边长为0.140～0.160m，锻造坯长度大于6m，且小于14m。
5)将锻造坯通过线材轧制工艺轧制为直径规格4.5～5.5mm的盘条。盘条成分按质量百分比包括[C]：0.92～1.1％，[Si]：0.3～0.4％，[Mn]：0.5～0.8％，[Al]<0.0008％，[N]<0.005％，[S]<0.01％，[P]<0.015％，余量为铁及不可避免 的杂质。
本发明所生产的盘条最终可以拉拔成直径为0.04～0.055mm的极细规格的金刚砂线母线，其拉拔过程不断丝，可用于高效率切割硅片、宝石等。
作为本技术方案的进一步改进，在步骤1)中，进一步要求真空感应炉冶炼结束时，钢水中各元素成分按质量百分比计包括[C]：0.94～1.1％，[Si]：0.35～0.45％，[Mn]：0.6～0.8％，[Al]<0.001％，[N]<0.0045％，[S]<0.01％，[P]<0.015％，余量为铁及不可避免的杂质。其中，考虑到电渣过程中硅会进一步衰减，所以真空感应炉冶炼结束时的硅含量要高一些；并且，由于电渣过程中铝会进一步衰减，如果在该阶段就要求[Al]＜0.0008％会很难实现，故设定[Al]<0.001％。
将真空感应炉冶炼结束时的钢水温度控制为1460～1500℃；且真空感应炉冶炼结束后适当吹氩保护，使炉内压力调至10000Pa～20000Pa，然后在保护气氛下浇注。保护气氛例如但不限于氩气，铸模采用铸铁模。
真空感应炉冶炼结束时，钢水中的碳、硅、铝含量要略高于它们在电渣炉重熔冶炼后在钢中的含量，这主要是考虑电渣炉重熔冶炼过程会使钢水中的碳、硅和铝含量有一定的衰减。真空感应炉冶炼结束时的钢水温度控制为1460～1500℃，主要是考虑浇注过热度在20～60℃之间，此范围温度可铸造出合格的用于电渣冶炼用的电极棒。在实际生产中，如仅浇注一个铸锭，终点温度可控制在靠近下限，即靠近1460℃；如果浇注2个锭，终点温度控制靠近上限，即靠近1500℃，否则可能无法完成第二个锭的浇注。真空保护浇注是为了防止浇注过程吸氮和二次氧化。
作为本技术方案的进一步改进，在步骤1)中，当铁质原料(铁质原料包括纯铁和低磷生铁)完全熔化后，向每吨铁质原料中加入石灰2～5kg以进行造渣脱磷脱硫。其中，真空感应炉冶炼不宜加太多造渣料(该技术方案中，造渣即是石灰)，否则会引起造渣料难以溶化而影响脱气等问题。但由于原料中不可避免含有硫和磷，为了确保脱硫和脱磷到位，可加入少量石灰来满足产品对硫和磷的要求。
作为本技术方案的进一步改进，在步骤3)中，电渣过程需要在保护气氛下进行，该保护气氛包括但不限于氩气；所述电渣炉重熔冶炼采用恒熔速重熔冶炼。
在保护气氛下进行电渣炉重熔冶炼主要是为了防止氧化，如果二次氧化严重，则容易导致钢水中的硅、碳因氧化衰减严重；同时，钢水二次氧化会形成更多二氧化硅夹杂物，对钢水夹杂物控制不利。
本发明开发了一种全新的工艺路径，即通过真空感应炉冶炼-电渣-锻造-线材轧制的步骤来生产金刚砂线用钢盘条，采用这样的工艺路径主要是基于金刚砂线用钢需求量低且要求高的特点考虑，可方便小规模组织生产金刚砂线用钢，解决了大型转炉流程或电炉流程生产此类钢种时，由于每炉钢重量远大于订货量而带来的余钢无法处置的问题。本方法通过电渣工艺将大颗粒夹杂物和脆性夹杂物完全去除，并能将夹杂物成分控制在夹杂物塑性化要求范围内，从而实现钢中全部夹杂物无害化，不会造成金刚砂线拉拔断丝。本工艺可选择夜间生产，这样能够充分利用低峰时段电网容量。
上述技术方案提供的工艺方法具有如下有益效果：
可实现小规模灵活稳定地生产极细金刚砂线用钢，最终得到的盘条内夹杂宽度全部小于7μm，确保了盘条在拉拔金刚砂线的各道工序中不因夹杂物而断丝。
具体实施方式
本发明提供了一种冶炼极细金刚砂线用钢的工艺方法，通过一种新的炼钢工艺路径设计，生产高端极细金刚砂线用钢，可实现金刚砂线用钢的灵活稳定生产，并从根本上解决了后续金刚砂线拉拔过程中因夹杂物控制不良而导致断丝的问题。
该工艺主要步骤如下；
1)采用真空感应炉，以不含碳的纯铁和含碳3.5％-4.5％、含磷小于0.06％的低磷生铁为原料冶炼极细金刚砂线用钢的钢水母液，随后浇铸为圆形铸锭；
2)将圆形铸锭制作为可供电渣冶炼用的电极棒；
3)采用电极棒为原料，通过电渣炉重熔冶炼制作电渣钢锭，电渣保护渣成分按质量百分比计包括：CaF 2:45～55％，Al 2O 3:15～25％，SiO 2:20～25％，Na 2O:2～4％，K 2O:1～2％；
4)锻造；
5)通过线材轧制工艺轧制为直径为4.5～5.5mm的盘条，盘条中的化学元 素成分按质量百分比计包括，[C]：0.92～1.1％，[Si]：0.3～0.4％，[Mn]：0.5～0.8％，[Al]<0.0008％，[N]<0.005％，[S]<0.01％，[P]<0.015％，余量为铁及不可避免的杂质。
盘条可拉拔成直径为0.04～0.055mm规格的金刚砂线，拉拔过程不会因夹杂物控制不良而导致断丝。
实施例1：
选用本申请提供的真空感应炉冶炼-电渣-锻造-线材轧制的工艺生产金刚砂线用钢，其主要工艺步骤如下：
1)选用2吨容量的真空感应炉冶炼，该真空感应炉具备真空浇注功能，以不含碳的纯铁棒1.5吨和含碳4％的生铁0.5吨(该生铁的磷含量小于0.06％)为原料在氩气保护条件下熔化成液态钢水2吨。待钢水完全熔化后，加入石灰10kg，并抽真空以开始真空熔炼，真空熔炼的条件为在低于300Pa高真空条件下脱气15min。在真空熔炼的过程中加高纯硅铁(含硅75％)8kg和纯锰合金18kg调整钢水成分，按质量百分比计，该步骤冶炼终点的各化学元素含量为[C]：1.05％，[Si]：0.41％，[Mn]：0.7％，[Al]：0.00079％，[N]：0.0040％，[S]：0.008％，[P]:0.014％，余量为铁及不可避免的杂质。向真空感应炉内吹入氩气，将炉内压力调整到10000Pa或略高，并调整钢水温度到1465℃，真空条件下浇铸为圆形铸锭1支，单根铸锭质量2吨，铸锭直径0.35m，长度2.8m。
2)对圆形铸锭表面打磨清理，切除带收缩端的大头5cm，制作为可供电渣冶炼用电极棒。
3)电极棒作为原料，在氩气保护气氛下进行电渣炉恒熔速重熔冶炼，电渣保护渣按质量百分比计，含有CaF 2：45％，Al 2O 3：25％，SiO 2：25％，Na 2O：3％，K 2O：2％；将电极棒通过电渣炉冶炼为圆柱形电渣锭，电渣锭直径0.45m，长1.6m。
4)将电渣锭锻造成可供轧制线材的锻造坯，锻造坯为方形坯，方形坯的断面为正方形，正方形断面的边长为0.140m，锻造坯长度12.5m。
5)将锻造坯通过线材轧制工艺轧制为直径为4.5mm的盘条。盘条中各化学元素按质量百分比计包括[C]：1.02％，[Si]：0.35％，[Mn]：0.6％，[Al]：0.0005％，[N]：0.0048％，[S]：0.008％，[P]：0.014％，余量为铁及不可避免的杂质。盘 条夹杂物经过检测为CaF 2-CaO-SiO 2-Al 2O 3-Na 2O-K 2O复合夹杂物，以及SiO 2-Al 2O 3-MnO-CaO-MgO-Na 2O-K 2O复合夹杂物(两种符合夹杂物中SiO 2含量均大于50％)，这两个系列的夹杂物均具有良好塑性，且夹杂物宽度全部小于6μm，为无害夹杂，不会引起盘条拉拔工序的断丝现象。
本实施例中所生产的盘条最终可以拉拔成直径为0.05mm规格的金刚砂线母线，拉拔过程不断丝，该金刚纱线能够用于高效率切割硅片、宝石等。
实施例2：
选用本申请提供的真空感应炉冶炼-电渣-锻造-线材轧制的工艺生产金刚砂线用钢，其主要工艺步骤如下：
1)选用5吨容量的真空感应炉冶炼，该真空感应炉具备真空浇注功能，以不含碳的纯铁棒3.75吨和含碳3.9％的生铁1.25吨为原料(该生铁的磷含量小于0.06％)，在氩气保护条件下熔化成液态钢水5吨。待钢水完全熔化后，加入石灰20kg，抽真空以开始真空熔炼，真空熔炼的条件为在低于300Pa的高真空条件下脱气20min。在真空熔炼过程中加入高纯硅铁(含硅75％)20kg和纯锰合金45kg，该步骤钢水冶炼结束时，钢水中各化学元素含量按质量百分比计包括[C]：0.96％,[Si]：0.45％，[Mn]：0.75％，[Al]：0.0009％，[N]：0.0038％，[S]：0.0095％，[P]：0.013％，余量为铁及不可避免的杂质。向真空感应炉内吹入氩气，将炉内压力调整到12000Pa或略高，并调整钢水温度到1485℃，真空条件下浇铸为圆形铸锭2支，每支铸锭质量2.5吨，铸锭直径0.4m，长度2.6m。
2)将圆形铸锭表面打磨清理，切除带收缩端的大头6cm，制作为可供电渣冶炼用的电极棒。
3)以电极棒作为原料，在氩气保护气氛下进行电渣炉恒熔速重熔冶炼，电渣保护渣按质量百分比计包括CaF 2：51％，Al 2O 3；22％，SiO 2：23％，Na 2O：3％,K 2O：1％；将电极棒通过电渣炉冶炼制作为圆柱形电渣锭，电渣锭直径0.5m，长1.5m。
4)电渣锭锻造成可供轧制线材的锻造坯，锻造坯为方形坯，方形坯的断面为正方形，正方形断面的边长为0.16m，锻造坯长度为12m。
5)将锻造坯通过线材轧制工艺轧制为直径为5mm的盘条，盘条中各化学 元素按质量百分比计含有[C]：0.93％，[Si]：0.4％，[Mn]：0.5％，[Al]：0.0006％，[N]：0.0040％，[S]：0.0095％，[P]：0.013％，余量为铁及不可避免的杂质。盘条夹杂物经过检测为CaF 2-CaO-SiO 2-Al 2O 3-Na 2O-K 2O复合夹杂物，以及SiO 2-Al 2O 3-MnO-CaO-MgO-Na 2O-K 2O复合夹杂(上述两种复合夹杂物中的SiO 2含量均大于60％)，这两个系列夹杂均具有良好塑性，夹杂物宽度全部小于7μm，为无害夹杂，不会引起盘条拉拔工序的断丝现象。
本实施例所生产的盘条最终可以拉拔成直径为0.055mm规格的金刚砂线母线，拉拔过程不断丝，该金刚纱线能够用于高效率切割硅片、宝石等。
实施例3：
选用本申请提供的真空感应炉冶炼-电渣-锻造-线材轧制的工艺生产金刚砂线用钢，其主要工艺步骤如下：
1)选用4吨容量的真空感应炉冶炼，该真空感应炉具备真空浇注功能，真空感应炉用不含碳的纯铁棒3吨和含碳4.2％生铁1吨(该生铁的磷含量小于0.06％)为原料在氩气保护条件下熔化成液态钢水4吨。待钢水完全熔化后，加入石灰15kg，抽真空以开始真空熔炼，真空熔炼的条件为在低于250Pa高真空条件下脱气18min。在真空熔炼过程中加高纯硅铁(含硅75％)15kg和纯锰合金33kg作为脱氧剂进行脱氧。该步骤冶炼终点的化学各元素按重量百分比计包括[C]：1.1％，[Si]：0.35％，[Mn]：0.6％，[Al]：0.0007％，[N]：0.0034％，[S]：0.0099％，[P]：0.012％，余量为铁及不可避免的杂质。向真空感应炉内吹入氩气，将炉内压力调整到15000Pa或略高，并调整钢水温度到1495℃，真空条件下浇铸为圆形铸锭2支，每根感应炉铸锭质量2吨，铸锭直径为0.38m，长度为2.4m；
2)对圆形铸锭表面打磨清理，切除带收缩端的大头8cm，制作为可供电渣冶炼用的电极棒；
3)以电极棒作为原料，在氩气保护气氛下进行电渣炉恒熔速重熔冶炼，电渣保护渣按质量百分比计包括CaF 2：55％，Al 2O 3：15％，SiO 2：24％，Na 2O：4％,K 2O：2％,电渣冶炼制作圆柱形电渣锭，电渣锭直径0.45m，长1.5m；
4)将电渣锭锻造成可供轧制线材的锻造坯，锻造坯为方形坯，方形坯的断面为正方形，正方形边长0.15m，锻造坯长度10.3m。
5)将锻造坯通过线材轧制工艺轧制为直径为5.5mm的盘条，盘条中各化学元素按质量百分比计包括[C]：1.05％，[Si]：0.3％，[Mn]：0.5％，[Al]：0.0005％，[N]：0.0038％，[S]：0.0099％，[P]：0.012％，余量为铁及不可避免的杂质。盘条夹杂物经过检测为CaF 2-CaO-SiO 2-Al 2O 3-Na 2O-K 2O复合夹杂物，以及SiO 2-Al 2O 3-MnO-CaO-MgO-Na 2O-K 2O复合夹杂物(上述两种复合夹杂物中的SiO 2含量均大于50％)，这两个系列夹杂均具有良好塑性，夹杂物宽度全部小于5μm，为无害夹杂，不会引起盘条拉拔工序的断丝现象。
本实施例所生产的盘条最终可以拉拔成直径为0.04mm规格的金刚砂线母线，拉拔过程实现不断丝，该金刚纱线可用于高效率切割硅片、宝石等。

Claims (7)

  1. 一种冶炼极细金刚砂线用钢的工艺方法，其特征在于，包括如下步骤：
    1)在真空感应炉中，以不含碳的纯铁和含碳质量百分比为3.5％～4.5％的低磷生铁为原料，在氩气保护条件下熔化成液态钢水；随后抽真空以开始真空熔炼，所述真空熔炼在低于300Pa的条件下脱气15min～20min，以高纯硅铁作为脱氧剂进行脱氧，以调整钢水成分；调整钢水成分结束后，在真空条件下浇铸为圆形铸锭，每根铸锭质量为1.5～2.5吨，铸锭直径为0.35～0.4m，长度为2～3m；
    2)对圆形铸锭表面进行清理，制作可供电渣冶炼用的电极棒；
    3)以电极棒为原料，进行电渣炉重熔冶炼，电渣保护渣按质量百分比计包括：
    CaF 2：45～55％，Al 2O 3：15～25％，SiO 2：20～25％，Na 2O：2～4％,K 2O：1～2％；
    将所述电极棒通过电渣炉冶炼为圆柱形电渣锭，所述电渣锭的直径为0.4～0.5m；
    4)将所述电渣锭锻造成可供轧制线材的锻造坯，所述锻造坯为方形坯，所述方形坯的断面为正方形，所述断面的边长为0.140～0.160m，锻造坯长度大于6m；
    5)将所述锻造坯通过线材轧制工艺轧制为直径为4.5～5.5mm的盘条，所述盘条中各化学元素含量按重量百分比计包括[C]：0.92～1.1％，[Si]：0.3～0.4％，[Mn]：0.5～0.8％，[Al]<0.0008％，[N]<0.005％，[S]<0.01％，[P]<0.015％。
  2. 根据权利要求1所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，所述真空感应炉的规模为2～5吨。
  3. 根据权利要求1所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，在所述步骤2)中，对圆形铸锭的表面进行清理后，切除收缩端5～10cm。
  4. 根据权利要求1所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，在所述步骤1)中，采用所述真空感应炉冶炼的步骤中，冶炼结束时，钢水中各元素成分按质量百分比计包括[C]：0.94～1.1％，[Si]：0.35～0.45％，[Mn]：0.6～0.8％，[Al]<0.001％，[N]<0.0045％，[S]<0.01％，[P]<0.015％，余量为铁及 不可避免的杂质，钢水的温度控制在1460～1500℃；在冶炼结束后，吹入氩气作为保护气氛，并将所述真空感应炉的炉内压力调至10000Pa～20000Pa，然后在保护气氛下浇注。
  5. 根据权利要求1或4所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，在所述步骤1)中，用于浇注所述铸锭的铸模为铸铁模。
  6. 根据权利要求1所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，在所述步骤1)中，当所述原料完全熔化后，向每吨原料中加入2～5kg的石灰以进行造渣脱磷脱硫的步骤。
  7. 根据权利要求1所述的冶炼极细金刚砂线用钢的工艺方法，其特征在于，所述步骤3)在保护气氛下进行，所述电渣炉重熔冶炼采用电渣炉恒熔速重熔冶炼。
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