Patent Description:
Bearings are almost the essential key basic parts of all the transmissions, the fatigue life of which determines the service life and reliability of the machine and equipment. At present, civilian bearing steels such as high-carbon chromium bearing steel with thorough hardenability (e.g., GCr15, GCr15SiMn, GCr15SiMo and GCr18Mo) and stainless bearing steel (e.g., 9Cr18Mo) as well as military bearing steel such as 8Cr4Mo4V are widely used at home and abroad. Domestic and foreign aerospace, mining machinery, transportation, marine ships and other high-end equipment fields all require long life and high reliability of bearings. However, the contact fatigue life of the bearing steel used for making bearings, especially high-carbon bearing steel with thorough hardenability is generally low, which cannot meet the requirements of long service life and high reliability for high-end equipment.

To improve the fatigue life of bearing steel, a lot of researches on improving the contact fatigue life of bearing steel have been carried out at home and abroad, which mainly employ the means of reducing the content of inclusions contained in the bearing steel, decreasing the size of inclusions in the bearing steel, and controlling the types and distribution of inclusions in the bearing steel. Under the guidance of this thought, by reducing the oxygen content in the bearing steel from <NUM>∼<NUM> ppm to the current <NUM>∼<NUM> ppm, the contact fatigue life of the commercialized bearing steel GCr15 at home and abroad is improved from L<NUM> ≥ <NUM><NUM> times for steel smelted in the atmosphere in <NUM> to L<NUM> ≥ <NUM><NUM> times for steel refined out of furnace in <NUM>. Further upon nearly <NUM> years of cross-century development, at present, the fatigue life of the high-carbon bearing steel GCr15 refined out of furnace has been kept at L<NUM> ≥ <NUM>~<NUM>×<NUM><NUM> times, and there has been no further progress, so the requirements of long life and high reliability for high-end equipment cannot be satisfied. Therefore, employing an out-of-furnace refining process to further reduce the oxygen content and decrease the size and content of inclusions not only greatly increases the cost and reduces the production efficiency, furthermore, the contact fatigue life cannot be enhanced greatly. Therefore, high-end bearings used in railway, shield, machine tools and the like require Electro-slag Remelting (ESR) GCr15 (L<NUM> ≥ <NUM>×<NUM><NUM> times) and double vacuum (Vacuum Induction Melting (VIM) + Vacuum Arc Remelting (VAR)) GCr15 (L<NUM> ≥ <NUM>× <NUM><NUM> times) which are expensive and have long contact fatigue life. However, with respect to the production and sales volume of more than <NUM> million tons of bearing steel, ESR bearing steel and VIM+VAR bearing steel cannot meet the production requirement, meanwhile the cost is greatly increased (<NUM> to <NUM> times higher than the cost of bearing steel refined out of furnace, respectively).

Research results at home and abroad show that, the contact fatigue life of bearing steel is not only affected by the inclusions, but also dependent on the thickness of the matrix of bearing steel, the size and distribution of carbides and the content of residual austenite in the steel. Studies have shown that the grain size of the bearing steel GCr15 and carbides can be refined by one time through integral double refinement and heat treatment, thereby enhancing the fatigue life of bearing steel by over <NUM> times. The content of austenite on the surface of bearing steel can be increased to <NUM>~<NUM> % by surface hardening heat treatment, thereby enhancing the contact fatigue life of bearing steel by <NUM>∼<NUM> times. The surface of bearing steel GCr15 is carburized to enhance the hardness of the bearing steel surface and control the carbides, thus enhancing the contact fatigue life of bearing steel by over <NUM> times. However, the above heat treatments not only increase the manufacturing difficulty of bearings and reduce the accuracy of bearings, but also greatly increase the manufacturing cost of bearings.

The <CIT> discloses a steel for bearing element parts having good machinability and rolling fatigue life. The steel contains <NUM> to <NUM> % of C, <NUM> to <NUM> % of Si, <NUM> to <NUM> % of Mn, <NUM> to <NUM> % of Cr, ≤ <NUM> % of Al, ≤ <NUM> % ofCu, ≤ <NUM> % of Ni, ≤ <NUM> % of Mo, ≤ <NUM> % of V, ≤ <NUM> % of Nb, ≤ <NUM> % of Ca and ≤ <NUM> % of Mg, and the balance is Fe with impurities. The relation among Si, Mn, Cr and Mo satisfies <NUM> ≤ <NUM> × % Si + <NUM> × % Mn + <NUM> × % Cr + <NUM> × % Mo ≤ <NUM>, and the concentration of Cr + Mn in cementite is ≥ <NUM> %.

The <CIT> discloses steel tubes for bearing element parts. The steel tube is specified on specific compositions and an accumulation intensity of {<NUM>} face with an impact property at ambient temperature in the longitudinal direction, and it has good machinability and fatigue life in rolling contact.

The <CIT> discloses a bearing steel achieving good rolling fatigue characteristics. A micro structure of the bearing steel is ferrite, an average equivalent circle diameter of carbides contained in the ferrite structure is <NUM> to <NUM>, and a standard deviation σ of the equivalent circle diameters of the carbides is <NUM> or less.

The <CIT> discloses a bearing steel for manufacturing a bearing member superior in workability and rolling fatigue characteristics when used in a high-temperature environment. The bearing steel comprises <NUM> to <NUM> % of C, <NUM> to <NUM> % of Si, <NUM> to <NUM> % of Mn, <NUM>,<NUM> to <NUM> % of Cr, <NUM> to <NUM> % of Mo and the balance of Fe with impurities. The C, Si and Mo satisfy the expression <NUM> ≤ [C] × ([Si] + [Mo]) ≤ <NUM>, and the carbides have a particle size controlled to <NUM> or smaller.

The <CIT> discloses a spheroidizing heat treated steel material for bearing with an improved rolling fatigue life. In the surface parallel to the rolling direction of the steel material, when an EPMA line analysis is carried out in the direction vertical to the rolling direction, the following relation is satisfied: (standard deviation σ of X-ray intensity values of Cr/average value a of X-ray intensity values of Cr) ≤ <NUM>; (standard deviation σ of spheroidized cementite particle diameters/average value of spheroidized cementite particle diameters) < <NUM>.

The <CIT> discloses bearing steel with good durability and life by incorporating an adequate ratio of C, Si, Mn and Cr into the steel, decreasing the contents of P, S, O and Ti as far as possible, and decreasing the contents of oxide and sulfide inclusions as far as possible.

The <CIT> discloses a bearing material having long rolling fatigue life. The bearing material has the following properties: when an area to be tested is <NUM>,<NUM>, the total number of oxide-based nonmetallic inclusions and sulfide-containing oxide-based nonmetallic inclusions with an average diameter of <NUM> or more is ≤ <NUM> pieces per <NUM>,<NUM>, and the total number of oxide-based nonmetallic inclusions and sulfide-containing oxide-based nonmetallic inclusions with an average diameter of <NUM> or more is ≥ <NUM> pieces per <NUM>,<NUM>.

The present invention is intended to provide a preparation method of a high-carbon bearing steel, in which no special heat treatment is required and microalloying elements are only utilized to enhance the anti-fatigue life of high-carbon bearing steel, thus meeting the extensive performance requirements of long life, high reliability and low cost for bearing steel used in high-end equipment.

The problem of the present invention is solved by a preparation method of a high-carbon bearing steel according to the independent claim <NUM>.

In the present invention, microalloying elements such as Nb, Mo and V, in combination with other elements, are added into the high-carbon bearing steel to effectively refine the matrix of bearing steel, refine the carbides in the bearing steel, and promote the precipitation of a large amount of nano-carbides, thereby enhancing the mechanical properties and the contact fatigue life of the high-carbon bearing steel. Results from examples show that, the fatigue life of the bearing steel containing Nb, Mo and V in the present invention has been enhanced by <NUM>~<NUM> times compared to the bearing steel without microalloying elements.

<FIG> is the SEM diagram of the steel MA5 smelted in the laboratory after tempering.

The present invention provides a high-carbon bearing steel, the chemical composition is as below: C: <NUM>~<NUM> wt%, Cr: <NUM>~<NUM> wt%, Mn: <NUM>~<NUM> wt%, Si: <NUM>~<NUM> wt%, Nb: <NUM>∼<NUM> wt%, Mo: <NUM>∼<NUM> wt%, optionally V: <NUM>∼<NUM> wt%, P ≤ <NUM> wt%, S ≤ <NUM> wt%, the remaining is Fe and unavoidable impurities; wherein the total quantity of Nb, Mo and V is <NUM> to <NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises C: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%, and more preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises Cr: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%, and more preferably <NUM>~<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises Mn: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%, and more preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises Si: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%, and more preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises P ≤ <NUM> wt%, preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises S ≤ <NUM> wt%, preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises Nb: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises Mo: <NUM>∼<NUM> wt%, preferably <NUM>∼<NUM> wt%.

The high-carbon bearing steel provided by the present invention comprises optionally V: <NUM>~<NUM> wt%, and preferably <NUM>~<NUM> wt%.

In the present invention, the total quantity of Nb, Mo and V is <NUM>∼<NUM> wt%, and preferably <NUM>∼<NUM> wt%.

In the present invention, microalloying elements such as Nb, Mo and V, in combination with other elements, are added into the high-carbon bearing steel to effectively refine the matrix of bearing steel, refine the carbides in the bearing steel, and promote the precipitation of a large amount of nano-carbides, thereby enhancing the mechanical properties and the contact fatigue life of the high-carbon bearing steel.

The present invention provides a preparation method of the high-carbon bearing steel in the above solution, comprising the following steps:.

In the present invention, preparation raw materials of the high-carbon bearing steel are smelted to get steel ingots. In the present invention, the smelting way is electro-slag remelting (ESR), double vacuum melting (VIM + VAR), out-of-furnace refining or vacuum induction melting. The present invention has no special requirement on the process of smelting, any processes that are well known in the art such as electro-slag remelting (ESR), double vacuum melting (VIM + VAR), out-of-furnace refining or vacuum induction melting, can be used. The smelting of the present invention is suitable for a converter, an electric furnace or an induction furnace. In the present invention, the chemical composition of the steel ingots corresponds to the chemical composition of the high-carbon bearing steel in the above solution. The present invention has no special requirements on the types and sources of various preparation raw materials, as long as meeting the requirement on the ingredients of the steel ingots. In the present invention, smelting is carried out so that the oxygen content in the bearing steel is not higher than <NUM> ppm and the size of large granular inclusions (DS) is ≤ <NUM> microns.

In the present invention, after the steel ingots are obtained, they are homogenized and then processed into bars.

In the present invention, the temperature for homogenization is <NUM>∼<NUM>, and preferably <NUM>∼<NUM>; the holding time is <NUM>∼<NUM> hours, and preferably <NUM>∼<NUM> hours. Upon the completion of homogenization, the resulting billet is processed into bars. In the present invention, the processing way is hot forging or hot rolling, and the temperature for hot forging or hot rolling is <NUM>∼<NUM>. The present invention has no special requirement on the size of the bars, as long as being set according to the requirements on the bearing steel. In the examples of the present invention, the size of the bars is Φ60 mm. In the present invention, the processed bars are cooled in the air to room temperature, and then subject to the subsequent steps.

In the present invention, after the bars are obtained, they are spheroidizing annealed to get the annealed bars.

In the present invention, the process of spheroidizing annealing comprises: the bars are held at <NUM>∼<NUM> for <NUM>-<NUM> hours, then cooled down to <NUM>∼<NUM> and held for <NUM>-<NUM> hours, and finally cooled in the air to room temperature. In the present invention, spheroidizing annealing is carried out to get uniform fine carbides.

In the present invention, after the annealed bars are obtained, they are quenched to get the quenched bars. In the present invention, the temperature for quenching is <NUM>∼<NUM>, and preferably <NUM>, the holding time is <NUM>~<NUM> hours, and preferably <NUM> hours; the cooling way for quenching is oil quenching. The present invention has no special requirement on the process of oil quenching, and any oil quenching well known in the art can be used.

In the present invention, after the quenched bars are obtained, they are tempered to get the high-carbon bearing steel. In the present invention, the temperature for tempering is <NUM>∼<NUM>, and preferably <NUM>, the holding time is <NUM>∼<NUM> hours, and preferably <NUM> hours; the cooling way for tempering is air cooling. Quenching and tempering are employed in the present invention so as to get ultrafine original austenite tissues and carbide particles, wherein the grain size of the original austenite is not less than grade <NUM>.

The high-carbon bearing steel provided by the present invention and the preparation method thereof will be illustrated in detail below in combination with the following examples, which are not construed as the limitation on the protection scope of the present invention.

The steel of the present invention is smelted in a laboratory vacuum induction melting furnace, and casted into round ingots of <NUM>. <NUM> furnaces of steel are totally smelted for forging into rod-like samples, with the chemical ingredients shown in Table <NUM>. MA5, MA7, and MA8 steel are the microalloying bearing steel of the present invention; MA1-MA4, MA6, MA9, MA10 are reference bearing steels, and C1-C3 are the bearing steel used as the control (wherein, the preparation method of round ingots is: C1 is GCr15 smelted in a laboratory vacuum induction melting furnace, C2 is GCr15 refined out of the furnace, and C3 is double vacuum GCr15).

The round ingots of the MA1-MA10 steels and the C1-C3 steels above are homogenized at a high temperature of <NUM> for <NUM> hours for the subsequent forging-cogging. The initial forging temperature is <NUM>, the initial section size is <NUM> casting blank, which is radially forged into round bars with a section size of <NUM>, and then cooled in the air. The round bars with a diameter of <NUM> are spheroidizing annealed (being held at <NUM> for <NUM> hours, then cooled down to <NUM> and held for <NUM> hours, and finally cooled in the air to room temperature), and then quenched (being held at <NUM> for <NUM> hours, followed by oil quenching) and tempered at low temperature (being held at <NUM> for <NUM> hours, followed by air cooling) to get the high-carbon bearing steel.

MA1-MA10 and C1-C3 are tested for their mechanical properties, impact toughness and contact fatigue life (Tensile test: the tensile rate is <NUM>-<NUM>/s, and the elongation adopts A5; Impact test: the size for impacting samples is U-shaped impact of <NUM> × <NUM> × <NUM>; Contact fatigue test: a thrust plate test with a maximum Hertz stress of <NUM> GPa), with the results shown in Table <NUM>.

It can be seen from Table <NUM> that, microalloying of Nb, V and Mo greatly enhances the tensile strength (Rm), the elongation (A5) and the impact toughness (Aku) of bearing steel. This mainly attributes to the ultrafine matrix and the ultrafine size of carbides. As shown in <FIG>, a large amount of carbides are finely and uniformly distributed in the high-carbon bearing steel, and the average size of carbides is <NUM> microns, which is finer than the carbides of traditional GCr15 by about <NUM> time. At the same time, due to the microstructure refinement and enhanced mechanical properties for the steel of the present invention, the contact fatigue life L<NUM> of microalloying bearing steel is enhanced by <NUM>~<NUM> times compared to L<NUM> of laboratory smelted bearing steel without microalloying (C1). Meanwhile, compared to the contact fatigue life of industrialized out-of-furnace refined steel GCr15 (C2) and double vacuum GCr15 (C3), it is also enhanced significantly. For example, compared to out-of-furnace refined GCr15, the fatigue life is enhanced by <NUM>~<NUM> times; and compared to double vacuum GCr15, the fatigue life also reaches <NUM>∼<NUM> times. At the same time, it can be found from the comparison between Table <NUM> and Table <NUM> that, when the total quantity of the compound microalloying is in a range of <NUM>∼<NUM> %, the contact fatigue performance can be enhanced better. The characteristics of low cost and long life for the steel of the present invention will greatly improve the service life and reliability of high-end equipment, thus having huge market application potentials in aerospace, mining machinery, transportation, marine ships and other fields.

Claim 1:
A preparation method of a high-carbon bearing steel, comprising the following steps:
preparation raw materials of the high-carbon bearing steel are smelted to get steel ingots; the steel ingots having a chemical composition corresponding to the chemical composition of the high-carbon bearing steel as below:
C: <NUM> to <NUM> wt%, Cr: <NUM> to <NUM> wt%, Mn: <NUM> to <NUM> wt%, Si: <NUM> to <NUM> wt%, Nb: <NUM> to <NUM> wt%, Mo: <NUM> to <NUM> wt%, optionally V: <NUM> to <NUM> wt%, P ≤ <NUM> wt%, S ≤ <NUM> wt%, the remaining is Fe and unavoidable impurities; wherein the total quantity of Nb, Mo and V is <NUM> to <NUM> wt%;
the steel ingots are homogenized and then processed into bars;
the bars are successively subjected to a spheroidizing annealing, a quenching and a tempering to get the high-carbon bearing steel,
wherein the smelting process is an electro-slag remelting, Vacuum Induction Melting + Vacuum Arc Remelting, an out-of-furnace refining or a vacuum induction melting,
wherein the temperature for the homogenization is <NUM> to <NUM>, and the holding time is <NUM> to <NUM> hours,
wherein after completion of the homogenization, the bars are processed by a hot forging or a hot rolling to obtain processed bars, and the processed bars are cooled in air to room temperature, and the temperature for the hot forging or the hot rolling is <NUM> to <NUM>,
wherein the process of the spheroidizing annealing comprises: the bars are held at <NUM> to <NUM> for <NUM> to <NUM> hours, then cooled down to <NUM> to <NUM> and held for <NUM> to <NUM> hours, and finally cooled in the air to room temperature,
wherein the temperature for the quenching is <NUM> to <NUM>, the holding time is <NUM> to <NUM> hours; and the cooling process for the quenching is an oil quenching,
wherein the temperature for the tempering is <NUM> to <NUM>, the holding time is <NUM> to <NUM> hours; and the cooling process for the tempering is an air cooling.