Development of technological solutions to improve the quality of railway rails by improving the technology of smelting, out-of-furnace processing and continuous casting of rail electric steel.

A. Umanskii, A. S. Borisov, S. V. Feiler
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Abstract

Based on a complex of metallographic and X-ray phase studies for the conditions of EVRAZ ZSMK, which is a leading domestic manufacturer of railway rails, the nature of characteristic defects of rails of metallurgical origin has been determined. These defects, which are the cause of rejection of rails during ultrasonic quality control in the flow of rail-block mill, are stratifications, in the localities of which accumulations of silicate, alumina and sulfide non-metallic inclusions are concentrated; at the same time, these defects in the vast majority of cases are located in the neck of the rail profiles. Analysis of contamination with non-metallic inclusions of suitable rails of the current production of EVRAZ ZSMK showed that, unlike the locations of defects in rejected rails, alumina non-metallic inclusions have an extremely low concentration, while manganese sulfides and silicate inclusions have the highest relative concentration. Based on the results obtained, technological measures were developed, pilot-industrial and implemented to improve the production technology of rail steel in the conditions of the electric steelmaking workshop of EVRAZ ZSMK. In order to reduce the concentration of oxide nonmetallic inclusions in rail steel, a new technology of ladle treatment of steel using a low-ash carburizer and calcium carbide for slag deoxidation has been developed. To reduce sulfide inclusions contamination, measures have been implemented to ensure the sulfur content in the finished steel at a level of no more than 0.008%. The optimization of the modes of electromagnetic mixing in the mold and the temperature regimes of continuous casting of steel was carried out, which also had an effect on reducing the concentration of non-metallic inclusions in continuously cast billets of rail steel and finished rails. The introduction of a set of these technological solutions and measures allowed to reduce the rejection of rails for internal defects from 7% to less than 2%
开发技术解决方案,通过改进冶炼、炉外加工和铁路电工钢连铸技术来提高铁路钢轨的质量。
根据对 EVRAZ ZSMK(国内领先的铁路钢轨制造商)条件进行的金相和 X 射线相位综合研究,确定了钢轨冶金特征缺陷的性质。这些缺陷是在钢轨块轧机流程中进行超声波质量控制时造成钢轨剔除的原因,是硅酸盐、氧化铝和硫化物非金属夹杂物集中积聚的分层;同时,这些缺陷在绝大多数情况下位于钢轨轮廓的颈部。对 EVRAZ ZSMK 当前生产的适用钢轨的非金属夹杂物污染分析表明,与废品钢轨的缺陷位置不同,氧化铝非金属夹杂物的浓度极低,而硫化锰和硅酸盐夹杂物的相对浓度最高。根据获得的结果,制定了技术措施,并在 EVRAZ ZSMK 电炉炼钢车间进行了试验和实施,以改进钢轨钢的生产技术。为了降低轨道钢中氧化物非金属夹杂物的浓度,开发了一种使用低灰份渗碳体和电石进行钢渣脱氧的钢包处理新技术。为减少硫化物夹杂物污染,已采取措施确保成品钢中的硫含量不超过 0.008%。对结晶器中的电磁搅拌模式和钢连铸的温度制度进行了优化,这也对降低连铸钢坯和成品钢轨中的非金属夹杂物浓度产生了影响。通过采用这些技术解决方案和措施,钢轨内部缺陷的废品率从 7% 降至 2% 以下。
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