Method for producing rolling bearing components with a high degree of toughness

Abstract

The invention relates to a method for producing rolling bearing components with a high degree of toughness, having the steps of: providing at least one rolling bearing component made of a steel material, said steel material having a high degree of purity such that in a microscopic test of stainless steels to check for non-metallic inclusions in accordance with DIN 50602 (1998), on average less than 100 non-metallic inclusions were present per 1000 mm 2 of the grinding surface, wherein the steel material comprises 0.70 - 1.1 wt.% of carbon and a mixture of alloy elements of more than 1.75 wt.% and less than 3.4 wt.%, and the mixture of alloy elements comprises manganese, chromium, and silicon. In a first method variant, the steps of austenizing, quenching, cooling, tempering, and subsequently cooling to room temperature are carried out, and a residual austenite content lying between 15 vol.% and 25 vol.% is produced in an obtained martensitic matrix. Alternatively, in a second method variant, the steps of austenizing, quenching, heating, and cooling to room temperature are carried out, and a residual austenite content lying between 2 vol.% and 18 vol.% is produced in an obtained bainitic matrix.

Description

[0001] Process for the production of highly tough rolling bearing components

[0002] The invention relates to a method for producing highly tough rolling bearing components, in particular for the production of rolling elements or rolling bearing rings.

[0003] For example, in the field of rolling bearings, such as ball bearings or spherical roller bearings, the requirements regarding rolling resistance and performance are constantly increasing. Performance improvements are particularly relevant with regard to fatigue life, contamination tolerance, and adverse operating conditions.

[0004] Rolling bearings and rolling bearing components, such as rolling elements and rolling bearing rings, especially inner and outer bearing rings, are manufactured according to the current state of the art primarily from hypereutectoid rolling bearing steels according to DIN EN ISO 683-17 (2015 edition). These are hardened either martensitic or bainitic to a hardness of more than 58 HRC.

[0005] Furthermore, it is known that, under constant external load, spherical roller bearings, especially, are subject to higher operating loads than ball bearings. This is due, among other things, to the fact that spherical roller bearings exhibit a higher degree of slip at the contact between the rolling element and the bearing ring compared to ball bearings, making spherical roller bearings more susceptible to surface-induced damage, pitting, and fatigue damage.

[0006] Surface-induced damage, or pitting, limits the load-bearing capacity and service life, i.e., the service life of a rolling bearing and its rolling bearing components. The higher the rolling pressure, the more likely pitting is to occur and the lower the so-called pitting load-bearing capacity. In this context, running tests on rolling bearings have shown that the tolerable rolling pressure depends on the service life, i.e., on the number of rollovers until pitting occurs. This relationship for certain materials is described by Wöhler curves of the pitting load-bearing capacity. Furthermore, it is known that contaminated lubricants, as well as the thickness of the lubricating film and the surface quality of the rolling bearing components, can reduce the service life of a rolling bearing, so that pitting can be expected more quickly.Contamination, surface condition, and lubrication condition impair the contact between the rolling element and the bearing ring. For example, a particle pressed into the raceway can alter the contact surface between the rolling element and the bearing ring, leading to increased surface pressure. This can cause the surface of the bearing ring to develop pitting, resulting in a shorter service life for the rolling bearing.

[0007] In this context, it is known that rolling bearings made of materials with high toughness, such as rolling bearing steels or rolling bearing steel alloys according to DIN EN ISO 683-17 (2015 edition), are prone to less pitting and thus have a longer service life than rolling bearings made of other materials. However, even with these materials, premature failures still occur.

[0008] Therefore, the object of the present invention is to provide a method for producing highly tough rolling bearing components that increases the load-bearing capacity, service life, and thus the service life of a rolling bearing component and a rolling bearing, so that pitting breakouts can be avoided and the pitting load-bearing capacity and service life of a rolling bearing component or a rolling bearing formed therewith can be increased. Furthermore, the object of the present invention is to provide a use of the method for producing highly tough rolling bearing components of a rolling bearing.

[0009] These objects are achieved according to the invention by the features of the independent patent claims. Further advantageous developments are the subject of the dependent claims.

[0010] A first aspect of the present invention comprises a method for producing highly tough rolling bearing components. Highly tough rolling bearing components tend to exhibit less pitting and thus have a high pitting load-bearing capacity, thus increasing the service life of a rolling bearing component, preferably a rolling bearing, in particular a spherical roller bearing.

[0011] The method comprises, as a first step, providing at least one rolling bearing component made of a steel material, wherein the steel material has a degree of purity such that, in a microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), on average less than 100 non-metallic inclusions per 1000 mm 2grinding surface, and wherein the steel material comprises 0.70 - 1.1 wt.% carbon and a mixture of alloying elements of more than 1.75 wt.% and less than 3.4 wt.%, wherein the mixture of alloying elements comprises manganese, chromium and silicon.

[0012] The subsequent step comprises austenitizing or the austenitization of the at least one rolling bearing component in a temperature range such that austenite and carbides coexist in the microstructure of the steel material. Austenitizing can be performed above the so-called austenitizing temperature Ac1 of the steel material of the at least one rolling bearing component. Furthermore, austenitizing can take place in a temperature range from 835 °C to 870 °C or in a temperature range from 845 °C to 860 °C.

[0013] This is followed by a targeted quenching of at least one rolling bearing component so that unconverted residual austenite is retained. During quenching, the rolling bearing component is cooled to a temperature 10 to 20 Kelvin below the martensite initiation temperature of the steel material used. This is done by transferring it to a warm bath with a temperature in the range of 170 to 220 °C and holding it there for 14 to 25 minutes. This results in the formation of martensite and the retention of unconverted residual austenite, and carbon migrates from the formed martensite into the unconverted residual austenite.

[0014] The warm bath is, in particular, a warm salt bath. The warm bath preferably has a temperature in the range of 190°C to 210°C. In the holding stage, at a temperature in the range of 170°C to 220°C, for example, at a temperature in the range of 190°C to 210°C, martensite is formed. In this holding stage, the carbon is precipitated from the newly formed martensite, and some of the carbon can migrate into any remaining retained austenite. This further stabilizes the latter against transformation because the supersaturation increases and thus the martensite start temperature of this retained austenite drops significantly. The carbon from the first martensite needles formed migrates into the remaining retained austenite. Reducing the carbon content has a positive effect on the toughness of the martensite.A further reduction of the matrix carbon cannot be achieved before the quenching process, for example by targeted under-austenitization of the material, since otherwise sufficient hardening of the workpieces cannot be achieved.

[0015] Furthermore, a steel material with a carbon content of 0.70 to 1.05 wt.%, in particular of 0.80 to 1.05 wt.%, further preferably of 0.89 to 1.05 wt.%, and a mixture of alloying elements of more than 1.75 wt.% and less than 3.4 wt.%, wherein the mixture of alloying elements comprises manganese, chromium and silicon, is preferred here.

[0016] All temperatures and / or times specified depend on the size and number of rolling bearing components and the batch size, as well as the batch structure. However, a person of ordinary skill in the art can adjust these accordingly.

[0017] Following quenching, two alternatives are conceivable for the further course of the process.

[0018] Alternative 1 according to claim 1:

[0019] Thus, in a first alternative of the present invention, quenching is followed by a step of cooling the at least one rolling bearing component to room temperature.

[0020] After cooling, the at least one rolling bearing component is tempered (so-called "partitioning") to obtain a material structure with a martensitic matrix, possibly with bainite, and with a specific residual austenite content. Tempering is performed by heating the rolling bearing component to a temperature in the range of 220 to 245°C and holding it there for a period of 1 to 4 hours. Redistribution of carbon during tempering further reduces the resulting carbon in the martensite matrix, which in turn increases toughness.

[0021] The steel material of at least one rolling bearing component is characterized by a martensitic matrix, optionally with bainite content, and a residual austenite content in the range of 15 vol.% to 25 vol.%.

[0022] Increased residual austenite contents meet higher requirements with regard to the tolerance of a rolling bearing when used in contaminated environmental conditions.

[0023] By thermally stabilizing the component using the treatment described above, the retained austenite can be formed with exceptional stability, preventing it from transforming—or only transforming to a limited extent—even at elevated application temperatures in the range of 150 °C to 180 °C or at elevated surface pressures. This stable retained austenite gives a rolling bearing component increased toughness in conjunction with a reduced carbon content in the martensite matrix.

[0024] The final step of the first alternative of the process is cooling to room temperature.

[0025] As already mentioned, all temperatures and / or times mentioned depend on the rolling bearing component and batch size, the number of rolling bearing components, and the batch structure. However, a person of ordinary skill in the art can adjust them accordingly.

[0026] As explained above, two alternatives are conceivable for the further course of the procedure following quenching. While the first alternative has already been described, the second alternative is presented below.

[0027] Alternative 2 according to claim 2:

[0028] In a second alternative of the present invention, quenching is followed by a step of heating the at least one rolling bearing component to a temperature above the martensite start temperature of the steel material used. For this purpose, the at least one rolling bearing component is transferred to a hot bath, in particular a hot salt bath, with a temperature in the range of 220 to 240°C and held there for a period of 3 to 24 hours in order to obtain a material structure with a bainitic matrix, in particular containing carbides, and with a specific residual austenite content. Thus, bainite is formed, and unconverted residual austenite remains. A redistribution of the carbon into the residual austenite during heating further reduces the resulting carbon content in the bainite matrix, which in turn increases toughness.

[0029] The steel material of the at least one rolling bearing component is obtained with a bainitic matrix, in particular containing carbides, and with a residual austenite content in the range of 2 vol.% to 18 vol.%.

[0030] Increased retained austenite content in rolling bearing components meets stricter requirements regarding the tolerance of a rolling bearing when used in contaminated environments. Thermal stabilization of the component using the treatment described above allows the retained austenite to become exceptionally stable and to no longer transform—or only to a limited extent—even at elevated application temperatures in the range of 150°C to 180°C or under increased surface pressures. This stable retained austenite, combined with a reduced carbon content in the bainite matrix, gives a rolling bearing component increased toughness.

[0031] The holding time in the hot bath can depend on the rolling bearing component and batch size, as well as the batch structure. However, a person skilled in the art can adjust it accordingly.

[0032] After the hot bath, the at least one rolling bearing component is transferred to a low-temperature furnace or another hot bath, such as a salt bath, at a higher or higher temperature than the hot bath, in particular at a temperature in the range of 220 °C to 280 °C, until the specified residual austenite content is reached. The holding time is in the range of 0.5 to 10 hours. The final step of the second alternative of the process is cooling to room temperature.

[0033] All of the following characteristics can apply to and be applied to both the first and second alternatives of the procedure.

[0034] Thus, the steel material of the at least one rolling bearing component can comprise 0.7 to 1.05 wt.% carbon and a mixture of alloying elements of more than 3.05 wt.%.

[0035] In addition, the steel material of the at least one rolling bearing component preferably comprises the following components:

[0036] - 0.7 - 1.05 wt.% carbon,

[0037] - 0.50 - 0.90 wt% or 0.40 - 0.75 wt% silicon,

[0038] - 0.90 - 1.30 wt% or 0.80 - 1.70 wt% manganese,

[0039] - 1.3 - 1.75 wt% or 0.90 - 2.05 wt% chromium, and

[0040] - Rest iron and unavoidable trace elements or impurities (such as antimony (Sb), tin (Sn), arsenic (As) and the like).

[0041] Furthermore, the steel material of the at least one rolling bearing component can contain at most 0.10 wt.% or at most 0.15 wt.% or between 0.50 wt.% and 0.6 wt.% molybdenum.

[0042] The above-mentioned elements within the described compositions of the steel material of the at least one rolling bearing component, in their combination, cause an increase in the toughness of the at least one rolling bearing component.

[0043] This is even more true when using the process for producing highly tough rolling bearing components. Specifically, the process steps of the first or second alternative of the process, in combination with the aforementioned composition of elements for a steel material of the at least one rolling bearing component, result in a significant increase in the toughness of the steel material compared to the prior art. The increase in toughness leads to a higher pitting load-bearing capacity or a higher rolling strength, and thus to an increase in the service life of the at least one rolling bearing component.

[0044] Preferably, the steel material of the at least one rolling bearing component comprises the following components:

[0045] - max. 0.35 wt.% nickel,

[0046] - max. 0.10 wt.% vanadium,

[0047] - max. 0.060% by weight aluminum,

[0048] - max. 0.08 wt% sulfur,

[0049] - max. 0.025 wt.% phosphorus,

[0050] - max. 0.003 wt.% titanium,

[0051] - max. 0.015 wt.% nitrogen,

[0052] - max. 0.007 wt% oxygen,

[0053] - max. 0.0035 wt% calcium,

[0054] - max. 0.30 wt% copper.

[0055] The maximum amount of the aforementioned elements within the composition of the steel material of at least one rolling bearing component influences the material properties little to not at all and to such a small extent that these components are acceptable individually or in total within the aforementioned limits or in the aforementioned concentration.

[0056] Furthermore, the steel material of the at least one rolling bearing component can comprise a rolling bearing steel alloy.

[0057] The rolling bearing steel alloy can be selected from DIN EN ISO 683-17 (2015 edition) or from the older DIN 17230 (1980 edition).

[0058] The preferred rolling bearing steel alloy is the alloy with the designation 100CrMnSi4-4 or with the material designation 1 .3518.

[0059] As an alternative to the above, the rolling bearing steel alloy can be the alloy with the designation 100CrMnSi6-6 or with the material designation 1.3519.

[0060] As a further alternative, the rolling bearing steel alloy can be the alloy designated 100CrMnSi6-4 or with the material designation 1.3520. Alternatively, the rolling bearing steel alloy can be the alloy designated 100CrMnMoSi8-4-6 or with the material designation 1.3539.

[0061] The aforementioned rolling bearing steel alloys increase the toughness of at least one rolling bearing component. This is even more true when using the method for producing highly tough rolling bearing components. Specifically, the method steps of the first or second alternative of the present invention in combination with the aforementioned rolling bearing steel alloys result in a significant increase in the toughness of the steel material compared to the prior art. The increase in toughness leads to a higher pitting load-bearing capacity or to a higher rolling strength and thus to an increase in the service life of the at least one rolling bearing component, for example, when using the aforementioned rolling bearing steel alloys in combination with the method steps of the first or second alternative of the method in rolling bearings, in particular spherical roller bearings.

[0062] Furthermore, a rolling bearing steel alloy according to DIN EN ISO 683-17 (2015 edition) can exhibit fewer inclusions in a microscopic examination of stainless steels for non-metallic inclusions than required by DIN EN ISO 683-17 (2015 edition). According to the invention, the steel material of the at least one rolling bearing component has a higher purity than DIN EN ISO 683-17 (2015 edition). The aforementioned rolling bearing steel alloy according to DIN EN ISO 683-17 (2015 edition) in combination with an increased purity or an increased degree of purity and in combination with the process steps of the first or second alternative of the process results in an increase in the toughness of the at least one rolling bearing component.The increase in toughness leads to a higher pitting load-bearing capacity or a higher rolling strength, and thus to an increase in the service life of the at least one rolling bearing component, for example, for the use of the aforementioned rolling bearing steel alloy according to DIN EN ISO 683-17 (2015 edition) in combination with the process steps of the first or second alternatives of the process for rolling bearings in the form of spherical roller bearings. According to the invention, the steel material of the at least one rolling bearing component exhibits, in a microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), in particular on average or averaged, fewer than 100 non-metallic inclusions per 1000 mm. 2 (square millimeters) ground surface or less than 0.1 non-metallic inclusions per 1 mm 2(square millimeter) ground surface. Thus, the steel material of at least one rolling bearing component has a high purity or a high degree of purity, for example, compared to the reference values ​​of DIN EN ISO 683-17 (2015 edition).

[0063] The small number of non-metallic inclusions for the steel material of the at least one rolling bearing component in combination with the corresponding steel material of the at least one rolling bearing component and further in combination with the process steps of the first or second alternative of the method result in an increase in the toughness of the at least one rolling bearing component. The increase in toughness leads to a higher pitting load-bearing capacity or to a higher rolling strength and thus to an increase in the service life of the at least one rolling bearing component, for example, for the use of the steel material of the at least one rolling bearing component in combination with the process steps of the first or second alternative of the method in rolling bearings, in particular spherical roller bearings.

[0064] Preferably, the steel material of the at least one rolling bearing component does not have any type 4 inclusions or inclusions with a size index of 4 or greater of oxides (OA ("dissolved lines"), OS ("line-like lines"), OG ("globular inclusions")) and / or sulfides (SS ("line-like lines")). It does not matter whether these are thin or thick inclusion lines or multiple lines relating to inclusion types OA and OS, as dealt with in DIN 50602 (1998 edition). Thus, the steel material of the at least one rolling bearing component has a high purity or a high degree of purity, for example, compared to the reference values ​​of DIN EN ISO 683-17 (2015 edition). The avoidance of the above-mentioned type 4 inclusions or inclusions with the size code 4 or larger according to DIN 50602 (1998 edition) is also an indication of the purity or degree of purity.The higher the degree of purity or the purity in connection with the steel material of the at least one rolling bearing component in combination with the corresponding steel material of the at least one rolling bearing component and further in combination with the process steps of the first or second alternative of the method, the higher the toughness of the at least one rolling bearing component. The increase in toughness leads to a higher pitting load-bearing capacity or to a higher rolling strength and thus to an increase in the service life of the at least one rolling bearing component, for example, for the use of the steel material of the at least one rolling bearing component in combination with the process steps of the first or second alternative of the method in rolling bearings in the form of spherical roller bearings.

[0065] In particular, the steel material of the at least one rolling bearing component has, in the microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), with regard to type 1 inclusions of sulphides (SS) or with regard to inclusions of sulphides (SS) of size 1 or smaller, a total value, in particular on average or averaged, of at most 100 per 1000 mm 2 (square millimeter) ground surface or a maximum of 0.1 non-metallic inclusions per 1 mm 2 (square millimeter) ground surface. Thus, the steel material of at least one rolling bearing component has a high purity or a high degree of purity, for example, compared to the reference values ​​of DIN EN ISO 683-17 (2015 edition).

[0066] Preferably, the steel material of the at least one rolling bearing component has, in the microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), with regard to type 1 inclusions of oxides (OA ("dissolved lines"), OS ("line-shaped lines"), OG ("globular inclusions")) or with regard to inclusions of oxides (OA ("dissolved lines"), OS ("line-shaped lines"), OG ("globular inclusions")) of size index 1 or smaller, a total value, in particular on average or averaged, of at most 10 per 1000 mm 2 (square millimeter) ground surface or a maximum of 0.01 non-metallic inclusions per 1 mm 2 (square millimeter) ground surface. Thus, the steel material of at least one rolling bearing component has a high purity or a high degree of purity, for example, compared to the reference values ​​of DIN EN ISO 683-17 (2015 edition).

[0067] Regarding the above-mentioned low number of non-metallic inclusions for the steel material of the at least one rolling bearing component in combination with the corresponding steel material of the at least one rolling bearing component and further in combination with the process steps of the first or second alternative of the method, an increase in the toughness of the at least one rolling bearing component is achieved. The increase in toughness leads - as already described several times - to a higher pitting load-bearing capacity or to a higher rolling strength and thus to an increase in the service life of the at least one rolling bearing component, for example for the use of the steel material of the at least one rolling bearing component in combination with the process steps of the first or second alternative of the method in rolling bearings, in particular spherical roller bearings.

[0068] Furthermore, the steel material of the at least one rolling bearing component can be obtained by a melting process or by remelting or by melting.

[0069] The melting or remelting or the melting process may include conventional air melting, vacuum treatment in secondary metallurgy and / or vacuum melting so that a steel with a high degree of purity or high purity can be produced.

[0070] Additionally or alternatively, the steel material of the at least one rolling bearing component can be obtained by a remelting process under protective gas or under vacuum, so that a steel with a high degree of purity or high purity can be produced.

[0071] The at least one rolling bearing component can be a rolling element or a rolling bearing ring, in particular in the form of an inner and / or outer bearing ring. The at least one rolling bearing component can also be at least a part of a ball bearing and / or a roller bearing and / or a spherical roller bearing and / or a transmission bearing and / or a transmission bearing and / or a wheelset bearing for railway applications and / or a pin for cam follower applications, on which rolling elements roll. The at least one rolling bearing component according to the presented method can be used generally in industry and / or in the automotive sector.

[0072] In addition, the at least one rolling bearing component can be a stationary component or housing part or a rotating component or a shaft on which rolling elements roll.

[0073] A second aspect of the present invention encompasses a use of the method for producing highly tough rolling bearing components, specifically a use for producing rolling elements and / or rolling bearing rings. Furthermore, a use of the method for producing shafts, bolts, or housing parts on which rolling elements roll, for the production of transmission bearings and / or for the production of wheelset bearings for railway applications and / or bolts for rocker arm applications.

[0074] It is expressly pointed out that the features of the process for the production of high-toughness rolling bearing components can be used individually or in combination with each other.

[0075] In other words, the characteristics relating to the procedure can also be combined with other characteristics.

[0076] The process for producing highly tough rolling bearing components can be used for the production of rolling elements and / or rolling bearing rings, in particular inner and / or outer bearing rings, and / or for the production of shafts or housing parts on which rolling elements roll, and / or for the production of gearbox bearings, and / or for the production of wheelset bearings for railway applications, and / or for the production of pins for rocker arm applications on which rolling elements roll. The rolling bearing components can be components of a ball bearing, a roller bearing, and / or a spherical roller bearing.

[0077] It is expressly pointed out that the features of the process for the production of high-toughness rolling bearing components can be used individually or in combination with each other.

[0078] In other words, the features relating to the process for producing high-toughness rolling bearing components can also be combined with other features here.

[0079] Thus, a rolling bearing component of a rolling bearing according to the invention is produced by the method according to the invention.

[0080] A rolling bearing component can be rolling elements and / or rolling bearing rings, in particular inner and / or outer bearing rings.

[0081] Specifically, the rolling bearing component can be part of a ball bearing and / or a roller bearing and / or a spherical roller bearing.

[0082] In the following, the inventive concept presented above is expressed again and additionally in other words.

[0083] This idea concerns - in simplified terms - the increase in load-bearing capacity, service life and lifetime of rolling bearings as a necessary further development with regard to improved sustainability of such machine elements.

[0084] To meet the higher tolerance requirements of a rolling bearing when used in contaminated environments, increased retained austenite contents are considered helpful. Furthermore, a thermomechanically stable microstructure is considered a necessary condition for rolling strength, since operationally induced retained austenite degradation can be considered part of the rolling fatigue process.

[0085] Furthermore, a particularly good degree of microscopic and macroscopic cleanliness may be necessary for maximum service life of rolling bearings, as this forms the basis of rolling resistance. Especially with regard to spherical roller bearings, it can be noted that all factors can occur simultaneously, as increased slip during operation can lead to increased contact temperatures, and stress near the edge can result in pronounced sensitivity to near-surface inclusions.

[0086] An increase in the performance of a rolling bearing component, such as a spherical roller bearing, can be achieved through heat treatment if the basis is a sufficiently good steel cleanliness that does not cause premature inclusion-related failure.

[0087] Basically, the inventive idea can be seen in a combination of heat treatment and an exceptionally high degree of microscopic purity in a region close to the raceway at the level of remelted steel grades and in a combination for certain compositions of a steel material.

[0088] This can be achieved by conventional air melting combined with high degrees of deformation and a new type of heat treatment, which has not previously been used in this form in the field of rolling bearings.

[0089] A steel material with the following composition has proven to be suitable for a process for producing highly tough rolling bearing components:

[0090] - 0.7 - 1.05 wt.% carbon,

[0091] - 0.50 - 0.9 wt% silicon,

[0092] - 0.9 - 1.3 wt% manganese,

[0093] - 1.3 - 1.75 wt% chromium,

[0094] - max. 0.35 wt.% nickel,

[0095] - max. 0.15 wt.% molybdenum,

[0096] - max. 0.1 wt.% vanadium,

[0097] - max. 0.060% by weight aluminum,

[0098] - max. 0.08 wt% sulfur,

[0099] - max. 0.025 wt.% phosphorus,

[0100] - max. 0.003 wt.% titanium, - max. 0.015 wt.% nitrogen,

[0101] - max. 0.007 wt% oxygen,

[0102] - max. 0.0035 wt% calcium,

[0103] - max. 0.30 wt.% copper, and

[0104] - Rest iron as well as unavoidable trace elements or impurities, such as antimony (Sb), tin (Sn), arsenic (As) and the like.

[0105] The sum of manganese, chromium and silicon can be greater than 2.95 wt.%, in particular more than 3.05 wt.%.

[0106] The steel material can also achieve a microscopic purity with an average inclusion density of 0.1 inclusions / mm 2(square millimeters) ground surface based on 1 -valent sulfides and 0.01 inclusions / mm 2 (square millimeters) of ground surface based on monovalent oxides. In any case, tetravalent inclusions (oxides and sulfides) should be avoided (see DIN 50602 (1998 edition)).

[0107] In addition, for maximum rolling strength, maximum Stribeck rolling stress, or maximum pitting strength, a particularly high degree of purity can be achieved through conventional air melting, vacuum treatment in secondary metallurgy, or vacuum melting and / or remelting processes under protective gas or vacuum. The structural stabilization of the steel material can be achieved through the use of adapted austenitization in combination with targeted heat treatment plus subsequent bainitic or martensitic hardening.

[0108] A low austenitizing temperature, preferably in a temperature range of 835 °C to 870 °C, preferably in a temperature range of 845 °C to 860 °C, can result in a reduced carbon content in the matrix significantly below the nominal 1 wt.% carbon, especially in the case of steel material 100CrMnSi6-4. This has a positive effect on the intrinsic toughness of the matrix. Of course, other steel materials or steel alloys, as described above, can also be used. Redistribution of carbon during heat treatment can further reduce the resulting carbon in the martensite or bainite matrix, which in turn can increase toughness.

[0109] In the holding stage according to Alternative 1, in the range from 170 °C to 220 °C, carbon is precipitated from the newly formed martensite, and some of the carbon migrates into the remaining retained austenite. This further stabilizes the remaining austenite against transformation, as supersaturation increases and the martensite start temperature of this retained austenite drops significantly. The carbon from the first martensite needles formed migrates into the remaining retained austenite. A reduction in carbon can have a positive effect on the toughness of the martensite.

[0110] A further reduction of the matrix carbon cannot be achieved before the quenching process, in particular by a targeted under-austenitization of the material, since otherwise sufficient hardening of the workpieces cannot be achieved.

[0111] In the martensitic version, i.e. the first alternative of the present invention, the workpiece is characterized by a martensitic matrix, possibly with bainite content, and a residual austenite content of 15 vol.% to 25 vol.%.

[0112] By thermally stabilizing the component through heat treatment, this retained austenite can be formed with exceptional stability and can no longer transform—or only to a limited extent—even at elevated application temperatures in the range of 150 °C to 180 °C or at increased surface pressures. This stable retained austenite, combined with the reduced carbon content in the martensite matrix, gives the component increased toughness.

[0113] In the bainitic version, i.e., the second alternative of the present invention, the rolling bearing component can be characterized by a bainitic matrix, in particular comprising carbides, and a remaining residual austenite according to the desired degree of transformation. This lies in the range of 2 vol.% to 18 vol.%.

[0114] The material properties achieved in this way are particularly advantageous for use in rolling bearings, which, for example in the case of spherical roller bearings, have higher slip rates due to their nature, i.e. no clean rolling of the contact partners, and also often experience mixed friction conditions due to the existing operating conditions.

[0115] The latter can cause increased friction in the contact surface, resulting in higher tangential stresses that increase the material load on the rolling bearing component surface. In addition, the inherent slip load can further increase the risk of surface-induced damage. By using the inventive method for producing highly tough rolling bearing components, the material load-bearing capacity can be significantly increased and the service life of a rolling bearing component significantly improved compared to the prior art, since the increased toughness counteracts the development of damage to the rolling bearing component.

[0116] By reducing the number of non-metallic inclusions, the risk of damage can be further reduced, due to their effect as a source of damage. In general, toughness-optimized material properties can be helpful for tolerance to surface-induced damage. This also applies to contamination in rolling bearings, as the increased toughness, both through the retained austenite and the carbon-reduced martensite or bainite matrix, effectively enables the necessary adaptive deformation in the contact gap when rolling over foreign material, without leading to rapid crack initiation.

[0117] The invention is explained in more detail below using an exemplary embodiment.

[0118] A method for producing highly tough rolling bearing components comprises, as a first step, providing a rolling bearing component made of a suitable steel material, which is austenitized in a next step.

[0119] Austenitizing takes place in a temperature range such that austenite and carbides coexist. Austenitizing is performed above the austenitizing temperature Ac1 of the steel material of the rolling bearing component. This typically occurs in a temperature range of 845 °C to 860 °C. The rolling bearing component is then selectively quenched to retain any unconverted residual austenite. This involves cooling to a temperature 10 to 20 K below the martensite start temperature of the steel material used.

[0120] Specifically, the rolling bearing component is transferred to a warm salt bath with a temperature range of 190 °C to 210 °C. The rolling bearing component remains in the warm bath for 14 to 25 minutes.

[0121] Following quenching, the first alternative for producing highly tough rolling bearing components is described below.

[0122] In the first alternative, quenching is followed by a step of cooling the rolling bearing component to room temperature.

[0123] After cooling, the rolling bearing component is tempered to obtain a material structure with a martensitic matrix (possibly with bainite) and a specific residual austenite content. Tempering is carried out below the austenitizing temperature Ac1 of the steel material of the rolling bearing component at a temperature in the range of 220 to 240 °C for a period of 1 to 4 hours.

[0124] The retained austenite content obtained is in the range of 15 vol% and 25 vol%.

[0125] The tempering time depends on the rolling bearing component and batch size as well as on the batch structure if several rolling bearing components are treated simultaneously.

[0126] Subsequently, the rolling bearing component is cooled to room temperature.

[0127] The second alternative for the production of highly tough rolling bearing components is described below, which, like the first alternative, follows the quenching process described above.

[0128] For example, after quenching in the second alternative, the rolling bearing component is heated to a temperature above the martensite start temperature of the steel material used. For this purpose, the rolling bearing component is immersed in a warm salt bath to obtain a material structure with a bainitic matrix (with carbides) and a specific residual austenite content.

[0129] The heating is carried out in such a way that the determined retained austenite content is in the range of 2 vol% to 18 vol%.

[0130] To achieve this, the salt bath has a temperature in the range of 220 °C to 240 °C. Furthermore, the rolling bearing component is left in the salt bath for a holding time of 6 to 24 hours to maintain the specified residual austenite content. The holding time depends on the rolling bearing component and batch size, as well as on the batch structure if multiple rolling bearing components are treated simultaneously.

[0131] After the holding time in the hot bath, the rolling bearing component is transferred to a low-temperature furnace with increasing or elevated temperature compared to the hot salt bath with a temperature in the range of 220 °C to 280 °C and held for a period of 0.5 to 10 h until the specified residual austenite content is reached.

[0132] Subsequently, the rolling bearing component is cooled to room temperature.

[0133] All of the following statements apply to the first alternative and second alternative of the present invention.

[0134] The steel material of the rolling bearing component preferably comprises 0.7 - 1.05 wt.% carbon and a mixture of alloying elements of more than 3.05 wt.%, wherein the mixture of alloying elements comprises manganese, chromium and silicon.

[0135] In particular, the steel material of the rolling bearing component has the following components:

[0136] - 0.7 - 1.05 wt.% carbon,

[0137] - 0.50 - 0.90 wt% silicon,

[0138] - 0.90 - 1.30 wt% manganese,

[0139] - 1.3 - 1.75 wt% chromium, and

[0140] - The remainder is iron and unavoidable trace elements or impurities (such as Sb, Sn, As, and the like). The steel material of the rolling bearing component preferably comprises the following components:

[0141] - max. 0.35 wt.% nickel,

[0142] - max. 0.10 wt.% vanadium,

[0143] - max. 0.060% by weight aluminum,

[0144] - max. 0.08 wt% sulfur,

[0145] - max. 0.025 wt.% phosphorus,

[0146] - max. 0.003 wt.% titanium,

[0147] - max. 0.015 wt.% nitrogen,

[0148] - max. 0.007 wt% oxygen,

[0149] - max. 0.0035 wt% calcium,

[0150] - max. 0.30 wt% copper.

[0151] The maximum amount of the above-mentioned elements within the composition of the steel material of the rolling bearing component influences the material properties little or not at all to such an extent that these components are acceptable individually or in total within the above-mentioned limits or in the above-mentioned concentration.

[0152] More specifically, the steel material of the rolling bearing component comprises a rolling bearing steel alloy selected from DIN EN ISO 683-17 (2015 edition) (formerly DIN 17230 (1980 edition)).

[0153] This particularly concerns the rolling bearing steel alloy with the designation 100CrMnSi6-4 or with the material designation 1 .3520.

[0154] Furthermore, the rolling bearing steel alloy according to DIN EN ISO 683-17 (2015 edition) has fewer inclusions in a microscopic examination of stainless steels for non-metallic inclusions than required in DIN EN ISO 683-17 (2015 edition).

[0155] In other words, the steel material of the rolling bearing component has, in a microscopic test of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), on average or averaged less than 100 non-metallic inclusions per 1000 mm 2(square millimeter) ground surface. Furthermore, the steel material of the rolling bearing component contains no type 4 inclusions of oxides (OA, OS, OG) or sulfides (SS).

[0156] More specifically, the steel material of the rolling bearing component has, in the microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), with regard to type 1 inclusions of sulphides (SS), a total value on average or averaged of at most 100 per 1000 mm 2 (square millimeter) ground surface.

[0157] Furthermore, the steel material of the rolling bearing component has a total value on average or averaged of not more than 10 per 1000 mm in the microscopic testing of stainless steels for non-metallic inclusions according to DIN 50602 (1998 edition), with regard to type 1 inclusions of oxides (OA, OS, OG). 2 (square millimeter) ground surface.

[0158] In order to obtain this low number of inclusions and to achieve an increased degree of purity, the steel material of the rolling bearing component is obtained by a melting process or by remelting or by smelting.

[0159] Melting or remelting, or the melting process, is carried out using vacuum melting, allowing steel with a high degree of purity to be produced. Alternatively, the steel material for the rolling bearing component can be obtained through a remelting process under protective gas or vacuum.

[0160] In principle, it should be noted that the rolling bearing component is preferably a rolling element and / or a rolling bearing ring, in particular an inner and / or outer bearing ring. The rolling bearing component is, in particular, a component of a spherical roller bearing.

[0161] However, it may also be the case that the rolling bearing component is at least part of a gearbox bearing or a wheelset bearing for railway applications and / or a bolt for a rocker arm application.

[0162] In other words, the presented process for the production of high-toughness rolling bearing components is used for the production of rolling elements and / or rolling bearing rings. The presented process can also be used for the production of shafts or housing parts on which rolling elements roll, or for the production of transmission bearings, wheelset bearings for railway applications, or for the production of pins for cam follower applications.

[0163] In principle, it should be noted that the aforementioned rolling bearing steel alloy selected as an example, with the designation 100CrMnSi6-4 or with the material designation 1.3520 according to DIN EN ISO 683-17 (2015 edition), in combination with increased purity or an increased degree of purity and in combination with the process steps of the first or second alternative of the present invention, results in an increase in the toughness of the rolling bearing component. The increase in toughness leads to a higher pitting load-bearing capacity or to a higher rolling strength and thus to an increase in the service life of the rolling bearing components, for example, for the use of the aforementioned rolling bearing steel alloy in combination with the process steps of the first or second alternative of the process in rolling bearings, such as spherical roller bearings.

Claims

Patent claims: Method for manufacturing high-toughness rolling bearing components comprising the steps: - Providing at least one rolling bearing component made of a steel material, wherein the steel material has a degree of purity such that, in a microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (edition 1998), on average less than 100 non-metallic inclusions per 1000 mm² are found. 2 polished surface, wherein the steel material comprises 0.70 - 1.1 wt.% carbon and a mixture of alloying elements of more than 1.75 wt.% and less than 3.4 wt.%, wherein the mixture of alloying elements comprises manganese, chromium and silicon, - Austenitizing at least one rolling bearing component in a temperature range such that austenite and carbides are present side by side in the microstructure of the steel material, - Quenching at least one rolling bearing component to a temperature 10 to 20 K below the martensite start temperature of the steel material by transferring the rolling bearing component to a hot bath with a temperature in the range of 170 to 220 °C and holding it there for 14 to 25 min, whereby martensite is formed and unconverted retained austenite is retained, and whereby carbon migrates from the formed martensite to the unconverted retained austenite, - Cooling at least one rolling bearing component to room temperature after quenching, - Tempering of at least one rolling bearing component after cooling by heating the rolling bearing component to a temperature in the range of 220 to 245°C and holding it at this temperature for a period of 1 to 4 hours, whereby a martensitic matrix with a retained austenite content in the range of 15 vol.% and 25 vol.% is obtained as the material structure, and - subsequent cooling of the rolling bearing component to room temperature, resulting in the formation of the highly tough rolling bearing component. A process for manufacturing high-toughness rolling bearing components comprising the steps: - Providing at least one rolling bearing component made of a steel material, wherein the steel material has a degree of purity such that, in a microscopic examination of stainless steels for non-metallic inclusions according to DIN 50602 (edition 1998), on average less than 100 non-metallic inclusions per 1000 mm² are found. 2 polished surface, wherein the steel material comprises 0.70 - 1.1 wt.% carbon and a mixture of alloying elements of more than 1.75 wt.% and less than 3.4 wt.%, wherein the mixture of alloying elements comprises manganese, chromium and silicon, - Austenitizing at least one rolling bearing component in a temperature range such that austenite and carbides are present side by side in the microstructure of the steel material, - Quenching at least one rolling bearing component to a temperature 10 to 20 K below the martensite start temperature of the steel material by transferring the rolling bearing component to a hot bath with a temperature in the range of 170 to 220 °C and holding it there for 14 to 25 min, whereby martensite is formed and untransformed retained austenite is retained, - Heating at least one rolling bearing component after quenching to a temperature above the martensite start temperature of the steel material used, by transferring the rolling bearing component to a hot bath with a temperature in the range of 220 to 240 °C and holding it there for a period of time in the range of 3 to 24 hours, Transferring at least one rolling bearing component for a holding period in the range of 0.5 to 10 hours into a low-temperature furnace or a further hot bath in which a temperature increasing or elevated compared to the hot bath, in particular in the range of 220 to 280°C, is present, wherein bainite is formed and unconverted retained austenite is retained, and wherein carbon migrates from the formed bainite into the unconverted retained austenite, wherein the material structure is a bainitic matrix with a retained austenite content in the range of 2 vol.% and 18 vol.%, and - Subsequent cooling of the rolling bearing component to room temperature, resulting in the formation of the highly tough rolling bearing component. A method according to claim 2, wherein the material structure is a bainitic matrix containing carbides and with a retained austenite content in the range of 2 vol.% to 18 vol.%. A method according to any one of claims 1 to 3, wherein the steel material of the at least one rolling bearing component comprises 0.7–1.05 wt.% carbon and a mixture of alloying elements of more than 2.95 wt.%. A method according to claim 4, wherein the steel material comprises a mixture of alloying elements of more than 3.05 wt.%. A method according to any one of the preceding claims. - wherein the steel material of at least one rolling bearing component comprises the following components: o 0.7 - 1.05 wt.% carbon, o 0.50 - 0.90 wt.% or 0.40 - 0.75 wt.% silicon, o 0.90 - 1.30 wt.% or 0.80 - 1.70 wt.% manganese, o 1.3 - 1.75 wt.% or 0.90 - 2.05 wt.% chromium, and o balance iron and unavoidable impurities, - wherein the steel material of at least one rolling bearing component optionally contains at most 0.10 wt.% or at most 0.15 wt.% or between 0.50 wt.% and 0.6 wt.% molybdenum. Method according to one of the preceding claims, - wherein the steel material of at least one rolling bearing component comprises a rolling bearing steel alloy, - wherein the bearing steel alloy is selected from DIN EN ISO 683-17 (2015 edition). Method according to claim 7, - where either the bearing steel alloy is the alloy designated 100CrMnSi4-4 or the material designation 1.3518, - or where the bearing steel alloy is the alloy designated 100CrMnSi6-6 or with the material designation 1.3519, - or where the bearing steel alloy is the alloy designated 100CrMnSi6-4 or with the material designation 1 .3520, - or wherein the bearing steel alloy is the alloy designated 100CrMnMoSi8-4-6 or with the material designation 1.3539. Use of the method for producing high-toughness rolling bearing components according to one of the preceding claims for the production of rolling elements and / or rolling bearing rings, in particular inner and / or outer bearing rings, and / or for the production of shafts or housing parts on which rolling elements roll, and / or for the production of gear bearings, and / or for the production of wheelset bearings for railway applications, and / or for the production of bolts for rocker arm applications. Rolling bearing component of a rolling bearing, in particular a spherical roller bearing, produced by a method according to one of claims 1 to 8.