Technical Field
[0001] The present invention relates to ferritic stainless steel and method for manufacturing
the ferritic stainless steel.
Background Art
[0002] High Al-containing ferritic stainless steels have high-temperature oxidation resistance
and therefore are used in applications in which heat resistance is required, such
as: a catalytic carrier (including an electric heating type) for exhaust gas purification
provided in an automobile, a two-wheeled vehicle, or the like; a plant; a combustion
tower; and the like.
[0003] Patent Literature 1 discloses that in a case where an oxide film of an Al
2O
3 columnar crystal has a thickness of not less than 0.1 pm and not more than 1.0 pm,
it is possible to prepare an Fe-Cr-Ar-based alloy foil that is sufficiently effective
for oxidation resistance and high-temperature deformation resistance.
[0004] Patent Literature 2 discloses that in a case where an Al
2O
3 film has a thickness of not less than 20 nm and 200 nm, a stainless steel foil that
is excellent in diffused junction properties and brazing properties can be prepared.
Citation List
[Patent Literature]
Summary of Invention
Technical Problem
[0006] However, although the technologies disclosed in Patent Literatures 1 and 2 are considered
to be effective in terms of oxidation resistance, the technologies have the problem
of poor brazing properties in a case where the technologies are applied to a product
requiring brazing properties, such as a catalytic carrier.
[0007] An object of an aspect of the present invention is to provide a ferritic stainless
steel which is oxidation resistant and is superior to conventional ferritic stainless
steels in terms of brazing properties.
Solution to Problem
[0008] In order to attain the object, a ferritic stainless steel in accordance with an aspect
of the present invention contains not more than 0.030% of C, 0.01% to 1.5% of Si,
0.01% to 1.00% of Mn, not more than 0.050% of P, not more than 0.005% of S, 15.0%
to 25.0% of Cr, 2.0% to 4.0% of Al, not more than 1.00% of Ni, 0.01% to 0.70% of Nb,
not more than 0.030% of N, 0.0003% to 0.01% of B, and 0.01% to 0.20% of REM, in percent
by mass, and the other part composed of Fe and an inevitable impurity, the ferritic
stainless steel including, on a surface of the ferritic stainless steel, an Al-based
oxide film having a thickness of not less than 8 nm and less than 20 nm.
[0009] A method for producing a ferritic stainless steel in accordance with an aspect of
the present invention, the ferritic stainless steel containing not more than 0.030%
of C, 0.01% to 1.5% of Si, 0.01% to 1.00% of Mn, not more than 0.050% of P, not more
than 0.005% of S, 15.0% to 25.0% of Cr, 2.0% to 4.0% of Al, not more than 1.00% of
Ni, 0.01% to 0.70% of Nb, not more than 0.030% of N, 0.0003% to 0.01% of B, and 0.01%
to 0.20% of REM, in percent by mass, and the other part composed of Fe and an inevitable
impurity, the method including:
a cold rolling step; and a final annealing step which is carried out after the cold
rolling step,
the final annealing step including a first step of carrying out heating to a temperature
range of 900°C to 1200°C in an inert gas atmosphere and under a condition of a dew
point of not higher than -40°C.
Advantageous Effects of Invention
[0010] According to an aspect of the present invention, it is possible to provide a ferritic
stainless steel which is oxidation resistant and is superior to conventional ferritic
stainless steels in terms of brazing properties.
Brief Description of Drawings
[0011] Fig. 1 is an SEM image of a cross section of an alumina layer which is mainly composed
of alumina and is formed by heating a ferritic stainless steel in accordance with
an embodiment of the present invention at 1050°C for 50 hours.
Description of Embodiments
[0012] The following description will discuss in detail an embodiment of the present invention.
In this specification, the term "stainless steel" means a stainless steel material
the shape of which is not specifically limited. Examples of the stainless steel material
include steel sheets, steel pipes, and steel bars. The unit "%" of the content of
each constituent element is intended to mean "percent by mass" unless otherwise noted.
Note also that, in the present application, the expression "A to B" indicates not
less than A and not more than B.
(Composition of ferritic stainless steel)
[0013] Firstly, the following description will discuss essential elements contained in a
ferritic stainless steel in accordance with the present embodiment.
[0014] The ferritic stainless steel in accordance with an embodiment of the present invention,
in terms of a composition of components of the steel, contains not more than 0.030%
of C, 0.01% to 1.5% of Si, 0.01% to 1.00% of Mn, not more than 0.050% of P, not more
than 0.005% of S, 15.0% to 25.0% of Cr, 2.0% to 4.0% of Al, not more than 1.00% of
Ni, 0.01% to 0.70% of Nb, not more than 0.030% of N, 0.0003% to 0.01% of B, and 0.01%
to 0.20% of REM, in percent by mass.
[0015] In the above composition, the Al content is reduced in comparison to conventional
high Al-containing ferritic stainless steels. Since the ferritic stainless steel in
accordance with an embodiment of the present invention has the above composition,
it is possible to obtain a ferritic stainless steel which is excellent in toughness.
[0016] The following description will discuss the significance of the amount of each element
contained in the ferritic stainless steel in accordance with an embodiment of the
present invention. Note that the ferritic stainless steel contains, in addition to
the components described below, iron (Fe) or a small amount of an impurity which is
inevitably contained (inevitable impurity).
<C: carbon>
[0017] C is an essential element in a ferritic stainless steel in accordance with an embodiment
of the present invention. As a C content increases, however, abnormal oxidation is
more likely to occur. Further, in a case where C is excessively contained, a slab
and a hot coil are deteriorated in toughness, and it becomes difficult to work the
ferritic stainless steel into a plate material by hot working. Therefore, in an aspect
of the present invention, the upper limit of the content of C is defined to be 0.030%.
In a case where C is contained in an amount of not more than 0.020%, it is possible
to further reduce the possibility of occurrence of abnormal oxidation and improve
workability. In light of the above reason, a more preferable content of C is 0.002%
to 0.015%.
<Si: silicon>
[0018] Si is an element effective for improving oxidation resistance and is an essential
element in a ferritic stainless steel in accordance with an embodiment of the present
invention. However, in a case where Si is excessively contained, toughness and workability
may be reduced. Therefore, in an aspect of the present invention, Si is contained
in an amount of 0.01% to 1.50%. In a case where Si is contained in an amount of 0.01%
to 1.0%, more preferably 0.01% to 0.50%, an effect as a deoxidizing agent and workability
are further improved.
<Mn: manganese>
[0019] Mn is an essential element in a ferritic stainless steel in accordance with an embodiment
of the present invention. However, in a case where Mn is excessively contained, the
ferrite phase may be destabilized, and high-temperature oxidation resistance may be
reduced. Therefore, in an aspect of the present invention, Mn is contained in an amount
of 0.01% to 1.00%. In a case where Mn is contained in an amount of 0.01% to 0.80%,
more preferably 0.01% to 0.50%, the possibility of generation of a corrosion-initiated
point is further reduced.
<P: phosphorus>
[0020] P is an essential element in a ferritic stainless steel in accordance with an embodiment
of the present invention. However, in a case where P is excessively contained, oxidation
resistance and toughness of a hot-rolled sheet may be deteriorated. Therefore, in
an aspect of the present invention, the content of P is defined to be not more than
0.050%. In a case where P is contained in an amount of not more than 0.040%, it is
possible to further reduce a deterioration in workability. In light of the above reason,
a more preferable content of P is 0.005% to 0.030%.
<S: sulfur>
[0021] S is an essential element in a ferritic stainless steel in accordance with an embodiment
of the present invention. However, in a case where S is excessively contained, the
ferritic stainless steel may be negatively affected in terms of formation of an Al
2O
3 film, and the oxidation resistance of the ferritic stainless steel may be deteriorated.
Therefore, in an aspect of the present invention, the content of S is defined to be
not more than 0.005%. In light of the above reason, a more preferable content of S
is 0.0001% to 0.002%.
<Cr: chromium>
[0022] Cr is a fundamental alloy element which is necessary in order to improve the high-temperature
oxidation resistance of a ferritic stainless steel. In a case where Cr is contained
in not less than a predetermined amount, an oxide film is formed on the surface of
the stainless steel, so that oxidation of the stainless steel is prevented. However,
in a case where Cr is excessively contained, toughness is reduced and producibility
is deteriorated. Therefore, in an aspect of the present invention, the content of
Cr is defined to be 15.0% to 25.0%. In a case where Cr is contained in an amount of
16.0% to 22.0%, more preferably 17.0% to 20.0%, it is possible to further improve
the oxidation prevention effect and producibility.
<A1: aluminum>
[0023] Al is a fundamental alloy element which is necessary in order to improve the high-temperature
oxidation resistance of the ferritic stainless steel. In a case where Al is contained
in not less than a predetermined amount, an oxide film of Al
2O
3 is formed on the surface of the stainless steel, so that oxidation of the stainless
steel is prevented. In a case where REM or Y is added, the oxide film becomes dense
and has an improved adhesion to the base steel, so that occurrence of abnormal oxidation
is prevented. However, in a case where Al is excessively contained, toughness of the
stainless steel is deteriorated, and producibility and workability are deteriorated.
Therefore, in an aspect of the present invention, the content of Al is defined to
be 2.0% to 4.0%. In a case where Al is contained in an amount of 2.5% to 3.7%, more
preferably 2.8% to 3.5%, it is possible to further improve high-temperature oxidation
resistance and producibility.
<Ni: nickel>
[0024] Ni is an element which improves corrosion resistance of the ferritic stainless steel
and is an essential element in the ferritic stainless steel in accordance with an
embodiment of the present invention. However, in a case where Ni is excessively contained,
the ferrite phase becomes unstable, and material costs increase. Therefore, in an
aspect of the present invention, the content of Ni is defined to be not more than
1.00%. In a case where Ni is contained in an amount of not more than 0.50%, it is
possible to further prevent an unstable ferrite phase and an increase in production
costs, each of which may otherwise be caused in a case where an excessive amount of
Ni is contained. In light of the above reason, a more preferable content of Ni is
0.02% to 0.30%.
<N: nitrogen>
[0025] N is an essential element in a ferritic stainless steel in accordance with an embodiment
of the present invention. However, in a case where N is excessively contained, N bonds
to Al in the steel to form AIN, which may serve as a starting point of accelerated
oxidation. Therefore, in an aspect of the present invention, the content of N is defined
to be not more than 0.030%. In a case where N is contained in an amount of not more
than 0.025%, it is possible to further reduce the possibility of hardening. In light
of the above reason, a more preferable content of N is 0.003% to 0.020%.
<Nb (niobium), B (boron), and REM (rare earth element)>
[0026] Nb is an element which is added to ensure the high-temperature strength. Further,
Nb has an effect of promoting formation of an Al
2O
3 film. Nb also prevents recrystallization of the stainless steel and causes the crystal
grains to be finer, so that the grain boundaries have an increased area. However,
in a case where Nb is excessively contained, toughness of a hot-rolled sheet may be
deteriorated.
[0027] B is an element which improves secondary workability and oxidation resistance of
a molded product manufactured with use of the ferritic stainless steel. However, in
a case where B is excessively contained, compounds of B serve as inclusions (impurities).
[0028] REM (rare earth elements, rare earth metals) means lanthanoids (elements having an
atomic number of 57 to 71, such as La, Ce, Pr, Nd, and Sm). REM is an element which
improves the high-temperature oxidation resistance. In a case where REM is contained
in not less than a predetermined amount, an Al oxide film is stabilized. Further,
REM improves adhesion between a base material and an oxide, thereby improving oxidation
resistance. However, in a case where REM is excessively contained, a surface defect
is generated during hot rolling, and producibility is reduced.
[0029] For the above reason, in an aspect of the present invention, the content of Nb is
defined to be 0.01% to 0.70%. In a case where Nb is contained in an amount of 0.05%
to 0.50%, more preferably 0.08% to 0.30%, it is possible to not only further reduce
the possibility of deterioration in workability but also improve oxidation resistance.
The upper limit of the content of Nb is yet even more preferably 0.20% or 0.15%. The
content of B is defined to be 0.0003% to 0.01%. In a case where B is contained in
an amount of 0.0003% to 0.005%, it is possible to further reduce the presence of inclusions
and improve secondary workability. The content of REM is defined to be 0.01% to 0.20%.
The content of REM is preferably 0.02% to 0.15%, and more preferably 0.04% to 0.10%.
(Other components)
[0030] The ferritic stainless steel in accordance with an aspect of the present invention
can further contain, as an element other than the above elements, at least one element
selected from the group consisting of Zr, V, Cu, Mo, W, Hf, Sn, Ta, Ti, Mg, and Ca.
<Zr: zirconium>
[0031] Zr is an element which improves the oxidation resistance. However, in a case where
Zr is excessively added, the steel may be hardened to cause a decrease in toughness.
As such, in an aspect of the present invention, Zr can be contained in an amount of
not more than 0.50%. In consideration of reduction of hardening and the like, it is
more preferable that Zr be contained in an amount of 0.01% to 0.40%.
<V: vanadium>
[0032] V is an element which improves workability and weld toughness. However, in a case
where V is excessively added, toughness of a hot-rolled sheet may be deteriorated.
In an aspect of the present invention, V can be contained in an amount of not more
than 0.50%. In consideration of reduction of hardening and the like, it is more preferable
that V be contained in an amount of 0.02% to 0.35%.
<Cu: copper>
[0033] Cu is an element which improves the corrosion resistance of the ferritic stainless
steel. However, in a case where Cu is excessively contained, oxidation resistance
and hot workability may be deteriorated. As such, in an aspect of the present invention,
Cu can be contained in an amount of not more than 1.0%. In consideration of material
costs and the like, it is more preferable that Cu be contained in an amount of 0.01%
to 0.5%.
<Mo: molybdenum>
[0034] Mo is an element which improves the corrosion resistance. However, in a case where
Mo is excessively contained, the ferritic stainless steel is hardened to cause a reduction
in toughness and an increase in material costs. As such, in an aspect of the present
invention, Mo can be contained in an amount of not more than 2.0%. In consideration
of workability, material costs, and the like, it is more preferable that Mo be contained
in an amount of 0.01% to 1.0%.
<W: tungsten>
[0035] W is an element which is added to ensure the high-temperature strength. However,
in a case where W is excessively contained, toughness of a hot-rolled sheet is deteriorated,
and material costs increase. As such, in an aspect of the present invention, W can
be contained in an amount of not more than 2.0%. In consideration of material costs
and the like, it is more preferable that W be contained in an amount of 0.01% to 1.0%.
<Hf: hafnium>
[0036] Hf is an element which improves the oxidation resistance. However, in a case where
Hf is excessively contained, toughness of a hot-rolled sheet is reduced, and material
costs increase. As such, in an aspect of the present invention, Hf can be contained
in an amount of not more than 0.50%. In consideration of toughness and material costs,
it is more preferable that Hf be contained in an amount of 0.001% to 0.20%.
<Sn: tin>
[0037] Sn (tin) is an element which improves the corrosion resistance of the ferritic stainless
steel. However, in a case where Sn is excessively contained, workability is reduced,
and material costs increase. As such, in an aspect of the present invention, Sn can
be contained in an amount of not more than 0.50%. In consideration of workability,
costs, and the like, it is more preferable that Sn be contained in an amount of 0.005%
to 0.20%.
<Ta: tantalum>
[0038] Ta is an element which improves the cleanliness and the oxidation resistance of the
steel. However, in a case where Ta is excessively contained, toughness is reduced,
and material costs increase. As such, in an aspect of the present invention, Ta can
be contained in an amount of not more than 0.5%. In consideration of toughness and
material costs, it is more preferable that Ta be contained in an amount of not more
than 0.40%. In light of the above reason, a more preferable content of Ta is 0.001%
to 0.30%.
<Ti: titanium>
[0039] Ti is an element which, by reacting with C and/or N, can form the ferritic stainless
steel into a ferritic single layer at 900°C to 1000°C. However, in a case where Ti
is excessively contained, TiO
2 may be produced in an oxide of Al, and oxidation lifetime may be deteriorated. As
such, in an aspect of the present invention, Ti can be contained in an amount of not
more than 0.20%. In consideration of workability and the like, it is more preferable
that Ti be contained in an amount of 0.005% to 0.15%.
<Mg: magnesium>
[0040] Mg forms a Mg oxide with Al in molten steel and acts as a deoxidizing agent. However,
in a case where Mg is excessively contained, toughness of the steel is reduced, and
producibility is reduced. As such, in an aspect of the present invention, Mg can be
contained in an amount of not more than 0.015%. In light of the above reason, a more
preferable content of Ma is 0.0002% to 0.0080%.
<Ca: calcium>
[0041] Ca is an element which improves hot workability. However, in a case where Ca is excessively
contained, toughness of the steel is reduced, and producibility is reduced. As such,
in an aspect of the present invention, Ca can be contained in an amount of not more
than 0.015%. In light of the above reason, a more preferable content of Ca is 0.0001%
to 0.012%.
[0042] The ferritic stainless steel in accordance with the present embodiment can satisfy
[Al]/(10×[Nb]) < 8 where [Al] is a percent by mass of Al and [Nb] is a percent by
mass of Nb. The inventors of the present invention have discovered that the amount
of Nb added needs to be appropriate in accordance with the amount of Al added, and
that when the above formula is satisfied, the various characteristics indicated in
Examples described later, such as oxidation resistance, are satisfied.
(Al-based oxide film)
[0043] The following description will discuss an Al-based oxide film on a surface of the
ferritic stainless steel in accordance with the present embodiment.
[0044] The ferritic stainless steel in accordance with the present embodiment includes,
on a surface thereof, an Al-based oxide film having a thickness of not less than 8
nm and less than 20 nm. The Al-based oxide film is a film mainly composed of alumina
and is formed through a final annealing step (described later). More specifically,
an Al-based oxide film in accordance with the present disclosure means a film having
an Al concentration of not less than 10%. By including the Al-based oxide film having
a thickness of not less than 8 nm, the ferritic stainless steel in accordance with
the present embodiment has oxidation resistance. Further, since the thickness of the
Al-based oxide film is less than 20 nm, it is possible to provide the ferritic stainless
steel which is excellent in brazing properties.
(Alumina layer)
[0045] The inventors of the present invention discovered through diligent research that,
regarding components of a ferritic stainless steel, in a case where Nb and REM are
contained as essential elements at concentrations within appropriate ranges, columnar
crystallization of an alumina layer formed under a use condition is improved. This
is considered to be due to increased concentrations of Nb and REM in grain boundaries
in the alumina layer. Further, the inventors of the present invention discovered that
the columnar crystallization is improved also in a case where B is contained as an
essential element at a concentration within an appropriate range.
[0046] The ferritic stainless steel in accordance with the present disclosure is suitably
applicable to purposes in which oxidation resistance at high temperatures is required.
As such, the use condition means a high temperature condition. For example, in the
present embodiment, an alumina layer 20 formed in a case where heating is carried
out at 1050°C for 50 hours is mentioned.
[0047] The ferritic stainless steel in accordance with the present embodiment contains not
more than 0.030% of C, 0.01% to 1.5% of Si, 0.01% to 1.00% of Mn, not more than 0.050%
of P, not more than 0.005% of S, 15.0% to 25.0% of Cr, 2.0% to 4.0% of Al, not more
than 1.00% of Ni, 0.01% to 0.70% of Nb, not more than 0.030% of N, 0.0003% to 0.01%
of B, and 0.01% to 0.20% of REM, in percent by mass.
[0048] The alumina layer 20 formed by heating the ferritic stainless steel containing the
above components at 1050°C for 50 hours has the following feature. That is, the alumina
layer 20 is 100% made up of a columnar crystal or satisfies the following formula
(1):

where (C) is a thickness of a columnar crystal in a cross section obtained by cutting
the alumina layer 20 in a thickness direction and (E) is a thickness of an equiaxial
crystal in the cross section obtained by cutting the alumina layer 20 in the thickness
direction.
[0049] Fig. 1 is an SEM image showing a cross section of the alumina layer 20 which is mainly
composed of alumina and is formed in a case where the ferritic stainless steel 1 in
accordance with an embodiment of the present invention is heated at 1050°C for 50
hours.
[0050] As shown in Fig. 1, in a case where the ferritic stainless steel including an Al-based
oxide film is heated at 1050°C for 50 hours, the alumina layer 20 mainly composed
of alumina is formed in the ferritic stainless steel 1. The alumina layer 20 includes
a columnar crystal 201 and an equiaxial crystal 202.
[0051] The columnar crystal 201 is tissue in which crystal grains that have grown long and
thin in the thickness direction of the alumina layer 20 are arranged. The equiaxial
crystal 202 is polycrystalline tissue in which the shape and orientation of the crystal
grains constituting the equiaxial crystal 202 are isotropic. The reference sign C
in Fig. 1 indicates a thickness of the columnar crystal in a cross section obtained
by cutting the alumina layer 20 in a thickness direction. The reference sign E in
Fig. 1 indicates a thickness of the equiaxial crystal in the cross section obtained
by cutting the alumina layer 20 in the thickness direction.
[0052] The equiaxial crystal 202 has a grain boundary density greater than that of the columnar
crystal 201 and therefore has increased routes through which oxygen is diffused at
the grain boundaries. As such, the equiaxial crystal 202 has a shorter oxidation lifetime
than the columnar crystal 201. The ferritic stainless steel in accordance with the
present embodiment is extremely excellent in oxidation resistance under high temperature
conditions, since the alumina layer 20 satisfies formula (1) above or is 100% made
up of a columnar crystal.
(Production method)
[0053] Firstly, the following will provide a brief description of an example of a production
process for a ferritic stainless steel in accordance with the present embodiment.
The production process for a ferritic stainless steel in accordance with the present
embodiment includes a pretreatment step, a hot rolling step, an annealing step, a
first pickling step, a cold rolling step, a process annealing step, a final annealing
step, and a second pickling step in this order.
[0054] In the pretreatment step, first, steel which has been adjusted so as to have composition
falling within the scope of the present invention is melted with use of a melting
furnace having a vacuum atmosphere or an argon atmosphere, and this steel is cast
to produce a slab. Subsequently, the slab is cut to obtain a slab piece for hot rolling.
Then, the slab piece is heated to a temperature range of 1100°C to 1300°C in an air
atmosphere. A time for which the slab piece is heated and held is not limited. Note
that, in a case where the pretreatment step is industrially carried out, the above
casting can be continuous casting.
[0055] The hot rolling step is a step of hot-rolling the slab (steel ingot), obtained in
the pretreatment step, to produce a hot-rolled steel strip having a predetermined
thickness.
[0056] The annealing step is a step of heating the hot-rolled steel strip obtained in the
hot rolling step to a temperature of, for example, 900°C to 1050°C, so as to soften
the steel strip. This annealing step is a step carried out as necessary, and may not
be carried out.
[0057] The first pickling step is a step of washing off, with use of a pickle such as hydrochloric
acid or a mixed solution of nitric acid and hydrofluoric acid, scales adhering to
the surface of the annealed steel strip obtained in the annealing step.
[0058] The cold rolling step is a step of rolling the annealed steel strip from which the
scales have been removed in the first pickling step, so as to make the annealed steel
strip thinner. A rolling reduction ratio in the cold rolling step is, for example,
50% to 90%.
[0059] The process annealing step is a step of heating the steel strip obtained in the cold
rolling step to a temperature of, for example, 900°C to 1050°C, so as to soften the
steel strip. This annealing step is a step carried out as necessary, and may not be
carried out.
[0060] The method for producing the ferritic stainless steel in accordance with the present
embodiment includes the final annealing step after the process annealing (after the
cold rolling step). In the final annealing step, a process is carried out, as a first
step, in which heating is carried out in an inert gas atmosphere and under the condition
of a dew point of not higher than -40°C until the temperature is in a temperature
range of 900°C to 1200°C. After the first step, a process can be carried out as a
second step in which the temperature is maintained in the temperature range of 900°C
to 1200°C for not longer than 5 minutes in an inert gas atmosphere and under the condition
of a dew point of not higher than -40°C. Carrying out the final annealing step makes
it possible to produce a ferritic stainless steel which includes, on a surface thereof,
an Al-based oxide film having a thickness of not less than 8 nm and less than 20 nm.
[0061] Note here that the inert gas can be, for example, Ar, H
2, or N
2. Alternatively, the inert gas can be a gas obtained by mixing two or three selected
from the group consisting of Ar, H
2, or N
2 such that each of the two or three selected is mixed in a ratio ranging from 1% to
99% and the two or three selected constitute 100% together. More specifically, the
inert gas can be, for example, a mixed gas of hydrogen, nitrogen, and/or argon. In
this case, the mixed gas can contain 70% to 90% of hydrogen, 10% to 30% of nitrogen
or argon, or the mixed gas can contain 70% to 90% of hydrogen and 5% to 25% of nitrogen
and argon so that a content of nitrogen and argon is 30%.
[0062] The second pickling step is a step of, as necessary, washing off, with use of a pickle
such as a mixed solution of nitric acid and hydrofluoric acid, scales adhering to
the surface of the steel strip obtained in the final annealing step.
[0063] Aspects of the present invention can also be expressed as follows:
A ferritic stainless steel in accordance with Aspect 1 of the present disclosure contains
not more than 0.030% of C, 0.01% to 1.5% of Si, 0.01% to 1.00% of Mn, not more than
0.050% of P, not more than 0.005% of S, 15.0% to 25.0% of Cr, 2.0% to 4.0% of Al,
not more than 1.00% of Ni, 0.01% to 0.70% of Nb, not more than 0.030% of N, 0.0003%
to 0.01% of B, and 0.01% to 0.20% of REM, in percent by mass, and the other part composed
of Fe and an inevitable impurity, the ferritic stainless steel including, on a surface
of the ferritic stainless steel, an Al-based oxide film having a thickness of not
less than 8 nm and less than 20 nm.
[0064] According to the above configuration, it is possible to provide a ferritic stainless
steel which is excellent in oxidation resistance and brazing properties.
[0065] In Aspect 2 of the present disclosure, the ferritic stainless steel in accordance
with Aspect 1 can be configured such that: in a case where the ferritic stainless
steel is heated at 1050°C for 50 hours, the ferritic stainless forms an alumina layer
20 mainly composed of alumina; and the alumina layer is 100% made up of a columnar
crystal or satisfies the following formula (1):

where (C) is a thickness of a columnar crystal 201 in a cross section obtained by
cutting the alumina layer 20 in a thickness direction and (E) is a thickness of an
equiaxial crystal 202 in the cross section obtained by cutting the alumina layer 20
in the thickness direction.
[0066] According to the above configuration, it is possible to provide a ferritic stainless
steel which has an excellent effect in oxidation resistance under high temperature
conditions. In particular, in a case where the alumina layer is 100% made up of a
columnar crystal, it is possible to provide a ferritic stainless steel which has an
even more excellent oxidation resistant effect.
[0067] In Aspect 3 of the present disclosure, the ferritic stainless steel in accordance
with Aspect 1 or 2 can be configured such that the ferritic stainless steel further
contains at least one selected from the group consisting of not more than 0.50% of
Zr, not more than 0.50% of V, not more than 1.0% of Cu, not more than 2.0% of Mo,
not more than 2.0% of W, not more than 0.50% of Hf, not more than 0.50% of Sn, not
more than 0.5% of Ta, not more than 0.20% of Ti, not more than 0.015% of Mg, and not
more than 0.015% of Ca, in percent by mass.
[0068] In Aspect 4 of the present disclosure, the ferritic stainless steel in accordance
with Aspect 1 or 2 can be configured such that the ferritic stainless steel satisfies
[Al]/(10×[Nb]) < 8
where [Al] is a percent by mass of Al and [Nb] is a percent by mass of Nb.
[0069] A method for producing a ferritic stainless steel in accordance with Aspect 5 of
the present disclosure is a method for producing a ferritic stainless steel that contains
not more than 0.030% of C, 0.01% to 1.5% of Si, 0.01% to 1.00% of Mn, not more than
0.050% of P, not more than 0.005% of S, 15.0% to 25.0% of Cr, 2.0% to 4.0% of Al,
not more than 1.00% of Ni, 0.01% to 0.70% of Nb, not more than 0.030% of N, 0.0003%
to 0.01% of B, and 0.01% to 0.20% of REM, in percent by mass, and the other part composed
of Fe and an inevitable impurity,
wherein a final annealing step after a cold rolling step includes a first step of
carrying out heating in an inert gas atmosphere and under a condition of a dew point
of not higher than -40°C until a temperature is in a temperature range of 900°C to
1200°C.
[0070] According to the above configuration, it is possible to produce a ferritic stainless
steel which includes, on a surface thereof, an Al-based oxide film having a thickness
of not less than 8 nm and less than 20 nm. This makes it possible to produce a ferritic
stainless steel which is excellent in oxidation resistance and brazing properties.
[0071] In Aspect 6 of the present disclosure, the method in accordance with Aspect 5 can
be configured such that the final annealing step includes a second step of maintaining
the temperature in the temperature range of 900°C to 1200°C for not longer than 5
minutes after the first step.
[0072] According to the above configuration, it is possible to produce a ferritic stainless
steel which includes, on a surface thereof, an Al-based oxide film having a thickness
of not less than 8 nm and less than 20 nm.
[0073] In Aspect 7 of the present disclosure, the method in accordance with Aspect 5 or
6 can be configured such that: in a case where the ferritic stainless steel obtained
through the final annealing step is heated at 1050°C for 50 hours, the ferritic stainless
steel forms an alumina layer mainly composed of alumina; and the alumina layer is
100% made up of a columnar crystal or satisfies the following formula (1):

[0074] where (C) is a thickness of a columnar crystal 201 in a cross section obtained by
cutting the alumina layer in a thickness direction and (E) is a thickness of an equiaxial
crystal 202 in the cross section obtained by cutting the alumina layer 20 in the thickness
direction.
[0075] According to the above configuration, it is possible to provide a ferritic stainless
steel which has an excellent effect in oxidation resistance under high temperature
conditions. In particular, in a case where the alumina layer is 100% made up of a
columnar crystal, it is possible to provide a ferritic stainless steel which has brazing
properties and an even more excellent oxidation resistant effect.
[0076] In Aspect 8 of the present disclosure, the method in accordance with any one of Aspects
5 through 7 can be configured such that the ferritic stainless steel further contains
at least one selected from the group consisting of not more than 0.50% of Zr, not
more than 0.50% of V, not more than 1.0% of Cu, not more than 2.0% of Mo, not more
than 2.0% of W, not more than 0.50% of Hf, not more than 0.50% of Sn, not more than
0.5% of Ta, not more than 0.20% of Ti, not more than 0.015% of Mg, and not more than
0.015% of Ca, in percent by mass.
[Examples]
[0077] In order to evaluate the physical properties of ferritic stainless steels in accordance
with embodiments of the present invention, ferritic stainless steels containing components
shown in Table 1 below as raw materials were produced as steel types of inventive
examples and steel types of comparative examples. In Table 1, steel types No. 1 through
16 are ferritic stainless steels which are examples of the present invention and were
prepared within the scope of the present invention. In Table 1, steel types No. 17
through 27 are ferritic stainless steels which are comparative examples and were prepared
under conditions falling outside the scope of the present invention.
[0078] In order to produce a steel material of a steel type shown in Table 1, first, a steel
containing the components shown in Table 1 was melted in vacuum to produce 30 kg of
slab. The slab was heated at 1230°C for 2 hours and then subjected to hot rolling
to prepare a hot-rolled sheet having a thickness of 3 mm. The obtained hot-rolled
sheet was annealed at a temperature of 900°C to 1050°C to prepare a hot-rolled annealed
sheet. The obtained hot-rolled annealed sheet was subjected to three times of cold
rolling and three times of process annealing to produce a cold-rolled sheet having
a thickness of 50 pm. The obtained cold-rolled sheet was subjected to final annealing
in an inert gas atmosphere under the conditions of temperature, time, and dew point
indicated in Table 2. For steel types No. 1 through 27, the final annealing was carried
out with use of, as the inert gas, a gas containing 70% to 90% of H
2 and 10% to 30% of N
2 or Ar.
[0079] Note that the cold rolling was carried out at a rolling reduction ratio of 60% to
85%, and the process annealing after the cold rolling was carried out at a temperature
condition in a range of 900°C to 1050°C. Note that the production method described
in Examples is merely an example, and does not limit the production method.
[Table 2]
| Steel type No. |
Temperature [°C] |
Time [sec] |
Dew point [°C] |
Category |
| 1 |
1050 |
30 |
-60 |
Example of present invention |
| 2 |
1150 |
30 |
-45 |
| 3 |
1050 |
260 |
-60 |
| 4 |
1050 |
60 |
-55 |
| 5 |
1000 |
60 |
-50 |
| 6 |
1050 |
60 |
-55 |
| 7 |
1050 |
60 |
-60 |
| 8 |
1075 |
180 |
-65 |
| 9 |
1100 |
30 |
-65 |
| 10 |
1100 |
60 |
-65 |
| 11 |
1050 |
60 |
-60 |
| 12 |
1050 |
60 |
-60 |
| 13 |
1050 |
60 |
-65 |
| 14 |
1100 |
30 |
-60 |
| 15 |
950 |
120 |
-70 |
| 16 |
1000 |
60 |
-60 |
| 17 |
1000 |
60 |
-55 |
Comparative example |
| 18 |
880 |
30 |
-65 |
| 19 |
975 |
30 |
-60 |
| 20 |
1050 |
60 |
-60 |
| 21 |
1050 |
60 |
-55 |
| 22 |
1050 |
30 |
-60 |
| 23 |
1100 |
180 |
-35 |
| 24 |
1150 |
60 |
-60 |
| 25 |
1150 |
60 |
-70 |
| 26 |
1100 |
30 |
-60 |
| 27 |
1075 |
360 |
-65 |
[0080] In Table 1, the composition of components contained in each steel type is indicated
in percent by mass. Note that a remainder other than the components shown in Table
1 is Fe or a small amount of an impurity which is inevitably contained (inevitable
impurity). Underlines shown in Table 1 each indicate that the range of a component
contained in a stainless steel of a comparative example of the present invention is
outside a range in accordance with the present invention.
(Measurement of film thickness)
[0081] The following description will discuss a thickness of an Al-based oxide film in each
of the examples of the present invention and the comparative examples prepared under
the conditions indicated in Tables 1 and 2.
[0082] The thickness of the Al-based oxide film was measured with use of a glow discharge
optical emission spectrometer (glow discharge spectroscopy: GDS) (GD-Profiler 2, manufactured
by Horiba, Ltd.). Specifically, a cold-rolled annealed sheet having a thickness of
50 pm in accordance with each of the examples of the present invention and the comparative
examples was subjected to measurement of an Al concentration, from a surface of the
cold-rolled annealed sheet to a position 0.1 pm deep from the surface, at a pitch
of 0.0025 pm. Measurement conditions in the GDS measurement were as follows. Gas replacement
time: 200 seconds, preliminary sputtering time: 30 seconds, background: 5 seconds,
depth: 1.01 pm, pressure: 600 Pa, output: 35 W, effective value: 8.75 W. Module: 8
V, phase: 4 V, frequency: 100 Hz, duty cycle: 0.25.
[0083] Note that the thickness of a film mainly composed of alumina was determined such
that a half-value width of an oxygen peak concentration was regarded as a thickness
of the film mainly composed of alumina. The results are shown in Table 2 below. In
determination of a film mainly composed of alumina in Table 2, "Good" indicates that
the film mainly composed of alumina has a thickness of less than 20 nm, and "Poor"
indicates that the film mainly composed of alumina has a thickness of not less than
20 nm.
(Brazing properties evaluation test)
[0084] The following description will discuss an evaluation test on brazing properties carried
out with respect to the examples of the present invention and the comparative examples
shown in Tables 1 and 2. The evaluation test on brazing properties was carried out
by preparing a JIS 13B test piece from a cold-rolled annealed sheet having a thickness
of 50 pm and then cutting the JIS 13B test piece in half. Specifically, the samples
thus cut in half are placed so as to overlap with each other by 10 mm, and a brazing
filler material (BNi-5: ASTM) was applied to one of the contact surfaces (12.5 mm
× 10 mm) so as to have a thickness of 0.1 mm. Then, with use of an atmosphere heat
treatment furnace, the samples overlapping with each other were subjected to brazing
in a vacuum (dew point: -65°C) at 1200°C, so that the samples were joined together.
After the joining, a tensile test was carried out. The numerical values shown in Table
3 each indicate a tensile strength (MPa) at a time point when a breakage occurred.
In a case where the tensile strength was not less than 250 MPa, it was determined
that the brazing properties were good. In a case where a breakage occurred from the
base material in the tensile test, it was determined that the brazing properties were
good. In a case where a breakage occurred from the brazed part, it was determined
that the brazing properties were poor. The brazing properties determined to be good
are indicated as "Good" in Table 3. The brazing properties determined to be poor are
indicated as "Poor" in Table 3.
(Measurement of ratio of columnar crystal to equiaxial crystal in alumina layer mainly
composed of alumina)
[0085] The following description will discuss measurement of a ratio of a columnar crystal
to an equiaxial crystal in an alumina layer mainly composed of alumina, carried out
with respect to the examples of the present invention and the comparative examples
shown in Tables 1 and 2. First, a test piece was heated at 1050°C for 50 hours and
then immersed in liquid nitrogen for 5 minutes. Then, the test piece was taken out
and immediately given an impact to break. Subsequently, with use of a scanning electron
microscope (SEM) SU5000 (manufactured by Hitachi High-Tech Corporation), a cross section
of the alumina layer was magnified and observed at a magnification of 20,000 times,
and a thickness (C) of a columnar crystal and a thickness (E) of an equiaxial crystal
were measured to calculate a ratio of the columnar crystal to the equiaxial crystal
((C)/(E)).
[0086] Note that the measurement of the ratio of the columnar crystal to the equiaxial crystal
was carried out by SEM observation of the alumina layer magnified at a magnification
of 20,000 times and calculation of an average value of data respectively measured
at three random portions of the alumina layer. In a case where the equiaxial crystal
was not formed in layers, a grain size of an equiaxial crystal that is present on
its own was determined as the thickness of the equiaxial crystal.
[0087] The results are shown in Table 3 below. In determination of a ratio of a columnar
crystal to an equiaxial crystal in an alumina layer in Table 2, "Good" indicates that
the ratio of the columnar crystal to the equiaxial crystal in the alumina layer is
not less than 1.2, and "Poor" indicates that the ratio of the columnar crystal to
the equiaxial crystal in the alumina layer is less than 1.2.
(High-temperature oxidation resistance evaluation test)
[0088] The following description will discuss an evaluation test on high-temperature oxidation
resistance carried out with respect to the examples of the present invention and the
comparative examples shown in Tables 1 and 2. First, for each steel type indicated
in Table 1, three test pieces each having a width of 20 mm and a length of 25 mm were
taken from a cold-rolled sheet having a thickness of 50 pm as described above regarding
production of a steel material. The test pieces were subjected to an air atmosphere
at 1050°C for 50 hours, and an average amount of increase in oxidation among the three
test pieces was measured. The present high-temperature oxidation resistance evaluation
test was carried out in an atmospheric air with use of an EREMA electric kiln. The
results are shown in Table 3 below. In determination on high-temperature oxidation
resistance in Table 3, "Good" indicates that an average increase in oxidation was
not more than 1 mg/cm
2, and "Poor" indicates that the average increase in oxidation was more than 1 mg/cm
2.
[Table 3]
| Steel type No. |
Thickness of Al-based oxide film < 20 nm [nm] |
Tensile strength at room temperature after brazing (≥ 250 MPa) [MPa] |
Ratio of columnar crystal to equiaxial crystal (1 050°C × 50 h) [-] |
Oxidation resistance 1050°C × 50 h [mg/cm2] |
Category |
| 1 |
18 |
Good |
339 |
Good |
4.1 |
Good |
0.61 |
Good |
Example of present invention |
| 2 |
17 |
Good |
368 |
Good |
2.8 |
Good |
0.71 |
Good |
| 3 |
19 |
Good |
353 |
Good |
2.5 |
Good |
0.65 |
Good |
| 4 |
16 |
Good |
332 |
Good |
4.3 |
Good |
0.62 |
Good |
| 5 |
18 |
Good |
348 |
Good |
3.9 |
Good |
0.96 |
Good |
| 6 |
15 |
Good |
353 |
Good |
3.7 |
Good |
0.59 |
Good |
| 7 |
16 |
Good |
346 |
Good |
3.4 |
Good |
0.63 |
Good |
| 8 |
17 |
Good |
341 |
Good |
3.7 |
Good |
0.62 |
Good |
| 9 |
14 |
Good |
358 |
Good |
3.6 |
Good |
0.60 |
Good |
| 10 |
19 |
Good |
336 |
Good |
2.1 |
Good |
0.88 |
Good |
| 11 |
15 |
Good |
339 |
Good |
3.3 |
Good |
0.83 |
Good |
| 12 |
14 |
Good |
355 |
Good |
3.4 |
Good |
0.61 |
Good |
| 13 |
17 |
Good |
344 |
Good |
3.5 |
Good |
0.62 |
Good |
| 14 |
13 |
Good |
359 |
Good |
2.9 |
Good |
0.65 |
Good |
| 15 |
18 |
Good |
344 |
Good |
3.2 |
Good |
0.61 |
Good |
| 16 |
13 |
Good |
348 |
Good |
3.2 |
Good |
0.64 |
Good |
| 17 |
31 |
Poor |
224 |
Poor |
0.9 |
Poor |
1.23 |
Poor |
Comparative example |
| 18 |
54 |
Poor |
165 |
Poor |
1.1 |
Poor |
1.63 |
Poor |
| 19 |
16 |
Good |
350 |
Good |
1.0 |
Poor |
3.21 |
Poor |
| 20 |
17 |
Good |
324 |
Good |
1.1 |
Poor |
3.92 |
Poor |
| 21 |
37 |
Poor |
138 |
Poor |
1.6 |
Good |
0.66 |
Good |
| 22 |
15 |
Good |
341 |
Good |
1.0 |
Poor |
4.31 |
Poor |
| 23 |
71 |
Poor |
86 |
Poor |
1.1 |
Poor |
3.98 |
Poor |
| 24 |
18 |
Good |
355 |
Good |
0.8 |
Poor |
2.65 |
Poor |
| 25 |
31 |
Poor |
107 |
Poor |
1.7 |
Good |
0.63 |
Good |
| 26 |
49 |
Poor |
88 |
Poor |
1.1 |
Poor |
1.56 |
Poor |
| 27 |
51 |
Poor |
129 |
Poor |
1.8 |
Good |
0.64 |
Good |
[0089] As indicated in a column "Thickness of Al-based oxide film" in Table 3, steel types
No. 1 through 16 of the inventive examples, which had been produced by a production
method within the scope of the present invention, all included an Al-based oxide film
having a thickness of less than 20 nm and had good brazing properties.
[0090] In contrast, comparative example steel types No. 17, 18, 21, 23, and 25 through 27
each included an Al-based oxide film having a thickness of not less than 20 nm and
were poor in brazing properties.
[0091] Further, from the results in the column "Thickness of Al-based oxide film" in Table
3, it was verified that a ferritic stainless steel including an Al-based oxide film
having a thickness of less than 20 nm was excellent in brazing properties.
[0092] Further, as indicated by the results in a column "Oxidation resistance" in Table
3, it was verified that steel types No. 1 through 16 of the inventive examples, each
of which had been heated at 1050°C for 50 hours in the final annealing step, all exhibited
a result that the steel type had a good oxidation resistance.
[0093] Further, from a column of results of a ratio of a columnar crystal to an equiaxial
crystal and a column of results of oxidation resistance in Table 3, it was verified
that a good high-temperature oxidation resistance is exhibited in a case where the
ratio of the columnar crystal to the equiaxial crystal is not less than 1.2.
[0094] That is, it was verified that in a case where a ferritic stainless steel within the
scope of the present invention is heated at 1050°C for 50 hours, the ferritic stainless
steel is excellent in brazing properties and oxidation resistance.
[0095] The following will explain the reason why comparative example steel types Nos. 17
through 27 did not exhibit results as good as the results of the steel types of the
examples of the present invention.
[0096] Comparative example steel type No. 17 had a Mn content of more than 1.0% and exhibited
a result that the steel type had a decrease in high-temperature oxidation resistance.
Further, comparative example steel type No. 17 not only decreased the secondary workability
by having a B content of less than 0.0003% but also failed to exhibit a good result
in terms of brazing properties.
[0097] Comparative example steel type No. 18 tended to have equiaxial crystallization due
to having a REM content of less than 0.01% and a Ti content of more than 0.20%. As
such, comparative example steel type No. 18 did not exhibit an excellent result in
terms of high-temperature oxidation resistance.
[0098] Comparative example steel type No. 19 had a Nb content of less than 0.01% and thus
had a possibility of deterioration in high-temperature oxidation resistance and workability.
As such, comparative example steel type No. 19 did not exhibit an excellent result
in terms of high-temperature oxidation resistance. However, comparative example steel
type No. 19 had a Ti content of less than 0.20% and therefore exhibited a good result
in terms of brazing properties.
[0099] Comparative example steel type No. 20 contained no Ti and did not tend to form a
Ti-based oxide. As such, comparative example steel type No. 20 exhibited a good result
in terms of brazing properties. However, comparative example steel type No. 20 had
a Zr content of more than 0.50% and thus tended to have segregation of Zr at alumina
grain boundaries to encourage equiaxial crystallization.
[0100] Comparative example steel type No. 21 had a Si content of more than 1.5%, and exhibited
an excellent result in terms of high-temperature oxidation resistance due to an effect
of a Si-based oxide such as SiO
2. However, comparative example steel type No. 21 did not exhibit a good result in
terms of brazing properties due to the Si content of more than 1.5% and formation
of the Si-based oxide.
[0101] Comparative example steel type No. 22 had an Al content of less than 2.0% and did
not tend to have formation of an oxide film of Al
2O
3. As such, comparative example steel type No. 22 exhibited a good result in terms
of brazing properties but did not exhibit a good result in terms of high-temperature
oxidation resistance.
[0102] Comparative example steel type No. 23 tended to have formation of a Ti oxide such
as TiO
2 due to having a Ti content of more than 0.20%. As such, comparative example steel
type No. 23 did not exhibit a good result in terms of high-temperature oxidation resistance
and brazing properties.
[0103] Comparative example steel type No. 24 had a Nb content of more than 0.70% and tended
to have equiaxial crystallization. As such, comparative example steel type No. 24
did not exhibit a good result in terms of high-temperature oxidation resistance.
[0104] Comparative example steel type No. 25 had an Al content of more than 4.0% and tended
to have formation of an oxide film of Al
2O
3. As such, comparative example steel type No. 25 exhibited a good result in terms
of high-temperature oxidation resistance but did not exhibit a good result in terms
of brazing properties.
[0105] Comparative example steel type No. 26 had a Cr content of more than 25.0%, and tended
to have an increased Cr concentration at alumina grain boundaries to form an equiaxial
crystal. Further, comparative example steel type No. 26 has formation of a Ti oxide
such as TiO
2 due to having a Ti content of more than 0.20%. As such, comparative example steel
type No. 26 did not exhibit a good result in terms of high-temperature oxidation resistance
and brazing properties.
[0106] Comparative example steel type No. 27 had a REM content of more than 0.20% and therefore
exhibited a good result in terms of high-temperature oxidation resistance. However,
comparative example steel type No. 27 did not exhibit a good result in terms of brazing
properties, due to the REM content of more than 0.20% and formation of an oxide such
as Y
2O
3 or CeO
2.
(Supplementary note)
[0107] The present invention is not limited to the embodiments, but can be altered by a
skilled person in the art within the scope of the claims. The present invention also
encompasses, in its technical scope, any embodiment derived by combining technical
means disclosed in differing embodiments.
Reference Signs List
[0108]
1: Ferritic stainless steel
20: Alumina layer
201: Columnar crystal
202: Equiaxial crystal
C: Thickness of columnar crystal
E: Thickness of equiaxial crystal