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Article(id=1199810029361656199, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, articleNumber=1009-5438(2022)06-0015-04, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1665504000000, receivedDateStr=2022-10-12, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1763986602391, onlineDateStr=2025-11-24, pubDate=1671897600000, pubDateStr=2022-12-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763986602391, onlineIssueDateStr=2025-11-24, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763986602391, creator=13701087609, updateTime=1763986602391, updator=13701087609, issue=Issue{id=1199810028623458694, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='6', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763986602216, creator=13701087609, updateTime=1764034375076, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200010402584163079, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200010402584163080, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=15, endPage=18, ext={EN=ArticleExt(id=1199810029604925833, articleId=1199810029361656199, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Evolution Rules of Non-metallic Inclusions in Smelting Process of Heavy Rail, columnId=1187100781414069182, journalTitle=Science & Technology of Baotou Steel, columnName=Production Practices and Management, runingTitle=null, highlight=null, articleAbstract=

The changes of morphology, component and size for non-metallic inclusions in smelting process are studied with metalloscope and scanning electron microscope-energy spectrum analysis by sampling in each link of technological process of heavy rail. The results showed that the non-metallic inclusions in smelting process were spherical and their main components were CaO-SiO2-MgO-Al2O3 as well as the proportion of content for each component was changed regularly with technological links, sizes were decreased gradually and quantity was reduced with the advance of technological process. The main source of inclusions in rail could be judged according to the change laws of components for inclusions in each process of smelting process for heavy rail. It could be inferred that the large size inclusions in heavy rail steel are compound inclusions composed of deoxidation product that is not upfloated combining with foreign inclusions during continuous casting process by analyzing the scanning electron microscope-energy spectrum detection results for large size inclusions in heavy rail.

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通过对重轨工艺流程各环节取样,采用金相显微镜、扫描电镜—能谱分析方法,研究了冶炼流程中非金属夹杂物的形貌、组分和尺寸的变化。结果表明,冶炼过程中非金属夹杂物均为球状,其主要组分为CaO-SiO2-MgO-Al2O3,各组分含量比例随工艺环节有规律变化,尺寸随工艺环节推进逐渐减小,数量随工艺流程推进逐步减少。根据重轨冶炼过程中各工序夹杂物组分的变化规律,可以判断成品钢轨中夹杂物的主要来源。通过分析重轨中大尺寸夹杂物扫描电镜—能谱检测结果,可以推断重轨钢中大尺寸夹杂物是在连铸过程中由未上浮的脱氧产物和外来的夹杂物相结合组成的复合夹杂物。

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张达先(1988-),男,内蒙古包头市人,硕士,工程师,现主要从事夹杂物控制及稀土在钢中应用研究工作。

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张达先(1988-),男,内蒙古包头市人,硕士,工程师,现主要从事夹杂物控制及稀土在钢中应用研究工作。

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张达先(1988-),男,内蒙古包头市人,硕士,工程师,现主要从事夹杂物控制及稀土在钢中应用研究工作。

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tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=CN, orderNo=3, keyword=夹杂物)], refs=[Reference(id=1200024822018310936, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, doi=null, pmid=null, pmcid=null, year=2017, volume=33, issue=6, pageStart=62, pageEnd=66, url=null, language=null, rfNumber=[1], rfOrder=0, authorNames=齐江华, 郑建国, 陈光友, journalName=炼钢, refType=null, unstructuredReference=齐江华, 郑建国, 陈光友, 等. 重轨钢中大颗粒夹杂物的来源探讨[J]. 炼钢, 2017, 33(6):62-66., articleTitle=重轨钢中大颗粒夹杂物的来源探讨, refAbstract=null), Reference(id=1200024822131557146, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, doi=null, pmid=null, pmcid=null, year=2021, volume=56, issue=5, pageStart=75, pageEnd=78, url=null, language=null, rfNumber=[2], rfOrder=1, authorNames=樊志明, 杨吉春, 朱君, journalName=中国铸造装备与技术, refType=null, unstructuredReference=樊志明, 杨吉春, 朱君, 等. 重轨钢中夹杂物的分析与控制[J]. 中国铸造装备与技术, 2021, 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取样工位 夹杂物尺寸范围
/μm		 夹杂物数量(平均)
/个		 平均直径
/μm		 现象说明
转炉出钢 13~100 2.3 56.0 钢中未加脱氧剂和合金,数量少,尺寸大。
脱氧合金化后 4~130 78.6 17.2 大量脱氧产物生成,部分夹杂物聚集长大,20 μm以下夹杂物占比80%以上。
LF处理出站后 4~130 22.7 22.9 大部分脱氧产物聚集长大,并上浮排出钢液,夹杂物数量大幅减少。
VD处理出站后 7~75 10.7 18.5 夹杂物数量和尺寸减少。
中间包 6~53 7.3 17.0 夹杂物数量和尺寸进一步减少。
), ArticleFig(id=1200024818243437316, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=CN, label=表1, caption=

各工序夹杂物尺寸变化情况

, figureFileSmall=null, figureFileBig=null, tableContent=
取样工位 夹杂物尺寸范围
/μm		 夹杂物数量(平均)
/个		 平均直径
/μm		 现象说明
转炉出钢 13~100 2.3 56.0 钢中未加脱氧剂和合金,数量少,尺寸大。
脱氧合金化后 4~130 78.6 17.2 大量脱氧产物生成,部分夹杂物聚集长大,20 μm以下夹杂物占比80%以上。
LF处理出站后 4~130 22.7 22.9 大部分脱氧产物聚集长大,并上浮排出钢液,夹杂物数量大幅减少。
VD处理出站后 7~75 10.7 18.5 夹杂物数量和尺寸减少。
中间包 6~53 7.3 17.0 夹杂物数量和尺寸进一步减少。
), ArticleFig(id=1200024818419598090, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
取样工位 夹杂物尺寸
/μm		 夹杂物主要成分(质量分数)/%
Si Ca Mg Al O S Mn Ba
脱氧合金化后 35 12.36 19.40 2.06 27.14 35.85 3.18
50 12.24 13.36 1.62 23.44 40.59 2.21
100 14.36 17.48 1.17 23.07 33.77 2.29 4.36
LF处理出站后 15 16.39 29.82 5.55 11.48 33.78 2.32
35 13.98 25.06 3.05 13.32 31.10 1.10 7.91
75 12.14 23.60 5.99 4.06 26.97 4.02
VD处理出站后 20 17.53 34.91 6.02 7.16 32.80 1.57
35 15.44 37.12 5.99 5.14 30.99 5.32
50 13.96 35.10 6.06 5.80 21.72 6.77
中间包 17 16.37 30.99 5.37 11.09 31.39 1.52 3.27
40 24.85 29.19 1.09 39.50
53 13.35 8.71 8.36 9.52 39.39
), ArticleFig(id=1200024818566398734, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=CN, label=表2, caption=

不同工序夹杂物成分变化情况

, figureFileSmall=null, figureFileBig=null, tableContent=
取样工位 夹杂物尺寸
/μm		 夹杂物主要成分(质量分数)/%
Si Ca Mg Al O S Mn Ba
脱氧合金化后 35 12.36 19.40 2.06 27.14 35.85 3.18
50 12.24 13.36 1.62 23.44 40.59 2.21
100 14.36 17.48 1.17 23.07 33.77 2.29 4.36
LF处理出站后 15 16.39 29.82 5.55 11.48 33.78 2.32
35 13.98 25.06 3.05 13.32 31.10 1.10 7.91
75 12.14 23.60 5.99 4.06 26.97 4.02
VD处理出站后 20 17.53 34.91 6.02 7.16 32.80 1.57
35 15.44 37.12 5.99 5.14 30.99 5.32
50 13.96 35.10 6.06 5.80 21.72 6.77
中间包 17 16.37 30.99 5.37 11.09 31.39 1.52 3.27
40 24.85 29.19 1.09 39.50
53 13.35 8.71 8.36 9.52 39.39
), ArticleFig(id=1200024818675450641, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
项目 转炉出钢 脱氧合金化后 LF处理出站后 VD处理出站后 中间包(小颗粒夹杂物)
ω(Ca)/ω(Si)均值 1.29 1.85 2.30 1.89
ω(Ca)/ω(Si)波动范围 1.09~1.57 1.79~1.94 1.99~2.51 1.65~1.93
ω(Ca)/ω(Al)均值 1.16 0.68 3.40 6.05 2.79
ω(Ca)/ω(Al)波动范围 1.03~1.33 0.57~0.76 1.88~5.81 4.88~7.22 2.11~4.35
), ArticleFig(id=1200024821733098258, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810029361656199, language=CN, label=表3, caption=

各工序夹杂物中ω(Ca)/ω(Si)、ω(Ca)/ω(Al)比值情况

, figureFileSmall=null, figureFileBig=null, tableContent=
项目 转炉出钢 脱氧合金化后 LF处理出站后 VD处理出站后 中间包(小颗粒夹杂物)
ω(Ca)/ω(Si)均值 1.29 1.85 2.30 1.89
ω(Ca)/ω(Si)波动范围 1.09~1.57 1.79~1.94 1.99~2.51 1.65~1.93
ω(Ca)/ω(Al)均值 1.16 0.68 3.40 6.05 2.79
ω(Ca)/ω(Al)波动范围 1.03~1.33 0.57~0.76 1.88~5.81 4.88~7.22 2.11~4.35
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重轨冶炼过程非金属夹杂物的演变规律
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张达先 1 , 倪磊 2 , 乔瑞栋 2 , 麻晓光 1 , 唐建平 1 , 肖远悠 3
包钢科技 | 生产实践与管理 2022,48(6): 15-18
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包钢科技 | 生产实践与管理 2022, 48(6): 15-18
重轨冶炼过程非金属夹杂物的演变规律
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张达先1, 倪磊2, 乔瑞栋2, 麻晓光1, 唐建平1, 肖远悠3
作者信息
  • 1 内蒙古包钢钢联股份有限公司技术中心, 内蒙古 包头 014010
  • 2 内蒙古包钢钢联股份有限公司炼钢厂, 内蒙古 包头 014010
  • 3 辽宁科技大学 材料与冶金学院, 辽宁 鞍山 114051

    • 张达先(1988-),男,内蒙古包头市人,硕士,工程师,现主要从事夹杂物控制及稀土在钢中应用研究工作。

Evolution Rules of Non-metallic Inclusions in Smelting Process of Heavy Rail
Da-xian Zhang1, Lei Ni2, Rui-dong Qiao2, Xiao-guang Ma1, Jian-ping Tang1, Yuan-you Xiao3
Affiliations
  • 1 Technical Center of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
  • 2 Steel-making Plant of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
  • 3 School of Materials and Metallurgy, University of Science and Technology Liaoning, Anshan 114051, Liaoning, China
出版时间: 2022-12-25
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摘要
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通过对重轨工艺流程各环节取样,采用金相显微镜、扫描电镜—能谱分析方法,研究了冶炼流程中非金属夹杂物的形貌、组分和尺寸的变化。结果表明,冶炼过程中非金属夹杂物均为球状,其主要组分为CaO-SiO2-MgO-Al2O3,各组分含量比例随工艺环节有规律变化,尺寸随工艺环节推进逐渐减小,数量随工艺流程推进逐步减少。根据重轨冶炼过程中各工序夹杂物组分的变化规律,可以判断成品钢轨中夹杂物的主要来源。通过分析重轨中大尺寸夹杂物扫描电镜—能谱检测结果,可以推断重轨钢中大尺寸夹杂物是在连铸过程中由未上浮的脱氧产物和外来的夹杂物相结合组成的复合夹杂物。

重轨  /  工艺流程  /  夹杂物

The changes of morphology, component and size for non-metallic inclusions in smelting process are studied with metalloscope and scanning electron microscope-energy spectrum analysis by sampling in each link of technological process of heavy rail. The results showed that the non-metallic inclusions in smelting process were spherical and their main components were CaO-SiO2-MgO-Al2O3 as well as the proportion of content for each component was changed regularly with technological links, sizes were decreased gradually and quantity was reduced with the advance of technological process. The main source of inclusions in rail could be judged according to the change laws of components for inclusions in each process of smelting process for heavy rail. It could be inferred that the large size inclusions in heavy rail steel are compound inclusions composed of deoxidation product that is not upfloated combining with foreign inclusions during continuous casting process by analyzing the scanning electron microscope-energy spectrum detection results for large size inclusions in heavy rail.

heavy rail  /  technological process  /  inclusion
张达先, 倪磊, 乔瑞栋, 麻晓光, 唐建平, 肖远悠. 重轨冶炼过程非金属夹杂物的演变规律. 包钢科技, 2022 , 48 (6) : 15 -18 .
Da-xian Zhang, Lei Ni, Rui-dong Qiao, Xiao-guang Ma, Jian-ping Tang, Yuan-you Xiao. Evolution Rules of Non-metallic Inclusions in Smelting Process of Heavy Rail[J]. Science & Technology of Baotou Steel, 2022 , 48 (6) : 15 -18 .
正文
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为保障列车运行安全,钢轨材质“高洁净度”的要求越来越严格。夹杂物是钢材中不可避免的一种冶金缺陷,钢轨中的夹杂物对其服役性能有不可忽视的影响。控制钢轨中夹杂物的级别,对提高钢轨使用寿命的作用显著,故而去除非金属夹杂物是提高重轨钢质量的主要途径之一[1]。本文对重轨生产冶炼各工艺环节夹杂物的数量、尺寸、组分、来源进行分析和归纳,为重轨冶炼工艺的优化提供参考。
1 试验方案及检验方法
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目前重轨的主要生产工艺流程为:铁水预处理脱硫→转炉→LF精炼→VD真空精炼→大方坯连铸[2]。重轨钢采用无铝脱氧工艺,常用的脱氧剂是硅钙钡合金。为了研究夹杂物在冶炼过程中的变化规律,在脱氧合金化后、LF处理出站后、VD真空处理出站后和中间包内取出固定规格的试样,试样规格为半径25 mm、高度10 mm的圆饼状或半径25 mm、高度100 mm的圆柱体[3],所有试样规格相同。
试验过程中涉及样本炉数共计13炉,每炉对应取样工位取样1—2个。将试样按照炉号和取样工序进行编号,经磨制和抛光后,使用金相显微镜观察试样100 mm×20 mm面积内的夹杂物尺寸和数量并统计分析,选出典型夹杂物[4],并使用扫描电镜—能谱观察对典型夹杂物进行定性分析。
2 夹杂物检验结果和分析
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2.1 各工序夹杂物尺寸和数量变化规律
重轨冶炼过程夹杂物均为球状。夹杂物的变化情况与结果分析如表1所示。
由表1可以看出,钢水中脱氧反应和夹杂物上浮主要在LF精炼工序前后发生。钢水经过VD处理和中间包放置过程夹杂物会进一步排出钢液,夹杂物平均尺寸逐步降低,但20 μm以上夹杂物依然存在。
从图1可以看出,钢液中夹杂物尺寸随工序推进而逐步减小,但平均尺寸在经过LF精炼处理后变化较小。钢液中夹杂物在脱氧合金化后数量最多,但大部分是小颗粒的脱氧产物,经过LF精炼处理后,大部分夹杂物上浮去除,在后续工序中夹杂物数量进一步减少。
2.2 夹杂物成分随工序变化趋势
从6炉钢液中取样,对各工序不同尺寸的典型夹杂物进行扫描电镜—能谱观察。典型夹杂物成分随工序变化情况见表2。
脱氧合金化后,夹杂物由于硅脱氧产生脱氧产物,使夹杂物中Si含量迅速上升,夹杂物中Ca含量较低,此时夹杂物中ω(Ca)/ω(Si)平均值为1.29(波动范围1.09~1.57),ω(Ca)/ω(Al)平均值为0.68(波动范围0.57~0.76)。
经过LF精炼,大部分Si、Al脱氧产物上浮,夹杂物中Ca元素占比升高,Al元素占比降低,此时夹杂物中ω(Ca)/ω(Si)平均值为1.85(波动范围1.79~1.94),ω(Ca)/ω(Al)平均值为3.40(波动范围1.88~5.81)。
经过VD真空处理后,夹杂物中Ca含量占比进一步升高,Al含量占比降低,夹杂物中ω(Ca)/ω(Si)平均值为2.30(波动范围1.99~2.51),ω(Ca)/ω(Al)平均值为6.05(波动范围4.88~7.22)。
到中包时,夹杂物中各元素含量变化情况复杂,小颗粒夹杂物成分特点符合LF精炼后钢液中夹杂物成分特点,ω(Ca)/ω(Si)平均值为1.89、ω(Ca)/ω(Al)平均值为2.79,此时小颗粒夹杂物组分依然显示脱氧产物特征。在中间包内发现的大颗粒夹杂物中ω(Ca)/ω(Si)=0.65、ω(Ca)/ω(Al)=0.91或ω(Ca)/ω(Si)=1.17、ω(Ca)/ω(Al)=26.78,从组分上看夹杂物中Ca含量极低或Al含量极低,与前面工序中夹杂物均无法相匹配,此类夹杂物为开浇引流砂和耐材侵蚀脱落形成的复合夹杂物,所以呈现出组分复杂和尺寸大的特征。表3为各工序夹杂物中ω(Ca)/ω(Si)、ω(Ca)/ω(Al)平均值与波动范围情况。
2.3 夹杂物尺寸与组分相关性分析
图2为夹杂物中各组分随工序变化情况,由图2可以看出夹杂物中各组分在各工序的变化趋势。将图2与图1比较,可以发现冶炼过程中夹杂物尺寸的变化规律与夹杂物中Al元素含量或Al和Mg元素含量之和的占比变化规律基本相同,与其他元素占比的变化规律不相符。这就说明,夹杂物的尺寸在各工序间的变化受夹杂物中Al元素含量或Al和Mg元素含量之和的占比影响。随着夹杂物中Al、Mg元素含量的减少,夹杂物的尺寸减小。
图3为重轨中大尺寸夹杂物扫描电镜—能谱检测结果。图3(a)夹杂物能谱分析结果ω(Ca)/ω(Si)=1.81、ω(Ca)/ω(Al)=2.60;图3(b)夹杂物能谱分析结果ω(Ca)/ω(Si)=1.42、ω(Ca)/ω(Al)=26.69。由此可以判断,该夹杂物是由脱氧产物和中间包外来夹杂物结合而产生的大尺寸夹杂物。对该夹杂物其他4个位置同样进行能谱分析,夹杂物中平均Al和Mg元素含量之和达到13.37%,高于中间包夹杂物中Al和Mg元素含量之和的平均水平(11.80%)。这也说明,重轨钢中大尺寸夹杂物是在连铸过程中由未上浮的脱氧产物和外来的夹杂物相结合组成的复合夹杂物。
3 结论
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(1)重轨钢冶炼过程随工序推进钢中夹杂物尺寸减小,数量减少。
(2)重轨钢冶炼过程产生的夹杂物在各工序呈现出不同的组分特性。夹杂物的组分特性决定其尺寸,通常夹杂物中Al、Mg含量越高,夹杂物尺寸越大。
(3)对重轨中大尺寸夹杂物进行分析,大尺寸夹杂物中Al和Mg元素含量之和高于中间包夹杂物中Al和Mg元素含量之和的平均水平;夹杂物中不同位置Al含量差异较大,说明重轨钢中大尺寸夹杂物是在连铸过程中由未上浮的脱氧产物和外来的夹杂物相结合组成的复合夹杂物。
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参考文献 引证文献
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齐江华, 郑建国, 陈光友, 等. 重轨钢中大颗粒夹杂物的来源探讨[J]. 炼钢, 2017, 33(6):62-66.
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樊志明, 杨吉春, 朱君, 等. 重轨钢中夹杂物的分析与控制[J]. 中国铸造装备与技术, 2021, 56(5):75-78.
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  • 接收时间：2022-10-12
  • 首发时间：2025-11-24
  • 出版时间：2022-12-25
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  • 收稿日期：2022-10-12
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    1 内蒙古包钢钢联股份有限公司技术中心, 内蒙古 包头 014010
    2 内蒙古包钢钢联股份有限公司炼钢厂, 内蒙古 包头 014010
    3 辽宁科技大学 材料与冶金学院, 辽宁 鞍山 114051
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2种不同金属材料的力学参数
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Number of
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Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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