Vacuum Carbon Reducing Iron Oxide Scale to Prepare Porous 316 Stainless Steel

In order to improve the added value of iron oxide scale and reduce the manufacturing cost of porous stainless steel, steel rolling iron oxide scale as an iron-containing raw material was used to prepare porous 316 stainless steel by high-temperature sintering under vacuum conditions, while carbon was used as a reducing agent and pore-forming agent, and the necessary metal powders were added. In our work, the specific reduction system was confirmed, including the sintering temperature, sintering time, vacuum degree and carbon amount, through thermodynamic calculation combined with experiments. Thermodynamic analysis results showed that the transformation process of the chromium element in the raw materials at 10−4 atm and 300~1600 °C was FeCr2O4 + Cr3O4→Cr2O3 + Cr3O4 + Cr23C6→Cr23C6 + Cr7C3 + FCC→FCC + Cr23C6→FCC→FCC + BCC→Cr(liq). The FCC phase with qualified carbon content could be obtained at 10−4 atm and 1200 °C, while 90.88 g iron oxide scale, 17.17 g carbon, 17.00 g metal chromium, 12.00 g metal nickel and 2.5 g metal molybdenum were necessary to produce 100 g porous 316 stainless steel. The porous 316 stainless steel with a carbon content of 0.025% could be obtained at 10−4 atm and 1200 °C for 180 min, while the chromium element underwent the transformation of metal, Cr→FeCr2O4→Cr23C6→Austenite. The porosity of the porous 316 stainless steel was 42.07%. The maximum size of impurity particles was 5 μm when the holding time reached 180 min. Magnetic separation was an effective method to reduce impurities in the porous stainless steel.