CN113305505A - Method for manufacturing cold-rolled hard-surface process roller - Google Patents
Method for manufacturing cold-rolled hard-surface process roller Download PDFInfo
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- CN113305505A CN113305505A CN202110512909.5A CN202110512909A CN113305505A CN 113305505 A CN113305505 A CN 113305505A CN 202110512909 A CN202110512909 A CN 202110512909A CN 113305505 A CN113305505 A CN 113305505A
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- 238000000034 method Methods 0.000 title claims abstract description 65
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 43
- 239000000758 substrate Substances 0.000 claims abstract description 50
- 238000004372 laser cladding Methods 0.000 claims abstract description 33
- 238000005253 cladding Methods 0.000 claims abstract description 19
- 238000000576 coating method Methods 0.000 claims abstract description 19
- 239000011248 coating agent Substances 0.000 claims abstract description 18
- 229910001105 martensitic stainless steel Inorganic materials 0.000 claims abstract description 11
- 238000005096 rolling process Methods 0.000 claims abstract description 11
- 239000011651 chromium Substances 0.000 claims abstract description 10
- 238000003466 welding Methods 0.000 claims abstract description 10
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 9
- 239000000956 alloy Substances 0.000 claims abstract description 9
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 7
- 238000005507 spraying Methods 0.000 claims abstract description 6
- 238000003754 machining Methods 0.000 claims description 19
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 238000000227 grinding Methods 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 230000007547 defect Effects 0.000 claims description 11
- 238000007514 turning Methods 0.000 claims description 7
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- 238000009713 electroplating Methods 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 229910000746 Structural steel Inorganic materials 0.000 claims description 4
- 238000005452 bending Methods 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 4
- 238000002360 preparation method Methods 0.000 claims description 4
- 239000004065 semiconductor Substances 0.000 claims description 4
- 230000003746 surface roughness Effects 0.000 claims description 4
- 229910001339 C alloy Inorganic materials 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 2
- 239000013307 optical fiber Substances 0.000 claims description 2
- 238000005552 hardfacing Methods 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 16
- 230000008901 benefit Effects 0.000 abstract description 9
- 238000005496 tempering Methods 0.000 abstract description 9
- 230000007613 environmental effect Effects 0.000 abstract description 4
- 239000010410 layer Substances 0.000 description 65
- 238000010791 quenching Methods 0.000 description 13
- 230000000171 quenching effect Effects 0.000 description 13
- 238000005516 engineering process Methods 0.000 description 7
- 238000005242 forging Methods 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- 238000007751 thermal spraying Methods 0.000 description 6
- 238000005260 corrosion Methods 0.000 description 4
- 229910000975 Carbon steel Inorganic materials 0.000 description 3
- 239000010962 carbon steel Substances 0.000 description 3
- 238000005097 cold rolling Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 229910000734 martensite Inorganic materials 0.000 description 3
- 238000007747 plating Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
- 239000012895 dilution Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910000954 Medium-carbon steel Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 238000013000 roll bending Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/106—Coating with metal alloys or metal elements only
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Rolls And Other Rotary Bodies (AREA)
- Reduction Rolling/Reduction Stand/Operation Of Reduction Machine (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a method for manufacturing a cold-rolled hard-surface process roller, which comprises the steps of firstly manufacturing a roller and roughly processing a roller body, rolling and forming a hot rolled plate and welding the hot rolled plate into the roller; preparing a martensitic stainless steel cladding layer prepared from special alloy components with the thickness of 2.5-4 mm on a pre-rolling roller with the thickness close to the wall thickness of a finished roller by using a laser cladding process, wherein the martensitic stainless steel cladding layer is used as a hard substrate layer of a cold-rolled hard-surface process roller, the hardness range is adjustable within 48-60 HRC, and then preparing a hot-sprayed or electroplated chromium coating on the surface of the processed laser-clad hard substrate. The invention solves the quality problems of the prior manufacturing method that the thickness and the hardness of the hard substrate layer of the roller body are not uniform, the hot spraying or the electroplated layer on the hard substrate layer shows stripe print after being prepared, the tempering and softening phenomena are generated at a certain environmental use temperature, and the like, simultaneously promotes the energy saving, the material saving, the cost reduction and the efficiency improvement, and has excellent economic benefit and social benefit.
Description
Technical Field
The invention relates to the technical field of metallurgical equipment, in particular to a manufacturing method of a cold-rolled hard-surface process roller.
Background
Hard surface process rollers of a cold rolling production line, such as a tension roller, a top roller, a steering roller, a deburring roller and the like, have the following characteristics: the roller is hollow, the roller wall is thin, the diameter is 450-2000 mm, and the roller surface is manufactured by adopting a technology of 'hard substrate layer + hot spraying or chromium plating coating'. The manufacturing method of the hard surface process roller is characterized in that a hard substrate layer with certain thickness or depth is obtained on the surface of a roller body through a specific process means, and a thin anti-corrosion wear-resistant coating is manufactured on the hard substrate layer through a thermal spraying or electroplating process. The hard substrate layer provides firm support for the surface coating on the hard substrate layer so as to prevent the roller surface from being failed due to local pressure feeding, and the composite manufacturing process of the hard substrate layer and the thermal spraying or chromium plating coating of the cold rolling process roller ensures the production of high-quality cold-rolled strip steel in the steel industry.
According to the different technologies and equipment capabilities, the manufacturing method adopted in the current industry has the following three technical routes:
1) the roller blank is obtained by forging, turned to the size before surface quenching, and subjected to surface quenching to obtain a surface-hardened substrate layer with a certain thickness. In order to obtain sufficient material quenching depth and hardness, the forging blank material is usually medium carbon or alloy structural steel. The roller blank obtained by the forging process is a solid bar or a roller formed by ring forging, a large machining allowance is reserved for ensuring the performance of a forged piece by using a sufficient forging ratio, and the thickness of the blank is 2-3 times of the actually required thickness. For example, the thickness of a roller ring forging blank with the size of 25mm is usually 60-80 mm, and the redundant thickness needs to be turned, bored and milled, so that a large amount of energy and raw material waste is generated, and the defects of overhigh cost and the like caused by a large amount of additional machining exist; in addition, when the product is used in a medium-high temperature working condition environment (above 400 ℃), the phenomenon that the hardness of the carbon steel surface quenching substrate layer is reduced due to tempering and softening exists, and the quality of the final cold-rolled strip steel is affected.
2) After a rolled steel plate winding drum is welded into a roller body, the surface of the roller body is directly subjected to surface quenching to obtain a hardened substrate layer with a certain depth. Also, to ensure a certain hardening depth, the material of the rolled steel plate is usually medium carbon steel or medium carbon alloy steel. Compared with the quenching method of the forge piece, the method can save a large amount of raw materials, does not need a large amount of mechanical processing and greatly reduces the manufacturing cost. However, the method also has other technical problems, such as macroscopically showing the strip-shaped color difference of the welding seam at the straight welding seam position of the roll body which is rolled and welded after surface quenching due to the difference of the structure and the performance, and more obvious strip-shaped color difference at the welding seam when a thermal spraying or chromium plating coating is manufactured later, which can seriously affect the surface quality of the cold-rolled strip steel in the using process of products. Secondly, the deformation of the surface of the roller caused by the surface quenching of the thin-wall roller can cause the inconsistency of the surface processing allowance of the roller body, and finally the phenomenon that the hardness of the whole roller surface is not uniform or the thickness of a hardening layer is insufficient can not meet the technical requirements of products. In addition, similar to the manufacturing method of surface quenching of the forged piece, the phenomenon that the hardness of the carbon steel surface quenching substrate layer is reduced due to tempering and softening can exist when the product is used in a medium-high temperature working condition environment (above 400 ℃).
3) And similarly, rolling a rolled plate by a roll bending machine, welding to form a roller, and overlaying the hard layer on the outer surface of the roller by adopting a submerged arc overlaying method to form a hard base layer. For example, chinese patent document CN1793423A discloses a thermal spraying and surfacing combined treatment method and a product thereof, the method is suitable for manufacturing an oversized-diameter hard-surface roll body (with a diameter of more than 1500 mm), and is provided on the basis that the conventional quenching technology and equipment cannot meet the manufacturing technical requirements of the large-diameter roll with the standard, the method has certain advantages in cost and production period compared with the first manufacturing method, but due to high heat input and high dilution rate of submerged arc surfacing, the required design components and hardness of a hard substrate layer can be obtained by surfacing with a thickness of more than 7-8 mm, and meanwhile, the large thickness of the surfacing layer causes the problem that the middle part of a hollow thin-wall roll is slightly shrunk and deformed, and the roll surface hardness of the surfacing layer is not uniform after mechanical processing. In addition, in order to ensure that the hard overlaying layer with the thickness does not crack in the overlaying process, higher preheating and interlayer temperature (generally above 300 ℃) need to be kept, the process environment of operators is poor, the process quality is difficult to control, the overlaying amount is large, and the overlaying working hours are longer, so that the problem of higher cost is caused.
In summary, the above three methods for manufacturing the hard substrate layer of the cold-rolled hard-surface process roller adopted in the industry all have disadvantages. The problems to be solved at present in the technical field are to select a proper manufacturing process or method to prepare the hard substrate layer on the surface of the cold-rolling process roller, so that the hard substrate layer has the advantages of high bonding strength with a substrate, uniform thickness and hardness, no stripe print after the preparation of a thermal spraying or electroplating layer on the hard substrate layer, no tempering softening at a certain environmental use temperature (above 400 ℃), and the like.
The laser cladding technology utilizes the characteristic of extremely high energy laser beam gathering energy to instantly melt the filled alloy powder with special physical, chemical or mechanical properties on the surface of the base material to form a cladding layer for metallurgical connection, and can effectively improve the properties of surface hardness, wear resistance, corrosion resistance, high temperature oxidation resistance and the like while restoring the size of parts. In recent years, with the maturity and development of laser cladding technology, the equipment and process cost is rapidly reduced, the laser output power is continuously improved, and the cladding efficiency is no longer the bottleneck restricting the application of the laser cladding technology.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for manufacturing a cold-rolled hard-surface process roller, which overcomes the defects of the traditional process roller, effectively saves energy and raw materials, improves the uniformity of the hardness of a hard substrate layer, avoids the occurrence of stripe marks on the roller surface, ensures that tempering softening is not generated in a higher temperature environment, and improves the quality of the final cold-rolled strip steel.
In order to solve the technical problem, the manufacturing method of the cold-rolled hard-surface process roller comprises the following steps:
step one, roller manufacturing, namely blanking according to the outer diameter size of a cold-rolled hard-surface process roller, rolling and molding a carbon structural steel or medium carbon alloy steel hot-rolled plate on a three-roller plate bending machine, and welding the rolled plate into a roller, wherein the inner diameter and the outer diameter of the roller are reserved with a machining allowance of 3-5 mm;
step two, roughly machining a roller body, boring an inner hole of the roller to a finished product size, preparing a roller shaft head, reserving a single-side machining allowance for all sizes of the outer diameter of the shaft head, turning the outer diameter of the roller to be 2.5-4 mm smaller than the theoretical size according to the theoretical size required by a process roller;
preparing a hard substrate layer by adopting laser cladding, clamping a roller body on a horizontal rotary jig frame of laser cladding complete equipment, preparing a martensitic stainless steel hard substrate layer by adopting a semiconductor or optical fiber laser through broadband laser cladding, wherein the effective thickness of the hard substrate layer is at least 2.5-4 mm, and the hardness range is 48-60 HRC (Rockwell hardness) adjustable;
step four, machining the roller body, wherein the roller surface and the roller shaft head are respectively turned to the theoretical size and added with a grinding allowance of 0.2-0.5 mm, and flaw detection is carried out on the roller surface, so that no crack or air hole defect is required;
step five, respectively grinding the roll surface and the roll shaft head to a theoretical size, and ensuring that the roll surface has no lead mark processing defect after grinding;
and sixthly, preparing a hard chromium coating for hot spraying or electroplating on the roller surface, wherein the thickness of the coating is 0.08-0.15 mm, and the surface roughness is Ra1.2-6.3.
Further, the preparation process of the laser cladding hard basal layer is characterized in that preheating treatment is not needed, 2-3 layers of laser cladding are carried out, the laser power is 5000-6300W, the cladding speed is 10-12 mm/s, the spot size is (12-18 mm) × (1-2.5 mm), and the lap joint rate is 40-60%.
Further, the laser cladding hard substrate layer comprises the following alloy powder components in percentage by weight: 0.3-0.5% of C, 0.6-1.0% of Si, 17-19% of Cr, 2.5-4.5% of Ni, 0.6-1.2% of Mo0.2-0.5% of Nb0.1-0.3% of Re, and the balance of Fe, wherein the granularity of the alloy powder is 100-270 meshes.
The manufacturing method of the cold-rolled hard-surface process roller adopts the technical scheme, namely, the method firstly performs roller manufacturing and roller body rough machining, adopts hot rolled plates for rolling forming and welding to form the roller; preparing a martensitic stainless steel cladding layer prepared from special alloy components with the thickness of 2.5-4 mm on a pre-rolling roller with the thickness close to the wall thickness of a finished roller by using a laser cladding process, wherein the martensitic stainless steel cladding layer is used as a hard substrate layer of a cold-rolled hard-surface process roller, the hardness range is adjustable within 48-60 HRC, and then preparing a hot-sprayed or electroplated chromium coating on the surface of the processed laser-clad hard substrate. The invention solves the quality problems of the prior manufacturing method that the thickness and the hardness of the hard substrate layer of the roller body are not uniform, the hot spraying or the electroplated layer on the hard substrate layer shows stripe print after being prepared, the tempering and softening phenomena are generated at a certain environmental use temperature, and the like, simultaneously promotes the energy saving, the material saving, the cost reduction and the efficiency improvement, and has excellent economic benefit and social benefit.
Detailed Description
Example 1: production of cold-rolled technology roller with phi 450 x 1950mm
The specific manufacturing process flow is as follows:
1. roller manufacturing:
selecting a 20# hot rolled steel plate as a roller body material, rolling the raw material plate with the thickness of 30mm by using a three-roller plate bending machine, and welding the raw material plate into a roller, wherein the inner diameter and the outer diameter of the roller are respectively reserved with 5mm machining allowance;
2. rough machining of the roller body:
boring an inner hole of the roller to phi 410, preparing a roller shaft head, and reserving a single side 2mm machining allowance for all sizes of the outer diameter of the roller shaft head. Turning the outer diameter of the roller to phi 444 to ensure that the effective thickness of a hard substrate layer prepared by subsequent laser cladding is 3 mm;
3. preparing a hard basal layer by laser cladding:
the roller is clamped on a horizontal rotary jig frame of a laser cladding complete set of equipment, a martensitic stainless steel hard substrate layer is prepared by adopting broadband laser cladding of a semiconductor laser, preheating treatment is not needed, 3 layers are laser cladded, the thickness of a single layer is 1.4mm, the cladding technological parameter is laser power 5800W, the cladding speed is 10mm/s, the spot size is 16mm multiplied by 2.5mm, and the lap joint rate is 50%.
The laser cladding hard substrate layer comprises the following chemical components in percentage by weight: 0.4% of C, 0.6% of Si, 18% of Cr, 3% of Ni, 0.6% of Mo0.6%, 0.25% of Nb0.1% of Re0.1% of Fe, and the balance of Fe;
4. and (3) turning the roller on a lathe:
turning the roll surface to phi 450.5mm, and reserving a grinding allowance of 0.5 mm; the surface of the roller surface is subjected to flaw detection without defects such as cracks, air holes and the like, and the hardness of the hard substrate layer is 52 +/-4 HRC;
5. grinding the shaft head and the surface of the roller to phi 450, and ensuring that the surface of the roller has no processing defects such as lead marks after grinding;
6. the surface of the roller is thermally sprayed with a WC coating, the thickness of the coating is 0.1mm, and the surface roughness is Ra2.5.
Example 2: manufacture of cold-rolled artistic roller with diameter of 1500X 2100mm
The specific manufacturing process flow is as follows:
1. roller manufacturing:
45# normalized hot rolled steel plates are selected as the material of the roller body, the thickness of the plates is 45mm, the plates are rolled by a three-roller plate bending machine according to the diameter of the roller body and welded into rollers, and 5mm machining allowance is reserved for the inner diameter and the outer diameter of each roller.
2. Rough machining of the roller body:
and (3) boring an inner hole of the roller to phi 1430, preparing a roller shaft head and a radial plate, and reserving a single-side machining allowance of 2mm for all the sizes of the outer diameter of the roller shaft head. And the outer diameter of the roller is turned to phi 1497, so that the effective thickness of the hard substrate layer prepared by subsequent laser cladding is ensured to be 2.5 mm.
3. Preparing a hard basal layer by laser cladding:
clamping the roller on a horizontal rotary jig frame of laser cladding complete equipment, and preparing a martensitic stainless steel hard substrate layer by adopting broadband laser cladding of a semiconductor laser; the method has the advantages that the preheating treatment is not needed, 2 layers are clad by laser, the thickness of a single layer is 1.8mm, the cladding technological parameters are 6000W of laser power, the cladding speed is 10mm/s, the spot size is 16mm multiplied by 2.5mm, and the lap joint rate is 50%.
The laser cladding hard substrate layer comprises the following chemical components in percentage by weight: 0.35% of C, 0.6% of Si, 17.5% of Cr17, 3.5% of Ni0.8% of Mo0.3% of Nb0.2% of Re0.2% of C and the balance of Fe.
4. And (3) turning the roller on a lathe:
turning the roll surface to phi 1502.5mm, and reserving grinding allowance of 0.5 mm; the surface of the roller surface is free from defects such as cracks, air holes and the like during flaw detection. The hard base layer hardness was 53 + -3 HRC.
5. And grinding the shaft head and the surface of the roller until the grinding process is finished, and ensuring that the surface of the roller has no processing defects such as lead marks after grinding.
6. The surface of the roller is thermally sprayed with a WC coating, the thickness of the coating is 0.12mm, and the surface roughness is Ra1.6.
According to the method, a martensite stainless steel cladding layer prepared from special alloy components with the thickness of 2.5-4 mm is prepared on a pre-rolling roller with the thickness close to the wall thickness of a finished roller by using a laser cladding process, the martensite stainless steel cladding layer is used as a hard substrate layer of a cold-rolled hard-surface process roller, the hardness range is adjustable within 48-60 HRC, and then a hot-sprayed or chromium-electroplated coating is prepared on the surface of the processed laser-clad hard substrate layer.
The principle and the beneficial effects of solving the problems in the traditional manufacturing method are as follows:
1) under the laser cladding process condition of the method, the designed material components and the high-hardness and smooth-surfaced roll body hard substrate layer can be obtained under the condition of thinner cladding thickness by utilizing the rapid cooling of laser cladding and controlling the extremely low dilution rate of the cladding. The thin hard cladding layer is designed on the premise of meeting the technical requirements of the hard substrate layer of the roller, the whole deformation of the roller can be effectively reduced, and the problems of large deformation of the hollow thin-wall roller body, uneven machining allowance and the like caused by excessive stress accumulation in the surfacing process due to the fact that a surfacing layer with large thickness can obtain required material components and hardness in a submerged arc surfacing manufacturing method are solved. Meanwhile, the blank for manufacturing the roller body can be formed by rolling and welding plates with the thickness close to that of the wall of a finished roller, and compared with the traditional first forging manufacturing method and the second submerged arc surfacing manufacturing method, the method greatly saves raw materials and machining cost.
2) The laser cladding hard substrate layer designed in the method is medium-carbon martensitic stainless steel, the high-temperature strength and the corrosion resistance of the coating are improved by adding a proper amount of Mo and Ni into the components, and simultaneously, certain rare earth elements are added to refine crystal grains and improve the crack resistance and the toughness of the coating. Compared with the martensitic carbon steel hard substrate obtained by surface quenching, the obtained martensitic stainless steel hard substrate has good high-temperature tempering stability, does not have the phenomenon of tempering and softening of a product manufactured by the traditional method at the working environment temperature (above 400 ℃), has stainless corrosion resistance, and is beneficial to the preparation of subsequent thermal spraying or electroplating coatings.
3) The roller hard substrate layer is obtained by laser cladding of a hard layer, and is not obtained by surface quenching of a base material, so that the requirement on the material of the roller base material can be reduced, the roller hard substrate layer only needs a common carbon structural steel material without high-carbon medium-high steel or alloy steel, and the cost of the base material is reduced.
4) The obtained martensitic stainless steel integral cladding layer with uniform hardness also avoids the color difference defect and the like formed by the difference of the structure hardness between the surface of the long and straight weld joint of the roller manufactured by the plate rolling method of the traditional third method and the matrix after the surface is quenched.
The method adopts the laser cladding process to prepare the thinner cladding layer, ensures the performance requirement of the cold-rolled process roller on the hard substrate layer, and solves the contradiction between quality, efficiency and cost in the manufacturing process of the prior cold-rolled process roller. In particular, the quality problems of uneven thickness and hardness of the hard substrate layer of the roller body, stripe print after the hot spraying or the electroplating layer is prepared, tempering and softening phenomena at a certain environmental use temperature (above 400 ℃) and the like existing in the traditional manufacturing method are solved, energy conservation, material saving, cost reduction and efficiency improvement are promoted, and the method has excellent economic benefit and social benefit.
Claims (3)
1. A method for manufacturing a cold-rolled hard-surface process roller is characterized by comprising the following steps:
step one, roller manufacturing, namely blanking according to the outer diameter size of a cold-rolled hard-surface process roller, rolling and molding a carbon structural steel or medium carbon alloy steel hot-rolled plate on a three-roller plate bending machine, and welding the rolled plate into a roller, wherein the inner diameter and the outer diameter of the roller are reserved with a machining allowance of 3-5 mm;
step two, roughly machining a roller body, boring an inner hole of the roller to a finished product size, preparing a roller shaft head, reserving a single-side machining allowance for all sizes of the outer diameter of the shaft head, turning the outer diameter of the roller to be 2.5-4 mm smaller than the theoretical size according to the theoretical size required by a process roller;
preparing a hard substrate layer by adopting laser cladding, clamping a roller body on a horizontal rotary jig frame of laser cladding complete equipment, preparing a martensitic stainless steel hard substrate layer by adopting a semiconductor or optical fiber laser through broadband laser cladding, wherein the effective thickness of the hard substrate layer is at least 2.5-4 mm, and the hardness range is 48-60 HRC (Rockwell hardness) adjustable;
step four, machining the roller body, wherein the roller surface and the roller shaft head are respectively turned to the theoretical size and added with a grinding allowance of 0.2-0.5 mm, and flaw detection is carried out on the roller surface, so that no crack or air hole defect is required;
step five, respectively grinding the roll surface and the roll shaft head to a theoretical size, and ensuring that the roll surface has no lead mark processing defect after grinding;
and sixthly, preparing a hard chromium coating for hot spraying or electroplating on the roller surface, wherein the thickness of the coating is 0.08-0.15 mm, and the surface roughness is Ra1.2-6.3.
2. The method of making a cold rolled hardfacing process roller of claim 1, wherein: the preparation process of the laser cladding hard basal layer is characterized in that preheating treatment is not needed, 2-3 layers of laser cladding are carried out, the laser power is 5000-6300W, the cladding speed is 10-12 mm/s, the spot size is (12-18 mm) × (1-2.5 mm), and the lap joint rate is 40-60%.
3. The method for manufacturing a cold-rolled hard-face process roller according to claim 1 or 2, characterized in that: the laser cladding hard basal layer comprises the following alloy powder components in percentage by weight: 0.3-0.5% of C, 0.6-1.0% of Si, 17-19% of Cr, 2.5-4.5% of Ni, 0.6-1.2% of Mo0.2-0.5% of Nb0.1-0.3% of Re, and the balance of Fe, wherein the granularity of the alloy powder is 100-270 meshes.
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