CN114603118B - Equipment and process for manufacturing metal roller by electroslag casting and surfacing compound (re) method - Google Patents
Equipment and process for manufacturing metal roller by electroslag casting and surfacing compound (re) method Download PDFInfo
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- CN114603118B CN114603118B CN202210228408.9A CN202210228408A CN114603118B CN 114603118 B CN114603118 B CN 114603118B CN 202210228408 A CN202210228408 A CN 202210228408A CN 114603118 B CN114603118 B CN 114603118B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/06—Melting-down metal, e.g. metal particles, in the mould
- B22D23/10—Electroslag casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/38—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for roll bodies
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses equipment and a method for composite manufacturing and composite remanufacturing of a metal roller by electroslag casting overlaying. The apparatus includes: crystallizer, consumable electrode group and ingot drawing device; the crystallizer adopts a two-stage crystallizer which comprises a T-shaped crystallizer and a copper water-cooling crystallizer, wherein the T-shaped crystallizer is positioned at the upper part of the copper water-cooling crystallizer, and the T-shaped crystallizer is connected with the copper water-cooling crystallizer through an insulating material; the outer wall of the T-shaped crystallizer is wrapped with an induction coil, and the induction coil is connected with an intermediate frequency power supply and is used for melting slag to form a molten pool and heating the surface of a roller; a molten steel liquid level detection device is arranged at the position of the T-shaped crystallizer, which is close to the insulating material, and is used for detecting a molten steel liquid level signal in the crystallizer; the consumable electrode group forms a power supply loop with a bottom baffle plate in the crystallizer through a power transformer; the ingot pulling device is connected with the bottom baffle plate and is used for pulling the roller downwards from the crystallizer. The composite roller manufactured by the equipment has the advantages of simple process, good composite layer quality and low production cost.
Description
Technical Field
The invention relates to equipment and a process for composite manufacturing and composite remanufacturing of a metal roller by utilizing an electroslag remelting welding technology, and belongs to the field of composite manufacturing and composite remanufacturing of metal rollers.
Background
The roller is one of important components in steel production, and phenomena such as flaking, abrasion, chipping, steel sticking, weld bead trace and the like often occur in the on-machine application due to the influence of working condition environments, so that the roller is invalid. And the composite (re) manufacturing treatment is carried out on the surface of the roller, so that the service life of the roller can be obviously prolonged, and the consumption of steel rolling can be reduced.
The existing composite manufacturing process of the roller surface mainly comprises the following steps: (1) a multi-electrode casting compounding method; (2) a self-consuming crystallizer casting compounding method; (3) a multi-wire electrode surfacing compounding method; (4) a tubular electrode casting surfacing compounding method; (5) a rotary crystallizer casting surfacing compounding method; (6) electroslag casting fusion welding compounding method; (7) a bimetal consumable electrode casting compounding method.
The electroslag casting overlaying welding compounding method is to overlay a layer of alloy steel around the worn old roller or core rod by an electroslag method to repair the old roller or manufacture the bimetal compounding roller. Namely, two metal materials with different properties are combined into a whole in a water-cooling crystallizer with a certain shape through a certain electroslag metallurgy process, so that the metal materials have different properties, and the requirements of different use processes are met. The roller surfacing layer manufactured by the electroslag casting surfacing composite method has the advantages of high purity, low sulfur content, less nonmetallic inclusion, smooth surface of alloy ingot, cleanness, uniformity, compactness, uniform metallographic structure, uniform chemical composition and the like, so that research and development of various electroslag casting surfacing composite roller manufacturing processes are actively conducted in all countries around the world.
The foreign countries mainly comprise Austrian and Japan and other countries in the aspects of engaging in the electroslag casting and overlaying composite roller. Although China is the earliest country in the world for researching, developing and applying electroslag metallurgical technology, there is a great gap in production and application compared with foreign countries. At present, the method has a certain application in the manufacture of steel ingots for cold rolls and small cold rolls, has less research on the electro-slag fusion welding surfacing composite manufacturing rolls, and has no electro-slag fusion welding surfacing composite manufacturing roll equipment and application precedent in China.
Disclosure of Invention
The invention aims to provide equipment for compositely (re) manufacturing a metal roller by electroslag casting and overlaying, which is used for compositely manufacturing and compositely remanufacturing a composite layer metal roller by an electroslag casting and overlaying technology.
Another object of the present invention is to provide a process for composite manufacturing and composite remanufacturing of metal rolls using the above apparatus.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
an apparatus for electro-slag casting build-up composite manufacturing and composite remanufacturing of metal rolls comprising: crystallizer, consumable electrode group and ingot drawing device; wherein, the liquid crystal display device comprises a liquid crystal display device,
the crystallizer adopts a two-stage crystallizer, and comprises a T-shaped crystallizer and a copper water-cooling crystallizer, wherein the T-shaped crystallizer is positioned at the upper part of the copper water-cooling crystallizer, and the T-shaped crystallizer is connected with the copper water-cooling crystallizer through an insulating material;
the outer wall of the T-shaped crystallizer is wrapped with an induction coil, and the induction coil is connected with an intermediate frequency power supply and is used for melting slag to form a molten pool and heating the surface of a roller; a molten steel liquid level detection device is arranged at the position of the T-shaped crystallizer, which is close to the insulating material, and is used for detecting a molten steel liquid level signal in the crystallizer;
the self-consuming electrode group forms a power supply loop with a bottom baffle plate in the crystallizer through a power transformer, wherein the self-consuming electrode is one pole, the bottom baffle plate is one pole, and the power supply loop is formed after the power is electrified;
the ingot pulling device is connected with the bottom baffle plate and is used for pulling the roller downwards from the crystallizer.
Further, the consumable electrode group is formed by connecting a plurality of electrodes with the same size in parallel.
Further, the consumable electrode set may employ a sleeve-shaped electrode.
Further, the T-shaped crystallizer is made of refractory materials.
Further, the insulating material is a high temperature insulating pad.
Further, the device also comprises a consumable electrode lifting device which is used for lifting the consumable electrode group when replacing the consumable electrode group.
Further, the molten steel liquid level detection device, the consumable electrode lifting device and the ingot pulling device are controlled by a computer control system.
Further, the arc striking plates are respectively arranged at the positions of the upper shaft head and the lower shaft head of the roller, wherein the arc striking plates at the positions of the lower shaft head of the roller are arranged between the end part of the roller and the bottom baffle, so that unstable parts before arc striking and arc extinguishing (arc extinguishing) can be removed, and the uniformity of the composite layer on the surface of the whole roller is ensured. Meanwhile, the arrangement of the lower arc striking plate is beneficial to preventing heat loss at high temperature and ensuring smooth progress of the slag melting process.
The working principle of the device of the invention is as follows:
solid slag is added to the upper part of a bottom baffle plate in the crystallizer, and the T-shaped crystallizer is heated by an intermediate frequency power supply to melt the slag into liquid slag so as to form a molten pool. The consumable electrode group is inserted into the liquid slag, and the arc is started by electrifying. The consumable electrode group is gradually melted and dripped in the liquid slag, and when the formed metal molten drops are gradually gathered in the space between the roller and the crystallizer and the bottom baffle plate, the liquid level of the metal melt, namely the cladding metal, is gradually increased; when the liquid surface of the metal melt contacts the molten steel liquid surface detection device, the detection device obtains a signal, and at the moment, the ingot pulling device is started to pull ingots. In the ingot drawing process, the lower copper water-cooling crystallizer cools the roller after slag compounding, so as to obtain the roller with high-quality composite layer.
In the apparatus of the present invention, the T-type crystallizer functions to heat the roll surface in addition to melting slag, thereby allowing the liquid slag to be easily clad on the roll surface.
The invention also provides a process for composite manufacturing and composite remanufacturing of the metal roller by using the equipment for electroslag casting and surfacing, which comprises the following steps of:
(1) Preparing a plurality of consumable electrode groups;
(2) Preparing a roller matrix, and removing fatigue layers and defects of a roller body;
(3) Wrapping the induction coil on a T-shaped crystallizer, connecting an intermediate frequency power supply, after electrifying, melting slag into liquid slag by utilizing electromagnetic induction, and simultaneously completing local heating of the surface of a roller to 700-850 ℃ by utilizing electromagnetic induction;
(4) Inserting the consumable electrode group into liquid slag, and electrifying to start arc;
(5) When the molten steel liquid level detection device detects a molten steel liquid level signal in the crystallizer, starting an ingot pulling device to pull out ingots, and cooling a roller by a copper water-cooled crystallizer below after pulling out the ingots;
(6) When the height of the rest part of the consumable electrode group is about 30-40 mm, the consumable electrode is exchanged; when the electrodes are exchanged, intermediate frequency heating is conducted, and the difference between the temperature of liquid slag and the slag temperature of electroslag casting overlaying welding is maintained to be less than or equal to 30 ℃;
(7) Repeating the steps (4) - (6) to finish the composite manufacturing of the roller;
(8) Removing the flat solidified slag shell on the surface of the composite layer, loading into a resistance furnace for tempering heat treatment, and then carrying out machining, flaw detection and packaging.
The invention creatively adopts a combined structure of two crystallizers, namely a T-shaped crystallizer and a copper water-cooling crystallizer on the basis of the traditional electroslag remelting technology. The double functions of melting slag in the crystallizer and easily cladding the surface of the heated roller are realized by heating the T-shaped crystallizer through an intermediate frequency power supply, and the composite roller is prepared through an electroslag casting overlaying welding mode. The specific advantages include:
(1) The T-shaped crystallizer has the advantages that: 1. preventing the consumable electrode from forming electromagnetic vortex after melting and excessively melting the roller parent metal; 2. the electric breakdown phenomenon, namely the electric breakdown defect which is easy to occur after the conductive contact among the metal crystallizer, the dummy ingot plate and the water cooling box is destroyed, is prevented; 3. the fatal accident caused by short circuit with molten metal when the metal crystallizer is not protected is avoided; 4. the continuous preservation of heat during intermediate frequency slagging is facilitated.
The copper water-cooling crystallizer is mainly used for cooling the part after ingot drawing and compounding, and the defects of stress concentration, cold cracks and the like caused by the traditional premature cooling of a composite metal layer are reduced.
(2) Intermediate frequency heating: on one hand, slag is melted into liquid slag, on the other hand, the surface of the roller is heated, and on the other hand, heat can be continuously provided when the electrode is replaced, so that the problem of surfacing composite manufacturing of the large roller is solved.
(3) The accurate position of the slag-gold (slag-deposited metal) liquid level can be detected by adopting the molten steel liquid level detection device, and the stability of a molten pool is ensured by controlling the accurate matching of the melting speed and the ingot drawing speed, so that the quality of high-quality deposited metal is obtained.
(4) The composite roller manufactured by the process has the advantages of simple manufacturing process, good quality of the composite layer, low production cost, compact microstructure at the joint, no segregation or crack, gradient distribution of the hardness and strength of the joint layer, and the like.
Drawings
Fig. 1 is a schematic diagram of the structure of the apparatus of the present invention.
FIG. 2 is a metallographic photograph of a composite layer roll obtained in example 1. Wherein the right side is parent metal, and gray tissue is sorbite (crystal after melting); the center is a transition area, and no defect exists.
FIG. 3 is a metallographic photograph of a composite layer roll obtained in example 2. The surface layer has fine structure, is a martensitic structure, and has no defects such as cracks.
Reference numerals:
1 consumable electrode group 2T type crystallizer 3 intermediate frequency power supply 4 molten steel liquid level detection device 5 high temperature insulating pad 6 copper water cooling crystallizer 7 solidified slag shell 8 deposited metal 9 melting pool 10 roller 11 ingot pulling device 12 induction coil 13 bottom baffle 14 arc striking plate 15 arc striking plate 16 power transformer
Detailed Description
The invention will be described in detail with reference to the accompanying drawings and specific embodiments.
Fig. 1 is a schematic diagram of the structure of the apparatus of the present invention. As shown in fig. 1, the apparatus for composite manufacturing and composite remanufacturing of a composite layer metal roll by electroslag casting surfacing according to the present invention comprises: crystallizer, consumable electrode group 1 and ingot drawing device 11; the crystallizer adopts a two-stage crystallizer, and comprises a T-shaped crystallizer 2 and a copper water-cooling crystallizer 6, wherein the T-shaped crystallizer 2 is made of refractory materials, is positioned at the upper part of the copper water-cooling crystallizer 6, and is connected with the copper water-cooling crystallizer 6 through an insulating material (a high-temperature insulating pad 5); the outer wall of the T-shaped crystallizer is wrapped with an induction coil 12, and the induction coil 12 is connected with an intermediate frequency power supply 3 and is used for melting slag to form a molten pool and heating the surface of the roller 10; a molten steel liquid level detection device 4 is arranged at the position of the T-shaped crystallizer, which is close to the insulating material, and is used for detecting a molten steel liquid level signal in the crystallizer; the consumable electrode group 1 forms a power supply loop with a bottom baffle 13 in the crystallizer through a power transformer 16; the ingot extractor 11 is connected to a bottom baffle 13 for extracting the rolls downwards from the crystallizer.
The consumable electrode group is formed by connecting a plurality of electrodes with the same size in parallel. And, the consumable electrode set may employ a sleeve-shaped electrode.
The apparatus further comprises a consumable electrode lifting device (not shown) for lifting and lowering the consumable electrode assembly when replacing the consumable electrode assembly. The molten steel liquid level detection device, the consumable electrode lifting device and the ingot pulling device are controlled by a computer control system.
In order to protect the roll head and the roll end, arc striking plates 14, 15 are respectively arranged at the upper head and the lower head of the roll, wherein the arc striking plate 15 at the lower head of the roll is arranged between the end of the roll and the bottom baffle 13. A graphite block of a certain thickness and height is previously added to the bottom baffle 13 and slag is placed on top of the graphite block.
When the device is used, solid slag is added to the upper part of a bottom baffle 13 (above a graphite block) in the crystallizer, and the slag is melted into liquid slag by heating the T-shaped crystallizer through an intermediate frequency power supply to form a molten pool 9. The consumable electrode assembly 1 is inserted into the melt pool 9 and energized to initiate an arc. The consumable electrode group is gradually melted and dripped in the liquid slag, and when the formed metal molten drops are gradually gathered in the space between the roller and the crystallizer and the bottom baffle plate, the liquid level of the metal melt (deposited metal 8) is gradually increased; when the liquid surface of the molten metal contacts the molten steel liquid surface detection device 4, the detection device 4 obtains a signal, and at the moment, the ingot pulling device 11 is started to pull ingots. In the ingot drawing process, the lower copper water-cooling crystallizer 6 cools the roller after slag compounding, so as to obtain a roller with a high-quality composite layer.
In the apparatus of the present invention, the T-type crystallizer functions to heat the roll surface in addition to melting slag, thereby allowing the liquid slag to be easily clad on the roll surface.
In the process of embodying the invention, the slag used is the slag purchased in the market, and a certain amount of iron powder can be added.
Example 1
And (3) performing electroslag remelting surfacing composite remanufacturing on a 92CrMo offline cold-rolled support roller with the diameter of phi 650mm multiplied by 1530mm, wherein the diameter size of the offline cold-rolled support roller is phi 600mm.
1.1 first turning fatigue layers and defects of the roll body. After the phi 580mm is turned, the surface and internal defects are not found through magnetic powder and ultrasonic nondestructive inspection, and the steel can be used as a roller base material.
1.2 selecting appropriate alloy materials to manufacture the consumable electrode set. The consumable electrode is prepared from a high carbon alloy material in this example. The high-carbon alloy material comprises the following components: c:0.8%; mn:1.5%; si:0.5%; cr:5.0%; v:2%; w:3.0%; mo:2.0% >; rare earth element: 0.1%; the balance being Fe. And smelting the high-carbon alloy material by adopting an electric arc furnace EBT primary smelting, LF refining and VD vacuum degassing. Round bars with diameter phi 40mm and length 1500mm are produced. Each consumable electrode group consists of 6 round bars and is uniformly and symmetrically distributed (parallel) on the cross beam.
1.3 corresponding crystallisers were prepared according to a roll Φ650mm, the internal diameter of a T-shaped crystalliser made of refractory material was chosen to be Φ700mm and the internal diameter at the T-shaped mouth was Φ900mm. The inner diameter of the copper water-cooling crystallizer is phi 700mm.
And 1.4, the upper part and the lower part (an upper shaft head and a lower shaft head) of the roller diameter shaft head are respectively attached with an arc striking plate, and graphite blocks are added on a bottom baffle. The roller is vertically placed on the base through hoisting and is fastened and fixed.
1.5 adding slag on the graphite blocks on the bottom baffle plate, wherein the adopted slag comprises the following components in percentage by weight: caF (CaF) 2 35％；CaO 35％；SiO 2 15％；Al 2 O 3 10％；Fe 5％。
1.6 intermediate frequency heating to about 1680 ℃ the slag is totally liquefied.
1.7 inserting the consumable electrode into the T-shaped crystallizer, starting an electroslag remelting power supply when the consumable electrode contacts the liquid slag, starting to melt the electrode, and using resistance heat generated when current passes through the slag as a heat source to melt the electrode, wherein the intermediate frequency power supply is powered off.
1.8 liquid metal falls as droplets through the slag layer of the slag bath into the underlying T-mould.
1.9 when the metal molten drop formed by the consumable electrode gradually gathers into the space between the T-shaped crystallizer and the graphite, and then the metal melt gradually rises, when the liquid level of the metal melt contacts the molten steel liquid level detection device, the molten steel liquid level detection device obtains a detection signal, and at the moment, the ingot pulling device is started to pull ingots.
1.10 molten metal drops uniformly melt a base metal on the surface of a roller in a T-shaped crystallizer, so that good metallurgical bonding is realized, cooling water (the direction shown by an arrow in fig. 1) of a copper crystallizer after ingot drawing accelerates solidification on the surface of the roller under the assistance of the cooling water, thereby avoiding supercooling solidification of cooling after crystallization and being beneficial to stress control.
1.11 when the height of the rest part of a consumable electrode is 30mm, stopping electroslag casting overlaying, restarting intermediate frequency heating, maintaining the temperature difference between the liquid slag and the slag during electroslag casting overlaying to be less than or equal to 30 ℃, and avoiding the phenomenon of slag solidification caused by rapid drop of the liquid slag temperature due to power failure.
1.12, continuously extracting the composite roller after the re-arcing from the copper water-cooling crystallizer through an ingot extracting device.
1.13 to ensure uniformity of welding quality, the roller was rotatable at a rotation speed of 80mm/min.
1.14 Heat treatment
After the rollers are compounded, the mixture is put into a furnace with the temperature of 300 ℃ for cooling along with the furnace; removing the flat solidified slag shell (solidified slag shell 7 shown in fig. 1) on the surface of the roller, loading into a resistance furnace, slowly heating to 550 ℃, cooling to 120 ℃ in the resistance furnace along with the furnace, and discharging and air-cooling to room temperature.
1.15 detection
The repairing thickness of the cold-rolled supporting roller repaired by the embodiment is 35mm on one side, the surface hardness of the composite roller is 54+/-1 HRC, and the hardness uniformity performance is good; the magnetic powder and the nondestructive inspection have no defects, and can be machined, inspected and packaged according to the drawing requirements.
As shown in fig. 2, the transition region between the base material and the composite layer in the composite roller has no defect, and the composite layer near the base material has a sorbite (crystalline after melting) structure.
Example 2
And (3) performing electroslag remelting surfacing composite remanufacturing on a 92CrMo offline cold-rolled support roller with the diameter of phi 650mm multiplied by 1530mm, wherein the diameter size of the offline cold-rolled support roller is phi 600mm.
2.1 first turning the fatigue layer and defects of the roll body. After the phi 580mm is turned, no surface and internal defects are found through magnetic powder and ultrasonic nondestructive inspection.
2.2 selecting appropriate alloy materials to manufacture the consumable electrode set. The consumable electrode is prepared from a high carbon alloy material in this example. The high-carbon alloy material comprises the following components: c:1.2%; mn:4.8%; si:1.3%; cr:11.0%; v:1% >; w:10.0%; mo:6.0%; rare earth element: 1.5%; the balance being Fe.
Weighing the batch according to the designed alloy content requirement, smelting, and adopting centrifugal casting to prepare the alloy with the inner diameter of: phi 620mm, phi 660mm in outer diameter and 1500mm in length.
2.3 corresponding crystallisers were prepared according to a roll Φ650mm, the internal diameter of a T-shaped crystalliser made of refractory material was chosen to be Φ700mm and the internal diameter at the T-shaped mouth was Φ880mm. The inner diameter of the water-cooled crystallizer is phi 700mm.
2.4 the upper and lower parts (upper and lower shaft heads) of the roller diameter shaft head are respectively attached with an arc striking plate, and graphite blocks are added on the bottom baffle. The roller is vertically placed on the base through hoisting and is fastened and fixed.
2.5 adding slag on the graphite blocks on the bottom baffle plate, wherein the adopted slag comprises the following components in percentage by weight: caF (CaF) 2 35％；CaO 35％；SiO 2 15％；Al 2 O 3 10％；Fe 5％。
2.6 intermediate frequency heating to about 1680 ℃ the slag is totally liquefied.
2.7 inserting the consumable electrode into the T-shaped crystallizer, starting an electroslag remelting power supply when the consumable electrode contacts the liquid slag, starting to melt the electrode, and using resistance heat generated when current passes through the slag as a heat source to melt the electrode, wherein the intermediate frequency is powered off.
2.8 liquid metal falls as droplets through the slag layer of the slag bath into the underlying T-mould.
2.9 when the metal molten drop formed by the consumable electrode gradually gathers into the space between the T-shaped crystallizer and the graphite, and then the metal melt gradually rises, when the liquid level of the metal melt contacts the molten steel liquid level detection device, the molten steel liquid level detection device obtains a detection signal, and at the moment, the ingot pulling device is started to pull ingots.
2.10 molten metal drops uniformly melt the mother material on the surface of the roller in the T-shaped crystallizer, thereby realizing good metallurgical bonding, and the copper crystallizer after ingot drawing is accelerated to be solidified on the surface of the roller under the assistance of cooling water, thereby avoiding supercooling solidification of cooling once crystallization and being beneficial to controlling stress.
2.11 when the height of the rest part of a consumable electrode is 30mm, stopping electroslag casting overlaying, restarting intermediate frequency heating, maintaining the temperature difference between the liquid slag and the slag during electroslag casting overlaying to be less than or equal to 30 ℃, and avoiding the phenomenon of slag solidification caused by rapid drop of the liquid slag temperature due to power failure.
2.12 continuously extracting the composite roller after the re-arcing from the copper water-cooling crystallizer through an ingot extracting device.
2.13 Heat treatment
After the rollers are compounded, the mixture is put into a furnace with the temperature of 300 ℃ for cooling along with the furnace; removing the flat solidified slag shell (solidified slag shell 7 shown in fig. 1) on the surface of the roller, loading into a resistance furnace, slowly heating to 550 ℃, cooling to 120 ℃ in the resistance furnace along with the furnace, and discharging and air-cooling to room temperature.
2.14 detection
The repairing thickness of the cold-rolled supporting roller repaired by the embodiment is 35mm on one side, the surface hardness of the composite roller is 54+/-1 HRC, and the hardness uniformity performance is good; the magnetic powder and the nondestructive inspection have no defects, and can be machined, inspected and packaged according to the drawing requirements.
As shown in fig. 3, the surface layer structure is fine, and is a martensitic structure without defects such as cracks.
Claims (9)
1. An apparatus for electro-slag casting build-up composite manufacturing and composite remanufacturing of metal rolls comprising: crystallizer, consumable electrode group and ingot drawing device; it is characterized in that the method comprises the steps of,
the crystallizer adopts a two-stage crystallizer, and comprises a T-shaped crystallizer and a copper water-cooling crystallizer, wherein the T-shaped crystallizer is positioned at the upper part of the copper water-cooling crystallizer, and the T-shaped crystallizer is connected with the copper water-cooling crystallizer through an insulating material;
the outer wall of the T-shaped crystallizer is wrapped with an induction coil, and the induction coil is connected with an intermediate frequency power supply and is used for melting slag to form a molten pool and heating the surface of a roller; a molten steel liquid level detection device is arranged at the position of the T-shaped crystallizer, which is close to the insulating material, and is used for detecting a molten steel liquid level signal in the crystallizer;
the consumable electrode group forms a power supply loop with a bottom baffle plate in the crystallizer through a power transformer;
the ingot pulling device is connected with the bottom baffle plate and is used for pulling the roller downwards from the crystallizer.
2. The apparatus for composite manufacturing and composite remanufacturing of metal rolls of claim 1 wherein said consumable electrode assembly is formed from a plurality of electrodes of equal size in parallel.
3. The apparatus for composite fabrication and composite remanufacturing of metal rolls of claim 2 wherein said consumable electrode assembly comprises sleeve-shaped electrodes.
4. The apparatus for composite fabrication and composite remanufacturing of metal rolls of claim 1 wherein the T-shaped mold is fabricated from a refractory material.
5. The apparatus for composite fabrication and composite remanufacturing of metal rolls of claim 1 wherein the insulating material is a high temperature insulating mat.
6. The apparatus for composite manufacturing and composite remanufacturing of metal rolls of claim 1, wherein the apparatus further comprises consumable electrode lifting means for lifting the consumable electrode assembly in place of the consumable electrode assembly.
7. The apparatus for composite manufacturing and composite remanufacturing of metal rolls of claim 1, wherein the molten steel level detection means, the consumable electrode lifting means and the ingot stripping means are controlled by a computer control system.
8. The apparatus for composite manufacturing and composite remanufacturing of metal rolls by electroslag casting build-up welding according to claim 1, wherein arc striking plates are respectively provided at the upper and lower stub shafts of the rolls, and wherein the arc striking plates at the lower stub shaft of the rolls are provided between the ends of the rolls and the bottom baffle.
9. A process for composite manufacture and composite remanufacturing of metal rolls using the apparatus of any one of claims 1-8, comprising the steps of:
(1) Preparing a plurality of consumable electrode groups;
(2) Preparing a roller matrix, and removing fatigue layers and defects of a roller body;
(3) Wrapping the induction coil on a T-shaped crystallizer, connecting an intermediate frequency power supply, after electrifying, melting slag into liquid slag by utilizing electromagnetic induction, and simultaneously completing local heating of the surface of a roller to 700-850 ℃ by utilizing electromagnetic induction;
(4) Inserting the consumable electrode group into liquid slag, and electrifying to start arc;
(5) When the molten steel liquid level detection device detects a molten steel liquid level signal in the crystallizer, starting an ingot pulling device to pull out ingots, and cooling a roller by a copper water-cooled crystallizer below after pulling out the ingots;
(6) When the height of the rest part of the consumable electrode group is about 30-40 mm, the consumable electrode is exchanged; when the electrodes are exchanged, intermediate frequency heating is conducted, and the difference between the temperature of liquid slag and the slag temperature of electroslag casting overlaying welding is maintained to be less than or equal to 30 ℃;
(7) Repeating the steps (4) - (6) to finish the composite manufacturing of the roller;
(8) Removing the flat solidified slag shell on the surface of the composite layer, loading into a resistance furnace for tempering heat treatment, and then carrying out machining, flaw detection and packaging.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210228408.9A CN114603118B (en) | 2022-03-08 | 2022-03-08 | Equipment and process for manufacturing metal roller by electroslag casting and surfacing compound (re) method |
Applications Claiming Priority (1)
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